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Mitsubishi 3000GT 1991, Service Manual

The Mitsubishi 3000GT 1991 Service Manual is a comprehensive manual with detailed instructions on maintenance, repair, and troubleshooting for the iconic sports car. Download this manual for free from manualshive.com to ensure your 3000GT is running smoothly and efficiently. Get your hands on this invaluable resource today!

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REAR AXLE

CONTENTS

 

REAR AXLE 

. . . . . . . . . . . . . . . . . . . . . 

AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . 

24

DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

LSD CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

39

SERVICE ADJUSTMENT PROCEDURES . . . . . . . .

13

Gear Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Limited-Slip Differential Check . . . . . . . . . . 

14

Rear Axle Total Backlash Check

. . . . . . . . . . . . . . . . . . . .

13

Rear Wheel Bearing End Play Check

  1 3

Rear Wheel Bearing Rotation Torque

Check

. . . . . . . . . . . . . . . . 

14

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

SPECIFICATIONS

................................................

6

General Specifications

.......................... ..........

6

Lubricants ............................................................

7

Sealants and Adhesives ....................................

7

Service Specifications

....................................

7

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Axle Shaft

Grease leakage

Noise while wheels are rotating

Differential (Limited Slip Differential)

Abnormal noise during driving or
gear changing

Abnormal noise when cornering

Break down

Gear noise

Gear oil leakage

Seizure

The limited slip differential does

not function

Drive Shaft

Noise

REAR AXLE 

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR AXLE HUB

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE ADJUSTMENT PROCEDURES ........

Rear Hub Rotary-sliding Resistance

(Torque) Inspection ............................................

Wheel Bearing End Play Inspection ................

SPECIFICATIONS

................................................

General Specifications

....................................

Service Specifications

....................................

TROUBLESHOOTING

. . . . . . . . . . 

Abnormal Sound

2

4

3

3

3

2

2

2

2

Summary of Contents for 3000GT 1991

Page 1: ...Volume lm I k 6 I I I Engine Chassis Body f...

Page 2: ......

Page 3: ...I V E S E R V I C E EXCELLSNCE I MITSUBISHI MOTOR SALES OF AMERICA Inc Mitsubishi Motors Corporation reserves the right to make changes in design or to make addltlons to or tmprovements in Its produc...

Page 4: ...INTERIOR FENDER FLOOR CONSOLE P 52A 11 FRONT SEAT INSTRUMENT PANEL P52A 18 P 52A 8 CHASSIS ELECTRICAL SEAT BELT COLUMN SWITCH HORN SWITCH IGNITION SWITCH P 52A 25 P 54 73 P 54 78 1 P 54 6 RADIO REMOT...

Page 5: ..._ _ Drive Shaft Boots Engine Coolant __ _ Engine Oil _ __ _ Engine Oil Filter _ _ __ Exhaust System _ _ _ __ _ Fuel Hoses __ __ 36 37 40 42 42 42 38 43 41 38 39 43 36 Fuel System Manual Transaxle _ _...

Page 6: ...c...

Page 7: ...or assembly must be kept functionally or in strength It is a value established outside the range of standard value REFERENCE VALUE Indicates the adjustment value prior to starting the work presented i...

Page 8: ...eps Specified in case reassembly is impossible in reverse order of disassembly steps Omitted if reassembly is possible in reverse order of dis assembly steps Classifications of Major Maintenance Servi...

Page 9: ...n reus able part SERVICE POINTS OF REMOVALJ Y 6 Ol6CONN6CTtON OF TIE ROD END Using the special tool disconnect the tie rod from the Operating procedures cau tions etc on removal installa tion disassem...

Page 10: ...face of the air con ditioner control unit Indicates the con nector number Numbers are used in the operation de scriptions only as necessary and these numbers correspond to the numbers used in harness...

Page 11: ...broken I line indi cates the same connec tor The connector symbol indicates the device side connector for an intermediate connector the male side connec tor as seen from the terminal front the con ne...

Page 12: ...bers contain 17 digits The vehicle number is a code which tells country make vehicle type etc J Japan A 3 X D s Mitsubishi 4 B Passenger Driver 1 3000GT M Premium Y Car 3 door 3 0 liters 000001 Air Ba...

Page 13: ...000GT AWD 3 0 liters 181 4 cu in Z15AMNGFL2M DOHC MPI Turbo ZlGAMNGFL2M VEHICLES FOR CALIFORNIA V I N except sequence number 1 Brand JA3XD54BClMY Mitsubishi 3000GT FWD 1 JA3XD64BlJMY I Engine displace...

Page 14: ...e model 5 COLOR INT R2587VQ3V OPT p izgTj Ly de CHASSIS NUMBER MOOCE STAMPING LOCATION The chassis number is stamped on the top center of the firewall located in the engine compartment CHASSIS NUMBER...

Page 15: ...in or attached as a label to the following major parts of the engine and transaxle as well as main outer panels Engine cylinder block Transaxle housing Fender Door Quar ter panel Hood Liftgate Bumper...

Page 16: ...00 12 GENERAL Vehicle Identification LOCATIO NS W5MGl Automatic transaxle F4A33 31FOO70 The illustration indicates left hand side outer Right hand side is symmetrically opposite TSS Revision...

Page 17: ...cation The illustration indicates right hand side outer Left hand side is symmetrically opposite 31FOO71 31FOO72 The illustration indicates left hand side outer Right hand side is symmetrically opposi...

Page 18: ...00 14 GENERAL Vehicle Identification Part Liftgate Front bummer 3ear bumper Target area for original equipment parts vmd for replacement parts 31FOO74 OOFO013 OOFO047 TSB Revision...

Page 19: ...ing switch If this is not done there is the possibility of semiconductor parts being damaged 2 After completion of the work steps when the battery s negative terminal is connected warm up the engine a...

Page 20: ...is vehicle is towed use wheel lift or flat bed equip ment L 3 Manual transaxle vehicles may be towed on the front wheels provided the transaxle is in neutral and the drive line has not been damaged Th...

Page 21: ...ever allow passengers to ride in a towed vehicle 5 State and local rules and regulations must be followed when towing a vehicle AWD Caution 1 If only the front wheels or only the rear wheels are lifte...

Page 22: ...ck is used at the following locations Front Under the mid point of No 1 crossmember NOTE On vehicles with active aero system the front jacking point can be accessed by removing the center cover panel...

Page 23: ...proximate center of gravrty Frame contact hoist twin post hoist or scissors lack emergency locatlons EMERGENCY JACKING Jack receptacles are located at the body sills to accept the scissors jack suppli...

Page 24: ...up the rear wheels and place an axle stand at the designated part of the side sill 2 Jack up the front wheels and set a pick up stand and balancing machine in place Caution 1 Set so that the front an...

Page 25: ...placement cm cu in 3000GT DOHC Non Turbo 4 545 178 9 1 840 72 4 1 285 50 6 2 470 97 2 1 560 61 4 1 580 62 2 1 025 40 4 1 050 41 3 145 5 7 12 2 16 9 1 455 3 208 1 495 3 296 1 925 4 244 1 100 2 425 850...

Page 26: ...on ENGINE SPECIFICATIONS Items Type Number of cylinders Bore mm in Stroke mm in Piston displacement cm3 cu in Compression ratio Firing order TRANSAXLE SPECIFICATIONS F L Items Type Gear ratio Final re...

Page 27: ...ts 4 If self tapping screws or self locking nuts are used Standard bolt and nut tightening torque Bolt nominal diameter mm M5 M6 M8 Pitch b m n 0 8 1 0 1 25 Head mark 2 5 1 8 5 0 3 6 12 8 7 Torque Nm...

Page 28: ...or cranks slowly Probable cause Starting system faulty Reference page 16 15 ENGINE WILL NOT START OR HARD TO START CRANKS OK 1 Symptom Engine will not start or hard to start Cranks OK Probable cause N...

Page 29: ...ction system problems Exhaust gas recirculation EGR system problems 17 11 Engine overheats 114 3 Compression too low I l l 1 5 ENGINE HESITATES OR POOR ACCELERATION L Reference page Symptom Probable c...

Page 30: ...Symptom Probable cause Reference page or remedy Excessive oil consumption Oil leak Repair as necessary Positive crankcase ventilation line clogged Valve stem seal worn or damaged 17 5 11 34 I Valve s...

Page 31: ...e pressure Excessive tightened rack support cover Damaged front wheel bearing Reference page 33A 4 31 3 37A 19 26 10 Low fluid level Replenish Air in power steering system 37A 10 Low tire pressure 313...

Page 32: ...oning shock absorber Reference page 33Ad 34 5 23 313 34 6 LJ 33A 5 34 l 3 33 ROAD WANDER Symptom Road wander Probable cause Improper front or rear wheel alignment Reference page 33A 34 5 23 Excessive...

Page 33: ...Replace Poor turning resistance of lower arm ball joint 33A 9 Excessive play of steering wheel 37A 5 Broken or weak front stabilizer 33A 10 Worn lower arm bushing 33A 8 Malfunctioning shock absorber...

Page 34: ...hus damaging surface Insufficient grease Excessive bearing preload Excessive load Faulty oil seal Smearing Damage or wear caused by minute particles adhering to surfaces results in rough movement and...

Page 35: ...or Service SGXD when available should be used These oils contain sufficient chemical additives to provide maximum engine protection Both the SAE grade and the API designation can be found on the conta...

Page 36: ...ilter and oil cooler Oil filter Oil cooler Turbo Cooling system including heater and coolant reserve system Manual transaxle FWD AWD Transfer Automatic transaxle Rear axle AWD Power steering 2ws 4ws F...

Page 37: ...prove fuel economy and conserve energy new lower friction engine oils have been developed These oils are readily available and can be identified by such labels as Energy Conserving II Energy Saving Im...

Page 38: ...8 at the coolant temperature of 20 C 68 F Caution 1 If the concentration of the coolant is below 30 the anti corrosion property will be adversely affected In addition if the concentration is above 60...

Page 39: ...80 96 Maintenance Intervals Mileage in Thousands 15 30 45 50 60 1 Check Fuel System Tank Line and Connections and Fuel Filler Cap for Leaks Every 5 Years or x 2 Check Fuel Hoses for Leaks or Damage E...

Page 40: ...conditions A Driving in dusty conditions E B Police taxi or commercial type operation F Driving in sandy areas C Extensive idling G Driving in salty areas D Short trip operation at freezing temperatu...

Page 41: ...nnector 3 Remove air intake hose A from the air flow sensor 4 Unclamp the air cleaner cover 5 Remove the air cleaner cover and air flow sensor Caution Remove the air cleaner cover with care not to giv...

Page 42: ...il is not very dirty or is free from coolant or gasoline and has an appropriate viscosity grade J Change MOOSAAH Always use lubricants which conform to the requirements of the API classification For S...

Page 43: ...6 psi 1 765 kpa manufacturer s specifications to avoid filter and engine damage The following is a highquality filter and is strongly recommended for use on this vehicle Mitsubishi Engine Oil Filter P...

Page 44: ...Check to see if fluid level is in HOT range on dipstick If fluid level is low add ATF until level reaches HOT range Low fluid level can cause a variety of conditions because it allows pump to take in...

Page 45: ...l after transaxle is at normal operating temperature Fluid level should be between upper and lower marks of HOT range Insert dipstick fully to prevent dirt from entering transaxle 11 ENGINE COOLANT Ch...

Page 46: ...ll U four pads must be replaced as a complete set Thickness of lining A Limit 2 0 mm 08 in 13 BRAKE HOSES Check for deterioration or leaks MOOSBHB Inspection of brake hoses and tubing should be includ...

Page 47: ...filler hole If the oil level is slightly below the filler hole it is in satisfactory condition 16 REAR AXLE LIMITED SLIP DIFFERENTIAL Oil change AWD MOOSBQE Before changing the rear axle oil check to...

Page 48: ...guard l Rear combination lamp 3M ATD Part No 8509 or equivalent 3M ATD Part No 8625 or equivalent Application Recommended brand 4 Adhesives for interior trim 1 Adhesion of polyvinyl chloride sheet 3M...

Page 49: ...ace 8 Anaerobic fast bonding adhesives I Fixing of bolts and screws 3M Stud locking l Tightening of drive gear Part No 4170 to differential case or equivalent l Bolts for coupling tilt steering upper...

Page 50: ......

Page 51: ...MP OIL PAN AND OIL SCREEN 20 49 53 34 23 17 55 2 3 2 40 22 PISTON AND CONNECTING ROD ROCKER ARM AND CAMSHAFT SERVICE ADJUSTMENT PROCEDURES Compression Pressure Check Curb Idle Speed Inspection Drive B...

Page 52: ...II 2 ENGINE General Information GENERAL INFORMATION MllBAEC SECTIONAL VIEW I 7EN0335 ii 7EN0334 TSB Revision...

Page 53: ...ENGINE General Information II 3 UBRICATION SYSTEM 7LUOO25 TSB Revision...

Page 54: ...6 Valve timing Intake valve Opens BTDC 1 6 1 6 Closes ABDC 55 55 Exhaust valve Opens BBDC 4 8 50 Closes ATDC 1 5 17 SERVICE SPECIFICATIONS MllCE Items Compression pressure kPa psi rpm Non Turbo Turbo...

Page 55: ...331 Oversize rework of valve guide hole both intake and exhaust mm in 0 05 f 002 0 s 13 050 13 068 5138 5145 0 25 OlO O S 13 250 13 268 5217 5224 0 50 020 0 s 13 500 13 518 5315 5322 Samshaft Cam hei...

Page 56: ...Less than 0 05 t 0020 0 10 0039 Piston 0 D mm in 91 I0 3 5866 Clearance Piston to cylinder mm in 0 03 0 05 0012 0020 Ring groove width mm in No 1 1 2 047 No 2 1 5 f 059 Oil 3 0 I 18 Service size mm in...

Page 57: ...nce mm in Body clearance 0 100 0 181 0039 0071 Side clearance 0 040 0 095 0016 0037 Relief spring Free length mm in 43 8 1 724 Load 137 N 8 3 Ibs mm in 40 1 1 579 Drive belt For alternator Vehicle wit...

Page 58: ...ified sealant MITSUBISHI GENUINE Part No MD9971 10 or equivalent Oil pressure gauge unit Rocker cover 3M ATD Part No 8660 or equivalent SPECIAL TOOLS MIlDA MD998051 01 Loosening and tightening of cyli...

Page 59: ...998765 Removal and installation of piston pin Use with MD998764 Supporting the cran crankshaft bolt and pulley are removed or reinstalled Use together with MB990767 01 Tensioner pulley socket wrench A...

Page 60: ...worn Thin or diluted engine oil Replace gears and or cover Change engine oil to correct viscosity 1 Oil relief valve stuck opened Repair relief valve Excessive bearing clearance Replace bearings I b...

Page 61: ...rly fit without misalignment 2 If creaking or slippage is observed check the belt for wear damage or breakage on the pulley contact surface check the pulley for scoring in addition to sag inspection 3...

Page 62: ...DITIONER COMPRESSOR DRIVE BELT Vehicle with air conditioner 1 Use straight handle box wrench to loosen tension pulley fixing nut 2 Adjust belt deflection with adjusting bolt 3 Use straight handle box...

Page 63: ...at idle 5 Check curb idle speed Curb idle speed 700 f 100 rpm NOTE The engine speed indicated is a third of actual speed In other words the reading of the tachometer times 3 is actual speed 6 Turn OFF...

Page 64: ...ing adjusting terminal 5 Start the engine and let it idle 6 Check whether or not the ignition timing is the standard value if not adjust Standard value 5 BTDC 2 NOTE Check the ignition timing with the...

Page 65: ...of the spark plug hole hot and fast so be sure to take the proper precautions 5 Set the compression gauge to the spark plug hole 6 Holding the throttle valve full open crank the engine and measure co...

Page 66: ...normal noise is heard from the lash adjusters check as follows 1 After warming up the engine stop it 2 While installed to the cylinder head press the part where the rocker arm contacts the lash adjust...

Page 67: ...ipe Refer to GROUP 15 Exhaust Pipe and Main Muffler l Installation of Air Hose and Air Pipe Turbo Refer to GROUP 14 Inter Cooler l Installation of Hood Refer to GROUP 42A Hood l Supplying of Engine Oi...

Page 68: ...or connector 27 Engine coolant temperature gauge unit connector 28 Condenser connector 29 Ignition coil connector 30 Power transistor connector 31 Fuel injector connector 32 Variable induction motor c...

Page 69: ...tallation bolt use a chain block or similar arrangement to suspend the engine assembly to the extent that there is no looseness of the chain 37 REMOVAL OF ENGINE ASSEMBLY After checking that the cable...

Page 70: ...e Manifold Refer to GROUP 15 Intake Manifold 3Nm 2 2 ftlbs 3Nm 2 2 f tlbs 1 Refer to GROUP 13 Engine Control 3Nm 90 Nm 65 ft lbs Removal steps 1 Center cover front bank 2 Connection for spark plug cab...

Page 71: ...n Do not hold the camshaft sprocket with a tool or a damaged sprocket could result 7 REMOVAL OF CAMSHAFT OIL SEAL 1 Cut out a portion in the camshaft oil seal lip 2 Cover the tip of a screwdriver with...

Page 72: ...efer to GROUP 51 Aero Parts l Under Cover Refer to GROUP 22 23 Transfer Assembly 13 Nm PI ll r w OlLO156 Sealant MITSUBISHI GENUINE Part No MD9971 10 or equivalent 9Nm 60 70Nm 43 51 ft lbs MllHA 9Nm 7...

Page 73: ...bs Cold engine A Q s 11 ft lbs 12 0 nng 3 Water 01 LO21 7 i2o IjONm Y rt lDS 87 94 ft lbs 76 83 ft lbs d Cold engine fl Turbo i20 130 Nm 87 94 ftlbs Non turbo 105 115Nm 76 83 ft lbs Removal steps I Pi...

Page 74: ...TALLATION OF CYLINDER HEAD GASKET 1 Make sure that the gasket has the proper identification mark for the engine 2 Lay the cylinder head gasket on the cylinder block with the identification mark at the...

Page 75: ...R COVER Tighten the rocker cover bolts in the order shown in the illustration NOTE 1 Only No 5 bolt in the rear bank differs from other bolts in length Rear bank No 5 bolt _ _ _ _ _____ __ _ 20 mm 79...

Page 76: ...ertoP ll 11 4 I 5 Crankshaft pulley 6 Brake fluid level sensor 7 Timing belt upper cover 8 Engine mount bracket 9 Idler pulley alternator air conditioner l 10 Engine support bracket l 11 Timing belt l...

Page 77: ...horten its life drastically so the removed timing belt sprocket and tensioner must be free from oil and water These parts should not be washed Replace parts if seriously contamin ated If there is oil...

Page 78: ...ft sprocket to move the timing mark to the area closest to the range A Caution In range A the cam lobe on the camshaft lifts the valve through the rocker arm and the camshaft sprocket is apt to rotate...

Page 79: ...erly 5 Remove the four clips ADJUSTMENT OF TIMING BELT TENSION 1 Rotate the crankshaft 114 turn counterclockwise then rotate it clockwise until the timing marks are aligned 2 Loosen the center bolt on...

Page 80: ...e J 10 INSTALLATION OF ENGINE SUPPORT BRACKET Since the mounting bolts of engine support bracket are different in size depending on location insert them in numbered sequence Caution When installing th...

Page 81: ...seal 4 Bearing cap rear 5 Circular packing 6 Bearing cap No 2 7 Bearing cap No 4 8 Bearing cap No 3 9 Camshaft 10 Rocker arm 11 Lash adjuster Installation steps 11 Lash adjuster 10 Rocker arm l 9 Cams...

Page 82: ...order to bleed out the air 3 Install the lash adjuster to the cylinder head 9 INSTALLATION OF CAMSHAFT 1 Turn the crankshaft to bring No 1 cylinder to the top dead center 2 Check that the rocker arm...

Page 83: ...t is exceeded Standard value 0 1 0 2 mm 004 008 in Limit 0 4 mm 016 in NOTE If the bearing cap is installed with the cylinder cap removed the valve will protrude Install therefore with the cylinder he...

Page 84: ...ead gasket l 5 Retainer lock 6 Valve spring retainer l 7 Valve spring 8 Intake valve l l 9 Retainer lock 10 Valve spring retainer Cold engine 125 Nm 90 ftlbs 7E NO254 l 11 Valve spring 12 Exhaust valv...

Page 85: ...cylinder head gasket surface Standard value 0 03 mm 0012 in or less Limit 0 2 mm 008 in 2 If the measured flatness exceeds the limit grind and repair the surface to gain the flatness of standard value...

Page 86: ...he valve seat with a seat grinder or cutter The valve seat width should be the specified value at the center of the valve face Inspect the valve seat with prussian blue to determine LJ where the valve...

Page 87: ...rinder or cutter correct the valve seat to the specified width and angle 5 See VALVE SEAT RECONDITIONING PROCEDURES VALVE GUIDE REPLACEMENT PROCEDURE MllPJDB 1 Using suitable rod and a press press the...

Page 88: ...d Caution 1 Incorrect installation of the seal without using the special tool will result in poor sealing and cause oil leakage down valve guide 2 Do not reuse stem seal 11 7 INSTALLATION OF VALVE SP...

Page 89: ...9 1 INSTALLATION OF CYLINDER HEAD BOLT 1 Using the special tool tighten the bolts in two to three stages in the illustrated sequence 2 Back off the bolts once and tighten them to the specified torque...

Page 90: ...A 10 Nm 14 75 Nm 55 ftlbs I 19 Nm 14 ft lbs 45 Nm 33 ft lbs 51u0010 5LUOOll Sealant 3M ATD Part No 8660 or equivalent 6Nrn 5 tklbs 7EN0317 Groove 4 Groove 4 Bolt hole 0110156 Bolt hole 0110156 portion...

Page 91: ...20 Oil pump case 21 Oil pump gasket 22 Oil pump cover 23 Oil pump outer rotor 24 Oil pump inner rotor 14 Oil screen 15 Oil screen gasket Side clearance Body clearance SERVICE POINTS OF REMOVAL MllRBB...

Page 92: ...lve has been dipped in 100 C 212 F oil Dimension L 40 mm 1 57 in or more SERVICE POINTS OF INSTALLATION MllRDEC 19 INSTALLATION OF CRANKSHAFT FRONT OIL SEAL Using the special tool knock the oil seal i...

Page 93: ...bottom view iTiming belt side 7EN030f 7EN030 12 TIGHTENING SEQUENCE OF OIL PAN BOLT Tighten the flange bolts in the sequence shown in the illustration illustration 11 INSTALLATION OF DRAIN PLUG GASKET...

Page 94: ...earing upper WV WC 6 rrston ring No 1 l 7 Piston ring No 2 I 8 Qil ring l _ v Y Hston oin 10 Piston 11 Connecting rod 12 Bolt 52 ihn 38 fklbs 7EN0266 6EN18 SERVICE POINTS OF REMOVAL MllT6EC 2 REMOVAL...

Page 95: ...ped for each cylinder n u m b e r INSPECTION PISTON RING MllTCEA 1 Check the clearance between the piston ring and the ring groove When it exceeds the limit replace the rings the piston or both Standa...

Page 96: ...LATION OF PISTON PIN 1 Insert the special tool Pushrod into the piston pin and install the guide A 2 Apply engine oil to the outside of the piston pin 3 Assemble the piston and connecting rod lining u...

Page 97: ...the piston groove If pressed with a finger as shown in the illustration it should enter easily NOTE The side rail may be broken like other piston rings if the gap is opened by the ring expander 3 In t...

Page 98: ...nder block Care must be taken not to nick crank pin 5 Using a suitable piston ring compressor tool install piston and connecting rod assembly into cylinder block Caution Insert the pistons so that the...

Page 99: ...ft lbs 7EN0318 1 Flywheel M T 2 Adaptor plate AIT 3 Drive plate QVT 4 Rear plate 5 Bell housing cover 6 Oil seal case 04 7 Crankshaft rear oil Seal 8 Bearing cap stay Turbo 9 Bearing cap IO Thrust bea...

Page 100: ...move it from the flywheel Caution The ring gear cannot be removed while it is hot 2 Heat the ring gear to 300 C 572 F and install it into the flywheel CRANKSHAFT Inspect out of roundness and taper of...

Page 101: ...on the plastigage sleeve If the clearance exceeds the repair limit the bearing should be replaced Should the standard clearance not be obtained even after bearing replacement replace the crankshaft S...

Page 102: ...ck the end plate If it exceeds the limit value replace the thrust bearing Standard value 0 05 0 25 mm 0020 0098 in Limit 0 3 mm 012 in rent of engine Timing Ielt side 8 LLiN03 ij 1 TSB Revision INSTAL...

Page 103: ...r bracket front 2 Roll stopper bracket front AWD only 3 Roll stopper bracket rear 4 Detonation sensor I 5 Detonation sensor bracket 6 Cylinder block 7EN0319 INSPECTION CYLINDER BLOCK MllVCAM 1 Using a...

Page 104: ...the reground bore size based on the measured value of the outside piston diameter NOTE Bore size outside piston diameter 0 03 to 0 05 mm 0012 to 0020 in gap between cylinder and piston 0 02 mm 0008 i...

Page 105: ...9 ft lbs 5 02FOOOi SERVICE POINTS OF REMOVAL MllMBAC 2 REMOVAL OF ENGINE OIL FEED HOSE 4 ENGINE OIL RETURN TUBE Caution Be sure to hold the weld nut of the oil cooler while loosening the eye bolt INSP...

Page 106: ......

Page 107: ...36 Active Exhaust Control Unit Turbo 130 Air Conditioner Switch and Power Relay 82 Air Flow Sensor 54 Anti lock Brake Signal Turbo 133 Barometric Pressure Sensor 60 CONTINUED ON NEXT PAGE SUPPLEMENTAL...

Page 108: ...Mode Changeover Switch Turbo 88 Oxygen Sensor Non Turbo 94 Oxygen Sensor Turbo 98 Power Steering Oil Pressure Switch 80 Power Supply and Ignition Switch IG 41 Purge Control Solenord Valve 1 19 Releas...

Page 109: ...FUEL SYSTEM L GENERAL INFORMATION MPI SYSTEM DIAGRAM Federal Non Turbo 4 xwo3 elOl alxesueJl aulfiu 1qt 6uluJeMaul6u 03 u0yJ61 E I c 8 4 hqa dwnd an hew XV z ONaS on o5 ownp a qe Je EC an lo a os 0 1...

Page 110: ...California Non Turbo E UT E X 0 S u E gg g 26 _I P 5 ash 13 4 FUEL SYSTEM General Information t I i E I 2 Ln 03 0 l 0 3 LL r TSB Revision...

Page 111: ...rmation 1 3 5 Turbo c1 iv Y an w p1oYa os am aSeM awn ploqor Oli OJ aE an en Oll OJ amrsa WI 6 X ONar 3SI iI 5 i an en plo apn Ol rn 833 r I I III I II 1 I I I J b ti z wf a a 5 239 B 5 K p ly PB I I...

Page 112: ...Non Turbo Turbo California Non Turbo Karman vortex type Barometric pressure sensor Semiconductor diffusion type Engine coolant temperature sensor Oxygen sensor Vehicle speed sensor Detonation sensor...

Page 113: ...le speed when air conditioner is on rpm M T 900 at neutral position Al r 650 at D range 3asic idle speed rpm 700 50 Throttle position sensor adjusting voltage V 0 4 1 o Throttle position sensor resist...

Page 114: ...13 8 SPECIAL TOOLS FUEL SYSTEM Special Tools MlBDA MB991359 l Reading diagnosis code l MPI system inspection Detonation sensor TSB Revision...

Page 115: ...the signals are normal judge the sensor input actuator control as normal and proceed to check the input output signals of the next check item 5 Inspection of MPI system component harness l If the engi...

Page 116: ...iate test harness for the particular connector is not available the use of the Test Harness Set MB991348 which can be connected directly between the terminals is recommended l When checking the termin...

Page 117: ...ition switch is turned off the light goes out Even if the ignition switch is turned on again the light does not come on until the irregularity is detected Here immediately after the ignition switch is...

Page 118: ...ry the diagnosis results are memorized even if the ignition key is turned off The malfunc tion codes will however be erased when the battery terminal or the engine control unit connector is disconnect...

Page 119: ...perature nn 21 Retained l Harness and connector sensor 0 Coolant temperature sensor 12A0107 7 Crank angle sensor nn 22 Retained l Harness and connector If harness and connector are normal replace cran...

Page 120: ...unit 16 lqnition coil 12A0105 52 power transistor unit INO 2 5 cylinder H L u Lnll qnition coil 12AO105 18 Retained l Harness and connector l Ignition coil l Power transistor unit Retained l Harness...

Page 121: ...nosis connector and ground terminal 2 Turn on the ignition switch 3 Read the diagnosis output pattern from the voltmeter and record it 4 Referring to the diagnosis chart repair the faulty part 5 Erase...

Page 122: ...Troubleshooting CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS stepper motor type 0 Warm en gine number inside indicates check order Cl Cold engine number inside indicates check order N T Non Turbo CT Tu...

Page 123: ...accelerator pedal is depressed or while it is being used Hesitation Sag Hesitation is the delay in response Hesitation of the vehicle speed engine rpm that L Normal occurs when the accelerator pedal i...

Page 124: ...RTER IGN I ION H ST 5 F I E 10A 1 l I4 c i 2 l I T A T I WITH WITHOUT THEFT ALARM Em 3 f 3 w INHIBITOR 8 SWITCH M r Lq 2 P 3 I 9 B 26 i Y a 4 D 15 fz7l9iq I c 29 fimzzaq t t v j0R 41 7 a cu c 3 f 3 I...

Page 125: ...3 6676 7 C 62 J B 6 C 71 1 4 c 30 123 IElI 456 r Y I R r J I FE cu G 4 z G L E w 9 c 34 p iaazj 6 1 I FUEL j PUMP F 16 2 5 F 14 I 2 m 3456 6 D 44 pYilasq A 17 Alhzb L KPW CONNECTOR 59 COMBINATION METE...

Page 126: ...5 6 1 2 4 l AIR FLOW SENSOR B 29 69 Q Q ip Sl 64 72 4 g wcu 4 d m 9 5 __ _____ 7 63 ENGINE CONTROL UNIT I m 56 I I I I c I ENGINE CONTROL RELAY c Y m L I 1 I I I jr I ml II d 1 1 2 I 1 2 4 01 I i ml c...

Page 127: ...NTROL SERVO x2 h5 B 35 1 1 l h h m H a2 2 z 5 m aJ d 6 I _ _ ___ 4 3 3 II 3 L 00 00 d d m I is co d V 53 110 1 I 3 m m d 4 3 LI 158 ri I I I I I I I I I I 51 I I I I I I I I I I I I I I I I m 3 II I I...

Page 128: ...L LIGHT RELAY iE FGER ikli IC 5 I 7 iZ CATED g J 0 I C 69 1 J B I w 8 A 36 7 DIODE Ire E 31 I 1 I T 6 A 67 C 52 r I Y 6 I 1 J CA 7 i t c POWER TRANSISTOR ENGINE COOLANT TEMPERATURE SWITCH FOR AIR COND...

Page 129: ...B 06 1 E l a 3 L __ 107 2 a B 36 1 c 79 1 Ia 1 IjELF DIAGNOSIS X i ON jrHECK CONNECTOR ADJUSTMENT EET pj Jgq Co cToR POWER STEERIK g iT ESSURE 113 _ 4 10 _ 111 s 1 F 1 4A T C NTROL 4 3 7f59 I 59 I 1E...

Page 130: ...c 71 I jLEl3za 1234 567 5 s 01112 1616 w 15A I t IOA 1 l C 83 m 7 pTEiEsq is 1 6 Efi l p i Ezq 3 A 67 I71 AIR m FLOW SENSOR i E N lO I OFF ON __O I 1 cte 4 5 0 D d N IN Gl c CL Y Y I J E N 3 3 I ENGIN...

Page 131: ...IT IN IGl 1234 liEI 5676 7 C 82 I J B c 71 1 5 D 44 i 4 E A 1 2 2 k N s I FUEL PUMP RESISTOR A 51 J E 1 i J A L I i I I 1 f J I2 r m c 30 3 n D 04 59 1 COMBINATION EEKPUMP CONNECTOR L D 03 c c 3 d WI...

Page 132: ...FLOW SENSOR v I 7 5 6 1 2 4 3 7 00 3 t A c z rti s t CL 0 I I I i I I I I I I I I I I I 1 I ZL i ____ L ____ 9 4 d vv CRANK ANGLE AND TOP DEAD z 7 CENTER SENSOR m m 2 E 7I N 21 4 E G G I CL g 1 G I I...

Page 133: ...LAY RES Q 0 65R 1 25R 4 1 n RKD 1 I T 1 STOR e I IDLE SPEED 2 CONTROL SERVO B 35 Y Y Y Y Y Y TOR m I I I I 4 I I I I I I I L w I I A 67 2 8 1 _ lO I I I I r 1 I I I I 5 c II m n 3 A Z I 1l I I I OXYGE...

Page 134: ...I 0 _ w 1DIODE I I 3 d STOP LIGHT SW ITCH C 61 1 2 El 34 c 29 1 r f I I __ _ __ ___ 1 I y J d 71 z 124 t r 7 I I I V I w Sk w t J I v _ 10 5 cb 3 x I _ 22 6 J 1 I 8 A 33 11 3 r103 c I 128 c 14 pER Eq...

Page 135: ...E If IIIIII J i B D i A 20 1 WASTE GATE SOLENOID VALVE 7 EGR i XE OID I A 21 L 1 A 70 j A 72 f ENGINE j jXICI ROL I 13 s 3 s 10 1 J c _ 1 A 18 3 P E DIAGNOSIS Fjhl ON CONNECTOR ADJUSTMENT EF fq g CONN...

Page 136: ...FUEL TANK AND FUEL LINE MlJE4AB Symptom Engine malfunctions due to insufficient fuel supply Evaporative emission 30ntroI system malfunctions When tank cap is removed pressure releasing noise is heard...

Page 137: ...ssories OFF l Transaxle Neutral P range on vehicles with automatic transaxle l Steering wheel Straightforward position 2 When using the multi use tester connect it to the diagnosis connector NOTE The...

Page 138: ...les or more it is probably due to deposits on the throttle valve In this case clean the throttle valve Refer to P 13 33 8 If the basic idle speed is out of specification adjust by turning the speed ad...

Page 139: ...le speed becomes unstable and fails in the worst case after plugging the bypass passage run the engine with the throttle valve slightly opened 6 If the deposit cannot be removed from the throttle valv...

Page 140: ...hen using the multi use tester connect it to the diagnosis connector 9 When not using the multi use tester proceed as follows Disconnect the throttle position sensor connectors and connect the special...

Page 141: ...e fixed SAS by turning it counterclock wise to fully close the throttle valve 4 Tighten the fixed SAS slowly to find a point at which it contacts the throttle lever where the throttle valve starts ope...

Page 142: ...ition coil power transistor Ignition timing adjusting terminal S Self diagnosis output terminal and self diagnosis R data transmission selector terminal B TDC sensor and crank angle sensor D P Throttl...

Page 143: ...STEM d On vehicle lnwection of MPI Components 1 3 3 7 with built in intake I air temperature sensor Vehicle speed sensor reed switch J wF or A anale sensor y v 7Fbd942 ii Oxygen sensor I 7FU1004 TSB R...

Page 144: ...iable induction control se DC motor with built in induction ontrol valve position sensor 7FUO8 Engine warning 1 Self diagn osls output terminal and self dlagnosisi data transmission selector terminal...

Page 145: ...FUEL SYSTEM On vehicle Inspection of MPI Components 1 3 3 9 California N Turbo Turbo i EGR control solenoid valve A 7FUlOll Ylil r 7FU1007 7FUlOlO TSB Revision...

Page 146: ...rmality is found check the body harness components etc and repair as necessary 2 After repair check again with the multi use tester to make sure that the input and output signals are now normal 3 Eras...

Page 147: ...njector the air flow sensor etc l When the ignition switch is turned on the battery voltage is applied from the ignition switch to the engine control unit which then turns ON the power transistor to e...

Page 148: ...he harness Ignition switch I Measure the power supply voltage of the control relay l Connector Disconnected Voltage V s v Repair the harness Battery IIN ontrol relay connector Discon Engine control un...

Page 149: ...y 0 terminal measure the voltage across terminals and of the control relay 4 Using jumper wires connect terminal of control relay to battery 0 terminal and terminal of control relay to battery 0 termi...

Page 150: ...01 1 Engine control unit connector 7FUO653 OPERATION Grounds the engine control unit TROUBLESHOOTING HINTS If the ground wire of the engine control unit is not connected securely to ground the unit wi...

Page 151: ...the fuel pump during cranking and engine operation l When the ignition switch is set to START current flows from the ignition switch through the control relay coil to ground This turns on the control...

Page 152: ...de for indicating fuel flow above two conditions Listen to pump operating sound near fuel tank Operating sound is heard HARNESS INSPECTION check terminal 7FUO954 Harness side connector 7FUO955 Check t...

Page 153: ...6 t Repair the harness Ignition switch IGI El Ignition switch ST El Check for an open circuit or a short circuit to ground between the control relay and the engine control unit l Control relay connec...

Page 154: ...13 48 FUEL SYSTEM On vehicle Inspection of MPI Components CONTROL RELAY INSPECTION Refer to P 13 43 FUEL PUMP Turbo I 03FOOO TSB Revision...

Page 155: ...r 9 3 Control reta i L Ll Harness side connector Enaine control unit Equipment side connector M ii Resistor w for fuel pump Equipment side connector I I A 8 A21 Equipment side I Harness side connector...

Page 156: ...wer to the fuel pump through the resistor If the amount of inlet air is large the engine load is high the engine control unit turns off the power transistor to send drive power directly to the fuel pu...

Page 157: ...ontrol Check for an open circuit or a short circuitto ground between the control relay for fuel pump and the engine control unit 0 Control relay for fuel pump con nector Disconnected un harness side c...

Page 158: ...y for fuel pump l Control relay connector Discon nected l Control relay for fuel pump con nector Disconnected zonnector 8 Harness side connector 7FUO96 T Check for continuity of the ground circuit l C...

Page 159: ...ive terminal of the battery 3 With the jumper wire connected to and disconnected from the negative terminal of the battery check the continuity between terminals and of fuel pump relay No 2 and betwee...

Page 160: ...etween the 5 V voltage supplied from the engine control unit and ground TROUBLESHOOTING HINTS Hint 1 If the engine stalls occasionally crank the engine and shake the air flow sensor harness If the eng...

Page 161: ...10 higher Air Flow Sensor Reset Signal Function Data list Item No Data display Check conditions Engine conditions Standard value 34 Reset signal l Engine warm up 700 rpm Idle ON condition 2 000 rpm O...

Page 162: ...connected l Ignition switch ON Voltage V eoair the check the control relay Measure the terminal voltage l Connector Disconnected l Ignition switch ON Check for continuity of the ground circuit l Conne...

Page 163: ...gnal l The 5 V power in the engine control unit is supplied via a resistor in the unit to the intake air temperature sensor Via the sensor which is a kind of resistor it is grounded in the engine cont...

Page 164: ...20 C At 40 C 104 F 40 C At 80 C 176 F 80 C HARNESS INSPECTION 7FUO657 I connector 7FUO660 7FUO661 I TSB I Check for continuity of the ground circuit l Connector Disconnected Repair the harness I3 q M...

Page 165: ...ntake air 3 Measure resistance while heating the sensor using a hair drier Temperature 1 C F Resistance kR Higher Smaller 4 If the value deviates from the standard value or the resistance remains unch...

Page 166: ...t connector 7FUO653 OPERATION l The barometric pressure sensor converts the barometric pressure into a voltage and inputs it to the engine control unit which then corrects the fuel injection rate etc...

Page 167: ...ft 760 mmHg At 600 m 1 969 ft 710 mmHg I At 1 200 m 3 937 ft 1660 mmHg I At 1 800 m 5 906 ft 610 mmHg HARNESS INSPECTION I I L 7FUO657 7FUO66 Check for continuity of the ground circuit l Connector Dis...

Page 168: ...rol unit is supplied via a resistor in the unit to the engine coolant temperature sensor Through the sensor which is a kind of resistor it is grounded in the engine control unit The engine coolant tem...

Page 169: ...ture Standard value Data reading 21 Sensor Ignition switch ON or At 20 C 4 F 20 C temperature engine operating At 0 C 32 F 0 C HARNESS INSPECTION Check for continuity of the ground circuit l Connector...

Page 170: ...ot water check resis tance Temperature C F Resistance kCI 0 32 5 8 20 68 2 4 40 104 1 1 80 176 0 3 3 If the resistance deviates from the standard value greatly replace the sensor INSTALLATION 1 Apply...

Page 171: ...r it is grounded in the engine control unit l As the throttle valve shaft rotates from the idle position to Wide open position the resistance between the variable resistor terminal of the throttle pos...

Page 172: ...Open slowly Increases with valve opening Open widely 4 500 5 500 mV HARNESS INSPECTION l Connector Disconnected l lgnrtion switch ON l Connector Disconnected connector I Engine control Check for an o...

Page 173: ...rminal sensor ground and terminal sensor output 4 Operate the throttle valve slowly from the idle position to the full open position and check that the resistance changes smoothly in proportion with t...

Page 174: ...nit is applied to the idle position switch through a resistor When the accelerator pedal is released the idle position switch is turned on to conduct the voltage to ground This causes the idle positio...

Page 175: ...AS Refer to P 13 35 2 Disconnect the throttle position sensor connector 3 Check the continuity across the throttle position sensor connector terminal Sensor ground and Idle position switch Accelerator...

Page 176: ...quence etc based on the input signal l Power to the top dead center sensor is supplied from the control relay and is grounded to the body The top dead center sensor generates a pulse signal as it repe...

Page 177: ...7Fuo495 HARNESS INSPECTION 7FUO496 r i 2 Harness side connector F 7FUO497 J Measure the power supply voltage l Connector Disconnected l Ignition switch ON Voltage VI OK I sv ib 0 2 Repair the harness...

Page 178: ...he engine stalls suddenly during idling shake the crank angle sensor harness If this causes the engine to stall poor contact of the sensor connector is suspected Hint 2 If the crank angle sensor outpu...

Page 179: ...fore 3 times the tachometer indication is the actual engine speed 2 When the tachometer is set to the 2 cylinder range it indicates actual engine speed Function Item No Data display Check condition Co...

Page 180: ...e power supply voltage I sv Repair the harness I Con trol relay r2 t Harness side connector Check for continuity of the ground cbrcux l Connector Disconnected 7FUO497 3 L 7FUO498 El 3 Repair the harne...

Page 181: ...voltage at cranking is applied through the ignition switch to the engine control unit which detects that the engine is cranking INSPECTION Using Multi use Tester Function Item No Data display Check co...

Page 182: ...In case the selector lever is in a position other than the P N range the battery voltage is not applied to the engine control unit l The inhibitor switch converts the selector lever position whether...

Page 183: ...side connector OlA0206 2 Harness srde connector l Engine control unit connector Connected l InhibItor switch connector Dis 6a L J cl 3 connected l Ignition switch ON Repair the harness Voltage VI El...

Page 184: ...t which then provides the idle speed control etc based on this signal l The vehicle speed sensor generates the vehicle speed signal by repeatedly opening and closing between the voltage of about 5 V a...

Page 185: ...PI ComDonents 2 Measure the power supply voltage of the vehicle speed sensor Harness side l Connector Dlsconnected l Ignition switch ON 8 6FU1265 l Connector Disconnected SENSOR INSPECTION Refer to GR...

Page 186: ...er steering load into low high voltage and inputs it to the engine control unit which then controls the idle speed control servo based on this signal l The battery voltage in the engine control unit i...

Page 187: ...ing Steering wheel neutral OFF position wheels straight ahead direction Steering wheel half turn ON Checking Oil Pressure Steering wheel Oil pump delivery pressure ref value Straight forward 700 1 200...

Page 188: ...gine control unit drives the idle speed control servo and turns ON the power transistor As a result the air conditioner power relay coil is energized to turn on the relay switch which activates the ai...

Page 189: ...cation OFF OFF compressor clutch non activa tion ON ON compressor clutch activation I unit harness side connector 7FUO695 Measure the power supply voltage of the air conditioner circuit l Air conditio...

Page 190: ...onal to the magnitude of cylinder block vibration due to knocking and inputs it to the engine control unit Based on this signal the engine control unit provides retard control of the ignition timing T...

Page 191: ...FUEL SYSTEM On vehicle Inspection of MPI Components 13 85 1 HARNESS INSPECTION Check for continuity of the ground circuit l Connector Disconnected Repair the harness 7 6FU1302 1 TSB Revision I id...

Page 192: ...ly equipment with a large electrical load to the engine control unit Based on this signal the engine control unit controls the idle speed control servo l When the switch of equipment with a large elec...

Page 193: ...unit l Engine control unit connector Disconnected l Lighting switch ON Tail light relay ON Measure the input voltage of engine control unit l Engine control unit connector Disconnected l Defogger swit...

Page 194: ...put terminal of the muffler mode changeover switch has battery voltage applied to it from the engine control unit through the resistor inside the unit Place the muffler mode changeover switch to the L...

Page 195: ...HARNESS INSPECTION 1 connector 7FU1054 7FU105 i i Measure the power supply voltage l Connector Disconnected l Ignition switch ON Voltage V sv i Repair the harness pJ Ilosi Check for continuity of the...

Page 196: ...tion control valve opening degree and converts it into a pulse signal to be input into the engine control unit which provides valve opening and closing control based on this signal l The induction con...

Page 197: ...r supply voltage of the air intake control valve position sensor l Connector Disconnected l Ignition switch ON Ha nnector 7FUO824 7FUO825 Check for continuity of the ground circuit l Connector Disconn...

Page 198: ...d on to notify the driver l Five volt power supply in the engine control unit is applied to the EGR temperature sensor through the resistance in the unit This power supply further passes through the E...

Page 199: ...ne is maintained in a constant state for 3 500 rpm 120 C 248 F or more 2 minutes or more HARNESS INSPECTION connector 2 I Harness side connector m 2 1 4 1 Measure the power supply voltage l Connector...

Page 200: ...l unit l The oxygen sensor outputs about 1 V when the air fuel ratio is richer than the theoretical ratio and outputs about 0 V when the ratio is leaner higher oxygen concentration in exhaust gas l Th...

Page 201: ...air flow sensor intake air temperature sensor barometric pressure sensor engine Data reading coolant temperature sensor INSPECTION Using Multi use Tester Function Item No Data display Check condition...

Page 202: ...HARNESS INSPECTION r Measure the power supply voltage of the oxygen sensor l Connector Disconnected l Ignition switch ON Voltage V sv Repair the harness m Con trol relay 7FUO827 e oxygen sensor Disco...

Page 203: ...erature becomes 80 C 176 F or higher 5 Using jumper wires connect terminals and of the oxygen sensor connector to battery 0 and 0 terminals respectively Caution Ensure that the jumper wires are connec...

Page 204: ...PERATION TROUBLESHOOTING Refer to OXYGEN SENSOR Non Turbo P 13 94 INSPECTION Using Multi use Tester Function Data reading Item No i rL f fzt 1 Data display Sensor detection voltage Check condition Eng...

Page 205: ...l Check for an open circuit or a short circuit to ground between the engine control unit and the oxygen sensor l Oxygen sensor connector Dis connected l Engine control unit connector Disconnected Repa...

Page 206: ...minals respectively Caution Ensure that the jumper wires are connected correctly as wrong connections result in a broken oxygen sensor 6 Connect a digital voltmeter across terminals black clip of 7 th...

Page 207: ...engine control unit l The injector has a fixed nozzle opening area and the fuel pressure against manifold inside pressure is regulated to a fixed level Therefore the volume of fuel injected by the inj...

Page 208: ...ion Item No Data display Check condition Coolant temperature Standard value Data reading 4 1 Drive time Engine Cranking 0 C 32 F z Approx 17 ms 20 C 68 F Approx 46 ms 8O C 176 F Approx 11 ms Function...

Page 209: ...check the waveform at the drive side of each injector Measure the power supply voltage of the front bank injector l Connector Disconnected l Ignition switch ON 1 Repair the harness m Control relay Mea...

Page 210: ...ntrol unit connector Disconnected I ACTUATOR INSPECTION Measurement of Resistance between Front Bank Termi nals 1 Remove the injector connector 2 Measure the resistance between terminals Standard valu...

Page 211: ...r Fuel Filter Injection 7FUO832 Injector No 1 coscliio Engine control unit Control relay Equipment side connector 8 Injector OscliioJ 1 Injector N o 5 1 osclllo d 2 4 I 1 1 7 4 3 A14 B r is 5 5 _ Inje...

Page 212: ...ge is 11 V and the cranking speed is less than 250 rpm 2 When coolant temperature is lower than 0 C 32 F injection is made by four cylinders simultaneously 3 When the vehicle is new within initial ope...

Page 213: ...the front bank injector l Resistor connector Connected 0 Injector connector Disconnected l Ignition switch ON Voltage V 0 OK 0 3 Repair the harness g pJ Control relay Check power supply Check resis t...

Page 214: ...e harness ilT ilpt iiWF4 ACTUATOR INSPECTION INJECTORS Measurement of Resistance between Front Bank Termi nals 1 Disconnect the injector connector 2 Measure the resistance between terminals Standard v...

Page 215: ...UO97 RESISTOR Measurement of Resistance between Terminals 1 Disconnect the resistor connector 2 Measure the resistance between terminals Measuring terminals Resistance 5 5 6 5 R At 20 C 68 F 1 3 If th...

Page 216: ...the stepper motor through the control relay As the engine control unit turns on power transistors in the unit one after another the stepper motor coil is energized and the motor rotates in normal or r...

Page 217: ...stp l irNconditioner switch 15 63 stp Non Turbo 0 Selector lever Shift to D range NOTE When the vehicle is new within initial operation of about 500 km 300 miles the stepper motor steps may be about 3...

Page 218: ...ol unit and the idle speed control servo l Engine control unit connector Disconnected l Idle speed control servo connec tar Disconnected ACTUATOR I NSPECTION Checking the Operation Sound 1 Check that...

Page 219: ...of the connector at the idle speed control servo side Standard value 28 33 2 at 20 C 68 F 3 Measure the resistance between terminal green clip of the special tool and either terminal yellow clip or te...

Page 220: ...of the stepper motor Connect the negative 0 terminal of the power supply to the red and black clip Connect the negative 0 terminal of the power supply to the blue and black clip Connect the negative...

Page 221: ...from the engine control unit primary current flows to the ignition coil A When the power transistor unit A is turned off the primaty current is shut off and a high voltage is induced in the secondary...

Page 222: ...justment terminal is terminal and ground grounded Ignition timing ad OFF justment terminal is disconnected from ground Standard Ignition Timing Function Actuator test Item No Drive Check condition Nor...

Page 223: ...unit and the power transistor l Engine control unit connector Disconnected l Power transistor connector Dis connected Engine Repair the control unit harness harness J 1101 stde connector T 6FU1251 Che...

Page 224: ...r the harness pJ Ground Measure the voltage of the control slgnal circuit of the power transistor l Connector Disconnected l lgnrtion switch START Voltage VI 0 5 4 0 f q 7 Repair the harness Measure t...

Page 225: ...trols introduction of purge air from the canister into the intake air plenum l The battery power is supplied to the purge control solenoid valve through the control relay When the engine control unit...

Page 226: ...r Disconnected 0 Ignition switch ON Check for an open circuit or a short circuit to ground between the purge control solenoid valve and the engine control unit l Engine control unit connector Disconne...

Page 227: ...ing negative pressure to the throttle body A port l Power supply from the battery is sent through the control relay to the EGR control solenoid valve When the engine control unit turns off the power t...

Page 228: ...10 Change solenoid valve from OFF to ON state Ignition switch ON Operating sound is heard when driven HARNESS INSPECTION 1 Harness side connector Measure the power supply voltage Y 01105 4 Engine cont...

Page 229: ...re control valve is an ON OFF type solenoid valve that switches the pressure introduced to the fuel pressure regulator between either intake manifold pressure or barometric pressure l Battery power is...

Page 230: ...when HARNESS INSPECTION Harness side connector Measure the power supply voltage l Connector Disconnected l Ignition switch ON Voltage V 2 q SV Repair the i harness m Con trol relay 7FUO527 Check for a...

Page 231: ...sconnect the harness connector 3 Apply a negative pressure to the nipple to which the black vacuum hose has been connected and check air tightness with and without the battery voltage applied to the s...

Page 232: ...ator l Battery power is supplied to this valve via the control relay When the engine control unit turns ON the internal power transistor the coil is energized to release part of the boost pressure app...

Page 233: ...hen HARNESS INSPECTION Measure the power supply voltage l Connector Disconnected l Ignition switch ON trol relay 7FUO525 Check for an open circuit or a short circuit to ground between the waste gate c...

Page 234: ...L SYSTEM On vehicle Inspection of MPI Components BOOST METER Turbo Ignition switch IG Equipment side connector Boost meter Engine control unit 111 i F 7FUO985 Engine control unit connector T S B R e v...

Page 235: ...the power supply voltage l Connector Disconnected l Ignition switch ON Voltage V sv Repair the harness I I ni tion coil 9IG Check for an open circuit or a short circuit to ground between the engine c...

Page 236: ...valve is opened or closed by turning the DC motor in the normal or reverse direction l The DC motor is driven in the normal or reverse direction by changing the direction of power flow by the motor d...

Page 237: ...s driven clockwise or counterclockwise by the signal from the engine control unit the variable induction valve opens or closes l The DC motor is driven clockwise or counterclockwise as the direction o...

Page 238: ...Check for an open circuit or a short circuit to ground between the engine control unit and the variable induction control servo connector l Variable induction control servo connector Disconnected l En...

Page 239: ...o the engine control unit from the anti lock brake system ABS control unit as a signal to indicate whether or not the motor relay is activated Based on this signal the engine control unit controls the...

Page 240: ...ing at 50 km h rarily 70 to 4th speed to 100 steps stop vehicle NOTE Select a place where a rear end collision is unlikely HARNESS INSPECTION side connector Engine control umt harness side connecm 6FU...

Page 241: ...ngine control unit This will change the terminal voltage of the transaxle control unit from HIGH to LOW If the transistor fitted inside the engine control unit changes from ON to OFF the terminal havi...

Page 242: ...ness control ss side 6FU1543 I 3 Transaxle control unit harness side Engine control unit harness side connector 6FU1543 Check for an open circuit or a short circuit to ground between the transax le co...

Page 243: ...nect the fuel pump harness connector 5 Apply the specified sealant to the rear floor pan Specified sealant 3M ATD Part No 8509 or equivalent 6 Install the fuel gauge cover FUEL PUMP OPERATION CHECK M1...

Page 244: ...Attach the special tool set in step 3 to the delivery pipe between high pressure hose 5 Connect the 0 battery terminal 6 Connect a jumper wire to the terminal for activation of the fuel pump and to th...

Page 245: ...range check for the probable cause by referring to the table below and then make the appropriate repair I Condition Probable cause 1 Remedy I l Fuel pressure is too low l Fuel pressure drops during ra...

Page 246: ...e fuel pressure immediately after the engine is stopped The check valve within the fuel pump is not closed Replace the fuel pump 15 Remove all remaining pressure from inside the fuel pipe 16 Disconnec...

Page 247: ...ion l Supplying of Coolant Refer to GROUP 00 Maintenance Service l Installation of Air intake Plenum Refer to GROUP 15 Air Intake Plenum l Checking for Fuel Leakage 03FOO17 Removal steps l l 1 Connect...

Page 248: ...e injector SERVICE POINTS OF INSTALLATION MlBSDAV 10 INSTALLATION OF INJECTOR While turning the injector to the left and right install it to the delivery pipe Check to be sure that the injector turns...

Page 249: ...accelerator cable 2 Connection of air intake hose 3 Connection of vacuum hose 4 Connection of TPS connector 5 Connection of ISC motor connec 6 Connedion of water hose 7 Vacuum pipe assembly 8 Throttle...

Page 250: ...sive has been applied these screws INSPECTION Ml3SHAt l DASH POT INSPECTION Turbo 1 Check the dash pot diaphragm for damage First push up the rod fully and closing tightly the nipple with a finger rel...

Page 251: ...SSEMBLY M13SGAN 4 INSTALLATION OF THROTTLE POSITION SENSOR 1 Set the throttle position sensor to the throttle body as shown in the diagram 2 After turning the throttle position sensor 90 in the clockw...

Page 252: ...OOO7 Removal steps I Fuel gauge cover 2 Fuel pump and fuel gauge unit assembly connector 3 Fuel tank cap 4 Drain plug 5 Splash shield 6 Fuel filler neck protector 7 Vapor hose 8 Fuel filler neck 9 Fue...

Page 253: ...lene 3 A neutral emulsion type detergent OVERFILL LIMITER TWO WAY VALVE Connect a clean rubber hose to the overfill limiter and check for operation Inspection procedure Lightly blow from the inlet fue...

Page 254: ...ighten it to the specified torque being careful that the high pressure fuel hose does not become twisted Caution When tightening flare nut be careful not to bend or twist line to prevent fuel pump fro...

Page 255: ...sure fuel hose connection body side a I 5 High pressure fuel hose connection tuel pump side 03FOOO7 l 6 Fuel pump and fuel gauge unit assembly 03FOOll ILJ I SERVICE POINTS OF REMOVAL MlSUBAC 4 DISCONN...

Page 256: ...BLY Align the three positioning projections of the packing with the holes in the fuel pump and fuel gauge unit assembly 5 4 CONNECTION OF HIGH PRESSURE FUEL HOSE Temporarily tighten the flare nut by h...

Page 257: ...her tank assembly 4 Purge control valve M 5 Fuelvapor hose 6 Canister 7 Vapor pipe assembly l 8 Fuel return hose a 9 Eye bolt 10 Gasket 11 High pressure fuel pipe l a 12 Fuel filter I 13 Eye bolt 14 G...

Page 258: ...part as shown in the illustration Iti 2 If the fuel pipe does not have a stepped part connect the fuel hose to the pipe securely so that it is the standard value Standard value 25 30 mm 1 0 1 2 in 15...

Page 259: ...MlSVBAB 3 9 REMOVAL OF EYE BOLT Remove the eye bolt while holding the fuel filter nut securely Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residu...

Page 260: ...e Plenum l Removal and Installation of the Intake Manifold Refer to GROUP 15 Intake Manifold l I Detonation sensor 20 25Nm SERVICE POINT OF REMOVAL 1 REMOVAL OF DETONATION SENSOR SERVICE POINT OF INST...

Page 261: ...ERATOR CABLE AND ACCELERATOR PEDAL MlSEGAC I Symptom Probable cause Remedy I Throttle valve will not fully open or close Misadjusted accelerator cable Misadjusted automatic speed control cable Broken...

Page 262: ...t the free play of th e inner cable will be the standard value Standard value M T 1 2 mm 04 08 in A T 3 5 mm 12 20 in NOTE J If there is excessive play of the accelerator cable the vehicle speed drop...

Page 263: ...spring 12 Accelerator switch A T 13 Accelerator arm stopper 14 Bolt A T 15 Stopper Ml30A Post installation Operation l Accelerator Cable Adjustment Refer to P 13 156 l Accelerator Switch Adjustment A...

Page 264: ...itch for cruise control Rated load A Clutch switch Rated load A Vacuum pump Type Rated load A Control valve release valve SERVICE SPECIFICATIONS MlBCB Items I Specifications Accelerator cable play mm...

Page 265: ...othly 3 Check each of the cables for excessive play or tension TROUBLESHOOTING QUICK REFERENCE CHART Cruise control system is canceled when cancellation not wanted Or the cruise control system cannot...

Page 266: ...fer to P 13 l 73 I Yes Is the result of input check O K b Check vacuum pump assembly circuit Refer to P 13 l 67 No NOTE If the results of checks on the vacuum pump assemblv circuit and actuator parts...

Page 267: ...pedal is depressed M T It is canceled however when the brake pedal is depressed Malfunction of the ECU Replace the ECU Damaged or disconnected If the input check Repair the harness or wiring of clutc...

Page 268: ...nsor system or replace there is no automatic cancellation the part at that speed Malfunction of the speedometer cable or the speedometer drive gear Non turbo Malfunction of the ECU Replace the ECU The...

Page 269: ...is set to OFF current to relay Ry is interrupted This opens the contact of relay Ry to stop the power supply to the control unit When the switch is released it automatically returns to the neutral po...

Page 270: ...switch Even if cruise operation is canceled the vehicle resumes cruising at the speed set before the cancellation Both when the main switch is set to OFF and when the vehicle speed is reduced to less...

Page 271: ...bination meter it lights as soon as the main switch is set to ON 2 Cruise control CRUISE indicator light During cruise control operation transistor Tr in the control unit is kept in the ON state to ke...

Page 272: ...als generated per rotation of the output gear Since the vehicle speed sensor is of the electronic type the power is supplied through the ignition switch IG Non Turbo The vehicle speed sensor is a reed...

Page 273: ...bly consists of a di aphragm type negative pressure pump that is driven by a DC motor and two solenoid valves control valve and relief valve and is controlled by the control unit as shown in the follo...

Page 274: ...al voltage Terminal No Signal name Condition Terminal voltage 15 Stop light switch When brake pedal is depressed System voltage When brake pedal is not depressed OV h z 15 d El 1 STOP LIGHT xx35 AX R1...

Page 275: ...STARTER L RX AK R1907 9 Inspection of throttle position sensor circuit ENGINE CONTROL UNIT l DOHC OFF 01 w2 3 THROTTLE f iON ml CRUISE CONTROL UNIT KX 95 AC R1308 DESCRIPTION OF OPERATION The throttl...

Page 276: ...tomatic transmis sion Since the accelerator pedal is not operated during vehicle speed control the cruise control unit forces transistor Tr into the OFF state creating the same state as when the accel...

Page 277: ...hicle speed falls more than about 7 km h 4 mph below the set vehicle speed the cruise control unit forces transistor Tr into the OFF state This cancels the overdrive mode because no OD switch ON signa...

Page 278: ...y the following procedure Place the ignition switch in the ON position With the SET switch in the ON state set the main switch to ON In less than 1 O second thereafter set the RESUME switch to ON With...

Page 279: ...is normal the diagnosis code is displayed as described below If a multi use tester is used NORMAL I will be displayed If a voltmeter is used Continuous ON OFF signals will be displayed at 0 5 second i...

Page 280: ...esults can be displayed 07FOO17 I 3 Reading a code Perform the individual input operations according to the input check table and read the codes NOTE 1 When two or more input operations are performed...

Page 281: ...km h 25 mph Vehicle speed sensor circuit normal if code Nos 24 and 25 are displayed 25 Vehicle speed less than approx 40 km h 25 mph 26 M T Clutch switch ON 1 o i sed SELECT lever placed in N positio...

Page 282: ...OUT ENGINE COMPARTMENT 01 Jumper connector 02 Vacuum pump 03 Throttle position sensor 04 Inhibitor switch A T 05 VeTkFo peed sensor INSTRUMENT PANEL AND FLOOR CONSOLE Combination meter Main switch Eng...

Page 283: ...spring 13 Accelerator pedal switch A T LOCATION OF CONTROL UNIT E sQ I LIlll I B Crutse t control unit GROUND POINT 14 Over drive switch A T 15 Cruise control unit 16 l 7 1 Front wiring harness and ju...

Page 284: ...4 Stop the engine and set the ignition switch to OFF 5 Check that the accelerator cable cruise control cable and throttle cable are routed without sharp bends 6 Depress the accelerator pedal to check...

Page 285: ...ontact with intermediate link C back off adjusting nut B the specified number of turns Amount adjusting nut B is to be backed off About one turn inner cable free travel 1 to 2 mm 04 to 08 in Secure th...

Page 286: ...n it was released becomes the driving speed NOTE Even if during acceleration the vehicle speed reaches or exceeds the high limit approximately 145 km h 90 mph acceleration will continue however when t...

Page 287: ...e main switch together with the switch garnish 2 Remove the main switch from the switch garnish 3 Operate the main switch and check for continuity across the individual terminals ILL 2 3 4 5 Press OFF...

Page 288: ...squib connector from the air bag module force the lock outward and pry it with a plain screwdriv er as shown at left so that no undue force will be exerted on the connector when it is removed The rem...

Page 289: ...ch pedal is depressed and that there is no continuity when the pedal is released INHIBITOR SWITCH N POSITION INSPECTION A T 1 Disconnect the connector 2 Check to be sure that there is continuity betwe...

Page 290: ...minals and and across terminals and 0 the operating sounds of the solenoid valves are heard 4 If the solenoid valves are defective replace the vacuum pump assembly Inspection of Motor 1 Disconnect the...

Page 291: ...ion of cruise control cable and link assembly 4 Connection of throttle cable and link assembly 5 Vacuum pump connector l 6 Connection of vacuum hose and vacuum pump 7 Link assembly and vacuum pump 8 V...

Page 292: ...ps of sensors and switches 28 Throttle position sensor 29 Accelerator pedal switch 30 Stop light switch 31 Clutch switch M T 32 Vehicle speed sensor Non turbo Refer to GROUP 54 Meters and Gauges 33 Ve...

Page 293: ...the air bag module force the lock outward and pry it with a plain screwdriv er as shown at left so that no undue force will be exerted on the connector when it is removed 3 The removed air bag module...

Page 294: ......

Page 295: ...URES 7 Cap Pressure Test _ 7 Engine Coolant Concentration Test 7 L Engine Coolant Leak Check 7 Engine Coolant Replacement 7 SPECIFICATIONS _ General Specifications ___ ___ _ ___ __ Lubricant _ _ Seala...

Page 296: ...Range of coolant antifreeze concentration 30 60 Thermostat Valve opening temperature of thermostat C F Full opening temperature of thermostat C F Opening pressure of cap high pressure valve kPa psi Th...

Page 297: ...ilated radiator fins Correct Water leaks Damaged radiator core joint Corroded or cracked hoses radiator hose heater hose etc Faulty cap valve or setting of spring Cracked thermostat housing Loose wate...

Page 298: ...shooting CIRCUIT DIAGRAM FUSIBL RADIATOR FAN ASSEMBLY RADIATOR FAN MOTOR r w F A 04X LINK0 J 0 A j IGNITION J B lx I ti 5 1 A 07X J1 I I ti cp Li 6 m R b3 2L R 1 RADIATOR FAN ASSEMBLY L a ml T X35 AC...

Page 299: ...ING Troubleshootina 14 5 i L 2L R IIIIIIII 1 nI I 1 6 IIIIIIIIIIIII ii II c I1 I G B FUSIBLE LINK _ __ _ _ L AIR CONDITIONER COMPRESSOR LOCK CONTROLLER RADIATOR FAN MOTOR RELAYCLO A 36 A 45 A TSB Revi...

Page 300: ...not rotate when the ail conditioner switch is turned ON l Check the radiator fan motor control relay 4 The radiator fan and condenser fan do not operate in the high speed mode but operate otherwise l...

Page 301: ...installing and removing the tester and when testing not to deform the water outlet fitting 4 If there is leakage repair or replace the appropriate part CAP PRESSURE TEST M14FBAH 1 Use a special tool...

Page 302: ...es with air conditioner 14 Radiator fan motor assembly 15 Upper insulator 16 Radiator assembly 17 Lower insulator Removal steps of radiator fan motor assembly 1 Drain plug 2 Cap 6 Radiator upper hose...

Page 303: ...on RADIATOR FAN MOTOR INSPECTION 1 Check to be sure that the radiator fan rotates when battery voltage is applied between terminals as shown in the figure 2 Check to see that abnormal noises are not p...

Page 304: ...the terminals when the battery power supply is applied to terminal 0 and terminal is grounded When current flows Between terminals 1 3 Continuity When no current flows Between terminals 1 3 No contin...

Page 305: ...INSPECTION M14GDAL l Check that valve closes tightly at room temperature l Check for defects or damage l Check for rust or encrustation on valve Remove if any l Immerse thermostat in container of wat...

Page 306: ...the thermostat with its jiggle valve lined up with the mark on the thermostat housing LJ 2 INSTALLATION OF AIR INTAKE HOSE A Assemble the air intake hose A with its notches arrow marked lined up with...

Page 307: ...r hose Turbo IO Water outlet fitting 11 Gasket 12 Connection of harness 13 Connection of heater hose 14 Connection of water hose A 15 Connection of water hose 16 Connection of water hose Turbo 17 Conn...

Page 308: ...n bolt size are different and caution must be paid to ensure that they are properly installed 22 INSTALLATION OF O RING 21 INLET WATER PIPE Replace the O rings at both ends of the water inlet pipe wit...

Page 309: ...f the Engine Coolant Refer to GROUP 00 Maintenance Service 30 Nm OlFOO38 Removal steps 1 Air hose A Turbo l 2 Air intake hose A Turbo IF 3 Air intake hose B Turbo 4 Connection of radiator upper hose 5...

Page 310: ...re switch is switched OFF when the oil temperature reaches the standard value Standard value 112 118 C 234 244 F Caution The oil used above should be engine oil and should be stirred well while being...

Page 311: ...URES Air Bypass Valve Inspection _ Intake Manifold Vacuum Inspection Supercharging Pressure Control System Inspection 33 9 13 14 27 28 30 31 16 11 6 8 8 7 Supercharging Pressure Relief Solenoid Valve...

Page 312: ...tion type Rubber hangers Exhaust gas turbine type TD04 09BS 6 Waste gate actuator and solenoid valve Air cooled type MVXB Items Intake and exhaust manifolds Distortion oJcnylirrdjer head contacting su...

Page 313: ...as leakage Abnormal noise Probable cause Loose joints Broken pipe or muffler Broken separator in muffler Broken rubber hangers Interference of pipe or muffler with vehicle body Broken pipe or muffler...

Page 314: ...haust Faulty switch Replace switch switch 3 Power window Check continuity between terminals Continuity present No continuity Faulty power relay and of relay window relay Replace power window relay Wit...

Page 315: ...MODE Not less than IOV I 2 T TOUR MODE signal TOUR MODE Not less than IOV Full open posrtion detection srgnal SPORT MODE Not lesi than 5V Engine control unit output signal Control unit ground Control...

Page 316: ...d terminal Between terminals and Continuity Present 15 35 0 20 C 68 F I 3 Make sure that when DC 6V is applied to terminals and of the variable induction control servo connector the induction control...

Page 317: ...AB 1 After the self diagnosis code of MPI system is completely read turn off the ignition switch 2 Disconnect the hose black from the waste gate solenoid valve and connect a three way joint between th...

Page 318: ...onnected Disconnected Open Negative pressure leaks Close Negative pressure is held Open Negative pressure is held COIL RESISTANCE INSPECTION Measure resistance between solenoid valve terminals Standar...

Page 319: ...aner cover 9 Air flow sensor gasket IO Air flow sensor assembly Removal steps of air intake hose Non Turbo 11 Breather hose 12 Air intake hose 13 Resonator Removal steps of air intake hose Turbo 14 Co...

Page 320: ...s slightly clogged remove dust by blowing air from inside of element AIR FLOW SENSOR CHECK For inspection of air flow sensor refer to GROUP 13 Air Flow Sensor Check SERVICE POINTS OF INSTALLATION Ml5F...

Page 321: ...ir hoseG 6 Air pipe A 7 Heat protector F I 8 Air hose B l 9 Air hose E 10 Air pipe B II Air pope C 12 Air hose F I 13 Engine oil cooler 14 Intercooler duct LH l 15 Intercooler left lo 13 Nm 7 9 ft lbs...

Page 322: ...ed by the arrows insert air intake hoses B and C until seated Insert the turbocharger end of air intake hoses B and C completely 15 INSTALLATION OF INTERCOOLER LEFT 12 AIR HOSE F 9 AIR HOSE E 8 AIR HO...

Page 323: ...n of air intake plenum stay 14 Air intake plenum installation bolts 15 Air intake plenum installation nuts 16 Air intake plenum 17 Air intake plenum gasket Throttle body SERVICE POINT OF REMOVAL M15UB...

Page 324: ...of brake booster vacuum hose 8 Harness connecter 9 Connection of clutch booster vacuum hose 10 EGR temperature sensor Vehicles for California 11 EGR valve 12 EGR valve gasket 13 EGR pipe installation...

Page 325: ...UM 1 Check air intake plenum for defect or cracks Replace if defective or cracked 2 Check load negative pressure of drain port Clean if required SERVICE POINT OF INSTALLATION Ml5UoAB3 4 INSTALLATION O...

Page 326: ...um Refer to P 1 5 13 14 l Filling of Engine Coolant Refer to GROUP 00 Maintenance Service l Adjustment of Accelerator Cable Referto GROUP 13 Engine Control Checkina for Fuel Leakage 6 5 2 bs Non turbo...

Page 327: ...r less Limit 0 2 mm 008 in SERVICE POINTS OF INSTALLATION MISMDAH 13 INSTALLATION OF INTAKE MANIFOLD GASKET Install with gasket protrusions in the position illustrated 10 INSTALLATION OF INTAKE MANIFO...

Page 328: ...D 4 Air hose A l 5 Air hose B 6 Air pipe B l 7 Air hose E 8 Air pipe C 9 Drive belt Refer to GROUP 11 Service Adjustment Procedures 10 Alternator assembly Referto GROUP 16 Alternator 11 Engine oil lev...

Page 329: ...compressor wheel for cracking or other damage l Check whether the turbine wheel and the compressor wheel can be easily turned by hand l Check for oil leakage from the turbocharger assembly l Check whe...

Page 330: ...insert securely into the stepped portion of the pipe or until seated Caution Be careful not to allow any foreign matter to get into the hoses or pipes 3 INSTALLATION OF AIR HOSE D 1 AIR HOSE C Aligni...

Page 331: ...val steps 1 Battery 2 Connection of accelerator cable 3 pg t eye l 4 AirpipeA 5 Heat protector F 6 Clutch booster vacuum hose 7 Connection of accelerator cable pedal side I 8 Air intake hose A O 9 Air...

Page 332: ...bly l Check whether or not the waste gate valve remains open If any problem is found replace the part after disassembly OIL PIPE AND OIL RETURN PIPE CHECK Check the oil pipe and oil return pipe for cl...

Page 333: ...n marks at the points indicated by the arrows insert until seated Insert the turbocharger end of air intake hose C completely 4 INSTALLATION OF AIR PIPE A 3 AIR HOSE A Aligning the marks at the points...

Page 334: ...OINTS OF DISASSEMBLY MISLFAC 5 REMOVAL OF SNAP RING Place the compressor cover assembly on the floor with its end surface down and remove the snap ring with pliers Caution During removal hold with a f...

Page 335: ...while installing it as oil leakage could result 6 INSTALLATION OF CARTRIDGE ASSEMBLY 1 Coat the outer circumference of the cartridge assembly O ring with a thin film of engine oil 2 Install the cartri...

Page 336: ...Using a tester apply a pressure of approx 48 kPa 6 8 psi to the actuator and make sure that the rod moves Lj Caution 90 not apply a pressure of more than 61 kPa 8 7 psi to the actuator Otherwise diap...

Page 337: ...lbs 1 Li 2 l 45 Nm 33 ft lbs MSNA 8 Removal steps of exhaust manifold front 1 Drive belt Alternator Refer to GROUP 11 Service Adjustment procedures 2 Alternator assembly 3 Oil level gauge guide 4 Hea...

Page 338: ...25 v Cone disc spring 7lNOll 5 TSB Revision INSPECTION Ml5NCAU3 Check the following points replace the part if a problem is found l Check for damage of cracking of any part SERVICE POINTS OF INSTALLAT...

Page 339: ...RONT Tighten the nuts in the following order 1 Tighten four nuts to 30 Nm 22 ft lbs 1 2 Temporarily tighten the turbocharger to the exhaust manifold 3 Tighten nut to 30 Nm 22 ft lbs 1 4 Tighten nuts a...

Page 340: ...ber hangers 15 Hanger bracket 16 Hanger brackets 17 Rear floor heat protector 13 Nm 13 Nm 9 ftlbs 9 ft lbs 5Nm 4 ft lbs 35hlm 25 ft lbs 18 Catalytic converter and front exhaust pipe installation bolts...

Page 341: ...converter and center exhaust pipe installation nuts 11 Hanger bracket 12 Rubber hangers 13 Nm 9 ft lbs 13 Center exhaust pipe 14 Gasket 15 Rubber hangers 16 Hanger brackets 17 Hanger bracket 18 Rear...

Page 342: ...CTION MlSRCAN l Check the mufflers and pipes for corrosion or damage l Check the rubber hangers for deterioration or damage l Check for gas leakage from mufflers and pipes l Check if the main muffler...

Page 343: ...val and Post installation l Removal and Installation of Rear Side Trim LH Refer to GROUP 52A Trims DSFDO21 Adjusting nuts 05FOO2 SERVICE POINTS OF INSTALLATION MISWDAA 5 INSTALLATION OF CABLE Muffler...

Page 344: ...P E C T I O N ACTIVE EXHAUST SWITCH MllWCAA 1 Remove switch garnish B from the knee protector 05FOO5 2 Operate the switch and check the continuity between the terminals NOTE O O indicates that there i...

Page 345: ...lve Purge Control System Inspection Non Turbo Purge Control System Inspection Turbo Purge Control Valve Turbo Purge Port Vacuum Check 14 14 14 6 10 10 10 6 10 10 9 7 8 9 9 EXHAUST GAS RECIRCULATION EG...

Page 346: ...50 C I 22 F 11 14 at 100 C 212 F l EGR control solenoid valve coil resistance 12 36 44 at 20 C 68 F l I TROUBLESHOOTING Symptom Engine will not start or hard to start Rough idle or engine stalls Prob...

Page 347: ...n Turbo 17 3 M17JA I Li Fuel pressure regulator Vehicle front id California Non Turbo L Light blue R Red B Black 7EM0131 EGR control solenoid valve r c cud valve Canister Fuel pressure regulator v Veh...

Page 348: ...ressure regulator Purge control valve Waste gate actuator TLrbocharger 7EM0133 INSPECTION M17JCAF 1 Referring to the VACUUM HOSES ROUTING confirm that the vacuum hoses are properly connected 2 Check t...

Page 349: ...tilation valve and check that the negative pressure of the intake manifold is felt with finger NOTE At this time the plunger in the positive crankcase ventila tion valve moves back and forth 3 If nega...

Page 350: ...vaporative Emission Control System EVAPORATIVE EMISSION CONTROL SYSTEM COMPONENTS LOCATION TUW pJJ 7FIIl Name Symbol Canister Purge control solenoid valve B A 1 Purge control valve Turbo I c I M17LA I...

Page 351: ...se is discon nected 3 Under the engine conditions shown below check by applying vacuum from a hand vacuum pump When engine is cold engine coolant temperature 60 C 140 F or less When engine is hot engi...

Page 352: ...vacuum pump When engine is cold engine coolant temperature 60 C 140 F or less Engine operating condition Applying vacuum Result Idling 375 mmHg Vacuum is maintained 3 000 rpm 14 8 in Hg When engine is...

Page 353: ...l valve 3 Apply a vacuum of 400 mmHg 15 7 in Hg 1 and check airtightness 4 Blow in air lightly from the canister side nipple and check conditions as follows I Hand vacuum pump vacuum I Normal conditio...

Page 354: ...value 36 44 R at 20 C 68 F AIR FLOW SENSOR ENGINE COOLANT TEMPER ATURE SENSOR AND INTAKE AIR TEMPERA TURE SENSOR M17lBGF To inspect these parts refer to GROUP 13 MPI System Components AIR CONDITIONER...

Page 355: ...ST GAS RECIRCULATION EGR SYSTEM rm MA COMPONENTS LOCATION L i vTT I 4 I Id 3Th 02 I 1 a I J l f An 7FUlOl Name Symbol California Non Turbo Turbo EGR control solenoidvalve 1 EGR temperature sensor Cahf...

Page 356: ...ve pressure rises to 100 mmHg 3 9 in Hg or more 3 Disconnect the three way terminal and connect the hand vacuum pump to the EGR valve 4 When a negative pressure of 230 mmHg 9 1 in Hg 1 is applied duri...

Page 357: ...M17lCYC INSPECTION 1 Remove the EGR temperature sensor 2 Place the EGR temperature sensor in water and then measure the resistance value between terminals 1 and 2 while increasing the water s temperat...

Page 358: ...her aspects of the self diagnosis function refer to GROUP 13 Self diagnosis J CATALYTIC CONVERTER Ml7N REMOVAL AND INSTALLATION Refer to GROUP 15 Exhaust Pipe Main Muffler and Catalytic Converter INSP...

Page 359: ...ROCEDURES Bleeding _ _ _ Check Valve Operation Check AWD _ Clutch Booster Operating Inspection AWD _ _ Clutch Pedal Inspection and Adjustment ____ 17 5 7 6 6 5 10 19 14 8 15 SPECIFICATIONS General Spe...

Page 360: ...sound of interlock switch is produced mm in Clutch pedal clevis pin play mm in Clutch pedaLfree play mm in Distance between the clutch pedal and the firewall when the clutch is disengaged mm in Specif...

Page 361: ...HOOTING tvl21EAAM Symptom Clutch slips Gear shifting failure Probable cause Clutch pedal play too small Excessive wear of clutch disc facing Hardened clutch disc facing or oil on facing Clutch release...

Page 362: ...21 4 CLUTCH Troubleshooting Clutch release fork not operating efective clutch booster AWD 1 TSB Revision...

Page 363: ...and turn the switch for standard clutch pedal height Tighten the lock nut to the specified torque Specified torque 13 Nm 9 ft lbs NOTE When the pedal height is lower than the standard value loosen th...

Page 364: ...draulic system or check the master cylinder release cylinder or clutch proper CLUTCH BOOSTER OPERATING INSPECTION AWD MZlFCAA For simple checking of clutch booster operation carry out the following te...

Page 365: ...on at the intake manifold side A negative pressure vacuum is not created Caution If the check valve is defective replace it as an assembly unit together with the vacuum hose BLEEDING MZlFBAG Whenever...

Page 366: ...4 Clevis pin 5 Return spring 6 Pedal support bracket EIe i pin 9 Turn over spring 10 RodB 11 Bush 12 Clutch pedal shaft 30 Nm 22 ftlbs 9 ft lbs 13 Nm 9 ft lbs Gw 8 7 9 I_ a 9ft lbs k16 08FOO47 13 Clut...

Page 367: ...ch pedal pad 37 Lever assembly 38 Bushing 39 Spacer 40 Support bracket 41 Clutch booster 42 Clutch switch 43 Interlock switch Ohmmeter 08AOO4L INSPECTION MZlPCAL l Check the pedal shaft and bushing f...

Page 368: ...Brake Booster 2 Clevis pin FWD 3 Clutch master cylinder l Adjustment of piston to push rod clearance AWD 4 Sealer 3 AWD 9 Cluch tube 1 5 6 l 7 8 9 IO 11 a l 12 AWD Gk MID 6 removal steps Brake booster...

Page 369: ...ir hose A AWD 8 Vacuum pipe AWD 6 Air cleaner cover air intake hose FWD 9 Battery l 7 Air cleaner cover air intake hose A AWD 10 Battery seat washer tank 8 Vacuum pipe AWD I l I 15 Clutch tube A cFWD...

Page 370: ...careful that the clutch hose does not become twisted 13 INSTALLATION OF CLUTCH RELEASE CYLINDER On AWD vehicles use a flat type short box wrench to tighten the clutch release cylinder mounting bolts 8...

Page 371: ...n D between the master cylin der mounting surface on clutch booster and the push rod end NOTE To obtain D first take measurement with a square placed on the clutch booster Then subtract the thickness...

Page 372: ...FOO41 AWD 8 6 0 Nm 4 0 ft lbs Master cvlinder kit 1 1 09FOl34 14LO193 SERVICE POINTS OF DISASSEMBLY M21NSAE 3 DISASSEMBLY OF PISTON STOP RING FWD 4 SNAP RING AWD Remove the piston stop ring or snap ri...

Page 373: ...ing 7 Cap 8 Bleeder plug 9 Release cylinder 7CLOOOl 6CLO3 SERVICE POINTS OF DISASSEMBLY M2lLBAF 5 DISASSEMBLY OF PISTON AND CUP 1 Remove the corrosion from the piston removal port of the release cylin...

Page 374: ...is scratched LI or shows signs of fatigue or if there is excessive wear of the lip where indicated in the figure SERVICE POINTS OF REASSEMBLY MZlLDAH 5 APPLICATION OF FLUID TO PISTON AND CUP Apply sp...

Page 375: ...4 Fitting Vacuum pipe A removal steps l 5 Air hose A I 6 Air cleaner cover air intake hose A 7 Vacuum pipe A Vacuum pipe B vacuum hose D removal steps 8 Brake booster Refer to GROUP 35 Brake Booster 9...

Page 376: ...HOSE B 1 VACUUM HOSE A If a hose is connected to a pipe with a stepped part insert the hose up to the stepped part a If it is connected to a pipe without any stepped part insert the hose until the ins...

Page 377: ...ND INSTALLATION 21 19 M21GA I I l Removal of the Transaxle Assembly 30 42Nm 1 15 21 Nm 11 15 klbs 2 Removal steps M w 1 Clutch cover assembly e W 2 Clutch disc 3 Return clip I 4 Clutch release bearing...

Page 378: ...bricant MITSUBISHI genuine grease Part No 0101011 or equivalent SERVICE POINTS OF REMOVAL MZlGBAK 1 REMOVAL OF CLUTCH COVER ASSEMBLY 2 CLUTCH DISC Diagonally loosen bolts which attach clutch cover to...

Page 379: ...and if defective replace the clutch disc l Combine the clutch disc with the input shaft and check sliding condition and check for play in the rotating direction If it does not slide smoothly check aft...

Page 380: ...cylinder s push rod and to the push rod hole in the release fork Specified grease MITSUBISHI genuine grease Part No 0101011 or equivalent 4 APPLICATION OF GREASE TO CLUTCH RELEASE BEAR ING FWD Pack t...

Page 381: ...ETER DRIVEN GEAR ASSEMBLY TRANSAXLE ASSEMBLY _____ _ __ TRANSAXLE CONTROL ________ ___ _ __ _ __ __ 36 41 9 10 9 9 9 13 42 6 3 z 6 3 3 45 14 11 TROUBLESHOOTING ___ _______ _____ 8 SUPPLEMENTAL RESTRAI...

Page 382: ...st weed Input shaft I get I 3r 1 st 2nd speed synchro nizer assembly I 3rd beed gear 3rd LIth L speed synchronizer assembly Lth speed gear I 5th speed gear Spacer i 5th speed synchronizer assembly noi...

Page 383: ...play Input shaft rear bearing end play Intermediate gear bearing end play Intermediate gear preload Output shaft preload Differential Differential case preload Differential pinion backlash Limit Speci...

Page 384: ...0504 N MD710458 1 31 0516 E MD706574 1 34 0527 0 M D7 10459 1 37 0539 P MD71 0460 1 40 0551 MD706573 1 43 t 0563 Q MD710461 1 46l 0575 R MD710462 1 4 l 0551 None MD703779 1 5 l 0591 Brown MD703780 1...

Page 385: ...MD700270 1 16 0457 K MD71 0455 1 I9 0468 L MD71 0456 1 22 0480 G MD700271 1 25 0492 M MD710457 1 28 0504 N MD710458 1 31 0516 E M D706574 1 34 0527 0 MD71 0459 0 80 0315 80 MD727661 0 83 0327 83 M D7...

Page 386: ...S AND ADHESIVES Items Transaxle case clutch housing mating surfaces Transaxle case rear cover mating surfaces Differential drive gear bolts Bearing retainer screw flush head screw Reverse brake cone m...

Page 387: ...moval of gears and bearings of input shaft intermediate gear and output shaft and intermediate shaft lock nut M D998808 01 Snap ring installer Installation of input shaft rear snap ring MD998822 insta...

Page 388: ...wear of synchronizer ring and gear cone c Weakened synchronizer spring d Use of inadequate grade of oil a Worn gear shift fork or broken poppet spring b Synchronizer hub to sleeve spline clearance too...

Page 389: ...assification GL 4 or higher C2 3 liters 2 4 pts SPEEDOMETER CABLE REPLACEMENT MUFEALl 1 Correctly insert the adapter into the instrument panel and fasten the new speedometer cable 2 Install the gromme...

Page 390: ...r to GROUP 26 Drive Shaft 2 Using a flat tip screwdriver remove the oil seal d 3 Using the special tool tap the drive shaft oil seal into the transaxle The drive shaft oil seal must be installed in th...

Page 391: ...al steps 1 Air cleaner Air intake hose 2 CD amp Vehicles with CD player I 3 Connection for transaxle control cable assembly Shift lever assembly side 4 Retainer 5 Transaxle control cable assembly 12 N...

Page 392: ...l position 2 With the shift lever on the passenger compartment side in the neutral position turn adjuster on select cable so that select cable end is positioned as shown with reference to lever B of s...

Page 393: ...washer 3 Plain washer 4 Shift lever 5 Bushing 6 Plain washer 7 Wave washer 8 Nut 9 Spring washer IO Plain washer 11 Return spring 12 Bushing 13 Pipe 14 Bolt 15 Lever A 16 Bushing 17 Bushing 18 Snap r...

Page 394: ...09FO112 19 Nm 13 ft lbs M22MA A Removal steps 1 Side under cover 2 Battery 3 Battery seat Washer tank 4 Air cleaner cover Air intake hose 5 Connection for clutch release cylinder 6 Connection for clut...

Page 395: ...bracket 4 17 Drive shaft Left side l 11 Mounting stopper inner shaft assembly 12 Transaxle assembly upper part 18 Drive shaft Right side coupling bolt 19 Transaxle stay Front bank side 4 13 Connectio...

Page 396: ...CTION OF LOWER ARM BALL JOINT Using the special tool disconnect the lower arm ball joint from the knuckle Caution 1 Be sure to tie the cord of the special tool to the nearby part 2 Loosen the nut but...

Page 397: ...LOWER PART COUPLING BOLT 22 TRANSAXLE ASSEMBLY Support transaxle assembly with a transaxle jack and remove transaxle assembly lower part coupling bolt then lower transaxle assembly SERVICE POINTS OF I...

Page 398: ...5 3 5 ftlbs 11 Disassembly steps 1 Bolt 2 Rear cover 3 Wave spring 4 Screw bolts 5 Reverse brake cone 6 Backup light switch 7 Gasket 8 Poppet plug 9 Poppet spring IO Poppet ball 11 Bolt 12 Speedometer...

Page 399: ...MANUAL TRANSAXLE FWD Transaxle Assemblv EALING AND ADHESION POINTS Adhesive 3M Stud Locking Part No 4170 TFM0016 M ATD Part No 8001 1 TSB Revision I...

Page 400: ...t 31 Restrict ball assembly 32 Gasket 33 Oil seal 34 Bearing outer race l a 35 Spacer 36 Bearing outer race l a 37 Spacer 38 Filter 39 Bearing outer race Sealant MITSUBISHI Genuine Part No 997740 or e...

Page 401: ...ring retainer 54 Intermediate gear assembly 55 Input shaft assembly 56 Output shaft assembly 57 Differential gear assembly 58 Bearing outer race 59 Bearing outer race 60 Oil guide 61 Bearing outer rac...

Page 402: ...CK NUTS 1 Unstake lock nuts of the input shaft and intermediate gear 2 Shift the transaxle in reverse using the control lever and select lever 3 Install the special tool onto the inout shaft 4 Screw a...

Page 403: ...the 4th speed MD998325 01 I I MD998325 01 I I 2010291 3 Remove the shift rail assembly INSPECTION M22MOAB BACKUP LIGHT SWITCH Operate the backup light switch to check continuity with a circuit tester...

Page 404: ...ift sleeve at 4th speed 3 Fit the shift forks of shift rail assembly to groove of sleeves LJ 4 Insert the shift rails into the shift rail holes of clutch housing 5 Turn the shift rails in the directio...

Page 405: ...2 Install the transaxle case and tighten the bolts to specified torque 3 Remove the transaxle case 4 Remove the outer races and remove the solder 5 If solder is not crushed perform steps 1 to 4 with...

Page 406: ...alant to the clutch housing side of the transaxle case Specified sealant MITSUBISHI genuine Part No MD997740 or equiva lent LJ Caution Squeeze out sealant from the tube uniformly with out excess or di...

Page 407: ...step as a spinner handle stopper 5 Loosen the lock nuts 6 Retighten the lock nuts to the specified torque 7 Stake the lock nut I MD998245 01 Spring pir Shift rail 14 INSTALLATION OF SPRING PIN 1 rr tl...

Page 408: ...ER SLEEVE AND HUB l Combine the synchronizer sleeve and hub and check that they slide smoothly l Check that the sleeve is free from damage at its inside front and rear ends l Check for wear of the hub...

Page 409: ...ONIZER HUB 4 SYN CHRONIZER KEY 2 SYNCHRONIZER SPRING 1 Assemble the synchronizer hub and key noting their direction 2 Assemble the synchronizer spring so that its projection may be engaged in the groo...

Page 410: ...ve I 3 Snap ring l l a 4 Taper roller bearing l 4 5 Snap ring 6 Conespring l 7 Subgear 8 4th speed gear 9 Needlebearing l 10 Bearing sleeve II Synchronizer ring l 12 3rd 4th speed synchronizer assembl...

Page 411: ...as illustrated 4 REMOVAL OF TAPER ROLLER BEARING Remove the taper roller bearing together using the special tool as illustrated 18 REMOVAL OF 3RD SPEED GEAR Remove the bearing sleeve 3rd 4th speed syn...

Page 412: ...wear and flaking l Force the synchronizer ring toward the clutch gear and check clearance A Replace if it is out of specification Limit 0 5 mm 02 in SYNCHRONIZER SLEEVE AND HUB l Combine the synchroni...

Page 413: ...LATION OF 3RD 4TH SPEED SYNCHRONIZER ASSEMBLY I Install the synchronizer assembly so that the part that has the small round indentation is in the oil groove at the hub end NOTE If the installation is...

Page 414: ...ion 4 INSTALLATION OF TAPER ROLLER BEARING Install the taper roller bearing over the input shaft using the special tool 3 REASSEMBLY OF SNAP RING 1 Select thickest possible snap ring which can enter t...

Page 415: ...VE 1 Using a special tool fit the bearing sleeve to the input shaft Caution After fitting check that the sleeve flange is closely fit to the bearing 1 INSTALLATION OF TAPER ROLLER BEARING Install the...

Page 416: ...ve I 9 Synchronizer key I I IO 1 st 2nd speed synchronizer hub l 11 Synchronizer ring l 12 2nd speed gear 13 Needle bearing l 14 Taper roller bearing d I 15 Intermediate gear MD998348 01 TSB Revision...

Page 417: ...reuse the bearing removed from the shaft 2 Replace the inner and outer races of the taper roller bearing as a set INSPECTION INTERMEDIATE GEAR l Check the outer surface of the intermediate gear where...

Page 418: ...sleeve and hub and check that they slide smoothly l Check that the sleeve is free from damage at its inside front and rear ends l Check for wear of the hub end surfaces in contact with each speed gear...

Page 419: ...ring has an identification mark 10 INSTALLATION OF lST 2ND SPEED SYNCHRONIZER HUB 9 SYNCHRONIZER KEY 8 lST 2ND SPEED SYNCHRONIZER SLEEVE 7 SYNCHRONIZER SPRING 1 Combine the Ist 2nd speed synchronizer...

Page 420: ...ing 2 After installation of the synchronizer assembly check that the 3rd speed gear rotates smoothly 3 INSTALLATION OF BEARING SLEEVE Install the 1st speed gear and bearing sleeve together over the in...

Page 421: ...trated Caution 1 Do not reuse the bearings removed from the shaft 2 Replace the inner and outer races of the taper roller bearing as a set Disassembly steps l I Taper roller bearing I I 2 Taper roller...

Page 422: ...ork 2 1 st 2nd speed shift rail 3 3rd4th speed shift fork 4 5th reverse speed shift rail l a 5 Interlock plunger 6 3rd 4th speed shift rail 7 Reverse shift lug 201073 Interlock Reverse shift lug SERVI...

Page 423: ...ide gear l 9 Spacer Select 10 Differential case TFM0054 Adhesive 3M Stud Locking _ PartNo 417Ooreqr 130 i40Nnl 94 101 ft lbs Press ti Bearmg SERVICE POINTS OF DISASSEMBLY 3 REMOVAL OF TAPER ROLLER BEA...

Page 424: ...n 2 Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears and turning them 3 Insert the pinion shaft 4 Measure the backlash...

Page 425: ...the entire threads of the bolts and quickly tighten in the order shown to specified torque Specified adhesive 3M Stud Locking Part No 4170 or equivalent Caution If a bolt is reused remove traces of oi...

Page 426: ...Bolt 2 Select lever assembly 3 Select lever shoe 4 Interlock plate bolt 5 Gasket 4 l a 6 Lock pin I 7 Spring pin 8 Neutral return spring 9 Stopper body 10 Control finger 11 Interlock plate 12 Neutral...

Page 427: ...ution When removing the spring pin pull the control shaft in the direction illustrated so that the spring pin will not contact the clutch housing SERVICE POINTS OF REASSEMBLY 17 16 INSTALLATION OF NEE...

Page 428: ...LE AWD GENERAL INFORMATION M22BAAV I i Ist 2nd speed synchronizer assembly Transaxle case 3rd 4th speed synchronizer assembly Input shaft 5th speed gear Center shaft Front differential Viscous couplin...

Page 429: ...ifferential Transfer Speedometer gear ratio driven drive Oil quantity liters qts Transaxle Transfer Specifications W5MGl 0 FNBR 6G72 DOHC Turbo 5 speed transaxle floor shift 3 071 1 739 1 103 0 823 0...

Page 430: ...22 50 MANUAL TRANSAXLE AWD Special T ools SPECIAL TOOLS MZZDA B foreign object entry TSB Revision...

Page 431: ...hicle on a flat level and remove filler and drain plugs to drain transmission oil 2 Pour in fresh transmission oil through filler port Transmission oil Hypoid gear oil SAE 75W 85W con forming to API c...

Page 432: ...al For R H 4 Install the oil seals using the following procedure Using the special tool tap the oil seal into the transaxle Note that there are two types of oil seals one for R H and the other for L H...

Page 433: ...25 Propeller Shaft 2 Using a flat tip screwdriver remove the oil seal 3 Using the special tool tap the drive shaft oil seal into the transfer 4 Apply a coating of the transmission oil to the lip of th...

Page 434: ...removal steps l 1 AirhoseA 2 Air cleaner cover Air intake hose A 3 Vacuum pipe Shift lever assembly removal steps l 1 AirhoseA I 2 Air cleaner cover Air intake hose A l l 4 CD amp vehicles with CD pla...

Page 435: ...STALLATION OF VACUUM PIPE If the vacuum pipe has a stepped part connect the vacuum hose to the pipe securely up to the stepped part as shown in the figure 2 CONNECTION OF AIR CLEANER COVER AIR INTAKE...

Page 436: ...l Supplying of Transmission Oil Refer to P 2351 l Checking Operation of Shift Lever at Each Position l Checking the Operation of Meters and Gauges MUMA B 19 Nm 13 f t lbs OSFOllO 1 Side under cover l...

Page 437: ...e I 15 Mounting stopper 16 Transaxle mount bracket Transaxle side 17 Transaxle assembly lower part coupling bolt 4 18 Connection for tie rod end l 19 Connection for lower arm ball joint 20 Right membe...

Page 438: ...e A Air hose C 4 INSTALLATION OF VACUUM PIPE If the vacuum pipe has a stepped part connect the vacuum hose to the pipe securely up to the stepped part as shown in the figure 3 INSTALLATION OF AIR CLEA...

Page 439: ...UP 15 Exhaust Pipe and Main Muffler 7 09FOOO6 1 Transfer assembly 8 5 61 Sleeve yoke lOGO Gear oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 or higher I 09FOOO8 I 09F...

Page 440: ...sfer oil seal guide Input shaft rear seal cap Center shaft oil seal Air vents breather caps for transaxle and transfer Oil filler plugs for transaxle and transfer Oil drain plugs for transaxle and tra...

Page 441: ...saxle Assembly 22 61 MD99 8812 5 INSTALLATION OF INPUT SHAFT REAR SEAL CAP Install the input shaft rear seal cap 2 INSTALLATION OF TRANSFER CASE OIL SEAL Using the special tool install the transfer ca...

Page 442: ......

Page 443: ...ter Stall Test 43 Diagnosis and Test 22 Element in Use at Each Position of Selector Lever 31 Inspection of Control System 28 Inspection of Electronic Control System Components 32 Oil Pressure Tests 39...

Page 444: ...23 2 AUTOMATIC TRANSAXLE General Information GENERAL INFORMATION CROSS SECTIONAL VIEW MZ3BABW I 1 TFA0540 TSB Revision...

Page 445: ...lon rear Torque l 2 shift valve k I h Transaxld I e 1 11 il valve I 1 Shik control I A ilEjJJBi IIsolenoid valve 6 S3ivcontroI I i sl valve Ex 011 filter J 011 pan m Line pressure Tyue converter and l...

Page 446: ......

Page 447: ...l solerwu alve To lubrrcatron c front To lubrrcatton c rear Reducing L valve II solenoid valve B Pressure control N R control valve Pressure control OFF solenord m Oil pump suction pressure 0 Modulate...

Page 448: ......

Page 449: ...alve To lubrmtl front Torque I31 converter F control valve EX Pressure control I Pressure x t l Y 4 ___ Oil filter Lme relief valve EX Oil pan Line pressure 0 Torque converter and lubrication pressure...

Page 450: ......

Page 451: ...Torque CO Wtei control valv ihlfr rontrol Vllve I k x 11 I PC P Rhln71 JI JPl f i 4 I PUW 2 4 LlrlC r t 1 VBIL B _____ E n I6 S _ t I Y __ II pan LIW pressure Torque cnnvertar and lubrication 1 pressu...

Page 452: ......

Page 453: ...m so1PPoic J 0 00 1 z ic ly V SVI Tc ricat ni i ifrunt c r0 IU II IIOII c irear 1 2 shift alVf3 I I _solsyd valve A ON 1 I oiqvc conve tar control valw 1 111 L1 LIneieii f 0 0 Vd P 0 0 pump Suctlotl p...

Page 454: ......

Page 455: ...lubrlcailarl kari I oiquc corlverler 0 m DO va a 3 x Kickdo rn sewn b 7 J j Shift cct troI 11 solewld valve Es ii m LIW pre55ure Toryue c nveit r and lubr cdt on S E j O l pump SUCtlcn pre3iure Damper...

Page 456: ......

Page 457: ...tl P i i o T r tp r nnverter V llVC lo ILibrlcatlon m To lubricd iw lreari ___ 1 1 J LlllC rel1rf j I plimp Suction pressu e Damper clutch pressure L I pir w w i Modulated line pressuie rorque co l cr...

Page 458: ......

Page 459: ...x lamper ClUtCh ontrol snlenold alvr lo lubrlcatlorl ifront To lubncatinn s Wiil I ON snlewld valve A m 011 pump iUCIIO I pressure u M t ted ne pisss ire Ii Darn ei clutch piessure Damper clutc l cont...

Page 460: ......

Page 461: ...p matlon c Torque converter control 0s valve F Shift control valve I Ex E Ive Pressure control 2 valve Pressure N R control 7 i ___ Oil filter H j I o valve EX 011 pan tro j Ire 0 Oil pump suction pre...

Page 462: ......

Page 463: ......

Page 464: ...3 958 36128 SERVICE SPECIFICATIONS M23CB C mm in d terns Standard value Accelerator switch switching point Sleeve and selector lever assembly end play Transfer driven gear preload Low reverse brake en...

Page 465: ...converter valve 1 3 051 9 0 354 22 6 f 890 9 5 spring Shift control valve spring 0 5 020 5 7 224 26 8 1 055 22 Damper clutch control valve 0 7 028 6 2 244 14 2 t 559 9 5 spring SPACER AND SNAP RING P...

Page 466: ...l 272 9 MD731 745 0 83 0327 83 MD720937 0 86 l 0339 86 MD720938 0 89 t 0350 89 MD720939 0 92 t 0362 92 MD720940 0 95 f 0374 95 MD720941 0 98 t 0386 98 MD720942 1 Ol f 0398 01 MD720943 1 04 l 0409 04 M...

Page 467: ...nt of end clutch end play 1 3 i 051 1 4 055 1 5 059 1 6 f 063 1 7 t 067 1 8 071 1 9 075 2 0 t 0791 2 1 f 083 2 2 t 087 2 3 091 2 4 094 1 05 f 0413 1 30 0512 1 55 0610 1 80 0709 2 05 0807 None Blue Bro...

Page 468: ...23 16 AUTOMATIC TRANSAXLE Special Tools SPECIAL TOOLS M23DA B Reassembly of valve body 1 TSB Revision...

Page 469: ...AUTOMATIC TRANSAXLE Special Tools 23 17 MD998829 Installer adapter 60 Driving of bearing i TSB Revision...

Page 470: ...ATIC TRANSAXLE SDecial Tools Removal and installation of low reverse pnng compressor MD998916 l 01 Kickdown servo wrench adapter MD998916 2 01 Outer sleeve MD998916 3 01 Inner sleeve Kickdown servo TS...

Page 471: ...I If the problem isunusually dirty ATF abnormal noises oil leakage or slippage of the clutch or brakes or an abnormal condition of the transaxle itself disassem ble and repair the transaxle TROUBLESH...

Page 472: ...se 38 Malfunction of transaxle control untt X NOTE indicates items of prlortty during Inspection PSCV Pressure control solenoid valve Abbrewatlons TPS Throttle powon sensor DCCSV Damper clutch control...

Page 473: ...AUTOMATIC TRANSAXLE Troubleshooting 23 21 L 1 i 4 E 7 E c II 1 1 1 lr l 11 1 12 15 2c 2 2 2 21 2 2c 2 2 2 3 3 3 3 3 3 3 3 3 i TSB Revision...

Page 474: ...tic Improper filling can also raise fluid level too high When transaxle has too much fluid gears churn up foam and cause same conditions which occur with low fluid level resulting in accelerated deter...

Page 475: ...hin the control unit l If the number of stored fault codes or fault patterns exceeds ten already stored fault codes will be erased in sequence beginning with the oldest l Do not disconnect the battery...

Page 476: ...Open circuited low oil temperature sensor l Check oil temperature sensor connector l Check oil temperature sensor on bench 16 Short circuited high oil I lMnnM temperature sensor 17 Open circuited high...

Page 477: ...oid valve connector l Check shift control solenoid valve B on bench Short circuited shift control solenoid valve B 45 uuuLNulM Open circuited pressure control l Check solenoid valve connector solenoid...

Page 478: ...speed shift not finish l Check pulse generators A and B on bench l Front clutch slipping l Rear clutch slipping l Check connectors of pulse generators A and B l Check pulse generators A and B on benc...

Page 479: ...Open circulted pulse Fixed at 3rd D 32 generator B or 2nd 2 L 8 3 Open or short circuited Fixed at 3rd shift control solenoid valve A 41 42 84 Open or short circuited Fixed at 3rd shift control soleno...

Page 480: ...below CONTROL SYSTEM INSPECTION TABLE Check Item sensor l Data list l Item No 15 Cold engine before start nglne warming up l Data list l Item No 23 or circuit harness Item No 26 lerator pedal switch l...

Page 481: ...No 47 DCCSV duty l Data list l Item No 49 D range 3rd speed 1 500 rpm t a c h o m e t e r r e a d i n g D range 3rd speed 3 500 rpm tachometer reading D range 3rd speed 1 500 rpm tachometer reading D...

Page 482: ...atron srgnai Power source Ground Ground Accelerator switch Diagnosis output terminal Air conditioner relay signal Engine communication signal Diagnosis control terminal Engine communication signal Pow...

Page 483: ...driver can select and switch to the desired pattern by using the power economy select switch on the center Iconsole The solid lines shown in these shift patterns indicate up shifts and the broken lin...

Page 484: ...l tinuous and smooth temperature sensor 4 1750447 Normal 1 1 LOW temperature side 2 Ground 3 High temperature side I 3 Throttle KCheck the resistance between I p t ion sensor terminals 1 and 4 of the...

Page 485: ...the selector lever at the L position and the engine running at 1 000 rpm check the voltage waveform between terminals 1 1 OOO mVp p or higher Noise iJh171092 f With the selector lever at the L positi...

Page 486: ...the trans axle case and terminal 2 switch ON and OFF and check for I 1 Foreign material caught l between the valve and guide 4 Replace the PCSV Check the resistance between terminal 3 or 4 of the sol...

Page 487: ...ling de press the foot brake firmly Set the selector 3 or D range Stop the engine Let the engine continue idling c I Normal I Improper adjustment of idling Readjust 1 Replace the damper clutch control...

Page 488: ...too low or too aged or disconnected wiring I Solenoid valve connector terminals 1 PCSV 2 DCCSV 3 SCSV A 4 SCSV B 1750338 Standard value 3 fWO 1 Connect 12 V between the trans Sticking is usually at th...

Page 489: ...Continuity exists t tinuity between termrnals 2 and 4 L Continuity exists 4 In the ti D range check for con tinuity between terminals 4 and 6 c Continuity exists I In the 2 range check for con tinuit...

Page 490: ...een the kickdown servo switch terminal Poor contact sticking and the transaxle case NOTE Be sure the brakes are applied during this check 4 Replace the K D servo No continuity switch I Normal I r Disc...

Page 491: ...lect Engme Red g 0 0 0 E 0 0 lever speed Gear K D brake WD brake Front Rear Low Torque posItloll v posltlon pressure pressure pressure clutch clutch clutch reverse converter application release pressu...

Page 492: ...seal ring and D ring of K D servo piston and seal ring a Disassemble K D servo and check seal ring of sleeve and D ring for damage Replace seal ring b Defective valve body assembly or D ring if damage...

Page 493: ...Troubleshootina 23 41 L l Seal ring g J Seal ring I O ring A Yr w 011 seal h 43 D ring D rmg A ring I Seal ring Seal rmg I Front clutch I Seal rmg r I tna cIuIcn Low reverse brake TFA0641 Seal ring T...

Page 494: ...I I I I I I I I I I I I I I I I I I I 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Vehiclespeed km h TFA0570 E range IOC 80 z 6 F 60 E 4 40 5 E 20 0 I 3 e 4 DA I 2000 3000 4000 50...

Page 495: ...tor lever to R position and perform stall test by the same procedure as in foregoing item Stall Speed Above Specification in D If stall speed is higher than specification rear clutch or overrunning cl...

Page 496: ...STEM TROUBLESHOOTING be selected into R from P by depressing brake pedal with ignition key in position other than LOCK n or sagging outer cable shift lot eck and adjust slide lever ide lever and ca Se...

Page 497: ...r inside key cylinder Check slide lever 23 55 Ignition key can be Damaged lock cam A Check and replace lock cam A 2 3 58 turned to LOCK position even with Loose key cylinder cover Check and retighten...

Page 498: ...tick If fluid level is low add automatic transmission fluid until level reaches HOT range Transmission fluid MITSUBISHI PLUS ATF Automatic transmission fluid DEXRON abr DEXRON II Low fluid level can c...

Page 499: ...diately before V groove in adjust rod see illustration on left and tighten special tool Inner Wrench until it contacts lock nut 5 Fit special tool Outer Wrench over the lock nut Turn Outer Wrench coun...

Page 500: ...PRESSURE ADJUSTMENT I Discharge AFT 2 Remove oil pan 3 Remove oil filter 4 Remove oil temperature sensor M23FSAC 5 Press solenoid valve harness grommet catch to push in grommet then remove valve body...

Page 501: ...tain the specified reducing pressure Turn it counterclockwise to increase the pressure Standard value 425 f 10 kPa 60 f 1 psi Oil pressure change for each turn of adjusting screw 45 kPa 6 psi 3 In the...

Page 502: ...the selector lever can be shifted to each position by button operation as shown in the illustration 3 Start the engine and check if the vehicle moves forward d when the selector lever is shifted from...

Page 503: ...position 4 Loosen nut that secures key interlock cable 5 Lightly pressing lock cam A in the direction of arrow lightly push key interlock cable to take up slack and tighten nut to secure key interlock...

Page 504: ...witch body TFA0359 Mounting bolt Section A A Manual control I Switch body 09N0062 Oil skal 1 v 0 o l II 0 0 I I 09K567 09K566 Specified torque 10 12 Nm 7 9 ftlbs 5 Loosen the nut shown in the figure a...

Page 505: ...the adapter into the instrument panel and fasten the new speedometer cable I OQFOO83 2 Install the grommet so that as shown in the illustration the cable attachment part and the projecting part are ho...

Page 506: ...CD player l 5 Connection for transaxle control cable assembly Select lever assembly side 6 Transaxle control cable assembly 7 Clamp 8 Adjuster 09FOO31 Selector lever assembly removal steps 1 Air clea...

Page 507: ...it 11 Knee protector Refer to GROUP 52A Instrument Panel 12 Column cover lower 13 Cover C 14 Cam lever 15 Key interlock cable I 16 Slide lever 17 Cable guide 18 Clamp OQFOO35 Shift lock cable removal...

Page 508: ...STEERING LOCK ASSEMBLY SIDE 14 CAM LEVER 1 Place the ignition key at the LOCK position or keep it removed 2 Install the slide lever key interlock cable and cam lever to the steering lock assembly as...

Page 509: ...ghtly push the key interlock cable to take up slack and tighten the nut to secure the key interlock cable in position 9 Turn the set lever and fit it onto the fixing pin on lock cam A then install the...

Page 510: ...OLD GLg changeover switch connector Cover I Selector knob 2 0 Nm Overdrive control switch button 1 6 ftlbs 13 Overdrive control switch Pin Pushbutton Spring Indicator panel Power PWRVEconomy ECOVHold...

Page 511: ...tent plate for wear l Check the bushing for wear or damage l Check the spring for damage or deterioration POWER PWR ECONOMY ECO HOLD HOLD SWITCH Check for continuity between terminals when the switch...

Page 512: ...ssembly 4 3 Feed hose 4 4 Return hose Vehicles with oil cooler 12 Nm 9 ft lbs Hose assembly removal steps 5 Air cleaner cover Air intake hose 4 6 Hose assembly Tube assembly removal steps 7 Front spla...

Page 513: ...1 Wipe the connection threads and tightly contacting surfaces clean of dust and dirt 2 Secure the oil cooler connector with a spanner to prevent excessive force from being applied to it then loosen th...

Page 514: ...umper 09FO112 Removal steps 1 Side under cover 2 Battery 3 Battery seat Washer tank 4 kiorsteaner cover Air intake l 5 Connection for transaxle control cable 4 6 Connection for oil cooler hose 7 Inhib...

Page 515: ...23 Bell housing cover 4 24 Special bolts 4 25 Transaxle assembly lower part coupling bolt 4 26 Transaxle assembly Post installation Operation l Installation of Front Under Cover Refer to GROUP 51 Fron...

Page 516: ...the torque converter toward transaxle so that it does not remain on the engine side 4 Remove coupling bolt at the bottom of transaxle assembly and lower the transaxle assembly SERVICE POINTS OF IliSTA...

Page 517: ...rust bearing 8 26 Thrust race 9 27 Forward sun gear 28 Planetary carrier asseml 29 Thrust bearing I 0 30 Output flange 31 Oil level gauge 32 Oil filler tube 33 Snap ring 34 Kickdown servo switch 35 Sn...

Page 518: ...2 60 7 I 6 6 Si 6s 63 Idler gear cover 64 Differential bearing retainer 65 Outer race 66 Differential front bearing cap 67 Differential assembly 68 Gasket 69 Differential cover 70 Output bearing retai...

Page 519: ...be used to clean the metalllic parts however be sure to dry them completely with air 5 Clean the clutch disc plastic thrust plates and rubber parts with ATF automatic transmission fluid to pre vent a...

Page 520: ...ody mounting bolts 11 IRemove the oil temperature sensor holder and remove the oil temperature sensor harness from the clamp 12 Press the solenoid valve harness grommet claw to push the grommet into t...

Page 521: ...shaft assembly 16 Remove the detent assembly 17 Remove the differential cover and gasket 18 Remove the differential front bearing cap 19 Remove the differential bearing retainer spacer and outer race...

Page 522: ...mbly TFAOl24 23 Remove the thrust plate 24 Remove the end clutch hub 25 Remove the thrust bearing NOTE The bearing may be adhering to the end clutch hub 26 Pull out the end clutch shaft 27 Remove the...

Page 523: ...hten the lock where it forms over the bolt and remove the bolt 29 Pull off the idler shaft and remove the idler gear and bearing inner race I 30 Remove the spacer 3 l Remove the oil pump bolts 32 Usin...

Page 524: ...and thrust race 34 Holding onto the input shaft remove the front clutch assembly and rear clutch assembly together 35 Remove the thrust bearing 36 Remove the rear clutch hub NOTE The thrust race may...

Page 525: ...emove the kickdown drum 39 Remove the kickdown band 40Enap off the snap ring and remove the kickdown servo switch 41 Using the special tool push in the kickdown servo piston to snap off the snap ring...

Page 526: ...le Assembly 43 Remove the anchor rod 44 Remove the plug and pull out the air exhaust plug 45 Remove the snap ring 46 Using the special tool remove the center support 47 Remove the reverse sun gear and...

Page 527: ...ing return spring reaction plate brake disc and brake plate 50 Remove the screw and remove the rear bearing retainer 51 Snap off the snap ring and remove the output flange I assemblv 52 Remove the out...

Page 528: ...AUTOMATIC TRANSAXLE Transaxle Assemblv 54 Using a sliding hammer remove the outer race 55 Remove oil seals TFA0478 TSB Revision...

Page 529: ...and sliding surfaces before reassembly A new clutch disc and brake disc should be dipped in ATF for more than 2 hours before installation 4 Do not use sealant or adhesive for gaskets 5 When replacing...

Page 530: ...solders are not crushed use larger dia 3 mm or 12 in solders to repeat steps 4 to 6 Measure the thickness of the solders crushed with a micrometer and select a spacer to obtain the specified preload S...

Page 531: ...2 lnstall the bearing retainer with new bolts 23 79 I Thrust earing lO 13 Stake the heads of the bolts 14 Coat thrust bearing lO with petrolatum and affix the bearing to the planetary carrier 15 lnsta...

Page 532: ...4 1 874 1 354 M D 7 0 7 2 7 1 4 4 2 6 M D 7 2 0 7 5 3 5 I 677 12180 2 1 Ii I c I 4 I 2 2 1 8 M D 7 3 1 2 1 2 2 25 3 38 7 1 6 M D 7 0 4 9 3 6 6 i 071 I 524 i 063 48 9 1 925 48 9 I 925 48 9 I 925 48 9...

Page 533: ...ding step into the planetary carrier 18 lnstall the reaction plate brake disc and brake plate Caution If a new brake disc is to be used it should be dipped in ATF for more than two hours 19 lnstall th...

Page 534: ...oat the O rings with ATF and align oil holes LJ 2 Install with care not to allow the wave spring to shift its position 22 Fit the snap ring 23 Using a feeler gauge measure the end play in low reverse...

Page 535: ...ated at the oil supply port indicated by arrows TSB Revision Thrust sher TFA0269 TFAo27 27 Using the special tools press the kickdown servo piston and sleeve into position and fit the snap ring 28 Fit...

Page 536: ...to the rear clutch hub TFA027l Thrust race 6 I TFA0273 32 Assemble the rear clutch hub to rear clutch 33 lnstall thrust race 6 to the rear clutch hub end face 34 lnstall thrust bearing 7 to the kickd...

Page 537: ...the special tool install a new oil pump gasket and oil pump assembly 39 Measure the end play in input shaft If the measurement is out of specification replace thrust race 3 and thrust washer I to obt...

Page 538: ...se the new lock plate for locking Id 42 lnstall the idler gear cover and new gasket 43 lnsert the end clutch shaft with its longer splines facing front Thrust washer 1 45 lnstall the end clutch hub to...

Page 539: ...petrolatum affix the thrust bearing to the end clutch hub 47 lnstall the end clutch assembly 48 Mount a new O ring onto the end clutch cover 49 lnstall the end clutch cover and tighten bolts to speci...

Page 540: ...the solders are not crushed use larger dia 3 mm I2 in solders to repeat steps 51 to 53 54 Measure the thickness of the solders crushed with a micrometer and select a spacer to obtain the specified en...

Page 541: ...ly apply ATF and insert it into the transaxle case 6O Align the groove in manual control shaft with the set screw hole and install the set screw 61 Mount the parking roller support 62 lnstall the oil...

Page 542: ...plate pin into the groove in manual valve temporarily secure the valve body Then install the oil temperature sensor and holder and tighten bolts to speci fication Bolt A 18 mm 71 in Bolt B 25 mm 98 in...

Page 543: ...andard value Approx 16 3 mm 642 in COMPONENT DISASSEMBLY REASSEMBLY PRECAUTIONS M23NEAB GENERAL CLEANING PRECAUTIONS 1 Clean parts and blow the oil passages and oil holes with compressed air to check...

Page 544: ...ing surfaces with ATF before installation 2 Replace all gaskets and O rings with new parts They should not be reused 3 Use petrolatum to secure parts in position TRANSFER SHAFT M23LMAE DISASSEMBLY AND...

Page 545: ...sing the special tool install the bearings to the transfer shaft 11 Nm hQ3LGAL 2 Disassembly steps 1 O ring 2 Reaction shaft support l 3 Steel ball l l 4 Drive gear l 5 Driven gear 6 Snap ring 7 Oil s...

Page 546: ...3 LOCATION OF STEEL BALL Install the steel ball at the location shown 2 INSTALLATION OF REACTION SHAFT SUPPORT I Assemble the reaction shaft support and the pump housing and tighten the bolts by fing...

Page 547: ...AH i DISASSEMBLY AND REASSEMBLY I 1 TFA0422 1 2 3 5 6 l a 1 Snap ring l a 2 Clutch reaction plate l 3 Clutch plate 4 Clutch disc l 5 Clutch pressure plate l l 6 Snap ring 7 Return spring 8 Front clutc...

Page 548: ...clutch reaction plate align the areas where one tooth is missing indicated by I N O T E This ensures that the automatic transmission fluid escapes well and the plate and disc are cooled efficiently 2...

Page 549: ...418 Disassembly steps 1 Seal ring l 2 Input shaft 3 O ring 4 Snap ring 5 Thrust race 6 Seal ring l 7 Snap ring M 8 Clutch reaction plate 9 Clutch disc l 10 Clutch plate 11 Wave spring I l a 12 Snap ri...

Page 550: ...nd reaction plate so that the areas where one tooth is missing indicated by are aligned with each other NOTE This ensures that the automatic transmission fluid escapes 4 well and the plate and disc ar...

Page 551: ...e 4 Clutch disc 5 Clutch plate l 6 Snap ring 7 Washer 8 Return spring 9 End clutch piston 10 Oil seal 11 D ring 12 End clutch retainer 13 Oil seal 8 9 T F A 0 6 0 7 8 7 13 6 5 TFA0608 I SERVICE POINTS...

Page 552: ...1 Ibs If the clearance is out of specification reselect the snap ring to obtain the specified clearance Standard value 0 6 0 85 mm 0 24 0 33 in M23LKAL Disassembly steps 1 Thrust bearing l 2 Rivet l...

Page 553: ...he arrow on its gauge points at a direction as shown 3 INSTALLATION OF WAVED WASHER Install the waved washer to the rivet so that its indentation is placed on the outer race side 2 INSTALLATION OF RIV...

Page 554: ...5 Transferdrivegear 6 Snap ring 7 Output flange 8 Annulus gear TFAO225 SERVICE POINTS OF DISASSEMBLY 3 4 REMOVAL OF BEARING 5 TRANSFER DRIVE GEAR 1 Using the special tool remove the transfer drive gea...

Page 555: ...BEARING 1 Using the special tool press fit the bearings into both sides of the transfer drive gear 2 Using the special tool install the transfer drive gear to the output flange 1 SELECTION OF SNAP RI...

Page 556: ...ear 163025 I 3 Bearing w 4 Lock pin 5 Pinion shaft I 6 Pinion l a 7 Washer l 8 Sidegear I 9 Spacer IO Differential cgse r SERVICE POINTS OF DISASSEMBLY 3 REMOVAL OF BEARING Using the special tool remo...

Page 557: ...nion shaft 4 Measure the backlash between the side gear and pinion Standard value 0 025 0 150 mm OOl 0059 in 5 If the backlash is out of specification select the appropriate spacer and disassemble and...

Page 558: ...al order shown d DISASSEMBLY AND REASSEMBLY M23LOAF 201078 Disassembly steps l 1 O ring 2 Spring pin l 3 Speedometer driven gear 4 Oil seal 5 Sleeve Ls Sli 20107s SERVICE POINTS OF REASSEMBLY 3 INSTAL...

Page 559: ...Y AND REASSEMBLY L 6 1750299 Disassembly steps 1 O ring 2 Kickdown servo 3 D ring 4 Seal ring 5 Lock nut 6 Kickdown servo rod 7 Kickdown servo piston LOW REVERSE BRAKE DISASSEMBLY AND REASSEMBLY Disas...

Page 560: ...lon ball _ l 20 N D plate 21 Block TFA0523 1 Manual valve l 2 Pressure control solenoid valve 3 Damper clutch control solenoid valve l 4 Shift control solenoid valve A l a 5 Shift control solenoid val...

Page 561: ...Torque converter control spring 28 Torque converter control valve 29 Adjusting screw 40 Rear end cover 41 Shift control plug B l 42 Stopper plate 43 Shift control valve 30 Regulator spring 44 31 Regu...

Page 562: ...clutch spring 51 End clutch valve 52 End cover 53 Damper clutch control sleeve 54 Damper clutch control valve 55 Damper clutch control spring 56 N R control valve 57 N R control spring 58 Adjusting sc...

Page 563: ...ER VALVE BODY SUB ASSEM BLY Install the special tool and secure the upper separating plate and intermediate plate with eight mounting bolts Then remove the special tool 16 INSTALLATION OF OIL FILTER 1...

Page 564: ...and then remove the special tool 5 4 3 2 INSTALLATION OF SOLENOID VALVE ASSEM BLY Install the solenoid valves as shown Solenoid valve Shift control solenoid valve A Shift control solenoid valve B Damp...

Page 565: ...L L E R SHAFT CONTENTS M25AA I PROPELLER SHAFT 3 Lubricants 2 I SPECIAL TOOL Service Specifications 2 3 SPECIFICATIONS TROUBLESHOOTING 3 2 General Specifications Noise and Vibration at High Speed 2 N...

Page 566: ...ed type 16 t 63 99 73 3 93 NOTE Propeller shaft length indicates the length between the center points of each joint SERVICE SPECIFICATIONS M25CE d Items Limit Propeller shaft runout Dial indicator rea...

Page 567: ...art Worn journal bearing Worn sleeve yoke spline Loose propeller shaft installation Replace Retighten Noise and vibration at high speed Unbalanced propeller shaft Worn journal bearing Replace Replace...

Page 568: ...foreign objects into the transfer 4 REMOVAL OF SPACER The number of spacers necessary may differ from one location to another front rear right left Record the number of spacers used to ensure correct...

Page 569: ...Caution M25GOAP Be cautious to avoid damage to the oil seal lip of the transfer 2 Install the propeller shaft to the companion flange with the mating marks properly aligned Caution Tighten installatio...

Page 570: ...Disassembly steps I I Front propeller shaft assembly I 2 Self locking nut 3 Companion flange a l 4 Center bearing assembly I l 5 Center propeller shaft assembly 6 Snap ring l 7 Boot band I 8 Lobro jo...

Page 571: ...E Put mating marks on the companion flange and the center propeller shaft before removing the companion flange 4 REMOVAL OF CENTER BEARING ASSEMBLY First remove the center bearing bracket and then rem...

Page 572: ...a puller commercially avail able NOTE When changing the grease on the Lobro joint assembly wipe off the grease and clean the outer and inner races cage and balls 4 If the outer race cannot be removed...

Page 573: ...TER BEARING ASSEMBLY 14 COMPANION FLANGE 13 SELF LOCKING NUT 1 Install the bearing in the rubber mount groove of the center bearing bracket 2 Install the center bearing assembly to the rear propeller...

Page 574: ...he cage are all on the same side Also ensure that the relative positions of the inner and outer races are as shown in the illustration 4 Install the remaining balls in their original positions 5 Check...

Page 575: ...to remove grease if present from around the bosses Grease obstructs the ventilation air passage 5 INSTALLATION OF CENTER PROPELLER SHAFT ASSEMBLY Install lining up the mating marks on the center prop...

Page 576: ......

Page 577: ...RIVE SHAFT _ 11 S P E C I F I C A T I O N S _ _ 2 HUB AND KNUCKLE General Specifications 2 6 Lubricants 2 i SERVICE ADJUSTMENT PROCEDURES 5 Service Specifications 2 Hub End Play Inspection 5 TROUBLESH...

Page 578: ...it ball bearing B J T J 419 16 5 391 15 4 M26CB A terns standard value Setting of T J boot length mm in L H R H Limit Hub end play mm in Wheel bearing starting torque Hub starting torque Nm in lbs Spe...

Page 579: ...MB990998 01 Front hub remover and installer Removal or press in the front hub FWD Measurement of front hub unit bearing rotation starting torque AWD of the hub FWD M B990955 01 Oil seal installer MB9...

Page 580: ...01 M B990938 01 Removal and installation of center bearing MB990930 01 MB990932 01 M 8990938 01 MB990925 01 Tool number Installer disc O D mm in I MB990926 01 MB990927 01 MB990928 01 M B990929 01 MB99...

Page 581: ...ion Abnormal wear play or seizure of center bearing Abnormal wear play or seizure of wheel bearing Loose wheel nut Malfunction of front suspension and steering Remedy Replace Replace Adjust or replace...

Page 582: ...ftlbs l l F O 0 2 6 Removal steps 4 1 Front speed sensor connection Vehicles with A B S l 2 Cotter pin 4 l 3 Drive shaft nut 4 4 Caliper assembly 5 Brake disc 6 Front hub unit bearing 7 Dust shield 4...

Page 583: ...oving the vehicle temporari ly secure the wheel bearing by using the special tools MB990998 01 etc 4 REMOVAL OF CALIPER ASSEMBLY Remove the caliper assembly and suspend it with wires 8 DISCONNECTION O...

Page 584: ...lding the special tool bolt tighten its nut to 200 to 260 Nm 145 to 188 ft lbs 3 Turn the hub to cause grease to distribute evenly over the bearing 4 Measure the rotation starting torque of the hub Li...

Page 585: ...e and front hub 2 Secure the knuckle in a vise 3 Tighten the nut of the special tool and remove the hub and rotor from the knuckle Caution 1 Be sure to use the special tools 2 If the hub and knuckle a...

Page 586: ...contact surfaces 3 With the wheel bearing inner race removed press in the bearing by using the special tools 4 Install the wheel bearing inner race to the wheel bearing 6 INSTALLATION OF OIL SEAL HUB...

Page 587: ...EAL DRIVE SHAFT SIDE Drive the oil seal drive shaft side into the knuckle until it contacts the snap ring Apply multipurpose grease to the lip of the oil seal M26aA Pre removal and Post installation 6...

Page 588: ...pecial tool disconnect the lower arm ball joint from the knuckle Caution 1 Be sure to tie the cord of the special tool to the nearby part 2 Loosen the nut but do not remove it 5 DISCONNECTION OF TIE R...

Page 589: ...n l Check the ball joints for wear or operating condition l Check the spline part for wear or damage SERVICE POINT OF INSTALLATION M26QLlAR 2 INSTALLATION OF DRIVE SHAFT NUT 1 Be sure to install the w...

Page 590: ...Dust shield 8 Bracket assembly l a 9 Dust seal outer 10 Dust seal inner w W 11 Center bearing 12 Center bearing bracket 13 Circlip M26QE 0 0 2 8 Bearing Dust Seal Repair Kit Bracket Assembly Repair Ki...

Page 591: ...in half for use respectively at the joint and inside the boot Special grease is used to lubricate the joint Do not mix old and new grease of different types of grease Grease Repair kit grease FWD 145...

Page 592: ...special tool to remove the inner shaft from the center bearing bracket 11 REMOVAL OF CENTER BEARING Use the special tools to remove the center bearing from the center bearing bracket 17 REMOVAL OF T...

Page 593: ...Wrap vinyl tape around the splines on the drive shaft and then install the R J boots and T J boots in that order 11 K03 2 Fill the inside of the B J and B J boot with the specified grease Specified gr...

Page 594: ...NSTALLATION OF CENTER BEARING 1 Apply multipurpose grease to the center bearing and inside the center bearing bracket 2 Use the special tools to press fit the center bearing into the center bearing br...

Page 595: ...FT ASSEMBLY 1 Apply multipurpose grease to the inner shaft spline then press fit it into the T J case 2 Using the special tool press the seal plate into the T J case TSB Revision 3 Fill the specified...

Page 596: ...LLATION OF T J BOOT BANDS Set the T J boot bands at the specified distance in order to adjust the amount of air inside the T J boot and then tighten the T J boot band securely d Standard value 85 3 mm...

Page 597: ...alants and Adhesives 7 Service Specifications 7 TROUBLESHOOTING 11 Axle Shaft Grease leakage Noise while wheels are rotating Differential Limited Slip Differential Abnormal noise during driving or gea...

Page 598: ...E SPECIFICATIONS Items Limit Wheel bearing end play mm in Rear hub rotary sliding resistance N Ibs Rear hub rotary sliding torque Nm ft lbs Specifications 0 05 l 002 or less 31 7 or less 1 8 1 30 or l...

Page 599: ...to within the limit REAR HUB ROTARY SLIDING RESISTANCE TOR QUE INSPECTION M27FFAD 1 Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack 2 Release the parking bra...

Page 600: ...OVAL OF REAR SPEED SENSOR VEHICLES WITH ABS Caution Be careful when handling the pole piece at the tip of the speed sensor and the toothed edge of the rotor so as not to damage them by striking agains...

Page 601: ...XLE FWD _ _ Rear Axle Hub 27 5 SERVICE POINT OF INSTALLATION tu27MDAG 5 INSTALLATION OF WHEEL BEARING NUT After tightening the wheel bearing nut align with the spindle s indentation and crimp 1 TSB Re...

Page 602: ...ifferential gear type and configuration Side gear Pinion gear Number of teeth Drive gear Drive pinion Side gear Pinion gear Bearing O D x I D mm in Side Front Rear Specifications Semi floating type 35...

Page 603: ...h rust prevention oil 0 3 0 5 3 4 New part reusable part gear oil application 0 15 0 25 1 2 Limit Rear axle total backlash mm in 5 2 Drive gear runout mm in 0 05 002 Rear wheel bearing end play mm in...

Page 604: ...27 8 REAR AXLE AWD Special Tools SPECIAL TOOLS MZ DA MB990799 01 TSB Revision...

Page 605: ...REAR AXLE AWD Special Tools 27 9 Removal of the drive pinion rear bearing inner remover step plate MB99081 O 01 Side bearing puller Removal of the drive pinion TSB Revision...

Page 606: ...of side bearing inner race Press fitting of the drive pinion oil seal Installation of drive pinion rear bearing outer race Installation of drive pinion front bearing outer race M B990932 01 MB990935...

Page 607: ...s take all possibilities into consideration and confirm the source of the noise Abnormal noise when cornering Gear noise Damaged differential gears Damaged pinion shaft Insufficient gear oil quantity...

Page 608: ...nsufficient gear oil quantity Replace Replenish In the event of seizure disassemble and replace the parts involved and also be sure to check all components for any irregularities and repair or replace...

Page 609: ...ove the differential carrier assembly and adjust the backlash Refer to P 27 26 GEAR OIL LEVEL CHECK M27FCAG 1 Remove the filler plug and check the oil level 2 The oil level is sufficient if it reaches...

Page 610: ...7 Nm 6 in lbs or less 4 If the rotation starting torque exceeds the standard value check the tightening torque of the axle shaft companion flange If it is normal replace the bearing LIMITED SLIP DIFFE...

Page 611: ...ompanion flange l 8 Axle shaft assembly l 9 Rear rotor Vehicles with A B S l 10 Outer bearing a l a 11 Dust shield l a 12 Dust shield 13 Axle shaft l 14 Oil seal l I 15 Inner bearing llN0021 llA0325 I...

Page 612: ...the axle shaft 10 REMOVAL OF OUTER BEARING 1 1 DUST SHIELD Remove the outer bearing and dust shield concurrently from the axle shaft 14 REMOVAL OF OIL SEAL 15 INNER BEARING With the special tool remo...

Page 613: ...l lip 12 INSTALLATlOkl OF DUST SHIELD Orienting the dust shield as shown in the illustration and using the special tool press fit the dust shield until it contacts the axle shaft shoulder NOTE When ta...

Page 614: ...ange 5 INSTALLATION OF SELF LOCKING NUT With the special tool secure the axle shaft and tighten the companion flange self locking nut DRIVE SHAFT REMOVAL AND INSTALLATION M27JA 55 65 Nm Removal steps...

Page 615: ...o ensure that the differential carrier oil seal is not damaged by the drive shaft spline 2 The right drive shaft for models equipped with the LSD having a VCU has a two part serration Be very careful...

Page 616: ...ir kit llNOO2 B J repair kit 11 NO024 T J repair kit M27JD llNOO22 Disassembly steps w 1 T J boot band large e 2 T J boot band small 3 T J case a 4 Snap ring w 5 Spider assembly II 6 T J boot l 7 B J...

Page 617: ...boot a half to each as a rule Special grease is used for the joint Do not mix old grease with new or mix different types Grease Repair kit grease Quantity to use 125 g 4 41 oz Caution _ Apply all of...

Page 618: ...B J boots are not damaged when they are removed 2 Withdraw the T J and B J boots from the drive shaft 10 REMOVAL OF GREASE FROM B J Wipe out the grease from the B J Caution Do not disassemble the B J...

Page 619: ...re the boot bands Caution 1 The boot bands should be tightened with the drive shaft at a 0 joint angle 2 The B J boot band and T J boot band are identified by the identification number stamped on the...

Page 620: ...n of Main Muffler Refer to Group 15 Exhaust Pipe and Muffler 24Nm 17 ft lbs 90 Nm 65 ft lbs 4 lIl8 c 90 Nm 65 ft lbs 63 i i f 43 51 ft lbs 90 Nm 65 ftlbs 55 65Nm 40 47 fklbs 22 25 ft lbs 90 Nm 65 ft l...

Page 621: ...n e c t i o n 3 Support the propeller shaft with wire 7 REMOVAL OF DIFFERENTIAL CARRIER Holding the bottom of the differential carrier and removing the rear wheel oil pump through the mounting hole r...

Page 622: ...AJ Hold the working base in a vice and attach the differential carrier to the working base FINAL DRIVE GEAR BACKLASH With the drive pinion locked in place measure the final drive gear backlash with a...

Page 623: ...n the normal direction and then once in the reverse direction while applying a load to the drive gear so that the revolution torque approximately 2 5 3 0 Nm 28 33 in lbs is applied to the drive pinion...

Page 624: ...g from insuffi cient pinion height ectdb e 5 2 3 4 I 2 3 4 The drive pinion is positioned too close to the center of the drive gear Decrease the thickness of the pinion height adjusting shim and posit...

Page 625: ...9 Drive gear for 4WS 4 10 Drive gear 11 Spring pin for 4WS 4 12 LSD case refer to P 2759 4 13 Self locking nut 14 Washer 4 4 4 4 4 64 1 11 FO032 15 Drive pinion assembly 16 Companion flange 17 Drive p...

Page 626: ...ht and left hand side bearing outer races for correct reassembly 2 Use a spacer approx 30 mm I 18 in long 10 mm I 39 in wide and 1 to 2 mm 04 to 08 in high made of copper sheet or the like to prevent...

Page 627: ...nner race by using the special tools 22 REMOVAL OF OIL SEAL 23 DRIVE PINION FRONT BEARING Drive out the drive pinion front bearing from the gear carrier 24 REMOVAL OF DRIVE PINION REAR BEARING OUTER R...

Page 628: ...on rear bearing inner race 9 Drive pinion spacer l Drive pinion preload adjustment 10 Drive pinion front shim 11 Drive pinion assembly 12 Drive pinion front bearing inner race 13 Oil seal 14 Companion...

Page 629: ...4170 or equivalent Spring pin Djive gear View A ilA0262 l l A 0 2 6 1 SERVICE POINTS OF REASSEMBLY M27UBG 1 INSTALLATION OF SPRING PIN FOR 4WS Tap the spring pin into the differential case to the posi...

Page 630: ...y the following procedures 1 Install special tools and drive pinion front and rear bearing inner races on the gear carrier in the sequence shown in the illustration NOTE Apply a thin coat of multipurp...

Page 631: ...ve pinion front shim s between the drive pinion spacer and the drive pinion front bearing inner race 2 Tighten the companion flange to the specified torque by using the tools NOTE Do not install the o...

Page 632: ...the special tools 8 Measure the drive pinion rotation torque with oil seal to verify that the drive pinion rotation torque complies with the standard value Standard value Bearing classification Bearrn...

Page 633: ...inner races to the differential case by using the special tool FINAL DRIVE GEAR BACKLASH ADJUSTMENT 1 Using the special tool temporarily tighten the side bearing nut until it is in the state just bef...

Page 634: ...k the drive gear and drive pinion for tooth contact If poor contact is evident make adjustment Refer to P 27 28 7 Measure the drive gear runout at the shoulder on the reverse side of the drive gear Li...

Page 635: ...gauge INSPECTION BEFORE DISASSEMBLY M27NFAA 1 CHECKING THE DIFFERENTIAL GEAR BACKLASH 1 Secure the differential case assembly in a vise so that the differential side gear right is facing upward Cauti...

Page 636: ...learance in the thrust direction of the side gear is not within the standard value range remove differential case A and make the adjustment by adjusting the thickness of the thrust washer left SERVICE...

Page 637: ...3 SELECTION OF THE THRUST WASHER LEFT If the differential side gear and pinion mate gear have been replaced select the thrust washer left by following the steps below 1 Wash the differential side gea...

Page 638: ...e gear right does not rotate Differential gear backlash Standard value clearance in thrust direction of side gear 0 03 0 09 mm 0012 0035 in NOTE If the clearance in the thrust direction of the side ge...

Page 639: ...NG 3 Tire Inflation Pressure Check 4 Bald Spots Tire Wear Check 4 Cracked Treads Wheel Runout Check 4 Feathered Edge SPECIFICATIONS 2 Rapid Wear at Center General Specifications 2 Rapid Wear at Should...

Page 640: ...00 29 DOHC T C 245145ZR 17 Aluminum type 17 x 8 5J 46 1 8 220 32 200 29 Spare wheel Tire size T125190D16 T135 90D16 Wheel size l6x4T l6x4T Amount of wheel offset mm in 46 1 8 46 1 8 Tire inflation pre...

Page 641: ...WHEEL AND TIRE Troubleshooting TROUBLESHOOTING M31EAAB at center Over inflation or lack of rotation Inspect the camber Adjust the unbalanced wheels wear e front suspension TSB Revision...

Page 642: ...C Measure the tread depth of tires Limit 1 6 mm 06 in If the remaining tread depth is less than the limit replace the tire NOTE When the tread depth of tire is reduced to 1 6 mm 06 in or less wear ind...

Page 643: ...S related components that may have to be removed installed in connection with SRS service or maintenance are indicated in the table of contents by an asterisk WARNING 1 Improper service or maintenance...

Page 644: ...E SPECIFICATIONS M32CB I Items Specifications I Standard value No 1 crossmember Bushing B projection mm in Crossmember Bushing A projection mm in Bushing B projection mm in 7 5 10 5 30 41 7 2 10 2 28...

Page 645: ...per 6 Dynamic damper OlFOO50 3emoval steps SERVICE POINT OF REMOVAL M32GBAK 2 REMOVAL OF CRUISE CONTROL PUMP AND LINK ASSEMBLY Remove the actuator mounting nuts and place the actuator where it will no...

Page 646: ...3 Transaxle mount bracket installation bolt 4 Transaxle mount bracket l 5 Mounting stopper 01 FOO44 INSPECTION M32GCAM2 l Check each insulator for cracks or damage l Check each bracket for deformatio...

Page 647: ...Air hose A Turbo 6 Air intake hose C Turbo l 7 Rear roll stopper bracket and engine connection bolt 8 Rear roll stopper bracket installation bolt 9 Rear roll stopper bracket IO Heat protector Turbo O...

Page 648: ...stment Procedures l Adjustment of the Front Wheel Alignment Refer to GROUP 33A Service Adjustment Procedures l Supplying of Transfer Oil AWD Refer to GROUP 00 Maintenance Service 60 70 Nm 43 51 ft lbs...

Page 649: ...bolt 18 Stopper 19 Rear roll stopper bracket mounting bolt 20 Self locking nut 21 Lower plate 22 Self locking nut 23 Lower plate 24 Crossmember 25 Stopper B 26 Stopper A 27 Bushing B 28 Bushing A NOTE...

Page 650: ...be within 1k5 of the crosswise direction Press in bushings A and B so that the projecting amount of the inner sleeve agrees with the standard value I Standard value No 1 crossmember Bushing B 7 5 10...

Page 651: ...AA A LOWER ARM 8 SPECIFICATIONS 2 General Specifications 2 SERVICE ADJUSTMENT PROCEDURES 4 2 Front Wheel Alignment Service Specifications 4 Wheel Bearing Adjustment 4 STABILIZER BAR 10 SPECIAL TOOLS 3...

Page 652: ...9 09 f 12 335 I 3 13 19 12 Hydraulic cylindrical double acting type 485 k 3 19 09 12 335 2 3 13 19 12 150 5 91 NOTE Option Hard 2 650 360 584 79 Medium 1 650 t 230 363 I 51 Soft 650 f 100 143 22 Hard...

Page 653: ...nsion malfunction vibrates or pulls to Ball joint Adjust orreplace one side Coil spring Wheel alignment Unbalanced or worn tires Adjust or replace Excessive vehicle Broken or deteriorated stabilizer r...

Page 654: ...dard value Inner wheel 33 45 Outer wheel 28 21 CAMBER AND CASTER Standard value Camber 0 IL 30 Caster 3 55 IL 30 Install the special tool by tightening it to the same torque as that applied to the dri...

Page 655: ...Nm 2 33 ft lbs 4 AI c 3 li I 7 I j I I I I I j j 1 r 11 Ii I Removal steps 1 Brake hose tube clamo mountina bolt 2 Brake hose tube clam 3 Fr tSs eed sensor clamp mountmg nut 4 Front speed sensor clam...

Page 656: ...r spring pad 6 Bump rubber 7 Dust shield 8 Front coil spring 9 Strut assembly 12L0254 1 SERVICE POINT OF DISASSEMBLY M33LFAI 2 REMOVAL OF SELF LOCKING NUT 1 Holding the spring upper seat with the spec...

Page 657: ...the notch in the rod to the shaped hole in spring seat 2 Line up the holes in the strut assembly spring lower seat with the hole in the spring upper seat NOTE The job is easily accomplished with a pip...

Page 658: ...arm ball joint to knuckle 5 Lower arm mounting nut 6 Lower arm mounting bolt 7 Clamp mounting self locking nut 8 Clamp mounting bolt small 9 Clamp mounting bolt large 10 Lower arm clamp mounting self...

Page 659: ...ioration or damage l Check the ball joint dust shield for cracks l Check all bolts for condition and straightness CHECKING BALL JOINT FOR STARTING TORQUE Mount two nuts on the ball joint and then meas...

Page 660: ...Member Left Member and Crossmember 36 26 ft lbs Removal steps 1 Tr smission stay B AWD vehicles with automatic transaxle I l a 2 Transfer AWD Refer to GROUP 22 Transfer 3 Stabilizer link 4 Stabilizer...

Page 661: ...yl tape to tape the stabilizer link where shown in the illustration and then install the dust shield to the stabilizer link 4 Secure the dust shield by the clip link At this time make sure that the cl...

Page 662: ......

Page 663: ...ors SRS diagnosis unit SRS warning light aiir bag module clock spring interconnecting wiring Other SRS related components that may have 1 o be removed installed in connection with SRS service or maint...

Page 664: ...orber Type Hydraulic cylindrical double acting type 485 19 1 335 13 2 150 5 9 Expansion Hard Medium Soft Contraction Hard 2 650 584 1 650 364 650 143 1 200 265 Pillow ball type REAR SUSPENSION Items I...

Page 665: ...24 0 356 14 0 407 16 0 159 6 3 203 8 0 1 800 397 1 200 265 550 121 950 209 850 187 850 143 10 37 Pillow ball type M33CB B SERVICE SPECIFICATIONS Rear suspension 1 F W D Items Front suspension Standar...

Page 666: ...a short circuited sensor output line or open circuited sensor power line is suspected 3 The vehicle speed sensor is a sensor associated with attitude controls anti dive anti squat and steering stabil...

Page 667: ...al 5 V No 3 terminal Continuity provided I Yes 1 Is continuity provided across the following areas Between G sensor and ECS control unit Between No 1 terminal and No 54 Between No 3 terminal and No 57...

Page 668: ...y entering simulated vehicle speed to simulate anti roll controls Refer to P 33B 16 N o No 2 3 and 4 terminal voltages up to specification Standard 5 V Yes Is continuity provided across the following...

Page 669: ...and battery and between No 2 terminal of vehicle speed sensor and ground l l Yes J I Nn i 1 Is continuity provided between No 3 terminal of vehicle speed sensor and No 53 terminal of ECS control unit...

Page 670: ...s of F L shock absorber Between No 1 and 13 terminals of R R shock absorber Between No 3 and 12 terminals of R R shock absorber Between No 1 and 16 terminals of R L shock absorber Between No 3 and 15...

Page 671: ...round up to specification Standards No 10 terminal 5 V No 11 terminal Continuity provided Yes Correct harness Check ECS switch Refer to P 33B Yes Replace ECS switch check ECS indicator light for burnt...

Page 672: ...heck by entering simulated vehicle speed from MUT to simulate anti dive control Refer to P 33B 16 Good I c h Disconnect stop light switch con nector and check harness connector f Between No 2 terminal...

Page 673: ...sition sensor and No 59 terminal of ECS control unity II Yes i Correct harness 1 Check throttle position sensor Refer to P 33B 20 Good I I I 1 connector and check harness con nector with ignition swit...

Page 674: ...iagnosis code If the defective portion is not completely repaired it may be impossible to erase the self diagnosis code by the MUT d 3 Perform self diagnosis output check again and check that the self...

Page 675: ...rn ftYrrZ NOTE 1 Control stop warning indication and fixed damping force return to normal when the ignition switch is set to OFF When any of the problems marked occurs if no subsequent problem occurs...

Page 676: ...tive When throttle opening of 30 1 5 V or more lasts for more than 60 seconds with the ignition switch at ON and if there is no input from the vehicle speed sensor during the period it is regarded as...

Page 677: ...onary HARD Tour mode with vehicle stationary SOFT Sport mode with vehicle stationary HARD 4 ACTUATOR CHECK I Using the MUT force drive the actuator and fix the damping force changeover 2 Check service...

Page 678: ...iginal damping force indication SOFT is restored a second later 5 2 Anti Dive Control Function Check 1 Select the Tour mode by the ECS switch 2 Enter a simulated vehicle speed of 100 km h 62 mph from...

Page 679: ...service data items No 61 through 64 change If the simulated vehicle speed is continuously cihanged by the Q and J keys of the MUT however the indications of service data items No 61 through 64 do not...

Page 680: ...ound of the actuator in the shock absorber can be heard each time the control modes are changed by pressing the ECS switch 6 2 Damping Force Check 1 Set the ignition switch to ON ECS indicator Tour ON...

Page 681: ...F 0 I I I I I I 1 NOTE O O indicates that there is continuity between the terminals STEERING ANGULAR VELOCITY SEN SOR M33ZHAB To mount or remove the steering angular velocity sensor refer to GROUP 54...

Page 682: ...ON SWITCH and DAMPING FORCE CHANGEOVER ACTUATOR M33ZCAD To remove or mount the position detection switch and damping force changeover actuator refer to GROUP 33A Strut L J Assembly and GROUP 34 Shock...

Page 683: ...ELECTRONIC CONTROL SUSPENSION ECS ECS Control Unit 33B 21 ECS CONTROL UNIT M33ZXAD REMOVAL AND INSTALLATION Removal steps 12FOO98 I Cargo floor box R H 2 Lid 3 ECS control unit TSB Revision...

Page 684: ...ELAY 1 F CATED 1234 m 5578 __ p7zERmj FUSIBLE LINK J B I 8 1GA I ELECTROMIC CONTROL SUSPEldSiOi d CONTRllL Ui dIT m 1 2 123E 1 II 1 u2 m I I JUIvPER B CONNECTOR LEd 1254 m M p 10 ___ _ lt f u 1 0 iLL...

Page 685: ...ON IG2 SV el ENGINE f BTROL GND Ifi 1234 J333 2 56 78 64 61 72 I I CL L2 c I J m4 THROTTLE EI ON 4 1 jV f I i ss 2 ___ _ _ 2 3 54 55 F p Ll cl w 11 4 3 __ I ni m CL IGNITION SWITCH IG1 18Bl NON TURBO...

Page 686: ...5Y l 3 5 z 3 5 pl Q gfz i TG 4 r 4 q y GNE I y l 1 5r I 114 ii0 d i L c Y 1 I 5j A KlqqEL I I i FFR 1112 m r fGiz j I i iI A I 7 j 1 ii 1 2 3456 3456 L 4 3 I r I5 3 ii n L f y w I I A tk ii j n A ___...

Page 687: ...34 TRAILING ARM _ _ _ 30 TROUBLESHOOTING _ 22 UPPER AND LOWER ARM t 27 FWD REAR AXLE HUB 17 REAR SUSPENSION ASSEMBLY 7 SERVICE ADJUSTMENT PROCEDURES 5 Rear Hub Rotary sliding Resistance Torque Inspec...

Page 688: ...type 515 f 3 20 2 i I 515 3 20 2 f I 356 3 14 0 1 356 Ifr 3 14 0 k I 159 6 3 159 6 3 1 000 150 220 33 Hard 1 800 250 397 f 55 Medium 1 200 rt 170 265 37 Soft 550 90 121 f 20 550_ 80 121 18 Hard 950 1...

Page 689: ...REAR SUSPENSION FWD Special Tools SPECIAL TOOLS 34 3 M34DA A pring compressor ompressfon 0 member 1 TSB Revision 1...

Page 690: ...rms deformed or damaged Crossmember deformed or damaged Excessive tire inflation pressure Malfunction of shock absorber Weakpr broken springs Stabilizer bar and or stabilizer link deformed or damaged...

Page 691: ...lockwise 0 camber Right wheel Clockwise 0 camber One graduation changes camber by about 15 TOE IN Standard value 0 5 2 5 mm Ol 09 in To adjust toe turn the assist link mounting bolts on crossmem ber s...

Page 692: ...e to within the limit REAR HUB ROTARY SLIDING RESISTANCE TOR QUE INSPECTION M34FCAC 1 Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack 2 Release the parking br...

Page 693: ...ssmember mounting nut I 14 Rear suspension assembly NOTE indicates parts which should be temporarily tightened and then fully tightened with the vehicle in the unladen condition Post installation Oper...

Page 694: ...rioration d Press out Press fit 12N009f CROSSMEMBER BUSHING REPLACEMENT M34GTAF 1 Using the special tool remove and press fit the bushing 2 When press fitting the bushing apply soapsuds to it and posi...

Page 695: ...g bolt and nut 4 Upper arm Lower arm removal steps 5 Lower arm mounting bolt and nut l 6 Self locking nut 7 Lower arm Assist link removal steps 8 Assist link mounting bolt and nut 4 9 Self locking nut...

Page 696: ...2NOlOl CHECKING OF BALL JOINT FOR STARTING TORQUE Mount two nuts on the ball joint and then measure the ball joint starting torque Standard value 2 9 Nm 17 78 in lbs BALL JOINT DUST COVER REPLACEMENT...

Page 697: ...amp bolt 4 Rear brake disc 5 Hubcap 6 Wheel bearing nut 7 Hub assembly 8 Parking brake cable clamp bolt I I 9 Parking brake cable end Refer to GROUP 36 Parking Brake IO Rear speed sensor clamp bolt AB...

Page 698: ...th a rope to prevent it from dropping INSPECTION M34TCABl l Check trailing arm for cracks and deformation l Check bushing for cracks deterioration and wear TRAILING ARM BUSHING REPLACEMENT M34TEABl Us...

Page 699: ...hock absorber lower mounting bolt 6 Shock absorber NOTE indicates parts which should be temporarily tightened and then fully tightened with the vehicle in the unladen condition 45 Nm 33 ft lbs 12FOO87...

Page 700: ...n SERVICE POINTS OF REASSEMBLY M34GPAC 11 INSTALLATION OF COIL SPRING 1 Use the special tool MB990987 01 to compress the coil spring and insert it in the shock absorber 2 Align the edge of the coil sp...

Page 701: ...cup A 11 Stabilizer rubber 12 Stabilizer bar 5 t I Z 4 l FOlOO 1210241 INSPECTION MWBACl l Check the bushing for wear and deterioration l Check the stabilizer bar for deterioration or damage l Check...

Page 702: ...SELF LOCKING NUT 4 SELF LOCKING NUT I Hold the stabilizer link ball studs with a wrench and install the self locking nut A 2 Holding the stabilizer link with a wrench tighten the self locking nut B so...

Page 703: ...AR SPEED SENSOR VEHICLES WITH ABS Caution Be careful when handling the pole piece at the tip of the speed sensor and the toothed edge of the rotor so as not to damage them by striking against other pa...

Page 704: ...SION FWD Rear Axle Hub Spindle _ 14NOOOt SERVICE POINT OF INSTALLATION M34MDAG 5 INSTALLATION OF WHEEL BEARING NUT After tightening the wheel bearing nut align with the spindle s indentation and crimp...

Page 705: ...rical double acting type 610 2 3 24 0 f I 407 f 3 16 0 2 I 203 8 0 Hard 1 800 250 397 55 Medium 1 200 rtr 170 265 t 37 Soft 550 f 90 121 20 Hard 950 140 209 t 31 Medium 850 2 130 187 29 Soft 650 f 100...

Page 706: ...34 20 REAR SUSPENSION AWD Special Tools SPECIAL TOOLS M34DA B remover an MB990241 01 TSB Revision...

Page 707: ...REAR SUSPENSION AWD Special Tools 34 21 I id TSB Revision...

Page 708: ...34 22 REAR SUSPENSION AWD Troubleshooting TROUBLESHOOTING M34EA B Trailing arms deformed or damaged Crossmember deformed or damaged TSB Revision...

Page 709: ...A0083 17FllO75 TOE IN Standard value 0 5 t 2 5 mm Ol 09 in To adjust toe turn the trailing arm mounting bolts on the crossmember side on both sides the same amount NOTE Left wheel Clockwise toe in Rig...

Page 710: ...ft coupling bolt and nut Post installation Operation l installation of the Center Exhaust Pipe and Main Muffler Refer to GROUP 15 Exhaust Pioe and Main Muffler l Installation of the Rear Side Trim Abs...

Page 711: ...the transmission jack requires three persons as the rear suspension assembly is very heavy Assign one person to the differential and one each to the left and right lower arm 3 Apply a wood block to th...

Page 712: ...andard value Dimension A 15 5 mm 59 in Dimension B 2 1 3 7 mm 08 15 in d CROSSMEMBER BUSHING REAR REPLACE MENT M34GTAH 1 Using the special tool remove and press fit the bushing 2 When press fitting po...

Page 713: ...temporarily tighten and then ground the vehicle to torque to specification where the vehicle is empty SERVICE POINTS OF REMOVAL M34SBAC 1 REMOVAL OF SELF LOCKING NUT Using the special tool disconnect...

Page 714: ...INT FOR STARTING TORQUE Mount two nuts on the ball joint and then measure the ball joint starting torque Standard value 2 9 Nm 17 78 in lbs MB991 073 12NOlOl Removal MB991 072 Press fit MB991 072 MB99...

Page 715: ...flush with the lower arm pipe edge SERVICE POINT OF INSTALLATION M34SDAB 7 INSTALLATION OF STABILIZER LINK TO LOWER ARM COUPLING NUT Holding the stabilizer link with a wrench tighten the self locking...

Page 716: ...ble end 8 Parking brake cable clamp bolt 9 Rear speed sensor ABS IO Rear speed sensor cable and parking brake cable bands ABS II Dust shield 12 Self locking nut upper arm 13 Self locking nut lower arm...

Page 717: ...LOCKING NUT LOWER ARM Using the special tool disconnect the ball joint from the knuckle NOTE 1 Do not remove the nut from the ball joint but just loosen it 2 Suspend the special tool with a rope to p...

Page 718: ...etc to turn the portion marked C in the illustration to remove the connecting rod 5 installation of the body special tool should be performed with the screw shaft and guide shaft center lines oriente...

Page 719: ...absorber lower mounting bolt 5 Shock absorber assembly M34NA 6 12FOO86 M34GM B DISASSEMBLY AND REASSEMBLY 20 25 Nm 14 18ft lbs Disassembly steps 1 Cap 2 Piston rod tightening nut Refer to P 34 14 3 ha...

Page 720: ...lizer rubber 5 Joint cup B I 6 Stabilizer link 7 Joint cup A 8 Stabilizer rubber 9 Tie rod end mounting nut IO Parking brake cable bracket mounting bolt 11 4WS prping fixing bolt 4WS 12 Rear shock abs...

Page 721: ...obtain a gap between the rear suspension and body 2 Remove the stabilizer bar INSPECTION M341BACZ l Check the bushing for wear and deterioration l Check the stabilizer bar for deterioration or damage...

Page 722: ...p ring At this time make sure that the clip ring ends are located at a point 90 f 20 with reference to the link axis SERVICE POINTS OF INSTALLATION M34lCAF 6 INSTALLATION OF STABILIZER LINK 2 SELF LOC...

Page 723: ...easurement of Wheel Speed Sensor Output Voltage Proportioning Valve Function Test Rear Brake Disc Run out Check Rear Brake Disc Run out Correction Rear Brake Disc Thickness Check Rear Disc Brake Pad C...

Page 724: ...0 37 Front brakes Type Floating caliper 2 piston Rigid caliper 4 piston ventilated disc M R57W ventilated disc M R66Z Disc effective dia mm in 227 9 0 249 9 8 Disc thickness mm in 24 94 30 1 18 Pad th...

Page 725: ...3 0 65 0 85 026 033 Disc brake drag force tangential force of wheel mounting bolts N Ibs 70 15 4 or less 70 15 4 or less Disc brake dragging torque Nm ft lbs 4 3 or less 4 3 or less Speed sensor s ABS...

Page 726: ...ide of inner shim A inner shim B and outer shim Brake grease SAE J310 NLGI No 1 Guide pin and lock pin sliding part Piston boot inner surface Pin boot inner surface Repair kit grease SEALANTS AND ADHE...

Page 727: ...ce Replace Inadequate contact of pad Correct Brake booster malfunction Correct Auto adjuster malfunction Adjust Clogged brake line Correct Proportioning valve malfunction Replace Increased pedal strok...

Page 728: ...lining parts Correct or replace Disc brakes burred or rusted calipers Clean or deburr Dirty greased contaminated or glazed pad Clean or replace Incorrect adjustment of brake pedal or booster push rod...

Page 729: ...DS Problems related to the anti lock braking system ABS can be classified into two general categories problems in the electrical system and those in the L hydraulic system For problems in the electric...

Page 730: ...ned to the ON ABS warning light remains lit because the valve position the ABS ECU causes the ABS warning relay is OFF light to flash twice in about one second during 3 When the ignition key is return...

Page 731: ...S warning light illuminate when starting to drive the car i Is there one sided braking insufficient CONTINUED ON NEXT PAGE I I Yes Trouble condition One sided braking Insufficient braking force ABS so...

Page 732: ...o P 35 11 1 No trouble codes output and normal codes are displayed No Trouble codes are output Y e s All ABS functions are normal Nor are there stored memory of past trouble code put terminals and the...

Page 733: ...ot be cleared the ECU is currently detecting the trouble and the ABS ECU is in fail safe If it can be cleared the trouble is either temporary or appears only when driving 4 When the trouble codes cann...

Page 734: ...using the MUT the diagnosis and repair vehicle must be stopped 1 Clear memory using MUT l During forced drive using the MUT forced drive No 7 DIAG ERASE in the actuator test is operation is stopped wh...

Page 735: ...warning lights do not light up either fuse is possibility that there is trouble with ABS warning probably blown light or with power to the light id r f ER RELAY 110 h g 6 5 d 2 Et 0 2 ____ EI5 fir4 I...

Page 736: ...m fuse No 11 is broken Yes yl Circuit in combination meter is broken Is there continuity between combination meter No 58 and No 59 terminals7 rT I Faulty1 I r No I Are instrument panel wiring harness...

Page 737: ...Yes Valve relay malfunction b Replace valve relay install the valve relay remove the HU connector and check I Does voltage between the INO I HU harness I Broken harness wire I I 1 1 Repair harness I...

Page 738: ...hen the warning light drive circuit is is not flowing to the ECU short circuited 8 IGNII SWIT Et J B C 151 E COMBINATION METER 1 9 7 ____ _ 1 2 610 2 lizEFg I I c 62 27 J r b L 1 IN IGl 1 ig 158 7 r T...

Page 739: ...ey in the ON position does voltage between ECU connector terminal No 18 and ground indicate the battery voltage I 1 Yes No I Harness wire between power relay and ECU is broken J 1 Repair harness I No...

Page 740: ...Consequently in the START position power is off and the ECU turns the valve relay OFF If the warning light does not illuminate at this time there is trouble in the warning light circuit on the valve r...

Page 741: ...tween the ECU and the warning light the warning light for approximately 1 sec while it light illuminates only when the valve relay is off in performs a valve relay test If there is a break in the the...

Page 742: ...abnormality l Distortion of rotor teeth missing l Low frequency noise interference when sensor harness wire is broken l Noise interference in sensor signal l Sensor output signal is below the standard...

Page 743: ...Z Malfunction of wheel speed sensor Yes Yes 1 I Is the standard value for the gap between the wheel speed sensor and rotor within the range Standard value fi3 0 9 mm LO12 poe288r 0 7 mm LOO8 Yes I Yes...

Page 744: ...ore than 15 minutes without ABS operation l The harness wire for the stop light switch may be open Hint Li If the stop light operates normal the harness for the stop light switch input circuit is brok...

Page 745: ...ted or the harness is If no current flows in the solenoid even if the ECU broken short circuited and then these trouble turns the solenoid ON or if it continues to flow even codes are output ii LJ l E...

Page 746: ...2 i I 1 2 13 1 a 5 16 17 18 Q IIO I 2 13 a i5 6 i7 IQ O Y 2 3 24 6 28 1 2 3 4 5 Remove and check the valve relay I When the valve relay is checked are the following conditions found No 85 No 86 Resist...

Page 747: ...10 5 1 n 7 9 rn E5 u p GEilq 10 3 3 _ ES ECU 2 5 26 4 I 1 1 12 I3 4 15 15 17 13 I g 10 1 12 19114 15 1 17118j ls o l e 3 4 415 2T E o l 5 X35 AK 33533 Does the motor make a noise during MUT forced dri...

Page 748: ...g which the valve relay self check is made again and then goes out I I I OFF u I I I ST ON ACC LOCK 1 14A0594 Yes CONTINUED ON NEXT PAGE No No Trouble condition Major causes Remedy 1 ABS warning light...

Page 749: ...transmitted Remedy Check using flow chart D Refer to P 35 37 Does the ABS warning light illuminate when starting to drive the car Trouble with the motor relay solenoid valve due to self test at start...

Page 750: ...US PAGE 1 I After a test drive use self diagnosis to check Refer to P 35 29 I No trouble codes output and normal codes are displayed No No diagnosis output No Trouble codes are output Yes All ABS func...

Page 751: ...check terminals 2 Read the diagnosis output codes from the ECU memory 3 Clear the diagnosis codes once from memory Refer to P 35 30 If the memory cannot be cleared the ECU is currently detecting the t...

Page 752: ...rom memory ABS ECU system is in fail safe mode when the ABS ECU system is in fail safe mode Proceed to diagnosis and repair l When using forced drive using the MUT the vehicle must be stopped 1 Clear...

Page 753: ...at all there is a strong If other warning lights do not light up either fuse is possibility that there is trouble with ABS warning probably blown light or with power to the light FUSIBLE LINE I L L5 i...

Page 754: ...place the fuse J Yes I T Efg harness connector terminal No 59 and ground indicate battery voltage F Repair harness Circuit in combination meter is broken Is there continuity between combination meter...

Page 755: ...o is valve relay normal Refer to P 35 62 Valve relay malfunction Replace valve relay I Yes Install the valve relay remove the HU connector and check Does voltage between the HU harness uLEm h Repair h...

Page 756: ...stem or when the warning light drive circuit is communicate there is a good possibility that power short circuited is not flowing to the ECU IGNITION SWITCH IG1 Caution l If the trouble code is output...

Page 757: ...ECU connector terminal No 18 and ground indicate the battery voltage Is there continuity between body harness terminals No 9 and No 34 and ground Repair harness v No Is there continuity between body h...

Page 758: ...light does not illuminate at this time there is trouble in the warning light circuit on the valve relay side EfiE 9 B w IGN SW1 J B F COMBINATION METER G R 11 G IN IGl I TSB I Remove the hydraulic un...

Page 759: ...ness between the ECU and the warning light the light illuminates only when the valve relay is off in performs a valve relay test If there is a break in the the valve relay test etc IGNITION SWITCH IG1...

Page 760: ...pection results wheel speed sensor output abnormality are normal if an abnormality cannot be found in l Distortion of rotor teeth missing the sensor circuit displayed as abnormal erase l Low frequency...

Page 761: ...Refer to P 35 57 No Is the resistance value of the wheel speed sensor part normal Standard value 0 8 1 2 kR z Malfunction of wheel speed sensor Yes I LY 14N0127 L 14N0181 1Yes No Check the output of...

Page 762: ...op light switch input l When there is a broken wire or short circuit in the harness for the G sensor system FUSIBLE LINK 4 pilGGRq I 4 Bd pEmg 1 a 2 __ 1 I t I 1 I I 1 I i I I I I I I I i I I I I I I...

Page 763: ...he stop light switch may be open L FUSIBLE LINK J B 0 I I ABS ECU 29 j 1 2 13 14 5 6 17 9 j 9 10 11 12 13 14 15 161171 9 9 0l21 2 3l9 6 9 0l31l321U13l35l KX35 AK 33306 F Check the stop light related g...

Page 764: ...ntrols the solenoid valve current and if the current value of the solenoid valves differs from j z d 9 E 6 T mA9 f NATIOM I N _ ____ IGNITION SWITCH IG2 F w 50 fm Eaq G R I G R I X35 AK K3507 each oth...

Page 765: ...GNlTION SWITCH IG1 I iz pi7TEaq d I 6 7 E d COMBINATION METER Gm 1 I 11 I I 710 4 I i m I d10 2 ii 3 Dz 62 27 iE b 11 12 j 3 1 a 15 6 7 16 18 10 11112113 14 15j16 17 181 18 20 21 2 3 4 5 2 0 31 2 3 35...

Page 766: ...4 I i ll21314 15 16 17 16 8 10 11 12 13 14 15 16 17 16 li 1Q 0 1 23 4 6 2 E Q 30 1 2 33 5J X35 AK R3500 during MUT forced drive mode Remove the motor relay I 1 pa4r rness between 1 5 Remove the motor...

Page 767: ...0 5 1 0 mm 02 04 in 2 On vehicles with automatic transaxle check the shift lock mechanism Refer to GROUP 23 Transaxle Control 3 With the engine stopped depress the brake pedal two or three times After...

Page 768: ...perly If the pedal height remains unchanged the booster is faulty 3 With the engine stopped step on the brake pedal several times with the same pressure to make sure that the pedal height will not cha...

Page 769: ...ges one each to the input side and output side of the proportioning valve as shown 2 Air bleed the brake line and the pressure gauge 3 While gradually depressing the brake pedal make the following mea...

Page 770: ...d the brake pedal 3 Let your fellow worker plug the master cylinder outlet with finger 4 Keeping the condition 3 release the brake pedal 5 Repeat steps 2 to 4 three to four times while filling the mas...

Page 771: ...emove the guide pin raise the caliper assembly and support it with a wire etc Caution The guide pin has been coated with special Igrease Do not wipe off the special grease on the lock pin and do not c...

Page 772: ...ring balance check the brake drag force 9 If the difference between the brake drag force and hub rotating force exceeds the standard value disassemble the piston and check the piston sliding surfaces...

Page 773: ...ting torque qf the hub with the pads removed to determine brake drag torque after pads are installed 5 Clean the piston and then push the piston into the cylinder 6 Apply repair kit grease to both sid...

Page 774: ...for sliding motion Standard value 70 N 15 4 Ibs 4 Nm 3 ft lbs or less INSPECTION OF FRONT BRAKE DISC THICKNESS 1 Remove dirt and rust off the surface of the brake disc 2 Measure the thickness of disc...

Page 775: ...brake disc once again Mount the brake disc on the position dislocated from the chalk mark 2 If the run out cannot be corrected by changing the phase of the brake disc replace the disc REAR DISC BRAKE...

Page 776: ...not deposit ease or other dirt on pad or brake disc friction surfaces 7 Clean the piston and then push the piston into the cylinder 8 With care not to allow the piston boot to be wedged lower the cali...

Page 777: ...auge approximately 5 mm 2 in from the outer circumference of the brake disc and measure the run out of the disc Limit 0 08 mm 0031 in or less NOTE Tighten nuts to secure the disc to the hub REAR BRAKE...

Page 778: ...one side when braking BRAKE DRUM INSIDE DIAMETER CHECK M35FJAD 1 Remove the rear brake assembly and support it by a wire etc 2 Remove the brake disc 3 Measure the inside diameter of the hub and drum a...

Page 779: ...24 21 8 5 26 23 3 9 3 Manually turning the wheel to be measured by 112 to 1 turn second measure the output voltage with a circuit tester or oscilloscope Output voltage When measured with circuit test...

Page 780: ...ally on ordinary roads It is therefore recommended to observe sensor output voltage waveform also under special conditions such as rough road driving ME 991 377 12FOO5i INSPECTION OF HYDRAULIC UNIT IN...

Page 781: ...y 04 FR VALVE M 05 FL VALVE M t 1 06 I I Rear VALVE M Operation 1 Depress brake pedal to lock wheel 2 Using the MUT select the wheel to be checked and force the actu ator to operate 3 Turn the selecte...

Page 782: ...the engine The ABS warning light lights up it goes into the MUT mode In the MUT mode ABS does not function 4 Operate the brake force tester roller 5 Depress the brake pedal until the brake force teste...

Page 783: ...23 _ 5 WGt WC c w g g 2 30 5 5 E o o s 2 w g 9 8 o L 0 v CW 5 c w OCm G s 5 Fm a gg 002 wars v X 0 E U t d 0 c wou gzz 0 c 2 E G EX ig 2 5 wg c w L Qv P F Z m S C f E g lik Q o 0 w w w 2 2y w i 225 Q...

Page 784: ...suffer misfiring and fail to start if an attempt is made to start without allowing the battery to recover sufficiently This is because the ABS consumes a great deal of current for its self check In s...

Page 785: ...0 600 and When energized between terminals and Between termrnals and Between terminals and N o contrnurty mm Continuity approx ORI vVhen de energized Between terminals 60 120 and Q Between terminals a...

Page 786: ...Refer to P 3545 Stop light switch removal steps I Stop light switch connector 2 Stop light switch Brake pedal removal steps I 3 Return spring 4 Cotter pin 5 Washer 6 Clevis pin 9 Brake pedal assembly...

Page 787: ...emoval steps l 3 Return spring 4 Cotter pin 5 Washer 12 Nlm 9 ftllbs 6 Clevis pin 7 Cotter pin 8 Shift lock cable connection 9 Brake pedal assembly parts from step 10 to step 21 10 11 12 13 14 15 16 1...

Page 788: ...t tester to the stop light switch 2 The stolj light switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4 mm 16 in from the outer case edge surface...

Page 789: ...BRAKE BOOSTER L REMOVAL AND INSTALLATION 14 Nm IO ft lbs 10 Nm 7 ft lbs Master cylinder removal steps I 1 Low pressure hose 2 Brake fluid level sensor connector 3 Brake tube connection 4 Master cylind...

Page 790: ...nsert the vacuum hose of the not to allow it to contact the check valve Then secure the hose with hose clip connected until it contacts the hexagonal edge of the fitting and then should be secured by...

Page 791: ...cylinder body 3 Measure the dimension D der mounting surface on brake booster and the push rod end NOTE To obtain D first take measurement with a square placed on the brake booster Then subtract the...

Page 792: ...ile depressing the piston 14 DISASSEMBLY OF SECONDARY PISTON ASSEMBLY NOTE If it is hard to remove the secondary piston from the cylinder gradually apply compressed air from the outlet port on the sec...

Page 793: ...g Brake Fluid l Bleeding Refer to P 35 48 Flared brake line nuts 15 Nm 11 ft lbs 1 Brake hose 2 Brake tube strut 3 Brake tube A 4 Brake tube B 5 Brake tube front R H 6 Brake tube front L H 7 Brake tub...

Page 794: ...draulic wnit 5 4 12 11 3 6 14FOOlS 1 Brake hose 2 Brake tube strut 3 Brake tube A 4 Brake tube B 5 Brake tube front R H 6 Brake tube front L H 7 Brake tube main R H 8 Brake tube main L H 9 Brake tube...

Page 795: ...INSPECTION MPBKCAE l Check the brake tubes for cracks crimps and corrosion l Check the brake hoses for cracks damage and leakage l Check the flared brake line nuts for damage and leakage SERVICE POINT...

Page 796: ...s Approx 200 N 44 Ibs Stop engine Turn brake disc forward 10 times Check brake drag torque with spring scale If the difference between brake drag torque and hub torque exceeds the standard value disas...

Page 797: ...in 3 Bushing 4 Caliper support pad clip shim 5 Pin boot 6 Boot ring 7 Piston boot 8 Piston 9 Piston seal IO Caliper body a l l Pad assembly disassembly steps I I Guide pin w 2 Lock pin 3 Bushing 4 Cal...

Page 798: ...AKES Front Disc Brake Lubrication points 14KO69 14Y184 ai Brake fluid Conforming to DOT3 Grease Repair kit grease orange 14A0541 Grease Repair kit grease orange 14LO128 Grease Repair kit grease orange...

Page 799: ...er surface 2 Clean piston surface and inher cylinder with trichloro ethylene alcohol or specified brake fluid Specified brake fluid Conforming to DOT3 INSPECTION MOBLGCB l Check cylinder for wear dama...

Page 800: ...n SERVICE POINTS OF REASSEMBLY M35LHCC 2 INSTALLATION OF LOCK PIN 1 GUIDE PIN I Install the guide pin and lock pin mating the head markings I on the guide and lock pins with the identification marking...

Page 801: ...assembly 5 Shim A 6 Shim B 7 Inner pad with wear indicator 8 Outer pad 9 Retaining nng 10 Piston boot I 11 Piston I 12 Piston seal 13 Washer 14 Caliper body 14FO117 MJSLE 8 V f 14FOO25 Caution The pis...

Page 802: ...ot to get your fingers to be pinched 2 Use care not to let the brake fluid splash d 12 REMOVAL OF PISTON SEAL 1 Remove the piston seal Caution Do not damage the cylinder inner surface 2 Clean the pist...

Page 803: ...3 ftlbs M35MA Flared brake line nuts 15 Nm 11 ft lbs INSPECTION INSPECTING THE BRAKE DISC l Check disc for wear Refer to P 35 55 l Check disc for runout Refer to P 35 55 l Check disc for damage M35MDA...

Page 804: ...Caliper support pad clip shim 5 Pin boot 9 Boot ring l 10 Piston boot 4 11 Piston a 12 Piston seal 13 Caliper body Pad assembly disassembly steps 1 Lock pin l 2 Guide pin 3 Bushing 4 Caliper support p...

Page 805: ...7 Lock pin boot 8 Guide pin boot 9 Boot ring I 10 Piston boot I 11 Piston 12 Piston seal 13 Caliper body Pad assembly disassembly steps 1 Lock pin 4 Caliper support pad clip shim 14 Pad and wear indic...

Page 806: ...contained in the seal and boot kit is coated with special grease Do not wipe off the grease Brake fluid Conforming to DOT3 AWD 4s 14N0121 Grease Repair kit grease orange t 14N0121 FWD 14LO12 Grease R...

Page 807: ...caliper body or sleeve for wear l Check pad for damage or adhesion of grease check backing metal for damage l Check wear indicator for damage PAD WEAR CHECK Measure the thickness at the thinnest worn...

Page 808: ...lic unit bolt 6 Grounding wire connection 1 Flared brake line nuts 15 Nm llftlbs 14FO33 Pre removal Operation l Removal of Splash Shield l Draining of Brake Fluid l Removal of Relay Box l Removal of A...

Page 809: ...avy Use care when removing it 2 The HU cannot be disassembled Never loosen its nuts or bolts 3 Do not drop or shock the HU 4 Do not turn the HU upside down or lay it on its side SERVICE POINTS OF INST...

Page 810: ...steps 2 Clip I 3 Front speed sensor w 4 Front speed sensor bracket I 5 Rear rotor Rear speed sensor removal steps 6 Clip a l 8 Rearspeedsensor M350A B L 1 Refer to Group 42 Fender 14FOO78 LJ Post inst...

Page 811: ...speed sensor a 5 Rear rotor Rear speed sensor removal steps 6 Clip 7 Cable band I l 8 Rear speed sensor 9 O ring Pre removal Operation l Removal of Splash Shield Front Only Refer to Group 42 Fender 1...

Page 812: ...the knuckle use care not to strike the tip of the pole piece against the rotor teeth or any other parts INSPECTION MJSOCAC INSPECTION OF SPEED SENSOR 1 Check the tip of the speed sensor pole piece for...

Page 813: ...tooth surface clearance is not adjustable in the case of AWD vehicles In this case measure the sensor mounting surface to rotor tooth surface clearance Standard value 28 15 28 45 mm 1 11 1 12 in 4 INS...

Page 814: ...2 G sensor 3 G sensor bracket 14FO115 1 14A019 14A0195 14A0196 I INSPECTION M350CAD 1 INSPECTION OF G SENSOR I Lay the G sensor on a level surface and check for continuity between its terminals 2 Incl...

Page 815: ...r Trim l Installation of Rear Seatback R l Installation of Rear Seat Cushion Removal steps 4 1 Control unit connector connection 2 Electronic control unit l inspection of A B S Refer to P 35 7 SERVICE...

Page 816: ......

Page 817: ...nnecting wiring Other SRS related components that may have to be removed installed in connection with SRS service or maintenance are indicated in the table of contents by an asterisk WARNING 1 Imprope...

Page 818: ...e and the rotor tooth Limit Brake lining thickness mm in Brake drum I D mm in Specifications 3 5 notches 2 8 I 1 168 0 6 6 0 2 0 7 LOO8 028 1 o f 039 169 0 6 7 LUBRICANTS M36CD d items Rear brake shoe...

Page 819: ...i TROUBLESHOOTING M36EAAL Symptom Brake drag Insufficient parking brake function Probable cause Incomplete release of parking brake lndorrect parking brake adjustment Worn brake pad Remedy Correct Ad...

Page 820: ...of the arrow to expand the shoe until brake is lightly applied where the disc cannot be turned with both hands approx 2 7 Nm 23 in lbs Then turn the adjuster five notches in the direction opposite th...

Page 821: ...oval of Front and Rear Console Refer to GROUP 52A Console Box Post installation Operation l Parking Brake Lever Stroke Adjustment Refer to P 36 4 l Installation of Front and Rear Console Refer to GROU...

Page 822: ...Cable adjuster 12 Adjuster l l 6 Rear speed sensor l a 13 Shoe to anchor spring Refer to GROUP 35 Speed Sensor 14 Strut 7 Rear brake assembly 15 Strut return spring 8 Rear brake disc 16 Shoe lining a...

Page 823: ...ANCHOR SPRINGS The shoe to anchor spring must be installed in the se quence shown in the illustration Caution Each shoe to anchor spring has a unique spring load and the spring a is painted to preven...

Page 824: ...pring 13 Shoe hold down cup 14 Shoe hold down spring 15 Shoe hold down pin l 16 Adjuster l a 17 Shoe to anchor spring 18 Strut 19 Strut return spring 20 Shoe lining assembly 21 Clip 23 Backing plate 7...

Page 825: ...isc 50 60Nm 36 43 ft lbs l l 9 Self locking nut 10 Companion flange l 11 Rear axle shaft 12 Adjusting wheel spring 13 Shoe hold down CUD 14 Shoe hold down spnng 15 Shoe hold down pin I 16 Adjuster I 1...

Page 826: ...REMOVAL OF AXLE SHAFT ASSEMBLY With the special tool remove the axle shaft from the trailing arm INSPECTION M36YCAI CHECKING FOR UNUSUAL WEAR OF THE BRAKE LINING AND BRAKE DRUM 1 Measure the thickness...

Page 827: ...ON OF ADJUSTER Install the adjuster facing the left adjusting bolt to the vehicle front and right adjusting bolt to the vehicle rear 9 INSTALLATION OF SELF LOCKING NUT With the special tool secure the...

Page 828: ......

Page 829: ...a driver side air bag has been installed in the 3000GT 2 The SRS includes the following components impact sensors SRS diagnosis unit SRS warning light air bag module clock spring interconnecting wiri...

Page 830: ...belt deflection mm in When belt tension is inspected or readjusted 9 1 1 35 43 When new belt is installed 7 8 5 28 33 Oil pump pressure MPa psi Pressure gauge valve closed 7 5 8 2 1 067 1 166 Pressure...

Page 831: ...ower steering fluid MITSUBISHI PLUS ATF Automatic trans 0 9 liter 95 qt mission fluid DEXRON or DEXRON II Flow control valve MITSUBISHI PLUS ATF Automatic trans As required mission fluid DEXRON or DEX...

Page 832: ...37A 4 STEERING Special Tools easuremen MB990993 01 Power steering oil pressure gauge adapter pump side Measurement of oil pressure MB991 204 Removal of rack housing needle bearing TSB Revision...

Page 833: ...lay Standard values steering wheel play with engine stopped 11 mm 43 in If the play exceeds the standard value remove steering gear box and check total pinion torque STEERING ANGLE CHECK M37FDBK 1 Set...

Page 834: ...eel s Off Center 1 For the road test take along chalk or tape and a ruler 2 Drive straight ahead on an uncambered level surface 3 When the vehicle s wheels are pointing straight ahead mark the steerin...

Page 835: ...e steering wheel is off center If the steering wheel is off center to the left center it by adjusting the tie rods to make the front wheels steer toward the left and vice versa 1 Mark the tie rods and...

Page 836: ...o make this test conduct a road test and check as follows 1 Make both gradual and sudden turns and check the steering feeling to be sure that there is no difference in the steering force required and...

Page 837: ...C 122 140 F 2 With the engine running turn the wheel all the way to the left and right several times 3 Check the fluid in the oil reservoir for foaming or milkiness Check the difference of the fluid l...

Page 838: ...Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir 7 Confirm that the fluid is not milky and that the level is up to the specified position on the level...

Page 839: ...standard value overhaul the oil pump 6 Remove the special tools and then tighten the pressure hose to the specified torque 7 Bleed the system CHECKING THE PRESSURE UNDER NO LOAD CONDI TIONS 1 2 3 4 5...

Page 840: ...box Remeasure fluid pressure Remove the special tools and then tighten the pressure hose to the specified torque Bleed the system OIL PRESSURE SWITCH CHECK M37FUAC 1 2 3 4 5 6 7 8 Disconnect the pres...

Page 841: ...lb 1 40 Nm 29 ftlbs i 13FOO35 Removal steps L Mb 1 Air bag module I l a 2 Steering wheel 3 Lower column cover E feTn switch assembly Automatic transaxle vehicles 4 Upper column cover 9 Key interlock...

Page 842: ...ult from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected 3 The removed air bag module should be stored in a clean dry place with the...

Page 843: ...6 Steering lock bracket I 7 Steering lock cylinder 8 Steering column assembly 13A0170 Steering lock cylinder 13FOO51 SERVICE POINTS OF DISASSEMBLY M37GFAS 6 REMOVAL OF STEERING LOCK BRACKET 7 STEER I...

Page 844: ...teering lock bracket to the column tube temporarily install the steering lock in alignment with the column boss 2 After checking that the lock works properly tighten the special bolts until the head t...

Page 845: ...Supplying of the Power Steering Fluid Refer to P 37A 9 l Bleeding of the Power Steering Fluid Line Refer to P 37A IO l Checking of Steering Wheel Position with Wheels Straight Ahead l Adjustment of t...

Page 846: ...measured value is not within the standard range first adjust the rack support cover and then check the total pinion starting torque again If the total pinion starting torque cannot be adjusted to with...

Page 847: ...of total pinion torque Cc a II End plug 12 Self locking nut 13 Locking nut cc 14 Rack support cover 15 Rack support spring 16 Rack support 17 Valve housing Steering gear seal kit 13FOO3l M37PE 1 Flar...

Page 848: ...ease Silicone grease Fluid MITSUBISHI PLUS ATF Automatic transmission fluid DEXRON or DEXRON II Sealant 1 3M ART Part No 8663 or equivalent L 1 I 13N0019 Fluid MITSUBISHI PLUS ATF Automatic transmissi...

Page 849: ...BANDS Using a screwdriver or similar tool loosen and then remove I the boot retaining band 7 REMOVAL OF TAB WASHER Unstake the tab washer which fixes the tie rod and rack with a chisel 11 REMOVAL OF E...

Page 850: ...sly 23 REMOVAL OF CIRCLIP 1 Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing 2 Turn the rack stopper anticlockwise to remove the circlip 26 REMOVA...

Page 851: ...inner surface of the rack cylinder of the gear housing INSPECTION RACK M37PGAH l Check the rack tooth surfaces for damage or wear l Check the oil seal contact surfaces for uneven wear 0 Check the rac...

Page 852: ...l 32 INSTALLATION OF NEEDLE ROLLER BEARING I 1 Apply specified fluid to housing bearing and oil seal I press fitting surface I Specified fluid MITSUBISHI PLUS ATF Automatic transmission fluid DEXRON o...

Page 853: ...shing and rack stopper Specified fluid MITSUBISHI PLUS ATF Automatic transmission fluid DEXRON or DEXRON II Caution Do not allow oil seal retainer spring to slip out 23 INSTALLATION OF CIRCLIP Insert...

Page 854: ...END PLUG 1 Apply the semi drying sealant to the threaded part of the end plug Specified sealant 3M ART Part No 8663 or equiva lent 2 Secure the threaded portion of the end plug at two places by using...

Page 855: ...ld tab washer end 2 locations to tie rod notch 3 INSTALLATION OF DUST SHIELD 1 Pack dust shield interior and lip with multipurpose grease 2 Apply semi drying sealant to dust shield Specified sealant 3...

Page 856: ...Line Refer to P 37A 10 l Checking of the Oil Pump Pressure Refer to P 37A 11 Removal steps 31 ft lbs 1 V belt 2 Suction hose 3 Pressure hose 4 O ring 5 Pressure switch connector 6 Oil pump 7 Oil pump...

Page 857: ...bs 13N0031 Disassembly steps 25 30 Nm 18 22 ft lbs 15 Plunger I a 3 4 l a 5 l a 6 a 7 8 9 10 11 Pump cover O ring Vanes Rotor Cam ring Side plate O ring Connector O ring Flow control Flow control Pist...

Page 858: ...the vanes for breakage CHECK OF GAP BETWEEN VANE AND ROTOR GROOVE Install vane to rotor groove as illustrated Measure the gap between vane and rotor groove with thickness gauge Limit 0 06 mm 0024 in...

Page 859: ...ine up the dowel pin hole of the side plate with the dowel pin of the pump body when installing the side plate 5 INSTALLATION OF CAM RING Install the cam ring with the punch mark facing the side plate...

Page 860: ...16 ft lbs 11 klbs 1 12 Nm 8 ftlbs M37TA _ Removal steps I Return hose 2 Suction hose 3 Return hose l a 4 Pressure hose 5 O ring 6 Cooler tube 7 Pressure tube 8 Return tube 9 O ring IO Oil reservoir 3...

Page 861: ...SPECIFICATIONS 2 REAR OIL LINE General Specifications 2 10 Lubricants 2 REAR OIL PUMP 11 Service Specifications 2 LJ SERVICE ADJUSTMENT PROCEDURES 4 TROUBLESHOOTING _ _ _ 3 Ball Joint Rotation Starti...

Page 862: ...ONS M37CEB Items Standard value Specifications Rear oil pump displacement at speedometer reading of 31 mph 50 km h for 30 seconds liter qts Power cylinder ball joint rotation starting torque Nm in lbs...

Page 863: ...forts excessive Control valve Oil leakage from control valve jornt Rear wheels cannot be steered Poor rear wheels return Hydraulic pressure for rear wheel is constantly high Long rear wheel steering d...

Page 864: ...osened more 9 Start the engine running the vehicle at an indicated speed I l1 I of about 70 80 km h 43 50 mph to circulate the fluid 13FOO13 Caution When replenishing the fluid take special care as al...

Page 865: ...the engine Increase speed slowly then hold the indicated speed of 50 km h 31 mph measuring discharge flow volume for 30 seconds Caution While performing this work continuously add fluid into the oil r...

Page 866: ...res l Bleeding of 4WS System Refer to P 37B 4 l Checking of 4WS System for Operation Refer to P 37B 5 0 Checking of Wheel Alignment Refer to GROUP 34 Service Adiustment 1 Procedures f i s yf 30Nm 78 N...

Page 867: ...ce the tie rod 4 If the swing resistance is less than the standard value the ball joint may be reused as long as it is not loose and operates smoothly POWER CYLINDER SLIDE RESISTANCE CHECK 1 Place the...

Page 868: ...e Silicone grease Disassembly steps 1 Nut 2 Tie rod end assembly 3 Clip 4 Wire l 5 Dust cover 6 Bleeder caps 7 Bleeder screws 8 Cylinder assembly 2 13A0128 13G0070 Rod 13A025 SERVICE POINTS OF REASSEM...

Page 869: ...fer to GROUP 34 Rear Suspension Assembly l Refillrng and Bleedrng of Power Steering System Refer to GROUP 37A Service Adjustment Procedures l Bleeding of 4WS System Refer to P 37B 4 l Checking of 4WS...

Page 870: ...Pressure tube assembly to pipe assembly connection 11 Suction hose 12 Reserve tank l Cleaning of Pipings with Steam Post installation Operation l Refilling and Bleeding of Power Steering System Refer...

Page 871: ...em Refer to P 37B 4 l Checking of 4WS System for Operation Refer to P 37B 5 IIO 130Nm 80 94 ft lbs Removal steps 1 Rear shock absorber lower mounting bolt 4 2 Crossmember bracket a 3 Crossmember mount...

Page 872: ...c c C...

Page 873: ...which uses a driver side air bag has been installed in the 3000GT 2 The SRS includes the following components impact sensors SRS diagnosis unit SRS warning light air bag module clock spring interconne...

Page 874: ...3 5 I41 Door glass 5 0 f 20 Quarter window glass 3 5 14 Power window motor Type Permanent magnet type Built in circuit breaker Revolutions under no load rpm 75 or more Revolutions under load vm At 1...

Page 875: ...e Play of door inside handle mm in A play B OPEN C FULL Adjustment of glass inclination amount Front pillar Roof 7 28 46 f 9 1 81 31 35 69 2 72 11 7 I I 1 O 46 I 04 11 8 f 1 O 46 041 L SEALANTS AND AD...

Page 876: ...42 4 BODY SDecial Tools SPECIAL TOOLS M42DA remover TSB Revision...

Page 877: ...ndow Defective body flange Correct Doors Door window malfunction Incorrect window glass installation Adjust position Damaged or faulty regulator Correct or replace Water leak through Cracked or faulty...

Page 878: ...iscovered 4 When such a place is found cover it again and continue with the procedure so as to determine if there are any other noise sources 5 If no others are found the last remaining tape is the on...

Page 879: ...GRAM FUSIBLE LINK POWER WINDOWS RELAY C 07X m I R B 5 l __ v 4 3 m I 2 F7 I I I I I I I I I I I I I I I I I I I I I I I I I _____ _ E 34 POWER WINDOW MAIN SWITCH 1 r L ETACS IJNIT 16 E 32 RH LH RH v H...

Page 880: ...ER WINDOWS RELAY J B C 68 p i p ii i JUMPER CONNECTOR r _ _ _ 11 i i v _ ___ _ ___ i3 Xl 0 5 c JA I t c 34 __ pEEL E c d 1 GND n 4 7x1 g 2 L4 j4 ___ __ I 14 l 1oy2 7 I SELF DIAGNOSIS CHECK C01 6NZCTOR...

Page 881: ...al current occurs within 60 seconds if then left as I flow time of four to 40 seconds reset is The timer function of the ETACS permits the power window relay to remain ON for 30 seconds after the igni...

Page 882: ...KING SYSTEM CIRCUIT DIAGRAM E 22 2 If J V L L g s B 4 I m E Al g 7 A Ei 20 19 15 18 17 _____I L I LIZ I 35 AC Rll02 NU M42EBFH I DOOR LOCK POWER RELAY J E 13 l VEHICLES WITHOUT POWER WINDOW X2 VEHICLE...

Page 883: ...IT C 66 ____ ____ _ i I 2 2 I I I I I I I I I I I L ____ I 4 14 60s3 I s CL d _ 4 3 10X4 T ci I t L 6 3 m i I iLARM I WITH t Z iALARM I I3 5 2 ir c 3 4 4 112 3 4 5 6 7 E 19 10 11 12 13 1 f I Z3 VEHICL...

Page 884: ...ETACS unit grounds the unlock side circuit of the door lock relay to unlock all doors This way failure to remove the key is prevented NOTE The door lock actuator contains a PTC thermister to prevent d...

Page 885: ...en the hood latch mounting bolts and move the hood latch to adjust the attachment between the hood latch and hood striker LIFTGATE ADJUSTMENT M42FCAF 1 Loosen the liftgate hinges mounting bolts and th...

Page 886: ...door Move the door to adjust the door position along the body surface Caution Attach protection tape to the fender edges where the hinge is installed 3 If the door does not open freely adjust the enga...

Page 887: ...djust glass to have standard clearance between the weatherstrip holder and window glass Caution Measure the clearance specified in section A A B B and C C at the corresponding weatherstrip holder scre...

Page 888: ...r tracks Caution Do not turn the adjusting bolts of guide tracks 12 Adjust the delta sash so that the window glass end and the delta sash lip end are positioned as illustrated and tighten in position...

Page 889: ...r for water to enter higher up and run downward to soak the mat Since a soaked mat should be removed for drying it s a good way to start your check Of course mat removal means you ll have to take off...

Page 890: ...1 Hood side weatherstrip RH 12 Heat protector panel 13 Heat protector 14 Hood garnish assembly 15 Hood switch Vehicles with theft alarm sys tern 16 Engine room inspection light 17 Inspection light swi...

Page 891: ...cates that there is continuity between the terminals INSPECTION LIGHT SWITCH Turn the switch ON OFF and check continuity between terminals between the connector terminal and the switch body I OFF NOTE...

Page 892: ...steps Washer tube Refer to GROUP 51 Wind shield Wtper and Washer _ Liftgate gas spring and liftgate opening weatnerstrllp removal steps Liftgate trim Rear side trim Refer to GROUP 52A Trims 4 Liftgat...

Page 893: ...ar panel garnish Garnishes and Mouldings 14 Liftgate lock cylinder switch 15 Retainer 16 Liftgate lock cylinder Caution 1 Never try to disassemble the liftgate gas spring or burn it 2 Always bore a ho...

Page 894: ...installation Operation l Removal and Installation of Rear Side Trim Quarter Trim and Scuff Plate Referto GROUP 52A Trims 18FOO86 18FOO69 Removal steps 1 Fuel filler door 2 Fuel filler door hook 3 Rele...

Page 895: ...625 or equivalent 18FOO62 Sealant 3M ATD Part No 8625 or equivalent M42KAAX 16FO126 Removal steps 1 Front splash shield Side airdam Refer to GROUP 51 Aero Parts 2 Front splash shield Front bumper Refe...

Page 896: ...42 24 BODY Loose Panel LOOSE PANEL REMOVAL AND INSTALLATION M42SAAN FOllQ support lntercoolkr duct 1 H 16FO121 Air guide duct 16FOl20 16FO124 Deck crossmember crossmember 18FO123 18FOll7 TSB Revision...

Page 897: ...3M SUPER FAST URETHAN PRIMER 8608 As required Reserve items Wire dia x length for cutting adhesive Five pieces of wire 0 6 mm x 1 m f 02 in x 3 3 ft Adhesive gun for adhesive application One 3M ATD P...

Page 898: ...ting adhesive com pletely and clean bondrng surface Cleaning bonding surface Clean the bonding surface and dry 3 minutes or more Applying primer Apply primer amply on bonding surface and dry 3 minutes...

Page 899: ...s sary Use care not to damage the coated surface 2 If the coated surface is damaged apply paint 4 Cut off the lower portion of a new moulding and install the moulding temporarily to check that it is s...

Page 900: ...51 Garnishes and Mouldings l Removal and lnstallatron of Headlrnrng Refer to GROUP 52A Headlrning l Removal and lnstallatron of Front Pillar Trim RefertoGROUP52A Tnms Removal steps 1 Windshield mouldi...

Page 901: ...ove the windshield glass 7 Using a sharp knife scoop out existing adhesive from the body flange to 2 mm 08 in or less thickness all around the window opening 8 Finish smooth the flange surfaces Cautio...

Page 902: ...tion 1 The primer is used to strengthen bonding pow er Make sure that it covers the surfaces com pletely Note that the primer if applied to thick can cause loss of bonding power 2 Never touch the prim...

Page 903: ...ass and body surfaces using a spatula and wipe the surfaces clean 8 After the work installation of the glass allow to stand until the adhesive hardens Caution If an infrared lamp or other means are us...

Page 904: ...ION j u Pre removal and Post installation Operation l Removal and Installation of Quarter Upper Trim Refer to GROUP 52A Trims l Removal and Installation of Center Pillar Garnish Refer to GROUP 51 Garn...

Page 905: ...ation of Center Pillar Garnish Refer to GROUP 51 Garnishes and 18FOOO2 18FO132 Removal steps l I 1 Quarter window moulding and glass 2 Packing 3 Window dam Section A Adhesive Cut off nozzle tip mm in...

Page 906: ...tion to the bolt Caution Hold the window glass with the glass holders to prevent it from falling when the adhesive is cut through 4 Using a sharp knife scoop out existing adhesive from the body flange...

Page 907: ...breaks or thin spots Caution 1 The primer is used to strengthen bonding pow er Make sure that it covers the surfaces com pletely Note that the primer if applied to thick can cause loss of bonding pow...

Page 908: ...es using a spatula and wipe the surfaces clean 6 After the work installationof the glass allow to stand until the adhesive hardens Caution If an infrared lamp or other means are used for quicker harde...

Page 909: ...on l Removal and Installation of Rear Wiper Arm Refer to GROUP 51 Windshield Wiper and Washer l Removal and Installation of Liftgate Upper Trim Referto GROUP 52A Trims l Removal and Installation of Li...

Page 910: ...king sure it is applied without breaks or thin spots Adhesive 3M SUPER FAST URETHAN PRIMER 8608 or equivalent Caution 1 The primer is used to strengthen bonding pow er Make sure that it covers the sur...

Page 911: ...n the glass and body surfaces using a spatula and wipe the surfaces clean 6 After the work installation of the glass allow to stand until the adhesive hardens Caution If an infrared lamp or other mean...

Page 912: ...ps 1 Connection for door wiring harness connector 2 Spring pin 3 Door assembly 4 Upper hinge 5 Lower hinge Door check strap removal steps Door trim Refer to P 42 41 Waterproof film Refer to P 42 41 St...

Page 913: ...LATION 6 INSTALLATION OF DOOR CHECK STRAP Install the door check strap with the identification mark facing up Position Identification mark Door LH WL L Door RH WR R DOOR TRIM AND WATERPROOF FILM M42MB...

Page 914: ...zL4 1 l Door Window Glass Adjustment 18FOlQi 2 Removal steps Door trim Refer to P 42 41 I Waterproof film Refer to P 42 41 I 1 Delta cover inner 2 Delta cover outer Door belt line outer weatherstrip R...

Page 915: ...ing normally If not the switch or switch input circuit is faulty Check the switch and the switch input circuit l Ignition switch l Door switch TROUBLESHOOTING QUICK REFERENCE TABLE For information con...

Page 916: ...dual part and the circuit check No 4 front door switch procedures P 42 49 Malfunction of the electronic control unit Replace the electron ic control unit The opening and closing operations of the powe...

Page 917: ...the power supply circuit other ETACS functions also will not operate Electronic control unit terminal voltage Connection status of electronic control unit connector ECU terminal No Signal Condition T...

Page 918: ...ration A condition for operation of this system is the sending of HIGH level signals to the electronic control unit when the ignition switch is switched to the ON position Electronic control unit term...

Page 919: ...ACTIVATION CIRCUIT Fusible link R B 0 5 ____ y3 4 I I I I I I I I I I I I I I _ __ Power window One touch dnwn circuit L I Vehicles without theft alarm system 2 Vehicles with theft alarm system Power...

Page 920: ...he switch ON of the power window relay NOTE Turn the ignition switch from ON to OFF and power will be supplied to the power window relay for 30 seconds However power supply will be stopped if the door...

Page 921: ...is switched ON LOW level signals are sent to the electronic control unit L Electronic control unit terminal voltage Connection status of electronic control unit connector ECU terminal No Signal Condi...

Page 922: ...door switch Driver door switch and passenger door switch Resistance Resistance Resistance 14 ground Driver door 16 ground Passenger door 1 O ground Driver door and or passenger door Closed No continu...

Page 923: ...9 6 Delta sash 7 Door window glass 8 Door window regulator assembly 9 Door glass guide track front 10 Door glass guide track rear Door belt line outer weatherstrip Refer to P 42 65 3 up stop 4 Stabili...

Page 924: ...otor terminal and check that the slider moves smoothly 2 Connect the battery in reverse polarity and check that the slider moves in opposite direction CIRCUIT BREAKER INCORPORATED IN THE POWER WIN DOW...

Page 925: ...s View A side switch lower window ock switch 18FO107 table Driver s side switch id NOTE O O indicates that there is continuity between the terminals Doe lock switch Power window switch View A 18FO108...

Page 926: ...e and latch removal steps 2 Door key cylinder unlock switch connector Vehicles with theft alarm system 3 Door outside handle 4 Ring 5 Door lock key cylinder 6 Door latch assembly INSPECTION DOOR KEY C...

Page 927: ...not the switch or switch input circuit is faulty Check the switch and the switch input circuit l Door lock actuator l Door switch l Key reminder switch IGNITION KEY REMINDER TROUBLESHOOTING QUICK REFE...

Page 928: ...o the battery If there is an abnormal condition of the power supply circuit other ETACS functions also will not operate Electronic control unit terminal voltage Connection status of electronic control...

Page 929: ...ctuators Electronic control unit terminal voltage Connection status of electronic control unit connector ECU terminal No Signal Condition Terminal voltage ll 13 LH Door lock actuator switch Door lock...

Page 930: ...s unlocked NOTE Before locking the front seat passenger door make sure that the driver door lock actuator is in the LOCK position If the driver door lock actuator is in the UNLOCK position the front p...

Page 931: ...er switch input circuit abnormal key reminder buzzer will result Electronic control unit terminal voltage Connection status of electronic control unit connector ECU terminal No Signal Condition Termin...

Page 932: ...closed the door switch is switched OFF HIGH level signals are sent to the electronic control unit when the front door is opened the door switch is switched ON LOW level signals are sent to the electro...

Page 933: ...s without theft alarm system 2 Vehicles with theft alarm system Connected to measured part Measurement ff e rion Check conditions Standard Driver door Closed Open Passenger door Closed Open Driver doo...

Page 934: ...driver s side or 1 for passenger s side1 and check to see that when the terminal l for driver s side or 3 for passenger s side is grounded the rod moves to the UNLOCK position 2 Then place the rod in...

Page 935: ...e LOCK I o Q I UNLOCK I I c o L NOTE O O indicates that there is continuity between the terminals Power window sub switch side 1 LOCK I o o I OFF I I I 1 UNLOCK I c NOTE O O indicates that there is co...

Page 936: ...3 Check for continuity between terminals under the condi tions described below I I I I I I I NOTE I O O indicates that there is continuity between the terminals 2 O O indicates terminals to which batt...

Page 937: ...ing weatherstrip lower Drip line weatherstrip removal steps 6 Drip line weatherstrip 7 Door weatherstrip holder 2 18FO219 SERVICE POINT OF REMOVAL 2 REMOVAL OF DOOR OUTER OPENING WEATHER STRIP Make a...

Page 938: ......

Page 939: ...spection of Active Aero System 10 FRONT BUMPER __ 11 SPECIAL TOOLS __ _ _ 4 GARNISHES AND MOULDINGS __ 16 REAR BUMPER 14 SPECIFICATIONS _ 2 General Specifications 2 Sealants and Adhesives 3 REAR WIPER...

Page 940: ...consumption A Time of continuous use sec With washer fluid Empty operation Nozzle jet pressure kPa psi Tank capacity lit qts 3ear window washer motor and pump Motor type Pump type Power consumption A...

Page 941: ...umn switch Intermittent interval min max sec Variable interval intermittent wiper Approx 3 12 Delay time in washer moving sec 0 6 Rear Intermittent interval sec 8 2 Door mirror Printed heater lines Wo...

Page 942: ...EXTERIOR SDecial Tools SPECIAL TOOLS MBlKG I system inspectlon MB991 359 TSB Revision...

Page 943: ...R A 11X E a d 53 1 i4 CT C 79 S DIAGNOSIS CONNECTOR EB p Jg g f pm1 X35 AC R1301 NY 1 x2 f l 13 L1 7 q I i 15 2 x2 fi5 x3 lTX2 pi2k hw 2 3 r I E I v s L IjWl z COLUMN n 11 SWITCH C 11 3 MITTENT FROii...

Page 944: ...T E iR r A 19 L II C I z a C FRON I WIPER SWITCH WIPER IGNITION RELAY SWITCH ACC 7 1 1 7 I I2 7 j A I CII BRE lk 5 l VEHICLES WITHCUT THEFT ALARM SYSTEU Z2 VEHICLES WITH THZFT ALARM SYSTEM 1 I _ CUIT...

Page 945: ...gized causing the rear intermittent wiper relay contacts to close and open repeatedly l When the contacts are closed the wiper motor is energized l When the rear wiper motor is energized the rear inte...

Page 946: ...Y I E 18 3 6 14 17 16 _ _ _ __ CL t 1 3 23 J m 0 3 x4 X7 I I I I I I I I 4 i T RELAY C 82 1 DEDICATED FUSE 0 85L d 3 C 6 9 1 J B ii m d 1 8 C 71 L ii m d 8 D 44 3 REAR LmFi ILL6 8 0 I ii m 6 O 5 8 D 4...

Page 947: ...l VEHICLES WITH MIRROR HEATER KXS AC R13C3 NY X2 VEHICLES WITHOUT MIRROR HEATEF OPERATION l When the remote controlled mirror switch is operated while the ignition key is in ACC or ON position current...

Page 948: ...switch to AUTO 2 to make sure that the active aero system is placed in the operative condition and the indicator light comes on Then turn off the active aero switch to confirm that the system LCJ retu...

Page 949: ...H SCREW Normally remove the clip with a Phillips screwdriver If however there is enough space to insert a screwdriver or the like behind the clip use the following procedure for ease of work 1 Removal...

Page 950: ...eld extension 8 Fog light 9 License plate bracket Vehicles without active aero system 7i Vehicles without active aero system Vehicles with active aero system 10 Front combination light 11 Optical horn...

Page 951: ...OF DISASSEMBLY 10 REMOVAL OF BUMPER ABSORBER Caution 1 Do not attempt to repair a bumper absorber that has been compressed in an accident replace it with a new one 2 Before discarding the bumper abso...

Page 952: ...remove the clip 2 Installation With the grommet inserted in the hole press the screw in REMOVAL AND INSTALLATION Pre removal and Post installation Operation l Removal and Installation of Rear Removal...

Page 953: ...inforcement SERVICE POINT OF DISASSEMBLY 6 REMOVAL OF BUMPER ABSORBER Caution 1 Do not attempt to repair a bumper absorber that has been compressed in an accident replace it with a new one 2 Before di...

Page 954: ...illar garnish Adhesive tape 3M ATD Part No 6382 or equivalent Windshield moulding removal steps 3 Drip moulding 5 Windshield moulding Refer to GROUP 42 Windshield Liftgate moulding removal 6 Liftgate...

Page 955: ...arnish 4 When the side qarnish is fastened with a clip or bolt pull the side garnish toward you to remove the clip or the bolt Caution 1 To reuse the side garnish remove it by pulling the fishing line...

Page 956: ...t the pressure sensitive double sided tape to 40 to 60 C 104 to 140 F for 5 to 10 minutes Caution Do not overheat the tape until its surface dries to turn white 2 Using a resin spatula or gasket scrap...

Page 957: ...removal 2 With its clips and bolts aligned with the respective holes in the body install the side garnish to the body NOTE If it is hard to affix the pressure sensitive double sided tape in winter hea...

Page 958: ...Adhesive 3M ATD Part No 8609 SUPER FAST URETHAN or equivalent 18FO251 Side air dam removal steps Front splash shield Refer to GROUP 42 Fender Quarter trim Refer to GROUP 52A Trims l 1 Side air dam Rea...

Page 959: ...ront under cover panel air dam link assembly removal steps 5 Side cover panel L H 6 Front cover panel 7 Center cover panel 8 Front under cover panel 9 Lower plate 10 Upper plate I 11 Air dam link asse...

Page 960: ...ty to make sure that the motor and spoiler operate freely 2 While performing the inspection described in 1 above check the limit switch for continuity FLAT standard position During operation 0 0 0 SLA...

Page 961: ...y between the terminals SERVICE POINTS OF INSTALLATION 11 INSTALLATION OF AIR DAM LINK ASSEMBLY Install the air dam link assembly in the operative condition for ease of front under cover panel 1 INSTA...

Page 962: ...ctor located at the right side of the junction block or connect the voltmeter between the ETACS terminal and the ground terminal 2 Check if the buzzer of the multi use tester sounds or the needle of t...

Page 963: ...s operate continuously at low speed not intermittent operation IThe wipers stop however when he wiper switch is set to O F F The intermittent time does not hange when the intermittent Jariable volume...

Page 964: ...position however inter mittent operation of the wipers is normal and the washer function is normal P 51 241 conduct check Damage or disconnection No 5 P 51 31 ofthe individual part and circuit of the...

Page 965: ...FO313 Operation Description As the condition for operation of the system HIGH level signals are sent to the electronic control unit when the ignition switch is set to the ACC or ON position Electronic...

Page 966: ...rmittent time interval according to the setting of the intermittent variable volume switch Electronic Control Unit Terminal Voltage Connection Status of Electronic Control Unit Connector ECU terminal...

Page 967: ...Signal Status Terminal voltage 13 15 2 Intermittent variable volume switch signal Intermittent variable volume switch FAST SLOW 0 2 5V Checking the Intermittent Variable Volume Switch Circuit Disconne...

Page 968: ...tor by the intermittent activation signal from the electronic control unit in order to activate the wiper relay Electronic Control Unit Terminal Voltage Connection Status of Electronic Control Unit Co...

Page 969: ...ime detection circuit simultaneous with the activation of the washer motor thus causing the transistor to be switched ON and the wipers to be activated for a certain fixed time Electronic Control Unit...

Page 970: ...16FO103 7 Linkage Removal steps of wiper motor 1 Wiper blade l 2 Wiper arm 5 Hole cover I 6 Wiper motor Removal steps of washer tank 8 Battery 9 Battery tray 10 Washer tank 11 Washer motor 12 Washer f...

Page 971: ...Inspection of Wiper Motor Operation at LOW and HIGH Speeds Connect the battery to the wiper motor as shown and check its operation at LOW and HIGH speeds Inspection of Wiper Motor STOP Position 1 Oper...

Page 972: ...ted on the washer tank and that the washer tank is filled with water 2 Connect the battery as shown to check whether water is pumped out INSPECTION OF WASHER FLUID LEVEL SENSOR 1 Connect a circuit tes...

Page 973: ...washer tube Front pillar trim RH Quarter trim RH Liftgate lower trim Refer to GROUP 52A Quarter upper trim RH Rear roof rail trim R f GRoUP 52A Trims Rear side trim RH i 4 Wiper motor l 8 Liftgate mou...

Page 974: ...Motor Connect a battery to the wiper motor as shown to check the operation of the wiper motor Wiper Motor Stop Position 1 Operate the wiper motor by the procedure described above and intermediately d...

Page 975: ...and check the voltage at terminal 0 WASHER MOTOR 1 When the washer motor is inspected make sure that it is mounted on the washer tank and that the washer tank is filled with water 2 Connect the batter...

Page 976: ...mote controlled mirror switch Pivnt Notches SERVICE POINTS OF REMOVAL 1 REMOVAL OF DOOR MIRROR Tilt the door mirror backward and forward to remove the attaching bolts 3 REMOVAL OF MIRROR Tilt the mirr...

Page 977: ...ch terminal is connected to the battery 2 Check to see that there is continuity between terminals 1 and 5 RIGHT 0 0 LEFT 0 0 0 0 NOTE I 2 O O indicates that each terminal is connected to the battery i...

Page 978: ......

Page 979: ...o be removed installed in connection with SRS service or maintenance are indicated in the table of contents by an asterisk WARNING I Improper service or maintenance of any component of the SRS or any...

Page 980: ...OR Troubleshooting TROUBLESHOOTING OWER SEAT CIRCUIT DIAGRAM MSZEBHA dl IGNI SWITl 3 I kt C 82 J B i 0 15A C 80 p77ziFq ON IGl TI I I 7 77 3 FUSIB E LINK Q b m 3 123 c 01 lm 456 1 4 m __ _ _ i 1 TSB R...

Page 981: ...NDOWS RELAY EXFR SWITCH D 21 m 3 2 5 6 I 11 I q z 1 I 12 4 3 2 1 IEe l34 3 ce Di b zs 5 5 m cu cu c 2 r Gt 1 M 2 LUMBAR SUPPORT MOTOR IQ 2 1 SIDE S U P P O R T MOTOR 1 Q 2 ROWER SEAT ASSEMBLY J B 2B I...

Page 982: ...Slm 3 pTE i r d F 19 6 E 26 yiq 2 FRONT SEAT B S Y H FRONT SEAT E 14 BELT SOLENOID EzJ RH LH 2 I E 20 m 1 EFS J _ ___ __ I 2 cp jX3 cc 3 51 ck j2 _ 1 k C 65 pziEgqX mx2 IIIIII 0 6 L v v ________ Y 7...

Page 983: ...n for 30 seconds after turning off the ignition switch with due consideration to elimination of the sudden rise in a sense of oppression caused by the belt immediately after the ignition switch is tur...

Page 984: ...Iy 101 COMBINATION METER D 05 dl s s sl BUZZER 102 A T I 3 c A II A c i n Y R piT Rq D 43 9 r 4 3 A E 2112 DOOR SWITCH LH DIODE c 09 cp 3 LT ON IGl MSZEBAF J B ETACS UNIT S DIAGNOSIS oIw CT R 3ET c 79...

Page 985: ...switch the buzzer the seat belt switch the ETACS unit and ground and the buzzer sounds for approx 6 seconds l When the driver buckles the seat belt the seat belt switch is switched OFF and the buzzer...

Page 986: ...of the instrument panel the bolts and screws described below are used They are indicated by symbols in the illustration 4 x 16 I6 x 63 5 x 16 20 x 63 4 x 12 I6 x 47 6 x 16 24 x 63 I I 6 x 25 24 x 98...

Page 987: ...Glove box striker 7 Glove box and cross pipe cover 8 Center air outlet assembly 9 Heater control assembly installation screws 10 Meter bezel i 11 Combination meter 12 Speedometer cable adapter Mechan...

Page 988: ...dapter locks from the instrument panel 3 Pull the speedometer cable slightly toward the passen ger compartment and remove the adapter DISASSEMBLY AND REASSEMBLY Q Glove box disassembly steps 1 Glove b...

Page 989: ...cover 8 Front console garnish 9 Manual transaxle shift lever knob 10 Front console assembly 3 19FO130 b DISASSEMBLY AND REASSEMBLY 19FO129 Front console disassembly steps I AIT garnish ATT 2 M T shif...

Page 990: ...cribed below REMOVAL 1 Use a cross tip screwdriver to push inward the pin at the center of the trim clip to a depth of about 2 mm 08 in 2 Pull the trim clip outward to remove it Caution Do not push th...

Page 991: ...nt pillar trim removal steps 4 Hanger bracket 5 Sash guide cover mounting bolt 6 Clip 7 Front pillar trim Rear roof rail trim removal steps 8 Screw 10 Rear roof rail trim Quarter upper trim removal st...

Page 992: ...belt anchor plate mounting bolt 20 Screw 21 Quarter trim 22 Rear side trim Refer to P 52A 15 23 Quarter trim bracket 16 Sash guide cover mounting bolt 17 Front seat belt anchor plate mounting bolt 18...

Page 993: ...k plate of seat cushion in the hole provided in the floor positively 4 A Rear end trim B B r Rear side trim rear end trim removal steps I Luggage compartment floor box R H 2 Luggage compartment floor...

Page 994: ...wer trim Clip Liftgate lower trim D D Liftbate side trim 19FO173 Liftgate trim removal steps 1 Shelf hook 2 Liftgate lower trim 3 Liftgate upper trim 4 Liftgate side trim 19FOO27 NOTE 1 Location of me...

Page 995: ...Rear Roof Rail Trim Refer to P52A 13 l Removal and lnstallatron of Front PillarTrim Refer to P 52A 13 Removal steps 1 Hanger bracket 2 Sash guide cover mounting bolt 3 Clip 4 Passenger compartment te...

Page 996: ...164 I Head restraint Front seat removal steps l 2 Seat anchor covers 3 Seat mounting nut 4 Seat mounting bolt 5 Harness connector l 6 Front seat assembly Power seat switch removal steps 7 Front consol...

Page 997: ...POINTS OF INSTALLATION 6 INSTALLATION OF FRONT SEAT ASSEMBLY I Locate the lower rails correctly so that the front side seat mounting holes may be positioned at the same relative positions on both R H...

Page 998: ...Then rotate the cover in the drrection of arrow to install d the side tabs in the side holes of the bracket 2 Insert the rear side seat anchor cover outer side to the front seat rearward installation...

Page 999: ...er L H 8 Side shield cover R H l a 9 Inner seat belt IO Seat cushion assembly 11 Memorv reclinina knob Driver seat 12 Sliding adjuster nob 13 Seat back panel Except standard driver seat 14 Seat back a...

Page 1000: ...d check to d I see that the motor rotation is reversed TSB Revision 1 INSPECTION OF LUMBAR SUPPORT MOTOR AND SIDE SUPPORT MOTOR I Disconnect the connector of each motor 2 Connect the battery directly...

Page 1001: ...the terminals 3 Make sure that portion A of the harness does not interfere with the selector gear SERVICE POINT OF REASSEMBLY 9 INSTALLATION OF INNER SEAT BELT 1 Route the seat belt switch connector...

Page 1002: ...ori 19FOO95 SERVICE POINT OF REMOVAL 1 REMOVAL OF REAR SEAT CUSHION With the lever pulled raise the seat cushion and remove the seat cushion SERVICE POINT OF INSTALLATION 1 INSTALLATION OF REAR SEAT...

Page 1003: ...to the ETACS unit so that switch can be considered to be functioning normally If not the switch or switch input circuit is faulty Check the switch and the switch input circuit l Ignition switch II TRO...

Page 1004: ...buzzer Malfunction of the Replace the key re key reminder switch or minder switch or the the seat belt switch seat belt switch Damaged or discon Check by following in Repair the wiring netted wiring o...

Page 1005: ...nal voltage Disconnect the connector of the electronic control unit and check the wiring harness side IECU terminal No Signal Condition 1 Standard I 52 Ignition switch ON Ignition switch OFF ON o v Sy...

Page 1006: ...in the ON position Electronic control unit terminal voltage Disconnect the connector of the electronic control unit and check the wiring harness side I I I I I ECU terminal No Signal Condition Termina...

Page 1007: ...er seat belt Inner seat belt removal steps Floor console assembly Refer to P 52A 11 I 3 Shield cover l a 4 Inner seat belt Buzzer removal steps Floor console assembly Refer to P 52A 1 j 5 Buzzer 4 45...

Page 1008: ...UTER SEAT BELT 1 Positively insert the paw1 to prevent the retractor from rotating in the hole provided on the body 2 Install the anchor plate along the bead of the body 4 INSTALLATION OF INNER SEAT B...

Page 1009: ...INTERIOR Seat Belt 52A 31 3 Insert the pawl of the belt guide in the hole provided on the body TSB Revision...

Page 1010: ......

Page 1011: ...AIR BAG MODULE DISPOSAL PROCEDURES 69 Air Bag Remote Deployment Devices 69 Deployed Air Bag Module Disposal Procedures _ _ 72 Undeployed Air Bag Module Disposal 69 FRONT IMPACT SENSORS _ _ _ _ 56 SRS...

Page 1012: ...act sensors simul taneously activate while the ignition switches ON That is designed to occur in frontal or near frontal impacts of moderate to severe force Only authorized service personnel should do...

Page 1013: ...pact sensor SRS diagnosis unit Incorporated safing impact sensor 19FO138 EHICLE 1 ENTIFICATION ODE CHART LATE module lQFO118 NOTE This construction diagram displays the general view of the SRS compone...

Page 1014: ...NG This vehicle has a supplemental driver s side air bag Refer to service manual before servicing or disassembling underhood components Read SRS section of manual for important instruc tions Improper...

Page 1015: ...marks Failure to do so may render SRS system inoperative risking serious driver injury I J WARNING SRS This air bag module cannot be repaired Do not disassemble or tamper Do not perform diagnosis Do n...

Page 1016: ...or lock switch r 1 UNLOCKi M T A A I Warning light malfunction detection circuit I Crank signal detection circuit Connector lock detection circuit Safing impact sensor 1 N i Multi use Tester interface...

Page 1017: ...M SRS General Information 526 7 ONFIGURATION DIAGRAMS q Engine compartment A 09X m 16 I I fc is IL iw I B f TJw dD L Y 3BFOO13 q Engine and transaxle Front view A T B 23 B 24 Starter motor B 26 Inhibi...

Page 1018: ...Multi use Tester IbJ Instrument panel and floor console D D 03 D 04 Combination meter D 05 D 23 14 pin red connector to body wiring harness D 24 Z pin blue connector to right front impact sensor D 25...

Page 1019: ...the lock spring fits in the notch of the connector The operating principle is described below When Connectors Are To Be Fitted I The SRS diagnosis unit and harness side connectors are fitted Primary l...

Page 1020: ...rify that the connectors have been locked CONNECTOR SHORTING MECHANISM The mechanism is designed for prevention of accidental explosion of the inflator when the clock spring connector for the squib ci...

Page 1021: ...ER SRS WARNING LIGHT M T A T 1 4w x 2 i E 1047 I y 105 pq g g l2 S 7 _ _ _ _ _ _____ 7 T m Y 1I WITHOUT THEFT ALfiF M INHIBITOR SSWITCH I WITH TIiFm 0 I I 1 8 I I I I I I I I I f I I I I I I I I I I I...

Page 1022: ...analogue ohmmeter to check SRS wiring or components use only special tools and digital multi meter shown on page 52B 16 1 2B W 2B W 7 B W I J B 0 MULTI PURPOSE FUSES 10A 0 85B W I 2 _ __ _ _ _ 5 SRS D...

Page 1023: ...SUPPLEMENTAL RESTRAINT SYSTEM SRS General Information 52B 13 COMPONENT LOCATION I i TSB Revision...

Page 1024: ...of the connectors is diagnosed as fault replace the wiring harness If the wires are diagnosed as faulty replace or repair the wiring harness according to the following table SDU Terminal No Harness Co...

Page 1025: ...ensors SRS diagnosis unit and air bag module and clock spring before drying or baking the vehicle after painting Recheck SRS system operability after re installing them j Whenever you finish servicing...

Page 1026: ...EM SRS SRS Sewice Pre utions TEST EQUIPMENT TO BE USED FOR TROUBLESHOOTING M52DA 0 heck harness is used on various connected 3R resistor Use a multwneter for which the less at the mnmum range of resls...

Page 1027: ...is functioning properly If no continue with following steps NOTE If the battery power supply multi purpose fuses No 11 or No 18 is disconnected with the ignition key in the ON position the SRS warnin...

Page 1028: ...ays CAN T COMM check the Multi use Tester and vehicle side self check diagnosis TSB Revision connector for poor connections Refer to the previous page and perform I If the 3000GT 91 MDL SRS AIR BAG sy...

Page 1029: ...i use Tester select 3000GT 91 MDL No 3 Non Turbo or No 4 Turbo and SRS AIR BAG system by entering the YES key 3 If the Multi use Tester displays CAN T COMM check the Multi use Tester and vehicle side...

Page 1030: ...s open or the wire from the air bag to the SDU clock spring is open circuit The capacitor integrated in the SDU terminal voltage is higher than the specified value for 5 seconds The capacitor integrat...

Page 1031: ...to the SDU is grounded does not extinguish 43 ground short I It takes at least 5 seconds with the light OFF that Perform TEST 11 the SDU detects this fault When SRS warning light does not illuminate P...

Page 1032: ...iagno Q sis unit while pressing down the lock of the connector Refer to P 52B 9 TSB Revision 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Ca...

Page 1033: ...rminal of SRS Check Harness connector and the No 8 terminal of the diagnosis check connector next to the right side of the junction block Diagnosis check connector v N o Is there continuity between th...

Page 1034: ...system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected so serious injury may result from unin tended air bag deployment if wor...

Page 1035: ...ion I I Does the voltage between the No 11 terminal of SRS Check Harness connec tor 0 and the No 19 or 20 terminal ground indicate system voltage Does the voltage between the No 12 terminal of SRS Che...

Page 1036: ...nditions for the respective detection circuits will go out of order For this reason both diagnosis codes may not be stored but only one of them may be indicated Their relationships are shown in the fo...

Page 1037: ...Remove the rear console assembly Refer to GROUP 52A Floor Console 3 Use a screwdriver to push in the lock spring of the lock lever of the SRS diagnosis unit to unlock the lock lever Caution A double l...

Page 1038: ...ng harness is grounded or open I I J No Is the resistance between the No 5 Is the resistance between No terminal of SRS Check Harness connec tor and the No 6 terminal normal the terminals of the right...

Page 1039: ...lue and yellow connectors for the wiring leading to the front impact sensors to the SDU and double lock them Refer to P 52B 9 NOTE If double locking cannot be made the connector is incorrectly or inco...

Page 1040: ...ttery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected so serious injury may...

Page 1041: ...nnectors of the clock spring to SRS Check Harness connector and SRS Check Harness connector 0 respectively NOTE When joining SRS Check Harness connector 0 align its white paint with the hollow portion...

Page 1042: ...tion of the clock spring V Malfunction of the air bag module Caution Never attempt to measure the circuit resistance of the air bag module squib even if you are using the specified tester If the circu...

Page 1043: ...k spring I 19FOllO To body wiring harness IQpin No Have the other diagnosis code test s Perform the other diagnosis been finished code test s prior to this test I Yes NOTE If combined front impact sen...

Page 1044: ...e lock mechanism is employed for the connector of the SRS diagnosis unit so care must be taken not to damage it by using excessive force or by not disconnecting it correctly 4 Disconnect the red 2 pin...

Page 1045: ...me even after the battery has been disconnected so serious injury may result from unintended air bag deploy ment if work is done on the SRS system im mediately after the battery cable is disconnected...

Page 1046: ...7 connectors of the clock spring to SRS Check Harness connector and SRS Check Harness connector 0 respectively NOTE When joining SRS Check Harness connector 0 align its white paint with the hollow por...

Page 1047: ...Malfunction of the clock spring z tion of the air bag Replace the clock spring Refer to P 52B 62 Caution Never attempt to measure the circuit resistance of the air bag module squib even if you are usi...

Page 1048: ...e SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected so serious injury may result from unin tended air bag deployment i...

Page 1049: ...gnition key to the LOCK po sition disconnect the negative battery cable and tape the terminal 2 After waiting at least 30 seconds replace the SDU Refer to P 52B 59 1 Turn the ignition key to the LOCK...

Page 1050: ...work The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected so serious injury may result from unintended air bag deploy...

Page 1051: ...ed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected so serious injury may result from unin tended air bag deployment if work is done on the...

Page 1052: ...he ON position the No 19 or 20 terminal ground and Yes 1 Turn the ignition key to the LOCK po sition disconnect the negative battery cable and tape the terminal 2 After waiting at least 30 seconds rep...

Page 1053: ...retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected so serious injury may result from unin tended air bag deployment if work is done on the SRS s...

Page 1054: ...nd and the No 11 terminal of the SRS ing of fuse No 11 or damaged Check Harness connector or disconnected body wiring harness Yes 1 Turn the ignition key to the LOCK po sition disconnect the negative...

Page 1055: ...isconnecting the battery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected so...

Page 1056: ...ve battery cable and tape the terminal 2 After waiting at least 30 seconds replace the SDU Refer to P 52B 59 A NOTE IMPORTANT I Turn the ignition key to the LOCK po sition disconnect the negative batt...

Page 1057: ...rther work The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected so serious injury may result from unin tended air bag...

Page 1058: ...ground and the the SIX Check Harness connector Yes Malfunction of the SDU 1 1 Turn the ignition key to the LOCK po sition disconnect the negative battery cable and tape the terminal 2 After waiting at...

Page 1059: ...nal Caution Wait at least 30 seconds after disconnecting the battery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag for a short time even...

Page 1060: ...o the vehicles driver 3 Check wiring harness for front impact sensor for binds connector for damage and terminals for deformi ties Replace sensor and or wiring harness if it fails visual check Refer t...

Page 1061: ...trol switch radio To body wiring harness SRS diagnosis unit 19FO150 19FO119 1 Remove air bag module from steering wheel Refer to P 52B 62 Caution When disconnecting the air bag module clock spring con...

Page 1062: ...lumn covers Refer to GROUP 52A Instrument Panel 8 Remove the clock spring Refer to P 52B 62 9 Check clock spring connectors and protective tube for damage and terminals for deformities 10 Visually che...

Page 1063: ...r to P 52B 62 Caution The SRS may not activate properly if any of the above components is not installed properly which could result in serious injury or death to the vehicle s driver 36FOO19 1 Check c...

Page 1064: ...the tester to Diagnosis Check Connector in glove compartment I i 2 Read and write down all displayed diagnosis codes J Refer to P 52B 18 NOTE If the battery power supply has been disconnected or disru...

Page 1065: ...connectors and lock lever for damage and terminals for deformities jir bag module Replace air bag module Refer to P 52B 62 1 Check pad cover for dents cracks or deformi ties 2 Remove air bag module fr...

Page 1066: ...ed for the purpose of check sheet metal repair painting etc they should be stored in a clean dry place until they are reinstalled FRONT IMPACT SENSORS Caution 1 Never repair or disassemble a front imp...

Page 1067: ...ious injury may result from unin tended air bag deployment if work is done on the SRS system immediately after the battery cable is discon nected INSPECTION I Check upper frame and sensor brackets for...

Page 1068: ...that has the standard value 19FOO6i 4 INSTALLATI ON OF FRONT IMPACT SENSOR 1 Bend the wiring harness slightly to the extent that there is no slack and clip securely by using the clip of the front imp...

Page 1069: ...gnosis unit with a new one 4 Never use an ohmmeter on or near the SRS diagnosis unit and use only the special test equipment described on P i2B 16 REMOVAL AND INSTALLATION Removal steps a Post install...

Page 1070: ...tely after the battery cable is discon nected 5 DISCONNECTION OF THE SRS DIAGNOSIS UNIT AND EACH HARNESS CONNECTOR 1 Use a screwdriver to push in the lock spring of the lock lever of the SRS diagnosis...

Page 1071: ...ely install the SRS diagnosis unit Caution The SRS may not activate properly if SRS diagnosis unit is not installed properly which could result in serious injury or death to the vehicle s driver 5 CON...

Page 1072: ...le and check the SRS operability 6 Wear gloves and safety glasses when han dling an air bag that has already deployed 7 An undeployed air bag module should only be disposed of in accordance with the p...

Page 1073: ...m the air bag module press the air bag s lock toward the outer side to spread it open Use a screwdriver as shown in the figure at the left to pry so as to remove the connector gently Caution When disc...

Page 1074: ...ed with a tester accidental air bag deployment will result in serious person al injury 1 Check pad cover for dents cracks or deformities 2 Check the air bag module for denting cracking or deforma tion...

Page 1075: ...OCK SPRING I Check connectors and protective tube for damage and terminals for deformities 2 Visually check the case and the gears for damage 3 Check for continuity between the No 1 connector of the c...

Page 1076: ...discovered replace the clock spring with a new one SERVICE POINTS OF INSTALLATION PRE INSTALLATION INSPECTION I Before the clock spring and air bag module are installed in the vehicle they must be vi...

Page 1077: ...11 INSTALLATION OF CLOCK SPRING Align the mating mark and NEUTRAL position indicator of the clock spring and after turning the front wheels to the straight ahead position install the clock spring to...

Page 1078: ...ght by it POST INSTALLATION INSPECTION 1 After installing the clock spring the steering wheel the column covers and the air bag module check steering wheel for noise binds or difficult operation 2 Rec...

Page 1079: ...ule is to be disposed of deploy the air bag outside the vehicle 1 DEPLOYMENT INSIDE THE VEHICLE when vehicle will no longer be driven 1 Open all windows and doors of the vehicle Move the vehicle to an...

Page 1080: ...g excessive force or by not disconnecting it correctly 5 Disconnect the clock spring connector from the SRS diagnosis unit while pressing down the lock of the connector Refer to P 52B 9 6 Connect two...

Page 1081: ...r regional Tech Line at 1 800 446 6064 for instructions DEPLOYMENT OUTSIDE THE VEHICLE 1 Disconnect the negative 4 and positive battery cables from the battery terminals and then remove the battery fr...

Page 1082: ...ough not poisonous do not inhale gas from air bag deployment See Deployed Air Bag Module Disposal Procedures as shown below for post deployment handling instructions 4 If the air bag module fails to d...

Page 1083: ...SEMBLY 18 CONTINUED ON NEXT PAGE SUPPLEMENTAL RESTRAINT SYSTEM SRS 1 A Supplemental Restraint System SRS which uses a driver side air bag has been installed in the 3000GT 2 The SRS includes the follow...

Page 1084: ...SISTOR BELT LOCK CONTROLLER 57 AIR CONDITIONER CONTROL UNIT 56 REFRIGERANT LINE 62 COMPRESSOR 62 SAFETY PRECAUTlONS 56 CONDENSER AND CONDENSER FAN MOTOR 62 SENSORS 60 DAMPER CONTROL MOTOR ASSEMBLY 58...

Page 1085: ...55CB Items Standard value Idle speed when air conditioner on rpm Resister resistance value 1R Refrigerant temperature sensor Sensor ON temperature C F Sensor OFF temperature C F Revolution pick up sen...

Page 1086: ...ied lubricants Each connection of refrigerant line FREOL S 83 or SUNISO 5GS Quantity As required SEALANT AND ADHESIVE M55CE I Items Specified sealant and adhesive I Engine coolant temperature switch t...

Page 1087: ...ection knob is operated Improperly adjusted control cables Plugged or partially plugged heater core Incorrect adjustment of mode selection dampers Incorrect installation of mode selection control wire...

Page 1088: ...Batte Alternator k 2 J l use Fuse yq L l Fuse vi o motor I Resistor r HI MH ML I n II Heater control panel I f I I Air conditioner switch 1 Air conditioner control unit A C I Regulator IT I f I 1 I I...

Page 1089: ...Air conditioner compressor relay When all conditions for switch ON of Battery the compressor are satisfied voltage I I Air conditioner switch A C When air conditioner switch pressed in Battery to seco...

Page 1090: ...ir magnetic clutch relay Replace magnetic clutch relay pa places where gas I I Vo continuity Faulty dual pressure switch Replace dual pressure Jo continuity I Faulty thermostat switch Replace thermost...

Page 1091: ...l handy when working on the refrigeration system Should any liquid re frigerant get into the eyes use a few drops of mineral oil to wash them out R 12 is rapidly absorbed by the oil Next splash the ey...

Page 1092: ...ow on charge The system has to be charged with some refrigerant MAGNETIC CLUTCH 1 Disconnect the wiring to the magnetic clutch 2 Connect battery voltage directly to the wiring for the magnetic clutch...

Page 1093: ...ced COMPRESSOR DRIVE BELT ADJUSTMENT M55FJAG Refer to GROUP 11 Engine Adjustment CHARGING PROCEDURES M55FTAB INSTALLATION OF CHARGE EQUIPMENT I Turn back the adaptor valve handle all the way and insta...

Page 1094: ...manufacturers instructions 1 Start up the vacuum pump Caution 1 Do not use the compressor for evacuation 2 Do not operate the compressor in the vacuum condition damage may occur 2 Evacuate to a vacuu...

Page 1095: ...maging it by liquid compression Keep the service can upright to ensure that refrigerant is charged in gas state 14 Upon completion of charging turn back the low pressure side adaptor valve handle all...

Page 1096: ...harge valve 12 Remove the adaptor valve from the service valve NOTE If the service can is not emptied completely keep the charge valve and adaptor valve connected to the can for next charging Adaptor...

Page 1097: ...TE If the clutch cycles take the reading before the clutch disengages Performance Temperature Chart Garage amb in L am perature 21 70 26 7 80 32 2 90 37 8 100 43 3 110 Iperature Discharge air C tem F...

Page 1098: ...for the installation you are servicing A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of the hose Sharper bends will reduce the flow of refrige...

Page 1099: ...relay box on the right of the engine compartment 2 Remove the radiator fan motor relay air conditioner condenser fan motor relays HI and LO and air conditioner compressor relay from the relay box on t...

Page 1100: ...ol wire 4 Ho01 lock release handle 5 Rheostat assembly 6 Rear wiper washer switch 7 Knee protector 8 Shower duct l 9 Connection of the mode control wire l 10 Connection of the temperature control wire...

Page 1101: ...ble by using a clip 9 INSTALLATION OF MODE SELECTION CONTROL WIRE Connect the mode selection control wire to the mode selection damper lever by following the steps below 1 Move the mode selection leve...

Page 1102: ...ock controller 2OPOOl I TSB I INSPECTION RESISTOR CHECK hl55JCAD Using a circuit tester measure the resistance between the terminals indicated below The condition can be considered satisfactory if the...

Page 1103: ...tions of the center air outlet assembly with a flat tip screwdriver remove the center air outlet assembly with the trim stick 2 REMOVAL OF AIR CONDITIONER SWITCH Remove the center air outlet assembly...

Page 1104: ...t of water hoses 4 Distribution duct foot 5 Foot shower duct 6 Lap cooler duct 7 Evaporator mounting bolt and nut Vehicles conditioner 8 Center duct 9 Heater unit 10 Plate 11 Heater core 2OFO104 Nith...

Page 1105: ...pper 2 Glove box 3 Glove box outer case assembly 4 Under cover 5 Lower frame 6 Evaporator mounting bolt and nut Vehicles with air conditioner l a 7 Connection of the air selection wire 8 Side frame 9...

Page 1106: ...ext reverse the polarity and check that the blower motor operates smoothly in the reverse direction SERVICE POINTS OF INSTALLATION M55KDAH 10 INSTALLATION OF BLOWER MOTOR ASSEMBLY Before installing th...

Page 1107: ...Discharge and Charging of Refrigerant l Removal and lns allation of Battery SERVICE POINTS OF REMOVAL M55RBAl 1 DISCONNECTION OF LIQUID PIPE AND SUCTION HOSE If the hoses or pipes are disconnected ca...

Page 1108: ...with manual air conditioner 5 Evaporator case lower 6 Evaporator assembly 7 Grommet 8 Insulator 9 Rubber insulator 10 Clip 11 Expansion valve 10 9 2OFOO40 1 TSB Revision SERVICE POINTS OF DISASSEMBLY...

Page 1109: ...1 Service Adjustment Procedures l Charging of Refrigerant Refer to P 55 11 21 Nm 15 ftlbs Removal steps a 1 Compressor drive belt 2 Condenser fan motor assembly 4 3 Connection of suction hose and disc...

Page 1110: ...belt l Check for unusual wear or abrasion of the air conditioner belt d OPERATION CHECK OF THE COMPRESSOR S MAGNETIC CLUTCH 1 Connect terminal at the compressor side to the positive terminal of the ba...

Page 1111: ...Nut l 4 Armature plate gI i yirring l 7 Snap ring F 8 Clutch coil 9 Shims Control valve disassembly 13 Snap ring 14 Control valve Thermostat and revolution pick up sensor disassem bly steps 15 Plate...

Page 1112: ...the system into the atmosphere when the high pressure level exceeds 3 550 kPa 505 psi during air conditioner operation Once the pressure inside the system has been reduced to 2 400 kPa 341 psi or lowe...

Page 1113: ...e air compressor 3 Operate the air conditioner with the engine running at idle 4 Gradually increase the engine speed while observing the low pressure gauge If the valve is normal the low pressure drop...

Page 1114: ...f the armature plate and then fit them together J 3 INSTALLATION OF NUT I Use the special tool to tighten the nut 2 Check whether or not the air gap of the clutch is within the standard value Standard...

Page 1115: ...Nm 7 0 8 0 ftlbs 9 23 Nm 17 ft lbs asset r Removal steps 1 Condenser fan motor 2 Fan 3 Motor assembly 4 Shroud w w 5 Radiator fan motor assembly Refer to GROUP 14 Radiator Insulator installation bolts...

Page 1116: ...ther damage l Check the condenser s high pressure hose and pipe in stallation parts for damage or deformation l Check the condenser fan shroud for damage CONDENSER FAN MOTOR CHECK 1 Apply battery volt...

Page 1117: ...Receiver 9 Dual pressure switch 23 Nm 17 ft lbs M55UA 1 Piping connection O ring 20N0089 1 O ring Compressor oil Freol S 83 or Suniso 5GS 13 Nm 9 0 ft lbs 9 0 11 Nm 7 0 8 0 ft lbs TE NUT I I 1 111 9 0...

Page 1118: ...r cover 5 Belt lock controller 6 Side defroster hoses A 7 Duct Vehicles without air conditioner l 8 instrument panel Refer to GROUP 52A instrument Panel 9 Center duct 10 Air duct right side 11 Air duc...

Page 1119: ...remove the defroster garnishes from the instrument panel 16 REMOVAL OF PHOTO SENSOR Using the trim stick remove the photo sensor from the defroster garnish 17 REMOVAL OF CENTER AIR OUTLET ASSEMBLY Di...

Page 1120: ...REMOVAL AND INSTALLATION inlet garnishes removal steps 1 Windshield wiper arm 2 Front deck garnish 3 Inlet garnish right 4 Inlet garnish left Rear ventilation duct removal steps 5 Rear ventilation duc...

Page 1121: ...quivalent BQQQQQ 20A0199 INSPECTION MSSXCAA ENGINE COOLANT TEMPERATURE SWITCH ALWAYS CLOSED TYPE CHECK 1 Immerse the engine coolant temperature switch in oil and heat by a gas stove or similar method...

Page 1122: ...c 0 SO 0s E 3 0 0 0 0 0 0 0 z b ij 2 s a F I 0 0 0 0 0 0 G s 5 5 5 n F 8 b 5 F 8 0 G 0 G is z G T 4 L c tE 2 G b 72 5 6 f 5 3 a0 G 8 6 E 3 0 a 3 i i b ii z E 0 a G E 2 1 z 6 1 D 0 if zz i t 5 5 d T C...

Page 1123: ...efective control panel Defective air conditioner control unit Correct air mix damper Correct harness Replace control panel Replace air conditioner control unit Defective room temperature sensor input...

Page 1124: ...AIR CONDITIONER Troubleshooting Open circuited harness between ower transistor and air conditioner Correct harness ective air conditioner control Defective air conditioner control TSB Revision d I I I...

Page 1125: ...tive outlet selector drive motor Replace outlet selector drive motor Incorrect engagement of outlet selector drive motor and outlet selector damper Engage correctly Malfunctioning DEF FACE and Correct...

Page 1126: ...unit terminal voltages I ermrnal No Slgnal name Conditron Terrmnal voltage 5 Outside air temperature sensor Temperature at sensor 25 C 77 F 4 kf2 2 2 2 8V 10 Sensor power source Normally 4 8 5 2 V 16...

Page 1127: ...k 2 E 28 6 3 r 7 7 L Power source 1 I I A Y Air conditioner control unit 2OFOO61 Troubleshooting Hints l Air conditioner control unit terminal voltage Terminal No Signal name Condition Terminal voltag...

Page 1128: ...2 t 4 3 1 Air mix damper potentiometer z 4 t e 1 1 I Outlet selector damper potentiometer 2OFOO57 Troubleshooting Hints l Diagnosis No 31 Fix air mix damper at MAX HOT position or at MAX COOL positio...

Page 1129: ...ooting Hints l Diagnosis No 11 12 Fix compartment temperature sensor input signal at 25 C 77 F No 13 14 Fix outside air temperature sensor input signal at 15 C 59 Fj I No 21 22 Fix fin therm0 sensor i...

Page 1130: ...L Solar radmtmn Fin speed arlth compensating ClrC it metIC ClrCUlt t A D convertion ND convemon J 2 0 1 0 0 4 3 I Troubleshooting Hints l Air conditioner control unit terminal voltages Terminal No Si...

Page 1131: ...ir condltloner c compressor command AH condmoner arithmetic circuit compressor ON stgnal Comparator Air condltloner compressor ON signal 20 FOO58 Revolution pickup sensor Li Troubleshooting Hints l Ai...

Page 1132: ...de air selector damper drive motor circuits Air mix damper drive motor Air conditioner Air conditioner control panel control panel h Outside air f nsor Damper drive motor 6 Outlet selector damper driv...

Page 1133: ...turns OFF 40 seconds after the damper moved to DEF position Inside outside air selector damper drive motor 0 Inside air switch ON Output turns OFF 40 seconds after inside air has been activated IOV O...

Page 1134: ...circuits llower Potor t lay El 1 2 3 4 Ignition switch IG2 Blower motor relay Air conditioner control panel I WY 2 a T Air conditioner control unit Fan speed anth mete circw lar diatlon nsor 2OFOO59 T...

Page 1135: ...rase the failure code 4 Check the system again When voltmeter is used 1 Connect an analog voltmeter across the self diagnosis output terminal and ground terminal of the diagnosis connector 2 Turn ON t...

Page 1136: ...to 86 9 F Largely deviates Poor connection of air Correct connector from approx 12 V conditioner control unit connection or replace connector or defective air conditioner control air conditioner contr...

Page 1137: ...C 35 6 F is detected 22 nn Short circuited air therm0 sensor 31 J u1 1 Short circuited and open circuited a i r m i x d a m p e r p o t e n t i o m e t e r MAX HOT or MAX COOL when it is at MAX COOL...

Page 1138: ...D MANUAL AIR CONDITIONER Refer to P 55 10 M55FEAV I AIR CONDITIONER CONTROL PANEL AIR CONDITIONER CONTROL UNIT REMOVAL AND INSTALLATION hl XGA E 2OFOO69 Removal steps I 1 Center air outlet assembly 2...

Page 1139: ...57 POWER TRANSISTOR BELT LOCK CONTROLLER REMOVAL AND INSTALLATION J n Power transistor removal steps 1 Stopper 2 Glove box outer case assembly 3 Power transistor 2OFOO73 Belt lock controller removal...

Page 1140: ...removal steps IO Knee protector 11 Side console cover Air mix damper motor assembly removal steps w a 4 Floor console Refer to GROUP 52A Floor Console 5 Air conditioner control unit a 6 Center outlet...

Page 1141: ...motor does not turn when battery voltage is applied INSPECTION OF AIR MIX DAMPER POTENTIOMETER Connect a circuit tester across terminals and of the motor assembly connector and check that resistance...

Page 1142: ...sor removal steps 2 Stopper I3 F it box outer case assembly 7 Water temperature sensor Outside air temperature sensor removal steps 2 Stopper 3 Glove box outer case assembly 8 Outside air temperature...

Page 1143: ...e reaches the specified temper ature Standard value 26 5 4 C 79 7 7 2 Fl OUTSIDE AIR TEMPERATURE SENSOR The condition can be considered normal if the resistances are measured within the ranges of 3 98...

Page 1144: ...ALLATION OF AIR INTAKE HOSE B 4 AIR INTAKE HOSE A Align the cutouts in air intake hose A indicated by arrows with the n markings on air intake hoses B and C and insert hoses B and C all the way into h...

Page 1145: ......

Page 1146: ......

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