Mitsubishi Pajero Pinin 1999 Workshop Manual Download | Manualshive

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General . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . . .

Engine and Emission Control . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission . . . . . . . . . . . .

Automatic Transmission . . . . . . . . .

Propeller Shaft . . . . . . . . . . . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . . .

Rear Axle . . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tyre . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . . .

Service Brakes . . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . . .

Body . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

Chassis Electrical . . . . . . . . . . . . . . .

WORKSHOP MANUAL

FOREWORD

This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
manual as required.

TECHNICAL INFORMATION MANUAL

IKRE00E1

WORKSHOP MANUAL

ELECTRICAL WIRING

EKRE00E1

BODY REPAIR MANUAL

BKRE00E1

ENGINE GROUP

PWEE9502-E

PARTS CATALOGUE

I603F509D

j

All information, illustrations and product descriptions
contained in this manual are current as at the time
of publication. We, however, reserve the right to
make changes at any time without prior notice or
obligation.

ªGDIº is a trade mark which Mitsubishi Motors
Corporation holds.

E

Mitsubishi Motors Corporation

August 1999

Interior and Supplemental
Restraint System (SRS) . . . . . . . .

Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . .

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Summary of Contents for Pajero Pinin 1999

Page 1: ...se the following manuals in combination with this manual as required TECHNICAL INFORMATION MANUAL IKRE00E1 WORKSHOP MANUAL ELECTRICAL WIRING EKRE00E1 BODY REPAIR MANUAL BKRE00E1 ENGINE GROUP PWEE9502 E PARTS CATALOGUE I603F509Dj All information illustrations and product descriptions contained in this manual are current as at the time of publication We however reserve the right to make changes at a...

Page 2: ... driver s and front passenger s air bag modules clock spring side impact sensors and front seat assemblies side air bag modules before drying or baking the vehicle after painting 3 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 4 MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP 52...

Page 3: ...Connector Inspection 10 Inspection Service Points for a Blown Fuse 11 Points to Note for Intermittent Malfunctions 11 VEHICLE IDENTIFICATION 12 Vehicle Information Code Plate 12 Models 13 Model Code 13 Chassis Number 14 Engine Model Number 15 MAJOR SPECIFICATIONS 15 PRECAUTIONS BEFORE SERVICE 17 SUPPLEMENTAL RESTRAINT SYSTEM SRS 21 SUPPORT LOCATIONS FOR LIFTING AND JACKING 25 Support Positions for...

Page 4: ...vicing procedures visual inspections should always be performed as well DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted It is given by tolerance LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the...

Page 5: ...dicates the gasoline direct injection DOHC Indicates an engine with the double overhead camshaft or a model equipped with such an engine M T Indicates the manual transmission or models equipped with the manual transmission A T Indicates the automatic transmission or models equipped with the automatic transmission A C Indicates the air conditioner ...

Page 6: ...assifications of Major Maintenance Service Points When there are major points relative to maintenance and servicing procedures such as essential maintenance and service points maintenance and service stan dard values information regarding the use of special tools etc these are ar ranged together as major maintenance and service points and explained in detail AA Indicates that there are essential p...

Page 7: ...ge is applied Indicates the section title Indicates the group num ber Indicates the page number Indicates the group title Denotes non reus able part Repair kit or set parts are shown Only very frequently used parts are shown Operating procedures cautions etc on removal installation dis assembly and reassembly are described The title of the page following the page on which the diagram of component ...

Page 8: ...de or communication with MUT II not possible Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS Refer to applicable group Diagnosis code displayed Read the diagnosis code Diagnosis code displayed No diagnosis code After taking note of the malfunction code erase the diagnosis code memory Recheck trouble symptom Diagnosis code displayed Read the diagnosis codes No diagnosis code Refer to the INSPECT...

Page 9: ...ectors inspection items and standard values have been provided in this chart as reference information 10 INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope these are listed here DIAGNOSIS FUNCTION METHOD OF READING DIAGNOSIS CODES WHEN USING THE MUT II Connect the MUT II to the diagnosis connector and take a reading of the diagnosis codes Caution...

Page 10: ...ere are trouble symptoms If trouble symptoms have disappeared the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection If it seems that trouble symptoms still remain proceed to the next page of instructions 7 If trouble symptoms still remain up to this stage there is a possibility that there is an open or short circuit in the harness between t...

Page 11: ...te that if the connector control unit etc is too small to permit insertion of the test bar it should not be forced use a special tool the extra thin probe in the harness set for checking for this purpose WHEN INSPECTING WITH CONNECTOR DISCONNECTED When Inspecting a Female Pin Use the special tool inspection harness for connector pin contact pressure in the harness set for inspection The inspection...

Page 12: ...rminal connections male and female pins will not be perfect even if the connector body is connected and the pins may pull out of the reverse side of the connector Therefore gently pull the harnesses one by one to make sure that no pins pull out of the connector CONNECTOR ENGAGEMENT INSPECTION Use the special tool connector pin connection pressure inspection harness of the inspection harness set to...

Page 13: ...e becomes simple In order to ascertain the conditions under which an intermittent malfunction occurs first ask the customer for details about the driving conditions weather conditions frequency of occurrence and trouble symptoms and then try to recreate the trouble symptoms Next ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration temperature or ...

Page 14: ... Contents Contents 1 MODEL H66W LNUEL H66W Vehicle model LNUEL LNUEL Model series 2 ENGINE 4G93 Engine model 3 EXT A01A Exterior code 4 TRANS AXLE V5M21 4875 W5M21 Transmission code AXLE 4875 4875 Rear differential reduction 5 COLOR INT OPT A01 11T 03V A01 Body colour code INT OPT 11T Interior code 03V Equipment code For monotone colour vehicles the body colour code shall be indicated For two tone...

Page 15: ...T WMRJCRA MODEL CODE No Items Contents 1 Development H6 MITSUBISHI PAJERO PININ Short wheelbase 2 Engine type 6 1 800 mȏ petrol engine 3 Sort W Wagon 4 Body style M 3 door 5 Transmission type N 5 speed manual transmission R 4 speed automatic transmission 6 Trim level J GL 7 Specification engine feature C GDI DOHC 8 Steering wheel location L Left hand R Right hand 9 Destination A For Europe 1 2 3 4...

Page 16: ...s 1 Steering wheel location JMP Left hand drive JMR Right hand drive 2 Body style 0 Standard roof 3 Transmission type N 5 speed manual transmission R 4 speed automatic transmission 4 Development order H6 PAJERO PININ Short wheelbase 5 Engine 6 4G93 1 834 mȏ petrol engine 6 Sort W Wagon 7 Model year Y 2000 8 Plant X Ooe Plant of Pininfarina Works 9 Serial number ...

Page 17: ...e model number is stamped on the cylinder block as shown below Engine model Engine displacement mȏ 4G93 1 834 2 The engine serial number is stamped near the engine model number Engine serial number AA0201 to YY9999 MAJOR SPECIFICATIONS 2 5 7 9 4 1 8 6 3 R H drive vehicles L H drive vehicles ...

Page 18: ...d clearance unladen 9 200 Vehicle i ht k Kerb weight 1 285 1 305 weight kg Max gross vehicle weight 1 690 1 700 Max axle weight rating front 740 750 Max axle weight rating rear 545 555 Seating capacity 4 Engine Model No 4G93 g Total displacement mȏ 1 834 Transmis i Model No V5M21 V4AW4 V5M21 V4AW4 sion Type 5 speed manual 4 speed automatic 5 speed manual 4 speed automatic Fuel system Fuel supply s...

Page 19: ... use the designated special tools and test equipment 5 Store components removed from the SRS in a clean and dry place The air bag modules should be stored on a flat surface and placed so that the deployment surfaces are facing upward Do not place anything on top of them 6 Never attempt to disassemble or repair the SRS components SRS air bag control unit air bag modules clock spring and side impact...

Page 20: ... oxygen sensor with a protective cover when applying anti corrosion agents and undercoats PRE INSPECTION CONDITION ªPre inspection conditionº refers to the condition that the vehicle must be in before proper engine inspection can be carried out If you see the words ªSet the vehicle to the pre inspection conditionº in this manual it means to set the vehicle to the following condition D Engine coola...

Page 21: ...e carried out which involve the electrical or fuel systems MUST be carried out in accordance with MMC s information Instructionsº ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin leading to dryness irritation and dermatitis In addition used engine oil contains potentially harmful contaminants which may cause skin ca...

Page 22: ...s a risk of eye contact eye protection should be worn for example chemical goggles or face shields in addition an eye wash facility should be provided Obtain First Aid treatment immediately for open cuts and wounds Wash regularly with soap and water to ensure all oil is removed especially before meals skin cleansers and nail brushes will help After cleaning the application of preparations containi...

Page 23: ...er panels inner monitor any shocks coming from the side of the vehicle The warning lamp on the instrument panel indicates the operational status of the SRS The clock spring is installed in the steering column The SRS side air bags deploy if an impact received at the side of the vehicle is stronger than a certain set value in order to protect the front seat occupant s torso in the event of a collis...

Page 24: ...g control unit SRS ECU Clock spring Driver s and front passenger s air bag modules Side air bag modules Side impact sensors NOTE If any of these components are diagnosed as faulty they should only be replaced in accordance with the INDIVIDUAL COM PONENTS SERVICE procedures in this manual Refer to GROUP 52B 4 After disconnecting the negative battery cable wait 60 seconds at least before any service...

Page 25: ...RS warning lamp 9 10 Instrument panel wiring harness Front passenger s air bag module 11 12 Instrument panel wiring harness Clock spring Driver s air bag module Repair or replace the dash wiring harness Replace clock spring 13 Instrument panel wiring harness Junction block fuse No 8 Repair or replace each wiring harness 16 Instrument panel wiring harness Junction block fuse No 6 harness 20 Instrum...

Page 26: ... will cause drops in reliability MB991222 SRS ECU harness connector SRS ECU harness connector rear view 7 SRS components should not be subjected to temperature over 93 C so remove the SRS ECU driver s and front passenger s air bag modules clock spring front impact sensor side impact sensors and front seat assemblies side air bag modules before drying or baking the vehicle after painting 8 Whenever...

Page 27: ...on Do not support the vehicles at locations other than specified supporting points Doing so will cause damage etc SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS GARAGE JACK Caution Never support any point other than the specified ones or deformation will result AXLE STANDS Notch Rubber Rubber Notch ...

Page 28: ...ST LIFT OR DOUBLE POST LIFT Caution When service procedures require removing the rear suspension spare tyre and rear bumper place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes DOUBLE POST LIFT SINGLE POST LIFT Notch Notch ...

Page 29: ...ocedure 1 Place the vehicle on the H bar lift same direction 2 Place attachments on the H bar lift at the designated chassis support positions When making the attachments refer to the section concerning making them Caution If support is at any location other than the designated positions the body or suspension might be deformed or otherwise damaged so care should be taken to support only at the co...

Page 30: ...he wood selected for the blocks must be hard 2 For the B blocks and C blocks use a saw and chisel or similar tool to make grooves of the dimensions shown in the figure 3 Make four ªATTACHMENTSº such as shown in the figure nailing B and C blocks so that each B blocks is sandwiches between C blocks Block A mm 1 800 90 95 Block B Block C 15 40 60 100 40 20 15 40 140 40 20 40 Block C 140 100 Block C N...

Page 31: ...tic or die cast inserted nuts 4 If self tapping screws or self locking nuts are used Standard bolt and nut tightening torque Thread size Torque Nm Bolt nominal diameter mm Pitch mm Head mark ª4º Head mark ª7º Head mark ª8º M5 0 8 2 5 4 9 5 9 M6 1 0 4 9 8 8 9 8 M8 1 25 12 22 25 M10 1 25 24 44 52 M12 1 25 41 81 96 M14 1 5 72 137 157 M16 1 5 111 206 235 M18 1 5 167 304 343 M20 1 5 226 412 481 M22 1 5...

Page 32: ...NOTES ...

Page 33: ...ve Belt Tension Check and Adjustment 6 Ignition Timing Check 9 Idle Speed Check 10 Idle Mixture Check 10 Compression Pressure Check 11 Manifold Vacuum Check 12 Lash Adjuster Check 13 CRANKSHAFT PULLEY 16 CAMSHAFT AND CAMSHAFT OIL SEAL 17 OIL PAN 21 CRANKSHAFT OIL SEAL 23 CYLINDER HEAD GASKET 25 TIMING BELT 28 ENGINE ASSEMBLY 33 ...

Page 34: ...ectronically controlled multipoint fuel injection Rocker arm Roller type Auto lash adjuster Equipped SERVICE SPECIFICATIONS Items Standard value Limit Alternator drive belt tension When checked Vibration frequency Hz 143 185 When checked Tension N 294 490 Deflection Reference value mm 9 7 12 9 Alternator drive belt tension When adjusted Vibration frequency Hz 155 175 When adjusted Tension N 343 44...

Page 35: ...n timing Approx 16_BTDC 1 Idle speed r min 600 50 1 CO contents 0 6 or less HC contents ppm 200 or less Compression pressure kPa r min 1 720 300 1 337 300 Compression pressure difference of all cylinder kPa Max 100 Intake manifold vacuum kPa Min 60 2 Cylinder head bolt shank length mm 96 4 Auto tensioner push rod movement mm Within 1 Timing belt tension torque Nm Reference value 2 5 4 0 Auto tensi...

Page 36: ... Holding the camshaft sprocket D Holding the crankshaft sprocket MD998719 or MD998754 Crankshaft pulley holder pin D Holding the camshaft sprocket D Holding the crankshaft sprocket MD998713 Camshaft oil seal installer Press in of the camshaft oil seal MD998781 Flywheel stopper Securing the flywheel or drive plate MD998776 Crankshaft rear oil seal installer Press in of the crankshaft rear oil seal ...

Page 37: ...NGINE 4G9 GDI Special Tools 11A 5 Tool Use Name Number MB991653 Cylinder head bolt wrench Cylinder head bolt removal and installation MD998767 Tension pulley socket wrench Timing belt tension adjustment ...

Page 38: ...ndicular to the belt within an angle of 15_ 5 Gently tap the middle of the belt between the pulleys the place indicated by the arrow with your finger as shown in the illustration and check that the vibration frequency of the belt is within the standard value Caution 1 The temperature of the surface of the belt should be as close as possible to normal temperature 2 Do not let any contaminants such ...

Page 39: ...r pivot bolt 2 Loosen the lock bolt 3 Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values Standard value Items When adjusted When replaced Vibration frequency Hz 155 175 203 234 Tension N 343 441 588 784 Deflection Reference value mm 10 5 12 0 6 7 8 5 4 Tighten the nut of the alternator pivot bolt Tightening torque 44 Nm 5 Tighten the lock bolt Tightening t...

Page 40: ...on frequency NOTE Refer to P 11A 7 for information regarding the vibration frequency measurement method using MUT II When measuring the tension Use a belt tension gauge to measure the belt tension When measuring the deflection Apply 98 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection 2 If the tension or deflection is outs...

Page 41: ...is within the standard value Standard value 5_ BTDC 3_ 8 If the basic ignition timing is outside the standard value inspect the GDI system while referring to GROUP 13A Troubleshooting 9 Press the MUT II clear key Select a forced driving cancel mode to release the Actuator test Caution If the test is not cancelled a forced driving will continue for 27 minutes Driving under this condition may damage...

Page 42: ...NOTE 1 After 4 minutes or more have passed in the idle running condition the idle speed will become 750 r min 2 The idle speed is controlled automatically by the idle speed control system 6 If the idle speed is outside the standard value inspect the GDI components by referring to GROUP 13A Troubleshooting IDLE MIXTURE CHECK 1 Before inspection set the vehicle to the pre inspection condition 2 Conn...

Page 43: ...ter and battery are normal In addition set the vehicle to the pre inspection condition 2 Remove all of the ignition coils and spark plugs 3 Disconnect the crank angle sensor connector NOTE Doing this will prevent the engine ECU from carrying out ignition and fuel injection 4 Cover the spark plug hole with a shop towel etc and after the engine has been cranked check that no foreign material is adhe...

Page 44: ...nition coils 11 Use the MUT II to erase the diagnosis codes NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected MANIFOLD VACUUM CHECK 1 Before inspection set the vehicle to the pre inspection condition 2 Turn off the ignition switch 3 Connect the engine tachometer or connect the MUT II to the diagnosis connector 4 Disconnect the ventilation ho...

Page 45: ...started and that the noise changes in accordance with changes in the engine speed If the noise does not occur immediately after the engine is started or if it does not change in accordance with the engine speed the problem is not being caused by the lash adjusters so check for some other cause of the problem Moreover if the noise does not change in accordance with the engine speed the cause of the...

Page 46: ... of oil air will be drawn in through the oil screen and will get into the oil passage 2 If the amount of oil is greater than normal then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil 3 If the oil is degenerated air and oil will not separate easily in oil and the amount of air mixed into the oil will increase 4 If the air which has been mixed in wit...

Page 47: ...itions but if there is no change in the noise level after 30 repetitions or more the problem is probably not due to air inside the lash adjusters 4 After the noise has disappeared repeat the drive pattern shown in the illustration at left a further 5 times 5 Run the engine at idle for 1 3 minutes and check that the noise has disappeared Gradually open the throttle valve Drive pattern for air bleed...

Page 48: ...ion Engine oil 1 2 3 4 177 186 Nm 5 Removal steps 1 Drive belt Power steering and A C 2 Drive belt Alternator AA AA 3 Crankshaft pulley bolt 4 Crankshaft pulley washer 5 Crankshaft pulley REMOVAL SERVICE POINT AA CRANKSHAFT PULLEY BOLT REMOVAL INSTALLATION SERVICE POINT AA CRANKSHAFT PULLEY BOLT INSTALLATION When installing the crankshaft bolt apply the minimum amount of engine oil to the bearing ...

Page 49: ...re and Fuel Pressure Regulator High Pressure Removal and Installation Refer to GROUP 13A 88 Nm 21 25 Nm 35 Nm 1 2 6 3 4 7 3 4 Nm 12 8 11 10 22 Nm 9 12 15 Nm 10 12 Nm 5 13 15 14 10 12 Nm 10 12 Nm 10 12 Nm 21 25 Nm Apply engine oil to all sliding parts during installation 16 Removal steps 1 Earth cable connection 2 Condenser 3 Rocker cover 4 Rocker cover gasket 5 Camshaft position sensor support 6 C...

Page 50: ...from underneath beam camshaft cap Sealant 3M ATD Part No 8660 or equivalent Seen from above cylinder head Sealant 3M ATD Part No 8660 or equivalent Sealant MITSUBISHI GENUINE PART MD970389 or equivalent Engine oil Engine oil Lip section Sealant 3M Stud locking 4170 or equivalent ...

Page 51: ... position sensing cylinder mounting bolt on the exhaust side camshaft BA BEAM CAMSHAFT CAP INSTALLATION 1 Place the camshaft dowel pin as shown in the illustration 2 Tighten the beam camshaft cap mounting bolts to the specified torque in the order shown in the illustration Tightening torque D 10 12 Nm d 21 25 Nm MB990767 MD998719 Exhaust camshaft Screw hole Camshaft sprocket side Approx 106_ Appro...

Page 52: ... to the entire circumference of the oil seal lip 2 Press fit the oil seal as shown in the illustration DA CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal and then tighten the bolt to the specified torque Tightening torque 88 Nm MD998713 ...

Page 53: ...T MD970389 or equivalent 10 93 Nm 42 Nm 7 Nm 7 Nm 9 7 Nm 11 5 14 1 4 4 2 3 12 Nm 18 Nm 42 Nm 11 39 Nm 7 5 7 Nm 14 19 Nm 48 Nm 24 Nm 13 Groove 69 Nm Removal steps 1 Splash shIeld 2 Power steering pressure hose clamp 3 Steering gear box and shaft connection AA 4 Steering gear box installation bolt AB 5 Lower oil pan 6 Drain plug AA 7 Gasket 8 Oil screen 9 Gasket 10 Free wheeling clutch engage switch...

Page 54: ...ort the front differential by a jack and remove the front differential mount center bolts and the front differential mount 2 Remove the jack and lower the front differential AD UPPER OIL PAN REMOVAL After removing all installation bolts install 2 bolts M6 85 in the upper oil pan as shown noting that one located on the left side and one on the right side Turn the bolts to remove the upper oil pan C...

Page 55: ...ine oil bolt washer surface Crankshaft front oil seal removal steps D Timing belt Refer to P 11A 29 D Crank angle sensor Refer to GROUP 16 1 Crankshaft sprocket 2 Key 3 Crankshaft sensing blade 4 Crankshaft spacer CA 5 Crankshaft front oil seal Crankshaft rear oil seal removal steps D Transmission assembly M T Refer to GROUP 22 A T Refer to GROUP 23 D Clutch cover and disc M T AA BA 6 Adapter plat...

Page 56: ... ADAPTER PLATE A T INSTALLATION 1 Clean off all sealant oil and other substances which are adhering to the threaded bolts crankshaft thread holes and the drive plate 2 Apply oil to the bearing surface of the drive plate bolts 3 Apply oil to the crankshaft thread holes 4 Apply sealant to the threaded mounting holes Specified sealant 3M Stud locking 4170 or equivalent 5 Use the special tool to hold ...

Page 57: ...re Removal and Installation Refer to GROUP 13A D Water Bypass Pipe Assembly Removal and Installation Refer to GROUP 14 Water Hose and Pipe D Timing Belt Removal and Installation Refer to P 11A 29 1 8 2 3 4 5 6 7 9 78 Nm 0 Nm 20 Nm 90_ 90_ 3 4 Nm 22 Nm 10 12 Nm 1 0 11 12 13 35 Nm 44 Nm 26 Nm 44 Nm 10 12 Nm Removal steps 1 Radiator upper hose connection 2 Idler pulley 3 Timing belt rear cover upper ...

Page 58: ...STALLATION SERVICE POINTS AA CYLINDER HEAD GASKET INSTALLATION 1 Wipe off all oil and grease from the gasket mounting surface 2 Install so that the shapes of the cylinder head holes match the shapes of the respective cylinder head gasket holes BA CYLINDER HEAD BOLT INSTALLATION 1 When installing the cylinder head bolts the length below the head of the bolts should be within the limit If it is outs...

Page 59: ...he order shown in the illustration Mark the head of the cylinder head bolt and cylinder head by paint 5 Tighten 90_ of a turn In the order shown in the illustration Check that the painted mark of the head bolt is lined up with that of the cylinder head Caution 1 Always make a tightening angle just 90_ If it is less than 90_ the head bolt will be loosened 2 If it is more than 90_ remove the head bo...

Page 60: ...Refer to P 11A 17 10 12 Nm 48 Nm 1 2 5 4 6 10 12 Nm 3 10 11 9 8 7 2 12 10 12 Nm 35 Nm 49 Nm 49 Nm 44 Nm 12 Nm 20 25 Nm 12 15 Nm Removal steps 1 Timing belt front upper cover 2 Radiator upper installation bolts 3 Alternator brace 4 Power steering oil pump bracket stay 5 Crank angle sensor connector 6 Timing belt front lower cover 7 Accessory mount 8 Front flange CA D Timing belt tension adjustment ...

Page 61: ...he movement of the push rod Standard value Within 1 mm A Length when it is free not pressed B Length when it is pressed A B Movement 2 If it is out of the standard value change the auto tensioner 3 Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned Caution If the compression speed is too fast the ...

Page 62: ...ckwise direction 4 Place the timing belt on the exhaust side camshaft sprocket and hold it in the position shown in the illustration with a paper clip 5 Place the timing belt on the intake side sprocket while using two wrenches to align the timing marks 6 Hold the belt in the position shown in the illustration with another paper clip Camshaft sprocket Timing marks Timing marks Crankshaft sprocket ...

Page 63: ...using the special tool and a torque wrench apply tension to the timing belt then tighten the fixing bolt at the specified torque Standard Value 2 5 4 0 Nm timing belt tension torque reference value Caution When tightening the fixing bolt ensure that the tensioner pulley shaft doesn t rotate with the bolt 3 Take out the 2 mm Allen wrench from the auto tensioner At this time check to be sure that 2 ...

Page 64: ...nserted then it is satisfactory if the amount of protrusion of the auto tensioner rod is within the standard value Standard value A 3 8 4 5 mm If it is outside the standard value repeat the operations in steps 1 to 4 4 Check to be sure that the timing marks on all sprockets are aligned A ...

Page 65: ...o GROUP 42 D Radiator Assembly Removal and Installation Refer to GROUP 14 D Air Cleaner and Resonance Tank Removal and Installation Refer to GROUP 15 D Transmission Assembly Removal and Installation Refer to GROUP 23 D Drive Belt Tension Adjustment Refer to P 11A 7 Post installation only 2 3 4 5 6 7 8 9 11 10 12 5 Nm 15 13 4 1 5 Nm 25 Nm 28 Nm 28 Nm 18 Nm 1 14 Removal steps 1 Engine harness connec...

Page 66: ...or connector and remove the compressor from the compressor bracket with the hose still attached NOTE Place the removed A C compressor where it will not be a hindrance when removing and installing the engine assembly and tie it with a cord AC ENGINE ASSEMBLY REMOVAL 1 Check that all cables hoses and harness connectors etc are disconnected from the engine 2 Lift the chain block slowly to remove the ...

Page 67: ...BRICATION CONTENTS GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 3 SEALANT 3 LUBRICANTS 3 SPECIAL TOOLS 3 ON VEHICLE SERVICE 4 Engine Oil Check 4 Engine Oil Replacement 4 Oil Filter Replacement 5 Oil Pressure Check 5 ...

Page 68: ...y used engine oils D Wear protective clothing including impervious gloves where practicable D Avoid contaminating clothes particularly underpants with oil D Do not put oily rags in pockets the use of overalls without pockets will avoid this D Do not wear heavily soiled clothing and oil impregnated foot wear Overalls must be cleaned regularly and kept separate from personal clothing D Where there i...

Page 69: ...lant Oil pressure switch 3M ATD Part No 8660 or equivalent LUBRICANTS Items Specifications Engine oil API classification SG or higher Engine oil quantity ȏ Oil filter 0 3 Total 3 8 SPECIAL TOOLS Tool Number Name Use MB991396 Oil filter wrench Removal and installation of engine oil filter When using the oil filter of MD135737 MD998054 Oil pressure switch wrench Removal and installation of oil press...

Page 70: ...2 Remove the engine oil filler cap 3 Remove the drain plug to drain oil Caution Use care as oil could be hot 4 Install a new drain plug gasket so that it faces in the direction shown in the illustration and then tighten the drain plug to the specified torque NOTE Install the drain plug gasket so it faces in the direction shown in the illustration 5 Refill with specified quantity of oil Specified E...

Page 71: ...ed torque 9 Install the drain plug and refill engine oil Refer to Engine Oil Replacement on P 12 4 10 Race the engine 2 3 times and check to be sure that no engine oil leaks from installation section of the oil filter Number Tool Tightening torque MD135737 MB991396 or equivalent tool Approx 1 turn 14 Nm MD136466 Commercially available tool Approx 3 4 turn 17 Nm MD325714 MD332687 Commercially avail...

Page 72: ...dle 29 kPa or more At 3 500 r min 294 686 kPa 7 Remove the oil pressure gauge 8 Apply the specified sealant to the thread of oil pressure switch Specified sealant 3M ATD Part No 8660 or equivalent 9 Use the special tool to tighten the oil pressure switch to the specified torque Tightening torque 19 Nm Caution Do not start the engine within one hour after the oil pressure switch has been installed ...

Page 73: ...13A 1 FUEL CONTENTS GASOLINE DIRECT INJECTION GDI 13A FUEL SUPPLY 13B ...

Page 74: ...elay Fuel Pump Relay Injector Driver Relay and Throttle Valve Control Servo Relay Continuity Check 102 Intake Air Temperature Sensor Check 102 Engine Coolant Temperature Sensor Check 102 Throttle Position Sensor Check 103 Accelerator Pedal Position Sensor 1st channel Check 104 Accelerator Pedal Position Sensor 2nd channel Check 104 Accelerator Pedal Position Switch Check 105 Oxygen Sensor Check 10...

Page 75: ...ne is under low or medium loads the air fuel ratio becomes leaner to reduce fuel consumption When the engine is running at medium or high loads after having warmed up the ªclosed loopº control uses the signal from the oxygen sensor to keep the air fuel ratio at the optimum theoretical level THROTTLE VALVE OPENING ANGLE CONTROL This system controls throttle valve opening angle electronically The en...

Page 76: ...in response to the engine coolant temperature and vehicle speed 4 Purge Control Solenoid Valve Control Refer to GROUP 17 5 EGR Control Servo Control Refer to GROUP 17 GENERAL SPECIFICATIONS Items Specifications Throttle body Throttle bore mm 60 Throttle position sensor Variable resistor type Throttle valve control servo Torque motor type Engine ECU Identification model No E2T71575 Sensors Air flow...

Page 77: ...or type and number Electromagnetic type 4 Injector identification mark DIM 100G Throttle valve control servo relay Contact switch type Throttle valve control servo Torque motor type EGR control servo Stepper motor type Purge control solenoid valve Duty cycle type solenoid valve Fuel pressure regulator low pressure Regulator pressure kPa 324 Fuel pressure regulator high pres sure Regulator pressure...

Page 78: ...d chan nel D Engine ECU Engine ECU From fuel pump low pressure To fuel tank 10 Fuel pressure sensor 5 Camshaft position sensor 4 Throttle position sensor 2nd channel 11 Throttle position sensor 1st channel z4 Throttle valve control servo 3 Intake airtemperature sensor 2 Air flow sensor 7 Barometric pressure sensor z2 EGR valve Stepper motor High pressure fuel regulator assembly integrated in fuel ...

Page 79: ...al position sensor kΩ 3 5 6 5 Intake air temperature sensor resistance kΩ at 20_C 2 3 3 0 resistance kΩ at 80_C 0 30 0 42 Engine coolant temperature sensor resistance kΩ at 20_C 2 1 2 7 sensor resistance kΩ at 80_C 0 26 0 36 Fuel pressure High pressure side MPa 4 6 9 Low pressure side kPa Approximately 324 Injector coil resistance Ω 0 9 1 1 Oxygen sensor output voltage at racing V 0 6 1 0 Oxygen s...

Page 80: ...al tester connection MB991502 MUT II sub assembly D Reading diagnosis code D GDI system inspection MB991348 Test harness set D Measurement of voltage during trouble shooting D Inspection using an analyzer MB991709 Test harness MB991519 Alternator harness connector Measurement of voltage during troubleshooting MB991536 TPS adjustment harness Adjustment of throttle position sensor MB991658 Test harn...

Page 81: ... inspection MD998478 Test harness 3 pin triangle D Measurement of voltage during trouble shooting D Inspection using an analyzer MB991529 Diagnosis code check harness Reading diagnosis code MD998709 Adaptor hose Measurement of fuel pressure MD998742 Hose adaptor MB991637 Fuel pressure gauge set ...

Page 82: ... engine warning lamp will illuminate If the lamp remains illuminated or if the lamp illuminates while the engine is running check the diagnosis code output Engine warning lamp inspection items Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor 1st channel Throttle position sensor 2nd channel Engine coolant temperature sensor Crank angle sensor Camshaft position se...

Page 83: ...r to GROUP 00 How to Use Troubleshooting Inspection Service Points INSPECTION USING MUT II DATA LIST AND ACTUATOR TESTING 1 Carry out inspection by means of the data list and the actuator test function If there is an abnormality check and repair the chassis harnesses and components 2 After repairing re check using the MUT II and check that the abnormal input and output have returned to normal as a...

Page 84: ...efective Engine coolant temperature sensor Controls as if the engine coolant temperature is 80_C Note that this control will continue until the ignition switch is turned off even if the sensor signal return to normal Camshaft position sensor Controls according to the conditions before a failure is detected Vehicle speed sensor 1 Disables lean mixture combustion However if a predetermined time elap...

Page 85: ...es lean mixture combustion 3 Disables engine speed feedback control However if the throttle valve opening is great controls as follows 1 Carries out lean mixture combustion continuously 2 Shuts off fuel supply for 2 cylinders continuously 3 Shuts off fuel supply when engine speed exceeds 3 000 r min Throttle valve control servo motor 1st motor malfunction Disables lean mixture combustion Throttle ...

Page 86: ...l fuel pressure system 13A 29 61 Communication line with A T ECU system 13A 31 64 Alternator FR terminal system 13A 31 66 Brake vacuum sensor system 13A 32 77 Accelerator pedal position sensor 2nd channel system 13A 33 78 Accelerator pedal position sensor 1st channel system 13A 34 79 Throttle position sensor 1st channel system 13A 35 89 Abnormality in fuel pressure system 13A 36 91 Electronic cont...

Page 87: ... 19 NG Check the harness wire between the engine ECU and the oxygen sensor connector OK Check trouble symptom OK Measure at the oxygen sensor connector A 67 D Disconnect the connector and measure at the harness side 1 Voltage between 1 and earth Ignition switch ON OK System voltage 2 Continuity between 2 and earth OK Continuity 1 NG Check the following connectors A 36 C 19 Check the oxygen sensor ...

Page 88: ...r A 71 OK Check trouble symptom OK Check the following connector A 71 NG Check the harness wire between the engine ECU and the air flow sensor and repair if necessary OK Check trouble symptom 2 3 NG Check the following connectors A 36 C 18 C 19 Measure at the air flow sensor connec tor A 71 D Connect the connector Use the test harness MB991709 1 Voltage between 3 and earth Engine Idling OK 2 2 3 2...

Page 89: ...rcuit D Malfunction of the engine ECU NG Repair NG Repair OK Replace the engine ECU NG Repair NG OK Check trouble symptom OK Check the following connector A 71 NG Check the harness wire between the engine ECU and the intake air temperature sensor OK Check trouble symptom OK Measure at the air flow sensor connector A 71 D Disconnect the connector and measure at the harness side D Voltage between 6 ...

Page 90: ...ace OK Measure at throttle position sensor con nector A 03 D Disconnect the connector and measure at the harness side D Voltage 1 and earth Ignition switch ON OK 4 8 5 2 V D Continuity between 3 and earth OK Continuity NG Check the following connector C 48 NG Repair OK Check trouble symptom NG Check the harness wire between the throttle position sensor and throttle valve controller OK NG Check the...

Page 91: ...minutes or more have passed since the engine coolant temperature after filtering has dropped from 40_C or more to less than this temperature NG Repair NG Repair OK Replace the engine ECU NG Repair NG OK Check trouble symptom OK Check the following connector A 69 NG Check the harness wire between the engine ECU and the engine coolant temperature sensor OK Check trouble symptom OK Measure at the eng...

Page 92: ...ne ECU and the crank angle sen sor OK Check trouble symptom 2 NG Check the following connector C 18 OK Check the following connector A 77 NG Measure at the crank angle sensor con nector A 77 D Disconnect the connector and measure at the harness side 1 Voltage between 2 and earth Ignition switch ON OK System voltage 2 Voltage between 3 and earth Ignition switch ON OK 4 8 5 2 V 3 Continuity between ...

Page 93: ...wire between the engine ECU and the camshaft position sensor OK Check trouble symptom 2 NG Check the following connector C 18 OK Check the following connector A 66 Measure at the camshaft position sen sor connector A 66 D Connect the connector Use the test harness MD991709 D Voltage between 2 and earth Engine Cranking OK 0 3 3 0 V D Voltage between 2 and earth Engine Idling OK 0 5 3 5 V NG Measure...

Page 94: ... circuited harness wire of the vehicle speed sensor circuit D Malfunction of the engine ECU Does the speedometer operate normally No Check the vehicle speed sensor circuit Refer to GROUP 54 Combination Meter Yes Measure at engine ECU connector C 19 D Connect the connector D Voltage between terminal 80 and earth Ignition switch ON OK Ifthevehicleismovedforwardwithoutstartingtheengine 0 V and system...

Page 95: ...ngine ECU OK Measure at the engine ECU connector C 18 D Connect the connector D Voltage between 51 and earth Ignition switch ON OK 3 7 4 3 V at altitude of 0 m 3 2 3 8 V at altitude of 1 200 m NG Check the harness wire between the engine ECU and the barometric pres sure sensor and repair if necessary NG Check the harness wire between the engine ECU and the barometric pres sure sensor OK Check trou...

Page 96: ...rcuit or short circuited harness wire of the detonation sensor D Malfunction of the engine ECU NG Repair NG Replace the engine ECU NG Check the harness wire between the detonation sensor and the earth and repair if necessary Check trouble symptom OK Replace the detonation sensor OK Check trouble symptom NG Check the harness wire between the engine ECU and the detonation sensor Measure at the deton...

Page 97: ...y and battery and repair if necessary NG Repair OK Measure at engine ECU connector C 18 D Disconnect the connector and measure at the harness side D Voltage between terminal 55 and earth Ignition switch ON OK System voltage NG Check the following connector A 44X OK Check trouble symptom NG Check the harness wire between the injector driver relay and engine ECU and repair if necessary NG Repair OK ...

Page 98: ...erminal 24 and earth Voltage between terminal 9 and earth Voltage between terminal 2 and earth Ignition switch ON OK 8 11 V OK Check the following connectors C 17 C 19 NG Repair OK Check trouble symptom NG Replace the injector driver Check trouble symptom NG Replace the engine ECU NG Check the following connector A 55 OK Check trouble symptom NG Check the harness wire between the injector driver a...

Page 99: ...stem D Damaged intake manifold gasket D Damaged vacuum hose D Damaged air intake hose D Malfunction of the EGR valve OK Check the injector system Refer to P 13A 25 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE No 41 NG Check the following items in the order given D Spark plugs D Compression pressure OK Check trouble symptom NG Check the harness wire between the engine ECU and the ignition coil OK Check...

Page 100: ...ngine radio interference may cause this code to be displayed 2 This code may be displayed when registering the key ID code Replace the engine ECU Check trouble symptom No Check the following connector C 19 C 29 C 62 1 Check the immobilizer system Refer to GROUP 54 Ignition Switch and Immobilizer System Check trouble symptom OK Is a diagnosis code output from the immobilizer ECU NG Yes Remove the e...

Page 101: ...r at least fifteen seconds After the air bleeding the diagnosis code must be erased by the MUT II D Air sucking due to no fuel supply OK NG D Replace the fuel pump high pressure poor pump discharge pressure D Replace the high pressure regula tor fuel leakage at the return side Check trouble symptom NG Check if input voltage from the fuel pressure sensor to engine ECU changes suddenly by performing...

Page 102: ...engine ECU and the fuel pressure sen sor OK Check trouble symptom NG Check the harness wire between the engine ECU and the fuel pressure sen sor OK Check trouble symptom OK Check the following connectors A 59 A 82 C 19 Measure at the fuel pressure sensor connector A 59 D Connect the connector Use test harness MB991348 D Voltage between 2 and earth OK 3 V or less Engine Cranking 0 3 4 7 V Engine Id...

Page 103: ... Input voltage from the alternator FR terminal is system voltage for 20 seconds D Open circuit in alternator FR terminal circuit D Malfunction of the engine ECU NG Repair NG Repair OK Replace the engine ECU NG Repair NG Repair OK Replace the alternator OK Replace the engine ECU NG Check the harness wire between the engine ECU and the alternator OK Check trouble symptom OK Check the following conne...

Page 104: ... the following connector A 56 OK Check trouble symptom Measure at the brake vacuum sensor connector A 56 D Connect the connector Use test harness MB991348 D Voltage between 1 and earth OK Voltage increases when depressing the brake pedal several times after the warmed engine is turned off from idle speed and the ignition switch is turned on NG Measure at the brake vacuum sensor connector A 56 D Di...

Page 105: ...n nel NG Repair OK Replace the throttle valve controller NG Repair OK Adjust the accelerator pedal position sensor Refer to P 13A 94 Check the accelerator pedal position sensor 2nd channel Refer to P 13A 104 NG Replace the accelerator pedal position sensor assembly OK Measure at accelerator pedal position sensor 2nd channel connector C 46 D Disconnect the connector and measure at the harness side ...

Page 106: ...n sensor Refer to P 13A 94 NG Repair OK Replace the engine ECU MUT II Data list 26 Accelerator pedal position switch P 13A 73 NG Check the accelerator pedal position switch system Refer to P 13A 65 INSPECTION PROCEDURE 27 OK Check the accelerator pedal position sensor 1st channel Refer to P 13A 104 NG Replace the accelerator pedal position sensor assembly OK Measure at the accelerator pedal posi t...

Page 107: ...the harness side D Voltage between terminal 1 and earth Ignition switch ON OK 4 8 5 2 V D Continuity between terminal 3 and earth OK Continuity NG Check the following connector C 48 NG Repair OK Check trouble symptom NG Check the harness wire between the throttle valve controller and throttle position sensor OK Measure at throttle valve controller con nector C 48 D Connect the connector D Disconne...

Page 108: ...3A 71 NG Check the air flow sensor system Refer to P 13A 16 INSPEC TION PROCEDURE FOR DIAGNOSIS CODE No 12 OK Replace the fuel pump high pressure Code No 91 Electronic controlled throttle valve system Probable cause Range of check D Ignition switch ON D Error in communication from the engine ECU to throttle valve controller Set conditions D Output voltage of the throttle position sensor 2nd channe...

Page 109: ...to P 13A 107 NG Replace OK Check the following connectors A 05 C 48 NG Repair OK Check trouble symptom NG Check the harness wire between the throttle control servo and throttle valve controller NG Repair OK Replace the throttle body Check trouble symptom NG Replace the throttle valve controller Code No 94 Communication line system with throttle valve controller Probable cause Range of check D Igni...

Page 110: ...the throttle valve control servo and throttle valve controller OK Replace the throttle valve controller NG Repair Code No 99 Malfunction in throttle valve control servo motor 2nd motor system Probable cause Range of check D Throttle valve control servo relay ON D System voltage 8V or more Set conditions D Throttle valve control servo drive circuit is shorted to earth D Other power source interfere...

Page 111: ...hunting 7 13A 47 Improper idling Idling speed is high Improper idling speed 8 13A 49 Idling speed is low Improper idling speed Idling stability Engine stalls When the engine is cold it stalls at idling Die out 9 13A 50 Engine stalls When the engine is hot it stalls at idling Die out 10 13A 51 The engine stalls when starting the car Pass out 11 13A 53 The engine stalls when decelerating 12 13A 54 D...

Page 112: ...om the accelerator pedal regardless of whether the vehicles is moving or not Engine stall Pass out The engine stalls when the accelerator pedal is depressed or while it is being used Driving Hesitation Sag ªHesitationº is the delay in response of the vehicle speed engine speed that occurs when the accelerator is depressed in order to accelerate from the speed at which the vehicle is now traveling ...

Page 113: ...mmunication with MUT II is not possible Communication with all systems is not possible Probable cause The cause is probably a defect in the power supply system including earth for the diagnosis line D Malfunction of the connector D Malfunction of the harness wire D Malfunction of the MUT II Measure at the diagnostic connector C 35 1 Voltage between 16 and earth OK System voltage 2 Continuity betwe...

Page 114: ...ine warning lamp to illuminate for five seconds immediately after the ignition switch is turned to ON If the engine warning lamp does not illuminate immediately after the ignition switch is turned to ON one of the malfunctions listed at right has probably occurred D Burnt out bulb D Defective warning lamp circuit D Malfunction of the engine ECU MUT II Data list 16 Engine ECU power supply voltage R...

Page 115: ...ignition circuit Besides that foreign material may be contaminated in fuel D Malfunction of the fuel supply system D Malfunction of the ignition system D Malfunction of the engine ECU Check system voltage while the engine is cranking OK 8 V or more NG Check the battery Refer to GROUP 55 Battery OK MUT II Self Diag code Is a diagnosis code displayed Yes Refer to P 13A 14 INSPECTION CHART FOR DIAGNO...

Page 116: ... OK The timing light flashes NG Check abnormal fuel combustion system Refer to P 13A 27 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE 44 OK Check ignition timing while the engine is cranking OK Approx 5_ BTDC NG Check that the crank angle sensor and timing belt cover are proper ly installed From the previous page OK Check ignition coil spark for each cylinder 1 Remove the ignition coil 2 Install a new ...

Page 117: ...nt temperature sensor Refer to P 13A 72 NG Check the engine coolant temperature system Refer to P 13A 19 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21 OK MUT II Data list 18 Cranking signal Refer to P 13A 72 NG Check the ignition switch ST system M T Refer to P 13A 63 INSPECTION PROCEDURE 25 Check the ignition switch ST system and inhibitor switch A T Refer to P 13A 64 INSPECTION PROCEDURE 26 OK MUT ...

Page 118: ...ution Never touch the connector terminal as approx 100 V is applied to the injector or you are seriously injured 4 Earth the spark plug electrode securely 5 Check that the spark plug ignites when the engine is cranked NG Replace the ignition coil OK Check all the following items D Spark plug D Compression pressure D Foreign material such as water or kerosine entered the fuel lines Check trouble sy...

Page 119: ...R DIAGNOSIS CODE 14 OK MUT II Data list 79 Throttle position sensor 1st channel Refer to P 13A 75 NG Check the throttle valve position feedback system Refer to P 13A 37 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 92 OK MUT II Data list 26 Accelerator pedal position switch Refer to P 13A 73 NG Check the accelerator pedal position switch system Refer to P 13A 65 INSPECTION PROCEDURE 27 OK MUT II Data li...

Page 120: ...park for each cylinder 1 Remove the ignition coil 2 Install a new spark plug to the removed ignition coil 3 Disconnect the injector intermediate connector Caution Never touch the connector terminal as approx 100 V is applied to the injector or you are seriously injured 4 Earth the spark plug electrode securely 5 Check that the spark plug ignites when the engine is cranked NG Replace the ignition c...

Page 121: ... 68 IN SPECTION PROCEDURE 30 OK MUT II Data list 26 Accelerator pedal position switch Refer to P 13A 73 NG Check the accelerator pedal position switch system Refer to P 13A 65 INSPECTION PROCEDURE 27 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 72 NG Check the engine coolant temperature sensor Refer to P 13A 19 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21 OK MUT II Data li...

Page 122: ...TION PROCEDURE 27 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 72 NG Check the engine coolant temperature sensor Refer to P 13A 19 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21 OK MUT II Data list 68 EGR valve Refer to P 13A 74 NG Check the EGR valve system Refer to P 13A 67 INSPECTION PROCEDURE 29 OK Does the engine stall immediately after the accelerator pedal is released...

Page 123: ...e following signals D Crank angle sensor signal D Injector drive signal D Fuel pump low pressure drive signal D Air flow sensor D Primary ignition signal D Power supply to the engine ECU Yes MUT II Data list 26 Accelerator pedal position switch Refer to P 13A 73 NG Check the accelerator pedal position switch Refer to P 13A 65 INSPECTION PROCEDURE 27 OK MUT II Data list 13 Intake air temperature se...

Page 124: ... PROCEDURE 29 OK Yes Clean around the throttle valve Refer to P 13A 92 No NG Check that the crank angle sensor and timing belt cover are proper ly installed OK Check ignition coil spark for each cylinder 1 Remove the ignition coil 2 Install a new spark plug to the removed ignition coil 3 Disconnect the injector intermediate connector Caution Never touch the connector terminal as approx 100 V is ap...

Page 125: ...CEDURE 29 OK MUT II Actuator test 08 Purge control solenoid valve Refer to P 13A 76 NG Check the purge control solenoid valve system Refer to P 13A 68 INSPECTION PROCEDURE 30 OK Check ignition coil spark for each cylinder 1 Remove the ignition coil 2 Install a new spark plug to the removed ignition coil 3 Disconnect the injector intermediate connector Caution Never touch the connector terminal as ...

Page 126: ...pedal position switch Refer to P 13A 65 INSPECTION PROCEDURE 27 OK MUT II Data list 79 Throttle position sensor 1st channel Refer to P 13A 75 NG Check the throttle valve position feedback system Refer to P 13A 37 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 92 OK MUT II Data list 68 EGR valve Refer to P 13A 74 NG Check the EGR valve system Refer to P 13A 67 INSPECTION PROCEDURE 29 OK Check ignition coi...

Page 127: ...or Refer to P 13A 19 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21 OK MUT II Data list 79 Throttle position sensor 1st channel Refer to P 13A 75 NG Check the throttle valve position feedback system Refer to P 13A 38 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 99 OK MUT II Data list 11 Oxygen sensor OK 0 400 mV and 600 1 000 mV alternates when the engine is idling wait for four minutes after the engine st...

Page 128: ... accelerating Probable cause The cause is probably an ignition leak being generated in line with an increase in the spark plug request voltage during acceleration D Malfunction of the ignition system NG Replace the ignition coil MUT II Self Diag code Is a diagnosis code displayed Yes Refer to P 13A 14 INSPECTION CHART FOR DIAGNOSIS CODES No MUT II Data list 79 Throttle position sensor 1st channel ...

Page 129: ...und the throttle valve Refer to P 13A 92 INSPECTION PROCEDURE 16 Knocking Probable cause The cause is probably incorrect detonation control or improper heat range of the spark plugs D Malfunction of the detonation sensor D Improper heat range of the spark plugs MUT II Self Diag code Is a diagnosis code displayed Yes Refer to P 13A 14 INSPECTION CHART FOR DIAGNOSIS CODES No Does knocking occur when...

Page 130: ...rometric pressure sensor Refer to P 13A 23 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE 25 NG Check the oxygen sensor system Refer to P 13A 15 INSPEC TION PROCEDURE FOR DIAGNOSIS CODE 11 OK MUT II Data list 11 Oxygen sensor OK 0 400 mV and 600 1 000 mV alternates when the engine is idling wait for four minutes after the engine started OK Replace the oxygen sensor Check trouble symptom NG NG Measure fu...

Page 131: ...between the alternator G terminal and the engine ECU D Malfunction of the engine ECU NG Repair OK Check trouble symptom OK Check the alternator Refer to GROUP 16 Charging System OK Check the following connectors A 86 C 17 Measure at the alternator connector A 79 D Connect the connector Use the test harness MB991519 D Voltage between 1 black clip and earth Engine Idling Radiator fan Not operating H...

Page 132: ...ctor C 17 D Disconnect the connector measure at the harness side D Voltage between terminal 18 and earth Ignition switch ON OK 4 8 5 2 V The fan runs at high speed D Earth terminal 21 Ignition switch ON OK The fan stops NG Check the following connector A 29 OK Check trouble symptom NG Check the harness wire between the engine ECU and fan control ler OK Check the radiator fan and condenser fan circ...

Page 133: ...fer to GROUP 54A Troubleshooting Check trouble symptom Check the following connectors C 29 C 55 Check the harness wire between the GDI ECO Indication lamp ECU and engine ECU NG NG Repair INSPECTION PROCEDURE 22 GDI ECO indicator lamp remains illuminated and does not go off Probable cause If the GDI ECO indicator lamp does not go off during high load operation the causes listed in the right column ...

Page 134: ... between 99 and earth Ignition switch ON OK System voltage 2 Voltage between 57 and earth OK System voltage 3 Voltage between 47 59 and earth Ignition switch ON OK System voltage When ter minal 57 is shorted to earth 4 Continuity between 46 58 and earth OK Continuity 5 Voltage between 60 and earth OK System voltage 1 NG Check the following connectors C 72 C 74 NG Repair INSPECTION PROCEDURE 24 Eng...

Page 135: ...ir OK Check the ignition switch Refer to GROUP 54 NG Repair Replace the engine ECU NG OK Check the trouble symptoms NG Check the harness wire between the inhibitor switch and the ignition switch connector NG Repair OK Check the trouble symptoms Check the following connector C 27 OK Check the following connector C 18 Measure at the engine ECU connector C 18 D Disconnect the connector and measure at...

Page 136: ...ary 3 NG NG Repair OK Check the ignition switch Refer to GROUP 54 NG Repair NG Repair OK Replace the engine ECU NG Check the harness wire between the engine ECU and the inhibitor switch OK Check the trouble symptoms NG Check the harness wire between the inhibitor switch and the ignition switch connector NG Repair OK Check the trouble symptoms Check the following connector C 39 D 02 OK Check the fo...

Page 137: ... D Malfunction of the engine ECU NG Repair NG Repair Check the accelerator pedal position switch Refer to P 13A 105 NG Replace the accelerator pedal position sensor assembly OK Measureat accelerator pedal position sensor 1st channel connec tor C 46 D Disconnect the connector and measure at the harness side D Voltage between terminal 4 and earth Ignition switch ON OK 4 V or more D Continuity betwee...

Page 138: ... 3 4 and earth Ignition switch ON OK System voltage NG Check the following connectors C 72 C 74 NG Repair OK Check trouble symptom NG Check the harness wire between the fuel pump relay and ignition switch OK Measure at engine ECU connector C 17 D Disconnect the connector and measure at the harness side D Voltage between terminal 21 and earth Ignition switch ON OK System voltage NG Check the follow...

Page 139: ...heck the following connector C 17 NG Repair OK Measure at the engine ECU connector C 17 D Disconnect the connector and measure at the harness side D Voltage between 5 6 32 34 and earth Ignition switch ON OK System voltage NG Check the following connectors A 60 A 82 NG Repair OK Measure at the EGR valve connector A 60 D Disconnect the connector and measure at the harness side D Voltage between 2 5 ...

Page 140: ...G Replace the engine ECU OK Check the following connector C 17 NG Repair OK Measure at the engine ECU connector C 17 D Disconnect the connector and measure at the harness side D Voltage between 16 and earth Ignition switch ON OK System voltage NG Check the following connector A 02 NG Repair OK Measure at the purge control solenoid valve connector A 02 D Disconnect the connector and measure at the ...

Page 141: ... trouble symptom Check the harness wire between the engine ECU and power steer ing fluid pressure switch NG Repair OK OK Check the following connector A 76 Check trouble symptom NG INSPECTION PROCEDURE 32 A C switch and A C relay system Probable cause If the engine ECU receives a A C on signal it operates the throttle control servo and A C compressor magnetic clutch so that idle speed increases D ...

Page 142: ... and earth Ignition switch ON OK 0 3 V when the brake pedal is not depressed System voltage when the brake pedal is depressed NG Check the following connectors C 02 C 04 C 28 OK Check trouble symptom Check the harness wire between the engine ECU and stop lamp and repair if necessary OK Check the following connector C 18 NG Repair OK Check trouble symptom NG Replace the engine ECU INSPECTION PROCED...

Page 143: ...lve has opened the accelerator pedal position switch and the accelerator pedal position sensor 1st channel need to be adjusted Item No Check items Requirements Normal condition Inspection procedure No Refer ence page 11 Oxygen sensor Engine After warm up Idling 0 mV 1 Code No 11 13A 15 up Sudden racing 600 1 000 mV No 11 2 500 r min 400 mV or less 600 1 000 mV alternates 12 Air flow sensor D Engin...

Page 144: ...M T 13A 64 s tc S Engine Cranking ON Procedure No 26 A T 13A 64 A T 21 Engine coolant temperature sensor Ignition switch ON Engine coolant tem perature 20_C 20_C Code No 21 13A 19 sensor Engine coolant tem perature 0_C 0_C Engine coolant tem perature 20_C 20_C Engine coolant tem perature 40_C 40_C Engine coolant tem perature 80_C 80_C 22 Crank angle sensor D Engine crank ing D Tachometer Connected...

Page 145: ...F Procedure No 32 13A 69 A C com ressor is running when the A C switch is on A C switch ON ON No 32 29 Inhibitor switch A T Ignition switch ON Selector lever P or N P N Procedure No 26 13A 64 Selector lever D 2 L or R D 2 L R 31 Small lamp switch Engine Idling Lighting switch OFF OFF Procedure No 34 13A 70 Lighting switch ON ON 34 Air flow sensor reset signal Engine After hav ing warmed up Engine ...

Page 146: ... switch OFF OFF compressor clutch is not oper ating Procedure No 32 13A 69 A C switch ON ON compressor clutch is operating 66 Brake vacuum sensor D Engine coolant temperature 80 95_C D Lamps electric cooling fan and all accessories OFF D Transmission Neutral A T P range Stop the engine from idling speed and then depress the brake pedal several times with the ignition switch on Displayed pres sure ...

Page 147: ...lease the accel erator pedal 935 1 135 mV Code No 78 13A 34 sensor 1st channel 3 Depress the accel erator pedal gradu ally Increases in re sponse to pedal depression stroke Depress the accel erator pedal fully 4 100 mV or more 79 Throttle posi tion sensor 1st channel D Engine coolant temperature 80 95_C Release the accel erator pedal 450 800 mV Code No 79 13A 35 channel 95_C D Ignition switch ON E...

Page 148: ... 04 Cut fuel to No 4 injector don t affect idling 07 Fuel pump low pressure Fuel pump operates and fuel is recirculated Ignition switch ON Sound of opera tion is heard Procedure No 28 13A 66 08 Purge control solenoid valve Solenoid valve turns from OFF to ON Ignition switch ON Sound of opera tion can be heard when solenoid valve is driven Procedure No 30 13A 68 17 Basic ignition timing Set the eng...

Page 149: ...rox three seconds 5 EGR valve D approx three seconds 34 EGR valve A 32 EGR valve B 8 Alternator G terminal D Engine Warm up and then idling D Radiator fan not operating D Headlamp OFF ON D Stop lamp OFF ON D Rear defogger switch OFF ON Voltage increases by 0 2 3 5 V 14 GDI ECO indicator lamp Engine idling 0 3 V lamp Engine Depress the accelerator pedal suddenly from the idle speed System voltage 1...

Page 150: ... 40_C 1 3 1 9 V Engine coolant temperature 80_C 0 3 0 9 V 45 Tachometer output Engine 3 000 r min 2 0 9 0 V 47 Power supply Ignition switch ON System voltage 59 50 Camshaft position sensor Engine Cranking 0 3 3 0 V sensor Engine Idling 0 5 3 5 V 51 Barometric pressure sensor Ignition switch ON Altitude 0 m 3 7 4 3 V sensor Altitude 1 200 m 3 2 3 8 V 52 Alternator FR terminal D Engine Warm up and t...

Page 151: ...e 0 3 V Selector lever Other than P or N range 8 14 V 68 Ignition switch ST Engine Cranking 8 V or more 71 Oxygen sensor Engine Warm up and then hold the engine speed at 2 500 r min Use a digital voltmeter 0 V 0 8 V alternates 74 Brake vacuum sensor Engine Stop the engine from idle speed turn the ignition switch ON and then depress the brake pedal several times Voltage increases 76 Air flow sensor...

Page 152: ...e 3 500 r min System voltage 92 Fuel pressure sensor Engine Idling 0 3 4 7 V 94 Accelerator pedal position sensor 1st channel Ignition switch ON Release the accelera tor pedal 0 935 1 135 V channel Depress the accelera tor pedal fully 4 1 V or more 96 Injector open circuit check signal Engine Increase engine speed from idle speed to 4 000 r min Decreases slightly approx 0 7 V from 4 5 V 5 0 V 97 A...

Page 153: ...e used instead of inserting a test probe 2 Checking need not be carried out in the order given in the chart Caution If the terminals that should be checked are mistaken or if connector terminals are not correctly shorted to earth damage may be caused to the vehicle wiring sensors engine ECU and or ohmmeter Be careful to prevent this 4 If the ohmmeter shows any deviation from the standard value che...

Page 154: ... 26 0 36 kΩ when engine coolant temperature is 80_C 46 Body earth Earth Continuity 0 Ω 58 Body earth 62 72 Intake air temperature sensor 5 3 6 7 kΩ when intake air temperature is 0_C 2 3 3 0 kΩ when intake air temperature is 20_C 1 0 1 5 kΩ when intake air temperature is 40_C 0 30 0 42 kΩ when intake air temperature is 80_C 67 Body earth Inhibitor switch A T Continuity when the selector lever is a...

Page 155: ...dal Fully closed fully opened Decreases slightly approx 2 V from system voltage 15 Throttle valve control servo B fully opened 2 Power supply to throttle valve control servo Ignition switch ON System voltage 5 Power supply Ignition switch ON System voltage 6 Sensor voltage Ignition switch ON 4 5 5 5 V 7 Throttle position sensor 1st channel Ignition switch ON Release the accelerator pedal 0 45 0 8 ...

Page 156: ...zer special patterns pickup to engine ECU terminal 61 Standard Wave Pattern Observation conditions Function Special patterns Pattern height Low Pattern selector Display Engine r min Idle speed Standard wave pattern V 10 0 The time cycle time T is reduced when the amount of intake air increases Times T1 and T2 are equal Time T T1 T2 Observation conditions from conditions above engine speed is incre...

Page 157: ...s MB991709 in between All terminals should be connected 2 Connect the analyzer special patterns pickup to camshaft position sensor terminal 2 3 Disconnect the crank angle sensor connector and connect the special tool test harness MB991658 in between 4 Connect the analyzer special patterns pickup to crank angle sensor terminal 2 Alternate Method Test harness not available 1 Connect the analyzer spe...

Page 158: ...TDC No 3 TDC No 4 TDC No 2 TDC Time 0 T 4 4 Wave Pattern Observation Points Check that cycle time T becomes shorter when the engine speed increases Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started D Example 2 Cause of problem Loose timing belt Abnormality ...

Page 159: ...ve Pattern Observation conditions Function Special pattern Pattern height Low Pattern selector Display Engine r min Idle speed Standard wave pattern 4 0 8 4 0 V Injector open circuit check signal Injector drive signal ms Wave Pattern Observation Points D Check that the injector drive time is identical to the time displayed on the MUT II D Check that the injector signals become greatly extended but...

Page 160: ...zer special patterns pickup to engine ECU terminal 3 No 1 ignition coil terminal 13 No 2 ignition coil terminal 12 No 3 ignition coil terminal 4 No 4 ignition coil respectively Standard Wave Pattern Observation condition Function Special patterns Pattern height Low Pattern selector Display Engine r min Approx 1 200 r min Standard wave pattern Crank angle sensor output wave pattern Power transistor...

Page 161: ... circuit Rectangular wave at power voltage Power transistor malfunction Examples of Abnormal Wave Patterns D Example 1 Wave pattern during engine cranking Cause of problem Open circuit in ignition primary circuit Wave pattern characteristics Top right part of the build up section cannot be seen and voltage value is approximately 2V too low D Example 2 Wave pattern during engine cranking Cause of p...

Page 162: ...e analyzer special patterns pickup to engine ECU terminal 34 connection terminal 32 connection terminal 6 and connection terminal 5 respectively Standard Wave Pattern Observation conditions Function Special patterns Pattern height High Pattern selector Display Engine condition Racing Standard wave pattern V 30 20 10 The wave pattern appears for an instant but soon disappears Point B Coil reverse e...

Page 163: ...ttern Probable cause Coil reverse electromotive force does not appear or is extremely small Short in the coil Examples of Abnormal Wave Pattern D Example 1 Cause of problem Motor is malfunctioning Motor is not operating Wave pattern characteristics Induced electromotive force from the motor turning does not appear D Example 2 Cause of problem Open circuit in the line between the EGR valve and the ...

Page 164: ...bon deposits are not removed from the throttle vale area repeat steps 3 and 4 6 Install the air intake hose 7 Use the MUT II or disconnect the negative battery cable from the battery terminal in order to erase a diagnosis code Wait for at least ten seconds and then let the engine run at idle again for approx ten minutes THROTTLE POSITION SENSOR ADJUSTMENT 1 Connect the MUT II to the diagnosis conn...

Page 165: ...l tool and the terminal No 3 sensor earth white clip of special tool of the throttle position sensor connector Standard value 4 2 4 8 V 7 If not within the standard value replace the throttle position sensor 8 Turn the ignition switch to OFF 9 Reconnect the throttle valve control servo connector 10 Remove the MUT II If the MUT II is not used remove the special tool and then connect the throttle po...

Page 166: ...1st channel and to the terminal No 1 earth terminal of accelerator pedal position sensor 1st channel 2 Loosen the accelerator pedal position sensor installation bolts 3 Contact the accelerator pedal arm to the stopper 4 Turn the ignition switch to the ON position but do not start the engine 5 Rotate the accelerator pedal position sensor with the knock pin as the centre and adjust the output voltag...

Page 167: ... tool 1 Install the special tool for measuring the fuel pressure between the high pressure fuel hose and the fuel pump high pressure 2 Install the fuel pressure gauge set special tool on the special tool for measuring the fuel pressure putting the gasket between them 3 Connect the lead wire of the fuel pressure gauge set special tool to the power supply cigarette lighter socket and to the MUT II W...

Page 168: ...lace fuel filter D Fuel pressure drops after racing Fuel leaking to return side due to poor fuel pressure regulator low pressure valve seating or settled spring Replace fuel pressure regulator low pressure Low fuel pump low pressure delivery pressure Replace the fuel pump low pressure Fuel pressure too high Binding valve in fuel pressure regula tor low pressure Replace fuel pressure regulator low ...

Page 169: ...CTORS NOTE Measurement of the fuel pressure between the fuel pump high pressure and the injectors should be carried out after checking that the fuel pressure between the fuel pump low pressure and the fuel pump high pressure is normal 1 Connect the MUT II to the diagnosis connector 2 Disconnect the injector intermediate harness connector 3 Turn the ignition switch to ON 4 Select ªItem No 74º from ...

Page 170: ...robable cause Remedy D Fuel pressure too low D Fuel pressure drops after racing Fuel leaking to return side due to poor fuel pressure regulator high pres sure valve seating or settled spring Replace fuel pressure regulator high pressure Low fuel pump high pressure delivery pressure Replace the fuel pump high pressure Fuel pressure too high Binding valve in fuel pressure regula tor high pressure Re...

Page 171: ...ition switch 8 Reconnect the injector intermediate connector 9 Remove the MUT II FUEL PUMP CONNECTOR DISCONNECTION HOW TO REDUCE FUEL PRESSURE When removing the fuel pipe hose etc since fuel pressure in the fuel pipe line is high do the following operation so as to release fuel pressure in the line and prevent fuel from running out 1 Remove the fuel filler cap to release pressure in the fuel tank ...

Page 172: ...Clean the spark plug which corresponds to the disconnected ignition coil connector 9 Remove the MUT II 10 Install the fuel pump relay FUEL PUMP OPERATION CHECK 1 Check the operation of the fuel pump by using the MUT II to force drive the fuel pump 2 If the fuel pump will not operate check by using the following procedure and if it is normal check the drive circuit 1 Turn off the ignition switch 2 ...

Page 173: ...pressure sensor Injector driver B Camshaft position sensor H Injector driver relay A Crank angle sensor E Oxygen sensor U Detonation sensor K Power steering fluid pressure switch M Diagnosis connector R Purge control solenoid valve C EGR valve F Throttle position sensor D Engine control relay A Throttle valve controller S Engine coolant temperature sensor L Throttle valve control servo D Engine EC...

Page 174: ...ier Normal condition Temperature _C Resistance kΩ Higher Smaller 4 If the value deviates from the standard value or the resistance remains unchanged replace the air flow sensor assembly ENGINE COOLANT TEMPERATURE SENSOR CHECK Caution Be careful not to touch the connector resin section with the tool when removing and installing 1 Remove the engine coolant temperature sensor Engine control relay Fue...

Page 175: ...CHECK 1 Disconnect the throttle position sensor connector 2 Measure the resistance between throttle position sensor side connector terminal 1 and terminal 3 Standard value 3 5 6 5 kΩ 3 Measure resistance between terminal Nos 1 and 2 as well as 1 and 4 of the throttle position sensor connector respectively Normal condition Throttle valve slowly open until fully open from the idle position Changes s...

Page 176: ...l position sensor Refer to P 13A 94 ACCELERATOR PEDAL POSITION SENSOR 2ND CHANNEL CHECK 1 Disconnect the accelerator pedal position sensor connector 2 Measure resistance between terminal No 8 sensor power supply and 7 sensor earth of the sensor connector Standard value 3 5 6 5 kΩ 3 Measure resistance between terminal No 8 sensor power supply and 6 sensor output of the connector Normal condition De...

Page 177: ... sure that there is continuity 11 18 Ω at 20_C between terminal 1 red cip of special tool and terminal 3 blue clip of special tool on the oxygen sensor connector 3 If there is no continuity replace the oxygen sensor 4 Warm up the engine until engine coolant is 80_C or higher 5 Use a jumper wire to connect terminal 1 red clip of the oxygen sensor connector to the battery terminal and terminal 3 blu...

Page 178: ... the sensor is defective replace the oxygen sensor NOTE For removal and installation of the oxygen sensor refer to GROUP 15 Exhaust Pipe and Main Muffler INJECTOR CHECK 1 Disconnect the injector intermediate harness connector 2 Measure the resistance between each of the terminals Standard value 0 9 1 1 Ω at 20_C Injector Measurement terminal No 1 cylinder 1 2 No 2 cylinder 3 4 No 3 cylinder 5 6 No...

Page 179: ...tance 1 Disconnect the throttle valve control servo connector 2 Measure resistance between the throttle valve control servo connector terminals Standard value Terminals to be measured Resistance value Ω 1 3 1 35 1 65 at 20_C 2 4 3 Check that there is no continuity between the terminals and body PURGE CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 Emission Control System EGR VALVE CHECK Refer to GR...

Page 180: ...on D Fuel Discharge Prevention before removal only Refer to P 13A 98 D Engine Cover Removal and Installation D Resonance Tank Removal and Installation Refer to GROUP 15 D Fuel Leak Check after installation only Refer to P 13A 98 O ring Engine oil 4 6 10 12 13 14 18 15 16 17 19 8 7 9 19 Nm 19 Nm 9 Nm 19 Nm 5 Nm 5 Nm 17 Nm 10 13 Nm 10 13 Nm 9 Nm 2 7 12 18 25 3 5 1 2 10 13 Nm 24 Nm 4 5 3 11 22 24 25 ...

Page 181: ...ure regulator high pressure 24 Spacer 25 Fuel nipple 26 O ring REMOVAL SERVICE POINT AA FUEL PUMP PROTECTOR REMOVAL Lift up the transmission with a jack to create clearance between the engine and front deck and then remove the fuel pump protector INSTALLATION SERVICE POINTS AA FUEL PRESSURE REGULATOR HIGH PRESSURE INSTALLATION 1 Install provisionally the fuel pressure regulator high pressure to th...

Page 182: ...engine oil to the fuel pump high pressure roller and O ring 2 Install temporarily the fuel pump high pressure to the cylinder head 3 Install the fuel feed pipe and then tighten the fuel pump high pressure mounting bolts to 5 Nm in the order shown in the illustration 4 Tighten the bolts to 17 Nm in the order shown in the illustration The overall difference in tightening torque between the four bolt...

Page 183: ...l 1 2 3 4 5 6 11 20 25 Nm 10 13 Nm 7 8 9 10 12 10 13 Nm 13 14 15 16 14 1 2 3 4 O ring Removal steps DA 1 Fuel feed pipe CA 2 Back up ring A CA 3 O ring CA 4 Back up ring B AA 5 Injector harness connector 6 Washer 7 Injector holder AB BA 8 Delivery pipe assembly 9 Insulator AB BA 10 Fuel injector assembly 11 Back up ring 12 O ring 13 Back up ring 14 Fuel injector 15 Gasket AA 16 Corrugated washer ...

Page 184: ... washer should always be replaced with a new part BA FUEL INJECTOR ASSEMBLY DELIVERY PIPE ASSEMBLY INSTALLATION 1 Apply a small amount of fresh engine oil to the O ring Caution Take care not to let any of the engine oil get inside the delivery pipe assembly 2 While being careful not to damage the O ring turn the fuel injector assembly to the left and right and connect it to the delivery pipe assem...

Page 185: ...s to the specified torque in the order shown in the illustration CA BACK UP RING B O RING BACK UP RING A INSTALLATION Install the back up rings and the O ring as shown in the illustration Caution Install the back up ring B facing its cutaway surface toward the opposite side of the O ring as shown in the illustration DA FUEL FEED PIPE INSTALLATION Apply a small amount of fresh engine oil to the O r...

Page 186: ...e position sensor connector connection 2 Throttle control servo connector con nection 3 Water hose connection AA 4 Throttle body assembly 5 Throttle body gasket INSTALLATION SERVICE POINT AA THROTTLE BODY INSTALLATION If the throttle body is replaced initialize the electronic controlled throttle valve system Initialization Turn on the ignition switch and turn it to LOCK OFF position within one sec...

Page 187: ...the screws 3 Measure resistance value between terminal Nos 1 sensor power supply and 2 throttle position sensor 1st channel output as well as 1 sensor power supply and 4 throttle position sensor 2nd channel output Normal condition Open the throttle valve slowly from the idle position to full open position Resistance value changes smoothly in response to throttle valve opening angle 4 If the resist...

Page 188: ...nector in the place shown in the illustration to disconnect the injector driver connector Caution 1 Disconnect the battery cable from its terminal before carrying out this operation 2 High tension current is flowing in the harness between the injector driver and the injector while engine is running and the injector driver will become hot after the vehicle has been driven so take care when handling...

Page 189: ...alve controller is replaced initialize the electronic controlled throttle valve system Initialization Turn on the ignition switch and turn it to LOCK OFF position within one second Then leave it for at least ten seconds with the ignition switch in LOCK OFF position Throttle valve controller Accelerator cable ...

Page 190: ...NOTES ...

Page 191: ...13B 1 FUEL SUPPLY CONTENTS FUEL TANK 2 Fuel Pump Module 4 ...

Page 192: ...ation Refer to GROUP 15 1 2 4 5 6 7 8 10 12 13 14 15 16 17 18 19 20 11 9 23 22 3 21 5 10 12 19 2 3 Nm 2 3 Nm 2 3 Nm 2 3 Nm 13 16 Nm Removal steps 1 Parking brake cable clamp mounting nut 2 Filler hose 3 Leveling hose AA 4 High pressure tube connection 5 Vapour hose connection 6 Return hose connection 7 Harness connector connection 8 Fuel tank assembly AA 9 High pressure tube 10 Return hose AA 11 S...

Page 193: ...uts and then remove the pipe and gauge assembly and fuel pump module 5 Install the pipe and gauge assembly and fuel pump module Tighten the mounting nuts to the specified torque Specified torque 2 3 Nm 6 Connect the fuel hose fuel tube and harness connector Caution After the connection pull the high pressure tube and suction tube gently in the direction of removal to check that they are firmly con...

Page 194: ...Bracket 4 Cushion 5 Fuel pump low pressure 6 Fuel tube A 7 Grommet 8 Housing 9 Stopper 10 Fuel pressure regulator low pressure and assist pump assembly A 11 O ring 12 Fuel hose 13 Fuel filter assembly REASSEMBLY SERVICE POINT A O RING GROMMET INSTALLATION Apply a fuel to O ring and grommet before installing them to prevent them from being damaged or twisted ...

Page 195: ...TOOL 3 TROUBLESHOOTING 3 ON VEHICLE SERVICE 8 Engine Coolant Leak Checking 8 Radiator Cap Valve Opening Pressure Check 8 Engine Coolant Replacement 9 Concentration Measurement 10 Fan Controller Check 10 Fan Control Relay Continuity Check 11 THERMOSTAT 12 WATER PUMP 14 WATER HOSE AND WATER PIPE 15 RADIATOR 18 ...

Page 196: ...he water pump is of the centrifugal type and is driven by the timing belt from the crankshaft The radiator is the corrugated fin down flow type and is cooled by the electrical radiator fan The cooling fans are controlled by a fan controller and the engine ECU depending on driving conditions Items Specifications Radiator Performance kJ h M T 152 791 A T 169 535 A T oil cooler Performance kJ h 5 652...

Page 197: ...harness adapter D probe Measurement of terminal voltage A Connector pin contact pressure inspection B Power circuit inspection C Power circuit inspection D Commercial tester connection TROUBLESHOOTING INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptoms Inspection procedure No Reference page Radiator fan and condenser fan do not operate Vehicles with A C Radiator fan does not operate Vehicles wi...

Page 198: ...and fan controller assembly OK Measure at the engine ECU connectors C 17 D Connect the connector D Pull out the terminal No 18 to disconnect it Ignition switch ON OK The radiator fan motor and condenser fan motor operate Engine ECU terminal voltage check Refer to GROUP 13 Trou bleshooting OK Measure at the engine ECU connectors C 17 D Connect the connector D Voltage between 18 and body earth Engin...

Page 199: ...gine ECU connectors C 17 D Connect the connector D Pull out the terminal No 18 to disconnect it Ignition switch ON OK The radiator fan motor operates OK Measure at the engine ECU connectors C 17 D Connect the connector D Voltage between 18 and body earth Engine idling OK 0 7 V or more When radiator fan is operating NG Check the harness wire between fan controller and engine ECU Measure at the fan ...

Page 200: ... D Connect the connector D Pull out the terminal No 18 to disconnect it Ignition switch ON OK The radiator fan motor and condenser fan motor operate D Connect the terminal No 18 to the body earth Ignition switch ON OK The radiator fan motor and condenser fan motor stop OK Fan controller check Refer to P 14 10 NG Replace the radiator fan motor and fan controller assembly Engine ECU terminal voltage...

Page 201: ...D Check the harness wire between fan control relay and engine control relay D Check the harness wire between fan control relay and body earth D Check the harness wire between fan control relay and fan controller NG Repair Fan control relay check Refer to P 14 11 NG Replace Inspection Procedure 3 Radiator fan does not operate Vehicles with A C Probable cause The cause could be a malfunction of the ...

Page 202: ...coolant from it 3 Be careful when installing and removing the tester and when testing not to deform the radiator filler neck 2 If there is leakage repair or replace the appropriate part RADIATOR CAP VALVE OPENING PRESSURE CHECK 1 Use a cap adapter to attach the cap to the radiator cap tester 2 Increase the pressure until the indicator of the gauge stops moving Standard value 75 105 kPa Limit 65 kP...

Page 203: ...ant into the mouth of the radiator until the radiator is full and pour also into the reserve tank up to the FULL line Recommended antifreeze MITSUBISHI GENUINE COOLANT or equivalent Quantity 6 Caution Do not use alcohol or methanol anti freeze or any engine coolants mixed with alcohol or methanol anti freeze The use of an improper anti freeze can cause the corrosion of the aluminium components 9 I...

Page 204: ...the anti freezing and engine cooling properties will decrease affecting the engine adversely For these reasons be sure to maintain the concentration level within the specified range FAN CONTROLLER CHECK 1 Disconnect the condenser fan motor connector 2 Start the engine and run it at idle 3 Turn the A C switch to ON and maintain the coolant temperature at 80_C or less 4 When measuring the voltage be...

Page 205: ...ENGINE COOLING On vehicle Service 14 11 FAN CONTROL RELAY CONTINUITY CHECK Battery voltage Terminal No 1 2 3 4 When current is not supplied When current is supplied Fan control relay ...

Page 206: ...nd Under Cover Removal and Installation D Air Cleaner Removal and Installation Refer to GROUP 15 1 22 25 Nm 2 3 Removal steps AA BA 1 Radiator lower or upper hose con nection 2 Water inlet or outlet fitting AA 3 Thermostat REMOVAL SERVICE POINT AA RADIATOR LOWER OR UPPER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp disconnect the radiator hose ...

Page 207: ...let fitting 2 Align the mating marks on the radiator hose and hose clamp and then connect the radiator hose INSPECTION THERMOSTAT CHECK 1 Immerse the thermostat in water and heat the water while stirring Check the thermostat valve opening temperature Standard value Valve opening temperature 82 1 5_C 2 Check that the amount of valve lift is at the standard value when the water is at the full openin...

Page 208: ...r Pulley Removal and Installation Refer to GROUP 11A 24 Nm 1 10 12 Nm 2 Sealant Mitsubishi Genuine Part No MD970389 or equivalent Removal steps 1 Timing belt rear cover AA 2 Water pump INSTALLATION SERVICE POINT AA WATER PUMP INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without sealant Specified Sealant Mitsubishi Genuin...

Page 209: ... Sealant Mitsubishi Genuine Part No MD970389 or equivalent 10 12 Nm 1 10 12 Nm 22 25 Nm 22 25 Nm 22 25 Nm 22 25 Nm 22 25 Nm 5 8 16 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 13 9 12 15 Nm 9 4 Removal steps AA BA 1 Radiator lower hose connection 2 Thermostat case assembly 3 Water pipe CA 4 O ring 5 Water fitting 6 Heater hose connection 7 Water pipe assembly AA 8 Water by pass fitting CA 9 O ring D EGR v...

Page 210: ...ivalent 3 Install the water fitting water bypass fitting and the water outlet fitting while the sealant is wet within 15 minutes after applying the sealant Do not apply sealant to the positions other than the required BA RADIATOR UPPER HOSE RADIATOR LOWER HOSE CONNECTION 1 Insert each hose as far as the projection of the water inlet fitting 2 Align the mating marks on the radiator hose and hose cl...

Page 211: ...ENGINE COOLING Water Hose and Water Pipe 14 17 INSPECTION WATER PIPE AND HOSE CHECK Check the water pipe and hose for cracks damage clog and replace them if necessary ...

Page 212: ... D A T Fluid Supplying Refer to GROUP 23 On vehicle Service 3 1 12 Nm 12 Nm 12 Nm 8 2 8 7 13 15 14 12 5 4 11 6 5 10 10 9 Radiator removal steps 1 Drain plug 2 Radiator cap AA AA 3 Radiator upper hose AA AA 4 Radiator lower hose AB 5 A T oil cooler hose connection 6 Rubber hose 7 Condense tank 8 Upper insulator 9 Radiator assembly 10 Lower insulator 11 Condenser fan motor assembly 12 Radiator fan m...

Page 213: ... A T OIL COOLER HOSE REMOVAL After removing the hose from the radiator plug the hose and the radiator nipple to prevent dust or foreign particles from getting in INSTALLATION SERVICE POINT AA RADIATOR LOWER HOSE RADIATOR UPPER HOSE CONNECTION 1 Insert each hose as far as the projection of the water inlet fitting 2 Align the mating marks on the radiator hose and hose clamp and then connect the radi...

Page 214: ...NOTES ...

Page 215: ...15 1 INTAKE AND EXHAUST CONTENTS SERVICE SPECIFICATION 2 SPECIAL TOOL 2 AIR CLEANER 3 INTAKE MANIFOLD 4 EXHAUST MANIFOLD 6 EXHAUST PIPE AND MAIN MUFFLER 7 CATALYTIC CONVERTER Refer to GROUP 35A ...

Page 216: ...cial Tool 15 2 SERVICE SPECIFICATION Items Standard value Limit Distortion of the intake manifold installation surface mm 0 15 or less 0 20 SPECIAL TOOL Tool Number Name Use MD998770 Oxygen sensor wrench Removal and installation of oxygen sensor ...

Page 217: ...peration Engine Cover Removal and Installation 10 Nm 9 Nm 1 2 3 4 5 6 7 8 9 10 Air cleaner removal steps 1 Air intake hose 2 Resonator 3 Air duct 4 Air flow sensor connector connection 5 Air cleaner cover 6 Air cleaner element 7 Air cleaner Resonance tank removal steps 8 Resonance tank 9 Air hose 10 Insulator ...

Page 218: ...Nm 16 17 11 28 Nm 19 Nm 11 10 12 Nm 19 21 10 12 Nm 10 12 Nm 10 12 Nm Removal steps 1 Engine coolant temperature sensor connector connection 2 Condenser connector connection 3 Camshaft position sensor connector connection 4 Injector harness connector connection 5 Purge control solenoid connector connection 6 EGR valve connector connection 7 Harness connector bracket 8 Water hose and pipe 9 Brake bo...

Page 219: ...the engine and the front deck and remove the fuel pump protector INSPECTION Check the following points replace the part if a problem is found INTAKE MANIFOLD CHECK 1 Check for damage or cracking of any part 2 Using a straight edge and thickness gauge check for distortion of the cylinder head installation surface Standard value 0 15 mm or less Limit 0 20 mm ...

Page 220: ...lation Air Cleaner Removal and Installation Refer to P 15 3 29 Nm 98 Nm 12 15 Nm 29 Nm 18 Nm 34 Nm 1 2 5 13 Nm 13 Nm 8 3 7 34 Nm 6 4 Removal steps 1 Front exhaust pipe connection 2 Exhaust manifold bracket 3 Engine oil level gauge guide 4 Washer tank filler tube 5 A C pressure switch connector connection 6 Exhaust manifold cover 7 Exhaust manifold 8 Exhaust manifold gasket ...

Page 221: ... Nm 9 49 Nm 10 49 Nm 6 5 2 4 14 34 Nm 13 Nm 13 Nm Main muffler removal steps 1 Main muffler 3 Gasket 4 Hanger Center exhaust pipe removal steps 2 Center exhaust pipe 3 Gasket 5 Gasket 6 Protector 7 Hanger Pre muffler removal steps 8 Pre muffler 11 Gasket Center exhaust pipe removal steps A A 9 Oxygen sensor 10 Front exhaust pipe 11 Gasket 12 Gasket 13 Heat protector 14 Hanger REMOVAL SERVICE POINT...

Page 222: ...NOTES ...

Page 223: ...uity Check 10 ALTERNATOR 11 STARTING SYSTEM 17 GENERAL INFORMATION 17 SERVICE SPECIFICATIONS 17 STARTER MOTOR 18 IGNITION SYSTEM 27 GENERAL INFORMATION 27 SERVICE SPECIFICATIONS 28 SPECIAL TOOL 28 ON VEHICLE SERVICE 29 Ignition Coil With Built in Power Transistor Check 29 Spark Plug Check and Cleaning 30 Camshaft Position Sensor Check 30 Crank Angle Sensor Check 30 Detonation Sensor Check 30 IGNIT...

Page 224: ...n the stator coil begins to generate power after the engine is started the field coil is excited by the output current of the stator coil The alternator output voltage rises as the field current increases and it falls as the field current decreases When the battery voltage alternator S terminal voltage reaches a regulated voltage of approx 14 4 V the field current is cut off When the battery volta...

Page 225: ... SPECIFICATIONS Items Standard value Limit Alternator output line voltage drop at 30 A V Max 0 3 Regulated voltage ambient temp at voltage regulator V 20_C 14 2 15 4 temp at voltage regulator V 20_C 13 9 14 9 60_C 13 4 14 6 80_C 13 1 14 5 Output current 70 of normal output current SPECIAL TOOL Tool Number Name Use MB991519 Alternator test harness Checking the alternator S terminal voltage ...

Page 226: ...le 4 Disconnect the alternator output wire from the alternator ªBº terminal and connect a DC test ammeter with a range of 0 100 A in series between the ªBº terminal and the disconnected output wire Connect the lead of the ammeter to the ªBº terminal and then connect the lead of the ammeter to the disconnected output wire NOTE An inductive type ammeter which enables measurements to be taken without...

Page 227: ...displayed on the voltmeter at this time When the value range is 40 A the limit is max 0 4 V 11 If the value displayed on the voltmeter is above the limit value there is probably a malfunction in the alternator output wire so check the wiring between the alternator ªBº terminal and the battery terminal including fusible link If a terminal is not sufficiently tight or if the harness has become disco...

Page 228: ... between the alternator ªBº terminal and the battery terminal 10 Turn the light switch on to turn on headlamps and then start the engine 11 Immediately after setting the headlamps to high beam and turning the heater blower switch to the high revolution position increase the engine speed to 2 500 r min and read the maximum current output value displayed on the ammeter Limit 70 of normal current out...

Page 229: ...ENGINE ELECTRICAL Charging System 16 7 REGULATED VOLTAGE TEST Ignition switch Charging warning lamp Load Alternator Alternator relay Yellow Engine ECU Battery Voltmeter Ammeter FR L S G MB991519 ...

Page 230: ...ter or the MUT II 9 Turn the ignition switch to the ON position and check that the reading on the voltmeter is equal to the battery voltage NOTE If the voltage is 0 V the cause is probably an open circuit in the wire or fusible link between the alternator ªSº terminal and the battery terminal 10 Turn all lamps and accessories off 11 Start the engine 12 Increase the engine speed to 2 500 r min 13 R...

Page 231: ...e at alternator B terminal 0 4 0 2 0 0 2 0 4 Time NOTE The voltage waveform of the alternator ªBº terminal can undulate as shown at left This waveform is produced when the regulator operates according to fluctuations in the alternator load current and is normal for the alternator In addition when the voltage waveform reaches an excessively high value approx 2 V or higher at idle it often indicates...

Page 232: ... Open diode Example 4 Short in stator coil Example 2 Short in diode Example 5 Open supplementary diode Example 3 Broken wire in stator coil At this time the charging warning lamp is illuminated ALTERNATOR RELAY CONTINUITY CHECK 1 Remove the alternator relay from the relay box inside the instrument panel 2 Set the analogue type circuit tester to the Ω range and check that there is continuity when t...

Page 233: ...emoval Operation Under Cover Removal Post installation Operation D Drive Belt Tension Adjustment D Under Cover Installation 3 20 25 Nm 5 1 2 4 44 Nm 44 Nm Disassembly steps 1 Drive belt Power steering A C 2 Drive belt Alternator 3 Alternator brace 4 Alternator connector 5 Alternator ...

Page 234: ... 7 6 5 3 4 14 13 12 11 10 9 8 Disassembly steps AA 1 Front bracket assembly AB 2 Alternator pulley BA 3 Rotor 4 Rear bearing 5 Bearing retainer 6 Front bearing 7 Front bracket AC 8 Stator 9 Plate AC AA 10 Regulator assembly 11 Brush 12 Slinger 13 Rectifier 14 Rear bracket ...

Page 235: ... rotor with a work bench and remove the pulley Caution Use care so that the rotor is not damaged AC STATOR REGULATOR ASSEMBLY REMOVAL 1 Use a soldering iron 180 to 250 W to unsolder the stator This work should complete within approximately four seconds to prevent heat from transferring to the diode 2 When removing the rectifier from the regulator assembly remove the soldered sections of the rectif...

Page 236: ...s fixed when a wire is inserted making rotor installation easier BA ROTOR INSTALLATION After installing the rotor remove the wire used to fix the brush INSPECTION ROTOR CHECK 1 Check the continuity between the rotor coil slip rings and replace the rotor if the resistance value is not at the standard value Standard value 3 5 Ω 2 Check the continuity between the slip ring and core and if there is co...

Page 237: ...nal using a tester probe If there is a continuity at both the diode is short circuited so replace the rectifier 2 Inspect the heat sink by checking the continuity between the heat sink and stator coil lead wire connection terminal using a tester probe If there is a continuity at both the diode is short circuited so replace the rectifier 3 Check the diode trio by connecting an ohmmeter to both ends...

Page 238: ...ation and replace the brush if the measured value is below the limit value Limit 2 mm or less 2 The brush can be removed if the solder of the brush lead wire is removed 3 When installing a new brush insert the brush into the holder as shown in the illustration and then solder the lead wires Protrusion length Soldered ...

Page 239: ...e starter motor When the ignition switch is returned to the ªONº position after starting the engine the starter clutch is disengaged from the ring gear An overrunning clutch is provided between the pinion and the armature shaft to prevent damage to the starter SYSTEM DIAGRAM Pull in coil Holding coil Ignition switch Battery Armature Brush Yoke Over running clutch Plunger Lever Pinion shaft STARTER...

Page 240: ...et switch to ªONº and pinion will move out Caution This test must be performed quickly in less than 10 seconds to prevent coil from burning 4 Check pinion to stopper clearance pinion gap with a thickness gauge Standard value 0 5 2 0 mm 5 If pinion gap is out of specification adjust by adding or removing gaskets between magnetic switch and front bracket S Switch Battery Field coil wire B M Stopper ...

Page 241: ...ion remains out everything is in order If pinion moves in hold in circuit is open Replace magnetic switch FREE RUNNING TEST 1 Place starter motor in a vise equipped with soft jaws and connect a fully charged 12 volt battery to starter motor as follows 2 Connect a test ammeter 100 ampere scale and carbon pile rheostat in series with battery positive post and starter motor terminal 3 Connect a voltm...

Page 242: ...een M terminal and body Caution This test must be performed quickly in less than 10 seconds to prevent coil from burning 3 Pull pinion out and release If pinion quickly returns to its original position everything is in order If it doesn t replace magnetic switch Caution Be careful not to get your fingers caught when pulling out the pinion Field coil wire M Battery ...

Page 243: ... 26 33 Nm 11 10 12 Nm 5 5 Nm 3 2 5 Nm 28 Nm 4 9 10 12 Nm 10 7 8 26 33 Nm 34 Nm Disassembly steps 1 Starter harness connection 2 A T oil pipe clamp 3 Earth cable connection 4 Intake manifold stay 5 Oxygen sensor connector connection 6 Front exhaust pipe connection AA AA D Transmission mount crossmember 7 Water pipe clamp 8 Injector harness connector connection 9 Harness connector bracket 10 Detonat...

Page 244: ...ROUP 32 2 Lower the jack holding the engine and transmission assembly to create clearance enough to remove the starter motor installation bolts AB STARTER MOTOR ASSEMBLY REMOVAL Pull the starter motor assembly out of space between the intake manifold and cylinder block INSTALLATION SERVICE POINT AA TRANSMISSION MOUNT CROSSMEMBER INSTALLATION Refer to GROUP 32 ...

Page 245: ...y steps 1 Screw AA 2 Magnetic switch 3 Screw 4 Through bolt 5 Rear bracket 6 Brush holder 7 Brush 8 Rear bearing AB 9 Armature 10 Yoke assembly AB 11 Ball 12 Packing A 13 Packing B 14 Plate 15 Planetary gear 16 Lever AC AA 17 Snap ring AC AA 18 Stop ring 19 Overrunning clutch 20 Internal gear 21 Planetary gear holder 22 Front bracket ...

Page 246: ...e the stop ring and overrunning clutch STARTER MOTOR PARTS CLEANING 1 Do not immerse the parts in cleaning solvent Immersing the yoke and field coil assembly and or armature will damage insulation Wipe these parts with a cloth only 2 Do not immerse the drive unit in cleaning solvent The overrunning clutch is pre lubricated at the factory and solvent will wash lubrication from clutch 3 The drive un...

Page 247: ...h a dial indicator Standard value 0 05 mm Limit 0 1 mm 2 Measure the commutator outer diameter Standard value 29 4 mm Limit 28 8 mm 3 Check the undercut depth between segments Standard value 0 5 mm Limit 0 2 mm OVERRUNNING CLUTCH 1 Check that the pinion locks when it is turned anti clockwise and moves smoothly when it is turned clockwise 2 Check the pinion for wear or damage Stop ring Overrunning ...

Page 248: ...T 1 Place armature in a growler 2 Hold a thin steel blade parallel and just above while rotating armature slowly in growler A shorted armature will cause blade to vibrate and be attracted to the core Replace shorted armature Caution Clean the armature surface thoroughly before checking 3 Check the insulation between each commutator segment and armature coil core If there is no continuity the insul...

Page 249: ...rmines which ignition coil should be controlled by means of the signals from the camshaft position sensor and the crank angle sensor It also detects the crankshaft position in order to provide ignition at the most appropriate timing in response to the engine operation conditions When the engine is cold or running at high altitudes the ignition timing is slightly advanced to provide optimum perform...

Page 250: ... coil SPARK PLUG SPECIFICATIONS Items Specifications NGK IZFR6B SERVICE SPECIFICATIONS SPARK PLUG Items Standard value Limit Spark plug gap mm 0 5 0 6 0 75 Spark plug insulation resistance MΩ 1 SPECIAL TOOL Tool Number Name Use MD998773 Detonation sensor wrench Detonation sensor removal and installation ...

Page 251: ... CHECK NOTE It is impossible to check the secondary coil through the continuity check as a diode is integrated in the secondary coil circuit of this ignition coil So check the secondary coil in the following procedure 1 Disconnect the ignition coil connector 2 Remove the ignition coil and install a new spark plug to the ignition coil 3 Connect the ignition coil connector 4 Earth the side electrode...

Page 252: ...ore easily than for conventional spark plugs so such blackening is not normally a problem Measure the insulation resistance of the spark plug to judge if the plug is still usable or not 1 Check the plug gap and replace the plug if the gap is greater than the limit value Standard Valve 0 5 0 6 mm Limit 0 75 mm 2 Measure the insulation resistance of the spark plug and replace the plug if the resista...

Page 253: ... and Post installation Operation D Engine Cover Removal and Installation D Resonance Tank Removal and Installation Refer to GROUP 15 D Air Cleaner Assembly and Air Intake Hose Removal and Installation 25 Nm 1 3 2 10 Nm Disassembly steps 1 Ignition Coil Connector 2 Ignition Coil 3 Spark Plug ...

Page 254: ...ALLATION Pre removal and Post installation Operation Timing Belt Front Lower Cover Removal and Installation Refer to GROUP 11 9 Nm Crank angle sensor CAMSHAFT POSITION SENSOR REMOVAL AND INSTALLATION Pre removal and Post installation Operation Engine Cover Removal and Installation Camshaft position sensor 9 Nm ...

Page 255: ...oval and Post installation Operation D Engine Cover Removal and Installation 20 25 Nm 10 12 Nm 2 1 10 12 Nm Disassembly steps 1 Water pipe clamp AA AA 2 Detonation sensor REMOVAL SERVICE POINT AA DETONATION SENSOR REMOVAL INSTALLATION SERVICE POINT AA DETONATION SENSOR INSTALLATION MD998773 ...

Page 256: ...NOTES ...

Page 257: ...AL TOOL 6 VACUUM HOSE 6 Vacuum Hose Piping Diagram 6 Vacuum Circuit Diagram 7 Vacuum Hose Check 7 Vacuum Hose Installation 7 CRANKCASE EMISSION CONTROL SYSTEM 8 General Information 8 System Diagram 8 Component Location 8 Positive Crankcase Ventilation System Check 9 PCV Valve Check 9 EVAPORATIVE EMISSION CONTROL SYSTEM 10 General Information 10 System Diagram 10 Component Location 10 Purge Control...

Page 258: ...CULA TION EGR SYSTEM 13 General Information 13 Operation 13 System Diagram 13 Component Location 13 Exhaust Gas Recirculation EGR ControL System Check 14 EGR Valve Stepper Motor Check 14 EGR VALVE 1 6 CATALYTIC CONVERTER 17 ...

Page 259: ... value Accelerator cable play mm 1 2 ON VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT 1 Check the accelerator cable play when the accelerator pedal is released Standard value 1 2 mm 2 If the play is not within the standard value turn the adjusting nut to adjust the play to the standard value Adjusting nut ...

Page 260: ...r Check and Adjustment Refer to GROUP 13A On vehicle Service D Kickdown Cable Adjustment Refer to GROUP 23 On vehicle Service 12 Nm 2 9 5 1 6 8 3 7 10 Nm 4 Removal steps 1 Kickdown cable connection 2 Spring nut 3 Bushing 4 Return spring 5 Accelerator pedal 6 Accelerator pedal pad 7 Accelerator pedal position sensor 8 Accelerator pedal bracket 9 Accelerator pedal stopper ...

Page 261: ...quipped Duty cycle type solenoid valve Purpose HC reduction Exhaust emission control system Air fuel ratio control device GDI system Oxygen sensor feedback type Purpose CO HC NOx reduction Exhaust gas recirculation system D EGR valve Equipped Stepper motor type Purpose NOx reduction Catalytic converter Monolith type Purpose CO HC NOx reduction EMISSION CONTROL DEVICE REFERENCE TABLE Related parts ...

Page 262: ...oil resistance at 20_C Ω 10 20 SPECIAL TOOL Tool Number Name Use MB991658 Test harness set Inspection of EGR valve VACUUM HOSE VACUUM HOSE PIPING DIAGRAM PCV valve From fuel pump low pressure Canister Purge control solenoid valve Oxygen sensor Fuel pressure regulator high pressure To fuel tank EGR valve stepper motor P Catalytic converter Fuel pump high pressure Injector Air cleaner Air ...

Page 263: ...ACUUM HOSE CHECK 1 Using the piping diagram as a guide check to be sure that the vacuum hoses are correctly connected 2 Check the connection condition of the vacuum hoses removed loose etc and check to be sure that there are no bends or damage VACUUM HOSE INSTALLATION 1 When connecting the vacuum hoses they should be securely inserted onto the nipples 2 Connect the hoses correctly using the vacuum...

Page 264: ... blow by gases inside the crankcase The blow by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation PCV valve The PCV valve lifts the plunger according to the intake manifold vacuum so as to regulate the flow of blow by gas properly In other words the blow by gas flow is regulated during low load engine operation to maintain engine stability while ...

Page 265: ...ng of the PCV valve and check that vacuum of the intake manifold is felt NOTE At this moment the plunger in the PCV valve moves back and forth 6 If vacuum is not felt clean the PCV valve or replace it PCV VALVE CHECK 1 Insert a thin rod into the PCV valve from the side shown in the illustration rocker cover installation side and move the rod back and forth to check that the plunger moves 2 If the ...

Page 266: ...the purge solenoid and purge port and go into the intake manifold to be sent to the combustion chamber When the engine coolant temperature is low or when the intake air quantity is small when the engine is at idle for example the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold This does not only insure the driveability when the engine is col...

Page 267: ...Vacuum is maintained 3 000 r min When engine is hot Engine coolant temperature 80_C or higher Engine condition Normal condition At idle Vacuum is maintained 3 000 r min fore approximately 3 minutes after the engine is started Vacuum will leak PURGE PORT VACUUM CHECK 1 Disconnect the vacuum hose red stripe from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple 2 Sta...

Page 268: ...ess connector 3 Connect a hand vacuum pump to nipple A of the solenoid valve refer to the illustration at left 4 Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage Jumper wire Nipple B Normal condition Connected Open Vacuum leaks Closed Vacuum maintained Disconnected Open Vacuum maintained 5 Measur...

Page 269: ...hamber through the intake manifold to decrease the air fuel mixture combustion temperature resulting in reduction of NOx The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability OPERATION The EGR valve is being closed and dose not recirculate exhaust gases under one of the following conditions Otherwise the EGR valve is opened and recirculate exhaust gases D The engi...

Page 270: ...2 If the operation sound cannot be heard check the stepper motor drive circuit NOTE If the circuit is normal the cause is probably a malfunction of the stepper motor or of the engine ECU Checking the Coil Resistance 1 Disconnect the EGR valve connector 2 Measure the resistance between the EGR valve side connector terminal No 2 and terminal No 1 or terminal No 3 Standard value 10 20 Ω at 20_C 3 Mea...

Page 271: ...t terminal No 3 and terminal No 4 to the negative terminal of the power supply 3 Connect terminal No 3 and terminal No 6 to the negative terminal of the power supply 4 Connect terminal No 1 and terminal No 6 to the negative terminal of the power supply 5 Connect terminal No 1 and terminal No 4 to the negative terminal of the power supply 6 Repeat the test in the order from 5 to 1 5 If the results ...

Page 272: ... 1 9 24 Nm 24 Nm 19 Nm 10 19 Nm 8 7 5 2 3 10 12 Nm 4 7 6 Removal steps AA 1 Fuel pump protector 2 EGR valve harness connector connection 3 Water hose 4 Water pipe 5 Water hose 6 EGR valve and support assembly 7 EGR pipe gasket 8 EGR valve 9 EGR valve gasket 10 Water hose REMOVAL SERVICE POINT AA FUEL PUMP PROTECTOR REMOVAL Lift up the transmission with a jack to create clearance between the engine...

Page 273: ...oxidizes carbon monoxides CO and hydrocarbons HC and reduces nitrogen oxides NOx When the mixture is controlled at stoichiometric air fuel ratio the three way catalytic converter provides the highest purification against the three constituents namely CO HC and NOx REMOVAL AND INSTALLATION 49 Nm 49 Nm 34 Nm 49 Nm 1 2 3 Removal steps 1 Oxygen sensor harness connector connection 2 Front exhaust pipe ...

Page 274: ...NOTES ...

Page 275: ... CLUTCH CONTENTS GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 2 LUBRICANTS 2 ON VEHICLE SERVICE 2 Clutch Pedal Inspection and Adjustment 2 Bleeding 3 CLUTCH PEDAL 4 CLUTCH CONTROL 5 Clutch Master Cylinder 7 ...

Page 276: ...een the clutch pedal and the toeboard when the clutch is disengaged mm 110 or more LUBRICANTS Items Specified lubricants Quantity Clutch fluid Brake fluid DOT3 or DOT4 As required Push rod assembly Rubber grease Release cylinder push rod MITSUBISHI genuine grease Part No 0101011 ON VEHICLE SERVICE CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1 Turn up the carpet etc under the clutch pedal 2 Measure the ...

Page 277: ... Standard value C 6 13 mm Standard value D 110 mm or more 5 If the clutch pedal free play and the distance between the clutch pedal and the toeboard when the clutch is disengaged do not agree with the standard values it is probably the result of either air in the hydraulic system or a faulty master cylinder release cylinder or clutch Bleed the air or disassemble and inspect the master cylinder rel...

Page 278: ...Pedal Adjustment Refer to P 21 2 2 4 5 6 7 3 12 Nm 1 12 Nm L H drive vehicles R H drive vehicles 2 4 6 7 3 12 Nm 1 12 Nm Removal steps 1 Snap pin 2 Clevis pin 3 Clutch master cylinder mounting nut 4 Master cylinder member mounting bolt 5 Stopper R H drive vehicles 6 Pedal pad 7 Clutch pedal assembly ...

Page 279: ...SUBISHI genuine grease Part No 0101011 15 Nm 11 13 5 Nm 19 Nm 13 Nm 13 5 10 11 12 13 20 25 Nm 12 Nm 5 Nm Clutch master cylinder assembly removal steps 1 Clevis pin 2 Clutch pipe connection 3 Breather hose connection 4 Clutch master cylinder assembly 5 Sealer Reservoir tank removal steps 3 Breather hose connection 5 Bolt 6 Reservoir bracket 7 Reservoir tank 8 Breather hose Clutch release cylinder a...

Page 280: ...Part No 0101011 15 Nm 7 6 19 Nm 5 Nm 7 20 25 Nm 12 Nm Clutch master cylinder assembly removal steps 1 Clevis pin 2 Clutch pipe connection 3 Clutch master cylinder assembly 4 Sealer Clutch release cylinder assembly removal steps 5 Clutch pipe connection 6 Clutch release cylinder assembly Clutch line removal steps 7 Clutch pipe 8 Bracket 9 Clutch hose ...

Page 281: ... ring 2 Piston assembly AA 3 Push rod assembly 4 Boot 5 Nipple L H drive vehicles 6 Reservoir cap R H drive vehicles 7 Spring pin 8 Reservoir tank R H drive vehicles 9 Seal 10 Master cylinder body L H drive vehicles 11 Master cylinder body R H drive vehicles INSTALLATION SERVICE POINT AA PUSH ROD ASSEMBLY INSTALLATION Set the length of the push rod assembly to the shown dimension to make the adjus...

Page 282: ...NOTES ...

Page 283: ...BRICANT 2 SEALANTS AND ADHESIVES 2 ON VEHICLE SERVICE 2 Transmission Oil Check 2 Transmission Oil Change 2 Transfer Oil Check 3 Transfer Oil Change 3 TRANSMISSION CONTROL 4 TRANSMISSION AND TRANSFER ASSEMBLY 8 4WD INDICATOR CONTROL UNIT 9 ...

Page 284: ...ing No 4170 or equivalent Anaerobic sealant ON VEHICLE SERVICE TRANSMISSION OIL CHECK 1 Remove the oil filler plug 2 Oil level should be at the lower portion of the oil filler plug hole 3 Check that the transmission oil is not noticeably dirty and that it has a suitable viscosity 4 Tighten the oil filler plug to the specified torque Tightening torque 29 34 Nm TRANSMISSION OIL CHANGE 1 Remove the o...

Page 285: ...34 Nm TRANSFER OIL CHANGE 1 Remove the oil drain plug to drain oil 2 Install the oil drain plug and then tighten it to the specified torque Tightening torque 29 34 Nm 3 Remove the oil filler plug and then fill with specified oil till the level comes to the lower portion of oil filler plug hole Specified oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API GL 4 Quantity 2 2 ȏ 4 Install the o...

Page 286: ...smoothly and correctly 1 2 3 4 5 6 7 9 10 13 8 11 19 Nm 12 14 19 Nm 19 Nm 19 Nm Transmission control lever assembly removal steps D Front floor console and rear floor console Refer to GROUP 52A 1 Harness connection 2 Retainer 3 Shift lever cover AA 4 Transmission control lever assembly 5 Control lever bushing CA 6 Stopper bracket assembly 7 Transmission control lever Transfer control lever assembl...

Page 287: ...CATION POINTS Sealant 3M ATD Part No 8660 or equivalent Both sides of gasket Sealant 3M ATD Part No 8660 or equivalent A B A Sealant 3M ATD Part No 8660 or equivalent B Sealant 3M Stud Locking No 4170 or equivalent Sealant 3M Stud Locking No 4170 or equivalent ...

Page 288: ...POINTS A STOPPER PLATE INSTALLATION Install the stopper plate as shown in the illustration B TRANSFER CONTROL LEVER ASSEMBLY INSTALLATION 1 Eliminate adhesive adhered to the transfer control lever assembly installation bolts 2 Use a tap M8 1 25 to eliminate adhesive adhered to the threaded holes of the control housing and then clean the holes with a compressed air 3 Apply the specified adhesive to...

Page 289: ... assembly installation nuts and then clean the holes with a compressed air 3 Apply the specified sealant to the stopper bracket assembly installation bolts A shown in the illustration and the specified adhesive to the threaded part of the stopper bracket assembly installation bolts B shown in the illustration and then install the stopper bracket assembly Specified sealant A 3M ATD Part No 8660 or ...

Page 290: ... Refer to GROUP 25 Front Exhaust Pipe and Catalytic Converter Removal and Installation Refer to GROUP 17 Emission Control Shift Lever Operation Check only after installation Instruments Operation Check only after installation 48 Nm 48 Nm 19 Nm 6 1 2 5 4 30 Nm 7 3 6 48 Nm 48 Nm 48 Nm 5 Removal steps 1 Clutch release cylinder installation bolts 2 Starter motor installation bolts 3 Oil pan connection...

Page 291: ...at Cushion Removal and Installation Refer to GROUP 52A Seat Front Scuff Plate Right and Quarter Trim Right Removal and Installation Refer to GROUP 52A Trims Front Floor Console and Rear Floor Console Removal and Installation Refer to GROUP 52A 1 2 2 5 Nm 4 3 2 Removal steps 1 Rear heater duct right Turn up the carpet 2 Harness connector connection 3 4WD indicator control unit 4 Bracket ...

Page 292: ...N Move from 4HLC to 4LLC or vice versa System voltage 4HLC 4LLC 0 V 2 4WD operation detection switch ON 2H System voltage 4H 0 V 3 Ignition switch OFF 0 V ON System voltage 4 4WD indicator lamp VCU lock lamp ON 4H System voltage lamp 4HLC 1 5 V or lower 5 VCU lock detection switch ON 4H System voltage 4HLC 0 V 6 Free wheel engage switch ON 2WD condition System voltage 4WD condition 0 V 7 VCU lock ...

Page 293: ... SRS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injury or death to service personnel from inadvertent firing of the air bag or to driver and passenger from rendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBIS...

Page 294: ...f solenoid valve No 2 at 25_C Ω 13 2 Coil resistance of solenoid valve No 3 at 25_C Ω 13 2 Stall speed r min 2 320 2 620 Line pressure kPa at idle speed D range 373 422 R range 520 579 at stall speed D range 765 863 R range 1 383 1 628 LUBRICANTS Items Specified lubricant Quantity ȏ Transmission fluid DEXRON II or equivalent 7 2 Transfer oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API ...

Page 295: ...s 23 3 SPECIAL TOOLS Tool Number Name Use MB991502 MUT II sub assembly Checking of the diagnosis code MD998330 including MD998331 Oil pressure gauge 2 942 kPa Measurement of oil pressure MD998920 Adapter Connection of oil pressure gauge ...

Page 296: ...vice Points Carry out the essential service Refer to P 23 34 Road test Refer to P 23 6 Abnormality exists no diagnosis code No abnormality Recheck diagnosis codes which were read before the road test Abnormality exists diagnosis code present Diagnosis code displayed No diagnosis code displayed To INSPECTION CHART FOR DIAGNOSIS CODES Refer to P 23 9 To INSPECTION CHART FOR TROUBLE SYMPTOMS Refer to...

Page 297: ...approximately 1 Hz N range lamp flashing items Input shaft speed sensor Output shaft speed sensor Each solenoid valve Caution If the N range lamp is flashing at a frequency of approximately 2 Hz faster than at 1 Hz it means that the A T fluid temperature is too high Stop the vehicle in a safe place and wait until the N range lamp switches off METHOD OF READING THE DIAGNOSIS CODE Use the MUT II or ...

Page 298: ...function P 23 24 3 Engine Warmed up Drive for 15 minutes or more so that the automatic fluid temperature becomes 70 90_C Data list No 15 Gradually rises to 70 90_C A T fluid temperature sensor A T fluid temperature sensor system P 23 10 4 Engine Idling Selector lever position N Accelerator pedal 1 Released 2 Half depressed 3 Fully depressed approx Data list No 13 1 0 5 2 Gradually rises from 1 3 8...

Page 299: ... with the selector lever in 2 Data list No 41 2 ON 3 OFF 4 ON Solenoid valve No 1 Code No 41 42 Solenoid valve No 1 system P 23 13 lever in 2 position Data list No 43 2 OFF 3 ON 4 ON Solenoid valve No 2 Code No 43 44 Solenoid valve No 2 system P 23 13 Data list No 47 1 OFF 2 OFF 3 ON 4 Accelerates smoothly and Solenoid valve No 3 Malfunction when shifting Code No 47 48 Solenoid valve No 3 system P...

Page 300: ...P 23 20 standstill 3 Accelerate to 4th gear atAPS opening angle of 50 For 4 5 and 6 downshifting should occur immediately after the shifting Upshifting occurs spontaneously P 23 19 of 50 4 While driving at 50 km h in 4th gear set the after the shifting operation is made Incorrect drive gear position P 23 21 gear set the overdrive switch to OFF position 5 Whil d i i Malfunction when driving the veh...

Page 301: ...mperature sensor system Short circuit 23 10 22 Wide open throttle switch Open circuit short circuit 23 11 31 Input shaft speed sensor system Open circuit 23 11 32 Output shaft speed sensor system Open circuit 23 11 38 Vehicle speed sensor system Open circuit 23 12 41 Solenoid valve No 1 system Open circuit 23 13 42 Solenoid valve No 1 system Short circuit 23 13 43 Solenoid valve No 2 system Open c...

Page 302: ...al position sensor and A T ECU Accelerator pedal position sensor check Refer to GROUP 13A On ve hicle Service NG Check the following connectors L H drive vehicles C 46 C 25 D 34 D 04 R H drive vehicles C 46 C 26 D 34 D 04 NG Replace Repair Repair OK NG Code No 15 16 A T fluid temperature sensor system Probable cause If the A T fluid temperature sensor output is 10 C or less 5 6 kΩ or more even aft...

Page 303: ...utput shaft speed sensor system Probable cause If no output pulse is detected from the input shaft speed sensor for 120 seconds or more while driving in 3rd gear at a speed of 60 km h or more there is judged to be an open circuit in the input shaft speed sensor and diagnosis code No 31 is output If no output pulse is detected from the output shaft speed sensor for 120 seconds or more while driving...

Page 304: ...ng connectors B 08 D 02 D 04 NG Check the harness wire between vehicle speed sensor and earth and repair if necessary Measure at the vehicle speed sensor connector B 08 D Disconnect the connector and measure at the harness side 1 Voltage between 1 and earth Ignition switch ON OK System voltage 2 Voltage between 3 and earth Ignition switch ON OK 4 8 5 2 V 3 Continuity between 2 and earth OK Continu...

Page 305: ... value for a solenoid valve No 2 is too small it is judged that there is a short circuit in the solenoid valve No 2 and the diagnosis code No 44 is output D Malfunction of solenoid valve No 2 D Malfunction of harness or connector D Malfunction of the A T ECU Solenoid valve No 2 check Refer to P 23 42 NG Replace OK Check the following connectors B 03 D 04 NG Repair OK Check the harness wire between...

Page 306: ... data being received is abnormal for a continuous period of 1 second under the same conditions D Malfunction of harness or connector D Malfunction of the engine ECU D Malfunction of the A T ECU MUT II Self Diag code D Is the diagnosis code No 61 output NO YES Check the following connectors L H vehicles C 19 C 25 D 34 D 04 R H vehicles C 19 C 26 D 34 D 04 NG Repair OK Check the harness wire between...

Page 307: ...es not reverse only 4 23 18 Malfunction when shifting Upshifting does not occur 5 23 19 shifting Downshifting does not occur 6 23 20 Shifting point abnormality 7 23 20 Upshifting occurs spontaneously 8 23 21 Incorrect drive gear position 9 23 21 Large shocks 10 23 22 Slippage vibration 11 23 23 Lockup malfunction 12 23 24 Abnormal engine braking 13 23 24 Electronic circuit systems Inhibitor switch...

Page 308: ...stem with the MUT II Yes Measure at A T ECU connector D 04 D Disconnect the connector and measure at the harness side D Voltage between terminals 9 and 24 and the earth OK System voltage D Continuity between terminal 25 and earth OK Continuity OK Check the following connectors L H drive vehicles D 04 D 34 C 37 C 70 C 35 R H drive vehicles D 04 D 34 C 39 C 70 C 35 NG Repair OK Check the trouble sym...

Page 309: ...the Transmission Workshop Manual OK Replace the torque converter L NG Check and repair or replace the oil pump L Check the trouble symptoms Is abnormal noise generated in D range Yes Is the source of the abnormal noise the torque converter or thetransmis sion Replace the torque converter L Torque converter No Transmission Check the power train L D Disassemble the transmission check the condition o...

Page 310: ... the brake No 3 L Yes Which is the drive gear in D range 2nd Check the brake No 1 No 2 L 3rd Check the direct clutch L Check the trouble symptoms NG Replace the A T ECU INSPECTION PROCEDURE 4 Does not reverse only Probable cause When the engine is idling the vehicle does not reverse even if the selector lever is shifted from N to R range In such cases the cause is probably a malfunction of a clutc...

Page 311: ... 9 Yes Does not the A T shift from 1 2 No Does the A T shift to 2nd gear in 2 range No Malfunction of 1 2 shift valve L Malfunction of solenoid valve No 2 L Yes Yes Check the brake No 2 system L Check one way clutch No 1 L Does not the A T shift from 2 3 No Does the vehicle reverse in R range No Check the direct clutch system L Yes Yes Malfunction of 2 3 shift valve L Malfunction of solenoid valve...

Page 312: ...ge DRIVE 4TH Malfunction of 2 3 shift valve L Yes DRIVE 1ST Malfunction of solenoid valve No 1 L A T does not shift from 2 1 Does the A T shift from 3 4 in Drange No Malfunction of solenoid valve No 2 L Yes Does the vehicle move forward in L range No Malfunction of 1 2 shift valve L Yes Does the vehicle reverse in R range No Check the brake No 1 L Yes Check the brake No 2 L Check the trouble sympt...

Page 313: ...ng off is not smooth D Malfunction of inhibitor switch D Malfunction of direct clutch D Malfunction of planetary gear D Malfunction of valve body D Malfunction of forward clutch D Malfunction of solenoid valve No 1 D Malfunction of A T ECU L Refer to the Transmission Workshop Manual MUT II SERVICE DATA D 37 Inhibitor switch OK MUT II display and selector lever position should match NG Inspection P...

Page 314: ...r ance L Check the brake No 3 clearance L No OK Check each accumulator L Is there a large shock when shifting from N D Yes MUT II SERVICE DATA D 28 Stop lamp switch OK ON when brake pedal is de pressed OFF when brake pedal is re leased NG Inspection Procedure 16 Stop lamp switch system Refer to P 23 26 No OK Check the kickdown cable NG Repair OK Check each modulator valve L Check each check ball L...

Page 315: ... moving forward and reversing Yes Check the torque converter NG Replace the torque converter L No OK Check the overdrive clutch system L Check the overdrive one way clutch system L Does slippage occur in R range Yes Check slippage in 3rd gear in D range NG Check the direct clutch system L No OK Check the brake No 3 system L Does slippage occur in 1st gear Yes Check for slippage in L range NG Check...

Page 316: ...heck the lockup control valve NG Replace the lockup control valve L OK Replace the torque converter L Check the trouble symptoms NG Replace the A T ECU INSPECTION PROCEDURE 13 Abnormal engine braking Probable cause Engine braking effectiveness is poor after downshifting has occurred D Malfunction of overdrive clutch D Malfunction of brake No 1 No 3 D Malfunction of valve body D Malfunction of A T ...

Page 317: ...ween the inhibitor switch and the A T ECU NG Repair OK Replace the A T ECU NG INSPECTION PROCEDURE 15 Overdrive switch system Probable cause If downshifting does not occur when overdrive switch is turned off while driving in 4th gear or if shifting to 4th gear is not possible the cause is probably a problem in the overdrive switch system D Malfunction of overdrive switch D Malfunction of harness o...

Page 318: ...ector D Malfunction of A T ECU MUT II SERVICE DATA D 28 Stop lamp switch OK ON when the brake pedal is depressed and OFF when the brake pedal is released OK Check the stop lamp switch Refer to GROUP 35 Brake Pedal NG Check the following connectors L H drive vehicles C 04 C 02 C 29 C 24 D 02 D 04 R H drive vehicles C 04 C 02 C 41 D 02 D 04 NG Repair OK Check the harness wire between the stop lamp s...

Page 319: ...Depressed ON 27 Shift position signal Accelerator pedal Fully released Engine Idle Vehicle stopped Selector lever position N Brake pedal Depressed Shifting from N to D 1st 3rd 1st Selector lever position L Idle Vehicle stopped 1st Selector lever position 2 Idle Vehicle stopped 1st Driving at 40 km h 20 seconds or more 2nd Selector lever position D Overdrive switch OFF Driving at constant speed of ...

Page 320: ... 43 Solenoid valve No 2 Selector lever position D Overdrive switch OFF Driving at constant speed of 5 km h 1st gear OFF Driving at constant speed of 50 km h 3rd gear ON 47 Solenoid valve No 3 Selector lever position D Overdrive switch ON Driving at constant speed of 5 km h 1st gear OFF Driving at constant speed of 50 km h 4th gear ON 53 N range switch Ignition switch ON Engine Stopped Selector lev...

Page 321: ...re input the order of priority for control is L 2 N Accelerator pedal position sensor If the output is 0 335 V or less or 4 8 V or more during idling condition gear shifting control when throttle is fully closed is carried out Solenoid valve No 3 If a problem is detected lockup is stopped over the whole range and the solenoid is turned off to prevent the engine from stalling during idling Solenoid...

Page 322: ...eleased 0 V 6 Free wheeling engage switch Transfer lever position Other than 4WD System voltage switch Transfer lever position 4WD 0 V 8 Inhibitor switch L Selector lever position L System voltage Selector lever position Other than L 0 V 9 Back up power supply Ignition switch OFF System voltage 10 Solenoid valve No 3 When lockup clutch is operating System voltage When lockup clutch is not operatin...

Page 323: ...ehicle Slowly moving forward Alternates between 0 Approx 5 V 28 A T fluid temperature sensor ATF temperature 120_C Approx 0 3 V sensor ATF temperature 150_C Approx 0 15 V 29 Overdrive switch Overdrive switch ON System voltage Overdrive switch OFF 0 V 30 Accelerator pedal position sensor throttle opening Accelerator pedal Released Approx 1 V sensor throttle opening voltage Accelerator pedal Fully d...

Page 324: ... at P position 6 23 33 Ignition key can be turned to LOCK OFF position when selector lever is at positions other than P 7 23 33 INSPECTION CHART FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Selector lever can be moved from P to R without depressing brake pedal when ignition key is at positions other than LOCK OFF Probable cause Lock cam or shift lock cable may be defective D Malfunction of lock cam...

Page 325: ...N PROCEDURE 5 Selector lever cannot be moved from R to P Probable cause Selector lever assembly or transmission control cable may be defective D Malfunction of selector lever assembly D Malfunction of transmission control cable Check items described in the column ªProbable causeº INSPECTION PROCEDURE 6 Ignition key cannot be turned to LOCK OFF position when selector lever is at P position Probable...

Page 326: ... particles from the bushes and friction materials a transmission overhaul and flushing the A T fluid cooler line may be necessary 5 Check that the A T fluid level is at the HOT mark on the oil level gauge If the A T fluid level is lower than this pour in more A T fluid until the level reaches the HOT mark Automatic transmission fluid DEXRON II or equivalent NOTE If the A T fluid level is low the o...

Page 327: ... should be stopped within one minute after it is started If the A T fluid has all drained out before then the engine should be stopped at that point Discharge volume Approx 3 4 3 Remove the drain plug from the bottom of the transmission case to drain the A T fluid Discharge volume Approx 0 8 4 Install the drain plug via a new gasket and tighten it to the specified torque Tightening torque 20 1 Nm ...

Page 328: ...arded as the standard level 13 Firmly insert the oil level gauge into the oil filler tube AUTOMATIC TRANSMISSION FLUID COOLER LINE FLUSHING Caution When the transmission has been replaced or overhauled or A T fluid is contaminated the A T fluid cooler line flushing should always be carried out 1 Disconnect the hose shown in the illustration which connects the transmission and the A T fluid cooler ...

Page 329: ...ADJUSTMENT 1 Release the accelerator pedal 2 Loosen the adjusting nut or adjusting bolt Move the outer cable of the kickdown cable to adjust the clearance A between the inner cable stopper and dust cover end to the standard value and then tighten the adjusting nut or adjusting bolt to secure the kickdown cable Standard value 0 8 1 5 mm Caution Adjust the accelerator cable assembly after the kickdo...

Page 330: ...inuity 2WD 4WD DETECTION SWITCH CONTINUITY CHECK Check the continuity between the terminal of the white connector installed in the side of transfer case shown in the illustration and the transfer case Transfer lever position Continuity 2H Continuity 4H No continuity VCU LOCK OPERATION DETECTION SWITCH CONTINUITY CHECK Check the continuity between the terminal of the brown connector installed in th...

Page 331: ... hole 3 Check that the oil is not noticeably dirty and that it has a suitable viscosity 4 Tighten the oil filler plug to the specified torque Tightening torque 29 34 Nm TRANSFER OIL REPLACEMENT 1 Remove the oil drain plug to drain oil 2 Tighten the oil drain plug to the specified torque Tightening torque 29 34 Nm 3 Remove the oil filler plug and fill with specified oil till the level comes to the ...

Page 332: ...r switch D Input shaft speed sensor C A T ECU N Output shaft speed sensor F A T fluid temperature sensor E Overdrive switch H Diagnosis connector M Solenoid valves E Dual pressure switch A Stop lamp switch J Engine ECU I Vehicle speed sensor G Free wheeling engage switch B Wide open throttle position switch L A B C D E F G H I J K L M N H I J K L M N ...

Page 333: ...cle Service VEHICLE SPEED SENSOR CHECK Refer to GROUP 54 On vehicle Service DUAL PRESSURE SWITCH CHECK Refer to GROUP 55 On vehicle Service FREE WHEELING ENGAGE SWITCH CHECK Refer to GROUP 26 On vehicle Service INPUT SHAFT SPEED SENSOR CHECK 1 Disconnect the input shaft speed sensor connector 2 Measure the resistance between terminals 9 and 10 of the input shaft speed sensor connector Standard val...

Page 334: ...place the output shaft speed sensor SOLENOID VALVE CHECK 1 Disconnect the solenoid valve connector 2 Measure the solenoid valve resistance Standard value Item Measurement terminal Resistance Solenoid valve No 1 Between terminal 6 and earth 13 2 Ω at 25_C Solenoid valve No 2 Between terminal 7 and earth Solenoid valve No 3 Between terminal 8 and earth 3 If the resistance is not within the standard ...

Page 335: ...luid temperature sensor connector 2 Measure the resistance between terminals 1 and 2 of the A T fluid temperature sensor connector Standard value Temperature _C Resistance 25 1 100 Ω 120 57 Ω 3 If the resistance is not the standard value replace the A T fluid temperature sensor A T fluid temperature sensor ...

Page 336: ...ngine maximum speed NOTE When doing so do not keep the engine running with throttle full open for more than 5 seconds If two or more stall tests are needed place the selector lever in the ªNº position and run the engine at about 1 000 r min to allow the transmission fluid to cool before another stall test Standard value 2 320 2 620 r min 7 Place the selector lever in the ªRº range and perform the ...

Page 337: ...he line pressure at each engine r min If the measured pressure is not nominal check adjustment of the throttle cable and readjust if necessary before conducting the test again 8 Place the selector lever in the ªRº range and test as above Standard value Items Line pressure kPa ªDº range ªRº range At idle 373 422 520 579 At stall 765 863 1 383 1 628 JUDGEMENT BY LINE PRESSURE Hydraulic pressure high...

Page 338: ...lve 9 2 3 shift valve 10 Solenoid valve No 1 11 Solenoid valve No 2 12 Low coast modulator valve 13 1 2 shift valve 14 Pressure relief valve 15 Solenoid valve No 3 16 Cut back valve 17 Throttle valve 18 Secondary regulator valve 19 Lockup control valve 20 Primary regulator valve 21 Reverse clutch sequence valve 22 3 4 shift valve 23 Intermediate modulator valve 24 Accumulator C1 25 Accumulator C2 ...

Page 339: ...A T mis operation prevention device the select or lever cannot be moved from the P position to an other position unless you turn the ignition key to a position other than LOCK OFF and depress the brake pedal first KEY INTERLOCK MECHANISM CHECK 1 Carry out the following inspection Inspection procedure Requirements Normal condition 1 Brake pedal Depressed Ignition key LOCK OFF or removed The selecto...

Page 340: ...he direction A shown in the illustration Tightening torque 12 Nm 6 Install the rear floor console Refer to GROUP 52A SHIFT LOCK MECHANISM CHECK 1 Carry out the following inspection Inspection procedure Requirements Normal condition 1 Brake pedal Depressed Ignition key ACC If the selector lever push button is not pushed the selector lever can not be moved from P position 2 If the selector lever pus...

Page 341: ...cam and then tighten the shift lock cable fixing nut to the specified torque Tightening torque 12 Nm 5 Install the rear floor console Refer to GROUP 52A TRANSMISSION CONTROL CABLE ADJUSTMENT 1 Move the selector lever to N position and set the transmission lever to N position 2 Loosen the fixing bolt Adjust the adjuster lever position so that the transmission control cable will be tight and then ti...

Page 342: ...elector lever assembly and transmission control cable assembly removal steps D Rear floor console assembly Refer to GROUP 52A 1 Key interlock cable connection 2 Shift lock cable connection 3 Transmission control cable connection selector lever side 4 Selector lever assembly 5 Transmission control cable connection transmission side Transfer control lever assembly removal steps D Front floor console...

Page 343: ...ion INSPECTION Slide the connector in the direction of arrow shown in the illustration to remove it from the bracket POSITION INDICATOR LAMP CHECK Check requirement Terminal No q 1 2 Always OVERDRIVE SWITCH CHECK Switch position Terminal No 3 4 5 ON OFF WIDE OPEN THROTTLE SWITCH CHECK Switch position Terminal No 1 2 OFF ON Front of vehicle Front of vehicle Connector Bracket OFF ON ...

Page 344: ...12 17 14 15 16 11 13 15 Nm 18 12 Nm Disassembly steps AA 1 Position indicator socket assembly 2 Bulb 3 Shift knob 4 Push button 5 Stopper 6 Spring 7 Overdrive switch 8 Indicator panel assembly AA 9 Sleeve 10 Adjuster lever 11 Lock cam 12 Pin 13 Ball spring 14 Ball support 15 Ball 16 Packing 17 Selector lever assembly 18 Stopper ...

Page 345: ...rminal of shift knob side from the position indicator socket assembly connector REASSEMBLY SERVICE POINT AA SLEEVE INSTALLATION Shift the selector lever to the N position and then turn the sleeve so that the clearance between the sleeve and lever assembly end is within the dimension shown in the illustration Terminal Screwdriver Sleeve Selector lever assembly 16 0 16 7 mm ...

Page 346: ...Instrument under cover Refer to GROUP 52A D Lower column cover Refer to GROUP 37A Steering Wheel and Shaft CA 1 Key interlock cable connection selector lever side 2 Cover BA 3 Key interlock cable connection steering lock cylinder side 4 Key interlock cable Shift lock cable removal steps D Front floor console Refer to GROUP 52A AA 5 Shift lock cable connection selector lever side 6 Shift lock cable...

Page 347: ... INTERLOCK CABLE STEERING LOCK CYLINDER SIDE INSTALLATION Turn the ignition key to LOCK OFF position and then install the key interlock cable CA KEY INTERLOCK CABLE SELECTOR LEVER SIDE INSTALLATION 1 Move the selector lever to P position 2 Turn the ignition key to LOCK OFF position 3 Connect the key interlock cable end to the lock cam 4 Install the key interlock cable temporarily 5 Tighten the key...

Page 348: ...P 15 Air Cleaner and Resonance Tank D Front Exhaust Pipe and Catalytic Converter Removal and Installation Refer to GROUP 15 D Vacuum Actuator Assembly Removal and Installation Refer to GROUP 26 Main Shaft D Kick down Cable Adjustment Only after installation Refer to P 23 37 D Accelerator Cable Assembly Check and Adjustment Only after installation Refer to GROUP 17 On vehicle Service 1 3 12 10 9 8 ...

Page 349: ... hose D Oil pan removal Refer to GROUP 11A AB 15 Drive plate connection bolt D Support the transmission with a transmission jack 16 Washer 17 Spacer 18 Transmission mount bushing 19 Transmission mount crossmember 20 Transmission mount insulator assembly BA 21 Transmission mount stopper 22 Adapter 23 Transmission upper part coupling bolts AA 24 Transmission assembly ...

Page 350: ...e INSTALLATION SERVICE POINTS AA TRANSMISSION ASSEMBLY INSTALLATION Press in the torque converter to the transmission side completely and then install the transmission assembly to the engine BA TRANSMISSION MOUNT STOPPER INSTALLATION 1 Install the transmission mount stopper so that the arrow faces the direction shown NOTE Disregard F and R stamped as a shared part 2 The sizes of the mounting bolts...

Page 351: ...val and Post installation Operation D Transmission Fluid Draining and Supplying Refer to P 23 35 D Under Cover Removal and Installation 2 3 4 6 44 Nm 5 1 Removal steps 1 Return hose 2 Feed hose 3 Oil cooler pipe assembly 4 Hose assembly D Transmission assembly Refer to P 23 56 5 Oil return pipe 6 Oil feed pipe ...

Page 352: ...LATION Caution Do not strike the G sensor when removing and installing the A T ECU Pre removal and Post installation Operation Rear Floor Console Removal and Installation 1 2 Removal steps 1 Floor console bracket 2 A T ECU 4WD INDICATOR CONTROL UNIT REMOVAL AND INSTALLATION Refer to GROUP 22 ...

Page 353: ...25 1 PROPELLER SHAFT CONTENTS GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 2 LUBRICANT 2 SPECIAL TOOL 2 PROPELLER SHAFT 3 ...

Page 354: ...aft runout mm Front 0 5 Rear 0 4 Length of rear propeller shaft mm 630 1 5 Clearance of snap ring groove mm Front 0 0 06 groove mm Rear 0 02 0 06 LUBRICANT Items Specified lubricant Quantity Front propeller shaft sleeve yoke Hypoid gear oil SAE 75W 90 or 75W 85W or 80W conforming to API GL 4 As required SPECIAL TOOL Tool Number Name Use MB990840 Universal joint remover and installer Disassembly an...

Page 355: ...the lever to ª2Hº D Transfer Gear Oil Draining M T Refer to GROUP 22 On vehicle Service A T Refer to GROUP 23 On vehicle Service Post installation Operation Transfer Gear Oil Supplying M T Refer to GROUP 22 On vehicle Service A T Refer to GROUP 23 On vehicle Service Gear Oil Hypoid gear oil SAE 75W 90 or 75W 85W or 80W conforming to API GL 4 49 59 Nm 49 59 Nm 2 2 1 Removal steps AA AA 1 Front prop...

Page 356: ...R SHAFT ASSEMBLY INSTALLATION When reusing the propeller shaft align the mating marks made during the removal and install the propeller shaft assembly to the companion flange Caution 1 Wipe out oil and grease on the threads of the mounting bolts and nuts before tightening or they will loosen 2 Do not damage the oil seal lips of the transmission and transfer INSPECTION PROPELLER SHAFT RUNOUT Limit ...

Page 357: ...3 2 1 Universal joint repair kit 1 2 3 2 3 Disassembly steps A B 1 Snap ring B A 2 Journal bearing 3 Journal 4 Flange yoke 5 Sleeve yoke 6 Propeller shaft DISASSEMBLY SERVICE POINTS A SNAP RING REMOVAL Make mating marks on the flange yoke sleeve yoke and propeller shaft Then remove the snap rings Mating marks ...

Page 358: ...yoke until the snap ring groove can be seen completely 2 Using the special tools press in the journal bearing on the opposite side to the yoke Caution Press in the journal bearing straight or the journal could damage the inside of the journal bearing 3 Align the mating marks on the yoke and propeller shaft On the propeller shaft side install the journal bearing in the same steps of 1 and 2 B SNAP ...

Page 359: ...ler shaft A 0 0 06 mm Rear propeller shaft A 0 02 0 06 mm Caution Always use snap rings of the same thickness on both sides 4 If the standard value s are not met use other snap rings to adjust the clearance Items Thickness mm Identification colour Front propeller shaft R ll h ft 1 28 Rear propeller shaft 1 31 Yellow 1 34 Blue 1 37 Purple Rear propeller shaft 1 40 Brown Snap ring A ...

Page 360: ...NOTES ...

Page 361: ...y Check 10 Front Axle Total Backlash Check 10 Front Axle Gear Oil Level Check 11 Hub Bolt Replacement 11 Differential Carrier Oil Seal Replacement 11 Solenoid Valve Operation Check 12 HUB AND KNUCKLE ASSEMBLY 14 DRIVE SHAFT 19 MAIN SHAFT 26 DIFFERENTIAL CARRIER 28 FREE WHEELING CLUTCH ASSEMBLY 45 SOLENOID VALVE VACUUM PIPES AND VACUUM TANK 48 FRONT DIFFERENTIAL MOUNT 50 ...

Page 362: ...of a double row angular contact ball bearing which features high thrust load resistance D The differential carrier is supported elastically at three points thus reducing vibration and noise FRONT AXLE Item Specifications Wheel bearing Type Double row angular contact ball bearing Bearing O D I D mm 74 40 Drive shaft Joint type Outer B J Inner D O J Shaft length 1 Shaft diameter mm Right side 316 24...

Page 363: ...erential Free wheeling clutch Differential mount bracket LH Differential mount crossmember Drive shaft LH Ball joint Drive shaft RH Plastic BJ boot ABS rotor Differential side Drive shaft LH B J D O J RH Differential side Knuckle Brake disc Ball bearing Dust cover Hub ...

Page 364: ...0 11 0 16 Drive gear runout mm 0 05 Differential gear backlash mm 0 0 076 0 2 Drive pinion turning torque Nm Without oil seal When replacing with anti rust agent 0 88 1 17 1 0 29 0 49 2 When replacing or reusing with gear oil applied 0 39 0 49 1 0 147 0 245 2 With oil seal When replacing with anti rust agent 0 98 1 27 1 0 49 0 69 2 When replacing or reusing with gear oil applied 0 49 0 58 1 0 343 ...

Page 365: ...ntial case mating surface 3M Stud Locking 4170 or equivalent Anaerobic sealant SPECIAL TOOLS Tool Number Name Use MB991618 Hub bolt remover Hub bolt removal MB990767 Front hub and flange yoke holder Hub fixing MB991115 Oil seal installer D Front axle hub oil seal press fitting Used together with MB990938 D Housing tube dust seal press fitting MB991406 or MB991113 Steering linkage puller Ball joint...

Page 366: ...l D Companion flange removal MB990925 Bearing and oil seal installer set D Outer wheel bearing inner race installation D Oil seal installation D Front housing assembly oil seal installation D Drive pinion front and rear bearing outer race removal and installation D Final drive gear backlash check A MB991045 A MB991050 Bush remover installer A Base B Wheel bearing pressing in Used together with bas...

Page 367: ... removal and installation MB990560 Rear axle shaft bearing remover Drive pinion bearing inner race removal A B MB990835 A MB990836 B MB990392 Dummy pinion set A Drive pinion gauge assembly B Cylinder gauge D Drive pinion rotation starting torque check D Drive pinion height measurement A T MB990326 Pre load socket Drive pinion turning torque measurement A MB990901 A MB990903 Pinion height gauge set...

Page 368: ... Oil seal pressing in MB990799 Ball joint remover and installer Free wheeling clutch gear and bearing installa tion MD999547 Oil seal installer Front differential mount insulator front removal MD999570 Crankshaft front oil seal installer Front differential mount insulator rear removal MB990947 Lower arm bushing arbour Front differential mount insulator front pressing in MB990847 Rear suspension bu...

Page 369: ... SERVICE TOOL MZ203827 Engine lifter Supporting the engine assembly when the differential carrier is removed and installed MB990925 Brass bar Installer adapter Tool box Bar snap in type A C B Type Tool number O D mm Type Tool number O D mm A MB990926 39 A MB990933 63 5 MB990927 45 MB990934 67 5 MB990928 49 5 MB990935 71 5 MB990929 51 MB990936 75 5 MB990930 54 MB990937 79 MB990931 57 B MB990938 MB9...

Page 370: ...prevent this follow the procedures below 1 Turn the ignition switch to the OFF position and then place the transfer shift lever in the 2H position to lock the front wheels Caution Do not jack up the vehicle 2 Rotate the propeller shaft until a click is heard to lock the free wheeling differential 3 Rotate the propeller shaft fully clockwise and then make mating marks on the companion flange dust c...

Page 371: ...ȏ HUB BOLT REPLACEMENT 1 Rotate the hub to align each hub bolt with the cutout section of the dust cover and push out each hub bolt while locking the hub with the special tool 2 To press in the hub bolt install each hub bolt at the cutout section of the dust cover and tighten the hub bolt with the hub nut as shown DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT 1 Remove the front housing assembly Refer ...

Page 372: ...lue stripe yellow stripe from the solenoid valves 2 Disconnect the harness connectors 3 Connect a hand vacuum pump to solenoid valve A and carry out the following inspections 1 When battery voltage is not applied to any terminals the negative pressure is not be held 2 The negative pressure is not held when battery voltage is applied to solenoid valve A However when the vacuum hose of solenoid valv...

Page 373: ... is not applied to any terminals the negative pressure is held 10 When battery voltage is applied to solenoid valve B the negative pressure is not held 11 When battery voltage is applied to solenoid valve A the negative pressure is not held 5 Measure the resistance of solenoid valves A and B Standard value 36 46 Ω Check valve Vacuum tank Solenoid valve A Solenoid valve B ...

Page 374: ...isc 3 Wheel speed sensor Vehicles with ABS 4 Dust cover AA AA 5 Castle nut AA 6 Washer AB 7 Lower arm and hub knuckle assembly connection AB 8 Tie rod end and hub knuckle assembly connection AC 9 Drive shaft and hub knuckle assembly connection 10 Strut assembly and hub knuckle assembly connection 11 Hub knuckle assembly REMOVAL SERVICE POINTS AA CASTLE NUT REMOVAL Caution Never apply the vehicle w...

Page 375: ...T INSTALLATION 1 Face the chamfered side of the washer against the castle nut 2 Use the special tool to tighten the castle nut securely Caution Never apply the vehicle weight to the wheel bearing while the castle nut is loosened If the vehicle weight is applied the wheel bearing will be damaged 3 If the split pin hole is not aligned with the castle nut slit always tighten the nut further within a ...

Page 376: ...al play check EA 1 Inner oil seal DISASSEMBLY SERVICE POINTS AA HUB REMOVAL Caution When the hub is removed the wheel bearing may be damaged Therefore if the hub is withdrawn the wheel bearing should be always be replaced with a new one AB WHEEL BEARING REMOVAL 1 Pry the outer oil seal at the shown positions with a screwdriver so that the jaws of the special tool can hook the wheel bearing outer i...

Page 377: ...LY SERVICE POINTS AA WHEEL BEARING INSTALLATION Caution When the wheel bearing is pressed in its outer race should be pushed in BA OUTER OIL SEAL INSTALLATION CA HUB ROTATION STARTING TORQUE CHECK 1 Tighten the special tools to the specified torque to press the hub into the knuckle 2 Rotate the hub so that the hub is lubricated sufficiently MB990810 Outer inner race Outer inner race MB991056 or MB...

Page 378: ...PLAY CHECK 1 Clamp the knuckle in a vise and measure the axial play while moving the hub in the axial direction Limit 0 2 mm 2 If the limit value can not be obtained after tightening the special tool within 196 255 Nm the wheel bearing the knuckle and the hub may be improperly assembled Disassemble these parts to replace the bearing and then assemble them again EA INNER OIL SEAL INSTALLATION MB990...

Page 379: ...with a Finger to Check Whether the Dust Cover is Cracked or Damaged D Engage the Stabilizer Link with the Strut Bar Refer to GROUP 33 Strut Bar and Lower Arm D Brake Disc Installation Refer to P 26 14 RH 7 3 4 5 1 2 6 6 196 255 Nm 59 71 Nm 59 71 Nm LH Removal steps AA AA 1 Castle nut AA 2 Washer AB 3 Tie rod end and hub knuckle assembly connection 4 Wheel speed sensor AB 5 Lower arm and hub knuckl...

Page 380: ...castle nut loosely Then pull the strut the hub knuckle assembly and the lower arm towards you and then withdraw the drive shaft from the front differential Caution Be sure to maintain the drive shaft horizontally not to bend the D O J at extreme angle when the drive shaft is withdrawn 3 If it is difficult to withdraw the drive shaft from the hub knuckle assembly use the special tools Caution Do no...

Page 381: ...air kit grease Quantity A T B J 85 g 40 g for joint 45 g for boot D O J 85 g 50 g for joint 35 g for boot M T B J 110 g 55 g for joint 55 g for boot D O J 100 g 60 g for joint 40 g for boot Caution The joint is filled with a special grease Do not mix the grease with an old one or other grease B J boot repair kit D O J boot repair kit D O J repair kit 4 1 7 3 5 4 2 13 12 13 11 RH LH 4 11 ...

Page 382: ...m damage REASSEMBLY SERVICE POINTS AAD O J BOOT INSTALLATION Wrap a plastic tape around the B J assembly spline to prevent damage and then install the boot BAD O J BOOT BAND BOOT BAND INSTALLATION 1 Slide the D O J outer race so that the distance between the boot bands meet the standard value in order to adjust the air amount inside the D O J boot Standard value A 80 3 mm 2 Remove the boot partial...

Page 383: ...g bolt changes the opening distance W by approx 0 7 mm 2 Do not turn the adjusting bolt more than one turn 5 Butt the boot band small against the boot end projection so that a certain clearance A is obtained 6 Use the special tool to crimp the boot band small Caution 1 Secure the drive shaft in an upright position and clamp the part of the B J boot band to be crimped securely in the jaws of the sp...

Page 384: ... is sticking out remove it and then repeat the operations in steps 4 to 7 using a new B J boot band 9 Fill the inside of the B J boot with the specified amount of the specified grease Specified grease Repair kit grease Amount to use A T 85 g 50 g for joint 35 g for boot M T 110 g 55 g for joint 55 g for boot 10 Position the boot so that the difference between the boot big end and the housing stepp...

Page 385: ...mple If E 2 9 mm then W 2 9 mm If the crimping amount is smaller than 2 4 mm Remove the B J boot band readjust the value of W in step 11 according to the following formula and then repeat the operations in steps 12 and 13 using a new B J boot band W 5 8 mm E Example If E 2 3 mm then W 3 5 mm 15 Check that the B J boot band is not sticking out past the place where it has been installed If the B J b...

Page 386: ...y Removal and Installation Refer to P 26 45 D Gear Oil Draining and Refilling Refer to P 26 11 4 5 88 Nm 2 98 118 Nm 3 1 7 9 8 9 6 17 Nm Sealant 3M ATD Part No 8661 or equivalent Apply to the lip Apply to the lip Removal steps 1 Vacuum pipe assembly 2 Vacuum hose assembly 3 Vacuum actuator assembly 4 Inner shaft assembly 5 Front housing assembly CA 6 Oil seal AA BA 7 Bearing 8 Main shaft AA 9 Oil ...

Page 387: ...L Install the special tool as shown in the illustration and use a press to drive out the bearing from the main shaft INSTALLATION SERVICE POINTS AAOIL SEAL INSTALLATION BABEARING INSTALLATION CAOIL SEAL INSTALLATION MB990673 MB990938 MB990926 MB990663 MB990927 MB990938 ...

Page 388: ...fer to P 26 19 D Stabilizer Bar Removal and Installation Refer to GROUP 33A D Gear Oil Draining and Refilling Refer to P 26 11 88 Nm 59 69 Nm 49 Nm Sealant 3M ATD Part No 8661 or equivalent 4 5 2 6 98 118 Nm 1 3 93 Nm 93 Nm 103 Nm 103 Nm 59 69 Nm 49 59 Nm Removal steps AA D Support the Engine Assembly 1 Front propeller shaft connection 2 Front differential assembly and differential mount crossmemb...

Page 389: ...cking nut 10 Washer AE 11 Drive pinion assembly 12 Companion flange 13 Drive pinion spacer 14 Drive pinion rear shim For drive pinion rotation torque adjustment AF 15 Drive pinion front bearing inner race 16 Drive pinion front shim For drive pinion height adjustment 17 Drive pinion AG 18 Oil seal AG 19 Drive pinion rear bearing inner race AG 20 Drive pinion rear bearing outer race AH 21 Drive pini...

Page 390: ...AR RUNOUT 1 Measure the drive gear runout at the shoulder on the reverse side of the drive gear Limit 0 05 mm 2 When runout exceeds the limit value check for foreign object between drive gear rear side and differential case or for loose drive gear installation bolts 3 When check 2 gives normal results reposition drive gear and differential case and remeasure 4 If adjustment is impossible replace d...

Page 391: ...surfaces of the drive gear teeth 2 Insert the special tool between the differential carrier and the differential case and then rotate the companion flange by hand once in 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 2 9 Nm is applied to the drive pinion Caution If the drive gear is rotated too mu...

Page 392: ...1 2 3 4 3 Tooth contact pattern resulting from insufficient pinion height The drive pinion is positioned too close to the centre of the drive gear 1 2 3 4 Decrease the thickness of the drive pinion rear shim and position the drive pinion farther from the centre of the drive gear Also for backlash adjustment position the drive gear closer to the drive pinion 1 2 3 4 NOTE Checking the tooth contact ...

Page 393: ... do not become mixed at the time of reassembly AB SIDE BEARING INNER RACE REMOVAL NOTE There are two notches provided at the differential case side for the jaws of the special tool use the special tool at that position If the special tool jaws cannot be inserted between the differential case and the bearing inner race file the jaw tips as necessary AC DRIVE GEAR REMOVAL 1 Make the mating marks on ...

Page 394: ... surface of the companion flange and the front propeller shaft 2 Use the special tool to drive out the drive pinion AF DRIVE PINION FRONT BEARING INNER RACE REMOVAL AG OIL SEAL DRIVE PINION REAR BEARING INNER RACE DRIVE PINION REAR BEARING OUTER RACE REMOVAL AH DRIVE PINION FRONT BEARING OUTER RACE REMOVAL AI LOCK PIN DRIVE OUT Companion flange MB990810 MB990560 MB990939 MB990939 Punch ...

Page 395: ...ustment 9 Drive pinion rear shim for drive pinion rotation torque adjustment 10 Drive pinion assembly 11 Drive pinion rear bearing inner race 12 Oil seal 13 Companion flange 14 Washer 15 Self locking nut 16 Differential case FA D Differential gear backlash adjustment 17 Side gear spacer 18 Side gear 19 Pinion washer 20 Pinion gear 21 Pinion shaft GA 22 Lock pin HA 23 Drive gear IA 24 Side bearing ...

Page 396: ...Apply to the entire circumfer ence of the lip Adhesive 3M Stud Locking 4170 or equivalent Sealant 3M ATD Part No 8661 or equivalent Sealant 3M ATD Part No 8661 or equivalent Apply to the entire circum ference of the lip REASSEMBLY SERVICE POINTS AA OIL SEAL INSTALLATION MB990938 MB991115 ...

Page 397: ...s to the gear carrier 3 Tighten the nut of the special tool while measuring the rotation torque of the drive pinion Gradually keep tightening the nut of the special tool until the rotation torque of the drive pinion without oil seal is at the standard value Standard value Bearing division Bearing lubrication Rotation torque Nm New None With anti rust agent 0 88 1 17 1 0 29 0 49 2 New or reused Gea...

Page 398: ...l tools 7 Remove the special tools 8 Use a micrometer to measure the special tool in the places B C shown in the illustration 9 Install the bearing cap and then use a cylinder gauge and micrometer to measure the inside diameter D of the bearing cap as shown in the illustration 10 Calculate the thickness E of the required drive pinion front shim by the following formula and then select a shim which...

Page 399: ... drive pinion rotation torque without the oil seal by using the special tool Standard value Bearing division Bearing lubrication Rotation torque Nm New None With anti rust agent 0 88 1 17 1 0 29 0 49 2 New reused Gear oil applied 0 39 0 49 1 0 147 0 245 2 NOTE 1 A T 2 M T 4 If the drive pinion rotation torque is not within the range of the standard value adjust it by replacing the drive pinion rea...

Page 400: ...aligned and use the special tool to hold the companion flange and then tighten the self locking nut to the specified torque 7 Measure the drive pinion rotation torque with the oil seal by using the special tool Standard value Bearing division Bearing lubrication Rotation torque Nm New None With anti rust agent 0 98 1 27 1 0 49 0 69 2 New reused Gear oil applied 0 49 0 58 1 0 343 0 441 2 NOTE 1 A T...

Page 401: ...ion gear 5 If the differential gear backlash exceeds the limit adjust the backlash by changing the side gear spacers 6 If adjustment is not possible replace the side gears and pinion gears as a set 7 Confirm that the differential gear backlash is correct and that the differential gear turns smoothly GALOCK PIN INSTALLATION 1 Align the pinion shaft lock pin hole with the differential case lock pin ...

Page 402: ... SIDE BEARING INNER RACE INSTALLATION Use the special tool to press the side bearing inner race into the differential case JA DRIVE GEAR BACKLASH ADJUSTMENT Adjust the drive gear backlash by the following procedures 1 Install the side bearing spacers which are thinner than those removed to the side bearing outer races and then mount the differential case assembly into the gear carrier NOTE Select ...

Page 403: ...rential case assembly as shown in the illustration to the gear carrier 5 Tap the side bearing spacers with the special tool to fit them to the side bearing outer race 6 Align the mating marks on the gear carrier and the bearing cap and then tighten the bearing cap 7 With the drive pinion locked in place measure the drive gear backlash with a dial indicator on the drive gear NOTE Measure at four po...

Page 404: ... poor contact is evident make adjustment Refer to P 26 31 10 Measure the drive gear runout at the shoulder on the reverse side of the drive gear Limit 0 05 mm 11 If the drive gear runout exceeds the limit reinstall by changing the phase of the drive gear and differential case and remeasure 12 If adjustment is not possible replace the differential case or replace the drive gear and drive pinion as ...

Page 405: ...lling Refer to P 26 11 D Drive Shaft Removal and Installation Refer to P 26 19 35 Nm 49 Nm 4 Sealant 3M ATD Part No 8661 or equivalent 1 4 5 59 69 Nm 93 Nm 103 Nm 49 59 Nm 3 2 3 mm Removal steps AA 1 Pin 2 Free wheeling engage switch assembly 3 Differential mount bracket assembly LH 4 Free wheeling clutch housing assembly 5 Collar REMOVAL SERVICE POINT AA PIN REMOVAL 1 Remove the one side of the d...

Page 406: ...ased OFF DISASSEMBLY AND REASSEMBLY 5 6 4 5 13 8 1 2 3 7 13 10 11 12 11 9 Apply to the lip Disassembly steps DA 1 Clutch sleeve 2 Snap ring 3 Shift fork assembly CA 4 Spring pin 5 Shift rod 6 Shift fork 7 Clutch gear assembly 8 Circlip AA BA 9 Bearing 10 Bearing 11 Clutch gear AA 12 Oil seal 13 Free wheeling clutch housing Shaft OFF ON Contact point Electrode ...

Page 407: ...pecial tool to press fit the bearing to the shoulder of the clutch gear CA SPRING PIN INSTALLATION Insert the spring pin into the pin hole with chamfered surface of the shift rod and then tap the spring pin in as shown in the illustration DA CLUTCH SLEEVE INSTALLATION Face the clutch sleeve tapered side towards the drive shaft to install the clutch sleeve Support MB991015 MB990938 MB990799 Shift f...

Page 408: ...1 1 1 1 1 17 Nm 1 Vacuum hose AA 2 Vacuum hose blue stripe AA 3 Vacuum hose yellow stripe 4 Vacuum pipe assembly 5 Vacuum pipe assembly 6 Solenoid valve assembly BA 7 Check valve 8 Vacuum tank assembly Vacuum actuator assembly removal steps AA 9 Vacuum hose blue stripe connection AA 10 Vacuum hose yellow stripe connection AA 11 Pin 12 Vacuum actuator assembly ...

Page 409: ...the pin hole of the collar and then drive out the pin with a punch INSTALLATION SERVICE POINTS AA VACUUM HOSE INSTALLATION Connect the vacuum hoses the solenoid valve and the vacuum pipes according to their identification colours BA CHECK VALVE INSTALLATION Face the arrow mark to the vacuum side Collar Dust cover Pin Solenoid valve side Vacuum side Arrow mark indicating ventilation direction ...

Page 410: ...he unladen condition 98 118 Nm 1 103 Nm 93 Nm 42 Nm 42 Nm 103 Nm 2 3 4 Differential mount bracket assembly front removal steps D Free wheeling clutch assembly removal Refer to P 26 45 1 Differential mount bracket assembly front Differential mount bracket assembly LH RH removal steps D Drive shaft assembly removal Refer to P 26 19 2 Differential mount bracket assembly Rear LH 3 Differential mount b...

Page 411: ...ion points to the shown direction and the insulator protrudes evenly Distance A is equal to distance B REAR 1 Use the special tool to drive out the insulator 2 Use the special tools and a press to press fit the insulators so that their hollow portion points to the shown direction and the insulator protrudes evenly Distance C is equal to distance D MD999547 MB990947 MB990847 MB990981 A B MD999570 M...

Page 412: ...NOTES ...

Page 413: ...CATIONS 3 LUBRICANTS 3 SEALANTS AND ADHESIVES 4 SPECIAL TOOLS 4 ON VEHICLE SERVICE 6 Rear Axle Total Backlash Check 6 Gear Oil Level Check 7 Wheel Bearing Axial Play Check 7 Axle Housing Oil Seal Replacement 7 AXLE ASSEMBLY 9 AXLE SHAFT 11 DIFFERENTIAL CARRIER 15 ...

Page 414: ...ve stream crossing performance a vent plug is fitted to the upper part of the axle housing Item Conventional differential Helical LSD Drive gear type Hypoid gear Hypoid gear Reduction ratio 4 875 4 875 Limited slip differential type Torque sensitive type Differential gear type Type quantity Side gear Straight bevel gear 2 Helical gear 2 Type quantity Pinion gear Straight bevel gear 2 Long pinion 4...

Page 415: ... gear runout mm 0 05 Differential gear backlash mm 0 01 0 25 0 2 Drive pinion turning torque Nm Without oil seal When replacing with a new bearing with rust prevention oil 0 59 0 88 Nm When using a new bearing or when reusing gear oil application 0 39 0 49 With oil seal When replacing with a new bearing with rust prevention oil 0 83 1 13 When using a new bearing or when reusing gear oil applicatio...

Page 416: ...170 or equivalent Anaerobic sealant SPECIAL TOOLS Tool Number Name Use B A MB990590 A MB990211 B MB990212 Rear axle shaft oil seal remover A Slide hammer B Adapter D Axle shaft removal D Axle housing oil seal removal B A MB990241 A MB990242 B MB990244 Axle shaft puller A Puller shaft B Puller bar Axle shaft removal MB991354 Puller body MB990560 Rear axle shaft bearing remover Rotor removal MB99128...

Page 417: ...990811 Side bearing cup Side bearing inner race removal MB990850 End yoke holder D Self locking nut removal D Drive pinion turning torque adjustment MB990339 Bearing puller Drive pinion rear bearing inner race removal MB990648 Bearing remover B A C MB991171 A MB990819 B MB991170 C MB991169 Drive pinion setting gauge set A Drive pinion gauge B Cylinder gauge C Drive pinion gauge attach ment Drive p...

Page 418: ...g For the details of installer refer to GROUP 26 Special Tool ON VEHICLE SERVICE REAR AXLE TOTAL BACKLASH CHECK 1 Place the transmission shift lever and the transfer shift lever in the neutral position apply the parking brake and then jack up the vehicle 2 Manually turn the propeller shaft clockwise as far as it will go and make mating marks on the companion flange dust cover and the differential ...

Page 419: ...he specified torque Tightening torque 49 Nm WHEEL BEARING AXIAL PLAY CHECK 1 Place a dial gauge against the axle shaft as shown in the illustration and then move the axle shaft in the axial direction and check the axial play Limit 0 025 mm 2 If the axial play exceeds the limit check the backing plate to axle housing tightening torque If it is correct replace the bearing AXLE HOUSING OIL SEAL REPLA...

Page 420: ...vehicle Service 27 8 4 Use the special tools to install a new oil seal in position 5 Apply multipurpose grease to the lip section of the oil seal 6 Install the axle shaft assembly Refer to P 27 11 MB990930 MB990938 ...

Page 421: ...GROUP 35A On vehicle Service D Parking Brake Lever Stroke Adjustment Refer to GROUP 36 On vehicle Service D Differential Gear Oil Filling Refer to P 27 7 14 2 7 59 Nm 9 10 8 3 11 12 101 Nm 81 Nm 15 Nm 13 1 59 Nm 15 49 59 Nm 16 4 49 Nm 6 5 17 18 60 Nm Removal steps AA 1 Rear propeller shaft connection 2 Caliper assembly 3 Brake disc 4 Parking brake shoe assembly Re fer to GROUP 36 Parking Brake Dru...

Page 422: ...prevent it from falling AB SHOCK ABSORBER DISCONNECTION Support the axle housing with a jack before removing the shock absorber lower mounting nut AC LATERAL ROD DISCONNECTION Disconnect the lateral rod from the axle assembly and then use a wire etc to suspend the lateral rod to prevent it from falling AD AXLE ASSEMBLY REMOVAL Take out the axle assembly toward the rear of vehicle Caution Take out ...

Page 423: ...Nm Oil lip part 6 5 4 15 Nm 2 Removal steps 1 Brake tube 2 Caliper assembly 3 Brake disc 4 Parking brake shoe Refer to Group 36 Parking brake drum 5 Parking brake cable connection 6 Wheel speed sensor Vehicles with ABS 7 O ring Vehicles with ABS AA 8 Axle shaft assembly BA 9 Packing s BA 10 Shim s BA 11 Packing s AB AA 12 Oil seal REMOVAL SERVICE POINTS AA AXLE SHAFT ASSEMBLY REMOVAL Use the speci...

Page 424: ...ion by the following procedure 1 Insert the axle shaft assembly into the axle housing without packing s and shim s Temporarily tighten the installation nuts to half of specified torque until the bearing outer race contacts the axle housing evenly in diagonal order in two steps 2 Use a thickness gauge to measure the clearance between the axle housing and the backing plate and then select the packin...

Page 425: ...AND REASSEMBLY 2 3 1 5 4 Disassembly steps AA 1 ABS rotor Vehicles with ABS AB AA 2 Bearing inner retainer AC AA 3 Wheel bearing AA 4 Bearing outer retainer 5 Axle shaft DISASSEMBLY SERVICE POINTS AA ABS ROTOR REMOVAL Use the special tool to press out the ABS rotor AB BEARING INNER RETAINER REMOVAL 1 Use a grinder to shave off a part of the bearing inner retainer until its thickness becomes 1 to 1...

Page 426: ...ng REASSEMBLY SERVICE POINT AA BEARING OUTER RETAINER WHEEL BEARING BEARING INNER RETAINER INSTALLATION 1 Install the bearing outer retainer wheel bearing and the bearing inner retainer to the axle shaft in that order as shown in the illustration 2 Press fit the bearing inner retainer to the axle shaft Caution Install the wheel bearing as shown in the illustration MB991284 Wheel bearing Metal plat...

Page 427: ...o P 27 11 D Differential Gear Oil Filling Refer to P 27 7 1 49 59 Nm Flange surface of axle housing 59 Nm 49 Nm 25 29 Nm 2 3 φ 2 3 mm Sealant 3M ATD Part No 8661 or equivalent Section A A A A Removal steps AA AA 1 Rear propeller shaft connection AB 2 Differential carrier assembly 3 Vent plug REMOVAL SERVICE POINTS AA REAR PROPELLER SHAFT DISCONNECTION Make mating marks on the companion flange and ...

Page 428: ...t the differential carrier will not fall when separating it from the axle housing 2 Do not strike the companion flange INSTALLATION SERVICE POINT AA REAR PROPELLER SHAFT CONNECTION Connect the propeller shaft so that the mating marks on the flange yoke and the companion flange of differential carrier are aligned INSPECTION BEFORE DISASSEMBLY For the inspection procedure except for the standard val...

Page 429: ...ring outer race AC 6 Side bearing inner race AD 7 Drive gear 8 Lock pin 9 Pinion shaft 10 Pinion gear 11 Pinion washer 12 Side gear 13 Side gear spacer 14 Differential case 15 Limited slip differential case assembly AE 16 Self locking nut 17 Washer AF 18 Drive pinion assembly AF 19 Companion flange 20 Drive pinion front shim for drive pinion turning torque adjustment 21 Drive pinion spacer AG 22 D...

Page 430: ...r races separate so that they will not be confused when assembling AC SIDE BEARING INNER RACE REMOVAL Use the special tools to pull out the side bearing inner race NOTE Position the two prongs of the special tool under the bottom of the side bearing inner race through the two notches in the differential case AD DRIVE GEAR REMOVAL 1 Make the mating marks to the differential case and the drive gear ...

Page 431: ...E REMOVAL Use the special tools to remove the drive pinion rear bearing inner race AH OIL SEAL DRIVE PINION FRONT BEARING INNER RACE DRIVE PINION FRONT BEARING OUTER RACE REMOVAL Use the special tool to remove the drive pinion front bearing outer race drive pinion front bearing inner race and oil seal AI DRIVE PINION REAR BEARING OUTER RACE REMOVAL Use the special tool to remove the drive pinion r...

Page 432: ...5 Drive pinion rear shim for drive pinion height adjustment 6 Drive pinion rear bearing inner race 7 Drive pinion spacer DA D Drive pinion turning torque adjustment 8 Drive pinion front shim for drive pinion turning torque adjustment 9 Drive pinion assembly 10 Drive pinion front bearing inner race 11 Oil seal 12 Companion flange 13 Washer 14 Self locking nut 15 Differential case 16 Limited slip di...

Page 433: ...e grease to the washer of special tool 2 Install the special tools and drive pinion front and rear bearing inner races to the differential carrier in the sequence shown in the illustration 3 Gradually tighten the nut of the special tool while checking the drive pinion turning torque until the standard value of drive pinion turning torque without oil seal is obtained Standard value Bearing Bearing ...

Page 434: ...p as shown in the illustration 10 Calculate the thickness F of the drive pinion rear shim from the following equation and select the shim that is closest in thickness to this value F A B C 1 2 D 100 11 Fit the selected drive pinion rear shim s to the drive pinion and press fit the drive pinion rear bearing inner race by using the special tool DA DRIVE PINION TURNING TORQUE ADJUSTMENT Adjust the dr...

Page 435: ... adjust the turning torque by replacing the drive pinion front shim s or the drive pinion spacer NOTE When selecting the drive pinion front shims if the number of shims is large reduce the number of shims to a minimum by selecting the drive pinion spacer Select either of the following drive pinion spacers Height A of drive pinion spacer mm Identification colour 56 67 57 01 White 5 Remove the compa...

Page 436: ...torque is not within the standard value check the tightening torque of the companion flange self locking nut and the oil seal installation condition EA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Adjust the differential gear backlash by the following procedures 1 Assemble the side gears side gear spacers pinion gears and pinion washers into the differential case 2 Temporarily install the pinion shaft NO...

Page 437: ...pressed air 3 Install the drive gear onto the differential case with the mating marks properly aligned Tightening torque 78 88 Nm GASIDE BEARING INNER RACE INSTALLATION Use the special tool to press fit the side bearing inner races into the differential case HA BEARING CAP INSTALLATION Install the bearing caps with the mating marks properly aligned and then tighten the bearing caps installation bo...

Page 438: ...nd left side bearing nuts on half the distance between centres of two neighboring holes in order to apply the preload to the side bearing 5 Measure the drive gear runout at the shoulder on the reverse side of the drive gear Limit 0 05 mm 6 If the drive gear runout exceeds the limit reinstall by changing the phase of the drive gear and differential case and remeasure 7 If adjustment is not possible...

Page 439: ...31 1 WHEEL AND TYRE CONTENTS GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 2 TROUBLESHOOTING 3 ON VEHICLE SERVICE 4 Tyre Inflation Pressure Check 4 Tyre Wear Check 4 Wheel Runout Check 4 WHEEL AND TYRE 4 ...

Page 440: ...ification Wheel Type Steel Aluminium Size 16 6JJ Amount of wheel offset mm 46 Pitch circle diameter P C D mm 114 3 Tyre Size 215 65R16 98S NOTE Optional items SERVICE SPECIFICATIONS Items Limit Tread depth of tyre mm 1 6 Wheel runout Radial runout mm Steel wheel 1 2 or less Aluminium wheel 1 0 or less Wheel runout Lateral runout mm Steel wheel 1 2 or less Aluminium wheel 1 0 or less ...

Page 441: ...ion Cracked treads Under inflation Adjust the tyre pressure 31 4 Wear on one side Excessive cam ber Inspect the cam ber Refer to GROUP 33A On vehicle Service Feathered edge Incorrect toe in Adjust the toe in Bald spots Unbalanced wheel Adjust the imbal anced wheels Scalloped wear Lack of rotation of tyres or worn or out of alignment suspension Rotate the tyres and check the front suspension alignm...

Page 442: ... or less wear indicators will appear WHEEL RUNOUT CHECK Jack up the vehicle so that the wheels are clear of the floor While slowly turning the wheel measure wheel runout with a dial indicator Limit Item Steel wheel Aluminium wheel Radial runout mm 1 2 1 0 Lateral runout mm 1 2 1 0 If wheel runout exceeds the limit replace the wheel WHEEL AND TYRE INSTALLATION SERVICE POINT Tighten the wheel nut to...

Page 443: ...32 1 POWER PLANT MOUNT CONTENTS ENGINE MOUNTING 2 TRANSMISSION MOUNTING 3 ...

Page 444: ...arts marked by an asterisk and then fully tighten after loading the full weight of the engine on the vehicle body Pre removal and Post installation Operation Crossmember Removal and Installation Refer to GROUP 33 25 Nm 2 44 Nm 44 Nm 25 Nm 25 Nm 25 Nm 2 1 Removal steps 1 Engine mount bracket 2 Engine mount insulator ...

Page 445: ...o weight on the Engine Mount Bracket Insulator 93 Nm 3 49 Nm 49 Nm 49 Nm 2 1 4 7 5 6 Removal steps 1 Washer 2 Spacer 3 Transmission mount bushing 4 Transmission mount crossmember assembly 5 Transmission mount insulator assembly AA 6 Transmission mount stopper 7 Adaptor INSTALLATION SERVICE POINT AA TRANSMISSION MOUNT STOPPER INSTALLATION Install the transmission mount stopper so that the arrow fac...

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Page 462: ...34 1 REAR SUSPENSION CONTENTS GENERAL INFORMATION 2 SPECIAL TOOLS 3 REAR SUSPENSION ASSEMBLY 4 ...

Page 463: ... coil spring type axle suspension which assures comfortable ride and outstanding steering stability COIL SPRING Items Specification Wire diameter outer diameter free length mm 11 131 306 CONSTRUCTION DIAGRAM Shock absorber Upper control arm Bump rubber Lateral rod Lower control arm Coil spring ...

Page 464: ...0832 Lower arm rear bushing remover and installer ring Upper arm rear bushing driving out and press fitting MB991154 Upper arm bushing guide MB991155 Lower arm bushing guide Lower arm rear bushing driving out and press fitting MB990831 Upper arm bushing remover and installer ring MB990958 Bushing remover and in staller D Upper arm front bushing driving out and press fitting D Lower arm front bushi...

Page 465: ...Nm 101 Nm 96 Nm 64 Nm 96 Nm 96 Nm 96 Nm 103 123 Nm 1 Shock absorber 2 Lower arm 3 Lateral rod 4 Shock absorber installation bolt Coil spring removal steps 4 Shock absorber installation bolt AA 5 Coil spring 6 Silencer sheet 7 Bump stopper 8 Lower spring pad Upper arm removal steps 5 Coil spring 9 Rear wheel speed sensor installa tion bolt Vehicles with ABS 10 Upper arm INSTALLATION SERVICE POINT A...

Page 466: ... bushing SPECIAL TOOL Item Upper arm rear bushing Lower arm rear bushing A MB990947 MB990947 B MB990832 MB990831 C MB990847 MB990847 D MB991154 MB991155 2 Apply ample amount of soapy water to the outer surface of bushing and inner surface of arm pipe and then press fit the bushing so that both ends protrude evenly UPPER ARM FRONT BUSHING LOWER ARM FRONT BUSHING 1 Use a press and the special tools ...

Page 467: ...NOTES ...

Page 468: ...BASIC BRAKE SYSTEM 35A ANTI SKID BRAKING SYSTEM ABS 4WD 35B 35A 1 SERVICE BRAKES CONTENTS ...

Page 469: ...ck 8 Load Sensing Spring Length Check and Adjustment 8 Load Sensing Proportioning Valve Function Test 9 Bleeding 10 Brake Fluid Level Sensor Check 10 Disc Brake Pad Check and Replacement 11 Disc Brake Rotor Check 12 Brake Disc Thickness Check 12 Brake Disc Run out Check and Correction 13 BRAKE PEDAL 14 MASTER CYLINDER AND BRAKE BOOSTER 15 Master Cylinder 19 FRONT DISC BRAKE 20 REAR DISC BRAKE 25 L...

Page 470: ...nsing proportioning valve Type Dual type valve Decompression ratio 0 25 Front disc brakes Type Floating caliper 1 piston ventilated disc Disc effective dia thickness mm 236 22 Wheel cylinder I D mm 57 2 Pad thickness mm 10 0 Clearance adjustment Automatic Rear disc brakes Type Floating caliper 1 piston solid disc Disc effective dia thickness 222 9 4 Wheel cylinder I D mm 34 93 Pad thickness mm 10 ...

Page 471: ...ing valve output fluid pressure Input fluid pres When load sensing spring length is 199 mm when unladen 4 2 6 0 9 8 pressure Input fluid pres sure MPa When load sensing spring length is 217 mm when laden 9 7 10 5 9 8 laden 14 5 16 3 16 7 Output fluid pressure difference between left and right MPa 0 39 Load sensing spring length Distance between spring ends mm 194 198 Front disc brake Pad thickness...

Page 472: ...dy DOT3 or DOT4 SEALANT Items Specified sealant Remarks Fitting 3M ATD Part No 8661 or equivalent Semi drying sealant SPECIAL TOOLS Tool Number Name Use A MB990964 A MB990520 Brake tool set Pushing in of the disc brake piston A B A MB990998 B MB991000 A Front hub re mover and installer B Spacer When bearing provisional holding MB991000 which belongs to MB990998 should be used as a spacer MB991568 ...

Page 473: ... Screw in the stop lamp switch until it touches the stopper At this time support the brake pedal to the highest position by hand 5 Lock the stop lamp switch by turning it approx 1 4 turns clockwise and confirm that the clearance between the switch plunger and the stopper is as shown 6 Connect the connector at the stop lamp switch Caution Check that the stop lamp does not illuminate when the brake ...

Page 474: ...ue check for air trapped in the brake line thickness of the disc brake pad or the drum brake lining and dragging in the parking brake Adjust and replace defective parts as required 4 Return the carpet etc BRAKE BOOSTER OPERATING TEST For simple checking of the brake booster operation carry out the following tests 1 Run the engine for one or two minutes and then stop it If the pedal depresses fully...

Page 475: ...ection at the brake booster side A A negative pressure vacuum is created and held Connection at the intake manifold side B A negative pressure vacuum is not created Caution If the check valve is defective always replace it as an assembly unit together with the vacuum hose LOAD SENSING SPRING LENGTH CHECK AND ADJUSTMENT 1 Park the vehicle on a level ground The vehicle should be unloaded and support...

Page 476: ...de 5 Check at this time whether or not the output fluid s pressure relative to the load sensing proportioning valve s input fluid pressure is within the standard value Standard value Spring length H mm Input fluid pressure MPa Output fluid pressure MPa 199 1 9 8 4 2 6 0 217 2 9 8 9 7 10 5 16 7 14 5 16 3 NOTE 1 and 2 indicate the applicable lengths for unladen and laden vehicles respectively 6 Meas...

Page 477: ...r cylinder 1 Fill the reserve tank with brake fluid 2 Keep the brake pedal depressed 3 Have another person cover the master cylinder outlet with a finger 4 With the outlet still closed release the brake pedal 5 Repeat steps 2 4 three or four times to fill the inside of the master cylinder with brake fluid BRAKE PIPE LINE BLEEDING Bleed the air in the sequence shown in the figure BRAKE FLUID LEVEL ...

Page 478: ...s less than the limit always replace the pads at an axle set 3 Remove the guide lock pin bolt Pivot the caliper assembly and hold it with wires 4 Remove the following parts from the caliper support 1 Pad and wear indicator assembly 2 Pad assembly 3 Clip 4 Inner shim 5 Outer shim 5 In order to measure the brake drag force after pad installation measure the rotary sliding resistance of the hub with ...

Page 479: ...sc and the lining pad Run out or drift Excessive run out or drift of the discs will increase the pedal depression resistance due to piston knock back Change in thickness parallelism If the thickness of the disc changes this will cause pedal pulsation shuddering and surging Inset or warping flatness Overheating and improper handling while servicing will cause inset or warping BRAKE DISC THICKNESS C...

Page 480: ...stud and the brake disc which run out is excessive as shown 2 Remove the brake disc Then place a dial gauge as shown and measure the end play by pushing and pulling the wheel hub Limit Front 0 2 mm Rear 0 025 mm 3 If the end play exceeds the limit disassemble the hub and knuckle assembly to check each part 4 If the end play does not exceed the limit dephase the brake disc and secure it Then rechec...

Page 481: ... 3 Adjuster 4 Pedal stopper 5 Snap pin 6 Pin assembly 7 Split pin A T 8 Shift lock cable connection A T 9 Pedal pad 10 Brake pedal and pedal support member INSPECTION STOP LAMP SWITCH CHECK 1 Connect an ohmmeter between the stop lamp switch connector terminals 2 There should be no continuity between the terminals when the plunger is pushed in as shown There should be continuity when it is released...

Page 482: ...S Pre removal Operation Brake Fluid Draining Post installation Operation D Brake Fluid Supplying and Air Bleeding Refer to P 35A 10 D Brake Pedal Adjustment Refer to P 35A 6 Specified Sealant 3M ATD Part No 8661 or equivalent Grease Silicone grease 11 4 7 8 14 9 10 1 2 12 12 Nm 15 Nm 14 Nm 15 Nm 1 3 11 6 14 14 7 17 7 Nm 12 10 Silicon grease 5 13 ...

Page 483: ...nstallation Operation D Brake Fluid Supplying and Air Bleeding Refer to P 35A 10 D Brake Pedal Adjustment Refer to P 35A 6 Specified Sealant 3M ATD Part No 8661 or equivalent Grease Silicone grease 11 4 7 8 14 9 10 1 2 12 12 Nm 15 Nm 14 Nm 15 Nm 1 3 11 6 14 14 7 17 7 Nm 12 10 5 13 L H drive vehicles 14 R H drive vehicles 14 7 17 7 Nm 6 Grease Silicone grease 12 4 ...

Page 484: ...ing removal 14 Fitting INSTALLATION SERVICE POINTS AA VACUUM HOSE CONNECTION Insert the vacuum hose to the fitting with its paint mark facing forward L H drive vehicles upward R H drive vehicles until the hose end reaches the edge of the hexagonal part of the fitting and then secure the hose by using the hose clip BA PUSH ROD PROTRUSION AMOUNT CHECK AND ADJUSTMENT 1 Measure dimension A Standard va...

Page 485: ...e nose pliers CA SEAL INSTALLATION 1 Apply silicone grease to the seal 2 Install the seal to the master cylinder as shown INSPECTION VACUUM SENSOR CHECK Refer to GROUP 13A Troubleshooting NOTE The vacuum sensor is monitored by the engine ECU Diagnosis code is output when the vacuum sensor has a malfunction Angle nose pliers MB991568 Seal Master cylinder L H drive vehicles with ABS L H drive vehicl...

Page 486: ...aster cylinder kit 4 5 9 6 12 11 10 9 10 11 12 11 12 10 Disassembly steps 1 Reservoir cap 2 Pin 3 Reservoir tank 4 Brake fluid level sensor 5 Reservoir seal AA 6 Stopper ring 7 Piston guide 8 Cylinder cup 9 Plate 10 Primary piston assembly 11 Secondary piston assembly 12 Master cylinder body DISASSEMBLY SERVICE POINT AA STOPPER RING REMOVAL Push the primary piston assembly and remove the stopper r...

Page 487: ...tallation measure the rotary sliding resistance of the hub by the following procedure with the pads removed 1 Withdraw the drive shaft Refer to GROUP 26 Front Axle 2 Attach the special tool to the front hub assembly as shown in the illustration and tighten it to the specified torque Tightening torque 196 255 Nm 3 Use a spring balance to measure the rotary sliding resistance of the hub in the forwa...

Page 488: ...es strongly Then stop the engine 6 Turn the brake disc forward 10 times 7 Use a spring balance to measure the rotary sliding resistance of the hub 8 Calculate the drag force of the disc brake difference between the values measured at steps 1 and 7 Standard value 69 N 9 If that drag force exceeds the standard value disassemble the piston assembly Then check the piston for contamination or rust and ...

Page 489: ...0 3 9 8 7 6 4 13 12 9 3 7 Clip kit 14 Shim kit 11 15 15 15 15 26 Nm 26 Nm 2 3 2 Disassembly steps 1 Guide pin lock bolt 2 Guide pin 3 Boot 4 Bushing 5 Bushing retainer 6 Caliper support including pad clip and shim AA 7 Piston boot AA 8 Piston AB 9 Piston seal 10 Caliper body 11 Pad and wear indicator assembly 12 Pad assembly 13 Inner shim 14 Outer shim 15 Clip ...

Page 490: ...LUBRICATION POINTS Piston seal Grease Repair kit grease Caution The piston seal inside the seal and boot kit is coated with special grease so do not wipe this grease off Brake fluid DOT3 or DOT4 Grease Repair kit grease Grease Repair kit grease ...

Page 491: ...o prevent damage to inner cylinder 2 Clean piston surface and inner bore with trichloroethylene alcohol or the specified brake fluid Specified brake fluid DOT3 or DOT4 INSPECTION D Check the cylinder for wear damage or rust D Check the piston surface for wear damage or rust D Check the caliper body or sleeve for wear D Check pad for damage or adhesion of grease check the backing metal for damage P...

Page 492: ...AA 2 Disc brake assembly 3 Brake disc INSTALLATION SERVICE POINT AA DISC BRAKE ASSEMBLY INSTALLATION 1 In order to measure the brake drag force after pad installation use a spring balance to measure the rotary sliding resistance of the hub with the pads removed 2 Install the caliper support to the backing plate and then assemble the pad clip and the pad to the caliper support Caution Do not contam...

Page 493: ...es strongly Then stop the engine 6 Turn the brake disc forward 10 times 7 Use a spring balance to measure the rotary sliding resistance of the hub 8 Calculate the drag force of the disc brake difference between the values measured at steps 1 and 7 Standard value 34 N 9 If that drag force exceeds the standard value disassemble the piston assembly Then check the piston for contamination or rust and ...

Page 494: ... set Seal and boots kit 2 3 5 1 10 5 9 8 7 6 13 12 9 3 5 5 7 Grease Shim set 6 11 3 2 13 15 Disassembly steps AA 1 Guide pin AA 2 Lock pin 3 Bushing 4 Caliper support pad clip shim 5 Pin boot 6 Boot ring AA 7 Piston boot AA 8 Piston AB 9 Piston seal 10 Caliper body 11 Pad and wear indicator assembly 12 Pad assembly 13 Inner shim 14 Outer shim 15 Clip ...

Page 495: ...LUBRICATION POINTS Piston seal Grease Repair kit grease Caution The piston seal inside the seal and boot kit is coated with special grease so do not wipe this grease off Brake fluid DOT3 or DOT4 Grease Repair kit grease Grease Repair kit grease ...

Page 496: ...e a flat tipped screwdriver or other tool to prevent damage to inner cylinder 2 Clean piston surface and inner bore with trichloroethylene alcohol or the specified brake fluid Specified brake fluid DOT3 or DOT4 REASSEMBLY SERVICE POINT AA LOCK PIN GUIDE PIN INSTALLATION Install the guide pin and lock pin as illustrated that each head mark of the guide pin and the lock pin matches the indication ma...

Page 497: ...worn area of the pad Replace the pad assembly if the pad thickness is less than the limit value Standard value 10 mm Limit 2 0 mm Caution 1 Always replace the brake pads as an axle set 2 If an excessive difference is found in the thickness between the right and left brake pads check moving parts ...

Page 498: ...pring support 2 Load sensing spring 3 Brake pipe connection 4 Load sensing proportioning valve 5 Bracket INSTALLATION SERVICE POINT AA SPRING SUPPORT INSTALLATION 1 Install the load sensing spring and then tighten the spring support to the axle assembly temporarily 2 Insert the lever of the load sensing proportioning valve fully into the valve side and hold it Then adjust the spring support so tha...

Page 499: ...NOTES ...

Page 500: ...er to GROUP 35A Load Sensing Proportioning Valve Function Test Refer to GROUP 35A Brake Fluid Level Sensor Check Refer to GROUP 35A Bleeding Refer to GROUP 35A Disc Brake Pad Check and Replacement Refer to GROUP 35A Disc Brake Rotor Check Refer to GROUP 35A Brake Disc Thickness Check Refer to GROUP 35A Brake Disc Run out Check and Correction Refer to GROUP 35A Wheel Speed Sensor Output Voltage Che...

Page 501: ...35B 2 FRONT DISC BRAKE Refer to GROUP 35A REAR DISC BRAKE Refer to GROUP 35A LOAD SENSING PROPORTIONING VALVE Refer to GROUP 35A HYDRAULIC UNIT AND ABS ECU 26 WHEEL SPEED SENSOR 29 G SENSOR 31 ...

Page 502: ...diagnosis codes and service data and actuator testing are possible by using the MUT II WHEEL SPEED SENSOR Type Magnet coil type ABS rotor teeth 43 CONSTRUCTION DIAGRAM Stop lamp switch ABS warning lamp Diagnosis connector Wheel speed sensor Wheel speed sensor Hydraulic unit assembly integrated with the ABS ECU G sensor SERVICE SPECIFICATIONS Items Standard value Wheel speed sensor internal resista...

Page 503: ...r checking of ABS Diagnosis code display when using the MUT II MB991529 Diagnosis code check harness For checking of ABS Diagnosis code display when using the ABS warning lamp MB991547 ABS check harness For measuring of ABS ECU terminal voltage MB991348 Test harness set For checking of G sensor ...

Page 504: ...bration of the brake pedal scraping 3 When ABS operates sound is generated from the vehicle chassis due to repeated brake application and release Thump suspension squeak tyres System check sound When depressing the brake pedal during driving a shock is sometime felt 2 For road surfaces such as snow covered roads and gravel roads the braking distance for vehicles with ABS can sometimes be longer th...

Page 505: ...een recorded because of a previous problem occurring In this case the ABS ECU keeps the warning lamp illuminated until the problem corresponding to that diagnosis code can be detected 4 If the illumination is other than the above check the diagnosis codes DIAGNOSIS FUNCTION READING DIAGNOSIS CODES Read a diagnosis code by the MUT II or ABS warning lamp Refer to GROUP 00 How to Use Troubleshooting ...

Page 506: ...ease the brake pedal Then turn the stop lamp switch on and off a total of 10 times NOTE If the ABS ECU function has been stopped because of fail safe operation it will not be possible to erase the diagnosis codes 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th Within 1 second Within 1 second Within 1 second Within 1 second Within 1 second Within 1 second Within 1 second Within 1 second Within 1 second Wi...

Page 507: ...top lamp switch system 35B 13 41 Front right solenoid valve The diagnosis codes are output when there is no response to the 35B 13 42 Front left solenoid valve when there is no response to the drive signals for respective solenoid valves or the ABS ECU power 43 Rear right solenoid valve valves or the ABS ECU power supply system is defective 44 Rear left solenoid valve 51 Valve relay problem stays ...

Page 508: ...heel speed sensor D Malfunction of wiring harness or connector D Malfunction of ABS rotor D Too much gap between the sensor and the ABS rotor D Malfunction of hydraulic unit and ABS ECU D Malfunction of wheel bearing NG Replace OK NG Check the harness wire and repair if necessary D Between each wheel speed sensor and ABS ECU NG Repair OK Wheel bearing check Refer to GROUP 26 and GROUP 27 On vehicl...

Page 509: ...CU NG Replace NG Check the harness wire and repair if necessary D Between each wheel speed sensor and ABS ECU OK YES OK Check the trouble symp tom Check the wheel bearing Refer to GROUP 26 and GROUP 27 On vehicle Service Are four tyres equal in size NO NG Repair NG Replace the hydraulic unit and ABS ECU OK Check the trouble symp tom Check the following connector A 58 NG Check the wheel speed senso...

Page 510: ...ns to standard value this code is no longer output Before carrying out the following inspection check the battery level and refill it if necessary NG Repair NG Replace the hydraulic unit and ABS ECU NG Repair NG Check the harness wire and repair if necessary D Between ignition switch and ABS ECU OK Check the trouble symp tom OK Check the trouble symp tom OK Check the following connector A 58 Measu...

Page 511: ...ollowing connector D 29 G sensor check Refer to P 35B 31 NG NG Repair NG Replace the hydraulic unit and ABS ECU OK Check the trouble symp tom Check the following connector A 58 NG Measure at the ABS ECU connector A 58 D Disconnect the connector and measure at the harness side connector D Ignition switch ON D Voltage between 7 and 20 OK 2 4 2 6 V When labeled surface is faced to vertical direction ...

Page 512: ...K Check the trouble symp tom OK Check the following connectors C 28 L H drive vehicles C 41 R H drive vehicles C 02 C 04 C 29 OK Check the stop lamp switch Refer to GROUP 35A Brake Pedal Does the stop lamp turn on and off normally NO Check the stop lamp switch installation condition Refer to GROUP 35A On vehicle Service Code Nos 41 42 43 and 44 Solenoid valve Probable cause Code No 52 Valve relay ...

Page 513: ... be able to be depressed Such phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Communication between the MUT II and the whole system is not possible Probable cause The cause may be a malfunction of the power supply circuit or the earth c...

Page 514: ...e following connector A 58 Measure at the ABS ECU connector A 58 D Disconnect the connector and measure at the harness side connector D Continuity between 21 and body earth and between 23 and body earth OK Continuity Check the following connector A 58 OK Check the trouble symp tom Measure at the ABS ECU connector A 58 D Disconnect the connector and measure at the harness side connector D Ignition ...

Page 515: ...nd ABS ECU NG Check the harness wire and repair if necessary D Between ABS warning lamp relay and earth OK Check the trouble symp tom OK Measure at the ABS warning lamp relay connector A 57 D Disconnect the connector and measure at the harness side connector D Ignition switch ON D Continuity between 1 and body earth OK Continuity NG Check the following connector A 57 OK Check the trouble symp tom ...

Page 516: ...ch ON D Voltage between 8 and body earth OK System voltage YES Check the following connectors A 58 A 57 NO ABS warning lamp relay check Refer to P 35B 23 NG Replace the ABS warning lamp relay Does the ABS warning lamp stay illuminated when the combination meter connector C 07 is disconnected and the ignition switch is turned to ON YES Replace the combination meter Measure at the ABS warning lamp r...

Page 517: ...or A 58 NG Measure at the ABS ECU connector A 58 D Disconnect the connector and measure at the harness side connector D Resistances between 17 and 18 15 and 14 4 and 5 2 and 1 OK 1 30 1 58 kΩ The sensor harness and connector should be moved while these inspections are carried out NG OK Check the trouble symptom OK Check the following connectors A 58 C 25 L H drive vehicles C 24 R H drive vehicles ...

Page 518: ...al OFF 2 When the ABS ECU shut off ABS operation When the diagnosis system stops the ABS ECU the MUT II display data will be unreliable ACTUATOR TEST REFERENCE TABLE The MUT II activates the following actuators for testing NOTE 1 If the ABS ECU runs down actuator testing cannot be carried out 2 Actuator testing is only possible when the vehicle is stationary ACTUATOR TEST SPECIFICATIONS No Item 01...

Page 519: ...nsor Ignition switch ON Vehicle is horizontal 2 4 2 6 V 8 ABS warning lamp relay transistor output Ignition switch ON When the lamp is switched off 2 V or less When the lamp is illu minated System voltage 9 MUT II When the MUT II is connected Serial communication with MUT II When the MUT II is not connected 1 V or less 10 ABS ECU power supply Ignition switch ON System voltage supply Ignition switc...

Page 520: ...k the resistance and continuity between the terminals indicated in the table below 4 The terminal layout is shown in the illustration ABS ECU terminal No Signal Normal condition 1 2 Wheel speed sensor rear left 1 30 1 58 kΩ 4 5 Wheel speed sensor rear right 14 15 Wheel speed sensor front left 17 18 Wheel speed sensor front right 21 Body earth Earth Continuity 23 Body earth Earth Check connector MB...

Page 521: ...cribed above Check the wheel speed sensor and replace if necessary D Too large clearance between the pole piece of the wheel speed sensor and ABS rotor D Faulty wheel speed sensor Inspecting Waveforms With An Oscilloscope Use the following method to observe the output voltage waveform from each wheel speed sensor with an oscilloscope D Start the engine and rotate the rear wheels by engaging 1st ge...

Page 522: ...s Correct harness Incorrectly mounted wheel speed sensor Mount correctly ABS rotor with missing or damaged teeth Replace ABS rotor Caution Because the wheel speed sensor cables move together with the front and rear suspension they vibrate greatly when driving over poor road surfaces As a result the sensor harnesses should also be shaken when monitoring of output waveforms of the wheel speed sensor...

Page 523: ...ngine 4 Use the MUT II to force drive the actuator NOTE 1 During the actuator test the ABS warning lamp will illuminate and the anti skid control will be cancelled 2 When the ABS has been interrupted by the fail safe function the MUT II actuator testing cannot be used 5 Turn the wheel by hand and check the change in braking force when the brake pedal is depressed When using the braking force teste...

Page 524: ... Replace hydrau lic unit assembly 7 After inspection disconnect the MUT II immediately after turning the ignition switch to OFF REMEDY FOR A FLAT BATTERY When booster cables are used to start the engine when the battery is completely flat and then the vehicle is immediately driven without waiting for the battery to recharge itself to some extent the engine may misfire and driving might not be poss...

Page 525: ...ration D Brake Fluid Draining D Air Cleaner Removal Refer to GROUP 15 Post installation Operation D Brake Fluid Supplying and Brake Line Bleeding Refer to GROUP 35A On vehicle Service D Hydraulic Unit Inspection Refer to P 35B 24 D Air Cleaner Installation Refer to GROUP 15 L H drive vehicles 15 Nm 2 3 5 1 3 4 ...

Page 526: ... Harness connector AA 3 Brake pipe connection AB 4 Hydraulic unit and ABS ECU 5 Hydraulic unit bracket assembly REMOVAL SERVICE POINTS AA HARNESS CONNECTOR DISCONNECTION Move the lock lever of the ABS ECU connector as shown in the illustration and then disconnect the harness connector Hydraulic unit and ABS ECU Lock lever ...

Page 527: ...it assembly must not be dropped or otherwise subjected to impact shocks 4 The hydraulic unit assembly must not be turned upside down or laid on its side INSTALLATION SERVICE POINT AA BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit assembly as shown in the illustration 1 To the proportioning valve Rear brake LH 2 To the proportioning valve Rear brake RH 3 From the master cylinder Prim...

Page 528: ...r to GROUP 26 Drive Shaft AA 3 Rear wheel speed sensor 4 Rear ABS rotor Refer to GROUP 27 Axle Shaft NOTE The front ABS rotor is integrated with the drive shaft Do not disassemble it REMOVAL SERVICE POINT AA FRONT WHEEL SPEED SENSOR REAR WHEEL SPEED SENSOR REMOVAL Caution Do not strike the pole piece at the tip of the wheel speed sensor against the ABS rotor tooth surface or other parts when remov...

Page 529: ...a new wheel speed sensor 2 Check the wheel speed sensor cable for breakage damage or disconnection replace with a new one if a problem is found NOTE When checking for cable damage remove the cable clamp part from the body and then bend and pull the cable near the clamp to check whether or not temporary disconnection occurs WHEEL SPEED SENSOR INSULATION INSPECTION 1 Remove all connections from the ...

Page 530: ...ors and then place the G sensor horizontally as shown in the illustration 3 Turn on the ignition switch and then measure the voltage between terminal No 2 and body earth Standard value 2 4 2 6 V 4 Face the labeled surface straight down with the special tool still connected Measure the voltage between terminal No 2 and body earth with the labeled surface faced straight down Standard value 3 3 3 7 V...

Page 531: ...NOTES ...

Page 532: ...L INFORMATION 2 SERVICE SPECIFICATIONS 2 LUBRICANTS 2 ON VEHICLE SERVICE 3 Parking Brake Lever Stroke Check and Adjustment 3 Parking Brake Switch Check 4 Lining Runing In 4 PARKING BRAKE LEVER 5 PARKING BRAKE CABLE 6 PARKING BRAKE DRUM 8 ...

Page 533: ...ever is used to apply the parking brake CONSTRUCTION DIAGRAM Parking brake lever Parking brake cable SERVICE SPECIFICATIONS Items Standard value Limit Parking brake lever stroke 3 5 notches Rear brake lining thickness mm 2 8 1 0 Rear drum inside diameter mm 168 0 169 0 LUBRICANTS Items Specified lubricants Backing plate Multipurpose grease Shoe and lining assembly Adjuster ...

Page 534: ...flat tip screwdriver to turn the adjuster in the direction of the arrow the direction which expands the shoe so that the disc will not rotate Return the adjuster five notches in the direction opposite to the direction of the arrow 4 Turn the adjusting nut to adjust the parking brake lever stroke to the standard value After adjusting check that there is no space between the adjusting nut and the pa...

Page 535: ...erformance is insufficient Caution Carry out running in in a place with good visibility and pay careful attention to safety 1 Adjust the parking brake stroke to the specified value Standard value Operation force Approx 196 N 3 5 notches 2 Hook a spring balance onto the centre of the parking brake lever grip and pull it with a force of 98 147 N in a direction perpendicular to the handle 3 Drive the...

Page 536: ...A Post installation Operation D Parking Brake Lever Stroke Adjustment Refer to P 36 3 D Rear Floor Console Installation Refer to GROUP 52A 5 Ratchet plate Section A A Section B B Ratchet pawl A B B A 4 2 3 1 Removal steps 1 Adjusting nut 2 Nut holder 3 Parking brake front cable assembly connection 4 Parking brake lever assembly 5 Parking brake switch ...

Page 537: ... and Adjustment Refer to P 36 3 D Rear Floor Console Installation Refer to GROUP 52A 12 13 12 55 65 Nm 1 2 3 6 7 4 5 8 9 10 11 Removal steps AA 1 Rear brake caliper assembly 2 Rear brake disc BA 3 Shoe to anchor spring 4 Adjusting screw spring AA 5 Adjuster 6 Strut 7 Strut return spring AB 8 Shoe hold down cup 9 Shoe hold down spring 10 Shoe hold down pin 11 Shoe and lining assembly 12 Clip 13 Par...

Page 538: ...er so that the shoe adjusting bolt of left hand wheel is attached towards the front of the vehicle and the shoe adjusting bolt of right hand wheel is towards the rear of the vehicle BA SHOE TO ANCHOR SPRING INSTALLATION Install the shoe to anchor springs in the order shown in the illustration Caution The load on the respective shoe to anchor springs is different so the spring in the figure has bee...

Page 539: ... Adjustment Refer to P 36 3 Brake grease Multipurpose grease 12 10 10 13 8 5 2 4 3 7 6 11 10 4 10 9 55 65 Nm 1 7 8 13 Removal steps 1 Rear brake caliper assembly Refer to P 36 7 2 Shoe to anchor spring Refer to P 36 7 3 Adjusting screw spring 4 Adjuster Refer to P 36 7 5 Strut 6 Strut return spring 7 Shoe hold down cup Refer to P 36 7 8 Shoe hold down spring 9 Shoe hold down pin 10 Shoe and lining...

Page 540: ...he thickness of the brake lining has worn down to the limit value or more replace the shoe and lining assemblies on both sides of the vehicle 3 Measure the inside diameter of the brake disc in two places or more Standard value 168 0 mm Limit 169 0 mm 4 If the inside of the brake disc has worn down to the limit value or more or if it is excessively worn on one side replace the brake disc ...

Page 541: ...NOTES ...

Page 542: ...RS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injury or death to service personnel from inadvertent firing of the air bag or to the driver and passenger from rendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUB...

Page 543: ...l pump with a fluid flow control system so that steering effort varies with engine speed Item Specifications Steering gear and linkage Type Integral type Gear type Rack and pinion Oil pump Type Vane type Oil pump Type Vane type Displacement mȏ rev 7 2 Displacement mȏ rev 7 2 Relief set pressure Mpa 8 3 9 0 CONSTRUCTION DIAGRAM Oil reservoir Steering gear box and linkage Steering wheel Steering col...

Page 544: ...STEERING General Information 37A 3 Oil reservoir Steering gear box and linkage Steering wheel Steering column and shaft Return hose Suction hose Pressure hose R H drive vehicles Oil pump ...

Page 545: ...ating pressure MPa OFF ON 1 5 2 0 ON OFF 0 7 2 0 Pinion total rotation torque Nm Total rotation torque 0 6 1 5 Torque variation 0 5 or less Tie rod joint swing resistance N Tie rod joint swing torque Nm 5 17 1 5 4 9 Special tool aperture dimension MB991561 mm 2 9 Band crimped width mm 2 4 2 8 LUBRICANTS Item Specified lubricant Quantity Power steering Automatic transmission fluid DEXRON or DEXRON ...

Page 546: ...ement MB990993 Power steering oil pressure gauge adapter pump side Oil pressure measurement MB990994 Power steering oil pressure gauge adapter hose side MB990662 Oil pressure gauge assembly MB990803 Steering wheel puller Steering wheel disconnection MB991006 Preload socket Total pinion torque measurement MB991621 Rack support cover wrench D Rack support cover removal D Total pinion torque adjustme...

Page 547: ...al installer set Oil seal and bearing press fitting Refer to GROUP 26 Special Tools MB991203 Oil seal and bearing installer Valve housing oil seal and bearing press fitting MB991317 Seal ring installer Pinion seal ring compression MB990941 Torque tube bearing installer Valve housing lower oil seal press fitting MB991561 Boot band crimping tool Bellows band installation MB990776 Front axle base Dus...

Page 548: ...ay Standard value 0 10 mm 5 In case the play exceeds the standard value again remove the steering gear box and linkage Then check and adjust total pinion torque Refer to P 37A 18 STEERING ANGLE CHECK 1 Put the front wheels on a turning radius gauge and measure steering angle Standard value Inner wheels 34_40 2_ Outer wheels For reference 32_10 2 If the standard values are not met toe in is probabl...

Page 549: ...ght within a range of 1 5 turns Also see that no significant fluctuation is present in the steering effort Standard value Steering effort 27 N or less Limit 30 N or less Fluctuation 5 9 N or less 4 If the standard values are not met check and adjust the related parts STEERING WHEEL RETURNABILITY CHECK Check returnability as follows on road test 1 Make both gradual and sudden turns and see by your ...

Page 550: ...º marks and then bleed air Specified fluid Automatic transmission fluid DEXRON or DEXRON II Caution Do not use ATF SP II as it damages the components of the power steering POWER STEERING SYSTEM BLEEDING 1 Jack up the vehicle and support the front wheels with rigid racks 2 Disconnect the ignition coil connectors Cranking the engine with the starter several times intermittently during 15 to 20 secon...

Page 551: ...s not met disassemble and assemble the oil pump again Then remeasure oil pressure 6 With the pressure gauge shut off valve fully open check the hydraulic pressure in unladen condition Standard value 0 2 0 7 MPa 7 If the standard value is not met the oil line or steering gear is probably defective So repair and measure oil pressure again 8 Turn the steering wheel fully either left or right and chec...

Page 552: ...ing the switch meets the standard value Standard value 1 5 2 0 MPa 6 Gradually open the shut off valve and reduce the hydraulic pressure Check that the hydraulic pressure deactivating the switch meets the standard value Standard value 0 7 2 0 MPa 7 Remove the special tools and tighten the pressure hose to the specified torque Tightening torque 57 Nm 8 Bleed the system BALL JOINT DUST COVER CHECK 1...

Page 553: ...Refer to GROUP 52A Post installation Operation D Instrument Under Cover Installation Refer to GROUP 52A D Checking Steering Wheel Position with Wheels Straight Ahead Standard bolt 12 Nm 22 Nm Earth bolt 18 Nm 12 Nm 41 Nm 7 9 1 6 4 2 3 8 5 9 Nm 1 Removal steps 1 Air bag module Refer to GROUP 52B AA 2 Steering wheel 3 Lower column cover 4 Upper column cover 5 Clock spring and column switch as sembly...

Page 554: ...STEERING Steering Wheel and Shaft 37A 13 REMOVAL SERVICE POINTS AA STEERING WHEEL REMOVAL MB990803 ...

Page 555: ... the special bolt drill a hole deep enough for the tap to stand 2 Using a left hand tap remove the special bolt REASSEMBLY SERVICE POINT AA STEERING LOCK CYLINDER ASSEMBLY STEERING LOCK BRACKET SPECIAL BOLT INSTALLATION 1 When installing the steering lock cylinder assembly and steering lock bracket to the steering column assembly temporarily install the steering lock in alignment with the column b...

Page 556: ...operative which results serious driver injury Pre removal Operation D Power Steering Fluid Draining Refer to P 37A 9 D Under Cover Removal Post installation Operation D Check the Dust Cover for Cracks or Damage by Pushing it with Finger D Under Cover Installation D Power Steering Fluid Supplying and bleeding Refer to P 37A 9 D Checking Steering Wheel Position with Wheels Straight Ahead D Front Whe...

Page 557: ...m 4 6 R H drive vehicles 12 Removal steps 1 Steering gear and joint connecting bolt 2 Splash shield 3 Split pin AA 4 Tie rod end and knuckle connection BA 5 Return hose AA 6 Pressure hose 7 Nut R H drive vehicles 8 Pressure tube 9 Return tube 10 O ring 11 Cylinder clamp 12 Gear housing clamp AB 13 Steering and gear linkage ...

Page 558: ...ecial tool with a cord so as not to fall off AB STEERING GEAR BOX AND LINKAGE REMOVAL Caution Do not damage the boots when removing the steering gear box and linkage INSTALLATION SERVICE POINTS AA PRESSURE HOSE CONNECTION Connect the pressure hose and pressure tube with their mating marks aligned BA RETURN HOSE CONNECTION Connect the return hose so that the claws of the hose clip are positioned as...

Page 559: ...if necessary Caution Secure the steering gear box and linkage in their mounting positions only Otherwise deformation or damage could result TIE ROD SWING RESISTANCE CHECK 1 Swing the tie rod 10 times hardly 2 With the tie rod end downwards as shown use a spring scale to measure swing resistance swing torque Standard value 5 17 N 1 5 4 9 Nm 3 If the measured value is above the standard value replac...

Page 560: ...nd 7 Bellows KA 8 Tie rod KA 9 Tab washer JA D Total pinion torque adjustment IA 10 Locking nut AA IA 11 Rack support cover 12 Rack support spring 13 Rack support 14 Valve assembly AB HA 15 Lower oil seal AB 16 Pinion and valve assembly AC GA 17 Seal ring AD FA 18 Upper bearing AD FA 19 Upper oil seal 20 Valve housing 21 Dust cover AE EA 22 Circlip AF 23 Rack stopper AF DA 24 Rack bushing assembly...

Page 561: ...KA 8 Tie rod KA 9 Tab washer JA D Total pinion torque adjustment IA 10 Locking nut AA IA 11 Rack support cover 12 Rack support spring 13 Rack support 14 Valve assembly AB HA 15 Lower oil seal AB 16 Pinion and valve assembly AC GA 17 Seal ring AD FA 18 Upper bearing AD FA 19 Upper oil seal 20 Valve housing 21 Dust cover AE EA 22 Circlip AF 23 Rack stopper AF DA 24 Rack bushing assembly AF DA 25 Rac...

Page 562: ...uid Automatic transmission fluid DEXRON or DEXRON II Fluid Automatic transmission fluid DEXRON or DEXRON II Fluid Automatic transmission fluid DEXRON or DEXRON II Sealant 3M ATD Part No 8661 or equivalent Grease Repair kit grease Fluid Automatic transmission fluid DEXRON or DEXRON II Grease Repair kit grease Fluid Automatic transmission fluid DEXRON or DEXRON II ...

Page 563: ...assembly Caution When cutting the seal ring be careful not to damage the pinion and valve assembly AD UPPER BEARING UPPER OIL SEAL REMOVAL Using a socket pull out the upper oil seal and bearing from the valve housing AE CIRCLIP REMOVAL 1 Turn the rack stopper clockwise until the circlip end comes out of the slot in the rack housing 2 Turn the rack stopper anticlockwise to remove the circlip Cautio...

Page 564: ...pipe or the like to pull out the oil seal REASSEMBLY SERVICE POINTS AA GEAR HOUSING MOUNTING RUBBER INSTALLATION 1 Install the gear housing mounting rubber on the rack housing so that the dimension shown is achieved NOTE The gear housing mounting rubber can be installed regardless of the installation direction of the slit 2 Apply specified adhesive to the slit of the gear housing mounting rubber S...

Page 565: ... II 4 Slowly insert the rack covered with the special tool from the power cylinder side of the gear housing Caution Carefully push in the rack with the oil seal centre and the special tool end matched This is to avoid the retainer spring coming off DA OIL SEAL RACK BUSHING RACK BUSHING ASSEMBLY INSTALLATION 1 Apply specified fluid to the outer surface of the oil seal Using the special tool press i...

Page 566: ... rack end with plastic tape and push the rack bushing onto the rack EA CIRCLIP INSTALLATION Align the mark on the rack stopper and the slot in the cylinder Then insert the circlip into the rack stopper hole through the cylinder hole Turn the rack stopper clockwise and insert the circlip firmly FA UPPER OIL SEAL UPPER BEARING INSTALLATION GASEAL RING INSTALLATION After installation using the specia...

Page 567: ...g the special tool to prevent the rack support cover from spinning JA PINION TOTAL ROTATION TORQUE ADJUSTMENT 1 Using the special tool measure total rotation torque by turning the pinion gear at a speed of one rotation per 4 to 6 seconds Standard value Total rotation torque 0 6 1 5 Nm Torque fluctuation 0 5 Nm or less 2 If the total rotation torque or torque fluctuation does not meet the standard ...

Page 568: ... one turn 2 Use the special tool to crimp the bellows band Caution 1 Hold the rack housing and use the special tool to crimp the bellows band securely 2 Crimp the bellows band until the special tool touches the stopper 3 See that the crimped width A meets the standard value Standard value A 2 4 2 8 mm When more than 2 8 mm Readjust the dimension W of step 1 to the value calculated by the following...

Page 569: ...r steering gear box and linkage are installed to the vehicle and toe in is adjusted TIE ROD END BALL JOINT DUST COVER REPLACEMENT Only when the dust cover is damaged accidentally during service work replace the dust cover as follows 1 Apply grease inside a new dust cover 2 Using the special tool press in the dust cover to the tie rod end 3 Check the dust cover for cracks or damage by pushing it wi...

Page 570: ...eeding Refer to P 37A 9 D Drive Belt Tension Adjusting Refer to GROUP 11A 1 3 4 9 28 Nm 8 57 Nm 28 Nm 49 Nm 5 7 6 25 Nm 44 Nm 10 44 Nm 21 Nm 2 7 Removal steps D Air intake duct 1 Drive belt 2 Pressure switch connector 3 Eye bolt 4 Pressure hose 5 Gasket AA 6 Suction hose 7 Oil pump assembly 8 Oil pump stay 9 Tensioner pulley 10 Oil pump bracket INSTALLATION SERVICE POINT AA SUCTION HOSE INSTALLATI...

Page 571: ...2 17 10 14 5 7 4 3 8 5 6 NOTE Automatic transmission fluid DEXRON or DEXRON II Caution Never disassemble the terminal assembly unable to be reassembled Disassembly steps 1 Pump cover 2 O ring EA 3 Vanes DA 4 Cam ring 5 Snap ring 6 Pulley and shaft CA 7 Rotor 8 Side plate AA 9 O ring BA 10 Oil seal 11 Terminal assembly AA 12 O ring 13 Inner plug AA 14 O ring 15 Flow control spring 16 Suction connec...

Page 572: ...4 BA OIL SEAL INSTALLATION CA ROTOR INSTALLATION Install the rotor with its punch mark towards the side plate DA CAM RING INSTALLATION Install the cam ring with its identification mark towards the side plate Inner plug Side plate Terminal assembly Suction connector mounting portion of oil pump body 1 3 5 2 4 MB990938 MB991203 Punch mark Identification mark ...

Page 573: ...ds towards cam ring POWER STEERING OIL HOSES REMOVAL AND INSTALLATION Pre removal and Post installation Operations D Power Steering Fluid Draining and Supplying and Bleeding Refer to P 37A 9 D Under Cover Removal and Installation D Air Intake Hose Resonator Air Duct Air Cleaner Cover Removal and Installation Refer to GROUP 15 Vane Round edge ...

Page 574: ... 5 1 L H drive vehicles R H drive vehicles 1 4 9 10 12 Nm 8 57 Nm 12 Nm 34 Nm 12 Nm 2 3 6 5 7 15 Nm Removal steps CA 1 Return hose BA 2 Suction hose 3 Oil reservoir D Splash shield Refer to P 37A 15 16 4 Eye bolt AA 5 Pressure hose 6 Gasket 7 Clip 8 Return tube 9 Pressure tube 10 O ring ...

Page 575: ...l with the mark at the end of the hose oil reservoir side and the alignment mark on the oil reservoir aligned 2 Install so that the mark at the end of the hose oil pump side is positioned as shown CA RETURN HOSE INSTALLATION Install so that the hose clip claws are placed as shown Mating mark Oil reservoir Alignment mark on oil reservoir Suction hose Oil pump Suction hose Return tube Hose clip Retu...

Page 576: ...WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injury or death to service personnel from inadvertent firing of the air bag or to the driver and passenger from rendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSUBI...

Page 577: ...or Fit Adjustment 33 Back Door Handle Play Check 33 BACK DOOR ASSEMBLY 34 BACK DOOR TRIM AND WATERPROOF FILM 36 BACK DOOR HANDLE AND LATCH 37 KEYLESS ENTRY SYSTEM 38 TROUBLESHOOTING 38 ON VEHICLE SERVICE 38 How to Replace a Battery of the Transmitter 38 Encrypted Code Registration Method 39 Hazard Lamp Answerback Adjustment 40 KEYLESS ENTRY SYSTEM 41 SUNROOF 42 SERVICE SPECIFICATION 42 TROUBLESHOO...

Page 578: ...od striker linkage 9 Nm 4 1 8 3 5 7 2 6 12 Nm 2 1 Hood latch removal steps D Front grille Refer to GROUP 51 1 Hood latch Hood lock release cable removal steps 2 Hood lock release handle 3 Hood lock release cable Hood removal steps 4 Hood silencer 5 Hood weatherstrip D Washer hose Refer to GROUP 51 6 Hood 7 Hood bumper 8 Hood support rod ...

Page 579: ...BODY Hood Fender 42 4 A A Section A A 6 4 Clip 4 6 Clip positions Clip positions FENDER SEALANT Item Specified sealant Remark Splash shield 3M ATD Part No 8625 or equivalent Ribbon sealer ...

Page 580: ... Post installation Operation D Front Bumper Removal and Installation Refer to GROUP 51 W0260AL Section A A Section B B 3 2 4 5 1 2 5 2 5 2 B B A A Side outer panel Clip 40 mm 6 mm Clip positions Sealant 3M ATD Part No 8625 or equivalent Removal steps 1 Mud guard 2 Splash shield 3 Grille filler panel AA 4 Side turn signal lamp Refer to GROUP 54 5 Fender ...

Page 581: ... D Rear Floor Console Removal and Installation Refer to GROUP 52A D Front Seat Driver s side Rear Seat Removal and Installation Refer to GROUP 52A D Quarter Trim Lower R H Removal and Installation Refer to GROUP 52A 5 1 4 2 3 Removal steps AA AA 1 Rivet 2 Fuel filler door panel assembly 3 Fuel filler door lock assembly 4 Fuel filler door lock release cable 5 Lid lock release handle Hook Fender pan...

Page 582: ...l rivets as follows 1 Insert a rivet in the body panel and fuel filler door panel assembly 2 Insert the riveter to the rod A shown of a rivet 3 Pressing the flange surface of the rivet with the riveter handle the riveter 4 The rod is cut at its thinnest point and the rivet is held in position Drill Fuel filler door panel assembly Rivet Riveter Fuel filler door panel assembly Body panel Rivet Rivet...

Page 583: ...lowing glass parts are installed with a liquid urethane adhesive method D Windshield D Quarter window glass D Back door window glass ITEMS NEEDED Name Remarks Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent Primer 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent Spacers Available as service part Dam Available as service part Anti rust solvent or Tectyl...

Page 584: ...ndow glass side Reusing the glass Replacing the glass Cleaning of adhesion surface Completely cut off all of the residual adhesive Clean the adhesion surface with isopropyl alcohol and let dry for 3 minutes or more Cleaning of adhesion surface Clean off any dirt adhering to the adhe sion surface with isopropyl alcohol and let dry for 3 minutes or more Gluing of window spacer glass stoppers and dua...

Page 585: ...GROUP 52A A B Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent A B C C Section A A Section B B Section C C mm Primer Primer Primer 14 15 15 15 7 9 5 4 7 8 1 2 3 6 5 5 6 1 7 Removal steps AA 1 Roof drip moulding Refer to GROUP 51 2 Roof drip moulding clip 3 Windshield lower moulding AB AA 4 Windshield AA 5 Windshield spacer AA 6 Windshield upper moulding AA 7 Clip A...

Page 586: ...ld 5 Make alignment marks on the windshield and body 6 Use the special tool to remove the windshield 7 Use a knife to cut away remaining adhesive to 2 mm thick or less around the entire circumference of the body flange 8 Smooth the flange surface Caution 1 Use care not to remove more adhesive than necessary or the adhesive could weaken 2 Be careful also not to damage the paintwork on the body surf...

Page 587: ... windshield spacers as shown to prevent the inside of windshield from warp or separation Glass stopper and windshield spacer installation position Glass stopper 14 mm Ceramic line Windshield spacer Ceramic line 14 mm Ceramic line Glass end line Windshield Windshield spacer Glass end line 25 mm 25 mm Ceramic line Glass end line Ceramic line Glass end line Windshield spacer Align glass stopper end w...

Page 588: ...align the alignment marks on the windshield and body Then press the windshield gently to seat 10 Use a spatula or the like to remove any excessive adhesive Then clean the surface with isopropyl alcohol Install the windshield moulding before the adhesive hardens 11 Wait 30 minutes or more and then test for water leakage Caution 1 Do not move the vehicle unless necessary If doing so move it very gen...

Page 589: ...eadlining Removal and Installation Refer to GROUP 52A W0390AL 1 2 2 3 A A Primer B B C C D D Section A A Section B B Section C C mm Section D D Primer Primer Primer 12 5 12 5 15 15 12 5 12 5 18 5 3 7 3 3 7 3 7 2 6 Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent 00008893 Removal steps AA AA 1 Quarter window glass AA 2 Dual lock fastener AA 3 Window dam ...

Page 590: ...stalled 2 Install the window dam 3 Install the dual lock fasteners to the body flange in the specified positions 4 Install the dual lock fasteners to the windshield in the positions corresponding to the ones on the body flange where the dual lock fasteners have been installed 5 Apply the primer and adhesive 6 Install the glass in the same manner as for the windshield Refer to P 42 12 Dual lock fas...

Page 591: ...ROUP 52A D Back Door Trim Removal and Installation Refer to P 42 34 C B 1 3 2 3 A A Primer B C Section A A Section B B Section C C mm Primer Primer 12 5 5 5 12 5 12 5 5 5 4 5 5 5 5 Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent Removal steps 1 Harness connector AA AA 2 Back door glass AA 3 Dual lock fastener AA 4 Glass stopper AA 5 Window dam ...

Page 592: ...lock fasteners and glass stoppers are installed 2 Install the window dam 3 Install the dual lock fasteners to the concavities on the body panel and the glass stoppers to the hole on the body panel respectively 4 Install the dual lock fasteners to the windshield in the positions corresponding to the ones on the body panel where the dual lock fasteners have been installed 5 Apply the primer and adhe...

Page 593: ...rs B 419 0 421 0 Between glass holder and glass front end C 55 0 SEALANT Items Specified sealant Remark Waterproof film 3M ATD Part No 8625 or equivalent Ribbon sealer SPECIAL TOOLS Tool Number Name Use MB990784 Ornament remover Door trim removal MB990480 Window glass holder Power window regulator and motor assembly removal MB990900 or MB991164 Door hinge adjusting wrench Adjustment of door fit TR...

Page 594: ...ot load more than 98 Nm on the special tool 3 If the door opening and closing is heavy adjust the meshing of the striker and the door latch forward and backward by adding shims to the striker and by moving the striker up and down or to the left and right DOOR WINDOW GLASS ADJUSTMENT Check that the door glass moves securely along the door glass runchannel when the window glass is fully raised and f...

Page 595: ...dition of the lower sash or the center sash NOTE The lower sash cannot normally be adjusted but it may be possible to adjust the sash span slightly within the range allowed by manufacturing tolerances by pushing the lower sash outwards while re installing it 4 If repair or adjustment is impossible replace the door assembly POWER WINDOW SAFETY MECHANISM CHECK 1 Place a wooden board about 10 mm thic...

Page 596: ... CIRCUIT BREAKER INCORPORATED IN POWER WINDOW MOTOR CHECK 1 Turn the power window switch to UP to close the window glass Keep the switch at the fully closed position for another 10 seconds 2 Release the power window switch and immediately turn it to DOWN Under this condition if the window glass starts to lower within 60 seconds the circuit breaker can be judged good DOOR INSIDE HANDLE PLAY CHECK A...

Page 597: ...12 Nm Door assembly removal steps 1 Harness connector 2 Door check connecting bolt 3 Door assembly 4 Door upper hinge 5 Door lower hinge Striker removal steps 6 Striker 7 Striker shim Door switch removal steps 8 Door switch cap 9 Door switch INSPECTION DOOR SWITCH CONTINUITY CHECK Driver s side Switch Terminal number Switch position 1 2 3 Earth Released ON Depressed OFF ...

Page 598: ...er windows Vehicles without power windows 14 18 Removal steps AA 1 Power window and remote controlled mirror switch assembly 2 Power window switch panel assembly 3 Power window switch 4 Remote controlled mirror switch AB 5 Door inside handle cover 6 Delta cover inner AC BA 7 Clip BA 8 Escutcheon BA 9 Regulator handle 10 Cap 11 Door trim 12 Grip bracket 13 Door grip 14 Front arm restraint cover 15 ...

Page 599: ... View B View C View E A A Door trim B B Door trim Door lamp lense Door trim View C View D View A View B A A View A Claw Power window and remote controlled mirror switch assembly Clip Front arm restraint cover Power window and remote controlled mirror switch assembly Front arm restraint cover D D E E View E Section D D Section E E Claws positions Clips positions NOTE ...

Page 600: ...OVER REMOVAL Use the special tool to pry out the rear part of door inside handle cover and then slide the door inside handle cover in the direction of arrow shown to remove it AC CLIP REMOVAL Use a cloth to remove the clip as shown in the illustration INSTALLATION SERVICE POINTS AA WATERPROOF FILM INSTALLATION Apply the specified sealant to the shown positions of waterproof film and then attach th...

Page 601: ... Door Window Glass Adjustment Refer to P 42 19 D Door Trim and Waterproof Film Installation Refer to P 42 23 D Door Mirror Installation Refer to GROUP 51 7 8 9 7 8 2 1 3 4 10 6 5 6 5 Door window glass removal steps DA D limit switch set up 1 Door window inner weather strip 2 Door belt line moulding assembly 3 Door window glass runchannel CA 4 Door window glass CA 5 Glass holder CA 6 Door glass pad...

Page 602: ...w rear sash at door securely BA POWER WINDOW MOTOR ASSEMBLY POWER WINDOW REGULATOR ASSEMBLY INSTALLATION Adjust the power window motor assembly and power window regulator assembly positions as follows 1 Connect the power window motor assembly connector and the power window switch connector to the wiring harness of body side 2 Turn on the power window switch to operate the power window motor for 3 ...

Page 603: ... 0 421 0 mm Standard value C 55 0 mm 2 Install the glass to the window regulator assembly Caution Do not activate the window regulator assemble before installing the glass as the resetting in the limit switch is cancelled DALIMIT SWITCH SETTING 1 Fully close the window glass NOTE The limit switch learning operation is complete once the window glass is fully closed 2 Check that the limit switch ope...

Page 604: ...Y Door 42 29 POWER WINDOW SUB SWITCH CONTINUITY CHECK Switch iti Terminal No position 1 4 6 UP DOWN POWER WINDOW RELAY CONTINUITY CHECK Battery lt Terminal No y voltage 1 3 4 5 Not applied Applied Power window relay ...

Page 605: ... 23 6 Nm 4 3 5 2 1 6 12 Nm Door handle and door latch assembly removal steps CA 1 Door inside handle D Waterproof film Refer to P 42 23 2 Door outside handle 3 Door lock key cylinder BA 4 Rear lower sash 5 Door latch assembly Door check removal steps D Waterproof film Refer to P 42 23 AA 6 Door check INSTALLATION SERVICE POINTS AA DOOR CHECK INSTALLATION Install with the following identification m...

Page 606: ... inner cable 2 Install the inside handle rod to the door inside handle 3 Install the door inside handle to the door INSPECTION DOOR LOCK ACTUATOR CHECK Left side Rod position Terminal No Rod operation 4 6 LOCK LOCK to UNLOCK UNLOCK UNLOCK to LOCK Right side Rod position Terminal No Rod operation 1 2 3 4 6 LOCK LOCK to UNLOCK UNLOCK UNLOCK to LOCK LOCK UNLOCK DOOR LOCK KEY CYLINDER SWITCH CONTINUIT...

Page 607: ...ower trim Refer to GROUP 52A 1 Door inner opening weatherstrip Door outer opening weatherstrip removal AA 2 Door outer opening weatherstrip Door window glass runchannel removal steps 3 Door window glass runchannel 4 Door window glass lower runchannel Door beltline moulding removal steps D Outside rear view mirror Refer to GROUP 51 5 Door beltline moulding REMOVAL SERVICE POINT AA DOOR OUTER OPENIN...

Page 608: ... refer to GROUP 54B Troubleshooting ON VEHICLE SERVICE BACK DOOR FIT ADJUSTMENT 1 If the striker and latch mesh badly move the striker forward and backward or right and left to adjust 2 If uneven clearance is present between back door and body reposition the hinge and striker and or change the thickness of shim change the number of shim to adjust the clearance BACK DOOR HANDLE PLAY CHECK 1 Measure...

Page 609: ...unted Stop Lamp Installation Refer to GROUP 54A D Spare Tyre Carrier Installation Refer to GROUP 51 D Back Door Fit Adjustment Refer to P 42 33 22 Nm 4 3 5 2 9 6 1 8 10 7 5 3 6 Removal steps D Back door trim and waterproof film Refer to P 42 36 1 Harness connector 2 Back door assembly 3 Back door upper hinge 4 Shim 5 Door check 6 Back door lower hinge 7 Shim 8 Damper mail BA 9 Striker AA 10 Back d...

Page 610: ...STALLATION Align the marking section on the back door opening weatherstrip with the centre of the body BA STRIKER INSTALLATION Install the striker so that the striker centre does not deviate more than 1 5 mm from the latch centre Striker centre Latch centre Striker Latch 1 5 mm 1 5 mm ...

Page 611: ...6 BACK DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION 2 1 View A View A Section A A 1 Clip positions Door panel Clip 1 A A Sealant 3M ATD Part No 8625 or equivalent Removal steps 1 Back door trim 2 Waterproof film ...

Page 612: ...emoval steps D Back door trim and waterproof film Refer to P 42 36 1 Back door handle 2 Back door lock key cylinder Back door latch removal steps D Back door trim and waterproof film Refer to P 42 36 3 Back door lock actuator 4 Back door latch assembly INSPECTION BACK DOOR LOCK ACTUATOR CHECK Rod position Terminal No Rod operation 4 6 LOCK LOCK to UNLOCK UNLOCK UNLOCK to LOCK A Lock Unlock View A ...

Page 613: ...ooting ON VEHICLE SERVICE HOW TO REPLACE A BATTERY OF THE TRANSMITTER 1 Remove the set screw to remove the battery from the transmitter 2 Install a battery with its side face down Battery required for replacement Coin type battery CR2032 3 Insert the claw first and with care not to displace the O ring assemble the transmitter 4 Check to see if the keyless entry system operates NOTE 1 Do not let wa...

Page 614: ...s sets the system in encrypted code registration standby mode If MUT II is not used connect terminal No 1 of the diagnosis connector to earth Caution Always turn the ignition switch to LOCK OFF position before connecting and disconnecting the MUT II or earth 4 Within 10 seconds after connecting the MUT II or earth press the hazard switch six times NOTE 1 The doors will lock and unlock once after p...

Page 615: ...ment mode The ETACS ECU sounds a buzzer once when all of the following conditions are satisfied and then enters the adjustment mode D Hazard warning lamp switch OFF D Diagnosis control ON Connect the MUT II or earth the diagnosis connector No 1 terminal D Key reminder switch OFF D Ignition switch LOCK OFF D Driver s door switch OFF Close the driver s door D If all of the conditions above are satis...

Page 616: ...ns From desactivation to activa tion When the windshield washer switch remains on for more than 20 seconds the buzzer sounds twice and then all of the following functions will be initialized D Automatic lighting sensor sensitivity D Automatic headlamp switch off function D Vehicle speed dependent wiper D Outside mirror automatic rest function The buzzer will sound in 10 seconds indicating that the...

Page 617: ... turned to ON 1 42 43 The motor does not reverse its direction when a load of 140 N or more is applied while the sunroof is closing 2 42 44 The timer does not operate during 30 seconds after the ignition switch is turned to LOCK OFF position 3 42 44 Opening or closing of the sunroof is possible immediately after turning the ignition switch to LOCK OFF position but the timer function does not opera...

Page 618: ...ctor D 06 D Disconnect the connector and measure at the harness side 1 Voltage between 1 and body earth 2 Voltage between 3 and body earth OK System voltage Measure at the sunroof ECU connector D 06 D Disconnect the connector and measure at the harness side D Ignition switch ON D Voltage between 2 and body earth OK System voltage NG NG Repair Measure at the sunroof ECU connector D 06 D Disconnect ...

Page 619: ...ck the following connectors C 74 C 76 C 02 C 43 D 06 Check the harness wire and repair if necessary D Between ignition switch IG2 and sunroof ECU OK Measure at the sunroof ECU connector D 06 D Disconnect the connector and measure at the harness side D Ignition switch ON D Voltage between 2 and body earth OK System voltage NG NG Repair NG Replace the sunroof ECU INSPECTION PROCEDURE 4 Opening or cl...

Page 620: ...lways 0 V 6 Sunroof switch CLOSE DOWN input Sunroof switch close position or down ON 0 V DOWN input close position or down position OFF System voltage 7 Sunroof switch UP input Sunroof switch up position ON 0 V up position OFF System voltage 8 Sunroof switch OPEN input Sunroof switch open position ON 0 V input open position OFF System voltage 9 Driver s door switch Driver s door Open Continuity Cl...

Page 621: ...m above the roof and let the water run onto the weatherstrip for 5 minutes or more 4 While doing this check if any water leaks through into the passenger compartment from around the roof lid glass SUNROOF FIT ADJUSTMENT 1 Fully close the roof lid glass 2 Fully open the sunshade 3 Loosen the roof lid glass assembly mounting screws and then slide the roof lid glass assembly along the slot in the mec...

Page 622: ...over 3 Sunroof switch Drain hose removal steps D Headlining Refer to GROUP 52A D Splash shield Rear drain hose D Cowl side trim and instrument lower panel Refer to GROUP 52A D Engine ECU throttle servo relay and throttle controller Driver s side drain hose AA AA 4 Drain hose Sunroof motor assembly removal steps D Headlining Refer to GROUP 52A AB BA 5 Sunroof motor assembly Sunroof assembly removal...

Page 623: ... sunroof will not operate properly NOTE If there is a problem with the sunroof motor so that the roof lid glass cannot close fully use an Allen key to turn the gear section of the sunroof motor to fully close the roof lid glass INSTALLATION SERVICE POINTS AA DRAIN HOSE INSTALLATION 1 Tie the cord that was used during removal to the end of the drain hose and wind tape around it so that there is no ...

Page 624: ...t the sunroof to full close position by using the close switch Do not stop the sunroof while it is moving NOTE Sunroof ECU will initialize when the sunroof motor stops INSPECTION ROOF LID GLASS OPERATION CURRENT CHECK 1 Remove the sunroof fuse and connect a circuit analyser as shown in the illustration 2 Press the sunroof switch to operate the sunroof and then measure the operation current while t...

Page 625: ... 9 10 10 11 9 11 9 Disassembly steps 1 Roof lid glass assembly 2 Weatherstrip 3 Sunroof motor assembly 4 Roof wind deflector panel 5 Rail end 6 Roof drip channel 7 Sunshade assembly 8 Drive unit cover 9 Mechanish assembly 10 Drive unit assembly 11 Frame assembly ...

Page 626: ...PECIAL TOOL 7 MOULDING AND GARNISH 8 WINDSHIELD WIPER AND WASHER 10 SERVICE SPECIFICATIONS 10 TROUBLESHOOTING 10 WINDSHIELD WIPER AND WASHER 11 REAR WIPER AND WASHER 14 SERVICE SPECIFICATION 14 TROUBLESHOOTING 14 REAR WIPER AND WASHER 15 HEADLAMP WASHER 17 TROUBLESHOOTING 17 HEADLAMP WASHER 17 MARKS 19 OUTSIDE DOOR MIRROR 21 ...

Page 627: ...2 3 4 1 Section A A Clip 6 5 Clip positions NOTE 1 A B B A Section B B Clip 1 Removal steps AA 1 Radiator grille 2 Splash shield installation clips 3 Headlamp 4 Fog lamp connector 5 Headlamp washer hose connection Vehicles with headlamp washer 6 Front bumper assembly ...

Page 628: ...r while lightly pulling the radiator grille towards you DISASSEMBLY AND REASSEMBLY 2 1 Section A A Clip A A 1 6 3 4 6 5 Disassembly steps 1 Front bumper reinforcement assembly D Headlamp washer assembly Vehicles with headlamp washer Refer to P 51 17 2 Fog lamp 3 Fog lamp cover Vehicles without fog lamp 4 Bumper net 5 Licence plate bracket 6 Front bumper face A A Clip Radiator grille Radiator grill...

Page 629: ...ATION 1 2 4 6 3 5 7 Removal steps 1 Rear mud guard 2 Rear splash shield 3 Rear combination lamp or rear fog lamp connection 4 Rear bumper assembly 5 Bumper step reinforcement assembly 6 Bumper center reinforcement assembly 7 Bumper side reinforcement assembly ...

Page 630: ... Nm Disassembly steps 1 Bracket R H drive vehicles 2 Bracket L H drive vehicles 3 Rear combination lamp assembly R H drive vehicles 4 Rear fog assembly L H drive vehicles 5 Rear bumper face EXTERIOR PARTS SPECIAL TOOL Tool Number Name Use MB990784 Ornament remover Removal of roof rack cover ...

Page 631: ...1 1 4 4 1 A A C C B B D D A A Section E E 5 6 Body 6 7 E E Roof rail removal steps AA 1 Roof rack cover front rear 2 Roof rack cover side 3 Center bracket 4 Roof bar Roof spoiler removal steps 5 cover 6 Roof spoiler Spare tyre carrier removal steps D Spare tyre cover Refer to GROUP 31 D Spare tyre D Back door trim and waterproof film Refer to GROUP 42 7 Spare tyre carrier ...

Page 632: ...ar as possible and remove the claw front by prying the roof rack cover toward you 3 Remove the claw rear Caution Spread out the roof rack cover sufficiently and pull it upward otherwise the claws will be broken MOULDING AND GARNISH SPECIAL TOOL Tool Number Name Use MB990449 Window moulding remover Removal of roof drip moulding View A MB990784 Claw rear Claw front Slit Slit Claw rear Claw front Vie...

Page 633: ...th roof rail Vehicles without roof rail B Clip positions NOTE Bolt positions Section D D Clip 5 D D Roof drip moulding removal steps D Roof rail assembly Vehices with roof rail Refor to P 51 6 1 Roof drip cover AA 2 Roof drip moulding 3 Windshield moulding Refer to GROUP 42 Windshield Side protector moulding removal AB AA 4 Side protector moulding Rear licence plate garnish removal steps D Back do...

Page 634: ...tape 4 Wipe the body surface and clean it with a rag moistened with isopropyl alcohol INSTALLATION SERVICE POINTS AA SIDE PROTECT MOULDING INSTALLATION Double sided tape affixing to the side protect moulding when reusing 1 Scrape off the double sided tape with a resin spatula or gasket scraper 2 Wipe off the side protect moulding adhesion surface and clean it with a shop towel moistened with isopr...

Page 635: ...otect moulding Body 40 60 C Side protect moulding 20 30 C Apply pressure fully to the side protect moulding WINDSHIELD WIPER AND WASHER SERVICE SPECIFICATIONS Items Standard value Park position of windshield wiper arm and blade assembly Distance between wiper blade and windshield lower moulding mm Driver s side 20 5 L H drive vehicles 30 5 R H drive vehicles Passenger s side 20 5 L H drive vehicle...

Page 636: ...nkage removal steps AA 3 Wiper arm and blade assembly 4 Washer 5 Front deck garnish R H drive vehicles 6 Front deck garnish L H drive vehicles AA 7 Wiper motor 8 Linkage assembly Washer tank removal steps D Air cleaner D Intake duct 1 Washer hose connection 9 Headlamp washer motor Vehicles with headlamp washer 10 Front washer motor 11 Rear washer motor 12 Washer tank assembly NOTE For removal and ...

Page 637: ...ard value A 20 5 mm L H drive vehicles 30 5 mm R H drive vehicles INSPECTION WIPER MOTOR CHECK Disconnect the wiring harness connector and then check the wiper motor operation with the wiper motor remaining installed to the body Wiper Motor Operation Speed Connect a battery to the wiper motor as shown in the illustration and check the operation speed Stop Position 1 Connect a battery to the wiper ...

Page 638: ...erminal 2 and terminal 1 is earthed WASHER FLUID EJECTION POINT CHECK Adjust the ejection angle by moving the nozzle Item Distance mm Item Distance mm A 350 E 320 B 475 F 200 C 165 G 310 D 200 H 200 50 mm Area to be ejected Passen ger s side Ceramic end line A B D E G H Driver s side 50 mm A Ceramic end line C C F F G B E H D Passen ger s side L H drive vehicles R H drive vehicles Driver s side 50...

Page 639: ...ms Standard value Park position of rear wiper arm and blade assembly Distance between wiper blade and back door glass ceramic end line mm 33 5 TROUBLESHOOTING The rear wiper and washer is controlled by the Smart Wiring System SWS For troublesshooting refer to GROUP 54B Troubleshooting ...

Page 640: ...Grommet 4 Wiper motor assembly Washer tank and washer motor removal 5 Washer tank and washer motor Refer to P 51 11 Rear washer hose removal steps D Rear seat Refer to GROUP 52A D Scuff plate and quarter trim Refer to GROUP 52A D Headlining Refer to GROUP 52A 6 Washer nozzle 7 Washer hose NOTE For removal and installation of the column switch assembly wiper and washer switch refer to GROUP 37A Ste...

Page 641: ...ct a battery to the wiper motor as shown in the illustration and check the motor operation Wiper Motor Stop Position 1 Operate the wiper motor and then disconnect the battery to stop the wiper motor while the wiper motor is operating 2 Reconnect the battery as shown in the illustration and confirm that after the motor starts turning it stops at the automatic stop position WASHER MOTOR CHECK 1 With...

Page 642: ...ing refer to GROUP 54B Troubleshooting HEADLAMP WASHER REMOVAL AND INSTALLATION 4 6 1 2 2 7 4 5 3 3 2 2 2 2 3 3 8 5 Nozzle and check valve removal steps Draining of washer fluid Front bumper Refer to P 51 2 1 Check valve 2 Washer hose 3 Joint 4 Bracket 5 Nozzle Washer tank removal steps Draining of washer fluid Air cleaner Intake duct 6 Washer hose 7 Washer tank assembly 8 Headlamp washer motor 50...

Page 643: ...check valve to check its opening pressure Opening pressure 78 kPa HEADLAMP WASHER MOTOR CHECK 1 With the washer motor installed to the washer tank fill the washer tank with water 2 Connect battery and cables to terminals 1 and 2 respectively to see that the washer motor runs and water is injected ...

Page 644: ...logo mark AA 5 Vehicle name decal AA 6 Three diamonds mark AA 7 ªGDIº mark INSTALLATION SERVICE POINT AA INSTALLATION OF MARKS 1 APPLICATION POSITION 5 Vehicle name decal Vehices except for Spain Vehicles for Spain Back door end line Align the application tape end with this slit Slit Back door end line Align the application tape end with this slit Slit ...

Page 645: ... reverse side of the marks and then attach the marks to the vehicle body so that they fit properly into position Caution When attaching the marks the surrounding temperature should be 20 38 C and the air should be completely free from dust If the surrounding temperature is lower than 20 C the marks and the places on the body where the marks are to be attached should be heated to 20 38 C When the m...

Page 646: ...con trolled door mirror Manual controlled door mirror Door mirror removal steps 1 Delta inner cover 2 Clip 3 Boot 4 Mirror assembly AA AA 5 Mirror Electric remote controlled mirror switch removal steps 6 Power window and remote controlled mirror switch assembly Refer to GROUP 42 Door trim and water proof film 7 Electric remote controlled mirror switch ...

Page 647: ...hind the mirror and the pivot plate and then pry off the lower part of mirror from the pivot plate INSTALLATION SERVICE POINT AA MIRROR INSTALLATION While holding the pivot plate with a flat tipped screwdriver push the mirror to engage the clips at its lower part with the pivot plate Section A A Flat tipped screwdriver Mirror Pivot plate Protection tape Notches A A A A Section A A Flat tipped scre...

Page 648: ...PERATION CHECK Battery connection terminal Direction of ti 1 2 3 6 7 operation UP DOWN LEFT RIGHT Vehicles with heater mirror ELECTRIC REMOTE CONTROLLED MIRROR SWITCH CONTINUITY CHECK Switch Switch position Terminal No position Left mirror Right mirror 1 6 9 10 11 1 2 3 6 9 Adjustment switch UP DOWN RIGHT LEFT ...

Page 649: ...NOTES ...

Page 650: ...INTERIOR 52A SUPPLEMENTAL RESTRAINT SYSTEM SRS 52B 52A 1 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM SRS CONTENTS ...

Page 651: ...senger from rendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP 52B Supplemental Restraint System SRS before beginning any service or maintenance of any component of the SRS or any SRS related component ...

Page 652: ...D INSTALLATION For installation of the instrument panel the bolts and screws described below are used They are indicated by symbols in the illustration Name Symbol Size mm D L Colour Shape Tapping screw a 5 12 b 5 20 c 5 16 d 5 16 Black Washer assembled screw e 5 10 Washer assembled bolt f 6 16 g 8 20 h 5 12 i 6 16 D Thread diameter L Effective thread length ...

Page 653: ... 5 Meter hood A 6 Multi center display hood 7 Multi center display 8 Multi display bracket 9 Center panel 10 Radio and tape player 11 Heater control assembly or auto matic A C control panel assembly 12 Glove box striker 13 Instrument tray Vehicles without front air bag module 14 Passenger s side air bag module Vehicles with front air bag module 15 Glove box 16 Switch panel assembly Vehicles with f...

Page 654: ...aw Claw F K K J E Section A A Section B B Claw Instrument panel Clip Section C C Claw Clip I B B C C A F F NOTE Claw positions Clip positions A A Instrument panel Instrument panel Instrument panel Section I I Section J J Section K K Instrument panel Instrument panel Clip Instrument panel Garnish Garnish Column cover Column cover Claw J I B G G A B ...

Page 655: ... a 2 12 1 6 a a 11 Claw NOTE Claw positions a A A Disassembly steps 1 Garnish 2 Parcel box 3 Connector holder 4 Distribution duct 5 Defroster duct 6 Side air outlet assembly 7 Center air outlet 8 Center air outlet case 9 Instrument panel reinforcement 10 Center support panel 11 Instrument panel side support bracket 12 Instrument panel ...

Page 656: ...Rear floor console 3 Transfer lever cover M T 4 Rear ashtray assembly 5 Holder 6 Ashtray bracket 7 G sensor Vehicles with ABS 8 Floor console bracket Vehicles with ABS 9 Front floor console 10 Box with lid 11 Heated seat switch Vehicles with heated seat 12 A T panel or M T panel 13 Switch panel Vehicles with heated seat 14 Front ashtray assembly ...

Page 657: ...w Front floor console Rear floor console Clip Rear floor console Claw Clip A A H H Section A A Front floor console C C F F B B Section D D Section E E Section F F Section G G Section H H Claw Claw Claw Claw Clip Front floor console Instrument panel Instrument panel E E Claw positions Clip Front floor console ...

Page 658: ... trim 4 Assist grip 5 Front pillar trim 6 Rear step plate Vehicles without luggage floor box D Rear seat Refer to P 52A 15 7 Luggage floor box Option 8 Luggage room hook 9 Front seat belt connection 10 Quarter trim 11 Quarter box 12 Hook 13 Front seat belt connection 14 Center pillar trim 15 Rear door opening trim 16 Rear seat belt connection 17 Rear pillar trim ...

Page 659: ...aw Clip Clip Head lining Front pillar trim Clip Clip Clip Clip A A Front pillar trim Front pillar trim Center pillar trim Center pillar trim Rear pillar trim Rear pillar trim Center pillar trim Quarter trim Quarter trim Quarter trim Claw Claw Rear step plate B B C C D D E E F F G G H H I I I I J J K K For door trim refer to GROUP 42 NOTE Clip positions Claw positions Instrument panel ...

Page 660: ...8 Front passenger s side only Removal steps 1 Assist grip 2 Sun visor assembly 3 Sun visor holder 4 Front room lamp assembly 5 Sunroof switch cover Vehicles with sunroof 6 Rear room lamp assembly D Front pillar trim Refer to P 52A 9 D Center pillar trim Refer to P 52A 9 D Rear pillar trim Refer to P 52A 9 7 Trim clip Vehicles without sunroof 8 Clip 9 Trim clip 10 Sunroof drip moulding Vehicles wit...

Page 661: ...ehicles with heated seat 2 Headrestraint Front seat assembly removal steps 3 Front seat anchor cover 4 Heated seat harness connector Vehicles with heated seat 5 Side air bag module harness connector Vehicles with SRS side air bag AA 6 Front seat assembly INSTALLATION SERVICE POINT AA FRONT SEAT ASSEMBLY INSTALLATION Temporarily tighten the mounting nuts and bolts and then tighten them to the speci...

Page 662: ...eat switch HI LO Passen ger s seat switch HI LO NOTE To inspect the diode match the polarity of the circuit tester with the polarities in the table HEATER CHECK Measure the resistance between terminals Standard value Between terminals 1 and 3 Approx 5 4 Ω Between terminals 1 and 2 Approx 4 2 Ω Between terminals 2 and 3 Approx 9 6 Ω ...

Page 663: ... steps 1 Front seat side shield cover 2 Height adjuster lever 3 Inner seat belt 4 Reclining adjuster lever 5 Front seat hinge cover 6 Front cover 7 Recliner cover 8 Front seat cushion assembly 9 Front seat cushion cover 10 Front seat cushion pad 11 Front seat cushion frame 12 Front seat back assembly AA 13 Headrestraint guide 14 Front seat back cover 15 Front seat back pad 16 Front seat back frame...

Page 664: ...MOVAL SERVICE POINT AA HEADRESTRAINT GUIDE REMOVAL REAR SEAT REMOVAL AND INSTALLATION 1 3 4 4 1 23 Nm 23 Nm 82 Nm 2 1 Headrestraint Rear seat assembly removal steps 2 Rear seat cushion assembly 3 Rear seat back assembly 4 Rear seat stopper ...

Page 665: ...E Hog ring positions Front view of rear seat cushion Front view of rear seat back Disassembly steps 1 Rear seat cushion cover 2 Rear seat cushion pad AA 3 Headrestraint guide 4 Rear seat back cover 5 Rear seat back pad 6 Rear seat back frame assembly 7 Rear seat center hinge 8 Folding knob assembly ...

Page 666: ...e seat belt pre tensioner refer to GROUP 52B SRS Service Precautions and Seat Belt with Pre tensioner 1 3 4 44 Nm 44 Nm 44 Nm 2 1 44 Nm Outer seat belt removal steps 1 Outer seat belt connection D Quarter trim Refer to P 52A 9 2 Outer seat belt 3 Front noise protector Inner seat belt removal 4 Inner seat belt ...

Page 667: ...3 4 5 44 Nm Removal steps D Rear seat cushion assembly Refer to P 52A 15 1 Sash guide cover 2 Outer seat belt connection D Luggage floor box Option Refer to P 52A 9 D Rear pillar trim Refer to P 52A 9 D Quarter trim Refer to P 52A 9 3 Outer seat belt 4 Rear noise protector 5 Inner seat belt ...

Page 668: ...Undeployed Air Bag Module and Seat Belt Pre tensioner Disposal 48 Deployed Air Bag Module or Operated Seat Belt Pre tensioner Disposal Procedures 60 CAUTION D Carefully read and observe the information in the SERVICE PRECAUTIONS P 52B 4 prior to any service D For information concerning troubleshooting or maintenance always observe the procedures in the Troubleshooting P 52B 8 section D If any SRS ...

Page 669: ...de member The side impact sensor inside the quarter panels inner monitors any shocks coming from the side of the vehicle The warning lamp on the instrument panel indicates the operational status of the SRS The clock spring is installed in the steering column The SRS side air bag deploys if an impact received at the side of the vehicle is stronger than a certain set value in order to protect the up...

Page 670: ...g module Diagnosis connector SRS ECU Seat belt pre tensioner Seat belts with pre tensioner Driver s air bag Side air bag Side impact sensor Front passenger s air bag Side air bag module SRS warning lamp SRS ECU Front impact sensor NOTE Indicates the parts equipped on the right and left sides ...

Page 671: ...are diagnosed as faulty they should only be replaced in accordance with the INDIVIDUAL COM PONENTS SERVICE procedures in this manual Refer to P 52B 30 4 After disconnecting the negative battery cable wait 60 seconds at least before any service and insulate the disconnected cable with tape The SRS retain enough voltage to deploy the air bag for a short time even after disconnection of the battery S...

Page 672: ... air bag module L H 23 24 Body wiring harness Side air bag module R H 27 28 Body wiring harness Seat belt with pre tensioner R H 29 30 Body wiring harness Seat belt with pre tensioner L H 34 35 36 Body wiring harness Side impact sensor L H 40 41 42 Body wiring harness Side impact sensor R H 6 Inspection of the SRS ECU harness connector should be carried out by the following procedure Insert the sp...

Page 673: ...s properly Refer to P 52B 8 9 Make certain that the ignition switch is OFF when the MUT II is connected or disconnected 10 If you have any questions about the SRS please contact your local distributor NOTE SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT SO USE ONLY THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL SPECIAL TOOLS Tool Number Name Use MB991502 MUT II sub assembly D R...

Page 674: ... Deployment of front passenger s side air bag module inside or outside the vehicle MR203491 or MB628919 SRS air bag adapter harness Deployment of driver s side air bag module outside the vehicle TEST EQUIPMENT Tool Name Use Digital multi meter Checking the SRS electrical circuitry Use a multi meter for which the maximum test current is 2 mA or less at the minimum range of resistance measurement ...

Page 675: ...t it illuminates for approximately 7 seconds and then switches off 3 If the above is not the cause inspect the diagnosis codes INSPECTION CHART FOR DIAGNOSIS CODES Inspect according to the inspection chart that is appropriate for the malfunction code Code No Diagnosis item Reference page 11 12 13 Front impact sensor system 52B 10 14 Analog G sensor system in the SRS ECU 52B 11 15 16 Front impact s...

Page 676: ...e air bag module R H squib system 52B 18 73 74 Side air bag module R H squib ignition drive circuit system 52B 11 79 93 Side impact sensor L H communication system 52B 19 81 2 82 2 85 86 Side air bag module L H squib system 52B 19 83 84 Side air bag module L H squib ignition drive circuit system 52B 11 89 96 Side impact sensor R H communication system 52B 20 91 1 Side impact sensor L H power suppl...

Page 677: ...sor harness leading to the power supply 12 D Open circuit in either left or right front impact sensor or harness D Short circuit in front impact sensor harness leading to the power supply 13 D Open circuit in both left or right front impact sensor or harness D Short circuit in front impact sensor harness leading to the power supply Front impact sensor check Refer to P 52B 33 NG OK OK Measure at SR...

Page 678: ...on volatile memory EE PROM D Non volatile memory EEPROM is abnormal 51 Driver s side air bag module squib ignition drive circuit D Short circuit in the squib ignition drive circuit 52 squib ignition drive circuit D Open circuit in the squib ignition drive circuit 54 Front passenger s side air bag module squib ignition D Short circuit in the squib ignition drive circuit 55 bag module squib ignition...

Page 679: ...rs which short positive and negative wires to prevent the air bags from accidental deployment during the disconnection of the connector are set in the squib circuit connectors In a defective connector the short bar may be still working even after the connection of the connector Check the following connectors C 32 C 65 Repair OK Check trouble symptoms NG Check wiring harness between clock spring an...

Page 680: ...enger s air bag module squib harness to earth NOTE The shorting bars which short positive and negative wires to prevent the air bags from accidental deployment during the disconnection of the connector are set in the squib circuit connectors In a defective connector the short bar may be still working even after the connection of the connector NO YES Replace the front passenger s air bag module squ...

Page 681: ...ss leading to the earth Check the following connectors D 36 D 41 L H drive vehicles D 38 R H drive vehicles Repair OK Check trouble symptoms NG Check wiring harness between the driver s side pre tensioner and SRS ECU Repair OK Replace SRS ECU NG NG Replace the driver s side pre tensioner SRS check harness MB991613 Check harness MUT II Self diag code D Disconnect the driver s side pre tensioner con...

Page 682: ...sioner squib harness leading to the earth Repair OK Check trouble symptoms NG Check wiring harness between the front passenger s side pre ten sioner and SRS ECU Repair OK Replace SRS ECU NG NG Check the following connectors D 36 D 38 L H drive vehicles D 41 R H drive vehicles Replace the front passenger s side pre tensioner SRS check harness MB991613 Check harness MUT II Self diag code D Disconnec...

Page 683: ...n IG1 terminal SRS ECU terminal 12 and earth is lower than specified for five successive seconds or more Code No 42 is displayed if voltage between IG1 terminal SRS ECU terminal 9 and earth is lower than specified for five successive seconds or more However once trouble is extinguished these codes will be automatically erased and SRS warning lamp will go out If codes 41 and 42 are displayed togeth...

Page 684: ...e circuit system Lamp does not go out Probable cause Harness between SRS warning lamp and SRS ECU is being shorted to earth However once trouble is extinguished this code will be automatically erased and SRS warning lamp will go out D Defective wiring harnesses or connectors D Malfunction of SRS ECU D Malfunction of combination meter NO NO Replace SRS ECU OK Replace SRS ECU Check SRS warning lamp ...

Page 685: ... power supply 76 D Side air bag module R H squib harness short to earth Check the following connectors D 01 D 36 Repair OK Check trouble symptoms NG Check wiring harness between the side air bag module R H and SRS ECU Repair OK Replace SRS ECU NG NG Replace the seat back assembly R H SRS check harness MB991613 Check harness MUT II Self diag code D Disconnect the side air bag module R H connector D...

Page 686: ... Check trouble symptoms NG Repair NG NG Repair Check the harness wire between the side impact sensor L H and SRS ECU Code No 81 82 85 86 Side air bag module L H squib system Probable cause Abnormal resistance is present between input terminals of SRS ECU for side air bag module L H squib See table below for what each code tells However as for code Nos 81 and 82 once trouble is extinguished SRS war...

Page 687: ...nal D Erase diagnosis code memory Is code No 81 82 85 or 86 displayed Resistance 3 Ω YES NO Resistance 3 Ω Check harness Probe MB991222 Body wiring harness Code No 89 or No 96 Side impact sensor R H communication system Probable cause These diagnosis codes are output if communication between the side impact sensor R H and the SRS ECU is not possible code No 89 or abnormal code No 96 D Malfunction ...

Page 688: ...e side impact sensor R H See INSPECTION CHART 6 below for what each code tells D Malfunction of side impact sensor L H Code No 92 D Malfunction of side impact sensor R H Code No 95 Code No Defective parts Trouble 92 Side impact analog G sensor D Not working D Having abnormal 95 D Having abnormal D Having abnormal output 95 D Having abnormal output Replace side impact sensor L H code No 92 Replace ...

Page 689: ...tive wiring harness es or connector s D Malfunction of SRS ECU Check MUT II diagnosis circuit and repair if necessary NG Repair OK Check trouble symptoms NG Check harness wire between SRS ECU and ignition switch IG1 repair if necessary Check harness wire between SRS ECU and diagnosis connector Replace SRS ECU Check following connectors B 32 C 35 OK NG NG OK Check trouble symptoms Repair NG Repair ...

Page 690: ...cable before doing any further work Refer to P 52B 4 SRS CONTROL UNIT SRS ECU 1 Check SRS ECU case and brackets for dents cracks deformation or rust Caution The SRS may not activate if the SRS ECU is not installed properly which could result in serious injury or death to the vehicle s driver or front passenger 2 Check connector for damage and terminals for deformation or rust Replace SRS ECU if it...

Page 691: ... mating marks of the clock spring and after turning the vehicle s front wheels to straight ahead position install the clock spring to the column switch Mating Mark Alignment Turn the clock spring clockwise fully and then turn back it approx 3 times counterclockwise to align the mating marks Caution If the clock spring s mating mark is not properly aligned the steering wheel may not be completely r...

Page 692: ...r damage bent terminals or clamping of the harness SIDE IMPACT SENSORS 1 Check that there is no bending or corrosion in the quarter panel inner 2 Check that there is no denting breakage bending or corrosion of the side impact sensor 3 Check that there is no clamping of the harness connector damage or bent terminals NOTE The illustration at left shows the side impact sensor R H The position of the ...

Page 693: ...T FAIL THE VISUAL INSPECTION Refer to P 52B 4 Caution The SRS may not activate if SRS harnesses or connectors are damaged or improperly connected which could result in serious injury or death to the vehicle s driver or front passenger POST INSTALLATION INSPECTION Reconnect the negative battery terminal Turn the ignition switch to the ªONº position Does the SRS warning lamp illuminate for about 7 s...

Page 694: ...been erased Data list No Service Data Item Applicability 92 Number indication how often the memory is cleared Maximum time to be stored 250 93 How long problem have lasted How long it takes from the occurrence of the problem till the first air bag squib igniting signal Maximum time to be stored 9 999 minutes approximately 7 days 94 How long problem s have lasted How long it takes from the first ai...

Page 695: ...1 Replace the following parts with new ones D SRS ECU Refer to P 52B 34 D Side impact sensors Refer to P 52B 46 D Front seat back assemblies Refer to P 52B 36 2 Check harnesses for binding connectors for damage poor connections and terminals for deformation Refer to P 52B 4 UNDEPLOYED AIR BAGS IN LOW SPEED COLLISION Check the SRS components If visible damage such as dents cracks or deformation are...

Page 696: ...Check the air bag modules for proper installation Clock spring 1 Check the clock spring connectors and protective tubes for damage and terminals for deformation 2 Visually check the case for damage Steering wheel steering column and intermediate joint 1 Check the driver s air bag module for proper installation to the steering wheel 2 Check the steering wheel for noise binds or difficult operation ...

Page 697: ...that the unit is installed correctly to the vehicle body INDIVIDUAL COMPONENT SERVICE If the SRS components and seat belt with pre tensioner are to be removed or replaced as a result of maintenance troubleshooting etc follow each procedure P 52B 32 P 52B 47 Caution 1 SRS components and seat belt with pre tensioner should not be subjected to heat so remove the front impact sensor SRS ECU air bag mo...

Page 698: ...low label instructions when servicing the SRS If the label s are dirty or damaged replace with new one s Steering wheel Driver s air bag module Clock spring Front passenger s air bag module SRS ECU Sun visor Steering gear box Side impact sensor Glove box Quarter panel inner Instrument panel Seat belt with pre tensioner Hood ...

Page 699: ... with a new front impact sensor Discard the old one 4 After deployment of an air bag replace the front impact sensor with a new one REMOVAL AND INSTALLATION Pre removal Operation D Turn Ignition Key to LOCK OFF position D Disconnect the Negative Battery Terminal Front side member 4 9 Nm 2 1 Removal steps 1 Under cover 2 Front impact sensor Installation steps AA D Pre installation inspection BA 2 F...

Page 700: ...emain extinguished for at least 5 seconds after turning OFF 4 If yes SRS system if functioning properly If no consult page 52B 8 INSPECTION 1 Check the front impact sensor for dents cracks deformation or rust Caution If a dent crack deformation or rust is detected replace with a new sensor 2 Measure the resistance between terminals and check whether it is within the standard value Standard value 8...

Page 701: ...d the old one 4 After deployment of the air bags replace the SRS ECU with a new one 5 Never use an ohmmeter on or near the SRS ECU and use only the special test equipment described on P 52B 7 REMOVAL AND INSTALLATION Pre removal Operation D Turn Ignition Key to LOCK OFF Position D Disconnect the Negative Battery Terminal 1 2 5 Nm 1 3 4 Removal steps D Floor console Refer to GROUP 52A 1 Bracket mou...

Page 702: ...urn the ignition switch to ON 2 Does the SRS warning lamp illuminate for about 7 seconds and then go out for more than 5 seconds 3 Yes The SRS warning lamp is working properly No Go to Troubleshooting Refer to P 52B 8 INSPECTION 1 Check the SRS ECU and brackets for dents cracks or deformation 2 Check connector for damage and terminals for deformation Caution If a dent crack deformation or rust are...

Page 703: ...or allow contact with water grease or oil Replace if a dent crack deformation or rust are present 4 Store the air bag modules on a flat surface with the deployment surface facing up Do not place anything on top of them 5 Do not store the air bag modules in a place more than 93_C 6 When the driver s and front passenger s air bags have been deployed replace the driver s and passenger s air bag modul...

Page 704: ... removal steps AA 1 Driver s air bag module AB 2 Steering wheel Driver s air bag module installation steps AA D Pre installation inspection CA 2 Steering wheel 1 Driver s air bag module D Negative battery cable connection DA D Post installation check Clock spring removal steps AA 1 Drive s air bag module AB 2 Steering wheel D Lower column cover AC 3 Clock spring Clock spring installation steps AA ...

Page 705: ...Claw Sections A A and C C A A B C C NOTE Claws Section B B 2 Instrument panel Claw Removal steps 1 Glove box AD 2 Passenger s air bag module Installation steps AA D Pre installation inspection 2 Passenger s air bag module 1 Glove box D Negative battery cable connection DA D Post installation inspection ...

Page 706: ... S AIR BAG MODULE REMOVAL After removing the clip shown in the illustration disconnect the connector Caution 1 The air bag module must not be measured with such equipment as an ohmmeter nor disassembled 2 The removed air bag module should be stored in a clean dry place with the deployment surface facing up AB STEERING WHEEL REMOVAL Caution Do not hammer on the steering wheel Doing so may damage th...

Page 707: ...t back assembly deploy the air bag as specified in the service procedure Refer to P 52B 48 2 Connect the negative battery terminal 3 Connect the MUT II to the diagnosis connector 16 pin Caution Turn the ignition switch to LOOK OFF position when connecting and disconnecting the MUT II 4 Turn the ignition switch to ON 5 Read a diagnostic code to Refer to that the SRS is operating properly except an ...

Page 708: ...bout 7 seconds and then go out for 5 seconds or more 4 Yes The SRS is working properly No Go to Troubleshooting Refer to P 52 8 INSPECTION DRIVER S AND PASSENGER S AIR BAG MODULE INSPECTION If any malfunction is found in the following inspection replace the air bag module s with new one s Discard the old one s after deployment as specified in the service procedure Refer to P 52B 48 Caution Never m...

Page 709: ...nd terminal No 4 of connector No 1 4 Remove the cover from the No 3 connector of the clock spring and then insert the probes MB991222 Caution The probe must not be inserted directly to the terminals from the front of the connector 5 Connect a digital multimeter to the probe MB991222 as shown to check that Standard value 0 62 0 12 Ω FRONT SEAT BACK ASSEMBLY WITH SIDE AIR BAG MODULE If any malfuncti...

Page 710: ...specified tester Measuring the circuit resistance with a tester causes accidental air bag deployment due to current that flows or static resulting in serious personal injury 1 Check the side air bag module deployment section for dents and deformation 2 Check the harness and connector for damage and the terminals for deformation ...

Page 711: ...e tensioner with a new part 6 Gloves and protective goggles should be worn when handling a pre tensioner once it has been used 7 If disposing of a seat belt with pre tensioner which has not yet been used its pre tensioner should be operated first before disposal Refer to P 52B 48 REMOVAL AND INSTALLATION Pre removal and Post installation Operation D Turn Ignition Key to LOCK OFF Position D Disconn...

Page 712: ...inal 2 Turn the ignition key to the ªONº position 3 Does the ªSRSº warning lamp illuminate for about 7 seconds and then remain extinguished for at least 5 seconds after turning OFF 4 If yes SRS system is functioning properly If no consult page 52B 8 INSPECTION SEAT BELT WITH PRE TENSIONER CHECK If any part is found to be faulty during the inspection it must be replaced with a new one Dispose of th...

Page 713: ...ide impact sensors with new ones 5 Never use an ohmmeter on or near the side impact sensors and use only the special test equipment described on P 52B 7 REMOVAL AND INSTALLATION Pre removal Operation D Turn Ignition Switch to LOCK OFF Position D Disconnect the Negative Battery Terminal 1 2 5 Nm Quarter panel inner Removal steps D Front seat belt Refer to GROUP 52A 1 Front noise protector 2 Side im...

Page 714: ...conds and go off for 5 seconds or more 3 YES The system is working properly NO Go to Troubleshooting Refer to P 52B 8 INSPECTION If any malfunction is found in the following inspections replace the side impact sensor s with new one s 1 Check the side impact sensors for dents cracks deformation and rust 2 Check the connector for damage and the terminals for deformation 3 Check the center pillar or ...

Page 715: ...osed of deploy the air bags and operate the seat belt pre tensioners outside the vehicle 2 Since a large amount of smoke is produced when the air bag are deployed or the seat belt pre tensioner is operated avoid residential areas whenever possible 3 Since there is a loud noise when the air bags are deployed and when the seat belt pre tensioners are operated avoid residential areas whenever possibl...

Page 716: ...out of the vehicle 5 Close all the doors with the windows fully closed and put a cover over the vehicle to minimize report Caution The cover is required as the glass if already damaged may break 6 Separate the deployment harnesses as far from the vehicle as possible and connect to the terminals of the battery removed from the vehicle Then deploy Caution 1 Before deploying the air bag see that no o...

Page 717: ...deployment harnesses out of the vehicle 5 Close all the doors with the windows fully closed and put a cover over the vehicle to minimize report Caution The cover is required as the glass if already damaged may break 6 Separate the deployment harnesses as far from the vehicle as possible and connect to the terminals of the battery removed from the vehicle Then deploy Caution 1 Before deploying the ...

Page 718: ...e terminals in one end to short circuit This is to prevent accidental deployment caused by static etc 3 Touch the vehicle s body with bare hands to discharge static in you Caution Never fail to do Step 3 in order to prevent accidental deployment caused by static 4 Using pliers cut the side air bag module connector from the harnesses Connect the deployment harnesses to each harness that has been cu...

Page 719: ...ed in the procedure Refer to P 52B 60 Seat belt pre tensioner 1 Remove the quarter trim Refer to GROUP 52A 2 Remove the connection between the seat belt pre tensioner 2 pin connector yellow and the body wiring harness connector 2 pin NOTE If the seat belt pre tensioner connector is disconnected from the body wiring harness both electrodes of the seat belt pre tensioner connector will be automatica...

Page 720: ...nd connect the wires to the terminals of the battery removed from the vehicle Operate the seat belt pre tensioner Caution 1 Before operating the seat belt pre tensioner in this manner first check to be sure that there is no one in or near the vehicle Wear safety glasses 2 The operation of the seat belt pre tensioner makes the inflator very hot Before handling the inflator wait more than 30 minutes...

Page 721: ...h air bag module seat belt pre tensioner in the following procedures Driver s air bag module 1 Remove the driver s air bag module from the vehicle Refer to P 52B 36 Caution The driver s air bag module should be stored on a flat surface and placed so that the air bag deployment surfaces are facing upward Do not place anything on top of them 2 Connect two wires each six meters or longer to the two l...

Page 722: ...driver s air bag module 7 Disconnect the deployment harnesses as far from the driver s air bag module as possible and connect the wires to the terminals of the battery removed from the vehicle Then deploy Caution 1 Before the deployment be sure that no one is near the driver s air bag module 2 The deployment of the driver s air bag makes the inflator very hot Before handling the inflator wait more...

Page 723: ...adapter harness with the deployment harnesses beneath an old tyre and wheel assembly Then connect the harnesses to the front passenger s air bag module 4 Route a thick wire through the holes in the front passenger s air bag module bracket With the deployment surface facing up secure the front passenger s air bag module to the old tyre and wheel assembly Caution 1 The deployment harnesses must not ...

Page 724: ...de air bag module from the vehicle Refer to P 52B 36 Caution Once disconnected both electrodes of the side air bag module connector short automatically to prevent accidental deployment caused by static etc Still in consideration of the accidental deployment store the air bag module on flat place with deployment surface facing up Also do not put anything on it 2 Prepare two wires longer than 6 m fo...

Page 725: ...cle Refer to P 52B 44 Caution The seat belt pre tensioner should be stored on a flat surface and placed so that the air bag operation surfaces are facing upward Do not place anything on top of them 2 Prepare two wires longer than 6 m for deployment and connect the terminals in one end to short circuit This is to prevent accidental operation caused by static etc 3 Touch the vehicle s body with bare...

Page 726: ...battery removed from the vehicle and operate Caution 1 Before the operation be sure that no one is near the seat belt pre tensioner 2 The operation of the seat belt pre tensioner makes itself very hot Before handling the seat belt pre tensioner wait more than 30 minutes for cooling 3 If the seat belt pre tensioner fails to deploy when the procedures above are followed do not go near the seat belt ...

Page 727: ...t water or oil on the air bag after deployment or on the seat belt pre tensioner after operation 3 There may be adhered to the deployed air bag module or the operated seat belt pre tensioner material that could irritate the eye and or skin so wear gloves and safety glasses when handling a deployed air bag module or a operated seat belt pre tensioner Caution If after following these precautions any...

Page 728: ...54A 1 CHASSIS ELECTRICAL CONTENTS CHASSIS ELECTRICAL 54A SMART WIRING SYSTEM SWS 54B ...

Page 729: ...ersonal injury or death to service personnel from inadvertent firing of the air bag or to the driver and passenger from rendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP 52B Supplemental Restraint Syst...

Page 730: ... SPECIAL TOOL 37 TROUBLESHOOTING 37 SIDE TURN SIGNAL LAMP 38 ROOM LAMP 38 TROUBLESHOOTING 38 REAR COMBINATION LAMP REAR FOG LAMP 38 SPECIAL TOOLS 38 TROUBLESHOOTING 38 REAR COMBINATION LAMP REAR FOG LAMP 39 HIGH MOUNTED STOP LAMP AND LICENCE PLATE LAMP 42 COLUMN SWITCH 43 RHEOSTAT 44 SPECIAL TOOL 44 RHEOSTAT 44 HAZARD WARNING LAMP SWITCH 45 SPECIAL TOOL 45 HAZARD WARNING LAMP SWITCH 45 HORN 46 CIG...

Page 731: ...54A 4 MULTI CENTER DISPLAY MIDDLE GRADE 67 SPECIAL TOOL 67 TROUBLESHOOTING 67 MULTI CENTER DISPLAY 79 MULTI CENTER DISPLAY HIGH GRADE 80 TROUBLESHOOTING 80 MULTI CENTER DISPLAY 108 ...

Page 732: ... battery fluid is over the UPPER LEVEL leakage could result 2 Use a hydrometer and thermometer to check the specific gravity of the battery fluid Standard value 1 220 1 290 20_C The specific gravity of the battery fluid varies with the temperature so use the following formula to calculate the specific gravity for 20_C Use the calculated value to determine whether or not the specific gravity is sat...

Page 733: ...the specific gravity of the battery fluid reaches 1 250 1 290 and remains constant for at least one hour 2 If the voltage of each cell reaches 2 5 2 8 V and remains constant for at least one hour Caution 1 Remove the battery caps during charging 2 Be careful since the battery fluid level may rise during charging 3 Keep all sources of fire away while charging because there is a danger of explosion ...

Page 734: ... load tester to the battery 2 Load the battery at the recommended discharge rate see LOAD TEST RATE CHART for 15 seconds 3 Read voltage after 15 seconds then remove load 4 Compare the measured value with the minimum voltage see LOAD TEST CHART OK Higher than minimum voltage NG Replace battery OK Normal LOAD TEST RATE CHART Battery type 65D23L Charging time when fully discharged h 5 amp rated curre...

Page 735: ...connection TROUBLESHOOTING Caution The encrypted code should always be re registered when replacing the immobilizer ECU STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING Refer to GROUP 00 How To Use Troubleshooting Inspection Service Points DIAGNOSIS FUNCTION DIAGNOSIS CODES CHECK Refer to GROUP 00 How To Use Troubleshooting Inspection Service Points ERASING DIAGNOSIS CODES Refer to GROUP 00 How To Use T...

Page 736: ... code Refer to P 54A 15 Code No 12 Encrypted code are not the same or are not registered Probable cause The encrypted code which is sent from the transponder is not the same as the encrypted code which is registered in the immobilizer ECU D The encrypted code in the ignition key being used has not been properly registered D Malfunction of the immobilizer ECU Re register the encrypted code Refer to...

Page 737: ...eck trouble symptoms NG Replace the engine ECU Register the password secret code and encrypted code Refer to P 54A 15 Inspection Procedure 2 Encrypted code cannot be registered using the MUT II Probable cause The cause is probably that there is no encrypted code registered in the immobilizer ECU or there is a malfunction of the immobilizer ECU D Malfunction of the transponder D Malfunction of the ...

Page 738: ...e engine ECU NO Refer to GROUP 13B or 13C Trouble shooting YES To inspection procedure for when there is no initial combustion Refer to GROUP 13A Troubleshooting NG Check trouble symptoms NG Check the immobilizer ECU power sup ply and earth circuit Refer to INSPEC TION PROCEDURE 4 OK Check trouble symptoms NG Replace the immobilizer ECU Inspection Procedure 4 Malfunction of the immobilizer ECU pow...

Page 739: ...lizer System 54A 12 CHECK AT IMMOBILIZER ECU TERMINAL VOLTAGE CHECK CHART Terminal No Signal Checking requirements Terminal voltage 1 Immobilizer ECU power supply Ignition switch ON System voltage 2 3 Engine ECU 4 Immobilizer ECU earth Always 0 V ...

Page 740: ...dule and Clock Spring Pre removal and Post installation Operation Clock Spring and Column Switch Removal and Installation Refer to GROUP 52B Air Bag Modules and Clock Spring 4 5 6 7 2 1 3 Section A A Clip A A Section B B Section C C Tab Tab Instrument panel B B C C A A 1 2 3 2 3 Removal steps 1 Instrument under cover 2 Column cover lower 3 Column cover upper 4 Ignition switch AA 5 Steering lock cy...

Page 741: ...cylinder toward you INSPECTION IGNITION SWITCH CONTINUITY CHECK 1 Remove the column cover lower and upper 2 Disconnect the wiring connector from the ignition switch 3 Operate the switch and check the continuity between the terminals Ignition key iti Terminal No g y position 1 2 4 5 6 LOCK ACC ON START KEY REMINDER SWITCH CONTINUITY CHECK Disconnect the key reminder switch connector with the switch...

Page 742: ...encrypted codes for each ignition key being used into the immobilizer ECU A maximum of eight different encrypted codes can be registered Moreover when the immobilizer ECU has been replaced you will need to use the MUT II to input the vehicle secret code and to register the password secret code that the user specifies into the immobilizer ECU Refer to the ªMUT II REFERENCE MANUALº or ªMUT II OPERAT...

Page 743: ... be registered and turn on the ignition switch NOTE After 5 seconds have elapsed the key registration must be repeated from the beginning because the key registration mode terminates 5 This completes the registration operation Turn the ignition switch to LOCK OFF position and wait for approx 10 seconds 6 Check that the engine can be started with each of the ignition keys 7 Check the diagnosis outp...

Page 744: ...point E 49 7 51 7 Sub Float point F 1 3 Float point E 55 3 57 3 Fuel gauge unit float height mm Main A Float point F 44 5 52 5 B Float point E 220 3 228 3 Sub A Float point F 30 4 36 4 B Float point E 238 5 244 5 Engine coolant temperature gauge unit resistance at 70_C Ω 104 13 5 Fuel gauge resistance Ω Power supply and earth 233 3 Power supply and fuel gauge 108 3 Fuel gauge and earth 125 0 Engin...

Page 745: ...uivalent Drying sealant SPECIAL TOOLS Tool Number Name Use A B C D MB991223 A MB991219 B MB991220 C MB991221 D MB991222 Harness set A Test harness B LED harness C LED harness adapter D Probe D Fuel gauge simple check A Connector pin contact pressure check B Power circuit check C Power circuit check D Commercial tester connection MB990784 Ornament remover Removal of meter hood ...

Page 746: ...y be a defective vehicle speed sensor circuit system or a defective speedometer Vehicle speed sensor is co used among the engine ECU and A T ECU D Malfunction of vehicle speed sensor D Malfunction of speedometer D Malfunction of harness or connector MUT II Self Diag Code Is the diagnosis code No 24 for GDI system output YES Check the vehicle speed sensor circuit Refer to P 54A 20 Inspection Proced...

Page 747: ...s C 76 C 74 MUT II Self Diag Code Is the diagnosis code No 44 for GDI system output YES Check the ignition coil and power transistor unit system Refer to GROUP 13A Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODE 44 Replace the tachometer OK NG Inspection Procedure 3 Vehicle speed sensor circuit system inspection Vehicle speed sensor inspection Refer to P 54A 27 NG Replace OK Measure at the...

Page 748: ... harness between the combination meter and fuel gauge and repair if necessary Repair NG OK Check trouble symptom NO Check the fuel gauge circuit D Disconnect the fuel gauge unit connector D 17 D Use the special tool to connect a test lamp 12 V 3 4 W to the harness side connector Refer to Fig 1 D Ignition switch ON 1 Test lamp condition OK Illuminates 2 Fuel gauge needle condition OK Moves to the m...

Page 749: ...rature gauge unit 2 NG NG Check the harness between the combination meter and engine coolant temperature gauge and repair if necessary Repair NG OK Check trouble symptom NO Check the engine coolant temperature gauge circuit D Disconnect the engine coolant temperature gauge unit connector A 68 D Use the special tool to connect a test lamp 12 V 3 4 W to the harness side connector Refer to Fig 1 D Ig...

Page 750: ...ication lamp at GDI ECO indication lamp ECU connector C 55 D Disconnect connector and measure at harness side D Ignition switch ON D Connect between terminal 2 and body earth OK Lamp illuminate Other illumination lamps normally darken with rheostat OK Check the rheostat Refer to P 54A 44 NG Check the harness wires between combination meter and GDI ECO indication lamp ECU NG Check following connect...

Page 751: ...tch suddenly Do not increase decrease speed rapidly while testing Standard values Standard indication km h mph Allowable range km h mph 40 20 40 48 20 25 80 40 80 92 40 47 120 60 120 136 60 69 160 80 160 180 80 91 100 100 114 TACHOMETER CHECK 1 Insert a paper clip in the engine speed detection connector from the harness side and attach the engine speedometer NOTE For tachometer check use of a flux...

Page 752: ...y when float moves slowly between point F highest and point E lowest FUEL GAUGE UNIT FLOAT HEIGHT 1 Move float and measure the height A at point F highest and B at point E lowest with float arm touching stopper Standard value Items Standard value mm Main Float point F 44 5 52 5 Float point E 220 3 228 3 Sub Float point F 30 4 36 4 Float point E 238 5 244 5 2 Check that resistance value changes smo...

Page 753: ... the terminals Float position Terminal No 3 4 When float is in contact with upper stopper When float is in contact with lower stopper ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK 1 Bleed the engine coolant Refer to GROUP 14 On vehicle Service 2 Remove the engine coolant temperature gauge unit 3 Immerse the unit in 70_C water to measure the resistance Standard value 104 13 5 Ω 4 After checking apply...

Page 754: ...ehicle speed sensor INSPECTION VEHICLE SPEED SENSOR INSPECTION 1 Lift up the vehicle 2 Remove the vehicle speed sensor and then connect the vehicle speed sensor and a resistance 3 10 kΩ as shown in the illustration 3 Use a circuit tester to check that the voltage between terminal 2 and terminal 3 changes when turning a shaft of the vehicle speed sensor 4 pulses per each one turn Circuit tester Bat...

Page 755: ... terminal be careful not to touch the printed board ENGINE COOLANT TEMPERATURE GAUGE RESISTANCE CHECK 1 Remove the power supply tightening screw 2 Use an ohmmeter to measure the resistance value between the terminals Standard value Power supply Earth 178 9 Ω Power supply Engine coolant temperature gauge 54 Ω Engine coolant temperature gauge Earth 232 9 Ω Caution When inserting the testing probe in...

Page 756: ...ide thermo sensor Ω At 25 _ Approx 1 700 OUTSIDE THERMO SENSOR REMOVAL AND INSTALLATION Outside thermo sensor INSPECTION OUTSIDE THERMO SENSOR INTERNAL RESISTANCE CHECK Check the internal resistance of the outside thermo sensor are at the standard value at temperatures of 25 _C Standard value Approx 1 700 Ω at 25 _C Thermometer Dryer Sensor ...

Page 757: ...tion where the 15_ sloping section intersects the vertical line V Headlamp intensity cd 30 000 or more Front fog lamp aiming Vertical direction 100 mm below horizontal H Horizontal direction Parallel to direction of vehicle travel SPECIAL TOOL Tool Number Name Use MB990784 Ornament remover Removal of switch garnish TROUBLESHOOTING The headlamp turn signal lamp and front fog lamp are controlled by ...

Page 758: ... vehicle is to be used adjust so as to meet those requirements 2 Alternately turn the adjusting screw to adjust the headlamp aiming Refer to P 54A 32 USING A SCREEN 1 Inflate the tyres to the specified pressures and there should be no other load in the vehicles other than driver or substituted weight of approximately 75 kg placed in driver s position 2 Put the headlamp leveling switch in ª0º posit...

Page 759: ...ometer and following its manufacture s instruction manual measure the headlamp intensity and check to be sure that the limit value is satisfied Limit 30 000 cd or more NOTE 1 When measuring the intensity maintain an engine speed of 2 000 r min with the battery in the charging condition 2 There may be special local regulations pertaining to headlamp intensity be sure to make any adjustments necessa...

Page 760: ... position 4 With the engine running at 2 000 r min aim the front fog lamp 5 Check if the beam shining onto the screen is at the standard value Standard value Vertical direction 100 mm below horizontal H Horizontal direction Parallel to direction of vehicle travel NOTE The horizontal direction is non adjustable If the deviation of the light beam axis exceeds the standard value check to be sure that...

Page 761: ...lamp socket by turning it anti clockwise then pull out the bulb from the socket Front fog lamp Bulb 1 Remove the front fog lamp 2 Remove the front fog lamp cover 3 Remove the front bulb mounting spring and then withdraw the bulb 4 Disconnect the connector and then replace the bulb Caution 1 Always use the genuine part for replacement 2 Do not touch the surface of the bulb with hands or dirty glove...

Page 762: ...mp switch and headlamp leveling switch removal steps 1 Switch panel 2 Fog lamp switch 3 Headlamp leveling switch Headlamp removal steps AA 4 Radiator grille 5 Headlamp 6 Front turn signal lamp socket 7 Front turn signal lamp bulb Front fog lamp removal steps 8 Splash shield front part mounting clips and screws 9 Front fog lamp NOTE For removal and installation of the column switch lighting switch ...

Page 763: ...them to the radiator grille temporarily for reinstallation INSPECTION HEADLAMP LEVELING SWITCH CONTINUITY CHECK 1 Check the continuity between terminals 4 and 5 illumination circuit 2 Operating the headlamp leveling switch check that the resistance between terminals 4 and 5 meets the condition below Switch position Resistance value 0 12 kΩ 1 5 1 kΩ 2 2 7 kΩ 3 1 5 kΩ 4 620 Ω FOG LAMP SWITCH CONTINU...

Page 764: ...K Battery voltage Terminal No 1 3 4 5 Not supplied Supplied SIDE TURN SIGNAL LAMP SPECIAL TOOL Tool Number Name Use MB990784 Ornament remover Removal of side turn signal lamp TROUBLESHOOTING The side turn signal lamp is controlled by the smart wiring system SWS For troubleshooting refer to GROUP 54B Troubleshooting Front fog lamp relay ...

Page 765: ...l lamp ROOM LAMP TROUBLESHOOTING The room lamp is controlled the smart wiring system SWS For troubleshooting refer to GROUP 54B Troubleshooting REAR COMBINATION LAMP REAR FOG LAMP SPECIAL TOOLS Tool Number Name Use MB990784 Ornament remover Removal of side turn signal lamp TROUBLESHOOTING The tail lamp turn signal lamp and rear fog lamp are controlled by the smart wiring system SWS For troubleshoo...

Page 766: ...5 4 A A A A 2 5 0 2 Nm Section B B Body panel Gronmet 3 1 BX0283AL Fog lamp switch removal steps 1 Switch panel 2 Fog lamp switch Rear combination lamp removal steps D Quarter Trim Removal and Installation Refer to GROUP 52A 3 Rear combination lamp 4 Socket assembly 5 Bulb Rear fog lamp removal steps D Rear mad guard Refer to GROUP 51 D Rear splash shield 6 Rear fog lamp 7 Bracket 8 Socket ...

Page 767: ...1 1 2 A A A A 9 2 5 0 2 Nm BX0283AL Fog lamp switch removal steps 1 Switch panel 2 Fog lamp switch Rear combination lamp removal steps D Quarter trim removal and installation Refer to GROUP 52A 3 Rear combination lamp Stop and back up lamp 4 Rear combination lamp Turn signal and tail lamp 5 Rear combination lamp Rear fog lamp turn signal lamp and tail lamp 6 Bracket 7 Socket assembly 8 Socket 9 Bu...

Page 768: ...amp Rear Fog Lamp 54A 41 INSPECTION FOG LAMP SWITCH CONTINUITY CHECK Terminal No 3 ILL 4 5 6 Relased Pressed INSPECTION REAR FOG LAMP RELAY CONTINUITY CHECK Battery voltage Terminal No y g 1 3 4 5 Not supplied Supplied Rear fog lamp relay ...

Page 769: ...4 5 6 7 8 9 10 A A High mounted stop lamp removal steps 1 High mounted stop lamp cover 2 Socket assembly 3 Bulb 4 High mounted stop lamp Licence plate lamp removal steps D Back door trim and waterproof film Refer to GROUP 42 D Licence plate lamp garnish Refer to GROUP 42 Back Door 5 Licence plate lamp assembly 6 Lens 7 Packing 8 Licence plate lamp 9 Bulb 10 Socket assembly ...

Page 770: ...olumn Switch 54A 43 COLUMN SWITCH REMOVAL AND INSTALLATION Section A A Tab A 4 2 A A A 3 B B B B 1 Section B B Tab 1 2 1 2 Removal steps 1 Column cover lower 2 Column cover upper 3 Wiper and washer switch 4 Lighting switch ...

Page 771: ...l of switch garnish RHEOSTAT REMOVAL AND INSTALLATION 2 1 A A Section A A Claw Instrument panel 1 A A Removal steps 1 Switch panel 2 Rheostat INSPECTION 1 Connect the battery and the test bulb 40W as shown in the illustration 2 Operate the rheostat and if the brightness changes smoothly without switching off then the rheostat function is normal 40W ...

Page 772: ... TOOL Tool Number Name Use MB990784 Ornament remover Removal of center panel HAZARD WARNING LAMP SWITCH REMOVAL AND INSTALLATION Section A A Clip Instrument panel 2 1 A A shows clips 1 Removal steps 1 Center panel 2 Hazard warning lamp switch INSPECTION Switch position Terminal No 1 2 3 4 OFF ON ...

Page 773: ...RN INSPECTION HORN RELAY CONTINUITY CHECK Battery voltage Terminal No y g 1 3 4 5 Not supplied Supplied CIGARETTE LIGHTER REMOVAL AND INSTALLATION 1 5 4 3 2 Removal steps 1 Plug 2 Floor console Refer to GROUP 52A 3 Bulb 4 Socket case 5 Socket Horn relay ...

Page 774: ...e on the element spot connection and for shreds of tobacco or other material on the element D Using a circuit tester check the continuity of the element ACCESSORY SOCKET INSPECTION ACCESSORY SOCKET RELAY CONTINUITY CHECK Battery voltage Terminal No y g 1 3 4 5 Not supplied Supplied Element Spot Accessory socket relay ...

Page 775: ...velling A 5 Ever present noise A 6 Radio When switch is set to ON no power is available B 1 No sound from one speaker B 2 There is noise but no reception for FM MW LW or no sound from FM MW LW B 3 Insufficient sensitivity B 4 Distortion on FM MW LW B 5 Too few automatic select stations B 6 Insufficient memory preset stations are erased B 7 Tape player Cassette tape will not be inserted C 1 No soun...

Page 776: ...Find out the following information from the user 1 Place 2 Locality conditions valley moun tain etc 3 Name and frequency of stations affected by noise No If due to vehicle noise It may not be possible to prevent noise if the signal is weak If there is more noise than other radios find out the noise conditions and the name and frequency of the receiving stations from the user and consult with the s...

Page 777: ...arance of a beating sound may occur Beat sound Two signals close in frequency interfere with each other creating a repetitious high pitched sound This sound is generated not only by sound signals but by electrical waves as well 2 Factors due to vehicle noise Alternator noise may be a cause Is the noise still obvious even with the lamps OFF No Yes Do the following measures eliminate the noise D Tun...

Page 778: ...No Is the radio body earth mounted securely No Securely tighten the nuts for the body earth Yes Is the antenna plug properly connected to the radio No Correctly attach the antenna plug Yes Is the antenna itself in good condition or is it properly mounted No Clean the antenna plug and earth wire mounting area Mount the antenna se curely Yes If there is more noise than other radios consult a service...

Page 779: ...e mounting bolts securely Cases where the problem is not eliminated by a single response to one area are common due to several body parts being imperfectly earthed Caution 1 Connecting a high tension cable to the noise filter may destroy the noise filter and should never be done 2 Check that there is no external noise Since failure caused by this may result in misdiagnosis due to inability to iden...

Page 780: ...y earthed Is the mounting screw tightened securely No Tighten the screw securely Yes Is the antenna correctly earthed If noise appears when the anten na is moved this means the earth is not securely connected No If rust is present at the antenna earth screw clean and tighten the earth securely Yes Repair or replace radio A 6 Ever present noise Noise is often created by the following factors and of...

Page 781: ...r of the radio Is the ACC power 12 V being supplied to the radio No Repair harness Yes Repair or replace radio B 2 No sound from one speaker Check to see if there is any sound when attached to another radio Yes Repair or replace radio No Remove the connector on the back of the radio and check the speaker har ness for conductance Yes It conducts electricity but is shorted out Repair speaker harness...

Page 782: ... problem disappear if connected to another radio No Replace the antenna B 4 Insufficient sensitivity No Replace the antenna Yes Repair or replace radio Yes Does the problem disappear when a different radio is connected OK Is the check being conducted under special electrical field conditions Yes Example In an underground garage or inside a building No Does tuning solve the problem Is proper perfor...

Page 783: ... Yes Repair or replace speakers No Check for deformation with speaker installed Yes Install speaker securely No Repair or replace radio B 6 Too few automatic select stations OK Is the check being conducted under special electrical field conditions Yes Example In an underground garage or inside a building No Is the antenna plug properly connected to the equipment Is proper performance obtained when...

Page 784: ... player may damage the mechanism The player should be taken to a service dealer for repair Does the tape player work if another tape is inserted Yes Replace tape 2 No Repair or replace tape player 2 Ensure that the tape label is not loose that the tape itself is not deformed and that the tape is tightly wound Also tape of C 120 or greater length often get caught in the mechanism and should not be ...

Page 785: ... that the tape itself is not deformed and that the tape is tightly wound D Tapes of C 120 or greater length often get caught in the mechanism and should not be used Does the player play properly when the tape player head is cleaned Yes OK No Is proper operation obtained when the tape player is replaced Yes Repair or replace tape player No Repair or replace speaker C 5 Cassette tape will not be eje...

Page 786: ... may damage the mechanism The player should be taken to a service dealer for repair No Is the head or capstan roller dirty Refer to the illustration below Yes Clean Repair or replace tape player C 7 Faulty auto reverse Does the player play OK if the tape is changed Yes OK No D Ensure that the tape label is not loose that the tape itself is not deformed and that the tape is tightly wound D Tapes of...

Page 787: ... this may damage the tape player mechanism Take the cassette to a service dealer for repair Does the player play OK if the tape 2 is changed Yes Tape used is bad No 2 Ensure that the tape label is not loose that the tape itself is not deformed and that the tape is tightly wound Also tapes of C 120 or greater length often get caught in the mechanism and should not be used Repair or replace tape pla...

Page 788: ...HASSIS ELECTRICAL Radio and Tape Player 54A 61 RADIO AND TAPE PLAYER REMOVAL AND INSTALLATION Section A A 1 2 1 A A Instrument panel Clip shows clips Removal steps 1 Center panel 2 Radio and tape player ...

Page 789: ...CHASSIS ELECTRICAL CD Autochanger 54A 62 CD AUTOCHANGER REMOVAL AND INSTALLATION 5 4 2 3 1 Removal steps D Front seat LH 1 Lid 2 Cover 3 CD autochanger assembly 4 Bracket 5 CD autochanger ...

Page 790: ...aker 54A 63 SPEAKER REMOVAL AND INSTALLATION 4 3 2 1 Front speaker Rear speaker Front speaker removal steps 1 Front door trim Refer to GROUP 42 2 Speaker Rear speaker removal steps 3 Quarter trim Refer to GROUP 52A 4 Speaker ...

Page 791: ... 5 Antenna feeder REMOVAL SERVICE POINT AA ANTENNA ASSEMBLY REMOVAL Observe the following steps to make the feeder cable of the antenna to be routed easily during reinstallation 1 Secure a cord to the end of the feeder cable 2 Pull out the feeder cable slightly until the tube end of the antenna can been seen 3 Insert a cord into the tube end and secure the cord with plastic tape as shown Caution 4...

Page 792: ...om A Move test bar slowly to negative terminal to detect where voltage changes suddenly 0V 4 If 0 V is indicated at A there is a break in the positive terminals from A Defect where the voltage changes suddenly 12 V in the same method described above REAR WINDOW DEFOGGER RELAY CONTINUITY CHECK Battery voltage Terminal No y g 1 2 3 5 Power is not supplied Power is supplied Normal characteristic curv...

Page 793: ...hicles with heated mirrors Switch position Terminal No 3 10 11 12 OFF ON NOTE Turn on the defogger switch and then check that there is continuity between the terminals 3 and 12 for 9 to 13 minutes and after it the defogger switch is turned off Vehicles without heated mirrors Switch position Terminal No 10 11 12 OFF ON Defogger switch Vehicles with heated mirrors Vehicles without heated mirrors ...

Page 794: ...ion Input function memory When battery is disconnected Radio Channels which are selected during a search Disappear after a few seconds Preset channels Tone Balance Position set on Bass Treble Balance and Fader Clock set on display Current time Keep a data for approx one hour Brightness set for display Position set on display Unit set for trip computer km or mile L 100km or mpg or km L Average spee...

Page 795: ... an applicable speaker according to the display FL FR RL RR Function explanation To diagnose speaker connections follow the procedure below to enter the test mode 1 Entry to test mode 1 Turn the ignition switch to ACC 2 Turn off the power supply switch of the audio unit 3 Press the ªCH1º button 4 Press the ªAutomatic tuning in down button º 5 Press the ªAutomatic tuning in up button º 6 Press the ...

Page 796: ...mode The service mode checks the following in that order 1 LCD segment check This screen is divided into four areas Each area will be active sequentially whenever the ªSETº button is pressed When the ªSETº button is pressed four times in this screen the service mode will proceed to the Sensor check 2 Sensor check This screen shows voltage signals from the outside temperature sensor the fuel gauge ...

Page 797: ...e ECU 6 7 Input Output M DATA AUDIO Hi 4 5 Lo 0 1 f f Audio display dose not appear Panel switch cannot be operated for audio unit Nighttime illumination dose not appear for audio unit 8 Input Output M CLOCK AUDIO Hi 4 5 Lo 0 1 f f Audio display dose not appear Panel switch cannot be operated for audio unit Nighttime illumination dose not appear for audio unit 9 14 15 Input Output K Hi System volt...

Page 798: ...lumination does not ap pear for any navigation system units voltage Lo 0 1 f Blown multipurpose fuse 25 Input ACC ACC power supply System voltage f Screen display does not appear supply voltage f Blown multipurpose fuse 26 Input B System voltage f Screen display does not appear voltage f Blown multipurpose fuse 27 Input VSS f No effect 28 GND Ground f Screen display does not appear 29 30 31 GND TE...

Page 799: ...f No sound is output from rear left speaker voltage AC f No sound is output from rear left and right speakers 3 4 Input ILL Hi System voltage f Nighttime illumination does not ap pear for audio unit voltage Lo 0 1 f Blown multipurpose fuse 5 Output SPEAKER FL 0 System voltage f No sound is output from front left speaker voltage AC f No sound is output from front left and right speakers 6 Output SP...

Page 800: ...use 11 Input B System voltage System voltage f Cassette is not ejected when the ignition switch is at ACC The memory are cleared f Blown multipurpose fuse 12 ILL 13 Output SPEAKER FL 0 System voltage f The front left speaker does not sound voltage AC f The front left and right speakers do not sound 14 Output SPEAKER FR 0 System voltage f The front right speaker does not sound voltage AC f The fron...

Page 801: ...uel consumption and average speed displays D Abnormal cruising distance displays 5 54A 77 No illumination of audio button 6 54A 78 Dim display 7 54A 78 Clock runs fast or slow 8 54A 78 INSPECTION PROCEDURES FOR EACH TROUBLE SYMPTOM INSPECTION PROCEDURE 1 No display appears after the ignition key is turned to ACC Check the connector C 52 NG Repair OK Measure at multi center display connector C 52 D...

Page 802: ...epair the harness Replace the multi center display unit Are there any audio set as option NG Check the DIN cable OK Replace the option audio NG Check cassette function with LOAD ING EJECT OK Replace the key panel and repair Replace the audio unit Check the detachable key panel dust or broken button etc NG OK Check output signals on the connector in multi center display unit side D Disconnect C 53 ...

Page 803: ... for M BUS Replace the audio unit Repair INSPECTION PROCEDURE 4 Outside air temperature data is not displayed Outside air temperature data is abnormal Check the connector C 52 NG Repair OK Does the multi center display unit show the vehicle identifications correctly YES Replace the multi center display unit NO Does the service mode show outside air temperature correctly YES End no abnormality NO I...

Page 804: ...h ON System voltage NG Ignition switch OFF 0 1 V Check a voltage on 5 terminal of C 53 connector after C 53 connector shall be out D ignition switch ON OK Low NG more than 80 of system voltage Check the harness between multi cen ter display unit and junction block and Replace the if necessary 2 When cruising distance display is abnormal NG OK Does the service mode show fuel amount correctly YES NO...

Page 805: ...rrect NO OK YES OK Check the brightness of display to change when lighting switch is on or off Replace the multi center display Replace the multi center display unit Repair the harness NG Repair the fuse and the harness Measure at multi center display con nector C 52 D Connector disconnected D Voltage between terminal 24 and body earth OK System voltage ILL ON 0 V ILL OFF Adjust brightness of disp...

Page 806: ...ade 54A 79 MULTI CENTER DISPLAY REMOVAL AND INSTALLATION 1 Section A A Clip Instrument panel shows tabs shows clips View A View A 1 1 1 2 3 Section B B A A B B Instrument panel Clip Removal steps 1 Center display hood 2 Bracket 3 Multi center display ...

Page 807: ...unction Current location Recommended route Destination Route search conditions Sensor initialization data Language selection setting Guidance volume setting Data search function data display and input Registered location names data display and input functions Past destinations Average fuel consumption average speed cruising range Disappear after a few seconds Clock display function Current time Ve...

Page 808: ...vered repair it and then re check the trouble symptoms 3 If there are no abnormalities in the harness connections check the harnesses themselves If there are no abnormalities in the harnesses replace the unit which controls that function 4 Notes on trouble diagnosis of the navigation function 1 The vehicle positioning accuracy of the navigation function is limited because of the principle of opera...

Page 809: ...his mode wiring and communication checking audio checking sensor checking and vehicle signal checking are carried out continuously This mode includes functions such as wiring and communication checking sensor checking vehicle signals and version data checking This checks system communication between all units This checks all of the sensors that are necessary to the navigation system This displays ...

Page 810: ...igation unit will be checked during this time 3 Once the transmission checking is completed the results of the wiring and transmission checking will appear on the screen After checking the results press the F1 switch to proceed to the next check The next check will start when the switch is pressed NOTE 1 If the fuel gauge and the engine ECU are checked while the ignition switch is at ACC an error ...

Page 811: ...ing will then be completed If there is an open circuit in the vehicle speed sensor sensor checking will not complete even after the vehicle has travelled more than 10 meters In this case press the F5 switch to stop checking If the vehicle does not move or there is an open circuit in vehicle speed sensor the vehicle speed sensor will be shown as defective 7 When sensor checking is completed the che...

Page 812: ...m each speaker each time the F2 switch is pressed At the early mass production sometimes radio sound will be output This is not a sign of abnormality 10 Press the F1 switch to end service mode The screen will change to navigation mode 3 MONITOR CHECKING 1 If the F6 switch is pressed at the service mode initial screen monitor checking will start ...

Page 813: ...tion switch to change to another screen The screen will return to the service mode initial screen if the F1 switch is pressed 4 AUDIO CHECKING 1 If the F5 switch is pressed at the service mode initial screen the audio checking menu screen will appear 2 Next press the function switches to carry out audio checking ...

Page 814: ...ressed the screen display color for that switch should change This indicates that this particular switch system is working normally Press the F1 switch to check the operation of the F1 switch Press the F1 switch once more to return to the audio checking menu screen 5 SELF DIAGNOSIS 1 If the F5 switch is pressed at the service mode initial screen the self diagnosis menu screen will appear 2 Next us...

Page 815: ...the vehicle is stopped so make sure that the vehicle is stopped for this check If the vehicle is moving when the sensor checking starts the vehicle speed sensor will be shown as defective Follow the guidance message on the multi center display 7 Next drive the vehicle for approximately 10 meters while changing the running direction in order to check the vehicle speed pulse and the gyro sensor outp...

Page 816: ...he F2 switch is pressed at the self diagnosis menu screen version data self diagnosis will be carried out and the check results will appear on the screen Press the F1 switch to return to the self diagnosis menu screen 6 DIAGNOSIS RECORDING 1 If the F6 switch is pressed at the service mode initial screen the diagnosis recording screen will appear 2 Press the F1 switch to return to the service mode ...

Page 817: ...ed during diagnosis Connection checking 54A 106 1031 GPS abnormality during diagnosis Connection checking 54A 106 1041 Engine ECU not connected during diagnosis Connection checking 54A 106 1051 SWS not connected during diagnosis This error does not occur when correct car type is set Connection checking 54A 106 1091 CD drive too hot during diagnosis Connection checking 54A 106 1092 1096 CD drive ab...

Page 818: ...lue white cyan and magenta do not appear in RGB screen 3 4 5 Input ISOK Hi System voltage Lo 0 1 f f MUT II cannot be used to check engine ECU 6 Input Output DATA Hi System voltage Lo 0 1 f f Switch operation sound buzzer does not peep 7 Input Output M DATA AUDIO Hi 4 5 Lo 0 1 f f Buzzer sounds 30 seconds after the power turned to on Nighttime illumination does not appear for any navigation system...

Page 819: ... f Buzzer sounds 30 seconds after the power turned to on Nighttime illumination does not appear for any navigation system 18 SHIELD GND 19 21 22 Input PS R Hi System voltage Lo 0 1 f f Current location is not correct when reversing 23 Input EX TEMP 0 5 f f Outside air temperature does not appear 24 Input ILL Hi System voltage f Nighttime illumination does not ap pear for any navigation system unit...

Page 820: ...e fuse 2 NAVIGATION UNIT DIN cable to audio unit Termi nal No Input Output Signal Symbol Terminal Voltage Harness Problem Trouble Symptom Resulting from Harness Problem nal No Output Voltage V Open Circuit Short circuit Harness Problem 1 3 4 Input VEHICLE SPEED PULSE Voltage should change when wheels are turning Hi 4 5 Lo 0 1 f f Compass display does not change when not following a route Guide doe...

Page 821: ... No sound is output from rear left speaker voltage AC f No sound is output from rear left and right speakers 3 4 Input ILL Hi System voltage f Nighttime illumination does not ap pear for audio unit voltage Lo 0 1 f Blown multipurpose fuse 5 Output SPEAKER FL 0 System voltage f No sound is output from front left speaker voltage AC f No sound is output from front left and right speakers 6 Output SPE...

Page 822: ...when ACC power turned off Contents of memory are cleared f Blown multipurpose fuse 12 Input ILL 13 Output SPEAKER FL 0 System voltage f No sound is output from front left speaker voltage AC f No sound is output from front left and right speakers 14 Output SPEAKER FR 0 System voltage f No sound is output from front right speaker voltage AC f No sound is output from front left and right speakers 21 ...

Page 823: ...ition key is turned to ACC but TAPE CD UML switches can be operative 3 54A 100 CD changer screen display does not appear when TAPE CD switch is operated 4 54A 101 GPS reception is not possible 5 54A 101 Outside air temperature data is not displayed 6 54A 101 Abnormal driving data display D Abnormal average fuel consumption and average speed displays D Abnormal cruising distance displays 7 54A 102 ...

Page 824: ...on nector C 53 D Ignition switch ACC D Measure waveform at terminal 7 8 17 of harness connector with an oscilloscope OK Hi 4 5 V Lo 0 1 V pulse signal OK Replace the multi center display NG NG Repair Check the harness between audio C 54 and multi center display C 53 connector OK Does the sound turn on off when the audio VOL POWER switch operated NO NG Repair fuse or harness YES OK Measure at audio...

Page 825: ...OK 2 Vpp AC 15 75kHz video signal NG OK Replace the audio unit NO YES Replace the navigation unit Does the sound turn on off when the audio VOL POWER switch operated NG OK Replace the multi center display Turn off the ignition key and turn to ACC position again Does the buzzer sound ªPiPi PiPi PiPiº after about 30 seconds NG Repair fuse or harness OK Measure at the navigation unit connec tor C 50 ...

Page 826: ... navigation unit NO YES YES NO Check the connector of CD changerand DIN connector between navigation unit and CD changer Is a CD changer connected Check connectors C 11 C 53 C 54 and DIN connectors between audio and navigation unit Replace the audio unit Measure at audio unit connector C 11 D Ignition switch ACC D Voltage between terminal 10 11 and body earth OK System voltage Repair Replace the D...

Page 827: ...econds after it NO OK Repair fuse or harness NG Check connectors C 11 C 53 C 54 and DIN connectors between audio and navigation unit Replace the multi center display Measure at the multi center display connector C 53 D Ignition switch ACC D Measure waveforms of terminal 1 2 13 of multi center display connector OK 0 2 Vpp 15 75kHz video signal OK Measure at the multi center display connector C 52 D...

Page 828: ...O Move the vehicle to a good reception area YES Turn the ignition switch to ACC and then wait for about 5 minutes Is GPS reception still not possible NO End no abnormality YES Replace the multi center Display unit INSPECTION PROCEDURE 6 Outside air temperature data is not displayed OK NO YES YES NO Check connectors A 28 C 28 C 52 NG Repair OK Carry out a wiring check service func tion Does the mes...

Page 829: ...k ser vice function Does the message ªKey position IGº appear Check the harness between multi cen ter display and the junction block and replace if necessary OK Replace the multi center display Measure at the multi center display connector C 52 D Connector disconnected D Voltage between terminal 36 and body earth OK Ignition switch ON System voltage Ignition switch OFF 0 1 V NO 2 When cruising dis...

Page 830: ...de of the cable between the audio unit and the navigation unit OK Replace the audio unit NG Check the RGB wave pattern at the DIN connector at the navigation unit side of the cable between the audio unit and the navigation unit NG Replace the navigation unit INSPECTION PROCEDURE 9 Daytime nighttime display mode does not change in conjunction with lighting switch operations Check connector C 52 NG ...

Page 831: ... INSPECTION PROCEDURE 11 One of the following messages appears during navigation mode D The CD drive has failure condition Confirm and reload the disc please D Wrong disc is in the CD drive Insert a map disc please D No disc is in the CD drive Insert a map disc please D A music disc is in the CD drive 1 ªThe CD drive has failure condition Confirm and reload the disc please º or ªWrong disc is in t...

Page 832: ...drive abnormality during diagnosis Connection checking 54A 107 10A1 10B1 Memory of navigation unit abnormality during diagnosis Connection checking 54A 107 20D1 30D1 Vehicle speed pulse abnormality during diagnosis Sensor checking 54A 107 20E1 20E2 30E1 30E2 Gyro level abnormality during diagnosis Sensor checking 54A 107 INSPECTION PROCEDURES FOR EACH ERROR CODE ACCORDING TO SCREEN DISPLAY Error C...

Page 833: ...n of the GPS inside the multi center display Replace the multi center display Error Code No 1041 Were the wiring check instructions followed NO Repeat the wiring check YES Connect MUT II and diagnose engine NG Check the harness between C 53 and C 19 OK Replace the multi center display Error Code No 1051 Were the wiring check instructions followed NO Repeat the wiring check YES Check connector C 53...

Page 834: ...k If the same problem occurs there is a malfunction of the memory within the navigation unit Replace the navigation unit Error Code No 20D1 30D1 Were the sensor check instructions followed NO Repeat the sensor check OK Measure at the navigation unit connector B 08 D Disconnect connector D Turn on the Ignition switch and then move the vehicle slowly D Voltage between terminal 4 and body eartth OK H...

Page 835: ...OVAL AND INSTALLATION 2 1 3 4 5 6 5 2 Navigation unit removal steps 1 Floor console Refer to GROUP 52A Floor console 2 Radio bracket 3 Navigation unit Multi center display removal steps 4 Multi center display hood Refer to P 54A 79 5 Multi center display bracket 6 Multi center display ...

Page 836: ...54B 1 SMART WIRING SYSTEM SWS CONTENTS GENERAL INFOMATION 54B 1 SPECIAL TOOLS 54B 5 TROUBLESHOOTING 54B 6 ...

Page 837: ... HEAD position the buzzer will sound continuously to remind the driver that the lights taillights or headlights are ON Multi center Display Buzzer Function If there is a request from the multi center display to make the buzzer sound the ETACS ECU causes the buzzer to sound CENTRAL DOOR LOCKING SYSTEM Central Door Locking System Operation If a door is locked or unlocked by using any one of the key ...

Page 838: ...N position the column switch sends a low speed wiper OFF and high speed wiper ON signals to the front ECU This turns both the wiper signal and the wiper speed switching relay on high speed causing the wipers to operate at high speed Windshield Intermittent Wiper Operation The ETACS ECU calculates the wiper operation interval according to the voltage signal sent from the column switch For vehicles ...

Page 839: ...e period the headlamps will be switched off automatically This prevents the battery from discharged In addition if the headlamps are turned on when the ignition switch is at LOCK OFF or ACC position the headlamps will not be switched off Headlamp Dimmer Switch Auto reset Function This function allows the dimmer switch to be reset to the low beam position whenever the headlamp switch is turned ON D...

Page 840: ...s later During that time timer controlled period the room lamp does out if the ignition key is inserted and turned to ON position or the door locking system is activated D Room lamp s answerback operation in response to door lock control by keyless entry system To allow the driver to ascertain the result of the door locking unlocking control action by the use of the keyless entry system the ETACS ...

Page 841: ...ition switch IG1 Turned from ACC to ON Key reminder switch Ignition key removed from ignition key cylinder from inserted position Hazard warning lamp switch Turned from OFF to ON Front fog lamp switch vehicles with front fog lamp Rear fog lamp switch Back up lamp switch M T Shift lever moved to R position Inhibitor switch reverse A T Selector lever moved to R position Rear wiper motor auto stop si...

Page 842: ...shield intermittent wiper interval adjusting knob from FAST to SLOW when the ignition switch is at ON position The ETACS ECU sends a signal around the medium knob position Windshield washer switch Turned from OFF to ON Rear wiper switch Rear washer switch Headlamp washer switch vehicles with head lamp washer Power window main switch Any switch vehicles with power window Transmitter Any switch vehi...

Page 843: ... request signal from the ETACS ECU for one second D Malfunction of column switch D Malfunction of ETACS ECU D Malfunction of wiring harness or connector Is diagnosis code No 12 output when the ignition switch is at the ON position No Measure at column switch connector C 63 D Disconnect connector and measure at harness side D Voltage between terminal 1 and body earth OK System voltage NG Check the ...

Page 844: ...tor A 37X D Disconnect connector and measure at harness side D Voltage between terminal 7 and body earth OK System voltage NG Check the following connector A 37X NG Check the harness wire between front ECU and fusible link 3 No Measure at front ECU connector A 38X D Disconnect connector and measure at harness side D Continuity between terminal 31 and body earth OK Continuity NG Check the following...

Page 845: ...s or connector Check the following connectors A 38X C 53 C 63 C 83 E 10 NG Repair OK Check trouble symptoms NG Check the harness wires between column switch and ETACS ECU front ECU and ETACS ECU power window main switch and ETACS ECU multi center display and ETACS ECU NG Repair OK Is diagnosis code No 21 no longer output when column switch connector C 63 is disconnected However code No 12 is still...

Page 846: ... main switch can not operate driver s window D 2 54B 18 Power window sub switch can not operate passenger s window D 3 54B 19 Power window main switch can not operate passenger s window D 4 54B 20 Power window timer function does not work normally D 5 54B 20 When the glass is raised it then lowers automatically D 6 54B 21 The glass is not lowered when something is jammed in the window D 7 54B 21 W...

Page 847: ...dimmer switch auto reset function does not work normally I 6 54B 31 Daytime running lamp DRL function does not work I 7 54B 31 Flasher timer Turn signal lamp do not flash when the turn signal lamp switch is turned on J 1 54B 32 Hazard warning lamps do not flash when the hazard warning lamp switch is turned on J 2 54B 33 Front fog lamp Front fog lamps do not illuminate when the front fog lamp switc...

Page 848: ...oor lock key cylinder switch signal is not sent to the ETACS ECU N 11 54B 43 Back door lock key cylinder switch signal is not sent to the ETACS ECU N 12 54B 43 Driver s door lock actuator switch signal is not sent to the ETACS ECU N 13 54B 44 Column switch Tail lamp switch signal is not sent to the ETACS ECU N 14 54B 45 Headlamp switch signal is not sent to the ETACS ECU Dimmer switch signal is no...

Page 849: ...lfunction of harness wire or connector Can MUT II communicate with other system No Check and repair the self diagnosis system with the MUT II Yes Is communication with the MUT II possible when the ignition switch is at the ON position Yes Check the ETACS ECU battery circuit Refer to P 54B 47 Inspec tion Procedure O 1 No Measure at ETACS ECU connector C 82 D Disconnect connector and measure at J B ...

Page 850: ... P 54B 47 Inspec tion Procedure O 1 Yes MUT II input signal check D Ignition switch IG1 D Driver s door switch D Tail lamp switch D Headlamp switch NG Check the defective input circuit Refer to P 54B 13 DefectsFound by Input Signal Check OK Replace the ETACS ECU Inspection Procedure B 2 Buzzer Multi center display buzzer function does not work normally Probable cause If the multi center display is...

Page 851: ...G Repair OK Check trouble symptoms NG Check the harness wire between ETACS ECU and door lock actua tor NG Repair OK Replace the ETACS ECU Inspection Procedure C 2 Central door locking system Some doors do not lock or unlock Probable cause The door lock actuator or the harness wire between ETACS ECU and the door lock actuator may be defective D Malfunction of driver s passenger s or back door lock ...

Page 852: ...witch D Malfunction of ETACS ECU D Malfunction of harness wire or connector MUT II input signal check D Passenger s door lock key cylinder switch D Back door lock key cylinder switch NG Check the defective input circuit Refer to P 54B 13 DefectsFound by Input Signal Check OK Replace the ETACS ECU Inspection Procedure C 5 Central door locking system Forgotten key prevention function does not work P...

Page 853: ...de power window motor or an abnormality in the power supply circuit D Malfunction of power window main switch D Malfunction of driver s power window motor D Malfunction of harness wire or connector OK Check trouble symptoms NG Repair NG Check the harness wire between driver s power window motor and power window relay NG Repair NG Check the harness wire between driver s power window motor and body ...

Page 854: ...nnectors L H drive vehicles E 04 E 06 R H drive vehicles E 09 E 12 NG Check the harness wire between power window sub switch and body earth OK Check trouble symptoms NG Repair NG 1 NG Check the following connectors L H drive vehicles C 21 C 71 E 06 R H drive vehicles C 45 C 71 E 12 NG Check the harness wire between power window sub switch and passenger s power window motor NG Repair OK Check troub...

Page 855: ...ptoms NG Check the harness wire between power window main switch and passenger s power window motor NG Repair OK Replace the power window main switch or passenger s power window motor Inspection Procedure D 5 Power window Power window timer function does not work normally Probable cause The ETACS ECU operates the power window timer function based on the input signals from the following switches D ...

Page 856: ...42 Door OK Replace the power window motor Check trouble symptoms NG Replace the window regulator assembly Inspection Procedure D 7 Power window The glass is jammed in the window Probable cause The cause may be a malfunction of the revolution detection sensor in the power window motor D Malfunction of power window motor Replace the power window motor Inspection Procedure D 8 Power window When the g...

Page 857: ...r connector Activate the answerback functions Refer to GROUP 42 Keyless Entry System Check trouble symptoms NG Are room lamp and hazard warning lamps operated normally No Check the defective device Refer to P 54B 11 Trouble Symptom Chart Yes Replace the ETACS ECU Inspection Procedure E 3 Keyless entry system The encrypted code cannot be registered Probable cause The ETACS ECU actives the encrypted...

Page 858: ... speed wiper switch D Windshield high speed wiper switch NG Check the defective input circuit Refer to P 54B 13 DefectsFound by Input Signal Check OK Check the windshield wiper motor Refer to GROUP 51 Wind shield Wiper and Washer NG Replace OK Check the installation of the windshield wiper motor to the vehicle body NG OK Measure at front ECU connector A 38X D Disconnect connector and measure at re...

Page 859: ...heck the harness wire between windshield wiper motor and front ECU NG Repair Inspection Procedure F 3 Windshield wiper and washer Windshield wiper does not stop at the predetermined park position Probable cause The windshield wiper motor or the front ECU may be defective D Malfunction of windshield wiper motor D Malfunction of front ECU D Malfunction of harness wire or connector Check the windshie...

Page 860: ...shield washer motor the column switch or the front ECU may be defective D Malfunction of windshield washer motor D Malfunction of column switch D Malfunction of front ECU D Malfunction of harness wire or connector Is the windshield wiper operated normally No Check the windshield wiper Refer to P 54B 11 Trouble Symptom Chart Yes MUT II input signal check D Windshield washer switch NG Check the wind...

Page 861: ... Washer NG Replace OK Measure at rear wiper motor connector F 05 D Disconnect connector and measure at harness side D Continuity between terminal 1 and body earth OK Continuity NG Check the following connector F 05 NG Repair OK Check trouble symptoms NG Check the harness wire between rear wiper motor and body earth NG Repair OK Check trouble symptoms OK Replace the front ECU OK Check the following...

Page 862: ...ocedure G 4 Rear wiper and washer Rear washer does not work Probable cause The rear washer motor the column switch or the ETACS ECU may be defective D Malfunction of rear washer motor D Malfunction of column switch D Malfunction of ETACS ECU D Malfunction of harness wire or connector Is the rear wiper operated normally No Check the rear wiper Refer to P 54B 12 Trouble Symptom Chart Yes MUT II inpu...

Page 863: ... Check the headlamp washer switch circuit Refer to P 54B 13 Inspection Procedure N 13 OK Check the headlamp washier motor Refer to GROUP 51 Head lamp Washer NG Replace OK Measure at headlamp washer motor connector A 21 D Disconnect connector and measure at harness side D Continuity between terminal 2 and body earth OK Continuity NG Check the following connector A 21 OK Check trouble symptoms NG Re...

Page 864: ...p switch NG Check the tail lamp switch input circuit Refer to P 54B 45 Inspec tion Procedure N 14 Inspection Procedure I 2 Headlamp tail lamp Headlamps low beam do not illuminate Probable cause The column switch or the front ECU may be defective D Malfunction of column switch D Malfunction of front ECU D Malfunction of harness wire or connector NOTE If only one of the headlamps low beam does not i...

Page 865: ...it Refer to P 54B 29 In spection Procedure I 2 Yes MUT II input signal check D Dimmer switch NG Check the dimmer switch input circuit Refer to P 54B 45 Inspec tion Procedure N 14 Inspection Procedure I 4 Headlamp tail lamp Headlamps do not illuminate when the passing switch is operated Probable cause If the headlamps low beam and high beam are defective the column switch or the front ECU is suspec...

Page 866: ...o the Diagnosis Code Chart on P 54B 7 Inspection Procedure I 6 Headlamp tail lamp Headlamps dimmer switch auto reset function does not work normally Probable cause The headlamp dimmer switch auto reset function is controlled by the front ECU If a defect appears the front ECU may be defective D Malfunction of front ECU Replace the front ECU Inspection Procedure I 7 Headlamp tail lamp Daytime runnin...

Page 867: ...lamp does not flash the harness wire between the lamp and ETACS ECU may be defective or the lamp bulb may be burned out In this case check the turn signal lamp and hazard warning lamp circuit Is the hazard warning lamp operated normally Yes MUT II input signal check D Ignition switch IG1 D Turn signal lamp switch No Measure at ETACS ECU connector C 82 D Disconnect connector and measure at J B side...

Page 868: ... lamp does not flash the harness wire between the lamp and ETACS ECU may be defective or the lamp bulb may be burned out In this case check the turn signal lamp and hazard warning lamp circuit OK Replace the ETACS ECU Is the turn signal lamp operated normally No Check the turn signal lamp circuit Refer to P 54B 32 Inspection Procedure J 1 Yes Do all of the following functions operate when the igni...

Page 869: ...P 54B 39 Inspection Procedure N 5 OK Check the front fog lamp relay Refer to GROUP 54A Headlamp Font Turn signal Lamp and Front Fog Lamp NG Replace OK Measure at front fog lamp relay connector A 40X D Disconnect connector and measure at relay box side D Voltage between terminal 3 and body earth OK System voltage D Voltage between terminal 4 and body earth OK System voltage NG Check the following c...

Page 870: ...rear fog lamp relay connector C 86 D Disconnect connector and measure at relay box side D Voltage between terminal 3 and body earth OK System voltage D Voltage between terminal 5 and body earth OK System voltage NG Check the following connectors C 76 C 77 C 86 OK Check trouble symptoms NG Repair NG Check the harness wire between rear lamp relay and battery OK Check the following connectors C 83 C ...

Page 871: ...ly circuit or the ETACS ECU may be defective D Malfunction of room lamp D Malfunction of ETACS ECU D Malfunction of harness wire or connector Does the room lamp turn on when the room lamp switch is set to the ON position Yes Check the following connectors C 73 C 82 D 07 OK Check trouble symptoms NG Repair NG Check the harness wire between room lamp and ETACS ECU OK Replace the ETACS ECU No Measure...

Page 872: ... Check the ETACS ECU battery circuit Refer to P 54B 47 Inspec tion Procedure O 1 OK MUT II input signal check D Ignition switch IG1 D Key reminder switch D Driver s door switch D Door switches D Driver s door lock actuator switch vehicles with keyless entry system NG Check the defective input circuit Refer to P 54B 13 DefectsFound by Input Signal Check Inspection Procedure N 1 Ignition switch ACC ...

Page 873: ...edure N 3 Key reminder switch signal is not sent to the ETACS ECU Probable cause The key reminder switch input signal is used to operate the following devices If the signal fails these devices will not work normally D Forgotten key prevention function Vehicles with keyless entry system D Keyless entry system Vehicles with keyless entry system D Room lamp dimming function D Malfunction of key remin...

Page 874: ... Check the following connectors C 08 C 83 OK Check trouble symptoms NG Repair NG Check the harness wire between hazard warning lamp switch and ETACS ECU NG Repair OK Replace the ETACS ECU Inspection Procedure N 5 Front fog lamp switch signal is not sent to the ETACS ECU Probable cause The front fog lamp switch input signal is used to operate the front fog lamp If the signal fails front fog lamp wi...

Page 875: ...h and ETACS ECU NG Repair OK Replace the ETACS ECU Inspection Procedure N 7 Back up lamp switch signal is not sent to the ETACS ECU M T Probable cause The back up lamp switch input signal is used to operate the rear wiper If the signal is an error the rear wiper will not operate consecutively twice when the rear wiper is on and the shift lever is moved to R position D Malfunction of back up lamp s...

Page 876: ... 02 C 39 C 83 D 02 OK Check trouble symptoms NG Repair NG Check the harness wire between inhibitor switch and ETACS ECU NG Repair OK Replace the ETACS ECU Inspection Procedure N 9 Rear wiper motor auto stop signal is not sent to the ETACS ECU Probable cause Rear wiper motor auto stop signal is used to operate the rear wiper If the signal is an error the rear wiper will not stop at the predetermine...

Page 877: ...s wire or connector Driver s and passenger s door switch Check the driver s or passenger s door switch Refer to GROUP 42 Door NG Replace OK Check the installation of the driver s side or passenger s door switch to the vehicle body NG Repair OK Check the following connectors Left door switch C 68 C 82 D 27 Right door switch C 68 C 82 D 05 NG Repair OK Check trouble symptoms NG Check the harness wir...

Page 878: ...epair NG Repair OK Check trouble symptoms OK Check trouble symptoms NG Check the harness wire between passenger s door lock key cylin der switch and body earth Inspection Procedure N 12 Back door lock key cylinder switch signal is not sent to the ETACS ECU Probable cause The back door lock key cylinder switch is used to operate the central door locking system If the signal fails central door locki...

Page 879: ...he driver s door lock actuator switch Refer to GROUP 42 Door NG Replace OK Check the following connectors L H drive vehicles C 45 C 84 E 17 R H drive vehicles C 21 C 84 E 06 NG Check the harness wire between driver s door lock actuator and ETACS ECU NG Repair OK Replace the ETACS ECU OK Measure at driver s door lock actuator connector E 17 L H drive vehicles or E 06 R H drive vehicles D Disconnect...

Page 880: ...l fails these systems or function will not work normally D Light reminder warning function D Windshield wiper and washer D Rear wiper and washer D Headlamp washer vehicles with headlamp washer D Headlamp tail lamp D Turn signal lamp D Front fog lamp vehicles with front fog lamp D Rear fog lamp D Malfunction of column switch D Malfunction of ETACS ECU No Replace the column switch or ETACS ECU Is a ...

Page 881: ...inal 1 and body earth OK System voltage 2 Continuity between terminal 5 and body earth OK Continuity 1 NG Check the following connectors L H drive vehicles C 45 C 71 C 74 E 10 R H drive vehicles C 21 C 71 C 74 E 10 OK Check trouble symptoms NG Repair NG Check the harness wire between power window main switch and power window relay OK Replace the power window main switch 2 NG Check the following co...

Page 882: ...r display and ETACS ECU NG Repair Inspection Procedure O 1 Check the circuit power supply line from the battery to the ETACS ECU Probable cause If that power supply circuit is defective the circuit flowing trough the ignition switch IG1 will function as a back up circuit In this case the following functions will not work when the ignition switch is at LOCK OFF position D Light reminder alarm funct...

Page 883: ...NOTES ...

Page 884: ... service personnel from inadvertent firing of the air bag or to the driver and passenger from rendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP 52B Supplemental Restraint System SRS before beginning an...

Page 885: ...k 17 Idle up Operation Check 18 HEATER CONTROL ASSEMBLY AND A C SWITCH 19 HEATER UNIT BLOWER UNIT RESISTER AND EVAPORATOR 22 BLOWER MOTOR ASSEMBLY AND INSIDE OUTSIDE AIR CHANGEOVER DAMPER MOTOR 25 COMPRESSOR AND TENSION PULLEY 26 CONDENSER AND CONDENSER FAN MOTOR 30 REFRIGERANT LINE 32 VENTILATORS 34 ...

Page 886: ...d temperatures that it tends to freeze anything it contacts For this reason extreme care must be taken to prevent any liquid refrigerant from contacting the skin and especially the eyes Always wear safety goggles when servicing the refrigeration part of the A C system Keep a bottle of sterile mineral oil handy when working on the refrigeration system Should any liquid refrigerant get into the eyes...

Page 887: ...oad 800 50 Resistor for blower motor Ω LO 2 3 ML 1 0 MH 0 3 Air gap Magnetic clutch 0 25 0 55 LUBRICANTS Items Specified lubricants Quantity Each connection of refrigerant line ZXL 200PG As required Compressor refrigerant unit lubricant mȏ ZXL 200PG 130 170 KC 50AG 160 200 KC 50G SPECIAL TOOLS Tool Number Name Use MB991367 Special spanner Removal and installation of armature mounting nut of compre...

Page 888: ...witch as sembly 55 21 Air thermosensor is defective Replace the air thermosensor 55 22 Engine ECU is defective Replace the engine ECU When the A C is operating tem perature inside Refrigerant leak Replenish the refrigerant and repair the leak 55 16 perature inside the passenger compartment Dual pressure switch is defective Replace the dual pressure switch 55 32 compartment doesn t decrease cool ai...

Page 889: ...an or ra diator fan does Harness or connector is defective Repair the harness or connector diator fan does not turn Condenser fan motor is defective Replace the condenser fan motor 55 30 Radiator fan motor is defective Replace the radiator fan motor GROUP14 Radiator Engine ECU is defective Replace the engine ECU Inside and out side changeover Harness or connector is defective Repair the harness or...

Page 890: ...mpressor relay OFF 0 V 22 2 A C compressor relay ON System voltage 45 A C switch input A C switch OFF 0 V A C switch ON System voltage 73 1 2 Air thermosensor earth Air thermosensor detection temperature 25_C 2 0 2 9 V 73 77 2 Air thermosensor earth Air thermosensor detection tem erature 25 C 2 0 2 9 V 92 Air thermosensor input Always 0 V NOTE 1 Vehicles with immobilizer 2 Vehicles without immobil...

Page 891: ...0 Turn on the A C switch and set the A C control to MAX COOL 11 Set the air outlet changeover to FACE mode and the inside air outside air changeover to the inside air recirculation mode 12 Adjust the engine speed to 1 500 r min 13 Check if the outside air temperature and air temperature blown out of FACE duct and the outside air temperature and refrigerant pressure high pressure and low pressure s...

Page 892: ... is restricted Replace the receiver drier COMPRESSOR DRIVE BELT ADJUSTMENT Refer to GROUP 11 On vehicle Service DUAL PRESSURE SWITCH CHECK 1 Remove the dual pressure switch connector and connect the high low pressure side terminals located on the harness side as shown in the illustration 2 Install a gauge manifold to the high pressure side service valve of the refrigerant line Refer to Performance...

Page 893: ... ensure that there are no bends in the hose 5 Close the high and low pressure valves of the gauge manifold 6 Install the vacuum pump adaptor to the vacuum pump 7 Connect the vacuum pump plug to the vacuum pump adaptor 8 Connect the charging hose yellow to the R 134a connection port of the vacuum pump adaptor 9 Tighten the adaptor valve handle valve open 10 Open the low pressure valve of the gauge ...

Page 894: ...d install the service can 18 Tighten the handle of the charging valve valve closed to puncture the service can 19 Turn the handle of the charging valve back valve open and tighten the handle of the adaptor valve valve open to charge the system with refrigerant Caution If the service can is inverted liquid refrigerant may be drawn into the compressor damaging it by liquid compression Keep the servi...

Page 895: ...g valve and adaptor valve closed for the next charging CORRECTING LOW REFRIGERANT LEVEL IN CASE THE SERVICE CAN IS USED 1 Install the charge valve with the handle turned all the way back valve open to the service can 2 Install the adaptor valve with the handle turned all the way back valve close to the charging valve 3 Connect the charging hose blue to the adaptor valve 4 Connect the charging hose...

Page 896: ...f 1 200 1 500 r min for approximately 5 minutes with the A C operating to return to the oil NOTE Returning the oil will be more effective if it is done while driving 2 Stop the engine 3 Connect the charging hose blue to the adaptor valve with its handle turned back all the way valve closed 4 Connect the quick joint to the charging hose blue 5 Install the quick joint to the low pressure service val...

Page 897: ...and low pressure valve of the gauge manifold 3 Connect the charging hose blue to the low pressure valve and connect the charging hose red to the high pressure valve of the gauge manifold 4 Install the quick joint for low pressure to the charging hose blue and connect the quick joint for high pressure to the charging hose red 5 Connect the quick joint for low pressure to the low pressure service va...

Page 898: ...ed 9 Engine should be warmed up with doors and windows closed 10 Insert a thermometer in the center A C outlet and operate the engine for 20 minutes 11 Note the discharge air temperature NOTE If the clutch cycles take the reading before the clutch disengages Performance Temperature Chart Garage ambient temperature _C 20 25 35 40 Discharge air temperature _C 2 5 4 5 2 5 4 5 4 0 6 5 6 5 9 0 Compress...

Page 899: ...ble 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 refrigerant The flexible hose lines should be routed so that they are at least 80 mm from the exhaust manifold It is good practice to inspect all flexible hose lines at least once a year to make sure they are in good condition and properly routed Unified plumbing connecti...

Page 900: ...le Service 55 17 POWER RELAY CHECK BLOWER RELAY Battery voltage Terminal No y g 1 3 2 5 Power is not supplied Power is supplied A C COMPRESSOR RELAY Battery voltage Terminal No y g 1 3 4 5 Power is not supplied Power is supplied FAN CONTROL RELAY Refer to GROUP 14 Radiator Blower relay A C compressor relay ...

Page 901: ... the idling speed is the standard value Standard value 600 50 r min 3 When the A C is running after turning the A C switch to ON and the blower switch to the MH or HI position check to be sure that the idle speed is at the standard value Standard value A C at low load 700 50 r min A C at high load 800 50 r min NOTE There is no necessity to make an adjustment because the idling speed is automatical...

Page 902: ...LLATION SERVICE POINTS AA AIR OUTLET CHANGEOVER DAMPER CABLE CONNECTION 1 Set the air outlet changeover control knob on the heater control assembly to the DEF position 2 Set the air outlet changeover damper lever of the heater unit to the DEF position turn clockwise the damper lever unit it stops and then connect the cable to the lever BA AIR MIX DAMPER CABLE CONNECTION 1 Set the temperature contr...

Page 903: ...Y CHECK Switch position Terminal No 1 2 3 4 5 6 OFF D LO D ML D MH D HI INSIDE OUTSIDE AIR CHANGEOVER SWITCH CONTINUITY CHECK Switch iti Terminal No position 1 2 3 IND 4 8 9 RECIRC FRESH ILL A C SWITCH CONTINUITY CHECK Switch position Terminal No 5 IND 6 7 8 9 OFF ON ILL Inside outside air changeover switch A C switch ...

Page 904: ...3 Air outlet changeover damper cable AA 4 Air mix damper cable 5 Heater control panel 6 Blower switch assembly DISASSEMBLY SERVICE POINT AA AIR OUTLET CHANGEOVER DAMPER CABLE AIR MIX DAMPER CABLE REMOVAL Insert a flat tipped screwdriver into the control base clip from inner side and then remove the cable by lifting the claw part of the clip Claw part Flat tipped screwdriver ...

Page 905: ...Refer to GROUP 11 Engine Assembly D Air Cleaner Assembly Removal and Installation D Front Scuff Plate Rear Scuff Plate Cowl Side Trim and Glove Box Removal and Installation Refer to GROUP 52A Trims D Front Seat Assembly Driver s side Removal and Installation Refer to GROUP 52A Seat D Shift Lever Assembly Removal and Installation Refer to GROUP 22 Transmission Control M T D Selector Lever Assembly ...

Page 906: ...er unit assembly Evaporator and Resister removal steps D Discharging and Charging of Re frigerant Refer to P 55 10 D Engine Cover Refer to GROUP 11 Engine Assembly D Air Cleaner D Glove Box Refer to GROUP 52A Instrument Panel 11 Joint duct 12 Resistor 13 Cover 14 Foot duct 8 Refrigerant line connection 15 Expansion valve 16 Joint 17 Evaporator 18 Air thermosensor ...

Page 907: ...tandard value Ω Between terminals 1 and 3 LO 2 3 Between terminals 1 and 6 ML 1 0 Between terminals 1 and 4 MH 0 3 DISASSEMBLY AND REASSEMBLY 2 3 1 4 5 6 7 Disassembly steps 1 Cover 2 Heater core 3 Expansion valve 4 Joint 5 Cover 6 Evaporator 7 Air thermosensor INSPECTION AIR THERMOSENSOR CHECK Measure the resistance between terminals under two or more temperature conditions The resistance should ...

Page 908: ...OVAL AND INSTALLATION 1 Blower motor assembly removal steps 1 Under cover 2 Blower motor assembly Inside outside air changeover damper motor removal steps 3 Instrument panel Refer to GROUP 52A 4 Inside outside air changeover damper motor INSPECTION BLOWER MOTOR CHECK When battery voltage is applied between the terminals check that the motor operates Also check that there is no abnormal noise ...

Page 909: ...r position COMPRESSOR AND TENSION PULLEY REMOVAL AND INSTALLATION Pre removal Operation Discharging of Refrigerant Refer to P 55 13 Post installation Operation D Charging of Refrigerant Refer to P 55 10 D Drive Belt Tension Adjustment Refer to GROUP 11 On vehicle Service 1 4 3 3 4 25 Nm 2 5 Piping connection Compressor oil ZXL 200PG OĆring Removal steps D Washer tank Refer to GROUP 51 1 Drive belt...

Page 910: ...ompressor is installed first adjust the amount of oil according to the procedures described below and then install the compressor 1 Measure the amount X mȏ of oil within the removed compressor 2 Drain from the new compressor the amount of oil calculated according to the following formula and then install the new compressor New compressor oil amount KC 50AG 150 mȏ X mȏ Y mȏ KC 50G 180 mȏ X mȏ Y mȏ ...

Page 911: ...nd earth the battery terminal to the body of the compressor The condition is normal if the sound of the magnetic clutch click can be heard MAGNETIC CLUTCH DISASSEMBLY AND REASSEMBLY 1 2 3 4 5 6 Magnetic clutch disassembly steps BA D Air gap adjustment AA 1 Armature plate 2 Shims AA 3 Snap ring 4 Rotor 5 Snap ring 6 Clutch coil DISASSEMBLY SERVICE POINT AA ARMATURE PLATE REMOVAL MB991386 MB991367 ...

Page 912: ... that the tapered surface is at the outer side BA AIR GAP ADJUSTMENT Check whether or not the air gap of the clutch is within the standard value Standard value 0 25 0 55 mm NOTE If there is a deviation of the air gap from the standard value make the necessary adjustment by adjusting the number of shims Field core Rotor Snap ring Tapered part AV1079AE ...

Page 913: ...teps D Discharging and charging of refrigerant Refer to P 55 10 D Radiator grille Refer to GROUP 51 AA 1 Receiver 2 Receiver bracket 3 Air intake duct 4 Fan motor and shroud assembly 8 Radiator fan motor and shroud as sembly Refer to GROUP 14 9 Condense tank AA 10 Discharge hose connection 11 Radiator mounting bolt D Engine cover Refer to GROUP 11A AB 12 Condenser assembly Condenser fan and motor ...

Page 914: ...nd the receiver absorb water vapour easily AB CONDENSER ASSEMBLY REMOVAL 1 Remove the mounting bolts from the front side of the headlamp support member 2 Disengage the lower part of the radiator and then move the radiator slightly toward the engine 3 Raise the condenser assembly to remove from the engine compartment INSTALLATION SERVICE POINT AA RECEIVER INSTALLATION Install the pipe coming from t...

Page 915: ... L H DRIVE VEHICLES Pre removal and Post installation Operation D Discharging and Charging of Refrigerant Refer to P 55 10 D Engine Cover Removal and Installation Refer to GROUP 11 Engine Assembly D Air Cleaner Assembly Removal and Installation Compressor oil ZXL 200PG 3 4 5 Piping connection OĆring 1 2 ...

Page 916: ...A 2 Suction hose AA 3 Discharge hose 4 Liquid pipe AA 5 Dual pressure switch REMOVAL SERVICE POINT AA HOSE PIPE DISCONNECTION Plug the nipples of the disconnected hose receiver evaporator and compressor to prevent foreign materials from entering Caution Plug the nipples with material that is not permeable to air as compressor oil and the receiver absorb water vapour easily ...

Page 917: ...sembly Refer to GROUP 52A D Front seat Refer to GROUP 52A D Floor carpet 1 Under cover 2 Rear heater duct B Defroster nozzle and distribution duct removal steps D Instrument panel Refer to GROUP 52A 3 Defroster nozzle assembly 4 Distribution duct assembly Foot distribution duct and rear heater duct A removal steps D Floor console assembly Refer to GROUP 52A D Instrument panel assembly Refer to GRO...

Page 918: ... Ventilators 55 35 7 8 9 7 Rear ventilation garnish 8 Rear ventilation duct A Rear vent duct removal steps D Rear bumper Refer to GROUP 51 9 Rear ventilation duct NOTE For the front deck garnish refer to GROUP 51 Windshield Wiper and Washer ...

Page 919: ...NOTES ...

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