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Mitsubishi 1992 3000GT, Руководство по обслуживанию

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Mitsubishi 1992 3000GT Скачать руководство пользователя страница 976

STEERING   Steering Wheel and Shaft

DISASSEMBLY AND REASSEMBLY

18 Nm

2

Disassembly steps

1. Boot

2. Cover assembly

 3. Bearing

4. Joint assembly

Steering lock cylinder

00002169

 5. Special bolts

 

 6. Steering lock bracket

 

 7. Steering lock cylinder

8. Steering column assembly

TSB Revision

DISASSEMBLY SERVICE POINT

 LOCK BRACKET   STEERING LOCK

CYLINDER REMOVAL

If it is necessary to remove the steering lock cylinder, use

a hacksaw to cut the special bolts at the steering lock bracket
side.

Содержание 1992 3000GT

Страница 1: ......

Страница 2: ......

Страница 3: ...hi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products...

Страница 4: ...ying after painting remove the SRS components air bag module SRS diagnosis unit front impact sensors beforehand 3 Service or maintenance of any SRS component or SRS related component must be performed...

Страница 5: ...ft Boots 52 Engine Coolant 51 Engine Oil 47 Engine Oil Filter 48 Evaporative Emission Control System 46 Exhaust System 60 Fuel Hoses 45 Fuel System Tank Pipe Line Connections and Fuel Tank Filler Tube...

Страница 6: ...FERENCE VALUE Indicates the adjustment value prior to starting the work presented in order to facilitate assembly and adjustment procedures and so they can be com pleted in a shorter time CAUTION Indi...

Страница 7: ...nit is indicated by sym bols output r input Input output Indicates a connector The broken line inc cates the same connec tor The connector symbol indicates the device side connector for an intermediat...

Страница 8: ...s Omitted if The part designation number corresponds to the reassembly is possible in reverse order of disas number in the illustration to indicate disassembly sembly steps steps Classifications of Ma...

Страница 9: ...andgfWboXcwnsctingbog 2 s mid v e OLxIlieEmr VeNc es wiU EPS 2 EenthenutbutdonatremoveK l FOG lJGl l RELAY coNnNulTY CHECX 0 0 indicates that there is continuity between the termi nals 0 0 indicates t...

Страница 10: ...usDfv At wnes 2 45 2 55v 15 RdrigQsm rapanue SmsoOr 1 SaM Pm temosmun 2 77 I 0 1511 4 k y se c i nonnaOFF BOD 16 passewm w SmawPmtarmaM 25 f77 F Iv tsv NR 4ko I 1 7 p t I smxmtampcrmrre2 whmarc mdlt a...

Страница 11: ...es for each trouble symptom will be found by means of this chart INSPECTION PROCEDURE FOR DIAGNOSTIC SYMPTOM Indicates the inspection procedures corresponding to each trouble symptoms classified in th...

Страница 12: ...aution If resistance and continuity checks are performed on the wrong terminals damage to the vehicle wiring sensors ECU and or ohmmeter may occur Use care to prevent this 4 If the ohmmeter shows any...

Страница 13: ...condition at each connector terminal Check trouble symptom Refer to Connector Inspection Service Points The connector position can be located in the wiring diagram in Vol _ ume 2 manual by means of t...

Страница 14: ...arts of that circuit s Be sure to use the inspection proce dures provided for diagnostic trouble codes and trouble symptoms For temperature and or moisture conditions re lated intermittent malfunction...

Страница 15: ...Others Line X 1992 models Driver Air Bag Passenger B 1993 models Manual Seat Belt A From 1994 Driver and Passenger Air models 1 Bag 1 D 3000GTFWD 11992 models Price class Convertible models W 3000GT...

Страница 16: ...MRXML7M JA3BM64JClPY 1993 model ZllAMNPML7M JA3XD64BElNY 1992 model Zl lAMRPML7M JA3BN74KOPY 1993 model JA3XE74CClNY 1992 model Mitsubishi 3000GT 3 0 dm3 181 4 cu in Z15AMNGFL7M AWD DOHC MFI Turbo ZlG...

Страница 17: ...Mitsubishi 3000GT AWD i 1 Engine displacement Hatch back 3 0 dm3 181 4 cu in DOHC MFI Con vertible 3 0 dm3 181 4 cuin DOHC MFI Turbo Con vertible T Models code ZllAMNPML7M ZllAMRPML7M VEHICLE INFORMA...

Страница 18: ...y certification label is attached to the face of left door pillar 2 This label indicates the month and year of manufacture Gross Vehicle Weight Rating G V W R and Gross Axle Weight Rating G A W R fron...

Страница 19: ...abel is attached to replacement parts for the body outer panel main components and the same data are stamped into replacement parts for the engine and the transaxle OOK621 00002280 Cautions regarding...

Страница 20: ...axle ZOOFOOS3 ZOOFOO16 Manual transaxle cF5M33 Manual transaxle cW SMGl Up to 1993 models cWGMGl From 1994 models Fender Door 231FOO70 the illustration indicates left hand side outer Right hand side i...

Страница 21: ...tached to the inner side of the part shown in the illustration The illustration indicates left hand side outer Right hand side is symmetrically opposite Liftgate 3ear bumper Target area A for original...

Страница 22: ...ations H o o d 0 Sun visor l Glove box l SRS diagnosis unit l Steering wheel l Air bag module l Clock spring l Steering gear and linkage clamp 6 Store components removed from the SRS in a clean and dr...

Страница 23: ...egative terminal is connected warm up the engine and allow it to idle for approximately ten minutes under the conditions described below in order to stabilize the engine control conditions and then ch...

Страница 24: ...connection of the scan tool should always be made with the ignition switch in the OFF position 2 Always use a ROM pack that is appropriate for the vehicle ROM Pack Applicable Model 1 1 MB991423 1 1992...

Страница 25: ...Manual transaxle vehicles may be towed on the front wheels provided the transaxle is in neutral and the drive line has not been damaged The steering wheel must be clamped in the straight ahead positio...

Страница 26: ...stands 4 Never allow passengers to ride in a towed vehicle 5 State and local rules and regulations must be followed when towing a vehicle AWD Caution 1 If only the front wheels or only the rear wheel...

Страница 27: ...Under the mid point of No 1 crossmember NOTE On vehicles with active aero system the front jacking point can be accessed by removing the center cover panel from the under cover Be sure to reinstall t...

Страница 28: ...ns Approximate center of gravity Frame contact hoist twin post hoist or scissors jack emergency locati s EMERGENCY JACKING Jack receptacles are located at the body sills to accept the scissors jack su...

Страница 29: ...force REAR WHEEL MEASUREMENTS After placing the rear wheels on the brake tester follow the same procedures as for the front wheel measurements WHEEL BALANCE FRONT WHEEL MEASUREMENTS 1 Jack up the rea...

Страница 30: ...ions GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS ZOOFOO15 I NOTE l 1 1992 model 3 4ws l 5 1995 model Hatchback l 2 l 7 1993 1996 model model 4 1994 model Hatchback l 6 1995 model Convertibl...

Страница 31: ...d manual W6MGl 2 6 speed manual Fuel system Model No Type Automatic transaxle Fuel supply system F4A33 4 speed automatic Multiport fuel injection system cMFI system F4A33 4 speed automatic Multiport f...

Страница 32: ...e used Standard bolt and nut tightening torque Bolt nominal diameter mm Pitch mm Head mark 4 Torque Nm ft lbs Head mark 7 Head mark 8 1 2 5 1 8 1 4 9 3 6 1 0 4 9 3 6 8 8 6 5 9 8 7 2 M8 1 25 12 8 7 22...

Страница 33: ...t crank Starting system faulty 16 19 or cranks slowly ENGINE WILL NOT START OR HARD TO START CRANKS OK Symptom Engine will not start or hard to start Cranks OK Probable cause No fuel supply to injecto...

Страница 34: ...30 GENERAL Master Troubleshooting ROUGH IDLE OR ENGINE STALLS rative emission purge control valve ENGINE HESITATES OR POOR ACCELERATION vaporative emission purge control valve l Vacuum hoses TSB Revis...

Страница 35: ...orn or damaged POOR FUEL MILEAGE Symptom Probable cause Poor fuel mileage Fuel leak Reference page or remedy Repair as necessary 17 56 Repair as necessary Repair as necessary Repair as necessary Refer...

Страница 36: ...cessively tightened steering gear box rack support cover 37A 20 Improper front wheel alignment 33A 6 Excessive turning resistance of tie rod ball joint 37A 7 Sticky flow control valve 37A 30 Bent rack...

Страница 37: ...33A 10 ABNORMAL TIRE WEAR Symptom Probable cause Reference page Abnormal tire wear Improper front or rear wheel alignment 33A 6 34 5 25 Improper tire pressure 31 3 lmbalanced wheels c Loose wheel bear...

Страница 38: ...turning resistance of lower arm ball 33A 11 joint Wheel bearing seizure Replace Broken or worn coil spring 33A 7 Bent front or rear axle drive shaft 26 12 Deformed lower arm 33A 10 STEERING WHEEL SHI...

Страница 39: ...on results from grease deteriora tion which causes particles of pigment contained in grease to adhere to surfaces Heat discoloration will appear as a deep brown or purple Probable cause Excessive bear...

Страница 40: ...assification SH ECII SH CD ECII SG ECII or SGKD EC11 For further details refer to LUBRICANTS SELECTION section Caution Test results submitted to EPA have shown that laboratory animals develop skin can...

Страница 41: ...mixture of 10 ethanol grain alcohol and 90 unleaded gasoline may be used in your car If driveability problems are experienced as a result of using gasohol it is recommended that the car be operated on...

Страница 42: ...Description Metric measure U S measure Engine oil Crankcase 4 0 dm3 4 2 qts Oil filter 0 3 dm3 32 qt Oil cooler Turbo 0 3 dm3 32 qt Total Non Turbo 4 3 dm3 4 5 qts Total Turbo 4 6 dms 4 9 qts Cooling...

Страница 43: ...are not available an API classification SH ECII SH CD ECII SG EC11 or SG CD EC11 can be used Oil Viscosity The SAE grade number indicates the viscosity of the oil A proper SAE grade number should be s...

Страница 44: ...erating temperature is 15 C 5 F when the measured specific gravity is 1 058 at the coolant temperature of 20 C 68 F Caution 1 If the concentration of the coolant is below 30 the anti corrosion propert...

Страница 45: ...Fuel hoses Air cleaner element Evaporative emission con trol system except evapo rative emission canister Sparks plugs Ignition cables Service to be Kilometers in thousands 24 48 72 96 120 144 168 per...

Страница 46: ...The maintenance items should be performed according to the following table VO 3 5 9 10 t 14 t 1Mileage intervals kilometers in thousands Miles in thousands Severe usage conditions Maintenance Service...

Страница 47: ...ace except platinum plugs X X X platinum plugs only X Replace Every 5 years or X Ignition cables NOTE I Except for Federal i GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE 10 General maint...

Страница 48: ...ands No Maintenance Service to be Miles in thousands Severe usage conditions Item performed ii i 60 75 90 105 96 120 144 168 A B c 1 I 3 Air cleaner Replace at element x x x x x x xx 5 Spark plugs Rep...

Страница 49: ...eplace it with a new one Non Turbo 1 Disconnect the volume air flow sensor connector 2 Remove the air intake hose from the volume air flow sen sor 3 Unclamp the air cleaner cover 4 Remove the air clea...

Страница 50: ...e properly to assure proper engine performance and emission control Therefore they should be replaced periodically with new ones Spark plug NGK PFRGJ 11 NIPPON DENS0 PK20PRPll Spark plug gap 1 0 1 1 m...

Страница 51: ...0 77 132 Deflection mm in 4 0 5 5 16 22 Reference value Tension N Ibs 250 500 55 l 10 Deflection mm in 9 5 13 5 37 53 Reference value Vehicle with air conditioning 1 Items I Specification I 1 For gene...

Страница 52: ...strongly recommended for use on this vehicle Oil Filter Part No MITSUBISHI Genuine Parts MD136790 or equivalent Any replacement oil filter should be installed in accordance with the oil filter manufac...

Страница 53: ...re reaches the usual temper ature 70 80 C 160 18O F 2 Place vehicle on level floor 3 Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid then p...

Страница 54: ...ence of contamination Replenish with new fluid after the cause of any contamination has been corrected 1 Remove drain plug at transaxle case bottom to let fluid drain 2 Place a drain container with la...

Страница 55: ...e the radiator cap to discharge coolant Remove the reservoir tank and discharge coolant When coolant has been discharged pour water through the filler port to flush coolant passage Coat the threads of...

Страница 56: ...aulty installation casing twisting or interference with wheel tire or chassis 17 BALL JOINT AND STEERING LINKAGE SEALS Inspect for grease leaks and damage 1 These components which are permanently lubr...

Страница 57: ...at the system is functioning properly 2 SRS COMPONENTS VISUAL CHECK 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 se...

Страница 58: ...ly if a front impact sensor is not installed properly which could result in serious injury or death to the vehicle s driver and passenger 3 Check wiring harness for front impact sensor for binds conne...

Страница 59: ...odels Ring gear Rotor Screw Caution label LJ Driver s side mote control b itch radio remote control switch To air bag module To cruis cvitch From 1994 models SRS diagnosis Ring gear Rotor Screw Flat c...

Страница 60: ...le from steering wheel Refer to GROUP 52Ei3 Air Bag Module and Clock Spring C a u t i o n When disconnecting the air bag module clock spring connector take care not to apply excessive force to it 2 Ch...

Страница 61: ...91 Conli From 1994 models Driver s side Inflator case Passenger s side 3 Check hooks and connectors for damage terminals defor mities and harness for binds 4 Check air bag inflator case for dents crac...

Страница 62: ...Check clock spring connectors and protective tube for damage and terminals for deformities 10 Visually check the clock spring case and the gears for damage 11 Align the mating mark and NEUTRAL positi...

Страница 63: ...he above components is not installed properly which could result in serious injury or death to the vehicle s driver and pas senger 2 4 Front Wiring Harness and Body Wiring Harness i L 236FOO19 1 Check...

Страница 64: ...ON OF MUFFLER PIPINGS AND CONVERTER HEAT SHIELDS Check and service as required d 1 Check for holes and gas leaks due to damage corrqsion etc 2 Check the joints and connections for looseness and gas le...

Страница 65: ...ded brand Sealing between tempered glass and weatherstrip Sealing between body flange and weatherstrip Sealing between laminated glass and weatherstrip 3M ATD Part No 8513 or equivalent 3M ATD Part No...

Страница 66: ...e 3M ATD Part No 8155 or equivalent ANAEROBIC FAST BONDING ADHESIVE Application Recommended brand Fixing of bolts and screws 3M Stud locking Part No 4170 or equivalent l Tightening of drive gear to di...

Страница 67: ...INE ASSEMBLY 18 TIMING BELT 31 ENGINE OIL COOLER m 36 TROUBLESHOOTING m 6 Li OIL PAN AND OIL SCREEN 23 ON VEHICLE SERVICE 7 Basic Idle Speed Adjustment Refer to GROUP 13A Compression Pressure Check 14...

Страница 68: ...e V type DOHC Number of cylinders 6 Bore mm in 91 l 3 587 Stroke mm in 76 0 2 992 Turbo V type DOHC 6 91 l 3 587 76 0 2 992 Piston displacement cc cu in 2 972 181 4 2 972 181 4 SERVICE SPECIFICATIONS...

Страница 69: ...or Vehicle without air Inspection 4 0 5 5 16 22 deflection conditioning mm in New belt 3 5 4 0 14 16 Reference value Used belt 4 0 5 0 l6 20 For generator and air conditioning Inspection 4 0 5 5 16 22...

Страница 70: ...before ser vice MB991 502 MB991502 All models Scan tool Idle speed check MUT II ROM pack MD998051 MD998051 01 Loosening and tightening of cylinder head bolt Cylinder head bolt wrench MD998727 General...

Страница 71: ...B MB990998 Used if the crankshaft needs to be rotated to at Q tach the timing belt etc when the piston and Crankshaft connecting rod assembly is assembled wrench SOHC Use only the large nut included i...

Страница 72: ...igh Noisy valves Oil relief valve stuck opened Excessive bearing clearance Oil relief valve stuck closed Incorrect lash adjuster Repair relief valve Replace bearings Repair relief valve Replace lash a...

Страница 73: ...midway between the pulleys as shown in the illustration check the belt tension for standard value Or apply a force of 98 N 22 Ibs to the belt to check the deflection for standard value Standard value...

Страница 74: ...ning 1 Use straight handle box wrench to loosen tension pulley fixing nut 2 Adjust belt deflection with adjusting bolt 3 Use straight handle box wrench to tighten fixing nut 4 Run the engine one time...

Страница 75: ...TE The engine speed indicated is a third of actual speed In other words the reading of the tachometer times 3 is actual speed 6 Turn OFF the ignition switch 7 Remove the water proof female connector f...

Страница 76: ...ion connector blue and connect a tachometer to the paper clip NOTE Do not use the scan tool If tested with the scan tool connected to the data link connector the ignition timing will not be the basic...

Страница 77: ...P ll 9 3 Set a timing light 4 Using a jumper wire ground the ignition timing adjusting terminal 5 Start the engine and let it idle 6 Check the ignition timing is the standard value if not adjust Stan...

Страница 78: ...the CO tester and HC tester 6 Check the CO concentration and HC concentration with the engine at idle Standard value CO concentration 0 5 or less HC concentration 100 ppm or less 7 If the standard va...

Страница 79: ...he data link connector white NOTE For the tachometer setting procedure refer to P ll 9 4 Start the engine 5 Open the throttle valve until the dashpot rod makes a full stroke 6 Close the throttle valve...

Страница 80: ...owel Caution 1 When you crank the engine keep away from the spark plug mounting holes 2 If a compression measurement is performed with wa ter oil fuel etc in the cylinder due to the cracks in the cyli...

Страница 81: ...ion of the crankshaft position sensor connector MANIFOLD VACUUM CHECK 1 The vehicle should be repaired as follows before the inspection l Engine coolant temperature 80 95 C 176 203 F l Lights electric...

Страница 82: ...conds and then decelerate it to the idling speed slowly in 30 seconds NOTE 1 When the vehicle is parked on a slope for a long period the oil in the lash adjuster will decrease When the engine is start...

Страница 83: ...shed down Therefore turn the crankshaft to keep the piston position down In addition the rocker arm located at the valve lifted by the cam cannot be removed Therefore turn the crankshaft to keep the c...

Страница 84: ...23 Transaxle Assembly l Front Exhaust Pipe Installation Refer to GROUP 15 Exhaust Pipe and Main Muffler l Air Hose and Air Pipe Turbo Installation Refer to GROUP 14 Charge Air Cooler l Hood Installati...

Страница 85: ...ensor connector 2 26 Engine coolant temperature switch connector Air conditioning 2 27 Engine coolant temperature sensor connector 28 Engine coolant temperature gauge unit connector 29 Condenser conne...

Страница 86: ...e mount bracket installation bolt use a chain block or similar arrangement to suspend the engine assembly to the extent that there is no looseness of the chain C ENGINE ASSEMBLY REMOVAL After checking...

Страница 87: ...installation Refer to GROUP 16 Cam Position Sensor and Crankshaft Position Sensor l Intake Manifold Installation Refer to GROUP 15 Intake Manifold l Timing Belt Installation Refer to P li 31 l Accele...

Страница 88: ...ATION SERVICE POINTS A CAMSHAFT OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the oil seal lip 2 Using the special tool insert the oil seal B CAMSHAFT SPROCKET INSTALLATION Using a wre...

Страница 89: ...pe Removal and Installation Refer to GROUP 15 Exhaust Pipe and Main Muffler l Transfer Assembly Removal and Installation cAWD Refer to GROUP 22 Transfer Assembly 19 Nm 1A fi Ihs w n l hs p I I 6 Nm A...

Страница 90: ..._ i _I i Q L zL0583 j 1 ri o o z REMOVAL SERVICE POINT dA OIL PAN REMOVAL After removing the bolts use the special tool and a brass bar to remove the oil pan from the cylinder block d Caution Remove t...

Страница 91: ...h a f t Eder Ypy s yp4 J G 1 Ah I Oil is I ZOlNOOld i A A g kshaft front oil seal REMOVAL SERVICE POINT dAbCRANKSHAFT FRONT OIL SEAL REMOVAL 1 Make a notch in the oil seal lip section with a knife etc...

Страница 92: ...eal Camshaft 73 77 Nm 53 56 ft lbs R E M O V A L S E R V I C E POINTS A FLYWHEEL REMOVAL Stop the crankshaft pulley from turning and remove the fly wheel Caution Use only the specified special tools o...

Страница 93: ...eal 11 27 INSTALLATION SERVICE POINT A CRANKSHAFT REAR OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the oil seal lip and then insert P I i 1 Oil s l ZOlM0031 2 Tap the oil seal into t...

Страница 94: ...Manifold Installation Refer to GROUP 15 Air Intake Manifold l Engine Coolant Supplying Refer to GROUP 00 Maintenance Service l Accelerator Cable Adjustment Refer to GROUP 13F Engine Control l Engine...

Страница 95: ...tion mark for the engine 2 Lay the cylinder head gasket on the cylinder block with the identification mark at the front top B CYLINDER HEAD ASSEMBLY INSTALLATION 1 Use a scraper to clean the gasket su...

Страница 96: ...LLATION Tighten the rocker cover bolts in the order shown in the illustra tion NOTE I Only No 5 bolt in the rear bank differs from other bolts in length Rear bank No 5 bolt 20 mm 79 in Except rear ban...

Страница 97: ...tion l Front Under Cover Panel Installation Vehicle with Active Aero l Cruise Control Link Assembly Installation Vehicle with Cruise Control Refer to GROUP 13G Cruise Control l Engine Adjustment Refer...

Страница 98: ...of rotation so it may be reassembled in the same direction if it is to be reused 3 Loosen the center bolt on the tensioner pulley to remove the timing belt Caution Water or oil on the belt shortens i...

Страница 99: ...ing marks on the camshaft sprockets for intake and exhaust valves are not within the range A in the illustration at left If the timing mark is within range A turn the camshaft sprocket to move the tim...

Страница 100: ...the tensioner pulley so that its pin holes are located above the center bolt Then press the tensioner pulley against the timing belt and at the same time temporarily tighten the center bolt 4 Check th...

Страница 101: ...are aligned properly Dl TIMING BELT LOWER COVER INSTALLATION Since the mounting bolts of timing cover are different in size depending on location insert them with care FE4 ENGINE SUPPORT BRACKET INSTA...

Страница 102: ...ine oil return hose 4W 4 Engine oil return tube 5 Engine oil cooler REMOVAL SERVICE POINTS dAbENGINE OIL FEED HOSE ENGINE OIL RETURN TUBE REMOVAL Caution Be sure to hold the weld nut of the oil cooler...

Страница 103: ...CONTROL TYPE CARBURETOR 13B CONVENTIONAL TYPE CARBURETOR 13c VARIABLE VENTURI TYPE CARBURETOR 13D DIESEL FUEL 13E FUEL SUPPLY 13F CRUISE CONTROL SYSTEM Refer to GROUP 17 TRACTION CONTROL SYSTEful t3l...

Страница 104: ...13 2...

Страница 105: ...268 240 270 279 200 279 211 211 247 263 264 229 230 Induction Control Valve Position Sensor 242 Injectors 257 Intake Air Temperature Sensor 215 Knock Sensor 237 Manifold Differential Pressure MDP Sen...

Страница 106: ...Turbocharger Waste Gate Solenoid 169 Variable Induction Control Motor DC Motor 174 Vehicle Speed Sensor Electrical Speedometer Type 119 Mechanical Speedometer Type 117 Volume Air Flow Sensor 85 ON VE...

Страница 107: ...r posItIon II Intake air temp sensor c From fuel tank w _ _ I 1 2 3 4k EVAP canister Electric load switch I i 6 7 8 module 27FU1323 NOTE 1 EVAP purge solenoid 2 lniector 3 ldie air control motor 4 Var...

Страница 108: ...valve position sensor Throttle position sensor Closed throttle position switch m lntake air temp sensor Volume air flow sensor Barometric pressure sensor m I 6 7 t Z7FU1325 NOTE 1 EVAP purge solenoid...

Страница 109: ...trol valve posrtron sensor I nrottle positron sensor Closed tnrottle poslkon swatch Intake arr temp sensor NOTE J Z7FU1462 1 f AP purge solenoid 2 Injector 3 EGR plnnni 4 mIII IY 4 Idle air control mo...

Страница 110: ...tion sensor _ Throttle position sensor Closed throttle cosition switch module NOTE l l EVAP purge solenoid 2 Injector 3 EGR solenoid 4 Idle air control motor 5 Variable induction contorl motor 6 Heate...

Страница 111: ...ntrol NOTE 1 injector 2 EGR solenoid 3 IAC motor 4 Fuel pressure solenoid 5 Evaporative emission purge solenoid 6 Turbocharger waste gate solenoid 7 AC compressor clutch relay 8 Fuel pump relay 9 Igni...

Страница 112: ...motet Engine ContrOl nlcd b 27FU1463 NOTE 1 Injector 2 EGR solenoid 3 Evaporative emission purge solenoid 4 IAC motor 5 Fuel pressure solenoid 6 Turbocharger waste gate solenoid 7 AK compressor clutch...

Страница 113: ...models EGR IAC motor ii Intake air temperature senso 1 1 1 1 C shaftposition sensor I FlW NC switch _ P S pressure switch c Vehicle speed sensqr _ T mohle lqnition coil Iqnition cower transistor e Ch...

Страница 114: ...SPECIFICATIONS GENERAL SPECIFICATIONS California Non Turbo emperature sensor c emiconductor type NOTE l l 1992 models l 2 1993 models 1 1994 and 1995 models E Except 1992 models From 1996 models Up t...

Страница 115: ...oid BDL360 Direct current motor type ON OFF type solenoid valve 4 Duty cycle type solenoid valve 5 EGR solenoid Duty cycle type solenoid valve California Non Turbo Turbo Federal Non Turbo From 1996 mo...

Страница 116: ...ERVICE SPECIFICATIONS e speed when air conditi gine coolant temperatu OTE Up to 1992 models 2 From 1993 models SEALANT Items Specified sealant Engine coolant temperature sensor threaded portion 3M NUT...

Страница 117: ...TIPORT FUEL INJECTION Special Tools SPECIAL TOOLS tester cMUT Reading diagnostic trouble code l MFI system inspection Test harness set Basic idle speed adjustment l Inspection by oscilloscop TSB Revis...

Страница 118: ...13A 14 MULTIPORT FUEL INJECTION Special Tools TSB Revision...

Страница 119: ...If the signals are normal judge the sensor input actuator control as normal and proceed to check the input output signals of the next check item 5 Inspection of MFI system component harness l If the e...

Страница 120: ...s for the particular connector is not available the use of the Test Harness Set MB991348 which can be connected directly between the terminals is recommended l When checking the terminal voltage with...

Страница 121: ...off the lamp goes out Even if the ignition switch is turned on again the lamp does not come on until the irregularity is detected Here immediately after the ignition switch is turned on the check eng...

Страница 122: ...13A 18 MULTIPORT FUEL INJECTION Troubleshooting ITEMS INDICATED BY THE CHECK ENGINE MALFUNCTION INDICATOR LAMP From 1996 models 2 sensor circuit malfunctio dle control system ma TSB Revision...

Страница 123: ...tch is turned on the lamp illuminates for about 5 seconds and then goes out 2 If the lamp does not illuminate check for open circuit in harness blown fuse and blown bulb ON BOARD DIAGNOSTIC Up to 1995...

Страница 124: ...also output when the ignition timing adjustment terminal is grounded to adjust the igni tion timing but this does not show any abnormality DIAGNOSTIC CHART FAULT TREE Code No Output signal pattern Di...

Страница 125: ...nmn If harness and connector are normal replace barometric L pressure sensor assembly v12Ao107 31 nnrLn Knock sensor l Harness and connector Retained If harness and connector are normal replace knock...

Страница 126: ...ss and connector I Retained omia model from 1994 lts z SenSor l Injectors Replace if defective s12Ao105 l Intake air leaks Acablefromtransaxlecontrolmod l Harness and connector Retained ule for transm...

Страница 127: ...eed is approx 1 900 2 200 r min l Vehicle is moving at constant speed on a flat level road surface Set Conditions The oxygen sensor output voltage does not cross specified voltage for specified second...

Страница 128: ...ck l Engine control module failed l Ignition switch ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts Set Conditions l Sensor output voltage is...

Страница 129: ...check l Ignition switch ON l Engine spped is approx 50 r min or more Set conditions l Ohe sensor output voltage increases from 1 6 V or less corresponding to an engine coolant temperature of 40 C 104...

Страница 130: ...50 r min or more supply 4 seconds Set conditions after a problem is detected After the Sensor output voltage does not change for 4 seconds no pulse signal input Range of check l Ignition switch ON l E...

Страница 131: ...ration of the cylinder block Switches the ignition l Open or shorted knock sensor into a voltage and outputs it If there is a malfunction of the timing from ignition tim circuit or loose connector kno...

Страница 132: ...at constant speed on a flat level road surface tput voltage does not cross specified voltage xygen sensor deteriorated pen or shorted oxygen l Incorrect fuel pressure l Injector failed l Engine contro...

Страница 133: ...ied out two times in succession a problem is detected after each operation Background l Ignition power transistor unit converts ON OFF variation of the ignition coil to the pulse signal Ignition signa...

Страница 134: ...after deceleration finished Set Conditions ntrol module failed heated oxygen sensor rear output voltage is 0 1 V or heated oxygen sensor front output voltage is 0 5 V or ve conditions continue for a c...

Страница 135: ...starting of the engine are carried out four times in succession a problem is detected after each operation Fault ID Title 69 cl994 and Right Bank Heated Oxygen Sensor ater Califor rear nia model Effe...

Страница 136: ...switch is set to OFF Camshaft position sensor 1 Fuel injected into the cylinders in the order l 2 3 4 5 6 with irregular timing Provided that no No 1 cylinder top dead center position has been detect...

Страница 137: ...stment is results can be read out with a scan tool grounded Moreover since memorization of the diagnostic Therefore it is not a malfunction that the code trouble codes is backed up directly by the bat...

Страница 138: ...han 10 seconds 3 Perform test drives under the following conditions 1 On vehicles with automatic transmission set selector lever in D range overdrive switch ON Power Economy changeover switch in P ran...

Страница 139: ...nk 1 Sensor 1 If harness and connector are normal replace Right bank 02 sensor front PO135 PO136 PO141 PO150 O2 Sensor Heater Circuit Mal l Harness and connector Retained function Bank 1 Sensor 1 l Ri...

Страница 140: ...pressure sensor Exhaust Gas Recirculation l Harness and connector Retained Solenoid Malfunction l EGR solenoid Warm Up Catalyst Efficiency l Exhaust manifold Retained Below Threshold Bank 1 Replace t...

Страница 141: ...tained Solenoid Malfunction l Turbocharger waste gate solenoid P1105 Fuel Pressure Solenoid l Harness and connector Retained Malfunction l Fuel pressure solenoid P1300 P1300 Ignition Timing Adjustment...

Страница 142: ...ttery voltage is 8 V or more Set Conditions l Sensor output voltage is 4 5 V or more corresponding to a barometric pressure of 114 kPa 33 7 in Hg or more for 4 seconds or l Sensor output voltage is 0...

Страница 143: ...6 V or more for 5 minutes Range of check l Engine coolant temperature is 20 68 F or more when the engine is started l Intake air temperature is 20 C 68 F or more when the engine is started Set conditi...

Страница 144: ...t leaner and richer circuit in oxygen sensor and checks the response speed of oxygen sensor In addition the engine control module also checks for an open circuit in the oxygen sensor e control module...

Страница 145: ...p control of the air fuel ratio The oxygen sensor output line is open circuit 1 DTC No L po155 Oxygen Sensor Heater Circuit Malfunction Probable causes Bank 2 Sensor 1 Background l Open or shorted oxy...

Страница 146: ...or failed l Engine control module failed ntake air temperature sensor etric pressure sensor l DTC No Title PO201 PO206 Injector Circuit Malfunction Cylinder l Cylinder 6 Background l A surge voltage i...

Страница 147: ...t voltage knock sensor peak voltage at each l 2 revolution of the crankshaft is less than 0 06 V for 200 times in succession Probable causes l Knock sensor failed l Open or shorted knock sensor circui...

Страница 148: ...ed EGR solenoid the solenoid is ON and OFF Range of Check Set Conditions 0 No surge voltage is detected even when the EGR solenoid is turned off circuit or loose connector 0 Engine control module fail...

Страница 149: ...oid has switched from OFF to ON current or loose connector does not flow to the coil for 4 seconds l Engine control module failed DTC No Title PO500 Vehicle Speed Sensor Malfunction Background l The v...

Страница 150: ...f Check Set Conditions l The park neutral position switch failure signal is input to the engine control module l Park neutral position switch failed l Open or shorted park neutral position switch circ...

Страница 151: ...on timing adjusting signal l If there is a short circuit in the line between the engine control module and the ignition wire circuit is shorted to the timing adjustment terminal the line voltage will...

Страница 152: ...d l The transaxle control module monitors the torque converter clutch solenoid shift control solenoid and pressure control solenoid l When some one of these solenoids failed the transaxle control modu...

Страница 153: ...position sensor Provided that no No 1 cylinder top dead center position has been detected since the ignition switch was placed in the ON position 2 Fuel cut 4 seconds after a failure was detected Prov...

Страница 154: ...harness of MUT II to connect MUT II to 1993 and earlier models 2 Turn the ignition switch to ON 3 Take a reading of the diagnostic output 4 Repair the problem location referring to the diagnostic char...

Страница 155: ...ck engine malfunction indicator lamp is used Typical blinking made while diagnostic trouble code is output In case of diagnostic trouble code No 24 1 5 second 0 5 second 0 5 second Ught comes on Light...

Страница 156: ...ensor Intake air temperature sensor 3 3 1 1 1 1 72 200 2 13 11 85 21 2 2 5 aa 215 2 gnltion switch ST and Park Neutral EGR solenoid California Non Turbo Turbo Federal Non Turbo From 1996 Variable indu...

Страница 157: ...or Non Turbo I4 4 16 6 133 242 2 Heated oxygen sensor I I I I I I I I 137 247 2 Injectors I 2 2 I 2 2 I 1 11 I 11 l I I 1 1 l44 257 2 Idle air control motor stepper motor type j I 1 9 7 I I 153 26 3 I...

Страница 158: ...lay in response of the vehicle speed engine speed that occurs when the accelerator pedal is depressed in order to accelerate from the speed at which the vehicle is now traveling or a temporary drop in...

Страница 159: ...he inspection and adjustment procedures set the vehicle in the following conditions l Engine coolant temperature 80 to 95 C 176 to 203 F l Lights electric cooling fan accessories OFF l Transaxle Neutr...

Страница 160: ...throttle valve Refer to P 13A 57 3 The tachometer should read l 3 of the actual engine speed This means that the actual engine speed is the tachometer reading multiplied by 3 8 If the basic idle spee...

Страница 161: ...the deposit cannot be removed from the throttle valve repeat steps 4 and 5 7 Disconnect the plug from the inlet of the bypass passage 8 Install the air intake hose 9 Use a scan tool to erase the diag...

Страница 162: ...is turned OFF continuity between terminals 3 and 4 disappears Then tighten the throttle position sensor mounting bolt securely 7 If not using the scan tool proceed as follows a Disconnect the throttl...

Страница 163: ...S by turning it counterclock wise to fully close the throttle valve 4 Tighten the fixed SAS slowly to find a point at which it contacts the throttle lever where the throttle valve starts opening From...

Страница 164: ...le position sensor with built in closed throttle C position switch B Turbocharger waste gate solenoid Turbo U X Variable induction control motor DC motor with J built in induction control valve positi...

Страница 165: ...NJECTION _ On Vehicle Inspection of MFI Components 13A 61 Volume air flow sensor with built in intake air Fro 19 models Mechanical Speedometer Type Vehicle speed sensor reed switch I 27FU1004 Y68FOOll...

Страница 166: ...ORT On Vehicle Inspection of MFI FUEL INJECTION ComDonents Variable induction control motor fi DC motor with built in induction Injector Idle air control control valG position sensor Z7FUO802 t7FU0803...

Страница 167: ...hicle Inspection of MFI FUEL INJECTION Components 1349 63 Check engine malfunction indicator lamp 1 z68FOOH and diagnostic test mode control terminal ZlBFO292 From 1994 models control terminal ZlEFC49...

Страница 168: ...tuator test function If any abnormality is found check the body harness corn ponents etc and repair as necessary iii 2 After repair check again with the scan tool to make sure that the input and outpu...

Страница 169: ...attery power is supplied to the engine control module the injector the volume air flow sensor etc l When the ignition switch is turned on the battery voltage is applied from the ignition switch to the...

Страница 170: ...the harness module harness side connector Ignition switch 62 201 Lo227 age of the MFI relay l MFI relay connector Discon A Harness side connector Engine control module con nector Disconnected Check f...

Страница 171: ...ltage at Voltage at terminal 4 terminal 5 I 1 Connected 1 B 1 B I 1 Disconnected 1 ov I ov I 4 Using jumper wires connect terminal 9 of MFI relay to battery terminal and terminal 6 of MFI relay to bat...

Страница 172: ...CH IG From 1994 models Engine control module 16FO292 1 bv 7FUO927 OPERATION Refer to P l3A 65 INSPECTION Refer to P l3A 65 Battery MFI relay 4 3 2 0 0 Ignition 1 8 6 itch IG A Equipment side connector...

Страница 173: ...ess side connector Z6AF0050 A Harness side connector Pleasure power voltage to the ac tuator l MFI relay connector Con nected l Engine control module con I Inectar Connected Engine cranking 8 V or hig...

Страница 174: ...mper wire to battery terminal measure the voltage at terminal 1 of the MFI relay Jumper wire Voltage Connected B Disconnected OV 5 Using jumper wires connect terminal 8 of MFI relay to battery termina...

Страница 175: ...OPERATION Grounds the engine control module TROUBLESHOOTING HINTS If the ground wire of the engine control module is not connected securely to ground the module will not operate correctly HARNESS INS...

Страница 176: ...nnector Z7FUO952 Engine control module connector 27FUO653 7Fu1574 OPERATION l Drives the fuel pump during cranking and engine operation l When the ignition switch is set to START current flows from th...

Страница 177: ...ers to feel pulsation pump Check is made for indicating fuel flow above two conditions Listen to pump operat Operating sound ing sound near fuel tank is heard HARNESS INSPECTION mu I F i pum check ter...

Страница 178: ...epair the harness Cl Measure the Dower SUDDIV volt age of the MF I relay l MFI relay connector Discon nected l Ignition switch START when ir the A9 checked harness l Ignition switch ON when A3 Ignitio...

Страница 179: ...13A 75 I i Check for an open circuit or a short circuit to ground between the MFI relay and the fuel pump l MFI relay connector Discon nected l Fuel pump connector Dis A connected Repair the harness A...

Страница 180: ...e control module connector i7FU06 53 7FU1575 OPERATION l The fuel pump is driven when the engine is cranking and while the engine is running l When the engine is cranking and while the engine is runni...

Страница 181: ...or Dis connected Repair the harness 82 Ground B Harness side connector u 4 Z7FUO954 Y la l L I3 E n 7 C Check for continuity between the fuel pump and the checking termi nal l Connector Disconnected Z...

Страница 182: ...I relay and the engine con trol module MFI relay connector Dacon netted l Engine control module con nector Disconnected Repair the harness AS 8 Check for an open circuit or a short circuit to ground b...

Страница 183: ...MULTIPORT On Vehicle Inspection of MFI FUEL INJECTION Components 13A 79 FUEL PUMP Turbo Fuel pump connector j 1 I i 1 w I 203kxl04 TSB vision _ 1...

Страница 184: ...L 7 2 Fuel t l I M pump D Fuel pump 2 Z5ElAO03 6 c connector Y Engine control module pikq 1 Fuel pump check terminal B Equipment side connector B Harness side connector 13A 80 MULTIPORT On Vehicle Ins...

Страница 185: ...l pump through the resistor If the amount of inlet air is large the engine load is high the engine control module turns off the power transistor to send drive power directly to the fuel pump without p...

Страница 186: ...fuel pump con nector Disconnected l Fuel pump connector Dis connected Repair the har ness Cl D2 I iD2 E2j short circuit to ground beheen the fuel pump relay II and the en Engine control module con ne...

Страница 187: ...rol module con nector Disconnected i Repair the harness A7 8 Check for continuity between the MFI relay and the fuel pump relay II II l MFI relay connector Discon nected l Fuel Dumb relav II connector...

Страница 188: ...ery 3 With the jumper wire connected to and disconnected from the negative terminal of the battery check the continuity between terminals 2 and 5 of fuel pump relay II and between terminals 4 and 5 of...

Страница 189: ...s a pulse signal as it repeatedly opens and closes between the 5 V voltage supplied from the engine control module and ground TROUBLESHOOTING HINTS Hint 1 If the engine stalls occasionally crank the e...

Страница 190: ...creases with racing NOTE When the vehicle is new within initial operation of about 500 km 300 miles the volume air flow sensor output frequency may be about 10 higher Volume Air Flow Sensor Reset Sign...

Страница 191: ...ay or check the control relay Connector Disconnected Ignition switch ON l 3 A Harness side connector 27FUO657 ml Engine control A Harness side q rls zde har connector r Z7FUO745 Check for continuity o...

Страница 192: ...n the input signal l The 5 V power in the engine control module is supplied via a resistor in the module to the intake air temperature sensor Via the sensor which is a kind of resistor it is grounded...

Страница 193: ...erature engine running At 0 C 32 F 0 C At 20 C 68 F 20 C At 40 C 104 F 40 C At 80 C 176 F 80 C HARNESS INSPECTION v T Check for continuity of the ground circuit l Connector Disconnected 0 2 Repair the...

Страница 194: ...ponents 3 Measure resistance while heating the sensor using a hair drier Temperature C OF Higher Resistance kL2 Smaller 4 If resistance does not decrease as heat increases or the resistance remains un...

Страница 195: ...nector l The barometric pressure sensor converts the barometric pressure into a voltage and inputs it to the engine control module which then corrects the fuel injection rate etc based on the input si...

Страница 196: ...h ON Altitude Standard value At 0 m 0 ft 101 kPa 760 mmHg At 600 m 1 969 ft 95 kPa 710 mmHg At 1 200 m 3 937 ft 88 kPa 660 mmHg At 1 800 m 5 906 ft 81 kPa 610 mmHg A Harness side Z7FUO657 Check for co...

Страница 197: ...rol module is supplied via a resistor in the module to the engine coolant temperature sensor Through the sensor which is a kind of resistor it is grounded in the engine control module The engine coola...

Страница 198: ...At 20 C 4 F 20 C temperature engine operating At 0 C 32 F 0 C At 20 C 68 F 20 C At 40 C 104 F 40 C At 80 C 176 F 80 C HARNESS INSPECTION A Harness side 27FlJO668 J 2 A Harness side connector 1 4 27FlJ...

Страница 199: ...in hot water check resistance Temperature C OF Resistance Wz 0 32 5 6 20 68 2 4 40 104 1 1 80 176 0 3 3 If the resistance deviates from the standard value greatly replace the sensor INSTALLATION 1 Ap...

Страница 200: ...voltage Engine coolant temperature 1621006 Engine coolant temperature sensor A Equipment side connector Engine control module ZPFUO106 OPERATION Refer to P l3A 93 TROUBLESHOOTING HINTS Refer to P l3A...

Страница 201: ...T ZPFUO114 SENSOR INSPECTION Refer to 13A 95 INSTALLATION Refer to 13A 95 Measure the impressed voltage l Engine coolant temperature sensor connector Discon nected l Engine control module con nectar...

Страница 202: ...sensor Through the resistor in the sensor it is grounded in the engine control module l As the throttle valve shaft rotates from the idle position to wide open position the resistance between the vari...

Страница 203: ...disconnected l Ignition switch ON 4 8 5 2 V 02 Repair the harness Al 61 I 2 Check for continuity of the ground circuit l Connector Disconnected 26FU1242 I I I Engine control module harness side conne...

Страница 204: ...between terminal 4 sensor ground and terminal 2 sensor output 4 Operate the throttle valve slowly from the idle position to the full open position and check that the resistance changes smoothly in pr...

Страница 205: ...rol module is applied to the closed throttle position switch through a resistor When the accelerator pedal is released the closed throttle position switch is turned on to conduct the voltage to ground...

Страница 206: ...ed adjust the fixed SAS Refer to P l3A 59 2 Disconnect the throttle position sensor connector 3 Check the continuity across the throttle position sensor connector terminal 4 Sensor ground and 3 Closed...

Страница 207: ...ction sequence etc based on the input signal l Power to the camshaft position sensor is supplied from the MFI relay and is grounded to the body The camshaft position sensor generates a pulse signal as...

Страница 208: ...gine at an idle speed 2 Connect the probe to the oscilloscope pick up point as shown in the circuit diagram and check the waveform Normal waveform HARNESS INSPECTION l Connector Disconnected 0 Ignitio...

Страница 209: ...ignal l Power to the camshaft position sensor is supplied from the MFI relay and is grounded to the body The camshaft position sensor generates a pulse signal as it repeatedly connects and disconnects...

Страница 210: ...Z6AF0057 A Harness side connector Z6AF0059 Measure the power supply volt age l Connector Disconnected l Ignition switch ON Battery voltage I relay Check for continuity of the ground circuit l Connect...

Страница 211: ...or the engine stalls suddenly during idling shake the crankshaft position sensor harness If this causes the engine to stall poor contact of the sensor connector is suspected Hint 2 If the crankshaft p...

Страница 212: ...tes actual engine speed Function Item No Data reading 22 Data display Check condition Coolant temperature Standard value Idle speed 0 gtine Running at At 20 C 4 F 1 300 1 500 rpm l Closed throttle pos...

Страница 213: ...496 Measure the power supply volt age 0 Connector Disconnected 0 Ignition switch ON Battery voltage I relay A Harness side connector Z7FUC497 connector Y7FUO496 Check for continuity of the ground circ...

Страница 214: ...aracteristic ZSEL1303 I Time _ 27FUO682 Engine control module connector 26AF0060 7FU0653m 7FU1587 OPERATION Refer to P l3A 107 TROUBLESHOOTING HINTS Refer to P l3A 107 INSPECTION Refer to P i3A 108 HA...

Страница 215: ...le Inspection of MFI FUEL INJECTION ComDonents 13A 111 A Harness side connector Check for continuity of the ground circuit l Connector Disconnected Z6AF0062 Repair the harness Al Ground A Harness side...

Страница 216: ...on switch to the engine control module which detects that the engine is cranking INSPECTION Using Scan Tool Function Item No Data display Check condition I Engine Normal indication 1 Data reading 18 S...

Страница 217: ...detects that the engine is cranking In case the selector lever is in a position other than the P N range the battery voltage is not applied to the engine control module l The park neutral position sw...

Страница 218: ...nector y ZOlA0206 Harness side connector ZOiA0206 YOl LO427 Measure the input voltage of engine control module l Engine control module connec _ P I A tor Disconnected l PNP switch connector Con nected...

Страница 219: ...SWITCH PNP SWITCH CAIT From 1993 models lqnition switch ST A Equipment side connector I OPERATION Refer to P l3A 113 TROUBLESHOOTING HINTS Refer to P l3A 113 PNP switch 8 r k Starter S MFI terminal re...

Страница 220: ...or Dis w P l connected I 0 Ignition switch START Battery voltage Check the power supply I circuit Check for continuity between the PNP switch and engine control module f Y I l Engine control module co...

Страница 221: ...peed into a pulse signal and inputs it to the engine control module which then provides the idle speed control etc based on this signal l The vehicle speed sensor generates the vehicle speed signal by...

Страница 222: ...PORT On Vehicle Inspection of MFI FUEL INJECTION Components A Harness side l Connector Disconnected l Ignition switch ON 0 Connector Disconnected SENSOR INSPECTION Refer to GROUP 54 Meters and Gauges...

Страница 223: ...O653 7FUl592 OPERATION l The vehicle speed sensor mounted directly to the speedometer driven gear of the transmission converts the vehicle speed to the pulse signal to be input to the engine control m...

Страница 224: ...y voltage L L I tion switch Check the vehicle speed sensor output circuit for continuity l Engine control module con f 1 A nectar Disconnected l Ignition switch ON C l Move the vehicle Continuity C o...

Страница 225: ...of power steering load into low high voltage and inputs it to the engine control module which then controls the idle air control motor based on this signal l The battery voltage in the engine control...

Страница 226: ...ght forward Turned Oil pump delivery pressure ref value 700 l 200 kPa loo 171 psi 1 500 2 000 kPa 213 284 psi HARNESS INSPECTION A Harness side connector Measure the power supply volt age 0 Connector...

Страница 227: ...input the engine control module drives the idle air control motor and turns ON the power transistor As a result the air conditioning power relay coil is energized to turn on the relay switch which act...

Страница 228: ...fter OFF ing relay OFF compressor I warm up clutch non activa state tion ON ON compressor clutch activation HARNESS INSPECTION II 1 120 Engine control module Engine control module harness side connect...

Страница 229: ...the magnitude of cylinder block vibration due to knocking and inputs it to the engine control module Based on this signal the engine control module provides retard control of the ignition timing TROU...

Страница 230: ...13A 126 MULTIPORT On Vehicle Inspection of MFI FUEL INJECTION Components HARNESS INSPECTION harness side short circuit to nectar Disconnected 0 Connector Disconnected I j I I I I d TSB Revision...

Страница 231: ...odule Based on this signal the engine control module controls the idle air control motor l When the switch of equipment with a large electrical load is turned ON the battery voltage is applied to the...

Страница 232: ...put voltage of en Battery voltage Check circuit related to tail light relay Measure the input voltage of en gine control module l Engine control module con nector Disconnected l Defogger switch ON Def...

Страница 233: ...s 13A 129 FAN MOTOR RELAY RADIATOR AIR CONDITIONING CONDENSER From 1994 models Ignitionswitch IG Air conditioner compressor lock controller Engine control module connector 1 TSB Revision 27FltO653 To...

Страница 234: ...the current flows to the condenser fan motor relay Lo The condenser fan motor relay Lo will operate to send driving power supply for low speed rotation from the battery to the condenser fan motor If t...

Страница 235: ...de muffler control l The output terminal of the muffler mode changeover switch has battery voltage applied to it from the engine control module through the resistor inside the module Place the muffler...

Страница 236: ...EL INJECTION Components HARNESS INSPECTION A H connector 27FU1054 Measure the power supply volt age l Connector Disconnected l Ignition switch ON Battery voltage Repair the harness A3 108 A Harness si...

Страница 237: ...to the engine control module which provides valve opening and closing control based on this signal l The induction control valve position sensor is supplied with 5V power engine control module and is...

Страница 238: ...he power supply volt age of the air intake control valve 4 8 5 2 V f Repair the harness Al 61 A Harness side connector Check for continuity of the ground circuit l Connector Disconnected 27FUO824 Repa...

Страница 239: ...n indicator lamp is turned on to notify the driver l Five volt power supply in the engine control module is applied to the EGR temperature sensor through the resistance in the module This power supply...

Страница 240: ...tes or more Disconnect vacuum hose green stripe from EGR solenoid and install blind caps to removed vacuum hose end and solenoid nipple Engine state 700 rpm Idle 3 500 rpm Standard value 100 C 212 F o...

Страница 241: ...a voltage and inputs it to the engine control module l The heated oxygen sensor outputs about 1 V when the air fuel ratio is richer than the theoretical ratio and outputs about 0 V when the ratio is l...

Страница 242: ...ed to air fuel ratio control system are suspected Examples L 1 Faulty injector 2 Air leaking into the intake manifold through gasket gap etc 3 Faulty volume air flow sensor intake air temperature sens...

Страница 243: ...Repair the harness A3 MFI relay Er1gine control Check for an open circuit or a module harness short circuit to ground between the engine control module and the heated oxygen sensor l Heated oxygen se...

Страница 244: ...4 of the heated oxygen sensor connector to battery and terminals respectively Caution Ensure that the jumper wires are connected correctly as wrong connections result in a broken heated oxy gen senso...

Страница 245: ...y Z7FU1332 TFU1602 OPERATION Refer to P l3A 137 TROUBLESHOOTING Refer to P l3A 138 INSPECTION Using Scan Tool Function Item No Data display Check condition Engine condition Standard value Data reading...

Страница 246: ...switch ON Battery voltage I hFi relay Check for an open circuit or a short circuit to ground between the engine control module and the heated oxygen sensor l Heated oxygen sensor con nector Disconnect...

Страница 247: ...nsor connector to battery and terminals respec tively Caution Ensure that the jumper wires are connected correctty as wrong connections result in a broken heated oxy gen sensor 6 Connect a digital vol...

Страница 248: ...module l The injector has a fixed nozzle opening area and the fuel pressure against manifold inside pressure is regulated to a fixed level Therefore the volume of fuel injected by the injector is det...

Страница 249: ...ta 41 Drive time reading Engine Cranking 0 C 32 F 2 15 3 18 7 ms Up to 1993 models 13 8 16 8 ms From 1994 models 20 C 68 F 41 4 50 6 ms Up to 1993 models 40 48 8 ms From 1994 models 80 C 176 F 9 9 12...

Страница 250: ...3A0209 HARNESS INSPECTION J 1 Harness side connector 27FUO669 Harness side connector 27FUO970 Harness side connector 1 I 8 33 I i i i 27FUO805 Measure the power supply volt age of the front bank injec...

Страница 251: ...con nector Disconnected 1 i41516 ACTUATOR INSPECTION Measurement of Resistance between Front Bank Terminals 1 Remove the injector connector 2 Measure the resistance between terminals Standard value 13...

Страница 252: ...7FUO832 MFI relay A Equipment side connector 6 Inject01 No 3 r 1 Q5 rI 4 P Injector No 2 OSCilla 1 3 b 7 4 Inject0 _ bisal3 14 K 5 5 Inject0 No 6 I5 K 6 E Rear bank connector I I r 1 3 A Engine contro...

Страница 253: ...upply voltage is 11 V and the cranking speed is less than 250 rpm 2 When coolant temperature iis lower than 0 C 32 F injection is made by 6 cylinders simultaneously 3 When the vehicle is new within in...

Страница 254: ...t bank injector l Resistor connector Con necteu l Injector connector Discon netted l Ignition switch ON Repair the harness B C Dl MFI relay Battery voltage Check pow er supply Check resis tor Measure...

Страница 255: ...nected ACTUATOR INSPECTION INJECTORS Measurement of Resistance between Front Bank Terminals 1 Disconnect the injector connector 2 Measure the resistance between terminals Standard value 2 3 0 at 20 C...

Страница 256: ...SISTOR Measurement of Resistance between Terminals 1 Disconnect the resistor connector 2 Measure the resistance between terminals I Measuring terminals I Resistance 1 4 2 4 VI k E65c 88 F 1 I 8 4 I 3...

Страница 257: ...MFI relay As the engine control module turns on power transistors in the module one after another the stepper motor coil is energized and the motor rotates in normal or reverse direction TROUBLESHOOTI...

Страница 258: ...switch ON compressor clutch to be ON if airconditioning switch is ON l Engine Idling Load state Standard value Air conditioning switch 2 25 step OFF Air conditioning switch Increase by ON 1 O 70 step...

Страница 259: ...t or a short circuit to around between the engine contr l module andthe idle air control motor l Enoine control module con nectar Disconnected l Idle air control motor connec Repair the tor Disconnect...

Страница 260: ...t the idle air control motor side Standard value 28 33 Q at 20 C 68 F 3 Measure the resistance between terminal 5 green clip of the special tool and either terminal 6 yellow clip or terminal 4 black c...

Страница 261: ...n of the stepper motor 1 Connect the negative terminal of the power supply to the red and black clip 2 Connect the negative terminal of the power supply to the blue and black clip 3 Connect the negati...

Страница 262: ...ignition power transistor unit A is turned off the primary current is shut off and a high voltage is induced in the secondary coil A causing the ignition plugs of No 1 and No 4 cylinders to spark Whe...

Страница 263: ...erminal condition Standard value ignition timing adjust ON ment terminal is grounded Ignition timing adjust OFF ment terminal is discon nected from ground Drive I Check condition I Normal condition I...

Страница 264: ...s side co Measure the power supply volt age of the ignition coil l Connector Disconnected l Ignition switch ON Battery voltage 0 OK 0 2 Repair the harness A3 Igni tion switch ZOl Lo4ll 0 Ignition powe...

Страница 265: ...it l Connector Disconnected cl 6 1 bound Measure the voltage of the control signal circuit of the ignition power transistor l Connector Disconnected e Ignition switch START 0 5 4 0 v Repair the harnes...

Страница 266: ...h controls introduction of purge air from the canister into the intake air plenum o The battery power is supplied to the evaporative emission purge solenoid through the MFI relay When the engine contr...

Страница 267: ...ss MFI relay A l Check for an open circuit or a short circuit to ground between the evaporative emission purge solenoid and the engine control module l Engine control module con nectar Disconnected l...

Страница 268: ...ting negative pressure to the throttle body A port l Power supply from the battery is sent through the MFI relay to the EGR solenoid When the engine control module turns off the power transistor insid...

Страница 269: ...r supply volt aae l Connector Disconnected 0 Ignition switch ON Battery voltage 1 relay Check for an open circuit or a short circuit to ground between the EGR solenoa and the engine control module 0 E...

Страница 270: ...3 7FU1609 OPERATION l The fuel pressure solenoid is an ON OFF type solenoid valve that switches the pressure introduced to the fuel pressure regulator between either intake manifold pressure or barome...

Страница 271: ...SS INSPECTION A Harness side connector Measure the power supply volt age l Connector Disconnected att zt h ON Repair the harness Al MFI relay ZOlA0524 Engine control module harness side CO Check for a...

Страница 272: ...ack from the solenoid valve 2 Disconnect the harness connector 3 Apply a negative pressure to the nipple to which the black vacuum hose has been connected and check air tightness with and without the...

Страница 273: ...attery power is supplied to this valve via the MFI relay When the engine control module turns ON the internal power transistor the coil is energized to release part of the boost pressure applied to th...

Страница 274: ...nnector l Measure the power supply volt age l Connector Disconnected 0 Ignition switch ON Battery voltage QCCQ J Repair the harness Al MFI r relay z7Fw525 connector Check for an open circuit or a shor...

Страница 275: ...f MFI FlJEL INJECTION Components 13 9171 BOOST METER Turbo r A l l 4 I449 I 7 E 22 lb I I teiter fy Boost ry Ignition switch IG I A Equipment side connector Boost meter Engine control module connector...

Страница 276: ...ttery voltage 1 Z7FUO986 Repair the harness A2 Igni tion coil IG Engine controt moduts Check for an open circuit or a short circuit to ground between the engine control module and the boost meter l Bo...

Страница 277: ...the normal or reverse direction l The DC motor is driven in the normal or reverse direction by changing the direction of power flow by the motor driving IC in the active exhaust control unit l The ac...

Страница 278: ...is driven clockwise or counterclockwise by the signal from the engine control module the variable induction valve opens or closes l The DC motor is driven clockwise or counterclockwise as the directi...

Страница 279: ...INSPECTION Engine control module connector f2 27FUO841 Check for an open circuit or a short circuit to ground between the engine control module and the variable induction control motor connector l Va...

Страница 280: ...ot the motor relay is activated Based on this signal the engine control module controls the idle air control motor to secure effective anti lock braking l When the motor relay is activated the ABS con...

Страница 281: ...ed in the engine control module This will change the terminal voltage of the transaxle control module from HIGH to LOW If the transistor fitted inside the engine control module changes from ON to OFF...

Страница 282: ...harness side connector Engine control modu e hamess Check for an open circuit or a short circuit to ground between the transaxle control module and the engine control module l Transaxle control modul...

Страница 283: ...uel pump harness connector 5 Apply the specified sealant to the rear floor pan Specified sealant 3M ATD Part No 8509 or equivalent 6 Install the fuel gauge cover FUEL PUMP OPERATION CHECK 1 Set the ig...

Страница 284: ...vent fuel leaks 4 Attach the special tool set in step 3 to the fuel rail between high pressure hoses 5 Connect a jumper wire to the terminal for activation of the fuel pump and to the positive termina...

Страница 285: ...to gently press the fuel return hose while repeatedly racing the engine and check to be sure that there is fuel pressure in the return hose also NOTE There will be no fuel pressure in the return hose...

Страница 286: ...rop of the The check valve within the fuel pump Replace the fuel pump fuel pressure immediately after the is not closed engine is stopped 14 Reduce the internal pressure of the fuel pipes and hoses 15...

Страница 287: ...tor terminal and ground could cause damage to the vehicle wiring sensors or ECM or all of them Use care to prevent it 3 If the voltmeter shows any deviation from the standard value check the correspo...

Страница 288: ...13A 184 MULTIPORT On Vehicle Inspection of MFI FUEL INJECTION Comtaonents Camshaft position sen 1TSB Revision...

Страница 289: ...r conditioning switch OFF ON Air more for a mo compressor in driven state ment O 3 V as A C clutch cycles 6 Fan motor relay Lo Radiator fan not operating B 1994and Coolant temperature below 90 C 194 F...

Страница 290: ...ium gasoline is O 3 V used 11 Turbo meter 21 Fuel pump relay 2 Ignition switch ON 4 13 v Turbo Engine Depress the accelerator pedal Falls temporari abruptly while the engine is idling ly from B Engine...

Страница 291: ...ontrol valve Engine Slowly decelerated from 5 000 rpm for a moment Closed to idling speed Anti lock braking signal Engine Idle B Turbo l When vehicle is put in motion for the B 3 O 3 V first time afte...

Страница 292: ...e sensor Evaporative emission purge solenoid Fuel pressure solenoid Turbo Heated oxygen sensor Idle air control motor stepper motor B Variable induction control motor DC motor with built in in J X duc...

Страница 293: ...e air temperature sensor and barometric pressure sensoc bank heated oxygen wxor rear 5cl nia T u r and Federal Turbo from 1996 l d ge I 1 sensor fro1 P Electrical Speedometer Type 1 i 2 y Heated oxyge...

Страница 294: ...13A 190 MULTIPORT On Vehicle Inspection of MFI FUEL INJECTION Components Variable air intake control s DC motor with built in air intak Injector I I 27FUO803 rtrad dt ode R16FOSQO 1 TSB Revision...

Страница 295: ...of MFI FUEL INJECTION Components 13A 191 ZlBFO292 California up to 1995 Imodels _ Federal Turbo up to 1995 models I v _E_G_ veraturel Iii i Z7FUlOlOI piagnostic output terminal and agnostic test mode...

Страница 296: ...IPORT On Vehicle Inspection of MFI FUEL INJECTION Components Camshaft position sensor From 1996 models Turbo 1 Non T u r b o Manifolddifferential pressure sensor Manifolddifferential pressure sensor T...

Страница 297: ...A 64 POWER SUPPLY MFI RELAY AND IGNITION SWITCH IG Up to 1995 models En ine control module I 1 16FO292 7FUO927 OPERATION MFI relay 4 8 6 Ignition switch IG A r 4 A Equipment side connector A Harness s...

Страница 298: ...elay l Ignition switch OFF l MFI relay connector Discon 0 nected I Battery voltage Repair the harness Battery 21 FUO808 A4 A8 Engine control module harness Check for an open circuit or a side connecto...

Страница 299: ...e r 1 Measure power voltage to the ac tuator connector I 26AFOO51 l MFI relay connector Con nected l Engine control module con nector Connected Engine cranking 8 V or higher Engine racing Battery volt...

Страница 300: ...ELAY AND IGNITION SWITCH IG From 1996 models Battery fl I lcmitionjvitch WI Y Engi mod A Equipment side connector 1 2 ED 3 4 r MFI relay 1 Engine control module 1 7FUl833 32 Engine control module conn...

Страница 301: ...ctor side connector Engine control module harness side connector 17FU1824 Check for an open circuit or a short circuit to ground between the engine control module and the MFI relay l Engine control mo...

Страница 302: ...I I Continuity approx 70 Q I 3 Use the jumper leads to connect relay terminal 4 to the battery terminal and terminal 2 to the battery termi nal 4 Check the continuity between relay terminals 1 3 while...

Страница 303: ...N Components 13A 199 ENGINE CONTROL MODULE POWER GROUND Engine control module 4 ZOlAOlQl Engine control module connector zpFuo393 7FU1617 OPERATION Refer to 13A 71 TROUBLESHOOTING HINTS LJ Refer to 13...

Страница 304: ...pump connector 03FOOM Ignition switch IG 7 r MFI relay Engine control module 8 I n C Fuel pump check terminal I OPERATION Refer to 13A 76 INSPECTION Refer to 13A 73 HARNESS INSPECTION Refer to 13A 77...

Страница 305: ...heck terminal Ignition switch IG A Equipment side connector a b cm L U 63 tol Fuel pump connector Fuel pump 7 B Equipment B Harness side connector Engine control C Fuel pump check terminal f module r...

Страница 306: ...ge to the checking terminal and oper ate the pump Check the ground circuit of the fuel pump l Fuel pump connector Dis connected I bround Check for continuity between the fuel pump and the checking ter...

Страница 307: ...y voltage switch A3 A4 or check the ignition switch short circuit to ground bekeen the MFI relay and the engine con l Engine control module con nectar Disconnected Repair the harness W 8 the MFI relay...

Страница 308: ...FUEL PUMP Turbo Up to 1995 models Equipment side connector A Harness side connector Ignition switch IG E Equipment sidl B Harness side 1 Equipment side connector J m t e r m i n a l C Fuel pump check...

Страница 309: ...the ground circuit of the 4 t Repair the harness B2 Ground Check for continuity between the fuel pump and the checking termi nal l Fuel pump connector Dis connected Repair the harness Bl Cl Harness si...

Страница 310: ...Check for continuity between the fuel pump relay II and the resistor for fuel pump l Fuel pump relay II connector Disconnected l Resistor for fuel pump con nector Disconnected Repair the harness D4 E...

Страница 311: ...hicle Inspection of MFI FUEL INJECTION Comraonents 13A 207 short circuit to Fuel pump relay II connector Disconnected D Harness side l Fuel pump connector Dis MFI RELAY INSPECTION Refer to P l3A 70 i...

Страница 312: ...A Ignition switch IG Fuel pump connector 03FOOO4 Fuel pump relay II D Equipment side connector 1 4 2 Fuel pump circuit resistor 8 E Equipment side connector Engine control module connector 2 rFuel pum...

Страница 313: ...ON l Fuel pump connector Dis connector Harness side Check for continuity between the co r checking terminal and the fuel pump relay II and between the re sistor for fuel pump l Fuel pump relay II conn...

Страница 314: ...the power supply volt age of the MFI relay l MFI relay connector Discon netted Ignition switch OFF 0 V Ignition switch ON Battery voltage Harness side IDI connector 7FUl822 1A Harness side connector E...

Страница 315: ...pump relay II and the fuel n A pump l Fuel pump relay II connector Disconnected j LTOA 0 Fuel pump connector Dis connected Repair the harness Bl D2 MULTIPORT FUEL INJECTION MFI RELAY AND FUEL PUMP REL...

Страница 316: ...ume air flow sensor A Harness side connector 7 6 5 4 3 2 1 SEL1803 I relay Engine control module J 7FUO654 Engine control module connector ZPFUO393 1 Function 1 Item No Data display 1 Check condition...

Страница 317: ...l Operation range idling to maximum output 15 35 Non Turbo 1 lo 30 Turbo Volume Air Flow Sensor Reset Signal tm N o lnct n Reset signal condition Data display Check conditions l Engine warm up 1 700 r...

Страница 318: ...omponents HARNESS INSPECTION l Connector Disconnected l Ignition switch ON l Connector Disconnected volume air flow sensor and the engine control unit 0 Volume air flow sensor con nector Disconnected...

Страница 319: ...sor intake air temperature sensor OPERATION Refer to P l3A 88 TROUBLESHOOTING HINTS Refer to P l3A 88 INSPECTION Refer to P l3A 89 Resistance I Temperature 2162460 A Equipment side connector Output vo...

Страница 320: ...JECTION Components HARNESS INSPECTION l Connector Disconnected 2 7FUO657 A Harness side 1 l Repair the harness A592 Measure the power supply volt SENSOR INSPECTION Refer to P l3A 89 age 0 Connector Di...

Страница 321: ...t voltage V Barometricpressure mmHg in Hg KISS OPERATION Refer to P l3A 91 TROUBLESHOOTING HINTS Refer to P l3A 92 INSPECTION Refer to P l3A 92 A EQuiDment side coitriector Barometric pressure sensor...

Страница 322: ...Disconnected Repair the harness AS 92 Measure the power supply volt age of the barometric pressure sensor l Y l Connector Disconnected l Ignition switch ON 4 8 5 2 v Repair the harness Al 81 Check fo...

Страница 323: ...L Resistance t I ___ Coolant temperature lOZ4l8 Coolant temperature 1621008 I Engine coolant temperature sensor Engine control module connector A Equipment connector Engine control module 9FUO393 OPER...

Страница 324: ...ture sensor connector Discon netted Repair the harness r A2 92 Z9FUO112 i I Measure the impressed voltage A Harness side l Engine coolant temperature connector a q sensor connector Discon nected a Eng...

Страница 325: ...Throttle shaft turning angle 2162461 OPERATION Refer to P l3A 98 TROUBLESHOOTING HINTS Refer to P l3A 98 INSPECTION Refer to P l3A 99 A Equipment side connector Throttle position sensor A Harness sid...

Страница 326: ...of MFI Components HARNESS INSPECTION A Harness side connector l Connector Disconnected l Throttle position sensor con nector Disconnected Engine control module con nector Disconnected nals like ECM D...

Страница 327: ...A Harness side connector Terminal voltage V OFF m e Ii I 1 Throttle shaft turning anglezo t002 OPERATION Refer to P l3A 101 TROUBLESHOOTING HINTS Refer to P l3A 101 INSPECTION Refer to P l3A 101 A Eq...

Страница 328: ...7FUO675 A 2 m Z k I gJ 0 I26FU1242 L Measure the power supply volt age of the closed throttle position switch l Connector Disconnected 0 Ignition switch ON 4 V or more Repair thl harness A3 87 Check f...

Страница 329: ...on sensor 7FU130t IV1 Output characteristic No 1 5 v No 4 Z7FUO677 Engine control module connector A Equipment side connector OPERATION Refer to P l3A 103 TROUBLESHOOTING HINTS Refer to P l3A 103 INSP...

Страница 330: ...mDonents HARNESS INSPECTION Measure the power supply volt age l Connector Disconnected 0 Ignition switch ON Battery voltage Repair the harness A3 MFI 27FU1330 relay A Harness side l Connector Disconne...

Страница 331: ...Data display Check condition Cranking l Engine cranking speed l Tachometer connected check on and off of primary current of ignition coil by tachometer 7FU1626 Check content Normal state Compare cran...

Страница 332: ...1 275 1 475 rpm switch ON 1 300 l 500 rpm 2 At 0 C 32 F 1 225 1 425 rpm 1 300 l 500 rpm 2 At 2O C 68 F l lOO 1 300 rpm l 1 300 l 500 rpm 2 At 4O C 104 F 950 1 150 rpm 1 050 l 250 rpm 2 At 8O C 176 F...

Страница 333: ...ition switch ST I 7FUl629 Engine control Measure the input voltage to the module harness engine control module side connector l Engine control module con nectar Disconnected 0 Ignition switch START I...

Страница 334: ...ontrol module 7FU1320 Engine control module connector zpFuo393 7FU1630 OPERATION Refer to P i3A 113 TROUBLESHOOTING HINTS Refer to P l3A 113 INSPECTION Refer to P l3A 114 HARNESS INSPECTlON A Harness...

Страница 335: ...connector Measure the impressed voltage to the PNP switch l Engine control module con nector Connected l PNP switch connector Dis connected 0 Ignition switch ON Bakery voltage 0 OK 7A STOP Replace th...

Страница 336: ...CTION _ On Vehicle Inspection of MFI Components OPERATION Refer to P l3A 117 TROUBLESHOOTING HINTS Refer to P l3A 117 HARNESS INSPECTION onnector Disconnected SENSOR INSPECTION Refer to GROUP 54 Meter...

Страница 337: ...ometer Type Terminal voltage V Frequency Hz 2162478 Vehicle speed km h mph 2162451 OPERATION Refer to P l3A 119 TROUBLESHOOTING HINTS Refer to P l3A 117 A Equipment side connector Ignition switch WI E...

Страница 338: ...itch Check the vehicle speed sensor output circuit for continuity l Engine control module con nector Disconnected l Ignition switch ON l Move the vehicle Engine control Continuity module harness side...

Страница 339: ...A Harness side connector L p 3 7 Power steering pressure switch 1 A Harness side connector En Z7FUO536 7FU1633 OPERATION Refer to P l3A 121 INSPECTION Refer to P l3A 122 HARNESS INSPECTION Measure th...

Страница 340: ...ine control module connector I d 27FUO966 mFuo393 OPERATION Refer to P l3A 123 TROUBLESHOOTING HINTS Refer to P l3A 123 INSPECTION Refer to P l3A 123 HARNESS INSPECTION 7FU1634 I 1 Engine control modu...

Страница 341: ...5 Engine control module connector 29Fuo393 7FU1635 OPERATION Refer to P l3A 125 TROUBLESHOOTING HINTS Refer to P l3A 125 HARNESS INSPECTION Engine control module harness side connector r connector 78...

Страница 342: ...k for continuity of the ground 2A STOP I bound ELECTRICAL LOAD SWITCH Engine control module connector Defog ger t relay I NOTE up to 2 From Engine control module 1995 models 1996 models 27FUO688 7FU16...

Страница 343: ...ure the input voltage of en gine control module l Engine control module con nectar Disconnected 0 Defogger switch ON Defogger relay ON Engine control module harness side connector 27FUO689 Battery vol...

Страница 344: ...AIR CONDITIONING CONDENSER z Battery z E I Ignition switch IG ECM Radiato fan mote relay 1 r1I Lo r 3r I 7 21 b i f 0 I 7c 4 1 Ari 4 w To air conditioning compressor u 0 Air conditioning compressor l...

Страница 345: ...I l Ignition switch ON Battery voltage Check the fan motor ECM harness side connector relay circuit Z6FU2008 FAN MOTOR RELAY INSPECTION Refer to Radiator Check in GROUP 14 and Power Relay Check in GRO...

Страница 346: ...34 61 Checkforcontinuity of the ground circuit l Connector Disconnected Repair the harness A2 Ground NOTE 1 Up to 1995 models From 1996 models INDUCTION CONTROL VALVE POSITION SENSOR Non Turbo Variabl...

Страница 347: ...the power supply volt age of the air intake control valve A Harness side connector 7 El l L H z 0 n c 27FUO824 A Harness side fc Z7FUO825 NOTE 1 Up to 1995 models From 1996 models Check for continuit...

Страница 348: ...fold differential pressure switch converts the intake manifold plenum pressure to the voltage and inputs to the engine control module Engine control module confirms the operation of EGR system from th...

Страница 349: ...92 9FUO414 LJ Engine control module harness side connector 74 t 9FUO415 Check for open circuit or short circuit to ground between the en gine control module and the man ifold differential pressure se...

Страница 350: ...nia Up to 1995 models Federal Turbo Up to 1995 models A Equipment side EGR temperature sensor connector A Harness side t output voltage 1 I Temperature Z 6Z1008 OPERATION Refer to P l3A 135 INSPECTION...

Страница 351: ...harness A Al 92 SENSOR INSPECTION Refer to GROUP 17 Exhaust Gas Recirculation EGR System HEATED OXYGEN SENSOR California Non Turbo Up to 1995 models ii 49 ii Riaht bank II L I Right bank heated oxygen...

Страница 352: ...condition of control by the engine control mod ule Engine state Standard value When sudden deceleration from 4 000 rpm When engine is suddenly raced 700 rpm Idling 2 000 rpm 200 mV or lower 600 1 000...

Страница 353: ...nector 74 i I 77 27FUl440 Check for an open circuit or a short circuit to ground between the engine control module and the heated oxygen sensor 0 Heated oxygen sensor con nectar Disconnected l Engine...

Страница 354: ...6 ZECIOO L A Equipment connector i Al Heated oxygen Heated oxygen B Equipment side connector T I MFI re ay Engine con Engine control module connector OPERATION Refer to P l3A 137 TROUBLESHOOTING Refer...

Страница 355: ...Z7FU1333 MFI relay Check for an open circuit or a short circuit to ground between the enginecontrol module and the heated oxygen sensor l Heated oxygen sensor con nector Disconnected l Engine control...

Страница 356: ...P l3A 138 INSPECTION Using Scan Tool Heated Oxygen Sensor front Function Data reading b item No Data display Check condition 11 39 Sensor Engine Warm up Make the mixture detection lean by engine speed...

Страница 357: ...re the power supply volt age of the heated oxygen sensor a Connector Disconnected f Y __ l Ignition switch ON OK I 2 I Battery voltage Repair the harness Al Bl Cl Dl MFI relay short circuit to ground...

Страница 358: ...s the oxygen concentration in exhaust gas converts it into a voltage and inputs it to the engine control module l The heated oxygen sensor outputs about 1 V when the air fuel ratio is richer than the...

Страница 359: ...e Check condition Engine Warm up Make the mixture lean by engine speed reduction and rich by racing t Engine Warm up Using the heated oxygen sensor signal check the air fuel mixture ra tio and also ch...

Страница 360: ...sor l Heated oxygen sensor con nectar Disconnected l Engine control module con nectar Disconnected i l D l MFI relay A B C D Harness sid connector Engine control module harness side connector L J 7FUl...

Страница 361: ...ger 3 Needle valve Y Fuel Filter Injection 7FUO832 MFI relay 1 A 2 ii h Injector No 2 i _ _ _ _ _ _ 1 B 1 2 3 1 Injector 1 No 4 1 2 1 lnjectoi NO 6 1 2 _ _ 3 oscillo 15 I 12 4 D Connector for rear ban...

Страница 362: ...To increase l The injector drive time refers to when the supply voltage is 11 V and the cranking speed is less than 250 rpm 2 When coolant temperature is lower than 0 C 32 F injection is made by 6 cyl...

Страница 363: ...ut off after engine warm up check the idling condi No 5 injector shut off tion 1 06 No 6 injector shut off I Normal state Idle state to change fur ther becoming less stable or stalling z A injector dr...

Страница 364: ...Fuel Solenoid coil Plunger q Needle valv Connector Filter Injection 7FUO832 OPERATION Refer to P l3A 144 TROUBLESHOOTING HINTS Refer to P l3A 145 lnjectc No 1 MFI relav E 4 Resistor _ _ A Equipment s...

Страница 365: ...ncrease l The injector drive time refers to when the supply voltage is 11 V and the cranking speed is less than 250 rpm 2 When coolant temperature is lower than 0 C 32 F injection is made by 6 cylinde...

Страница 366: ...le or stalling sequence during idling No 4 injector shut off after engine warm up check the idling condi No 5 iniector shut off tion I No 6 injector shut off J 1 A A injector drive time Normal wavefor...

Страница 367: ...Y r MFI relay I 2 5 A Y G i 1 3 T Oscillo Oscillo I I r 1 A Equipment side connector IAC motor Oscillo Oscillo n I A 4 h17h5 A 18 __ Engine control module V v 0 V Z7FUO518 Engine control module connec...

Страница 368: ...uipment side connector B Harness side connector r 1 Ii B l B 2 I _ i Tachometer __ Engine control module G r 5 v Batterv Engine speed check control terminal 13 Ignition coil g 5 7 iransistor bll ignit...

Страница 369: ...terminal is grounded Ignition timing adjust OFF ment terminal is discon nected from ground Standard Ignition Timing id Function Item No Drive Check condition Normal condition Actuator test 17 Set to i...

Страница 370: ...gnition coil l Connector Disconnected 0 Ignition switch ON Battery voltage Repair the harness B6 Igni tion switch i Check for an open circuit or a short circuit to ground between the engine control un...

Страница 371: ...he ground circuit 0 Connector Disconnected 27FUO700 Repair the harness B4 Ground Measure the voltage of the control signal circuit of the ignition power transistor l Connector Disconnected 0 Ignition...

Страница 372: ...NOID MFI relay EVAP purge solenoid Engine control module I j d side 7FU1851 Engine control module connector I 9FUO393 d 7FUl850 OPERATION Refer to P l3A 162 INSPECTION Refer to P l3A 162 HARNESS INSPE...

Страница 373: ...GR SOLENOID EGR solenoid J 1 Cl O MFI relay T EGR solenoid Engine control module Engine control module connector 7FU1649 OPERATION Refer to P l3A 164 TROUBLESHOOTING HINT Refer to P l3A 164 INSPECTION...

Страница 374: ...s 2 From 1996 models Engine control module connector 29Fuo393 7FU1650 OPERATION Refer to P l3A 166 INSPECTION Refer to P l3A 167 HARNESS INSPECTION I 1 A Harness side connector Measure the power suppl...

Страница 375: ...ressure solenoid and the engine control module n A l Engine control module con OK roA nectar Disconnected I a Fuel pressure solenoid con nector Disconnected Repair the harness A2 7 403 YOlA0525 NOTE I...

Страница 376: ...CTUATOR INSPECTION Refer to GROUP 15 T Measure the power supply volt age Connector Disconnected l Ignition switch ON Battery voltage I relay Check for an open circuit or a short circuit to ground betw...

Страница 377: ...gnition switch IG A Equipment side connector Engine control module NOTE Up to 1995 models 2 From 1996 models 7FUO985 Engine control module connector 29Fuo393 7FU1662 A Harness side connector Z7FUO986...

Страница 378: ...f MFI FUEL INJECTION Components Z7FUO987 NOTE I Up to 1995 models 2 From 1996 models ACTUATOR INSPECTION Refer to GROUP 54 l Engine control module con nector Disconnected Repair the harness A3 41 39 2...

Страница 379: ...35 7 2 r Measure the input voltage of en gine control module 0 Engine control module con nector Disconnected 0 Ignition switch ON Battery voltage A Repair the Engine control harness module harness si...

Страница 380: ...control motor ZlFUO646 ZPFUO393 7FU1654 OPERATION Refer to P l3A 174 INSPECTION Refer to P l3A 174 HARNESS INSPECTION Enaine control module hasess side connector ACTUATOR INSPECTION Refer to GROUP 15...

Страница 381: ...ECU Engine control module d r 5 v 28 ABS HU 44 J Z6FU1542 OPERATION Refer to P l3A 176 HARNESS INSPECTION Engine control module 26FU1543 Check for an open circuit or a short circuit to ground between...

Страница 382: ...TAL CONTROL SIGNAL A T 16FO292 Transaxle control module 7r NOTE l Up to 1995 models 2 From 1996 models I Engine control module f I 27 FUO903 7 46 A Transaxle control module connector 5v P Z7FUO843 6 9...

Страница 383: ...control module connector Disconnected l Engine control module con nector Disconnected Repair the harness A7 46 Check for an open circuit or a short circuit to ground between the transaxle control modu...

Страница 384: ...terminal ground terminal 3 Withdraw the ECM for easier access to the connector terminals 4 The inspection need not be performed in the order of the chart Caution Short circuiting the positive probe be...

Страница 385: ...altitude is 0 m 0 ft 3 7 4 3 V switch ON When altitude is 3 2 3 8 V 1 200 m 3 937 ft Ignition When water temperature 3 2 3 8 V switch ON is 0 C 32 F When water temperature 2 3 2 9 V is 20 C 68 F When...

Страница 386: ...ditioning switch set B to ON Non Turbo l From 1996 Indoor set temperature models brought closer to atmo spheric temperature 22 Air conditioning relay 21 Fan motor relay Lo l Engine Idle B or 6 V or 0...

Страница 387: ...Warm B O 3V Al Check immediately after hot restart Changed 17 Stepper motor coil repeated A2 5 Stepper motor coil Bl 18 Stepper motor coil B2 10 Ignition power transistor unit A Engine speed 3 000 rpm...

Страница 388: ...ound 36 Check engine malfunc Ignition switch OFF ON o 3v tion indicator lamp 9 13 v Several se conds later 6 EGR solenoid Ignition switch ON B up to 1995 California Non Engine Idle Suddenly depress th...

Страница 389: ...o Induction control valve Engine Slowly decelerated from 5 000 rpm for a moment Closed to idling speed Anti lock braking signal Engine idle B Turbo 0 When vehicle is put in motion for the B O 3 V firs...

Страница 390: ...ervice Refer to GROUP 15 Intake Manifold Plenum ZO3FOO17 00002423 O ring 03N0012 4 O ring 03FOO18 Engine oil Removal steps A C 1 High pressure fuel hose connection 2 Fuel return hose connection 3 Vacu...

Страница 391: ...reinsert it into the fuel rail and check again BA FUEL PRESSURE REGULATOR INSTALLATION 1 Apply a small amount of new engine oil to a new O ring and insert it to the fuel rail carefully Caution Do not...

Страница 392: ...cuum nose connectron 4 TPS connector connection 5 ISC motor connector connection 7 Vacuum pipe assembly 8 Throttle body A4 9 Gasket 6 Water hose connection NOTE The layout of vacuum hoses No 3 of the...

Страница 393: ...e Manifold Removal and Installation Plenum Refer to GROUP 15 Intake Manifold 20 25 Nm 14 18 ft lbs 203FOO21 A A 1 Knock sensor REMOVAL SERVICE POINT qA KNOCK SENSOR REMOVAL Remove the knock sensor wit...

Страница 394: ...NOTES...

Страница 395: ...FUEL FILTER 10 SPECIFICATIONS 2 FUEL LINE AND VAPOR LINE 8 General Specifications 2 Sealant 2 FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY AND FUEL TANK PRESSURE TROUBLESHOOTING 2 CONTROL VALVE 6 Fuel Tank...

Страница 396: ...acity dm3 gal 75 19 8 1Return system Equipped I I I I 1 Filter 1 High pressure type SEALANT Items Specified sealant Fuel tank hole cover 3M ATD Part No 8509 or equivalent TROUBLESHOOTING FUEL TANK AND...

Страница 397: ...Nm 8 ft lbs 25 Ribs v 203F0007 26 Nm 19 ft lbs Removal steps Fq 1 Fuel gauge cover 2 Fuel pump and fuel gauge assembly connector 3 Fuel tank cap 4 Drain plug 5 Splash shield 6 Fuel tank filler tube p...

Страница 398: ...the pipe has a stepped part connect the vapor hose to the pipe securely up to the stepped part as shown in the illustration 2 If the pipe does not have a stepped part connect the vapor hose to the pip...

Страница 399: ...eck the fuel tank filler tube cap for malfunction l Check the fuel tank for deformation corrosion or crack l Check the fuel tank for dust or foreign material NOTE If the inside of the fuel tank is to...

Страница 400: ...e A bB4 4 High pressure fuel hose connection body side B Bd 5 High pressure fuel hose connection fuel pump side A4 6 Fuel pump and fuel gauge unit assembly REMOVAL SERVICE POINTS A HIGH PRESSURE FUEL...

Страница 401: ...then tighten it to the specified torque being careful that the high pressure fuel hose does not become twisted Caution When tightening flare nut be careful not to bend or twist line to prevent fuel p...

Страница 402: ...Nm 6 8 ft lbs CT Fuel rail t Removal steps 1 Reserve tank 2 Battery 3 Battery tray with washer tank assembly 4 Purge control valve A 5 Fuel vapor hose 6 Evaporative emission canister 7 Vapor pipe asse...

Страница 403: ...1 0 l 2 in B HIGH PRESSURE FUEL HOSE INSTALLATION Apply small amount of new engine oil to the hose union Insert the hose being careful not to damage the O ring and tighten securely Caution Because the...

Страница 404: ...the eye bolt while holding the fuel filter nut securely Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line INSTA...

Страница 405: ...OLANT TEMPERATURE SWITCH 13 ON VEHICLE SERVICE 4 Cap Pressure Test 4 Engine Coolant Concentration Test 4 Engine Coolant Leak Check 4 Engine Coolant Replacement 4 RADIATOR 5 SPECIFICATIONS 2 General Sp...

Страница 406: ...ange of coolant antifreeze concentration Standard value 30 60 Limit Thermostat Valve opening temperature C OF Full opening temperature C F Opening pressure of cap high pressure valve kPa psi 76 5 170...

Страница 407: ...reign substance Clean Inoperative electric Faulty coolant temperature sensor Replace cooling fan Up to 1993 models Engine coolant temperature sensor From 1994 models Faulty electrical motor Water leak...

Страница 408: ...ul when installing and removing the tester and when testing not to deform the water outlet fitting 4 If there is leakage repair or replace the appropriate part CAP PRESSURE TEST 1 Use a cap adapter to...

Страница 409: ...sensor connector Reserve tank Radiator upper hose Radiator lower hose Automatic transaxle oil cooler hoses Vehicles with AIT Condenser fan motor connector Vehicles with air conditioning Condenser fan...

Страница 410: ...9 Condenser fan motor connector Vehicles with air conditioning 10 Condenser fan motor assembly Vehicles with air conditioning A4 11 Radiator fan motor connector 12 Therm0 sensor connection For radiato...

Страница 411: ...insert into the shroud hole and fix securely INSPECTION l Check for foreign material between radiator fins l Check the radiator fins for bent or damage l Check the radiator for corrosion damage rust o...

Страница 412: ...models 1 Immerse the water temperature switch in hot water as shown 2 Change the water temperature and check continuity with a circuit tester If it is as specified below the switch is functioning corr...

Страница 413: ...4 Radiator lower hose connection 5 Water inlet fitting 6 Gasket A 7 Thermostat Air intake hose B ZOSFOO23 INSTALLATION SERVICE POINTS A4 THERMOSTAT INSTALLATION Install the thermostat with its jiggle...

Страница 414: ...hermostat in container of water Stir to raise water temperature and check that thermostat opening valve temperature and the temperature with valve fully open valve lift over 8 mm 31 in are at the stan...

Страница 415: ...Water hose connection Turbo 10 Water outlet fitting 11 Gasket 12 Harness connection 13 Heater hose connection 14 Water hose A connection 15 Water hose connection 16 Water hose connection Turbo 17 Radi...

Страница 416: ...to help smooth insertion of the pipe into the water pump thermostat housing Caution Care must be taken not to permit engine oil or other greases to adhere to the O ring C AIR INTAKE HOSE C AIR INTAKE...

Страница 417: ...removal and Post installation operation l Engine Coolant Draining and Supplying Refer to GROUP 00 Maintenance Service cup to 1993 models 30 Nm From 1994 models 30 Nm 1 i JdZOlFOO38 Removal steps 1 Air...

Страница 418: ...are bottomed INSPECTION ENGINE COOLANT TEMPERATURE GAUGE UNIT Refer to GROUP 54 Meters and Gauges ENGINE COOLANT TEMPERATURE SENSOR Engine control Refer to GROUP 13A MFI System Inspection AIR CONDITI...

Страница 419: ...11 26 28 30 33 17 13 15 5 Intake Charge Pressure Control System Check 7 Intake Manifold Vacuum Check Refer to Group 11 Turbocharger Bypass Valve Check 8 Turbocharger Supercharging Pressure Check 6 Tur...

Страница 420: ...r head contacting surface mm in Less than 0 15 0059 0 2 008 Turbocharger waste gate solenoid terminal resistance at 20 C 36 44 68 F 2 Turbocharger Supercharging pressure kPa psi Approx 69 10 SPECIAL T...

Страница 421: ...e Abnormal noise Probable cause Loose joints Broken pipe or muffler Broken separator in muffler Broken rubber hangers Interference of pipe or muffler with vehicle body Broken pipe or muffler Remedy Re...

Страница 422: ...dy 1 Valve Operate valve manually Operates freely Valve sticking Replace main muffler Active Refer to P 1540 exhaust Faulty switch Replace switch switch 3 Power window Check continuity be Continuity p...

Страница 423: ...applied to terminals 11 and 12 of the variable induction control motor connector the induction control valve shaft turns smoothly Caution Be sure to apply a voltage of not higher than DC 6V to the var...

Страница 424: ...ontinu ity Standard value Measured terminal Continuity Between terminals 11 and Present 12 5 35 Q 20 C 68 F 4 Make sure that when DC 6V is applied to terminals 11 and 12 of the variable induction cont...

Страница 425: ...SURE CONTROL SYSTEM CHECK Turbo 1 After the diagnostic trouble code of MFI system is com pletely read turn off the ignition switch 2 Disconnect the hose black from the turbocharger waste gate solenoid...

Страница 426: ...r wire B nipple condition Normal condition I Connected Disconnected Open Close Open Negative pressure leaks Negative pressure is held Negative pressure is held COIL RESISTANCE CHECK Measure resistance...

Страница 427: ...flow sensor gasket 10 Volume air flow sensor assembly Air intake hose removal steps Non Turbo 11 Breather hose 12 Air intake hose 1 3 R e s o n a t o r 05FOOO1 00000608 Air intake hose removal steps T...

Страница 428: ...t air intake hoses B and C until seated Insert the turbocharger end of air intake hoses B and C com pletely INSPECTION l Check the air cleaner body cover or packing for deforma tion corrosion or damag...

Страница 429: ...ir hose D 3 Charge air cooler duct RH C 4 Charge air cooler right Charge air cooler left removal steps B 5 Air hose G 6 Air pipe A 7 Heat protector F B 8 Air hose B B 9 Air hose E 10 Air pipe B 11 Air...

Страница 430: ...end of air intake hoses B and C com pletely B CHARGE AIR COOLER LEFr AIR HOSE F AIR HOSE E AIR HOSE B AIR HOSE G INSTALLATION Aligning the marks at the points indicated by the arrows insert securely...

Страница 431: ...r cable bracket A 4 Throttle body gasket 5 Brake booster vacuum hose connec 14 Intake manifold plenum stay connec tion tion 6 Harness connectors 15 Intake manifold plenum installation bolts 7 VIC moto...

Страница 432: ...HROTTLE BODY GASKET INSTALLATION Install with the gasket protrusion positioned as shown Caution If installed in an incorrect direction idling failure or other problems may occur INSPECTION Cheek the f...

Страница 433: ...for California 11 Manifold differential pressure sensor From 1996 model 12 EGR valve Up to 1995 model for California and from 1996 model ml IO 3 Nm 05FOO89 0 0 0 0 4 1 5 0 7 9 ft lbs 13 EGR valve gask...

Страница 434: ...protrusion positioned as shown Caution L If installed in an incorrect direction idling failure or other problems may occur INSPECTION Check the following points replace the part if a problem is found...

Страница 435: ...Refer to GROUP 13F Engine Control l Fuel Leakage Checking lo 13 Nm 8 9 ft lbs q 2 4 ft lbs 5 Nm 1 3 6 24 Nm 17 ft lbs 14 17 ft lbs i 8 x ryLy gg 05FOO24 0 0 0 0 0 6 1 2 Removal steps 1 High pressure f...

Страница 436: ...5 Nm 2 2 to 3 6 ftlbs 2 Tighten the nuts in the rear bank to 12 to 15 Nm 9 to 11 ftlbs 3 Tighten the nuts in the front bank to 12 to 15 Nm 9 to 11 ftlbs 4 Repeat steps 2 and 3 one more time respective...

Страница 437: ...found INTAKE MANIFOLD CHECK 1 Check for damage or cracking of any part 2 Clogging of the negative pressure vacuum outlet port or clogging of the gas passages 3 Check deflection of installation surface...

Страница 438: ...ft lbs 25 05FOO43 0 0 0 0 0 6 1 4 Removal steps D 1 Air hose C E 2 Air intake hose B D 3 Air hose D 4 Air hose A C 5 Air hose B 6 Air pipe B C 7 Air hose E 8 Air pipe C 9 Drive belt Refer to GROUP 11...

Страница 439: ...l installation of the turbocharger assembly INSTALLATION SERVICE POINTS bAdTURBOCHARGER ASSEMBLY INSTALLATION Clean the alignment surfaces shown in the illustration Supply clean engine oil through the...

Страница 440: ...e arrows insert until seated Insert the turbocharger end of air intake hose 6 completely INSPECTION TURBOCHARGER ASSEMBLYCHECK l Visually check the turbine wheel and the compressor wheel for cracking...

Страница 441: ...m 33 ft lbs Removal steps 1 Battery 2 Accelerator cable connection engine side Ed 3 Air hose A Ed 4 Air pipe A 5 Heat protector F 6 Clutch booster vacuum hose 7 Accelerator cable connection pedal 13 E...

Страница 442: ...that a piece of the gasket does not enter the oil passage hole B OIL PIPE INSTALLATION Supply clean engine oil through the oil pipe installation hole of the turbocharger assembly C HEATED OXYGEN SENSO...

Страница 443: ...the turbine wheel and the compressor wheel can be easily turned by hand l Check for oil leakage from the turbocharger assembly l Check whether or not the turbocharger waste gate valve remains open If...

Страница 444: ...moval and Installa tion Vehicles with Air Conditioning Refer to GROUP 14 Radiator 3 12 15 Nm 9 11 ft lbs 30 Nm 22 ft lbs 12 15 Nm 9 11 ft lbs 45 Nm 33 ft lbs Exhaust manifold removal steps front Exhau...

Страница 445: ...el 60 Nm 43 ft lbs Up to 1993 models 60 Nm 43 ft lbs 33 ft lbs 12 15 Nm 0 0 0 0 0 6 1 7 Exhaust manifold removal steps front 1 Drive belt Generator Refer to GROUP 11 Service Adjustment Procedures 2 Ge...

Страница 446: ...ion Operation l Turbocharger Assembly Removal and Installation Refer to P 1520 23 12 15 Nm 9 11 ft lbs 9 11 ft lbs Exhaust manifold removal steps front 1 Heat protector bC 2 Exhaust manifold front Bq...

Страница 447: ...STAY INSTALLATION With the exhaust manifold stay resting on the exhaust man ifold fit it along with the exhaust manifold over the studs Cd EXHAUST MANIFOLD INSTALLATION FRONT Tighten the nuts in the...

Страница 448: ...s 1 Main muffler and center exhaust pipe installation bolts 2 Gasket 3 Rubber hanaers 4 Rubber hanker 5 14 Rubber hangers 15 bracket Hanger 16 brackets Hanger 17 Rear floor heat protector 18 6 i 10 11...

Страница 449: ...14 Rubber hangers 15 Hanger bracket 16 Hanger brackets 17 Rear floor heat protector 18 Catalytic converter and front exhaust pipe installation bolts 19 Catalytic converter 13 Nm A05F0069 9 ft lbs 20...

Страница 450: ...REMOVAL SERVICE POINTS I dAbRUBBER HANGER MAIN MUFFLER REMOVAL Support with a transmission jack etc d INSPECTION l Check the mufflers and pipes for corrosion or damage l Check the rubber hangers for...

Страница 451: ...Nm 9 ftlbs 13 Nm 9 ft lbs cOSFOO72 Removal steps 1 Main muffler and center exhaust pipe installation bolts 2 Protector i B 3 Cable assembly connection 4 Rubber hangers 4w 5 Rubber hangers 6 Main muff...

Страница 452: ...ket 22 Self locking nuts 23 Rubber hanger 24 Front exhaust pipe 25 Gaskets 26 Self locking nuts 27 Right bank warm up threelway catalytic converter 28 Gasket 29 Hanger bracket B A4 30 Heated oxygen se...

Страница 453: ...tch Control l Drive Shaft Left Side Inner Shaft Assembly Removal and Installation Refer to GROUP 26 Drive Shaft 13 Nm 9 ft lbs 3 6 ft lbs 13 13 Nm m 4 n 8 5 Nm 4 ft lbs 13 Nm 9 ft lbs 13 Nm 9 ft lbs A...

Страница 454: ...gen sensor protector 23 Heated oxygen sensor connection 24 Self locking nuts 25 Rubber hanger 26 Front exhaust pipe 27 Gaskets 28 Self locking nuts 29 Right bank warm up three way catalytic converter...

Страница 455: ...nd Installation l Refer to GROUP 21 Clutch Control Drive Shaft Left Side Inner Shaft Assembly Removal and Installation Refer to GROUP 26 Drive Shaft J 13 Nm 9 ft lbs 37 6 l rl I A 7 x jf 1 3 13 Nm 9 f...

Страница 456: ...talytic converter 19 Gasket 20 Oxygen sensor protector 21 Heated oxygen sensor connection 22 Self locking nuts 23 Rubber hanger 24 Front exhaust pipe 25 Gaskets 26 Self locking nuts BO5FOO71 27 Z 4Bb...

Страница 457: ...STALLATION SERVICE POINTS A4 HEATED OXYGEN SENSOR INSTALLATION Use the special tool to install the heated oxygen sensor B CABLE ASSEMBLY INSTALLATION Install with the paint mark facing up and adjust t...

Страница 458: ...exhaust system control module B1 2 Cable connection Actuator side 3 Actuator 205FOO22 4 Protector A I connection Muffler side INSTALLATION SERVICE POINTS A4 CABLE INSTALLATION Muffler Side Install wi...

Страница 459: ...r 1 I Ll t t 7 f t y o 205FOO51 INSPECTION ACTIVE EXHAUST SWITCH CHECK 1 Remove switch garnish B from the knee protector 2 Operate the switch and check the continuity between the terminals Switch posi...

Страница 460: ...NOTES...

Страница 461: ...ine Coolant Temperature Sensor and intake Air Temperature Sensor 65 CONTINUED ON NEXT PAGE WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper servic...

Страница 462: ...Non Turbo from 1996 model 67 Mixture Control MFI System 70 Vacuum Control Valve Non Turbo 69 POSITIVE CRANKCASE VENTILATION SYSTEM 56 Component Location 56 Crankcase Ventilation System Inspection 56...

Страница 463: ...OR PEDAL Symptom ProbabUe cause Remedy Throttle valve will not Misadjusted accelerator cable fully open or close Adjust Misadjusted automatic speed control cable Adjust Broken return spring Replace Th...

Страница 464: ...m 12 20 in 4 If the play is out of the standard limits loosen the adjusting bolts slide the plate so that the inner cable play will fall within the standard limits and then retighten theadjust ing bol...

Страница 465: ...celerator cable 5 Accelerator pedal 6 Spring 7 Accelerator switch connector connec 9 Split pin 10 Accelerator arm 11 Return spring 12 Accelerator switch A T 13 Accelerator arm stopper 14 Bolt A T 15 S...

Страница 466: ...E AND EMISSION CONTROL Cruise Control System CRUISE CONTROL SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS NOTE l Vehicles built up to April 1991 2 Vehicles built from May 1991 SERVICE SPECIFICATIONS TS...

Страница 467: ...SION CONTROL Cruise Control System 17 7 SPECIAL TOOLS Up to 1993 models Checking of the diagnostic output Checking of the diagnostic trouble code Checking of the diagnostic trouble code check harness...

Страница 468: ...nsion TROUBLESHOOTING QUICK REFERENCE CHART Cruise control system is canceled when cancellation not wanted Or the cruise control system cannot be set after an automatic cancellation Check the diagnost...

Страница 469: ...hen RESUME switch is set to RESUME switch ON Replace control switch OFF code No 22 does not go away P 17 13 malfunction Even when CANCEL switch is set to CANCEL switch ON Replace control switch OFF co...

Страница 470: ...rake switch for cruise No 6 canceled when the brake pedal is control malfunction depressed short circuit drive circuit short circuit Remedy Repair the vehicle speed sensor system or replace the part R...

Страница 471: ...Malfunction of the ECU Zruise control ON indicator light Burned out indicator light No 3 joes not come on However bulb ruise control is functional Open or short circuit in harness Malfunction of cont...

Страница 472: ...it automati cally returns to the neutral position Since the current from switch S2 flows to relay Ryl the contact of relay Ryl remains closed 3 When the main switch is set to OFF current to relay Ryl...

Страница 473: ...and neutral position there Battery positive after voltage Main switch OFF and neutral position 0 V thereafter 8 14 Control unit ground 16 Control unit back up power supply At all times At all times o...

Страница 474: ...TROUBLESHOOTING HINTS Diagnosis No 15 Automatically canceled ECU terminal voltage to OFF and when the vehicle speed is reduced to less than 40 km h 25 mph the vehicle I will not resume cruising at th...

Страница 475: ...tion meter it lights as soon as the main switch is set to ON 2 Cruise control CRUISE indicator light During cruise control operation transistor Trl in the control unit is kept in the ON state to keep...

Страница 476: ...the output gear Since the ve hicle speed sensor is of the electronic type the power is supplied through the ignition switch IG TROUBLESHOOTING HINTS Diagnosis No 12 Automatically canceled Kxs5 AK R13...

Страница 477: ...LJ ENGINE AND EMISSION CONTROL Cruise Control System 17 17 I 5 Inspection of vacuum pump assembly drive circuit I r Lp s 1 14 21 I 126 J 13 112 V V V 23 ULW AI RlsW YI NO O 48P3d b id TSB Revision...

Страница 478: ...f valve and is controlled by the con power to the vacuum pump assembly trol unit as shown in the following table When The vacuum pump assembly consists of a dia the brake pedal is depressed during cru...

Страница 479: ...pedal position switch circuit Mm DESCRIPTION OF OPERATION When the clutch pedal is depressed during vehicle speed control the contact of the clutch pedal position switch is closed As a result a cance...

Страница 480: ...is placed in the N position during vehicle speed control a cancel signal is input to the control unit which internally interrupts the power supply to the vacuum pump assembly drive circuit for cancel...

Страница 481: ...l unit regarding the opening of the accelerator The as well as cruise control closed throttle position switch inputs the data to the control unit on whether or not the accelerator The throttle positio...

Страница 482: ...ator pedal switch is used to detect the operating state of the accelerator pedal It is one during vehicle speed control the cruise control unit of the sensors of the ELC 4A T automatic transmis forces...

Страница 483: ...e OFF state When the vehicle speed control is in the overdrive This cancels the overdrive mode because no OD mode if the actual vehicle speed falls more than switch ON signal is input to the ELC 4A T...

Страница 484: ...iagnostic trouble codes When connecting the scan tool to a vehicle up to 1993 models use the adapter harness supplied together Caution Turn off the ignition switch beforehand whenever the scan tool is...

Страница 485: ...s when a scan tool is used From 1994 models Connect a voltmeter to the diagnostic output terminal and the ground terminal of the data link connector using the special tool Observe the voltmeter pointe...

Страница 486: ...ostic trouble code first and conduct input check 2 Input check can be conducted by set operations On board diagnostic terminal outputs display patterns 3 Display codes are displayed only if the circui...

Страница 487: ...24 and 25 are displayed Vehicle speed less than approx 40 km h 25 mph 26 M T Clutch pedal position Clutch pedal position switch switch ON clutch pedal circuit normal depressed A T Park neutral positio...

Страница 488: ...1 16FO256 Engine front view Engine rear view 36FOO60 INSTRUMENT PANEL AND FLOOR CONSOLE 01 02 03 04 05 06 07 08 09 16FO175 Jumper connector Vacuum pump Throttle position sensor Park neutral position s...

Страница 489: ...ol relay 15 Over drive switch CA T 16 Cruise control unit 17 Front wiring harness and junction block combination 18 Front wiring harness and junction block combination 19 Front wiring harness and junc...

Страница 490: ...30 ENGINE AND EMISSION CONTROL Cruise Control System LOCATION OF CONTROL UNIT AND RELAY 216FO204 L 264 GROUND POINT Engine control module control unit 216FO396 A Ii I T f J c I 2 iFc259 1 TSB Revisio...

Страница 491: ...engine and set the ignition switch to OFF 5 Check that the accelerator cable cruise control cable and throttle cable are routed without sharp bends 6 Depress the accelerator pedal to check that the t...

Страница 492: ...ith intermediate link C back off adjusting nut B the specified number of turns Amount adjusting nut B is to be backed off About one turn inner cable free travel l 2 mm 04 08 in 7 Secure the throttle c...

Страница 493: ...released the constant speed at the time when it was released becomes the driving speed NOTE Even if during acceleration the vehicle speed reaches or exceeds the high limit acceleration will continue...

Страница 494: ...H CHECK 1 Remove the main switch together with the switch garnish 2 Remove the main switch from the switch garnish 3 Operate the main switch and check for continuitv across the individual terminals NO...

Страница 495: ...spring connector squib connector from the air bag module force the lock outward and pry it with a plain screwdriver as shown at left so that no undue force will be exerted on the connector when it is...

Страница 496: ...when the pedal is released PARK NEUTRAL POSITION SWITCH N POSITION CHECK A T 1 Disconnect the connector 2 On 1992 models check to be sure that there is continuity between connector terminals 8 and 9 w...

Страница 497: ...olenoid valves are defective replace the vacuum pump assembly Inspection of Motor 1 Disconnect the connector of the vacuum pump assembly 2 Check that when the battery voltage is applied across termina...

Страница 498: ...k assembly connection 4 Throttle cable and link assembly connection 5 Vacuum pump connector A4 6 w x wiorose and vacuum pump 7 Link assembly and vacuum pump 8 Vacuum pump 9 Pump bracket 11 07FOO31 000...

Страница 499: ...eps 20 Air bag module Refer to GROUP 52B Air Bag Module and Clock Spring 21 Air bag module bracket 22 Cruise control switch 23 Switch garnish 24 Main switch 07FOO28 0 0 0 0 2 4 4 5 Control unit and re...

Страница 500: ...eters and Gauges 34 Vehicle speed sensor 3 Refer to GROUP 54 Meters and Gauges 35 Park neutral position switch A T INSTALLATION SERVICE POINT bAdVACUUM HOSE TO VACUUM PUMP CONNECTION Route the vacuum...

Страница 501: ...4 at 20 C 68 F Catalytic converter 1 Monolith type Location California Non Turbo up to 1993 model Federal Non turbo UP to 1995 model Under floor Location Turbo California Non Turbo from 1994 model Fed...

Страница 502: ...orativ emkm AThrottle body purge solenoid L Light blue R R6d B Black Fuel pressure regulator Federal Non Turbo From 1993 up to 1995 models Evaporative emission purge solenoid Evaporative emission cani...

Страница 503: ...low Fuel prkssure regulator Vehicle front 7EM0132 L Light blue R Red 8 Black L California Non Turbo From 1993 up to 1995 models EGR solenoid I I LliLlI FGR al m b n a Evaporative v emission purge sole...

Страница 504: ...l System Non Turbo From 1996 models Evaporative emission purge solenoid EGR solenoid valve Evaporative emission canister Throttle body G Green Y Yellow L Light blue R Red B Black W White Fuel pressure...

Страница 505: ...lenoid Bypass valve G Green Y Yellow Fuel pressure regulator Purge control valve I Vehicle front L Light blue R Red B Black W White Turbocharger waste gate actuator Turbocharger Turbo From 1993 up to...

Страница 506: ...trol System Turbo From 1996 models EVAP purge solenoid PUI C waste gate solenoid TC waste gate Turbocharger I Ucil IJ cJ U r r e g u l a t o r Check valve G Green Y Yellow L Light blue R Red B Black W...

Страница 507: ...System VACUUM CIRCUIT DIAGRAM Federal Non Turbo 1992 models 17 47 b Y lntake z num Throes I To combustion chamber From air cleaner B Black L Light blue R Red Fuel pressure regulator EVAP canister EVAP...

Страница 508: ...17 48 ENGINE AND EMISSION CONTROL Emission Control System Federal Non Turbo From 1993 up to 1995 models Intake manifold plenum EVAP canister B Black L Light blue R Red 27EM0287 1 TSB Revision...

Страница 509: ...ifornia Non Turbo 1992 models Intake manifold plenum Throttle body I To combustion chamber B Black G Green L Light blue R Red Y Yellow Fuel pressure t regulator From air cleaner I G r EGR valve Y 1 A...

Страница 510: ...on Turbo From 1993 up to 1995 models Intake manifold plenum Throttle body i To combustion chamber 0 Fuel pressure regulator B Black G Green L Light blue R Red Y Yellow B d EVAP purge solenoid ON open...

Страница 511: ...rol System 17 51 Non Turbo From 1996 models take manifold plenum Jp I To combustion chamber a Throttle body I wm17zi imii 1 From G Green Y Yellow L Light blue 6 Red B Black W White Fuel pressure regul...

Страница 512: ...1992 models Throttle body To combustion chamber a Fuel pressure regulator TC waste gate solenoid ON open Turbocharger bypass vah Air cleaner EGR valve 12 ao EVAP canister EVAP purge solenoid ON close...

Страница 513: ...urbo From 1993 up to 1995 models Intake manifold plenum To combustion chamber Throttle body cd Fuel pressure regulator Turbocharger bypass valve EVAP purge solenoid ON close tii rn I I e n valve I 1 W...

Страница 514: ...fold plenum Throttle body F 1 m I1 To combustion chamber II G Green Y Yellow L Light blue R Red B Black W White Fuel pressure regulator IL 13 3 I EGR valve EVAP canister Check valve Air cleaner TC was...

Страница 515: ...m that the vacuum hoses are properly connected 2 Check the hoses for irregularities disconnection loose ness etc and confirm that there is no breakage or dam age INSTALLATION 1 When connecting a hose...

Страница 516: ...lation valve and check that the negative pressure of the intake manifold is felt with finger NOTE At this time the plunger in the positive crankcase ventila tion valve moves back and forth 3 If negati...

Страница 517: ...ission Control System 17 57 EVAPORATIVE EMISSION CONTROL SYSTEM COMPONENT LOCATION Name Symbol Name Symbol Evaporative emission EVAP canister C Purge control valve Turbo B Evaporative emission EVAP pu...

Страница 518: ...T Non Turbo From 1993 up to 1995 models Engine control module Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Volume air flow sensor Engine control module Z...

Страница 519: ...engine is cold engine coolant temperature 60 C 140 F or less I Engine operating condition Applying vacuum Result I Idling 3 000 mm 375 mmHg 14 8 in Hg Vacuum is main tained When engine is hot engine...

Страница 520: ...ne coolant temperature 60 C 140 F or less I Engine operating condition Applying vacuum Result 1 Idling 3 000 mm 375 mmHg 14 8 in Hg Vacuum is maintained When engine is hot engine coolant temperature 7...

Страница 521: ...n below check by apply ZFXM0405 ing vacuum from a hand vacuum pump When engine is cold engine coolant temperature 60 C 140 F or less Engine operating condition Applying vacuum Result 3 000 rpm 375 mmH...

Страница 522: ...gher Applying vacuum Engine operating condition Result 375 mmHg Idling Vacuum is maintained 14 8 in Hg Sudden racing Vacuum leaks PURGE CONTROL SYSTEM INSPECTION Turbo From 1996 models To air intake h...

Страница 523: ...rom the air intake hose and plug the air intake hose Then connect the hand vacuum pump to the purge air hose 6 Apply vacuum in hot engine coolant temperature 70 C 158 F or higher and check to see that...

Страница 524: ...VE Turbo INSPECTION 1 Remove the purge control valve of the purge control valve mmHg in Hg airtightness 4 Blow in air lightly from the canister side nipple and check conditions as follows 5 Connect a...

Страница 525: ...ard value 36 44 Q at 20 C 68 F VOLUME AIR FLOW SENSOR ENGINE COOLANT TEMPERATURE SENSOR AND INTAKE AIR TEMPERATURE SENSOR To inspect these parts refer to GROUP 13A MFI System Components AIR CONDITIONI...

Страница 526: ...STEM COMPONENT LOCATION Name Symbol Name Symbol EGR valve California Non Turbo Turbo Federal Non Turbo from 1996 model S EGR solenoid California Non Turbo Turbo Federal Non Turbo from 1996 model A EGR...

Страница 527: ...arm condition of engine Engine operation Normal state Race the engine by rapidly The negative pressure rises to press in the accelerator pedal 100 mmHg 3 9 in Hg or more 3 Disconnect the three way ter...

Страница 528: ...passage of the EGR to check condition as follows Applying vacuum Result 45 mmHg 1 8 in Hg or less Air does not blow through 230 mmHg 9 1 in Hg or more Air blows through INSTALLATION Install a new gas...

Страница 529: ...ng the vacuum hose make an identification mark on it so that it can be reconnected to the original position 1 cup to 1995 models Disconnect the vacuum hose yellow and green stripe from the solenoid Fr...

Страница 530: ...connected 4 Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage Battery voltage B Nipple condition N...

Страница 531: ...misfiring occurs Under this condi tion the exhaust system will operate at abnormally high temperature which may cause damage to the catalyst or underbody parts of the vehicle 2 Alteration or deterior...

Страница 532: ...NOTES...

Страница 533: ...icants 3 CLUTCH MASTER CYLINDER 14 Sealant 3 CLUTCH PEDAL 8 Service Specifications _ 2 TROUBLESHOOTING 3 CLUTCH RELEASE CYLINDER 16 CLUTCH VACUUM LINE VACUUM TANK AWD 18 id ON VEHICLE SERVICE 5 Bleedi...

Страница 534: ...Specifications SPECIFICATIONS GENERAL SPECIFICATIONS 225 x 150 8 86 x 5 91 250 x 160 9 84 x 6 30 Clutch booster Boosting ratio Clutch pedal depressing force 1 7 at 110 N 24 Ibs SERVICE SPECIFICATIONS...

Страница 535: ...valent TROUBLESHOOTING Symptom Clutch slips Gear shifting failure Probable cause Remedy Clutch pedal play too small Adjust Excessive wear of clutch disc facing Replace Hardened clutch disc facing or o...

Страница 536: ...21 4 CLUTCH Troubleshooting Excessive wear of clutch disc facin I LJ 1 TSB Revision...

Страница 537: ...ontrol system disconnect the clutch pedal position switch connector and turn the switch for standard clutch pedal height Tighten the lock nut _ to the specified torque Specified torque 13 Nm 9 ft lbs...

Страница 538: ...disengages In the case of AWD vehicles measure with the engine running Clearance to toe board when clutch disengages Standard value 55 mm 2 2 in or more 7 If the play and or clearance is out of speci...

Страница 539: ...OPERATION CHECK AWD When checking the check valve keep the check valve fit in the vacuum hose 1 Remove the vacuum hose Caution The check valve is press fit inside the vacuum hose and do not remove the...

Страница 540: ...dal adjustment Refer to GROUP 35 Service Adjustment Procedures 2 Clutch master cylinder connection 3 Clevis pin 4 Clevis pin 5 Return spring 6 Pedal support bracket Ie i pin 9 Turn over spring 10 Rod...

Страница 541: ...2 1 9 33 Bushing 34 Spacer 35 Clutch pedal pad 36 Bolt 37 Lever assembly 38 Bushing 39 Spacer 40 Support bracket 41 Clutch booster 42 Clutch pedal position switch 43 Interlock switch INSPECTION l Che...

Страница 542: ...ke booster Refer to GROUP 35 Brake Booster 2 Clevis pin WD 3 Clutch master cylinder bF l Piston adjustment to push rod clearance cAWD 4 Sealer 1 v 208FOO44 00002214 Clutch tube removal steps 1 Brake b...

Страница 543: ...D V ZOEFOO45 15 Nm 13 00002215 11 ft lbs Cd Fare pipe AWD 10 Battery seat washer tank C A4 14 Clutch hose Clutch tube A tube B tube C damper removal steps E 5 Air hose A cAWD 6 Air cleaner air intake...

Страница 544: ...ER INSTALLATION On AWD vehicles use a flat type short box wrench to tighten the clutch release cylinder mounting bolts Cd VACUUM PIPE AWD INSTALLATION If the vacuum pipe has a stepped part connect the...

Страница 545: ...en the clutch booster mounting surface on the master cylinder and the end face 3 Measure the dimension D between the master cylinder mounting surface on clutch booster and the push rod end NOTE To obt...

Страница 546: ...hose or tube for cracks or clogging CLUTCH MASTER CYLINDER DISASSEMBLY AND REASSEMBLY FWD Master cylinder kit t 4 Q 8 i EF 10 ES i c 5iR g a 7 g P Ii n 3 Mu 6 ZOBFOO40 13 Nm 9 0 ft lbs 1 A ZOXFOO39 AW...

Страница 547: ...the master cylinder body and piston assembly 2 Do not disassemble piston assembly REASSEMBLY SERVICE POINT A PUSH ROD INSTALLATION NOTE Set the push rod length to the dimension shown in the illustrati...

Страница 548: ...Conforming to DOT3 or DOT4 6 Conical smina 7 8 Bleeder plug 9 Release cylinder DlSASSEMbLY SERVICE POINT dA PISTON AND CUP DISASSEMBLY 1 Remove the corrosion from the piston removal port of the relea...

Страница 549: ...ace of the piston and piston cup and push the piston cup assembly in the cylinder Specified brake fluid Conforming to DOT3 or DOT4 INSPECTION 1 Check the inner surface of the release cylinder for scra...

Страница 550: ...heck valve 4 Fitting Vacuum pipe A removal steps Cd 5 Air hose A B 6 Air cleaner cover air intake hose A 7 Vacuum pipe A Vacuum tank assembly vacuum hose E vacuum pipe C removal steps 11 Right member...

Страница 551: ...ipe without any stepped part insert the hose until the insertion amount reaches the standard value Standard value 20 25 mm 8 1 0 in BdAIR CLEANER COVER AIR INTAKE HOSE A INSTALLATION Align slots indic...

Страница 552: ...Transaxle Assembly Removal Refer to GROUP 22 Transaxle Assembly Post installation Operation l Transaxle Assembly Installation Refer to GROUP 22 Transaxle Assembly 30 42 Nm 1 15 21 Nm ft lbs 2 4Ab C 4A...

Страница 553: ...EMOVAL SERVICE POINT Lubricant MITSUBISHI genuine grease Part No 0101011 or eauivalent 6CLO33 ATFM0857 dAbCLUTCH COVER ASSEMBLY CLUTCH DISC REMOVAL Diagonally loosen bolts which attach clutch cover to...

Страница 554: ...to the push rod hole in the release fork Specified grease MITSUBISHI genuine grease Part No 0101011 or equivalent B GREASE APPLICATION TO CLUTCH RELEASE BEARING FWD Pack the inner surface of the clut...

Страница 555: ...f defective replace the clutch disc Combine the clutch disc with the input shaft and check sliding condition and check for play in the rotating direction If it does not slide smoothly check after clea...

Страница 556: ...NOTES...

Страница 557: ...CING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injuryordeathtoservi...

Страница 558: ...ing to API classifica tion GL 4 As required SEALANTS AND ADHESIVES Items 7 Specrfred sealants and adhesives Transaxle case clutch housing mating surfaces Transaxle case rear cover mating surfaces Diff...

Страница 559: ...ten or replace mounts b Inadequate shaft end play b Correct end play c Worn of damaged gears c Replace gears d Use of inadequate grade of oil d Replace with specified oil e Low oil level e Replenish f...

Страница 560: ...e 2 Install the grommet so that as shown in the illustration the cable attachment part and the projecting part are horizontal Caution The cable arrangement should be made so that the radius of cable b...

Страница 561: ...Refer to GROUP 26 Drive Shaft 2 Using a flat tip screwdriver remove the oil seal 3 Using the special tool tap the drive shaft oil seal into the transaxle The drive shaft oil seal must be installed in...

Страница 562: ...0 Nm 2 9 ft lbs 12 Nm 9 ft lbs 5 ZO9FOO79 Transaxle control cable assembly removal steps 1 Air cleaner Air intake hose Shift lever assembly removal steps 1 Air cleaner Air intake hose A 2 Transaxle co...

Страница 563: ...of shift lever 3 Install the select cable so that the flange side of the plastic bushing at the end of select cable is on the end face side of lever B 4 Turn adjuster on shift cable so that shift cabl...

Страница 564: ...ssembly steps 1 Nut 2 Spring washer 3 Plain washer 4 Shift lever 5 Bushing 6 Plain washer 7 Wave washer 8 Nut 9 Spring washer 10 Plain washer 11 Return spring 12 Bushing 13 Pipe 14 Bolt 15 Lever A 16...

Страница 565: ...Service Adjustment Procedures l Shift Lever at Each Position Checking Operation l Meters and Gauges Checking Operation 19 Nm 209FO112 09FOO99 00001532 Removal steps 1 Side under cover 2 Battery 3 Batt...

Страница 566: ...all joint connection 15 Right member 16 Starter 4Eb 17 Drive shaft Left side Inner shaft assembly F A 18 Drive shaft Right side 19 Transaxle stay Front bank side 4G 4Gb 20 Transaxle stay Rear bank sid...

Страница 567: ...BALL JOINT DISCONNECTION Using the special tool disconnect the lower arm ball joint from the knuckle Caution 1 Be sure to tie the cord of the special tool to the nearby part 2 Loosen the nut but do n...

Страница 568: ...ER PART COUPLING BOLT TRANSAXLE ASSEMBLY REMOVAL Support transaxle assembly with a transaxle jack and remove transaxle assembly lower part coupling bolt then lower trans axle assembly INSTALLATION SER...

Страница 569: ...D999563 Oil pressure gauge 10 kg cm2 H MD998332 MD998332 01 Connection of the oil pressure gauge Adapter 3 A MD99891 5 MD99891 6 01 Adjustment of kickdown servo MD99891 6 l 01 A Kickdown servo wrench...

Страница 570: ...22 14 MANUAL TRANSAXLE AWD Special Tools SPECIAL TOOLS Oil seal installer TSB Revision...

Страница 571: ...enance Service 22 15 R H side For L H Dust seal For R H DRIVE SHAFT OIL SEALS REPLACEMENT 1 Disconnect the drive shaft from the transaxle Refer to GROUP 26 Drive Shaft 2 Remove the transfer assembly 3...

Страница 572: ...rm ing to API classification GL 4 TRANSFER OIL SEAL REPLACEMENT 1 Pull out the propeller shaft from the transfer Refer to GROUP 25 Propeller Shaft 2 Using a flat tip screwdriver remove the oil seal 3...

Страница 573: ...ransaxle controll cable assembly removal steps Dd 1 Air hose A Cd 2 Air cleaner cover Air intake hose A Bd 3 Vacuum pipe A 4 Transaxle control cable assembly connection Shift lever assembly side 5 Ret...

Страница 574: ...ts indicated by arrows in air intake hose A with A markings on air intake hoses B and C then insert hoses B and C all the way into air intake hose A DqAIR HOSE A CONNECTION Connect the hoses ensuring...

Страница 575: ...llation Refer to P 22 22 l Transmission Oil Supplying Refer to l 22 15 l Shift Lever at Each Position Checking Operation l Meters and Gauges Checking the Operation c Hose clamp 4 0 Nm 09FOllO 00001537...

Страница 576: ...5 Mounting stopper 16 Transaxle mount bracket Transaxle side 17 Transaxle assembly lower part 4B coupling bolt 18 Tie rod end connection 4B 19 Lower arm ball joint connection 20 Right member 6 21 Star...

Страница 577: ...VACUUM PIPE INSTALLATION If the vacuum pipe has a stepped part connect the vacuum hose to the pipe securely up to the stepped part as shown in the figure C AIR CLEANER COVER AIR INTAKE HOSE A INSTALLA...

Страница 578: ...leeve yoke lOG0001 Gear oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classifi Removal steps 1 Bolts and nuts 2 Gaskets 3 Warm up catalytic converter and front exhaust pipe 4 Transfer as...

Страница 579: ...below are defective replace the transaxle assembly REPLACEMENT PART ZfFM0157 1 Transfer mounting bolts D 5 Input shaft rear seal cap Fd 2 Transfer case oil seal C 6 Center shaft oil seal E 3 Transfer...

Страница 580: ...the illustration drive the oil seal until it is flush with the case Do not drive the oil seal more than necessary DdlNPUT SHAFT REAR SEAL CAP INSTALLATION Using the special tool install the input sha...

Страница 581: ...pection of Electronic Control System Components 32 Shift Patterns 29 Transaxle Control Module 27 Troubleshooting Guide 15 WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEH...

Страница 582: ...i...

Страница 583: ...brake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve 11 Torque converter clutch soieno d 12 Reducing valve...

Страница 584: ...I di...

Страница 585: ...rake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve 11 Torque converter clutch solenoid 12 Reducing valve 1...

Страница 586: ......

Страница 587: ...h t Rear clutch 5 Low reverse brake End clutch 7 Kickdown servo 8 Transaxle control module Torque converter clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve Torque converter clutch sole...

Страница 588: ......

Страница 589: ...22 23 24 25 26 End clutch valve Torque converter control valve Shift control solenoid valve B Shift control valve N D control valve Regulator valve Manual valve Pressure control valve N R control valv...

Страница 590: ......

Страница 591: ...rse brake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve 10 Z 3 4 3 shift valve Il Torque converter clutch solenoid 12 Reducing va...

Страница 592: ......

Страница 593: ...2 Front clutch 3 Rear clutch 16 Torque converter control valve 17 Shift control solenoid valve B 4 Low reverse brake 18 Shift control valve 5 End clutch 19 N D control valve 6 Kickdown servo 20 7 Tran...

Страница 594: ......

Страница 595: ...r clutch 4 Low reverse brake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve IO 2 3 4 3 shift valve 11 Torque converter clutch sole...

Страница 596: ......

Страница 597: ...3 Rear clutch 4 Low reverse brake 5 End clutch 6 Kickdown servo 7 Transaxle control mod ule 8 Torque convertor clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve 11 Torque converter clutc...

Страница 598: ......

Страница 599: ...h 4 Low reverse brake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve 11 Torque converter clutch solenoid 12...

Страница 600: ...I I I LJ LJ I L...

Страница 601: ...l at 20 C 68 F Up to 1993 model Q Specifications Approx 3 Resistance of torque converter clutch solenoid valve coil at 20 C 68 F From 1995 model Q Approx 13 Line pressure Line pressure kPa psi Oil pre...

Страница 602: ...lubricants DIAMOND ATF SP or equivalent Quantity 7 5 7 9 As required SPECIAL TOOLS and lower arm ball joint l Disconnection of thecoupling of the knuckle and tie rod end ball joint ecking of the diagn...

Страница 603: ...I 4th 1 0 823 0 918 I Reduction ratio 6th Reverse Primary 0 589 3 076 3 153 1 375 1 222 Front differential 2 888 3 166 Transfer 0 814 0 958 Speedometer gear ratio driven drive 27136 28136 Oil quantit...

Страница 604: ...related to the valve body check the hydraulic pressure oassaaes for leakaae etc If the problem is unusually dirty ATF abnormal noises oil leakage or slippage of the clutch or brakes or an abnormalcon...

Страница 605: ...19 0 ring of low reverse brake circuit between valve body and case notinstalled I I X I 20 Malfunction of end clutch or piston check ball hole other 21 Malfunction of park neutral position switch dama...

Страница 606: ...ff Engine stalls Clutch slips at Clutch slips at Enginestarts when Stall rpm Vehicle D stall rpm too or vehicle Parking Abnormal N DorR R stall rpm too moves vibration shock high too low moves doesn t...

Страница 607: ...AUTOMATIC TRANSAXLE Troubleshooting 23 17 Won t shift from Won t shift to 4th xcessive creep I I I I 37 X X X X X X X TSB Revision...

Страница 608: ...23 18 AUTOMATIC TRANSAXLE Troubleshooting Excessive vibration shock during upshift TSB Revision...

Страница 609: ...AUTOMATIC TRANSAXLE Troubleshooting 23 I 9 L L 1 TSB Revision...

Страница 610: ...per filling can also raise fluid level too high When transaxle has too much fluid gears churn up foam and cause same conditions which occur with low fluid level resulting in accelerated deterioration...

Страница 611: ...chart 4 After turning the ignition switch once to OFF turn it back to ON When using a voltmeter cl993 model 1 Connect an analog voltmeter to the diagnostic output terminal No 6 terminal and the groun...

Страница 612: ...ol is used METHOD OF ERASE THE DIAGNOSTIC TROUBLE CODES When using the scan tool Multi use tester MUT cup to 1993 model or MUT II All models 1 Turn the ignition switch to OFF and then back to ON again...

Страница 613: ...ted or improperly adjusted accelerator l Check accelerator switch connector switch l Check accelerator switch on bench cl 992 model only l Adjust accelerator switch Open circuited pulse generator A l...

Страница 614: ...erators A and B on bench l Front clutch slipping l Rear clutch slipping l Check connectors of pulse generators A and B l Check pulse generators A and B on bench l End clutch slipping l Kickdown brake...

Страница 615: ...rator pedal cable is defective if change is not smooth Equivalent to out l Defective oil temperature sensor or side temperature circuit harness Gradually increases After engine warming up L range idle...

Страница 616: ...h or circuit harness l Defective manual control cable If selector lever does not move check shift lock mechanism Vehicle speed reed D Data list D Item No 38 l Duty should become 100 when ac D range ge...

Страница 617: ...elay signal 7 Engine communication signal 8 Diagnostic test mode control terminal 9 Engine communication signal 10 Power source backup 11 Kickdown servo switch 12 Closed throttle position switch 13 14...

Страница 618: ...ngine communication signal 18 Engine communication signal 19 20 Closed throttle position switch ZTFA0744 Throttle position sensor TPS 23 Oil temperature sensor 24 Sensor ground 25 Power source 26 Grou...

Страница 619: ...ntrol unit of this transaxle One is the power pattern for more powerful perfor mance and the other is the economy pattern for improved fuel consumption and quieter operation The driver can select and...

Страница 620: ...rspeed rpm I I I I I I I I I I I I I I I 1 I I I I 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Vehiclespeed km h ZTFA0570 100 I i I I J I I I _ 80 I I I 60 40 3 4ol i 1 27 I ii 20...

Страница 621: ...L I 1 I 1 1 1 1 I 1 1 1 I 1 I 1 I 1 c 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Vehicle speed km h ZTFA0817 L E range I I Ii I 11 I I 1000 2000 3000 4000 Transferdrivegearspeed...

Страница 622: ...ngcon nection 1 Reconnecttheconnector repair or replace the harness 1 Low temperature side 2 Ground 3 High temperature side 3 Oil temperature Vatythethermo sensitivepartfromlowtempera sensor ture to h...

Страница 623: ...the resistance between terminals 4 and w Resistance more or 2 with the engine idling after throttle valve open less than 0 4 kW2O C ing warm up 68 F 1 Readjust the TPS installation 1 Resistance approx...

Страница 624: ...n of the age waveform between terminals 1 and 2 pulse generator I I Oscilloscope waveform tion or replace the pulse gener Improper grounding of the pulse generator circuits shielded wir 1 ins I TFA132...

Страница 625: ...operation noise stroke 0 3 mm 012 in or less tween the valve and guide 4 Noise exists Replace the PCSV Normal 8 Shift control solenoid valve SCSV A or B Check the resistance between terminal 3 or 4 o...

Страница 626: ...rake firmly Let the engine continue idling Normal Improper adjustment of idling I f Readjust the idling c d Poor closure sticking of the torque converter clutch solenoid I Replace the torque converter...

Страница 627: ...itch ON and OFF and check operation Check for sticking l Foreign terminal caught be for operation noise Valve stroke in or tween the valve and guide i less I Noise exists Sticking is usually 1 Replace...

Страница 628: ...11 21750339 I I Continuity exists In the N range check for continuity between terminals 2 and 4 and terminals 8 and 9 In the D range check for continuity between ContinuiD exists 1 In the 2 range che...

Страница 629: ...he R range check for continuity between terminals 2 and 3 and terminals 5 and 6 1 Continuity exists 1 In the D range check for continuity between terminals 3 and 10 1 Continuity exists In the 2 range...

Страница 630: ...or continuity between the kickdown servo switch terminal and the Continuity exists 1Poor contact sticking I t No continuity J Normal 15 Transaxle control module Disconnect the harness both A and B con...

Страница 631: ...C PRESSURE TABLE No Conditions Standard oil pressure kPa psi W W Select Engine Gear a IUD brake CC Cd W 9 WD brake Front Rear 0 Low re Torque lever speed Reducing pressure End clutch verse converter p...

Страница 632: ...15 of input shaft Defective torque converter Remedy Visually check oil filter and replace it if plugged Measure line pressure b K D brake pressure and readjust line pressure if it is out of specifica...

Страница 633: ...ina l 5 Seal ring I ii 7 Seal ring 14 O ring I 4 D ring 6 D ring 12 Oil seal D ring 8 Seal ring 15 Seal ring Y Rear clutch 13 Front clutch O ringI End tch 10 SeaI ring L Low reverse brake 1 Seal ring...

Страница 634: ...l test is required operate engine at approximately 1 000 rpm in neutral for 2 minutes to cool transmission fluid between tests Stall speed 2 200 3 200 rpm TRANSAXLE CONTROL Symptom Selector lever oper...

Страница 635: ...and Check and adjust lock cams A 23 59 B and B Improperly adjusted shift lock cable elon Check adjust and replace shift 23 56 gated inner cable lock cable Sticking slide lever and cam lever inside ke...

Страница 636: ...ck slide lever 23 56 Ignition key can be Damaged lock cam A turned to LOCK posi Check and replace lock cam A 23 59 tion even with selec Loose key cylinder cover Check and retighten cover 23 56 tor lev...

Страница 637: ...on Caution 1 Do not push piston with the special tool 2 Secure adapter only hand tight to L R brake pres sure take up port and do not apply excessive torque 4 Loosen lock nut to immediately before V g...

Страница 638: ...orque wrench could result in lock nut being turned with adjust rod 9 Remove the special tool to secure the piston and torque plug to specification at UR brake pressure take up port LINE PRESSURE ADJUS...

Страница 639: ...gth 25 mm 98 in Bolt C Length 40 mm 1 57 in Caution Secure solenoid valve and oil temperature sensor harness at locations shown Especially the pressure control solenoid valve PCSV harness must be rout...

Страница 640: ...oil pan 4 Perform hydraulic test Adjust as necessary When scan tool is used 1 Use scan tool to measure the K D brake apply pressure when the pressure control solenoid valve is force driven at 50 duty...

Страница 641: ...o be sure the selector lever can be shifted to each position by button operation as shown in the illustra tion 3 Start the engine and check if the vehicle moves forward when the selector lever is shif...

Страница 642: ...gnition key to the LOCK position 4 Loosen nut that secures key interlock cable 5 Lightly pressing lock cam A in the direction of arrow lightly push key interlock cable to take up slack and tighten nut...

Страница 643: ...n illustration on left of manual control lever is aligned with the hole in park neu tral position switch body flange 5 Tighten the mounting bolts of the park neutral position switch body to the specif...

Страница 644: ...the adapter into the instrument panel and fasten the new speedometer cable 2 Install the grommet so that as shown in the illustration the cable attachment part and the projecting part are horizontal...

Страница 645: ...OO31 Transaxle control cable removal steps 1 Air cleaner cover Air intake hose C 4 Transaxle control cable assembly connection Select lever assembly side 5 Transaxle control cable assembly 6 Clamp 7 A...

Страница 646: ...rotector Refer to GROUP 52A Instrument Panel 11 Column cover lower 12 Cover B 13 Cam lever B 14 Key interlock cable B 15 Slide lever 16 Cable guide 17 Clamp 09FOO35 00001854 Shift lock cable removal s...

Страница 647: ...ustment 1 Place the selector lever in N position 2 Loosen the nut and slightly pull the transaxle control cable in the direction of the arrow then tighten the nut DdSHlFT LOCK CABLE CONNECTION SELECTO...

Страница 648: ...MBLY SIDE 1 Place the selector lever into P position 2 Connect the key interlock cable to lock cam A and temporarily tighten the nut At this time install the spring and washer which have been fitted t...

Страница 649: ...nomy ECO Hold HOLD changeover switch connector 2 Cover 3 Selector knob 4 Overdrive control switch button 5 Overdrive control switch 6 Pin 7 Pushbutton 8 Spring 9 Indicator panel 10 Power PWR Economy E...

Страница 650: ...overdrive control switch button 2 Remove the overdrive control switch mounting screw 3 Pressing the switch remove the overdrive control switch REASSEMBLY SERVICE POINT A SLEEVE INSTALLATION Place the...

Страница 651: ...OFF 6 RW Bw i 09FOO99 09FO101 00001858 OVERDRIVE CONTROL SWITCH CHECK Check for continuity between terminals when the switch is OFF and when ON 1 Switch position Terminal No I I I 1 ON Overdrive activ...

Страница 652: ...OUP 51 Front Bumper Vehicles with oil cooler 12 Nm 9 ft lbs 4 0 2 9 N m 10 ft lbs q 30 35 Nm 22 25 ft lbs 4 0 Nm 2 9 ft lbs 09FO 16 00001859 4Ab t 4Ab 4Bb 1 Hose 2 Tube assembly 3 Feed hose 4 Return h...

Страница 653: ...AL 1 Wipe the connection threads and tightly contacting surfaces clean of dust and dirt 2 Secure the oil cooler connector with a spanner to prevent excessive force from being applied to it then loosen...

Страница 654: ...aintenance Service l Selector Lever Operation Check 0 Speedometer Operation Check 51 ft lbs m 70 Nm 51 ft lbs ZOSFO112 OSFOO61 00001860 Removal steps 1 Side under cover 2 Battery 3 Battery seat Washer...

Страница 655: ...rive shaft right side 21 Transaxle stay front bank side 22 Transaxle stay rear bank side 23 Bell housing cover 24 Special bolts 25 Transaxle assembly lower part coupling bolt 4D A 26 Transaxle assembl...

Страница 656: ...al bolts push the torque converter toward transaxle so that it does not remain on the engine side 4 Remove coupling bolt at the bottom of transaxle assembly and lower the transaxle assembly INSTALLATI...

Страница 657: ...PROPELLER SHAFT CONTENTS PROPELLER SHAFT 3 General Specifications 2 SPECIAL TOOL 3 Lubricants 2 Service Specifications 2 SPECIFICATIONS 2 Adhesive TROUBLESHOOTING 2 3...

Страница 658: ...joint O D Specifications Cross type Cross type Constant velocity type Cross type Pre packed type 16 63 99 73 3 93 NOTE Propeller shaft length indicates the length between the center points of each joi...

Страница 659: ...mptom Probable cause Remedy Noise at start Noise and vibration at high speed Worn journal bearing Worn sleeve yoke spline Loose propeller shaft installation Unbalanced propeller shaft Worn journal bea...

Страница 660: ...serted in the boot 2 Use the special tool provided as a cover to prevent the entry of foreign objects into the transfer B SPACER REMOVAL The number of spacers necessary may differ from one location to...

Страница 661: ...yokes for wear damage or cracks l Check the propeller shaft for bends twisting or damage l Measure the propeller shaft runout with a dial indicator Limit Front propeller shaft 0 6 mm 024 in or less Ce...

Страница 662: ...0 0 1 0 2 6 Adhesive 3M ATD Part No 8155 or equivalent 9 Rubber packing B 10 Lobro joint boot 11 Washer 4Fb 12 Center propeller shaft A 13 Self locking nut G A 14 Companion flange H A 15 Center beari...

Страница 663: ...the companion flange and the center propeller shaft before removing the companion flange C CENTER BEARING ASSEMBLY REMOVAL First remove the center bearing bracket and then remove the center bearing u...

Страница 664: ...y available NOTE When changing the grease on the Lobro joint assembly wipe off the grease and clean the outer and inner races cage and balls 4 If the outer race cannot be removed remove the complete L...

Страница 665: ...the companion flange B LOBRO JOINT BOOT INSTALLATION Tape the serration of the center propeller shaft and then install the Lobro joint boot Cq L6BRO JOINT ASSEMBLY INSTALLATION Assemble the Lobro join...

Страница 666: ...three locations illustrated to prevent displacement of the rubber packing and fix it to the Lobro joint assembly temporarily Specified adhesive 3M ATD Part No 8155 or equivalent 8 Lining up the mating...

Страница 667: ...he Lobro joint assembly and the companion flange F CENTER BEARING ASSEMBLY COMPANION FLANGE SELF LOCKING NUT INSTALLATION 1 Install the bearing in the rubber mount groove of the center bearing bracket...

Страница 668: ...NOTES...

Страница 669: ...AXLE CONTENTS DRIVE SHAFT 12 HUB AND KNUCKLE 6 ON VEHICLE SERVICE 5 SPECIFICATIONS 2 General Specifications 2 Lubricants 2 Service Specifications 2 Hub End Play Check 5 TROUBLESHOOTING 5 SPECIAL TOOL...

Страница 670: ...1 77 DRIVE SHAFT Items FWD AWD Joint type Length mm in Outer Inner L H shaft R H shaft B J T J 417 16 4 405 15 9 or 393 15 5 B J T J 419 16 5 391 15 4 NOTE Al r SERVICE SPECIFICATIONS Items Setting of...

Страница 671: ...IAL TOOLS A MB990244 Preload socket rement of the lower arm ball joint starting ment of the stabilizer link rotation Press out of the center bearing Press fitting of the center bearing Press fitting o...

Страница 672: ...90890 01 Press fitting of the dust seal Rear suspension Press fitting of the wheel bearing oil seal drive shaft side bushing base MB990883 MB990883 01 Fate suspension MB990947 4 ki i bor MB990947 01 P...

Страница 673: ...eplace Broken boot grease leakage Replace repack grease Bend damage or abnormal wear of drive shaft Replace Play of drive shaft and hub serration Replace Abnormal wear play or seizure of center bearin...

Страница 674: ...bs r llFO026 00000628 Removal steps 4Ab 1 Front speed sensor connection Vehicles with ABS A 2 Cotter pin I A 3 Drive shaft nut 4 5 Callper assembly Brake disc 6 Front hub unit bearing 7 Dust shield 4D...

Страница 675: ...icle temporarily secure the wheel bearing by using the special tools MB990998 etc C CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it with wires AD LOWER ARM BALL JOINT DISCONNECTION...

Страница 676: ...wear l Check the oil seal for damage l Check the knuckle for cracks l Check for defective bearing NOTE If the meshing of the wheel bearing outer race and the knuckle or of the wheel bearing inner rac...

Страница 677: ...h ABS llLO125 211 A0281 DISASSEMBLY SERVICE POINTS A HUB AND ROTOR REMOVAL 1 Attach the special tools to the knuckle and front hub 2 Secure the knuckle in a vise 3 Tighten the nut of the special tool...

Страница 678: ...grease 2 Apply a thin coating of multipurpose grease to the knuckle and bearing contact surfaces 3 With the wheel bearing inner race removed press in the bearing by using the special tools 4 Install t...

Страница 679: ...6 If the starting torque and hub end play are not within the limit range while the nut is tightened to 200 260 Nm 145 188 ftlbs the bearing hub and or knuckle have probably not been installed correctl...

Страница 680: ...bracket installation bolt 7 Drive shaft and inner shaft assembly L H 8 Drive shaft R H 9 Circlip Caution In the case of AWD vehicles with ABS take care not to damage the rotor for ABS installed to the...

Страница 681: ...e sure to tie the cord of the special tool to the nearby part 2 Loosen the nut but do not remove it D DRlVE SHAFT AND INNER SHAFT FokllLY L H DRIVE SHAFT R H 1 Using the special tool push out the driv...

Страница 682: ...hicle to the ground and finally tighten the wheel bearing nut 3 If the position of the cotter pin holes does not match tighten the nut up to 260 Nm 188 ftlbs in maximum 4 Install the cotter pin in the...

Страница 683: ...and inner shaft T J case Seal plate Inner shaft Dust shield Bracket assembly Dust seal outer Dust seal inner Center bearing Center bearing bracket Circlip 00000632 Bracket Assemblv Bearing Dust Seal R...

Страница 684: ...respectively at the joint and inside the boot Special grease is used to lubricate the joint Do not mix old and new grease or different types 1 of grease Grease Repair kit grease cFWDr 145 g 5 11 oz cA...

Страница 685: ...erneath 2 Use the special tool to remove the inner shaft from the center bearing bracket B CENTER BEARING REMOVAL Use the special tools to remove the center bearing from the center bearing bracket C T...

Страница 686: ...grease is used to lubricate the joint Do not mix old and new grease or different types of grease 3 Secure the boot bands Caution 1 The boot bands should be tightened with the drive shaft at a 0 joint...

Страница 687: ...bearing bracket DA DUST SEALS INSTALLATION 1 Apply multipurpose grease to the rear surfaces of all dust seals Dust seal inner 14 20 g 49 71 oz Dust seal outer 8 12 g 28 42 oz 2 Press the oil seal into...

Страница 688: ...press the seal plate into the T J case 3 Fill the specified grease furnished in the repair kit to the T J case Specified grease Repair kit grease 160 g 5 64 oz Caution 1 The grease in the repair kit...

Страница 689: ...Check the dust cover for damage or deterioration 1 11X0138 r MB991561 Stopper 1x0131 Adjusting bolt 11x0141 00003420 B J BOOT RESIN BOOT REPLACEMENT 1 Remove the large and small boot bands NOTE Do no...

Страница 690: ...mount of crimping is above 2 8 mm llO in Readjust W given in 4 above to the value calculated by the following formula and repeat work described in 6 W 5 5 mm 217 in B Example When B mm 102 in 2 9 mm 1...

Страница 691: ...14 Make sure that the amount of boot band crimping is within the range of standard value E Standard value E 2 4 2 8 mm 094 110 in When amount of crimping is above 2 8 mm llO in Readjust W given in 11...

Страница 692: ...NOTES...

Страница 693: ...el Bearing End Play Check 14 Rear Wheel Bearing Rotary Sliding Resistance Check 15 SPECIAL TOOLS 8 SPECIFICATIONS 6 General Specifications 6 Lubricants 7 Sealants and Adhesives 7 Service Specification...

Страница 694: ...SPECIFICATIONS d GENERAL SPECIFICATIONS Item Specification Wheel bearing Type Unit ball bearing SERVICE SPECIFICATIONS Items Limit Wheel bearing end play mm in 0 05 002 or less Rear hub rotary slidin...

Страница 695: ...ace the rear hub bearing unit if an adjustment cannot be made to within the limit REAR HUB ROTARY SLIDING RESISTANCE CHECK 1 Inspect the play of the bearings while the vehicle is jacked up and resting...

Страница 696: ...Rear rotor Vehicles with ABS 9 Rear hub unit bearing Caution Rear hub unit bearing cannot be disassembled REMOVAL SERVICE POINTS A REAR SPEED SENSOR REMOVAL VEHICLES WITH ABS Caution Be careful when...

Страница 697: ...nd not to drop it If the rotor s toothed surface is chipped or the rotor is deformed it might not be able to accurately sense the wheel rotation speed and the system as a result might not perform norm...

Страница 698: ...Hypoid gear Up to 1993 models 3 545 From 1994 models 3 307 Differential gear type Side gear and configuration Pinion gear Number of teeth Drive gear Drive pinion Side gear Pinion gear 1 O D x I D mm...

Страница 699: ...25 l 2 gear oil application Rear wheel bearing rotation torque N Ibs I 12 2 6 I Rear axle total backlash mm in Drive gear runout mm in 5 2 I 1 0 05 002 Rear wheel bearing end play mm in I I 0 8 031 I...

Страница 700: ...of axle shaft inner bearing Installation of axle shaft inner bearing Installation of drive pinion rear bearing outer race Installation of drive pinion front bearing outer race Installation of differen...

Страница 701: ...r gauge MB990802 MB990802 01 Pressing of drive pinion rear bearing inner race Pressing of side bearing inner race Bearing installer MB990326 General tool service Measurement of the drive pinion preloa...

Страница 702: ...eral service tool General service tool MB991367 01 P 334 MB990339 01 MB990811 01 MIT44801 MIT303173 MB990767 01 Application Driving out and press fitting of differential support bushing and differenti...

Страница 703: ...Application MB990339 General service Removal of drive pinion rear bearing inner race Taper roller bear tool ing puller MB990648 General service Bearing remover tool MB990890 MB990890 01 Press fitting...

Страница 704: ...er components abnormal noise can also be caused by the universal joint of the propeller shaft the axle shafts the wheel bearings etc Before disassembling any 2 2 parts take all possibilities into cons...

Страница 705: ...ufficient gear oil quantity Replenish Breakdown 2 Incorrect final drive gear backlash Adjust Insufficient drive pinion preload Insufficient side bearing preload Excessive differential gear backlash Lo...

Страница 706: ...ve the differential carrier assembly and adjust the backlash Refer to P 27 27 GEAR OIL LEVEL CHECK 1 Remove the filler plug and check the oil level 2 The oil level is sufficient if it reaches the fill...

Страница 707: ...ary sliding resistance exceeds the limit value check the tightening torque of the axle shaft companion flange If it is normal replace the bearing LIMITED SLIP DIFFERENTIAL CHECK 1 Block the front whee...

Страница 708: ...7 Companion flange 4W 8 Axle shaft assembly dE F 9 Rear rotor Vehicles with ABS 4F FE 10 Outer bearing F D 11 Dust shield C 12 Dust shield 13 Axle shaft 4G B 14 Oil seal G A4 15 Inner bearing REMOVAL...

Страница 709: ...AL With the special tool remove the axle shaft from the axle housing E REAR ROTOR REMOVAL VEHICLES WITH ABS Using the special tool remove the rear rotor from the axle shaft dF OUTER BEARING DUST SHIEL...

Страница 710: ...SHIELD INSTALLATION Orienting the dust shield as shown in the illustration and using the special tool press fit the dust shield until it contacts the axle shaft shoulder NOTE When tapping the oil sea...

Страница 711: ...al tool secure the axle shaft and tighten the companion flange self locking nut INSPECTION l Check the companion flange for wear or damage l Check the dust shield for deformation or damage l Check the...

Страница 712: ...uipped with the LSD having a VCU has a two part serration Be very careful to install each one on the correct side NOTE The left and right drive shafts can also be distinguished from each other by the...

Страница 713: ...1 lN0023 B J repair kit P i 1 2 c f g llNO024 0 0 0 0 1 0 4 6 T J repair kit llN0022 Disassembly steps C 1 T J boot band large C 2 T J boot band small 3 T J case 4W 4 Snap ring A FBI 5 Spider assembl...

Страница 714: ...to each as a rule Special grease is used for the joint Do not mix old grease with new or mix different types llA0369 Grease Repair kit grease Quantity to use 125 g 4 41 oz Caution Apply all of the gr...

Страница 715: ...t the T J and B J boots are not damaged when they are removed 2 Withdraw the T J and B J boots from the drive shaft C GREASE FROM B J REMOVAL Wipe out the grease from the B J Caution Do not disassembl...

Страница 716: ...d grease Repair kit grease 2 Install the spider assembly with the chamfered spline end first C T J BOOT BANDS INSTALLATION Set the T J boot bands at the specified distance in order to adjust the amoun...

Страница 717: ...aintenance Service l Main Muffler Removal and Installation Refer to Group 15 Exhaust Pipe and Muffler 24 Nm 17 ft lbs 6 90 Nm 90 Nm 65 ft lbs L 22 25 ft lbs 90 Nm 65 ft lbs Removal steps A 1 Drive sha...

Страница 718: ...er shaft connection 3 Support the propeller shaft with wire C DIFFERENTIAL CARRIER REMOVAL Holding the bottom of the differential carrier and removing the rear wheel oil pump through the mounting hole...

Страница 719: ...ools in a vice and attach the differential carrier to the working base FINAL DRIVE GEAR BACKLASH CHECK With the drive pinion locked in place measure the final drive gear backlash with a dial indicator...

Страница 720: ...on and then once in the reverse direction while applying a load to the drive gear so that the revolution torque approximately 2 5 3 0 d Nm 28 33 in lbs is applied to the drive pinion Caution If the dr...

Страница 721: ...pattern resulting from insufficient pinion height The drive pinion is positioned too close to the center of the drive gear Decrease the thickness of the pinion height adjusting shim and position the...

Страница 722: ...earing inner race 9 Drive gear for 4WS 10 Drive gear 11 Spring pin for 4WS 12 LSD case Refer to P 27 40 13 Self locking nut 14 Washer 4F 15 Drive pinion assembly 16 Companion flange 17 Drive pinion fr...

Страница 723: ...mm 39 in wide and 1 to 2 mm 04 to 08 in high made of copper sheet or the like to prevent damage to the bearing C SlDE BEARING INNER RACES DRIVE GEAR FOR 4WS REMOVAL Pull out the side bearing inner rac...

Страница 724: ...special tools H OIL SEAL DRIVE PINION FRONT BEARING REMOVAL Using the special tool drive out the drive pinion front bearing from the gear carrier I DRIVE PINION REAR BEARING OUTER RACE REMOVAL Using...

Страница 725: ...n rear bearing inner race Drive pinion spacer Drive pinion preload adjustment Drive pinion front shim Drive pinion assembly Drive pinion front bearing inner race Oil seal Companion flange Aen I YllFOO...

Страница 726: ...dhesive 3M Stud Locking Part No 4170 or equivalent Spring pin Drive gear I REASSEMBLY SERVICE POINTS bAdSPRING PIN INSTALLATION FOR 4WS Tap the spring pin into the differential case to the position sh...

Страница 727: ...e outer race at an angle D DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures 1 Install special tools and drive pinion front and rear bearing inner races on the...

Страница 728: ...front shim s between the drive pinion spacer and the drive pinion front bearing inner race 2 Tighten the companion flange to the specified torque by using the special tools NOTE Do not install the oi...

Страница 729: ...al tools 6 fvleasure the drive pinion rotation torque with oil seal to verify that the drive pinion rotation torque complies with the standard value Standard value Bearing classification Bearing lubri...

Страница 730: ...side bearing inner races to the differential case by using the special tool H FINAL DRIVE GEAR BACKLASH ADJUSTMENT 1 Using the special tool temporarily tighten the side bearing nut until it is in the...

Страница 731: ...Check the drive gear and drive pinion for tooth contact If poor contact is evident make adjustment Refer to P 27 29 7 Measure the drive gear runout at the shoulder on the reverse side of the drive ge...

Страница 732: ...tial side gear R H 9 Thrust washer R H A4 10 Differential case B BEFORE DISASSEMBLY CHECK DIFFERENTIAL GEAR BACKLASH CHECKING 1 Secure the differential case assembly in a vise so that the differential...

Страница 733: ...n the standard value range the backlash of the differential gear is normal 6 If the clearance in the thrust direction of the side gear is not within the standard value range remove differential case A...

Страница 734: ...erential case assembly too tightly 4 Insert a 0 03 mm 0012 in feeler gauge at two places diagonally between differential case B and the thrust washer right Caution Do not insert a feeler gauge in the...

Страница 735: ...left from the eleven types in the kit i Differential side Differential INSPECTION 1 Check the gears and differential pinion shaft for unusual wear or damage 2 Check the spline part of the differentia...

Страница 736: ...surface with the viscous unit 2 Contact surface with the pinion mate washer 3 and 4 Contact surfaces with thrust washer ZllFOO35 Contact surface with differential 5 Check the spline part of the visco...

Страница 737: ...e Inflation Pressure Check 4 Bald Spots Tire Wear Check 4 Cracked Treads Wheel Runout Check 4 Feathered Edge SPECIFICATIONS Rapid Wear at Center 2 General Specifications I 2 Rapid Wear at Shoulders Se...

Страница 738: ...17 x 4 r 17 x 4T 2 Amount of wheel 14 55 14 55 14 III 1 o 55 zk 04 offset mm in 14 1 o 55 04 2 Pitch circle diameter 114 3 4 50 114 3 4 50 114 3 4 50 P C D mm in Spare tire Size T125 90D16 T125 90016...

Страница 739: ...k of rotation llXO110 11x0117 Cracked treads Under inflation Adjust the tire pressure Wear on one side Excessive camber Inspect the camber Feathered edge Incorrect t o e i n Adjust the toe in Bald spo...

Страница 740: ...th is less than the limit replace the tire NOTE When the tread depth of tire is reduced to 1 6 mm 06 in or less wear indicator will appear WHEEL RUNOUT CHECK Jack up the vehicle so that the wheels are...

Страница 741: ...RS 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 thi...

Страница 742: ...41 Crossmember Bushing A projection mm in 7 2 10 2 28 40 Bushing B projection mm in 6 5 9 5 26 37 SPECIAL TOOLS Tool TROUBLESHOOTING Symptom Excessive engine Probable cause Cracked rubber parts of ins...

Страница 743: ...h31 1 c 4A 35 Nm R 25 ft lbs i I Removal steps 1 Air hose G connection Turbo 2 Cruise control pump and link assembly Vehicles with Cruise Control 3 Engine mount bracket and body connection bolt 4 Eng...

Страница 744: ...VICE POINT A4 MOUNTING STOPPER INSTALLATION Attach the engine mounting bracket so that the arrow mark on the mounting stopper is in the direction as shown in the d illustration INSPECTION l Check each...

Страница 745: ...installation bolt 4 Transaxle mount bracket A 5 Mounting stopper Transaxle mount bracket E n g i n e Arrow mark INSTALLATION SERVICE POINT A MOUNTING STOPPER INSTALLATION Attach the transaxle mountin...

Страница 746: ...1 2 43 Front roil stopper bracket and engine connection bolt Front roll stopper bracket installation bolt Front roll stopper bracket Heat protector Turbo ZOlFOO30 Rear roll stopper bracket removal ste...

Страница 747: ...LATION Install the rear roll stopper bracket as shown in the illustration B REAR ROLL STOPPER BRACKET AND ENGINE CONNECTION BOLT INSTALLATION Install the bolt as shown in the illustration INSPECTION l...

Страница 748: ...Power steering Fluid Air Bleeding Refer to GROUP 37A Service Adjustment Procedures l Front Wheel Alignment Adjustment Refer to GROUP 33A Service Adjustment Procedures l Transfer Oil Supplying AWD Ref...

Страница 749: ...Stabilizer l Steering gear box Refer to GROUP 37A Power Steering Gear Box 13 Self locking nut 14 Clamp installal ion bolt short 15 Clamp installal ion bolt long 16 Clamp 17 Lower arm mounting bolt 18...

Страница 750: ...rows on their bottom surfaces may be directed in the crosswise direction except those on No 1 crossmember of FWD vehicles Caution Shifting of the arrow in the direction of rotation shall be within 5 o...

Страница 751: ...N S I O N CONTENTS FRONT SUSPENSION 33A ELECTRONIC CONTROL SUSPENSION ECS 33B ELECTRONIC CONTROL SUSPENSION ACTIVE PREVIEW ECS 33C NOTE i 1 Shaded groups in the above list are not included in this man...

Страница 752: ...33 2 NOTES...

Страница 753: ...ENTS LOWER ARM 10 SPECIFICATIONS s 2 ON VEHICLE SERVICE 6 General SpecificationS 2 Front Wheel Alignment 6 Service Specifications 3 Wheel Bearing Adjustment 6 STABILIZER BAR 12 SPECIAL TOOLS 4 STRUT A...

Страница 754: ...I Orange x 1 Blue x 1 A T Orange x 2 Spring constant N mm Ibs in 30 168 From 1994 models Items Wire dia x O D x free length mm in Coil spring identification color FWD MTT 14 4 x 170 x 322 7 56x 6 69 x...

Страница 755: ...out ECS Vehicles with ECS up to 1995 models I 150 5 91 1 080 238 Hard 2 530 558 Medium 1 580 348 Soft 620 137 Hard 1 190 262 Medium 1 120 247 Soft 970 214 Items Camber Caster Toe in mm in Standard val...

Страница 756: ...Tools SPECIAL TOOLS Tool A MB991 237 B MB991 238 Compression of the front coil spring MB990326 General service P r e l o a d s o c k e t too Measurement of the ball joint and stabilizer link ball join...

Страница 757: ...ring Wheel alignment Unbalanced or worn tires Broken or deteriorated stabilizer Shock absorber malfunction Improper tire inflation pressure Broken or deteriorated coil spring Shock absorber malfunctio...

Страница 758: ...ner wheel 33 45 Outer wheel 28 21 CAMBER AND CASTER Standard value Camber 0 f 30 Caster 3 55 30 Install the special tool by tightening it to the same torque as that applied to the drive shaft nut To a...

Страница 759: ...P 33A 6 i Removal steps 1 Brake hose tube clamp mounting bolt 2 Brake hose tube clamp 3 Front speed sensor clamp mounting nut ABS 4 Front speed sensor clamp ABS 5 Strut lower mounting bolt 6 Strut upp...

Страница 760: ...does not adhere to the insulator s rubber part DISASSEMBLY SERVICE POINT A SELF LOCKING NUT REMOVAL 1 Holding the spring upper seat with the special tool loosen the self locking nut Caution The self...

Страница 761: ...s easily accomplished with a pipe Q 8 mm x 300 mm 3 in x 11 8 in B SELF LOCKING NUT INSTALLATION 1 With the coil spring held compressed by the special tools MB991 237 and MB991 238 provisionally tight...

Страница 762: ...izer link 4 Self locking nut connecting lower arm ball joint to knuckle 5 Lower arm mounting nut 6 Lower arm mounting bolt 7 Clamp mounting self locking nut 8 Clamp mounting bolt small 9 Clamp mountin...

Страница 763: ...e tilts 6 1 with respect to the bottom surface of the lower arm then mount the self locking nut INSPECTION l Check the bushing for wear and deterioration l Check the lower arm for bend or breakage l C...

Страница 764: ...cles with automatic transaxle 2 Transfer AWD Refer to GROUP 22 Transfer 6 40 Nm 29 ft lbs 1210011 0 0 0 0 0 6 2 7 3 Stabilizer link 4 Stabilizer bar bracket mounting bolt A 5 Stabilizer bar bracket 6...

Страница 765: ...RQUE Install the nut to each stud Then use the special tool to measure the ball joint breakaway torque Standard value 1 7 3 2 Nm 15 28 in lbs BALL JOINT DUST SHIELD REPLACEMENT 1 Remove the clip ring...

Страница 766: ...NOTES...

Страница 767: ...to personal injuryordeathtoservicepersonnel from inadvertentfiringoftheairbag ortothedriverandpassenger from rendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related...

Страница 768: ...color Green x 1 Green x 2 Brown x 1 Spring constant 29 162 29 38 N mm Ibs in 162 212 COIL SPRING Convertible Items Wire dia x O D x free length mm in Coil spring identification color Spring constant N...

Страница 769: ...57 From 1994 models Items FWD AWD Wire dia x center dia x free length 11 6 x 105 x 350 0 mm in 46 x 4 13 x 13 78 11 5x105x379 3 45 x 4 13 x 14 93 Green x 1 Brown x 1 34 190 28 157 COIL SPRING Converti...

Страница 770: ...Rear suspension FWD Rear suspension AWD Standard value Camber 0 30 0 t 30 0 10 30 Caster 3 55 ri 30 Toe in mm in Ozk3 Ok 12 At 2 5 02 1j 5 2 5 1 02f l SPECIAL TOOLS Tool ectronic control suspension l...

Страница 771: ...r line is open circuited however it cannot be detected In a situation where anti roll control only stops if diagnostic trouble code No 21 is not on display a short circuited sensor output line 3 or op...

Страница 772: ...terminal of G sensor and No 61 terminal of ECS control unit Correct harness Yes Is trouble cleared by replaced G sensor Yes 1 End Replace ECS control unit When diagnostic trouble code No 21 is output...

Страница 773: ...e speed sensor Sensor power supply and ground and ground Is continuity provided between No 3 terminal of vehicle speed sensor and No 53 terminal of ECS control unit Yes 1 No Check vehicle speed sensor...

Страница 774: ...ltage force drive actuator by scan tool Is terminal voltage up to specification Standard 9 V during forced drive of actuator for approx 1 sec 0 V except during forced drive Yes P N o Is trouble correc...

Страница 775: ...ulb I LBetween No 11 and 3 terminals J 1 Yes 1 Is continuity provided between No 2 terminal of combination meter and ground Ee Correct harness I Yes I 1 Istroubleclearedbyreplacing combinationmwL Repl...

Страница 776: ...connector with ignition switch at ON Check throttle position sensor Refer to P 33B 19 Good Yes 1No Replace E control unit 7 Replace throttle position sensor f N o No 1 terminal voltage and continuity...

Страница 777: ...ng force changeover actuator including posi tion detection switch 2 ON BOARD DIAGNOSTIC OUTPUT CHECK When using the scan tool multi use tester MUT Up to 1993 models or MUT II call models 1 Connect sca...

Страница 778: ...the basis of the deflection of the pointer of the voltmeter 5 Based on the diagnostic trouble code repair the associated defective portion 6 Set the ignition switch to OFF 7 Disconnect the battery cab...

Страница 779: ...j lJljljL EEiPlZZL R L damping force ha zrr actuator NOTE 1 Control stop warning indication and fixed damping force return to normal when the ignition switch is set to OFF When any of the problems mar...

Страница 780: ...is regarded as a problem 61 64 Damping force changeover ac If no damping force changeover is made in a second afteractuatordrive tuator defective signal has been output position detection switch outp...

Страница 781: ...stationary condition 5 1 Anti Roll Control Function Check 1 Raise the front wheels on a jack and have them supported by rigid racks 2 Place the steering wheel in straight ahead position 3 Select the T...

Страница 782: ...mulated vehicle speed at 60 km h 37 mph and 90 km h 56 mph similarly operate the accelerator pedal and check that the scan tool indications change over Entered simulated vehicle speed Accelerator oper...

Страница 783: ...HECK 6 1 Actuator Operating Sound Check 1 Set the ignition switch to ON 2 Bring your ear near the top of the shock absorber NOTE In the case of the rear shock absorbers remove the trim cover at the to...

Страница 784: ...0 0 0 0 OFF 0 0 STEERING ANGULAR VELOCITY SENSOR To mount or remove the steering angular velocity sensor refer to GROUP 54 Column Switch Remove the Steering wheel and clock spring before mounting or r...

Страница 785: ...DAMPING FORCE CHANGEOVER ACTUATOR To remove or mount the position detection switch and damping force changeover actuator refer to GROUP 33A Strut As sembly and GROUP 34 Shock Absorber Assembly Caution...

Страница 786: ...33B 20 ECS ECS Control Unit ECS CONTROL UNIT REMOVAL AND INSTALLATION Z12FOO98 Removal steps 1 Cargo floor box R H 2 Lid 3 ECS control unit 1 TSB Revision...

Страница 787: ...ILIZER BAR 38 TRAILING ARM 32 TROUBLESHOOTING 24 UPPER AND LOWER ARM 29 REAR SUSPENSION cFWD ON VEHICLE SERVICE 5 Rear Hub Rotary sliding Resistance Check 6 Rear Wheel Alignment Check 5 Wheel Bearing...

Страница 788: ...sAn SHOCK ABSORBER Items Specification Multi link Vehicles without ECS Vehicles with ECS 12X95X350 12 2 105 350 47 x 3 74 x 13 78 48x 4 13 x 13 78 Pink x 1 Orange x 1 35 196 35 196 Vehicles without EC...

Страница 789: ...mm in 8 5 9 5 33 37 1 Wheel bearing end play mm in 1 Rear hub rotary sliding resistance N Ibs 0 05 002 or less 31 7 or less SPECIAL TOOLS Tool TOOI number and Supersession name MB991113 MB991 113 01...

Страница 790: ...Arm set MB991 045 Bushing remov er and installer MB990880 Arbor MB990847 Base Supersession MIT62220 MB991 005 01 MB991389 01 Application Compression of the coil spring Removal and installation of the...

Страница 791: ...r One graduation changes camber by about 15 TOE IN Standard value 0 5 2 5 mm Ol 09 in To adjust toe turn the assist link mounting bolts on crossmem ber side on both sides the same amount NOTE 1 The di...

Страница 792: ...place the rear hub bearing unit if an adjustment cannot be made to within the limit REAR HUB ROTARY SLIDING RESISTANCE CHECK 1 inspect the play of the bearings while the vehicle is jacked up and resti...

Страница 793: ...ehicle Service l Absorber Lid to Rear Side Trim Installation Refer to GROUP 52A Trims Z12FOllO Removal steps 1 Shock absorber mounting nuts upper 2 ECS connector EC 3 Cap 4 Brake tube clannp bolt 5 Br...

Страница 794: ...unting nut and rear suspension assembly INSPECTION l Check the crossmember for cracks or deformation l Check the bushings for cracks or deterioration CROSSMEMBER BUSHING REPLACEMENT 1 Using the specia...

Страница 795: ...nd nut Assist link removal steps 8 Assist link mounting bolt and nut 9 Self locking nut 10 Assist link 4 Upper arm Lower arm removal steps 5 Lower arm mounting bolt and nut 6 Self locking nut 7 Lower...

Страница 796: ...over Snap ring 212R0119 Removal Pressure fitting l NOIOl J BALL JOINT BREAKAWAY TORQUE CHECKING Using the special tool measure the ball joint breakaway torque Standard value 2 9 Nm 17 78 in lbs BALL J...

Страница 797: ...lt Rear brake disc Hub cap Wheel bearing nut Rear hub assembly Parking brake cable clamp bolt bAd 13 4Bb 2 16 17 Parking brake cable end Refer to GROUP 36 Parking Brake Rear speed sensor clamp bolt CA...

Страница 798: ...kle from the lower arm upper arm and assist link Caution 1 Be sure to tie the cord of the special tool to a nearby part 2 Loosen the nut but do not remove it wrench 212AOlOO Press fit I I Removal INST...

Страница 799: ...orber upper mounting nut 3 l clc nnnnnrtnr CCC L L IIIIU L I L n n J biqJ 4 Brake tube clamp bolt 5 Shock absorber lower mounting bolt 6 Shock absorber NOTE I Indicates parts which should be temporari...

Страница 800: ...acket assembly 5 Upper spring pad 6 Upper bushing B Z12A0328 7 Collar 8 Cup assembly 9 Dust cover 10 Bump rubber A 11 Coil spring 12 Shock absorber DISASSEMBLY SERVICE POINT A PlSTON ROD TIGHTENING NU...

Страница 801: ...he shock absorber spring seat as shown FBdBRACKET ASSEMBLY t PISTON ROD TIGHTENING NUT INSTALLATION 1 With the position of the bracket assembly as shown in the figure tighten the tightening nut to the...

Страница 802: ...locking nut A 9 Stabilizer link 10 Joint cup A 11 Stabilizer rubber 12 Stabilizer bar INSTALLATION SERVICE POINTS AdSTABlLlZER LINK SELF LOCKING NUT SELF LOCKING NUT INSTALLATION 1 Hold the stabilize...

Страница 803: ...r wear and deterioration l Check the stabilizer bar for deterioration or damage l Check the stabilizer link ball joint dust cover for cracks l Check all bolts for condition and straightness STABILIZER...

Страница 804: ...8 Rear rotor CABS 9 Rear hub unit bearing Caution Rear hub unit bearing cannot be disassembled REMOVAL SERVICE POINTS dA REAR SPEED SENSOR REMOVAL ABS Caution Be careful when handling the pole piece...

Страница 805: ...al lip is pushed in the reverse direction resulting in oil leaks or loose mounting D REAR ROTOR REMOVAL CABS Caution Care must be taken not to scratch or scar the rotor s toothed surface and not to dr...

Страница 806: ...3 45x4 13x14 93 I I Coil spring identification color 1Light brown x 2 Spring constant N mm IbeAn cl 996 models Items 28 0 157 Specifications Wire dia x O D x free length mm in Coil spring identificati...

Страница 807: ...ylindrical double acting type 610 24 0 Min length mm in 407 16 0 Stroke mm in Damping force at 0 3 m set 0 9 ft set N Ibs Expansion 203 8 0 1 400 309 I Contraction 500 110 SERVICE SPECIFICATIONS Items...

Страница 808: ...MB991113 MB991113 01 Disconnection of the ball joint Steering linkage puller Em MB990326 General service Measurement of the ball joint break away tool torque 0 J Preload socket 8 0 MB990800 Ball joint...

Страница 809: ...REAR SUSPENSION AWD Special Tools 34 23 B lMB990244 i TSB Revision...

Страница 810: ...34 24 REAR SUSPENSION AWD Troubleshooting TROUBLESHOOTING TSB Revision...

Страница 811: ...e turn the trailing arm mounting bolts on the crossmember side on both sides the same amount NOTE Left wheel Clockwise toe out Right wheel Clockwise toe in The difference between right and left wheels...

Страница 812: ...36 On vehicle Service 50 60 Nm 4 _ 12 36 43 ft lbs 5 30 35 Nm Bi 1 45 Nm 3 3 ft lbs 2 80 94 ft lbs bx Ibs 6 Removal steps 1 Shock absorber mounting nuts bweO 2 ECS connector cECS 3 Cap 4 Brake tube t...

Страница 813: ...jack requires three persons as the rear suspension assembly is very heavy Assign one person to the differential and one each to the left and right lower arm 3 Apply a wood block to the ball joint of...

Страница 814: ...e Dimension A 15 5 mm 59 in Dimension B 2 1 3 7 mm 08 15 in CROSSMEMBER BUSHING REAR REPLACEMENT 1 Using the special tool remove and press fit the bushing 2 When press fitting position the bushing as...

Страница 815: ...12FOO93 00001036 Nm ft lbs Lower arm removal steps 5 Lower arm mounting nut 6 Lower arm mounting bolt A4 7 fzbilizer link to lower arm coupling 4Bb 8 Self locking nut 9 Lower arm NOTE Indicates parts...

Страница 816: ...the self locking nut so that the protrusion of the stabilizer link dimension A indicated in illustration is within the standard value Standard value A 5 7 mm 197 276 in INSPECTION l Check the bushing...

Страница 817: ...B991 073 YlZNOlOl Press fit Pipe lower am OLer pipe bushing 12A003 LQWER ARM BUSHING REPLACEMENT 1 Use the special tool to remove and press fit the bushing 2 Press fit the lower arm bushing until the...

Страница 818: ...to companion flange mounting bolt and nut 4 Self locking nut 5 Companion flange 6 Rear axle shaft 7 Parking brake cable end 8 Parking brake cable clamp bolt 9 Rear speed sensor CABS 10 Rear speed sen...

Страница 819: ...he ball joint from the knuckle Caution 1 Be sure to tie the cord of the special tool to a nearby part 2 Loosen the nut but do not remove it Press fit Removal Trailina arm bushina 2i2A0298 INSPECTION l...

Страница 820: ...rked C in the illustration to remove the connecting rod 5 Installation of the body special tool should be performed with the screw shaft and guide shaft center lines oriented as shown in the illustrat...

Страница 821: ...lbs 58 Nm A12F0126 A 1 Assist link NOTE L H side shown Bolt Lock nut A12FO125 42 ft lbs INSTALLATION SERVICE POINT A ASSIST LINK INSTALLATION If the ball studs of the assist link does not align with...

Страница 822: ...LATION Pre removal and Post installation Operation 0 Rear Side Trim Absorber Lid Removal and Installation Refer to GROUP 52A Trims Removal steps 1 Shock absorber upper mounting nut 2 ECS connector EC...

Страница 823: ...tightening nut Refer to P 34 14 i 3 Washer 4 Upper bushing A 5 Bracket assembly Refer to P 34 15 6 Spring pad bushing B 9 Cup assembly 10 Dust cover 11 Bump rubber 12 Coil spring Refer to P 34 15 13 S...

Страница 824: ...Ibs 11 4WS piping fixing bolt 4WS 12 Rear shock absorber mounting bolt 13 Power cylinder mounting bolt 4WS 14 Crossmember bracket t 15 Crossmember mounting nut 16 Stabilizer bracket 4Bb 17 Bushing 18...

Страница 825: ...B STABILIZER BAR REMOVAL 1 Lower the transmission jack a little to obtain a gap between the rear suspension and body 2 Remove the stabilizer bar INSTALLATION SERVICE POINTS A STABlLlZER LINK SELF LOC...

Страница 826: ...E CHECKING Using the special tool measure the ball joint breakaway torque Standard value 1 7 3 2 Nm 15 28 in lbs BALL JOINT DUST COVER REPLACEMENT 1 Remove the clip ring and the dust cover 2 Apply mul...

Страница 827: ...and Adjustment 63 Service Specifications 3 Check Valve Operation Check 65 TROUBLESHOOTING 5 Front Brake Disc Run out Check 70 WHEEL SPEED SENSOR ABS 113 I Front Brake Disc Run out Correction 70 WARNIN...

Страница 828: ...Brake pedal depressing force PROPORTIONING VALVE Items Convertible Hatchback Split point MPa psi 4 95 5 45 704 775 3 75 4 25 533 604 Decompression ratio 0 43 0 96 FRONT BRAKES REAR BRAKES Items FWD AW...

Страница 829: ...ngenti mounting bolts N Ibs Speed sensor s internal resistance CABS kQ Solenoid valve HU resistance R Up to 1995 models Hydraulic unit solenoid valve inte nal resistance R G sensor output voltage V cl...

Страница 830: ...e of inner shim A inner shim Brake grease SAE J310 NLGI No 1 B and outer shim Guide pin and lock pin sliding part Piston boot inner surface Pin boot inner surface Repair kit grease SEALANTS Items Spec...

Страница 831: ...uate contact of pad Correct Auto ad juster malfunction Adjust Insufficient braking Low or deteriorated brake fluid Add or refill Dower Air in brake system Bleed air from system Overheated brake rotor...

Страница 832: ...otina Insufficient parking brake function Excessive parking brake lever stroke the parking brake lever stroke ck the parking brake cable rout Scraping or grinding noise when brakes are applied when br...

Страница 833: ...m is functioning nor mally 2 When the vehicle speed reaches approximately 6 km h 4 mph after the engine is started and the vehicle starts off for the first time a whining motor noise may be heard from...

Страница 834: ...S warning light remains lit because the valve position the ABS ECU causes the ABS warn relay is OFF ing light to flash twice in about one second 3 When the ignition key is returned from the during whi...

Страница 835: ...or malfunction of ABS op CONTINUED ON NEXT PAGE eration i Yes T r o u b l e c o n d i t i o n Major causes One sided braking lnsuff icient braking force l Hydraulic line in HU is clogged l Mechanical...

Страница 836: ...l No layout for troubleshooting Terminal No layout shown on the special tool connector 00002535 If trouble does not reappear 1 watch vehicle movements until it reappears Refer to P 35 11 Caution 1 Whe...

Страница 837: ...cleared LJ Actuator test specifications I I No Scan tool display Drive solenoid Drive pattern valve and motor The actuator can be forcibly driven in the following way by using the scan tool NOTE l The...

Страница 838: ...the light Hint If other warning lights do not light up either fuse is probably blown IGNITION SWITCH IG2 IGNIT SWITC 3N Gl 127 KXI kKK R35Rl I1 2 f I w A k s 00 3 d 2 ____ ________ J B 0 I IN5g ABS P...

Страница 839: ...BS warning light normal for burned bulb Remove the combination me ter and check with the igni tion key ON i Does voltage between har ness connector terminal No 14 and ground indicate bat tery positive...

Страница 840: ...nstall the valve relay remove the HU connector and check K i E3 4 Repair harness Does positive voltage between the HU harness connector termrnal No 8 and ground rndrcate battery positive voltage while...

Страница 841: ...l safe mode In such a case erase the diagnostic trouble code and then restart the engine to check if the system is currently in a fault condition EYWP E b IGNiTlOW SWITCti IG1 86 87 I t I 30 1 85 87a...

Страница 842: ...cate with scan tool function Repair and re check Yes Correct cause of blown Disconnect ECU connector and check harness connector Is there continuity between body harness terminals No 9 and No 34 and g...

Страница 843: ...ntrol No Scan tool related mal systems communicate with scan tool function Repair and re check Correct cause of blown fuse and replace fuse Disconnect ECU connector and check harness connector No Yes...

Страница 844: ...ow er to the ABS ECU Discon nect the hydraulic unit connec tor A 64 and the ABS valve relay connector A 65 In spect the harness side of both connectors for damage to the terminal pins Repair terminal...

Страница 845: ...s only when the valve relay is off in the valve relay test etc IGNITION SWITCH lG1 T j w J B ABS ECU Disconnect the hydraulic unit connector A 64 and the ABS ECU connector E 12 Inspect the harness sid...

Страница 846: ...e scan tool mode ABS does not function If it does not go into the scan tool mode check the ECU power circuit and the harness between the ECU and diagnostic output terminals 2 Read the on board diagnos...

Страница 847: ...ty l Distortion of rotor teeth missing l Low frequency noise interference when sensor harness wire is broken l Noise interference in sensor signal l Sensor output signal is below the standard val ue o...

Страница 848: ...lue Front 0 3 0 9 mm 012 035 in Rear 0 2 0 7 mm 008 028 in Adjust the gap between the Yes t Is the wheel speed sensor ro No Replace rotor that has mis tor normal with no missing or sing or damaged tee...

Страница 849: ...tch may remain on for more than is a malfunction in the ABS ECU 15 minutes without ABS operation l The harness wire for the stop light switch may be open Do the stop lights light up and go out normall...

Страница 850: ...and then these diagnostic trouble codes are output IGR ITION SWiTCy IG1 G R l G R SOLENOID I I ABS ECU Ll 121 3 14 15 1617 6 19 jlO l1 12 13 i4 15 16 17 16 19 20 1e2 23 426i26 7 6 30 1 2l 5 Iu 35 AK R...

Страница 851: ...7a III81 __ _ 1 I p iiazq __________________ 1 T P B 1 1227 I ABS 22 ECU P 1 i SE L L IGNITION SWITOH IG1 Remove and check the valve relay t When the valve relay is checked are the following conditio...

Страница 852: ...motor ground line is disconnected and the motor does not revolve FUGIBLE LINK I Does the motor make a noise Yes during scan tool forced drive mode No Remove the motor relay i I No Remove the motor re...

Страница 853: ...ng which the valve relay self check is made again and then goes out 214AO594 0 0 0 0 2 1 6 5 7 No Trouble condition Major causes Remedy 1 ABS warning light does not light up at all l ABS warning light...

Страница 854: ...ficient CONTINUED ON NEXT PAGE braking force or malfunction of ABS op eration Yes Trouble condition Major causes One sided braking lnsuff icient braking force Decline in ABS function ABS sometimes fun...

Страница 855: ...minals and the diagnosis check connector Referring to the diagnostic trouble code check chart E l E 7 make the diagnostic trouble code reoccur to discov er the main cause of intermit tent or other tro...

Страница 856: ...ions ACTUATOR TEST FUNCTION The actuator can be forcibly driven in the following way by using the scan tool NOTE l The actuator test cannot be carried out when the ABS ECU system is in fail safe mode...

Страница 857: ...not light up either fuse is probably blown IGNITION SWITCH IG2 IGNI SWITi N IGl TIO 3 m d t r i 2 _ __ ____ J B 0 G 1234 BE 5678 3 3 7 i i 6 2 5 I I c R i Efi RELAY RELAY E KoEgg4 B E5LS c 6 2 5 0 G...

Страница 858: ...er t Turn the ignition switch OFF and check No c ABS warning light bulb Replace ABS warning light Check for burned bulb burned bulb i Yes Is there continuity between combination meter No 58 and No 59...

Страница 859: ...efer to P 3583 I 1 Valve relay malfunction Replace valve relay I 1Yes Install the valve relay remove the HU con 1 No Does voltage between the HU harness connector terminal No 8 and ground indi w 1 Bro...

Страница 860: ...l If the diagnostic trouble code is output the system can be in the fail safe mode In such a case erase the diagnostic trouble code and then restart the engine to check if the system is currently in a...

Страница 861: ...3565 I Yes No Power relay malfunction I Replace power relay Disconnect ECU connector and check harness connector 1 With the ignition key in the ON position does voltage be tween ECU connector terminal...

Страница 862: ...er electronic control systems communicate with scan tool tion Repair and recheck Disconnect ECU connector and check harness connector Is there continuity between body harness terminals No 9 and No 34...

Страница 863: ...rcuit on the valve relay side sequently in the START position power is off L FUS LIN IGNIT IN swm 1Gl G R 11 G R I L SmJ 12 8 1I L1 17 7 u 1 I 30 ii ______ _______ ABS ECU KK35 AK R3513 N Remove the N...

Страница 864: ...is a break in the harness between the ECU and the warning light the light illuminates only when the valve relay is off in the valve relay test etc IGNITION SWITCH IG1 I J B fX NAT ON A 3 ECU I25 Disco...

Страница 865: ...he scan tool mode In the scan tool mode ABS does not function If it does not go into the scan tool mode check the ECU power circuit and the harness between the ECU and diagnostic output terminals 2 Re...

Страница 866: ...ormality l Distortion of rotor teeth missing l Low frequency noise interference when sensor harness wire is broken l Noise interference in sensor signal l Sensor output signal is below the standard va...

Страница 867: ...cuit is broken Repair harness L 214NOlW i Is the front wheel speed sen sor to rotor clearance nor mal Standard value Owl 0 3 0 9 mm 012 035 in Yes I Yes Is the rear speed sensor mounting surface to ro...

Страница 868: ...sensor OFF trouble It is judged that the G sensor continues to be OFF for more than approximately 13 seconds except when the l When there is a broken wire or short circuit in the harness for the G se...

Страница 869: ...h remains on for more than 15 is a malfunction in the ABS ECU minutes while the ABS is not functioning l The harness wire for the stop light switch may be open cup to 1994 models F SiSLE LINKQ 1995 mo...

Страница 870: ...CU con 1 When the brake pedal is No py I Repair harness 1 Zjrr o ZtKYZ pjii zq bl Repair harness I I Yes Is resistor resistance 780 to 860 a Replace resistor IYes Is there continuity 2 terminal and gr...

Страница 871: ...d if the current value of the solenoid valves differs from each other in the same mode solenoid valve drift error is produced and the ABS ECU goes into the failsafe mode iLJ c iGNiTlON SWITCH IG1 m 59...

Страница 872: ...uble code will be output is normal In addition normally it monitors whether IGNITION SWITCH IGil Remove and check the valve relay No 30 No 87a Continuity No 30 No 87 No continuity When battery voltage...

Страница 873: ...r make a noise during scan tool forced drive mode No Remove the motor relay I Remove the motor relav and check resistance values No 85 No 86 Resistance value 72 88 SLZ No 30 No 87 No continuity Batter...

Страница 874: ...can sometimes be heard coming from inside the engine compartment but this is because the system operation check is being performed This is considered normal 1 2 Sound of the motor inside the ABS hydr...

Страница 875: ...ecial tool diagnostic trouble code check harness to ground the terminal 1 of the data link connector 2 Take a reading of the diagnostic trouble code from the flashing of the ABS warning light Diagnost...

Страница 876: ...succession according to the timing given below Caution The memory cannot be erased under the following conditions 1 When the stop light switch is not turned on and off according to the table below 2 W...

Страница 877: ...shorted 23 R R wheel speed sensor system shorted 24 R L wheel speed sensor system shorted 26 G sensor system open or short circuited or signal provided abnormally 38 Stop light switch system open cir...

Страница 878: ...sensor and ABS ECU t Check wheel speed sensor output voltage Check wheel speed sensor IOK Replace wheel speed sensor y Repair 1 C h e c k r o t o r loK ILeI Check the following connector Replace roto...

Страница 879: ...ssary l Start engine Measure voltage between terminal No 83 and body ground OK Batterv voltaae Check harness between ignition Repair Check battery lnu Code Nos 21 22 23 and 24 Wheel speed sensor syste...

Страница 880: ...nsor and ABS ECU and repair if necessarv NG Check the following Repair 1OK r Check trouble symptoms Replace ABS ECU Code No 38 Stop light switch system open circuited or ON trouble Probab e cauSe Outp...

Страница 881: ...ABS ECU defective or short circuited or harness is judged to be broken or shorted and output is provided Check solenoid valve Refer to P 35 112 IOK Replace HU t vleasure at HU connector A 64 and jBS E...

Страница 882: ...12 l Disconnect connectors and make measurements on har ness side l Resistance between 82 47 c 94 A 80 1OK Repair NG L Check solenoid valve Refer to P 35 112 AOK Replace HU Check harness between ABS v...

Страница 883: ...est Check harness between HU and ABS ECU and Is sound of HU pump motor running is heard Check ABS motor relay Refer to i 35 83 Check harness between main fusible link No and ABS motor relay and repair...

Страница 884: ...ent the wheels from locking There is nothing abnormal INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 No communication is possible between scan tool and any cbable cauSe of control sy...

Страница 885: ...ECU Data link side connector side 68 1 38 7 OK lG I Check the followina connector 1 NG Repair WNG Confirm trouble symptoms i Check harness between ABS ECU 1Check the f 1 NG Repair Measure at ABS ECU c...

Страница 886: ...air if Inspection procedure 4 Check that bulb has not burned out Replace ABS warning light bulb OK NG Repair D l 6 D 04 D 44 C 71 C 82 OK Check trouble symptoms Replace combination meter ABS warning l...

Страница 887: ...osited on it Check wheel speed sensor NG Repair installation Check HU Refer to P 35 76 l Wheel bearing defective l HU defective l ABS ECU defective Check wheel speed sensor 1OK Replace wheel speed sen...

Страница 888: ...CHART The following actuators can be force driven by use of the scan tool NOTE 1 Actuator test cannot be made when ABS ECU is not functioning 2 Actuator test can be carried out only when the vehicle...

Страница 889: ...turn and secure by tightening the lock nut 4 Connect the connector of the stop light switch 5 Check to be sure that the stop light is not illuminated with the brake pedal released Reference value B O...

Страница 890: ...re is continuity when the float surface is below A BRAKE BOOSTER OPERATING CHECK For simple checking of brake booster operation carry out the following tests 1 Run the engine for one or two minutes an...

Страница 891: ...eplace it as an assem bly unit together with the vacuum hose PROPORTIONING VALVE FUNCTION TEST 1 Connect two pressure gauges one each to the input side and output side of the proportioning valve as sh...

Страница 892: ...w worker plug the master cylinder outlet with finger 4 Keeping the condition 3 release the brake pedal 5 Repeat steps 2 to 4 three to four times while filling the master cylinder with brake fluid BLEE...

Страница 893: ...ed with special grease Do not wipe off the special grease on the lock pin and do not contaminate the lock pin 3 Remove the following parts from the caliper support 1 Pad and wear indicator assembly 2...

Страница 894: ...heck for dirty or corroded piston sliding surface and deteriorated piston seal cAWD 1 Visually check the brake pad thickness Through the open ing in the caliper body Standard value 10 0 mm 39 in Limit...

Страница 895: ...I No 1 Caution 1 Make sure that the friction surfaces of pads and brake discs are free of grease and other contami nants 2 The grease should never squeeze out from around the shim 7 Start the engine d...

Страница 896: ...rake lathe MAD DLl 8700PF or equivalent Be sure to follow the exact brake lathe manufacturer instructions FRONT BRAKE DISC RUN OUT CHECK 1 Remove the front brake assembly and support it with a wire et...

Страница 897: ...often have a lower run out than a new brake disc REAR DISC BRAKE PAD CHECK AND REPLACEMENT 1 Check brake pad thickness through caliper body check port Standard value 10 0 mm 39 in Limit 2 0 mm 08 in C...

Страница 898: ...he pad clip to the caliper support Caution Do not deposit grease or other dirt on pad or brake disc friction surfaces 7 Clean the piston and then using the special tool push the piston into the cylind...

Страница 899: ...port it by a wire etc 2 Place a dial gauge approximately 5 mm 2 in from the outer circumference of the brake disc and measure the run out of the disc Limit 0 08 mm 0031 in or less NOTE Tighten nuts to...

Страница 900: ...any location of the brake lining thickness is less than the limit Caution Whenever the shoe and lining assembly is replaced replace both RH and LH assemblies as a set to prevent car from pulling to o...

Страница 901: ...No same for AWD and FWD 3 Manually turning the wheel to be measured by l 2 to 1 turn second measure the output voltage with a circuit tester or oscilloscope Output voltage When measured with circuit...

Страница 902: ...odels or MUT II All models 1 Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack up points 2 Release the parking brake and determine the drag force drag torque of...

Страница 903: ...ation Normal Abnormal condition condition Probable cause Remedy 04 FR VALVE M 1 Depress brake pedal Brake force Wheel does Clogged Check and to lock wheel released for 6 not lock when brake line clean...

Страница 904: ...nition switch beforehand whenever the scan tool is connected or disconnected 3 After confirming that the shift lever or selector lever is in the neutral position start the engine The ABS warning light...

Страница 905: ...normal Probable condition cause Brake force in Step 1 shows very little or almost no decrease Brake force de creases in Step 1 but in Step 2 it shows very little or almost no in crease Increasing brak...

Страница 906: ...the ignition key to the OFF position and set the scan tool as shown in the diagram 4 After checking that the shift lever M T or the selector lever A T is in neutral start the engine NOTE 1 At this tim...

Страница 907: ...e Wheel does Clogged Check and M lock wheel released for not lock brake line clean brake 2 Using the scan tool 2 seconds when brake otherthan HU line FL VALVE select the wheel to be after locking peda...

Страница 908: ...misfiring and fail to start if an attempt is made to start without allowing the batterty to recover sufficientry This is because the ABS consumes a great deal of current for its self check In such a...

Страница 909: ...ized and de energized Motor Relay When de energized Between terminals 30 60 A 85 and 86 Between terminals No continuity 30 and 87 Q When energized be Between terminals Continuity Ede 8 rminals 85 30 a...

Страница 910: ...Brake Pedal Adjustment Refer to P 35 63 FWD MTT 14 14 w 214A0256 21 30 Nm 22 ft lbs i m 6 214FO106 20 0 0 0 0 2 1 2 9 Stop light switch removal steps 1 Stop light switch connector 2 Stop light switch...

Страница 911: ...rn spring 4 Cotter pin 5 Washer 6 Clevis pin 7 Cotter pin 8 Shift lock cable connection 9 Brake pedal assembly parts from step 10 to step 21 10 Brake pedal shaft bolt 11 Lever assembly installation nu...

Страница 912: ...g for wear l Check the brake pedal for bend or twisting l Check the brake pedal return spring for damage STOP LIGHT SWITCH CHECK 1 Connect a circuit tester to the stop light switch 2 The stop light sw...

Страница 913: ...02132 Master cylinder removal steps 1 Low pressure hose 2 Brake fluid level sensor connector 3 Brake tube connection 4 Master cylinder Brake booster removal steps B l Clearance between brake booster p...

Страница 914: ...he brake booster nipple as shown in the figure Secure the hose with the hose clip Caution The check valve and the pipe part of the brake booster must not contact each other 2 Install the other end of...

Страница 915: ...ter 0 55 0 75 mm 022 030 in 8 9 inch brake booster 0 65 0 85 mm 026 033 in If the clearance is not within the standard value range turn the push rod screw to achieve desired length Caution Improper cl...

Страница 916: ...epressing the piston C SECONDARY PISTON ASSEMBLY DISASSEMBLY NOTE If it is hard to remove the secondary piston from the cylinder gradually apply compressed air from the outlet port on the secondary en...

Страница 917: ...leeding Refer to P 35 66 1 Brake hose 2 Brake tube strut 3 Brake tube A 4 Brake tube B 5 Brake tube front R H 6 Brake tube front L H 7 Brake tube main R H 8 Brake tube main L H 14 Proportioning valve...

Страница 918: ...of hydraulic unit Up to 1995 models From 1996 models m 5 4 12 11 3 6 14FOOlQ 4 5 12 11 1480167 14FOllO 00003717 1 Brake hose 2 Brake tube strut 8 Brake tube main L H 3 Brake tube A 9 Brake tube cup t...

Страница 919: ...for right front and left rear From 1996 models 1 HU front brake L H 2 HU rear brake R H 3 H U rear brake L H 4 HU front brake R H 5 Master cylinder HU for left front and right rear 6 Master cylinder...

Страница 920: ...tool and then install the caliper body 3 Start the engine depress the brake pedal firmly two to three times and stop the engine 4 Turn the brake disc ten times in the forward direction 5 Using a spri...

Страница 921: ...pl 1 Guide pin Pad assembly disassembly steps A 1 Guide pin A4 2 Lo pin A 2 LOCK pin 3 Busnlng 3 Bushing 4 Caliper support pad clip shim 4 Caliper support pad clip shim 11 Pad wear indicator 5 Pin bo...

Страница 922: ...ont Disc Brake Lubrication points 214K069 Zl4Yl84 Brake fluid Conforming to DOT3 or DOT4 Grease Repair kit grease orange r Z14AO54 I Grease Repair kit grease orange I Z14L0128 1 Grease Repair kit grea...

Страница 923: ...one cannot be removed dB PISTON SEAL REMOVAL 1 Remove piston seal with finger tip Caution Do not damage the cylinder inner surface 2 Clean piston surface and inner cylinder with trichloroethy lene al...

Страница 924: ...s less than the i limit value d Standard value 10 0 mm 39 in Limit value 2 0 mm 08 in 14WOD95 Caution 1 When the limit is exceeded the brake pads on both the left and right wheels must be replaced as...

Страница 925: ...I Seal and boot kit l2 10 g 43 10 0 4 0 d Q Q S r eaY b I 214FO120 Brake caliper kit Z14FO118 Disassembly steps 1 Clip 2 Pad pin 3 Cross spring 2 ma mbly 8 Outer pad 9 Retaining ring 10 Piston boot 1...

Страница 926: ...tion ZUY184 The piston seal contained in the seal and boot kit is coated with special grease lo not wipe off the grease Brake fluid Conforming to DOT3 or DOT4 214FOO24 1 Grease _ Zl4FOO97 I Grease Bra...

Страница 927: ...ut evenly Caution 1 Be careful not to get your fingers to be pinched 2 Be careful not to let the brake fluid splash D PISTON SEAL REMOVAL 1 Remove the piston seal Caution Do not damage the cylinder in...

Страница 928: ...thickness is less than the limit value d Standard value 10 0 mm 39 in Limit 2 0 mm 08 in Caution 1 When the limit is exceeded the brake pads on both the left and right wheels must be replaced as a set...

Страница 929: ...15 Nm AWD 50 60 Nm 36 43 ft lbs 11 ft lbs Z14N0036 0 0 0 0 2 1 4 6 i Removal steps 1 Brake hose A 2 Rear brake assembly 3 Brake disc INSTALLATION SERVICE POINT FAA REAR BRAKE ASSEMBLY INSTALLATION Ins...

Страница 930: ...Grease Caliper assembly disassembly steps A 1 Lock pin FAA 2 Guide pin 3 Bushing 4 Caliper suppart Boot 4 7 shim 10 5 ring 12 Piston boot 13 Piston 14 Piston seal 15 Caliper body Pad assembly disasse...

Страница 931: ...Seal and boot kit 9 2018 l7 11 Grease 214FO140 Z14FO120 Caliper assembly disassembly steps 9 Pad pin 11 Retaining ring 12 Piston boot 13 Piston 14 Piston seal 15 Caliper body Pad assembly disassembly...

Страница 932: ...pad clip shim 7 Lock pin boot 8 Guide pin boot 10 Boot ring 12 Piston boot 13 14 Piston Piston seal 15 Caliper body A 00002147 Pad kit Seal and boot kit Z14N0156 4 8 Grease Z14N0157 Pad assembly disas...

Страница 933: ...luid Conforming to DOT3 or DOT4 Y14N0121 Grease Repair kit grease orange AWD From 1994 model2 Caution The piston seal contained in the seal and boot kit is coated with special grease Do noi wipe off t...

Страница 934: ...h your fingers 2 Be careful not to splash the brake fluid B PISTON SEAL REMOVAL 1 Remove piston seal with finger tip Caution Do not damage the cylinder inner surface 2 Clean piston surface and inner c...

Страница 935: ...ad thickness is less than the limit value Standard value 10 0 mm 39 in Limit 2 0 mm 08 in Caution 1 When the limit is exceeded the brake pads on both the left and right wheels must be replaced as a se...

Страница 936: ...2 Fender l Air Duct installation l Relay Box Installation l Brake Fluid Filling 0 Bake Line Bleeding Refer to P 3566 Flared brake line nuts 15 Nm 11 ft lbs 4FO3s Hydraulic unit removal steps A B 1 Bra...

Страница 937: ...Caution 1 The HU is heavy Use care when removing it 2 The HU cannot be disassembled Never loosen its nuts or bolts 3 Do not drop or shock the HU 4 Do not turn the HU upside down or lay it on its side...

Страница 938: ...N SOLENOID VALVE CHECK From 1996 models Measure resistance between terminals of each of the following solenoid valves Standard value L Front IN left side 2 1 2 8 5 9 5 Sz Front OUT left side 6 1 2 4 4...

Страница 939: ...BS REMOVAL AND INSTALsLATION 4WD 9 ft lbs 5 i 1 Front rotor 2 Rear rotor Front speed sensor removal steps 214FOO78 Rear speed sensor removal steps 6 Clip 8 Rear speed sensor 3 Clip qB C 4 Front speed...

Страница 940: ...teps 3 Clip AB C 4 Front speed sensor Rear speed sensor removal steps 6 Clip 7 Cable band B A 8 Rear speed sensor 9 O ring REMOVAL SERVICE POINTS dAbFRONT ROTOR REAR ROTOR REMOVAL Caution Do not damag...

Страница 941: ...les In this case measure the sensor mounting surface to rotor tooth surface clearance Standard value 28 15 28 45 mm 1 11 1 12 in BA FRONT SPEED SENSOR BRACKET INSTALLATION NOTE 1 The right and left sp...

Страница 942: ...ole piece is damaged accurate wheel speed detection may not be expected 2 Measure resistance between speed sensor terminals Standard value cFWD Front 0 8 1 2 kL Rear 0 6 0 8 k 2 AWD 0 8 1 2 kG If the...

Страница 943: ...G sensor 3 G sensor bracket Z14AO194 Z14A0195 INSPECTION G SENSOR CHECK cup to 1995 models 1 Lay the G sensor on a level surface and check for continu ity between its terminals 2 Incline the G sensor...

Страница 944: ...2 With the ignition switch turned ON read output voltage between terminals No 2 and No 3 Standard value 2 3 2 7 V 3 With the special tool connected fix the connector in such a manner as to direct the...

Страница 945: ...ushion Installation l ABS Inspection Refer to P 357 14FOO79 From 1996 models 14FO169 00003719 Removal steps 1 Control unit connector connection 2 Electronic control unit 3 ABS ECU bracket REMOVAL SERV...

Страница 946: ...NOTES...

Страница 947: ...bag ortothedriverandpassenger fromrendering 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 MITSU...

Страница 948: ...type Lever type Cable arrangement V type SERVICE SPECIFICATIONS LUBRICANTS Items Specified lubricant Rear brake shoe and backing plate contact surfaces Brake grease SAE J310 NLGI No 1 Contact surface...

Страница 949: ...e shaft assembly General service tool MB990211 01 General service tool Application Symptom Brake drag lnsuff icient parking brake function 1Probable cause 1 Remedy Incomplete release of parking brake...

Страница 950: ...expand the shoe until brake is lightly applied where the disc cannot be turned with both hands approx 2 7 Nm 23 in lbs Then turn the adjuster five notches in the direction opposite the arrow Reference...

Страница 951: ...rive the vehicle at a constant speed of 35 50 km h 22 31 mph for 100 m 328 ft 4 Release the parking brake and let the brakes cool for 5 10 minutes 5 Repeat the procedure in steps 2 to 4 4 5 times Caut...

Страница 952: ...val steps 1 Cable adjuster 6 Rear speed sensor Refer to GROUP 35Speed Sensor 7 Rear brake assembly 8 Rear brake disc 9 Adjusting wheel spring 10 Shoe hold down cup 11 Shoe hold down pin Bd 12 Adjuster...

Страница 953: ...TALLATION The shoe to anchor spring must be installed in the sequence shown in the illustration Caution Each shoe to anchor spring has a unique spring load and the spring a is painted to prevent erron...

Страница 954: ...5 a Z14D0650 Grease Brake grease SAE 5310 NLGI No 1 Removal steps A E 1 Rear speed sensor 3 Rear brake assembly 4 Rear brake disc 5 Hub cap WI paw nut 8 Rear hub unit bearing 12 Adjusting wheel spring...

Страница 955: ...e SAE 5310 NLGI No 1 Removal steps 4Ab 1 Rear speed sensor 2 O ring 3 Rear brake assembly 4 Rear brake disc B C 9 Self locking nut 10 4Cb Companion flange 11 Rear axle shaft 12 Adjusting wheel spring...

Страница 956: ...C AXLE SHAFT ASSEMBLY REMOVAL With the special tool remove the axle shaft from the trailing arm INSTALLATION SERVICE POINTS A4 SHOE TO ANCHOR SPRING INSTALLATION The shoe to anchor spring must be ins...

Страница 957: ...d tighten the speed sensor at such position where the gap is as specified below over the entire circumference Standard value 0 2 O 7 mm 008 028 in INSPECTION CHECKING FOR UNUSUAL WEAR OF THE BRAKE LIN...

Страница 958: ...NOTES...

Страница 959: ...CONTENTS STEERING 37A 4 WHEEL STEERING SYSTEM 4WS 378 CWHEEL STEERING SYSTEM ACTIVE 4WS 37C 1 I 37 1 L STEERING NOTE Shaded groups in the above list are not included in this manual...

Страница 960: ...37 2...

Страница 961: ...proper service or maintenance of any component of the SRS or any SRS related component can lead to personal injuryordeathtoservicepersonnel from inadvertentfiringoftheair bag ortothedriverand passenge...

Страница 962: ...41 49 When new belt is installed 7 5 9 0 30 35 3il pump pressure MPa psi Pressure gauge valve closed 7 5 8 2 1 067 1 166 Pressure gauge valve opened 0 8 l O 114 142 Oil pressure switch operating Oil...

Страница 963: ...ng part Bellows Silicone grease As required Power steering fluid Automatic transmission fluid DEXRON II 0 9 dm3 95 qt Flow control valve Automatic transmission fluid DEXRON II As required Friction sur...

Страница 964: ...37A 4 STEERING Snecial Tools SPECIAL TOOLS Preload socket General service TSB Revision...

Страница 965: ...ce To press in the oil seal for the rack tool Oil seal installer MB991197 Bar long type General service tool To press in the oil seal for the rack MB991 202 General service Press fitting of rack housi...

Страница 966: ...l circumference and check play Standard values steering wheel play with engine stopped 11 mm 43 in If the play exceeds the standard value remove steering gear box and check total pinion torque STEERIN...

Страница 967: ...value check for play or ratcheting in ball joint If none of these it is still serviceable STEERING WHEEL CENTERING SIMPLIFIED STEERING WHEEL CENTERING Determining Steering Wheel s Off Center 1 For th...

Страница 968: ...n center as possible PRECISION STEERING WHEEL CENTERING In general the tie rods are adjusted to steer the front wheels in the same direction that the steering wheel is off center If the steering wheel...

Страница 969: ...Steering effort 35 N 8 Ibs or less Fluctuation allowance 6 N 1 3 Ibs or less STEERING WHEEL RETURN TO CENTER CHECK To make this test conduct a road test and check as follows 1 Make both gradual and su...

Страница 970: ...d level changes considerably air bleeding should be done FLUID REPLACEMENT 1 Raise the front wheels on a jack and then support them with rigid racks 2 Disconnect the return hose connection 3 Connect a...

Страница 971: ...he steering wheel to the left and right until there are no air bubbles in the oil reservoir 7 Confirm that the fluid is not milky and that the level is up to the specified position on the level gauge...

Страница 972: ...verhaul the oil pump 6 Remove the special tools and then tighten the pressure hose to the specified torque 7 Bleed the system CHECKING THE PRESSURE UNDER NO LOAD CONDITIONS 1 2 3 4 5 6 7 Disconnect th...

Страница 973: ...and then tighten the pressure hose to the specified torque 8 Bleed the system OIL PRESSURE SWITCH CHECK 1 2 3 4 5 6 7 8 Disconnect the pressure hose from the oil pump and then connect the special too...

Страница 974: ...ROUP 52B Air Bag Module and Clock Spring A A4 2 Steering wheel 3 Lower column cover 4 Upper column cover 5 Knee protector Refer to GROUP 52A Instrument Panel 6 Lap cooler duct and foot shower duct 7 C...

Страница 975: ...LATION SERVICE POINT A STEERING WHEEL INSTALLATION Line up the NEUTRAL mark of the clock spring with the mating mark before installing the steering wheel Caution If the clock spring s mating mark is n...

Страница 976: ...ylinder 213FOOSl 213FOO58 00002169 A 5 Special bolts A A 6 Steering lock bracket A A4 7 Steering lock cylinder 8 Steering column assembly TSB Revision DISASSEMBLY SERVICE POINT dAbSTEERING LOCK BRACKE...

Страница 977: ...The steering lock bracket and bolts must be replaced with new ones when the steering lock cylinder is installed B BEARING INSTALLATION 1 Fill the inside of the bearing with multipurpose grease 2 Insta...

Страница 978: ...ne Bleeding Refer to P 37A 1 I l Steering Wheel Position with Wheels Straight Ahead Checking l Front Wheel Alignment Adjustment Refer to GROUP 33A On vehicle Service 35 Nm 25 ft lbs 15 Nm 11 ft lbs ZU...

Страница 979: ...the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque Standard value 0 6 1 3 Nm 5 11 in lbs NOTE Measure the pinion torque through the whole stroke of the rack If...

Страница 980: ...ws W W 7 Tab washers N 8 Tie rods 9 Feed tubes 10 O rings FM4 l Total pinion torque adjustment 4D bL4 11 End plug 12 Self locking nut 4Eb 13 Locking nut 14 Rack support cover 15 Rack support spring 16...

Страница 981: ...XRON II Z13POO77 21310564 Sealant 3M ATD Part No 8663 or equivalent 213G0070 Grease Silicone grease I Fluid Automatic transmission fluid DEXRON II Sealant 3M ATD Part No 8663 or equivalent J Z13N0019...

Страница 982: ...VAL Using a screwdriver or similar tool loosen and then remove the boot retaining band C TAB WASHER REMOVAL Unstake the tab washer which fixes the tie rod and rack with a chisel D END PLUG REMOVAL Dis...

Страница 983: ...from the valve housing simultaneously dH CIRCLIP REMOVAL 1 Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing 2 Turn the rack stopper anticlockwise...

Страница 984: ...gear housing Caution Be careful not to damage the inner surface of the rack cylinder of the gear housing REASSEMBLY SERVICE POINTS bAdBACK UP WASHER OIL SEAL INSTALLATION 1 Apply a coating of the spe...

Страница 985: ...ACK INSTALLATION 1 Apply a coating of multipurpose grease to the rack teeth face Caution Do not close the vent hole in the rack with grease 2 Cover rack serrations with special tool 3 Apply specified...

Страница 986: ...I BALL BEARING INSTALLATION Apply a coating of the specified fluid to the outside of the ball bearing Using the special tools press the ball bearing into the valve housing Specified fluid Automatic tr...

Страница 987: ...upport cover 30 60 and adjust torque to the standard value Standard value O 6 1 3 Nm 5 11 in lbs Caution 1 When adjusting set the standard value at its highest value 2 Assure no ratcheting or catching...

Страница 988: ...ack for bends PINION AND VALVE ASSEMBLY CHECK l Check the pinion gear tooth surfaces for damage or wear l Check for worn or defective seal ring BEARING CHECK l Check for roughness or abnormal noise du...

Страница 989: ...Pump Pressure Checking Refer to P 37A 12 Removal steps 1 Drive belt 2 Suction hose A 3 Pressure hose 4 O ring 43 N m 31 ft lbs Nm ft lbs Zl3NOO29 5 Pressure switch connector 6 Oil pump INSPECTION 7 Oi...

Страница 990: ...Nm 16 22 ft lbs Zl3N0031 00002179 6 Disassembly steps 1 Pump cover E 5 D 5 j Cam ring C 6 Side plate A 7 O ring 8 Connector A 9 O ring 10 Flow control valve 11 Flow control spring 12 Terminal assembl...

Страница 991: ...r No I D x Width mm in 1 11 x 1 9 433 x 075 2 13x 1 9 512x 075 3 17 8 x 2 4 701 x 094 4 13 5 x 1 5 531 x 059 5 3 8 x 1 9 150x 075 6 16 8 x 2 4 661 x 094 B SPRING INSTALLATION Fit the spring to the oi...

Страница 992: ...g for wear l Check the shaft of the pulley for play and round movement l Check the groove of rotor vane for stepped wear l Check the contact surface of cam ring and vanes for stepped wear l Check the...

Страница 993: ...8 ft lbs _ 12 Nm 15 Nm 11 ft lbs Removal steps 1 Return hose 2 Suction hose 3 Return hose l 2 9ure hose Z13N0060 White line Z13PO143 mFoo2s 6 Cooler tube 7 Pressure tube 8 Return tube 9 O ring 10 Oil...

Страница 994: ...NOTES...

Страница 995: ...LE SERVICE m m s m 4 Ball Joint Rotation Starting Torque Check 5 Bleeding 4 Function Check 5 Rear Oil Pump Discharge Flow Volume Check 5 SPECIAL TOOLS 2 SPECIFICATIONS 2 General Specifications 2 Lubri...

Страница 996: ...Power cylinder tie rod swing torque N Ibs Nm in lbs 1 9 55 2 12 0 5 3 0 4 26 1 I Power cylinder slide resistance N Ibs 1 67 15 or less LUBRICANTS Items 1 Specified lubricant 1 Quantity Power steering...

Страница 997: ...racks or deformation Feeling of friction in steering Poor steering return Steering wheel efforts exces Control valve Oil leakage from control valve joint sive Power cylinder Oil leakage from piston ro...

Страница 998: ...d more 9 Start the engine and keep the front wheels in a straight ahead position Increase the engine speed once to a speedometer reading of 70 80 km h 43 50 mph to operate the oil pump for the rear wh...

Страница 999: ...se speed slowly then hold the indicated speed of 50 km h 31 mph measuring discharge flow volume for 30 seconds Caution While performing this work continuously add fluid into the oil reservoir Standard...

Страница 1000: ...fer to GROUP 37A On vehicle Service l 4WS System Bleeding Refer to P 37B 4 l 4WS System Operation Checking Refer to P 37B 5 l Wheel Alignment Checking Refer to GROUP 34 On vehicle Service 78 Nm 110 13...

Страница 1001: ...full stroke to determine its neutral position 3 Align tie rod ends and the installation holes at trailing arm 4 When the tie rod ends and the installation holes at the trailing arm do not meet loosen...

Страница 1002: ...lance as shown in the illustra tion Standard value 67 N 15 Ibs or less 3 If the slide resistance exceeds the standard value replace the power cylinder 4 If the slide resistance is less than the standa...

Страница 1003: ...vice l Rear Suspension Assembly Removal Refer to GROUP 34 Rear Suspension Assembly L Post installation Operation l Rear Suspension Assembly Installation Refer to GROUP 34 Rear Suspension Assembly l Po...

Страница 1004: ...WS System Operation Checking Refer to P 378 5 12 Nm 9 ft lbs Removal steps 1 Return hose 2 Suction hose 3 Protector 4 Pipe assembly to pressure tube connection 5 6 Pipe assembly Suction hose 213FOO24...

Страница 1005: ...4 l 4WS System Operation Checking Refer to P 37B 5 110 130 Nm 80 94 ft lbs 80 94 ft lbs 213FOO2 t Removal steps 1 r shock absorber lower mounting 2 Crossmember bracket 3 Crossmember mounting nut 4 gt...

Страница 1006: ...NOTES...

Страница 1007: ...SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injuryordeathtoserviceperso...

Страница 1008: ...ype Inner hinged with gas damper POWER WINDOW Power window motor Items Type Specifications Permanent magnet type Built in circuit breaker Revolutions under no load rpm Revolutions under At 1 Nm 72 ftl...

Страница 1009: ...0 5 A after power connection SERVICE SPECIFICATIONS Items Standard value 1 Play of door inside handle mm in 1 A Way 1 7 28 I B OPEN 46 f 9 1 81 f 35 C FULL 69 2 72 Clearance of window glass to weathe...

Страница 1010: ...n MB990834 MB990834 01 l x djusting Adjustment of door fit MB990449 EG P ld Removal of window moulding MB991 341 MB991341C Up to 1993 models Scan tool Checking the power windows system and the Multi u...

Страница 1011: ...t locking and unlocking Uneven body clearance Uneven height Water leak through door window glass Water leak through liftgate window Door window mal function Water leak through door edge Water leak fro...

Страница 1012: ...is discovered 4 When such a place is found cover it again and continue with the procedure so as to determine if there are any other noise sources 5 If no others are found the last remaining tape is th...

Страница 1013: ...unit so that switch can be considered to be functioning normally If not the switch or switch input circuit is faulty Check the switch and the switch input circuit All models When using the scan tdol...

Страница 1014: ...2 Door switch All doors close Door switch OFF Battery positive voltage One of doors open Door switch ON I o v 6 Door lock actuator L H LOCK I 5V 1 UNLOCK 9 Keyless entry control unit power source Igni...

Страница 1015: ...ll be operated for a further 30 seconds If it is impossible l Malfunction of sunroof control unit the driver s door switch or the sunroof control unit may be defective l Malfunction of wiring harness...

Страница 1016: ...No 7 and the sunroof control unit Repair if necessarv 3 NG Check the following connector E 45 NG c Repair NG Replace OK Measure at sunroof switch terminal Checkthe harness between the sunroof l Discon...

Страница 1017: ...sen the hood latch mounting bolts and move the hood latch to adjust the attachment between the hood latch and hood striker LIFTGATE ADJUSTMENT 1 Loosen the liftgate hinges mounting bolts and then adju...

Страница 1018: ...e door position along the body surface Caution Attach protection tape to the fender edges where the hinge is installed 3 If the door does not open freely adjust the engagement of the striker with the...

Страница 1019: ...as shown in the illustration Weatherstrip Section A A Section B B 2 Section C C 218FO156 218FO155 moo1234 Adjustment Adjustment procedures Standard value mm in Adjust by turning the adjust Section A A...

Страница 1020: ...the adjusting bolts of guide tracks 12 Adjust the delta sash so that the window glass end and the delta sash lip end are positioned as illustrated and tighten in position 13 Install the drip line wea...

Страница 1021: ...window glass assembly 6 Tighten the stabilizer inner rear so that it presses against the window glass assembly 7 Check that the clearance between the weatherstrip holder and the top edge of the windo...

Страница 1022: ...1 81 35 in C FULL 69 mm 2 72 in 2 If out of specifications adjust as described below 1 Remove the door trim Refer to P 42 42 2 Loosen the screw attaching the inside handle and slide the inside handle...

Страница 1023: ...he water pressure so that water comes out of the hose to a height of approximately 50 cm 20 in when the hose is held vertically facing upwards 3 Hold the end of the hose about 30 cm 12 in above the ro...

Страница 1024: ...LH 11 Hood side weatherstrip RH 12 Heat protector panel 13 Heat protector 14 Hood garnish assembly 15 Hood switch Vehicles with theft alarm system ZlRFO261 From 1994 models y 20 bs 7 ft lbs m v 8 ft...

Страница 1025: ...CTION HOOD SWITCH CHECK Check the continuity between the terminals Switch position Terminal No 1 2 Lid switch unpressed 0 0 Lid switch depressed LIGHT SWITCH CHECK Turn the switch ON OFF and check con...

Страница 1026: ...te and liftgate hinge removal steps l Washer tube Refer to GROUP 51 Windshield Wiper and Washer I b Nm 5 Nm 4 ft lbs 7 ft lbs Z18FO138 00002240 l Liftgate trim Refer to GROUP 52A Trims l Liftgate side...

Страница 1027: ...52A Trims 11 Liftgate latch 12 Liftgate lock release cable Liftgate latch removal steps l Rear end trim Refer to GROUP 52A Trims 11 Liftgate latch Liftgate striker removal steps 0 Liftgate trim Refer...

Страница 1028: ...illustration INSPECTION LIFTGATE LATCH SWITCH CHECK 1 Unlock the liftgate latch 2 Check the continuity between the terminals Switch position Terminal No 1 2 Liftgate latch locked Liftgate latch unloc...

Страница 1029: ...ter Trim and Scuff Plate Remov al and lnstallatlon Refer to GROUP 52A Trims Adjustment l Fuel Filler Door Adjustment Refer to f 42 12 I Z18FOO68 i Z18FO130 Z18FOO85 Removal steps 1 Fuel filler door 2...

Страница 1030: ...rt No 8625 or equivalent Z18FOO62 Section A A Fender Sealant 3M ATD Part No 8625 or equivalent Removal steps 1 Front splash shield l Side airdam Refer to GROUP 51 Aero Parts 2 Front splash shield 218F...

Страница 1031: ...BODY Loose Panel 42 25 LOOSE PANEL REMOVAL AND INSTALLATION Air guide duct 18FO120 Liftgate gas spring r bracket 18FO124 Rear floor side member fiEfZE L z a xossmemuar TSB Revision...

Страница 1032: ...AST URETHAN PRIMER 8608 Wire dia x length Adhesive gun 3M ATD Part No 8906 Wiping rags Sealer Glass holder Windshield moulding Service Part Window dam Service Part One cartridge As required for cuttin...

Страница 1033: ...ng upper and lower clips Apply primer amply on bonding surface and dry 3 minutes or more Glass side I When glass is reused When glass is replaced Cleaning bonding surface Scoopoutexistingadhesivecompl...

Страница 1034: ...ces sary Be careful not to damage the coated surface 2 If the coated surface is damaged apply paint 4 Cut off the lower portion of a new moulding and install the moulding temporarily to check that it...

Страница 1035: ...ROUP 52A Trims 2 Yellow White NOTE Vehicles with sun Section A Vehicles without sun roofj Section B Adhesive x 12 15 z 4 C Cut off nozzle end Section A Vehicles with sun roof Section C 6 Adhesive Adhe...

Страница 1036: ...ass edge 5 Put matchmarks on the body and the glass 6 Using the special tool remove the windshield glass 7 Using a sharp knife scoop out existing adhesive from the body flange to 2 mm 08 in or less th...

Страница 1037: ...pecified area of the windshield 2 Affix the window spacer lower to the specified area of the windshield 3 When replacing glass fit a new glass once to the body and put matchmarks on the body and glass...

Страница 1038: ...he adhesive line up the match marks on the glass and body and force the glass lightly and evenly onto the body for complete fitting 9 Remove adhesive from around and on the glass and body surfaces usi...

Страница 1039: ...LJ Pre removal and Post installation Operation l Quarter Upper Trim Removal and Installation Refer to GROUP 52A Trims l Center Pillar Garnish Removal and Installation Refer to GROUP 51 Garnishes and M...

Страница 1040: ...Center Pillar Garnish Removal and Installation Refer to GROUP 51 Garnishes and Mouldings Zl8FOOO2 Q 218FO132 r I II Cut off nozzle tip mm in 218F0060 Section A Adhe 7 Adhesive 50 1 97 Section C Adhes...

Страница 1041: ...tion to the bolt Caution Hold the window glass with the glass holders to prevent it from falling when the adhesive is cut through 4 Using a sharp knife scoop out existing adhesive from the body flange...

Страница 1042: ...king sure it is applied without breaks or thin spots Caution 1 The primer is used to strengthen bonding power Make sure that it covers the surfaces completely Note that the primer if applied to thick...

Страница 1043: ...and body surfaces using a spatula and wipe the surfaces clean 6 After the work installation of the glass allow to stand until the adhesive hardens Caution If an infrared lamp or other means are used...

Страница 1044: ...allation Refer to GROUP 52A Trims 4A AA 21 SF0323 Section A mm in Section B 12 15 47 59 Adhesive Primer lfib 7 26 1 0 39 7 Section C 27 1 06 _I 12 15 10 39 8F0308 00002317 Adhesive 3M SUPER FAST URETH...

Страница 1045: ...the liftgate glass 3 Apply a uniform coat of primer to the illustrated areas of the body and glass making sure it is applied without breaks or thin spots Adhesive 3M SUPER FAST URETHAN PRIMER 8608 or...

Страница 1046: ...n the glass and body surfaces using a spatula and wipe the surfaces clean 8 After the work installation of the glass allow to stand until the adhesive hardens Caution If an infrared lamp or other mean...

Страница 1047: ...s 2 From 1995 models 16FO206 00002320 Door assembly removal steps 1 Connection for door wiring harness connector 2 Spring pin 3 Door assembly 4 Upper hinge 5 Lower hinge Door check strap removal steps...

Страница 1048: ...itch and check the continuity between the terminals Switch position Terminal No 1 2 3 Switch Open ON 0 A 0 Depressed OFF DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION Sealant 3M ATD Part No 8...

Страница 1049: ...AND INSTALLATION Adjustment l Door Window Glass Adjustment Refer to P 42 12 218FO200 00002323 Removal steps l Door trim Refer to P 42 42 l Waterproof film Refer to P 42 42 1 Delta cover inner 2 Delta...

Страница 1050: ...outerweatherstrip Refer to P 42 63 3 up stop 4 Stabilizer inner front 5 Stabilizer inner rear 6 Delta sash 7 Door window glass 8 Door window regulator assembly 9 Door glass guide track front 10 Door...

Страница 1051: ...terminal and check that the slider moves smoothly 2 Connect the battery in reverse polarity and check that the slider moves in opposite direction CIRCUIT BREAKER CHECK INCORPORATED IN THE POWER WINDO...

Страница 1052: ...ection table Switch position Terminal No Power window switch I Driver s side switch I Passenger s side switch 1 v UP 0 0 0 0 Power 0 0 window lock OFF 0 n 0 0 0 switch lock DOWN 0 0 0 0 o 0 Door lock...

Страница 1053: ...ion Refer to P 42 42 3 6 ZlSFO202 OoooP325 ZlSFOO41 Door inside handle removal l Door inside handle play check Refer to P 42 16 1 Door inside handle Door outside handle and latch removal steps 2 Door...

Страница 1054: ...and there is continuity when it is turned further From 1994 models Insert the key and turn it to the LOCK or UNLOCK position to check for continuity as follows Vehicles with central door locking syste...

Страница 1055: ...e terminal 3 for driver s side or 1 for passen ger s side and check to see that when the terminal l for driver s side or 3 for passenger s side is grounded the rod moves to the UNLOCK position 2 Then...

Страница 1056: ...r continuity in accordance to the following connection table Vehicles with power window Power window main switch side Power window sub switch side Vehicles without power window l UNLOCK 0 0 DOOR LOCK...

Страница 1057: ...BODY Central Door Locking System 42 51 i 4 Check for continuity between terminals under the condi tions described below Continuity no voltage TSB Revision...

Страница 1058: ...STEM From 1993 model REMOVAL AND INSTALLATION ZlSF0317 Removal steps l Quarter trim L H Refer to GROUP 52A Trims 1 Antenna 2 Light automatic shut off unit 3 Rear intermittent wiper relay 4 Door lock p...

Страница 1059: ...itter water dust etc may enter the transmitter resulting in transmitter troubles SECRET CODE REGISTERING METHOD Up to 1995 models The transmitter has each individual secret code stored in memory When...

Страница 1060: ...ceiver is replaced or cause of the trouble is presumed to be due to faulty registration of the code Since two different codes at the most can be memorized in the memory space of EEPROM the old code wi...

Страница 1061: ...t one was completed 6 After the second registration is completed the door will be locked and unlocked once 7 Registration mode finishes under the following conditions l Registration of two transmitter...

Страница 1062: ...inge 6 Roof lid glass A4 7 Roof inner weatherstrip 8 Roof lid female hinge 9 Deflector Front of vehicle 219FO203 Roof lid regulator assembly removal steps 1 Sunroof trim assembly 2 Roof lid glass asse...

Страница 1063: ...i 7 4 6 8 Roof lid removal steps 1 Roof lid trim 2 Roof lid 3 Roof lid weatherstrip Sunroof switch removal steps 4 Cover 5 Sunroof switch panel assembly 6 Sunroof switch A18FO389 Slide tilt ECU remova...

Страница 1064: ...Front holder 14 Rear holder 15 Slide rail 16 Lifter assembly 17 Slider assembly 18 Rear timing 19 Tube cover 20 Drive unit assembly A18FO390 Frame assembly removal steps A 1 Roof lid trim A 2 Roof li...

Страница 1065: ...the passenger compartment INSTALLATION SERVICE POINTS A DRAIN HOSE INSTALLATION 1 Tie the cord which has been used for removal again to the end of the drain hose and wind tape around the tie until it...

Страница 1066: ...connection Tilt of roof lid SLIDING FORCE OF SUNROOF MOTOR S CLUTCH CHECK 1 Insert the sunroof wrench of the on board tools into the hexagonal hole in the motor drive shaft and hook a spring balance a...

Страница 1067: ...mit switch B OFF 2 Check the identification colors Then install the limit switches as shown in the illustration ROTATION SENSOR CHECK 1 When connecting an ohmmeter negative probe to terminal 3 and the...

Страница 1068: ...42 62 BODY Sunroof SUNROOF SWITCH CONTINUITY CHECK 18FO403 TSB Revision...

Страница 1069: ...p front 4 Door inner opening weatherstrip rear 5 Door opening weatherstrip lower Drip line weatherstrip removal steps 6 Drip line weatherstrip 7 Door weatherstrip holder REMOVAL SERVICE POINT A DOOR O...

Страница 1070: ...NOTES I...

Страница 1071: ...MIRROR 31 SPECIAL TOOLS 4 FRONT BUMPER 8 SPECIFICATIONS 2 GARNISHES AND MOULDINGS 15 Adhesives 4 General Specifications 2 ON VEHICLE SERVICE 7 Service Specifications 4 Active Aero System Check 7 TROU...

Страница 1072: ...e Nm ft lbs REAR WIPER MOTOR Items Type Braking system rpm at load of 0 6 Nm 0 43 ftlbs Specifications Ferrite magnet type Dynamic braking system 38f5 WINDSHIELD WIPER BLADE REAR WIPER BLADE Items Wip...

Страница 1073: ...age drop at 12V Wiper switch and the rated load V Washer switch Specifications 4 0 22 0 05 Max 4 0 2 or less 0 5 or less REAR WIPER AND WASHER SWITCH i Items Specifications Rated load A Wiper switch W...

Страница 1074: ...tool Window moulding remover MB991 341 MB991341C Scan tool Multi use tester MUT ROM pack Forthe number refer to GROUP 00 Precau tions Before Service MB991 502 MB991 502 Scan tool MUT II ROM pack MB99...

Страница 1075: ...ch switch are being input to the ETACS unit 1 Connect the scan tool to the data link connector or connect the voltmeter between the ETACS terminal and the ground terminal 2 Check if the buzzer of the...

Страница 1076: ...tch beforehand whenever the scan tool is connected or disconnected 3 The ECU input signal of individual circuit systems is nor mal if the scan tool buzzer sounds once when the respec tive switches are...

Страница 1077: ...nds and then goes out 2 If the front venturi skirt does not return to the standard condition properly in normal use the warning light comes on 2 INSPECTION BY ACTIVE AERO SWITCH AT AUTO 2 1 With the v...

Страница 1078: ...can tool is connected or disconnected 2 Turn the ignition switch to ACC or ON 3 Place the active aero switch to AUTO 1 4 Using the scan tool increase the vehicle speed to approx 80 km h 50 mph or more...

Страница 1079: ...aero system 3 Side cover panel Vehicles with active aero system 4 Front cover panel Vehicles with active aero system 5 Center cover panel Vehicles with active aero system A 6 Front under cover panel V...

Страница 1080: ...active aero system 5 Center cover panel Vehicles with A active aero system 6 Front under cover panel Vehicles with active aero system 7 Front splash shield extension 8 Fog light 9 License plate bracke...

Страница 1081: ...mper face outer corner plate From 1994 models 4 Bumper face inner corner plate From 1994 models 5 C corner plate From 1994 models 6 Bumper face upper front plate 7 Bumper face upper center plate 8 Bum...

Страница 1082: ...a 3 mm 13 in diameter hole to discharge the gas contained in the unit Be sure to wear safety goggles while performing this operation as the gas is not harmful but chips may be ejected with it 3 If the...

Страница 1083: ...e inside of the bumper to remove the clip 2 Installation With the grommet inserted in the hole press the screw in Pre removal and Post installation Operation l Rear End Trim and Rear Side Trim Removal...

Страница 1084: ...ffler plate 4 Bumper face 4Ab 8 Bumper reinforcement stay 9 Bumper absorber 10 Bumper reinforcement DISASSEMBLY SERVICE POINT dA BUMPER ABSORBER REMOVAL Caution 1 Do not attempt to repair a bumper abs...

Страница 1085: ...indshield moulding Refer to GROUP 42 Windshield Liftgate moulding removal Hatchback 6 Liftgate moulding Refer to GROUP 42 Liftgate Glass Rear 218FO337 Front 9 Z18FO178 00002336 Adhesive tape 3M ATD Pa...

Страница 1086: ...e garnish 4 When the side garnish is fastened with a clip or bolt pull the side garnish toward you to remove the clip or the bolt Caution 1 To reuse the side garnish remove it by pulling the fishing l...

Страница 1087: ...he pressure sensitive double sided tape to 40 to 60 C 104 to 140 F for 5 to 10 minutes Caution Do not overheat the tape until its surface dries to turn white 2 Using a resin spatula or gasket scraper...

Страница 1088: ...removal 2 With its clips and bolts aligned with the respective holes in the body install the side garnish to the body NOTE If it is hard to affix the pressure sensitive double sided tape in winter hea...

Страница 1089: ...or equivalent m Adhesive 3M ATD Part No 8609 SUPER FAST URETHAN or equivalent Side air dam removal steps l Front splash slhield Refer to GROUP 42 Fender l Quarter trim Refer to GROUP 52A Trims A B 1...

Страница 1090: ...gate lower trim Refer to GROUP 52A Trims 2 Rear spoiler assembly 4 High mounted stop light Front under cover panel air dam link assembly removal steps 5 Side cover panel L H 6 Front cover panel 7 Cent...

Страница 1091: ...ure as the side garnish refer to P 51 15 provided that specified adhesive is used Specified adhesive 3M ATD Part No 8609 SUPER FAST URETHAN or equivalent INSPECTION 1 REAR SPOILER MOTOR AND LIMIT SWIT...

Страница 1092: ...e operate freely 2 While performing the inspection described in 1 above check the limit switch for continuity Linkage position 1 Termi lNo 4 1 1 UP standard position b OI During operation 1 1 I DOWN o...

Страница 1093: ...ive tape Ul ATD Part No 6382 or equivalent Standard position of motor Gear for limi switch zlAFO27CI Allen wrench 218F0267 I I i A MOTOR INSTALLATION 1 Make sure that the motor is in the standard posi...

Страница 1094: ...ble assembly the drive gear of the motor may not engage with the cable In such a case they can be engaged with each other by tightening the motor mounting screw Bd MOTOR AND CABLE ASSEMBLY INSTALLATIO...

Страница 1095: ...t garnish RH 5 Hole cover 4Ab 6 Wiper motor 7 Linkage Wiper motor removal steps 1 Wiper blade A 2 Wiper arm 5 Hole cover 4Ab 6 Wiper motor Column switch wiper and washer switch removal 15 Column switc...

Страница 1096: ...ification symbol 2 After the wiper blades have been set install them in such a way that the ends of the wiper blades will stop at the specified positions standard values Standard value A 15 20 mm 6 8...

Страница 1097: ...002342 21 EN0075 Wiper and Washer Switch Check Operate the switch to check for continuity between the termi nals Switch position I Terminal No I 3 4 5 6 7 8 9 1 0 Wiper OFF 0 0 switch INT 0 0 0 I I I...

Страница 1098: ...Washer tank removal steps l Rear end trim Refer to GROUP 52A Trims 5 Cap 6 Washer tank 7 Washer motor 4Ab Quarter upper trim RH Refer to GROUP 52A Trims Rear roof rail trim Refer to GROUP 52A Trims 0...

Страница 1099: ...mic part INSPECTION WIPER MOTOR CHECK Check the wiper motor with it mounted on the vehicle and with its harness connector disconnected Wiper Motor Operation Connect a battery to the wiper motor as sho...

Страница 1100: ...elay connected to the wiring harness connector let the wiper operate intermittently and check the voltage at terminal 2 I Condition Standard 1 When wiper is stationary o v I When wiper is in operation...

Страница 1101: ...ic remote controlled mirror switch Zl6FO16 9 B MIRROR REMOVAL Tilt the mirror upward and fit a screwdriver blade covered with protective tape in the notch between the mirror and the pivot plate to pry...

Страница 1102: ...able when each terminal is connected to the battery 2 Check to see that there is continuity between terminals 1 and 5 ELECTRIC REMOTE CONTROLLED MIRROR SWITCH CHECK Operate switches and check for cont...

Страница 1103: ...52 1 i INTERIOR CONTENTS INTERIOR 52A SUPPLEMENTAL RESTRAINT SYSTEM SRS 528 i...

Страница 1104: ...52 2 NOTES...

Страница 1105: ...ce 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 especiall...

Страница 1106: ...mounting bolts 1 3M Stud Locking Part No 41 70 or equivalent 1 L I I I SPECIAL TOOLS Tool g the seat belt warning light and buzzer Checking the seat belt warning light and buzzer MB991 529 Diagnostic...

Страница 1107: ...needle of the voltmeter moves when each switch is operated if the buzzer sounds or the needle moves the input signals are being input to the ETACS unit so that switch can be considered to be functioni...

Страница 1108: ...dels When a voltmeter is used Connect a voltmeter to the ETACS terminal and the ground terminal of the data link connector using the special tool Observe the voltmeter pointer deflection to read out t...

Страница 1109: ...below are used They are indicated 1 by symbols in the illustration id Name Symbol Size mm in PxL Color I Shape E Washer assembled F screw 4x16 16x 63 5x16 20x 63 G 4x12 16x 47 I 6 x 16 24x 63 J 6 x 20...

Страница 1110: ...garnish B 4 Knee protector assembly 5 Column cover 6 Glove box striker 4W 7 Glove box and cross pipe cover 9 Center air outlet assembly 10 Heater control assembly installation screws 219FO131 0000234...

Страница 1111: ...cedures of GROUP 528 Air Bag Module and Clock Spring J I 00 3 2 Removal steps 1 Hood lock release handle 2 Rheostat 4Ab 3 Switch garnish B 4 Knee protector assembly 5 Column cover 6 Glove box striker...

Страница 1112: ...clips of the center air outlet assembly with a fiat tip screwdriver remove the center air outlet assembly with the trim stick C SPEEDOMETER CABLE ADAPTER MECHANICAL TYPE SPEEDOMETER REMOVAL 1 Disconne...

Страница 1113: ...box 1 I r f t 4 Instrument panel disassembly steps 7 Glove box lower frame Refer to GROUP 55 Ventilators l Side air outlet Refer to GROUP 55 Ventilators l Photo sensor Refer to GROUP 55 Ventilators e...

Страница 1114: ...nish 9 Manual transaxle shift lever knob 5 Radio 10 Front console assembly DISASSEMBLY AND REASSEMBLY Front console disassembly steps 1 PJT garnish A T 2 M T shift lever cover M T 3 Ashtray 4 Cigarett...

Страница 1115: ...river to push inward the pin at the center of the trim clip to a depth of about 2 mm 08 in 2 Pull the trim clip outward to remove it Caution Do not push the pin inward more than necessary be cause it...

Страница 1116: ...rim Front pillar trim removal steps 4 Hanger bracket 5 Sasli guide cover mounting bolt 6 Clip 7 Front pillar trim NOTE 1 0 Location of metallic clip 2 C Location of resin clip 3 indicates trim clip Re...

Страница 1117: ...bly 13 Shelf catcher 14 Cover 15 Garnish 16 Sash guide cover mounting bolt 17 Front seat belt anchor plate mounting bolt 18 Retractor cover 19 Rear seat belt anchor plate mounting bolt 20 Screw 21 Qua...

Страница 1118: ...oor positively LHole iEm_ 1 REMOVAL AND INSTALLATION Luggage compartment 8 karter trim 4 A 1 0 Rear end trim B B Clip 219FOO47 Rear side trim rear end trim removal steps 1 Luggage compartment floor bo...

Страница 1119: ...m 219FOO16 D D 1 E Liftgate side trim 219FO173 7 r Liftgate trim removal steps 1 Shelf hook 2 Liftgate lower trim 3 Liftgate upper trim 4 Liftgate side trim 3 BJ Clip NOTE 1 e Location of metallic cli...

Страница 1120: ...ip 19FO283 Removal steps 1 Hanger bracket 2 Sash guide cover mounting bolt 3 Clip 4 Interior temperature sensor 5 Sunvisor assembly 6 Sunvisor holder 7 Room light assembly 8 Regulator cover Vehicle wi...

Страница 1121: ...s center line CAUTIOPI SRS When removing and installing the floor console as sembly don t allow any impact or shock to the SRS diagnosis unit Standard type f Y A 1 eSnartv tvnab 1 Head restraint Front...

Страница 1122: ...tration Refer to procedure 2 1 Procedure for removal and installation of seat stopped at forward position 1 Working from behind the seat remove the bolt from under the seat cushion as illustrated 2 In...

Страница 1123: ...1 1 TSB Revision ront seat forward installation bracket Fe hard tab 1 A A kross c e ion ZlQFoom INSTALLATION SERVICE POINTS A FRONT SEAT ASSEMBLY INSTALLATION 1 Locate the lower rails correctly so th...

Страница 1124: ...3 Insert the rear tab of the rear seat anchor cover in the front seat rear mounting bracket positively Then rotate the cover in the direction of arrow to install the side tabs in the side holes of the...

Страница 1125: ...seat 6 Side shield cover L H 9 Side shield cover R H _ A 10 Inner seat belt 11 Seat cushion assembly Sporty seat 19 n 219FO192 00002359 12 Memory reclining knob 13 Sliding adjuster knob 14 Seat back p...

Страница 1126: ...Seat back panel 15 Seat back assembly 16 Seat belt guide 19 Head restraint guide 24 Walk in knob 25 Walk in knob garnish 26 Slide adjuster REASSEMBLY SERVICE POINT pm ll fl q j i Harness Locmg claw A...

Страница 1127: ...CHECK 194 Rear height motor rg 219F0199 00002360 1 Disconnect each motor at the connector To disconnect the lumbar support and side support motors remove the seatback panel in advance 2 Connect the t...

Страница 1128: ...isconnect each limit switch at the connector and connect a circuit tester between the terminals 2 Operate each switch to check for continuity between the terminals 3 If there is any abnormality replac...

Страница 1129: ...AL SERVICE POINT qA REAR SEAT CUSHION REMOVAL With the lever pulled raise the seat cushion and remove the seat cushion INSTALLATION SERVICE POINT A4 REAR SEAT CUSHION INSTALLATION 1 Fit the attachment...

Страница 1130: ...shock to the SRS 45 Nm 33 ftlbs s Outer seat belt removal steps 1 Quarter trim Refer to P 52A 13 C 2 Outer seat belt Inner seat belt removal steps l Floor console assembly Refer to P 52A 10 3 Shield...

Страница 1131: ...t iotation YlQFO12Q INSTALLATION SERVICE POINTS A4 OUTER SEAT BELT INSTALLATION 1 Positively insert the pawl to prevent the retractor from rotating in the hole provided on the body 2 Install the ancho...

Страница 1132: ...e belt guide in the hole provided on the body 4 Install the final anchor of the front seat belt with the belt twisted 180 at the section between the sash guide and the final anchor so that the tip of...

Страница 1133: ...rvice Specification 21 SRS DIAGNOSIS UNIT SDU 71 TEST EQUIPMENT 23 TROUBLESHOOTING 23 Diagnostic Sequence 24 SRS Diagnostic Procedures Initial Steps 23 CAUTION I l Carefully read and observe the infor...

Страница 1134: ...t impact sensors simulta neously activate while the ignition switch is in the ON position These sensors are designed to acti vated in frontal or near frontal impacts of moderate to server force Only a...

Страница 1135: ...front impact sensor SRS diagnosis unit Incorporated safing 19FO138 00004055 VEHICLE y 19FOO73 0020008 19FO118 NOTE This construction diagram displays the general view of the SRS components For detail...

Страница 1136: ...I I Rightfront impact sensor Passkger s side 19FO244 19FO241 SRS diagnosis unit Incorporated safing imnsrt cancnri 19FO230 00004054 NOTE This construction diagram displays the general view of the SRS...

Страница 1137: ...ions when servicing Shown here are the contents of the caution labels SRS attached to a vehicle from 1994 model On caution If labels are dirty or damaged replace them with labels attached to 1992 and...

Страница 1138: ...rst start the vehicle see your dealer for If defective remove and replace entire unit per service manual service instructions See your owner s manual for more information Before replacement read servi...

Страница 1139: ...I Crank signal detection circuit 1 IGNITION SWITCH IGl I Multi purpose fuses Connector lock switch r Combina 1 tion meter SRS wam ing light L Warning light malfunction detection circuit sensor Frc 1 I...

Страница 1140: ...ock switch I r malfunction detection circuit UNLOCK 1 Connector lock detection circuit I I I D C DC converter u I I m ti VI LI t rl ib u m 0 Safing impact sensor Front impact sensor R H ON m FF Front...

Страница 1141: ...A 09X f l 38 A 09X Starter relay A 38 Front impact sensor L H A 63 Front impact sensor R H B Engine and transaxle Front view B 23 Starter motor B 24 Starter motor B 26 Park neutral position switch NO...

Страница 1142: ...1 00002555 D 26 Combination meter For SRS warning light Combination meter For SRS warning light Combination meter For SRS warning light 14 pin red connector to body wiring harness e pin blue connector...

Страница 1143: ...osis unit side connector is pressed down until a click is heard indicating that the connectors have been locked Second ary lock If the harness and SRS diagnosis unit connectors do not properly fit the...

Страница 1144: ...plies monitoring current to the circuit to electrically verify that the connectors have been locked CONNECTOR SHORTING MECHANISM The mechanism is designed for prevention of accidental igni tion of the...

Страница 1145: ...IlY THEFT I ggy RLAEU I FM I ION H 1992 MODEL g g y 1993 MODEL z IGNITION SWITCHtIGl 2B W COMBINATION METER SRS WARNING LIGHT 8 CRANKING SIGNAL DETECTION CIRCUIT DRIVE CIRCUIT t L IIIIIIIIIII Y 93 z m...

Страница 1146: ...eplace wiring if necessary after reading and following all precautions and procedures in this manual 2 Do not use an analogue ohmmeter to check SRS wiring or components use only special tools and digi...

Страница 1147: ...Y 1 25B Y i MFI SYSTEM XWING 0 85B 2B Y 2B Y L 4LARM g 4RM 2B Y I8 LTp PARK NEUTRAL I 2B Y 2B Y 28 R rr STARTING 0 858 F M T A T t lm 0 858 Y MFI SYSTEM CONNECTOR 1 I A 1IX R B n r 7 I I i R LIGHT 1 l...

Страница 1148: ...in this manual 2 Do not use an analogue ohmmeter to check SRS wiring or components use only special tools and digital multi meter shown on page 528 22 IGNI SWiT 0 w 2B W 63 IOA 0 833 k 0 858 R ON I IG...

Страница 1149: ...PONENT LOCATION Name Symbol Name Symbol Data link connector From 1994 models D Front impact sensor A Data link connector Up to 1993 models C SRS diagnosis unit B 1 cur to 1993 models L YlQFO243 From 1...

Страница 1150: ...age 52B 681 4 Do not attempt to repair the wiring harness connectors of the SRS If any of the connectors is diagnosed as fault replace the wiring harness If the wires are diagnosed as faulty replace o...

Страница 1151: ...impact sensor L H To front impact sensor R H harness 14 pin 2 pin blue connector to right front impact sensor SDU e pin yellow connector to left front impact sens 2 pin red connector to clock spring Y...

Страница 1152: ...estination of Harness Body wiring harness Junction block Body wiring harness Ground NOTE 1 The sensor cable marked with is available as service part 2 The sensor cable used as a replacement part is ro...

Страница 1153: ...rk is done on the SRS system immediately after the battery cables are disconnected 6 SRS components should not be subjected to heat over 93 C 2OO F so remove the front impact sensors SRS diagnosis uni...

Страница 1154: ...ing diagnostic trouble code l Reading trouble period l Reading erase times l Reading diagnostic trouble code l Erasing diagnostic trouble code Reading trouble period l Reading erase times SRS check ha...

Страница 1155: ...ition Does SRS warning light illuminate for about 7 seconds and then turn OFF If yes SRS system is functioning properly If no continue with following steps NOTE 1 From 1993 model the SRS warning light...

Страница 1156: ...the displayed diag nostic trouble codes and service data fault duration and how many time memories are erased using the scan tool NOTE 1 Maximum stored period 9999 minutes approximately 7 days 2 Maxim...

Страница 1157: ...s air bag module squib are shorted to Perfom TEST 6 each other or the circuit is grounded 22 The driver s seat air bag module squib circuit is open or the wire from the driver s air bag module to the...

Страница 1158: ...rminal with sulation Then charge NOTE IMPORTANT 1 After repairing the SRS reconnect the battery cable erase the diagnostic trouble code memory from the scan tool and check the SRS warning light operat...

Страница 1159: ...p to 1993 models 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnecting the ba...

Страница 1160: ...se excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a notch on the lock lever Type 2 Place a flat t...

Страница 1161: ...trument panel wiring harness Check for continuity between the grouna and terminal No 12 or No 13 of the body wiring harness s connector which is con netted to the instrument panel wiring bar ness yes...

Страница 1162: ...93 models 2 From 1994 models J 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnecting the bat ter...

Страница 1163: ...rd the inside of the unit Caution 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a n...

Страница 1164: ...al 2 After waiting at least 80 seconds repair or reDiaCethebodvwiring harness Reier to P 528 18 20 1 Tum the ignition key to the LOCK position disconnect the nega tive battery cable and tape the termi...

Страница 1165: ...odule squib failure modes simultaneously occur in two places the preconditions for the respective detection circuits will go out of order For this reason both diagnostic trouble codes may not be store...

Страница 1166: ...emove the rear console assembly Refer to GROUP 52A Floor Console 3 Apply a flat tip screwdriver to the lock spring metallic portion of the SDU connector lock lever as illustrated and push it horizonta...

Страница 1167: ...impact sensor normal I Yes c SRS check harness connector 5 is there continuitv between each of them and the body ground I IUO 1 CONTINUED ON NEXT PAGE 1Short circuit of the harness between left 1 w f...

Страница 1168: ...Harness 2 Reconnect blue and yellow connectors for the wiring lead ing to the front impact sensors to the SDU and double lock them Refer to P 52B 11 NOTE If double locking cannot be made the connector...

Страница 1169: ...erminals Passenger s air bag module To c ock spring To body wiring Zl9N0303 harness 14 pin 00002608 If combined front impact sensor and air bag module squib failure modes simultaneously occur in two p...

Страница 1170: ...re In case that there is no notch on the lock lever Type 1 Place a flat tip screwdriver against the lock spring metal section of the connector lock lever as shown in the illustra tion and push the spr...

Страница 1171: ...front impact sensor normal Replace the right front impact sensor t For terminals No 15 and No 18 of the SRS check harness connector 5 is there continuity between each of them and the body ground Yes t...

Страница 1172: ...connector 1 of the SRS Check Harness 2 Reconnect 16pin red connectors for the wiring leading to the front impact sensors to the SDU and double lock them Refer to P 52B 11 NOTE If double locking canno...

Страница 1173: ...s measured with a tester accidental driver s air bag deployment will result in serious personal injury L FUSIBLE LINK C IGNITION SWITCH IG1 SRS DIAGNOSIS UNIT t t 22 z El B d r c d G isi84FPG i I r Ic...

Страница 1174: ...but only one of them may be indicatpd Their relationships are shown in the following table Perform TEST 5 if it does not become proper even through TEST 6 is executed Failure modes Front impact Front...

Страница 1175: ...GROUP 52A Floor Console 3 Release the lock of SDU connector in accordance with the following procedure In case that there is no notch on the lock lever Crwe 1 Place a flat tip screwdriver against the...

Страница 1176: ...de connector of the SDU which were connected to the driv er s air bag module squib through the clock spring NOTE A 3 ohm resistor that corresponds to the resistance of the driver s air bag module squi...

Страница 1177: ...o 1993 model use the adapter harries supplied together Caution Before connecting or disconnecting the scan tool make sure that the ignition switch is placed at tht OFF position 3 Turn the ignition key...

Страница 1178: ...has been discon nected Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected Apply a flat tip screwdriver t...

Страница 1179: ...s the resistance between terminal 1 and terminal 21 of SRS Check Harness connector 5 and between termi nal 2 and terminal 22 of SRS Check Harness connector 5 normal Standard value less than 0 4 12 IYO...

Страница 1180: ...uit resistance is measured with a tester accidental passenger s air bag deployment will result in serious personal injury FUSIBLE LINK Q IGNITION SYITCH IGI 1 7p PURPOSE Q 1 7 m i 2 8 1 2 R Hi r MO SR...

Страница 1181: ...codes may not be stored but only one of them may be indicated Their relationships are shown in the following table Perform TEST 5 if it does not become proper even through TEST 7 is executed Failure...

Страница 1182: ...fter the battery has been discon nected Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected Disconnect th...

Страница 1183: ...ignition key from the ON to the LOCK position and then back to the ON position 1 Defective passenger s air bag module Replace passenger s air bag module Re fer to P 52575 Caution Never attempt to meas...

Страница 1184: ...p to 1993 models 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnecting the ba...

Страница 1185: ...tally toward the inside of the unit Caution 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that th...

Страница 1186: ...cable and tape the terminal 2 After waiting at least 60 seconds repair or replace the body wiring har ness Refer to P52B 16 20 NOTE IMPORTANT 1 If more than 45 seconds of cranking is required to star...

Страница 1187: ...he battery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected Se rious injury may result from un...

Страница 1188: ...NOTE harness 14 pin o l Up to 1993 models l 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds...

Страница 1189: ...de of the unit Caution 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a notch on the...

Страница 1190: ...OCK position disconnect the negative battery cable and tape the terminal repair or replace the body wiring har Replace the SDU Refer to P 52B 64 ground and the No 11 terminal of Damagedordisconnectedw...

Страница 1191: ...n OC NOTE l Up to 1993 models 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconn...

Страница 1192: ...not use excessive force to raise the lock lever 4 Disconnect the red 14 pin connector from the SDU 5 Reconnect negative terminal of battery and turn the igni tion key to the ON position 6 Check accor...

Страница 1193: ...ess 1Cpin OC I NOTE l Up to 1993 models 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution I Wait at least 60 seconds a...

Страница 1194: ...Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a notch on the lock lever Type 2 Place...

Страница 1195: ...m out SRS warning light bulbs or c damaged or disconnected body wiring harness 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal 2 After waiting...

Страница 1196: ...cted or disrupted by the collision the scan tool cannot communicate with the SRS diagnosis unit Inspect and if necessary repair the body wiring harness be fore proceeding further 3 Read the service da...

Страница 1197: ...howing any visible damage such as dents cracks or deformation replace them with new ones Concerning parts removed for inspection replacement with new parts and cautionary points for working refer to a...

Страница 1198: ...arness 3 Check air bag inflator case for dents cracks or deformities 4 Install air bag module to steering wheel to check fit or alignment with the wheel Passenger s side 1 Check module cover for dents...

Страница 1199: ...ing wheel and con nectors for damage and terminals for deformities 2 Install air bag module to check fit or alignment with steering wheel 3 Check steering wheel for noise binding or difficult opera ti...

Страница 1200: ...et metal repair painting etc they should be stored in a clean dry place until they are reinstalled FRONT IMPACT SENSORS Caution 1 Never repair or disassemble a front impact sensor If faulty replace it...

Страница 1201: ...ted If a dent crack or other deformation or rust is detected discard the sensor and replace it with a new one that passes the visual inspection 2 Before any front impact sensor is installed in the veh...

Страница 1202: ...for damage and terminals for deformities 3 Check for dents cracks or deformation of the front impact sensor Caution If a dent crack deformation or rust is detected re place with a new sensor 4 Remove...

Страница 1203: ...is unit with a new one 4 Never use an ohmmeter on or near the SRS diagnosis unit and use only the special test equipment described on P 528 23 Y19FO130 I i 2 pin yellow connector to left front impact...

Страница 1204: ...sh the spring horizontally toward the inside of the unit Caution 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock s...

Страница 1205: ...unit D POST INSTALLATION INSPECTION Reconnect the negative battery terminal Turn the ignition switch to ON Does the SRS warning light illuminate for about 7 seconds turn OFF and then remain OFF for a...

Страница 1206: ...AND INSTALLATION Air bag module driver s side clock spring Pre removal Operation l After setting the steering wheel and the front wheels to the straightahead position remove the ignition key I Up to...

Страница 1207: ...s side Air bag module removal steps Passenger s side 4Ab F l Post installation inspection 1 Negative battery cable connection 12 Glove box assembly 13 Cross pipe cover 14 Air bag module passenger s s...

Страница 1208: ...r bag module press the air bag s lock toward the outer side to spread it open Use a screwdriver as shown in the figure at the left to pry so as to remove the connector gently Caution 1 When disconnect...

Страница 1209: ...INSPECTION Caution Dispose of an air bag module only according to the specified procedure Refer to P 528 82 to P 528 87 2 Connect the scan tool to the data link connector When connecting the scan tool...

Страница 1210: ...ever of the SRS diagnosis unit D STEERING WHEEL INSTALLATION 1 Before installing the steering wheel be sure to first turn the vehicle s front wheels to the straight ahead position and align the mating...

Страница 1211: ...efer to P 52B 82 P 52B 87 Caution Never attempt to measure the circuit resistance of the air bag module squib even if you are using the specified tester If the circuit resistance is measured with a te...

Страница 1212: ...Up to 1993 and 1996 models Check for continuity between the No 1 connector of the I t i clock spring and connectors No 3 4 5 and 6 I Iesigna T o To To To To ion cruise ACC horn To steering To cruise...

Страница 1213: ...the terminals a Join the No 2 connector air bag module side and No 7 connector of clock spring to connector 4 and connector 3 respectively of the SRS Check Har ness NOTE When joining SRS Check Harnes...

Страница 1214: ...hen disposing a vehicle 1 Open all windows and doors of the vehicle Move the vehicle to an isolated spot 2 Disconnect the negative and positive battery cables from the battery terminals and then remov...

Страница 1215: ...HARNESS A and cover the connections with insula tion tape The other ends of the two wires should be connected to each other short circuited to pre vent sudden unexpected deployment of the air bag 5 C...

Страница 1216: ...vehicle Wear safety glasses suitable ear protection 2 The inflator will be quite hot immediately following the deployment so wait at least 30 minutes to allow it to cool before attempting to handle it...

Страница 1217: ...four bolts at the back of air bag module and connect thick wires to these bolts to secure the module to the wheel 4 Pass SRS air bag adapter harness B connected with wires under the used tire wheel as...

Страница 1218: ...be connected to each other short circuited to pre vent sudden unexpected deployment of the air bag 3 Connect the deployment wires to the SRS air bag adaptor harness A pass it beneath the tire and whe...

Страница 1219: ...air bag module fails to deploy when the procedures above are followed do not near the module Contact your local distributor DEPLOYED AIR BAG MODULE DISPOSAL After deployment the air bag module should...

Страница 1220: ...NOTES dl...

Страница 1221: ...N NEXT PAGE WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can l...

Страница 1222: ...ment 18 Compressor Noise 28 Handling Tubing and Fittings 28 Idle up Operation Check 29 Performance Test 26 Power Relay Check 29 Refrigerant Leak Repair Procedure 28 Test Procedures 16 REFRIGERANT LINE...

Страница 1223: ...lubricant FREOL S 83 or SUNISO 5GS SUN PAG 56 cc cu in 160 20 9 8f1 2 160 20 9 851 2 Drive belt size mm in 1 150 45 3 1 150 45 3 Dual pressure High pressure switch OFF 2 700 384 switch kPa psi OFF 3...

Страница 1224: ...olution pick up sensor standard resistance Sz when ambient temperature is 20 C ter motor assembly resistance tiometer assembly r Engine coolant temperature Sensor ON temperature sensor C F 26 5 f 4 79...

Страница 1225: ...1 386 Pin MIT217213 MB991 341 MB991 341 C Up to 1993 models Inspection of full auto air conditioning Scan tool Multi use tester MUT ROM pack For the num ber refer to GROUP 00 Precautions Be fore Servi...

Страница 1226: ...etely connected crushed bent or clogged Adjust Repair or replace Burn out fuse Poor grounding Malfunction blower switch Correct Replace Replace 55 30 Malfunction resistor Malfunction blower motor Malf...

Страница 1227: ...the engine and compressor exceed 92 for more than three seconds the A C compressor lock controller turns off the magnetic clutch relay which opens the mag netic clutch circuit 2 when a signal is rece...

Страница 1228: ...A C ECU to activate the compressor warning indicator d The indicator will blink 4 The NC compressor lock controller does not contain a memory circuit It will operate the compressor and check for belt...

Страница 1229: ...95 models Generator t Fuse Fuse Ignition coil 1 I 1 I n Fin therm0 sensor Air inlet sensor I A 1 Engine tprn calculation I NC compressor L calculation Circuit lock controller Y cl Fuse Resistor Heater...

Страница 1230: ...I MH Heatercontrol panel I Pk J OFF WI Air conditioning switch I II 1 conditioning control unit 1 T 1 1 1 Fin therm0 sensor Air inlet C n I A I t Compressor rpm NC compressor calculation circuit lock...

Страница 1231: ...osi tive voltage 6 Air conditioning compressor relay 7 Air conditioning switch A C When all conditions for switch ON of the Battery posi compressor are satisfied tive voltage When air conditioning swi...

Страница 1232: ...switch ON System voltage power source A C switch indicator Compressor ON Normally 0 7 VDC 0 9 VDC Compressor drive belt 5 VDC Slipping slip ratio 92 or more Engine revolution input When engine is runn...

Страница 1233: ...299 to 384 psi Correct places where gas leaks Gas leakage i 4 6 Dual pres sure switch Replace dual pressure switch Check for continuity be tween switch terminals Check for continuity be tween thermos...

Страница 1234: ...e mineral oil handy when working on the refrigeration system Should any liquid refrigerant get into the eyes use a few drops of mineral oil to wash them out R 12 is rapidly absorbed by the oil Next sp...

Страница 1235: ...y id when working on the refrigeration system Should any liquid refrigerant get into the eyes use a few drops of mineral oil to wash them out R 134a is rapidly absorbed by the oil Next splash the eyes...

Страница 1236: ...the magnetic clutch 2 Connect battery to compressor body 3 Connect battery voltage directly to the wiring for the magnetic clutch 4 If the magnetic clutch is normal there will be a click If the pulley...

Страница 1237: ...mal The magnet clutch is fre quently turned on and off The difference between the high and low pressures is not observed Abnormal Blow out tem perature is high Probable cause Faulty com pressor Faulty...

Страница 1238: ...Vehicles using R l 2 refrigerant CHARGE EQUIPMENT INSTALLATION 1 Turn the adaptor valves 1 and 2 handles back fully valves shut and attach adaptor valves 1 and 2 to the high and low pressure service v...

Страница 1239: ...ans Follow the safety precautions for handling R 12 as listed in this group TSB Revision CHARGING THE REFRIGERANT Vehicles using R l 2 refrigerant CHARGING WITH SMALL CANS When using disposable cans o...

Страница 1240: ...e 1 handle fully clockwise valve open I j 1 Caution 1 m 1 If the service can is inverted liquid refrigerant may be drawn into the compressor damaging it by liquid Service can compression Keep the serv...

Страница 1241: ...erant checking level with the sight glass 12 Upon completion of charging turn back the adaptor valve 2 handle all the way valve shut 13 Remove the adaptor valve 2 from the service valve NOTE If the se...

Страница 1242: ...e vacuum pump 8 Connect the charging hose yellow to the R l 34a connec tion port of the vacuum pump adaptor 9 Tighten the adaptor valve handle valve open 10 Open the low pressure valve of the gauge ma...

Страница 1243: ...the handle of the adaptor valve back all the way valve closed 21 Check for gas leaks using a leak detector If a gas leak is detected re tighten the connections and then repeat the charging procedure...

Страница 1244: ...all the quick joint for low pressure to the low pressure service valve NOTE The low pressure service valve should be connected to the low pressure hose 8 Start the engine 9 Operate the air conditioner...

Страница 1245: ...ING SYSTEM Too little oil will provide inadequate compressor lubrication and cause a compressor failure Too much oil will increase discharge air temperature When a compressor is installed at the facto...

Страница 1246: ...control MAX COOL position Air selection Recirculation position Blower switch HI Fast position 8 Adjust engine speed to 1 000 rpm with air conditioning clutch engaged 9 Engine should be warmed up with...

Страница 1247: ...the service valve until a click is heard When connecting run your hand along the hose while press ing to ensure that there are no bends in the hose 6 Start the engine 7 Set the A C controls as follows...

Страница 1248: ...rged before opening any fitting of connection in the refrigeration system Open fittings with caution even after the system has been discharged If any pressure is noticed as a fitting is loosened allow...

Страница 1249: ...he radiator fan motor relays HI and LO from the relay box on the right of the engine compartment 2 Remove the radiator fan motor relay air conditioning Up to 1993 models condenser fan motor relays HI...

Страница 1250: ...2 Glove box outer case assembly Cd 3 Air selection control wire connection 4 Hood lock release handle 5 Rheostat assembly 6 Rear wiper and washer switch 7 Knee protector 8 Shower duct B 9 Mode contro...

Страница 1251: ...wing the steps below 1 Move the mode selection lever to the defroster position 2 With the mode selection damper lever pressed inward in the direction indicated by the arrow connect the inner cable of...

Страница 1252: ...ssor lock controller J zmPo011 00002624 I N S P E C T I O N RESISTOR CHECK Using a circuit tester measure the resistance between the terminals indicated below The condition can be considered satisfact...

Страница 1253: ...ter air outlet assembly with a flat tip screwdriver remove the center air outlet assembly with the trim stick B AIR CONDITIONING SWITCH REMOVAL Remove the center air outlet assembly and insert hand to...

Страница 1254: ...on 2 Center reinforcement 3 Under cover 4 Distribution duct foot 5 Foot shower duct 6 Lap cooler duct 22OFO104 4 7 Evaporator mounting bolt and nut 8 Vehicles with air conditioning Center duct 9 Heate...

Страница 1255: ...the heater core for clogging and water leakage BLOWER ASSEMBLY REMOVAL AND INSTALLATION m 5 J 7 8 yy dT J Li w 66 6 Y 4 6 Pa 7 __ q ZZOFOO79 Blower case assembly removal steps 1 Stopper 2 Glove box 3...

Страница 1256: ...er lever as it contacts stopper 3 Connect the inner cable of the air selection control wire to the end of the air selection lever and then secure the outer cable by using a clip INSPECTION l Check for...

Страница 1257: ...wer frame 9 A C control unit Up to 1995 models A 10 Evaporator REMOVAL SERVICE POINT A DlSCHARGE PIPE C AND SUCTION HOSE B DISCONNECTION If the hoses or pipes are disconnected cap the hoses or pipes w...

Страница 1258: ...case upper 9 Insulator 4 Fin therm0 sensor Up to 1995 10 Rubber insulator models 11 5 Air inlet sensor Up to 1995 models Clip with manual air conditioning 4B 12 Expansion valve DISASSEMBLY SERVICE PO...

Страница 1259: ...odels I O ring w 3 Cf I t 70N0089 Compressor oil FREOL S 83 or SUNISO 5GS dehicles using R 12 refrigeranb SUN PAG 56 Vehicles using R 134a refrigerant Removal steps 1 Compressor drive belt 2 Condenser...

Страница 1260: ...nt X cm3 X fl oz of oil within the removed compressor 2 Wipe away from the new compressor the amount of oil calculated according to the following formula and then install the new compressor New compre...

Страница 1261: ...onsidered satisfactory if the operation sound a click sound of the magnetic clutch can be heard when this check is made Magnetic clutch disassembly steps 1 Bolts 2 Pulley A D 3 N u t C 4 Armature plat...

Страница 1262: ...etic clutch disassembly steps 1 Bolts 2 Pulley A D 3 N u t C 4 Armature plate S ztr ring A4 CJ h coil High pressure relief valve disassembly 4B 12 High pressure relief valve Thermostat and revolution...

Страница 1263: ...snap ring from inside the fitting block and remove the refrigerant temperature switch 3 Remove the revolution pick up sensor from the fitting block REASSEMBLY SERVICE POINTS A4 CLUTCH COIL INSTALLATI...

Страница 1264: ...cracks or scoring on the sealing d surfaces l Check the compressor shaft for scoring HIGH PRESSURE RELIEF VALVE CHECK The high pressure relief valve is a safety feature which releases part of the refr...

Страница 1265: ...ts a low pressure level during the operation of the air conditioning and adjusts the amount of refrigerant to be bypassed 1 Operate the air conditioning under a high temperature load condition when ve...

Страница 1266: ...r oil FREOL S 83 or SUNISO 5GS Vehicles using R 12 refrigerant SUN PAG 56 Vehicles using R 134a refrigerant Removal steps d 9 Nm 7 ft lbs Z2OFOO28 00002630 1 Condenser fan motor assembly 2 Fan 3 Motor...

Страница 1267: ...s using R 12 refrigerants SUN PAG 56 Vehicles using R 134a refrigerant Quantity 15 cm3 S fl 02 INSPECTION l l Check the condenser fan for crushing or other damage Check the condenser s discharge hose...

Страница 1268: ...2 refrigerant SUN PAG 56 X20N0089 Vehicles using R l 34a refrigerant n 6 I 13 Nm 9 ft lbs 2 23 Nm 17 ft lb 13 Nm 9 11 Nm 7 8 ft lbs 12 15 Nm 9 11 ft lbs f3 i From Oct 1992 models IL 22OFO161 00002631...

Страница 1269: ...cified amount of oil in the compressor before installing these parts in the vehicle Compressor oil FREOL S 83 or SUNISO 5GS Vehicles using R 12 refrigerant SUN PAG 56 Vehicles using R 134a refrigerant...

Страница 1270: ...65 i Knee protector Refer to GROUP 52A Instrument Panel Foot shower duct Lap cooler duct Under cover A C compressor lock controller Side defroster hoses A Duct Vehicles without air conditioning Instru...

Страница 1271: ...OINTS A PHOTO SENSOR REMOVAL Using the trim stick remove the photo sensor from the defroster garnish B CENTER AIR OUTLET ASSEMBLY REMOVAL Disengaging the clips 2 positions of the center air outlet ass...

Страница 1272: ...AL AND INSTALLATION 13 Nm 9 4 ft lbs Inlet garnishes removal steps 1 Windshield wiper arm 2 Front deck garnish 3 Inlet garnish RH 4 Inlet garnish LH ZZOFOO98 00002632 Rear ventilation duct removal ste...

Страница 1273: ...e coolant temperature switch xTk 22OAO199 INSPECTION AIR CONDITIONING ENGINE COOLANT TEMPERATURE SWITCH ALWAYS CLOSED TYPE CHECK 1 immerse the A C engine coolant temperature switch in oil and heat by...

Страница 1274: ...Reference Chart to know the inspection items and then start the inspection procedure detailed in the following pages 6 When checking components be sure to disconnect the connectors first TROUBLESHOOT...

Страница 1275: ...olant temperature switch Up to 1993 models Pressure switch Air conditionia control panel 4 3 3 3 Refrigerant amount Receiver Expansion valve Compressor 1 Thermostat I I I I T 1 A C compressor lock con...

Страница 1276: ...A C compressor lock controller Defective MFI control unit Replace MFI control unit Defective interior temperature sensor Check on board diagnos input circuit tic output Defective blend air damper pot...

Страница 1277: ...eiver 55 48 Clogged expansion valve Replace expansion valve 55 38 Defective compressor Replace compressor 55 39 Defective air inlet sensor Replace air inlet sensor 55 77 Defective magnetic clutch Repl...

Страница 1278: ...control Condenser fan does Defective condenser fan motor relay Replace power relay 55 29 not operate when the air conditioning is acti Defective condenser fan motor Replace condenser fan 55 46 vated m...

Страница 1279: ...adjust GROUP 11 Defective compressor drive belt Replace Defective compressor Check and replace 55 17 39 Defective revolution pick up sensor Check and replace 55 41 42 45 Defective air conditioning sw...

Страница 1280: ...ltages Termtnal No Slgnal name Condmon Terminal voltage _ Connectors are keyed by terminal numbers I 55 1 Air inlet sensor 1 Temperature at sensor 25 C 77 F 4 kW I2 2 2 8V I 60 sensor power source Nor...

Страница 1281: ...purpose fuse I r 1 I r m Air conditioning control unit Troubleshooting Hints l Air conditioning control unit terminal voltage Terminal No Signal name Condition Terminal voltage 53 Backup power source...

Страница 1282: ...Fix air selection damper at FACE position or at FACE position when it is at FACE position l Air conditioning control unit terminal voltages Terminal No Signal name Condition Terminal voltage 56 Blend...

Страница 1283: ...155 Troubleshooting Hints l Diagnosis No 11 12 Fix interior temperature sensor input signal at 25 C 77 F No 13 14 Fix air inlet sensor input signal at 15 C 59 F No 21 22 Fix air therm0 sensor input si...

Страница 1284: ...ccm Fin speed arith pensatina circuit metic circuit t ND conversion ND conversion i Air conditioning tar drive wcuit power transistor L 69 22OFOl50 Z2OFO149 00002634 Troubleshooting Hints l Air condi...

Страница 1285: ...ioning control unit Revolution pickup sensor j68 j61 j116 IG2 1 eecontrol Condenser fan motor relay LO I 7 Air conditioning compressor lock controller NC color monitor Blinking 22OFOO26 2OFO177 Operat...

Страница 1286: ...r control motor circuits Blend air damper control motor Air conditioning Air inlet sensor Blend air damper control motor Z2OFO152 Mode selection damper control motor Air conditioning control panel Eng...

Страница 1287: ...F 40 seconds after the damper moved to FACE position DEF switch ON tov Output turns OFF 40 seconds after the damper moved to DEE position Inside air switch ON 1ov Output turns OFF 40 seconds after ins...

Страница 1288: ...r I I transis 4 I tor drive circuit ZZOFO158 Troubleshooting Hints l Air conditioning control unit terminal voltages Terminal No Signal name Condition Terminal voltage Air conditioning power transisto...

Страница 1289: ...referring to diagnostic chart 3 Erase the failure code 4 Check the system again With voltmeter meter _ Y2OFO107 I Ground tya Diagnostic output l When using the voltmeter Up to 1993 models 1 Connect a...

Страница 1290: ...models I Connect a voltmeter to the diagnostic output terminal and I the ground terminal of the data link connector using the special tool Read out the diagnostic trouble code by observing the voltme...

Страница 1291: ...d air damper po tentiometer and air condi tioning control unit Replace blend airdamp er potentiometer Correct harness Poor connection of air conditioning control unit connector or defective air condit...

Страница 1292: ...r or MAX COOL when it is at MAX COOL 32 n17n Short circuited and open circuited mode DEF selection damper potentiometer or FACE when it is at FACE u12A0107 41 nnnn Defective blend air damper motor 42...

Страница 1293: ...l and Post installation Operation l Floor Console Removal and Installation Refer to GROUP 52A Floor Console CAUTION SRS When installing or removing the floor console don t allow any impact or shock to...

Страница 1294: ...POWER TRANSISTOR AIR CONDITIONING COMPRESSOR LOCK CONTROLLER REMOVAL AND INSTALLATION t20F0073 Power transistor removal steps 1 Stopper 2 Glove box outer case assembly 3 Power transistor A C compress...

Страница 1295: ...r conditioning control unit 6 Center outlet assembly zPOFOO77 7 Air conditioning control panel 8 Air conditioning control unit 9 Blend air damper motor assembly Mode selection damper motor assembly re...

Страница 1296: ...does not turn when battery voltage is applied BLEND AIR DAMPER POTENTIOMETER CHECK Connect a circuit tester across terminals 5 and 6 of the motor assembly connector and check that resistance graduall...

Страница 1297: ...FOO15 8 00002638 Engine coolant temperature sensor removal steps 2 Stopper e box outer case assembly 7 Engine coolant temperature sensor Air inlet sensor removal steps 2 Stopper 3 Glove box outer case...

Страница 1298: ...he engine coolant tempera ture 2 Check that the engine coolant temperature sensor is con ductive when the engine coolant temperature reaches the specified temperature Standard value 26 5 4 C 79 7 f 7...

Страница 1299: ...models REMOVAL AND INSTALLATION The service procedures are the same as those for manual air conditioning except for those parts described below on turbocharged vehicles 4 L Compressor condenser and co...

Страница 1300: ...other end of air intake hose B all the way into turbocharger side B AIR PIPE AIR HOSE B INSTALLATION When installing the air hoses make sure that the alignment marks at places indicated by arrows are...

Страница 1301: ...3A 171 273 l BRAKE Parking 36 8 l BOOSTER 35 87 l Operating Check 35 64 l DISC 35 93 103 I Front Check 35 70 l Rear Check 35 73 l FLUID LEVEL SENSOR Check 35 64 t HOSES Maintenance 00 52 I LINE 35 91...

Страница 1302: ...COOLANT Maintenance 00 51 I Replacement 14 4 l COOLANT TEMPERATURE GAUGE UNIT 14 13 l COOLANT TEMPERATURE SENSOR Engine and Emission Control 17 65 l Engine Cooling 14 l 3 l On vehicle Inspection 13A 9...

Страница 1303: ...44 257 l INSTRUMENT PANEL 52A 5 l INTAKE AIR TEMPERATURE SENSOR 17 65 l On vehicle Inspection 13A 88 215 l CHARGE PRESSURE CONTROL SYSTEM Check 15 7 l INTAKE MANIFOLD 15 17 l PLENUM Non Turbo 15 13 l...

Страница 1304: ...6 11 54 156 11 54 188 11 37 11 I 378 5 l 54 192 11 54 203 11 Leak Repair Procedure 55 28 l LINE Full Auto A C 55 79 l ManualAJC 55 48 l REGULATOR Door 42 43 l RELEASE CYLINDER Clutch 21 16 l RESISTOR...

Страница 1305: ...BELT 11 31 i Maintenance 00 46 I TIRE 31 4 l TRAILING ARM AWD 34 32 l FWD 34 11 l TRANSAXLE T 23 64 l M T AWD 22 19 23 l M T FWD 22 9 l Automatic Maintenance 00 49 l i Manual Maintenance 00 48 I Is CO...

Страница 1306: ...6 ALPHABETICAL INDEX Output Voltage Measurement 35 75 l WINDOW GLASS 42 26 l 4 a Door Adjustment 42 12 l Quarter 42 34 l WINDSHIELD 42 29 l WASHER 51 26 l WIPER 51 25 l RJHY506014 1294...

Страница 1307: ...1 1 I I I 1 I 1 1 I I I j I i i i I i I j j...

Страница 1308: ......

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