Mitsubishi Outlander Service Manual

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00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 00-2 SUPPLEMENTAL RESTRAINT

SYSTEM (SRS) . . . . . . . . . . . . . . . . . . 00-27
HOW TO USE
TROUBLESHOOTING/INSPECTION SRS SERVICE PRECAUTIONS . . . . . 00-28
SERVICE POINTS . . . . . . . . . . . . . . . 00-6
SUPPORT LOCATIONS FOR LIFTING
VEHICLE IDENTIFICATION . . . . . . . 00-16 AND JACKING . . . . . . . . . . . . . . . . . . 00-31
GENERAL DATA AND STANDARD PART/TIGHTENING-

SPECIFICATIONS . . . . . . . . . . . . . . . 00-20 TORQUE TABLE . . . . . . . . . . . . . . . . 00-33
PRECAUTIONS BEFORE SERVICE. 00-22

00-2 GENERAL
HOW TO USE THIS MANUAL

M1001000100660
SCOPE OF MAINTENANCE, REPAIR AND REFERENCE VALUE
SERVICING EXPLANATIONS Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
This manual provides explanations, etc. concerning
adjustment procedures, and so they can be
procedures for the inspection, maintenance, repair
completed in a shorter time).
and servicing of the subject model. Note, however,
that for engine and transmission-related component DANGER, WARNING, AND CAUTION
parts, this manual covers only on-vehicle DANGER, WARNING, and CAUTION call special
inspections, adjustments, and the removal and attention to a necessary action or to an action that
installation procedures for major components. For must be avoided. The differences among DANGER,
detailed information concerning the inspection, WARNING, and CAUTION are as follows:
checking, adjustment, disassembly and reassembly • If a DANGER is not followed, the result is severe
of the engine, transmission and major components bodily harm or even death.
after they have been removed from the vehicle, • If a WARNING is not followed, the result could be
please refer to separate manuals covering the bodily injury.
engine and the transmission. • If a CAUTION is not followed, the result could be
ON-VEHICLE SERVICE damage to the vehicle, vehicle components or
"On-vehicle Service" is procedures for performing service equipment.
inspections and adjustments of particularly important
locations with regard to the construction and for INDICATION OF TIGHTENING TORQUE
maintenance and servicing, but other inspection (for Tightening torques (units: N⋅m) are set to take into
looseness, play, cracking, damage, etc.) must also account the central value and the allowable
be performed. tolerance. The central value is the target value, and
the allowable tolerance provides the checking range
INSPECTION
for tightening torques. If bolts and nuts are not
Under this title are presented inspection and
provided with tightening torques, refer to P.00-33.
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
MODEL INDICATIONS
procedures, visual inspections should always be The following abbreviations are used in this manual
performed as well. for identification of model types.
MPI::Indicates the multipoint injection.
DEFINITION OF TERMS SOHC::Indicates an engine with the single overhead
camshaft.
STANDARD VALUE DOHC::Indicates an engine with the double
Indicates the value used as the standard for judging overhead camshaft.
the quality of a part or assembly on inspection or the 2000:: Indicates models equipped with the 2,000 mL
value to which the part or assembly is corrected and <4G63> petrol engine.
adjusted. It is given by tolerance. 2400::Indicates models equipped with the 2,400 mL
LIMIT <4G69> petrol engine.
Shows the standard for judging the quality of a part M/T:: Indicates the manual transmission.
or assembly on inspection and means the maximum A/T:: Indicates the automatic transmission.
or minimum value within which the part or assembly A/C:: Indicates the air conditioner.
must be kept functionally or in strength. It is a value
established outside the range of standard value.
GENERAL 00-3
NOTES
00-4 GENERAL
(s
.
<<A>> disassembly.
>>A<< or reassembly.
Symbols are used to show the locations for lubrication

. Multi-purpose grease unless there is a
These symbols are included in the diagram of compo-
nent parts or on the page following the component
parts page. The symbols do not always have accomp-
anying text to support that symbol.
AC301960
GENERAL 00-5
For bolts and nuts which do

not have a tightening torque
listed, refer to the "Standard
Parts tightening-torque Table"
parts sets are
On removal,
reassembly are described
AC300860
00-6 GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS
M1001000200582
CONTENTS OF TROUBLESHOOTING
Troubleshooting of electronic control systems for which the MUT-II/III can be used follows the basic outline
described below. Even in systems for which the MUT-II/III cannot be used, some of these systems still follow
this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from
that given below, or if additional explanation is required, the details of such differences or additions will also
be listed.
Diagnosis method
Gathering information
from the customer.
Check trouble symptom.

Reoccurs Does not reoccur
Read the diagnosis code. Read the diagnosis code.

Diagnosis code Diagnosis code
displayed. displayed.
After taking note of the

malfunction code, erase the
diagnosis code memory. No diagnosis
No diagnosis code
or communication code.
with MUT-II/III not
possible Recheck trouble symptom.
Read the diagnosis codes.

No diagnosis
Diagnosis code code.
displayed.
Refer to the INSPECTION CHART Refer to the INSPECTION CHART INTERMITTENT MALFUNCTIONS
FOR TROUBLE SYMPTOMS FOR DIAGNOSIS CODES
(Refer to applicable group.) (Refer to applicable group.)
AC300864AC
2. SYSTEM OPERATION AND SYMPTOM 4. DIAGNOSIS CODE CHART

VERIFICATION TESTS Diagnostic trouble codes and diagnostic items are
If verification of the symptom(s) is difficult, shown.
procedures for checking operation and verifying
symptoms are shown. 5. DIAGNOSIS CODE PROCEDURES
Indicates the inspection procedures corresponding to
3. DIAGNOSIS FUNCTION each diagnosis code (Refer to How to read
Details which are different from those in the inspection procedure ).
"Diagnosis function " section are described.
GENERAL 00-7
6. TROUBLE SYMPTOM CHART <Using the MUT-III>

If there are trouble symptoms even though the
<Using the MUT-III>
MUT-II/III does not find any diagnosis codes,
Inspection procedures for each trouble symptom will
be found by means of this chart.
16-PIN
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptoms classified in the Symptom Chart
(Refer to How to read inspection procedure P.00-9).
8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgment values have MB991911
been provided in this chart as reference information.
MB991824
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors,
inspection items, and judgment values have been
provided in this chart as reference information.
10. INSPECTION PROCEDURE BY USING AN

OSCILLOSCOPE
MB991827 AC308915 AC
When there are inspection procedures using an
oscilloscope, these are described here. Connect the MUT-III to the 16-pin diagnosis
connector, and read the diagnosis code.
DIAGNOSIS FUNCTION NOTE: For details on how to use the MUT-III, refer to
HOW TO READ DIAGNOSIS CODE the "MUT-III operation manual."
1. Ensure that the ignition switch is at the
CAUTION
"LOCK" (OFF).
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK" 2. Start up the personal computer.
(OFF) position. 3. Connect MUT-III USB cable MB991827 to
special tool Vehicle Communication Interface
<Using the MUT-II> (V.C.I.) MB991824 and the personal
<Using the MUT-II> computer.
4. Connect MUT-III main harness B MB991911
Steering shaft
to the V.C.I.
5. Connect MUT-III main harness B to the
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON"
MUT-II position.
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green
AC300830 AC
colour.
Connect the MUT-II to the diagnosis connector, and 7. Start the MUT-III system on the PC and turn
read the diagnosis code. the ignition switch to the "ON" position.
8. Read the diagnosis code.
9. Disconnecting the MUT-III is the reverse of
the connecting sequence, making sure that
the ignition switch is at the "LOCK" (OFF).
00-8 GENERAL
NOTE: The ABS warning lamp may flash when the ERASING DIAGNOSIS CODE (BY USING NO
ignition switch is turned ON with the MUT-II/III MUT-II/III)
connected. This is because the diagnosis display CAUTION
function of the ABS warning lamp is activated by Some diagnosis codes can not be erased
grounding the diagnosis connector terminal No.1, according to the procedure below. If you attempt
and is not detrimental in any way. to erase a diagnosis code, refer to an applicable
GROUP.
ERASING DIAGNOSIS CODE (BY USING THE 1. Turn the ignition switch to the "LOCK" (OFF)
MUT-II/III) position.
CAUTION 2. Disconnect the negative battery cable, wait for at
Before connecting or disconnecting the least 10 minutes, and then reconnect it.
MUT-II/III, turn the ignition switch to the "LOCK" 3. Start the engine and let it run at idle for 10
(OFF) position. minutes.
<Using the MUT-II>
INPUT SIGNAL CHECK (WHEN USING THE
Steering shaft MUT-II/III) <SWS>
CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
MUT-II (OFF) position.
<Using the MUT-II>
AC300830 AC Steering shaft
<Using the MUT-III>
MUT-II
16-PIN
AC300830 AC
<Using the MUT-III>
MB991911
16-PIN
MB991824
MB991911
MB991827 AC308915 AC MB991824

Connect the MUT-II/III to the diagnosis connector,
and erase the diagnosis code. The procedure is the
same as "HOW TO READ DIAGNOSIS CODE ".
MB991827 AC308915 AC
GENERAL 00-9
1. Connect the MUT-II/III to the diagnosis connector, 1. Use the special tool diagnosis code check
and erase the diagnosis code. harness (MB991529) to connect the ETACS
2. If the MUT-II/III buzzer sounds once when each terminal (terminal 9) and the earth terminals
switch is operated (ON/OFF), the input signal for (terminals 4 and 5) of the diagnosis connector to
that switch circuit system is normal. the voltmeter.
2. If the needle of the voltmeter flickers once when
INPUT SIGNAL CHECK (WHEN USING A each switch is operated (ON/OFF), the input
VOLTMETER) <SWS> signal for that switch circuit system is normal.
Steering shaft HOW TO USE THE INSPECTION

MB991529
PROCEDURES
The causes of many of the problems occurring in
electric circuitry are generally the connectors,
components, the ECU, the wiring harnesses
between connectors, in that order. These inspection
1 2 3 4 5 6 7 8 procedures follow this order. They first try to discover
9 10 11 12 13 14 15 16 a problem with a connector or a defective
AC300831AB component.
00-10 GENERAL
Relevant circuit(s) of the component which

the Code No. indicates are described.
AC301964AB
GENERAL 00-11
Start of diagnosis Describes

Explains about the basic
procedure inspection
operation of the components.
procedure.
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
Describes possible
causes(s) for that
diagnosis code.
AC301965AB
HARNESS CHECK IF INSPECTING WITH THE CONNECTOR

Check for an open or short circuit in the harness CONNECTED
between the terminals which were faulty according to
<Waterproof Connectors>
the connector measurements. Carry out this
inspection while referring to the Electrical Wiring MD998459
Manual. Here, "Check the wiring harness between
the power supply and terminal xx" also includes
checking for blown fuse. For inspection service
points when there is a blown fuse, refer to
"Inspection Service Points for a Blown Fuse ."
MEASURES TO TAKE AFTER REPLACING THE

ECU
If the trouble symptoms have not disappeared even AC300881AB
after replacing the ECU, repeat the inspection
Be sure to use special tool harness connector
procedure from the beginning. (MD998459). Never insert a test probe from the
harness side, as this will reduce the waterproof
CONNECTOR MEASUREMENT SERVICE performance and result in corrosion.
POINTS
Turn the ignition switch to the "LOCK" (OFF) position
when connecting and disconnecting the connectors.
Turn the ignition switch to "ON" when measuring,
unless there are instructions to the contrary.
00-12 GENERAL
<Ordinary (non-waterproof) Connectors> Use the special tool inspection harness (MB991219)
(inspection harness for connector pin contact
pressure in the harness set for inspection). The
inspection harness for connector pin contact
pressure should be used. the test bar should never
be forcibly inserted, as it may cause a defective
contact.
<When Inspecting a Male Pin>

Connector CAUTION
AC300882AB
Check by inserting the multi-meter test probe from

the harness side. Note that if the connector (control
unit, etc.) is too small to permit insertion of the test
probe, it should not be forced; use the backprobing
tool for this purpose.
IF INSPECTING WITH THE CONNECTOR

DISCONNECTED
<When Inspecting a Female Pin> AC300890
At this time, be careful not to short the connector

pins with the test bars. To do so may damage the
circuits inside the ECU.Touch the pin directly
with the test bar.
MB991219
ACX00865AB
GENERAL 00-13
CONNECTOR INSPECTION SERVICE • Low connection pressure due to rusted terminals

POINTS or foreign matter lodged in terminals
VISUAL INSPECTION
• CONNECTOR PIN INSPECTION
Connector disconnected or
improperly connected
AC300898
Stretched or broken wires If the connector pin stopper is damaged, the terminal
connections (male and female pins) will not be
perfect even if the connector body is connected, and
the pins may pull out of the reverse side of the
connector. Therefore, gently pull the harnesses one
by one to make sure that no pins pull out of the
connector.
CONNECTOR ENGAGEMENT INSPECTION
Harness wire breakage

MB991219
at terminal section
Low contact
pressure
Good
Bad
AC300899AB
Use the special tool inspection harness (MB991219)

AC300896AB
(connector pin connection pressure inspection
Connector is disconnected or improperly connected harness of the inspection harness set) to inspect the
• Connector pins are pulled out engagement of the male pins and females pins. (Pin
• Due to harness tension at terminal section drawing force: 1 N or more)
• Low contact pressure between male and female
terminals
00-14 GENERAL
INSPECTION SERVICE POINTS FOR A Remove the blown fuse and measure the resistance
BLOWN FUSE between the load side of the blown fuse and the
earth. Close the switches of all circuits which are
connected to this fuse. If the resistance is almost 0 Ω
at this time, there is a short somewhere between
these switches and the load. If the resistance is not 0
Ω, there is no short at the present time, but a
Battery momentary short has probably caused the fuse to
blow.
The main causes of a short circuit are the following.
• Harness being clamped by the vehicle body
• Damage to the outer casing of the harness due to
Fuse wear or heat
• Water getting into the connector or circuitry
• Human error (mistakenly shorting a circuit, etc.)
Short-circuit
Load occurrence
switch section
Load
AC300900AB
GENERAL 00-15
HOW TO COPE WITH INTERMITTENT Intermittent malfunctions often occur under certain
MALFUNCTIONS conditions, and if these conditions can be
ascertained, determining the cause becomes simple.
NOTE: If determining the cause is difficult, the flight In order to ascertain the conditions under which an
recorder function of the MUT-II/III can also be used. intermittent malfunction occurs, first ask the
customer for details about the driving conditions,
weather conditions, frequency of occurrence and
trouble symptoms, and then try to recreate the
trouble symptoms. Next, ascertain whether the
reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or
some other factor. If vibration is thought to be the
cause, carry out the following checks with the
connectors and components to confirm whether the
trouble symptom occurs. The objects to be checked
are connectors and components which are indicated
by inspection procedures or given as probable
causes (which generates diagnosis codes or trouble
symptoms).
• Gently shake the connector up, down and to the
left and right.
• Gently shake the wiring harness up, down and to
the left and right.
• Gently rock each sensor and relay, etc. by hand.
• Gently shake the wiring harness at suspensions
and other moving parts.
AC300901
00-16 GENERAL
VEHICLE IDENTIFICATION
M1001000400713
VEHICLE IDENTIFICATION CODE PLATE The plate shows model code, engine model,
transmission model and body colour code.
1
No. Item Content
1 MODEL CU2WXNMM CU2W:
3 L6 Vehicle model
2
XNMML6:
Model series
2 ENGINE 4G63 Engine model
3 EXT W83A Exterior code
5 4 6 7
4 TRANS AXLE F5M42 F5M42:Trans
mission
model
5 COLOUR W83 W83: Body
colour code
6 INT 62A 62A: Interior
code
7 OPT ZP3 ZP3:
Equipment
code
AC301477AB
For monotone colour vehicles, the body colour code
The vehicle information code plate is riveted to the shall be indicated.
back of the hood.
MODELS
Model code Engine model Price class Transmission Fuel supply
model system
CU2W XNMML6 4G63-DOHC (1,997 Comfort F5M42 MPI
mL) <2WD, 5M/T>
XNMMZL6 W5M42
XNHMZL6 Sport <4WD, 5M/T>
CU5W XNMYZL6 4G69-SOHC MIVEC Comfort W5M42
(2,378 mL) <4WD, 5M/T>
XRMYZL6 W4A42
XRMYZR6 <4WD, 4A/T with
sport mode>
XNHYZL6 Sport W5M42
<4WD,5M/T>
XRHYZL6 W4A42
XRHYZR6 <4WD, 4A/T with
sport mode>
GENERAL 00-17
MODEL CODE No. Item Content

1 Development CU: MITSUBISHI
OUTLANDER
CU 2 W X N M M Z L 6 2 Engine type 2: 1,997 mL petrol engine
5: 2,378 mL petrol engine
3 Sort W: Wagon
4 Body style X: 5-door hatchback
1 2 3 4 5 6 7 8 9 10
5 Transmission N: 5-speed manual
type transmission
AC301363 AB R: 4-speed automatic
transmission
6 Trim level M: COMFORT
H: SPORT
7 Specification M: MPI-DOHC
engine feature Y: MPI-SOHC MIVEC
8 Special feature None: 2WD
Z: 4WD
9 Steering wheel L: Left hand
location R: Right hand
10 Destination 6: For Europe
00-18 GENERAL
CHASSIS NUMBER The chassis number is stamped on the toeboard

inside the engine compartment.
AC300903AB
J M B X N CU 2 W 4 U 000001
1 2 3 4 5 6 7 8 9 10 11
AC309285AB
No. Item Content
1 Fixed figure J Asia

2 Distribution channel M Japan channel
3 Destination A For Europe, right hand drive
B For Europe, left hand drive
4 Body style X 5-door hatchback
5 Transmission type N 5-speed manual transmission
R 4-speed automatic transmission
6 Development order CU OUTLANDER
7 Engine 2 1,997 mL petrol engine
5 2,378 mL petrol engine
8 Soft W Station wagon
9 Model year 4 2004
10 Plant U Mizushima
11 Serial number − −
GENERAL 00-19
ENGINE MODEL STAMPING The engine model is stamped on the cylinder block.
This engine model numbers are shown as follows.
<4G63>
Engine model Engine displacement
4G63 1,997 mL
4G69 2,378 mL
The engine serial number is stamped near the
engine model number.
Front of the
vehicle
AC300905AD
<4G69>
Front of the vehicle

AC309481AB
00-20 GENERAL
GENERAL DATA AND SPECIFICATIONS

M1001000900558
7
9
1
3 4 5
2 6
AC300072AB
Items CU2W
XNMML6 XNMMZL6 XNHMZL6
Vehicle Front track 1 1,495
dimensions mm Overall width 2 1,750
Front overhang 3 945
Wheel base 4 2,625
Rear overhang 5 975
Overall length 6 4,545
Ground clearance (unladen) 7 195
Overall height (unladen) 8 1,620/1,670*
Rear track 9 1,505
Vehicle weight kg Kerb weight 1,435 1,540
Max. gross vehicle weight 1,970 2,070
Max. axle weight rating-front 1,050
Max. axle weight rating-rear 1,065
Max. trailer weight With brake 1,500
Without brake 570
Max. trailer-nose weight 75
Seating capacity 5
Engine Model code 4G63
Total displacement mL 1,997
Transmission Model code F5M42 W5M42
Type 5-speed manual
Fuel system Fuel supply system MPI
NOTE: *: Vehicles with roof rails
GENERAL 00-21
Items CU5W
XNMYZL6 XRMYZL6/R XNHYZL6 XRHYZL6/R
6 6
Vehicle Front track 1 1,495
dimensions Overall width 2 1,750
mm
Front overhang 3 945
Wheel base 4 2,625
Rear overhang 5 975
Overall length 6 4,545
Ground clearance (unladen) 7 195
Overall height (unladen) 8 1,620/1,670*
Rear track 9 1,505
Vehicle Kerb weight 1,540 LHD: 1,560, 1,540 LHD: 1,560,
weight kg RHD: 1,565 RHD: 1,565
Max. gross vehicle weight 2,070
Max. axle weight rating-front 1,050
Max. axle weight rating-rear 1,065
Max. trailer weight With brake 1,500
Without 570
brake
Max. trailer-nose weight 75
Seating capacity 5
Engine Model code 4G69
Transmission Model code W5M42 W4A42 W5M42 W4A42
Type 5-speed 4-speed 5-speed 4-speed
manual automatic manual automatic
Fuel system Fuel supply system MPI
NOTE: *: Vehicles with roof rails
00-22 GENERAL
PRECAUTIONS BEFORE SERVICE

M1001000500538
SUPPLEMENTAL RESTRAINT SYSTEM 8. Be sure to deploy the air bag before
(SRS) disposing of the air bag module or disposing
of a vehicle equipped with an air bag (Refer to
CAUTION GROUP 52B − Air Bag Module Disposal
Items to review when servicing SRS: Procedures).
1. Be sure to read GROUP 52B − Supplemental Observe the following when carrying out
Restraint System (SRS). For safe operation, operations on places where SRS components are
please follow the directions and heed all installed, including operations not directly
warnings. related to the SRS air bag.
2. Wait at least 60 seconds after disconnecting 1. When removing or installing parts, do not
the battery cable before doing any further allow any impact or shock to the SRS
work. The SRS system is designed to retain components.
enough voltage to deploy the air bag even
2. If heat damage may occur during paint work,
after the battery has been disconnected.
remove the SRS-ECU, the air bag module,
Serious injury may result from unintended air
clock spring, the front impact sensor, the side
bag deployment if work is done on the SRS
impact sensor, and the seat belt
system immediately after the battery cable is
pre-tensioner.
disconnected.
• SRS-ECU, air bag module, clock spring,
3. Warning labels must be heeded when
front impact sensor, the side impact
servicing or handling SRS components.
sensor: 93 °C or more
Warning labels can be found in the following
• Seat belt pre-tensioner: 90 °C or more
locations.
• Front impact sensor
• Hood
• Sun visor
• Glove box
• SRS-ECU
• Steering wheel
• Clock spring
• Steering joint cover
• Air bag module (Driver's or front
passenger's)
• Side air bag module (Driver's side or front
passenger's side)
• Side impact sensor
• Seat belt pre-tensioner
• Instrument panel
4. Always use the designated special tools and
test equipment.
5. Store components removed from the SRS in a
clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward. Do
not place anything on top of it.
6. Never attempt to disassemble or repair the
SRS components (SRS-ECU, air bag module
and clock spring).
7. Whenever you finish servicing the SRS, check
the SRS warning lamp operation to make sure
that the system functions properly.
GENERAL 00-23
INITIALIZATION PROCEDURE FOR LEARNING PROCEDURE FOR IDLING IN

LEARNING VALUE IN MPI ENGINE MPI ENGINE
Initialization Procedure Purpose
1. After the ignition switch is in "LOCK" (OFF) When the engine-ECU <M/T> or the
position, connect MUT-II/III with the diagnosis engine-A/T-ECU <A/T> is replaced, or when the
connector. learning value is initialized, the idling is not stabilized
2. Select the item on the screen of the initialization because the learning value in MPI engine is not
for learning, and perform the initialization. completed. In this case, carry out the learning
method for the idling through the following
Service Item procedures.
At replacing engine All ranges
Learning Procedure
assembly *1,*2
1. Start the engine and carry out the warm-up for the
− *3 Misfire-related engine coolant temperature to reach 80°C or
At replacing injector and Learning value for more.
at cleaning *2 air/fuel ratio 2. When the engine coolant temperature is 80°C or
more, the warm-up is not needed if the ignition
At replacing throttle body Idle speed
switch is in "ON" position once.
and at cleaning *2 control-related
3. Place the ignition switch in "LOCK" (OFF) position
At replacing detonation Learning value for and stop the engine.
sensor knocking 4. After 10 seconds or more, start the engine again.
NOTE: *1: Initialize A/T-related learning value. 5. For 10 minutes, carry out the idling under the
NOTE: *2: After initializing the learning value, the condition shown below and then confirm the
idling learning in MPI engine is required (Refer to engine has the normal idling.
LEARNING PROCEDURE FOR IDLING IN MPI • Transmission: Neutral (A/T: "P" range)
ENGINE). • Operation in ignition-related, fan and
NOTE: *3: The datum items on MUT-II/III display are attachments: Not to be operated
shown, but do not use them. • Engine coolant temperature: 80°C or more
NOTE: When the engine stalls during the idling,
check the dirtiness (on the throttle valve) of the
throttle body and then perform the service from
Procedure 1 again.
00-24 GENERAL
SERVICING ELECTRICAL SYSTEM PRE-INSPECTION CONDITION

CAUTION "Pre-inspection condition" refers to the condition that
Before connecting or disconnecting the negative the vehicle must be in before proper engine
(−) cable, be sure to turn off the ignition switch inspection can be carried out. If you see the words
and the lighting switch (If this is not done, there "Set the vehicle to the pre-inspection condition". In
is the possibility of semiconductor parts being this manual, it means to set the vehicle to the
damaged). following condition.
• Engine coolant temperature 80 to 90°C
• Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
• A/T: P range
VEHICLE WASHING
AC300693
Approximately 40 cm
Before replacing a component related to the
electrical system and before undertaking any repair
procedures involving the electrical system, be sure to
first disconnect the negative (−) cable from the
battery in order to avoid damage caused by
short-circuiting.
AC300832AB
APPLICATION OF ANTI-CORROSION If high-pressure car-washing equipment or steam

AGENTS AND UNDERCOATS car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to
If oil or grease gets onto the oxygen sensor, it will
avoid damage to plastic components, etc.
cause a drop in the performance of the sensor.
• Spray nozzle distance: Approx. 40 cm or more
Cover the oxygen sensor with a protective cover
• Spray pressure: 3,900 kPa or less
when applying anti-corrosion agents and undercoats.
• Spray temperature: 82°C or less
• Time of concentrated spray to one point: within
30 sec.
GENERAL 00-25
MUT-II/III
MUT-III sub assembly
MUT-II Sub-assembly
Vehicle communication interface (V.C.I.)
Rom pack
MB991824
MUT-III USB cable
AC300834AB
MB991827
MUT-III main harness A
Do not used
MB991910
MUT-III main harness B
MB991911
MUT-III measurement adapter
MB991825
MUT-III trigger harness
MB991826
AC305090AB
Refer to the "MUT-II REFERENCE MANUAL",
"MUT-II OPERATING INSTRUCTIONS" or "MUT-III
OPERATION MANUAL" for instructions on handling
the MUT-II/III.
00-26 GENERAL
CAUTION ENGINE OILS

<Using the MUT-II> Health Warning
Prolonged and repeated contact with mineral oil will
Steering shaft result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
MUT-II
facilities must be provided.
Recommended Precautions
AC300830 AC
The most effective precaution is to adapt working
<Using the MUT-III> practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
16-PIN before handling them.
Other precautions:
• Avoid prolonged and repeated contact with oils,
particularly used engine oils.
• Wear protective clothing, including impervious
gloves where practicable.
MB991911 • Avoid contaminating clothes, particularly
underpants, with oil.
MB991824 • Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
• Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from
personal clothing.
• Where there is a risk of eye contact, eye
MB991827 AC308915 AC
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
Turn the ignition switch to the "LOCK" (OFF) facility should be provided.
position before connecting or disconnecting the • Obtain First Aid treatment immediately for open
MUT-II/III. cuts and wounds.
Connect the MUT-II/III to the diagnosis connector as • Wash regularly with soap and water to ensure all
shown in the illustration. oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
IN ORDER TO PREVENT VEHICLES cleaning, the application of preparations
FROM FIRE containing lanolin to replace the natural skin oils
"Improper installation of electrical or fuel related parts is advised.
could cause a fire. In order to retain the high quality • Do not use petrol, kerosine, diesel fuel, gas oil,
and safety of the vehicle, it is important that any thinners or solvents for cleaning skin.
accessories that may be fitted or • Use barrier creams, applying them before each
modifications/repairs that may be carried out which work period, to help the removal of oil from the
involve the electrical or fuel systems, MUST be skin after work.
carried out in accordance with MMC's • If skin disorders develop, obtain medical advice
information/Instructions". without delay.
GENERAL 00-27
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

M1001009800020
The Supplemental Restraint System (SRS) and seat G-sensor, front air bag analog G-sensor and a side
belt with pre-tensioner is designed to supplement the air bag safing G-sensor. The front impact sensor is
driver's and front passenger's seat belts to help assembled outside the headlamp support panel to
reduce the risk or severity of injury to the driver and monitor impact in case of front impact. The side
front passenger by activating and deploying both impact sensors inside the centre pillars monitor the
front air bags in certain frontal collisions. shock incurred by the sides of the vehicle. The
The SRS consist of four air bag modules, SRS air warning lamp on the instrument panel indicates the
bag control unit (SRS-ECU), two front impact operational status of the SRS. The clock spring is
sensors, two side impact sensors, SRS warning installed in the steering column. The seat belt
lamp, clock spring and seat belt pre-tensioner. Front pre-tensioner is built into the driver's and
air bags are located in the centre of the steering passenger's front seat belt retractor.
wheel and above the glove box. Side air bag are Only authorized service personnel should do work on
located inside the front seatback assemblies. Each or around the SRS components. Those service
air bag is made up of a folded air bag and an inflator personnel should read this manual carefully before
unit. The SRS-ECU under the front floor console starting any such work.
monitors the system and has a front air bag safing
SRS warning lamp
Seat belt with pre-tensioner
Driver's air bag

module Passenger's (front)
air bag module
Side air bag module
Side impact sensor
Clock spring
SRS-ECU
Side impact sensor
Side air bag module
Front impact sensor

AC301343 AB
00-28 GENERAL
SRS SERVICE PRECAUTIONS

M1001006000047
DANGER CAUTION
In order to avoid injury to yourself or others
from accidental deployment of the air bag
SRS-ECU connector
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-9.
AC300634 AB
CAUTION
Never Attempt to Repair the Following Do not attempt to repair the wiring harness
Components: connectors of the SRS. If a defective wiring
harness is found, repair or replace it by referring
1. SRS air bag control unit (SRS-ECU)
to the table below.
2. Front impact sensor
3. Clock spring
4. Driver's and front passenger's air bag
modules
5. Side air bag module
6. Side impact sensor
7. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE
procedures in this manual, starting at page
P.52B-174.
SRS-ECU terminal No. Destination of harness Remedy
1, 2 Instrument panel wiring harness → Correct or replace each wiring
Front wiring harness (RH) → Front harness.
impact sensor (RH)
3, 4 Instrument panel wiring harness → Correct or replace each wiring
Front wiring harness (LH) → Front harness.
impact sensor (LH)
7 Instrument panel wiring harness→ Correct or replace the instrument
Earth panel wiring harness.
8 Instrument panel wiring harness → Correct or replace the instrument
SRS warning lamp panel wiring harness.
9, 10 Instrument panel wiring harness → Correct or replace the instrument
Air bag module (Front passenger's panel wiring harness.
side)
11, 12 Instrument panel wiring harness → Correct or replace instrument panel
Clock spring → Air bag module wiring harness. Replace the clock
(Driver's side) spring.
Junction block (fuse No.3) panel wiring harness.
GENERAL 00-29
SRS-ECU terminal No. Destination of harness Remedy

Junction block (fuse No.2) panel wiring harness.
Diagnosis connector panel wiring harness.
21, 22 Floor wiring harness (RH) → Side air Correct or replace the floor wiring
bag module (LH) harness.
23, 24 Floor wiring harness (RH) → Side air Correct or replace the floor wiring
bag module (RH) harness.
27, 28 Floor wiring harness (RH) → Seat Connect or replace the floor wiring
belt pre-tensioner (Front harness.
passenger's side)
29, 30 Floor wiring harness (LH) → Seat Connect or replace the floor wiring
belt pre-tensioner (driver's side) harness.
34, 36 Floor wiring harness (LH) → Side Connect or replace the floor wiring
impact sensor (LH) harness.
40, 42 Floor wiring harness (RH) → Side Connect or replace the floor wiring
impact sensor (RH) harness.
DANGER
Insulating tape
Battery
Battery cable
AC300580AB
After disconnecting the battery cable, wait 60

seconds or more before proceeding with the
following work. In addition, insulate the
negative battery terminal with a tape. The
condenser inside the SRS-ECU is designed
to retain enough voltage to deploy the air
bag for a short time even after the battery
has been disconnected, so serious injury
may result from unintended air bag
deployment if work is done on the SRS
system immediately after the battery cables
are disconnected.
00-30 GENERAL
CAUTION
The SRS components and seat belt with
pre-tensioner should not be subjected to heat, so
remove the SRS-ECU, driverís and front
passengerís air bag modules, clock spring, side
air bag modules, and seat belt pre-tensioner
before drying or baking the vehicle after painting.
• SRS-ECU, air bag modules, clock spring,
impact sensors: 93°C or more
• Seat belt with pre-tensioner 90°C or more
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.
CAUTION
SRS-Harness connector
SRS-ECU harness connector

(rear side)
AC300673AB
If checks are carried out by using the SRS-ECU

harness connector, observe the following
procedures: Insert the special tool (probe in the
harness set) MB991222 into connector from
harness side (rear side), and connect the tester
to this probe. If any tool than special tool is used,
damage to the harness and other components
will result. Never insert the probe directly to the
terminals from the front of the connector. The
terminals are plated to increase their
conductivity, so that if they are touched directly
by the probe, the plating may break, which will
cause drops in reliability.
GENERAL 00-31
SUPPORT LOCATIONS FOR LIFTING AND JACKING

M1001000700093
SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR
DOUBLE-POST LIFT AND PLATE TYPE LIFT
CAUTION
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.
GARAGE JACK
CAUTION
Never support any point other than the specified one, or that point will be deformed.
<2WD> Rear suspension crossmember <4WD> Rear differential
AC300835
00-32 GENERAL
AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT

CAUTION
• If rubber attachments with grooves that are too thick are used at the front support positions, the
front fender may become bent, so be sure to use rubber attachments with groove thicknesses of
18 mm or less.
• If attachments which are not high enough are used, they may damage areas such as the side step.
Be sure to use attachments which are high enough, or remove the side step if not using
attachments.
AXLE STANDS
Bolts Bolts
Rubber
Rubber
SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Bolts Bolts
AC300836AB
GENERAL 00-33
STANDARD PART/TIGHTENING-TORQUE TABLE
PLATE TYPE LIFT

CAUTION
To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift.
Support the side sill flange with a lift.
STANDARD PART/TIGHTENING-TORQUE TABLE

M1001001100362
Each torque value in the table is a standard value for 2. If plastic parts are fastened.
tightening under the following conditions. 3. If bolts are tightened to plastic or die-cast
1. Bolts, nuts and washers are all made of steel and inserted nuts.
plated with zinc. 4. If self-tapping screws or self-locking nuts are
2. The threads and bearing surface of bolts and used.
nuts are all in dry condition.
The values in the table are not applicable:
Standard bolt and nut tightening torque
1. If toothed washers are inserted.
Thread size Torque N⋅m
Bolt nominal Pitch Head mark "4" Head mark "7" Head mark "8"
diameter (mm) (mm)
M5 0.8 2.5 ± 0.5 5.0 ± 1.0 6.0 ± 1.0
M6 1.0 5.0 ± 1.0 9.0 ± 2.0 10 ± 2
M8 1.25 12 ± 2 22 ± 4 25 ± 4
M10 1.25 24 ± 4 44 ± 10 53 ± 7
M12 1.25 41 ± 8 83 ± 12 98 ± 12
M14 1.5 73 ± 12 140 ± 20 155 ± 25
M16 1.5 110 ± 20 210 ± 30 235 ± 35
M18 1.5 165 ± 25 300 ± 40 340 ± 50
M20 1.5 225 ± 35 410 ± 60 480 ± 70
M22 1.5 300 ± 40 555 ± 85 645 ± 95
M24 1.5 395 ± 55 735 ± 105 855 ± 125
Flange bolt and nut tightening torque
Thread size Torque N⋅m
Bolt nominal Pitch Head mark "4" Head mark "7" Head mark "8"
diameter (mm) (mm)
M6 1.0 5.0 ± 1.0 10 ± 2 12 ± 2
M8 1.25 13 ± 2 24 ± 4 27 ± 5
M10 1.25 26 ± 4 49 ± 9 58 ± 7
M10 1.5 24 ± 4 45 ± 8 55 ± 10
M12 1.25 46 ± 8 95 ± 15 105 ± 15
M12 1.75 43 ± 8 83 ± 12 98 ± 12
NOTE: .
• Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
• Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the
bolt strength.
NOTES
11A-1
GROUP 11A
00
11
ENGINE 12
MECHANICAL 13
14
15
CONTENTS 16
17
GENERAL INFORMATION . . . . . . . . 11A!" CAMSHAFT AND VALVE STEM
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A!%& 21
SERVICE SPECIFICATIONS. . . . . . . 11A!" REMOVAL AND INSTALLATION . . . . . . . . 11A!&)
22
SEALANTS . . . . . . . . . . . . . . . . . . . . 11A!# OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A!"# 25
REMOVAL AND INSTALLATION <2WD>. . 11A!*(
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A!# REMOVAL AND INSTALLATION <4WD>. . 11A!*) 26
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A!*#
ON-VEHICLE SERVICE. . . . . . . . . . . 11A!$
27
DRIVE BELT TENSION CHECK. . . . . . . . . 11A!" CRANKSHAFT OIL SEAL . . . . . . . . . 11A!"' 31
AUTO-TENSIONER CHECK . . . . . . . . . . . 11A!# REMOVAL AND INSTALLATION . . . . . . . . 11A!*$
IGNITION TIMING CHECK . . . . . . . . . . . . . 11A!$ 32
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A!% CYLINDER HEAD GASKET . . . . . . . . 11A!#(
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A!% REMOVAL AND INSTALLATION . . . . . . . . 11A!('
33
COMPRESSION PRESSURE CHECK. . . . 11A!&' 34
MANIFOLD VACUUM CHECK . . . . . . . . . . 11A!&' TIMING BELT . . . . . . . . . . . . . . . . . . . 11A!#&
LASH ADJUSTER CHECK . . . . . . . . . . . . . 11A!&& REMOVAL AND INSTALLATION . . . . . . . . 11A!() 35
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A!+(
CRANKSHAFT PULLEY . . . . . . . . . . 11A!%#
36
REMOVAL AND INSTALLATION . . . . . . . . 11A!&( ENGINE ASSEMBLY . . . . . . . . . . . . . 11A!)& 37
REMOVAL AND INSTALLATION . . . . . . . . 11A!+)
42
51
52
54
55
ENGINE MECHANICAL
11A-2 GENERAL INFORMATION
GENERAL INFORMATION
M1111000100356
Item 4G63
Bore ! Stroke mm 85 ! 88
Compression ratio 10.0
Compression chamber Pentroof
Camshaft arrangement DOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake opening BTDC 17"
Intake closing ABDC 51"
Exhaust opening BBDC 57"
Exhaust closing ATDC 13"
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type
Auto-lash adjuster Equipped
SERVICE SPECIFICATIONS
M1112000300234
Item Standard value Limit

Drive belt tension Vibration frequency Hz 110 # 144 #
(Reference)
Tension N (Reference) 245 # 412 #
Basic ignition timing 5" BTDC $ 2" #
Ignition timing Approximately #
10" BTDC
Idle speed r/min 750 $ 100 #
CO contents % 0.5 or less #
HC contents ppm 100 or less #
Compression pressure kPa-r/min 1,370 # 250 930 # 250
Compression pressure difference of all cylinders kPa # Maximum 98
Intake manifold vacuum kPa # Minimum 60
Cylinder head bolt nominal length mm # 99.4
Balancer timing belt tension (When Deflection mm 5#7 #
adjusted)
Balancer timing belt tension (When Deflection mm 5#7 #
replaced)
ENGINE MECHANICAL
SEALANTS
11A-3
Balancer timing belt tension (When Deflection mm 5 # 10 #
checked)
Timing belt tensioner adjuster rod protrusion amount mm 3.8 # 4.5 #
Timing belt tensioner adjuster rod movement mm Within 1 #
SEALANTS
M1112000500238
Item Specified Sealant Remark

Cylinder head MITSUBISHI GENUINE PART MD970389 or Semi-drying
Camshaft position sensor support equivalent sealant
Rocker cover
Camshaft end seal 3M ATD Part No.8660 or equivalent
Rocker cover gasket MITSUBISHI GENUINE PART MD970389 or
Engine oil pan <2WD> equivalent
Engine upper oil pan <4WD>
Engine lower oil pan <4WD>
SPECIAL TOOLS
M1112000600279
Tool Number Name Use

MB991502 MUT-II sub assembly % Drive belt tension check
% Checking the ignition timing
% Checking the idle speed
B991502
MB991668 Belt tension meter set Drive belt tension check (used
together with MUT-II)
B991668
MD998772 Valve spring compressor Compressing valve spring
MD998772
MD998737 Valve stem seal installer Valve stem seal installation

ENGINE MECHANICAL
11A-4 SPECIAL TOOLS

MD998713 Camshaft oil seal installer Camshaft oil seal installation
D998713
MD998727 Oil pan remover Oil pan removal <2WD>
D998727
MD998781 Flywheel stopper Supporting the flywheel
D998781
MB990938 Installer bar Crankshaft rear oil seal

installation
B990938
MD998776 Crankshaft rear oil seal

installer
D998776
MD998285 Crankshaft front oil seal Crankshaft front oil seal

guide installation
D998285
MD998375 Crankshaft front oil seal

installer
MB991654 Cylinder head bolt wrench Removal and installation of

(12) cylinder head bolt
B991654
ENGINE MECHANICAL
SPECIAL TOOLS
11A-5
MD998738 Adjusting bolt Supporting the timing belt
tensioner arm and timing belt
tensioner adjuster
D998738
MB991367 Special spanner Holding the crankshaft camshaft

drive sprocket
B991367
MB991385 Pin
B991385
MD998767 Tensioner wrench Valve timing belt tension

adjustment
D998767
ENGINE MECHANICAL
11A-6 ON-VEHICLE SERVICE

MB991454 Engine hanger balancer When the engine hanger is used:
Supporting the engine assembly
during removal and installation of
the transmission assembly
B991454 NOTE: Special tool MB991454 is
a part of engine hanger
MB991527 Hanger attachment set MB991453.
B991527
MB991895 Engine hanger
Z203830

Slide bracket (HI) A: MB991929 A: Joint (50) ! 2
B: MB991930 B: Joint (90) ! 2
E C: MB991931 C: Joint (140) ! 2
D: MB991932 D: Foot (standard) ! 4
F E: MB991933 E: Foot (short) ! 2
A F: MB991934 F: Chain and hook
D
assembly
B
C
B991928
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK 2. If the mark is out of the area, replace the drive
M1111003100399 belt. (Refer to ,-11A!&(.)
CAUTION NOTE: The drive belt tension check is not
Check the drive belt tension after turning the necessary as auto-tensioner is adopted.
crankshaft clockwise one turn or more.
Indicator mark
AC107639AB
1. Make sure that the indicator mark is within the

area marked with A in the illustration.
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-7
AUTO-TENSIONER CHECK CAUTION
M1111003000154
OPERATION CHECK
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner. 16-pin
2. Remove the drive belt.(Refer to ,-11A!&(.)
MUT-II
AC107640 AB
3. Securely insert the spindle handle or ratchet

handle with a 12.7 mm insertion angle into the jig MB991668
hole of the auto tensioner. Turn the auto-tensioner AC211862 AB
to the left and right to check and see that there is
no threading. To prevent damage to MUT-II, always turn the
ignition switch to the "LOCK" (OFF) position
4. If there are any problems in the procedure 1 or 3,
replace the auto-tensioner.(Refer to ,-11A!().) before connecting or disconnecting MUT-II.
(1) Connect special tool belt tension meter set
5. Install the drive belt.(Refer to ,-11A!&(.)
(MB991668) to the MUT-II.
(2) Connect the MUT-II to the diagnosis
FUNCTION CHECK connector.
You can verify if the auto-tensioner is defective or not (3) Turn the ignition switch to ON position, and
by checking the drive belt tension. select "BELT TENSION" on the menu screen.
When using MUT-II
1. Check the drive belt tension. (Refer to ,-11A!".)
2. Measure the drive belt tension vibration frequency
by the following procedures:
ENGINE MECHANICAL
CAUTION Belt tension gauge Power steering

% The temperature of the surface of the belt oil pump pulley
should be as close to normal temperature as
possible. Water pump
% Do not allow any contaminants such as water pulley
or oil to get onto the microphone.
% If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual AC102807AB
values.
% If the microphone is touching the belt while 2. Use a belt tension gauge in the middle of the belt
the measurement is being made, the values between the pulleys (at the place indicated by the
measured by the microphone may not arrow) to measure that the belt tension is within
correspond to actual values. the standard value.
% Do not take the measurement while the Standard value: 245 # 412 N
vehicle’s engine is running. 3. If not within the standard value, replace the auto-
Power steering tensioner.(Refer to ,-11A!().)
10 – 20 mm
oil pump pulley
MB991668 15˚ IGNITION TIMING CHECK
M1111001700425
Water pump 15˚
AC102022
pulley Y0195AU
MUT-II
Gentry tap with
your finger
AC102806 AB
(4) Hold special tool belt tension meter set

(MB991668) to the middle of the drive belt
between the pulleys (at the place indicated by
AK000871 AC
arrow), approximately 10 # 20 mm away from
the rear surface of the belt so that it is 1. Before inspection, set the vehicle to the pre-
perpendicular to the belt (within an angle of $ inspection condition.
15 degree). 2. Turn the ignition switch to the "LOCK" (OFF)
(5) Gently tap the middle of the belt between the position and then connect the MUT-II to the
pulleys (the place indicated by the arrow) with diagnosis connector.
your finger as shown in the illustration, and 3. Connect a timing light.
measure that the vibration frequency of the 4. Start the engine and let it run at idle.
belt is within the standard value. 5. Use the MUT-II to measure engine idle speed and
Standard value: 110 # 144 Hz check that it is within the standard value.
3. If not within the standard value, replace the auto- Standard value: 750 $ 100 r/min
tensioner. (Refer to ,-11A!().) 6. Select No. 17 of the MUT-II Actuator test.
When using a tension gauge 7. Check that basic ignition timing is within the
1. Check the drive belt tension. (Refer to ,-11A!".) standard value.
Standard value: 5" BTDC $ 2"
8. If the basic ignition timing is outside the standard
value, inspect the MPI system (Refer to ,-13A!&*,
GROUP 13A # Troubleshooting # Inspection chart
for diagnosis code).
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-9
CAUTION Standard value: 750 $ 100 r/min
If the test is not cancelled, a forced driving will NOTE: .
continue for 27 minutes. Driving under this % The idle speed is controlled automatically by
condition may damage the engine. the idle speed control system.
9. Press the MUT-II clear key (Select a forced driving % When using the MUT-II, select item No. 22 and
cancel mode) to release the Actuator test. take a reading of the idle speed.
10.Check that ignition timing is at the standard value. 8. If the idle speed is outside the standard value,
Standard value: approximately 10" BTDC inspect the MPI system (Refer to ,-13A!&*,
GROUP 13A # Troubleshooting # Inspection chart
NOTE: .
% The ignition timing may fluctuate within $ 7"
BTDC. This is normal. IDLE MIXTURE CHECK
% In higher altitude, the ignition timing is more M1111002100255
advanced than the standard value by AC102022

Y0195AU
approximately 5".
11.Remove the timing light. MUT-II
12.Turn off the ignition switch and then remove the
MUT-II.
IDLE SPEED CHECK

M1111003500472
AC102022
Y0195AU
AK000871 AC
MUT-II
1. Before inspection, set the vehicle to the pre-
inspection condition.
2. Turn the ignition switch to "LOCK" (OFF) position.
3. Connect the MUT-II to the diagnosis connector or
connect a tachometer to the engine speed
detection connector.
AK000871 AC
4. Connect a timing light.
1. Before inspection, set the vehicle to the pre-

inspection condition.
3. Connect the MUT-II to the diagnosis connector or
connect a tachometer to the engine speed
detection connector.
Engine speed
4. Connect a timing light. ditection connector
AK000899 AC
5. Start the engine and let it run at idle.

6. Check that ignition timing is at the standard value.
Standard value: approximately 10" BTDC
Engine speed 7. Run the engine at 2,500 r/min for 2 minutes.
ditection connector 8. Set the CO, HC tester.
9. Check the CO contents and the HC contents at
AK000899 AC idle.
Standard value
5. Start the engine and let it run at idle. CO contents: 0.5 % or less
6. Check that ignition timing is at the standard value. HC contents: 100 ppm or less
Standard value: approximately 10" BTDC 10.If there is a deviation from the standard value,
7. Check the idle speed. check the following items:
ENGINE MECHANICAL
% Diagnosis output 8. Measure the compression pressure for all the

% Fuel pressure cylinders, and check that the pressure differences
% Injector of the cylinders are below the limit.
% Ignition coil, spark plug cable, spark plug Limit: Maximum 98 kPa
% EGR control system
9. If there is a cylinder with compression or a
% Evaporative emission control system
compression difference that is outside the limit,
% Compression pressure
pour a small amount of engine oil through the
NOTE: Replace the three way catalyst when the spark plug hole, and repeat the operations in
CO and HC contents are not within the standard steps from (6) to (8).
value, even though the result of the inspection is (1) If the compression increases after oil is added,
normal on all items. the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
COMPRESSION PRESSURE CHECK surface.
M1111002600465
(2) If the compression dose not rise after oil is
added, the cause is a burnt or defective valve
seat, or pressure is leaking from the gasket.
Crank angle 10.Connect the crank angle sensor connector.
sensor 11.Install the spark plugs and spark plug cables.
connector
12.Use the MUT-II to erase the diagnosis codes.
NOTE: This will erase the diagnosis code
resulting from the crank angle sensor connector
being disconnected.
AK201364 AC
MANIFOLD VACUUM CHECK
1. Before inspection, set the vehicle to the pre- M1111002700417
inspection condition. AC102022

Y0195AU
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs. MUT-II
4. Disconnect the crank angle sensor connector.
NOTE: Doing this will prevent the engine-ECU<M/
T> or engine-A/T-ECU<A/T> from carrying out
ignition and fuel injection.
CAUTION
% Keep away from the spark plug hole when
AK000871 AC
cranking.
% If compression is measured with water, oil, 1. Before inspection, set the vehicle to the pre-
fuel, etc., that has come from cracks inside inspection condition.
the cylinder, these materials will become 2. Turn the ignition switch to "LOCK" (OFF) position.
heated and will gush out from the spark plug 3. Connect a tachometer or connect the MUT-II to
hole, which is dangerous. the diagnosis connector.
5. Cover the spark plug hole with a shop towel etc.,
and after the engine has been cranked, check that Vacuum
gauge
no foreign material is adhering to the shop towel.
6. Set compression gauge to one of the spark plug
holes.
7. Crank the engine with the throttle valve fully open
and measure the compression pressure. Fuel pressure
Standard value (at engine speed of 250 r/ regulator
min):
1,370 kPa AK201369AB
Limit (at engine speed of 250 r/min):

Minimum 930 kPa
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-11
4. Attach a three-way joint to the vacuum hose 3. While the engine is idling, check that the noise
between the fuel pressure regurator and the air level does not change when the engine load is
intake plenum, and connect a vacuum gauge. varied (for example, by shifting from N to D).
5. Start the engine and check that idle speed is If the noise level changes, the cause of the noise
within the standard valve. is probably parts striking because of worn
Standard value: 750 $ 100 r/min crankshaft bearings or connecting rod bearings
6. Check the intake manifold vacuum. (In such cases, the lash adjusters are normal).
4. After the engine has warmed up, run it at idle and
Limit: Minimum 60 kPa
check if any noise can be heard.
7. Turn off the ignition switch.
If the noise has become smaller or disappeared,
8. Remove the vacuum gauge and the three-way
oil sludge could make the lash adjusters stick.
joint, and then connect the vacuum hose.
Clean the lash adjusters (Refer to GROUP 11D #
9. Remove the engine tachometer or the MUT-II. Rocker Arms and Camshaft # Rocker Arms and
Camshaft Inspection ,-11B!((). If not improved,
LASH ADJUSTER CHECK
M1111002900336 go to step 5.
If an abnormal noise (knocking) that seems to be 5. Bleed air from the lash adjusters (Refer to ,-11A!
coming from the lash adjuster is heard after starting &&).
the engine and dose not stop, carry out the following 6. If the noise has not disappeared even after the air
check. bleeding, clean the lash adjusters (Refer to
NOTE: . GROUP 11D # Rocker Arms and Camshaft #
% The abnormal noise which is caused by a Rocker Arms and Camshaft Inspection ,-11B!(().
problem with the lash adjusters is generated after <LASH ADJUSTER AIR BLEEDING>
the engine is started, and will vary according to
NOTE: .
the engine speed. However, this noise is not
% If the vehicle is parked on a slope fir a long period
related to the actual engine load.
of time, the amount of oil inside the lash adjuster
Because of this, if the noise dose not occur
will decrease, and air may get into the high
immediately after the engine is started, if it dose
pressure chamber when starting the engine.
not change in accordance with the engine speed,
% After parking the vehicle for long periods, the oil
or if it changes in accordance with the engine
drains out of the oil passage, and it takes time for
load, the source of the noise is not the lash
the oil to be supplied to the lash adjuster, so air
adjusters.
can get into the high-pressure chamber.
% If there is a problem with the lash adjusters, the
% If either of the above situations occur, the
noise will almost never disappear, even if the
abnormal noise can be eliminated by bleeding
engine has been run at idle to let it warm up.
the air from inside the lash adjusters.
The only case where the noise might disappear is if
the oil in the engine has not been looked after
properly and oil sludge has caused the lash
adjusters to stick.
1. Start the engine.
Good
2. Check that the noise occurs immediately after the
engine is started, and that the noise changes in
Max
accordance with changes in the engine speed.
If the noise dose not occur immediately after the
engine is started, or if it dose not change in Min.
AKX00328 AE
accordance with the engine speed, the problem is
not being caused by the lash adjusters, so check 1. Check the engine oil and replenish or replace the
for some other cause of the problem. Moreover, if oil if necessary.
the noise dose not change in accordance with the
engine speed, the cause of the problem is
probably not with the engine (In these cases, the
lash adjusters are normal).
ENGINE MECHANICAL
NOTE: . Drive pattern for air breeding

% If there is an only small amount of oil, air will Gradually open
Close the throttle valve
be drawn in through the oil screen and will get the throttle valve
into the oil passage. Approximately
% If the amount of oil is greater than normal, then 3,000 r/min
the oil will being mixed by the crankshaft and a
large amount of air may get mixed into the oil. Idle speed 15 s 15 s
% If the oil is degenerated, air and oil will not
separate easily in oil, and the amount of air
Once
mixed into the oil will increase. AKX00330AE
2. Run the engine at idle for 1 # 3 minutes to let it

warm up.
3. With no load on the engine, repeat the drive
pattern shown in the illustration above and check
if the abnormal noise disappears (The noise
should normally disappear after 10 # 30
repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is
High-pressure chamber
AK100001AC
probably not due to air inside the lash adjusters).
4. After the noise has disappeared, repeat the drive
% If the air which has been mixed in with the oil pattern shown in the illustration above a further 5
due to any of the above reasons gets into the times.
high pressure chamber of the lash adjuster,
5. Run the engine at idle for 1 # 3 minutes and check
the air inside the high pressure chamber will
that the noise has disappeared.
be compressed when the valve is open and
the lash adjuster will over-compress, resulting
in abnormal noise when the valve close. This
is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air
inside the lash adjusters is then released, the
operation of the lash adjusters will return to
normal.
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-13
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600409
Pre-removal Operation Post-installation Operation

% Under Cover Removal (Refer to GROUP 51, Under Cover % Drive Belt Tension Check (Refer to ,-11A!").
,-51!&$). % Under Cover Installation (Refer to GROUP 51, Under
Cover ,-51!&$).
25 ± 4 N·m
AC300537AB
Removal steps
<<A>> 1. Drive belt
2. Crank shaft damper pulley
ENGINE MECHANICAL
11A-14 CRANKSHAFT PULLEY
REMOVAL SERVICE POINT CAUTION

<<A>> DRIVE BELT REMOVAL To reuse the drive belt, draw an arrow indicating
The following operations will be needed due to the the rotating direction (clockwise) on the back of
serpentine drive system with the drive belt auto- the belt using chalk.
tensioner.
Auto-tensioner
Auto-tensioner
Hole B
L-shaped
hexagon
wrench AC107641AB
Hole A AC107640AC
2. Align hole A with hole B, insert an L-shaped
1. Securely insert the spindle handle or ratchet hexagon wrench, etc. to fix and then remove the
handle with a 12.7 mm insertion angle into the jig drive belt.
hole of the auto-tensioner, and turn the auto-
tensioner anti-clockwise until it hits the stopper.
ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
11A-15
M1112006600211
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
% Engine Coolant Draining (Refer to GROUP 14, On-vehicle % Valve Timing Belt Installation (Refer to ,-11A!()).
Service # Engine Coolant Replacement ,-14!&)). % Battery and Battery Tray Installation
% Air Cleaner and Air Cleaner Bracket Removal (Refer to % Air Cleaner and Air Cleaner Bracket installation (Refer to
GROUP 15, Air Cleaner ,-15!(). GROUP 15, Air Cleaner ,-15!().
% Battery and Battery Tray Removal % Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
% Valve Timing Belt Removal (Refer to ,-11A!()). Service # Engine Coolant Replacement ,-14!&)).
% Drive Belt Tension Check (Refer to ,-11A!").
11 ± 1 N·m
11 ± 1 N·m
3.0 ± 0.5 N·m 2 4
6
3.5 ± 0.5 N·m
5
8
9.0 ± 2.0 N·m
1
8.8 ± 1.0 N·m 11 ± 1 N·m
9
N 11 12
11 ± 1 N·m
N 10
3 7
AC300538 AB
Removal steps Removal steps*+,-./0.1234

1. Accelerator cable connection 5. Rocker cover PCV hose
2. Rocker cover centre cover 6. Rocker cover breather hose
3. Crank angle sensor connector 7. Control wiring harness connection
4. Control wiring harness connection >>N<< 8. Rocker cover
% Spark plug cables and ignition coils >>M<< 9. Camshaft end seal
(Refer to GROUP 16, Ignition Coil 10. Spark plug hole gaskets
,-16!(*).
ENGINE MECHANICAL
11A-16 CAMSHAFT AND VALVE STEM SEAL
Removal steps*+,-./0.1234
>>L<< 11. Rocker cover gasket
<<A>> >>K<< 12. Radiator upper hose connection
20
22
24 Apply engine oil to all
25 moving parts before
20 ± 1 N·m 23 installation.
21
19 26
N 18
17
89 ± 9 N·m 11 ± 1 N·m
30 13
25 ± 4 N·m 29 22 ± 4 N·m
15
16
31* 27 10 ± 2 N·m
32* 28
33*
N 34* 14 N
14 ± 1 N·m
31*
32*
33*
35* N
AC300539 AB

13. Camshaft position sensor support >>F<< 24. Camshaft bearing caps, No.4
cover >>E<< 25. Inlet camshaft
14. Camshaft position sensor support >>E<< 26. Exhaust camshaft
cover gasket 27. Rocker arms
>>J<< 15. Camshaft position sensing cylinder >>D<< 28. Rocker arm lash adjusters
>>I<< 16. Camshaft position sensor support 29. Oil delivery body
<> >>H<< 17. Camshaft sprockets 30. Spark plugs
>>G<< 18. Camshaft oil seals <<C>> >>C<< 31. Valve spring retainer locks
>>F<< 19. Camshaft bearing caps, front 32. Valve spring retainers
>>F<< 20. Camshaft bearing caps, rear >>B<< 33. Valve springs
>>F<< 21. Camshaft bearing caps, No.2 >>A<< 34. Inlet valve stem seals
>>F<< 22. Camshaft bearing caps, No.5 >>A<< 35. Exhaust valve stem seals
>>F<< 23. Camshaft bearing caps, No.3
ENGINE MECHANICAL
11A-17
LUBRICATION AND SEALING POINTS
<The bottom view of the rocker cover>
10 mm 10 mm
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Rocker
<View A> cover
Cylinder
10 mm A head
10 mm 10 mm Sealant: 3M ATD Part No.8660

or equivalent
A
Sealant: A
MITSUBISHI GENUINE
PART MD970389 or
equivalent
φ 3 mm
(Lip section) Sealant: MITSUBISHI GENUINE

PART MD970389 or equivalent
Engine oil AC300541
<Top view of cylinder head>
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

ENGINE MECHANICAL
REMOVAL SERVICE POINTS <<C>> VALVE SPRING RETAINER LOCKS

<<A>> RADIATOR UPPER HOSE REMOVAL
DISCONNECTION CAUTION
When removing valve spring retainer locks, leave
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.
Mating marks
MD998772
AC200641AC
Make mating marks on the radiator hose and the

hose clamp. Disconnect the radiator hose.
<> CAMSHAFT SPROCKETS REMOVAL AC201799 AB
Use special tool valve spring compressor

(MD998772) to compress the valve spring, remove
the valve spring retainer locks.
INSTALLATION SERVICE POINTS

>>A<< EXHAUST VALVE STEM SEALS/INLET
VALVE STEM SEALS INSTALLATION
Gray Gray green

AC201457AB
1. Hold the hexagon part of the camshaft with a

wrench.
2. Loosen the camshaft sprocket mounting bolts and
remove the camshaft sprocket.
Inlet side Exhaust side

AC201542AB
1. Check the valve stem seal colour to identify the

inlet side or exhaust side.
2. Apply a small amount of engine oil to the valve
stem seals.
ENGINE MECHANICAL
11A-19
CAUTION
% Valve stem seals cannot be reused. >>D<< ROCKER ARM LASH ADJUSTERS
% The special tool valve stem seal installer INSTALLATION
(MD998737) must be used to install the valve CAUTION
stem seal. Improper installation could result If the rocker arm lash adjuster is reused, always
in oil leaking past the valve guide. clean and check it before installation. (Refer to
GROUP 11B, Rocker Arms and Camshaft #
MD998737 Inspection).
Valve
>>E<< EXHAUST CAMSHAFT/INLET CAMSHAFT
Valve stem INSTALLATION
seal 1. Remove sealant remained on the cylinder head.
2. Apply engine oil to the cam and the journal of the
Valve guide
camshaft.
AC107414 AC CAUTION
3. Use special tool to fill a new valve stem seal in the Engine front
valve guide using the valve stem area as a guide.
>>B<< VALVE SPRINGS INSTALLATION Slit

Rocker arm side
Exhaust camshaft
AC201458AB
Do not install wrong camshaft at the side of inlet

Identification or exhaust. The exhaust camshaft has a slit at the
colour rear surface.
3. Install the camshaft to the cylinder head.
AC201453 AB
Install the valve springs with its identification colour >>F<< CAMSHAFT BEARING CAPS, NO. 4/
painted end facing the locker arm. CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT
BEARING CAPS, NO. 5/CAMSHAFT BEARING
>>C<< VALVE SPRING RETAINER LOCKS CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/
INSTALLATION CAMSHAFT BEARING CAPS, FRONT
INSTALLATION
Approximately 3˚
MD998772 Dowel pin
Inlet side Exhaust side

AC201799 AB
AC201459 AB
(MD998772) to compress the valve spring in the 1. Set the dowel pin of the camshaft to the position
same manner as removal. as shown in the illustration.
ENGINE MECHANICAL
5. Check the identification marks on the camshaft

bearing caps, front so that inlet side and exhaust
side cannot be mistaken in the same way as that
Bearing of bearing caps No.2 # 5.
Engine front cap No.
CAUTION
E4 Identification of
Then wait at least one hour. Never start the
inlet side and engine or let engine oil or coolant touch the
exhaust side adhesion surface during that time.
6. Tighten the bearing cap mounting bolts increasing
AC201460AB the pressure in 2 to 3 times and finally tighten to
the specified torque.
2. Since the shape of camshaft bearing caps No.2 #
5 is identical, check the identification marks so Tightening torque: 20 $ 1 N&m
that the bearing cap No., inlet side, or exhaust 7. Ensure that the rocker arms are installed properly.
side cannot be mistaken to install to the direction NOTE: Remove an excess of sealant completely.
as shown in the illustration.
Identification mark (engraved on the front >>G<< CAMSHAFT OIL SEALS INSTALLATION
and bearing caps No.2 # 5)
I: Inlet side
E: Exhaust side
Engine front
MD998713 AC102323 AB
1. Apply engine oil to the entire inner diameter of the

oil seal lip.
AC201461AB
2. Use special tool camshaft oil seal installer
3. Apply sealant to the positions (6 areas) of the (MD998713) to press-fit the oil seals.
upper side of the cylinder head as shown in the
illustration. >>H<< CAMSHAFT SPROCKETS INSTALLATION
Specified sealant: MITSUBISHI GENUINE
NOTE: Install the camshaft bearing caps, rear
and camshaft bearing caps, front within 15
minutes after applying liquid gasket.
Front
Engine front marking AC201457AB
1. Hold the hexagon part of the camshaft with a

wrench in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolts to
AC201462 AB
Tightening torque: 89 $ 9 N&m
4. Position the camshaft bearing caps, rear in the
direction as shown in the illustration for
installation.
ENGINE MECHANICAL
11A-21
>>I<< CAMSHAFT POSITION SENSOR SUPPORT 2. Install the vane (small) of the camshaft position
INSTALLATION sensing cylinder at an angle of approximately 45
1. Remove sealant from the camshaft position degrees to the position of the dowel pin of the
sensor support and cylinder head surfaces. exhaust camshaft.
3. Tighten the camshaft position sensing cylinder
mounting bolts to the specified torque.
>>K<< RADIATOR UPPER HOSE CONNECTION
Projection
φ 3 mm AC201463 AB
2. Apply the sealant to the camshaft position sensor

support flange in a continuous bead as shown in
the illustration. Water outlet fitting Mating marks
PART MD970389 or equivalent AC200642 AE
NOTE: Install the camshaft position sensor 1. Insert each hose as far as the projection of the
support within 15 minutes after applying liquid water outlet fitting.
gasket. 2. Align the mating marks on the radiator hose and
3. Install the camshaft position sensor support to the hose clamp, and then connect the radiator hose.
cylinder head.
CAUTION >>L<< ROCKER COVER GASKET INSTALLATION
Then wait at least one hour. Never start the 1. Remove sealant remained on the rocker cover.
engine or let engine oil or coolant touch the
adhesion surface during that time.
4. Tighten the camshaft position sensor support
>>J<< CAMSHAFT POSITION SENSING

CYLINDER INSTALLATION
Approximately 45˚ AC201465AB
Dowel pin
Vane (small) 2. Apply sealant to the positions (4 areas) of the
lower side of the rocker cover as shown in the
illustration.
NOTE: Install the rocker cover gasket within 15
Vane (large) minutes after applying liquid gasket.
AC201464AB
3. Install the rocker cover gasket to the rocker cover.
1. Set the dowel pin of the exhaust camshaft to the
position (No.1 cylinder at compression TDC) as
shown in the illustration.
NOTE: Use the force of the exhaust valve spring
to rotate anti-clockwise.
ENGINE MECHANICAL
>>M<< CAMSHAFT END SEAL INSTALLATION

>>N<< ROCKER COVER INSTALLATION
Engine front
AC201469 AB
10 mm 1. Apply sealant to the positions of the rocker cover

gasket (6 areas) as shown in the illustration.
10 mm Specified sealant: MITSUBISHI GENUINE
NOTE: Install the rocker cover within 15 minutes
after applying liquid gasket.
2. Install the rocker cover to the cylinder head.
Cylinder head
AC201468 AB CAUTION
Apply sealant to the positions of the camshaft end
seal as shown in the illustration and install to the
adhesion surface during that time.
cylinder head.
3. Tighten the rocker cover mounting bolts to the
Specified sealant: 3M ATD Part No.8660 or
specified torque.
equivalent
Tightening torque: 3.5 $ 0.5 N&m
NOTE: Install the camshaft end seal within 15
minutes after applying liquid gasket.
ENGINE MECHANICAL
OIL PAN
11A-23
OIL PAN
REMOVAL AND INSTALLATION <2WD>
M1112002800592

% Under Cover Removal (Refer to GROUP 51, Under Cover % Front Exhaust Pipe Installation (Refer to GROUP 15,
,-51!&$). Exhaust Pipe and Main Muffler ,-15!$).
% Engine Oil Draining (Refer to GROUP 12, On-vehicle % Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service # Engine Oil Replacement ,-12!(). Service # Engine Oil Replacement ,-12!().
% Front Exhaust Pipe Removal (Refer to GROUP 15, % Under Cover Installation (Refer to GROUP 51, Under
Exhaust Pipe and Main Muffler ,-15!$). Cover ,-51!&$).
N 4 35 ± 6 N·m
39 ± 5 N·m 3
9.0 ± 3.0 N·m 2
26 ± 5 N·m
9.0 ± 1.0 N·m
9.0 ± 3.0 N·m AC300542 AB

1. Exhaust manifold bracket >>B<< 4. Engine oil pan drain plug gasket
2. Flywheel housing front lower cover <<A>> >>A<< 5. Engine oil pan
3. Engine oil pan drain plug
ENGINE MECHANICAL
11A-24 OIL PAN
REMOVAL SERVICE POINT 3. Assemble the engine oil pan to the cylinder block.
<<A>> ENGINE OIL PAN REMOVAL CAUTION
1. Remove the engine oil pan mounting bolts. Then wait at least one hour. Never start the
CAUTION
Perform this slowly to avoid deformation of the sealant surface during that time.
engine oil pan flange.
MD998727 MD998727
M6 × 8 mm
AC102698 AB
AC102324 AB 4. Tighten the engine oil pan mounting bolts to the

2. Remove the engine oil pan using special tool oil specified torque. Be careful when installing, as the
pan remover (MD998727). oil pan mounting bolts (indicated in the illustration)
have different lengths from the other bolts.
INSTALLATION SERVICE POINTS Tightening torque: 9.0 $ 3.0 N&m
>>A<< ENGINE OIL PAN INSTALLATION
1. Remove sealant from the engine oil pan and >>B<< ENGINE OIL PAN DRAIN PLUG GASKET
cylinder block surfaces. INSTALLATION
Engine
oil pan
side
φ 4 mm
Groove portion Bolt hole portion
AC102133AB AC102325 AE
2. Apply a bead of the sealant to the cylinder block Replace the gasket with a new gasket. Install the
mating surface of the engine oil pan as shown. new gasket in the direction shown in the illustration.
NOTE: Install the engine oil pan within 15 minutes
after applying sealant.
ENGINE MECHANICAL
OIL PAN
11A-25
M1112002800600

% Under Cover Removal (Refer to GROUP 51, Under Cover % Centre Member Installation (Refer to GROUP 32, Engine
,-51!&$). Roll Stopper and Centre Member ,-32!").
% Engine Oil Draining (Refer to GROUP 12, On-vehicle % Front Exhaust Pipe Installation (Refer to GROUP 15,
Service # Engine Oil Replacement ,-12!(). Exhaust Pipe and Main Muffler ,-15!$).
% Front Exhaust Pipe Removal (Refer to GROUP 15, % Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Exhaust Pipe and Main Muffler ,-15!$). Service # Engine Oil Replacement ,-12!().
% Centre Member Removal (Refer to GROUP 32, Engine % Under Cover Installation (Refer to GROUP 51, Under
Roll Stopper and Centre Member ,-32!"). Cover ,-51!&$).
9.0 ± 3.0 N·m
N 4 2
3 9.0 ± 3.0 N·m
39 ± 5 N·m
44 ± 10 N·m
1 9.0 ± 1.0 N·m
22 ± 4 N·m
5
9.0 ± 3.0 N·m 9.0 ± 3.0 N·m

AC300543 AB

>>D<< 1. Transmission housing front lower <<A>> >>B<< 5. Engine lower oil pan
cover stay <> >>A<< 6. Engine upper oil pan
2. Flywheel housing front lower cover
3. Engine oil pan drain plug
>>C<< 4. Engine oil pan drain plug gasket
ENGINE MECHANICAL
11A-26 OIL PAN
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

<<A>> ENGINE LOWER OIL PAN REMOVAL >>A<< ENGINE UPPER OIL PAN INSTALLATION
1. Remove the engine lower oil pan mounting bolts. 1. Remove sealant from the engine upper oil pan
CAUTION and cylinder block surfaces.
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
φ 4 mm
Groove Bolt hole
portion portion AC102242AB
2. Apply a bead of the sealant to the mating surface

Engine lower oil pan of the engine upper oil pan as shown.
AC102931AB
2. Apply a piece of wood to the lower oil pan and PART MD970389 or equivalent
strike it with a hammer to remove the engine lower NOTE: Install the engine upper oil pan within 15
oil pan. minutes after applying sealant.
3. Assemble the engine upper oil pan to the cylinder
<> ENGINE UPPER OIL PAN REMOVAL block.
1. Remove the engine upper oil pan mounting bolts.
CAUTION
CAUTION Then wait at least one hour. Never start the
Do not use special tool oil pan remover engine or let engine oil or coolant touch the
(MD998727). The engine upper oil pan is made of sealant surface during that time.
B B
B B
B
A
A B
B B
B B
AC102946AB
B B
2. Screw in the bolt into bolt hole A in the location
shown. Then lift the upper oil pan and remove it.
B
B
B
A
A
AC102929AB
4. Insert the bolts to the engine upper oil pan as

shown, and tighten them to the specified torque.
ENGINE MECHANICAL
OIL PAN
11A-27
Name Symbol Quantity Size mm Name Symbol Quantity Size mm
(D ! L) (D ! L)
Flange bolt A 2 M6 ! 16 Flange bolt A 1 M6 ! 75
B 16 M6 ! 18 B 11 M6 ! 10
NOTE: D: Nominal diameter, L: Nominal length NOTE: D: Nominal diameter, L: Nominal length
Tightening torque: 9.0 $ 3.0 N&m Tightening torque: 9.0 $ 3.0 N&m
>>B<< ENGINE LOWER OIL PAN INSTALLATION >>C<< ENGINE OIL PAN DRAIN PLUG GASKET
1. Remove sealant from the engine lower oil pan and INSTALLATION
engine upper oil pan.
Engine lower
oil pan side
φ 4 mm
AC102325 AF
Groove Bolt hole
portion portion AC102243AB Replace the gasket with a new one. Install the new
2. Apply a bead of the sealant to the mating surface gasket in the direction shown in the illustration.
of the engine lower oil pan as shown.
Specified sealant: MITSUBISHI GENUINE >>D<< TRANSMISSION HOUSING FRONT
PART MD970389 or equivalent LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cover
NOTE: Install the engine lower oil pan within 15 stay in the following order.
minutes after applying sealant. 1. Tighten the engine side four mounting bolts to the
3. Assemble the engine lower oil pan to the engine specified torque.
upper oil pan.
CAUTION 2. Tighten the transmission side two mounting bolts
to the specified torque.
sealant surface during that time. Tightening torque: 44 $ 10 N&m
B-1 B-11 INSPECTION
B-10
M1112002900210
% Check the oil pan for cracks.
B-4 % Check the oil pan sealant-coated surface for
B-7
damage and deformation.
B-5
B-6
B-8 A-3
B-9 B-12 B-2

AC102930AB
4. Insert the bolts to the engine lower oil pan as

shown, and tighten them to the specified torque in
the order shown.
ENGINE MECHANICAL
11A-28 CRANKSHAFT OIL SEAL
CRANKSHAFT OIL SEAL

M1112003100273
132 ± 5 N·m
4
5
7 6
8
9 N
3 9
N 3
2 Lip section Lip section
1 Engine oil
AC300544 AB
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
% Valve timing belt, balancer timing <<A>> % Transmission assembly
belt (Refer to ,-11A!()). <> >>B<< 4. Flywheel bolts
>>D<< 1. Crankshaft balancer shaft drive 5. Flywheel adapter plate
sprocket 6. Flywheel assembly
2. Crankshaft key 7. Flywheel adapter plate
>>C<< 3. Crankshaft front oil seal 8. Crankshaft bush
>>A<< 9. Crankshaft rear oil seal
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-29
REMOVAL SERVICE POINTS 2. Use the following special tools to press-fit the oil
<<A>> TRANSMISSION ASSEMBLY REMOVAL seal.
% Installer bar (MB990938)
CAUTION % Crankshaft rear oil seal installer (MD998776)
>>B<< FLYWHEEL BOLTS INSTALLATION
Engine front
MD998781
Flywheel
assembly
Flywheel bolt
AC300897 AB
Do not remove the flywheel bolt shown by the

arrow. If this bolt is removed, the flywheel AC211914AC
assembly will become out of balance and
damaged. 1. Use special tool flywheel stopper (MD998781) to
Refer to GROUP 22A, Transmission Assembly secure the flywheel in the same manner as
,-22A!&'. removal.
2. Tighten the flywheel bolts to the specified torque.
<> FLYWHEEL BOLTS REMOVAL Tightening torque: 132 $ 5 N&m
MD998781 >>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION
Crankshaft MD998375
(Engine oil)
AC211914AC
1. Use special tool flywheel stopper (MD998781) to MD998285 Oil seal

secure the flywheel. (Oil applied to the
circumference)
2. Remove the flywheel bolts. AC102329 AC
1. Apply a small amount of engine oil to the entire

INSTALLATION SERVICE POINTS inner diameter of the oil seal lip.
>>A<< CRANKSHAFT REAR OIL SEAL 2. Apply a small amount of engine oil to the outer
INSTALLATION diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
Oil seal 3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal.
MB990938
(Engine oil)
MD998776 Crankshaft
AC102328 AB

inner diameter of the oil seal lip.
ENGINE MECHANICAL
11A-30 CYLINDER HEAD GASKET
>>D<< CRANKSHAFT BALANCER SHAFT DRIVE

SPROCKET INSTALLATION
: Clean
: Clean and degrease
Crankshaft
Front case
Crankshaft
balancershaft
drive sprocket
Engine front
AC211222 AB
1. Clean or degrease the front case, the crankshaft

and the crankshaft balancer shaft drive sprocket
as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket
in the direction shown in the illustration.
CYLINDER HEAD GASKET

M1112004000655

% Fuel Line Pressure Reduction [Refer to GROUP 13A, On- % Valve Timing Belt Installation (Refer to ,-11A!()).
vehicle Service # Fuel Pump Connector Disconnection % Rocker Cover Centre Cover Installation (Refer to ,-11A!
(How to Reduce Pressurized Fuel Lines) ,-13A!(&'.] &)).
% Under Cover Removal (Refer to GROUP 51, Under Cover % Battery Installation
,-51!&$). % Air Cleaner and Air Cleaner Bracket installation (Refer to
% Engine Oil Draining (Refer to GROUP 12, On-vehicle GROUP 15, Air Cleaner ,-15!().
Service # Engine Oil Replacement ,-12!(). % Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
% Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service # Engine Coolant Replacement ,-14!&)).
Service # Engine Coolant Replacement ,-14!&)). % Engine Oil Refilling (Refer to GROUP 12, On-vehicle
% Air Cleaner and Air Cleaner Bracket Removal (Refer to Service # Engine Oil Replacement ,-12!().
GROUP 15, Air Cleaner ,-15!(). % Accelerator Cable Adjustment (Refer to GROUP 17, On-
% Battery Removal vehicle Service # Accelerator Cable Check and
% Rocker Cover Centre Cover Removal (Refer to ,-11A! Adjustment ,-17!().
&)). % Drive Belt Tension Check (Refer to ,-11A!").
% Valve Timing Belt Removal (Refer to ,-11A!()). % Under Cover Installation (Refer to GROUP 51, Under
Cover ,-51!&$).
% Fuel Leak Check
ENGINE MECHANICAL
11A-31
9
5.0 ± 1.0 N·m 10
16
7 12
5 6
17
14
8
5.0 ± 1.0 N·m 15
4
13 11
9.0 ± 2.0 N·m
18 3
20
13 ± 1 N·m 2
1
(Engine oil) N 19
AC300545 AB

1. A/C compressor connector 12. Oxygen sensor connector
2. Power steering fluid pressure 13. Engine coolant temperature sensor
switch connector connector
3. Crank angle sensor connector 14. Engine coolant temperature gauge
4. Ignition coil connectors unit connector
5. Detonation sensor connector 15. Capacitor connector
6. Purge control solenoid valve 16. Accelerator cable connection
connector 17. Brake booster vacuum hose
7. EGR control solenoid valve connection
connector 18. Engine oil level gauge and guide
8. Injector connectors assembly
9. Throttle position sensor connector 19. O-ring
10. Idle speed control servo connector 20. Canister vacuum hose connection
11. Camshaft position sensor
connector
ENGINE MECHANICAL
24
25
26
<Cold engine> 5.0 ± 1.0 N·m
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
27 N (Engine oil)
28
(Engine oil)
29
22
11 ± 1 N·m
21
30 N
31 ± 3 N·m
23
AC300546 AB

21. Detonation sensor connection 25. Fuel return line hose connection
22. Battery wiring harness connection >>C<< 26. Fuel high-pressure hose
23. Inlet manifold stay connection
% Exhaust manifold (Refer to GROUP >>C<< 27. O-ring
15, Exhaust Manifold ,-15!"). <<A>> >>B<< 28. Cylinder head bolts
% Water outlet fitting and thermostat 29. Cylinder head assembly
case assembly (Refer to GROUP >>A<< 30. Cylinder head gasket
14, Water Hose and Water Pipe
,-14!*&).
% Rocker cover (Refer to ,-11A!&)).
24. Heater water hose connection
ENGINE MECHANICAL
11A-33
REMOVAL SERVICE POINT
<<A>> CYLINDER HEAD BOLTS REMOVAL
Identification
mark "63"
MB991654 Exhaust side
AC107217AC
2. Assemble to the cylinder block so the cylinder

head gasket identification mark "63" is at the top
surface and on the exhaust side.
Engine front
>>B<< CYLINDER HEAD BOLTS INSTALLATION

3 5 10 8 2
(Engine oil)
1 7 9 6 4
AC201623 AB
A
Using special tool cylinder head bolt wrench
(MB991654), loosen the cylinder head bolts in two or
AC102537AB
three steps in the order of the numbers shown in the
illustration. 1. Check that the nominal length of each cylinder
NOTE: If the cylinder head bolts cannot be pulled out head bolt meets the limit. If it exceeds the limit,
due to the washer being trapped in the valve spring, replace the bolt with a new one.
raise the bolt slightly, then remove it while holding it Limit (A): 99.4 mm
by using a magnet. 2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.
>>A<< CYLINDER HEAD GASKET INSTALLATION
CAUTION
Do not allow any foreign materials to get into the
coolant passages, oil passages and cylinder.
1. Remove the gasket from the cylinder head and
cylinder block.
ENGINE MECHANICAL
CAUTION
The bolt is not tightened sufficiently if the bolt is
tightened less than 90 degree angle.
(5) Tighten the bolt an additional 90 degree angle
as shown. Then check to see that the paint
MB991654 mark on the head of the cylinder head bolts
and the paint mark on the cylinder head are
aligned.
(6) If tightening the bolt 90 degree angle results in
moving the paint mark on the bolt past the
paint mark on the cylinder head, remove the
Engine front bolt and start over from step 1.
8 6 1 3 9 >>C<< O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
10 4 2 5 7 Do not let any engine oil get into the delivery
pipe.
1. Apply a small amount of new engine oil to the O-
ring.
AC201625 AB
2. Turning the fuel high-pressure hose to the right
3. Use special tool cylinder head bolt wrench and left, install it to the delivery pipe, while being
(MB991654) to tighten the cylinder head bolts as careful not to damage the O-ring. After installing,
follows: check that the hose turns smoothly.
(1) Tighten the cylinder head bolts to 78 $ 2 N&m 3. If the hose does not turn smoothly, the O-ring is
in the order shown. probably being clamped. Disconnect the fuel high-
(2) Loosen the bolts fully in the reverse order of pressure hose and check the O-ring for damage.
that shown. After this, re-insert it to the delivery pipe and
(3) Tighten the cylinder head bolts to 20 $ 2 N&m check that the hose turns smoothly.
in the order shown. 4. Tighten the fuel high-pressure hose mounting
Step (4) Step (5) bolts to the specified torque.
90˚ 90˚
Paint marking Paint marking
AC102331AB
(4) Apply a paint mark to the heads of the cylinder

head bolts and cylinder head, then tighten 90
degree angle as shown.
ENGINE MECHANICAL
TIMING BELT
11A-35
TIMING BELT
M1112004300656

% Under Cover Removal (Refer to GROUP 51, Under Cover % Crankshaft Shaft Damper Pulley Installation (Refer to
,-51!&$). ,-11A!&().
% Crankshaft Shaft Damper Pulley Removal (Refer to % Drive Belt Tension Check (Refer to ,-11A!").
,-11A!&(). % Under Cover Installation (Refer to GROUP 51, Under
Cover ,-51!&$).
10
9
2 8 48 ± 5 N·m
11 ± 1 N·m
21 ± 4 N·m
3
8.8 ± 1.0 N·m 23 ± 3 N·m 11
1
6
44 ± 10 N·m
N 5
4
79 ± 5 N·m
7
22 ± 4 N·m 11 ± 1 N·m
9.0 ± 1.0 N·m
AC300547 AB

1. Control wiring harness connection % Engine front mounting bracket
2. Timing belt upper cover (Refer to GROUP 32, Engine
3. Water pump pulley Mount ,-32!().
4. Idler pulley >>G<< % Valve timing belt tension
>>H<< 5. End cap adjustment
6. Auto-tensioner <<A>> >>F<< 8. Valve timing belt
7. Timing belt lower cover >>E<< 9. Timing belt tensioner pulley
10. Timing belt tensioner arm
>>D<< 11. Timing belt tensioner adjuster
ENGINE MECHANICAL
11A-36 TIMING BELT
12 22 ± 4 N·m
16
35 ± 6 N·m
21
20 22 ± 4 N·m
13
19 ± 3 N·m
14
(Engine oil)
49 ± 9 N·m
15 49 ± 9 N·m
17
19
18 8.8 ± 1.0 N·m
167 N·m
AC300548 AB

12. Power steering fluid pressure <<C>> >>C<< 18. Crankshaft camshaft drive sprocket
switch connector >>C<< 19. Crankshaft angle sensing blade
<> 13. Power steering oil pump assembly >>B<< % Balancer timing belt tension
14. A/C compressor connector adjustment
15. Power steering oil pump bracket >>A<< 20. Balancer timing belt tensioner
16. Timing belt idler pulley <<D>> >>A<< 21. Balancer timing belt
17. Crank angle sensor
REMOVAL SERVICE POINTS

<<A>> VALVE TIMING BELT REMOVAL
CAUTION
Never turn the crankshaft anti-clockwise. MD998738
Timing mark
Timing belt
under cover
AC102492 AB
2. Remove the timing belt under cover rubber plug

and then set the special tool adjusting bolt
AC102487
(MD998738).
1. Turn the crankshaft clockwise, align each timing
mark to set No.1 cylinder to TDC of its
compression stroke.
ENGINE MECHANICAL
TIMING BELT
11A-37
CAUTION
The special tool can be gradually installed at a <> POWER STEERING OIL PUMP ASSEMBLY
rate of a 30 degree turn per second. If it is REMOVAL
screwed in all at once, the timing belt tensioner With the hose installed, remove the power steering
adjuster rod will not easily retract and the special oil pump assembly from the bracket.
tool may bend. NOTE: Secure the removed power steering oil pump
assembly with cord or rope at a position where they
Timing belt will not interfere with the removal of the balancer
tensioner arm timing belt.
<<C>> CRANKSHAFT CAMSHAFT DRIVE

MD998738 SPROCKET REMOVAL
Crankshaft
camshaft MB991385
drive
AC107289 AB sprocket
3. Screw in the special tool until it comes in contact
with the timing belt tensioner arm.
MB991367
A
B AC102332 AB
1. Use the following special tools to support the

crankshaft camshaft drive sprocket.
% Special spanner (MB991367)
% Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
AC102775AB remove the crankshaft camshaft drive sprocket.
4. Gradually screw in the special tool. Then align the
<<D>> BALANCER TIMING BELT REMOVAL
timing belt tensioner adjuster rod set hole A with
the timing belt tensioner adjustor cylinder set hole CAUTION
B. To reuse the balancer timing belt, draw an arrow
indicating the rotating direction (clockwise) on
Timing belt the back of the belt using chalk.
tensioner pulley
mounting bolt
>>A<< BALANCER TIMING BELT/BALANCER
Wire
TIMING BELT TENSIONER INSTALLATION
Balancershaft sprocket
Belt tension side
AC107185 AB Timing mark

Timing mark
5. Insert a wire, etc.in the set hole.
CAUTION
To reuse the valve timing belt, draw an arrow Crankshaft
indicating the rotating direction (clockwise) on balancershaft
the back of the belt using chalk. drive sprocket AC102689 AB
6. After removal of adjusting bolt special tool, loosen 1. Ensure that the crankshaft balancershaft drive
the timing belt tensioner pulley mounting bolt and sprocket timing marks and balancershaft sprocket
remove the valve timing belt. timing marks are aligned.
ENGINE MECHANICAL
11A-38 TIMING BELT
2. Install the balancer timing belt on the crankshaft 1. With your fingers, lift the balancer timing belt
balancershaft drive sprocket and balancershaft tensioner in the direction of the arrow. Apply
sprocket. There should be no slack on the tension pressure of 3.0 $ 0.4 N&m to the balancer timing
side. belt. Tighten the assembling bolt to the specified
torque. Then, fix the balancer timing belt
Centre of the tensioner.
mounting bolt
Balancershaft sprocket
Timing mark
Centre of Timing mark
the pulley
AC102690 AB
3. Assemble and temporarily fix the centre of the Crankshaft

pulley of the balancer timing belt tensioner so that balancershaft
it is at the top left from the centre of the mounting drive sprocket AC102689AC
bolt, and the pulley flange is at the front-side of 2. Turn the crankshaft clockwise two turns to set
the engine. No.1 cylinder to TDC of its compression stroke
4. Adjust the balancer timing belt tension. and check that the sprocket timing marks are
aligned.
>>B<< BALANCER TIMING BELT TENSION
ADJUSTMENT
CAUTION
When tightening the mounting bolt, ensure that
the tensioner does not rotate with the bolt.
Allowing it to rotate with the bolt can cause
excessive tension of the belt.
AC102691
ENGINE MECHANICAL
TIMING BELT
11A-39
2. Install the crankshaft angle sensing blade and
crankshaft camshaft drive sprocket in the direction
Approximately 100 N shown.
3. Place the larger chamfer side of the crank shaft
pulley washer in the direction shown and then
assemble on the crankshaft pulley centre bolt.
Deflection 4. Apply some engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
AC102693 AB Crankshaft
camshaft MB991385
3. Apply a pressure of approximately 100N at the drive
centre (arrow area) between the sprocket as sprocket
shown, then inspect whether the belt deflection is
within the standard value.
Standard value: MB991367
At adjustment: 5 # 7 mm
At replacement: 5 # 7 mm
AC102332 AB
4. If not within the standard value, adjust the belt
tension again. 5. Use the following special tool as during removal to
support the crankshaft camshaft drive sprocket.
>>C<< CRANKSHAFT ANGLE SENSING BLADE/ % Special spanner (MB991367)
CRANKSHAFT CAMSHAFT DRIVE SPROCKET % Pin (MB991385)
INSTALLATION 6. Tighten the crankshaft pulley centre bolts to the
specified torque.
Tightening torque: 167 N&m
: Clean
: Clean and degrease
: Apply engine oil >>D<< TIMING BELT TENSIONER ADJUSTER
INSTALLATION
Crankshaft pulley 1. Install according to the following procedures when
center bolt the timing belt tensioner adjuster rod is fully
Crankshaft camshaft extended.
drive sprocket CAUTION
Crankshaft If the compression is too fast, the procedure may
damage the rod.
B
A
Crankshaft
pulley washer Crankshaft angle
sensing blade
Engine front
AC211535AB
AC102334 AB
1. Clean or degrease the crankshaft, the crankshaft (1) Slowly compress the timing belt tensioner
angle sensing blade, the crankshaft camshaft adjuster rod using a press or vice, then align
drive sprocket and crankshaft pulley washer as the set hole A of the rod with set hole B of the
shown. timing belt tensioner adjuster cylinder.
NOTE: Also clean the degreased surfaces.
ENGINE MECHANICAL
11A-40 TIMING BELT
>>F<< VALVE TIMING BELT INSTALLATION

Wire
Timing mark
AC102335 AB
Camshaft sprocket
(2) Insert a wire or pin into the aligned set hole.
NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin. Crankshaft
2. Assemble the timing belt tensioner adjuster to the camshaft
drive sprocket Engine oil
engine, then tighten the assembling bolt to the pump sprocket
specified torque. Do not remove the wire or pin
until the tension of the valve timing belt is
adjusted.
Timing mark
Timing mark AC102486 AC
>>E<< TIMING BELT TENSIONER PULLEY
INSTALLATION 1. Align the timing marks on the camshaft sprocket,
crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt
Balancershaft
Timing belt tensioner

pulley hole Plug
AC102336AB Cylinder
block
Temporarily tighten the timing belt tensioner pulley as
AC102337 AE
shown.
2. Adjust the timing mark of the engine oil pump
sprocket. Unplug the cylinder block plug. Insert a
bolt (M6 sectional width 10 mm, minor diameter
45 mm) from the plug hole and then check. If the
bolt comes in contact with the balancer shaft turn
the sprocket one rotation. Re-adjust the timing
mark and then check to see that the bolt fits. Do
not remove the bolt until the valve timing belt is
assembled.
ENGINE MECHANICAL
TIMING BELT
11A-41
3. Install the valve timing belt as follows: Timing mark
Inlet side Exhaust side Timing mark

camshaft sprocket camshaft sprocket
AC201802 AB
(3) Use two wrenches to align the timing mark on

Timing belt Timing belt the rocker cover with that on the camshaft
tensioner idler pulley sprocket. Pass the valve timing belt around the
pulley inlet-side camshaft sprocket.
Crankshaft Engine
camshaft oil pump
drive sprocket
sprocket
AC102488 AC Paper clip
(1) Pass the valve timing belt around the

crankshaft camshaft drive sprocket, the engine
AC201803 AB
oil pump sprocket and the timing belt idler
pulley in that order. (4) Hold the valve timing belt with paper clips.
(5) Pass the valve timing belt around the timing
belt tensioner pulley.
CAUTION
Paper clip Incorporate the valve timing belt. Then apply
reverse rotation (anti-clockwise rotation)
pressure to the cam shaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is tight.
(6) Remove the two paper clips.
AC201801AB
(2) Pass the valve timing belt around the exhaust-

side camshaft sprocket, and hold the valve
timing belt with paper clip.
MD998767
AC102694 AB
4. Turn the timing belt tensioner in the direction

shown using special tool tensioner wrench
(MD998767) to apply tension to the valve timing
belt. Then pre-tighten the timing belt tensioner
pulley.
5. Check that the timing marks are aligned.
ENGINE MECHANICAL
11A-42 TIMING BELT
Bolt CAUTION
Balancershaft When tightening the mounting bolt, ensure that
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
Plug
Cylinder
block
AC102337 AE
6. Remove the bolt inserted in Step 2 above, then MD998767

assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque.
AC102695AB
6. With special tool tensioner wrench (MD998767)
8. Adjust the valve timing belt tension.
and torque wrench, apply tension torque 3.5 N&m,
and tighten the timing belt tensioner pulley
>>G<< VALVE TIMING BELT TENSION mounting bolt to the specified torque.
ADJUSTMENT
MD998738
Wire
Timing belt
under cover
AC102492 AB
AC102776 AB
1. Set special tool adjusting bolt (MD998738) when
removing the valve timing belt. 7. Remove wire or pin inserted to timing belt
tensioner.
CAUTION
Always screw in special tool by hand, since use
of a spanner or other tools may damage the wire
MD998738
or pin inserted in the timing belt tensioner
adjuster.
2. Gradually screw in special tool until the wire or pin
inserted in the timing belt tensioner adjuster lightly
moves.
3. Turn the crankshaft 1/4 turn anti-clockwise. Timing belt
4. Turn the crankshaft in the clockwise direction until under cover
you align each timing mark to set No.1 cylinder to AC102492 AB
TDC of its compression stroke. 8. Remove the special tool adjusting bolt
5. Loosen the timing belt tensioner pulley mounting (MD998738), and install the rubber plug to the
bolt. timing belt under cover.
9. Rotate the crankshaft clockwise two turns, and
leave it for about 15 minutes.
ENGINE MECHANICAL
TIMING BELT
11A-43
CAUTION
Always check the tightening torque of the crank
shaft pulley centre bolt when turning the crack
shaft pulley centre bolt anti-clockwise. Re-
Wire
tighten if it is loose.
Timing mark
AC102776 AB
10.Insert wire or pin removed in Step 7 again, and

ensure that it can be pulled out easily. When wire
or pin can be easily removed, appropriate tension
is applied on timing belt. In this case, remove wire Camshaft
or pin. sprocket
Crankshaft
camshaft Engine
A drive sprocket oil pump
sprocket
Timing belt
tensioner Timing mark
adjuster
AC102338AB Timing mark AC201411AB
If the projection of timing belt tensioner adjuster 12.Check again that the timing marks on sprockets
rod is within the standard value, appropriate are aligned.
tension is applied.
Standard value (A): 3.8 # 4.5 mm >>H<< END CAP INSTALLATION
11.If wire or pin cannot be easily pulled out, repeat CAUTION
Step 1 through Step 9 to reach proper valve timing Always replace the end cap with new parts since
belt tension. there may be fall-off or sealing defect if the end
cap is re-used.
INSPECTION
M1112004400352
TIMING BELT TENSIONER ADJUSTER

CHECK
1. Check for oil leak from seal, and replace it if leak
is detected.
2. Check for wear or damage at the top of the rod.
Replace it, if required.
ENGINE MECHANICAL
11A-44 TIMING BELT
BALANCER TIMING BELT TENSION

98 – 196 N Movement
CHECK
Check the balancer timing belt tension as follows:
A B
Approximately 100 N
Timing belt
Rod
tensioner
adjuster
AC102339 AB Deflection
3. Hold the timing belt tensioner adjuster by hand,

and press the top end of the rod onto the metal
(e.g. cylinder block) under a pressure of 98 # 196 AC102693 AB
N to measure the movement of the rod. 1. Apply a pressure of approximately 100 N at the
Standard value: Within 1 mm centre (arrow area) between the sprocket as
A: Length when it is free (not pressed) shown then inspect whether the deflection is
B: Length when it is pressed within the standard value.
A # B: Movement Standard value: 5 # 10 mm
4. If the measured value is out of the standard value, 2. If not within the standard value, adjust the belt
replace the timing belt tensioner adjuster. tension. (Refer to ,-11A!()).
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-45
ENGINE ASSEMBLY
M1112001000720
CAUTION
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
% Fuel Line Pressure Reduction [Refer to GROUP 13A, On- % Starter Assembly Installation (Refer to GROUP 16,
vehicle Service # Fuel Pump Connector Disconnection Starter Motor Assembly ,-16!&$).
(How to Reduce Pressurized Fuel Lines) ,-13A!(&'.] % Front Exhaust Pipe Installation (Refer to GROUP 15,
% Hood Removal (Refer to GROUP 42, Hood ,-42!+). Exhaust Pipe and Main Muffler ,-15!$).
% Under Cover Removal (Refer to GROUP 51, Under Cover % Radiator Assembly Installation (Refer to GROUP 14,
,-51!&$). Radiator ,-14!*().
% Engine Oil Draining (Refer to GROUP 12, On-vehicle % Battery and Battery Tray Installation
Service # Engine Oil Replacement ,-12!(). % Rocker Cover Centre Cover Installation (Refer to ,-11A!
% Engine Coolant Draining (Refer to GROUP 14, On-vehicle &)).
Service # Engine Coolant Replacement ,-14!&)). % Air Cleaner and Air Cleaner Bracket installation (Refer to
% Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner ,-15!().
GROUP 15, Air Cleaner ,-15!(). % Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
% Battery and Battery Tray Removal Service # Engine Coolant Replacement ,-14!&)).
% Rocker Cover Centre Cover Removal (Refer to ,-11A! % Engine Oil Refilling (Refer to GROUP 12, On-vehicle
&)). Service # Engine Oil Replacement ,-12!().
% Radiator Assembly Removal (Refer to GROUP 14, % Accelerator Cable Adjustment (Refer to GROUP 17, On-
Radiator ,-14!*(). vehicle Service # Accelerator Cable Check and
% Front Exhaust Pipe Removal (Refer to GROUP 15, Adjustment ,-17!().
Exhaust Pipe and Main Muffler ,-15!$). % Drive Belt Tension Check (Refer to ,-11A!").
% Starter Assembly Removal (Refer to GROUP 16, Starter % Under Cover Installation (Refer to GROUP 51, Under
Motor Assembly ,-16!&$). Cover ,-51!&$).
% Hood Installation (Refer to GROUP 42, Hood ,-42!+).
% Fuel Leak Check
ENGINE MECHANICAL
11A-46 ENGINE ASSEMBLY
9
5.0 ± 1.0 N·m
10
17
7 12
5 6
14
5.0 ± 1.0 N·m 8

15
4 9.0 ± 2.0 N·m 11
13
3
2
1 9.0 ± 2.0 N·m
18
5.0 ± 1.0 N·m
16
9.0 ± 2.0 N·m

5.0 ± 1.0 N·m
AC300549 AB

1. A/C compressor connector 10. Idle speed control servo connector
2. Power steering fluid pressure 11. Camshaft position sensor
switch connector connector
3. Crank angle sensor connector 12. Oxygen sensor connector
4. Ignition coil connectors 13. Engine coolant temperature sensor
5. Detonation sensor connector connector
6. Purge control solenoid valve 14. Engine coolant temperature gauge
connector unit connector
7. EGR control solenoid valve 15. Capacitor connector
connector 16. Battery wiring harness connection
8. Injector connectors 17. Accelerator cable connection
9. Throttle position sensor connector <<A>> 18. Drive belt
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-47
23
24
25
19
5.0 ± 1.0 N·m
26 N (Engine oil)
12 ± 2 N·m
20
44 ± 10 N·m*
22 ± 4 N·m
27 N
22
45 ± 5 N·m* 22 ± 4 N·m
29
28
21
AC300550 AB

19. Brake booster vacuum hose >>E<< 25. Fuel high-pressure hose
connection connection
20. Canister vacuum hose connection >>E<< 26. O-ring
<> 21. A/C compressor and clutch <<C>> >>D<< % Transmission assembly
assembly >>C<< 27. Self-locking nuts
<> 22. Power steering oil pump assembly <<D>> >>B<< 28. Engine front mounting bracket
23. Heater water hoses connection <<E>> >>A<< 29. Engine assembly
24. Fuel return line hose connection
ENGINE MECHANICAL
REMOVAL SERVICE POINTS <<C>> TRANSMISSION ASSEMBLY REMOVAL

<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the
serpentine drive system with the drive belt auto-
tensioner.
Auto-tensioner
AC300950AB
Hole B
1. Pre-tighten the 2 bolts on the car to assemble the
radiator support upper insulator to set the special
Hole A AC107640AC
tools engine hanger MB991895 or engine hanger
MB991928.
1. Securely insert the spindle handle or ratchet 2. Remove the transmission assembly (Refer to
handle with a 12.7 mm insertion angle into the jig GROUP 22A, Transmission Assembly ,-22A!&').
hole of the auto-tensioner, and turn the auto-
tensioner anti-clockwise until it hits the stopper. <<D>> ENGINE FRONT MOUNTING BRACKET
REMOVAL
CAUTION 1. Support the engine with a garage jack.
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of 2. Remove the following special tool.
the belt using chalk. MB991895
Auto-tensioner MB991527
MB991454
L-shaped
AC107631AB
hexagon
wrench AC107641AB (1) <Special tool engine hanger (MB991895) is
used>
2. Align hole A with hole B, insert an L-shaped Remove special tool MB991895.
hexagon wrench, etc. to fix and then remove the
drive belt. MB991928
<> A/C COMPRESSOR AND CLUTCH

ASSEMBLY/POWER STEERING OIL PUMP
ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly, and power steering oil pump MB991527
assembly from the bracket.
MB991454
NOTE: Secure the removed A/C compressor and
AC211405 AB
clutch assembly, and power steering oil pump
assembly with cord or rope at a position where they (2) <Special tool engine hanger (MB991928) is
will not interfere with the removal of the engine used>
assembly. Remove special tool MB991928.
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-49
2. Support the engine assembly with a garage jack.
MB991454 3. Remove the chain block.
MB991527 4. Use the following special tool as during removal to
support the engine.
MB991895
MB991527
AC107632 AB
3. Hold the engine assembly with a chain block, etc.

4. Place a garage jack against the engine oil pan
MB991454
with a piece of wood in between so that the weight
AC107631AB
of the engine assembly is no longer being applied
to the engine front mounting bracket. (1) <Special tool engine hanger (MB991895) is
5. Loosen the engine front mounting bracket used>
mounting nuts and bolt, and remove the engine Set special tool MB991895. (Refer to
front mounting bracket. GROUP 22A, Transmission Assembly
,-22A!&').
<<E>> ENGINE ASSEMBLY REMOVAL MB991928
After checking that all cables, hoses and wiring
harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
the engine assembly upward from the engine
compartment.
MB991527
>>A<< ENGINE ASSEMBLY INSTALLATION MB991454
AC211405 AB
MB991454 (2) <Special tool engine hanger (MB991928) is

MB991527 used>
Set special tool MB991928 (Refer to
GROUP 22A, Transmission Assembly
,-22A!&').
>>C<< SELF-LOCKING NUTS INSTALLATION

CAUTION
AC107632 AB Do not tighten the self-locking nuts while the
Install the engine assembly, being careful not to engine is hot.
pinch the cables, hoses or wiring harness Tighten the self-locking nuts to the specified torque
connectors. while the engine is cold.
>>B<< ENGINE FRONT MOUNTING BRACKET
INSTALLATION >>D<< TRANSMISSION ASSEMBLY
1. Place a garage jack against the engine oil pan INSTALLATION
with a piece of wood in between, and install the 1. Install the transmission assembly (Refer to
engine front mounting bracket while adjusting the GROUP 22A, Transmission Assembly ,-22A!&').
position of the engine.
ENGINE MECHANICAL
>>E<< O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
Do not let any engine oil get into the delivery
pipe.
1. Apply a small amount of new engine oil to the O-
ring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
AC300950AB careful not to damage the O-ring. After installing,
check that the hose turns smoothly.
2. Remove from the car the 2 bolts, to assemble the
radiator support upper insulator. 3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel high-
pressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
11B-1
GROUP 11B
00
11
ENGINE OVERHAUL 12
13
14
CONTENTS
15
HOW TO USE THIS MANUAL . . . . . . 11B!" EXHAUST MANIFOLD REMOVAL AND
16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11B!%(
GENERAL INFORMATION . . . . . . . . 11B!# 17
WATER PUMP AND WATER HOSE . 11B!"%
GENERAL SPECIFICATIONS . . . . . . 11B!# WATER PUMP AND WATER HOSE 21
REMOVAL AND INSTALLATION . . . . . . . . 11B!%)
22
SERVICE SPECIFICATIONS. . . . . . . 11B!#
ROCKER ARMS AND CAMSHAFT . . 11B!(&
ROCKER ARMS AND CAMSHAFT
25
REWORK DIMENSIONS . . . . . . . . . . 11B!$
REMOVAL AND INSTALLATION . . . . . . . . 11B!#"
26
TORQUE SPECIFICATIONS . . . . . . . 11B!$ INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B!## 27
SEALANTS . . . . . . . . . . . . . . . . . . . . 11B!% CYLINDER HEAD AND VALVES. . . . 11B!($ 31
CYLINDER HEAD AND VALVES
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B!&' REMOVAL AND INSTALLATION . . . . . . . . 11B!#* 32
ALTERNATOR AND IGNITION INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B!#( 33
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B!&(
34
ALTERNATOR AND IGNITION SYSTEM OIL PAN AND OIL PUMP. . . . . . . . . . 11B!#"
REMOVAL AND INSTALLATION . . . . . . . . 11B!"# OIL PAN AND OIL PUMP REMOVAL AND 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11B!$%
TIMING BELT. . . . . . . . . . . . . . . . . . . 11B!&# OIL PAN AND OIL PUMP INSPECTION. . . 11B!&+ 36
TIMING BELT REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 11B!"$ PISTON AND CONNECTING ROD . . 11B!)& 37
TIMING BELT INSPECTION. . . . . . . . . . . . 11B!%# PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION . . . . . . . . 11B!&"
42
FUEL AND EMISSION PARTS . . . . . 11B!") PISTON AND CONNECTING ROD 51
FUEL AND EMISSION PARTS REMOVAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B!&*
AND INSTALLATION . . . . . . . . . . . . . . . . . 11B!%& 52
CRANKSHAFT AND CYLINDER BLOCK
INTAKE MANIFOLD . . . . . . . . . . . . . 11B!"* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B!)+ 54
INTAKE MANIFOLD REMOVAL AND CRANKSHAFT AND CYLINDER BLOCK
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 11B!%' REMOVAL AND INSTALLATION . . . . . . . . 11B!&(
55
EXHAUST MANIFOLD. . . . . . . . . . . . 11B!"+ INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B!*"
ENGINE OVERHAUL
11B-2 HOW TO USE THIS MANUAL

M1113025100155

Scope of Service Explanations
This manual describes service procedures performed after removal of the engine from the vehicle.
For removal of the engine from the vehicle, installation of the engine in the vehicle, and on-vehicle inspection and service of
the engine, please use the separate Workshop Manuals prepared for the vehicle.
How to Read Explanations
Service steps
(1) A component part drawing is shown at the beginning of each section to enable the technician to ascertain the installed con-
dition of the component parts.
(2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such,
and tightening torques are shown.
·Removal steps
The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence.
·Installation steps
Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse.
·Disassembly steps
The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence.
·Reassembly steps
Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.
Classification of Service Points

Key service points, service standards, and instructions for <<A>>: Outward-pointing brackets denote removal service points
using special tools are collated as service points and ex- or disassembly service points.
plained in detail. >>A<<: Inward-pointing brackets denote installation service points
or reassembly service points.
Lubricant and Sealant Symbols

Every location where a lubricant or sealant must be applied . . . . . . . . . . Grease
or added is indicated using a relevant symbol in the compo-
nent part drawing and/or on the page after the component . . . . . . . . . . Sealant or form-in-place gasket (FIPG)
part drawing.
. . . . . . . . . . Brake fluid
. . . . . . . . . . Engine oil or gear oil
Inspection
Only those inspection procedures which use special tools or measuring appliances are described. You must perform general visual inspec-
tion and part cleaning whenever necessary although their procedures are not described in this manual.
AK202851
ENGINE OVERHAUL
11B-3
Page number Section title
ENGINE OVERHAUL
11-54 CRANKSHAFT AND CYLINDER BLOCK

3 2
Apply engine oil Denotes non-reusable part.
to all moving
parts before
11 ± 1 N·m 1
installtion. 6 132 ± 5 N·m
9
8 4 A
16 5
9.0 ± 1.0 N·m

11 ± 1 N·m 7
Tightening torque
15
14
13
12
11
25 ± 2 N·m + 90º to 100º

10
AK204351AB
Removal steps INSTALLATION SERVICE POINTS

1. Drive plate bolt
2. Adapter plate >>A<< THRUST BEARING INSTALLATION
3. Drive plate
4. Crankshaft bushing
5. Rear plate
6. Bellhousing cover
>>E<< 7. Oil seal case
>>D<< 8. Oil seal
>>C<< 9. Bearing cap bolt
10. Bearing cap
>>B<< 11. Crankshaft bearing, lower
>>A<< 12. Crankshaft
Grooves
AK100786AB
The alphabetical character in this category of

heading matches that of the relevant removal
steps, installation steps, disassembly steps, or Procedures and cautions for removal, instal-
reassembly steps. lation, disassembly, and reassembly are ex-
AK300250
plained under this category of heading.
ENGINE OVERHAUL
11B-4 GENERAL INFORMATION
GENERAL INFORMATION
M1113000100233
VEHICLE AND ENGINE MODELS

Vehicle name Vehicle Engine model Displacement Specification
model mL
Outlander CU2W 4G63-7 1,997 Double overhead camshaft, 16-valve
GENERAL SPECIFICATIONS
M1113000200478
Items Specification
Bore ! stroke mm 85 ! 88
Displacement mL 1,997
Combustion chamber Pentroof type
Number of cylinders 4
Valve mechanism Type Double overhead camshaft
Number of intake valves 2
Number of exhaust 2
valves
Lash adjusters Hydraulic
Rocker arms Roller cam followers
Compresssion ratio 10.0
Fuel injection system Electronically controlled multi-point injection (MPI)
system
Ignition system Electronically controlled two-coil system
Generator Alternator (with built-in IC regulator)
Starter motor Gear reduction drive type
M1113000300419
Items Standard value Limit

TIMING BELT
Auto-tensioner rod extension length 3.8 " 4.5 "
(with timing belt installed) mm
Auto-tensioner rod extension length (when free) mm 12.0 "
Auto-tensioner rod retraction length Less than 1 "
(when pressed with force of 98 to 196 N) mm
ROCKER ARMS AND CAMSHAFTS
Cam height mm 34.91 34.41
Cylinder head gasket surface warp mm Less than 0.05 0.2
ENGINE OVERHAUL
11B-5
Cylinder head gasket surface grinding limit " 0.2
(including cylinder block grinding amount) mm
Cylinder head overall height mm 131.9 " 132.1 "
Cylinder head bolt nominal length mm " 99.4
Valve margin mm Intake valves 1.0 0.5
Exhaust valves 1.5 1.0
Valve stem diameter mm 6.6 "
Valve face angle 45.5# "
Valve stem-to-guide clearance mm Intake valves 0.02 " 0.05 0.10
Exhaust valves 0.05 " 0.09 0.15
Valve height mm Intake valves 109.5 109.0
Valve stem projection mm Intake valves 49.2 49.7
Valve spring free height mm 48.3 47.3
Valve spring load/height N/mm 294/40 "
Valve spring squareness 1.5#or less 4#
Valve face-to-seat contact width mm 0.9 " 1.3 "
Valve guide inside diameter mm 6.6 "
Valve guide press-in height mm 19.2 " 19.8 "
OIL PAN AND OIL PUMP
Oil pump gear side clearance mm Drive gear 0.08 " 0.14 "
Driven gear 0.06 " 0.12 "
PISTONS AND CONNECTING RODS
Piston outside diameter mm 85.0 "
Piston ring side clearance in ring No. 1 0.02 " 0.06 0.1
groove mm No. 2 0.02 " 0.06 0.1
Piston ring end gap mm No. 1 0.20 " 0.30 0.8
No. 2 0.30 " 0.45 0.8
Oil ring 0.10 " 0.40 1.0
Piston pin outside diameter mm 22.0 "
Piston pin press-in load (at ambient temperature) N 7,350 " 17,100 "
Oil clearance at crankshaft pins mm 0.03 " 0.05 0.1
Connecting rod big end thrust clearance mm 0.10 " 0.25 0.4
Crankshaft end play mm 0.05 " 0.25 0.4
Crankshaft journal diameter mm 57.0 "
Crankshaft pin diameter mm 45.0 "
Oil clearance at crankshaft journals mm 0.03 " 0.04 0.1
Cylinder block gasket surface warp mm 0.05 0.1
ENGINE OVERHAUL
11B-6 REWOK DIMENSIONS

Cylinder block gasket surface grinding limit " 0.2
(including cylinder head grinding amount) mm
Cylinder block overall height mm 284 "
Cylinder bore diameter mm 85 "
Taper of cylinder mm 0.01 or less "
Cylinder-to-piston clearance mm 0.02 " 0.04 "
Crankshaft bearing cap bolt nominal length mm " 71.1
REWOK DIMENSIONS
M1113024300178
Items Standard value

Diameter of oversize valve seat ring hole in cylinder head Intake 0.03 oversize 35.30 " 35.33
mm 0.06 oversize 35.60 " 35.63
Exhaust 0.03 oversize 33.30 " 33.33
0.06 oversize 33.60 " 33.63
Diameter of oversize valve guide hole in cylinder head mm 0.05 oversize 12.05 " 12.07
0.25 oversize 12.25 " 12.27
0.50 oversize 12.50 " 12.52
TORQUE SPECIFICATIONS
M1113023400503
Items Tightening torque N$m

ALTERNATOR AND IGNITION COIL
Oil level gauge guide bolts 13 % 1
Idler pulley bolt 79 % 5
Auto-tensioner assembly bolts (M8) 22 % 4
Auto-tensioner assembly bolts (M10) 44 % 10
Water pump pulley bolt 8.8 % 1.0
Alternator brace bolt (flange bolt) 23 % 3
Alternator brace bolt (washer assembled bolt) 22 % 4
Alternator nuts 44 % 10
Crankshaft pulley bolt 25 % 4
Center cover bolts 3.0 % 0.5
Ignition coil bolts 10 % 2
Spark plugs 25 % 5
TIMING BELT
Timing belt cover bolts (flange bolts) 11 % 1
Timing belt cover bolts (washer-assembled bolts) 9.0 % 1.0
ENGINE OVERHAUL
11B-7
Power steering pump bracket bolts 49 % 9
Tensioner pulley bolt 48 % 5
Tensioner arm bolt 21 % 4
Auto-tensioner bolts 23 % 3
Idler pulley bolt 35 % 6
Crank angle sensor bolts 8.8 % 1.0
Oil pump sprocket nut 54 % 4
Crankshaft bolt 167
Tensioner B bolt 19 % 3
Counterbalance shaft sprocket bolt 45 % 3
Rocker cover bolts 3.5 % 0.5
Engine support bracket bolts 49 % 5
Camshaft sprocket bolt 88 % 10
FUEL SYSTEM
Vacuum hose and pipe clamp bolt 11 % 1
Throttle body bolts 19 % 3
EGR valve bolts 20 % 2
Fuel pressure regulator bolts 9.0 % 2.0
Delivery pipe and injector assembly bolts 11 % 1
Solenoid valve assembly bolts 9.0 % 1.0
INTAKE MANIFOLD
Intake manifold stay bolts 31 % 3
Intake manifold bolts (M8) 20 % 2
Intake manifold bolts and nuts (M10) 36 % 6
Engine hanger bolt 19 % 3
EXHAUST MANIFOLD
Oxygen sensor 44 % 5
Exhaust manifold cover bolts 14 % 1
Exhaust manifold bracket bolt (Cylinder block side) 35 % 6
Exhaust manifold bracket bolt (Exhaust manifold side) 44 % 5
Exhaust manifold nuts (M8) 29 % 3
Exhaust manifold nuts (M10) 49 % 5
WATER PUMP AND WATER HOSE
Coolant temperature sensor 29 % 10
Coolant temperature gauge unit 10.8 % 1.0
Water inlet fitting bolts 13 % 2
Water outlet fitting bolts 13 % 2
Thermostat housing bolts 23 % 4
Water inlet pipe bolts 13 % 2
Water pump bolts 14 % 1
ENGINE OVERHAUL
11B-8 TORQUE SPECIFICATIONS

Knock sensor 23 % 2
ROCKER ARMS AND CAMSHAFTS
Camshaft position sensor bolts 8.8 % 1.0
Cover bolts 10 % 2
Camshaft position sensing cylinder bolt 22 % 4
Camshaft position sensor support bolts 14 % 1
Bearing cap bolts 20 % 1
Oil delivery body bolts 11 % 1
Cylinder head bolts 78 % 2 & loosen completely & 20 % 2
& 90# + 90#
OIL PUMP CASE AND OIL PAN
Drain plug 39 % 5
Transmission stay bolts 22 % 4
Oil pan upper section bolts 9.0 % 3.0
Oil pan lower section bolts 9.0 % 3.0
Oil screen bolts 19 % 3
Oil pressure switch 19 % 3
Relief plug 44 % 5
Oil filter bracket bolts 19 % 3
Plug cap 23 % 3
Flange bolts 36 % 3
Oil pump case bolts 23 % 3
Oil pump cover bolts 17 % 1
Oil pump cover screws 10 % 2
PISTONS AND CONNECTING RODS
Connecting rod cap nuts 20 % 2 & 90# to 94#
Flywheel bolts 132 % 5
Rear plate bolts 11 % 1
Bell housing cover bolts 9.0 % 1.0
Rear oil seal case bolts 11 % 1
Beam bearing cap bolts 25 % 2 & 90# to 100#
ENGINE OVERHAUL
SEALANTS
11B-9
SEALANTS
M1113000500402
Items Specified sealants

Engine support bracket bolts Mitsubishi Genuine Part No.MD970389
or equivalent
Semicircular packing 3M ATD No.8660 or equivalent
Rocker cover Mitsubishi Genuine Part No. MD970389
or equivalent
Engine coolant temperature sensor 3M Nut Locking Part No.4171 or
equivalent
Engine coolant temperature e gauge unit 3M ATD No.8660 or equivalent
Water outlet fitting* Mitsubishi Genuine Part No. MD970389
Thermostat housing* or equivalent
Cylinder head (camshaft bearing cap fitting section) 3M ATD No.8660 or equivalent
Camshaft position sensor support* Mitsubishi Genuine Part No. MD970389
or equivalent
Oil pressure switch 3M ATD No.8660 or equivalent
Oil pan* Mitsubishi Genuine Part No. MD970389
Rear oil seal case* or equivalent
NOTE: *: Part to be sealed with a form-in-place gas-

ket (FIPG)
FORM-IN-PLACE GASKET (FIPG)
This engine has several areas where the form-in- CLEANING FIPG APPLICATION SURFACE
place gasket (FIPG) is used for sealing. To ensure Thoroughly remove all substances deposited on the
that the FIPG fully serves its purpose, it is necessary FIPG application surface, using a gasket scraper or
to observe some precautions when applying it. wire brush. Make sure that the FIPG application sur-
Bead size, continuity and location are of paramount face is flat and smooth. Also make sure that the sur-
importance. Too thin a bead could cause leaks. Too face is free from oils, greases and foreign
thick a bead, on the other hand, could be squeezed substances. Do not fail to remove old FIPG that may
out of location, causing blocking or narrowing of fluid remain in the fastener fitting holes.
passages. To prevent leaks or blocking of passages,
therefore, it is absolutely necessary to apply the APPLICATION OF FIPG
FIPG evenly without a break, while observing the Applied FIPG bead should be of the specified size
correct bead size. and free of any break. FIPG can be wiped away
FIPG hardens as it reacts with the moisture in the unless it has completely hardened. Install the mating
atmospheric air, and it is usually used for sealing parts in position while the FIPG is still wet (in less
metallic flange areas. than 15 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during installa-
REMOVAL OF FIPG SEALED PARTS tion. Avoid operating the engine or letting oils or
Parts sealed with a FIPG can be easily removed water come in contact with the sealed area before a
without need for the use of a special method. In time sufficient for FIPG to harden (approximately one
some cases, however, the FIPG in joints may have to hour) has passed. FIPG application method may
be broken by tapping parts with a mallet or similar vary from location to location. Follow the instruction
tool. You can also tap a flat, thin gasket scraper into for each particular case described later in this man-
the joint to break the FIPG, taking extreme care not ual.
to damage the mating surfaces.The oil pan remover
(MD998727) is available as a special tool for remov-
ing the oil pan. The tool, however, must not be
ENGINE OVERHAUL
11B-10 SPECIAL TOOLS
SPECIAL TOOLS
M1113000600465

MD998781 Flywheel stopper Retention of flywheel
D998781
MD998778 Crankshaft sprocket Removal of crankshaft sprocket

puller and crankshaft sprocket B
MD998785 Sprocket stopper Retention of counterbalancer

shaft sprocket
MD998767 Tension pulley socket Manipulation of tensioner pulley

wrench during adjustment of timing belt
tension
D998767
MD998738 Set screw Retention of tentioner arm and

auto-tensioner during timing belt
installation
D998738
MD998713 Camshaft oil seal Installation of camshaft oil seal

installer
D998713
MD998442 Air bleed wire Air bleeding of lash adjuster

ENGINE OVERHAUL
SPECIAL TOOLS
11B-11
MB991654 Cylinder head bolt Removal and installation of
wrench cylinder head bolts
B991654
MD998772 Valve spring Compression of valve spring

compressor
MD998735 Valve spring Compression of valve spring

compressor
MD998737 Valve stem seal Installation of valve stem seal

installer
MD998162 Plug wrench Removal and installation of front

case plug cap
(Use with MD998783.)
MD998783 Plug wrench retainer Removal and installation of front

case plug cap
MD998371 Silent shaft bearing Removal of counterbalancer shaft

puller front bearing
MD998372 Silent shaft bearing Removal of counterbalancer shaft

puller front and rear bearings
ENGINE OVERHAUL
11B-12 SPECIAL TOOLS

MB991603 Silent shaft bearing Guide and stopper for removal
installer stopper and press-fitting of
counterbalancer shaft rear
bearing
MD998705 Silent shaft bearing Press-fitting of counterbalancer

installer shaft front and rear bearings
MD998375 Crankshaft front oil Installation of crankshaft front oil

seal installer seal
MD998285 Crankshaft front oil Guide for installation of

seal guide crankshaft front oil seal
D998285
MD998780 Piston pin setting tool Removal and press-fitting of

piston pin
MD998776 Crankshaft rear oil Installation of crankshaft rear oil

seal installer seal
D998776
MB990938 Handle Installation of crankshaft rear oil

seal
B990938
ENGINE OVERHAUL
ALTERNATOR AND IGNITION SYSTEM
11B-13
ALTERNATOR AND IGNITION SYSTEM
M1113001000392
12 3.0 ± 0.5 N·m
N 2
1
10 ± 2 N·m
13
14
13 ± 1 N·m 15
25 ± 5 N·m
3
10
44 ± 10 N·m
N4
9
22 ± 4 N·m
44 ± 10 N·m
23 ± 3 N·m
8.8 ± 1.0 N·m
25 ± 4 N·m
11
79 ± 5 N·m
6N
22 ± 4 N·m 5 AK204441AB
Removal steps Removal steps,-./01203456

1. Oil level gauge 9. Alternator brace
2. O-ring 10. Alternator
3. Oil level gauge guide 11. Crankshaft pulley
4. O-ring 12. Center cover
5. Idler pulley 13. Spark plug cable
6. Cap 14. Ignition coil
7. Auto-tensioner assembly 15. Spark plug
8. Water pump pulley
ENGINE OVERHAUL
11B-14 TIMING BELT
TIMING BELT
M1113001900500
3.5 ± 0.5 N·m

24
21 28
11 ± 1 N·m 1 22 25
20
5 6
48 ± 5 N·m
N 23
21 ± 4 N·m 26 N
12 7
11 ± 1 N·m 23 ± 3 N·m
27 N
32
11 ± 1 N·m
11 ± 1 N·m
11 33
167 N·m 29
2 49 ± 5 N·m
9.0 ± 1.0 N·m
4 45 ± 3 N·m 17
31 16
19 ± 3 N·m
14 3
30 34 9
88 ± 10 N·m 19
18 8.8 ± 1.0 N·m 49 ± 9 N·m
15
13
8 10
35 ± 6 N·m AK204445 AB
54 ± 5 N·m

1. Timing belt front upper cover <<D>> >>I<< 12. Crankshaft sprocket
2. Timing belt front lower cover >>I<< 13. Crankshaft sensing blade
3. Power steering pump bracket 14. Tensioner B
<<A>> >>M<< 4. Timing belt <<E>> >>H<< 15. Timing belt B
>>L<< 5. Tensioner pulley <<F>> >>G<< 16. Counterbalancer shaft sprocket
6. Tensioner arm >>F<< 17. Spacer
>>K<< 7. Auto-tensioner <<G>> >>E<< 18. Crankshaft sprocket B
8. Idler pulley 19. Crankshaft key
9. Crank angle sensor 20. Breather hose
<> >>J<< 10. Oil pump sprocket 21. Positive crankcase ventilation (PCV)
<<C>> >>I<< 11. Crankshaft bolt hose
ENGINE OVERHAUL
TIMING BELT
11B-15
Removal steps,-./01203456 CAUTION
22. PCV valve Never remove the timing belt with any piston at
23. PCV valve gasket the top dead center (TDC). If a piston is at TDC,
24. Oil filler cap
the exhaust valves of the cylinder are pushed by
>>D<< 25. Rocker cover
>>D<< the exhaust cams, compressing the valve
26. Rocker cover gasket A
27. Rocker cover gasket B springs. If the belt is removed under this condi-
>>C<< 28. Semicircular packing tion, the sprocket will be turned in the reverse
>>B<< 29. Engine support bracket direction by the force of the springs, incurring
<<H>> >>A<< 30. Camshaft sprocket bolt risk of injury.
31. Camshaft sprocket 2. Set the timing mark of the exhaust camshaft
32. Timing belt rear cover, right sprocket to a point about one tooth before the
33. Timing belt rear upper cover, left TDC of the No.1 cylinder piston on compression
34 Timing belt rear lower cover, left
stroke.
3. Loosen the lock nut of the tensioner pulley, then
remove the timing belt.
<<A>> TIMING BELT REMOVAL
<> OIL PUMP SPROCKET REMOVAL
Crosspoint
screwdriver
AK202756AB
1. If the timing belt is to be reused, make an arrow AK202825 AB
mark with something like chalk on the back of the

1. Remove the plug on the left side of cylinder block.
belt indicating the direction of rotation so it may be
2. Insert a crosspoint screwdriver (shank diameter 8
reinstalled in the same direction.
mm) to prevent the counterbalancer shaft from
Timing mark rotating.
3. Remove the flange bolt.
4. Remove the oil pump sprocket.
<<C>> CRANKSHAFT BOLT REMOVAL
AK202757 AB
MD998781
AK202738 AB
1. Hold the drive plate with the special tool Fly wheel
stopper(MD998781).
2. Remove the crankshaft bolt.
ENGINE OVERHAUL
11B-16 TIMING BELT
<<D>> CRANKSHAFT SPROCKET REMOVAL 1. Use the special tool Sprocket stopper
(MD998785) to prevent the counterbalancer shaft
sprocket from rotating.
2. Remove the counterbalancer shaft mounting bolt.
MD998778
<<G>> CRANKSHAFT SPROCKET B REMOVAL
MD998778
AK202741 AB
Use the special tool Crankshaft sprocket puller

(MD998778) if the sprocket is stuck and hard to
remove.
AK202740AB
<<E>> TIMING BELT B REMOVAL
Use the special tool Crankshaft sprocket puller
(MD998778) if the sprocket is stuck and hard to
remove.
<<H>> CAMSHAFT SPROCKET BOLT REMOVAL
AK202758AB
If the timing belt is to be reused, make an arrow mark

with something like chalk on the back of the timing
belt indicating the direction of rotation so it may be
reinstalled in the same direction.
AK202858AB
<<F>> COUNTERBALANCER SHAFT SPROCKET Remove the camshaft sprocket bolt while preventing
REMOVAL the camshaft from rotation using a wrench fitted on
the hexagonal portion of the camshaft.
MD998785
AK202739AB
ENGINE OVERHAUL
TIMING BELT
11B-17
INSTALLATION SERVICE POINTS >>C<< SEMICIRCULAR PACKING INSTALLATION
>>A<< CAMSHAFT SPROCKET BOLT INSTALLA- 1. Remove thoroughly the old sealant and FIPG
TION remaining on the semicircular packing, cylinder
head, and rocker cover.
AK202858AB
AK202860AB
2. Apply sealant to the surface indicated in the

drawing of the semicircular packing.
Specified sealant:
3M ATD No.8660 or equivalent
3. Install the semicircular packing on the cylinder
head.
10 mm
AK202859
Tighten the camshaft sprocket bolt to 88 % 10 N$m

while preventing the camshaft from rotation using a
wrench fitted on the hexagonal portion of the cam-
shaft.
10 mm
Semicircular
>>B<< ENGINE SUPPORT BRACKET packing
INSTALLATION Cylinder head AK202861 AB
4. Apply sealant to the area indicated in the drawing

of the semicircular packing and cylinder head.
Specified sealant:
>>D<< ROCKER COVER/ROCKER COVER

GASKET A INSTALLATION
Timing belt side
AK202743AB
1. Remove thoroughly the old sealant remaining on

the indicated bolt and in its hole.
2. Coat the bolt with sealant, then install and tighten
it.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
AK202862 AB
1. Apply beads of FIPG on the surfaces of the rocker

cover indicated in the drawing.
ENGINE OVERHAUL
11B-18 TIMING BELT
Specified sealant: >>F<< SPACER INSTALLATION

equivalent Spacer
Oil
2. Install the rocker cover gasket A on the rocker seal
cover before the FIPG hardens.
Timing belt side
Counter-
balancer
Chamfer shaft
AK202820 AB
CAUTION
If the spacer is opposite in direction to that
shown in the drawing when installed, it will dam-
AK202863 AB age the oil seal lip.
3. Apply beads of FIPG to the surfaces of the rocker 1. Smear slightly oil on the outer surface of the
cover indicated in the drawing. spacer that comes into contact with the oil seal.
Specified sealant: 2. Install the spacer with the chamfered end toward
Mitsubishi Genuine Part No.MD970389 or the oil seal.
equivalent
4. Install the rocker cover on the cylinder head >>G<< COUNTERBALANCER SHAFT SPROCKET
before the FIPG hardens. INSTALLATION
>>E<< CRANKSHAFT SPROCKET B

INSTALLATION
Sprocket "B" MD998785

Crankshaft
AK202739AB
1. Use the special tool Sprocket stopper

Degrease (MD998785) as shown in the drawing to prevent
Front case AK101651AC the counterbalancer shaft sprocket from rotating.
Clean and then degrease the crankshaft sprocket B 2. Tighten the sprocket mounting bolt to 45 % 3 N$m.
and the sprocket fitting surface of the crankshaft.
NOTE: Degreasing is necessary to prevent lack of
frictional coefficient between the mating surfaces.
ENGINE OVERHAUL
TIMING BELT
11B-19
>>H<< TIMING BELT B INSTALLATION 5. Make sure that the timing marks on the oil pump
case and those of the sprockets are all aligned
with each other.
Timing
marks 5 – 7 mm
Timing
marks
AK202920 AB
1. Align the timing marks on the crankshaft sprocket

AK202919 AB
B and counterbalancer shaft sprocket with the
corresponding timing marks on the oil pump case. 6. Push a central point of the timing belt B tension
2. Install the timing belt B on the crankshaft sprocket section lightly with an index to see if it deflects 5 "
B and counterbalancer shaft sprocket. There 7 mm.
should be no slack in the tension section of the
belt. >>I<< CRANKSHAFT BOLT/CRANKSHAFT
Tension section of belt
SPROCKET/CRANKSHAFT SENSING BLADE
Tensioner B
Timing
INSTALLATION
belt B
Crankshaft sensing blade
Crankshaft bolt Crankshaft
Clean
Tensioner B
center
Mounting bolt center AK202921 AB Washer
Chamfer Degrease
3. Make sure that the tensioner B center is Crankshaft sprocket
AK202838 AB
positioned as shown in the drawing relative to the
mounting bolt center. 1. Clean and then degrease the crankshaft sprocket,
sprocket fitting surface of the crankshaft, and
crankshaft sensing blade. Install the crankshaft
sprocket and crankshaft sensing blade on the
crankshaft.
2. Clean the bolt hole in the crankshaft, and then
washer.
3. Apply a necessary minimum amount of oil to the
threads and seating surface of the crankshaft bolt.
AK202922AB
4. Lift the tensioner B with fingers to move it in the

direction of the arrow until the tension section of
the timing belt becomes taut. While keeping the
tensioner B in this position, tighten its bolt.
NOTE: When the bolt is tightened, prevent the
tensioner B shaft from turning. If the shaft turns, MD998781
the belt will be overtightened.
AK202738 AB
ENGINE OVERHAUL
11B-20 TIMING BELT
4. Hold the drive plate using the special tool Fly

wheel stopper(MD998781).
5. Tighten the crankshaft bolt to a torque of 167 N$m.
>>J<< OIL PUMP SPROCKET INSTALLATION
AK202767
2. Install the auto-tensioner in position. Leave the

wire installed until the auto-tensioner is
completely installed.
Crosspoint screwdriver
AK202732 AB
>>L<< TENSIONER PULLEY INSTALLATION
1. Prevent the counterbalancer shaft from rotating in
the same method as in the removal procedure.
2. Install the oil pump sprocket.
3. Install the oil pump sprocket.
4. Tighten the flange nut to 54 % 5 N$m.
>>K<< AUTO-TENSIONER INSTALLATION

Tensioner
pulley holes
A
AK202759AB
B
Install the tensioner pulley with its holes aligned as
shown in the drawing.
>>M<< TIMING BELT INSTALLATION
Timing marks
AK202768 AB
1. If the auto-tensioner rod remains in its fully

extended position, reset it to the retracted position
as follows:
(1) Clamp the auto-tensioner in a vise at right
angles to the jaws.
(2) Push in the rod little by little with the vise until
the set hole A in the rod is aligned with the set AK202903 AB
hole B in the cylinder. 1. Bring the timing mark on the exhaust camshaft
(3) Insert a piece of wire (1.4 mm diameter) into sprocket to a point one sprocket tooth away from
the set holes.
the timing mark on the rocker cover in the
(4) Remove the auto-tensioner from the vise. counterclockwise direction.
NOTE: If the timing marks were aligned, the
exhaust camshaft would be turned counterclock-
wise by one sprocket tooth and stay there by the
force of the valve springs.
ENGINE OVERHAUL
TIMING BELT
11B-21
(2) Insert a crosspoint screwdriver with a shank
diameter of 8 mm through the plug hole. If it
Timing marks
can be inserted 60 mm or more, the sprocket
is in the correct phase. If the insertion depth is
up to 20 " 25 mm, the screwdriver is blocked
by the counterbalancer shaft. Then turn the oil
pump sprocket one turn and realign the timing
marks. Then check that the screwdriver can be
inserted 60 mm or more. Keep the screwdriver
AK202904 AB
inserted until installation of timing belt is
finished.
2. Align the timing mark on the intake camshaft
sprocket with that on the rocker cover.
NOTE: The intake camshaft will be turned slightly
clockwise from where the timing marks are
aligned by the force of the valve springs and stay
there.
(3) Turn the oil pump sprocket counterclockwise

by one sprocket tooth.
AK202760
3. Bring the timing mark on the crankshaft sprocket

to a point one sprocket tooth away from the
mating timing mark in the counterclockwise
direction like in the operation with the exhaust
camshaft sprocket.
5. Install the timing belt on the exhaust camshaft

sprocket, and hold it in place with a paper clip at
the point indicated in the drawing.
4. Align the timing mark on the oil pump sprocket

with that on the cylinder block.
(1) Remove the plug from the cylinder block.
ENGINE OVERHAUL
11B-26 FUEL AND EMISSION PARTS
INSTALLATION SERVICE POINTS 3. Check that the fuel pressure regulator turns
>>A<< INJECTOR INSTALLATION smoothly. If it does not, the O-ring may be
1. Apply a thin coat of engine oil to a new O-ring. jamming, so remove the fuel pressure regulator
and check the O-ring for damage. If the O-ring is
CAUTION intact, insert it into the delivery pipe and check it
Prevent engine oil from getting into the delivery for smooth rotation again.
pipe.
2. Insert the injector into the delivery pipe while >>C<< THROTTLE BODY GASKET
turning it in both directions carefully not to INSTALLATION
damage the O-ring.
3. Check that the injector turns smoothly. If it does
Tab
not, the O-ring may be jamming, so remove the
injector and check the O-ring for damage. If the O-
ring is intact, insert the injector into the delivery
pipe and check it for smooth rotation again.
>>B<< FUEL PRESSURE REGULATOR

INSTALLATION
1. Apply a thin coat of engine oil to a new O-ring.
AK202905 AB
CAUTION Install the throttle body gasket with its tab located as
Prevent engine oil from getting into the delivery
pipe.
2. Insert the fuel pressure regulator into the delivery
pipe while turning it in both directions carefully not
to damage the O-ring.
ENGINE OVERHAUL
INTAKE MANIFOLD
11B-27
INTAKE MANIFOLD
M1113002700286
36 ± 6 N·m
19 ± 3 N·m
2 4
3
36 ± 6 N·m
20 ± 2 N·m
31 ± 3 N·m
AK204438 AB

>>A<< 1. Intake manifold stay >>A<< INTAKE MANIFOLD STAY INSTALLATION
2. Intake manifold
3. Intake manifold gasket
4. Engine hanger
Intake manifold
stay
AK202865 AB
Tighten the bolts to the specified torque 31 % 3 N$m

on both ends after making sure that the stay is in
close contact with the bosses on the intake manifold
and cylinder block.
ENGINE OVERHAUL
11B-28 EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1113004900383
14 ± 1 N·m
44 ± 5 N·m
29 ± 3 N·m
1
14 ± 1 N·m
2
6
4
5
49 ± 5 N·m
3 35 ± 6 N·m
44 ± 5 N·m
AK204437 AB

1. Oxygen sensor 4. Engine hanger
2. Exhaust manifold cover 5. Exhaust manifold
3. Exhaust manifold bracket 6. Exhaust manifold gasket
ENGINE OVERHAUL
11B-29
M1113017900220
13 ± 2 N·m
7
9 13 ± 2 N·m
13 ± 2 N·m
6
1
23 ± 4 N·m
2
11 5
10 4
8
10.8 ± 1.0 N·m
29 ± 10 N·m
14
23 ± 2 N·m
13
12
14 ± 1 N·m
AK204436AB
Removal sequence INSTALLATION SERVICE POINTS

1. Water hose >>A<< O-RING/WATER INLET PIPE INSTALLA-
2. Water hose TION
>>E<< 3. Coolant temperature sensor
>>D<< 4. Coolant temperature gauge unit CAUTION
5. Water inlet fitting ' Never allow any oil or grease to touch the O-
6. Thermostat rings.
>>C<< 7. Water outlet fitting ' Clamp the water inlet pipe only after installa-
>>B<< 8. Thermostat housing tion of the thermostat case.
>>A<< 9. O-ring Replace the O-rings at both ends of the water inlet
>>A<< 10. Water inlet pipe pipe with new ones. Insert the O-rings into the water
>>A<< 11. O-ring pump and thermostat housing after wetting their
12. Water pump peripheries with water.
13. Water pump gasket
14. Knock sensor
ENGINE OVERHAUL
11B-30 WATER PUMP AND WATER HOSE
>>B<< THERMOSTAT HOUSING INSTALLATION >>D<< COOLANT TEMPERATURE GAUGE UNIT

INSTALLATION
AK202918AB
AK202800AB
1. Remove all old FIPG remaining on the thermostat
housing and cylinder head. 1. Remove all old sealant remaining on the threaded
2. Apply a 2.7 % 0.3 mm diameter bead of FIPG on hole in the coolant temperature gauge unit and
the indicated surface of the thermostat housing. the thermostat housing.
Specified sealant: NOTE: A new coolant temperature gauge unit is
Mitsubishi Genuine Part No.MD970389 or coated with sealant. It does not require coating
equivalent with sealant before installation.
2. Apply sealant to the indicated threads of the
>>C<< WATER OUTLET FITTING INSTALLATION coolant temperature gauge unit.
Specified sealant:
3M Nut Locking Part No.4171 or equivalent
>>E<< COOLANT TEMPERATURE SENSOR

INSTALLATION
AK202755AB
1. Remove all old FIPG remaining on the water

outlet fitting and thermostat housing.
2. Apply a 2.7 % 0.3 mm diameter bead of FIPG to
the indicated surface of the water outlet fitting.
AK202799AB
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or CAUTION
equivalent When using a tool, avoid letting it touch the con-
nector portion which is made of plastic.
1. Remove all old sealant remaining on the threads
of the coolant temperature sensor and in the
threaded hole in the thermostat housing.
2. Apply sealant to the coolant temperature sensor’s
threads indicated in the drawing.
Specified sealant:
3M ATD Part No.8660 or equivalent
ENGINE OVERHAUL
11B-31
M1113005400455
10 ± 2 N·m
3
8 N4
11
6
14
9
13
20 ± 1 N·m
12 14 ± 1 N·m
2N
10 1
22 ± 4 N·m
15 5
8.8 ± 1.0 N·m
11 ± 1 N·m
18
N7
16
17
Apply engine oil

to all moving
parts before
installation.
AK202894 AB

1. Camshaft position sensor >>C<< 10. Bearing cap, front
2. O-ring >>C<< 11. Bearing cap No.5
3. Cover >>C<< 12. Bearing cap No.2
4. Gasket >>C<< 13. Bearing cap No.3
>>F<< 5. Camshaft position sensing cylinder >>C<< 14. Bearing cap No.4
>>E<< 6. Camshaft position sensor support >>B<< 15. Camshaft
>>D<< 7. Camshaft oil seal 16. Rocker arm
>>C<< 8. Bearing cap, rear right <<A>> >>A<< 17. Lash adjuster
>>C<< 9. Bearing cap, rear left 18. Oil delivery body
ENGINE OVERHAUL
11B-32 ROCKER ARMS AND CAMSHAFT
SERVICE POINTS FOR REMOVAL 1. Set each camshaft with its dowel pin at the top.
<<A>> LASH ADJUSTER REMOVAL
CAUTION
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
7811B!((, the instruction under LASH ADJUSTER Cap number
in the INSPECTION section.) Intake/exhaust
identification
letter
>>A<< LASH ADJUSTER INSTALLATION
AK202870 AB
CAUTION
When reusing a lash adjuster, it must be washed 2. The bearing caps No. 2 to 5 are identical in shape
and inspected before installation. (Refer to for both intake and exhaust camshafts. Check the
7811B!((, the instruction under LASH ADJUSTER identification mark on each cap before installation.
in the INSPECTION section.) Identification mark (stamped on front and
Install the lash adjuster into the rocker arm, being Nos. 2 " 5 bearing caps)
careful not to spill the diesel fuel it contains. I: intake camshaft
E: exhaust camshaft
>>B<< CAMSHAFT INSTALLATION 3. Remove completely sealant remaining on the
bearing caps and cylinder head.
Timing belt side
Slit
Exhaust camshaft
AK202869 AB
AK202871AB
CAUTION
' Do not confuse the intake camshaft with the 4. Apply sealant to the surfaces indicated in the
exhaust camshaft. drawing.
' The exhaust camshaft has a 4 mm wide slit at
Specified sealant:
the rear end.
>>C<< BEARING CAP INSTALLATION 5. Install each bearing cap and tighten its bolts in
two or three passes.
Dowel pin 6. Finally tighten the bolts to 20 % 1 N$m.
7. Check that the rocker arms are correctly installed.
NOTE: Wipe off any squeezed out sealant com-
pletely.
AK203979 AC
ENGINE OVERHAUL
11B-33
>>D<< CAMSHAFT OIL SEAL INSTALLATION 1. Turn the exhaust camshaft to the No.1 cylinder top
dead center position.
MD998713 NOTE: The camshaft will slightly turn counter-
clockwise by the force of the exhaust valve spring.
2. Install the camshaft position sensing cylinder with
the smaller vane located as shown in the drawing.
INSPECTION
M1113005500388
CAMSHAFT
AK202872 AB
Use the special tool Camshaft oil seal installer

(MD998713) to drive each oil seal into position in the
cylinder head.
>>E<< CAMSHAFT POSITION SENSOR

SUPPORT INSTALLATION
AK202797AB
Measure the cam height (nose-to-heel diameter).

If any cam is worn beyond the limit, replace the cam-
shaft.
Standard value: 34.91 mm
Limit: 34.41 mm
AK202754AB LASH ADJUSTERS

1. Remove completely the FIPG remaining on the CAUTION
camshaft position sensor support and cylinder ' The lash adjuster is a precision-engineered
head. component. Do not allow dust or other foreign
2. Apply a 3 % 1 mm diameter bead of FIPG to the matter to enter it.
indicated surface of the camshaft position sensor ' Do not disassemble lash adjusters.
support. ' Use only non-contaminated diesel fuel to
clean the lash adjuster.
Specified sealant:
equivalent For rough For finish For diesel
cleaning cleaning fuel filling
>>F<< CAMSHAFT POSITION SENSING

CYLINDER INSTALLATION
Smaller vane
A B C
AK202836 AB
1. Prepare three containers and approximately five

liters of diesel fuel. Pour into each container the
diesel fuel in an amount enough for a lash
Cam position adjuster placed in the container in its upright
sensor position to completely submerge.
AK202844 AB
ENGINE OVERHAUL
11B-34 ROCKER ARMS AND CAMSHAFT
CAUTION
The hole in the side of the lash adjuster must be
directed toward the inside of container A. Never
direct it against any person.
4. Take the lash adjuster out of the container, then
move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
chamber.
AK202837
2. Place the lash adjuster in container A and wash

its outside surface.
NOTE: Use a nylon brush if there are hard-to-
remove deposits.
Diesel fuel
MD998442
AK202839 AB
CAUTION
The steel ball spring of the lash adjuster is
extremely weak. The lash adjuster’s functionality
Diesel fuel may be badly affected if the special tool is
MD998442 inserted too strongly.
AK202839 AB 5. Soak the lash adjuster in the diesel fuel in
container B. Move the plunger in and out 5 " 10
CAUTION times by gently pushing the internal steel ball
The steel ball spring of the lash adjuster is
using the special tool Air bleed wire (MD998442)
extremely weak. The lash adjuster’s functionality
until the plunger moves smoothly to wash the lash
may be badly affected if the special tool is
adjuster’s pressure chamber.
inserted too strongly.
3. While gently pushing the internal steel ball using
the special tool Air bleed wire (MD998442), move
the plunger in and out 5 " 10 times to eliminate
stiffness in the plunger and expel contaminated
oil.
NOTE: The plunger must be free from jamming
and any other abnormalities. If a defect is found in MD998442
plunger operation, replace the lash adjuster.
Diesel fuel
AK202840 AB
CAUTION
The hole in the side of the lash adjuster must be
directed toward the inside of container B. Never
direct it against any person.
6. Take the lash adjuster out of the container, then
MD998442 move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
Diesel fuel
AK202840 AB chamber.
ENGINE OVERHAUL
11B-35
8. Place the lash adjuster upright with the plunger at
the top. Push the plunger firmly until it makes a full
stroke, then return the plunger slowly and release
the hold of the steel ball to allow the pressure
chamber to be filled with diesel fuel.
Diesel fuel
MD998442
AK202841 AB
CAUTION
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could
enter the pressure chamber when the chamber is
AK202843
filled with diesel fuel.
7. Soak the lash adjuster in the diesel fuel in 9. Take the lash adjuster out of the container, place it
container C. Gently push the internal steel ball upright with the plunger at the top, and push the
using the special tool Air bleed wire (MD998442). plunger firmly. The plunger must not move at all.
NOTE: If the lash adjuster contracts, perform the
operations 7. through 9. again. Replace the lash
adjuster if it still contracts even after the pressure
chamber has completely been filled with diesel
fuel (air has been bled).
10.Keep the serviced lash adjusters in their upright
positions to prevent diesel fuel from spilling out.
MD998442 Diesel fuel Protect them from dust or other foreign matter.
Install the lash adjusters onto the engine as soon
AK202842 AB
as possible.
ENGINE OVERHAUL
11B-36 CYLINDER HEAD AND VALVES

M1113006900389
78 ± 2 N·m → loosen completely

→ 20 ± 2 N·m → 90˚ + 90˚
1
2
8
9
4 10
5 20 14 N
6 15
12 N 17 N
13
16 N
19 N
18 N 11
3N
Apply engine oil

to all moving
parts before
installation.
AK202895 AB

<<A>> >>D<< 1. Cylinder head bolt 7. Intake valve
2. Cylinder head assembly <> >>C<< 8. Retainer lock
3. Cylinder head gasket 9. Valve spring retainer
<> >>C<< 4. Retainer lock >>B<< 10. Valve spring
5. Valve spring retainer 11. Exhaust valve
>>B<< 6. Valve spring >>A<< 12. Valve stem seal
13. Valve spring seat
ENGINE OVERHAUL
11B-37
Removal steps,-./01203456 INSTALLATION SERVICE POINTS
>>A<< 14. Valve stem seal
>>A<< VALVE STEM SEAL INSTALLATION
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head
MD998737
<<A>> CYLINDER HEAD BOLT REMOVAL
AK202874 AB
CAUTION
MB991654 The special tool must always be used when
installing the valve stem seal. Improper installa-
tion could result in oil leaks past the valve guide.
1. Install the valve spring seat.
2. Install the valve.
AK202723 AB
3. Apply a thin coat of engine oil to a new valve stem
seal.
Use the special tool Cylinder head bolt wrench 4. Use the special tool Valve stem seal installer
(MB991654) to loosen the cylinder head bolts. (MD998737) to install the stem seal on the valve
guide. Use the stem of the valve to guide the stem
<> RETAINER LOCK REMOVAL seal.
MD998772 Intake valve stem seal
Colour: Gray
Exhaust valve stem seal
Colour: Grayish green
AK202742 AB AK202875 AB
MD998735
NOTE: Do not confuse the stem seals for intake
valves with those for exhaust valves.
>>B<< VALVE SPRING INSTALLATION
Spring
retainer
Painted
end
AK202873 AB Stem
seal
Compress the valve spring using the special tool
Valve spring compressor (MD998772), then remove Spring
the retainer lock. seat
NOTE: Store removed valves, springs and other AK202551AB
parts, after putting to each of them a tag that identi- Install each valve spring with the painted end toward
fies its cylinder No. or installation location. the rocker arm.
ENGINE OVERHAUL
>>C<< RETAINER LOCK INSTALLATION 2. Apply engine oil to the threads and washer of the
bolt.
MD998772
NOTE: Use the special tool Cylinder head bolt
wrench (MB991654) to tighten the bolts.
Timing belt side
8 6 1 3 9
AK202742 AB
10 4 2 5 7
MD998735
AK202806 AB
3. Tighten the bolts to 78 % 2 N$m in the indicated

sequence.
4. Loosen all the bolts completely.
5. Tighten the bolts again to a torque of 20 % 2 N$m
in the indicated sequence.
AK202873 AB
Compress the valve spring using the special tool

Valve spring compressor (MD998772), then install 90˚
the retainer lock.
>>D<< CYLINDER HEAD BOLT INSTALLATION

90˚
Paint marks
AK202720 AB
CAUTION
' If the tightening angle is smaller than 90#,
Nominal length proper fastening performance could not be
assured. Be sure to respect that angle.
' If the bolt is tightened to an angle greater than
the specified angle, loosen the bolt com-
AK202750 AB
pletely and then retighten it beginning with
the first step.
6. Make paint marks on each bolt’s head and on the
cylinder head.
7. Turn the bolts 90# in the tightening direction and in
MB991654
the indicated sequence.
8. Give another 90# turn in the tightening direction to
each bolt, making sure that the paint mark on the
bolt head and that on the cylinder head are on the
same line.
AK202723 AB
INSPECTION
1. When reusing a cylinder head bolt, check that its M1113007000378
nominal length (shank length) is not greater than CYLINDER HEAD
the limit. If the limit is exceeded, replace the bolt. 1. Before cleaning the cylinder head, check it for
Limit: 99.4 mm traces of water and gas leakage and for cracks
and any other damage.
ENGINE OVERHAUL
11B-39
2. Thoroughly remove oils, scale, sealants, carbon Standard values:
and other contamination. Clean the oil passages, Intake 1.0 mm
then check using compressed air that they are not Exhaust 1.5 mm
blocked.
Limits:
Intake 0.5 mm
Exhaust 1.0 mm
AK202724
Total length
CAUTION
The thickness of the metal that can be removed AK202876 AB
by grinding from both the cylinder head and the
mating cylinder block is limited to 0.2 mm in 3. Measure the total length of the valve.
total. Replace the valve if the length is less than the
3. Check the cylinder head gasket surface for warp limit.
using a straightedge and thickness gauge. Standard values:
If the surface is warped beyond the limit, grind the Intake 109.50 mm
surface for rectification. Exhaust 109.70 mm
Gasket surface warp Limits:
Standard value: Less than 0.05 mm Intake 109.00 mm
Limit: 0.2 mm Exhaust 109.20 mm
Grinding limit: 0.2 mm
Cylinder head height (standard value for new VALVE SPRINGS
part):
131.9 " 132.1 mm Out of square
VALVES
1. Check the valve face for correct contact with the
seat. Reface the valve if the contact is partial or Free height
one sided.
AK202706 AB
Contact 1. Measure the free height of the spring.

(Should be at
center of face) Replace the spring if its height is smaller than the
Margin limit.
Limit: 46.0 mm
AK202729 AB 2. Measure the squareness of the spring.
2. Measure the margin. Replace the spring if it is out of square beyond the
limit.
Replace the valve if its margin is smaller than the
limit. Standard value: 1.5# or smaller
Limit: 4#
ENGINE OVERHAUL
VALVE GUIDE With the valve installed in position and its face
pressed against the valve seat, measure the valve
stem projection (distance between the the valve stem
end and spring seating surface). If the measurement
exceeds the limit, replace the valve seat.
Standard values:
valve
guide Intake 49.20 mm
Exhaust 48.40 mm
Limits:
Stem diameter Intake 49.70 mm
Guide inside diameter AK202709 AB
Exhaust 48.90 mm
Measure the valve guide inside diameter and valve
stem diameter to calculate the clearance between VALVE SEAT RECONDITIONING
the valve guide and valve stem. 1. Before reconditioning the valve seat, check the
If the limit is exceeded, replace the valve guide or clearance between the valve guide and valve
valve, or both. stem and, if necessary, replace the valve guide.
Standard values:
Intake 0.02 " 0.05 mm 0.9 – 1.3mm 0.9 – 1.3 mm
Exhaust 0.05 " 0.09 mm
65˚ 65˚
Limits:
Intake 0.10 mm
Exhaust 0.15 mm
15˚ 25˚
VALVE SEATS 44˚
Valve stem AK202850 AB
end
2. Resurface the valve seat to the indicated width
Valve stem
projection and angles.
3. After resurfacing, lap the valve and valve seat
using lapping compound.
Spring
seating
surface
AK202814 AB
ENGINE OVERHAUL
11B-41
VALVE SEAT REPLACEMENT 4. Resurface the valve seat. See the VALVE SEAT
RECONDITIONING section.
0.5 – 1 mm
VALVE GUIDE REPLACEMENT
1. Force out the valve guide toward the cylinder
block using a press.
Cut
CAUTION
0.5 – 1 mm Do not use a replacement valve guide of the
same size as the removed one.
2. Machine the valve guide hole in the cylinder head
AK202707 AB to the size matched to the selected oversize valve
guide.
1. Cut inside of the valve seat to be replaced until its Valve guide hole diameters
wall becomes thin enough for removal, then 0.05 oversize: 12.05 " 12.07 mm
remove the valve seat. 0.25 oversize: 12.25 " 12.27 mm
0.50 oversize: 12.50 " 12.52 mm
Valve seat
height
Oversize hole diameter
AK202708 AB
19.2 – 19.8 mm
2. Rebore the valve seat hole in the cylinder head to AK202877 AB
a diameter matched to the diameter of the
3. Press-fit the valve guide until it remains protruded
selected oversize valve seat.
above the cylinder head by the amount indicated
Intake valve seat hole diameters: in the drawing.
0.3 oversize: 35.30 " 35.33 mm
NOTE: .
0.6 oversize: 35.60 " 35.63 mm
1. Press the valve guide from above the cylinder
Exhaust valve seat hole diameters: head.
0.3 oversize: 33.30 " 33.33 mm 2. The valve guides for the intake valves are dif-
0.6 oversize: 33.60 " 33.63 mm ferent in length from those for the exhaust
3. Before fitting the valve seat, cool it in liquid valves (45.5 mm for intake valves; 50.5 mm for
nitrogen to prevent damage to its hole in the exhaust valves)
cylinder head due to interference. 4. After installing the valve guide, insert a new valve
in it to check for smooth movement.
ENGINE OVERHAUL
11B-42 OIL PAN AND OIL PUMP

M1113008100301
19 ± 3 N·m 32
31
Apply engine oil 10
to all moving 28 30
parts before
installtion.
21
23 ± 3 N·m
10 ± 2 N·m
29
20 22
23 ± 3 N·m
23 24 8 9
16 7
19 ± 3 N·m 19 ± 3 N·m
15 26
17 ± 1 N·m
25
19 27
14 4
17 18 23 ± 3 N·m
13
36 ± 3 N·m 9.0 ± 3.0 N·m
11 23 ± 3 N·m
39 ± 5 N·m
1
12 2
3
44 ± 5 N·m
5
6
9.0 ± 3.0 N·m 22 ± 4 N·m
9.0 ± 3.0 N·m
39 ± 5 N·m
2
1
9.0 ± 3.0 N·m
AK202676 AB
9.0 ± 3.0 N·m
1. Drain plug >>K<< 11. Relief plug
>>O<< 2. Drain plug gasket 12.Gasket
>>N<< 3. Oil filter 13.Relief spring
4. Transmission stay <4WD> 14.Relief plunger
<<A>> >>M<< 5. Oil pan <2WD> 15.Oil filter bracket
<> >>L<< 6. Oil pan lower section <4WD> 16.Gasket
<<C>> >>L<< 7. Oil pan upper section <4WD> <<D>> >>J<< 17.Plug
8. Oil screen 18.O-ring
9. Gasket <<E>> >>I<< 19.Flange bolt
10.Oil pressure switch >>H<< 20.Front case
ENGINE OVERHAUL
11B-43
Removal steps,-./01203456 <<C>> OIL PAN UPPER SECTION REMOVAL
21.Gasket <4WD>
22.Oil pump cover
>>G<< 23.Oil pump driven gear A
>>G<< 24.Oil pump drive gear
>>F<< 25.Crankshaft front oil seal
>>E<< 26.Counterbalancer shaft oil seal
>>D<< 27.Oil pump oil seal
28.Counterbalancer shaft, right
29.Counterbalancer shaft, left
<<F>> >>C<< 30.Counterbalancer shaft front bearing
<<G>> >>B<< 31.Counterbalancer shaft rear bearing,
right A
AK202692 AB
<<G>> >>A<< 32.Counterbalancer shaft rear bearing,
left Screw bolts into the bolt holes A shown in the draw-
ing (holes at both ends) to remove the oil pan.
REMOVAL SERVICE POINTS CAUTION
<<A>> OIL PAN REMOVAL <2WD> Do not use a scraper or the special tool to
remove the oil pan.
MD998727
<<D>> PLUG REMOVAL
MD998162
AK202574 AB
1. Remove the oil pan bolts. MD998783

2. Insert the special tool Oil pen remover AK202585 AB
(MD998727) into the joint between the cylinder
block and oil pan by tapping the tool with a Fit the teeth of the special tool in notches of the plug
hammer. as shown in the drawing and support the tool with the
special tool to loosen the plug.
3. Remove the oil pan by tapping an edge of the
' Plug wrench (MD998162)
special tool Oil pen remover (MD998727) with a
' Plug wrench retainer (MD998783)
hammer to move it sideways.
<<E>> FLANGE BOLT REMOVAL

<> OIL PAN LOWER SECTION REMOVAL
<4WD>
Remove the oil pan by tapping it through a piece of
wood applied to a side with a plastic hammer.
CAUTION
Do not use a scraper or the special tool to
remove the oil pan.
Plug
Crosspoint
screwdriver
AK202586 AB
1. Remove the plug on the left side of the cylinder

block. Insert a cross point screwdriver (shank
diameter 8 mm) into the plug hole more than 60
mm to prevent the left counterbalancer shaft from
rotating.
ENGINE OVERHAUL
2. When removing the rear bearing of the left

counterbalancer shaft, install the special tool
Silent shaft bearing installer stopper (MB991603)
on the front of the cylinder block and use a special
tool Silent shaft bearing puller (MD998372) to pull
out the bearing.

>>A<< LEFT COUNTERBALANCER SHAFT REAR
AK202642 BEARING INSTALLATION
2. Loosen and remove the flange bolt. MB991603
<<F>> COUNTERBALANCER SHAFT FRONT

BEARING REMOVAL
MD998705
AK202548 AB
1. Install the special tool Silent shaft bearing installer

Front stopper (MB991603) on the cylinder block.
bearing
MD998371
AK202633 AB
MB991603
CAUTION MD998705
Remove the front bearing first. Otherwise, the
special tool cannot be used.
Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
front bearing from the cylinder block. Rear bearing
AK202635 AB
<<G>> COUNTERBALANCER SHAFT REAR
BEARING REMOVAL 2. Set the rear bearing on the special tool Silent
1. Use the special tool Silent shaft bearing puller shaft bearing installer (MD998705).
(MD998371) to remove the counterbalancer shaft NOTE: The left counterbalancer shaft rear bear-
rear bearings from the cylinder block. ing has no oil hole.
3. Force the rear bearing into the cylinder block by
MB991603
sticking the special tool.
MD998372
AK202634 AB
ENGINE OVERHAUL
11B-45
>>B<< RIGHT COUNTERBALANCER SHAFT
REAR BEARING INSTALLATION MD998705
Guide pin
AK202581 AB
AK202579 AB
>>C<< COUNTERBALANCER SHAFT FRONT
1. Install the guide pin on the cylinder block. BEARING INSTALLATION
Rear bearing (Right)

Ratchet ball Oil
hole
Tool element for

rear bearing
installation
AK202549 AB AK202582 AB
2. Set the bearing on the special tool Silent shaft 1. Detach from the special tool Silent shaft bearing
bearing installer (MD998705) with its oil hole on installer (MD998705) its element for rear bearing
the ratchet ball. installation.
MD998705
Guide pin
Guide pin
AK202580 AB AK202579 AB
3. Insert the special tool Silent shaft bearing installer 2. Install the guide pin on the cylinder block.
(MD998705) while passing the guide pin through
Front bearing
its hole and force the bearing into position by
striking the tool. Ratchet ball Oil
hole
AK202549 AC
3. Set the bearing on the special tool Silent shaft

bearing installer (MD998705) with its oil hole on
the ratchet ball.
ENGINE OVERHAUL
>>E<< COUNTERBALANCER SHAFT OIL SEAL

INSTALLATION
MD998705
Socket wrench
Oil seal Front case
Guide pin
AK202580 AB
4. Insert the special tool Silent shaft bearing installer AK202646 AB

(MD998705) into the cylinder block while passing
the guide pin through its hole and force the Use an appropriate socket wrench to install the coun-
bearing into position by striking the tool. terbalancer shaft oil seal.
>>F<< CRANKSHAFT OIL SEAL INSTALLATION
MD998375
Oil seal
Front case
AK202583AB
AK202645 AB
>>D<< OIL PUMP OIL SEAL INSTALLATION
Use the special tool Crankshaft front oil seal installer
(MD998375) to install the crankshaft oil seal.
Socket
Oil seal wrench >>G<< OIL PUMP DRIVEN GEAR/OIL PUMP
DRIVE GEAR INSTALLATION
Front case
Alignment
marks
AK202639 AB
Use an appropriate socket wrench to install the oil

pump oil seal.
AK202660 AB
Apply engine oil generously to the gears and line up

the alignment marks.
ENGINE OVERHAUL
11B-47
>>H<< FRONT CASE INSTALLATION 1. Insert a correspond screwdriver (shank diameter
8 mm) into the hole in the left side of the cylinder
Counterbalancer
shaft, left block to prevent the counterbalancer shaft from
rotating.
Counterbalancer
shaft, right
MD998285
AK202577 AB
1. Install the special tool crankshaft front oil seal

guide (MD998258) on the front end of crankshaft
AK202642
and apply a thin coat of engine oil to the outer
surface of the special tool. Be sure to use the 2. Tighten the flange bolts.
special tool when the front case is fitted with an oil
seal. >>J<< PLUG INSTALLATION
2. Install the front case on the cylinder block with a 1. Install a new O-ring on the front case.
new front case gasket in between and temporarily
tighten all the flange bolts except those that are
MD998162
used for tightening the filter bracket.
3. Install the oil filter bracket on the front case with
the oil filter bracket gasket in between and
temporarily tighten the washer-assembled bolts.
MD998783
AK202585 AB
2. Use the special tool to tighten the plug to the

specified torque.
MD998285 ' Plug wrench (MD998162)
' Plug wrench retainer (MD998783)
AK202656 AB
>>K<< OIL PRESSURE SWITCH INSTALLATION
4. Tighten all the bolts to the specified torques.
>>I<< FLANGE BOLT INSTALLATION
AK202625AB
Crosspoint CAUTION
screwdriver
AK202641 AB Be careful not to block the oil passage with seal-
ant.
1. Apply sealant to the threaded portion.
Specified Sealant:
3M ATD Part No.8660 or equivalent
ENGINE OVERHAUL
Specified sealant:
MD998054
equivalent
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the center of the groove.
M6 × 16
AK204037AD
2. Tighten the oil pressure switch together with the

cylinder block by the specified torque using of the
special tool Oil pressure switch wrench
MD998054.
AK202685 AB
Tightening torque: 19 % 3 N$m
3. Install the shorter bolts in the locations indicated
in the drawing.
>>L<< OIL PAN UPPER SECTION/OIL PAN
LOWER SECTION INSTALLATION <4WD> CAUTION
Do not apply FIPG over remaining old FIPG.
CAUTION
Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage.
Doing so could result in oil leakage. 4. Thoroughly remove old FIPG from the gasket
1. Clean the gasket surfaces of the cylinder block surfaces of the oil pan upper and lower sections.
and oil pan.
Timing belt side
Bolt hole
Timing belt side area Bolt hole
area
Grooved area AK202686 AB

Grooved
area
AK202688 AB
CAUTION
Too much FIPG will squeeze out, blocking cool-
CAUTION
Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could
ant or oil passages, while too thin a bead could result in leakage.
result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan.
ENGINE OVERHAUL
11B-49
5. Apply a 4 mm diameter bead of FIPG to the flange Specified sealant:

surface all around the oil pan. Mitsubishi Genuine Part No.MD970389 or
Specified sealant: equivalent
Mitsubishi Genuine Part No.MD970389 or NOTE: In the grooved areas on the oil pan flange,
equivalent apply FIPG bead along the center of the groove.
NOTE: In the grooved areas on the oil pan flange,
Timing belt side
apply FIPG bead along the center of the groove.
Timing belt side M6 × 8
9 8
5 4 1
12 11
3
2 6 AK202693 AB
7 10
3. Install the shorter bolts in the locations indicated
AK202687 AB
in the drawing.
6. Install the oil pan lower section by tightening the
bolts in the indicated sequence. >>N<< OIL FILTER INSTALLATION
>>M<< OIL PAN INSTALLATION <2WD> Bracket side

CAUTION
Do not apply FIPG over remaining old FIPG.
Doing so could result in oil leakage.
Engine oil
1. Thoroughly remove old FIPG from the gasket
surfaces of the cylinder block and oil pan.
Timing belt side
AK202556 AB
Bolt hole 1. Clean the installation surface of the filter bracket.

area
2. Apply engine oil to the o-ring of the oil filter.
3. Install the oil filter to the bracket and tighten it to
Tightening torque: 14 % 2 N$m
Grooved
area 4. If no torque wrench can be used for tightening,
AK202694 AB
use the following procedure:
CAUTION (1) Screw in the oil filter until its o-ring contacts
Too much FIPG will squeeze out, blocking cool- the oil filter bracket.
ant or oil passages, while too thin a bead could (2) Tighten the oil filter 3/4 turn.
result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan.
ENGINE OVERHAUL
>>O<< DRAIN PLUG GASKET INSTALLATION
Drain plug
AK202835AB
Oil pan 2. Check the journals for seizure, damage and

Gasket defective contact with bearings.
Oil pan
side If any of these faults is found, replace the
counterbalance shaft, bearings and/or oil pump
case assembly.
OIL PUMP
AK202603AB
CAUTION
Installing the gasket with the wrong side facing
the oil pan will result in oil leakage.
Replace the drain plug gasket with a new one. Install
it with the side indicated in the drawing toward the oil
AK202831
pan.
1. Install the drive and driven gears in the oil pump
INSPECTION case.
M1113008200212
COUNTERBALANCE SHAFTS 2. Measure the gear side clearance using a straight
1. Check that the oil holes are not blocked. edge and thickness gauge.
Clean if necessary. Standard values:
Drive gear 0.08 " 0.14 mm
Driven gear 0.06 " 0.12 mm
ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-51
M1113008400528
6
Apply engine oil to
7
all moving parts 8
before
installation.
10
9 4
12
11
2
20 ± 2 N·m + 90˚ to 94˚
1
AK202896 AB

>>G<< 1. Connecting rod cap nut >>C<< 7. Piston ring No. 2
<<A>> >>F<< 2. Connecting rod cap >>B<< 8. Oil ring
>>E<< 3. Connecting rod bearing <> >>A<< 9. Piston pin
>>D<< 4. Piston and connecting rod assembly 10. Piston
5. Connecting rod bearing 11. Connecting rod
>>C<< 6. Piston ring No. 1 12. Bolt
ENGINE OVERHAUL
11B-52 PISTON AND CONNECTING ROD

<<A>> CONNECTING ROD CAP REMOVAL
Push rod
Cylinder
number
Front mark
Front
mark
AK202812 AB Guide C
Mark the cylinder number on the side of the connect-

Base
ing rod big end as a guide for reassembly.
<> PISTON PIN REMOVAL
Guide A: 17.9 mm
Push
rod Guide B
AK202781 AB
1. Insert the tool element, Push rod, into the piston

Guide A: 18.9 mm from the front mark side, then attach the element,
Guide C, to the push rod.
2. Place the piston and connecting rod assembly on
GuidE C
the element, Base, with the front mark facing up.
3. Use a press to remove the piston pin.
Guide A: 20.9 mm
NOTE: Keep the disassembled pistons, piston
Base pins and connecting rods cylinder by cylinder.

Guide A: 21.9 mm >>A<< PISTON PIN INSTALLATION
Timing belt side Crankshaft
bore size mark
AK202783 AB
No.4
The special tool Piston pin setting tool (MD998780),
No.3
consists of the elements shown in the drawing.
No.2
No.1
AK202923 AB
1. When replacing a piston, check the cylinder bore

size mark stamped at the indicated location on the
cylinder block and select an appropriate
replacement piston using the following table.
Cylinder bore size mark Piston size mark
I A
II No mark
III C
ENGINE OVERHAUL
11B-53
NOTE: The piston size mark is located on the pis-
ton top surface. 3 mm + L
D C Guide B Guide A
AK202789 AB
Connecting rod 8. Screw the tool element, Guide B, into the tool
Piston pin element, Guide A until the gap between both the
Piston elements is equal to the dimension L (obtained in
step 3.) plus 3 mm.
B A
Push rod
Piston pin
Front mark
AK202784 AB
Front
mark
2. Measure the following dimensions:
A: Piston pin insertion hole length
B: Distance between piston bosses Guide A
C: Piston pin length
D: Connecting rod small end width Base
3. Obtain dimension L from the measurements using
the following formula.
Guide B
L = [(A-C) " (B-D)] ()2
4. Insert the tool element, Push rod, into the piston
pin and attach the element, Guide A, to the push
rod end. AK202782 AB
5. Assemble the connecting rod with the piston with
9. Place the piston and connecting rod assembly
their front marks facing in the same direction.
onto the element, Piston setting base, with the
6. Apply engine oil to the outside surface of the front marks facing up.
piston pin.
10.Install the piston pin using a press. If the required
7. Insert the assembly of piston pin, Push rod, and press force is less than the standard value,
Guide A (put together in step 4.) into the piston
replace the piston and piston pin assembly or the
holes from the front mark side.
connecting rod, or both.
Standard value: 7,350 " 17,100 N
ENGINE OVERHAUL
>>B<< OIL RING INSTALLATION >>C<< PISTON RING NO. 2/PISTON RING NO. 1
INSTALLATION
Upper Lower
side side
rail rail
end gap end gap
Piston ring
expander
Spacer end gap AK202879 AB

AK202786 AB
1. Fit the oil ring spacer into the piston ring groove.
Install the upper side rail, then the lower side rail. Identification mark
NOTE: . Size marks
1. Locate the side rail and spacer end gaps as
2. New spacers and side rails are an identified by
No. 1
color marks as follows:
Size Color mark No. 2
Standard Non mark

AK202807 AB
0.50 mm oversize Blue
1.00 mm oversize Yellow Using a piston ring expander, install the piston rings
with their identification marks facing up (toward the
CAUTION piston crown).
Use of ring expander to expand the side rail end
gap can break the side rail, unlike other piston Identification marks:
rings. No. 1 ring 1R
No. 2 ring 2R
Side rail end
NOTE: Each of the available piston rings has a size
mark as follows:
Size Size mark
Standard No. 1 ring No mark
(blue paint on periphery)
No. 2 ring No mark
(green paint on periphery)
AK202785 AB 0.50 mm oversize 50
2. To install each side rail, first fit one end of the rail 1.00 mm oversize 100
into the piston groove, then press the remaining
portion progressively into position by finger as >>D<< PISTON AND CONNECTING ROD
shown in the drawing. ASSEMBLY INSTALLATION
3. Make sure that the installed side rails move 1. Apply engine oil generously to the piston’s outside
smoothly in either direction. surface, piston rings, and oil ring.
ENGINE OVERHAUL
11B-55
Side rail 2. Crankshaft pin diameter marks are stamped in the
indicated locations.
No. 1
No. 2 Side rail

AK202730 AB
2. Align the end gaps of the piston rings and oil ring
AK202719AB
(side rails and spacer) as shown in the drawing.
3. Insert the piston and connecting rod assembly 3. Connecting rod bearing identification mark is
from the top of cylinder with the front mark on the stamped in the indicated location on each
crown toward the camshaft sprocket. bearing.
Crankshaft pin Connecting rod
bearing
Identification Diameter mm Identification
mark mark
I 44.995 " 45.000 1
II 44.985 " 44.995 2
III 44.980 " 44.985 3
<Bearing selection example>
AK202798
If the crankshaft pin diameter mark is “I”, select a
CAUTION bearing marked “1”.
' Do not strike the assembly with a large force. If the crankshaft pin diameter mark is illegible,
Doing so could break the piston rings. measure the pin diameter and select a bearing
' When striking the assembly into cylinder, do with the mark corresponding to the measurement.
not allow it to interfere with the oil jet. 4. Install the upper and lower halves of the selected
4. Use a piston ring band to hold the piston rings bearing on the connecting rod big end and cap,
compressed when inserting the piston and respectively.
connecting rod assembly into the cylinder.
>>F<< CONNECTING ROD CAP INSTALLATION
>>E<< CONNECTING ROD BEARING
INSTALLATION
1. When replacing the connecting rod bearing,
select a bearing of the size appropriate for the Cylinder
crankshaft pin diameter in accordance with the number
crankshaft pin and connecting rod bearing
matching table shown below.
Locations of crankshaft pin diameter Bearing
marks locating
notches
AK202813 AB
1. Install the bearing cap on the connecting rod while

aligning the marks made during disassembly. If
No. 2 the connecting rod is new and has no alignment
No. 1 No. 3 mark, assemble it with the cap such that the both
bearing locating notches are on the same side as
No. 4 AK202909 AB
ENGINE OVERHAUL
CAUTION
' If the tightening angle is less than 90#, ade-
quate tightness could not be assured.
' If the tightening angle exceeds 94#, loosen the
nut completely and then perform the tighten-
ing procedure again beginning with the first
step.
7. Turn the nut 90# to 94# to bring the mark on the
nut into alignment with that on the bolt.
AK202821
INSPECTION
2. Make sure that the thrust clearance of the M1113008500365
connecting rod big end is proper. PISTON RING

Standard value: 0.10 " 0.25 mm
Limit: 0.4 mm
>>G<< CONNECTING ROD CAP NUT

INSTALLATION
1. The connecting rod cap bolts and nuts are
tightened using the torque-to-yield method. For
this reason, each bolt to be reused must be
checked for elongation before installation. AK202787
Whether or not the bolt has been elongated can
be determined by running a nut with fingers 1. Measure the clearance between each piston ring
through all the threads of the bolt. If the nut does and its groove. If the limit is exceeded, replace the
not turn smoothly over all the threads, the bolt has ring or piston, or both.
been elongated and must be replaced. Standard values:
2. Apply engine oil to the threads and bearing No. 1 ring: 0.03 " 0.07 mm
surface of each nut before installation. No. 2 ring: 0.02 " 0.06 mm
3. Finger-tighten the nuts on the bolts, then tighten Limits: 0.1 mm
the nuts alternately and repeatedly to install the
cap properly. Force ring down
4. Tighten the nuts to a torque of 20 % 2 N$m. with piston
Paint marks
90˚ to 94˚
Paint marks
Piston ring End gap AK202788 AB
Nut Bolt
2. Install a piston ring or oil ring side rail into the
cylinder bore and force it down with the head of a
AK202721 AB
piston until the ring is at right angles to the
5. Make a paint mark on the head of each nut. cylinder wall. Measure the end gap with a
6. Make a paint mark on the bolt at a point 90#to 94# thickness gauge.
away from the paint mark made on the nut in the NOTE: If the end gap is excessive, replace the
tightening direction. piston ring.
Standard values:
No. 1 ring: 0.25 " 0.35 mm
No. 2 ring: 0.40 " 0.55 mm
Oil ring: 0.10 " 0.40 mm
ENGINE OVERHAUL
11B-57
Limits:
No. 1 ring: 0.8 mm
No. 2 ring: 0.8 mm
Oil ring: 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC

GAUGE METHOD)
1. Wipe off oil from the crankshaft pin and
connecting rod bearing.
2. Cut a piece of plastic gauge whose length is AK202848
equivalent to the width of the bearing and place it
5. Measure the largest width of the crushed plastic
on the crankshaft pin in parallel with its axis.
gauge using the ruler printed on the bag of the
3. Install the connecting rod cap carefully and tighten
plastic gauge.
the nuts to the specified torque20 % 2 N$m + 90# to
94#. Standard value: 0.03 " 0.05 mm
4. Remove the nuts, then remove the connecting rod Limit: 0.1 mm
cap carefully.
ENGINE OVERHAUL
11B-58 CRANKSHAFT AND CYLINDER BLOCK

M1113008700507
CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Remov-
ing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in
damage.
3 2
Apply engine oil
to all moving
parts before
11 ± 1 N·m 1
installtion. 6 132 ± 5 N·m
9
8 4 A
16 5
9.0 ± 1.0 N·m

11 ± 1 N·m 7
15
14
13
12
11
25 ± 2 N·m + 90º to 100º

10
AK204351AB

1. Flywheel bolt >>C<< 9. Oil seal
2. Adapter plate >>C<< 10. Bearing cap bolt
3. Flywheel >>B<< 11. Beam bearing cap
4. Adapter plate 12. Crankshaft bearing, lower
5. Crankshaft bushing >>B<< 13. Crankshaft
6. Rear plate >>A<< 14. Crankshaft bearing, upper
>>E<< 7. Bell housing cover 15. Thrust bearing
>>D<< 8. Oil seal case 16. Cylinder block
ENGINE OVERHAUL
11B-59
INSTALLATION SERVICE POINTS If the crankshaft journal diameter mark is “0” and
>>A<< THRUST BEARING INSTALLATION the cylinder block bearing bore mark is “1”, then
select a bearing with a “2” mark as the No. 1, 2, 4
or 5 bearing and a bearing with a “1” mark as the
No. 3 bearing.
If the crankshaft journal diameter mark is illegible,
measure the journal diameter and select a
bearing with the mark corresponding to the
measurement.
Groove
Timing belt side
AK202769 AB
Diameter identification marks of
Install the two thrust bearings in the No. 3 bearing bearing bores in cylinder block
bore in the cylinder block. Each thrust bearing must No. 4
be installed with the grooved end toward the crank- No. 3
No. 1 No. 2 No. 5
shaft web.
NOTE: Applying engine oil to the bearings will help
facilitate holding them in position.
>>B<< CRANKSHAFT BEARING INSTALLATION Cylinder

Location of crankshaft journal bore size
diameter marks mark
No. 2
No. 1 No. 3
AK202777 AB
No. 4 No. 5 AK202908 AB
2. The diameter identification marks of the bearing
1. Location of crankshaft journal diameter marks bores in the cylinder block are stamped in the
location shown in the drawing.
<Bearing selection example>
Crankshaft journal diameter Cylinder block Crankshaft bearing marking
Identification mark Journal diameter bearing bore No. 1, 2, 4 and 5 No. 3 bearing
measurement mm marking bearing
0 56.994 " 57.000 0 1 0
1 2 1
2 3 2
1 56.988 " 56.994 0 2 1
1 3 2
2 4 3
2 56.982 " 56.988 0 3 2
1 4 3
2 5 4
ENGINE OVERHAUL
Crankshaft bearing size mark location

size mark
8 4 1 5 9
7 3 2 6 10
Size mark
AK202753 AB Arrow AK202737 AB
3. The size mark of each crankshaft bearing is 4. Tighten the bolts to 25 % 2 N$m in the indicated
indicated by ink in the location shown in the sequence.
drawing. 5. Make a paint mark on the head of the bolt.
6. Make a paint mark on the bearing cap at a point
90 to 100# away from the paint mark made on the
Groove bolt head in the tightening direction.
Paint mark Paint mark
Upper bearing half
Lower bearing half

AK202770 AB 90˚ to 100˚
4. Install bearing halves with oil grooves in the

AK202722 AB
cylinder block bearing bores.
5. Install bearing halves with no oil grooves in the CAUTION
beam bearing cap. ' If the tightening angle is less than 90#, ade-
quate tightness could not be assured.
>>C<< BEAM BEARING CAP/BEARING CAP ' If the tightening angle exceeds 100#, loosen
BOLT INSTALLATION the bolt completely and then perform the
1. Install the beam bearing cap on the cylinder block tightening again beginning with the first step.
with the arrow pointing to the timing belt. 7. Turn clockwise the bolts 90 to 100# in the
indicated tightening sequence to bring the mark
on each bolt head into alignment with that on the
bearing cap.
Nominal length
AK202805 AB
2. Measure the nominal length of each bearing cap

bolt before installation. If the measurement
exceeds the limit, replace the bolt.
Limit: 71.1 mm 8. After installing the beam bearing cap, measure
3. Apply engine oil to the threads and bearing the end play of the crankshaft. If the end play
surface of the bolt. exceeds the limit, replace the crankshaft bearings.
Standard value: 0.05 " 0.25 mm
ENGINE OVERHAUL
11B-61
Limit: 0.4 mm Measure the crankshaft oil clearance using a plastic
gauge as follows:
>>D<< REAR OIL SEAL INSTALLATION 1. Wipe off oil from the crankshaft journal surface
and the crankshaft bearing inner surface.
2. Install the crankshaft.
MB990938
Plastic gauge
MD998776
AK202827 AB
Use the special tools to press-fit the rear oil seal in

AK202826 AB
the rear oil seal case.
' Handle (MB990938) 3. Cut a piece of plastic gauge whose length is
' Crankshaft rear oil seal installer (MD998776) equivalent to the width of the bearing and place it
on the crankshaft journal in parallel with its axis.
>>E<< REAR OIL SEAL CASE INSTALLATION 4. Install the crankshaft bearing cap carefully and
1. Remove completely old FIPG remaining on the tighten the bolts to the specified torque of 25 % 2
rear oil seal case and cylinder block. N$m + 90# to 100#.
5. Remove the bolts, then remove the crankshaft
bearing cap carefully.
AK202824AB
Plastic gauge
2. Apply a bead of FIPG to the surface of the rear oil AK202822 AB
seal case as shown in the drawing.
Specified sealant: 6. Measure the largest width of the crushed plastic
Mitsubishi Genuine Part No.MD970389 or gauge using the ruler printed on the bag of the
equivalent plastic gauge.
3. Install the oil seal into the cylinder block after Standard value: 0.02 " 0.04 mm
applying an appropriate amount of engine oil to Limit: 0.1 mm
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts CYLINDER BLOCK
to 11 % 1 N$m. 1. Visually check the cylinder block for scratches,
rust, and any other corrosion. Also check it for
INSPECTION cracks using a flaw detecting penetrant.
M1113008800366
CRANKSHAFT OIL CLEARANCE If any defect is evident, replace the cylinder block.
(PLASTIC GAUGE METHOD)
This plastic gauge method is recommended as a
simplest way of measuring the crankshaft oil clear-
ance.
ENGINE OVERHAUL
BORING CYLINDERS
1. Select an oversize of the pistons to be used based
on the largest of the cylinder bores.
AK202833
2. Use a straightedge and thickness gauge to check 11.65 mm

the cylinder block top surface for warp. Piston diameter
AK202880 AB
Make sure that the surface is free from remaining
gasket material and other foreign matter. 2. Oversize pistons are available in two oversizes:
Standard value: 0.05 mm 0.50 mm and 1.00 mm. Bore each cylinder to a
size that provides the standard clearance when
Limit: 0.1 mm combined with the selected piston. The reference
3. Check cylinder walls for scratches and seizure. position for piston diameter measurement is as
If defects are evident, rebore to oversize or shown in the drawing.
replace the cylinder block. 3. Based on the piston diameter measurement,
calculate the boring finish dimension.
' Boring finish dimension = [Piston diameter] +
[0.02 " 0.04 mm (clearance between piston and
cylinder)] " [0.02 mm (honing margin)]
CAUTION
To prevent deformation of cylinder block that
12 mm
would result from the heat generated by boring,
bore the cylinders in the following sequence: No.
2 & No. 4 & No. 1 & No. 3.
AK202731 AB 4. Bore all the cylinders to the calculated boring
finish dimension.
4. Use a cylinder gauge to measure the cylinder
5. Hone the bored cylinders to the final finish
bore diameter and taper.
dimension (piston diameter + clearance between
If the cylinder is worn badly, rebore it to an piston and cylinder).
oversize and replace the piston and piston rings 6. Check the clearance between the piston and
with ones matched with the new bore size. cylinder.
Standard value: 85.00 mm Standard value: 0.02 " 0.04 mm
Taper: 0.01 mm
11C-1
GROUP 11C
ENGINE
MECHANICAL
<4G69>
CONTENTS
GENERAL INFORMATION . . . . . . . . 11C-2 REMOVAL AND INSTALLATION . . . . . . . . 11C-17
SERVICE SPECIFICATIONS. . . . . . . 11C-2 CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11C-18
SEALANTS . . . . . . . . . . . . . . . . . . . . 11C-3 REMOVAL AND INSTALLATION . . . . . . . . 11C-18
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11C-4 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11C-23

REMOVAL AND INSTALLATION . . . . . . . . 11C-23
ON-VEHICLE SERVICE. . . . . . . . . . . 11C-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11C-26
DRIVE BELT TENSION CHECK. . . . . . . . . 11C-8
AUTO-TENSIONER CHECK . . . . . . . . . . . 11C-8 CRANKSHAFT OIL SEAL . . . . . . . . . 11C-26
VALVE CLEARANCE CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 11C-26
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11C-11
ROCKER ARM PISTON OPERATION CYLINDER HEAD GASKET . . . . . . . . 11C-30
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11C-11 REMOVAL AND INSTALLATION . . . . . . . . 11C-30
IGNITION TIMING CHECK . . . . . . . . . . . . . 11C-13
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11C-14 TIMING BELT . . . . . . . . . . . . . . . . . . . 11C-36
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11C-14 REMOVAL AND INSTALLATION . . . . . . . . 11C-36
COMPRESSION PRESSURE CHECK. . . . 11C-15 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11C-45
MANIFOLD VACUUM CHECK . . . . . . . . . . 11C-16
ENGINE ASSEMBLY . . . . . . . . . . . . . 11C-47
CRANKSHAFT PULLEY . . . . . . . . . . 11C-17 REMOVAL AND INSTALLATION . . . . . . . . 11C-47
11C-2 ENGINE MECHANICAL <4G69>
GENERAL INFORMATION
GENERAL INFORMATION
M1111000100505
Item 4G69
Bore × Stroke mm 87 × 100
Compression ratio 9.5
Compression chamber Pentroof
Camshaft arrangement SOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake valve Open (BTDC) 10° <low speed cam A>
12° <low speed cam B>
24° <High speed cam>
Closes (ABDC) 42° <low speed cam A>
44° <low speed cam B>
68° <High speed cam>
Exhaust valve Open (BTDC) 58°
Closes (ABDC) 18°
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type
M1112000300278

Drive belt tension Vibration frequency Hz A/C compressor type: 113 − 145 −
(Reference) MSC90CA
A/C compressor type: 120 − 154 −
MSC105CA
Tension N (Reference) 340 − 555 −
Valve clearance (at hot) mm Intake valve 0.20 −
Exhaust valve 0.30 −
Basic ignition timing 5° BTDC ± 3° −
Ignition timing Approximately −
10° BTDC
Idle speed r/min M/T 680 ± 100 −
A/T 750 ± 100 −
CO contents % 0.5 or less −
HC contents ppm 100 or less −
Compression pressure kPa-r/min 1,560 − 200 1,130 − 200
Compression pressure difference of all cylinders kPa − Maximum 98
ENGINE MECHANICAL <4G69> 11C-3
SEALANTS

Intake manifold vacuum kPa − Minimum 60
Cylinder head bolt nominal length mm − 99.4
Balancer timing belt tension (When adjusted) Deflection mm 5−7 −
Balancer timing belt tension (When replaced) Deflection mm 5−7 −
Balancer timing belt tension (When checked) Deflection mm 5 − 10 −
Timing belt tensioner adjuster rod protrusion amount mm 3.8 − 4.5 −
Timing belt tensioner adjuster rod movement mm Within 1 −
SEALANTS
M1112000500294
Item Specified sealant Remark

Camshaft position sensor support MITSUBISHI GENUINE PART MD970389 or Semi-drying
Engine upper oil pan equivalent sealant
Engine lower oil pan
Taper plug LOCTITE203MP Anaerobic
sealant
SPECIAL TOOLS
SPECIAL TOOLS
M1112000600332

MB991502 MUT-II sub assembly • Drive belt tension check
• Checking the ignition timing
• Checking the idle speed
B991502
MB991955 MUT-III sub assembly • Drive belt tension check

A A: MB991824 A: Vehicle communication • Checking the ignition timing
B: MB991827 interface (V.C.I.) • Checking the idle speed
C: MB991910 B: MUT-III USB cable
D: MB991911 C: MUT-III main harness A
MB991824
E: MB991825 (Vehicles with CAN
B F: MB991826 communication system)
D: MUT-III main harness B
(Vehicles without CAN
communication system)
MB991827 E: MUT-III measurement
C
adapter
F: MUT-III trigger harness
DO NOT USED
MB991910
MB991911
MB991825
MB991826
MB991955
MB991668 Belt tension meter set Drive belt tension check (used
together with MUT-II or MUT-III)
B991668
SPECIAL TOOLS

MB990767 Front hub and flange yoke Holding the camshaft sprocket
holder
B990767
MD998719 Pin
D998719
MD998772 Valve spring compressor Compressing valve spring
MD998772
MD998774 Valve stem seal installer Valve stem seal installation
MD998713 Camshaft oil seal installer Camshaft oil seal installation
D998713
MD998781 Flywheel stopper • Supporting the flywheel

assembly <M/T>
• Supporting the A/T drive plate
<A/T>
D998781
MB990938 Installer bar Crankshaft rear oil seal

installation
B990938
MD998776 Crankshaft rear oil seal

installer
D998776
SPECIAL TOOLS

MD998285 Crankshaft front oil seal Crankshaft front oil seal
guide installation
D998285
MD998375 Crankshaft front oil seal

installer
MD998738 Adjusting bolt Supporting the timing belt

tensioner arm and timing belt
tensioner adjuster
D998738
MB991654 Cylinder head bolt wrench Removal and installation of

(12) cylinder head bolt
B991654
MB991367 Special spanner Holding the crankshaft camshaft

drive sprocket
B991367
MB991385 Pin
B991385
MD998767 Tensioner wrench Valve timing belt tension

adjustment
D998767
SPECIAL TOOLS

MB991454 Engine hanger balancer When the engine hanger is
used: Supporting the engine
assembly during removal and
installation of the transmission
B991454
assembly
NOTE: Special tool MB991454
MB991527 Hanger is a part of engine hanger
attachment set MB991453.
B991527
Z203830

Slide bracket (HI) A: MB991929 A: Joint (50) × 2
B: MB991930 B: Joint (90) × 2
E C: MB991931 C: Joint (140) × 2
D: MB991932 D: Foot (standard) × 4
F E: MB991933 E: Foot (short) × 2
A F: MB991934 F: Chain and hook assembly
D
B
C
B991928
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK 4. If there are any problems in the procedure 1 or 3,
M1111003100548 replace the auto-tensioner.(Refer to P.11C-36).
CAUTION 5. Install the drive belt.(Refer to P.11C-17).
Check the drive belt tension after turning the
crankshaft clockwise one turn or more. FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
Indicator mark
When using MUT-II
1. Check the drive belt tension. (Refer to P.11C-8).
2. Measure the drive belt tension vibration frequency
A by the following procedures:
CAUTION
AC301702AB
1. Make sure that the indicator mark is within the

area marked with A in the illustration. 16-pin
2. If the mark is out of the area, replace the drive
belt. (Refer to P.11C-17).
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.
AUTO-TENSIONER CHECK
M1111003000251 MUT-II
OPERATION CHECK
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner.
2. Remove the drive belt.(Refer to P.11C-17).
MB991668
AC211862 AB
To prevent damage to MUT-II, always turn the

before connecting or disconnecting MUT-II.
(1) Connect special tool belt tension meter set
(MB991668) to the MUT-II.
AC301703 connector.
(3) Turn the ignition switch to "ON" position, and
3. Securely insert the spindle handle or ratchet select "BELT TENSION" on the menu screen.
handle with a 12.7 mm insertion angle into the jig
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
ON-VEHICLE SERVICE
CAUTION Standard value:

• The temperature of the surface of the belt <A/C compressor type: MSC90CA> 113 − 145
should be as close to normal temperature as Hz
possible. <A/C compressor type: MSC105CA> 120 − 154
Hz
• Do not allow any contaminants such as water
or oil to get onto the microphone. 3. If not within the standard value, replace the
• If strong gusts of wind blow against the auto-tensioner. (Refer to P.11C-36).
microphone or if there are any loud sources
When using V.C.I.
of noise nearby, the values measured by the
microphone may not correspond to actual 1. Check the drive belt tension. (Refer to P.11C-8).
values. 2. Measure the drive belt tension vibration frequency
• If the microphone is touching the belt while by the following procedures:
the measurement is being made, the values CAUTION
measured by the microphone may not
correspond to actual values.
• Do not take the measurement while the
vehicle's engine is running.
16-pin
Water MB991668
pump
pulley
15˚ 10 – 20 mm
15˚
MB991824
Gentry tap MB991668

with your
finger
MB991911
AC211863AB
Alternator
pulley To prevent damage to special tool V.C.I.
(MB991824), always turn the ignition switch to
the "LOCK" (OFF) position before connecting or
disconnecting special tool V.C.I. (MB991824).
AC301266AB (1) Connect special tool belt tension meter set
(4) Hold special tool belt tension meter set (MB991668) to special tool V.C.I. (MB991824).
(MB991668) to the middle of the drive belt (2) Connect special tool MUT-III main harness B
between the pulleys (at the place indicated by (MB991911) to special tool V.C.I. (MB991824).
arrow), approximately 10 − 20 mm away from (3) Connect special tool MUT-III main harness B
the rear surface of the belt so that it is (MB991911) to the diagnosis connector.
perpendicular to the belt (within an angle of ± (4) Turn the ignition switch to "ON" position, and
15 degree). select "Belt Tension" on the menu screen.
(5) Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and
measure that the vibration frequency of the
belt is within the standard value.
ON-VEHICLE SERVICE
CAUTION (6) Gently tap the middle of the belt between the
• The temperature of the surface of the belt pulleys (the place indicated by the arrow) with
should be as close to normal temperature as your finger as shown in the illustration, and
possible. measure that the vibration frequency of the
• Do not allow any contaminants such as water belt is within the standard value.
or oil to get onto the microphone. Standard value:
• If strong gusts of wind blow against the <A/C compressor type: MSC90CA> 113 − 145
microphone or if there are any loud sources Hz
of noise nearby, the values measured by the <A/C compressor type: MSC105CA> 120 − 154
microphone may not correspond to actual Hz
values. 3. If not within the standard value, replace the
• If the microphone is touching the belt while alternator drive belt auto tensioner. (Refer to
the measurement is being made, the values P.11C-36).
measured by the microphone may not
correspond to actual values. When using a tension gauge
• Do not take the measurement while the 1. Check the drive belt tension. (Refer to P.11C-8).
vehicle's engine is running.
Belt tension
Water pump
gauge
Water MB991668 pulley
pump
pulley
15˚ 10 – 20 mm
15˚
Gentry tap
with your
finger
Alternator
pulley
Alternator
pulley
AC301267AB
AC301266AB
2. Use a belt tension gauge in the middle of the belt
(5) Hold special tool belt tension meter set between the pulleys (at the place indicated by the
(MB991668) to the middle of the drive belt arrow) to measure that the belt tension is within
between the pulleys (at the place indicated by the standard value.
arrow), approximately 10 − 20 mm away from
Standard value: 340 − 555 N
the rear surface of the belt so that it is
perpendicular to the belt (within an angle of ± 3. If not within the standard value, replace the
15 degree). auto-tensioner. (Refer to P.11C-36).
ON-VEHICLE SERVICE
VALVE CLEARANCE CHECK AND Standard value (hot engine):

Intake valve: 0.20 mm
ADJUSTMENT
M1111001500131 Exhaust valve: 0.30 mm
1. Start the engine and allow it to warm up until the 10.While holding the adjusting screw with a
engine coolant temperature reaches 80 − 95°C. screwdriver to prevent it from turning, tighten the
2. Turn the ignition switch to the "LOCK" (OFF) lock nut to the specified torque.
position. Tightening torque: 9 ± 1 N⋅m
3. Remove all ignition coils.
11.Turn the crankshaft through 360° to line up the
4. Remove all spark plugs from the cylinder head for notch on the crankshaft pulley with the "T" mark
easy inspection. on the timing indicator.
5. Remove the rocker cover. 12.Repeat steps (9) and (10) on other valves for
6. Turn the crankshaft clockwise until the notch on clearance adjustment.
the pulley is lined up with the "T" mark on the 13.Install the rocker cover.
timing indicator.
14.Install the spark plugs and tighten to the specified
7. Move the rocker arms on the No.1 and No.4 torque.
cylinders up and down by hand to determine
Tightening torque: 25 ± 4 N⋅m
which cylinder has its piston at the top dead
center on the compression stroke. If both intake 15.Install the ignition coils.
and exhaust valve rocker arms have a valve lash,
the piston in the cylinder corresponding to these ROCKER ARM PISTON OPERATION
rocker arms is at the top dead center on the CHECK
compression stroke. M1111051000023
Intake valve side Taper plug

Oil control valve
Ignition coils
No. 1 No. 2 No. 3 No. 4
Exhaust valve side Rocker cover AK304505AB
AK303689 AB
1. Remove all of the ignition coils.

8. Valve clearance inspection and adjustment can be
performed on rocker arms indicated by white 2. Remove the rocker cover.
arrow mark when the No.1 cylinder piston is at the 3. Remove the oil control valve.
top dead centre on the compression stroke, and 4. Remove the taper plug.
on rocker arms indicated by black arrow mark 5. Turn the crankshaft clockwise until the notch on
when the No.4 cylinder piston is at the top dead the crankshaft pulley is lined up with "T" mark on
centre on the compression stroke. the lower cover of timing belt.
9. Measure the valve clearance. 6. Move the rocker arms on the No.1 and No.4
If the valve clearance is not as specified, loosen cylinders up and down by hand to determine
the rocker arm lock nut and adjust the clearance which cylinder has its piston at the top dead
using a thickness gauge while turning the centre on the compression stroke.
adjusting screw.
ON-VEHICLE SERVICE
NOTE: 7. While shutting up the oil passage hole at the

Intake valve side depth of the oil control valve's installation hole by
finger not to leak air, blow compression air into the
taper plug's installation hole by air blowgun. At
this time, confirm that the rocker arm piston can
operate.
NOTE: To fully confirm the check, prevent the
compression air from leaking as much as possible by
No. 1 No. 2 No. 3 No. 4 installing the O-ring to the end of air blowgun.
Exhaust valve side 8. Turn the crankshaft clockwise until the notch on
AK303689 AC
the crankshaft pulley is lined up with "T" mark on
The rocker arm piston operation check can be the lower cover of timing belt.
performed on rocker arms indicated by white arrow
9. Confirm the rest of the rocker arm pistons under
mark when the No.1 cylinder piston is at the top dead
the procedure 7.
centre on the compression stroke, and on rocker
arms indicated by black arrow mark when the No.4 10.When the rocker arm piston does not operate,
cylinder piston is at the top dead centre on the replace the rocker arm assy.
compression stroke. 11.Apply sealant to threaded portion.
Specified sealant: LOCTITE203MP
Rocker arm Rocker arm
piston CAUTION
Do not start the engine within one hour after the
engine taper plug has been installed.
12.Install the taper plug and tighten to the specified
torque.
Oil passage Tightening torque: 10 ± 2 N⋅m
Blow
compression 13.Install the oil control valve. (Refer to Camshaft
air AK302684AC and Valve Stem Seal − Removal and Installation
P.11C-18.)
14.Install all of the ignition coils.
15.Install the rocker cover.
ON-VEHICLE SERVICE
IGNITION TIMING CHECK 2. Turn the ignition switch to the "LOCK" (OFF)
M1111001700607 position and then connect the MUT-II/III to the
3. Connect a timing light.
5. Use the MUT-II/III to measure engine idle speed
and check that it is within the standard value.
Standard value
: 680 ± 100 r/min <M/T>
16 PIN
MB991502 : 750 ± 100 r/min <A/T>
AK303691AF 6. Select No. 17 of the MUT-II/III Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5° BTDC ± 3°
8. If the basic ignition timing is outside the standard
16-PIN
value, inspect the MPI system (Refer to P.13B-20,
GROUP 13B − Troubleshooting − Inspection chart
CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this
MB991911
condition may damage the engine.
MB991824 9. Press the MUT-II/III clear key (Select a forced
driving cancel mode) to release the Actuator test.
10.Check that ignition timing is at the standard value.
Standard value: approximately 10° BTDC
NOTE: .
• The ignition timing may fluctuate within ± 7°
BTDC. This is normal.
MB991827 AK303690AB • In higher altitude, the ignition timing is more
advanced than the standard value by
1. Before inspection, set the vehicle to the
approximately 5°.
pre-inspection condition.
11.Remove the timing light.
12.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.
ON-VEHICLE SERVICE
IDLE SPEED CHECK 7. If the idle speed is outside the standard value,
M1111003500654 inspect the MPI system (Refer to P.13B-20,
GROUP 13B − Troubleshooting − Inspection chart
8. Turn the ignition switch to the "LOCK" (OFF)
IDLE MIXTURE CHECK

M1111002100426
16 PIN
MB991502
AK303691AF
16-PIN 16 PIN
MB991502
AK303691AF
MB991911
16-PIN
MB991824
MB991911
MB991827 AK303690AB MB991824

pre-inspection condition.
position and then connect the MUT-II/III to the
3. Connect a timing light. MB991827 AK303690AB
5. Check that ignition timing is at the standard value. pre-inspection condition.
Standard value: approximately 10° BTDC 2. Turn the ignition switch to the "LOCK" (OFF)
6. Check the idle speed. position and then connect the MUT-II/III to the
Standard value diagnosis connector.
: 680 ± 100 r/min <M/T> 3. Connect a timing light.
: 750 ± 100 r/min <A/T> 4. Start the engine and let it run at idle.
NOTE: . 5. Check that ignition timing is at the standard value.
• The idle speed is controlled automatically by Standard value: approximately 10° BTDC
the idle speed control system.
6. Run the engine at 2,500 r/min for 2 minutes.
• When using the MUT-II/III, select item No. 22
and take a reading of the idle speed. 7. Set the CO, HC tester.
ON-VEHICLE SERVICE
8. Check the CO contents and the HC contents at CAUTION

idle. • Keep away from the spark plug hole when
Standard value cranking.
CO contents: 0.5 % or less • If compression is measured with water, oil,
HC contents: 100 ppm or less fuel, etc., that has come from cracks inside
9. If there is a deviation from the standard value, the cylinder, these materials will become
check the following items: heated and will gush out from the spark plug
• Diagnosis output hole, which is dangerous.
• Fuel pressure 4. Cover the spark plug hole with a shop towel etc.,
• Injector and after the engine has been cranked, check that
• Ignition coil, spark plug no foreign material is adhering to the shop towel.
• EGR control system 5. Set compression gauge to one of the spark plug
• Evaporative emission control system holes.
• Compression pressure 6. Crank the engine with the throttle valve fully open
NOTE: Replace the three way catalyst when the and measure the compression pressure.
CO and HC contents are not within the standard Standard value (at engine speed of 200
value, even though the result of the inspection is r/min):
normal on all items. 1,560 kPa
10.Turn the ignition switch to the "LOCK" (OFF)
Limit (at engine speed of 200 r/min):
Minimum 1130 kPa
COMPRESSION PRESSURE CHECK 7. Measure the compression pressure for all the
M1111002600636 cylinders, and check that the pressure differences
of the cylinders are below the limit.
Limit: Maximum 98 kPa
8. If there is a cylinder with compression or a
Crank angle compression difference that is outside the limit,
sensor pour a small amount of engine oil through the
connector
spark plug hole, and repeat the operations in
steps from (5) to (7).
(1) If the compression increases after oil is added,
AK303421AB
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
1. Before inspection, set the vehicle to the surface.
pre-inspection condition. (2) If the compression dose not rise after oil is
2. Remove all of the ignition coils and spark plugs. added, the cause is a burnt or defective valve
3. Disconnect the crank angle sensor connector. seat, or pressure is leaking from the gasket.
NOTE: Doing this will prevent the 9. Connect the crank angle sensor connector.
engine-ECU<M/T> or engine-A/T-ECU<A/T> from 10.Install the spark plugs and tighten to the specified
carrying out ignition and fuel injection. torque.
11.Install the ignition coils.
12.Use the MUT-II/III to erase the diagnosis codes.
NOTE: This will erase the diagnosis code
resulting from the crank angle sensor connector
being disconnected.
ON-VEHICLE SERVICE
MANIFOLD VACUUM CHECK 1. Before inspection, set the vehicle to the

M1111002700569 pre-inspection condition.
position and then connect the MUT-II/III to the
Ventilation hose
16 PIN
MB991502 Plug
PCV valve
AK303691AF
Vacuum gauge
AK303422 AB
16-PIN 3. Disconnect the ventilation hose from the PCV

valve, and connect a vacuum gauge to the
ventilation hose.
4. Plug the PCV valve.
5. Start the engine and check that idle speed is
within the standard valve.
MB991911 Standard value
: 680 ± 100 r/min <M/T>
MB991824 : 750 ± 100 r/min <A/T>
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
7. Turn off the ignition switch.
8. Remove the vacuum gauge and then connect the
ventilation hose.
MB991827 AK303690AB
CRANKSHAFT PULLEY
CRANKSHAFT PULLEY
M1112001600539

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Tension Check (Refer to P.11C-8).
P.51-19). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
1
2
25 ± 4 N·m
AC308973AB
Removal steps 1. Securely insert the spindle handle or ratchet

<<A>> 1. Drive belt handle with a 12.7 mm insertion angle into the jig
2. Crank shaft damper pulley hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the CAUTION
introduction of the serpentine drive system with the To reuse the drive belt, draw an arrow indicating
drive belt auto-tensioner. the rotating direction (clockwise) on the back of
the belt using chalk, etc.
AC301703
Auto-tensioner
Auto-tensioner
Hole B
Hole A L-shaped
hexagon
AC301704AB
wrench AC301705AB
3. Insert an L-shaped hexagon wrench, etc. into the

hole to fix and then remove the drive belt.

M1112006600330
CAUTION
* Remove and assemble the marked parts in each cylinder unit.
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Timing Belt Upper Cover Installation (Refer to P.11C-36).
P.15-4). • Ignition Coils Installation (Refer to GROUP 16, Ignition
• Ignition Coils Removal (Refer to GROUP 16, Ignition System − Ignition Coil P.16-41).
System − Ignition Coil P.16-41). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Timing Belt Upper Cover Removal (Refer to P.11C-36). P.15-4).
• Drive Belt Tension Check (Refer to P.11C-8).
• Valve Clearance Check and Adjustment (Refer to
P.11C-11).
3.5 ± 0.5 N·m

1
7
N8
4 11 ± 1 N·m
9.0 ± 2.0 N·m 24 ± 3 N·m

N 9
5
6N (Engine oil)
44 ± 5 N·m
10
AC308974 AB
Camshaft removal steps Camshaft removal steps

1. Rocker cover PCV hose connection 7. Rocker cover assembly
2. Rocker cover breather hose 8. Rocker cover gasket
connection 9. Spark plug guide oil seals
3. Control wiring harness connection 10. Accumulator assembly
4. Engine hanger • Valve timing belt (Refer to
>>J<< 5. Oil control valve P.11C-36).
>>J<< 6. O-ring
Apply engine oil to all 31 ± 3 N·m

moving parts before 11 11 ± 1 N·m
installation. 13 ± 1 N·m
18
12
19
47 ± 7 N·m 21
22
16 14 ± 1 N·m
25 ± 4 N·m
22 ± 4 N·m
23 13
24* 17
25* 20
26*
N 28*
29* 24*
25*
27*
28* N
89 ± 9 N·m
29*
15 N
14 AC308975AB
Camshaft removal steps Valve stem seal removal steps

11. Connector bracket 1. Rocker cover PCV hose connection
>>I<< 12. Camshaft position sensor support 2. Rocker cover breather hose
13. Camshaft position sensing cylinder connection
<<A>> >>H<< 14. Camshaft sprocket 3. Control wiring harness connection
>>G<< 15. Camshaft oil seal 4. Engine hanger
>>F<< 16. Exhaust rocker arm shaft caps 7. Rocker cover assembly
<> >>F<< 17. Exhaust rocker arm and shaft 8. Rocker cover gasket
assembly 9. Spark plug guide oil seals
>>E<< 18. Inlet rocker arm shaft caps >>F<< 16. Exhaust rocker arm shaft caps
<> >>E<< 19. Inlet rocker arm and shaft assembly <> >>F<< 17. Exhaust rocker arm and shaft
>>D<< 20. Camshaft assembly
• Water inlet fitting and thermostat >>E<< 18. Inlet rocker arm shaft caps
case assembly (Refer to GROUP <> >>E<< 19. Inlet rocker arm and shaft assembly
14, Water Hose and Water Pipe 23. Spark plugs
P.14-27). <<C>> >>C<< 24. Valve spring retainer locks
21. Cylinder head plug 25. Valve spring retainers
22. Oil control valve filter >>B<< 26. Inlet valve springs
>>B<< 27. Exhaust valve springs
>>A<< 28. Valve stem seals
29. Valve spring seats
REMOVAL SERVICE POINTS Use special tool valve spring compressor

<<A>> CAMSHAFT SPROCKET REMOVAL (MD998772) to compress the valve spring and then
remove the valve spring retainer lock.
MB990767
>>A<< VALVE STEM SEALS INSTALLATION
1. Apply a small amount of engine oil to the valve
stem seals.
MD998719 CAUTION
• Do not re-use the valve stem seal.
• Special tool valve stem seal installer
AC102532AB (MD998774) must be used to install the valve
stem seal. Improper installation could result
1. Use the following special tools to hold the
in oil leaking past the valve guide.
camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719) MD998774
2. Loosen the camshaft sprocket mounting bolt and Valve
remove the camshaft sprocket.
Valve stem
<> EXHAUST ROCKER ARM AND SHAFT seal
ASSEMBLY/INLET ROCKER ARM AND SHAFT
Valve guide
ASSEMBLY REMOVAL
CAUTION AC308654AB
Never disassemble the exhaust rocker arm and
shaft assembly, and inlet rocker arm and shaft 2. Use the special tool to fill a new valve stem seal in
assembly. the valve guide using the valve stem area as a
guide.
<<C>> VALVE SPRING RETAINER LOCKS
REMOVAL >>B<< EXHAUST VALVE SPRINGS/INLET VALVE
SPRINGS INSTALLATION
CAUTION
When removing valve spring retainer locks, leave Rocker arm side
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.
Identification
colour
Inlet side:
Light blue
MD998772
Exhaust side:
Orange AC107415AC
Install the valve springs with its identification colour

painted end facing the locker arm.
AC301867AB
>>C<< VALVE SPRING RETAINER LOCKS 1. Place the inlet rocker shaft so that its 5.5 mm hole
INSTALLATION faces toward the cylinder head.
2. Install the inlet rocker arm shaft caps.
3. Tighten the inlet rocker shaft mounting bolts to the
MD998772 specified torque.
>>F<< EXHAUST ROCKER ARM AND SHAFT

ASSEMBLY/EXHAUST ROCKER ARM SHAFT
CAPS INSTALLATION
AC301867AB Engine front
(MD998772) to compress the valve spring and then
install the valve spring retainer lock in the same
manner as removal.
>>D<< CAMSHAFT INSTALLATION

Notch
Dowel pin AC301870AB
1. Install the exhaust rocker shaft so that its notch is

positioned as shown.
2. Install the exhaust rocker arm shaft caps.
3. Tighten the exhaust rocker shaft mounting bolts to
AC301868AB
Set the dowel pin of the camshaft in the position

>>G<< CAMSHAFT OIL SEAL INSTALLATION
shown in the figure.
Camshaft oil seal
>>E<< INLET ROCKER ARM AND SHAFT
ASSEMBLY/INLET ROCKER ARM SHAFT CAPS
INSTALLATION
Engine front
(Engine oil)
φ 5.5 mm
MD998713 AC102323AC
1. Apply engine oil to the entire inner diameter of the

oil seal lip.
2. Use special tool camshaft oil seal installer
AC301869AB (MD998713) to press-fit the oil seal as shown.
>>H<< CAMSHAFT SPROCKET INSTALLATION NOTE: Install the camshaft position sensor
support within 15 minutes after applying the
sealant.
MB990767 3. Install the camshaft position sensor support to the
cylinder head.
CAUTION
Wait at least one hour. Never start the engine or
MD998719
let engine oil or coolant touch the adhesion
surface during that time.
4. Tighten the camshaft position sensor support
AC102532AB
1. Use the following special tool as during removal to Tightening torque: 14 ± 1 N⋅m
hold the camshaft sprocket.
>>J<< O-RING/OIL CONTROL VALVE
• Pin (MD998719)
INSTALLATION
2. Tighten the camshaft sprocket mounting bolt to
the specified torque. CAUTION
• Never re-use the O-ring.
Tightening torque: 89 ± 9 N⋅m •
>>I<< CAMSHAFT POSITION SENSOR SUPPORT

INSTALLATION Tape
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.
φ 3 mm
AK303651AD
Before installing O-ring, wind the tape with the

soft adhesion (sealing tape) around the oil
passages cut-out area of engine oil control
valve to prevent the damage. If the O-ring is
damaged, it can be the cause of oil leak.
AC301268AB
1. Apply a small amount of engine oil to the O-ring
2. Apply the sealant to the camshaft position sensor and then install it to the oil control valve.
support flange in a continuous bead as shown in 2. Assemble the oil control valve to the cylinder
the illustration. head.
Specified sealant: MITSUBISHI GENUINE 3. Tighten the oil control valve mounting bolt to the
PART MD970389 or equivalent specified torque.
OIL PAN
OIL PAN
M1112002800763

• Under Cover Removal (Refer to GROUP 51, Under Cover • Centre Member Installation (Refer to GROUP 32, Engine
P.51-19). Roll Stopper and Centre Member P.32-12).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Front Exhaust Pipe Installation (Refer to GROUP 15,
Service − Engine Oil Replacement P.12-3). Exhaust Pipe and Main Muffler P.15-13).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Exhaust Pipe and Main Muffler P.15-13). Service − Engine Oil Replacement P.12-3).
• Centre Member Removal (Refer to GROUP 32, Engine • Under Cover Installation (Refer to GROUP 51, Under
Roll Stopper and Centre Member P.32-12). Cover P.51-19).
N 1
48 ± 7 N·m
2
8
N 1
12 ± 2 N·m
48 ± 7 N·m
9.0 ± 3.0 N·m

4
N 6
9.0 ± 3.0 N·m
9.0 ± 1.0 N·m
3
44 ± 10 N·m
39 ± 5 N·m 5
7 22 ± 4 N·m
9.0 ± 3.0 N·m 9.0 ± 3.0 N·m AC308976 AB
Removal steps Removal steps (Continued)

1. Engine oil cooler tube gaskets 4. Flywheel housing front lower cover
<M/T> <M/T> or torque converter housing
2. Engine oil cooler hose and bracket front lower cover <A/T>
assembly <M/T> 5. Engine oil pan drain plug
>>D<< 3. Transmission housing front lower >>C<< 6. Engine oil pan drain plug gasket
cover stay <<A>> >>B<< 7. Engine lower oil pan
<> >>A<< 8. Engine upper oil pan
OIL PAN
REMOVAL SERVICE POINTS 2. Screw in the bolt into bolt hole A in the location
<<A>> ENGINE LOWER OIL PAN REMOVAL shown. Then lift the upper oil pan and remove it.
1. Remove the engine lower oil pan mounting bolts.
CAUTION
>>A<< ENGINE UPPER OIL PAN INSTALLATION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of 1. Remove sealant from the engine upper oil pan
aluminium and this tool will damage it. and cylinder block surfaces.
φ 4 mm
Engine lower oil pan Groove Bolt hole
AC102931AB
2. Apply a piece of wood to the lower oil pan and 2. Apply a bead of the sealant to the mating surface
strike it with a hammer to remove the engine of the engine upper oil pan as shown.
lower oil pan. Specified sealant: MITSUBISHI GENUINE
<> ENGINE UPPER OIL PAN REMOVAL NOTE: Install the engine upper oil pan within 15
1. Remove the engine upper oil pan mounting bolts. minutes after applying sealant.
CAUTION 3. Assemble the engine upper oil pan to the cylinder
Do not use special tool oil pan remover block.
(MD998727). The engine upper oil pan is made of
A
A
AC102946AB
OIL PAN
CAUTION 2. Apply a bead of the sealant to the mating surface

Then wait at least one hour. Never start the of the engine lower oil pan as shown.
engine or let engine oil or coolant touch the Specified sealant: MITSUBISHI GENUINE
sealant surface during that time. PART MD970389 or equivalent
NOTE: Install the engine lower oil pan within 15
B B
B B
minutes after applying sealant.
3. Assemble the engine lower oil pan to the engine
B upper oil pan.
B CAUTION
B B engine or let engine oil or coolant touch the
sealant surface during that time.
B B B-1 B-11
B-10
B B B-4
B-7
B B-5
B B-6
B B-8 A-3
B
B-9 B-12 B-2
A AC102930AB
A
4. Insert the bolts to the engine lower oil pan as
AC102929AB shown, and tighten them to the specified torque in
4. Insert the bolts to the engine upper oil pan as the order shown.
shown, and tighten them to the specified torque. Name Symbol Quantity Size mm
Name Symbol Quantity Size mm (D × L)
(D × L) Flange bolt A 1 M6 × 75
Flange bolt A 2 M6 × 16 B 11 M6 × 10
B 16 M6 × 18 NOTE: D: Nominal diameter, L: Nominal length
NOTE: D: Nominal diameter, L: Nominal length Tightening torque: 9.0 ± 3.0 N⋅m
Tightening torque: 9.0 ± 3.0 N⋅m
>>C<< ENGINE OIL PAN DRAIN PLUG GASKET
>>B<< ENGINE LOWER OIL PAN INSTALLATION INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.
Engine lower
oil pan side
AC102325 AF
φ 4 mm
Replace the gasket with a new one. Install the new
Groove Bolt hole
gasket in the direction shown in the illustration.
CRANKSHAFT OIL SEAL
>>D<< TRANSMISSION HOUSING FRONT 2. Tighten the transmission side two mounting bolts
LOWER COVER STAY INSTALLATION to the specified torque.
Install the transmission housing front lower cover Tightening torque: 44 ± 10 N⋅m
stay in the following order.
1. Tighten the engine side four mounting bolts to the INSPECTION
specified torque. M1112002900254
• Check the oil pan for cracks.
• Check the oil pan sealant-coated surface for
damage and deformation.
CRANKSHAFT OIL SEAL

M1112003100411
<M/T>
6 4 132 ± 5 N·m
7
9N
3 9
(Lip section) (Lip section)
3N Engine oil
1
AC308977 AB
steps steps
• Valve timing belt, balancer timing <<A>> • Transmission assembly
belt (Refer to P.11C-36). <> >>B<< 4. Flywheel bolts
>>D<< 1. Crankshaft balancer shaft drive 5. Flywheel adapter plate
sprocket 6. Flywheel assembly
2. Crankshaft key 7. Flywheel adapter plate
>>C<< 3. Crankshaft front oil seal 8. Crankshaft bush
CRANKSHAFT OIL SEAL
<A/T>
4 132 ± 5 N·m
6
N 8
5
7
3 8
(Lip section) (Lip section)
3N Engine oil
1
AC308978AB
steps steps
• Valve timing belt, balancer timing • Transmission assembly (Refer to
belt (Refer to P.11C-36). GROUP 23A, Transmission
>>D<< 1. Crankshaft balancer shaft drive Assembly P.23A-172).
sprocket <> >>B<< 4. A/T drive plate bolts
2. Crankshaft key 5. A/T drive plate adapter plate
>>C<< 3. Crankshaft front oil seal 6. A/T drive plate
7. Crankshaft bush
CRANKSHAFT OIL SEAL
REMOVAL SERVICE POINTS 1. Apply a small amount of engine oil to the entire
<<A>> TRANSMISSION ASSEMBLY REMOVAL inner diameter of the oil seal lip.
CAUTION 2. Use the following special tools to press-fit the oil
seal.
AC300897
• Installer bar (MB990938)
• Crankshaft rear oil seal installer (MD998776)
Engine front >>B<< FLYWHEEL BOLTS/A/T DRIVE PLATE

Flywheel BOLTS INSTALLATION
assembly
Flywheel
bolt
AC308604 AB MD998781
Do not remove the flywheel bolt shown by the
arrow. If this bolt is removed, the flywheel
assembly will become out of balance and
damaged.
Refer to GROUP 22A, Transmission Assembly AC301855AB
P.22A-15.
1. Use special tool flywheel stopper (MD998781) to
<> FLYWHEEL BOLTS/A/T DRIVE PLATE secure the flywheel assembly or A/T drive plate in
BOLTS REMOVAL the same manner as removal.
2. Tighten the flywheel bolts or A/T drive plate bolts
MD998781 >>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION
Crankshaft MD998375
AC301854AB
1. Use special tool flywheel stopper (MD998781) to (Engine oil)

secure the flywheel assembly or A/T drive plate.
2. Remove the flywheel bolts or A/T drive plate bolts.
MD998285 Oil seal
INSTALLATION SERVICE POINTS (Oil applied to the
circumference) AC102329AC
>>A<< CRANKSHAFT REAR OIL SEAL
INSTALLATION 1. Apply a small amount of engine oil to the outer
diameter of special tool crankshaft front oil seal
Oil seal guide (MD998285) and install it to the crankshaft.
MB990938 inner diameter of the oil seal lip.
3. Use special tool crankshaft front oil seal installer
(Engine oil) (MD998375) to press-fit the oil seal.
MD998776 Crankshaft
AC102328 AB
CRANKSHAFT OIL SEAL
>>D<< CRANKSHAFT BALANCER SHAFT DRIVE 1. Clean or degrease the front case, the crankshaft
SPROCKET INSTALLATION and the crankshaft balancer shaft drive sprocket
as shown.
: Clean
: Clean and degrease NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket
Crankshaft in the direction shown in the illustration.
balancershaft
drive sprocket
Crankshaft
Front case
Engine front
AC301346AB

M1112004000848

• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Accelerator Cable Installation (Refer to GROUP 17,
On-vehicle Service − Fuel Pump Connector Accelerator Cable and Pedal P.17-7).
Disconnection (How to Reduce Pressurized Fuel Lines) • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.13B-428]. P.15-4).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-17). Service − Engine Coolant Replacement P.14-17).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Accelerator Cable Adjustment (Refer to GROUP 17,
P.15-4). On-vehicle Service − Accelerator Cable Check and
• Accelerator Cable Removal (Refer to GROUP 17, Adjustment P.17-5).
Accelerator Cable and Pedal P.17-7). • Fuel Leak Check
5
4
5.0 ± 1.0 N·m
6 2
9.0 ± 2.0 N·m
13 ± 1 N·m
1
14 ± 3 N·m
(Engine oil) N 7
AC308979AB

1. Control wiring harness connection 5. Brake booster vacuum hose
2. Battery wiring harness connection connection
3. Radiator lower hose clamp 6. Engine oil level gauge and guide
4. Canister vacuum hose connection assembly
7. O-ring
13
14 (Engine oil)
<Cold engine>
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
15 12
(Engine oil)
9 16
8
11 ± 1 N·m
11 17 N
31 ± 3 N·m
10
31 ± 3 N·m
89 ± 9 N·m AC308980AB

8. Detonation sensor connection • Water inlet fitting and thermostat
9. Battery wiring harness connection case assembly (Refer to GROUP
10. Inlet manifold stay 14, Water Hose and Water Pipe
• Exhaust manifold (Refer to GROUP P.14-27).
15, Exhaust Manifold P.15-11). <<C>> >>C<< 14. Fuel high-pressure hose
• Timing belt upper cover (Refer to connection
P.11C-36). • Rocker cover assembly (Refer to
<<A>> >>E<< 11. Camshaft sprocket P.11C-18).
<> >>D<< 12. Radiator upper hose connection <<D>> >>B<< 15. Cylinder head bolts
13. Water hose connection 16. Cylinder head assembly
>>A<< 17. Cylinder head gasket
REMOVAL SERVICE POINTS 3. Screw in the special tool until it comes in contact
<<A>> CAMSHAFT SPROCKET REMOVAL with the timing belt tensioner arm.
AC107621
CAUTION
Never turn the crankshaft anti-clockwise. Wiring band
Timing mark
AC301451AC
4. Secure the camshaft sprocket and valve timing

AC301450AB belt with wiring bands and so on to prevent
slippage between the camshaft sprocket and
1. Turn the crankshaft clockwise, align the timing
valve timing belt.
marks on the camshaft sprocket to set No.1
cylinder to TDC of its compression stroke.
MB990767
MD998738
MD998719
Timing belt AC100302 AB

under cover
AC301452AB 5. Use the following special tools to hold the
camshaft sprocket.
2. Remove the timing belt under cover rubber plug
and then set special tool adjusting bolt
• Pin (MD998719)
(MD998738).
CAUTION
Do not rotate the crankshaft after camshaft
Timing belt sprocket removal.
tensioner arm
6. Remove the camshaft sprocket with the valve
MD998738 timing belt and place it on the timing belt lower
cover.
AC301373AB
<> RADIATOR UPPER HOSE 2. Remove the fuel high-pressure hose in the
DISCONNECTION direction shown in the figure while the retainer is
pulled up.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.
<<D>> CYLINDER HEAD BOLTS REMOVAL
Mating marks
AC200641AB
Make mating marks on the radiator upper hose and MB991654

the hose clamp. Disconnect the radiator upper hose.
<<C>> FUEL HIGH-PRESSURE HOSE REMOVAL
Engine front
3 5 10 8 2
Stopper
1 7 9 6 4
AC304581AB
1. Remove the fuel high-pressure hose stopper. AC301454AB
Use special tool cylinder head bolt wrench

(MB991654) to loosen the cylinder head bolts in two
or three steps in the order of the numbers shown in
the illustration. If the cylinder head bolts cannot be
pulled out due to the washer being trapped in the
valve spring, raise the bolt slightly, then remove it
while holding it by using a magnet.
Retainer
AC304582AB

>>A<< CYLINDER HEAD GASKET
INSTALLATION
CAUTION
Do not allow any foreign materials get into the MB991654
coolant passages, oil passages and cylinder.
1. Degrease the cylinder head gasket mounting
surface.
Engine front
Identification
mark "381" 8 6 1 3 9
Exhaust side
10 4 2 5 7
AC302180AB
2. Assemble to the cylinder block so the cylinder AC301456AB

head gasket identification mark of "381" is at the
top surface and on the exhaust side. 3. Use special tool cylinder head bolt wrench
(MB991654) to tighten the cylinder head bolts in
the following procedures.
>>B<< CYLINDER HEAD BOLTS INSTALLATION
(1) Tighten the bolts to 78 ± 2 N⋅m in the order
shown.
(Engine oil)
(2) Loosen the bolts fully in the reverse sequence
to that shown.
(3) Tighten the bolts to 20 ± 2 N⋅m in the order
shown.
Step (4) Step (5)
A
90˚ 90˚
AC102537AC
1. Check that the nominal length of each cylinder

head bolt meets the limit. If it exceeds the limit,
replace the bolts with a new one.
Paint marking Paint marking
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of AC102331AB
the bolts and to the washers. (4) Apply a paint mark to the heads of the cylinder
head bolts and cylinder head, then tighten 90
degree angle as shown.
CAUTION
• The bolt is not tightening sufficiently if the >>D<< RADIATOR UPPER HOSE CONNECTION
tightening angle is less than a 90 degree
angle.
Projection
• If the tightening angle exceeds the standard
specification, remove the bolt and start over
from step 1.
(5) Tighten in a 90 degree angle as shown in the
instructions of the figure, then check to see
that the paint mark on the head of the cylinder Water outlet fitting
Mating marks
head bolts and the paint mark on the cylinder
head is on a linear line. AC200642 AB
1. Insert radiator upper hose until it contacts the

>>C<< FUEL HIGH-PRESSURE HOSE
projection on the water outlet fitting.
INSTALLATION
2. Align the mating marks on the radiator upper hose
CAUTION and hose clamp, and then secure the radiator
Fuel upper hose.
high-pressure
3 mm
hose
>>E<< CAMSHAFT SPROCKET INSTALLATION
MB990767
Fuel line pipe
(Engine oil applied)
AC301864AB MD998719
AC100302 AB
1. Use the following special tool as during removal to

hold the camshaft sprocket.
• Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
Stopper the specified torque.
AC304583AB
After connecting the fuel high-pressure hose, Tightening torque: 89 ± 9 N⋅m

slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.
TIMING BELT
TIMING BELT
M1112004300827

• Under Cover Removal (Refer to GROUP 51, Under Cover • Crankshaft Shaft Damper Pulley Installation (Refer to
P.51-19). P.11C-17).
• Crankshaft Shaft Damper Pulley Removal (Refer to • Drive Belt Tension Check (Refer to P.11C-8).
P.11C-17). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
2
14 ± 3 N·m
11 ± 1 N·m
1 3
5
4
14 ± 1 N·m 12
11
48 ± 5 N·m
14 ± 1 N·m
6
9
8.8 ± 1.0 N·m 11 ± 1 N·m
21 ± 4 N·m
8
13
44 ± 10 N·m
23 ± 3 N·m
22 ± 4 N·m
10
7
79 ± 5 N·m
11 ± 1 N·m
9.0 ± 1.0 N·m
AC308981AB

1. Control wiring harness connection 7. Idler pulley
2. Battery wiring harness connection 8. Auto-tensioner
3. Connector bracket 9. Timing belt lower cover
• Engine front mounting bracket >>G<< • Valve timing belt tension
(Refer to GROUP 32, Engine adjustment (Installation only)
Mount P.32-5). <<A>> >>F<< 10. Valve timing belt
4. Harness bracket >>E<< 11. Timing belt tensioner pulley
5. Timing belt upper cover 12. Timing belt tensioner arm
6. Water pump pulley >>D<< 13. Timing belt tensioner adjuster
TIMING BELT
14
35 ± 6 N·m
22
21
19 ± 3 N·m
18
(Engine oil)
20 16
15
19
167 N·m 17 8.5 ± 0.5 N·m
AC308982 AB

14. Timing belt Idler pulley >>C<< 20. Crankshaft angle sensing blade
15. Timing belt lower cover bracket >>B<< • Balancer timing belt tension
16. Crank angle sensor adjustment (Installation only)
<> >>C<< 17. Crankshaft pulley centre bolt >>A<< 21. Balancer timing belt tensioner
<> >>C<< 18. Crankshaft pulley washer <<C>> >>A<< 22. Balancer timing belt
<> >>C<< 19. Crankshaft camshaft drive sprocket
TIMING BELT
REMOVAL SERVICE POINTS 2. Remove the timing belt under cover rubber plug
<<A>> VALVE TIMING BELT REMOVAL and then set special tool adjusting bolt
(MD998738).
CAUTION
Never turn the crankshaft anti-clockwise.
Timing belt
tensioner arm
Timing mark
MD998738
AC301373AB
Camshaft
sprocket
3. Screw in the special tool with hands until it
contacts the timing belt tensioner arm.
Timing mark CAUTION
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner
Timing mark adjuster rod will not easily retract and the special
Engine oil pump
tool may bend.
Crankshaft sprocket
camshaft
A
drive sprocket AC301866AB B
1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke.
MD998738
AC301856 AB
4. Gradually screw in the special tool and then align

the timing belt tensioner adjuster rod set hole A
with the timing belt tensioner adjuster cylinder set
hole B.
Timing belt
under cover
AC301452AB
TIMING BELT
Timing belt tensioner INSTALLATION SERVICE POINTS

pulley mounting bolt >>A<< BALANCER TIMING BELT/BALANCER
Wire or pin TIMING BELT TENSIONER INSTALLATION
Balancershaft
sprocket
Belt tension
AC302414AB side
5. Insert a wire or pin in the set hole aligned.

Timing
CAUTION mark
To reuse the valve timing belt, draw an arrow Timing
indicating the rotating direction (clockwise) on mark
the back of the belt using chalk, etc.
6. After removal of the special tool, loosen the timing
belt tensioner pulley mounting bolts and remove
the valve timing belt.
<> CRANKSHAFT PULLEY CENTRE Crankshaft

balancershaft
BOLT/CRANKSHAFT PULLEY drive sprocket
WASHER/CRANKSHAFT CAMSHAFT DRIVE
SPROCKET REMOVAL AC301402AB
Crankshaft 1. Ensure that the crankshaft balancer shaft drive

camshaft MB991385 sprocket timing marks and balancer shaft
drive sprocket timing marks are aligned.
sprocket
2. Install the balancer timing belt on the crankshaft
balancer shaft drive sprocket and balancer shaft
sprocket. There should be no slack on the tension
MB991367 side.
Centre of the
AC102332AB mounting bolt
1. Use the following special tools to hold the

crankshaft camshaft drive sprocket.
• Special spanner (MB991367)
• Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
Centre of
remove the crankshaft pulley washer and the pulley
crankshaft camshaft drive sprocket. AC301403AB
<<C>> BALANCER TIMING BELT REMOVAL 3. Assemble and temporarily fix the centre of the
pulley of the balancer timing belt tensioner so that
CAUTION it is at the top left from the centre of the
To reuse the balancer timing belt, draw an arrow assembling bolt, and the pulley flange is at the
indicating the rotating direction on the back of front-side of the engine.
the belt using chalk, etc.
4. Adjust the balancer timing belt tension.
TIMING BELT
>>B<< BALANCER TIMING BELT TENSION

ADJUSTMENT
CAUTION Balancershaft
When tightening the mounting bolts, ensure that sprocket
the tensioner does not rotate with the bolts.
Allowing it to rotate with the bolts can cause
excessive tension of the belt.
Timing
mark
Timing
mark
AC301404
Crankshaft
1. Lift with your fingers the balancer timing belt balancershaft
drive sprocket
tensioner in the direction of the arrow. Apply a
tensile torque of 3.0 ± 0.4 N⋅m to the balancer AC301402AC
timing belt so the belt is tense without any
looseness. Tighten the assembling bolt to the 2. Turn the crankshaft clockwise two turns to set
specified torque in this state. Then, fix the No.1 cylinder to TDC of its compression stroke
balancer timing belt tensioner. and check that sprocket timing marks are aligned.
Approximately 100 N
Deflection
AC301405AB
3. Apply a pressure of approximately 100 N at the

centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the belt
deflection is within the standard value.
Standard value:
<When adjusting> 5 − 7 mm
<When replacing> 5 − 7 mm
tension again.
TIMING BELT
>>C<< CRANKSHAFT ANGLE SENSING 5. Use the following special tool as during removal to
BLADE/CRANKSHAFT CAMSHAFT DRIVE hold the crankshaft camshaft drive sprocket.
SPROCKET/CRANKSHAFT PULLEY • Special spanner (MB991367)
WASHER/CRANKSHAFT PULLEY CENTRE BOLT • Pin (MB991385)
INSTALLATION 6. Tighten the crankshaft pulley centre bolt to the
specified torque.
: Clean
: Clean and degrease Tightening torque: 167 N⋅m
: Apply engine oil
>>D<< TIMING BELT TENSIONER ADJUSTER

Crankshaft pulley INSTALLATION
centre bolt 1. Set according to the following procedures when
Crankshaft angle the timing belt tensioner adjuster rod is fully
sensing blade extended.
Crankshaft CAUTION
pulley washer
If the compression is too fast the procedure may
damage the rod. Make a point to slowly and
thoroughly compress.
A B
Crankshaft camshaft Crankshaft

drive sprocket
Engine front
AC301347AB
1. Clean or degrease the crankshaft, the crankshaft AC302024 AB

angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as (1) Slowly compress the timing belt tensioner
shown. adjuster rod using a press or vice, then align
NOTE: Also clean the degreased surfaces. the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.
2. Install the crankshaft angle sensing blade and
crankshaft camshaft drive sprocket in the Wire or pin
direction shown.
3. Place the larger chamfer side of the crankshaft
pulley washer in the direction shown in the Figure
and then assemble on the crankshaft pulley
centre bolt.
4. Apply a small of engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
AC302025AB
Crankshaft
camshaft MB991385 (2) Insert a wire or pin in the set hole aligned.
drive
sprocket
NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin.
2. Install the timing belt tensioner adjuster to the
MB991367 engine and then tighten the mounting bolt to the
specified torque. Do not remove the wire or pin
AC102332AB
until the tension of the valve timing belt is
adjusted.
TIMING BELT
Tightening torque: 23 ± 3 N⋅m 2. Adjust the timing mark of the engine oil pump
sprocket. Unplug the cylinder block plug. Insert a
>>E<< TIMING BELT TENSIONER PULLEY bolt (M6, section width 10 mm, nominal length 45
INSTALLATION mm) from the plug hole. If the bolt comes in
contact with the balancer shaft, turn the engine oil
sprocket one rotation. Re-adjust the timing mark
and then check to see that the bolt fits. Do not
remove the bolt until the valve timing belt is
assembled.
Camshaft
Timing belt tensioner sprocket
pulley hole
AC102336AB
Temporarily tighten the timing belt tensioner pulley

as shown. Timing belt
tensioner Belt tension
pulley side
>>F<< VALVE TIMING BELT INSTALLATION
Timing mark
Timing belt
Idler pulley
Engine oil pump

Camshaft
Crankshaft sprocket
sprocket
camshaft
drive sprocket AC301372AC
Timing mark
3. Incorporate the valve timing belt in the following
manner so that the tensile force of the belt is not
lax.
Timing mark (1) Place the valve timing belt on the timing belt
tensioner pulley and crankshaft camshaft
Engine oil pump driver sprocket and then support it with your
Crankshaft sprocket
left hand so it does not slide.
camshaft
drive sprocket (2) Place the valve timing belt on the engine oil
AC301374AB
pump sprocket while pulling it with the right
1. Align the timing marks on the camshaft sprocket, hand.
crankshaft camshaft drive sprocket and engine oil (3) Place the valve timing belt on the timing belt
pump sprocket. idler pulley.
Bolt
CAUTION
Balancershaft Incorporate the valve timing belt. Then apply
reverse rotation (anti-clockwise rotation)
pressure to the camshaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is right.
(4) Place the valve timing belt on the camshaft
sprocket.
Plug
Cylinder block
AC301871AB
TIMING BELT
Bolt
Balancershaft
MD998767
Plug
Cylinder block
AC301858 AB AC301871AB
4. Turn the timing belt tensioner pulley in the 6. Remove the bolt inserted in Step 2 above, then
direction shown in the figure using special tool assemble the cylinder block plug.
tensioner wrench (MD998767) to apply tension to 7. Tighten the cylinder block plug to the specified
the valve timing belt. Then temporarily tighten and torque.
fix the timing belt tensioner pulley mounting bolt.
8. Adjust the valve timing belt tension.
Timing mark
>>G<< VALVE TIMING BELT TENSION
ADJUSTMENT
MD998738
Camshaft
sprocket
Timing mark
Timing belt
under cover
AC301452AB
Timing mark 1. Set special tool adjusting bolt (MD998738) used

Engine oil pump when removing the valve timing belt.
Crankshaft sprocket CAUTION
camshaft Always screw in the special tool in with your
drive sprocket AC301372AB hands, since use of a spanner or other tools may
damage the wire or pin inserted in the timing belt
5. Check that the timing marks are aligned.
tensioner adjuster.
2. Gradually screw in the special tool to a position in
which the wire or pin inserted in the timing belt
tensioner adjuster lightly moves.
3. Turn the crankshaft 1/4 of a revolution in the
anti-clockwise direction.
TIMING BELT
Timing mark
Wire or pin
Camshaft
sprocket
AC301857AB
Timing mark
7. Remove wire or pin inserted to timing belt
tensioner adjuster.
Timing mark MD998738

Engine oil pump
Crankshaft sprocket
camshaft
drive sprocket AC301372AB
4. Turn the crankshaft in the clockwise direction, Timing belt

align each timing mark to set No.1 cylinder to TDC under cover
of its compression stroke. AC301452AB
5. Loosen the timing belt tensioner pulley mounting

8. Remove special tool adjusting bolt (MD998738),
bolt.
and install the rubber plug to the timing belt under
CAUTION cover.
When tightening the mounting bolt, ensure that 9. Rotate crankshaft clockwise two turns, and leave
the timing belt tensioner pulley does not rotate it for about 15 minutes.
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
Wire or pin
MD998767
AC301857AB
AC301859 AB 10.Insert wire or pin removed in Step 7 again, and

ensure that it can be pulled out with a light load.
6. With special tool tensioner wrench (MD998767) When wire or pin can be lightly removed,
and torque wrench, apply tension torque 3.5 N⋅m appropriate tension is applied on timing belt. In
to the valve timing belt, and tighten the timing belt this case, remove wire or pin.
tensioner pulley mounting bolt to the specified
torque.
TIMING BELT
12.Check again that the timing marks on sprockets

are aligned.
A
INSPECTION
M1112004400460
TIMING BELT TENSIONER ADJUSTER

Rod CHECK
1. Check for oil leak from seal, and replace it if leak
is detected.
AC301375AB 2. Check for wear or damage at the top of the rod.
Replace it, if required.
Also the projection of timing belt tensioner
adjuster rod (A) is within the standard value, 98 – 196 N
appropriate tension is applied.
Standard value (A): 3.8 − 4.5 mm A Movement
B
11.If wire or pin cannot be easily pulled out, repeat
Step 1 through Step 9 to reach proper valve timing Rod
belt tension.
CAUTION
Always check the tightening torque of the
crankshaft pulley centre bolt when turning the AC301376AB
crankshaft pulley centre bolt anti-clockwise.
Re-tighten if it is loose. 3. Hold the timing belt tensioner adjuster by hand,
and press top end of the rod onto the metal (e.g.
cylinder block) under a pressure of 98 − 196 N to
Timing mark measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A − B: Movement
4. If the measured value is out of the standard value,
Camshaft replace the timing belt tensioner adjuster.
sprocket
Timing mark
Timing mark
Engine oil pump

Crankshaft sprocket
camshaft
drive sprocket AC301866AB
TIMING BELT
BALANCER TIMING BELT TENSION 1. Apply a pressure of approximately 100 N at the

CHECK centre (arrow area) between the sprocket as
Check the balancer timing belt tension in the shown in the figure, then inspect whether the
following procedures. flexure is within the standard value.
Standard value: 5 − 10 mm
Approximately 100 N
tension. (Refer to P.11C-36).
Deflection
AC301405AB
ENGINE ASSEMBLY
ENGINE ASSEMBLY
M1112001000946
<M/T>
CAUTION
• Under Cover Removal (Refer to GROUP 51, Under Cover • Front Exhaust Pipe Installation (Refer to GROUP 15,
P.51-19). Exhaust Pipe and Main Muffler P.15-13).
• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Radiator Assembly Installation (Refer to GROUP 14,
On-vehicle Service − Fuel Pump Connector Radiator P.14-29).
Disconnection (How to Reduce Pressurized Fuel Lines) • Accelerator Cable Installation (Refer to GROUP 17,
P.13B-428]. Accelerator Cable and Pedal P.17-7).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Battery and Battery Tray Installation
Service − Engine Oil Replacement P.12-3). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle P.15-4).
Service − Engine Coolant Replacement P.14-17). • Hood Installation (Refer to GROUP 42, Hood P.42-4).
• Transmission Oil Draining (Refer to GROUP 22A, • Transfer Oil Refilling (Refer to GROUP 22A, On-vehicle
On-vehicle Service − Transmission Oil Replacement Service − Transfer Oil Replacement P.22A-8).
P.22A-8). • Transmission Oil Refilling (Refer to GROUP 22A,
• Transfer Oil Draining (Refer to GROUP 22A, On-vehicle On-vehicle Service − Transmission Oil Replacement
Service − Transfer Oil Replacement P.22A-8). P.22A-8).
• Hood Removal (Refer to GROUP 42, Hood P.42-4). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner Service − Engine Coolant Replacement P.14-17).
P.15-4). • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Battery and Battery Tray Removal Service − Engine Oil Replacement P.12-3).
• Accelerator Cable Removal (Refer to GROUP 17, • Accelerator Cable Adjustment (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7). On-vehicle Service − Accelerator Cable Check and
• Radiator Assembly Removal (Refer to GROUP 14, Adjustment P.17-5).
Radiator P.14-29). • Fuel Leak Check
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Drive Belt Tension Check (Refer to P.11C-8).
Exhaust Pipe and Main Muffler P.15-13). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-6).
ENGINE ASSEMBLY
9.0 ± 2.0 N·m
4 1
3
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m
N 6 6N
48 ± 7 N·m 9.0 ± 2.0 N·m
7
5.0 ± 1.0 N·m
N 6 12 ± 2 N·m
48 ± 7 N·m
AC308983 AB

1. Control wiring harness connection <<A>> 5. Drive belt
2. Battery wiring harness connection 6. Engine oil cooler tube gaskets
3. Canister vacuum hose connection 7. Engine oil cooler hose and bracket
4. Brake booster vacuum hose assembly
connection
ENGINE ASSEMBLY
10 11
(Engine oil)
15
24 ± 4 N·m
8 44 ± 10 N·m
N 13 70 ± 4 N·m*
44 ± 10 N·m*
22 ± 4 N·m
44 ± 10 N·m*
12 9
14
AC308984 AB

<> 8. Power steering oil pump and <<E>> >>D<< • Transmission assembly
bracket assembly 12. Earth cable connection
<<C>> 9. A/C compressor and clutch 13. Self-locking nuts
assembly <<F>> >>B<< 14. Engine front mounting bracket
10. Heater water hoses connection <<G>> >>A<< 15. Engine assembly
<<D>> >>E<< 11. Fuel high-pressure hose
connection
ENGINE ASSEMBLY
<A/T>
CAUTION
• Under Cover Removal (Refer to GROUP 51, Under Cover • Front Exhaust Pipe Installation (Refer to GROUP 15,
P.51-19). Exhaust Pipe and Main Muffler P.15-13).
• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Radiator Assembly Installation (Refer to GROUP 14,
On-vehicle Service − Fuel Pump Connector Radiator P.14-29).
Disconnection (How to Reduce Pressurized Fuel Lines) • Accelerator Cable Installation (Refer to GROUP 17,
P.13B-428]. Accelerator Cable and Pedal P.17-7).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Battery and Battery Tray Installation
Service − Engine Oil Replacement P.12-3). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle P.15-4).
Service − Engine Coolant Replacement P.14-17). • Hood Installation (Refer to GROUP 42, Hood P.42-4).
• Transmission Fluid Draining (Refer to GROUP 23A, • Transfer Oil Refilling (Refer to GROUP 23A, On-vehicle
On-vehicle Service − Automatic Transmission Fluid Service − Transfer Oil Replacement P.23A-147).
Change P.23A-144). • Transmission Fluid Refilling (Refer to GROUP 23A,
• Transfer Oil Draining (Refer to GROUP 23A, On-vehicle On-vehicle Service − Automatic Transmission Fluid
Service − Transfer Oil Replacement P.23A-147). Change P.23A-144).
• Hood Removal (Refer to GROUP 42, Hood P.42-4). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner Service − Engine Coolant Replacement P.14-17).
P.15-4). • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Battery and Battery Tray Removal Service − Engine Oil Replacement P.12-3).
• Accelerator Cable Removal (Refer to GROUP 17, • Accelerator Cable Adjustment (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7). On-vehicle Service − Accelerator Cable Check and
• Radiator Assembly Removal (Refer to GROUP 14, Adjustment P.17-5).
Radiator P.14-29). • Fuel Leak Check
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Drive Belt Tension Check (Refer to P.11C-8).
Exhaust Pipe and Main Muffler P.15-13). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
GROUP 33, On-vehicle Service − Front Wheel Alignment
ENGINE ASSEMBLY
9.0 ± 2.0 N·m
4 1
3
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m

AC308985AB

1. Control wiring harness connection 4. Brake booster vacuum hose
2. Battery wiring harness connection connection
3. Canister vacuum hose connection <<A>> 5. Drive belt
ENGINE ASSEMBLY
8 9
(Engine oil)
13
24 ± 4 N·m
6 44 ± 10 N·m
44 ± 10 N·m*
N 11 45 ± 5 N·m*
22 ± 4 N·m
44 ± 10 N·m*
10
12
7 AC308986AB

<> 6. Power steering oil pump and <<E>> >>D<< • Transmission assembly
bracket assembly 10. Earth cable connection
<<C>> 7. A/C compressor and clutch >>C<< 11. Self-locking nuts
assembly <<F>> >>B<< 12. Engine front mounting bracket
8. Heater water hoses connection <<G>> >>A<< 13. Engine assembly
<<D>> >>E<< 9. Fuel high-pressure hose
connection
ENGINE ASSEMBLY
REMOVAL SERVICE POINTS NOTE: After removing the power steering oil pump
<<A>> DRIVE BELT REMOVAL and bracket assembly, secure it with a cord in the
The following operations will be needed due to the location where the removal and installation of the
introduction of the serpentine drive system with the engine assembly cannot be hindered.
drive belt auto-tensioner.
AC301703
<<C>> A/C COMPRESSOR AND CLUTCH
Auto-tensioner ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly from the bracket.
NOTE: After removing the A/C compressor and
clutch assembly, secure it with a cord in the location
Hole B where the removal and installation of the engine
assembly cannot be hindered.
Hole A
AC301704AB
<<D>> FUEL HIGH-PRESSURE HOSE REMOVAL
1. Securely insert the spindle handle or ratchet

handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
CAUTION Stopper
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc. AC304581AB
1. Remove the fuel high-pressure hose stopper.

Auto-tensioner
L-shaped
hexagon
wrench AC301705AB
3. Insert an L-shaped hexagon wrench, etc. into the Retainer

hole to fix and then remove the drive belt. AC304582AB
2. Remove the fuel high-pressure hose in the

<> POWER STEERING OIL PUMP AND
direction shown in the figure while the retainer is
BRACKET ASSEMBLY REMOVAL
pulled up.
With the hose installed, remove the power steering
oil pump and bracket assembly from the engine NOTE: If the retainer is released, install it after
assembly. removing the fuel high-pressure hose.
ENGINE ASSEMBLY
<<E>> TRANSMISSION ASSEMBLY REMOVAL (2) <Special tool engine hanger (MB991928) is
used>
Remove special tool MB991928.
MB991454
MB991527
AC300950AB
1. Pre-tighten the 2 bolts on the car to assemble the

AC107632 AB
radiator support upper insulator to set special tool
engine hanger MB991895 or engine hanger 3. Hold the engine assembly with a chain block, etc.
MB991928.
4. Place a garage jack against the engine oil pan
2. Remove the transmission assembly (M/T: Refer to with a piece of wood in between so that the weight
GROUP 22A, Transmission Assembly P.22A-15, of the engine assembly is no longer being applied
A/T: Refer to GROUP 23A, Transmission to the engine front mounting bracket.
Assembly P.23A-172).
5. Loosen the engine front mounting bracket
mounting nuts and bolts, and remove the engine
<<F>> ENGINE FRONT MOUNTING BRACKET front mounting bracket.
REMOVAL
1. Support the engine with a garage jack. <<G>> ENGINE ASSEMBLY REMOVAL
2. Remove the following special tool. After checking that all cables, hoses and wiring
MB991895 harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
MB991527 the engine assembly upward from the engine
compartment.

>>A<< ENGINE ASSEMBLY INSTALLATION
MB991454 MB991454
AC107631AB
MB991527
(1) <Special tool engine hanger (MB991895) is
used>
Remove special tool MB991895.
MB991928
AC107632 AB
Install the engine assembly, being careful not to

pinch the cables, hoses or wiring harness
MB991527 connectors.
MB991454
AC211405AB
ENGINE ASSEMBLY
>>B<< ENGINE FRONT MOUNTING BRACKET

INSTALLATION >>D<< TRANSMISSION ASSEMBLY
1. Place a garage jack against the engine oil pan INSTALLATION
with a piece of wood in between, and install the 1. Install the transmission assembly. (M/T: Refer to
engine front mounting bracket while adjusting the GROUP 22A, Transmission Assembly P.22A-15,
position of the engine. A/T: Refer to GROUP 23A, Transmission
2. Support the engine assembly with a garage jack. Assembly P.23A-172).
3. Remove the chain block.
4. Use the following special tool as during removal to
support the engine.
MB991895
MB991527
AC300950AB
2. Remove from the car the two bolts, to assemble

MB991454 the radiator support upper insulator.
AC107631AB
(1) <Special tool engine hanger (MB991895) is >>E<< FUEL HIGH-PRESSURE HOSE
used> INSTALLATION
Set special tool MB991895. (M/T: Refer to CAUTION
Fuel
P.22A-15, A/T: Refer to GROUP 23A, high-pressure
Transmission Assembly P.23A-172). 3 mm
hose
MB991928
Fuel line pipe

(Engine oil applied)
MB991527 AC301864AB
MB991454
AC211405AB
(2) <Special tool engine hanger (MB991928) is

used>
Set special tool MB991928. (M/T: Refer to
P.22A-15, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-172).
Stopper
AC304583AB
>>C<< SELF-LOCKING NUTS INSTALLATION After connecting the fuel high-pressure hose,
CAUTION slightly pull it to ensure that it is installed
Do not tighten the self-locking nuts while the securely. Also confirm that there is a play
engine is hot. approximately 3 mm. Then install the stopper
Tighten the self-locking nuts to the specified torque securely.
while the engine is cold. Apply a small amount of engine oil to the fuel line
Tightening torque: 45 ± 5 N⋅m pipe and then install the fuel high-pressure hose.
NOTES
12-1
GROUP 12
ENGINE
LUBRICATION
CONTENTS
GENERAL INFORMATION . . . . . . . . 12-2 ON-VEHICLE SERVICE . . . . . . . . . . . 12-3

ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-3
SERVICE SPECIFICATION . . . . . . . . 12-2 ENGINE OIL REPLACEMENT . . . . . . . . . . 12-3
ENGINE OIL FILTER REPLACEMENT. . . . 12-4
LUBRICANT. . . . . . . . . . . . . . . . . . . . 12-2 OIL PRESSURE CHECK . . . . . . . . . . . . . . 12-5
SEALANT. . . . . . . . . . . . . . . . . . . . . . 12-3 ENGINE OIL COOLER . . . . . . . . . . . . 12-6

REMOVAL AND INSTALLATION . . . . . . . . 12-6
SPECIAL TOOLS. . . . . . . . . . . . . . . . 12-3
12-2 ENGINE LUBRICATION
GENERAL INFORMATION
GENERAL INFORMATION
M1121000100346
The lubrication method is a fully force-fed, full-flow • Avoid contaminating clothes, particularly
filtration type. The oil pump is a gear type which is underpants, with oil.
driven by the crankshaft via the timing belt. • Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
ENGINE OILS • Do not wear heavily soiled clothing and
Health Warning oil-impregnated foot-wear. Overalls must be
Prolonged and repeated contact with mineral oil will cleaned regularly and kept separate from
result in the removal of natural fats from the skin, personal clothing.
leading to dryness, irritation and dermatitis. In • Where there is a risk of eye contact, eye
addition, used engine oil contains potentially harmful protection should be worn, for example, chemical
contaminants which may cause skin cancer. goggles or face shields; in addition an eye wash
Adequate means of skin protection and washing facility should be provided.
facilities must be provided. • Obtain First Aid treatment immediately for open
cuts and wounds.
Recommended Precautions • Wash regularly with soap and water to ensure all
The most effective precaution is to adapt working oil is removed, especially before meals (skin
practices which prevent, as far as practicable, the cleansers and nail brushes will help). After
risk of skin contact with mineral oils, for example by cleaning, the application of preparations
using enclosed systems for handling used engine oil containing lanolin to replace the natural skin oils
and by degreasing components, where practicable, is advised.
before handling them. Other precautions: • Do not use petrol, kerosine, diesel fuel, gas oil,
• Avoid prolonged and repeated contact with oils, thinners or solvents for cleaning skin.
particularly used engine oils. • Use barrier creams, applying them before each
• Wear protective clothing, including impervious work period, to help the removal of oil from the
gloves where practicable. skin after work.
• If skin disorders develop, obtain medical advice
without delay.
SERVICE SPECIFICATION
M1121000300254
Item Standard value

Oil pressure kPa at idle 29 or more
at 3,500 r/min 294 − 686
LUBRICANT
M1121000400529
Item Specification
Engine oil ACEA classification A1, A2 or A3
Engine oil API classification SG or higher
Engine oil quantity L 4G63, 4G69 (A/T) Oil filter 0.3
Total 4.3
4G69 (M/T) Oil filter 0.3
Oil cooler 0.3
Total 4.6
ENGINE LUBRICATION 12-3
SEALANT
SEALANT
M1121000500258

Oil pressure switch 3M ATD Part No. 8660 or equivalent Semi-drying sealant
SPECIAL TOOLS
M1121000600363

MB991610 Oil filter wrench Removal and installation
of engine oil filter (When
using the oil filter of
MD356000)
MB991610
MD998054 Oil pressure switch Removal and installation

wrench of oil pressure switch
ON-VEHICLE SERVICE
ENGINE OIL CHECK
M1121000900320
Drain plug
1. Pull out the level gauge slowly and check that the
oil level is in the illustrated range.
2. Check that the oil is not excessively dirty, that Drain plug
gasket
there is no coolant or petrol mixed in, and that it
has sufficient viscosity.
Oil pan side Oil pan
ENGINE OIL REPLACEMENT
M1121001000494
1. Start the engine and allow it to warm up until the AC300837AB
temperature of the coolant reaches 80 °C to 90
4. Install a new drain plug gasket so that it faces in
°C. the direction shown in the illustration, and then
2. Remove the engine oil filler cap. tighten the drain plug to the specified torque.
CAUTION Tightening torque: 39 ± 5 N⋅m
Use care as oil could be hot. NOTE: Install the drain plug gasket so it faces in
3. Remove the drain plug to drain oil. the direction shown in the illustration.
ON-VEHICLE SERVICE
MB991610 or
commercially-
available tool
AC000093 AH
AC301513
5. Refill with specified quantity of oil. 5. Use the respective tool in the following table to
Specified Engine Oil (ACEA and API remove the engine oil filter.
classification): ACEA A1, A2 or A3/API SG or 6. Clean the filter bracket side mounting surface.
higher
Total quantity (Includes volume inside engine
oil filter):
4.3 L <4G63, 4G69 (A/T)>
4.6 L <4G69 (M/T)>
6. Install the engine oil filler cap.
7. Check oil level.
ENGINE OIL FILTER REPLACEMENT O-ring

M1121001100350 AC103250AD
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80 °C to 90 7. Apply a small amount of engine oil to the O-ring of
°C. the new oil filter.
2. Remove the engine oil filler cap. 8. Once the O-ring of the oil filter is touching the
flange, use the respective tool in the following
CAUTION
table to tighten to the specified torque.
Use care as oil could be hot.
9. Install the drain plug and refill the engine oil (Refer
3. Remove the drain plug to drain oil. to P.12-3).
4. Remove the under cover. 10.Race the engine 2−3 times, and check to be sure
that no engine oil leaks from installation section of
the oil filter.
Number Special tool Tightening torque

MD356000 Oil filter wrench (MB991610) Approximately 3/4 turn (14 ± 2 N⋅m)
or equivalent
MD136466, Commercially- available tool Approximately 3/4 turn (17 ± 3 N⋅m)
MD322508
ON-VEHICLE SERVICE
OIL PRESSURE CHECK Standard value:

M1121002300432 At idle: 29 kPa or more
At 3,500 r/min: 294 − 686 kPa
7. Remove the oil pressure gauge.
Cylinder block
Oil pressure switch
AK000197AF
1. Check engine oil quantity.

2. Remove the oil pressure switch terminal. AKX00295AD
CAUTION 8. Apply the specified sealant to the thread of oil

pressure switch.
MD998054
Specified sealant: 3M! ATD Part No. 8660 or
equivalent
CAUTION
MD998054
AKX00294 AD
Since sealant is applied to the thread of oil

pressure switch, take care not to damage the oil
pressure switch when removing it.
3. Use the special tool Oil pressure switch wrench
AKX00294 AD
(MD998054) to remove the oil pressure switch.
4. Install the oil pressure gauge. Do not start the engine within one hour after the
oil pressure switch has been installed.
NOTE: Use an adapter of PT 1/8 thread.
9. Use the special tool Oil pressure switch wrench
5. Run the engine to warm it. (MD998054) to tighten the oil pressure switch to
6. After the engine has been warmed up, check that the specified torque.
oil pressure is within the standard value.
10.Install the oil pressure switch terminal.
ENGINE OIL COOLER
ENGINE OIL COOLER

M1121001300116

• Front Under Cover (LH) Removal (Refer to GROUP 51, • Front Under Cover (LH) Installation (Refer to GROUP 51,
Under Cover P.51-19). Under Cover P.51-19).
• Engine Oil Refilling and Level Check (Refer to P.12-3).
12 ± 2 N·m 5.0 ± 1.0 N·m
12 ± 2 N·m
27
26 45 ± 5 N·m
21
12 ± 2 N·m
13
17 24
48 ± 7 N·m
1
14 20 22
2 N 33 ± 2 N·m
45 ± 5 N·m N 23
3 12 ± 2 N·m
12 ± 2 N·m
11
4N
15 10
4N 25
9 19 N
12
12 ± 2 N·m
9 16 12 ± 2 N·m
10 48 ± 7 N·m
8
18
7 12 ± 2 N·m
5 6
AC309226AB
Engine oil cooler removal steps Engine oil cooler removal steps
⋅• Splash Shield Mounting Clips (LH) 9. Collar
(Refer to GROUP 51, Front Bumper 10. Bush
P.51-3). Engine oil cooler hose removal
1. Eye bolt steps (Engine oil cooler side)
2. Gasket 11. Engine oil cooler return hose
3. Eye bolt connection
4. Gasket 1. Eye bolt
5. Engine oil cooler assembly 2. Gasket
6. Bracket 12. Engine oil cooler return hose
7. Bracket 13. Bolt
8. Engine oil cooler
ENGINE OIL COOLER
Engine oil cooler hose removal

steps (Engine oil cooler side)
• Reserve tank assembly (Refer to
GROUP 14, Radiator P.14-29).
14. Engine oil cooler feed hose
connection
3. Eye bolt
4. Gasket
Engine oil cooler hose removal
steps (Engine side)
⋅• Side under cover (RH) (Refer to
GROUP 51, Under cover P.51-3).
16. Clamp
17. Engine oil cooler return hose
connection
18. Eye bolt
19. Gasket
connection
22. Eye bolt
23. Gasket
25. Bracket
Engine oil cooler feed and return
tube removal steps
⋅• Front bumper beam (Refer to
GROUP 51, Front bumper assembly
P.51-3).
connection
connection
connection
connection
26. Engine oil cooler feed and return tube
27. Clamp
NOTES
13A-1
GROUP 13A
00
11
MULTIPORT FUEL 12
INJECTION (MFI) 13
14
15
CONTENTS 16
17
GENERAL INFORMATION . . . . . . . . 13A!" ENGINE CONTROL RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A!"'( 21
SERVICE SPECIFICATIONS. . . . . . . 13A!# FUEL PUMP RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A!"'( 22
INTAKE AIR TEMPERATURE SENSOR
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13A!#
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A!"'( 25
ENGINE COOLANT TEMPERATURE 26
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13A!$ SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A!"'"
TROUBLESHOOTING . . . . . . . . . . . . 13A!%
THROTTLE POSITION SENSOR CHECK . 13A!"'" 27
OXYGEN SENSOR CHECK . . . . . . . . . . . . 13A!"'"
INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A!"') 31
ON-VEHICLE SERVICE. . . . . . . . . . . 13A!&'$
IDLE SPEED CONTROL (ISC) SERVO
THROTTLE BODY (THROTTLE VALVE (STEPPER MOTOR) CHECK . . . . . . . . . . . 13A!"'$ 32
AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A!"#$
THROTTLE POSITION SENSOR 33
INJECTOR . . . . . . . . . . . . . . . . . . . . . 13A!&(%
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13A!"#$
BASIC IDLE SPEED ADJUSTMENT . . . . . 13A!"#%
REMOVAL AND INSTALLATION . . . . . . . . 13A!"'& 34
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A!"#&
THROTTLE BODY ASSEMBLY . . . . . 13A!&() 35
FUEL PUMP CONNECTOR
REMOVAL AND INSTALLATION . . . . . . . . 13A!"'*
DISCONNECTION (HOW TO REDUCE 36
PRESSURIZED FUEL LINES) . . . . . . . . . . 13A!"'# THROTTLE BODY ASSEMBLY
FUEL PUMP OPERATION CHECK . . . . . . 13A!"'# DISASSEMBLY AND REASSEMBLY . . . . . 13A!"(# 37
COMPONENT LOCATION . . . . . . . . . . . . . 13A!"''
ENGINE ECU . . . . . . . . . . . . . . . . . . . 13A!&"" 42
REMOVAL AND INSTALLATION . . . . . . . . 13A!"((
51
52
54
55
MULTIPORT FUEL INJECTION (MFI)
GENERAL INFORMATION
M1131000100701
The Multipoint Fuel Injection System consists of sen- ECU carries out activities such as fuel injection con-
sors which detect the engine conditions, the engine- trol, idle speed control and ignition timing control. In
ECU which controls the system based on signals addition, the engine-ECU is equipped with several
from these sensors, and actuators which operate diagnosis modes which simplify troubleshooting
under the control of the engine-ECU. The engine- when a problem develops.
FUEL INJECTION CONTROL
The injector drive times and injection timing are con- engine is cold or operating under high load condi-
trolled so that the optimum air/fuel mixture is sup- tions in order to maintain engine performance. In
plied to the engine to correspond to the continually- addition, when the engine is warm or operating under
changing engine operation conditions. normal conditions, the engine-ECU controls the
A single injector is mounted at the intake port of each air/fuel mixture by using the oxygen sensor signal to
cylinder. Fuel is sent under pressure from the fuel carry out "closed-loop" control in order to obtain the
tank by the fuel pump, with the pressure being regu- theoretical air/fuel mixture ratio that provides the
lated by the fuel pressure regulator. The fuel thus maximum cleaning performance from the three way
regulated is distributed to each of the injectors. catalyst.
Fuel injection is normally carried out once for each
cylinder for every two rotations of the crankshaft. The
firing order is 1-3-4-2. This is called sequential fuel
injection. The engine-ECU provides a richer air/fuel
mixture by carrying out "open-loop" control when the
IDLE AIR CONTROL

The idle speed is kept at the optimum speed by con- air conditioner load. In addition, when the air condi-
trolling the amount of air that bypasses the throttle tioner switch is turned off and on while the engine is
valve in accordance with changes in idling conditions idling, the idle speed control motor operates to adjust
and engine load during idling. The engine-ECU the throttle valve bypass air amount in accordance
drives the idle speed control motor to keep the with the engine load conditions in order to avoid fluc-
engine running at the pre-set idle target speed in tuations in the engine speed.
accordance with the engine coolant temperature and
IGNITION TIMING CONTROL

The power transistor located in the ignition primary
circuit turns ON and OFF to control the primary cur-
rent flow to the ignition coil. This controls the ignition
timing in order to provide the optimum ignition timing
with respect to the engine operating conditions. The
ignition timing is determined by the engine-ECU from
the engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.
SELF-DIAGNOSIS FUNCTION
! When an abnormality is detected in one of the ! The RAM data inside the engine-ECU that is
sensors or actuators related to emission control, related to the sensors and actuators can be read
the engine warning lamp (check engine lamp) by means of the MUT-II. In addition, the actuators
illuminates as a warning to the driver. can be force-driven under certain circumstances.
! When an abnormality is detected in one of the
sensors or actuators, a diagnosis code corre-
sponding to the abnormality is output.
OTHER CONTROL FUNCTIONS

1. Fuel Pump Control Turns the fuel pump relay ON so that current is sup-
plied to the fuel pump while the engine is crank-
ing or running.
GENERAL INFORMATION
13A-3
2. A/C Relay Control (Refer to +,17!*, GROUP 17 " Engine And Emission
Turns the compressor clutch of the A/C ON and OFF. Control " Evaporative Emission Control System).
3. Fan Motor Control 5. EGR Control Solenoid Valve Control
The revolutions of the radiator fan and condenser fan [Refer to +,17!'(, GROUP 17 " Engine And Emis-
are controlled in response to the engine coolant sion Control " Exhaust Gas Recirculation (EGR)
temperature and vehicle speed. System].
4. Purge Control Solenoid Valve Control
Items Specifications
Throttle body Throttle bore mm 60
Throttle position sensor Variable resistor type
Idle speed control servo Stepper motor type
Engine-ECU Identification No. E6T38971
Sensors Air flow sensor Karman vortex type
Barometric pressure Sensor Semiconductor type
Intake air temperature sensor Thermistor type
Engine coolant temperature Thermistor type
Oxygen sensor Zirconia type
Inhibitor switch Contact switch type
Camshaft position sensor Hall element type
Crank angle sensor Hall element type
Detonation sensor Piezoelectric type
Power steering fluid pressure switch Contact switch type
Actuators Engine control relay type Contact switch type
Fuel pump relay type Contact switch type
Injector type and number Electromagnetic type, 4
Injector identification mark HDA 250E
EGR control solenoid valve Duty cycle type solenoid valve
Purge control solenoid valve Duty cycle type solenoid valve
Fuel pressure Regulator pressure kPa 329
regulator
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM
1 Oxygen sensor (front) Power supply 1 Injector Engine control relay

2 Oxygen sensor (rear) Ignition switch-IG Engine-ECU 2 Idle speed control Fuel pump relay
3 Air flow sensor Ignition switch-ST servo (Stepper motor) A/C compressor relay
4 Intake air temperature A/C switch 3 EGR control solenoid Ignition coil
sensor A/C load signal valve Fan controller
5 Throttle position sensor A/C pressure 4 Purge control solenoid Engine warning lamp
6 Camshaft position sensor valve Diagnosis output
sensor Power steering Alternator G terminal
7 Crank angle sensor fluid pressure switch Oxygen sensor heater
8 Barometric pressure Alternator FR Tachometer
sensor terminal
9 Engine coolant Vehicle speed
temperature sensor sensor
10 Detonation sensor
4 Intake air temperature sensor

2 Idle speed control servo
(Stepper motor) 3 Air flow sensor
8 Barometric
6 Camshaft position sensor 5 Throttle position pressure sensor
sensor
Fuel pressure Air

regulator M M A
To From
fuel tank fuel pump
EGR valve
1 Oxygen sensor Canister
(front)
1 Injector
Catalytic 9 Engine coolant 3 EGR control
converter temperature sensor solenoid valve
10 Detonation sensor 4 Purge control
solenoid valve
7 Crank angle sensor
2 Oxygen sensor (rear)
Catalytic
converter
AK204338 AB
13A-5
M1131000300459
Basic idle speed r/min 700 # 50
Throttle position sensor adjusting voltage mV 535 " 735
Throttle position sensor resistance k$ 3.5 " 6.5
Idle speed control servo coil resistance (at 20%C) $ 28 " 33
Intake air temperature sensor "20%C 13 " 17
resistance k$ 0%C 5.3 " 6.7
20%C 2.3 " 3.0
40%C 1.0 " 1.5
60%C 0.56 " 0.76
80%C 0.30 " 0.42
Engine coolant temperature "20%C 14 " 17
sensor resistance k$ 0%C 5.1 " 6.5
20%C 2.1 " 2.7
40%C 0.9 " 1.3
60%C 0.48 " 0.68
80%C 0.26 " 0.36
Oxygen sensor output voltage (at racing) V 0.6 " 1.0
Oxygen sensor heater front 4.5 " 8.0
resistance (at 20%C) $ rear 11 " 18
Fuel pressure kPa Vacuum hose disconnection 330 " 350 at curb idle
Vacuum hose connection Approximately. 270 at curb idle
Injector coil resistance (at 20%C) $ 10.5 " 13.5
SEALANT
M1131000500237

Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent Drying sealant
Threaded portion
13A-6 SPECIAL TOOLS
SPECIAL TOOLS
M1131000600342

MB991502 MUT-II sub ! Reading diagnosis code
assembly ! MPI system inspection
B991502
MB991348 Test harness set ! Measurement of voltage during

troubleshooting
! Inspection using an oscilloscope
MB991348
MB991709 Test harness ! Measurement of voltage during

troubleshooting
! Adjusting of idle speed control servo
MD998478 Test harness (3- ! Measurement of voltage during

pin, triangle) Troubleshooting
MB991536 Check harness ! Measurement of voltage during

for throttle Troubleshooting
position sensor ! Adjusting of throttle position sensor
adjustment
MB991536
MD998464 Test harness (4- ! Measurement of voltage during

pin, square) Troubleshooting
! Inspection of oxygen sensor (front)
MB991658 Test harness ! Measurement of voltage during

Troubleshooting
! Inspection of oxygen sensor (rear)
MB991658
SPECIAL TOOLS
13A-7
MB991223 Harness set ! Check at the ECU terminals
A: MB991219 A: Test harness A: Connector pin contact inspection
B: MB991220 B: LED harness B: Power circuit inspection
C: MB991221 C: LED harness C: Power circuit inspection
D: MB991222 adapter D: Commercial tester connection
D: Probe
MB991223
MD998709 Adaptor hose Measurement of fuel pressure
MD998742 Hose adaptor
MB991637 Fuel pressure

gauge set
MB991637
13A-8 TROUBLESHOOTING

MD998706 Injector test set Checking the spray condition of
injectors
MD998706
MB991607 Injector test

harness
MB991607
MD998741 Injector test

adaptor
MD998741
MB991608 Clip
MB991608
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1131150000342
Refer to +,00!$, GROUP 00 " How to Use Trouble- DIAGNOSIS FUNCTION
shooting/Inspection Service Points. M1131155500074
NOTE: If the engine-ECU is replaced, the steering ENGINE WARNING LAMP (CHECK
lock cylinder and ignition key should be replaced ENGINE LAMP)
together with it.
Engine warning lamp

(check engine lamp)
AK300251AB
If an abnormality occurs in any of the following items

related to the Multipoint Fuel Injection (MPI) system,
the engine warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illumi-
nates while the engine is running, check the diagno-
sis code output.
TROUBLESHOOTING
13A-9
ENGINE WARNING LAMP INSPECTION ITEMS
Code No. Diagnosis item
" Engine-ECU
P0100 Air flow sensor system
P0105 Barometric pressure sensor system
P0110 Intake air temperature sensor system
P0115 Engine coolant temperature sensor system
P0120 Throttle position sensor system
P0125* Feedback system monitor
P0130 Oxygen sensor (front) system <Sensor 1>
P0135 Oxygen sensor heater (front) system <Sensor 1>
P0136 Oxygen sensor (rear) system <Sensor 2>
P0141 Oxygen sensor heater (rear) system <Sensor 2>
P0170 Abnormal fuel system
P0201 No. 1 injector system
P0300 Random cylinder mis-fire detection system
P0301* No. 1 cylinder mis-fire detection system
P0325 Detonation sensor system
P0335 Crank angle sensor system
P0340 Camshaft position sensor system
P0403 EGR control solenoid valve system
P0420 Catalyst deterioration system
P0443 Purge control solenoid valve system
P0500 Vehicle speed sensor system
P0505 Idle speed control system
P0551* Power steering fluid pressure switch system
P1603* Battery back-up line system
P1610 Immobilizer system
NOTE: .
! If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
! After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is
next turned on and the same malfunction is re-detected.However, for items marked with a "*" in the diag-
nosis code number column, the engine warning lamp illuminates only on the first detection of the malfunc-
tion.
! After the engine warning lamp illuminates, it will be switched off under the following conditions.
! When the engine-ECU monitored the power train malfunction three times* met set condition require-
ments, it detected no malfunction.
*: In this case, "one time" indicates from engine start to stop.
! For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
! Sensor 1 indicates, the sensor mounted at a position closest to the engine, and sensor 2 indicates the
sensor mounted at the position second closest to the engine.
METHOD OF READING AND ERASING INSPECTION USING MUT-II DATA LIST

DIAGNOSIS CODES AND ACTUATOR TESTING
Refer to +,00!$, GROUP 00 " How to Use Trouble- 1. Carry out inspection by means of the data list and
shooting/Inspection Service Points. the actuator test function, if there is an
abnormality, check and repair the chassis harness
DIAGNOSIS USING DIAGNOSIS 2 CODES and components.
1. Switch the diagnosis mode of the engine control 2. After repairing, re-check using the MUT-II and
unit to DIAGNOSIS 2 mode using the MUT-II. check that the abnormal input and output have
2. Carry out a road test. returned to normal as a result of the repairs.
3. Take a reading of the diagnosis code and repair 3. Erase the diagnosis code memory.
the problem location. 4. Remove the MUT-II, and then start the engine
4. Turn the ignition switch to OFF and then back to again and carry out a road test to confirm that the
ON again. problem has disappeared.
NOTE: By turning the ignition switch to OFF, the
ENGINE-ECU will switch the diagnosis mode FREEZE FRAME DATA
from DIAGNOSIS 2 mode to DIAGNOSIS 1 When the engine-ECU detects a malfunction and
mode. stores a diagnosis code, it also stores a current sta-
5. Erase the diagnosis codes. tus of the engine. This function is called "Freeze
frame data". By analysing this "Freeze frame" data
with the MUT-II, an effective troubleshooting can be
performed.
The display items of freeze frame data are shown
below.
DISPLAY ITEM LIST

Item No. Data Unit
21 Engine coolant temperature sensor %C
22 Engine speed r/min
24 Vehicle speed km/h
80 Long-term fuel compensation (long-term fuel trim) %
82 Short-term fuel compensation (short-term fuel trim) %
TROUBLESHOOTING
13A-11
Item No. Data Unit
88 Fuel control condition Open loop OL
Closed loop CL
Open loop owing to drive condition OL-DRV.
Open loop owing to system malfunction OL-SYS.
Closed loop based on one oxygen sensor CL- H02S
87 Calculation load value %
Diagnosis code during data recording -
NOTE: If malfunctions have been detected in multi- In addition, if diagnosis codes are erased or the bat-
ple systems, store one malfunction only, which has tery cable is disconnected, this history will also be
been detected first. erased (the memory will be reset).
! Catalyst: P0420
READINESS TEST STATUS ! Oxygen sensor: P0130
The engine-ECU monitors the following main diagno- ! Oxygen sensor heater: P0135, P0141
sis items, judges if these items are in good condition
or not, and the stores its history. this history can be
read out by using MUT-II. (If the ECU has judged a
item before, the MUT-II displays "Complete").
FAIL-SAFE FUNCTION REFERENCE TABLE

When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by
means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item Control contents during malfunction

Air flow sensor 1. Uses the throttle position sensor signal and engine speed signal (crank angle
sensor signal) to take reading of the basic injector drive time and basic ignition
timing from the pre-set mapping.
2. Fixes the idle speed control servo in the appointed position so idle control is not
performed.
Intake air temperature Controls as if the intake air temperature is 25%C.
sensor
Barometric pressure Controls as if the barometric pressure is 101 kPa.
sensor
Throttle position sensor No increase in fuel injection amount during acceleration due to the throttle position
sensor signal.
Engine coolant Controls as if the engine coolant temperature is 80%C.
temperature sensor
Camshaft position Injectors fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
sensor ignition switch is turned to the "ON" position, the No. 1 cylinder top dead centre is
not detected at all)
Oxygen sensor (front) Air/fuel ratio feedback control (closed loop control) is not performed.
Oxygen sensor (rear) Performs the feedback control (closed loop control) of the air/fuel ratio by using
only the signal of the oxygen (front) installed on the front of the catalytic converter.
Detonation sensor Fixes the ignition timing as that for regular gasoline.

Ignition coil Cuts off the fuel supply to cylinders with an abnormal ignition.
(incorporating power
transistor)
Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works
as a normal alternator)
Misfiring If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be
shut down.
INSPECTION CHART FOR DIAGNOSIS CODE

M1131151000624
Code No. Diagnosis item Reference page

P0100 Air flow sensor system +,13A!'-
P0105 Barometric pressure sensor system +,13A!(-
P0110 Intake air temperature sensor system +,13A!""
P0115 Engine coolant temperature sensor system +,13A!-#
P0120 Throttle position sensor system +,13A!-&
P0125* Feedback system monitor +,13A!)$
P0130 Oxygen sensor (front) system <Sensor 1> +,13A!$'
P0135 Oxygen sensor heater (front) system <Sensor 1> +,13A!$%
P0136 Oxygen sensor (rear) system <Sensor 2> +,13A!%(
P0141 Oxygen sensor heater (rear) system <Sensor 2> +,13A!%&
P0170 Abnormal fuel system +,13A!&"
P0201 No.1 Injector system +,13A!&%
P0202 No.2 Injector system +,13A!*(
P0203 No.3 Injector system +,13A!*%
P0204 No.4 Injector system +,13A!'#(
P0300 Random cylinder mis-fire detection system +,13A!'#$
P0301* No.1 cylinder mis-fire detection system +,13A!''#
P0302* No.2 cylinder mis-fire detection system +,13A!''(
P0303* No.3 cylinder mis-fire detection system +,13A!''-
P0304* No.4 cylinder mis-fire detection system +,13A!''$
P0325 Detonation sensor system +,13A!''*
P0335 Crank angle sensor system +,13A!'("
P0340 Camshaft position sensor system +,13A!'""
P0403 EGR control solenoid valve system +,13A!'-(
P0420 Catalyst deterioration system +,13A!'-%
P0443 Purge control solenoid valve system +,13A!'-&
P0500 Vehicle speed sensor system +,13A!')"
P0505 Idle speed control system +,13A!')$
P0551* Power steering fluid pressure switch system +,13A!'$'
TROUBLESHOOTING
13A-13
P0622 Alternator FR terminal system +,13A!'$$
P1603* Battery back-up line system +,13A!'%'
P1610 Immobilizer system +,13A!'%"
NOTE: .
! Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
! Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
! After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the engine
is started and the same malfunction is re-detected. However, for items marked with "*", the diagnosis
code is recorded on the first detection of the malfunction.
! Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates the sen-
sor mounted at the position second closest to the engine.
INSPECTION PROCEDURE FOR

DIAGNOSIS CODES
Code No. P0100 Air Flow Sensor System
Air flow sensor circuit
Battery
W-B
W-B
4 3
B-17X
1 2 Engine control relay

3 4
1 2
4
B-08
1 2 3 4 5 6 7 Air flow sensor
7 5 3
G-W
20
J/C (1)
C-16 W-R C-135
G-B
17 31 32 33 34 35 36 37 38
G-W 39 40 41 42 43 44 45 46
19 40 90
C-137 C-134
71 72 73 74 75 76 77 78 79 80 81 1 2 3 4 5 6 7 8 9 10 11 12 13
82 83 84 85 86 87 88 89 90 9192 14 15 16 17 18 19 20 21 22 23 24 25 26
5V
Engine-ECU
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300252 AB
TROUBLESHOOTING
13A-15
OPERATION DIAGNOSIS PROCEDURE
! Power is supplied to the air flow sensor (terminal
No. 4) from the engine control relay (terminal No.
1) and earthed to the engine-ECU (terminal No. STEP 1. MUT-II data list
40) from the air flow sensor (terminal No. 5). ! Refer to Data list reference table +,13A!(&%.
! A power voltage of 5 V is applied to the air flow a. Item 12: Air flow sensor
sensor output terminal (terminal No. 3) from the Q: Is the check result normal?
engine-ECU (terminal No. 90). YES : Intermittent malfunction (Refer to GROUP
! An air flow sensor filter reset signal is inputted to 00 " How to Use
the air flow sensor (terminal No. 7) from the Troubleshooting/Inspection Service Points
engine-ECU (terminal No. 19). +,00!$).
NO : Go to Step 2 .
FUNCTION
! Air flow sensor outputs a pulse signal propor-
STEP 2. Connector check: B-08 air flow sensor
tional to the intake air flow rate.
connector
! The engine-ECU determines the basic injection
timing of the injector using the pulse signal output Connector: B-08
from the air flow sensor and the engine speed
signal.
! When the throttle position sensor output is low,
the engine-ECU causes the power transistor in
the unit to be ON to send an air flow sensor filter
B-08 (B)
reset signal to the air flow sensor. In response to
the reset signal, the air flow sensor resets the fil-
ter circuit to improve the ability of the air flow sen- 7 6 5 4 3 2 1
sor to measure the air flow rate in the area where Harness side connector AK300253 AB
the intake air flow rate is low.
Q: Is the check result normal?
TROUBLE JUDGMENT YES : Go to Step 3 .
NO : Repair.
Check Condition
! Engine speed is 500 r/min or more.
STEP 3. Measure voltage at B-08 air flow sensor
Judgment Criterion connector.
! Sensor output frequency of 3.3 Hz or less for 2
seconds. Connector: B-08
PROBABLE CAUSE
! Failed air flow sensor
! Open/short circuit in air flow sensor circuit or
loose connector contact
B-08 (B)
! Failed engine-ECU
7 6 5 4 3 2 1
Harness side connector AK300253 AB
! Disconnect connector, and measure at harness

side.
! Ignition switch: ON
! Voltage between terminal No. 3 and earth.
OK: 4.9 " 5.1 V
YES : Go to Step 9 .
NO : Go to Step 4 .
STEP 4. Measure voltage at C-137 engine-ECU STEP 5. Connector check: C-137 engine-ECU
connector. connector
CONNECTOR: C-137 CONNECTOR: C-137
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
Harness side connector Harness side connector
AK300254 AB AK300254 AB
! Measure engine-ECU terminal voltage.

Connector: B-08
OK: 4.9 " 5.1 V
B-08 (B)
NO : Go to Step 6 .
7 6 5 4 3 2 1

YES : Check and repair harness between B-08
(terminal No. 3) air flow sensor connector
and C-137 (terminal No. 90) engine-ECU
connector.
! Check output line for open circuit.
NO : Repair.
TROUBLESHOOTING
13A-17
STEP 6. Connector check: C-137 engine-ECU STEP 7. Check harness between B-08 (terminal
connector. No. 3) air flow sensor connector and C-137
(terminal No. 90) engine-ECU connector.
CONNECTOR: C-137
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Harness side connector CONNECTOR: C-137
AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Harness side connector
AK300254 AB
! Check output line for short circuit.

NO : Repair.
STEP 8. MUT-II data list

! Refer to Data list reference table +,13A!(&%.
a. Item 12: Air flow sensor
YES : Intermittent malfunction (Refer to GROUP
00 " How to Use
Troubleshooting/Inspection Service Points
+,00!$).
NO : Replace engine-ECU.
STEP 9. Measure voltage at B-08 air flow sensor STEP 10. Connector check: B-17X engine control
connector. relay connector
Connector: B-08 CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
B-08 (B) 2 1
4 3
7 6 5 4 3 2 1 Harness side
connector AK300255 AB

Connector: B-08
side.
OK: System voltage
Q: Is the check result normal? B-08 (B)
NO : Go to Step 10 .
7 6 5 4 3 2 1

and B-17X (terminal No.1) engine control
relay connector.
! Check power supply line for
open/short circuit.
NO : Repair.
STEP 11. Check at B-08 air flow sensor

connector.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
! Disconnect and measure at harness side.

! Resistance between terminal No. 5 and earth.
OK: 2 $ or less
TROUBLESHOOTING
13A-19
connector No. 5) air flow sensor connector and C-135
CONNECTOR: C-135
Connector: B-08
C-135 B-08 (B)
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB
NOTE: Before checking harness, check intermediate

connector C-16, and repair if necessary.
! Check earthing line for open circuit and damage.
NO : Repair.
STEP 14. Measure voltage at B-08 air flow sensor STEP 16. Check harness between B-08 (terminal
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
Harness side connector AK300253 AB 7 6 5 4 3 2 1
! Use special tool test harness (MB991709) to con-
nect connector, and measure at pick-up harness.
CONNECTOR: C-134
OK: 7 " 8 V
C-134
STEP 15. Connector check: C-134 engine-ECU

connector
13 12 11 10 9 8 7 6 5 4 3 2 1
CONNECTOR: C-134 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
! Check reset signal line for short circuit.

C-134
YES : Replace air flow sensor.
NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
TROUBLESHOOTING
13A-21
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
CONNECTOR: C-134
! Transmission: Neutral
OK:
0 " 1 V (Engine: Idling)
6 " 9 V (Engine: 3,000 r/min)
C-134
STEP 18. Connector check: C-134 engine-ECU 13 12 11 10 9 8 7 6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14
connector
CONNECTOR: C-134
AK300257 AB
! Check reset signal line for open circuit and dam-

age.
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
STEP 20. Measure output waveform at B-08 air STEP 23. Check harness between B-08 (terminal
flow sensor connector (Use oscilloscope). No. 4) air flow sensor connector and B-17X
(terminal No. 1) engine control relay connector.
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
CONNECTOR: B-17X
! Engine: Idling
B-17X
! Transmission: Neutral Relay box’s
triangle marks
OK: Waveforms should be displayed on
inspection procedure using an oscilloscope
2 1
(Refer to *+13A!")%) and noise should not be
displayed in the waveform. 4 3
Q: Is the check result normal? Harness side

connector
YES : Go to Step 8 . AK300255 AB
NO : Go to Step 21 . ! Check power supply line for damage.

STEP 21. Replace air flow sensor. YES : Go to Step 24 .
! After replacing the air flow sensor, re-check the NO : Repair.
trouble symptoms.
Q: Is the check result normal? STEP 24. Connector check: C-134 engine-ECU
YES : Go to Step 22 . connector
NO : Check end.
CONNECTOR: C-134
STEP 22. Connector check: B-17X engine control

relay connector
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
C-134
2 1
13 12 11 10 9 8 7 6 5 4 3 2 1
4 3 26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side Harness side connector
AK300257 AB

NO : Repair.
NO : Repair.
TROUBLESHOOTING
13A-23
STEP 25. Check harness between B-08 (terminal STEP 26.Connector check: C-135 engine-ECU
No. 3) air flow sensor connector and C-137 connector
CONNECTOR: C-135
Connector: B-08
B-08 (B) C-135
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-137 Harness side connector
AK300256 AB
Connector: B-08
C-137
B-08 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
7 6 5 4 3 2 1
AK300254 AB
! Check output line for damage. YES : Check intermediate connector C-16, and
Q: Is the check result normal? repair if necessary. If intermediate
YES : Go to Step 26 . connector is normal, check and repair
NO : Repair. harness between B-08 (terminal No. 5) air
flow sensor connector and C-135 (terminal
No. 40) engine-ECU connector.
! Check earthing line for damage.
No : Repair.
Code No. P0105: Barometric Pressure Sensor System
Barometric pressure sensor circuit
B-08
Barometric pressure sensor
1 2 3 4 5 6 7 (Incorporated in air flow sensor)
1 2 5
B-W
20
Y-B G-W J/C (1)

C-16
17
B-W
81 85 40
C-135 C-137
31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code
AK300258 AB
OPERATION ! In response to the signal, the engine-ECU cor-

! A power voltage of 5 V is applied to the baromet- rects the fuel injection amount, etc.
ric pressure sensor power terminal (terminal No.
1) of the air flow sensor connector from the TROUBLE JUDGMENT
engine-ECU (terminal No. 81) and earthed to the Check Condition
engine-ECU (terminal No. 40) from the air flow ! 2 seconds later after the ignition switch has been
sensor (terminal No. 5). in "ON" position or the engine has started up.
! The sensor signal is inputted to the engine-ECU ! The battery voltage is 8 V or more.
(terminal No. 85) from the barometric pressure
sensor output terminal (terminal No. 2) of the air Judgment Criterion
flow sensor connector. ! The sensor output voltage is 4.5 V or more (Baro-
metric pressure of above 114 kPa or equivalent)
FUNCTION for 2 seconds.
! The barometric pressure sensor converts the bar- Or
ometric pressure into a voltage signal and inputs ! The sensor output voltage is 0.2 V or less (Baro-
the signal to the engine-ECU. metric pressure of below 53kpa or equivalent) for
2 seconds.
TROUBLESHOOTING
13A-25
PROBABLE CAUSE STEP 3. Measure voltage at B-08 air flow sensor
! Failed barometric pressure sensor connector.
! Open/short circuit in barometric pressure sensor
circuit or loose connector contact Connector: B-08
! Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list B-08 (B)

a. Item 25: Barometric pressure sensor 7 6 5 4 3 2 1
Q: Is the check result normal? Harness side connector AK300253 AB
YES : Intermittent malfunction (Refer to GROUP ! Disconnect connector, and measure at harness
00 " How to Use side.
Troubleshooting/Inspection Service Points ! Ignition switch: ON
+,00!$). ! Voltage between terminal No. 1 and earth.
NO : Go to Step 2 .
OK: 4.9 " 5.1 V
connector NO : Go to Step 4 .
Connector: B-08
STEP 4. Measure voltage at C-137 engine-ECU
connector.
CONNECTOR: C-137
B-08 (B)
7 6 5 4 3 2 1
Q: Is the check result normal? C-137

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

OK: 4.9 " 5.1 V
NO : Go to Step 6 .
STEP 5. Connector check: C-137 engine-ECU STEP 6. Connector check: C-137 engine-ECU
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB
Connector: B-08 Q: Is the check result normal?

NO : Repair.
B-08 (B)
7 6 5 4 3 2 1

connector.
! Check power supply line for open
circuit.
NO : Repair.
TROUBLESHOOTING
13A-27
STEP 7. Check harness between B-08 (terminal STEP 9. Measure voltage at B-08 air flow sensor
No. 1) air flow sensor connector and C-137 connector.
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1 Harness side connector AK300253 AB
side.
CONNECTOR: C-137
OK: 2 $ or less
C-137 STEP 10. Connector check: C-135 engine-ECU

connector
CONNECTOR: C-135
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB
! Check power supply line for short circuit.

C-135
NO : Repair.
38 37 36 35 34 33 32 31
STEP 8. MUT-II data list 46 45 44 43 42 41 40 39
! Refer to Data list reference table +,13A!(&%. Harness side connector
a. Item No. 25: Barometric pressure sensor
AK300256 AB
YES : Intermittent malfunction (Refer to GROUP Q: Is the check result normal?
00 " How to Use YES : Go to Step 11 .
Troubleshooting/Inspection Service Points NO : Repair.
+,00!$).
STEP 11. Check harness between B-08 (terminal STEP 12. Measure voltage at B-08 air flow sensor
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1 Harness side connector AK300253 AB
nect only terminal No. 1, No. 2 and No. 5, and
CONNECTOR: C-135
then measure at pick-up harness.
OK: 4.9 " 5.1 V
C-135 NO : Go to Step 13 .
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

! Check earthing line for open circuit or damage.
NO : Repair.
TROUBLESHOOTING
13A-29
STEP 13. Connector check: C-137 engine-ECU STEP 14. Measure voltage at B-08 air flow sensor
connector connector.
CONNECTOR: C-137 Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71 ! Use special tool test harness (MB991709) to con-

92 91 90 89 88 87 86 85 84 83 82 nect only terminal No. 1, No. 2 and No. 5, and
Harness side connector then measure at pick-up harness.
AK300254 AB
Connector: B-08 OK: 0.5 V or less
B-08 (B)
7 6 5 4 3 2 1

connector.
! Check power supply line for damage.
NO : Repair.
STEP 15. Connector check: C-135 engine-ECU STEP 16. Measure voltage at B-08 air flow sensor
B-08 (B)
C-135
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31 ! Use special tool test harness (MB991709) to con-

46 45 44 43 42 41 40 39 nect only terminal No. 1, No. 2 and No. 5, and
Harness side connector then measure at pick-up harness.
AK300256 AB
Connector: B-08 OK:
Altitude 0m: 3.8 " 4.2 V
Altitude 600m: 3.5 " 3.9 V
Altitude 1,200m: 3.3 " 3.7 V
Altitude 1,800m: 3.0 " 3.4 V
B-08 (B) Q: Is the check result normal?
7 6 5 4 3 2 1
Q: Is the check result normal? connector
YES : Check intermediate connector C-16, and
CONNECTOR: C-137
repair if necessary. If intermediate
connector is normal, check and repair
harness between B-08 (terminal No. 5) air
NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
TROUBLESHOOTING
13A-31
STEP 18. Check harness between B-08 (terminal STEP 19. Measure voltage at C-137 engine-ECU
CONNECTOR: C-137
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

OK:
C-137 Altitude 0m: 3.8 " 4.2 V
Altitude 600m: 3.5 " 3.9 V
Altitude 1,200m: 3.3 " 3.7 V
8180 79 78 77 76 75 74 73 72 71 Altitude 1,800m: 3.0 " 3.4 V
92 91 90 89 88 87 86 85 84 83 82
Harness side connector Q: Is the check result normal?
AK300254 AB NO : Go to Step 20 .
! Check output line for short circuit and damage.
YES : Replace air flow sensor.
NO : Repair.
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

NO : Repair.
B-08 (B)
7 6 5 4 3 2 1

connector.
! Check output line for open circuit and
damage.
NO : Repair.
TROUBLESHOOTING
13A-33
Code No. P0110: Intake Air Temperature Sensor System
Intake air temperature sensor circuit
B-08
1 2 3 4 5 6 7 Intake air temperature sensor

(Incorporated in air flow sensor)
5 6
B-W
20
J/C (1)
C-16
Y-L
17
B-W
40 72
C-137 C-135
71 72 73 74 75 76 77 78 79 80 81 31 32 33 34 35 36 37 38
82 83 84 85 86 87 88 89 90 9192 39 40 41 42 43 44 45 46
5V
Engine-ECU
Wire colour code
AK300259 AB
OPERATION TROUBLE JUDGMENT

! A power voltage of 5 V is applied to the intake air
Check Condition
temperature sensor output terminal (terminal No.
! 2 seconds later after the ignition switch has been
6) of the air flow sensor connector from the
in "ON" position or the engine has started up.
engine-ECU (terminal No. 72)
! The power voltage is earthed to the engine-ECU Judgment Criterion
(terminal No. 40) from the air flow sensor (termi- ! The sensor output voltage is 4.6 V or more
nal No. 5). (intake air temperature of below "45%C or equiva-
lent) for 2 seconds.
FUNCTION Or
! The intake air temperature sensor converts the ! The sensor output voltage is 0.2 V or loss (intake
intake air temperature into a voltage and inputs air temperature above 125%C or equivalent) for 2
the voltage signal to the engine-ECU. seconds.
! In response to the signal, the engine-ECU cor-
rects the fuel injection amount, etc. PROBABLE CAUSE
! The intake air temperature sensor is a kind of ! Failed intake air temperature sensor
resistor, which has characteristics to reduce its ! Open/short circuit in intake air temperature sen-
resistance as the intake air temperature rises. sor circuit or loose connector contact
Therefore, the sensor output voltage varies with ! Failed engine-ECU
the intake air temperature, and becomes lower as
the intake air temperature rises.
DIAGNOSIS PROCEDURE STEP 4. Measure voltage at B-08 air flow sensor

connector.
STEP 1. MUT-II data list Connector: B-08
a. Item 13: Intake air temperature sensor
OK: At ambient temperature (atmospheric
temperature) or equivalent.
00 " How to Use
7 6 5 4 3 2 1
+,00!$).
NO : Go to Step 2 . ! Disconnect connector, and measure at harness
side.
connector OK: 2 $ or less

NO : Go to Step 5 .

connector
B-08 (B)
CONNECTOR: C-135
7 6 5 4 3 2 1

NO : Repair.
C-135
STEP 3. Check intake air temperature sensor

itself.
! Check intake air temperature sensor itself (Refer 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
to +,13A!"'().
NO : Replace air flow sensor.
NO : Repair.
TROUBLESHOOTING
13A-35
STEP 6. Check harness between B-08 (terminal STEP 7. MUT-II data list
No. 5) air flow sensor connector and C-135 ! Refer to Data list reference table +,13A!(&%.
(terminal No. 40) engine-ECU connector. a. Item 13: Intake air temperature sensor
Connector: B-08 OK: At ambient temperature (atmospheric
temperature) or equivalent.
00 " How to Use
B-08 (B)
+,00!$).
7 6 5 4 3 2 1
STEP 8. Measure voltage at B-08 air flow sensor
CONNECTOR: C-135 connector.
Connector: B-08
C-135 B-08 (B)
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31 Harness side connector AK300253 AB
46 45 44 43 42 41 40 39
side.
AK300256 AB ! Ignition switch: ON
OK: 4.5 " 4.9 V
! Check earthing line for open circuit and damage. Q: Is the check result normal?
Q: Is the check result normal? NO : Go to Step 9 .
NO : Repair.
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB
Connector: B-08 Connector: B-08
B-08 (B) B-08 (B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
Harness side connector AK300253 AB Harness side connector AK300253 AB
! Measure engine-ECU terminal voltage. Q: Is the check result normal?

! Disconnect B-08 air flow sensor connector. YES : Check and repair harness between B-08
! Ignition switch: ON (terminal No. 6) air flow sensor connector
! Voltage between terminal No. 72 and earth. and C-137 (terminal No. 72) engine-ECU
OK: 4.5 " 4.9 V connector.
Q: Is the check result normal? ! Check output line for open circuit.
YES : Go to Step 10 . NO : Repair.
TROUBLESHOOTING
13A-37
connector No. 6) air flow sensor connector and C-137
CONNECTOR: C-137
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
nect only terminal No. 5 and No. 6, and then
CONNECTOR: C-137
measure at pick-up harness.
OK:
Ambient temperature at "20%C: 3.8 " 4.4 V
Ambient temperature at 0%C: 3.2 " 3.8 V
C-137
8180 79 78 77 76 75 74 73 72 71
Q: Is the check result normal? 92 91 90 89 88 87 86 85 84 83 82
YES : Go to Step 7 . Harness side connector
AK300254 AB
! Check output line for damage.

connector Q: Is the check result normal?
CONNECTOR: C-137 NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
TROUBLESHOOTING
13A-39
connector
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1

YES : Check intermediate connector C-16 and
NO : Repair.
Code No. P0115: Engine Coolant Temperature Sensor System
Engine coolant temperature sensor circuit
B-108
(MU802406)
1 2 Engine coolant temperature sensor
2 1
BR Y-G
92 83
C-137
Engine-ECU
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192 5V
Wire colour code

AK300260 AB
OPERATION ! The engine coolant temperature sensor is a kind

! A power voltage of 5 V is applied to the engine of resistor, which has characteristics to reduce its
coolant temperature sensor output terminal (ter- resistance as the engine coolant temperature
minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
83). with the engine coolant temperature, and
! The power voltage is earthed to the engine-ECU becomes lower as the engine coolant tempera-
(terminal No. 92) from the engine coolant temper- ture rises.
ature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Condition
! The engine coolant temperature sensor converts
! 2 seconds later after the ignition switch has been
the engine coolant temperature into a voltage sig-
in "ON" position or just after the engine has
nal, and inputs the voltage to the engine-ECU.
started up.
! In response to the signal, the engine-ECU con-
trols the fuel infection amount and the fast idle Judgment Criterion
speed when the engine is cold state. ! The sensor output voltage is 4.6 V or more (water
temperature of below "45%C or equivalent) for 2
seconds.
Or
! The sensor output voltage of 0.1 V or less (water
temperature of above 140%C or equivalent) for 2
seconds.
TROUBLESHOOTING
13A-41
Check Condition STEP 3. Measure resistance at B-108 engine
! After the engine has started up. coolant temperature sensor connector.
Judging Conditions Connector: B-108
! The sensor output voltage rises 1.6 V or more
2 1
(engine coolant temperature below 40%C or
Harness side
equivalent) from 1.6 V or less (engine coolant connector
temperature above 40%C or equivalent).
PROBABLE CAUSE
! Failed engine coolant temperature sensor
! Open/short circuit in engine coolant temperature B-108 (B)
sensor circuit or loose connector contact
AK300261 AB
! Failed engine-ECU
! Disconnect connector, and measure at sensor
DIAGNOSIS PROCEDURE side.
! Resistance between terminal No. 1 and No. 2.
OK:
Engine coolant temperature at "20%C: 14 " 17
k$
a. Item 21: Engine coolant temperature sensor
Engine coolant temperature at 0%C: 5.1 " 6.5
OK: k$
Engine cold state: At ambient temperature Engine coolant temperature at 20%C: 2.1 " 2.7
(atmospheric temperature) or equivalent. k$
Engine hot state: At 80 " 120%C Engine coolant temperature at 40%C: 0.9 " 1.3
Q: Is the check result normal? k$
YES : Intermittent malfunction (Refer to GROUP Engine coolant temperature at 60%C: 0.48 "
00 " How to Use 0.68 k$
Troubleshooting/Inspection Service Points Engine coolant temperature at 80%C: 0.26 "
+,00!$). 0.36 k$
NO : Go to Step 2 .
STEP 2. Connector check: B-108 engine coolant NO : Replace engine coolant temperature
temperature sensor connector sensor.
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

NO : Repair.
STEP 4. Measure voltage at B-108 engine coolant STEP 5. Measure voltage at C-137 engine-ECU
temperature sensor connector. connector.
Connector: B-108 CONNECTOR: C-137
2 1
Harness side
connector
B-108 (B) C-137
AK300261 AB
! Disconnect connector, and measure at harness 8180 79 78 77 76 75 74 73 72 71

side. 92 91 90 89 88 87 86 85 84 83 82
! Ignition switch: ON Harness side connector

AK300254 AB
OK: 4.5 " 4.9 V
Connector: B-108
YES : Go to Step 10 . 2 1
NO : Go to Step 5 . Harness side
connector
B-108 (B)
AK300261 AB

! Disconnect B-108 engine coolant temperature
sensor.
OK: 4.5 " 4.9 V
NO : Go to Step 7 .
TROUBLESHOOTING
13A-43
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

2 1 YES : Go to Step 8 .
NO : Repair.
Harness side
connector
B-108 (B)
AK300261 AB

(terminal No. 1) engine coolant temperature
sensor connector and C-137 (terminal No.
83) engine-ECU connector.
NO : Repair.
STEP 8. Check harness between B-108 (terminal STEP 10. Measure voltage at B-108 engine
No. 1) engine coolant temperature sensor coolant temperature sensor connector.
connector and C-137 (terminal No. 83) engine- Connector: B-108
ECU connector.
2 1
Connector: B-108 Harness side
2 1 connector
Harness side
connector
B-108 (B)
B-108 (B) AK300261 AB
! Disconnect connector and measure at harness

AK300261 AB
side.
CONNECTOR: C-137
OK: 2 $ or less

C-137 connector
8180 79 78 77 76 75 74 73 72 71 CONNECTOR: C-137
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

YES : Go to Step 9 . C-137
NO : Repair.
STEP 9. MUT-II data list 8180 79 78 77 76 75 74 73 72 71

! Refer to Data list reference table +,13A!(&%. 92 91 90 89 88 87 86 85 84 83 82
a. Item 21: Engine coolant temperature sensor Harness side connector
OK: AK300254 AB
Engine cold state: At ambient temperature YES : Go to Step 12 .
(atmospheric temperature) or equivalent. NO : Repair.
Engine hot state: At 80 " 120 %C
00 " How to Use
+,00!$).
TROUBLESHOOTING
13A-45
STEP 12. Check harness between B-108 (terminal STEP 13. Measure voltage at B-108 engine
No. 2) engine coolant temperature sensor coolant temperature sensor connector.
connector and C-137 (terminal No. 92) engine- Connector: B-108
ECU connector.
2 1
Connector: B-108 Harness side
2 1 connector
Harness side
connector
B-108 (B)
B-108 (B) AK300261 AB

AK300261 AB
CONNECTOR: C-137
OK:
Engine coolant temperature at "20%C: 3.9 " 4.5
V
Engine coolant temperature at 0%C: 3.2 " 3.8 V
V
C-137
V
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
V
Harness side connector Engine coolant temperature at 80%C: 0.3 " 0.9
V
AK300254 AB
! Check earthing line for open circuit and damage. YES : Go to Step 9 .
NO : Repair.
connector No. 1) engine coolant temperature sensor
connector and C-137 (terminal No. 83) engine-
CONNECTOR: C-137
ECU connector.
Connector: B-108
2 1
Harness side
connector
C-137
B-108 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 AK300261 AB

CONNECTOR: C-137
AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
TROUBLESHOOTING
13A-47
connector
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

YES : Check harness between B-108 (terminal
No. 2) engine coolant temperature sensor
connector and C-137 (terminal No. 92)
engine-ECU connector.
NO : Repair.
Code No. P0120: Throttle Position Sensor System
Throttle position sensor circuit
B-06
(MU802724)
Throttle position sensor
1 2 3 4
1 2 4
Y-B O BR
81 84 92
C-137
71 72 73 74 75 76 77 78 79 80 81
Engine-ECU
82 83 84 85 86 87 88 89 90 9192
5V
Wire colour code

AK300262 AB

! A power voltage of 5 V is applied to the throttle
Check Condition
position sensor (terminal No. 1) from the engine-
ECU (terminal No. 81).
Or
! The power voltage is earthed to the engine-ECU
! Excluding 2 seconds after the ignition switch has
(terminal No. 92) from the throttle position sensor
been in "ON" position or just after the engine has
(terminal No. 4).
started up.
! The sensor signal is inputted to the engine-ECU
(terminal No. 84) from the throttle position sensor Judgment Criteria
output terminal (terminal No. 2). ! The sensor output voltage is 0.2 V or less for 2
seconds.
FUNCTION Or
! The throttle position sensor converts the opening ! When the engine speed is 1,000 r/min or less and
of the throttle valve into a voltage and inputs the the charging efficiency is 40% or less, the throttle
voltage signal to the engine-ECU. position sensor output voltage is 4.4 V or more for
! In response to the signal, the engine-ECU checks 2 seconds.
the opening of the throttle valve.
TROUBLESHOOTING
13A-49
PROBABLE CAUSE STEP 4. Measure voltage at B-06 throttle position
! Failed throttle position sensor sensor connector.
! Open/short circuit in throttle position sensor cir-
cuit or loose connector contact Connector: B-06
! Failed engine-ECU B-06 (B)
DIAGNOSIS PROCEDURE

a. Item 14: Throttle position sensor 4 3 2 1
YES : Intermittent malfunction (Refer to GROUP ! Disconnect connector, and measure at harness
00 " How to Use side.
Troubleshooting/Inspection Service Points ! Ignition switch: ON
+,00!$). ! Voltage between terminal No. 1 and earth.
NO : Go to Step 2 .
OK: 4.9 " 5.1 V
STEP 2. Connector check: B-06 throttle position
sensor connector NO : Go to Step 5 .
Connector: B-06
B-06 (B) STEP 5. Measure voltage at C-137 engine-ECU
connector.
CONNECTOR: C-137
4 3 2 1

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
STEP 3. Check throttle position sensor itself. 92 91 90 89 88 87 86 85 84 83 82
! Check throttle position sensor itself (Refer to Harness side connector
+,13A!"'").
AK300254 AB
NO : Replace throttle position sensor.
OK: 4.9 " 5.1 V
NO : Go to Step 7 .
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

B-06 (B) YES : Go to Step 8 .
NO : Repair.
4 3 2 1

(terminal No. 1) throttle position sensor
circuit.
NO : Repair.
TROUBLESHOOTING
13A-51
STEP 8. Check harness between B-06 (terminal STEP 10. Measure resistance at B-06 throttle
No. 1) throttle position sensor connector and C- position sensor connector.
137 (terminal No. 81) engine-ECU connector.
Connector: B-06
Connector: B-06 B-06 (B)
B-06 (B)
4 3 2 1
4 3 2 1 Harness side connector AK300263 AB
side.
CONNECTOR: C-137
OK: 2 $ or less

connector
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB
! Check power supply line for short circuit.

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
STEP 9. MUT-II data list 92 91 90 89 88 87 86 85 84 83 82
! Refer to Data list reference table +,13A!(&%. Harness side connector
a. Item 14: Throttle position sensor
AK300254 AB
00 " How to Use YES : Go to Step 12 .
+,00!$).
STEP 12. Check harness between B-06 (terminal STEP 13. Measure voltage at B-06 throttle
No. 4) throttle position sensor connector and C- position sensor connector.
Connector: B-06
Connector: B-06 B-06 (B)
B-06 (B)
4 3 2 1
CONNECTOR: C-137
OK: 4.9 " 5.1 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
TROUBLESHOOTING
13A-53
STEP 14. Connector check: C-137 engine-ECU STEP 15. Measure voltage at B-06 throttle
connector position sensor connector.
B-06 (B)
C-137
4 3 2 1

92 91 90 89 88 87 86 85 84 83 82 nect connector, and measure at pick-up harness.
Harness side connector ! Ignition switch: ON
AK300254 AB
OK: 0.5 V or less
Connector: B-06
4 3 2 1

NO : Repair.
STEP 16. Connector check: C-137 engine-ECU STEP 17. Measure voltage at B-06 throttle
connector position sensor connector.
B-06 (B)
C-137
4 3 2 1

AK300254 AB
OK:
Connector: B-06 Accelerator pedal fully released: 0.535 " 0.735
B-06 (B) V
Accelerator pedal fully depressed: 4.5 " 5.0 V
4 3 2 1 STEP 18. Adjust throttle position sensor

Harness side connector AK300263 AB ! Adjust throttle position sensor (Refer to +,13A!
"#$).
Q: Is the adjusted value normal?
(terminal No. 4) throttle position sensor NO : Adjust throttle position sensor.
NO : Repair.
TROUBLESHOOTING
13A-55
STEP 19. Connector check: C-137 engine-ECU STEP 20. Measure voltage at C-137 engine-ECU
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

Connector: B-06
B-06 (B)
OK:
Accelerator pedal fully released: 0.535 " 0.735
V
Accelerator pedal fully depressed: 4.5 " 5.0 V
4 3 2 1 YES : Go to Step 22 .
Harness side connector AK300263 AB NO : Go to Step 21 .

! Check output line for short circuit and
damage.
NO : Repair.
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

NO : Repair.
4 3 2 1

! Check output line for open circuit and
damage.
NO : Repair.
Code No. P0125: Feedback system monitor
OPERATION ! If the heated oxygen sensor (front) has deterio-

! Refer to P0201 injector circuit +,13A!&%. rated, corrections will be made by the heated oxy-
Refer to P0202 injector circuit +,13A!*(. gen sensor (rear).
Refer to P0203 injector circuit +,13A!*%. ! diagnosis code P0125 becomes stored in mem-
Refer to P0204 injector circuit +,13A!'#(. ory if a failure is detected in the above air/fuel
! Refer to P0130 Oxygen sensor (front) circuit ratio feedback control system.
+,13A!$'.
TROUBLE JUDGMENT
FUNCTION
Check Conditions
! The engine-ECU effects air-fuel ratio feedback
! The engine coolant temperature approximately.
control in accordance with the signals from the
82%C or more.
heater oxygen sensor (front).
TROUBLESHOOTING
13A-57
! Within the range of air-fuel ratio feedback opera- STEP 3.Check for intake of air from intake hose
tion. and inlet manifold.
! Not in low speed operation.
Judgment Criteria YES : Go to Step 4 .
! The oxygen sensor output voltage is not deviated NO : Repair.
from 0.5 V for 30 seconds.
PROBABLE CAUSE STEP 4.Check for leakage of exhaust emission

! Failed oxygen sensor (front) from exhaust manifold.
! Harness damage in oxygen sensor (front) circuit Q: Is the check result normal?
or loose connector contact YES : Go to Step 5 .
! Failed oxygen sensor (rear) NO : Repair.
NOTE: When the oxygen sensor (front) begins to
deteriorate, the oxygen sensor output voltage will STEP 5.Check throttle body (throttle valve
deviate from the voltage when the sensor was new portion) for contamination.
(normally 0.5 volt at stoichiometric ratio). This devia-
tion will be corrected by the oxygen sensor (rear).If Q: Is the check result normal?
the oxygen sensor (rear) responds poorly because it YES : Go to Step 6 .
has deteriorated, it will improperly correct the oxygen NO : Clean throttle body (throttle valve portion)
sensor (front). Thus, even when closed loop control (Refer to +,13A!"#$).
is being effected, the fluctuation of the oxygen sen-
sor (front) output voltage decreases, without inter- STEP 6. Connector check: B-112 oxygen sensor
secting with 0.5 volt. As a result, there is a possibility (front) connector, C-137 engine-ECU connector
of diagnosis code P0125 becoming registered.
Connector: B-112
! Failed fuel system
Oxygen sensor (front)
! Failed exhaust system
! Failed engine-ECU
B-112 (B)
DIAGNOSIS PROCEDURE
2 1
STEP 1. MUT-II self-diag code
4 3
Q: Is any other diagnosis code than P0170 output? Harness side connector AK300264 AB
YES : Inspection chart for diagnosis code (Refer
to +,13A!'(). CONNECTOR: C-137
NO : Go to Step 2 .
STEP 2.MUT-II data list

b. Item 21: Engine coolant temperature sensor
c. Item 25: Barometric pressure sensor C-137
d. Item 69: Oxygen sensor (rear)
Q: Are the check results normal?
YES : Go to Step 3 . 8180 79 78 77 76 75 74 73 72 71
NO : Perform the diagnosis code classified check 92 91 90 89 88 87 86 85 84 83 82
procedure for the sensor that has shown an Harness side connector
abnormal data valve (Refer to Inspection AK300254 AB
Chart for Diagnosis Codes +,13A!'().
NO : Repair.
STEP 7. Check oxygen sensor (front) itself. STEP 9. Connector check: Injector connector
! Check oxygen sensor (front) itself (Refer to
Connector: B-01, B-02, B-04, B-05
+,13A!"'").
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
NO : Replace oxygen sensor (front).
STEP 8. Check harness between B-112 oxygen

sensor (front) connector and C-137 engine-ECU M
connector. 2 1
Connector: B-112
a. B-01 (No.1 injector connector)
b. B-02 (No.2 injector connector)
B-112 (B)
c. B-04 (No.3 injector connector)
d. B-05 (No.4 injector connector)
2 1 NO : Repair.
4 3
STEP 10. Check injector itself.
! Check Injector itself (Refer to +,13A!"')).
CONNECTOR: C-137
NO : Replace injector.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
TROUBLESHOOTING
13A-59
STEP 11. Connector check: B-17X engine control STEP 12. Check harness between B-17X engine
relay connector and B-134 engine-ECU control relay connector and injector connector.
connector.
CONNECTOR: B-17X
CONNECTOR: B-17X B-17X
Relay box’s
Relay box’s B-17X triangle marks
triangle marks
2 1
2 1 4 3
4 3 Harness side
Connector: B-01, B-02, B-04, B-05
CONNECTOR: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
M
C-134 2 1
a. Check harness between B-17X (terminal No. 1)

13 12 11 10 9 8 7 6 5 4 3 2 1 engine control relay connector and B-01 (terminal
26 25 24 23 22 21 20 19 18 17 16 15 14 No. 1) No. 1 injector connector.
Harness side connector b. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-02 (terminal
AK300257 AB
No. 1) No. 2 injector connector.
Q: Is the check result normal? c. Check harness between B-17X (terminal No. 1)
YES : Go to Step 12 . engine control relay connector and B-04 (terminal
NO : Repair. No. 1) No. 3 injector connector.
d. Check harness between B-17X (terminal No. 1)
NO : Repair
STEP 13. Check harness between injector STEP 14. Measure fuel pressure.
connector and C-134 engine-ECU connector. ! Measure fuel pressure (Refer to +,13A!"#&).
Connector: B-01, B-02, B-04, B-05 Q: Is the check result normal?
YES : Repair.
NO : Replace engine-ECU
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
M
2 1
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
a. Check harness between B-01 (terminal No. 2)

No. 1injector connector and C-134 (terminal No.
b. Check harness between B-02 (terminal No. 2)
No. 2 injector connector and C-134 (terminal No.
c. Check harness between B-04 (terminal No. 2)
d. Check harness between B-05 (terminal No. 2)
NO : Repair
TROUBLESHOOTING
13A-61
Code No. P0130: Oxygen Sensor (Front) System <sensor 1>
Oxygen sensor (front) circuit
B-112
(MU802605)

1 2
3 4
1 3 2 4
From Engine control relay
To engine-ECU
B
2
B W J/C (2)
C-17
92 76 1
B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code
AK300266 AB

Check Condition
(terminal No. 76) from the oxygen sensor output
! Above 3 minutes later after the engine has
terminal (terminal No. 4).
started up.
! The oxygen sensor (terminal No. 2) is earthed
! The engine coolant temperature approximately
with engine-ECU (terminal No. 92).
82%C or more.
FUNCTION ! The engine speed is 1,200 r/min or more.
! The oxygen sensor converts the concentration of ! The volumetric efficiency 25% or more.
oxygen in the exhaust emission into a voltage ! The monitoring time is 5 seconds.
and inputs the signal to the engine-ECU. Judgment Criteria
! When the air-fuel ratio is richer than the theoreti- ! When the oxygen sensor (front) output voltage is
cal air-fuel ratio, the oxygen sensor outputs a volt- 0.2 V or less and a power voltage of 5 V is
age of about 1 V. When it is leaner than the applied to the oxygen sensor (front) in the
theoretical air-fuel ratio, it outputs a voltage of engine-ECU, the sensor output voltage is 4.5 V or
about 0 V. more.
trols the fuel infection amount so that the air-fuel Check Condition
ratio can be equivalent to the theoretical air-fuel ! The engine speed is 3,000 r/min or less.
ratio. ! During the air-fuel ratio feedback control
Judgment Criteria STEP 3. Measure voltage at B-112 oxygen sensor

! When the oxygen sensor (front) output frequency (front) connector.
is 6 or less for 10 seconds on the average.
Connector: B-112
PROBABLE CAUSE Oxygen sensor (front)
! Failed oxygen sensor
! Open/short circuit in oxygen sensor (front) circuit B-112 (B)
or loose connector contact
! Failed engine-ECU
DIAGNOSIS PROCEDURE 2 1
4 3
! Refer to Data list reference table +,13A!(&%. ! Disconnect connector, and measure at harness
a. Item 11: Oxygen sensor (front) side.
YES : Intermittent malfunction (Refer to GROUP OK: 2 $ or less
00 " How to Use Q: Is the check result normal?
Troubleshooting/Inspection Service Points YES : Go to Step 7 .
+,00!$). NO : Go to Step 4 .
NO : Go to Step 2 .
STEP 2. Connector check: B-112 oxygen sensor connector
(front) connector
CONNECTOR: C-137
Connector: B-112
B-112 (B)
2 C-137
1
4 3
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
NO : Repair. AK300254 AB

NO : Repair.
TROUBLESHOOTING
13A-63
No. 2) oxygen sensor (front) connector and C-137 ! Refer to Data list reference table +,13A!(&%.
(terminal No. 92) engine-ECU connector. a. Item 11: Oxygen sensor (front)
Oxygen sensor (front) YES : Intermittent malfunction (Refer to GROUP
00 " How to Use
B-112 (B) Troubleshooting/Inspection Service Points
+,00!$).
2 1
4 3
STEP 7. Measure at B-112 oxygen sensor (front)
connector.
Connector: B-112
CONNECTOR: C-137 Oxygen sensor (front)
B-112 (B)
2 1
4 3
C-137
! Use special tool test harness (MD998464) to con-

8180 79 78 77 76 75 74 73 72 71 nect connector, and measure at pick-up harness.
92 91 90 89 88 87 86 85 84 83 82 ! Engine: After warm-up
AK300254 AB
OK: 0.5 V or less
NO : Go to Step 8 .
NO : Repair.
STEP 8. Connector check: C-137 engine-ECU STEP 9. Measure voltage at B-112 oxygen sensor
connector (front) connector.
B-112 (B)
2 1
C-137
4 3
8180 79 78 77 76 75 74 73 72 71 ! Use special tool test harness (MD998464) to con-

Harness side connector ! Engine: After warm-up
AK300254 AB
OK:
Connector: B-112 600 " 1,000 mV when 200 mV or lower abrupt
Oxygen sensor (front) racing is done a few seconds after abrupt
deceleration from 4,000 r/min.
B-112 (B)
2 1
4 3 STEP 10. Check oxygen sensor itself
Harness side connector AK300264 AB ! Check oxygen sensor (front) itself (Refer to
+,13A!"'").
(terminal No. 2) oxygen sensor (front) NO : Replace oxygen (front) sensor.
NO : Repair.
TROUBLESHOOTING
13A-65
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

Connector: B-112
! Engine: After warm-up
B-112 (B)
OK:
600 " 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
2 1 deceleration from 4,000 r/min.
4 3
Harness side connector AK300264 AB YES : Go to Step 14 .
(terminal No. 4) oxygen sensor (front)
NO : Repair.
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

Oxygen sensor (front) YES : Go to Step 6 .
NO : Repair.
B-112 (B)
2 1
4 3

NO : Repair.
TROUBLESHOOTING
13A-67
Code No. P0135: Oxygen Sensor Heater (Front) System <Sensor 1>
Oxygen sensor (front) heater circuit
Battery
W-B
W-B
4 3 Oxygen sensor (front)

B-17X
B-112
Engine (MU8026053)
1 2
control
3 4 relay 1 2
3 4
1 2
1 3 2 4
To engine-ECU
R
Y-R
60
C-136
51 52 53 54 55 56
57 58 59 60 61 62
Engine-ECU
Wire colour code
AK300267 AB
OPERATION FUNCTION
! Power is supplied to the heater power terminal ! The power supply to the oxygen sensor heater
(terminal No. 1) of the oxygen sensor (front) con- (front) is controlled by the ON/OFF control of the
nector from the engine control relay (terminal No. power transistor in the engine-ECU.
1). ! Heating the oxygen sensor heater (front) enables
! The heater (terminal No. 3) of the oxygen sensor the oxygen sensor to provide good response
(front) connector is controlled by the power tran- even when the exhaust emission temperature is
sistor in the engine-ECU (terminal No. 60). low.
TROUBLE JUDGMENT STEP 2. Measure resistance at B-112 oxygen

Check Conditions sensor (front) connector.
! The engine coolant temperature is approximately.
Connector: B-112
20%C or higher.
! The oxygen sensor heater (front) is in "ON" posi-
tion. B-112 (B)
! The engine speed is 50 r/min or more.
! The battery voltage is 11 " 16 V.
Judgment Criteria
2 1
! The heater current of oxygen sensor heater
4 3
(front) is below 0.2 A or above 3.5 A for 1 second.
PROBABLE CAUSE
! Failed oxygen sensor heater
side.
! Open/short circuit in oxygen sensor (front) circuit
! Failed engine-ECU OK: 4.5 " 8.0 $
DIAGNOSIS PROCEDURE YES : Go to Step 3 .
NO : Replace oxygen sensor (front).
STEP 1. Connector check: B-112 oxygen sensor

(front) connector STEP 3. Measure voltage at B-112 oxygen sensor
(front) connector.
Connector: B-112
Oxygen sensor (front) Connector: B-112
B-112 (B)
B-112 (B)
2 1
4 3 2 1
Harness side connector 4 3
AK300264 AB
side.
NO : Repair.
OK: System voltage
NO : Go to Step 4 .
TROUBLESHOOTING
13A-69
STEP 4. Connector check: B-17X engine control STEP 5. Measure voltage at C-136 engine-ECU
relay connector connector.
CONNECTOR: B-17X CONNECTOR: C-136
Relay box’s B-17X
triangle marks
2 1
4 3 C-136
Harness side
56 55 54 53 52 51
Connector: B-112 62 61 60 59 58 57
Oxygen sensor (front) Harness side connector
B-112 (B) AK300268 AB

2 1 ! Voltage between terminal No. 60 and earth.
4 3 OK: System voltage
Harness side connector AK300264 AB Q: Is the check result normal?
(terminal No. 1) oxygen sensor connector
and B-17X (terminal No. 1) engine control STEP 6. Connector check: C-136 engine-ECU
relay connector. connector
! Check power supply line for CONNECTOR: C-136
open/short circuit.
NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AB

NO : Repair.
STEP 7. Check harness between B-112 (terminal STEP 8. Connector check: C-136 engine-ECU
No. 3) oxygen sensor (front) connector and C-136 connector
CONNECTOR: C-136
Connector: B-112
B-112 (B)
C-136
2 1
4 3
56 55 54 53 52 51
62 61 60 59 58 57
CONNECTOR: C-136
AK300268 AB

NO : Repair.
C-136
STEP 9. Check harness between B-112 (terminal
No. 1) oxygen sensor (front) connector and B-
56 55 54 53 52 51
17X (terminal No. 1) engine control relay
62 61 60 59 58 57 connector.
Harness side connector Connector: B-112
AK300268 AB Oxygen sensor (front)
! Check earthing line for open/short circuit. B-112 (B)

YES : Replace engine-ECU.
NO : Repair.
2 1
4 3
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
13A-71
STEP 10. Check harness between B-112 (terminal STEP 11. Check the trouble symptoms.
No. 3) oxygen sensor (front) connector and C-136 Q: Does trouble symptom persist?
(terminal No. 60) engine-ECU connector. YES : Replace engine-ECU.
Connector: B-112 NO : Intermittent malfunction (Refer to GROUP
Oxygen sensor (front) 00 " How to Use
B-112 (B) +,00!$).
2 1
4 3
CONNECTOR: C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AB

NO : Repair.
Code No. P0136: Oxygen Sensor (Rear) System <Sensor 2>
Oxygen sensor (rear) circuit
C-18
(MU801688)
1 2 Oxygen sensor (rear)

3 4
2 1 3 4
From engine control relay
To engine-ECU B
3
P L
J/C (2)
C-17
92 75 1
B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code
AK300269 AB

Check Conditions
(terminal No. 75) from the oxygen sensor (rear)
! Above 3 minutes later after the engine has
output terminal (terminal No. 4).
started up.
! The oxygen sensor (rear) (terminal No. 3) is
earthed with engine-ECU (terminal No. 92).
82%C or higher.
FUNCTION ! The engine speed is 1,200 r/min or more.
! The oxygen sensor (rear) converts the concentra- ! The volumetric efficiency is 25% or more.
tion of oxygen in the exhaust emission into a volt- ! The monitoring time is 5 seconds.
age signal and inputs the voltage signal to the Judgment Criteria
engine-ECU. ! When the oxygen sensor (rear) output voltage is
! When the air-fuel ratio is richer than the theoreti- 0.2 V or less and a power voltage of 5 V is
cal air-fuel ratio, the oxygen sensor (rear) outputs applied to the oxygen sensor (rear) in the engine-
a voltage of about 1 V. When it is leaner than the ECU, the sensor output voltage is 4.5 V or more.
theoretical air-fuel ratio, it outputs a voltage of
about 0 V. PROBABLE CAUSE
! In response to the signal, the engine-ECU con- ! Failed oxygen sensor
trols the fuel infection amount so that the air-fuel ! Open/short circuit in oxygen sensor (rear) circuit
ratio can be equivalent to the theoretical air-fuel or loose connector contact
ratio. ! Failed engine-ECU
TROUBLESHOOTING
13A-73
DIAGNOSIS PROCEDURE STEP 3. Measure voltage at C-18 oxygen sensor
(rear) connector.
STEP 1. MUT-II data list Connector: C-18
a. Item 59: Oxygen sensor (rear) 1 2
3 4
YES : Intermittent malfunction (Refer to GROUP Harness side
connector
00 " How to Use
Troubleshooting/Inspection Service Points C-18
+,00!$).
NO : Go to Step 2 .
Oxygen sensor (rear)
STEP 2. Connector check: C-18 oxygen sensor

(rear) connector
Connector: C-18
AK300270 AB
1 2
3 4 ! Disconnect connector, and measure at harness
side.
Harness side
connector ! Resistance between terminal No. 3 and earth.
OK: 2 $ or less
C-18
Oxygen sensor (rear) NO : Go to Step 4 .

connector
AK300270 AB CONNECTOR: C-137

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
STEP 5. Check harness between C-18 (terminal STEP 6. MUT-II data list
No. 3) oxygen sensor (rear) connector and C-137 ! Refer to Data list reference table +,13A!(&%.
(terminal No. 92) engine-ECU connector. a. Item 59: Oxygen sensor (rear)
Connector: C-18 Q: Is the check result normal?
1 2 00 " How to Use
3 4 Troubleshooting/Inspection Service Points
Harness side +,00!$).
connector NO : Replace engine-ECU.
C-18
STEP 7. Measure voltage at C-18 oxygen sensor
(rear) connector.
Connector: C-18
1 2
3 4
Harness side
AK300270 AB
connector
CONNECTOR: C-137 C-18
C-137
AK300270 AB

8180 79 78 77 76 75 74 73 72 71 nect connector, and measure at pick-up harness.
92 91 90 89 88 87 86 85 84 83 82 ! Engine: After warm-up
AK300254 AB
OK: 0.5 V or less
NO : Go to Step 8 .
NO : Repair.
TROUBLESHOOTING
13A-75
STEP 8. Connector check: C-137 engine-ECU STEP 9. Measure voltage at C-18 oxygen sensor
connector (rear) connector.
CONNECTOR: C-137 Connector: C-18
1 2
3 4
Harness side
connector
C-18
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB
AK300270 AB
Connector: C-18 ! Use special tool test harness (MB991658) to con-

1 2 ! Engine: After warm-up
Harness side OK:
connector
600 " 1,000 mV when 200 mV or lower abrupt
C-18 racing is done a few seconds after abrupt
Oxygen sensor (rear) Q: Is the check result normal?
STEP 10. Check oxygen sensor (rear) itself.

AK300270 AB ! Check oxygen sensor (rear) itself (Refer to
+,13A!"'").
YES : Check and repair harness between C-18
(terminal No. 3) oxygen sensor connector NO : Replace oxygen (rear) sensor.
connector.
NO : Repair.
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

Connector: C-18
1 2 ! Engine: After warm-up
Harness side OK:
connector 600 " 1,000 mV when 200 mV or lower abrupt
C-18
racing is done a few seconds after abrupt
AK300270 AB

(terminal No. 4) oxygen sensor connector
connector.
NO : Repair.
TROUBLESHOOTING
13A-77
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB
Connector: C-18 Q: Is the check result normal?

1 2 NO : Repair.
3 4
Harness side
connector
C-18
AK300270 AB

(terminal No. 4) oxygen sensor (rear)
NO : Repair.
Code No. P0141: Oxygen Sensor Heater (Rear) System <Sensor 2>
Oxygen sensor (rear) heater circuit
Battery
W-B
W-B
4 3 Oxygen sensor (rear)

B-17X
1 2 Engine C-18
control (MU801688)
3 4 relay
1 2
3 4
1 2
2 1 3 4
R
R To engine-ECU
2
J/C (2)
C-17
1
Y-R
54
C-136
51 52 53 54 55 56
57 58 59 60 61 62
Engine-ECU
Wire colour code
AK300271 AB
OPERATION FUNCTION
! Power is supplied to the heater power terminal ! The power supply to the oxygen sensor heater
(terminal No. 2) of the oxygen sensor (rear) con- (rear) is controlled by the ON/OFF control of the
nector from the engine control relay (terminal No. power transistor in the engine-ECU.
1). ! Heating the oxygen sensor heater (rear) enables
! The heater (terminal No. 1) of the oxygen sensor the oxygen sensor to provide good response
(rear) connector is controlled by the power tran- even when the exhaust emission temperature is
sistor in the engine-ECU (terminal No. 54). low.
TROUBLESHOOTING
13A-79
TROUBLE JUDGMENT STEP 2. Measure resistance at C-18 oxygen
Judgment Criteria sensor (rear) connector.
Connector: C-18
20 %C or higher.
! The oxygen sensor heater (rear) is in "ON" posi- 1 2
tion. 3 4
! The engine speed is 50 r/min or more. Harness side
! The battery voltage is 11 " 16 V. connector
Judgment Criteria C-18

! The heater current of front oxygen sensor heater
(rear) is below 0.2 A or above 3.5 A for 1 second.
PROBABLE CAUSE
! Failed oxygen sensor heater (rear)
! Open/short circuit in oxygen sensor (rear) circuit
! Failed engine-ECU AK300270 AB

STEP 1. Connector check: C-18 oxygen sensor OK: 11 " 18 $
(rear) connector
Connector: C-18 YES : Go to Step 3 .
NO : Replace oxygen (rear) sensor.
1 2
3 4
STEP 3. Measure voltage at C-18 oxygen sensor
Harness side
connector (rear) connector.
C-18 Connector: C-18
1 2
Oxygen sensor (rear) 3 4
Harness side
connector
C-18
AK300270 AB
NO : Repair.
AK300270 AB

side.
OK: System voltage
NO : Go to Step 4 .
C-137 C-136
8180 79 78 77 76 75 74 73 72 71 56 55 54 53 52 51
92 91 90 89 88 87 86 85 84 83 82 62 61 60 59 58 57
AK300254 AB AK300268 AB

Connector: C-18
Harness side Q: Is the check result normal?
connector
C-18 NO : Go to Step 6 .
Oxygen sensor (rear) STEP 6. Connector check: C-136 engine-ECU

connector
CONNECTOR: C-136
AK300270 AB

repair if necessary. If intermediate C-136
harness between C-18 (terminal No. 2)
oxygen sensor (rear) connector and B-17X
56 55 54 53 52 51
(terminal No. 1) engine control relay 62 61 60 59 58 57
connector.
open/short circuit. AK300268 AB
NO : Repair.
NO : Repair.
TROUBLESHOOTING
13A-81
STEP 7. Check harness between C-18 (terminal STEP 8. Connector check: C-136 engine-ECU
No. 1) oxygen sensor connector and C-136 connector
CONNECTOR: C-136
Connector: C-18
1 2
3 4
Harness side
connector
C-18 C-136

56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AB
AK300270 AB
CONNECTOR: C-136
NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AB
! Check earthing line for open/short circuit.

NO : Repair.
STEP 9. Check harness between C-18 (terminal STEP 10. Check harness between C-18 (terminal
No. 2) oxygen sensor connector and B-17X No. 1) oxygen sensor connector and C-136
(terminal No. 1) engine control relay connector. (terminal No. 54) engine-ECU connector.
Connector: C-18 Connector: C-18
1 2 1 2
3 4 3 4
Harness side Harness side
connector connector
C-18 C-18
Oxygen sensor (rear) Oxygen sensor (rear)
AK300270 AB AK300270 AB

Relay box’s B-17X
triangle marks
2 1
4 3 C-136
Harness side
NOTE: Before checking harness, check intermediate 56 55 54 53 52 51

62 61 60 59 58 57
! Check power supply line for damage. Harness side connector
Q: Is the check result normal? AK300268 AB
YES : Go to Step 10 . ! Check earthing line for damage.

NO : Repair.
NO : Repair.
STEP 11. Check the trouble symptoms.

Q: Does trouble symptom persist?
NO : Intermittent malfunction (Refer to GROUP
00 " How to Use
+,00!$).
TROUBLESHOOTING
13A-83
Code No. P0170: Abnormal Fuel System
OPERATION STEP 2. MUT-II data list

! Refer to P0201 injector circuit +,13A!&%. ! Refer to Data list reference table +,13A!(&%.
! Refer to P0202 injector circuit +,13A!*(. a. Item 12: Air flow sensor
! Refer to P0203 injector circuit +,13A!*%. b. Item 13: Intake air temperature sensor
! Refer to P0204 injector circuit +,13A!'#(. c. Item 21: Engine coolant temperature sensor
FUNCTION d. Item 22: Barometric pressure sensor
! If the fuel system goes out of order, the fuel cor- Q: Are the check results normal?
rection value will become larger. YES : Go to Step 3 .
! The engine-ECU checks whether the fuel correc- NO : Perform the diagnosis code classified check
tion value is within the standard limits. procedure for the sensor that has shown an
abnormal data value (Refer to Inspection
TROUBLE JUDGMENT Chart for Diagnosis Codes +,13A!'().
Check Conditions
! In learning air-fuel ratio STEP 3. Check for intake of air from intake hose
Judgment Criteria and inlet manifold.
! The compensation value of fuel injection amount Q: Is the check result normal?
is too low for 2 seconds or more. YES : Go to Step 4 .
Or NO : Repair.
! The compensation value of fuel injection amount
is too high for 2 seconds or more. STEP 4. Check for leakage of exhaust emission
from exhaust manifold.
PROBABLE CAUSE
! Failed fuel supply system Q: Is the check result normal?
! Failed oxygen sensor (front) YES : Go to Step 5 .
! Failed intake air temperature sensor NO : Repair.
! Failed air flow sensor
! Failed purge control solenoid valve STEP 5. Check throttle body (throttle valve
! Failed engine-ECU portion) for contamination.
DIAGNOSIS PROCEDURE Q: Is the check result normal?

NO : Clean throttle body (throttle valve portion)
STEP 1. MUT-II self-diag code (Refer to +,13A!"#$).
Q: Is any other diagnosis code than P0170 output?
YES : Inspection chart for diagnosis code (Refer STEP 6. MUT-II data list
to +,13A!'(). ! Refer to Data list reference table +,13A!(&%.
NO : Go to Step 2 . a. Item 11: Oxygen sensor (front).
NO : Check oxygen sensor (front) system (Refer
to+,13A!$', Code No. P0130).
STEP 7. Connector Check: Injector connector STEP 9. Connector check: B-17X engine control
relay connector and B-134 engine-ECU
Connector: B-01, B-02, B-04, B-05
connector
CONNECTOR: B-17X
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR) Relay box’s B-17X
triangle marks
M 2 1
2 1
Harness side connector AK300265 AB 4 3
a. B-01 (No.1 injector connector). Harness side

b. B-02 (No.2 injector connector).
c. B-04 (No.3 injector connector).
CONNECTOR: C-134
d. B-05 (No.4 injector connector).
NO : Replace.

C-134
! Check Injector itself (Refer to +,13A!"')).
NO : Replace injector. 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Replace.
TROUBLESHOOTING
13A-85
STEP 10. Check harness between B-17X engine STEP 11. Check harness between injector
control relay connector and injector connector. connector and C-134 engine-ECU connector.
Connector: B-01, B-02, B-04, B-05 Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR) B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
M M
2 1 2 1

Relay box’s B-17X
triangle marks
2 1
4 3 C-134
Harness side
a. Check harness between B-17X (terminal No. 1) 13 12 11 10 9 8 7 6 5 4 3 2 1

engine control relay connector and B-01 (terminal 26 25 24 23 22 21 20 19 18 17 16 15 14
No. 1) No. 1 injector connector. Harness side connector

b. Check harness between B-17X (terminal No. 1) AK300257 AB
No. 1) No. 2 injector connector. a. Check harness between B-01 (terminal No. 2)
c. Check harness between B-17X (terminal No. 1) No. 1injector connector and C-134 (terminal No.
engine control relay connector and B-04 (terminal 1) engine-ECU connector.
No. 1) No. 3 injector connector. b. Check harness between B-02 (terminal No. 2)
d. Check harness between B-17X (terminal No. 1) No. 2 injector connector and C-134 (terminal No.
engine control relay connector and B-05 (terminal 14) engine-ECU connector.
No. 1) No. 4 injector connector. c. Check harness between B-04 (terminal No. 2)
! Check power supply line for damage. No. 3 injector connector and C-134 (terminal No.
Q: Are the check results normal? d. Check harness between B-05 (terminal No. 2)
NO : Replace.
NO : Replace.
STEP 12. Check purge control solenoid valve

itself.
! Check purge control solenoid valve itself (Refer to
GROUP 17 " Emission Control System " Evapo-
rative Emission Control System +,17!'').
NO : Replace purge control solenoid valve.
STEP 13. Measure fuel pressure.

! Measure fuel pressure (Refer to +,13A!"#&).
NO : Repair.
TROUBLESHOOTING
13A-87
Code No. P0201: No. 1 Injector System
Injector circuit
Battery
W-B
W-B
4 3
B-17X
1 2
Engine control relay
3 4
1 2
R R R R
Injector 1 Injector 1 Injector 1 Injector 1

No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 14 2 15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code
AK300272 AB
OPERATION STEP 2. Connector check: B-01 No. 1 injector

! Power is supplied to the injector (terminal No. 1) connector
from the engine control relay (terminal No. 1).
! The engine-ECU (terminal No. 1) makes the Connector: B-01
power transistor in the unit be in "ON" position,
and that makes currents go on the injector (termi-
nal No. 2). B-01 (GR)
FUNCTION
! The engine-ECU controls the power supply inter-
val of the injector. M
! The fuel injection amount of the injector depends 2 1
on the power supply interval. Harness side connector AK300265 AC
TROUBLE JUDGMENT Q: Is the check result normal?

Check Conditions
NO : Repair.
! The engine speed is 50 " 1,000 r/min.
! The throttle position sensor output voltage is 1.15
V or less. STEP 3. Measure resistance at B-01 No. 1 injector
! Injector not in forced drive (actuator test) mode connector.
Judgment Criterion Connector: B-01
! No surge voltage of the injector coil is detected
for 2 seconds.
B-01 (GR)
PROBABLE CAUSE
! Failed No. 1 injector
! Open/short circuit in injector circuit or loose con-
nector contact M
! Failed engine-ECU 2 1
Harness side connector AK300265 AC
DIAGNOSIS PROCEDURE ! Disconnect connector, and measure at injector
side.
STEP 1. MUT-II actuator test ! Resistance between terminal No. 1 and No. 2.
! Refer to Actuator test reference table list +,13A! OK: 10.5 " 13.5 $
(*". Q: Is the check result normal?
a. Item 01: No. 1 injector YES : Go to Step 4 .
OK: Idling state varies. NO : Replace No. 1 injector.
00 " How to Use
+,00!$).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-89
STEP 4. Measure voltage at B-01 No. 1 injector STEP 5. Connector check: B-17X engine control
Relay box’s B-17X

triangle marks
B-01 (GR)
2 1
4 3
M
2 1 Harness side

Connector: B-01
side.
B-01 (GR)
OK: System voltage
NO : Go to Step 5 . M
2 1

YES : Check and repair harness between B-17X
(terminal No. 1) engine control relay
connector and B-01 (terminal No. 1) No. 1
injector connector.
open/short circuit.
NO : Repair.

relay connector
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
STEP 7. Check harness between B-17X (terminal STEP 9. Check harness between B-01 (terminal
No. 1) engine control relay connector and B-01 No. 2) No.1 injector connector and C-134
(terminal No. 1) No. 1 injector connector. (terminal No. 1) engine-ECU connector.
CONNECTOR: B-17X Connector: B-01
Relay box’s B-17X
triangle marks
B-01 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AB Harness side connector AK300265 AC
B-01 (GR)
C-134
M
2 1
! Check power supply line for damage. 13 12 11 10 9 8 7 6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14
! Check output line for open/short circuit and dam-

STEP 8. Connector check: C-134 engine-ECU age.
connector
CONNECTOR: C-134 YES : Go to Step 10 .
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
TROUBLESHOOTING
13A-91
STEP 10. Measure signal waveform at C-134
engine-ECU connector (Use oscilloscope).
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
! Engine: Idling
OK: Waveforms should be display on
Inspection procedure using an oscilloscope
(Refer to *+13A!")%).
00 " How to Use
+,00!$).
Injector circuit
Battery
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R R R R

No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 14 2 15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code
AK300272 AB
TROUBLESHOOTING
13A-93
nal No. 2). B-02 (GR)
FUNCTION
on the power supply interval. Harness side connector AK300265 AD

Check Conditions
NO : Repair.
! The engine speed is 50 " 1,000 r/mim.
! The throttle position sensor output voltage 1.15 V
or less. STEP 3. Measure at resistance B-02 No. 2 injector
Judgment Criteria Connector: B-02
for 2 seconds.
B-02 (GR)
PROBABLE CAUSE
! Open/short circuit in No. 2 injector circuit or loose
connector contact M
Harness side connector AK300265 AD
side.
00 " How to Use
+,00!$).
NO : Go to Step 2 .
Relay box’s B-17X

triangle marks
B-02 (GR)
2 1
4 3
M
2 1 Harness side

Connector: B-02
side.
B-02 (GR)
OK: System voltage
2 1

injector connector.
open/short circuit and damage.
NO : Repair.

relay connector
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
13A-95
No. 1) engine control relay connector and B-02 No. 2) No. 2 injector connector and C-134
Relay box’s B-17X
triangle marks
B-02 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AB Harness side connector AK300265 AD
B-02 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

connector
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.

CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
! Engine: Idling
OK: Waveform should be display on Inspec-
tion procedure using an oscilloscope (Refer
to *+13A!")%).
00 " How to Use
+,00!$).
TROUBLESHOOTING
13A-97
Injector circuit
Battery
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R R R R

No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 14 2 15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code
AK300272 AB

nal No. 2). B-04 (GR)
FUNCTION
on the power supply interval. Harness side connector AK300265 AE

Check Conditions
NO : Repair.
! The throttle position sensor output voltage is 1.15
V or less. STEP 3. Measure resistance at B-04 No. 3 injector
Judgment Criteria Connector: B-04
for 2 seconds.
B-04 (GR)
PROBABLE CAUSE
connector contact M
Harness side connector AK300265 AE
side.
00 " How to Use
+,00!$).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-99
Relay box’s B-17X

triangle marks
B-04 (GR)
2 1
4 3
M
2 1 Harness side

Connector: B-04
side.
B-04 (GR)
OK: System voltage
2 1

injector connector.
open/short circuit.
NO : Repair.

relay connector
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
Relay box’s B-17X
triangle marks
B-04 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AB Harness side connector AK300265 AE
B-04 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

connector
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
TROUBLESHOOTING
13A-101
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
! Engine: Idling
to *+13A!")%).
00 " How to Use
+,00!$).
Injector circuit
Battery
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R R R R

No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 14 2 15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code
AK300272 AB
TROUBLESHOOTING
13A-103
nal No. 2). B-05 (GR)
FUNCTION
on the power supply interval. Harness side connector AK300265 AF

Check Conditions
NO : Repair.
! The throttle position sensor output 1.15 V or less.
! Injector not in forced drive (actuator test) mode STEP 3. Measure resistance at B-05 No. 4 injector
connector.
Judgment Criterion
! No surge voltage of the injector coil is detected Connector: B-05
for 2 seconds
PROBABLE CAUSE B-05 (GR)

connector contact
! Failed engine-ECU M
2 1
DIAGNOSIS PROCEDURE Harness side connector AK300265 AF
! Disconnect connector, and measure at injector

STEP 1. MUT-II actuator test side.
! Refer to Actuator test reference table list +,13A! ! Resistance between terminal No. 1 and No. 2.
(*". OK: 10.5 " 13.5 $
a. Item 04: No. 4 injector Q: Is the check result normal?
OK: Idling state varies. YES : Go to Step 4 .
Q: Is the check result normal? NO : Replace No. 4 injector.
00 " How to Use
+,00!$).
NO : Go to Step 2 .
Relay box’s B-17X

triangle marks
B-05 (GR)
2 1
4 3
M
2 1 Harness side
Harness side connector AK300265 AF

Connector: B-05
side.
B-05 (GR)
OK: System voltage
2 1

injector connector.
open/short circuit and damage.
NO : Repair.

relay connector
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

YES : Go to Step 7.
NO : Repair.
TROUBLESHOOTING
13A-105
Relay box’s B-17X
triangle marks
B-05 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AB Harness side connector AK300265 AF
B-05 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

connector
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.

CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
! Engine: Idling
to *+13A!")%).
00 " How to Use
+,00!$).
Code No. P0300: Random cylinder mis-fire detected
OPERATION ! The barometric pressure is 72 kPa or more.

! Refer to P0201 injector circuit +,13A!&%. ! The volumetric efficiency is 30 " 60%.
! Refer to P0202 injector circuit +,13A!*(. ! The adaptive learning has been completed with
! Refer to P0203 injector circuit +,13A!*%. the vane that generates the crankshaft position
! Refer to P0204 injector circuit +,13A!'#(. signals.
! During the engine operation except the shift
FUNCTION change or low speed driving and rapid accelera-
! If a misfire occurs while the engine is running, the tion and deceleration, also intermittent operation
engine speed changes for an instant. of air compressor (A/C: within the 3 seconds after
! The engine-ECU checks for such changes in changing to ON from OFF or to OFF from ON).
engine speed. ! The throttle deviation is within the range of "
0.059 V/10ms to 0.059 V/10ms.
TROUBLE JUDGMENT
Judgment Criteria
Check Conditions
! The number of misfiring (in the catalyst tempera-
! 5 seconds later after the engine has started up.
ture of above 950%C) is beyond the specified
! The engine speed is 500 " 4,500 r/min.
number (of 7.3 % on more than the two cylinders)
! The engine coolant temperature is "10%C or
with the engine speed of 200 r/min.
higher.
Or
! The intake air temperature is "10%C or higher.
TROUBLESHOOTING
13A-107
! The number of misfiring (that is 1.5 times the STEP 3.Check ignition coil spark.
emission standard limit) is beyond the specified
number (of 2 % on more than the two cylinders) Q: Is the check resuit normal?
with the engine speed of 1000 r/min. YES : Go to Step 4 .
NO : Check ignition circuit system (Refer to
PROBABLE CAUSE Inspection procedure 29 +,13A!(%').
! Ignition system related part(s) failed
! Failed crank angle sensor STEP 4.Connector check: Injector connector
! Incorrect air-fuel ratio
! Low compression pressure Connector: B-01, B-02, B-04, B-05
! Failed coolant temperature sensor
! Skipping of timing belt teeth.
! EGR system and EGR valve failed B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
! Failed engine-ECU
DIAGNOSIS PROCEDURE
M
2 1
STEP 1.MUT-II data list Harness side connector AK300265 AB
! Item 22: Crank angle sensor
a. B-01 (No.1 injector connector)
OK: Keep the engine speed constant to b. B-02 (No.2 injector connector)
make the pulse width of output waveform c. B-04 (No.3 injector connector)
constant. d. B-05 (No.4 injector connector)
Q: Is the check result normal? Q: Are the check results normal?
YES : Go to Step 2 . YES : Go to Step 5 .
NO : Check crank angle sensor system (Refer to NO : Repair.
Code No. P0335 +,13A!'(").
STEP 5.Check injector itself.

STEP 2.MUT-II data list ! Check Injector itself (Refer to +,13A!"')).
a. Item 21: Engine coolant temperature sensor Q: Is the check result normal?
b. Item 81: Long-term fuel compensation
c. Item 82: Short-term fuel compensation
NO : Perform the diagnosis code classified check
procedure for the sensor that has shown an
abnormal data valve (Refer to, Inspection
STEP 6.Connector check: B-17X engine control STEP 7. Check harness between B-17X engine
relay connector and B-134 engine-ECU control relay connector and injector connector.
connector
CONNECTOR: B-17X
CONNECTOR: B-17X B-17X
Relay box’s
Relay box’s B-17X triangle marks
triangle marks
2 1
2 1 4 3
4 3 Harness side
Connector: B-01, B-02, B-04, B-05
CONNECTOR: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
M
C-134 2 1
a. Check harness between B-17X (terminal No. 1)

13 12 11 10 9 8 7 6 5 4 3 2 1 engine control relay connector and B-01 (terminal
26 25 24 23 22 21 20 19 18 17 16 15 14 No. 1) No. 1 injector connector.
Harness side connector b. Check harness between B-17X (terminal No. 1)
AK300257 AB
Q: Is the check result normal? c. Check harness between B-17X (terminal No. 1)
YES : Go to Step 7 . engine control relay connector and B-04 (terminal
NO : Repair. No. 1) No. 3 injector connector.
d. Check harness between B-17X (terminal No. 1)
NO : Repair.
TROUBLESHOOTING
13A-109
STEP 8. Check harness between injector STEP 9. Measure fuel pressure.
connector and C-134 engine-ECU connector. ! Measure fuel pressure (Refer to fuel pressure
test +,13A!"#&)
Connector: B-01, B-02, B-04, B-05
NO : Repair.
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
STEP 10. Check for intake of air from intake hose

and inlet manifold.
M
2 1 Q: Is the check result normal?
NO : Repair.
CONNECTOR: C-134
STEP 11. Check for skipped timing belt teeth.
NO : Repair.
C-134 STEP 12. Exhaust gas recirculation system

check.
! Exhaust gas recirculation system check [Refer to
GROUP 17 " Exhaust gas recirculation (EGR)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 system +,17!'"].
YES : Replace engine-ECU
AK300257 AB
NO : Repair.
NO : Repair.
Code No. P0301: No. 1 cylinder mis-fire detection system
OPERATION PROBABLE CAUSE

! Refer to P0201 injector circuit +,13A!&%. ! Ignition system related part(s) failed
! Low compression pressure
FUNCTION ! Failed engine-ECU
! If a misfire occurs while the engine is running, the
engine speed changes for an instant. DIAGNOSIS PROCEDURE
! The engine-ECU checks for such changes in
engine speed.
STEP 1.Check ignition coil spark.
TROUBLE JUDGMENT
Check Conditions YES : Go to Step 2 .
! 5 seconds later after the engine has started up. NO : Check ignition Circuit System (Refer to
! The engine speed is 500 " 4,500 r/min. Inspection procedure 29 +,13A!(%')
higher. STEP 2.Connector check: B-01 No.1 injector
! The intake air temperature is "10%C or higher. connector
! The barometric pressure is 72 kPa or more.
! The volumetric efficiency is 30 " 60 %. Connector: B-01
! The adaptive learning has been completed with
the vane that generates the crankshaft position
signals. B-01 (GR)
! During the engine operation except the shift
change or low speed driving and rapid accelera-
tion and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after M
changing to ON from OFF or to OFF from ON). 2 1
! The throttle deviation is within the range of "
0.059 V/10ms to 0.059 V/10ms. Q: Is the check result normal?
Judgment Criterion YES : Go to Step 3 .
! The number of misfiring (in the catalyst tempera- NO : Repair.
number (of 7.3 % on more than the two cylinders) STEP 3.Check No.1 injector itself.
with the engine speed of 200 r/min. ! Check Injector itself (Refer to +,13A!"')).
Or
! The number of misfiring (that is 1.5 times the Q: Is the check result normal?
emission standard limit) is beyond the specified
NO : Replace No.1 injector.
number (of 2 % on more than the two cylinders)
with the engine speed of 1,000 r/min.
TROUBLESHOOTING
13A-111
STEP 4.Connector check: B-17X engine control STEP 5.Check harness between B-17X (terminal
relay connector and B-134 engine-ECU No. 1) engine control relay connector and B-01
connector (terminal No. 1) No.1 injector connector.
CONNECTOR: B-17X CONNECTOR: B-17X
Relay box’s B-17X Relay box’s B-17X

triangle marks triangle marks
2 1 2 1
4 3 4 3
connector AK300255 AB connector AK300255 AB
B-01 (GR)
C-134
M
2 1
13 12 11 10 9 8 7 6 5 4 3 2 1 ! Check power supply line for damage.

26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB NO : Repair.

NO : Repair.
STEP 6. Check harness between B-01(terminal STEP 7. Measure fuel pressure.

No. 2) No.1 injector connector and C-134 ! Measure fuel pressure (Refer to fuel pressure
(terminal No. 1) engine-ECU connector test +,13A!"#&).
NO : Repair.
B-01 (GR)
M
2 1
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
OPERATION ! The intake air temperature is "10%C or higher.

! Refer to P0202 injector circuit +,13A!*(. ! The barometric pressure is 72 kPa or more.
! The volumetric efficiency is 30 " 60 %.
FUNCTION ! The adaptive learning has been completed with
! If a misfire occurs while the engine is running, the the vane that generates the crankshaft position
engine speed changes for an instant. signals.
! The engine-ECU checks for such changes in ! During the engine operation except the shift
engine speed. change or low speed driving and rapid accelera-
TROUBLE JUDGMENT
of air compressor (A/C: within the 3 seconds after
Check Conditions changing to ON from OFF or to OFF from ON).
! 5 seconds later after the engine has started up. ! The throttle deviation is within the range of "
! The engine speed is 500 " 4,500 r/min. 0.059 V/10ms to 0.059 V/10ms.
higher.
TROUBLESHOOTING
13A-113
Judgment Criterion STEP 3.Check No.2 injector itself.
! The number of misfiring (in the catalyst tempera- ! Check Injector itself (Refer to +,13A!"')).
number (of 7.3 % on more than the two cylinders) Q: Is the check result normal?
with the engine speed of 200 r/min. YES : Go to Step 4 .
Or NO : Replace No.2 injector.
! The number of misfiring (that is 1.5 times the
emission standard limit) is beyond the specified STEP 4.Connector check: B-17X engine control
number (of 2 % on more than the two cylinders) relay connector and B-134 engine-ECU
with the engine speed of 1,000 r/min. connector
PROBABLE CAUSE CONNECTOR: B-17X
! Ignition system related part(s) failed Relay box’s B-17X
! Low compression pressure triangle marks
! Failed engine-ECU
DIAGNOSIS PROCEDURE 2 1
4 3
STEP 1.Check ignition coil spark. Harness side
NO : Check ignition circuit system (Refer to CONNECTOR: C-134
Inspection procedure 29 +,13A!(%').
STEP 2.Check connector: B-02 No.2 injector

connector
Connector: B-02
C-134
B-02 (GR)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
M AK300257 AB
2 1
Harness side connector AK300265 AD Q: Is the check result normal?
NO : Repair.
NO : Repair.
STEP 5.Check harness between B-17X (terminal STEP 6. Check harness between B-02 (terminal
No. 1) engine control relay connector and B- No. 2) No.2 injector connector and C-134
02(terminal No. 1) No.2 injector connector. (terminal No. 14) engine-ECU connector
Relay box’s B-17X
triangle marks
B-02 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AB Harness side connector AK300265 AD
B-02 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

! Measure fuel pressure (Refer to fuel pressure
test +,13A!"#&)
NO : Repair.

! Refer to P0203 injector circuit +,13A!*%.
Check Conditions
FUNCTION ! 5 seconds later after the engine has started up.
! If a misfire occurs while the engine is running, the ! The engine speed is 500 " 4,500 r/min.
engine speed changes for an instant. ! The engine coolant temperature is "10%C or
! The engine-ECU checks for such changes in higher.
engine speed. ! The intake air temperature is "10%C or higher.
TROUBLESHOOTING
13A-115
! The volumetric efficiency is 30 " 60%. STEP 3.Check No.3 injector itself.
! The adaptive learning has been completed with ! Check Injector itself (Refer to +,13A!"')).
signals. Q: Is the check result normal?
! During the engine operation except the shift YES : Go to Step 4 .
change or low speed driving and rapid accelera- NO : Replace No.3 injector.
of air compressor (A/C: within the 3 seconds after STEP 4.Connector check: B-17X engine control
changing to ON from OFF or to OFF from ON). relay connector, B-134 engine-ECU connector
! The throttle deviation is within the range of "
CONNECTOR: B-17X
0.059 V/10ms to 0.059 V/10ms.
Relay box’s B-17X
Judgment Criterion triangle marks
! The number of misfiring (in the catalyst tempera-
2 1
Or 4 3
! The number of misfiring (that is 1.5 times the Harness side
emission standard limit) is beyond the specified connector AK300255 AB
number (of 2 % on more than the two cylinders)
with the engine speed of 1,000 r/min. CONNECTOR: C-134
PROBABLE CAUSE
! Failed engine-ECU
DIAGNOSIS PROCEDURE C-134
STEP 1.Check ignition coil spark.

13 12 11 10 9 8 7 6 5 4 3 2 1
Q: Is the check result normal? 26 25 24 23 22 21 20 19 18 17 16 15 14
Inspection procedure 29 +,13A!(%'). AK300257 AB

STEP 2.Connector check: B-04 No.3 injector YES : Go to Step 5 .
connector NO : Repair.
Connector: B-04
B-04 (GR)
M
2 1

NO : Repair.
(terminal No. 1) No.3 injector connector. (terminal No. 2) engine-ECU connector
Relay box’s B-17X
triangle marks
B-04 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AB Harness side connector AK300265 AE
B-04 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

test +,13A!"#&)
NO : Repair.

! Refer to P0204 injector circuit +,13A!'#(.
Check Conditions
FUNCTION ! 5 seconds later after the engine has started up.
! If a misfire occurs while the engine is running, the ! The engine speed is 500 " 4,500 r/min.
engine speed changes for an instant. ! The engine coolant temperature is "10%C or
! The engine-ECU checks for such changes in higher.
engine speed. ! The intake air temperature is "10%C or higher.
TROUBLESHOOTING
13A-117
! The volumetric efficiency is 30 " 60%. STEP 3.Check No.4 injector itself.
! The adaptive learning has been completed with ! Check Injector itself (Refer to +,13A!"')).
signals. Q: Is the check result normal?
! During the engine operation except the shift YES : Go to Step 4 .
change or low speed driving and rapid accelera- NO : Replace No.4 injector.
of air compressor (A/C: within the 3 seconds after STEP 4.Connector check: B-17X engine control
changing to ON from OFF or to OFF from ON). relay connector and B-134 engine-ECU
! The throttle deviation is within the range of " connector
0.059 V/10ms to 0.059 V/10ms.
CONNECTOR: B-17X
Judgment Criterion B-17X
Relay box’s
! The number of misfiring (in the catalyst tempera- triangle marks
2 1
Or
! The number of misfiring (that is 1.5 times the 4 3
emission standard limit) is beyond the specified Harness side
number (of 2 % on more than the two cylinders) connector AK300255 AB
with the engine speed of 1,000 r/min.
CONNECTOR: C-134
PROBABLE CAUSE
! Failed engine-ECU
DIAGNOSIS PROCEDURE
C-134
STEP 1.Check the ignition coil spark.

13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 2 . 26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Check ignition Circuit System (Refer to
Inspection procedure 29 +,13A!(%').
AK300257 AB
STEP 2.Connector check: B-05 No.4 injector Q: Is the check result normal?
connector YES : Go to Step 5 .
NO : Repair.
Connector: B-05
B-05 (GR)
M
2 1

NO : Repair.
(terminal No. 1) No.4 injector connector. (terminal No. 15) engine-ECU connector.
Relay box’s B-17X
triangle marks
B-05 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AB Harness side connector AK300265 AF
B-05 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

test +,13A!"#&)
NO : Repair.
TROUBLESHOOTING
13A-119
Code No. P0325: Detonation Sensor System
Detonation sensor circuit
C-137
71 72 73 74 75 76 77 78 79 80 81 Engine-ECU
82 83 84 85 86 87 88 89 90 9192
78
B B
B B-103
(MU802661)
2 1 1 2
Detonation sensor
Wire colour code

R: Red P: Pink V: Violet
AK300273 AB

Check Condition
(terminal No. 78) from the detonation sensor (ter-
! 2 seconds later after the engine has started up.
minal No. 1).
Judgment Criteria
FUNCTION ! The change amount of the detonation sensor out-
! The detonation sensor detects the vibration of the put voltage (the detonation sensor peak voltage
cylinder block caused by detonation waves, and in every one third a turn of the crankshaft) is
inputs a signal to the engine-ECU. below 0.08 V in 200 consecutive times.
! In response to the signal, the engine-ECU pro-
vides controls to retard the ignition timing when
the detonation occurs.
PROBABLE CAUSE STEP 2. Measure resistance at B-103 detonation

! Failed detonation sensor sensor connector.
! Open/short circuit in detonation sensor circuit or
loose connector contact Connector: B-103
! Failed engine-ECU
2 1
DIAGNOSIS PROCEDURE Harness side
connector
B-103 (GR)
STEP 1. Connector check: B-103 detonation
sensor connector
Connector: B-103
2 1
Harness side
connector
B-103 (GR)
Detonation sensor
Alternator
AK300274 AB

side.
Detonation sensor
OK: 2 $ or less
Alternator YES : Go to Step 3 .
AK300274 AB
NO : Check and repair harness between B-103
(terminal No. 2) detonation sensor
Q: Is the check result normal? connector and body earth.
YES : Go to Step 2 . ! Check earthing line for open circuit
NO : Repair. and damage.
TROUBLESHOOTING
13A-121
connector No. 1) detonation sensor connector and C-137
(terminal No.78) engine-ECU connector.
CONNECTOR: C-137
Connector: B-103
2 1
Harness side
connector
B-103 (GR)
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair. Detonation sensor
Alternator
AK300274 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

age.
NO : Repair.

00 " How to Use
+,00!$).
STEP 6. Replace detonation sensor.

! After replacing the detonation sensor, re-check
the trouble symptoms.
NO : Check end.
TROUBLESHOOTING
13A-123
Code No. P0335: Crank Angle Sensor System
Crank angle sensor circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
B-29 3
(MU802603)
1 2
Crank angle sensor
3
1 2
B-W
18
J/C(1) G-R
C-16
17
B-W
40 89
C-135 C-137
31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code
AK300275 AB

! Power is supplied to the crank angle sensor (ter-
minal No. 3) from the engine control relay (termi-
nal No. 1) and is earthed to the engine-ECU STEP 1. MUT-II data list
(terminal No. 40) from the crank angle sensor ! Refer to Data list reference table +,13A!(&%.
(terminal No. 1). a. Item 22: Crank angle sensor
! A power voltage of 5 V is applied to the crank Q: Is the check result normal?
angle sensor output terminal (terminal No. 2) YES : Intermittent malfunction (Refer to GROUP
from the engine-ECU (terminal No. 89). 00 " How to Use
FUNCTION +,00!$).
! The crank angle sensor detects the crank angle NO : Go to Step 2 .
(position) and inputs a pulse signal to the engine-
ECU.
STEP 2. Connector check: B-29 crank angle
sensor connector
trols the injector, etc.
Connector: B-29
TROUBLE JUDGMENT
Check Condition 2 1
! Engine in cranking state. 3
Harness side B-29 (B)
Judgment Criterion connector
! The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.
PROBABLE CAUSE
! Failed crank angle sensor
! Open/short circuit in crank angle sensor circuit or
! Failed engine-ECU
Crank angle sensor
AK300276 AB

NO : Repair.
TROUBLESHOOTING
13A-125
STEP 3. Measure voltage at B-29 crank angle STEP 4. Measure voltage at C-137 engine-ECU
sensor connector. connector.
2 1
3
connector
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB
Connector: B-29
2 1
Crank angle sensor
3
AK300276 AB
connector
side.
OK: 4.9 " 5.1 V
NO : Go to Step 4 .
Crank angle sensor
AK300276 AB

! Disconnect B-29 crank angle sensor connector.
OK: 4.9 " 5.1 V
NO : Go to Step 6 .
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB

2 1 NO : Repair.
3
connector
Crank angle sensor
AK300276 AB

(terminal No. 2) crank angle sensor
NO : Repair.
TROUBLESHOOTING
13A-127
No. 2) crank angle sensor connector and C-137 ! Refer to Data list reference table +,13A!(&%.
(terminal No. 89) engine-ECU connector. a. Item 22: Crank angle sensor
2 1 00 " How to Use
3 Troubleshooting/Inspection Service Points
B-29 (B)
Harness side +,00!$).
connector NO : Replace engine-ECU.
STEP 9. Measure voltage at B-29 crank angle

sensor connector.
Connector: B-29
2 1
3
connector
Crank angle sensor
AK300276 AB
CONNECTOR: C-137
Crank angle sensor

C-137
AK300276 AB

8180 79 78 77 76 75 74 73 72 71 side.
92 91 90 89 88 87 86 85 84 83 82 ! Ignition switch: ON
Harness side connector ! Voltage between terminal No. 3 and earth.
AK300254 AB OK: System voltage
! Check output line for short circuit. Q: Is the check result normal?
NO : Repair.
STEP 10. Connector check: B-17X engine control STEP 11. Measure resistance at B-29 crank angle
relay connector sensor connector.
Relay box’s B-17X

triangle marks 2 1
3
connector
2 1
4 3
Harness side
Connector: B-29
21
3
connector
Crank angle sensor
AK300276 AB

side.
OK: 2 $ or less
Crank angle sensor

AK300276 AB
connector
Q: Is the check result normal? CONNECTOR: C-135
connector and B-17X (terminal No. 1)
engine control relay connector.
open/short circuit.
NO : Repair. C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
TROUBLESHOOTING
13A-129
STEP 13. Check harness between B-29 (terminal STEP 14. Measure output waveform at B-29 crank
No. 1) crank angle sensor connector and C-135 angle sensor connector (Use oscilloscope).
(terminal No. 40) engine-ECU connector. Connector: B-29
Connector: B-29
2 1
2 1 3
3
Harness side B-29 (B) connector
connector
Crank angle sensor

Crank angle sensor
AK300276 AB
AK300276 AB
CONNECTOR: C-135
! Engine: Idling
(Refer to *+13A!")%), its maximum value
C-135 should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in
waveform.
38 37 36 35 34 33 32 31 Q: Is the check result normal?
46 45 44 43 42 41 40 39 YES : Go to Step 8 .
Harness side connector NO : Go to Step 15 .
AK300256 AB

NO : Repair.
STEP 15. Connector check: B-17X engine control STEP 16. Check harness between B-29 (terminal
relay connector No. 3) crank angle sensor connector and B-17X
CONNECTOR: B-17X
B-17X Connector: B-29
Relay box’s
triangle marks
21
3
2 1 connector
4 3
Harness side

NO : Repair.
Crank angle sensor
AK300276 AB
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
13A-131
STEP 17. Connector check: C-135 and C-137 STEP 18. Check harness between B-29 (terminal
engine-ECU connectors No. 2) crank angle sensor connector and C-137
CONNECTOR: C-135, C-137
Connector: B-29
2 1
3
connector
C-135
C-137
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
C-135 Harness side connector
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300277 AB Crank angle sensor

NO : Repair. CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
STEP 19. Check harness between B-29 (terminal STEP 20. Check the crankshaft sensing blade.
No. 1) crank angle sensor connector and C-135 Q: Is the check result normal?
(terminal No. 40) engine-ECU connector. YES : Go to Step 21 .
Connector: B-29 NO : Replace the crankshaft sensing blade.
2 1 STEP 21: MUT-II data list

3 ! Refer to Data list reference table +,13A!(&%.
connector a. Item 22: Crank angle sensor
00 " How to Use
+,00!$).
NO : Replace crank angle sensor.
Crank angle sensor
AK300276 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
TROUBLESHOOTING
13A-133
Code No. P0340: Camshaft Position Sensor System
Camshaft position sensor circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
R
B-106 3
(MU802337)
1 2 3 Camshaft position sensor
1 2
B-W
19
J/C (1)
C-16 L-Y
17
B-W
40 88
C-135 C-137
31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code
AK300278 AB
OPERATION ! A power voltage of 5 V is applied to the camshaft

! Power is supplied to the camshaft position sensor position sensor output terminal (terminal No. 2)
(terminal No. 3) from the engine control relay (ter- from the engine-ECU (terminal No. 88).
minal No. 1) and is earthed to the engine-ECU
(terminal No. 40) from the camshaft position sen- FUNCTION
sor (terminal No. 1). ! The camshaft position sensor detects the top
dead center on the compression stroke of the No.
1 cylinder and inputs a pulse signal to the engine-
ECU.
TROUBLE JUDGMENT STEP 2. Measure voltage at B-106 camshaft

Check Condition position sensor connector.
! After the engine has started up.
Connector: B-106
Judgment Criterion
! The sensor output voltage remains unchanged 3 2 1
(no pulse signal is inputted) for 2 seconds. Harness side
connector
PROBABLE CAUSE
! Failed camshaft position sensor
! Open/short circuit in camshaft position sensor cir- B-106 (B)
cuit or loose connector contact
! Failed engine-ECU AK300279 AB

STEP 1. Connector check: B-106 camshaft ! Voltage between terminal No. 3 and earth.
position sensor connector OK: System voltage
3 2 1 NO : Go to Step 3 .
Harness side
connector
B-106 (B)
AK300279 AB

NO : Repair.
TROUBLESHOOTING
13A-135
STEP 3. Connector check: B-17X engine control STEP 4. Measure voltage at B-106 camshaft
relay connector position sensor connector.
Relay box’s B-17X

triangle marks 3 2 1
Harness side
connector
2 1
4 3 B-106 (B)
Harness side
connector AK300255 AB AK300279 AB

Connector: B-106
side.
3 2 1 ! Ignition switch: ON
Harness side
connector OK: 4.9 " 5.1 V
B-106 (B)
NO : Go to Step 5 .
AK300279 AB

(terminal No. 3) camshaft position sensor
open/short circuit.
NO : Repair.
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB
3 2 1 3 2 1
connector connector
B-106 (B) B-106 (B)
AK300279 AB AK300279 AB

! Disconnect B-106 camshaft position sensor con- YES : Check and repair harness between B-106
nector. (terminal No. 2) camshaft position sensor
! Ignition switch: ON connector and C-137 (terminal No. 88)
! Voltage between terminal No. 88 and earth. engine-ECU connector.
OK: 4.9 " 5.1 V ! Check output line for open circuit.
Q: Is the check result normal? NO : Repair.
NO : Go to Step 7 .
TROUBLESHOOTING
13A-137
connector No. 2) camshaft position sensor connector and
C-135 (terminal No. 56) engine-ECU connector.
CONNECTOR: C-137
Connector: B-106
3 2 1
Harness side
connector
C-137
B-106 (B)
AK300279 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.

00 " How to Use
+,00!$).
STEP 10. Measure resistance at B-106 camshaft STEP 12. Check harness between B-106 (terminal
position sensor connector. No. 1) camshaft position sensor connector and
Connector: B-106
Connector: B-106
3 2 1
Harness side 3 2 1
connector Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB
AK300279 AB
side.
CONNECTOR: C-135
OK: 2 $ or less
C-135
connector
CONNECTOR: C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

C-135
38 37 36 35 34 33 32 31
NO : Repair.
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
TROUBLESHOOTING
13A-139
STEP 13. Measure output waveform at B-106 STEP 15. Check harness between B-106 (terminal
camshaft position sensor connector (Use No. 3) camshaft position sensor connector and
oscilloscope). B-17X (terminal No. 1) engine control relay
connector.
Connector: B-106
Connector: B-106
3 2 1
Harness side 3 2 1
connector
B-106 (B)
B-106 (B)
AK300279 AB
AK300279 AB
CONNECTOR: B-17X
! Engine: Idling
Relay box’s B-17X
triangle marks
2 1
(Refer to *+13A!")%), its maximum value
should be 4.8 V or more, and its minimum 4 3
value should be 0.6 V or less with no noise in Harness side
waveform. connector AK300255 AB
Q: Is the check result normal? ! Check power supply line for damage.
NO : Go to Step 14 . Q: Is the check result normal?
NO : Repair.
relay connector.
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
STEP 16. Connector check: C-135 and C-137 STEP 17. Check harness between B-106 (terminal
engine-ECU connectors No. 2) camshaft position sensor connector and
Connector: B-106
3 2 1
Harness side
connector
C-135
C-137
B-106 (B)
AK300279 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300277 AB C-137

8180 79 78 77 76 75 74 73 72 71
NO : Repair. 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

NO : Repair.
TROUBLESHOOTING
13A-141
STEP 18. Check harness between B-106 (terminal STEP 19. Check camshaft position sensing
No. 1) camshaft position sensor connector and cylinder.
C-135 (terminal No. 40) engine-ECU connector. Q: Is the check result normal?
Connector: B-106 YES : Go to Step 20 .
NO : Replace camshaft position sensing cylinder.
3 2 1
Harness side STEP 20. Check the trouble symptoms.
connector
YES : Replace camshaft position sensor.
B-106 (B) NO : Intermittent malfunction (Refer to GROUP
00 " How to Use
AK300279 AB
+,00!$).
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
Code No. P0403: EGR Control Solenoid Valve System
EGR control solenoid valve circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
1
B-102
1 2 EGR control solenoid valve
76
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300280 AB
OPERATION ! The engine-ECU (terminal No. 6) makes the

! Power is supplied to the EGR control solenoid power transistor in the unit be in "ON", and that
valve (terminal No. 1) from the engine control makes currents go on the EGR control solenoid
relay (terminal No. 1). valve (terminal No. 2).
TROUBLESHOOTING
13A-143
FUNCTION STEP 3. Measure resistance at B-102 EGR
! In response to the signal from the engine-ECU, control solenoid valve connector.
the EGR control solenoid valve controls the oper-
ation of the EGR valve. Connector: B-102
2 1
TROUBLE JUDGMENT Harness side

connector
Check Conditions
! Except the engine stalling
! The battery voltage is 10 " 16 V. B-102 (BR)
Judgment Criteria
! If the off surge voltage from the motor coil is not
generated when the EGR valve control motor is AK300281 AB
driven.
! Disconnect connector, and measure at solenoid
PROBABLE CAUSE valve side.
! Failed EGR control solenoid valve ! Resistance between terminal No. 1 and No. 2.
! Open/short circuit in EGR control solenoid valve OK: 29 " 35 $ (at 20%C)
circuit or loose connector contact Q: Is the check result normal?
! Failed engine-ECU YES : Go to Step 4 .
NO : Replace EGR control solenoid valve.
DIAGNOSIS PROCEDURE
STEP 4. Measure voltage at B-102 EGR control
STEP 1. MUT-II actuator test solenoid valve connector.
! Refer to Actuator test reference table +,13A!(*". Connector: B-102
a. Item 10: EGR control solenoid valve 2 1
OK: Operating sound can be heard and the Harness side
connector
valve vibrates.
00 " How to Use B-102 (BR)
+,00!$).
NO : Go to Step 2 . AK300281 AB

STEP 2. Connector check: B-102 EGR control side.
solenoid valve connector ! Ignition switch: ON
Connector: B-102
Harness side
NO : Go to Step 5 .
B-102 (BR)
AK300281 AB

NO : Repair.
Relay box’s B-17X
triangle marks
2 1
4 3 C-134
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
Connector: B-102
2 1 26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side Harness side connector

connector
AK300257 AB

side.
B-102 (BR)
OK: System voltage
AK300281 AB
Q: Is the check result normal? YES : Go to Step 8 .
YES : Check and repair harness between B-102 NO : Go to Step 7 .
(terminal No. 1) EGR control solenoid valve
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-145
connector connector
C-134 C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB AK300257 AB

2 1
Harness side NO : Repair.
connector
B-102 (BR)
AK300281 AB

(terminal No. 2) EGR control solenoid valve
! Check output line for open/short
circuit.
NO : Repair.
STEP 9. Check harness between B-102 (terminal STEP 10. Check harness between B-102 (terminal
No. 2) EGR control solenoid valve connector and No. 1) EGR control solenoid valve connector and
C-134 (terminal No. 6) engine-ECU connector. B-17X (terminal No. 1) engine control relay
Connector: B-102
connector.
2 1
Connector: B-102
Harness side 2 1
connector
B-102 (BR)
B-102 (BR)
AK300281 AB
AK300281 AB
CONNECTOR: C-134
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
C-134
4 3
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 ! Check power supply line for damage.
AK300257 AB YES : Go to Step 11 .
NO : Repair.
YES : Go to Step 10 . STEP 11. MUT-II actuator test
NO : Repair. ! Refer to actuator test reference table list +,13A!
(*".
! Item 10: EGR control solenoid valve
OK: Operating sound can be heard and the
valve vibrates.
00 " How to Use
+,00!$).
TROUBLESHOOTING
13A-147
Code No. P0420: Catalyst malfunction
FUNCTION STEP 2.MUT-II data list

! The signal from the heated oxygen sensor (rear) ! Refer to Data list reference table +,13A!(&%.
differs from the heated oxygen sensor (front). a. Item 11: Oxygen sensor (front)
That is because the catalytic converter purifies b. Item 59: Oxygen sensor (rear)
exhaust gas. When the catalytic converter has
deteriorated, the signal from the heated oxygen Q: Is the check result normal?
sensor (front) becomes similar to the heated oxy- YES : Go to Step 3 .
gen sensor (rear). NO : Perform the diagnosis code classified check
! The engine-ECU compares the output of the front procedure for the sensor that has shown an
and rear heated oxygen sensor signals. abnormal data valve (Refer to Inspection
TROUBLE JUDGMENT
Check Conditions STEP 3.MUT-II data list
! Engine speed: 3,000 r/min or less. a. Item 11: Oxygen sensor (front)
! During the driving. OK: 0 " 0.4 and 0.6 " 1.0 volt should alternate
! During the air-fuel ratio feedback control. 15 times or more within 10 seconds (engine
Judgment Criterion speed at 2,000 r/min).
! When the output frequency ratio of the oxygen Q: Is the check result normal?
sensor (rear) vs. The oxygen sensor (front) is 0.8 YES : Go to Step 4 .
or more on the average for 12 seconds. NO : Replace the oxygen sensor (front).
PROBABLE CAUSE
STEP 4.Replace the oxygen sensor (rear).
! Catalytic converter deteriorated
! After replacing the oxygen sensor (rear), re-
! Failed oxygen sensor (front)
check the trouble symptoms.
! Failed oxygen sensor (rear)
! Failed engine-ECU Q: Is the check result normal?
DIAGNOSIS PROCEDURE NO : Check end.
STEP 1.Check for leakage of exhaust emission STEP 5.Replace the catalytic converter.
from exhaust manifold. ! After replacing the catalytic converter, re-check
YES : Go to Step 2 . Q: Is the check result normal?
NO : Repair. YES : Replacing engine-ECU.
NO : Check end.
Code No. P0443: Purge Control Solenoid Valve System
Purge control solenoid valve circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
2
B-101
(MU802779)
1 2 Purge control solenoid valve
BR
9
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
Engine-ECU
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300282 AB
OPERATION ! The engine-ECU (terminal No. 9) makes the

! Power is supplied to the purge control solenoid power transistor in the unit be in "ON" position,
valve (terminal No. 2) from the engine control and that makes currents go on the purge control
relay (terminal No. 1). solenoid valve (terminal No. 1).
TROUBLESHOOTING
13A-149
FUNCTION STEP 3: Measure resistance at B-101 purge
! In response to a signal from the engine-ECU, the control solenoid valve connector.
purge control solenoid valve controls the flow rate
of the purge air to be introduced into the surge Connector: B-101
tank. 2 1
Harness side
TROUBLE JUDGMENT connector
Check Conditions
! The battery voltage is 10 V or more. B-101 (B)
Judgment Criteria
! The surge voltage (system voltage + 2 V) of sole- AK300283AB
noid coil is not detected when the purge control ! Disconnect connector, and measure at solenoid
solenoid valve is turned in OFF position from ON. valve side.
! The battery voltage is 10 V or more. ! Resistance between terminal No. 1 and No. 2.
PROBABLE CAUSE OK: 30 " 34 $ (at 20%C)
! Failed purge control solenoid valve Q: Is the check result normal?
! Open/short circuit in purge control solenoid value YES : Go to Step 4 .
circuit or loose connector contact NO : Replace purge control solenoid valve.
! Failed engine-ECU
STEP 4. Measure voltage at B-101 purge control
DIAGNOSIS PROCEDURE
solenoid valve connector.
Connector: B-101
STEP 1. MUT-II actuator test 2 1
! Item 08: Purge control solenoid valve Harness side
OK: Operating sound can be heard and the connector
valve vibrates
YES : Intermittent malfunction (Refer to GROUP B-101 (B)
00 " How to Use
+,00!$). AK300283AB
NO : Go to Step 2 . ! Disconnect connector, and measure at harness

side.
STEP 2. Connector check: B-101 purge control ! Ignition switch: ON
solenoid valve connector ! Voltage between terminal No. 2 and earth.
OK: System voltage
Connector: B-101
Harness side YES : Go to Step 6 .
connector NO : Go to Step 5 .
B-101 (B)
AK300283AB

NO : Repair.
Relay box’s B-17X
triangle marks
2 1
4 3 C-134
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
Connector: B-101
26 25 24 23 22 21 20 19 18 17 16 15 14
2 1
Harness side

side.
B-101 (B) ! Ignition switch: ON
AK300283AB
OK: System voltage
YES : Check and repair harness between B-101 NO : Go to Step 7 .
(terminal No. 2) purge control solenoid valve
! Check power line for open/short
circuit.
NO : Repair.
TROUBLESHOOTING
13A-151
connector connector
C-134 C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB AK300257 AB

connector
B-101 (B)
AK300283AB

! Check output line for open and short
circuit.
NO : Repair.
No. 1) purge control solenoid valve connector No. 2) purge control solenoid valve connector
and C-134 (terminal No. 9) engine-ECU and B-17X (terminal No. 1) engine control relay
connector. connector.
2 1 2 1
connector connector
B-101 (B) B-101 (B)
AK300283AB AK300283AB
CONNECTOR: C-134 CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
C-134 4 3
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1 ! Check power line for damage.

26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB NO : Repair.
STEP 11. MUT-II actuator test
YES : Go to Step 10 . ! Item 08: purge control solenoid valve
NO : Repair. OK: Operating sound can be heard and the
valve vibrates
00 " How to Use
+,00!$).
TROUBLESHOOTING
13A-153
Code No. P0500: Vehicle speed sensor system
Vehicle speed sensor circuit
Ignition switch Engine-ECU

C-137
C-303
R LOCK
1 2 3 71 72 73 74 75 76 77 78 79 80 81
4 5 6 ST ACC 82 83 84 85 86 87 88 89 90 9192
IG1 IG2
2
L-B 86
C-203
6
W-L
2 J/B
7.5A
3
C-202 J/C (1)
C-16 Meter and gauge
11 1
B-W 2
C-106
3
W-L
B-W
1 3
B-115
1 2 3 Vehicle speed sensor
2
B
8
J/C (2)
C-17
B 1
Wire colour code

AK300284 AB
OPERATION FUNCTION
! A power voltage of 5 V is applied to the vehicle ! The vehicle speed sensor converts the vehicle
speed sensor (terminal No. 3) from the engine- speed to the voltage, and then input it into the
ECU (terminal No. 86). engine-ECU
TROUBLE JUDGMENT STEP 2.MUT-II data list

Check Conditions ! Refer to Data list reference table +,13A!(&%.
! 2 seconds later after the engine has started up. a. Item 24: Vehicle speed sensor
! Engine speed: 2,000 r/min or more. Q: Is the check result normal?
! Under the high load operation (The volumetric YES : Go to Step 3 .
efficiency is 40 " 75 %). NO : Intermittent malfunction (Refer to GROUP
Judgment Criterion 00 - How to Use Troubleshooting/Inspection
! The sensor output voltage remains unchanged Service Points +,00!$).
STEP 3.Check connector: C-137 engine-ECU
PROBABLE CAUSE connector
! Failed Vehicle speed sensor
! Open/short circuit in vehicle speed sensor circuit CONNECTOR: C-137
! Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1.Check the speedometer

C-137
NO : Check the speedometer (Refer to GROUP 8180 79 78 77 76 75 74 73 72 71
54A "Combination Meter Assembly and 92 91 90 89 88 87 86 85 84 83 82
Vehicle speed sensor " On-vehicle Service Harness side connector
+,54A!-").
AK300254 AB

NO : Repair.
TROUBLESHOOTING
13A-155
STEP 4.Check harness between C-137 (terminal STEP 5.Check the trouble symptoms.
No. 86) engine-ECU connector and B-115 Q: Does trouble symptom persist?
(terminal No. 3) Vehicle speed sensor connector. YES : Replacing engine-ECU.
CONNECTOR: C-137 NO : Intermittent malfunction (Refer to GROUP
00 - How to Use Troubleshooting/Inspection
Service Points +,00!$).
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB
CONNECTOR: B-115
3 2 1
B-115 (B) Harness side
connector
AK300285AB

! Check output line for open circuit and damage.
NO : Repair.
Code No. P0505: Idle Speed Control Servo System
Idle speed control servo circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
R
R R
2 5
B-105
1 2 3
Idle speed control servo
4 5 6
1 3 4 6
L-Y Y-L W G-Y
4 17 5 18
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code
AK300286 AB
TROUBLESHOOTING
13A-157
OPERATION Judgment Criteria
! The power is supplied to the idle speed control ! The actual idle speed is higher than the target
servo (terminal No. 2 and No. 5) from the engine idle speed by 100 r/min or more for 10 seconds.
control relay (terminal No. 1).
! The engine-ECU (terminal No. 4, No. 5, No. 17 PROBABLE CAUSE
and No. 18) makes power transistor in the unit be ! Failed idle speed control servo
in "ON" position in order, and that makes currents ! Open/short circuit in idle speed control servo cir-
go on the idle speed control servo (terminal No. cuit or loose connector contact
1, No. 3, No. 4 and No. 6). ! Failed engine-ECU
FUNCTION DIAGNOSIS PROCEDURE

! The idle speed control servo opens and closes
the servo valve in response to a signal from the
STEP 1. MUT-II Data List
engine-ECU to control the intake air flow rate dur-
ing idling.
a. Item 45: Idle speed control position
Check conditions YES : Intermittent malfunction (Refer to GROUP
! The vehicle speed has reached 1.5 km/h or more 00 " How to Use
at least once. Troubleshooting/Inspection Service Points
! During the closed-loop idle speed control. +,00!$).
NO : Go to Step 2 .
Judgment Criteria
! The actual idle speed is higher than the target
STEP 2. Connector check: B-105 idle speed
idle speed by 300 r/min or more for 10 seconds.
control servo connector
Check conditions
Connector: B-105
! The vehicle speed has reached 1.5 km/h or more
at least once.
! During the closed-loop idle speed control. 3 2 1
! The highest ambient temperature at the last drive 6 5 4
is 45 %C or less. Harness side
connector
82%C or higher.
! The battery voltage is 10 V or more. B-105 (B)
AK300287 AB
Judgment Criteria
! The actual idle speed is higher than the target Q: Is the check result normal?
idle speed by 200 r/min or more for 10 seconds. YES : Go to Step 3 .
NO : Repair.
Check conditions
! During the closed-loop idle speed control.
STEP 3. Check idle speed control servo itself.
! Check idle speed control servo itself (Refer to
82%C or higher.
+,13A!"'$).
! The battery voltage is 10 V or more.
! The power steering switch is in OFF position. Q: Is the check result normal?
! The charging efficiency is 40 % or less. YES : Go to Step 4 .
! The intake air temperature is "10%C or higher. NO : Replace idle speed control servo.
STEP 4. Measure voltage at B-105 idle speed STEP 5. Check connector: B-17X engine control
control servo connector. relay connector
Relay box’s B-17X

3 2 1 triangle marks
6 5 4
Harness side
connector
2 1
4 3
B-105 (B) Harness side
AK300287 AB connector AK300255 AB

Connector: B-105
side.
! Voltage between terminal No. 2 and earth, also 3 2 1
between terminal No. 5 and earth. 6 5 4
Harness side
OK: System voltage connector
NO : Go to Step 5 . B-105 (B)
AK300287 AB

(terminal No. 2 or No. 5) idle speed control
servo connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-159
STEP 6. Measure voltage at C-134 engine-ECU ! Check power supply line for
connector. open/short circuit.
CONNECTOR: C-134
connector
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
AK300257 AB
26 25 24 23 22 21 20 19 18 17 16 15 14
Connector: B-105 Harness side connector
AK300257 AB
3 2 1
6 5 4 Q: Is the check result normal?
Harness side
connector NO : Repair.
B-105 (B)
AK300287 AB

side.
! Voltage between terminal No. 4 and earth,
between terminal No. 5 and earth, between termi-
nal No. 17 and earth, also voltage between termi-
nal No. 18 and earth.
OK: System voltage
idle speed control servo and C-134 engine-
ECU.
1. Harness between idle speed control
servo terminal No. 1 and engine-
ECU connector terminal No. 4
STEP 8. Check harness between B-105 idle STEP 9. Check harness between B-105 (terminal
speed control servo and C-134 engine-ECU. No. 2 or No. 5) idle speed control servo
Connector: B-105
connector and B-17X (terminal No. 1) engine
control relay connector.
3 2 1 Connector: B-105
6 5 4
Harness side 3 2 1
connector 6 5 4
Harness side
connector
B-105 (B)
AK300287 AB
B-105 (B)
CONNECTOR: C-134 AK300287 AB
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
C-134
2 1
4 3
13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side connector ! Check power supply line for damage.
AK300257 AB Q: Is the check result normal?
1. Harness between idle speed control servo termi-
NO : Repair.
nal No. 1 and engine-ECU connector terminal
No. 4
2. Harness between idle speed control servo termi- STEP 10. MUT-II Data List
nal No. 3 and engine-ECU connector terminal ! Refer to Data list reference table +,13A!(&%.
No. 17 a. Item 45: Idle speed control position
3. Harness between idle speed control servo termi- Q: Is the check result normal?
nal No. 4 and engine-ECU connector terminal YES : Intermittent malfunction (Refer to GROUP
No. 5 00 " How to Use
4. Harness between idle speed control servo termi- Troubleshooting/Inspection Service Points
nal No. 6 and engine-ECU connector terminal +,00!$).
No. 18 NO : Replace engine-ECU.
NO : Repair.
TROUBLESHOOTING
13A-161
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering pressure switch
C-135
31 32 33 34 35 36 37 38
Engine-ECU
39 40 41 42 43 44 45 46
37
B-28 1
(MU801211)
1
Power steering pressure switch
Wire colour code

AK300288 AB
CONDITION ! The engine coolant temperature is approximately

! The battery voltage is applied to the power steer- 30%C or higher.
ing fluid pressure switch (terminal No. 1) from the ! Repeat, 10 times or more, the *1 running and
engine-ECU (terminal No. 37). stop also *2 running.
*1 running: engine speed of 2,500 r/min or more
FUNCTION (Vehicle speed of 50 km/h or more).
! It is detected whether a load is applied on the *2 running: Vehicle speed of 1.5 km/h or less.
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU. When Judgment Criteria
the power steering fluid pressure switch "ON" sig- ! The power steering pressure switch remains in
nal (a large load on the power steering fluid ON position.
pump) is inputted, the engine-ECU provides the
PROBABLE CAUSE
idle-up control.
! Failed power steering fluid pressure switch
TROUBLE JUDGMENT ! Open/short circuit in power steering fluid pres-
sure switch circuit or loose connector contact
Check Conditions ! Failed engine-ECU
DIAGNOSIS PROCEDURE STEP 3. Measure voltage at C-135 engine-ECU

connector.
STEP 1. Connector check: B-28 power steering CONNECTOR: C-135
fluid pressure switch connector
CONNECTOR: B-28
B-28 (B) C-135
1
Harness side 38 37 36 35 34 33 32 31
connector AK300289 AB 46 45 44 43 42 41 40 39
NO : Repair. ! Measure engine-ECU terminal voltage.

STEP 2. Measure voltage at B-28 power steering ! Voltage between terminal No. 37 and earth.
fluid pressure switch connector. OK: System voltage
CONNECTOR: B-28 Q: Is the check result normal?
NO : Go to Step 5 .
B-28 (B)
1
Harness side

side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
13A-163
connector connector
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AB AK300256 AB

NO : Repair.
B-28 (B)
1
Harness side

(terminal No. 1) power steering fluid
pressure switch connector and C-135
NO : Repair.
STEP 6. Check harness between B-28 (terminal STEP 8. Measure voltage at C-135 engine-ECU
No. 1) power steering fluid pressure switch connector.
CONNECTOR: C-135
ECU connector.
CONNECTOR: B-28
B-28 (B) C-135
1
Harness side 38 37 36 35 34 33 32 31
connector AK300289 AB 46 45 44 43 42 41 40 39
CONNECTOR: C-135
AK300256 AB

! Engine: Idling
OK:
C-135
System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
NO : Go to Step 9 .
AK300256 AB
connector
CONNECTOR: C-135
NO : Repair.

a. Item 27: Power steering fluid pressure switch C-135

00 " How to Use 38 37 36 35 34 33 32 31
Troubleshooting/Inspection Service Points 46 45 44 43 42 41 40 39
+,00!$). Harness side connector

NO : Replace engine-ECU. AK300256 AB

NO : Repair.
TROUBLESHOOTING
13A-165
No. 1) power steering fluid pressure switch connector
CONNECTOR: C-135
ECU connector.
CONNECTOR: B-28
B-28 (B) C-135
1
Harness side 38 37 36 35 34 33 32 31
connector AK300289 AB 46 45 44 43 42 41 40 39
CONNECTOR: C-135
AK300256 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

YES : Replace power steering fluid pressure
switch.
NO : Repair.
Code No. P0622: Alternator FR Terminal System
Alternator circuit
C-135
31 32 33 34 35 36 37 38 Engine-ECU
39 40 41 42 43 44 45 46
41
Y-B
B-19
1
Y-B
B-30 4
(MU802046)
1 2 3 4 IC Voltage
regulator Alternator
Wire colour code

AK300290 AB

! The energized state of the alternator field coil is
Check Condition
inputted from the alternator (terminal No. 4) to the
! Engine speed is 50 r/min or more.
engine-ECU (terminal No. 41).
Judgment Criterion
FUNCTION ! Input voltage from alternator FR terminal is the
! A signal of the power supply duty ratio for the system voltage or more for 20 seconds.
alternator field coil is inputted to the engine-ECU.
! In response to the signal, the engine-ECU PROBABLE CAUSE
detects the alternator output current and controls ! Alternator FR terminal circuit open circuited
the idling speed according to the output current ! Failed engine-ECU
(electric load).
TROUBLESHOOTING
13A-167
DIAGNOSIS PROCEDURE STEP 3. Connector check: C-135 engine-ECU
connector
STEP 1. Connector check: B-19 intermediate CONNECTOR: B-19
connector
CONNECTOR: B-19
B-19 (B)
B-19 (B)
3 2 1
6 5 4
3 2 1 Female side
6 5 4
Female side
AK300294 AB
NO : Repair. STEP 4. Check harness between B-19 (terminal
No. 1) intermediate connector and C-135
STEP 2. Measure voltage at B-19 intermediate (terminal No. 41) engine-ECU connector.
connector. CONNECTOR: B-19
CONNECTOR: B-19
B-19 (B)
B-19 (B)
1 2 3
1 2 3 4 5 6
4 5 6 Male side
Male side
CONNECTOR: C-135
! Disconnect connector, and measure at male con-
nector side.
OK: System voltage
C-135
NO : Go to Step 3 .
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
STEP 5. Check the trouble symptoms. STEP 7. Connector check: B-30 alternator
connector
YES : Replace engine-ECU. CONNECTOR: B-30
00 " How to Use
+,00!$). B-30 (GR)
STEP 6. Measure voltage at B-19 intermediate

connector. 4 3 2 1
Harness side
CONNECTOR: B-19 connector AK300296 AB

B-19 (B)
NO : Repair.
3 2 1 STEP 8. Check harness between B-30 (terminal

6 5 4 No. 4) alternator connector and B-19 (terminal
Female side No. 1) intermediate connector.
CONNECTOR: B-30
B-30 (GR)
OK: System voltage
YES : Go to Step 9 . 4 3 2 1
CONNECTOR: B-19
B-19 (B)
3 2 1
6 5 4
Female side

YES : Replace alternator.
NO : Repair.
TROUBLESHOOTING
13A-169
STEP 9. Measure voltage at B-19 intermediate STEP 11. Check harness between B-30 (terminal
connector. No. 4) alternator connector and B-19 (terminal
No. 1) intermediate connector pin No. 1.
CONNECTOR: B-19
CONNECTOR: B-30
B-19 (B)
B-30 (GR)
3 2 1
6 5 4
Female side 4 3 2 1
connector AK300294 AB Harness side
CONNECTOR: B-19
! Engine: Idle after warm-up
! Radiator fan: Inactive
! Voltage between terminal No. 1 and earth. B-19 (B)
OK: Switching the headlamps to ON from

OFF causes the voltage to fall. 3 2 1
Q: Is the check result normal? 6 5 4
YES : Go to Step 5 . Female side
NO : Go to Step 10 . connector AK300294 AB

STEP 10. Connector check: B-30 alternator Q: Is the check result normal?
NO : Repair.
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side

NO : Repair.
STEP 12. Check harness between B-19 (terminal STEP 13. Check trouble symptom.
No. 1) intermediate connector and C-135 Q: Same symptoms regenerated?
(terminal No. 41) engine-ECU connector. YES : Replace alternator.
CONNECTOR: B-19 NO : Intermittent malfunction (Refer to Group 00
" How to Use troubleshooting/Inspection
B-19 (B)
1 2 3
4 5 6
Male side
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
TROUBLESHOOTING
13A-171
Code No. P1603: Battery Backup Line System
Battery backup circuit
Battey
Relay box 9
20A
W-B
A-14
5
W-B
80
C-137
Battery Engine-ECU
71 72 73 74 75 76 77 78 79 80 81
backup
82 83 84 85 86 87 88 89 90 9192
Wire colour code

AK300297 AB

! Power is directly supplied to the engine-ECU (ter-
Check Condition
minal No. 80) from the battery.
FUNCTION Judgment Criterion
! The engine-ECU is check the open circuit of bat- ! The battery backup line voltage 6 V or less.
tery backup line.
PROBABLE CAUSE
! Open/short circuit in battery backup line circuit or
! Failed engine-ECU

connector
STEP 1 MUT-II self-diag code CONNECTOR: C-137
! Temporarily place the ignition switch in "LOCK"
(OFF) position, and 10 seconds after that, place it
in "ON" position again.
Q: Is the diagnosis code P1603 set?
00 " How to use Troubleshooting/Inspection C-137
STEP 2. Measure voltage at C-137 engine-ECU 8180 79 78 77 76 75 74 73 72 71

92 91 90 89 88 87 86 85 84 83 82
connector.
CONNECTOR: C-137
AK300254 AB

NO : Repair.

C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 00 " How to Use
Harness side connector Troubleshooting/Inspection Service
Points+,00!$).
AK300254 AB

side.
OK: System voltage
NO : Check intermediate connector A-14, and
harness between battery and C-137
open/short circuit.
TROUBLESHOOTING
13A-173
Code No. P1610: Immobilizer System
Immobilizer-ECU circuit
Signal
transmission Immobilizer-ECU
circuit
C-304-1 3
1 2 C-304
7 3 4 5 6 7 (MU801547)
V
C-104
11
V
51
C-136
51 52 53 54 55 56 Engine-ECU
57 58 59 60 61 62
Wire colour code

AK300298 AB

! The signals are sent and received between
Check Condition
engine-ECU (terminal No. 51) and immobilizer-
ECU (terminal No. 7).
Judgment Criterion
FUNCTION ! Improper communication problems between the
! Engine-ECU sends or receives the control sig- engine-ECU and the immobilizer-ECU are
nals to or from immobilizer-ECU to certify the detected.
ignition key.
NOTE: . PROBABLE CAUSE
! If the registered ignition keys are close each ! Open/short circuit in immobilizer system circuit or
other when starting the engine, radio interfer- loose connector contact
ence may cause this code to be displayed. ! Failed immobilizer-ECU
! This code may be displayed when registering ! Failed engine-ECU
the key encrypted code.
DIAGNOSIS PROCEDURE STEP 2. Check harness between C-304 (terminal

No. 3) immobilizer-ECU connector and C-136
STEP 1. Connector check: C-304 immobilizer- (terminal No. 51) engine-ECU connector.
ECU connector and C-136 engine-ECU connector Connector: C-304
Connector: C-304 Harness side
connector
Harness side 2 1
connector 7 6 5 4 3
2 1
7 6 5 4 3
C-304
C-304
AK203418 AC
AK203418 AC
CONNECTOR: C-136
CONNECTOR: C-136
C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57
56 55 54 53 52 51
62 61 60 59 58 57 Harness side connector
AK300268 AB
YES : Go to Step 2 . ! Check output line for open/short circuit and dam-
NO : Repair. age.
NO : Repair.

00 " How to Use
+,00!$).
STEP 4. After replacing the immobilizer-ECU, re-

NO : Check end.
TROUBLESHOOTING
13A-175
INSPECTION CHART FOR TROUBLE SYMPTOMS
M1131151500522
Items Trouble symptom Inspection

procedure
No.
Communication Communication with all system is not possible 1
with MUT-II is Communication with engine-ECU only is not possible 2
impossible
Engine warning The engine warning lamp does not illuminate right after the ignition switch 3
lamp is turned the "ON" position
The engine warning lamp remains illuminating and never goes out 4
Starting Starting impossible The starter is impossible to operate. 5
(No initial combustion)
Starting impossible The starter is operative and cranks 6
(Starter operative but no initial the engine, but none of initial
combustion) combustion is in the cylinders and
the engine is not started.
Starting impossible The initial combustion occurs, but 7
(Initial combustion but no complete the engine stalls soon due to the
combustion) incomplete combustion.
Improper starting It is long cranking to start the engine.
(Long time to start)
Improper idling Unstable idling The engine speed is not constant 8
(Rough idling, hunting) and changeable during the idling.
Usually, the judgment can be based
on the movement of the tachometer
pointer, also on the vibration
transmitted to the steering wheel, sift
lever, vehicle body and so on.
Improper idling speed The proper idling speed is not
satisfied.
Engine stalled during idling The engine stalls during the idling in
(Die out) no relation to the vehicle movement.
Engine stalls The engine stalls when starting the The engine stalls during the 9
car operation, or when the accelerator
(Pass out) pedal is depressed from the idling.
The engine stalls when The engine stalls at the deceleration. 10
decelerating

procedure
No.
Driving Engine does not revolve up The engine speed is not higher when 11
the accelerator pedal is depressed.
Hesitation, sag The response of vehicle speed 12
(engine speed) is delayed when the
accelerator pedal is depressed, or
the vehicle speed (engine speed) is
temporarily dropped during the
acceleration. These phenomena are
called "hesitation" and the serious
hesitation is called "sag".
Poor acceleration The engine cannot obtain the
acceleration corresponding to the
degree of throttle opening although
the engine is smooth at the constant
speed.
Stumble The engine speed increase is
delayed when the accelerator pedal
is initially depressed at the starting.
Surge The vehicle body is repeated to
vibrate jollity in the forward and
backward directions at the constant
speed or acceleration.
The feeling of impact or vibration The large impact feeling occurs at 13
when accelerating the acceleration.
when decelerating the deceleration.
Knocking Sharp sound like a hammer striking 15
on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
Ignition timing offset The basic ignition timing is deviated 16
from the datum value.
Stopping Run on (Dieseling) The engine continues to run after the 17
ignition switch is in "LOCK (OFF)"
position.
Exhaust gas Odor, white smoke, black smoke, The exhaust gas is extremely rank 18
high-concentration CO/HC during odor, white smoke or black smoke.
idling The concentration of CO & HC is
high during the idling.
Charging Battery rundown The battery is soon rundown or the 19
performance charging ability of battery is small.
TROUBLESHOOTING
13A-177
procedure
No.
Cooling Overheating The temperature of engine cooling 20
performance water is extremely high.
Abnormal rotation of fan Motor The fan motor is abnormally rotated 21
when the ignition switch is in "ON"
position in no relation to the engine
cooling water temperature.
A/C performance Poor A/C Performance The temperature of air cooling from 22
A/C is not efficient or very far from
the target temperature.
PROBLEM SYMPTOMS TABLE
Inspection Trouble symptom Reference
procedure page
No.
1 Communication with all system is not possible +,13A!'%*
2 Communication with engine-ECU only is not possible +,13A!'&(
3 The engine warning lamp does not illuminate right after the ignition switch is +,13A!'&-
turned the "ON" position
4 The engine warning lamp remains illuminating and never goes out +,13A!'*#
5 Starting impossible (No initial combustion) +,13A!'*(
6 Starting impossible (Starter operative but no initial combustion) +,13A!'*$
7 Starting impossible (Initial combustion but no complete combustion) +,13A!'**
Starting impossible (Long time to start)
8 Unstable idling (Rough idling, hunting) +,13A!(#(
Improper idling speed (Too high or too low)
Engine stalls during idling (Die out)
9 The engine stalls when starting the car (pass out) +,13A!(#*
10 The engine stalls when decelerating +,13A!(''
11 Engine does not revolve up +,13A!('(
12 Hesitation, sag +,13A!('-
Poor acceleration
Stumble
Surge
13 The feeling of impact or vibration when accelerating +,13A!('$
14 The feeling of impact or vibration when decelerating +,13A!('%
15 Knocking +,13A!('&
16 Ignition timing offset +,13A!('*
17 Run on (Dieseling) +,13A!(('
18 Odor, white smoke, black smoke, high-concentration CO/HC during idling +,13A!(('
19 Battery rundown +,13A!(("
20 Overheating +,13A!((&

procedure page
No.
21 Abnormal rotation of fan motor +,13A!((*
22 Poor A/C performance +,13A!("'
23 Engine-ECU power supply, engine control relay, ignition switch-IG1 system +,13A!(""
24 Fuel pump system +,13A!(-'
25 Fan control relay system +,13A!()#
26 A/C switch system +,13A!()$
27 A/C compressor relay system +,13A!($#
28 A/C load signal system +,13A!($%
29 A/C pressure sensor system +,13A!(%'
30 Ignition circuit system +,13A!(&#
TROUBLESHOOTING
13A-179
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is not Possible
Data link connector circuit
Fusible link (1)
C-116
15
R
C-204
1
15 J/B
15A
12
C-205
W-B
C-24 16
1 2 3 4 5 6 7 8 Data link connector
9 10 1112 13 14 1516
4 5
B B
Wire colour code

AK300300 AB
OPERATION COMMENT ON TROUBLE SYMPTOM

! Battery voltage is applied to diagnosis connector ! Failure is possibly caused by failed power supply
(terminal No.16). circuit or failed earthing circuit of diagnosis con-
! Diagnosis connector (terminals No. 4 and 5) are nector.
earthed to the vehicle body.
PROBABLE CAUSE
! Failed diagnosis connector
! Open/short circuit in diagnosis connector circuit
! Failed MUT-II
DIAGNOSIS PROCEDURE STEP 3: Measure voltage at C-24 diagnosis

connector.
STEP 1: Check connector: C-24 diagnosis Connector: C-24
connector
Connector: C-24
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)
1 2 3 4 5 6 7 8 Harness side connector
AK203424 AE
9 10 1112 13 14 1516
Harness side connector ! Disconnect connector, and measure at the har-
AK203424 AE ness side.
YES : Go to Step 2 . OK: System voltage
NO : Repair. Q: Is the check result normal?
NO : Check intermediate connectors C-116, C-204
STEP 2: Measure resistance at C-24 diagnosis
connector. and C-205, and repair if necessary. If
connectors are normal, check and repair
Connector: C-24 harness between C-24 (terminal No. 16)
diagnosis connector and battery.
open/short circuit.
C-24 (B) STEP 4: Replace MUT-II

1 2 3 4 5 6 7 8
! After replacing the MUT-II, re-check the trouble
9 10 1112 13 14 1516
symptoms.
AK203424 AE Q: Does trouble symptom persist?
NO : Check end
side.
! Resistance between terminal No. 4 and earth,
also between terminal No. 5 and earth.
OK: 2 $ or less
NO : Check and repair harness between C-24
(terminal No. 4) diagnosis connector and
body earth, also between C-24 (terminal No.
5) diagnosis connector and body earth.
! Check earthing line for open circuit
and damage.
TROUBLESHOOTING
13A-181
STEP 5: Check harness between C-24 (terminal
No. 6) diagnosis connector and battery.
Connector: C-24
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
AK203424 AE

connectors C116, C-204 and C-205, and repair if
necessary.
(terminal No. 4 and No. 5) diagnosis
connector and body earth.
NO : Repair.
Inspection Procedure 2: Communication with Engine-ECU only is not Possible.
Data link connector circuit
C-136
Engine-ECU
51 52 53 54 55 56
57 58 59 60 61 62
62
O-W
C-105
5
O-W
32
J/C (3)
C-02
29
O-L
C-24 7
1 2 3 4 5 6 7 8 Data link connector
9 10 1112 13 14 1516
Wire colour code

AK300301 AB

! There is data communication between diagnosis
connector output terminal (terminal No. 7) and
engine-ECU (terminal No. 62). STEP 1: Check engine warning lamp.
! Ignition switch: OFF & ON
COMMENT ON TROUBLE SYMPTOM Q: Is lamp illuminating for few seconds?
! Failure is possibly caused by failed power supply YES : Go to Step 2 .
circuit or failed earthing circuit of engine-ECU. NO : Check engine-ECU power supply, engine
control relay and ignition switch IG1 system
PROBABLE CAUSE (Refer to Inspection Procedure 23 +,13A!
! Open/short circuit in engine-ECU power circuit ("").
! Between engine-ECU and diagnosis connector
for short circuit
! Failed engine-ECU
TROUBLESHOOTING
13A-183
STEP 2: Connector check: C-136 engine-ECU STEP 3: Check harness between C-24 (terminal
connector No. 7) diagnosis connector and C-136 (terminal
CONNECTOR: C-136
Connector: C-24
C-24 (B)
C-136 1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
AK203424 AE
56 55 54 53 52 51
62 61 60 59 58 57
CONNECTOR: C-136
AK300268 AB

NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AB
NOTE: Before Checking harness, check intermedi-

ate connectors C-105 and C-02, and repair if neces-
sary.
! Check communication line for open/short circuit
and damage.
NO : Repair.
STEP 4: Check the trouble symptom.

00 " How to Use
+,00!$).
Inspection Procedure 3: The Engine Warning Lamp Does not Illuminate Right after the Ignition Switch
is Turned The "ON" Position
Malfunction indicator lamp (Engine warning lamp) circuit
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
L-B
C-203
6
2 J/B
7.5A
25
C-205
C-04
B-W
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G G
C-05 Malfunction indicator lamp

(Engine warning lamp)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122 14
G G
R-W
7
C-105
R-W
36
C-135
Engine-ECU
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Wire colour code

AK300302 AB
OPERATION ! Engine-ECU (terminal No. 36) makes power tran-

! Battery voltage is applied to engine warning lamp sistor in unit be in "ON" position, and that makes
of combination meter connector (terminal No. 42) currents go on engine warning lamp of combina-
from ignition switch. tion meter connector (terminal No. 14).
TROUBLESHOOTING
13A-185
COMMENTS ON TROUBLE SYMPTOM STEP 3: Connector check: C-04 combination
! Engine-ECU turns on engine warning lamp for 5 meter connector
seconds to check for burnt-out bulb immediately
after ignition switch is turned to ON. CONNECTOR: C-04
! If engine warning lamp is not lit just after turning
C-04
ignition switch to "ON" position, failure is possibly
caused by burn-out bulb, open/short circuit or
other faults.
PROBABLE CAUSE
! Engine warming lamp bulb burnt out
! Failed ignition switch
! Open/short circuit in engine warning lamp circuit
for or loose connector contact
! Failed engine-ECU
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
DIAGNOSIS PROCEDURE
G G
STEP 1: Check engine start-up. AK300303AB
Q: Is engine started?
NO : Check engine-ECU power supply, engine
NO : Repair
control relay and ignition switch IG1 system
(Refer to Inspection Procedure 23 +,13A!
(""). STEP 4: Measure voltage at C-04 combination
meter connector.
STEP 2: Check engine warning lamp for burnt- CONNECTOR: C-04
out bulb.
C-04
NO : Replace engine warning lamp.
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G G
AK300303AB
! Disconnect connector, and measure at the har-

ness side.
OK: System voltage
NO : Go to Step 5 .
STEP 5: Connector check: C-303 ignition switch STEP 6: Connector check: C-135 engine-ECU
connector connector
C-303
3 2 1
6 5 4
C-135
Harness side
connector
AK300304 AB
38 37 36 35 34 33 32 31
CONNECTOR: C-04 46 45 44 43 42 41 40 39
C-04
AK300256 AB

NO : Repair.
STEP 7: Measure voltage at C-135 engine-ECU

connector.
41 40 39 38 37 36 35 34 33 32 31 CONNECTOR: C-135
52 51 50 49 48 47 46 45 44 43 42
G G
AK300303AB

YES : Check intermediate connectors C-203 and C-135
C-205, and repair if necessary. If
intermediate connectors are normal, check
and repair harness between C-04 (terminal
38 37 36 35 34 33 32 31
No. 42) combination meter connector and 46 45 44 43 42 41 40 39
C-303 (terminal No. 2) ignition switch Harness side connector
connector.
! Check power supply line for AK300256 AB
open/short circuit. ! Disconnect connector, and measure at the har-

NO : Repair ness side.
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING
13A-187
STEP 8: Check connector: C-05 combination STEP 9: Connector check: C-303 ignition switch
meter connector connector
C-05 (L)
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

11 10 9 8 7 6 5 4 3 2 1 YES : Go to Step 10 .
22 21 20 19 18 17 16 15 14 1312
NO : Repair.
G G
AK300305 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

combination meter connector and C-135
circuit.
NO : Repair
STEP 10: Check harness between C-04 (terminal STEP 11: Connector check: C-05 ignition switch
No. 42) combination connector and C-303 connector
(terminal No. 2) ignition switch connector.
CONNECTOR: C-05
CONNECTOR: C-04
C-05 (L)
C-04
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 1312
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G G
G G Harness side connector
AK300305 AB
AK300303AB
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

connectors C-203 and C-205, and repair if neces-
sary.
NO : Repair.
TROUBLESHOOTING
13A-189
STEP 12: Check harness between C-05 (terminal STEP 13: Check the trouble symptoms.
No. 14) combination connector and C-135 Q: Does trouble symptom persist?
(terminal No. 36) engine-ECU connector. YES : Replace engine-ECU.
CONNECTOR: C-05 NO : Intermittent malfunction (Refer to GROUP
00 " How to Use
C-05 (L) Troubleshooting/Inspection Service Points
+,00!$).
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 1312
G G
AK300305 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out
Malfunction indicator lamp (Engine warning lamp) circuit
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
L-B
C-203
6
2 J/B
7.5A
25
C-205
C-04
B-W
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G G
C-05 Malfunction indicator lamp

(Engine warning lamp)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122 14
G G
R-W
7
C-105
R-W
36
C-135
Engine-ECU
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Wire colour code

AK300302 AB
OPERATION ! Engine-ECU (terminal No. 36) makes power tran-

! Battery voltage is applied to engine warning lamp sistor in unit be in "ON" position, and that makes
(terminal No. 42) from ignition switch. currents go on engine warning lamp (terminal No.
14).
TROUBLESHOOTING
13A-191
COMMENT ON TROUBLE SYMPTOM STEP 3: Measure voltage at C-135 engine-ECU
! Engine-ECU has detected failed sensor or failed connector.
actuator. Or failure is possibly caused by short
circuit or other faults. CONNECTOR: C-135
PROBABLE CAUSE
! Short circuit in between engine warning lamp and
engine-ECU circuit.
! Failed engine-ECU
STEP 1: MUT-II self-diag code

38 37 36 35 34 33 32 31
Q: Diagnosis code set? 46 45 44 43 42 41 40 39
YES : Inspection chart for diagnosis code (Refer Harness side connector
to +,13A!'(.)
NO : Go to Step 2 . AK300256 AB
CONNECTOR: C-05
STEP 2: Connector check: C-135 engine-ECU
connector C-05 (L)
CONNECTOR: C-135
C-135
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 1312
38 37 36 35 34 33 32 31 G G
AK300256 AB
ness side.
Q: Is the check result normal? ! Ignition switch: ON
YES : Go to Step 3 . ! Voltage between terminal No. 36 and earth.
NO : Repair OK: System voltage
NO : Check intermediate connector C-105, and
STEP 4: Check the trouble symptoms.

00 " How to Use
+,00!$).
Inspection Procedure 5: Starting impossible (No Initial Combustion)
COMMENT ON TROUBLE SYMPTOM STEP 3: Connector check: C-137 engine-ECU

! Failure is possibly caused by failed starter itself connector
or failed related circuit.
CONNECTOR: C-137
PROBABLE CAUSE
! Failed battery
! Failed starter motor
! Open/short circuit in starter associated circuit or
STEP 1: Check battery voltage.

! Measure battery voltage at cranking. 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
OK: 8 V or higher Harness side connector
AK300254 AB
NO : Check battery (Refer to GROUP 54A "
Battery " On-vehicle Service " Battery Test YES : Go to Step 4 .
+,54A!)). NO : Repair.
STEP 2: MUT-II data list

! Item 18: Cranking signal
OK:
ON (Ignition switch: ST)
OFF (Ignition switch: ON)
NO : Go to Step 3 .
TROUBLESHOOTING
13A-193
STEP 4: Measure voltage at C-137 engine-ECU STEP 6: Check ignition switch.
connector.
CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82
92 91 90 89 88 87 86 85 84 83 82 Harness side connector
AK300254 AB
AK300254 AB
CONNECTOR: C-303
ness side.
! Ignition switch: ST
C-303
OK: System voltage
3 2 1
YES : Go to Step 7 . Harness side
NO : Go to Step 5 . connector
AK300304 AB
STEP 5: Connector check: C-303 ignition switch ! Check ignition switch (Refer to GROUP 54A "
connector Ignition Switch " Ignition Switch +,54A!(").
CONNECTOR: C-303 Q: Is the check result normal?
YES : Check intermediate connectors C-106 and
B-19, and repair if necessary. If intermediate
connector are normal, check and repair
C-303 inhibitor switch connector and C-303
3 2 1
6 5 4
Harness side open/short circuit.
connector
AK300304 AB NO : Replace ignition switch.

NO : Repair.
STEP 7: Connector check: C-303 ignition switch STEP 8: Check connector: B-26 starter connector
connector and B-26 starter connector
CONNECTOR: B-26
CONNECTOR: C-303
C-303 B-26 (B)

3 2 1
6 5 4 1

connector connector AK300306 AB
AK300304 AB
CONNECTOR: B-26 YES : Go to Step 9 .
NO : Repair.
STEP 9: Measure voltage at B-26 starter

connector.
B-26 (B)
CONNECTOR: B-26
1
Harness side

B-19, and repair if necessary. If intermediate 1
connectors are normal, check and repair Harness side
harness between C-303 (terminal No. 5) connector AK300306 AB
ignition switch connector and B-26 (terminal ! Disconnect connector, and measure at the har-
No. 1) starter connector. ness side.
! Check output line for short circuit. ! Ignition switch: ST
NO : Repair.
OK: System voltage
TROUBLESHOOTING
13A-195
STEP 10: Connector check: C-303 ignition switch STEP 11: Connector check: B-25 starter
connector connector
CONNECTOR: C-303 CONNECTOR: B-25
C-303
3 2 1 B-25
6 5 4 1
Harness side

NO : Repair.
STEP 12: Measure voltage at B-25 starter

B-26 (B) connector.
1 CONNECTOR: B-25
Harness side

YES : Check intermediate connectors B-19 and C- B-25
106, and repair if necessary. If intermediate 1
harness between C-303 (terminal No. 5) Harness side
ignition switch connector and B-26 (terminal connector AK300307 AB
No. 1) starter connector. ! Disconnect connector, and measure at the har-
! Check output line for open circuit and ness side.
damage. ! Voltage between terminal No. 1 and earth.
NO : Repair.
OK: System voltage
(terminal No. 1) starter connector and
battery.
open/short circuit.
STEP 13: Check harness between C-303 (terminal STEP 14: Check harness between B-25 (terminal
No. 5) ignition switch connector and B-26 No. 1) starter connector and battery.
(terminal No. 1) starter connector.
CONNECTOR: B-25
CONNECTOR: C-303
C-303 B-25
3 2 1 1
6 5 4
connector connector AK300307 AB
AK300304 AB
YES : Replace starter.
NO : Repair.
B-26 (B)
1
Harness side

connectors B-19 and C-106, and repair if necessary.
NO : Repair.
Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion)
COMMENT ON TROUBLE SYMPTOM DIAGNOSIS PROCEDURE

! Failure is possibly caused by failed ignition cir-
cuit, failed fuel feed or other faults.
PROBABLE CAUSE ! Measure battery voltage at cranking.
! Failed battery OK: 8 V or higher
! Timing belt broken
! Failed idle speed control
YES : Go to STEP 2 .
! Throttle valve fouled around NO : Check battery (Refer to GROUP 54 "
! Failed ignition system Battery " On-vehicle Service " Battery test
! Failed fuel system +,54A!)).
! Failed immobilizer system
! Failed engine-ECU
TROUBLESHOOTING
13A-197
STEP 2: Check engine warning lamp for burnt out STEP 8: MUT-II DATA LIST
bulb. ! Item 18: Cranking signal
Q: Is the check result normal? OK:
YES : Go to Step 3 . ON (Ignition switch: ST)
NO : Check engine-ECU power supply, engine OFF (Ignition switch: ON)
control relay and ignition switch IG1 system Q: Is the check result normal?
(Refer to Inspection Procedure 23 +,13A! YES : Go to Step 10 .
(""). NO : Go to Step 9 .
STEP 3: MUT-II self-diag code STEP 9: Connector check: C-137 engine-ECU

Q: Diagnosis code set? connector
YES : Inspection chart for diagnosis codes (Refer
CONNECTOR: C-137
to +,13A!'()
NO : Go to Step 4 .
STEP 4: MUT-II actuator test

! Item 07: Fuel pump
OK: Operating sound of fuel pump can be
heard. C-137

NO : Check fuel pump system (Refer to 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Inspection Procedure 24 +,13A!(-')
STEP 5. Check timing belt for breakage. AK300254 AB
! Engine: Cranking
CONNECTOR: C-303
OK: Camshaft rotates.
NO : Replace timing belt.
C-303
3 2 1
STEP 6. Check the engine start ability. 6 5 4
! With depressing the accelerator pedal slightly, Harness side
and start the engine. connector
AK300304 AB
Q: Is the start ability good?
NO : Go to Step 8 . YES : Check intermediate connectors B-19 and C-
106, and repair if necessary. If intermediate
STEP 7: Check idling speed control for operating
sound.
ignition switch connector and C-137
! Check idle speed control servo for operating
sound (Refer to +,13A!"'$).
Q: Is the check result normal? circuit.
YES : Clean throttle body (throttle valve portion) NO : Repair.
(Refer to +,13A!"#$).
NO : Check idle speed control servo system
(Refer to code No. P0505 +,13A!')$).
STEP 10: MUT-II DATA LIST STEP 12: Connector check: B-110 and B-111
! Refer to Data list reference table +,13A!(&%. ignition coil connectors
a. Item 22: Crank angle sensor
Connector: B-110, B-111
YES : Go to Step 11 . 3 2 1
NO : Check crank angle sensor system (Refer to Harness side
connector
Code No. P0335 +,13A!'("). B-111 (GR)
STEP 11: Check injector for operating sound.

! Check injector for operating sound (Refer to B-110 (GR)
+,13A!"')).
AK300308 AB
Q: Can operating sound be heard?
NO : Check the injector system of the defective YES : Go to Step 13 .
cylinder. NO : Repair.
(Refer to Code No. P0201: No. 1 injector
system +,13A!&%.)
STEP 13: Measure voltage at each of B-110 and
B-111 ignition coil connectors.
system +,13A!*(.)
(Refer to Code No. P0203: No. 3 injector Connector: B-110, B-111
system +,13A!*%.)
3 2 1
Harness side
system +,13A!'#(.) connector
B-111 (GR)
B-110 (GR)
AK300308 AB

ness side.
OK: System voltage
TROUBLESHOOTING
13A-199
STEP 14: Connector check: C-303 ignition switch STEP 15: Check ignition coil spark.
connector
CONNECTOR: C-303
CONNECTOR: C-303
C-303
C-303 3 2 1
3 2 1 6 5 4
6 5 4 Harness side
AK300304 AB
3 2 1
3 2 1 Harness side
connector B-111 (GR)
B-111 (GR)
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB
YES : Check intermediate connectors A-14, C- NO : Check intermediate connectors A-14, C-116,
116, C-203 and C-205, and repair if C-203 and C-205, and repair if necessary.
necessary. Check and repair harness Check and repair harness between C-303
between C-303 (terminal No. 2) ignition (terminal No. 2) ignition switch connector
switch connector and (terminal No. 1) and (terminal No. 1) affected cylinder’s
affected cylinders ignition coil connector. ignition coil connector.
! Check power supply line for ! Check power supply line for damage.
open/short circuit.
NO : Repair.
STEP 16: Replace engine-ECU
! After replacing the engine-ECU, re-check the
trouble symptoms.
YES : Check for foreign matters (water, kerosene,
etc.) in fuel and replace if necessary.
NO : Check end.
Inspection Procedure 7: Starting Impossible (Initial Combustion But no Complete Combustion),

Improper Starting (Long time to Start)
COMMENT ON TROUBLE SYMPTOM ! Air-fuel ratio control

! Failure is possibly caused by poor ignition, incor- ! Failed idle speed control system
rect air-fuel ratio at cranking, improper fuel pres- ! Failed intake system
sure or other faults. ! Failed exhaust gas cleaning system
! Throttle valve fouled around
PROBABLE CAUSE ! Timing belt not in place
! Failed battery ! Compression pressure improper
! Failed ignition system ! Failed engine-ECU
! Failed fuel system
DIAGNOSIS PROCEDURE STEP 6: Check idle speed control servo for

operating sound.
STEP 1: Check battery condition. ! Check idle speed control servo for operating
sound (Refer to +,13A!"'$).
Q: Have the battery terminal been disconnected?
YES : After warm-up engine, idle for about 10 Q: Is the check result normal?
minutes. YES : Clean throttle body (throttle valve portion)
NO : Go to Step 2 . (Refer to +,13A!"#$).
(Refer to Code No. P0505 +,13A!')$).
! Measure battery voltage at cranking.
STEP 7: MUT-II actuator test
OK: 8 V or higher
! Item 07: Fuel pump
Q: Is the check result normal? OK: Operating sound of fuel pump can be
heard.
NO : Check battery (Refer to GROUP 54 "
Battery " On-vehicle Service " Battery Test Q: Is the check result normal?
+,54A!)). YES : Go to Step 8 .
NO : Check fuel pump system (Refer to
Inspection Procedure 24 +,13A!(-').
STEP 3: MUT-II self-diag code
Q: Diagnosis code set? STEP 8: Check air intake from intake hose and
inlet manifold.
to +,13A!'()
NO : Repair.
STEP 4: MUT-II data list
a. Item 13: Intake air temperature sensor STEP 9: Check injector for operating sound.
b. Item 21: Engine coolant temperature sensor ! Check injector for operating sound at engine
c. Item 25: Barometric pressure sensor cranking (Refer to +,13A!"')).
Q: Are the check results normal? Q: Can operating sound be heard?
NO : Perform the diagnosis code classified check NO : Check the injector system of the defective
procedure for the sensor that has shown an cylinder.
abnormal data value (Refer to Inspection (Refer to Code No. P0201: No.1 injector system
Chart for Diagnosis Codes +,13A!'(). +,13A!&%.)
(Refer to Code No. P0202: No.2 injector system
+,13A!*(.)
STEP 5: Check start ability. (Refer to Code No. P0203: No.3 injector system
! With depressing the accelerator pedal slightly, +,13A!*%.)
and start the engine. (Refer to Code No. P0204: No.4 injector system
Q: Is the start ability good? +,13A!'#(.)
NO : Go to Step 7 .
STEP 10. Check timing marks of timing belt.
NO : Align timing marks.
TROUBLESHOOTING
13A-201
STEP 11: Measure voltage at C-134 engine-ECU STEP 13: Connector check: B110 and B-111
connector. ignition coil connectors
CONNECTOR: C-134 Connector: B-110, B-111
3 2 1
Harness side
connector
B-111 (GR)
C-134
B-110 (GR)
AK300308 AB
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Repair.
AK300257 AB
! Measure engine-ECU terminal voltage. STEP 14: Check ignition coil spark.
! Ignition switch: ON Q: Is the check result normal?
! Voltage between terminal No. 13 and earth, also YES : Go to Step 19 .
between terminal No. 26 and earth. NO : Go to Step 15 .
OK: 0.5 V or less
Q: Is the check result normal? STEP 15: Check spark plug.
NO : Replace spark plug.
STEP 12: Connector check: C-134 engine-ECU
connector
STEP 16: Check spark plug cable itself.
CONNECTOR: C-134 ! Check spark plug cable itself (Refer to GROUP
16 " Ignition System " On-vehicle Service +,16!
(%).
NO : Replace spark plug cable.
C-134
STEP 17: Check ignition coil itself.
! Check ignition coil itself (Refer to GROUP 16 "
Ignition System " On-vehicle Service +,16!($).
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 Q: Is the check result normal?
Harness side connector YES : Go to Step 18 .
NO : Replace ignition coil.
AK300257 AB

(terminal No. 13 and No. 26) engine-ECU
and damage.
NO : Repair.
STEP 18: Check harness between terminal No. 2 STEP 19: Check spray condition of injector.
of each cylinder’s ignition coil connector and ! Check each injector for spray condition (Refer to
vehicle body earth. +,13A!"')).
Connector: B-110, B-111 Q: Is the check result normal?
3 2 1 NO : Replace injector.
Harness side
connector
B-111 (GR) STEP 20: Check compression pressure.
! Check compression pressure (Refer to GROUP
11A " On-vehicle Service +,11A!'#).
B-110 (GR) Q: Is the check result normal?
AK300308 AB
NO : Repair.
CONNECTOR: C-134
STEP 21: Check EGR control solenoid valve
itself.
! Check EGR control solenoid valve itself [Refer to
GROUP 17 " Emission Control System "
Exhaust Gas Recirculation (EGR) System +,17!
')].
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side connector STEP 22: Check EGR valve itself.
! Check EGR valve itself [Refer to GROUP 17 "
AK300257 AB Emission Control System " Exhaust Gas Recir-
! Check earthing line for open circuit and damage. culation (EGR) System +,17!'-].
Q: Is the check result normal? Q: Is the check result normal?
YES : Check and repair harness between terminal YES : Go to Step 23 .
No. 3 of each cylinder’s ignition coil NO : Replace EGR valve.
connector and C-134 engine-ECU
connector. STEP 23: Replace engine-ECU.
! Check signal line for open/short ! After replacing the engine-ECU, re-check the
circuit and damage. trouble symptoms.
NO : Repair.
NO : Check end.
Inspection Procedure 8: Unstable idling (Rough idling, hunting), Improper idling speed (Too high or
too low), Engine stalls during idling (Die out)
COMMENT ON TROUBLE SYMPTOM PROBABLE CAUSE

! Probable causes can be widely found in ignition ! Failed ignition system
system, air-fuel ratio control system, idle speed ! Failed fuel system
control system, fuel system, etc. A sudden ! Failed air-fuel ratio control system
engine stall is possibly caused by poor connector ! Failed idle speed control system
contact. ! Failed intake/exhaust system
TROUBLESHOOTING
13A-203
! Failed emission gas cleaning system STEP 5: Check idle speed control servo for
! Throttle valve body fouled operating sound.
! Timing belt out of place ! Check idle speed control servo for operating
! Compression pressure improper sound (Refer to +,13A!"'$).
! Failed engine-ECU
STEP 1: Check battery condition.
Q: Has the battery terminal been disconnected? STEP 6: Check throttle body (throttle valve
YES : After warm-up engine, idle for about 10 portion) for contamination.
minutes.
STEP 2: MUT-II self-diag code (Refer to +,13A!"#$).
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer STEP 7: Check air intake from intake hose and
to +,13A!'(). inlet manifold.
NO : Go to Step 3 .
STEP 3: MUT-II data list NO : Repair.
STEP 8: Check injector for operating sound.
b. Item 13: Intake air temperature sensor
! Check injector for operating sound (Refer to
c. Item 14: Throttle position sensor
+,13A!"')).
d. Item 21: Engine coolant temperature sensor
e. Item 25: Barometric pressure sensor Q: Can operating sound be heard?
NO : Check the injector system of the defective
cylinder.
system +,13A!&%.)
system +,13A!*(.)
STEP 4: MUT-II data list system +,13A!*%.)
! Refer to Data list reference table +,13A!(&%. (Refer to Code No. P0204: No. 4 injector
a. Item 27: Power steering fluid pressure switch system +,13A!'#(.)
YES : Go to Step 5 . STEP 9: Check timing marks of timing belt.
NO : Check power steering fluid pressure switch
system (Refer to Code No. P0551 +,13A! Q: Is the check result normal?
'$').

a. Item 11: Oxygen sensor (front)
NO : Check oxygen sensor (front) system (Refer
to Code No. P0130 +,13A!$').
STEP 11: Measure voltage at C-134 engine-ECU STEP 13. Measure voltage at C-135 engine-ECU
C-134 C-135
13 12 11 10 9 8 7 6 5 4 3 2 1 38 37 36 35 34 33 32 31
26 25 24 23 22 21 20 19 18 17 16 15 14 46 45 44 43 42 41 40 39
AK300257 AB AK300256 AB
! Measure engine-ECU terminal voltage. ! Measure engine-ECU terminal voltage.

! Ignition switch: ON ! Engine: Idling after warm-up
! Voltage between terminal No. 13 and earth, also ! Transmission: Neutral
between terminal No. 26 and earth. ! Radiator fan: Not operating
OK: 0.5 V or less ! Voltage between terminal No. 33 and earth.
YES : Go to Step 13 . OFF causes the voltage to increase by 0.2 "
NO : Go to Step 12 . 3.5 V.
STEP 12: Connector check: C-134 engine-ECU YES : Go to Step 16 .
connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

(terminal No. 13 and No. 26) engine-ECU
and damage.
NO : Repair.
TROUBLESHOOTING
13A-205
STEP 14. Connector check: C-135 engine-ECU STEP 15. Check harness between C-135 (terminal
connector and B-30 alternator connector No. 33) engine-ECU connector and B-30 (terminal
No. 1) alternator connector.
CONNECTOR: C-135
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
Harness side connector 46 45 44 43 42 41 40 39
AK300256 AB
AK300256 AB
CONNECTOR: B-30
CONNECTOR: B-30
B-30 (GR)
B-30 (GR)
4 3 2 1
Harness side 4 3 2 1
connector AK300296 AB Harness side
YES : Go to Step 15 . NOTE: Before checking harness, check intermediate
NO : Repair. connector B-19, and repair if necessary.
age.
NO : Repair.
connector. connector and B-30 alternator connector
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AB AK300256 AB

CONNECTOR: B-30
! Engine: Idling after warm-up
! Radiator fan: Not operating
B-30 (GR)
OFF causes the voltage to fall.
Q: Is the check result normal? 4 3 2 1
NO : Go to Step 17 . connector AK300296 AB

NO : Repair.
TROUBLESHOOTING
13A-207
STEP 18. Check harness between C-135 (terminal STEP 20. Measure voltage at C-134 engine-ECU
No. 54) engine-ECU connector and B-30 (terminal connector.
CONNECTOR: C-134
CONNECTOR: C-135
C-134
C-135
13 12 11 10 9 8 7 6 5 4 3 2 1
38 37 36 35 34 33 32 31 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
AK300256 AB
! Engine: Idling
CONNECTOR: B-30
! A/C switch: ON (A/C compressor ON)
OK:
B-30 (GR) 1 V or less (with outside air temperature sen-
sor ambient temperature at 18%C or higher
and A/C set for maximum air flow at mini-
4 3 2 1 mum temperature)
Harness side System voltage (with A/C set for minimum air
connector AK300296 AB flow at room temperature)
NOTE: Before checking harness, check intermediate Q: Is the check result normal?
connector B-19, and repair if necessary.
NO : Check A/C load signal system (Refer to
Inspection Procedure 28 +,13A!($%).
age.
YES : Go to Step 19 . STEP 21. Connector check: B-110 and B-111
NO : Repair. ignition coil connectors
STEP 19. Check the trouble symptoms. 3 2 1
Q: Does trouble symptom persist? Harness side
YES : Replace alternator. connector
B-111 (GR)
00 " How to Use
+,00!$). B-110 (GR)
AK300308 AB

NO : Repair.
STEP 22. Check ignition coil spark. STEP 26. Check harness between terminal No. 2
of ignition coil connector of each cylinder and
YES : Go to Step 27 . body earth.
NO : Go to Step 23 . Connector: B-110, B-111
3 2 1
STEP 23. Check spark plug.
Harness side
Q: Is the check result normal? connector
B-111 (GR)
STEP 24. Check individual spark plug cable B-110 (GR)

! Check spark plug cable itself (Refer to GROUP AK300308 AB
(%). CONNECTOR: C-134
Q: Q: Is the check result normal?

STEP 25. Check ignition coil itself.

! Check ignition coil itself (Refer to GROUP 16 " C-134
YES : Go to Step 26 . 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Replace ignition coil. 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
! Check earthing line for open/short circuit and

damage.
YES : Check and repair harness between terminal
No. 3 of ignition coil connector of each
cylinder and C-134 engine-ECU
! Check signal line for open/short and
damage.
NO : Repair.
STEP 27. Check injector for spray condition.

! Check each injector for spray condition (Refer to
+,13A!"')).
STEP 28. Check compression pressure.

NO : Repair.
TROUBLESHOOTING
13A-209
STEP 29. Check purge control solenoid valve STEP 31. Check EGR control solenoid valve
itself. itself.
! Check purge control solenoid valve itself (Refer to ! Check EGR control solenoid valve itself [Refer to
GROUP 17 " Emission Control System " Evapo- GROUP 17 " Emission Control System "
rative Emission Control System +,17!'') Exhaust Gas Recirculation (EGR) System +,17!
'-].
NO : Replace purge control solenoid valve. YES : Go to Step 32 .
NO : Replace EGR valve.
STEP 30. Check EGR control solenoid valve
itself. STEP 32. MUT-II actuator test
! Check EGR control solenoid valve itself [Refer to ! Item 07: Fuel pump
GROUP 17 " Emission Control System " OK: Operating sounds of fuel pump can be
Exhaust Gas Recirculation (EGR) System +,17! heard.
')].
YES : Go to Step 31 . NO : Check fuel pump system (Refer to
NO : Replace EGR control solenoid valve. inspection Procedure 24 +,13A!(-').
STEP 33. Replace engine-ECU.

! After engine-ECU is replaced, re-check for trou-
ble symptom.
Q: Does trouble system persist?
NO : Check end.
Inspection Procedure 9: The Engine Stalls when Starting the Car (Pass Out)
COMMENT ON TROUBLE SYMPTOM STEP 2. Check EGR control solenoid valve itself.
! Engine stall on starting is possibly caused by mis- ! Check EGR control solenoid valve itself [Refer to
fire due to failed spark plug, improper air-fuel GROUP 17 " Emission Control System "
ratio at accelerator pedal depression or other Exhaust Gas Recirculation (EGR) System +,17!
faults. ')].
PROBABLE CAUSE Q: Is the check result normal?
! Failed ignition system YES : Go to Step 3 .
! Failed intake system NO : Replace EGR control solenoid valve.
! Failed emission gas cleaning system
! Failed engine-ECU STEP 3. Check EGR valve itself.
! Check EGR valve itself [Refer to GROUP 17 "
DIAGNOSIS PROCEDURE Emission Control System " Exhaust Gas Recir-
culation (EGR) System +,17!'-].
STEP 1. MUT-II self-diag code Q: Is the check result normal?
Q: Diagnosis code set? YES : Go to Step 4 .
YES : Inspection chart for diagnosis code (Refer NO : Replace EGR valve.
to +,13A!'().
NO : Go to Step 2 .
STEP 4. Check air intake from intake hose and STEP 9. Check ignition coil itself.
inlet manifold. ! Check ignition coil itself (Refer to GROUP 16 "
NO : Repair. YES : Go to Step 10 .
STEP 5. Connector check: B-110 and B-111
ignition connectors. STEP 10. Check harness between terminal No. 2
of ignition coil connector of each cylinder and
body earth.
3 2 1
Harness side
connector 3 2 1
B-111 (GR)
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB
B-110 (GR)
NO : Repair. CONNECTOR: C-134
STEP 6. Check ignition coil spark.

NO : Go to Step 7 .
C-134
YES : Go to Step 8 . 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Replace spark plug. 26 25 24 23 22 21 20 19 18 17 16 15 14
STEP 8.Check spark plug cable itself. AK300257 AB

! Check spark plug cable itself (Refer to GROUP ! Check earthing line for open circuit and damage.
(%). Q: Is the check result normal?
Q: Is the check result normal? No. 3 of ignition coil connector of each
YES : Go to Step 9 . cylinder and C-134 engine-ECU.
! Check signal line for open/short
circuit and damage.
NO : Repair.
TROUBLESHOOTING
13A-211
Inspection Procedure 10. The Engine Stalls when Decelerating
COMMENT ON TROUBLE SYMPTOM STEP 5. Check EGR valve itself.

! Engine stall on deceleration is possibly caused ! Check EGR valve itself [Refer to GROUP 17 "
by insufficient air intake, improper air-fuel ratio Emission Control System " Exhaust Gas Recir-
due to failed exhaust gas recirculation system or culation (EGR) System +,17!'-].
other faults.
PROBABLE CAUSE YES : Go to Step 6 .
! Failed idle speed control system NO : Replace EGR valve.
! Failed ignition system
! Failed emission control system STEP 6. Check throttle body (throttle valve
! Throttle valve fouled portion) for contamination.
! Failed engine-ECU
(Refer to +,13A!"#$).
Q: Diagnosis code set? STEP 7. Connector check: B-110 and B-111
YES : Inspection chart for diagnosis code (Refer ignition coil connectors
to +,13A!'().
NO : Go to Step 2 . Connector: B-110, B-111
3 2 1
STEP 2. MUT-II data list Harness side
connector
! Refer to Data list reference table +,13A!(&%. B-111 (GR)
a. Item 14: Throttle position sensor
B-110 (GR)
NO : Check throttle position sensor system
(Refer to Code No. P0120 +,13A!-&). AK300308 AB

STEP 3. MUT-II data list YES : Go to Step 8 .
! Item 45: Idle speed control servo position NO : Repair.
OK: Idle speed control servo drops to 0 " 2
Steps at deceleration (engine at 1,000 r/min STEP 8. Check ignition coil spark.
or higher).
Q: Is the check result normal? YES : Replace engine-ECU.
YES : Go to Step 4 . NO : Go to Step 9 .
STEP 4. Check EGR control solenoid valve itself. Q: Is the check result normal?
! Check EGR control solenoid valve itself [Refer to
GROUP 17 " Emission Control System "
')].
STEP 10. Check spark plug cable itself. STEP 12. Check harness between terminal No. 2
! Check spark plug cable itself (Refer to GROUP of ignition coil connector of each cylinder and
16 " Ignition System " On-vehicle Service +,16! body earth.
(%).
NO : Replace spark plug cable. Harness side
connector
B-111 (GR)
Ignition System " On-vehicle Service +,16!($). B-110 (GR)
NO : Replace ignition coil. CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

cylinder and C-134 engine-ECU.
circuit and damage.
NO : Repair.
Inspection Procedure 11: Engine does not Revole Up

! Failure is possibly caused by failed fuel system,
ignition system or other faults.
PROBABLE CAUSE Q: Diagnosis code set?
! Failed ignition system YES : Inspection chart for diagnosis code (Refer
! Failed fuel system to +,13A!'().
! Timing belt out of place NO : Go to Step 2 .
! Failed engine-ECU
TROUBLESHOOTING
13A-213
STEP 2. Check timing marks of timing belt. STEP 8. Check harness between terminal No. 2 of
ignition coil connector of each cylinder and body
YES : Go to Step 3 . earth.
NO : Align match marks. Connector: B-110, B-111
3 2 1
STEP 3. Connector check: B-110 and B-111
Harness side
ignition coil connectors connector
B-111 (GR)
3 2 1
Harness side B-110 (GR)
connector
B-111 (GR) AK300308 AB
CONNECTOR: C-134
B-110 (GR)
AK300308 AB

NO : Repair C-134

YES : Go to Step 9 . 26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Go to Step 5 . Harness side connector
AK300257 AB
STEP 5. Check spark plug. ! Check earthing line for open circuit and damage.
YES : Go to Step 6 . YES : Check and repair harness between terminal
cylinder and C-134 engine-ECU.
STEP 6. Check spark plug cable itself. ! Check signal line for open/short
! Check spark plug cable itself (Refer to GROUP circuit and damage.
16 " Ignition System " On-vehicle Service +,16! NO : Repair
(%).
Q: Is the check result normal? STEP 9. Measure fuel pressure.
YES : Go to Step 7 . ! Measure fuel pressure (Refer to +,13A!"#&).
STEP 7. Check ignition coil itself. NO : Repair
Inspection Procedure 12: Hesitation, sag,poor acceleration, stumble, surge
COMMENT ON TROUBLE SYMPTOM STEP 3. MUT-II data list

! Failure is possibly caused by failed ignition sys- ! Refer to Data list reference table +,13A!(&%.
tem, improper air-fuel ratio, improper compres- a. Idem 13: Intake air temperature sensor
sion pressure or other faults. b. Item 14: Throttle position sensor
PROBABLE CAUSE c. Item 21: Engine coolant temperature sensor
! Failed air-fuel ratio control system d. Item 25: Barometric pressure sensor
! Failed ignition system Q: Are the check results normal?
! Failed fuel system YES : Go to Step 4 .
! Failed intake and exhaust system NO : Perform the diagnosis code classified check
! Failed emission control system Procedure for the sensor that has shown an
! Throttle valve fouled abnormal data value (Refer to Inspection
! Improper compression pressure Chart for Diagnosis Codes +,13A!'().
! Failed engine-ECU
DIAGNOSIS PROCEDURE itself.
! Check purge control solenoid valve itself (Refer
STEP 1. MUT-II self-diag code to GROUP 17 " Emission Control System "
Evaporative Emission Control System +,17!'').
YES : Inspection chart for diagnosis code (Refer Q: Is the check result normal?
to +,13A!'(). YES : Go to Step 5 .
NO : Go to Step 2 . NO : Replace purge control solenoid valve.
STEP 2. Check injector for operating sound. STEP 5. Check EGR control solenoid valve itself.
! Check injector for operating sound (Refer to ! Check EGR control solenoid valve itself [Refer to
+,13A!"')). GROUP 17 " Emission Control System "
Q: Can operating sound be heard? ')].
NO : Check the injector system of the defective Q: Is the check result normal?
cylinder. YES : Go to Step 6 .
(Refer to code No. P0201: No. 1 injector system NO : Replace EGR control solenoid valve.
+,13A!&%).
(Refer to code No. P0202: No. 2 injector system STEP 6. Check EGR valve itself.
+,13A!*(). ! Check EGR itself [Refer to GROUP 17 " Emis-
(Refer to code No. P0203: No. 3 injector system sion Control System " Exhaust Gas Recirculation
+,13A!*%). (EGR) System +,17!'-].
(Refer to code No. P0204: No. 4 injector system
+,13A!'#().
NO : Replace EGR valve.

a. Item 11: Oxygen sensor (front)
NO : Check oxygen sensor system (Refer to
Code No. P0130 +,13A!-&).
TROUBLESHOOTING
13A-215
STEP 8. Connector check: B-110 and B-111 STEP 13. Check harness between terminal No. 2
ignition coil connectors of ignition coil connector of each cylinder and
body earth.
3 2 1
Harness side 3 2 1
B-111 (GR) connector
B-111 (GR)
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB
YES : Go to Step 9 . CONNECTOR: C-134
NO : Repair

NO : Go to Step 10 . C-134

YES : Go to Step 11 . 26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Replace spark plug. Harness side connector
AK300257 AB
STEP 11. Check spark plug cable itself. ! Check earthing line for open circuit and damage.
! Check spark plug cable itself (Refer to GROUP
16 " Ignition System " On-vehicle Service +,16! Q: Is the check result normal?
(%). YES : Check and repair harness between terminal
Q: Is the check result normal? cylinder and C-134 engine-ECU
YES : Go to Step 12 . ! Check signal line for open/short
circuit and damage.
NO : Repair.
! Check ignition coil itself (Refer to GROUP 16 " STEP 14. Check throttle body (throttle valve
Ignition System " On-vehicle Service +,16!($). portion) for contamination.
(Refer to +,13A!"#$).

! Measure fuel pressure (Refer to +,13A!"#&).
NO : Repair.

NO : Repair.
Inspection Procedure 13. The Feeling of Impact or Vibration when Accelerating
COMMENT ON TROUBLE SYMPTOM STEP 3. Check ignition coil spark.

! Failure is possibly caused by failed ignition leak
with rise in spark plug-required voltage at accel- Q: Is the check result normal?
eration. YES : Replace engine-ECU.
NO : Go to Step 4 .
PROBABLE CAUSE
! Failed ignition system STEP 4. Check spark plug.
! Failed engine-ECU

STEP 5. Check spark plug cable itself.
Q: Diagnosis code set? ! Check spark plug cable itself (Refer to GROUP
YES : Inspection chart for diagnosis code (Refer 16 " Ignition System " On-vehicle Service +,16!
to +,13A!'(). (%).
NO : Go to Step 2 .
STEP 2. Check connector: B-110 and B-111 NO : Replace spark plug cable.
ignition coil connectors
Connector: B-110, B-111 STEP 6. Check ignition coil itself.
3 2 1 Ignition System " On-vehicle Service +,16!($).
Harness side
B-111 (GR) YES : Go to Step 7 .
B-110 (GR)
AK300308 AB

NO : Repair.
TROUBLESHOOTING
13A-217
STEP 7. Check harness between terminal No. 2 of
ignition coil connector of each cylinder and body
earth.
3 2 1
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

3 of ignition coil connector of each cylinder
and C-134 engine-ECU
circuit and damage.
NO : Repair.
Inspection Procedure 14: The feeling of impact or vibration when decelerating

! Failure is possibly caused by insufficient air
intake due to failed idle speed control system.
PROBABLE CAUSE Q: Diagnosis code set?
! Failed idle speed control system YES : Inspection chart for diagnosis code (Refer
! Throttle valve body fouled to +,13A!'().
! Failed engine-ECU NO : Go to Step 2 .
STEP 2. Check idle speed control servo for STEP 3. MUT-II data list
operating sound. ! Refer to Data list reference table +,13A!(&%.
! Check idle speed control servo for operating a. Item 14: Throttle position sensor
sound (Refer to +,13A!"'$). Q: Is the check result normal?
YES : Go to Step 3 . NO : Check throttle position sensor system
NO : Check idle speed control servo system (Refer to Code No. P0120 +,13A!-&).
STEP 4. Check throttle body (throttle valve)
contamination.
(Refer to +,13A!"#$).
Inspection Procedure 15: Knocking
COMMENT ON TROUBLE SYMPTOM STEP 2. Connector check: B-110 and B-111

! Failure is possibly caused by failed detonation ignition coil connectors
control, improper thermal value of spark plug or
other faults. Connector: B-110, B-111
PROBABLE CAUSE 3 2 1
! Defective detonation sensor Harness side
connector
! Failed detonation control system B-111 (GR)
! Failed ignition system
! Defective spark plug
! Failed engine-ECU
B-110 (GR)
DIAGNOSIS PROCEDURE AK300308 AB

STEP 1. MUT-II self-diag code YES : Go to Step 3 .
Q: Diagnosis code set? NO : Repair.
to +,13A!'(). STEP 3. Check ignition coil spark.
NO : Go to Step 2 .
YES : Check detonation sensor (Refer to Code
No. P0325 +,13A!''*).
NO : Go to Step 4 .

TROUBLESHOOTING
13A-219
STEP 5. Check spark plug cable itself. STEP 7. Check harness between ignition coil
! Check spark plug cable itself (Refer to GROUP connector terminal No. 2 of each cylinder and
16 "Ignition System " On-vehicle Service +,16! body earth.
(%).
NO : Replace spark plug cable. Harness side
connector
B-111 (GR)
Ignition System " On-vehicle Service +,16!($). B-110 (GR)
NO : Replace ignition coil. CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

YES : Check and repair harness between ignition
coil connector terminal No. 3 of each
cylinder and C-134 engine-ECU connector.
! Check signal line for open circuit,
short circuit and damage.
NO : Repair.
Inspection Procedure 16: Ignition Timing Offset

! Failure is possibly caused by failed crank angle
sensor, failed camshaft position sensor, improper
installed timing belt or other faults. STEP 1. MUT-II self-diag code
PROBABLE CAUSE YES : Inspection chart for diagnosis code (Refer
! Failed crank angle sensor to +,13A!'().
! Failed camshaft position sensor NO : Go to Step 2 .
! Improperly installed timing belt
! Failed engine-ECU

STEP 2. Measure output waveforms of crank
angle sensor and camshaft position sensor (Use NO : Go to Step 4 .
oscilloscope).
Connector: B-29
2 1 Q: Does trouble symptom persist?
3 YES : Replace engine-ECU.
Harness side B-29 (B) NO : Intermittent malfunction (Refer to GROUP
connector 00 " How to Use
+,00!$).
STEP 4. Check crank angle sensor and camshaft

position sensor mounted conditions.
NO : Repair.

Crank angle sensor YES : Go to Step 6 .
AK300276 AB
Connector: B-106 STEP 6. Check crank angle sensor vane.

3 2 1
Harness side NO : Replace crank angle sensor vane.
connector
STEP 7. Check camshaft position sensing

B-106 (B) cylinder.
NO : Replace camshaft position sensing cylinder.
Crank Angle Sensor
nect B-29 crank angle sensor connector, and STEP 8. Replace crank angle sensor.
measure at pick-up harness. ! After replacing the crank angle sensor, re-check
! Engine: Idling the trouble symptoms.
! Transmission: Neutral Q: Does trouble symptom persist?
! Voltage between terminal No. 2 and earth. YES : Go to Step 9 .
NO : Check end.
Camshaft Position Sensor
! Use special tool test harness (MD991709) to con-
nect B-106 camshaft position sensor connector,
and measure at pick-up harness.
! Engine: Idling
OK: Output waveform timings of both sen-
sors are the same as the check procedure
(Refer to *+13A!")%) using an oscilloscope.
TROUBLESHOOTING
13A-221
STEP 9. Replace camshaft position sensor.
! After replacing the camshaft position sensor, re-
00 " How to Use
+,00!$).
Inspection Procedure 17: Run on (Dieseling)

! Failure is possibly caused by leakage from injec-
tor.
STEP 1. Check injector for spray condition.
PROBABLE CAUSE ! Check each injector for spray condition (Refer to
! Failed injector +,13A!"')).
! Failed engine-ECU Q: Does trouble symptom persist?
Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC during
Idling
COMMENT ON TROUBLE SYMPTOM STEP 2. Check injector for operating sound.

! Failure is possibly caused by improper air-fuel ! Check injector for operating sound (Refer to
ratio, deteriorated catalyst, failed ignition system, +,13A!"')).
failed fuel system, failed compression pressure or
other faults. Q: Can operating sound be heard?
PROBABLE CAUSE NO : Check the injector system of the defective
! Incorrect air/fuel ratio cylinder.
! Failed ignition system (Refer to +,13A!&%, Code P0201: No. 1 injector
! Failed fuel system System)
! Failed intake and exhaust system (Refer to +,13A!*(, Code P0202: No. 2 injector
! Failed emission control system System)
! Failed compression pressure (Refer to +,13A!*%, Code P0203: No. 3 injector
! Failed catalytic converter System)
! Failed engine-ECU (Refer to +,13A!'#(, Code P0204: No. 4
injector System)
DIAGNOSIS PROCEDURE
STEP 3. Check ignition timing.
STEP 1. MUT-II self-diag code ! Check ignition timing. (Refer to GROUP 11A "
On-vehicle Service +,11A!&).
to +,13A!'(). YES : Go to Step 4 .
NO : Go to Step 2 . NO : Check for offset ignition timing (Refer to
Inspection Procedure 16 +,13A!('*).
STEP 4. MUT-II Data List STEP 10. Check EGR control solenoid valve
! Refer to Data list reference table +,13A!(&%. itself.
a. Item 12: Air flow sensor ! Check EGR control solenoid valve itself [Refer to
b. Item 13: Intake air temperature sensor GROUP 17 " Emission Control System "
c. Item 21: Engine coolant temperature sensor Exhaust Gas Recirculation (EGR) System +,17!
d. Item 25: Barometric pressure sensor ')].
Q: Are the check results normal? Q: Is the check result normal?
NO : Perform the diagnosis code classified check NO : Replace EGR control solenoid valve.
Procedure for the sensor that has shown an
abnormal data value (Refer to Inspection STEP 11. Check EGR valve itself.
Chart for Diagnosis Codes +,13A!'(). ! Check EGR valve itself [Refer to GROUP 17 "
Emission Control System " Exhaust Gas Recir-
STEP 5. Check air intake from intake hose and culation (EGR) System +,17!'-].
inlet manifold. Q: Is the check result normal?
YES : Go to Step 6 . NO : Replace EGR valve.
NO : Repair.
STEP 6. Check for emission leakage from ! Measure fuel pressure (Refer to +,13A!"#&).
exhaust manifold. Q: Is the check result normal?
NO : Repair.
STEP 13. Check positive crankcase ventilation
STEP 7. Check throttle body (throttle valve valve itself.
portion) for contamination. ! Check positive crankcase ventilation valve itself
(Refer to GROUP 17 " Emission Control System
YES : Go to Step 8 . " crankcase Emission Control System +,17!*).
NO : Clean throttle body (throttle valve portion) Q: Is the check result normal?
(Refer to +,13A!"#$). YES : Go to Step 14 .
NO : Replace positive crankcase ventilation
STEP 8. MUT-II data list valve.
a. Item 11: Oxygen sensor (front) STEP 14. Check spark plug.
NO : Check oxygen sensor (front) system (Refer NO : Replace spark plug.
to Code No. P0130 +,13A!$').
STEP 9. Check Purge control solenoid valve ! Check spark plug cable itself (Refer to GROUP
itself. 16 " Ignition System " On-vehicle Service +,16!
! Check purge control solenoid valve itself (Refer (%).
to GROUP 17 " Emission Control System " Q: Is the check result normal?
Evaporative Emission Control System +,17!''). YES : Go to Step 16 .
Q: Is the check result normal? NO : Replace spark plug cable.
TROUBLESHOOTING
13A-223
STEP 16. Check ignition coil itself. STEP 18. Check injector for spraying condition.
! Check ignition coil itself (Refer to GROUP 16 " ! Check each injector for spray condition (Refer to
Ignition System " On-vehicle Service +,16!($). +,13A!"')).
Q: Is the check result normal? Q: Does trouble symptom persist?
NO : Replace ignition coil. NO : Replace injector.
STEP 17. Check compression pressure. STEP 19. Replace catalytic converter.
! Check compression pressure (Refer to GROUP ! After replacing the catalytic converter, re-check
11A " On-vehicle Service +,11A!'#). the trouble symptoms.
YES : Go to Step 18 . YES : Replace engine-ECU.
NO : Repair. NO : Check end
Inspection Procedure 19: Battery Rundown
COMMENT ON TROUBLE SYMPTOM STEP 2. Connector check: B-19 intermediate

! Failure is possibly caused by failed alternator, connector
failed generation control circuit or other faults.
CONNECTOR: B-19
PROBABLE CAUSE
! Failed battery
! Alternator G terminal short-circuited B-19 (B)
! Failed alternator
! Failed engine-ECU
3 2 1
DIAGNOSIS PROCEDURE 6 5 4
Female side
STEP 1. Check battery voltage.
! Measure battery voltage during cranking. Q: Is the check result normal?
OK: 8 V or more YES : Go to Step 3 .
NO : Repair.
NO : Check battery (Refer to GROUP 54 "
Battery " On-vehicle Service " Battery test
+,54A!)).
STEP 3. Measure voltage at B-19 intermediate STEP 4. Connector check: C-303 ignition switch
CONNECTOR: B-19 CONNECTOR: C-303
B-19 (B)
C-303
3 2 1
1 2 3 6 5 4
4 5 6
Harness side
Male side connector
! Disconnect connector, and measure at male con-

CONNECTOR: B-19
nector side.
B-19 (B)
OK: System voltage
NO : Go to Step 4 . 4 5 6
Male side

YES : Check intermediate connectors C-04, C-05,
C-105, C-203 and C-205, and repair if
necessary. If intermediate connectors are
normal, check and repair harness between
B-19 (terminal No. 5) intermediate
ignition switch connector.
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-225
STEP 5. Measure voltage at B-19 intermediate STEP 7. Check harness between B-19 (terminal
connector. No. 4) intermediate connector and B-30 (terminal
CONNECTOR: B-19
CONNECTOR: B-19
B-19 (B)
B-19 (B)
3 2 1
6 5 4 3 2 1
Female side 6 5 4
connector AK300294 AB Female side
! Disconnect connector, and measure at female
connector side.
CONNECTOR: B-30
OK: System voltage
Q: Is the check result normal? B-30 (GR)
NO : Go to Step 6 .
4 3 2 1
Harness side
STEP 6. Connector check: B-30 alternator connector AK300296 AB
connector
CONNECTOR: B-30
NO : Repair.
B-30 (GR)
4 3 2 1
Harness side

NO : Repair.
No. 5) intermediate connector and B-30 (terminal No. 3) alternator connector and C-303 (terminal
No. 3) alternator connector. No. 2) ignition switch connector.
CONNECTOR: B-19 CONNECTOR: B-30
B-19 (B)
B-30 (GR)
3 2 1
6 5 4 4 3 2 1
Female side Harness side
B-30 (GR)
C-303
3 2 1
6 5 4
4 3 2 1
Harness side
! Check power supply line for open/short circuit. NOTE: Before checking harness, check intermediate
Q: Is the check result normal? connectors C-04, C-05, C-105, C-203 and C-205 and
YES : Go to Step 9 . repair if necessary.
NO : Repair. ! Check power supply line for damage.
NO : Repair.

connector
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
TROUBLESHOOTING
13A-227
STEP 11. Measure voltage at C-135 engine-ECU STEP 12. Measure voltage at C-135 engine-ECU
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AB AK300256 AB

CONNECTOR: B-19
! Engine: Idling after warm-up
! Radiator fan: Inactive
B-19 (B) ! Voltage between terminal No. 8 and earth.
1 2 3 OFF causes the voltage to increase by 0.2 "
4 5 6 3.5 V.
Male side Q: Is the check result normal?
connector AK300295 AB YES : Go to Step 13 .
! Disconnect connector, and measure at harness NO : Check alternator.
side.
! Ignition switch: ON STEP 13. Check the trouble symptoms.
OK: System voltage YES : Replace engine-ECU.
Q: Is the check result normal? NO : Intermittent malfunction (Refer to GROUP
YES : Go to Step 12 . 00 " How to Use
NO : Check and repair harness between B-19 Troubleshooting/Inspection Service Points
(terminal No. 4) intermediate connector and +,00!$).
C-135 (terminal No. 33) engine-ECU
connector.
Inspection Procedure 20: Overheating
COMMENT ON TROUBLE SYMPTOM STEP 3. MUT-II actuator test

! Failure is possibly caused by failed engine cool- ! Item 21: Fan controller
ing system, failed fan controller, failed engine
coolant temperature sensor or other faults. OK: Fan motor rotating
! Insufficient or deteriorated engine coolant NO : Check fan control relay system (Refer to
! Failed fan controller Inspection Procedure 25 +,13A!()#).
! Failed engine coolant temperature sensor
! Failed thermostat
! Failed water pump
! Item 21: Engine coolant temperature sensor
! Failed radiator core
! Failed engine-ECU OK:
Engine cold state: At ambient temperature
DIAGNOSIS PROCEDURE (atmospheric temperature) or equivalent.
Engine hot state: At 80 " 120%C
STEP 1. MUT-II self-diag code Q: Is the check result normal?

Q: Diagnosis code set? NO : Check engine coolant temperature sensor
YES : Inspection chart for diagnosis code (Refer system (Refer to Code No. P0115 +,13A!
to +,13A!'(). -#).
NO : Go to Step 2 .
STEP 5. Check thermostat.

STEP 2. Check engine coolant ! Check thermostat (Refer to GROUP 14 " Ther-
NOTE: If engine coolant level falls too early, check mostat +,14!'*).
for leaky spots, and repair if necessary. Q: Is the check result normal?
! Check engine coolant (Refer to GROUP 14 " On- YES : Go to Step 6 .
vehicle Service +,14!')). NO : Replace thermostat.
YES : Go to Step 3 . STEP 6. Check water pump.
NO : Replace or add engine coolant.
! Check water pump.
YES : Replace radiator.
NO : Replace water pump.
TROUBLESHOOTING
13A-229
Inspection Procedure 21: Abnormal Rotation of Fan Motor
Fan controller (Radiator fan, A/C condensor fan) Circuit
5V
A-20
(MU802322)
1 2 3
Fan controller
L-W
7
A-14
L-W
21
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300309 AB

! The control (duty) signal is inputted to the fan ! Failed fan controller
controller (terminal No. 2) from the engine-ECU ! Open/short circuit in fan controller circuit or loose
(terminal No. 21). connector contact
! Failed engine-ECU
FUNCTION
! The engine-ECU inputs a duty signal suitable for
the engine coolant temperature, vehicle speed
and A/C switch position to the fan controller. In
response to the signal, the fan controller controls
the rotating speeds of the radiator fan and A/C
condenser fan (The fan speed becomes higher
as the average voltage of the terminal comes
nearer to 5V).
DIAGNOSIS PROCEDURE STEP 3. Check the trouble symptoms.

STEP 1. Connector check: C-134 engine-ECU YES : Replace engine-ECU.
connector NO : Intermittent malfunction (Refer to GROUP
00 " How to Use
CONNECTOR: C-134
+,00!$).

connector.
C-134 CONNECTOR: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
C-134
AK300257 AB

13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Repair. 26 25 24 23 22 21 20 19 18 17 16 15 14
STEP 2. Check at C-134 engine-ECU connector.
AK300257 AB
CONNECTOR: C-134 ! Disconnect connector, and measure at harness
side.
OK: 4.9 " 5.1 V
C-134 YES : Replace fan controller.
NO : Go to Step 5 .
13 12 11 10 9 8 7 6 5 4 3 2 1 STEP 5. Connector check: A-20 fan controller

26 25 24 23 22 21 20 19 18 17 16 15 14 connector
Connector: A-20
AK300257 AB

side.
! Ignition switch: ON A-20 (GR)
! Short-circuit terminal No. 21 to earth.
OK: Fan motor stops rotating.
3 2 1
YES : Go to Step 3 . connector AK203423 AC
NO : Go to Step 4 .
NO : Repair.
TROUBLESHOOTING
13A-231
STEP 6. Check harness between A-20 (terminal
No. 2) fan controller connector and C-134
Connector: A-20
A-20 (GR)
3 2 1
Harness side
connector AK203423 AC
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

connector A-14, and repair if necessary.
YES : Replace fan controller.
NO : Repair.
Inspection Procedure 22: Poor A/C Performance
COMMENT ON TROUBLE SYMPTOM ! Failed engine-ECU

! Failure is possibly caused by short /overcharged
A/C refrigerant, failed A/C control system, failed DIAGNOSIS PROCEDURE
fan control system or other faults.
PROBABLE CAUSE STEP 1. MUT-II self-diag code

! Short or overcharged A/C refrigerant Q: Diagnosis code set?
! Failed A/C compressor relay YES : Inspection chart for diagnosis code (Refer
! Failed fan controller to +,13A!'().
! Failed A/C-ECU NO : Go to Step 2 .
STEP 2. A/C compressor magnet clutch STEP 4. MUT-II data list

operation check. ! Item 49: A/C relay
! Engine: Idling a. Engine: Running at idle
! A/C set temperature: b. A/C set temperature:
Maximum Cool when temperature in cabin is Maximum Cool when temperature in cabin is
25%C or more 25%C or more.
Maximum Hot when temperature in cabin is 25%C Maximum Hot when temperature in cabin is
or less 25%C or less.
OK: OK:
Magnet clutch active (when A/C is ON) ON (when A/C is ON)
Magnet clutch inactive (when A/C is OFF) OFF (when A/C is OFF)
YES : Go to Step 5 . YES : Check A/C system (Refer to GROUP 55A "
NO : Go to Step 3 . Troubleshooting +,55A!)).
NO : Check A/C compressor relay (Refer to
STEP 3. MUT-II data list inspection procedure 27 +,13A!($#).
! Item 28: A/C switch
a. Engine: Idling STEP 5. Check charged amount of A/C
b. A/C set temperature: refrigerant.
Maximum Cool when temperature in cabin is ! Check charged amount of A/C refrigerant (Refer
25%C or more to GROUP 55A " On-vehicle Service +,55A!-&).
Maximum Hot when temperature in cabin is Q: Is the check result normal?
25%C or less YES : Go to Step 6 .
OK: NO : Adjust charged amount of A/C refrigerant.
ON (when A/C is ON)
OFF (when A/C is OFF)
STEP 6. MUT-II actuator test
Q: Is the check result normal? ! Item 21: Fan controller
YES : Go to Step 4 . OK: Fan motor rotates.
NO : Check A/C switch (Refer to Inspection
Procedure 26 +,13A!()$). Q: Is the check result normal?
YES : Check A/C load signal system (Refer to
Inspection Procedure 28 +,13A!($%).
NO : Check fan control relay system (Refer to
Inspection Procedure 25+,13A!()#).
TROUBLESHOOTING
13A-233
Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1
System
Power supply and ignition switch-IG circuit
Battery
9
Relay box
20A Ignition switch
LOCK
C-303
R
1 2 3
W-B ST ACC 4 5 6
IG1 IG2
A-14
5 2
W-B L-B
W-B
W-B 8
J/B
7.5A
4 3
B-17X
1
Engine C-202
1 2 control
relay
3 4 L-B
1 2
4 C-106
10
J/C (2) Y-G W-B
C-17
L-B
9 10
R R
12 25 38 80 82
Power Battery
source backup Engine-ECU
C-134 C-135 C-137
1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
Wire colour code

R: Red P: Pink V:Violet AK300310 AB
OPERATION STEP 2. Connector check: B-17X engine control

! The battery voltage is applied to the engine con- relay connector
trol relay (terminal No. 3 and 4).
! The engine-ECU (terminal No. 38) makes the CONNECTOR: B-17X
power transistor in the unit be in "ON" position Relay box’s B-17X
and makes currents go on the engine control triangle marks
relay coil, and that makes the relay be in "ON"
position.
! When the engine control relay is in "ON" position, 2 1
the battery voltage is supplied to the engine-
4 3
ECU, the sensor and the actuator from the
engine control relay (terminal No. 1). Harness side
FUNCTION
! When the ignition switch ON signal is input to the Q: Is the check result normal?
engine-ECU, the engine-ECU places the engine YES : Go to Step 3 .
control relay in the ON position. Accordingly, the NO : Repair.
battery voltage is supplied to the engine-ECU,
sensor and actuator. STEP 3. Check engine control relay.
! Check engine control relay (Refer to +,13A!"'().
PROBABLE CAUSE
! Failed engine control relay Q: Is the check result normal?
! Open/short circuit in engine control relay circuit or YES : Go to Step 4 .
NO : Replace engine control relay.
! Failed engine-ECU
STEP 4. Measure voltage at B-17X engine control
DIAGNOSIS PROCEDURE relay connector.
CONNECTOR: B-17X
STEP 1. Check battery voltage. Relay box’s B-17X
! Measure battery voltage during cranking. triangle marks
OK: 8 V or more
NO : Check battery (Refer to GROUP 54 " 4 3
Battery " On-vehicle Service " Battery test Harness side
+,54A!)). connector AK300255 AB
! Remove relay, and measure at relay box side.

! Voltage between terminal No. 3 and earth, also
between terminal No. 4 and earth.
OK: System voltage
harness between B-17X (terminal No. 4)
engine control relay connector and battery.
open/short circuit.
TROUBLESHOOTING
13A-235
C-134
C-137
13 12 11 10 9 8 7 6 5 4 3 2 1 8180 79 78 77 76 75 74 73 72 71
26 25 24 23 22 21 20 19 18 17 16 15 14 92 91 90 89 88 87 86 85 84 83 82
AK300257 AB AK300254 AB
! Measure engine-ECU terminal voltage. ! Measure engine-ECU terminal voltage.

! Ignition switch: ON ! Ignition switch: ON
! Voltage between terminal No. 12 and earth, also ! Voltage between terminal No. 82 and earth.
between terminal No. 25 and earth. OK: System voltage
OK: System voltage Q: Is the check result normal?
YES : Check and repair C-134 engine-ECU NO : Go to Step 8 .
connector.
NO : Go to Step 6 .
connector
CONNECTOR: C-137
connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71 Harness side connector

92 91 90 89 88 87 86 85 84 83 82
AK300254 AB
AK300254 AB
NO : Repair.
STEP 9. Check ignition switch. STEP 11. Check harness between C-303 (terminal
! Check ignition switch (Refer to GROUP 54A " No. 2) ignition switch connector and C-137
Ignition Switch " Ignition Switch +,54A!%%). (terminal No. 82) engine-ECU connector.
NO : Replace ignition switch.
STEP 10. Connector check: C-303 ignition switch C-303

connector 3 2 1
6 5 4
CONNECTOR: C-303
Harness side
connector
AK300304 AB
C-303 CONNECTOR: C-137

3 2 1
6 5 4
Harness side
connector
AK300304 AB

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

connectors C-106, C-202 and C-203, and repair if
necessary.
! Check output line for open/short circuit.
YES : Check and repair ignition switch IG1 power
supply line harness and connector.
! Check power supply line for short
circuit.
NO : Repair.
TROUBLESHOOTING
13A-237
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AB AK300256 AB

CONNECTOR: B-17X
Relay box’s B-17X
triangle marks
OK: 1 V or less
4 3
Harness side

! Ignition switch: OFF
OK: System voltage
NO : Check and repair harness between B-17X
! Check earthing line for open/short
circuit.
connector, C-303 ignition switch connector No. 2) ignition switch connector and C-137
CONNECTOR: C-135
CONNECTOR: C-303
C-303
3 2 1
C-135 6 5 4
Harness side
connector
AK300304 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB
CONNECTOR: C-303
C-137
C-303
3 2 1
6 5 4
8180 79 78 77 76 75 74 73 72 71
Harness side 92 91 90 89 88 87 86 85 84 83 82
connector Harness side connector
AK300304 AB
AK300254 AB
NO : Repair. connectors C-106, C-202 and C-203 and repair if
necessary.
NO : Repair.

00 " How to Use
+,00!$).
TROUBLESHOOTING
13A-239
STEP 17. Check harness between B-17X STEP 18. Check engine control relay output
(terminal No. 1) engine control relay connector power supply harness and connector for short
and C-134 (terminal No. 12 and No. 25) engine- circuit.
ECU connector. Q: Is the check result normal?
CONNECTOR: B-17X YES : Go to Step 19 .
B-17X NO : Repair.
Relay box’s
triangle marks
STEP 19. Check harness between B-17X
(terminal No. 3 and No. 4) engine control relay
2 1 connector and battery.
4 3 CONNECTOR: B-17X
Harness side Relay box’s B-17X
connector AK300255 AB triangle marks
CONNECTOR: C-134
2 1
4 3
Harness side
C-134 NOTE: Before checking harness, check intermediate

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Repair.
AK300257 AB

age.
NO : Repair.

(terminal No. 2) engine control relay connector
connector.
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
TROUBLESHOOTING
13A-241
Inspection Procedure 24: Fuel Pump System
Fuel pump circuit
Battery
C-303
W R LOCK
1 2 3 Ignition switch
4 5 6 ST ACC
IG1 IG2
24
Reray box
15A 2
W
L-B
C-116
41
W
C-202 C-203
2 6
4 3 1 3 8
7.5A
C-215 C-213
1 2 1 2 OFF ON OFF ON J/B
Fuel Fuel
3 4 3 4 pump 1 2 pump 4 2
relay (1) relay (2)
C-215 C-213
C-205 11 C-209 1 C-205

14
B-L
D-24 6
B
G
B-L
5
Fuel pump
D-16
(MU802058) M
1 2 3
4 8
4 5
B
D-24 4
G
B
22
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300311 AB
OPERATION STEP 2. Check fuel pump relay.

! The battery voltage is applied to the fuel pump ! Fuel pump relay, continuity check (Refer to
relay (1) (terminal No. 3) form the ignition switch +,13A!"'().
and is earthed to the vehicle body from the fuel
pump relay (1) (terminal No. 2). Q: Is the check result normal?
! The battery voltage is applied to the fuel pump YES : Go to Step 3 .
relay (1) (terminal No. 4) and to the fuel pump NO : Replace fuel pump relay.
relay (2) (terminal No. 1) from the fuel pump relay
(1) (terminal No. 1). STEP 3. Measure resistance at C-215 fuel pump
! The battery voltage is applied to the fuel pump relay (1) connector.
relay (2) (terminal No. 3) from the ignition switch.
CONNECTOR: C-215
The engine-ECU (terminal No. 22) makes the Junction block’s
triangle marks
power transistor in the unit be in "ON" position
and makes currents go on the fuel pump relay (2) C-215
coil, and that makes the relay be in "ON" position. 2 1
! When the fuel pump relay (2) is in "ON" position, 4 3
the battery voltage is supplied to the fuel pump Harness side
(low pressure) from the fuel pump relay (2) (ter- connector
minal No. 4).
AK300313 AB
FUNCTION
! When the ignition switch ON signal is input to the ! Remove relay, and measure at junction block
engine-ECU, the engine-ECU places the fuel side.
pump relay in the "ON" position. Accordingly, the ! Resistance between terminal No. 2 and earth.
battery voltage is supplied to the fuel pump. OK: 2 $ or less
! Failed fuel pump relay YES : Go to Step 4 .
! Failed fuel pump NO : Check intermediate connector C-205, and
! Open/short circuit in fuel pump drive circuit or repair if necessary. If intermediate
loose connector contact connector is normal, check and repair
! Failed engine-ECU harness between C-215 (terminal No. 2)
fuel pump relay (1) connector and body
DIAGNOSIS PROCEDURE earth.
and damage.
STEP 1. Connector check: C-215 fuel pump relay
(1) connector and C-213 fuel pump relay (2)
connector
Junction block’s
triangle marks
C-215
2 1
C-213
4 3
Harness side
connector
AK300312 AB

NO : Repair.
TROUBLESHOOTING
13A-243
STEP 4. Measure voltage at C-215 fuel pump STEP 5. Connector check: C-303 ignition switch
relay (1) connector. connector
Junction block’s
triangle marks
C-215
2 1
4 3 C-303
3 2 1
Harness side
connector 6 5 4
Harness side
connector
AK300313 AB AK300304 AB
! Remove relay, and measure at junction block CONNECTOR: C-215

side. Junction block’s
triangle marks
! Voltage between terminal No. 3 and earth. C-215
OK: System voltage 2 1
4 3
Harness side
YES : Go to Step 6 . connector
NO : Go to Step 5 .
AK300313 AB

fuel pump relay (1) connector and C-303
circuit and damage.
NO : Repair.
STEP 6. Measure voltage at C-215 fuel pump STEP 8. Connector check: C-303 ignition switch
relay (1) connector. connector
Junction block’s
triangle marks
C-215
2 1
4 3 C-303
3 2 1
Harness side
connector 6 5 4
Harness side
connector
AK300313 AB AK300304 AB
! Remove relay, and measure at junction block CONNECTOR: C-213

side. Junction block’s
triangle marks
OK: System voltage
2 1
4 3
Harness side
NO : Check intermediate connectors C-116 and connector
and repair harness between C-215 (terminal AK300321 AB
No. 4) fuel pump relay (1) connector and

battery. Q: Is the check result normal?
open/short circuit.
STEP 7. Measure voltage at C-213 fuel pump ignition switch connector and C-213
relay (2) connector. (terminal No. 3) fuel pump relay (2)
CONNECTOR: C-213 connector.
Junction block’s
triangle marks ! Check power supply line for
open/short circuit.
NO : Repair.
2 1
C-213
4 3
Harness side
connector
AK300321 AB
! Remove relay, and measure at junction block

side.
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING
13A-245
C-134 C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB AK300257 AB

Junction block’s
YES : Go to Step 10 . triangle marks
NO : Repair.
2 1
C-213
4 3
Harness side
connector
AK300321 AB

side.
OK: System voltage
NO : Check intermediate connectors C-106 and
No. 2) fuel pump relay (2) connector and C-
134 (terminal No. 22) engine-ECU
connector.
! Check earthing line for open/short
circuit.
STEP 11. Connector check: D-16 fuel pump STEP 13. Check harness between C-213 (terminal
connector No. 4) fuel pump relay (2) connector and D-16
(terminal No. 5) fuel pump connector.
Connector: D-16
CONNECTOR: C-213
Junction block’s
triangle marks
2 1
D-16 (GR) C-213
4 3
3 2 1 Harness side
5 4 connector
Harness side
connector AK203431AC
AK300321 AB
YES : Go to Step 12 . Connector: D-16
NO : Repair.
STEP 12. Measure voltage at D-16 fuel pump

connector.
D-16 (GR)
Connector: D-16
3 2 1
5 4
Harness side

D-16 (GR)
connectors D-209 and D-24, and repair if necessary.
3 2 1
5 4
Harness side age.
! Disconnect connector, and measure at harness YES : Replace engine-ECU.
side. NO : Repair.
! Using a jumper wire, connect C-134 (terminal No.
22) engine-ECU connector and earth.
OK: System voltage
TROUBLESHOOTING
13A-247
STEP 14. Measure resistance at D-16 fuel pump STEP 16. Check harness between C-303 (terminal
connector. No. 2) ignition switch connector and C-215
(terminal No. 3) fuel pump relay (1) connector.
Connector: D-16
CONNECTOR: C-303
D-16 (GR) C-303

3 2 1 3 2 1
5 4 6 5 4
connector AK203431AC connector
AK300304 AB
side. CONNECTOR: C-215
! Resistance between terminal No. 4 and earth. Junction block’s
triangle marks
OK: 2 $ or less
C-215
2 1
4 3
NO : Check intermediate connector D-24, and
Harness side
repair if necessary. If intermediate connector
harness between D-16 (terminal No. 4) fuel
pump connector and body earth. AK300313 AB

NOTE: Before checking harness,check intermediate
and damage.
STEP 15. Connector check: C-303 ignition switch
connector YES : Go to Step 17.
STEP 17. Check harness between battery and C-

215 (terminal No. 4) fuel pump relay (1)
C-303 connector.
3 2 1
CONNECTOR: C-215
6 5 4 Junction block’s
triangle marks
Harness side
connector
AK300304 AB
C-215
2 1
Q: Is the check result normal? 4 3
connector
NO : Repair.
AK300313 AB

NO : Repair.
No. 1) fuel pump relay (1) connector and C-213 No. 3) fuel pump relay (2) connector and C-134
(terminal No. 1) fuel pump relay (2) connector. (terminal No. 22) engine-ECU connector.
CONNECTOR: C-213, C-215 CONNECTOR: C-213
Junction block’s Junction block’s
C-215
2 1 2 1
C-213 C-213
4 3 4 3
connector connector
AK300312 AB AK300321 AB

CONNECTOR: C-134
NO : Repair.
STEP 19. Check harness between C-303 (terminal

No. 2) ignition switch connector and C-213
C-134
CONNECTOR: C-303
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
C-303
3 2 1 AK300257 AB
6 5 4 NOTE: Before checking harness, check intermediate

Harness side connectors C-106 and C-205, and repair if neces-
connector
AK300304 AB
sary.
! Check earthing line for open/short circuit.
CONNECTOR: C-213 Q: Is the check result normal?
Junction block’s
triangle marks YES : Go to Step 21.
NO : Repair.
2 1
C-213
4 3
Harness side
connector
AK300321 AB

NO : Repair.
TROUBLESHOOTING
13A-249
No. 3) fuel pump relay (2) connector and D-16
(terminal No.5) fuel pump connector.
CONNECTOR: C-213
Junction block’s
triangle marks
2 1
C-213
4 3
Harness side
connector
AK300321 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

connectors D-24 and C-205, and repair if necessary.
YES : Replace fuel pump.
NO : Repair.
Inspection Procedure 25: Fan Control Relay System
Fan control relay Circuit
Battery
9
20A
W-B
A-14
5
W-B
W-B
4 3
B-17X

3 4
1 2
Engine control system R
4 To engine-ECU
Fusible link (2) J/C (2)
C-17
5
R
L-W A-14
11
R
4 1
A-10X
2 Fan control relay
1 3
4
2 3
B
L
A-20
(MU802322)
Smoothing Fan controller
1 2 3 circuit
Wire colour code

AK300323 AB
TROUBLESHOOTING
13A-251
OPERATION STEP 2. Check fan control relay.
! The battery voltage is applied to the fan control ! Check fan control relay (Refer to GROUP 14 "
relay (terminal No. 1) from the engine control On"vehicle Service +,14!'$).
relay (terminal No. 1) and is earthed to the vehi-
cle body from the fan control relay (terminal No. Q: Is the check result normal?
3). YES : Go to Step 3 .
! The battery voltage is applied to the fan control NO : Replace fan control relay.
relay (terminal No. 4).
! When the fan control relay is in "ON" position, the STEP 3. Measure resistance at A-10X fan control
battery voltage is supplied to the fan controller relay connector.
(terminal No. 3) from the fan control relay (termi-
CONNECTOR: A-10X
nal No. 2).
FUNCTION
! When the engine control relay is in "ON" position, A-10X
the fan control relay is also simultaneously
placed in "ON" position. Accordingly, the battery
voltage is supplied to the fan controller. 2
3 1
4
PROBABLE CAUSE Harness side
! Failed fan control relay connector AK300324 AB
! Failed fan controller ! Remove relay and measure at relay box side.
! Failed radiator fan motor ! Resistance between terminal No. 3 and earth.
! Failed condenser fan motor
OK: 2 $ or less
! Open/short circuit in fan control relay circuit or
loose connector contact Q: Is the check result normal?
NO : Check and repair harness between A-10X
DIAGNOSIS PROCEDURE (terminal No. 3) fan control relay connector
and body earth.
STEP 1. Connector check: A-10X fan control and damage.
relay connector
CONNECTOR: A-10X STEP 4. Measure voltage at A-10X fan control
relay connector.
CONNECTOR: A-10X
A-10X
2 A-10X
3 1
4
Harness side
connector AK300324 AB 2
3 1
4
YES : Go to Step 2 . connector AK300324 AB
NO : Repair. ! Remove relay and measure at relay box side.
OK: System voltage
NO : Go to Step 5 .
STEP 5. Connector check: B-17X engine control STEP 6. Measure voltage at A-10X fan control
relay connector relay connector.
CONNECTOR: B-17X CONNECTOR: A-10X
Relay box’s B-17X

triangle marks
A-10X
2 1
2
4 3 3 1
4

CONNECTOR: A-10X
! Voltage between terminal No. 4 and earth
OK: System voltage
A-10X Q: Is the check result normal?
NO : Check and repair harness between battery
2 and A-10X (terminal No. 4) fan control relay
3 1
4 connector.
Harness side ! Check power supply line for
connector AK300324 AB open/short circuit.
YES : Check intermediate connectors A-14 and C- STEP 7. Connector check: A-20 fan controller
17, and repair if necessary. If intermediate connector
connectors are normal, check and repair Connector: A-20
engine control relay connector and A-10X
(terminal No. 1) fan control relay connector.
open/short circuit. A-20 (GR)
NO : Repair.
3 2 1
Harness side

NO : Repair.
TROUBLESHOOTING
13A-253
STEP 8. Measure voltage at A-20 fan controller STEP 10. Connector check: B-17X engine control
Connector: A-20 CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
A-20 (GR)
2 1
4 3
3 2 1
! Disconnect connector, and measure at harness Q: Is the check result normal?

side. YES : Go to Step 11 .
! Ignition switch: ON NO : Repair.
OK: System voltage
Q: Is the check result normal? (terminal No. 1) engine control relay connector
YES : Go to Step 12 . and A-10X (terminal No. 1) fan control relay
NO : Go to Step 9 . connector.
CONNECTOR: B-17X
STEP 9. Check harness between A-10X (terminal B-17X
Relay box’s
No. 2) fan control relay connector and A-20 triangle marks
(terminal No. 3) fan controller connector.
CONNECTOR: A-10X
2 1
4 3
A-10X
Harness side
2
3 1 CONNECTOR: A-10X
4
Harness side
A-10X
Connector: A-20
2
3 1
4
Harness side
A-20 (GR) connector AK300324 AB

3 2 1 connectors A-14 and C-17, and repair if necessary.
Harness side ! Check power supply line for damage.
! Check output line for open/short circuit. YES : Check and repair harness between A-10X
Q: Is the check result normal? (terminal No. 3) fan control relay connector
YES : Go to Step 10 . and body earth.
NO : Repair. ! Check earthing line for damage.
NO : Repair.
STEP 12. Connector check: C-134 engine-ECU STEP 14. MUT-II actuator test
connector ! Item 21: Fan controller
CONNECTOR: C-134 OK: Fan motor rotates.
00 " How to Use
+,00!$).
C-134

connector.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 CONNECTOR: C-134
AK300257 AB

NO : Repair.
C-134
STEP 13. Fan motor drive test.

CONNECTOR: C-134 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

side.
C-134 ! Ignition switch: ON
OK: 4.9 " 5.1 V
13 12 11 10 9 8 7 6 5 4 3 2 1 Q: Is the check result normal?
26 25 24 23 22 21 20 19 18 17 16 15 14 YES : Go to Step 16 .
AK300257 AB
! Disconnect C-134 engine-ECU connector.

OK: Fan motor rotates.
TROUBLESHOOTING
13A-255
STEP 16. Check harness between A-10X STEP 18. Check harness between A-20 (terminal
(terminal No. 4) fan control relay connector and No. 2) fan controller connector and C-134
battery. (terminal No. 21) engine-ECU connector.
CONNECTOR: A-10X Connector: A-20
A-10X
A-20 (GR)
2
3 1
4 3 2 1
connector AK300324 AB connector AK203423 AC

CONNECTOR: C-134
NO : Repair.
STEP 17. Check harness between A-10X

(terminal No. 2) fan control relay connector and
C-134
A-20 (terminal No. 3) fan controller connector.
CONNECTOR: A-10X
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
A-10X Harness side connector
AK300257 AB
2
3 1 NOTE: Before checking harness, check intermediate
4 connector A-14, and repair if necessary.
Harness side
Connector: A-20 YES : Replace fan motor and fan controller.
NO : Repair.
A-20 (GR)
3 2 1
Harness side

YES : Replace fan motor and fan controller.
NO : Repair.
Inspection Procedure 26: A/C Switch System
A/C Switch circuit
C-06
A/C-ECU
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
4 <Manual A/C>
34 <Auto A/C>
G-B
C-104
7
G-B
45
C-135
31 32 33 34 35 36 37 38 Engine-ECU
39 40 41 42 43 44 45 46
Wire colour code

AK300325 AB

! The battery voltage is applied to the engine-ECU ! Failed A/C
(terminal No. 45) from the A/C-ECU (terminal No. ! Failed A/C system
4) <Manual A/C> or A/C-ECU (terminal No. 34) ! Open/short circuit in A/C circuit or loose connec-
<Auto A/C>. tor contact
! Failed engine-ECU
FUNCTION
! When the A/C switch is in "ON" position, A/C
switch ON signal is inputted to the engine-ECU
from the A/C-ECU. In response to the signal, the
engine-ECU controls the A/C compressor relay.
TROUBLESHOOTING
13A-257
DIAGNOSIS PROCEDURE STEP 2. Measure voltage at C-06 A/C-ECU
connector <Manual A/C> or C-26 A/C-ECU
STEP 1. Measure voltage at C-135 engine-ECU connector <Auto A/C>.
connector. Connector: C-06
<Manual A/C>
CONNECTOR: C-135
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
C-135 Harness side
Connector: C-26
38 37 36 35 34 33 32 31 <Auto A/C>
46 45 44 43 42 41 40 39
AK300256 AB

! Engine: Running at idle 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B)
! A/C set temperature:
Harness side
Maximum Cool when temperature in cabin is connector
AK300327AB
25%C or more
Maximum Hot when temperature in cabin is 25%C ! Measure engine-ECU terminal voltage.
or less ! Engine: Idling
! Voltage between terminal No. 45 and earth. ! A/C set temperature:
OK: Maximum Cool when temperature in cabin is
System voltage (when A/C is ON) 25%C or more
0.5 V or less (when A/C is OFF) Maximum Hot when temperature in cabin is 25%C
or less
Q: Is the check result normal? ! Voltage between terminal No. 4 and earth <Man-
YES : Go to Step 6 . ual A/C>
NO : Go to Step 2 . ! Voltage between terminal No. 34 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 3 .
STEP 3. Connector check: C-06 A/C-ECU STEP 4. Check harness between C-06 A/C-ECU
connector <Manual A/C> or C-26 A/C-ECU connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C> C-135 engine-ECU connector <Auto A/C> and C-135 (terminal No.
connector 45) engine-ECU connector.
<Manual A/C> <Manual A/C>
C-06 (B) C-06 (B)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9

<Auto A/C> <Auto A/C>
28 27 26 25 24 23 22 21 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B) 36 35 34 33 32 31 30 29 C-26 (B)
connector connector
AK300327AB AK300327AB
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AB AK300256 AB
Q: Is the check result normal? NOTE: Before checking harness, check intermediate
YES : Go to Step 4 . connector C-104, and repair if necessary.
NO : Repair. ! Check output line for short circuit.
YES : Check A/C system (Refer to GROUP 55A "
Troubleshooting +,55A!)).
NO : Repair.
TROUBLESHOOTING
13A-259
STEP 5. Connector check: C-06 A/C-ECU STEP 6. Connector check: C-135 engine-ECU
connector <Manual A/C> or C-26 A/C-ECU connector
connector <Auto A/C> and C-135 engine-ECU
CONNECTOR: C-135
connector
Connector: C-06
<Manual A/C>
C-06 (B)
C-135
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side 38 37 36 35 34 33 32 31
connector AK300326 AB 46 45 44 43 42 41 40 39
Connector: C-26
<Auto A/C>
AK300256 AB

NO : Repair.
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B) STEP 7. MUT-II data list
Harness side ! Item 28: A/C switch
connector a. Engine: Idling
AK300327AB
b. A/C set temperature:
CONNECTOR: C-135 Maximum Cool when temperature in cabin is
25%C or more.
Maximum Hot when temperature in cabin is
25%C or less.
OK:
ON (when A/C is ON)
C-135
00 " How to Use
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
+,00!$).
AK300256 AB

harness between C-06 (terminal No. 4) or
C-26 (terminal No. 34) A/C-ECU connector
connector.
NO : Repair.
Inspection Procedure 27: A/C Compressor Relay System
A/C compressor relay Circuit
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
4
L-R
C-203
2
Battery
W 5 J/B
7.5A
10 C-205
Relay box
10A 16
L-R
B-R
A-14 C-106
9 11
B-R L-R
4 3
B-18X
1 2 A/C compressor relay

3 4
1 2
A/C-ECU
B-W G
1 8
Engine-ECU
A/C compressor
assembly A/C refrigerant
temperature
switch
B-27
(MU802653)
1 Magnetic C-134
clutch
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300328 AB
TROUBLESHOOTING
13A-261
OPERATION STEP 2. A/C compressor relay check.
! The battery voltage is applied to the A/C com- ! Check A/C compressor relay (Refer to GROUP
pressor relay (terminal No. 4). 55A " On-vehicle Service +,55A!)-).
! The battery voltage is applied to the A/C com-
pressor relay (terminal No. 3) from the ignition Q: Is the check result normal?
switch. The engine-ECU (terminal No. 8) makes YES : Go to Step 3 .
the power transistor in the unit be in "ON" posi- NO : Replace A/C compressor relay.
tion and makes currents go on the A/C compres-
sor relay coil, and that makes the relay be in "ON" STEP 3. Measure voltage at B-18X A/C
position. compressor relay connector.
! When the A/C compressor is in "ON" position, the
CONNECTOR: B-18X
battery voltage is supplied to the A/C compressor
B-18X
(terminal No. 1) from the A/C compressor relay Relay box’s
(terminal No. 1). triangle marks
FUNCTION
! When the A/C switch "ON" signal is input to the 2 1
engine-ECU, the engine-ECU places the A/C
4 3
compressor relay in the "ON" position. Accord-
ingly, the battery voltage supplied to the A/C com- Harness side
pressor operates the magnet clutch.
PROBABLE CAUSE ! Ignition switch: ON
! Failed A/C compressor relay ! Voltage between terminal No. 3 and earth.
! Failed A/C compressor magnet clutch
OK: System voltage
! Open/short circuit in A/C compressor relay circuit
or loose connector contact Q: Is the check result normal?
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-18X A/C

compressor relay connector
CONNECTOR: B-18X
B-18X
Relay box’s
triangle marks
2 1
4 3
Harness side

NO : Repair.
STEP 4. Connector check: C-303 ignition switch STEP 5. Measure voltage at B-18X A/C
connector compressor relay connector.
CONNECTOR: C-303 CONNECTOR: B-18X
B-18X
Relay box’s
triangle marks
C-303
3 2 1 2 1
6 5 4
4 3
Harness side

CONNECTOR: B-18X
B-18X
Relay box’s OK: System voltage
triangle marks
2 1
4 3 connector is normal, check and repair
Harness side harness between B-18X (terminal No. 4)
connector AK300329 AB A/C compressor relay connector and
battery.
Q: Is the check result normal? ! Check power supply line for
YES : Check intermediate connectors C-106, C-
open/short circuit.
202 <Auto A/C>, C-203 and C-205 <Manual
A/C>, and repair if necessary. If
intermediate connectors are normal, check STEP 6. Connector check: B-27 A/C compressor
and repair harness between B-18X connector
(terminal No. 3) A/C compressor relay CONNECTOR: B-27
ignition switch connector.
open/short circuit.
NO : Repair.
B-27 (B)
1
Harness side

NO : Repair.
TROUBLESHOOTING
13A-263
STEP 7. Measure voltage at B-27 A/C compressor STEP 8. Measure voltage at C-134 engine-ECU
B-27 (B)
1 C-134
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
CONNECTOR: B-18X
26 25 24 23 22 21 20 19 18 17 16 15 14
B-18X
Relay box’s Harness side connector
triangle marks
AK300257 AB

2 1 ! Ignition switch: ON
4 3
OK: System voltage
Harness side
connector AK300329 AB Q: Is the check result normal?
NO : Go to Step 9 .
side.
! Remove B-18X (terminal No. 1 and No. 4) A/C
compressor relay and short-circuit of harness STEP 9. Connector check: C-134 engine-ECU
side connector. connector
CONNECTOR: C-134
OK: System voltage
(terminal No. 1) A/C compressor connector
C-134
and B-18X (terminal No. 1) A/C compressor
relay connector.
circuit. 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
STEP 10. Check harness between B-18X STEP 11. MUT-II Data List
(terminal No. 2) A/C compressor relay connector ! Item 49: A/C relay
and C-134 (terminal No. 8) engine-ECU a. Engine: Idling
connector. b. A/C set temperature:
Maximum Cool when temperature in cabin is
CONNECTOR: B-18X
25%C or more
B-18X
Relay box’s Maximum Hot when temperature in cabin is
triangle marks 25%C or less
OK:
ON (when A/C is ON)
2 1 OFF (when A/C is OFF)
4 3
Harness side YES : Intermittent malfunction (Refer to GROUP
connector AK300329 AB 00 " How to Use
CONNECTOR: C-134 +,00!$).

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
C-134
AK300257 AB

YES : Go to Step 11 . 26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Repair. Harness side connector
AK300257 AB

NO : Repair.
TROUBLESHOOTING
13A-265
STEP 13. Check harness between B-18X STEP 15. Check harness between C-303 (terminal
(terminal No. 2) A/C compressor relay connector No. 4) ignition switch connector and B-18X
and C-134 (terminal No. 8) engine-ECU (terminal No. 3) A/C compressor relay connector.
connector.
CONNECTOR: C-303
CONNECTOR: B-18X
B-18X
Relay box’s
triangle marks
C-303
3 2 1
2 1 6 5 4
Harness side
4 3 connector
Harness side AK300304 AB
CONNECTOR: B-18X
CONNECTOR: C-134 B-18X
Relay box’s
triangle marks
2 1
4 3
C-134
Harness side

13 12 11 10 9 8 7 6 5 4 3 2 1 connectors C-106, C-202 <Auto A/C>, C-203 and C-
26 25 24 23 22 21 20 19 18 17 16 15 14
205 <Manual A/C>, and repair if necessary.
Harness side connector ! Check power supply line for damage.
! Check earthing line for damage. YES : Go to Step 16 .
NO : Repair.
NO : Repair. STEP 16. Check harness between battery and B-
18X (terminal No. 4) A/C compressor relay
connector.
connector CONNECTOR: B-18X
B-18X
CONNECTOR: C-303 Relay box’s
triangle marks
2 1
C-303
3 2 1 4 3
6 5 4
Harness side
connector
AK300304 AB NOTE: Before checking harness, check intermediate
Q: Is the check result normal? ! Check power supply line for damage.
NO : Repair.

(terminal No. 1) A/C compressor relay connector
and B-27 (terminal No. 1) A/C compressor relay
connector.
CONNECTOR: B-18X
B-18X
Relay box’s
triangle marks
2 1
4 3
Harness side
CONNECTOR: B-27
B-27 (B)
1
Harness side

YES : Replace A/C compressor magnet clutch.
NO : Repair.
TROUBLESHOOTING
13A-267
Inspection Procedure 28: A/C Load Signal System
A/C load signal circuit
C-06
A/C-ECU
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
5 <Manual A/C>
32 <Auto A/C>
L-W
C-106
6
L-W
24
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13 Engine-ECU
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300338 AB

! The A/C load signal is inputted to the engine- ! Failed A/C-ECU
ECU (terminal No. 24) from the A/C-ECU (termi- ! Open/short circuit in A/C load signal circuit or
nal No. 5). <Manual A/C> or (terminal No. 32) loose connector contact
<Auto A/C> ! Failed engine-ECU
FUNCTION
! The magnitude of the A/C compressor load is
detected and input to the engine-ECU. The
engine-ECU provides A/C idle up control accord-
ing to the A/C compressor load condition.

connector
STEP 1. Measure voltage at C-134 engine-ECU CONNECTOR: C-134
connector.
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
AK300257 AB
! Measure engine-ECU terminal voltage. NO : Repair.
! Engine: Idling
! A/C switch: ON (A/C compressor in driven state)
! Voltage between terminal No. 24 and earth
OK: Q: Does trouble symptom persist?
1 V or less (when the temperate around the
atmospheric air temperature sensor is 18%C
00 " How to Use
or more, and the A/C is set to the lowest tem-
perature and the maximum air flow rate)
+,00!$).
System voltage (when the A/C is set to the
temperature in the cabin and the minimum
air flow rate) STEP 4. Connector check: C-134 engine-ECU
connector
YES : Go to Step 2 . CONNECTOR: C-134
NO : Go to Step 4 .
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
TROUBLESHOOTING
13A-269
STEP 5. Measure voltage at C-06 A/C-ECU STEP 6. Connector Check: C-06 A/C-ECU
connector <Manual A/C> or C-26 A/C-ECU connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C>. connector <Auto A/C>
<Manual A/C> <Manual A/C>
C-06 (B) C-06 (B)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9

<Auto A/C> <Auto A/C>
28 27 26 25 24 23 22 21 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B) 36 35 34 33 32 31 30 29 C-26 (B)
connector connector
AK300327AB AK300327AB
! Measure A/C-ECU terminal voltage. Q: Is the check result normal?

! Engine: Idling YES : Go to Step 7 .
! A/C set temperature: NO : Repair.
25%C or more
Maximum Hot when temperature in cabin is 25%C
or less
! Voltage between terminal No. 5 and earth <Man-
ual A/C>
! Voltage between terminal No. 32 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 6 .
STEP 7. Check harness between C-06 (terminal STEP 8. Check connector: C-06 A/C-ECU
No. 5) or C-26 (terminal No. 32) A/C-ECU connector <Manual A/C> or C-26 A/C-ECU
connector and C-134 (terminal No. 24) engine- connector <Auto A/C>
ECU connector. Connector: C-06
Connector: C-06 <Manual A/C>
<Manual A/C>
C-06 (B)
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 Harness side
Connector: C-26
Connector: C-26 <Auto A/C>
<Auto A/C>
28 27 26 25 24 23 22 21
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B)
36 35 34 33 32 31 30 29 C-26 (B) Harness side
AK300327AB
connector
AK300327AB
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14
26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side connector
AK300257 AB
AK300257 AB
NOTE: Before checking harness, check intermediate YES : Check intermediate connector C-104, and
connector C-104, and repair if necessary. repair if necessary. If intermediate
! Check output line for short circuit. connector is normal, check and repair
Q: Is the check result normal? harness between C-06 (terminal No. 5) or
YES : Check A/C system (Refer to GROUP 55A " C-26 (terminal No. 32) A/C-ECU connector
Troubleshooting +,55A!)). and C-134 (terminal No. 24) engine-ECU
NO : Repair. connector.
NO : Repair.
TROUBLESHOOTING
13A-271
Inspection Procedure 29: A/C Pressure Sensor System
A/C Pressure sensor circuit
A-02
(MU802509) A/C Pressure sensor
1 2 3
3 1 2
G-Y BR G-R
C-116
17 5
A-14
17 BR G-R
C-105 C-104
21 4
G-Y
A/C-ECU
BR G-R
81 92 42
C-135 C-137
31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code

AK300339 AB
OPERATION FUNCTION
! A power voltage of 5 V is applied to the A/C pres- ! The A/C pressure sensor detects the A/C refrig-
sure sensor power terminal (terminal No. 3) from erant pressure and inputs the pressure signal to
the engine-ECU (terminal No. 81) and is earthed the engine-ECU. The engine-ECU uses the sig-
to the engine-ECU (terminal No. 92) from the A/C nal for ON/OFF control of the magnet clutch of
pressure sensor (terminal No. 1). the A/C compressor.
(terminal No. 42) from the A/C pressure sensor PROBABLE CAUSE
output terminal (terminal No. 2). ! Failed A/C pressure sensor
! Open/short circuit in A/C pressure sensor circuit
! Failed engine-ECU
DIAGNOSIS PROCEDURE STEP 3. Measure voltage at A-02 A/C pressure

sensor connector.
STEP 1. MUT-II Data List Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
3 2 1 Harness side
connector
Harness side AK300340AB
connector
AK300340AB ! Disconnect connector, and measure at harness
! Refer to Data list reference table +,13A!(&%. side.
a. Item 3A: A/C pressure sensor ! Ignition switch: ON
YES : Intermittent malfunction (Refer to GROUP OK: 4.9 " 5.1 V
00 " How to Use Q: Is the check result normal?
+,00!$). NO : Go to Step 4 .
NO : Go to Step 2 .
STEP 2. Connector check: A-02 A/C pressure connector.
sensor connector
CONNECTOR: C-137
Connector: A-02
A-02 (B)
3 2 1 C-137
Harness side
connector
AK300340AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Q: Is the check result normal? Harness side connector

OK: 4.9 " 5.1 V
NO : Go to Step 5 .
TROUBLESHOOTING
13A-273
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AB AK300254 AB
Connector: A-02 Q: Is the check result normal?

NO : Repair.
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

YES : Check intermediate connector A-14, and
harness between A-02 (terminal No. 3) A/C
pressure sensor connector and C-137
! Check power line for open circuit.
NO : Repair.
STEP 7. Check harness between A-02 (terminal STEP 9. Measure resistance at A-02 A/C pressure
No. 3) A/C pressure sensor connector and C-137 sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
3 2 1 Harness side
connector AK300340AB
AK300340AB
side.
CONNECTOR: C-137
! Resistance between terminal No. 1 and earth
OK: 2 $ or less

connector
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

! Check power line for short circuit. C-137

NO : Repair. 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB
a. Item 3A: A/C pressure sensor Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP NO : Repair.
00 " How to Use
+,00!$).
TROUBLESHOOTING
13A-275
STEP 11. Check harness between A-02 (terminal STEP 12. Measure voltage at A-02 A/C pressure
No. 1) A/C pressure sensor connector and C-137 sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
3 2 1 Harness side
AK300340AB
CONNECTOR: C-137
OK: 4.9 " 5.1 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

sary.
! Check earthing line for open circuit or damage.
NO : Repair.
STEP 13. Connector check: C-137 engine-ECU STEP 14. Measure voltage at A-02 A/C pressure
connector sensor connector.
CONNECTOR: C-137 Connector: A-02
A-02 (B)
3 2 1
C-137 Harness side
connector
AK300340AB

AK300254 AB
OK: 0.5 or less
Connector: A-02
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

! Check power line for damage.
NO : Repair.
TROUBLESHOOTING
13A-277
STEP 15. Connector check: C-137 engine-ECU STEP 16. Measure voltage at A-02 A/C pressure
connector sensor connector.
CONNECTOR: C-137 Connector: A-02
A-02 (B)
3 2 1
C-137 Harness side
connector
AK300340AB

Harness side connector ! Engine: Running at idle
AK300254 AB
! A/C switch: ON
Connector: A-02 OK:
1.8 " 2.0 V (A/C refrigerant pressure: 1 kPa)
A-02 (B)
3 2 1
Harness side STEP 17. Connector check: C-135 engine-ECU
connector
AK300340AB connector
CONNECTOR: C-135
and repair harness between A-02 (terminal
No. 1) A/C pressure sensor connector and
C-135
connector.
NO : Repair.
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

NO : Repair.
STEP 18. Check harness between A-02 (terminal STEP 19. Measure voltage at C-135 engine-ECU
No. 2) A/C pressure sensor connector and C-135 connector.
(terminal No. 42) engine-A/T-ECU connector.
CONNECTOR: C-135
Connector: A-02
A-02 (B)
C-135
3 2 1
Harness side
connector
AK300340AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AB

! Engine: Running at idle
! A/C switch: ON
C-135
OK:
38 37 36 35 34 33 32 31
AK300256 AB

sary.
! Check output line for short circuit and damage.
YES : Replace A/C pressure sensor.
NO : Repair.
TROUBLESHOOTING
13A-279
connector connector
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AB AK300256 AB
Connector: A-02 Q: Is the check result normal?

NO : Repair.
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

connector.
! Check power line for open circuit and
damage.
NO : Repair.
Inspection Procedure 30: Ignition Circuit System
Ignition circuit
Ignition switch
C-303
R LOCK
1 2 3 ST
4 5 6 ACC
IG1 IG2
2
L-B
C-203
6
J/B 1
10A
10
W C-205
C-116
26
W
A-14
16
W W
W
1 1
Ignition coil 1 Ignition coil 2 1

B-110 B-111
B-107
Capacitor
1 2 3 1 2 3
3 2 Spark 2 3
plug
B B
B-L W-L
B
10 23
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
Engine-ECU 14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300341 AB
TROUBLESHOOTING
13A-281
OPERATION STEP 3. Connector check: B-111 and B-110
! The battery voltage is applied to the ignition coil ignition coil connectors
(terminal No. 1) from the ignition switch and is
earthed to the vehicle body from the ignition coil Connector: B-110, B-111
(terminal No. 2).
3 2 1
! A power voltage of 12 V is applied to the ignition
Harness side
coil output terminal (terminal No. 3) from the connector
engine-ECU (terminal No. 10 and No. 23). B-111 (GR)
FUNCTION
! When the engine-ECU makes the power transis-
tor in the unit be in "OFF" position, the battery B-110 (GR)
voltage in the unit is applied to the power transis- AK300308 AB
tor unit, and that makes the power transistor unit
be in "ON" position. The engine-ECU makes the Q: Is the check result normal?
power transistor in the unit be in "ON", and that YES : Go to Step 4 .
makes the power transistor unit be in "OFF" posi- NO : Repair.
tion.
! In response to the signal from the engine-ECU, STEP 4. Check ignition coil itself.
the power transistor unit is in "ON" position. The ! Check ignition coil itself (Refer to GROUP 16 "
primary current is going to the ignition coil. When Ignition System " On-vehicle Service +,16!($).
the power transistor unit is in "OFF" position, the
primary current is interrupted and high voltage is YES : Go to Step 5 .
generated in the secondary coil. NO : Replace ignition coil.
PROBABLE CAUSE
! Failed ignition coil STEP 5. Measure voltage at B-111 and B-110
! Failed spark plug ignition coil connectors.
! Failed spark plug cable
! Open/short circuit in ignition primary circuit or
loose connector contact 3 2 1
! Failed engine-ECU Harness side
connector
B-111 (GR)
DIAGNOSIS PROCEDURE

B-110 (GR)
! Check spark plug cable itself (Refer to GROUP
16 " Ignition System " On-vehicle Service +,16! AK300308 AB
(%). ! Disconnect connector, and measure at harness

Q: Is the check result normal? side.
YES : Go to Step 2 . ! Ignition switch: ON
NO : Replace spark plug cable. ! Voltage between terminal No. 1 and earth.
OK: System voltage
STEP 2. Check spark plug. Q: Is the check result normal?
YES : Go to Step 3 . NO : Go to Step 6 .
STEP 6. Connector check: C-303 ignition switch STEP 7. Measure voltage at B-111 and B-110
connector ignition coil connectors.
CONNECTOR: C-303 Connector: B-110, B-111
3 2 1
Harness side
connector
B-111 (GR)
C-303
3 2 1
6 5 4
Harness side B-110 (GR)
connector
AK300304 AB AK300308 AB

side.
3 2 1 ! Engine: Cranking
Harness side ! Voltage between terminal No. 3 and earth.
connector
B-111 (GR) OK: 0.5 " 4.0 V
NO : Go to Step 8 .
B-110 (GR)
AK300308 AB

YES : Check intermediate connectors A-14, C-
203, C-205 and C-116, and repair if
normal, check and repair harness between
C-303 (terminal No. 2) ignition switch
connector and B-111 (terminal No. 1)
ignition coil connector, also between C-303
(terminal No. 2) ignition switch connector
and B-110 (terminal No. 1) ignition coil
connector.
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-283
C-134 C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB AK300257 AB
Connector: B-110, B-111 Connector: B-110, B-111
3 2 1 3 2 1
connector connector
B-111 (GR) B-111 (GR)
B-110 (GR) B-110 (GR)

AK300308 AB AK300308 AB

! Disconnect B-111 and B-110 ignition coil connec- YES : Check and repair harness between B-111
tors. (terminal No. 3) ignition coil connector and
! Engine: Cranking C-134 (terminal No. 23) engine-ECU
! Voltage between terminal No. 10 and earth, also connector, also between B-110 (terminal
between terminal No. 23 and earth. No. 3) ignition coil connector and C-134
OK: 0.5 " 4.0 V (terminal No. 10) engine-ECU connector.
Q: Is the check result normal? ! Check output line for open circuit.
connector No. 3) ignition coil connector and C-134 (terminal
No. 23) engine-ECU connector, also between B-
CONNECTOR: C-134
110 (terminal No. 3) ignition coil connector and
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
AK300257 AB
26 25 24 23 22 21 20 19 18 17 16 15 14
Q: Is the check result normal? Harness side connector

NO : Repair.
3 2 1
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB

NO : Repair.

00 " How to Use
+,00!$).
TROUBLESHOOTING
13A-285
STEP 13. Measure resistance at B-111 and B-110 STEP 14. Check harness between C-303 (terminal
ignition coil connectors. No. 2) ignition switch connector and B-111
(terminal No. 1) ignition coil connector, also
between C-303 (terminal No. 2) ignition switch
3 2 1 connector and B-110 (terminal No. 1) ignition coil
Harness side connector.
connector
B-111 (GR) CONNECTOR: C-303
B-110 (GR)
C-303
AK300308 AB
3 2 1
! Disconnect connector, and measure at harness 6 5 4
side. Harness side
! Resistance between terminal No. 2 and earth. connector
AK300304 AB
OK: 2 $ or less
Q: Is the check result normal? Connector: B-110, B-111
3 2 1
Harness side
(terminal No. 2) ignition coil connector and connector
body earth, also between B-110 (terminal B-111 (GR)
No. 2) ignition coil connector and body
earth.
B-110 (GR)
and damage.
AK300308 AB

connectors A-14, C-116, C-203 and C-205, and
repair if necessary.
NO : Repair.

No. 3) ignition coil connector and C-134 (terminal
No. 23) engine-ECU connector, also between B-
110 (terminal No. 3) ignition coil connector and C-
3 2 1
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
TROUBLESHOOTING
13A-287
Data List Reference Table
M1131152000735
Item Inspection Inspection condition Normal Inspection Reference

No. item condition procedure page
No.
11 Oxygen Engine: After Excessive 200 mV or less Code No. +,13A!$'
sensor (front) warm-up (leaner deceleration from P0130
by deceleration, 4,000 r/min
richer by At excessive 600 " 1,000 mV
acceleration) acceleration
Engine: After Idle operation 400 mV or less
warm-up (using 2,500 r/min ' 600 " 1,000
oxygen sensor, mV (altered)
check air-fuel
ratio as well as
control status by
engine-ECU.
12 Air flow ! Engine coolant Idle operation 16 " 24 Hz " "
sensor *1 temperature: 2,500 r/min 72 " 112 Hz
80 " 95%C
! Lamps, electric Acceleration According to
cooling fan and acceleration,
all frequency is
accessories: amplified.
OFF
! Transmission:
Neutral
13 Intake air Ignition switch: Intake air "20%C Code No. +,13A!""
temperature “ON” or engine temperature: P0110
sensor running "20%C
Intake air 0% C
temperature: 0%C
Intake air 20%C
temperature: 20%C
Intake air 40%C
temperature: 40%C
Intake air 80% C
temperature: 80%C
14 Throttle Ignition switch: Set to Idle position 535 " 735 mV Code No. +,13A!-&
position “ON” Release accelerator Increased P0120
sensor pedal gradually according to
accelerator pedal
stroke
Release accelerator 4,500 " 5,000
pedal fully mV
16 Power supply Ignition switch: “ON” System voltage Procedure +,13A!(""
voltage No. 23

No.
18 Cranking Ignition switch: Engine: Stopped OFF Procedure +,13A!(""
signal “ON” Engine: Cranking ON No. 23
(ignition
switch-ST)
21 Engine Ignition switch: Coolant temperature: "20%C Code No. +,13A!-#
coolant “ON” or engine "20%C P0115
temperature running Coolant temperature: 0%C
sensor 0% C
Coolant temperature: 20%C
20%C
40%C
80%C
22 Crank angle ! Engine: Compare engine Matched Code No. +,13A!'("
sensor Cranking speed on tachometer P0335
! Tachometer: with the value
Connected displayed on MUT-II
Engine: Idle Coolant temperature: 1,100 " 1,300
operation "20%C r/min
Coolant temperature: 1,100 " 1,300
0% C r/min
20%C r/min
Coolant temperature: 940 " 1,140 r/min
40%C
Coolant temperature: 650 " 850 r/min
80%C
25 Barometric Ignition switch: Altitude: 0m 101 kPa Code No. +,13A!(-
pressure “ON” Altitude: 600m 95 kPa P0105
sensor
Altitude: 1,200m 88 kPa
27 Power Engine: Idle Steering wheel: Not OFF Code No. +,13A!'$'
steering fluid operation operated P0551
pressure Steering wheel: ON
switch Operated
28 A/C switch Engine: Idle AC switch: OFF OFF Procedure +,13A!()$
AC A/C OFF No. 26
switch: compressor
ON is not driven
A/C ON
compressor
is driven
TROUBLESHOOTING
13A-289
No.
37 Volumetric ! Engine coolant Idel operation 13 " 33 % " "
efficiency temperature: 2,500 r/min 12 " 32 %
80 " 95%C
! Lamps, electric Excessive According to
cooling fan and acceleration acceleration,
all volumetric
accessories: efficiency is
OFF increased.
3A A/C pressure ! After engine A/C in MAX COOL 2,200 mV or Procedure +,13A!(%'
sensor warm-up, idle state (under high more No. 29
operation load)
! A/C switch: ON A/C in MAX HOT 1,800 mV or less
state (under low load)
41 Injectors *2 Engine: Cranking Coolant temperature: 5.6 " 8.4 ms " "
0%C (all cylinders in
simultaneous
injecting operation)
Coolant temperature: 5.6 " 8.4 ms
20%C
Coolant temperature: 5.6 " 8.4 ms
80%C
Injectors*3 ! Engine coolant Idle operation 2.0 " 3.2 ms
temperature: 2,500 r/min 2.2 " 3.4 ms
80 " 95%C
! Lamps, electric Excessive Increased
cooling fan and acceleration
all
accessories:
OFF
! Transmission:
Neutral
44 Ignition ! Engine: After Idle operation 2 " 18%BTDC Procedure +,13A!(&#
advance warm-up 2,500 r/m 18 " 38%BTDC No. 30
! Install timing
light (for use to
measure
actual ignition
timing)

No.
45 ISC (stepper ! Engine coolant A/C switch: OFF 2 " 25 steps " "
motor) servo temperature: A/C switch: OFF & Increased 10 "
position*4 80 " 95%C ON 70 steps
! Lighting,
electric cooling
fan and
accessories:
OFF
! Transmission:
Neutral
! Engine: Idle
operation
(When A/C
switch is ON,
A/C
compressor
must be ON)
49 A/C relay Engine: After A/C switch: OFF OFF Procedure +,13A!($%
warm-up, idle A/C A/C OFF No. 27
operation after switch: compressor
warm-up ON is not driven
A/C ON
compressor
is driven
59 Oxygen Engine: After At excessive 0 mV or less ' Code No. +,13A!%(
sensor (rear) warm-up acceleration 600 - 1,000 mV P0136
(altered)
12 Air flow ! Engine coolant Idle operation 0.9 " 4.9 gm/s " "
*5 sensor temperature: 2,500 r/min 7.2 " 13.2 gm/s
80 " 95%C
! Lamps, electric Acceleration According to
cooling fan and acceleration,
all frequency is
accessories: amplified.
OFF
! Transmission:
Neutral
TROUBLESHOOTING
13A-291
No.
13 Intake air Ignition switch: Intake air "20%C Code No. +,13A!""
*5 temperature “ON” or engine temperature: P0110
sensor running "20%C
Intake air 0% C
temperature: 0%C
Intake air 20%C
temperature: 20%C
Intake air 40%C
temperature: 40%C
Intake air 80% C
temperature: 80%C
21 Engine Ignition switch: Coolant temperature: "20%C Code No. +,13A!-#
*5 coolant “ON” or engine "20%C P0115
temperature running Coolant temperature: 0%C
sensor 0%C
20%C
40%C
80%C
22 Crank angle ! Engine: Compare engine Matched " "
*5 sensor Cranking speed on tachometer
! Tachometer: with the value
Connected displayed on MUT-II
Engine: Idle Coolant temperature: 1,100 " 1,300
operation "20%C r/min
0%C r/min
20%C r/min
Coolant temperature: 940 " 1,140 r/min
40%C
Coolant temperature: 650 " 850 r/min
80%C
24 Vehicle Drive 40 km/h Approximately 40 Code No. +,13A!')"
*5 speed sensor km/h P0500
44 Ignition ! Engine: After Idle operation 2 " 18 deg " "
*5 advance warm-up 2,500 r/m 18 " 38 deg
! Install timing
light (for use to
measure
actual ignition
timing)

No.
81 Long-term Engine: After warm-up, 2,500 r/min "12.5 " 12.5 % Code No. +,13A!&"
*5 fuel without any load (during closed loop) P0170
compensatio
n
82 Shot-term Engine: After warm-up, 2,500 r/min "25 " 25 % Code No. +,13A!&"
*5 fuel without any load (during closed loop) P0170
compensatio
n
87 Calculation Engine: After Idle operation 13 " 33 % " "
*5 losd value warm-up 2,500 r/m 12 " 32 %
88 Fuel control Engine: After 2,500 r/m Closed loop " "
*5 condition warm-up Acceleration Open loop-drive
condition
8A Throttle Ignition switch: Set to Idle position 0 " 10 % Code No. +,13A!-&
*5 position “ON” Release accelerator Increased P0120
sensor pedal gradually according to
(Throttle accelerator pedal
opening stroke
angle)
Release accelerator 80 " 100 %
pedal fully
A1 Oxygen Engine: After Excessive 0.2 V or less ' Code No. +,13A!$'
*5 sensor (front) warm-up (leaner deceleration from 0.6 " 1 V P0130
by deceleration, 4,000 r/min (altered)
richer by
acceleration)
Engine: After Idle operation 0.4 V or less '
warm-up (using 2,500 r/min 0.6 " 1 V
oxygen sensor, (altered)
check air-fuel
ratio as well as
control status by
engine-A/ECU.
A1 Oxygen Engine: After At excessive 0 V or less ' 0.6 Code No. +,13A!%(
*5 sensor (rear) warm-up acceleration " 1 V (altered) P0136
CAUTION
When shifting the select lever to D range, the brakes should be applied so that the vehicle does not
move forward
NOTE: *1: On the new vehicle (mileage: 500 km or less), air flow sensor output frequency may be higher by
approx. 10%.
NOTE: *2: Injector drive time ranges shown are when power voltage is 11 V and the cranking speed is 250
r/min. or less.
NOTE: *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approx. 10%.
NOTE: *4: On the new vehicle (mileage: 500 km or less), the number of steps of stepper motor may be larger
by approx. 30 steps.
NOTE: *5: When service data in check mode is selected, the data is not displayed.
TROUBLESHOOTING
13A-293
Actuator Test Reference Table
M1131152500439
Item Inspection Drive content Inspection conditions Normal Code No. Reference
No. item condition /Inspection page
procedure
No.
01 Injector Cut off No. 1 Engine: After warm-up, Engine is Code No. +,13A!&%
injector idle operation (Cut off changed P0201
02 Cut off No. 2 injectors sequentially to (becomes Code No. +,13A!*(
injector check for a cylinder that unstable or P0202
does not change engine in stalled)
03 Cut off No. 3 idle status. Code No. +,13A!*%
injector P0203
04 Cut off No. 4 Code No. +,13A!'#(
injector P0204
07 Fuel pump Drive fuel Ignition Hold return Pulse is felt Procedure +,13A!(-'
pump to switch: "ON" hose with No. 24
circulate fuel fingers to
feel pulse of
fuel flowing
Check for Operating
pump noise audible
operating
noise near
fuel tank
08 Purge Switch solenoid Ignition switch: "OFF" When the valve Code No. +,13A!'-&
control valve from OFF is actuated, P0443
solenoid to ON operating noise
valve is audible
10 EGR control Switch solenoid Ignition switch: "ON" When the valve Code No. +,13A!'-(
solenoid valve from OFF is actuated, P0403
valve to ON operating noise
is audible.
17 Basic ignition Switch engine- ! Engine: Idle operation 5% BTDC " "
timing ECU to ignition ! Install timing light
timing adjusting
mode
21 Fan Actuate fan ! Ignition switch: "ON" Fan motor is Procedure +,13A!((*
controller motor ! A/C switch: ON rotated No. 21
CHECK AT THE ECU TERMINALS NOTE: .

M1131153500175 1. Make the voltage measurement with the
TERMINAL VOLTAGE CHECK CHART engine-ECU connector connected.
2. You may find it convenient to pull out the
Needle-nosed wire probe engine-ECU to make it easier to reach the
connector terminals.
3. The checks can be carried out off the order
given in the chart.
CAUTION
Short-circuiting the positive (+) probe between a
connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU or all of
AK201749AB them. Be careful to prevent this!
3. If voltmeter shows any division from standard
1. Connect a needle-nosed wire probe to a voltmeter value, check the corresponding sensor, actuator
probe. and related electrical wiring, then repair or
2. Insert the needle-nosed wire probe into each of replace.
the engine-ECU connector terminals from the wire 4. After repair or replacement, recheck with the
side, and measure the voltage while referring to voltmeter to confirm that the repair has corrected
the check chart. the problem.
Engine-ECU Connector Terminal Arrangement

Engine-ECU Connector
C-134 C-135 C-136 C-137
1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 51 52 53 54 55 56 71 72 73 74 75 76 77 78 79 80 81
14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 57 58 59 60 61 62 82 83 84 85 86 87 88 89 90 9192
AK300342 AB
Terminal Check item Check condition (Engine condition) Normal condition

No.
1 No. 1 injector While engine is idling after having warmed From 11 " 14 V,
14 No. 2 injector up, suddenly depress the accelerator pedal. momentarily drops slightly
2 No. 3 injector
15 No. 4 injector
4 Stepper motor coil ! Engine: Soon after the warmed up engine System voltage ' 1 V or
<A1> is star less (Changes repeatedly)
17 Stepper motor coil ! A/C switch: OFF & ON (A/C compressor
<A2> is operating)
5 Stepper motor coil
<B1>
18 Stepper motor coil
<B2>
6 EGR control Ignition switch: "ON" System Voltage
solenoid Valve While engine is idling, suddenly depress the From system voltage,
accelerator pedal. momentarily drops
TROUBLESHOOTING
13A-295
No.
8 A/C relay ! Engine: Idle speed System voltage or
! A/C switch: OFF & ON (A/C compressor Momentarily 6V or more
is operating) & 1 V or less
9 Purge control Ignition switch: "ON" System voltage
solenoid valve Running at 3,500 r/min while engine is 1 V or less
warming up after having been started.
10 Ignition coil " No. 1, Engine r/min: 3,000 r/min 0.3 " 3.0 V
No. 4
23 Ignition coil " No. 2,
No. 3
12 Power supply Ignition switch: "ON" System voltage
25
19 Air flow sensor reset Engine: Idle speed 0"1V
Signal Engine r/min: 3,000 r/min 6"9V
21 Fan controller Radiator and condenser fan is not operating 0 " 0.3 V
Radiator and condenser fan is operating 0.7 V or more
22 Fuel pump relay Ignition switch: ON System voltage
Engine: Idle speed 1 V or less
24 A/C load signal Refer to GROUP 55 - Troubleshooting (Inspection at the Automatic
compressor - ECU Terminal)
33 Alternator G terminal ! Engine: Warm, idle (radiator fan: OFF) Voltage increases by 0.2 "
! Headlamp: OFF & ON 3.5 V
! Stop lamp: OFF & ON
! Rear defogger switch: OFF & ON
36 Engine warming Ignition switch: "LOCK" (OFF) & "ON" 1 V or less & System
lamp voltage (After several
seconds have elapsed)
37 Power steering fluid Engine: Idling after When steering wheel System voltage
pressure switch warming up is Stationary
When steering wheel 1 V or less
is turned
38 Control relay (Power Ignition switch: "LOCK" (OFF) System voltage
supply) Ignition switch: "ON" 1 V or less
41 Alternator FR ! Engine: Warm, idle (radiator fan: OFF) Voltage decreases
terminal ! Headlamp: OFF & ON
! Stop lamp: OFF & ON
! Rear defogger switch: OFF & ON
42 A/C pressure sensor ! Engine: Idling When A/C is "MAX, 2.2 V or more
! A/C switch: ON COOL" condition
(when the load by
A/C is high)
When A/C is "MAX, 1.8 V or less
HOT" condition (when
the load by A/C is
low)

No.
45 A/C switch Engine: Idle speed Turn the A/C switch 0.5 V or less
OFF
Turn the A/C switch System voltage
ON (A/C compressor
is operating)
54 Oxygen sensor Engine: Idling after warming up 1 V or less
heater (rear) Engine r/min:Racing System voltage
58 Tachometer signal Engine r/min: 3,000 r/min 0.3 " 3.0 V
60 Oxygen sensor Engine: Idling after warming up 1 V or less
heater (front) Engine r/min:5,000 r/min System voltage
71 Ignition switch " ST Engine: Cranking 8 V or more
72 Intake air Ignition switch: "ON" When intake air 3.8 " 4.4 V
temperature sensor temperature is "20%C
When intake air 3.2 " 3.8 V
temperature is 0%C
temperature is 20%C
temperature is 40%C
temperature is 60%C
temperature is 80%C
75 Oxygen sensor Engine: Idling after warmed up (Check using 0 ' 0.6 V (Changes
(rear) a digital type voltmeter) repeatedly)
76 Oxygen sensor Engine: Running at 2,500 r/min after warmed 0 ' 0.8 V (Changes
(front) up (Check using a digital type voltmeter) repeatedly)
80 Backup power Ignition switch: "LOCK" (OFF) System voltage
supply
81 Sensor impressed Ignition switch: "ON" 4.9 " 5.1 V
voltage
82 Ignition switch " IG Ignition switch: "ON" System voltage
83 Engine coolant Ignition switch: "ON" When engine coolant 3.9 " 4.5 V
temperature sensor temperature is "20%C
When engine coolant 3.2 " 3.8 V
temperature is 0%C
temperature is 20%C
temperature is 40%C
temperature is 60%C
temperature is 80%C
TROUBLESHOOTING
13A-297
No.
84 Throttle position Ignition switch: "ON" Set throttle valve to 0.535 " 0.735 V
sensor idle Position
Fully open throttle 4.4 " 5.3 V
valve
85 Barometric pressure Ignition switch: "ON" Altitude: 0 m 3.8 " 4.2 V
sensor Altitude: 600 m 3.5 " 3.9 V
Altitude: 1,200 m 3.3 " 3.7 V
Altitude: 1,800 m 3.0 " 3.4 V
86 Vehicle speed ! Ignition switch: "ON" 0 ' 5 V Changes
sensor ! Move the vehicle forword slowly repeatedly
88 Camshaft position Engine: Cranking 0.4 " 3.0 V
sensor Engine: Idling 1.5 " 3.0 V
89 Crank angle sensor Engine: Cranking 0.4 " 4.0 V
Engine: Idling speed 1.5 " 2.5 V
90 Air flow sensor Engine: Idle speed 2.2 " 3.2 V
Engine r/min: 2,500 r/min
CHECK CHART FOR RESISTANCE AND CAUTION

CONTINUITY BETWEEN TERMINALS If the terminals that should be checked are mis-
1. Turn the ignition switch to "LOCK" (OFF) position. taken, or if connector terminals are not correctly
2. Disconnect the engine-ECU connector. shorted to earth, damage may be caused to the
3. Measure the resistance and check for continuity vehicle wiring, sensors, engine-ECU and/or ohm-
between the terminals of the engine-ECU meter. Be careful to prevent this!
harness-side connector while referring to the 4. If the ohmmeter shows any deviation from the
check chart. standard value, check the corresponding sensor,
actuator and related electrical wiring, and the
NOTE: .
repair or replace.
1. When measuring resistance and checking
5. After repair or replacement, recheck with the
continuity, a harness for checking contact pin
ohmmeter to confirm that the repair or
pressure should be used instead of inserting a
replacement has corrected the problem.
test probe.
2. Checking need not be carried out in the order
given in the chart.
Engine-ECU Harness Side Connector Terminal Arrangement

Engine-ECU Harness Side Connector
C-137 C-136 C-135 C-134
8180 79 78 77 76 75 74 73 72 71 56 55 54 53 52 51 38 37 36 35 34 33 32 31 13 12 11 10 9 8 7 6 5 4 3 2 1
92 91 90 89 88 87 86 85 84 83 82 62 61 60 59 58 57 46 45 44 43 42 41 40 39 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300343 AB
Terminal Inspection item Normal condition (Check condition)

No.
1 " 12 No. 1 injector 13 " 16 $ (At 20%C)
12 " 14 No. 2 injector
4 " 12 Stepper motor coil (A1) 26 " 33 $ (At 20%C)
12 " 17 Stepper motor coil (A2)
5 " 12 Stepper motor coil (B1)
12 " 18 Stepper motor coil (B2)
6 " 12 EGR control solenoid valve 29 " 35 $ (At 20%C)
9 " 12 Purge control solenoid valve 29 " 35 $ (At 20%C)
12 " 54 Oxygen sensor heater(rear) 11 " 18 $ (At 20%C)
12 " 60 Oxygen sensor heater(front) 4.5 " 8.0 $ (At 20%C)
13 " Body ECU earth Continuity (0 $)
earth
26 " Body
earth
81 " 83 Engine coolant temperature sensor 14 " 17 k$ (When coolant temperature is "20%C)
5.1 " 6.5 k$ (When coolant temperature is 0%C)
72 " 81 Intake air temperature sensor 13 " 17 k$ (When intake air temperature is "20%C)
5.3 " 6.7 k$ (When intake air temperature is 0%C)
INSPECTION PROCEDURE USING the oscilloscope.

OSCILLOSCOPE
M1131154500479
The output signals of the sensors and the conditions
of the actuation signals of the actuators can be
inspected visually by observing the waveforms on
TROUBLESHOOTING
13A-299
AIR FLOW SENSOR 2. Connect the oscilloscope special patterns pickup
Measurement Method to air flow sensor connector terminal No. 3.
Alternate Method (Test harness not available)

Oscilloscope
1. Connect the oscilloscope special patterns pickup
1 2 3 4 5 6 7 to engine-ECU terminal No. 90.
Special
patterns Standard Wave Pattern
pickup
Observation conditions
Function Special patterns
Pattern height Low
AK000786 AE Pattern selector Display
1. Disconnect the air flow sensor connector, and Engine speed Idle
connect the special tool Test harness (MB991709)
in between (All terminals should be connected).
Standard wave pattern

(V)
10 The time (cycle time) T is reduced when
T the amount of intake air inereases.
T1 T2 Times T1 and T2 are equal.
Time
0
AK202334 AB
Observation conditions (from conditions above engine is increased by racing.)

(V)
10
T
Time
0
AK202335 AB
Wave Pattern Observation Points

Check that cycle time T becomes shorter and the fre-
quency increases when the engine speed is
increased.
Examples of Abnormal Wave Patterns CAMSHAFT POSITION SENSOR AND

CRANK ANGLE SENSOR
Measurement Method
Camshaft position Oscilloscope
sensor connector
1 2 3 Special patterns
pick-up
AKX01597
1 2
! Example 1 3 Crank angle
Cause of problem sensor connector
AK000840AC
Sensor interface malfunction
1. Disconnect the camshaft position sensor
Wave pattern characteristics connector and connect the special tool Test
Rectangular wave pattern is output even when harness (MB991709) in between (All terminals
the engine is not started. should be connected).
! Example 2 2. Connect the oscilloscope special pattern pickup to
Cause of problem camshaft position sensor terminal No. 2.
Damaged rectifier or vortex generation column 3. Disconnect the crank angle sensor connector and
Wave pattern characteristics connect the special tool Test harness
Unstable wave pattern with non-uniform fre- (MD998478) in between.
quency. However, when an ignition leak 4. Connect the oscilloscope special patterns pickup
occurs during acceleration, the wave pattern to crank angle sensor terminal No. 2.
will be distorted temporarily, even if the air
flow sensor is normal. Alternate Method (Test harness not available)
to engine-ECU terminal No. 88 (When checking
the camshaft position sensor signal wave
pattern).
the crank angle sensor signal wave pattern).
TROUBLESHOOTING
13A-301
Standard Wave Pattern
Observation condition
Pattern height Low
Pattern selector Display
Engine speed Idle
Standard Wave Pattern 2 engine revolutions

(V) (1 camshaft revolution)
The time (cycle time)
75˚ BTDC T is reduced when the
5˚ BTDC
engine speed increases
Crank angle
sensor output
wave pattern
Camshaft position
sensor output
wave pattern
Time
0
TDC: Top dead centre No.1 TDC No.3 TDC No.4 TDC No.2 TDC
AK202336 AB
Wave Pattern Observation Points Wave pattern characteristics

Check that cycle time T becomes shorter when the Rectangular wave pattern is output even when
engine speed increases. the engine is not started.
Examples of Abnormal Wave Patterns
AKX01602
AKX01597
Example 2
Cause of problem
Example 1
Loose timing belt
Cause of problem Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.
INJECTOR Alternate Method (Test harness not available)

Measurement Method 1. Connect the oscilloscope special patterns pickup
to engine- ECU terminal No. 1 (When checking
the No. 1 cylinder).
Oscilloscope
the No. 2 cylinder).
1 2
Special to engine-ECU terminal No. 2 (When checking the
patterns No. 3 cylinder).
pickup
AK101807AC the No. 4 cylinder).
1. Disconnect the injector connector, and then
connect the special tool Test harness set
(MB991348) in between (All terminals should be Observation conditions
connected). Function Special patterns
2. Connect the oscilloscope special patterns pickup Pattern height Variable
to terminal No. 2 of the injector connector.
Variable knob Adjust while viewing the
wave pattern
Engine speed Idle
(V) Point A.
Solenoid back
50 electromotive
force
(Approx.7×10V)
Point B
Injector drive
time
Time
Power
voltage
0 Drive signal: ON Drive signal: OFF
AK202347AB
TROUBLESHOOTING
13A-303
Wave Pattern Observation Points 1. Disconnect the ISC servo connector, and connect
Point A: Height of solenoid back electromotive force the special tool Test harness (MB991709) in
Contrast with standard wave Probable between.
pattern cause 2. Connect the oscilloscope special patterns pickup
to the ISC servo-side connector terminal No. 1,
Solenoid coil back electromotive Short in the No. 3, No. 4 and No. 6 respectively.
force is low or doesn’t appear at injector solenoid
all. Alternate Method (Test harness not available)
Point B: Injector drive time 1. Connect the oscilloscope special patterns pickup
to engine-ECU terminal No. 4, connection
terminal No. 5, connection terminal No. 17, and
connection terminal No. 18 respectively.

Observation conditions
Pattern height High
When idling Pattern selector Display
When racing AKX01605AE
Engine condition When the engine coolant
The injector drive time will be synchronized with the temperature is 20%C or
MUT-II tester display. below, turn the ignition
! When the engine is suddenly raced, the drive switch from LOCK (OFF)
time will be greatly extended at first, but the drive position to ON (without
time will soon match the engine speed. starting the engine).
While the engine is
IDLE SPEED CONTROL (ISC) SERVO idling, turn the A/C
(STEPPER MOTOR) switch to ON.
Measurement Method Immediately after
starting the warm
Oscilloscope engine.
1 2 3
4 5 6
Special
patterns
pickup
AK300344AB
(V) The wave pattern

appears for an
instant, but soon Point B
Point A
disappears. Coilreverse electromotive
30 Induced electromotive force
force (Approx.3x10V)
from the motor turning
Stepper 20
motor
control
signal
wave 10
pattern
Time
AK201857 AB
Wave pattern Observation Points

Check that the standard wave pattern appears when Example 1
the stepper motor is operating. Cause of problem
Point A: Presence or absence of induced electromo- Motor is malfunctioning. (Motor is not operating.)
tive force from the motor turning (Refer to the abnor-
mal wave pattern).
Induced electromotive force from the motor turn-
Contrast with standard wave Probable ing does not appear.
pattern cause
Induced electromotive force does Motor is Open
not appear or is extremely small. malfunctioning circuit
side
Point B: Height of coil reverse electromotive force
Contrast with standard wave Probable
pattern cause
Coil reverse electromotive force Short in the
does not appear or is extremely coil Normal
side
small. AKX01609AF
Example 2
Examples of Abnormal Wave Pattern
Cause of problem
Open circuit in the line between the stepper
motor and the engine-ECU.
Current is not supplied to the motor coil on the
open circuit side (Voltage does not drop to 0
V).
Furthermore, the induced electromotive force
waveform at the normal side is slightly differ-
ent from the normal waveform.
AKX01608AE
TROUBLESHOOTING
13A-305
IGNITION COIL AND POWER TRANSIS- 2. Connect the oscilloscope special patterns pickup
TOR to terminal No. 3 of each ignition coil connector in
turn.
Measurement Method
Oscilloscope 1. Connect the oscilloscope special patterns pickup
to engine-ECU terminal No. 10 (No. 1 " No. 4),
connection terminal No. 23 (No. 2 " No.3)
1 2 3 respectively.
Special
patterns Standard Wave Pattern
pickup
AK300345 AB Pattern height Low
1. Disconnect the ignition coil connector, and Pattern selector Display
connect the special tool Test harness set
Engine r/min Approximately. 1,200
(MB991348) in between (All terminals should be
r/min
connected).
(V)
6 T
5˚ BTDC
4 75˚ BTDC
Crank angle Compression top dead center
sensor output 2
wave pattern
0
Power transistor T1
2 Ignition period
control signal
wave pattern
0
OFF ON
Dwell section
T : Revolution time corresponding to a crank angle of 180˚

T1 : Time computed by the engine-ECU
: Spark advance angle
AK204435 AC
Wave Pattern Observation Points Condition of wave pattern Probable cause

Point: Condition of wave pattern build-up section and build-up section and
maximum voltage (Refer to abnormal wave pattern maximum voltage
examples 1 and 2).
Rises from approximately. 2 V Normal
to approximately 4.5 V at the
top-right
2 V rectangular wave Open-circuit in
ignition primary
circuit
Rectangular wave at power Power transistor
voltage malfunction

Normal wave pattern
VB
Normal wave pattern
2V
AKX01613AD
AKX01612AD
Example 2
Example 1 Wave pattern during engine cranking
Wave pattern during engine cranking Cause of problem
Cause of problem Malfunction in power transistor
Open-circuit in ignition primary circuit Wave pattern characteristics
Wave pattern characteristics Power voltage results when the power transistor
Top-right part of the build-up section cannot be is ON.
seen, and voltage value is approximately 2 V
too low.
ON-VEHICLE SERVICE
THROTTLE BODY (THROTTLE VALVE 5. Adjust the basic idle speed (Refer to +,13A!"#%).
AREA) CLEANING
M1131001000332 THROTTLE POSITION SENSOR
1. Remove the air intake hose from the throttle body. ADJUSTMENT
2. Spray cleaning fluid on a clean cloth. M1131001100414
CAUTION
Throttle position
! Do not spray the cleaning fluid directly to the sensor
throttle valve.
! Make sure the cleaning fluid does not enter
the motor from the bypass line. Also make
sure it does not enter the sensor through the
shaft.
! Be careful not to rub off the molybden applied
1 2 3 4
around the throttle valve shaft.
Equipment side connector AK300346 AB
1. Connect the MUT-II to the diagnosis connector.

When not using the MUT-II, proceed as follows.
15 mm
15 mm
Throttle position
sensor
Areas on throttle valve to
apply molybdenum disulfide AK000833AD
MB991536
3. Wipe off the dirt around the throttle valve with the
cloth sprayed with cleaning fluid.
4. Attach the air intake hose. AK201752AB
ON-VEHICLE SERVICE
13A-307
(1) Disconnect the throttle position sensor BASIC IDLE SPEED ADJUSTMENT
connector and connect the special tool Test M1131001800468
harness (MB991536) between the CAUTION

disconnected connector taking care not to ! The standard idling speed has been adjusted
confuse the terminal to be connected. by the speed adjusting screw (SAS) by the
(2) Connect digital voltmeter between the terminal manufacturer, and there should usually be no
No. 2 (special tool’s yellow clip on the sensor need for readjustment.
output) and the terminal No. 4 (special tool’s ! If the adjustment has been changed by mis-
red clip on the sensor earth) of the throttle take, the idle speed may become too high or
position sensor connector. the idle speed may drop too low when loads
2. Turn the ignition switch to "ON" position (but do from components such as the A/C are placed
not start the engine). on the engine. If this occurs, adjust by the fol-
3. Check the output voltage of the throttle position lowing procedure.
sensor. ! The adjustment, if made, should be made
after first confirming that the spark plugs, the
Standard value: 535 " 735 mV
injectors, the idle speed control servo, the
compression pressure, etc., are all normal.
1. Before inspection and adjustment, set the vehicle
to the pre-inspection condition.
2. Connect the MUT-II to the diagnosis connector
(16-pin).
NOTE: When the MUT-II is connected, the diag-
nosis control terminal should be earthed.
3. Start the engine and run at idle.
4. Select the item No. 30 of the MUT-II Actuator test.
AK300347AB
NOTE: This holds the ISC servo at the basic step
4. If not within the standard value, loosen the throttle to adjust the basic idle speed.
position sensor mounting bolts. Then rotate the 5. Check the idle speed.
sensor body to adjust. Standard value: 700 # 50 r/min
NOTE: .
6. Remove the MUT-II. If the MUT-II is not used, ! The engine speed may be 20 to 100 r/min
remove the special tool, and then connect the lower than indicated above for a new vehicle
throttle position sensor connector. [driven approximately 500 km or less], but no
7. If a diagnosis code is displayed, erase the adjustment is necessary.
diagnosis code by using the MUT-II or disconnect ! If the engine stalls or the engine speed is low
the negative battery cable from the battery even though the vehicle has been driven
terminal and then leave it for at least 10 seconds. approximately 500 km or more, it is probable
After that, reconnect the battery cable, and then that deposits are adhered to the throttle valve,
let the engine run at idle for approximately 10 so clean it (Refer to !"13A#$%&).
minutes.
AK300348
6. If not within the standard value range, turn the

speed adjusting screw (SAS) to make the
necessary adjustment.
NOTE: If the idling speed is higher than the stand- <When using the fuel pressure gauge set (spe-
ard value range even when the SAS is fully cial tool)>
closed, check whether or not there is any indica- a. Remove the union joint and bolt from the special
tion that the fixed SAS has been moved. If there is tool Adaptor hose (MD998709) and attach the
an indication that it has been moved, adjust the special tool Hose adaptor (MD998742) to the
fixed SAS. adaptor hose.
7. Press the MUT-II clear key, and release the ISC b. Via a gasket, install the special tool Fuel pressure
servo from the Actuator test mode. gauge set (MB991637) into the special tool that
NOTE: Unless the ISC servo is released, the has already assembled as described in (a)
Actuator test mode will continue 27 minutes. above.
8. Turn the ignition switch to "LOCK" (OFF) position. <When using the fuel pressure gauge>
9. Disconnect the MUT-II. a. Remove the union joint and bolt from special tool
10.Start the engine again and let it run at idle speed Adaptor hose (MD998709) and attach the special
for about 10 minutes; check that the idling tool Hose adaptor (MD998742) to the adaptor
condition is normal. hose.
b. Via a suitable O-ring or gasket, install the fuel
FUEL PRESSURE TEST pressure gauge to the special tool that has
M1131001900368
already assembled as described in (a) above.
1. Release residual pressure from the fuel pipe line
to prevent fuel gush out (Refer to +,13A!"'#). Fuel pressure
gauge set
CAUTION
O-ring or gasket
Cover the hose connection with rags to prevent
splash of fuel that could be caused by some MD 998709
residual pressure in the fuel pipe line. Delivery
pipe
MD 998742
High-pressure
fuel hose
AKX01457AF
4. Install the assembled fuel pressure measurement

tools between the fuel rail and fuel high-pressure
hose.
CAUTION
AK300349AB To prevent damage to the MUT-ll, always turn the
2. Disconnect the high-pressure fuel hose at the
before connecting or disconnecting the MUT-ll.
delivery pipe side.
6. Turn the ignition switch to "ON" position (But do
MB 991637 not start the engine).
Gasket 7. Select "Item No. 07" from the MUT-II Actuator test
MD 998709 to drive the fuel pump. Check that there are no
fuel leaks from any parts.
Delivery
pipe 8. Finish the actuator test or turn the ignition switch
MD 998742
to "LOCK" (OFF) position.
High-pressure
fuel hose 9. Start the engine and run at idle.
10.Measure fuel pressure while the engine is running
AKX01458 AG
at idle.
3. Assemble the fuel pressure measurement tools as Standard value: Approximately. 270 kPa at
follows. cerb idle
ON-VEHICLE SERVICE
13A-309
Standard value: 330 " 350 kPa at cerb idle
12.Check to see that fuel pressure at idle does not
drop even after the engine has been raced several
times.
13.Racing the engine repeatedly, hold the fuel return
hose lightly with fingers to feel that fuel pressure
is present in the return hose.
NOTE: If the fuel flow rate is low, there will be no
fuel pressure in the return hose.
AK300349AB 14.If any of fuel pressure measured in steps 10 to 13
11.Disconnect the vacuum hose from the fuel is out of specification, troubleshoot and repair
pressure regulator and measure fuel pressure according to the table below.
with the hose end closed by a finger.
Symptom Probable cause Remedy
! Fuel pressure too low Clogged fuel filter Replace fuel filter
! Fuel pressure drops after racing Fuel leaking to return side due to Replace fuel pressure regulator
! No fuel pressure in fuel return poor fuel regulator valve seating or
hose settled spring
Low fuel pump delivery pressure Replace fuel pump
Fuel pressure too high Binding valve in fuel pressure Replace fuel pressure regulator
regulator
Clogged fuel return hose or pipe Clean or replace hose or pipe
Same fuel pressure when vacuum Damaged vacuum hose or Replace vacuum hose or clean
hose is connected and when Clogged nipple nipple
disconnected
15.Stop the engine and check change of fuel
pressure gauge reading. Normal if the reading
does not drop within 2 minutes. If it does, observe
the rate of drop and troubleshoot and repair
according to the table below.
Fuel pressure drops gradually after Leaky injector Replace injector
engine is stopped Leaky fuel regulator valve seat Replace fuel pressure regulator
Fuel pressure drops sharply Check valve in fuel pump is held Replace fuel pump
immediately after engine is open
stopped
16.Release residual pressure from the fuel pipe line 18.Replace the O-ring at the end of the fuel high
(Refer to +,13A!"'#). pressure hose with a new one. Furthermore,
CAUTION apply engine oil to the new O-ring before
Cover the hose connection with rags to prevent replacement.
splash of fuel that could be caused by some 19.Fit the fuel high pressure hose over the delivery
residual pressure in the fuel pipe line. pipe and tighten the bolt to specified toque.
17.Remove the fuel pressure gauge and special tool Tightening torque: 8.8 # 1.9 N(m
from the delivery pipe. 20.Check for any fuel leaks by following the
procedure in step 7.
21.Disconnect the MUT-II.
FUEL PUMP CONNECTOR (2) Remove the rear seat assembly (Refer to
DISCONNECTION (HOW TO REDUCE GROUP 52A,Rear Seat Assembly Removal
and Installation +,52A!()).
PRESSURIZED FUEL LINES)
M1131000900558 Service hole cover
WARNING
When removing the fuel pipe, etc., release
fuel pressure to prevent fuel spray.
1. Remove the rear seat assembly (Refer to GROUP
52A " Rear Seat Assembly +,52A!()).
Service hole cover
AC102784 AB
(3) Remove the service hole cover.
AC102784 AB
2. Remove the service hole cover.
Fuel pump assembly <2WD>

or fuel tank pump and gauge assembly <4WD>
connector AC101011AE
(4) Disconnect the fuel pump assembly <2WD> or

the fuel tank pump and gauge assembly
<4WD> connector.
Fuel pump assembly <2WD> or
fuel tank pump and gauge assembly <4WD>
1 2 3
connector
AC101011AD 4 5
3. Disconnect the fuel pump assembly connector

<2WD> or fuel tank pump and gauge assembly
connector <4WD>.
4. After starting the engine and letting it run until it
stops naturally, turn the ignition switch to the
"LOCK" (OFF) position. AC101012 AD
5. Connect the fuel pump assembly connector
(5) When the fuel pump drive connector is
<2WD> or fuel tank pump and gauge assembly
attached directly to the battery, check if the
connector <4WD>.
sound of the fuel pump operation can be
6. Install the service hole cover and rear seat heard. If no operating sound is heard, replace
assembly (Refer to GROUP 52A " Rear Seat the fuel tank pump (Refer to GROUP 13A,
Assembly +,52A!()). Fuel Pump Module Disassembly and
Assembly +,52A!()).
FUEL PUMP OPERATION CHECK
M1131002000584 NOTE: As the fuel pump is an in-tank type, the
1. Check the operating of the fuel pump by MUT-II to fuel pump sound is hard to hear. Remove the
force-drive the fuel pump. fuel tank filler tube cap and check from the tank
2. If the fuel pump will not operate, check by using inlet.
the following procedure. If normal, check the fuel (6) Check for fuel pressure by pinching the fuel
pump drive circuit. hose with fingertips.
(1) Turn the ignition switch to the "LOCK" (OFF)
position.
ON-VEHICLE SERVICE
13A-311
(7) Connect the fuel pump assembly <2WD> or (8) Install the service hole cover and rear seat
the fuel tank pump and gauge assembly assembly (Refer to GROUP 52A, Rear Seat
<4WD> connector. Assembly Removal and Installation P.52A-25).
COMPONENT LOCATION
M1131002100622
Name Symbol Name Symbol

Air flow sensor G Engine-ECU T
(with intake air temperature sensor and Engine warming lamp Q
barometric pressure sensor) (check engine lamp)
A/C relay O Fuel pump relay (1) and (2) P
A/C switch S Idle speed control servo F
A/C pressure sensor A Ignition coil I
Camshaft position sensor L Injector D
Crank angle sensor C Oxygen sensor (front) K
Detonation sensor H Oxygen sensor (rear) U
Diagnosis connector R Power steering fluid pressure switch B
EGR control solenoid valve J Purge control solenoid valve J
Engine control relay O Throttle position sensor E
Engine coolant temperature sensor M Vehicle speed sensor N
A B C D E F G
H I J K L M N O
P Q R S T U
AK300351 AB
ENGINE CONTROL RELAY CONTINUITY INTAKE AIR TEMPERATURE SENSOR

CHECK CHECK
M1131050000185 M1131002800364
Intake air
Relay box’s temperature
triangle marks Engine control relay sensor
1 2
3 4
1 2 3 4 5 6 7
Equipment side Equipment side connector
Tester Battery Voltage Normal 1. Disconnect the air flow sensor connector.
Connectio State 2. Measure resistance between terminals No. 5 and
n Terminal No. 6.
2"3 No Voltage Continuity Standard value:
13 " 17 k$ (at "20%C)
1"4 No Voltage No continuity
5.3 " 6.7 k$ (at 0%C)
Voltage (Connect Continuity 2.3 " 3.0 k$ (at 20%C)
positive (+) terminal of 1.0 " 1.5 k$ (at 40%C)
battery to terminal No. 3 0.56 " 0.76 k$ (at 60%C)
and negative (") 0.30 " 0.42 k$ (at 80%C)
terminal of battery to
3. Remove the air flow sensor
terminal No. 2.)
FUEL PUMP RELAY CONTINUITY CHECK

M1131033000193 Intake air temperature
sensor
Junction block’s
triangle marks
Fuel pump
relay (1)
1 2
Fuel pump 3 4
relay (2) AKX01621AD
Equipment side
connector
4. Measure resistance while heating the sensor
AK300353 AB using a hair drier.
Normal condition:
Tester Battery Voltage Normal
Temperature (%C) Resistance (k$)
Connectio State
n Terminal Higher Smaller
2-3 No Voltage Continuity 5. If the value deviates from the standard value or
the resistance remains unchanged, replace the air
1-4 No Voltage No continuity
flow sensor assembly.
Voltage (Connect Continuity 6. Install the air flow sensor and tighten it to the
positive (+) terminal of specified torque.
battery to terminal No. 3
Tightening torque: 8.8 # 1 N(m
and negative (")
terminal No. 2.)
ON-VEHICLE SERVICE
13A-313
ENGINE COOLANT TEMPERATURE 4. Apply sealant to threaded portion.
SENSOR CHECK Specified sealant:
M1131003100335 3M NUT Locking Part No. 4171 or equivalent
CAUTION 5. Install the engine coolant temperature sensor and
Be careful not to touch the connector (resin sec- tighten it to the specified torque.
tion) with the tool when removing and installing.
Tightening torque: 29 # 10 N(m
THROTTLE POSITION SENSOR CHECK

1 2 M1131003200398
Throttle position
sensor
AK300355
1. Remove the engine coolant temperature sensor. 1 2 3 4

1. Disconnect the throttle position sensor connector.

2. Measure the resistance between the throttle
position sensor side connector terminal No. 1 and
terminal No. 4.
Standard value: 3.5 " 6.5 k$
3. Measure the resistance between the throttle
position sensor side connector terminal No. 2 and
AKX01622
terminal No. 4.
2. With temperature sensing portion of engine Normal condition:
coolant temperature sensor immersed in hot Throttle valve slowly Changes smoothly in
water, check resistance. open until fully open from proportion to the opening
Standard value: the idle position angle of the throttle valve
14 " 17 k$ (at "20%C) 4. If the resistance is outside the standard value, or if
5.1 " 6.5 k$ (at 0%C) it doesn’t change smoothly, replace the throttle
2.1 " 2.7 k$ (at 20%C) position sensor.
0.9 " 1.3 k$ (at 40%C) NOTE: For the throttle position sensor adjustment
0.48 " 0.68 k$ (at 60%C) procedure, refer to !"13A#$%&.
0.26 " 0.36 k$ (at 80%C)
3. If the resistance deviates from the standard value OXYGEN SENSOR CHECK
M1131005000497
greatly, replace the sensor.
1 2
3 4
AKX01623AD
1. Disconnect the oxygen sensor connector and CAUTION

connect the special tool Test harness ! Be very careful when connecting the jumper
(MD998464) to the connector on the oxygen wire; incorrect connection can damage the
sensor side. oxygen sensor.
2. Make sure that there is continuity (4.5 " 8.0 $ at ! Be careful the heater is broken when voltage
20%C) between terminal No. 1 (red clip of special of beyond 8V is applied to the oxygen sensor
tool) and No. 3 (blue clip of special tool) on the heater.
oxygen sensor connector. NOTE: If the sufficiently high temperature (of
3. If there is no continuity, replace the oxygen approximate 400%C or more) is not reached
sensor. although the oxygen sensor is normal, the output
4. Warm up the engine until engine coolant is 80%C voltage would be possibly low although the rich
or higher. air-fuel ratio. Therefore, if the output voltage is
5. Perform a tracing for 5 minutes or more with the low, use a jumper wire to connect the terminal
engine speed of 4,500 r/min. No.1 (red clip of special tool) and the terminal No.
3 (blue clip of special tool) of the oxygen sensor
with a (+) terminal and (-) terminal of 8 V power
supply respectively, then check again.
Oxygen
Black sensor 8. If the sensor is defective, replace the oxygen
equipment sensor.
side connector
NOTE: For removal and installation of the oxygen
White
sensor, refer to GROUP 15 " Exhaust Manifold.
!"15#&.
AKX01624 AF
MD998464 Oxygen sensor (rear)
6. Connect a digital voltage meter between terminal
No. 2 (black clip of special tool) and No. 4 (white
clip of special tool). 2 1
7. While repeatedly racing the engine, measure the 4 3
oxygen sensor output voltage. Equipment side
connector
Standard value:
Engine Oxygen Remarks
sensor Oxygen sensor
output connector (rear)
voltage
When 0.6 " 1.0 V If you make the air-fuel
racing the ratio rich by racing the
engine engine repeatedly, a
normal oxygen sensor AK300357 AB
will output a voltage of
0.6 " 1.0 V. 1. Disconnect the oxygen sensor connector and
to the connector on the oxygen sensor side.
2. Make sure that there is continuity (11 " 18 $ at
20%C) between terminal No. 1 and No. 2 on the
oxygen sensor connector.
3. If there is no continuity, replace the oxygen
sensor.
4. Warm up the engine until engine coolant is 80%C
or higher.
5. Perform a tracing for 5 minutes or more with the
engine speed of 4,500 r/min.
ON-VEHICLE SERVICE
13A-315
INJECTOR CHECK
M1131005200327
Oxygen sensor Check the Operation Sound
Injector
1 2
Equipment side
connector
MB991658
AK000121 AC

No. 3 and No. 4. AK300358 AB
7. While repeatedly racing the engine, measure the
oxygen sensor output voltage. 1. Use a stethoscope to listen to the operation sound
(clicking) of the injectors while the engine is idling
Standard value:
or cranking.
sensor CAUTION
output Beware that the operation sounds of other injec-
voltage tors can be heard even if the injector that is being
inspected might not be operating.
When 0.6 " 1.0 V If you make the air-fuel
2. Verify that the operation sound increases with the
engine speed.
normal oxygen sensor NOTE: If the operating sound cannot be heard,
will output a voltage of inspect the injector actuation circuit.
0.6 " 1.0 V.
Measurement of Resistance between Ter-
CAUTION minals
! Be very careful when connecting the jumper
wire; incorrect connection can damage the 1. Disconnect the injector connector.
oxygen sensor. 2. Measure the resistance between terminals.
! Be careful the heater is broken when voltage Standard value: 10.5 " 13.5 $ (at 20%C)
of beyond 8V is applied to the oxygen sensor 3. Connect the injector connector.
heater.
NOTE: If the sufficiently high temperature (of Check the Injection Condition
approximate 400%C or more) is not reached 1. Following the steps below, bleed out the residual
although the oxygen sensor is normal, the output pressure within the fuel pipe line to prevent flow of
voltage would be possibly low although the rich the fuel (Refer to +,13A!"'#).
air-fuel ratio. Therefore, if the output voltage is 2. Remove the injector.
low, use a jumper wire to connect the terminal 3. Assemble the following special tools as shown in
No.2 and the terminal No. 1 of the oxygen sensor Fig.
with a (+) terminal and (-) terminal of 8 V power ! Injector test set (MD998706)
supply respectively, then check again. ! Injector test harness (MB991607)
8. If the sensor is defective, replace the oxygen ! Injector test adaptor (MD998741)
sensor. ! Clip (MB991608)
NOTE: For removal and installation of the oxygen
sensor, refer to GROUP 15 " Exhaust Pipe and
Main Muffler !"15#'.
High-pressure fuel hose

MD998741
Return hose
MB991607
Pressure regulator
Clip (MB991608) MD998706
Injector
Battery
AK101794 AD
4. Connect the MUT-II to the diagnosis connector. IDLE SPEED CONTROL (ISC) SERVO
5. Turn the ignition switch to "ON" position (But do (STEPPER MOTOR) CHECK
not start the engine). M1131005400417
6. Select "Item No. 07" from the MUT-II Actuator test Check the Operation Sound
to drive the fuel pump.
Mainhose 1 2 3
4 5 6
Equipment side
connector
Return hose
Injector
Idle speed
control servo
AK300359 AB
Battery AK101795 AC
1. Check that the engine coolant temperature is
7. Activate the injector and check the atomized 20%C or below.
spray condition of the fuel. NOTE: Disconnecting the engine coolant temper-
The condition can be considered satisfactory ature sensor connector and connecting the har-
unless it is extremely poor. ness-side of the connector to another engine
8. Stop the actuation of the injector, and check for coolant temperature sensor that is at 20%C or
leakage from the injector’s nozzle. below is also okay.
Standard value: 1 drop or less per minute 2. Check that the operation sound of the stepper
9. Activate the injector without activating the fuel motor can be heard after the ignition is turned to
pump; then, when the spray emission of fuel from the "ON" position (but without starting the engine).
the injector stops, disconnect the special tool and 3. If the operation sound cannot be heard, check the
restore it to its original condition. stepper motor’s activation circuit.
10.Disconnect the MUT-II. If the circuit is normal, it is probable that there is a
malfunction of the stepper motor or of the engine-
ECU.
ON-VEHICLE SERVICE
13A-317
Check the Coil Resistance Operation Check
1 2 3
4 5 6 AKX01626
1. Remove the throttle body.

2. Remove the stepper motor.
3. Connect the special tool Test harness
1 2 3 (MB991709) to the idle speed control servo
4 5 6 connector.
4. Connect the positive (+) terminal of a power
supply (approximately 6 V) to the terminals No. 2
and No. 5.
5. With the idle speed control servo as shown in the
illustration, connect the negative (") terminal of
AKX01561AE
the power supply to each clip as described in the
1. Disconnect the idle speed control servo following steps, and check whether or not a
connector. vibrating feeling (a feeling of very slight vibration
2. Measure the resistance between terminal No. 2 of the stepper motor) is generated as a result of
and either terminal No. 1 or terminal No. 3 of the the activation of the stepper motor.
connector at the idle speed control servo side. (1) Connect the negative (") terminal of the power
Standard value: 28 " 33 $ (at 20%C) supply to the terminal No. 1 and terminal No.
4.
3. Measure the resistance between terminal No. 5
(2) Connect the negative (") terminal of the power
and either terminal No. 6 or terminal No. 4 of the
supply to the terminal No. 3 and terminal No.
connector at the idle speed control servo side.
4.
Standard value: 28 " 33 $ (at 20%C) (3) Connect the negative (") terminal of the power
6.
6.
4.
(6) Repeat the tests in sequence from (5) to (1).
6. If vibration is detected during the test, the stepper
motor can be considered to be normal.
13A-318 INJECTOR
INJECTOR
M1131007100649

! Fuel Discharge Prevention (Refer to +,13A!"'#). ! Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
! Air Cleaner Removal (Refer to GROUP 15, Air Cleaner +,15!").
+,15!"). ! Fuel Leakage Inspection.
3 8.9 ± 1.9 N·m 11 ± 1 N·m

4 8
9
7N
5
6
19 5.0 ± 1.0 N·m
10 15 N
16
N 11 18 14
6,10
7,11 17
2 12
13
16 19
N 15 18
1
Engine Oil
AC300484 AB
Removal steps
1. PCV hose connection REMOVAL SERVICE POINT
2. Injector connector
3. Idle speed control servo connector
<<A>> FUEL DELIVERY PIPE AND FUEL INJEC-
4. Throttle position sensor connector TOR ASSEMBLY REMOVAL
5. Emission control equipment hose CAUTION
connector Do not drop the injector.
>>A<< 6. Fuel high-pressure hose Remove the fuel delivery pipe with the fuel injector
connection assembly attached to it.
7. O-ring
8. Fuel return hose connection INSTALLATION SERVICE POINT
9. Fuel hose
>>A<< 10. Delivery pipe pressure regulator >>A<< FUEL INJECTOR ASSEMBLY/DELIVERY
11. O-ring PIPE PRESSURE REGULATOR/FUEL HIGH-
<<A>> 12. Fuel delivery pipe and fuel injector PRESSURE HOSE INSTALLATION
assembly CAUTION
13. Insulators Do not let the engine oil get into the delivery pipe
>>A<< 14. Fuel injector assembly will be damaged.
15. O-ring
1. Apply a drop of new engine oil to the O-ring.
16. Fuel injector sheets
17. Insulators
18 Fuel injectors
19. Fuel delivery pipe
THROTTLE BODY ASSEMBLY
13A-319
2. Turn the fuel injector assembly. To the right and 4. Tighten the delivery pipe pressure regulator and
left to install to the fuel delivery pipe. Repeat for fuel high-pressure hose to the specified torque.
delivery pipe pressure regulator and fuel high- Tightening torque:
pressure hose. Be careful not to damage the O- 8.9 # 1.9 N(m <Delivery pipe pressure regula-
ring. After installing, check that the item turns tor>
smoothly. 5.0 # 1.0 N(m <Fuel high-pressure hose>
3. If it dose not turn smoothly, the O-ring may be
trapped, remove the item, re-install it into the fuel
delivery pipe and check again.

M1131007700544

! Engine Coolant Draining (Refer to GROUP 14, On-vehicle ! Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
Service " Engine Coolant Replacement +,14!')). +,15!").
! Air Cleaner Removal (Refer to GROUP 15, Air Cleaner ! Engine Coolant Supplying (Refer to GROUP 14, On-vehi-
+,15!"). cle Service " Engine Coolant Replacement +,14!')).
! Accelerator Cable Adjustment (Refer to GROUP 17, On-
vehicle Service " Accelerator Cable Adjustment +,17!").
7
2
5.0 ± 1.0 N·m

1 19 ± 3 N·m
N 8
3
4
5 AC300416AB

1. Accelerator cable connection 6. Emission vacuum hose
2. Throttle position sensor connector connection
3. Idle speed control servo connector 7. Throttle body assembly
4. Water return hose connection >>A<< 8. Throttle body gasket
5. Water feed hose connection
13A-320 THROTTLE BODY ASSEMBLY
INSTALLATION SERVICE POINT Install the throttle body gasket as shown in the illus-
>>A<< THROTTLE BODY GASKET INSTALLA- tration.
TION
CAUTION
Poor idling etc. may result if the throttle body
gasket is installed incorrectly.
Up
Towards front
of vehicle AC200313AB
THROTTLE BODY ASSEMBLY DISASSEMBLY AND REASSEMBLY

M1131009700409
6
2.0 ± 0.5 N·m
2.0 ± 0.5 N·m
4
AK203824 AB

<<A>> >>A<< 1. Throttle position sensor 5. Speed adjusting screw
2. Idle speed control servo 6. O-ring
3. O-ring
<> 4. Throttle body
13A-321
NOTE: . 1. Install the throttle position sensor to the throttle
! The speed adjusting screw is correctly adjusted body as shown in the illustration.
at the factory and should not be removed. 2. Turn the throttle position sensor 90 degrees
! If the speed adjusting screw should happen to counterclockwise to set it, and tighten the screws.
have been removed, carry out speed adjusting
screw adjutment.
DISASSEMBLY SERVICE POINTS Throttle position

Earth
sensor power
<<A>> THROTTLE POSITION SENSOR DISASSE-
BLY
1. Do not disassemble the sensor and motor.
2. Do not clean the sensor and motor by dipping
them into cleaning solvent. Clean them with shop
towel. Throttle position
sensor output
AK200203 AB
<> THROTTLE BODY DISASSEMBLY
1. Do not disassemble the throttle body. 3. Connect an ohmmeter between terminals 2
2. Check if the vacuum port or passage is clogged. (output) and 4 (earth), or between terminals 1
Use compressed air to clean the vacuum (power) and 2 (output).
passage. Then, make sure that the resistance changes
smoothly when the throttle valve is slowly moved
REASSEMBLY SERVICE POINT to the fully open position.
>>A<< THROTTLE POSITION SENSOR (TPS)
INSTALLATION
AK203835 AB
13A-322 ENGINE ECU
ENGINE ECU
M1131033800036
Pre-removal and Post-installation Operation

Cowl Side Trim (RH) Removal and Installation (Refer to
GROUP 52A, Instrument Panel Assembly +,52A!().
5.0 ± 1.0 N·m
1
5.0 ± 1.0 N·m
AC300630AB
REMOVAL STEPS REMOVAL STEPS,-./01203456

1. Engine-ECU connector 2. Engine-ECU
3. Engine-ECU bracket
13B-1
GROUP 13B
00
11
FUEL SUPPLY 12
13
14
CONTENTS
15
GENERAL INFORMATION . . . . . . . . 13B!" FUEL TANK GAUGE UNIT REPLACEMENT
16
<2WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B!#
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13B!" FUEL TANK GAUGE UNIT REPLACEMENT 17
<4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B!$
ON-VEHICLE SERVICE. . . . . . . . . . . 13B!" 21

FUEL TANK . . . . . . . . . . . . . . . . . . . . 13B!#
FUEL PUMP OPERATION CHECK . . . . . . 13B!"
REMOVAL AND INSTALLATION . . . . . . . . 13B!% 22
FUEL GAUGE UNIT CHECK . . . . . . . . . . . 13B!"
FUEL PUMP ASSEMBLY <2WD>, FUEL
FUEL PUMP ASSEMBLY <2WD>, FUEL TANK
TANK PUMP AND GAUGE ASSEMBLY 25
PUMP AND GAUGE ASSEMBLY <4WD>
<4WD> DISASSEMBLY AND REASSEMBLY 13B!&&
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 13B!"
FUEL TANK GAUGE UNIT DISASSEMBLY
26
FUEL GAUGE UNIT REPLACEMENT . . . . 13B!#
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 13B!&'
27
31
32
33
34
35
36
37
42
51
52
54
55
FUEL SUPPLY
13B-2 GENERAL INFORMATION
GENERAL INFORMATION
M1135000100350
! The fuel tank is located under the floor of the rear ! A fuel pump assembly <2WD>, fuel pump and
seats to provide increased protection and a more gauge assembly <4WD> including fuel pump, fuel
luggage space. filter, reservoir and fuel gauge unit, has been
! A fuel tank safety valve assembly has been adopted to lighten weight and improve servicea-
adopted to prevent fuel from leaking out in case bility.
of a collision.
SEALANT
M1135005200017
Item Specified sealant

Service hole cover and floor pan <2WD> 3M# 8513 Grommets windshield sealer (Black)
ON-VEHICLE SERVICE
FUEL PUMP OPERATION CHECK 2. Remove the service hole cover mounting screws
M1135001000118 and remove the service hole cover.
Refer to GROUP 13A " On-vehicle Service, Fuel
Pump Operation Check ()13A!'&*. Fuel pump assembly <2WD>
or fuel tank pump and gauge assembly <4WD>
FUEL GAUGE UNIT CHECK connector
M1135003100296
Refer to GROUP 54A " Combination Meter, On-vehi-
cle Service, Fuel Gauge Unit Check ()54A!## Fuel suction
<2WD>, ()54A!#$ <4WD>. tube <4WD>

TANK PUMP AND GAUGE ASSEMBLY
<4WD> REPLACEMENT
M1135004900240
1. Remove the rear seat cushion assembly (Refer to
GROUP 52A " Rear seat assembly ()52A!"$).
Service hole cover
Fuel return hose

Fuel high-pressure
hose
AC102778AB
3. Disconnect the fuel pump assembly <2WD> or

AC102784 AB fuel tank pump and gauge assembly <4WD>
connector, fuel return hose, fuel high-pressure
hose and fuel suction tube <4WD>.
FUEL SUPPLY
ON-VEHICLE SERVICE
13B-3
CAUTION CAUTION
Fuel tank pump and
gauge assembly
Corresponding side
Fuel high-pressure hose or
fuel pump suction tube <4WD>
Service hole
Float
3 mm
Quick connector
AC107193 AC AC300047AC
For 4WD: Pay attention not to damage the float After connecting the fuel high-pressure hose or
when removing and installing fuel tank pump and fuel pump suction tube <4WD>, slightly pull it to
gauge assembly through the service hole. ensure that it is installed securely. Also confirm
4. Remove the mounting nuts and fuel pump bracket that there is a play approximately 3 mm.
plate, and remove the fuel pump assembly
Fuel pump assembly <2WD>
<2WD>, fuel tank pump and gauge assembly or fuel tank pump and gauge assembly <4WD>
<4WD> from the service hole. connector
5. Install the fuel pump assembly <2WD>, fuel tank
pump and gauge assembly <4WD> to the fuel
tank through the service hole. Fuel suction
tube <4WD>
Fuel pump braket plate
2.5 ± 0.4 N·m
AC107194 AC
6. Install the fuel pump bracket plate to the fuel tank

and tighten the mounting nuts to the specified Fuel return hose
torque. Fuel high-pressure
hose
Tightening torque: 2.5 $ 0.4 N%m AC102778AB
7. Connect the fuel pump assembly <2WD> or fuel

tank pump and gauge assembly <4WD>
Service hole cover
AC102784 AB
FUEL SUPPLY
13B-4 ON-VEHICLE SERVICE
8. Tighten the service hole cover mounting screws CAUTION

and install the service hole cover.
Fuel tank gauge unit
9. Install the rear seat cushion assembly. (Refer to
GROUP 52A " Rear seat assembly ()52A!"$).
FUEL GAUGE UNIT REPLACEMENT

Gauge unit
FUEL TANK GAUGE UNIT
REPLACEMENT <2WD>
M1135001400279
Service hole AC107188AD
GROUP 52A " Rear Seat Assembly ()52A!"$).
Flat-tipped screwdriver
Pay attention not to damage the gauge unit and
the float of the fuel tank gauge unit when with-
drawing it from the service hole.
4. Remove the fuel tank gauge unit mounting nuts
and remove the fuel tank gauge unit from service
hole.
CAUTION
Service hole cover AC107600AC
2. Pry off the service hole cover using a flat-tipped

screwdriver, etc.
Gauge unit
Service hole AC107188AE

the float of the fuel tank gauge unit when insert-
ing it from the service hole.
AC107601AC
2.5 ± 0.4 N·m
harness connector
3. Disconnect the fuel tank gauge unit harness

connector.
AC107602 AC
5. Install the fuel tank gauge unit to the fuel tank

through the service hole, and tighten the mounting
nuts to the specified torque.
Tightening torque: 2.5 $ 0.4 N%m
FUEL SUPPLY
ON-VEHICLE SERVICE
13B-5
Fuel tank gauge unit Service hole cover

harness connector AC107601AC AC107603AC
6. Connect the fuel tank gauge unit harness 2. Remove the service hole cover mounting screws
connector. and remove the service hole cover.
Fuel pump suction tube
Service hole cover

Floor pan Fuel tank gauge

unit harness
connector
AC100961AD AC107189AC
7. Apply the specified sealant to the contact surfaces 3. Disconnect the fuel tank gauge unit harness
of the service hole cover and the floor pan, and connector and fuel pump suction tube.
install the service hole cover. CAUTION
Specified sealant: 3M# 8513 Grommets
Windshield Sealer (Black)
8. Install the rear seat cushion assembly (Refer to
GROUP 52A " Rear Seat Assembly ()52A!"$). Gauge unit
REPLACEMENT <4WD> Service hole
M1135001400280
GROUP 52A " Rear Seat Assembly ()52A!"$). Float
AC107190AD

the float of the fuel tank gauge unit when with-
drawing it from the service hole.
hole.
FUEL SUPPLY
13B-6 ON-VEHICLE SERVICE
CAUTION CAUTION
Main pipe nozzle or

fuel main pipe
Gauge unit
Fuel tank gauge unit fuel pump suction tube
Service hole
3 mm
Float Quick connector
AC107190 AE AC300047AB
Pay attention not to damage the gauge unit and After connecting the fuel high-pressure hose or
the float of the fuel tank gauge unit when insert- fuel pump suction tube, slightly pull it to ensure
ing it from the service hole. that it is installed securely. Also confirm that
there is a play approximately 3 mm.
2.5 ± 0.4 N·m
Fuel tank gauge

unit harness
AC107618AC
connector
AC107189AC
through the service hole, and tighten the mounting 6. Connect the fuel tank pump gauge unit harness
nuts to the specified torque. connector and fuel suction tube.
Tightening torque: 2.5 $ 0.4 N%m Service hole cover
AC107603AC
7. Tighten the service hole cover mounting screws

GROUP 52A " Rear Seat Assembly ()52A!"$).
FUEL SUPPLY
FUEL TANK
13B-7
FUEL TANK
M1135001900401

! Draining Fuel ! Propeller Shaft Installation <4WD> (Refer to GROUP 25,
! Fuel Pump Connector Disconnection (How to Reduce Propeller Shaft ()25!').
Fuel Pressure) (Refer to GROUP 13A " On-vehicle Serv- ! Centre Exhaust Pipe Installation (Refer to GROUP 15,
ice ()13A!'&*). Exhaust Pipe and Main Muffler ()15!+).
! Centre Exhaust Pipe Removal (Refer to GROUP 15, ! Refilling Fuel
Exhaust Pipe and Main Muffler ()15!+). ! Checking for Fuel Leaks
! Propeller Shaft Removal <4WD> (Refer to GROUP 25,
Propeller Shaft ()25!').
<2WD>
8
2.5 ± 0.4 N·m
21
11
8 2.5 ± 0.4 N·m 12
5
15 13
13 15 13
17 22
18 N
2.5 ± 0.4 N·m 4 3
20 N 19
20 N 19
9 2.5 ± 0.4 N·m 13 13 24 2
14
25
1
23
6
26 ± 4 N·m
26 ± 4 N·m 7
AC212356 AB
FUEL SUPPLY
13B-8 FUEL TANK
<4WD>
8
2.5 ± 0.4 N·m
2.5 ± 0.4 N·m 21

16 11
8 12
2.5 ± 0.4 N·m 13 5
15
13 15 13
22
17 N 18 2.5 ± 0.4 N·m
4 3
13 20 N
20 N 19 14 19
13 2
24
10
25 1
23
26 ± 4 N·m 7 AC212516AB
Fuel tank assembly removal Fuel tank assembly removal

steps steps$%&'()*(+,-.
1. Fuel filler hose connection <Fuel >>A<< 11. Fuel high-pressure hose
filler neck side> 12. Fuel return hose
2. Fuel filler neck breather hose 13. Fuel tank hose
connection <Fuel filler neck side> 14. Fuel tank vapour hose 2way valve
3. Main pipe connection 15. Fuel vapour pipe
4. Return pipe >>A<< 16. Fuel pump suction tube <4WD>
5. Fuel vapour pipe <> 17. Fuel tank gauge unit
6. Parking brake cable clamp 18. Gasket
connection <RH side> 19. Fuel tank safety valve
7. Wiring harness clamp connection 20. Gasket
8. Fuel tank gauge unit assembly, fuel 21. Fuel pump bracket plate
pump assembly <2WD>, fuel tank <> 22. Fuel pump assembly <2WD>, fuel
pomp and gauge assembly <4WD> tank pump and gauge assembly
connector connection <4WD>
<<A>> ! Rear differential support member 23. Fuel filler hose
installation nuts and bolts <4WD> 24. Fuel filler neck breather hose
(Refer to GROUP 27B " Rear 25. Fuel tank
Differential Carrier Assembly
()27B!&$).
9. Fuel tank assembly <2WD>
<<A>> 10. Fuel tank assembly <4WD>
FUEL SUPPLY
FUEL TANK
13B-9
<FUEL FILLER NECK>
30
27
28
29
1
26
AC300410AB
Fuel filler neck removal steps Fuel filler neck removal steps$
1. Fuel filler hose connection <Fuel 27. Fuel tank cap
filler neck side> 28. Fuel filler neck
2. Fuel filler neck breather hose 29. Fuel filler neck valve
connection <Fuel filler neck side> 30. Gasket
26. Fuel filler neck protector
FUEL SUPPLY
13B-10 FUEL TANK

<<A>> REAR DIFFERENTIAL SUPPORT MEM- Support the fuel tank assembly securely so that
BER INSTALLATION NUTS AND BOLTS <4WD>/ it does not fall off from the transmission jack.
FUEL TANK ASSEMBLY <4WD> REMOVAL 3. Tilt the fuel tank assembly to disconnect the
Rear differential connectors.
Fuel tank assembly
carrier assembly
Towards front Rear differential
of vehicle carrier assembly
Tilt
Towards front
Lower
Fuel tank assembly AC300043 AB
1. Remove the rear differential support member
installation nuts and bolts, and then tilt the rear 4. Remove the fuel tank assembly to the direction
differential carrier assembly (Refer to GROUP shown, being careful not to strike it against the
27A " Rear Differential Carrier Assembly ()27B! rear differential carrier assembly.
&$).
<> FUEL TANK GAUGE UNIT/FUEL PUMP
ASSEMBLY <2WD>, FUEL TANK PUMP AND
GAUGE ASSEMBLY <4WD> REMOVAL
CAUTION
When withdrawing the fuel tank gauge unit, fuel
tank pump and gauge assembly from the fuel
tank, be careful not damage the module unit and
the float.
Fuel tank assembly
Transaxle jack AC107196 AD INSTALLATION SERVICE POINTS
2. Raise and support the fuel tank assembly with a >>A<< FUEL PUMP SUCTION TUBE <4WD>/FUEL
transmission jack, and remove the mounting nuts HIGH-PRESSURE HOSE INSTALLATION
and bolts. CAUTION
Towards front
of vehicle Rear differential
Fuel tank assembly carrier assembly
Corresponding side
Tilt 3 mm
Quick connector
AC300040 AB AC300047AC
After connecting the fuel high-pressure hose or

fuel pump suction tube <4WD>, slightly pull it to
ensure that it is installed securely. Also confirm
that there is a play approximately 3 mm.
FUEL SUPPLY
FUEL TANK
13B-11
<4WD> DISASSEMBLY AND
REASSEMBLY
M1135004600294
<2WD>
10
1N
N 5 8
6
N 5 4
11
7
AC300077AB
Disassembly steps Disassembly steps$%&'()*(+,-.

1. Gasket 6. Fuel pump tube
2. Fuel tank pump connector 7. Fuel pump bracket
connection 8. Fuel tank pump
3. Fuel pump bracket 9. Fuel tank pump cushion
4. Fuel pump hose >>A<< 10. Fuel tank grommet
>>A<< 5. O-ring 11. Fuel tank filter assembly
FUEL SUPPLY
13B-12 FUEL TANK
<4WD>
4
N 13
2
1N
3 N 8
9 11
N 8 6
7 12
10
14
AC300470AB

1. Gasket 11. Fuel tank pump
2. Fuel tank gauge unit connector 12. Fuel tank pump cushion
connection >>A<< 13. Fuel tank grommet
3. Fuel tank gauge unit 14. Fuel tank filter assembly
4. Fuel tank pump connector
connection REASSEMBLY SERVICE POINT
5. Fuel pump bracket >>A<< FUEL TANK GROMMET/O-RING INSTAL-
6. Fuel pump hose LATION
7. Fuel tank assist pump
Apply gasoline on the grommet and the O-ring before
>>A<< 8. O-ring
9. Fuel tank tube
mounting them to prevent damage or twisting.
10. Fuel pump bracket
FUEL SUPPLY
FUEL TANK
13B-13
FUEL TANK GAUGE UNIT DISASSEMBLY AND REASSEMBLY
M1135051100057
<2WD> <4WD>
3
3
1
1
2
AC102461 AD

1. Gasket 2. Fuel in tank filter <4WD>
3. Fuel tank gauge unit
/0123
13B-1
GROUP 13B
MULTIPORT FUEL
INJECTION (MPI)
<4G69>
CONTENTS
GENERAL INFORMATION . . . . . . . . 13B-2 FUEL PUMP OPERATION CHECK . . . . . . 13B-428

COMPONENT LOCATION . . . . . . . . . . . . . 13B-428
SERVICE SPECIFICATIONS. . . . . . . 13B-6 ENGINE CONTROL RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-429
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13B-6 FUEL PUMP RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-430
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13B-7 THROTTLE VALVE CONTROL SERVO RELAY
CONTINUITY CHECK . . . . . . . . . . . . . . . . . 13B-430
INTAKE AIR TEMPERATURE SENSOR
TROUBLESHOOTING . . . . . . . . . . . . 13B-10 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-430
DIAGNOSIS TROUBLESHOOTING FLOW 13B-10
ENGINE COOLANT TEMPERATURE SENSOR
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 13B-10 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-431
INSPECTION CHART FOR DIAGNOSIS ACCELERATOR PEDAL POSITION SENSOR
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-20 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-431
INSPECTION PROCEDURE FOR DIAGNOSIS ACCELERATOR PEDAL POSITION SWITCH
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-23 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-432
INSPECTION CHART FOR TROUBLE OXYGEN SENSOR CHECK . . . . . . . . . . . . 13B-432
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13B-281
INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13B-435
SYMPTOM PROCEDURES . . . . . . . . . . . . 13B-285
THROTTLE VALVE CONTROL SERVO
CHECK AT THE ECU TERMINALS . . . . . . 13B-411 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-436
INSPECTION PROCEDURE USING OIL CONTROL VALVE CHECK . . . . . . . . . 13B-436
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13B-418
INJECTOR . . . . . . . . . . . . . . . . . . . . . 13B-437
ON-VEHICLE SERVICE. . . . . . . . . . . 13B-425 REMOVAL AND INSTALLATION . . . . . . . . 13B-437
THROTTLE BODY (THROTTLE VALVE AREA)
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . 13B-425
THROTTLE BODY ASSEMBLY . . . . . 13B-438
ACCELERATOR PEDAL POSITION SWITCH AND
REMOVAL AND INSTALLATION . . . . . . . . 13B-438
ACCELERATOR PEDAL POSITION SENSOR (APS)
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13B-425
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13B-426 ENGINE ECU AND
FUEL PUMP CONNECTOR DISCONNECTION ENGINE-A/T-ECU . . . . . . . . . . . . . . . . 13B-439
(HOW TO REDUCE PRESSURIZED FUEL REMOVAL AND INSTALLATION . . . . . . . . 13B-439
LINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-428
13B-2 MULTIPORT FUEL INJECTION (MPI) <4G69>
GENERAL INFORMATION
GENERAL INFORMATION
M1131000101016
The Multipoint Fuel Injection System consists of <A/T> carries out activities such as fuel injection
sensors which detect the engine conditions, the control, idle speed control and ignition timing control.
engine-ECU <M/T> or engine-A/T-ECU <A/T> which In addition, the engine-ECU <M/T> or
controls the system based on signals from these engine-A/T-ECU <A/T> is equipped with several
sensors, and actuators which operate under the diagnosis modes which simplify troubleshooting
control of the engine-ECU <M/T> or engine-A/T-ECU when a problem develops.
<A/T>. The engine-ECU <M/T> or engine-A/T-ECU
FUEL INJECTION CONTROL
The injector drive times and injection timing are mixture by carrying out "open-loop" control when the
controlled so that the optimum air/fuel mixture is engine is cold or operating under high load
supplied to the engine to correspond to the conditions in order to maintain engine performance.
continually-changing engine operation conditions. In addition, when the engine is warm or operating
A single injector is mounted at the intake port of each under normal conditions, the engine-ECU <M/T> or
cylinder. Fuel is sent under pressure from the fuel engine-A/T-ECU <A/T> controls the air/fuel mixture
tank by the fuel pump, with the pressure being by using the oxygen sensor signal to carry out
regulated by the fuel pressure regulator. The fuel "closed-loop" control in order to obtain the theoretical
thus regulated is distributed to each of the injectors. air/fuel mixture ratio that provides the maximum
Fuel injection is normally carried out once for each cleaning performance from the three way catalyst.
cylinder for every two rotations of the crankshaft. The
firing order is 1-3-4-2. This is called sequential fuel
injection. The engine-ECU <M/T> or
engine-A/T-ECU <A/T> provides a richer air/fuel
THROTTLE VALVE OPENING CONTROL

This system electrically controls the opening of the
throttle valve. The engine-ECU <M/T> or
engine-A/T-ECU <A/T> detects the amount of travel
of the accelerator pedal via the accelerator pedal
position sensor, and controls the actuation of the
throttle actuator control motor, which is mounted on
the throttle body, in order to attain the target throttle
valve opening that has been predetermined in
accordance with driving conditions.
IDLE AIR CONTROL

The idle speed is kept at the optimum speed by air conditioning switch is turned off and on while the
controlling the amount of air that passes through the engine is idling, the throttle valve control servo
throttle valve in accordance with changes in idling adjusts the throttle valve passes through air amount
conditions and engine load during idling. according to the engine load conditions to avoid
The engine-ECU <M/T> or engine-A/T-ECU <A/T> fluctuations in the engine speed.
drives the throttle valve control servo to keep the
engine running at the pre-set idle target speed in
accordance with the engine coolant temperature and
A/C and other electrical load. In addition, when the
IGNITION TIMING CONTROL

The power transistor located in the ignition primary engine-ECU <M/T> or engine-A/T-ECU <A/T> from
circuit turns ON and OFF to control the primary the engine speed, intake air volume, engine coolant
current flow to the ignition coil. This controls the temperature and atmospheric pressure.
ignition timing in order to provide the optimum
ignition timing with respect to the engine operating
conditions. The ignition timing is determined by the
MULTIPORT FUEL INJECTION (MPI) <4G69> 13B-3
GENERAL INFORMATION
SELF-DIAGNOSIS FUNCTION
• When an abnormality is detected in one of the • The RAM data inside the engine-ECU <M/T> or
sensors or actuators related to emission control, engine-A/T-ECU <A/T> that is related to the
the engine warning lamp (check engine lamp) sensors and actuators can be read by means of
illuminates as a warning to the driver. the MUT-II/III. In addition, the actuators can be
• When an abnormality is detected in one of the force-driven under certain circumstances.
sensors or actuators, a diagnosis code
corresponding to the abnormality is output.
OTHER CONTROL FUNCTIONS

1. Fuel Pump Control The revolutions of the radiator fan and condenser fan
Turns the fuel pump relay ON so that current is are controlled in response to the engine coolant
supplied to the fuel pump while the engine is temperature and vehicle speed.
cranking or running. 5. Alternator Output Current Control
2. A/C Relay Control Prevents alternator output current from increasing
Turns the compressor clutch of the A/C ON and OFF. suddenly and idle speed from dropping at times
3. Oil Control Valve Control such as when the headlamp are turned on.
The engine-ECU <M/T> or engine-A/T-ECU <A/T> 6. Purge Control Solenoid Valve Control
effects duty cycle control on the engine oil control (Refer to P.17-17, GROUP 17 − Engine And
valve, in accordance with the engine speed. This Emission Control − Evaporative Emission Control
regulates the supply of engine oil to the intake System).
rocker shaft, which switches the cams. 7. EGR Control Solenoid Valve Control
4. Fan Motor Control [Refer to P.17-22, GROUP 17 − Engine And
Emission Control − Exhaust Gas Recirculation
(EGR) System].
GENERAL INFORMATION
Throttle body Throttle bore mm 60
Throttle position sensor Hall element type
Throttle valve control servo DC motor type, having broshes
engine-ECU Identification No. E6T38973
<M/T>
Engine-A/T-E Identification No. E6T41592 <L. H. drive vehicles>
CU <A/T> E6T41593 <R. H. drive vehicles>
Sensors Air flow sensor Heat sensitizing type
Barometric pressure Sensor Semiconductor type
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor Thermistor type
Oxygen sensor Zirconia type
Accelerator pedal position sensor Variable resistor type
Accelerator pedal position switch Contact switch type
Vehicle speed sensor <M/T> Magnetic resistive element type
Inhibitor switch <A/T> Contact switch type
Camshaft position sensor Magneto resistance element type
Crank angle sensor Magneto resistance element type
Detonation sensor Piezoelectric type
Manifold absolute pressure sensor Semiconductor type
Power steering fluid pressure switch Contact switch type
Actuators Engine control relay type Contact switch type
Fuel pump relay type Contact switch type
Injector type and number Electromagnetic type, 4
Injector identification mark IDH322S
Throttle actuator control motor relay Contact switch type
Oil control valve Duty cycle type solenoid valve
EGR valve Stepper motor
Purge control solenoid valve Duty cycle type solenoid valve
Fuel pressure Regulator pressure kPa 324
regulator
GENERAL INFORMATION
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM

1 Cylinder 1, 4 oxygen Power supply Engine-ECU 1 Oil control valve Engine control relay
sensor (front) Ignition switch-IG <M/T> or 2 Throttle valve Fuel pump relay
2 Cylinder 2, 3 oxygen Ignition switch-ST Engine-A/T- control servo A/C compressor relay
sensor (front) A/C switch ECU <A/T> 3 Injector Throttle valve control
3 Cylinder 1, 4 oxygen A/C load signal Barometric 4 EGR valve servo relay
sensor (rear) A/C pressure pressure (Stepper motor) Ignition coil
4 Cylinder 2, 3 oxygen sensor sensor 5 Purge control solenoid Fan controller
sensor (rear) Power steering valve Engine warning lamp
5 Camshaft position fluid pressure switch Diagnosis output
sensor Alternator FR Alternator G terminal
6 Engine coolant terminal Tachometer
temperature sensor Accelerator pedal Cylinder 1, 4 oxygen
7 Crank angle sensor position switch sensor (front)
8 Detonation sensor Accelerator pedal
9 Throttle position sensor position sensor Cylinder 2, 3 oxygen
(main) (main) sensor (front)
10 Throttle position sensor Accelerator pedal
(sub) position sensor Cylinder 1, 4 oxygen
11 Intake air temperature (sub) sensor (rear)
sensor Vehicle speed
12 Air flow sensor sensor <M/T> Cylinder 2, 3 oxygen
13 Manifold absolute Inhibitor switch sensor (rear)
pressure sensor <A/T>
9 Throttle position sensor (main)

10 Throttle position sensor (sub)
5 Camshaft position sensor
2 Throttle valve 11 Intake air temperature sensor
control servo
2 Cylinder 2, 3 oxygen 13 Manifold absolute
pressure sensor 12 Air flow sensor
sensor (front)
1 Cylinder 1, 4 oxygen
sensor (front)
Air
1 Oil control valve
M
From
fuel pump
4 EGR valve
(stepper motor)
Canister
Catalytic 3 Injector
converter 6 Engine coolant
temperature sensor 5 Purge control
solenoid valve
8 Detonation sensor
7 Crank angle sensor
Catalytic
3 Cylinder 1, 4 oxygen converter
sensor (rear)
4 Cylinder 2, 3 oxygen
sensor (rear) AK302916 AB
M1131000300675
Intake air temperature sensor −20°C 13 − 17
resistance kΩ
0°C 5.3 − 6.7
20°C 2.3 − 3.0
40°C 1.0 − 1.5
60°C 0.56 − 0.76
80°C 0.30 − 0.42
Engine coolant temperature −20°C 14 − 17
sensor resistance kΩ 0°C 5.1 − 6.5
20°C 2.1 − 2.7
40°C 0.9 − 1.3
60°C 0.48 − 0.68
80°C 0.26 − 0.36
Oxygen sensor output voltage (at racing) V 0.6 − 1.0
Oxygen sensor heater front 4.5 − 8.0
resistance (at 20°C) Ω rear 11 − 18
Fuel pressure kPa Approximately. 324 at curb idle
Injector coil resistance (at 20°C) Ω 10.5 − 13.5
Throttle valve control servo coil resistance (at 20°C) Ω 0.3 − 80
Oil control valve (at 20°C) Ω 6.9 − 7.9
SEALANT
M1131000500419

Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent Drying sealant
Threaded portion
SPECIAL TOOLS
SPECIAL TOOLS
M1131000600580

MB991502 MUT-II sub • Reading diagnosis code
assembly • MPI system inspection
• Measurement of fuel pressure
B991502
MB991955 MUT-III sub • Reading diagnosis code

A A: MB991824 assembly • MPI system inspection
B: MB991827 A: Vehicle • Measurement of fuel pressure
C: MB991910 communicatio
D: MB991911 n interface
MB991824 E: MB991825 (V.C.I.)
B F: MB991826 B: MUT-III USB
cable
C: MUT-III main
harness A
MB991827 (Vehicles with
CAN
C
communicatio
DO NOT USED n system)
D: MUT-III main
harness B
MB991910
(Vehicles
D without CAN
communicatio
n system)
E: MUT-III
MB991911 measurement
adapter
E F: MUT-III trigger
harness
MB991825
MB991826
MB991955
MB991348 Test harness set • Measurement of voltage during

troubleshooting
MB991348
SPECIAL TOOLS

MB991709 Test harness • Measurement of voltage during
troubleshooting
• Inspection using an oscilloscope

(4-pin, square) Troubleshooting
• Inspection of oxygen sensor (rear)
MD998464 Test harness • Measurement of voltage during

(4-pin, square) Troubleshooting
• Inspection of oxygen sensor (rear)

Troubleshooting
• Inspection using an oscilloscope
• Inspection of data list
MB991658
MB991223 Harness set • Check at the ECU terminals

A: MB991219 A: Test harness A: Connector pin contact inspection
B: MB991220 B: LED harness B: Power circuit inspection
C: MB991221 C: LED harness C: Power circuit inspection
D: MB991222 adapter D: Commercial tester connection
D: Probe
MB991223
SPECIAL TOOLS

MD998709 Adaptor hose Measurement of fuel pressure
MD998742 Hose adaptor
MB991637 Fuel pressure

gauge set
MB991637
MD998706 Injector test set Checking the spray condition of

injectors
MD998706

harness
MB991607
MD998741 Injector test

adaptor
MD998741

holder assembly
MB991976
TROUBLESHOOTING
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1131150000568
Refer to P.00-6, GROUP 00 − How to Use If an abnormality occurs in any of the following items
Troubleshooting/Inspection Service Points. related to the Multipoint Fuel Injection (MPI) system,
the engine warning lamp will illuminate.
DIAGNOSIS FUNCTION If the lamp remains illuminated or if the lamp
M1131155500212
illuminates while the engine is running, check the
ENGINE WARNING LAMP (CHECK diagnosis code output.
ENGINE LAMP)
Engine warning lamp

(check engine lamp)
AK300251AB
ENGINE WARNING LAMP INSPECTION ITEMS

− Engine-ECU <M/T> or engine-A/T-ECU <A/T>
P0100 Air flow sensor system
P0105 Manifold absolute pressure sensor system
P0110 Intake air temperature sensor system
P0115 Engine coolant temperature sensor system
P0122* Throttle position sensor (main) circuit low input
P0123* Throttle position sensor (main) circuit high input
P0125* Feedback system monitor
P0130 Cylinder 1, 4 oxygen sensor (front) system
P0135 Cylinder 1, 4 oxygen sensor (front) heater system
P0136 Cylinder 1, 4 oxygen sensor (rear) system
P0141 Cylinder 1, 4 oxygen sensor (rear) heater system
P0150 Cylinder 2, 3 oxygen sensor (front) system
P0155 Cylinder 2, 3 oxygen sensor (front) heater system
P0156 Cylinder 2, 3 oxygen sensor (rear) system
P0161 Cylinder 2, 3 oxygen sensor (rear) heater system
P0170 Abnormal fuel system (cylinder 1,4)
P0173 Abnormal fuel system (cylinder 2,3)
P0201 No.1 injector system
TROUBLESHOOTING

P0222* Throttle position sensor (sub) circuit low input
P0223* Throttle position sensor (sub) circuit high input
P0300* Random/multiple cylinder misfire detected
P0301* No.1 cylinder misfire detected
P0325 Detonation sensor system
P0335 Crank angle sensor system
P0340 Camshaft position sensor system
P0403 Exhaust gas recirculation control system
P0421 Warm up catalyst malfunction (cylinder 1,4)
P0431 Warm up catalyst malfunction (cylinder 2,3)
P0443 Purge control solenoid valve system
P0500 Vehicle speed sensor system <M/T>
P0505 Idle speed control (ISC) system
P0513 Immobilizer malfunction
P0551* Power steering fluid pressure switch system
P0606* Engine-ECU <M/T> or engine-A/T-ECU <A/T> main processor malfunction
P0622 Alternator FR terminal system
P0638* Throttle valve control servo circuit range/performance problem
P0642* Throttle position sensor power supply
P0657* Throttle valve control servo relay circuit malfunction
P0705 Inhibitor switch system
P0710 A/T fluid temperature sensor system
P0715* Input shaft speed sensor system
P0720* Output shaft speed sensor system
P0740* Torque converter clutch solenoid valve system
P0750* Low-reverse solenoid valve system
P0755* Underdrive solenoid valve system
P0760* Second solenoid valve system
P0765* Overdrive solenoid valve system
P1010 Oil control valve system
P1602* Communication malfunction (between engine-ECU <M/T> or engine-A/T-ECU <A/T>
main processor and system LSI)
P1603* Battery backup circuit malfunction
P1751* A/T control relay system
P2100* Throttle valve control servo circuit (open)
P2101* Throttle valve control servo magneto malfunction
P2102* Throttle valve control servo circuit (shorted low)
TROUBLESHOOTING

P2103* Throttle valve control servo circuit (shorted high)
P2121* Accelerator pedal position sensor (main) circuit range/performance problem
P2122* Accelerator pedal position sensor (main) circuit low input
P2123* Accelerator pedal position sensor (main) circuit high input
P2126* Accelerator pedal position sensor (sub) circuit range/performance problem
P2127* Accelerator pedal position sensor (sub) circuit low input
P2128* Accelerator pedal position sensor (sub) circuit high input
P2135* Throttle position sensor (main and sub) range/performance problem
P2138* Accelerator pedal position sensor (main and sub) range/performance problem
P2173* Abnormal intake air amount
NOTE: .
• If the engine warning lamp illuminates because of a malfunction of the engine-ECU <M/T> or
engine-A/T-ECU <A/T>, communication between MUT-II/III and the engine-ECU <M/T> or
engine-A/T-ECU <A/T> is impossible. In this case, the diagnosis code cannot be read.
• After the engine-ECU <M/T> or engine-A/T-ECU <A/T> has detected a malfunction, the engine warning
lamp illuminates when the engine is next turned on and the same malfunction is re-detected.However, for
items marked with a "*" in the diagnosis code number column, the engine warning lamp illuminates only
on the first detection of the malfunction.
• After the engine warning lamp illuminates, it will be switched off under the following conditions.
• When the engine-ECU <M/T> or engine-A/T-ECU <A/T> monitored the power train malfunction three
times* met set condition requirements, it detected no malfunction.
*: In this case, "one time" indicates from engine start to stop.
• For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
• Sensor 1 indicates, the sensor mounted at a position closest to the engine, and sensor 2 indicates the
sensor mounted at the position second closest to the engine.
METHOD OF READING AND ERASING 5. Erase the diagnosis codes.

DIAGNOSIS CODES
Refer to P.00-6, GROUP 00 − How to Use INSPECTION USING MUT-II/III DATA LIST
Troubleshooting/Inspection Service Points. AND ACTUATOR TESTING
1. Carry out inspection by means of the data list and
DIAGNOSIS USING DIAGNOSIS 2 CODES the actuator test function, if there is an
1. Switch the diagnosis mode of the engine control abnormality, check and repair the chassis harness
unit to DIAGNOSIS 2 mode using the MUT-II/III. and components.
2. Carry out a road test. 2. After repairing, re-check using the MUT-II/III and
3. Take a reading of the diagnosis code and repair check that the abnormal input and output have
the problem location. returned to normal as a result of the repairs.
4. Turn the ignition switch to OFF and then back to 3. Erase the diagnosis code memory.
ON again. 4. Remove the MUT-II/III, and then start the engine
NOTE: By turning the ignition switch to OFF, the again and carry out a road test to confirm that the
ENGINE-ECU <M/T> or ENGINE-A/T-ECU problem has disappeared.
<A/T> will switch the diagnosis mode from
DIAGNOSIS 2 mode to DIAGNOSIS 1 mode.
TROUBLESHOOTING
FREEZE FRAME DATA The display items of freeze frame data are shown
When the engine-ECU <M/T> or engine-A/T-ECU below.
<A/T> detects a malfunction and stores a diagnosis
code, it also stores a current status of the engine.
This function is called "Freeze frame data". By
analyzing this "Freeze frame" data with the
MUT-II/III, an effective troubleshooting can be
performed.
DISPLAY ITEM LIST

Item No. Data Unit
12 Air flow sensor °C
13 Intake air temperature sensor r/min
21 Engine coolant temperature sensor °C
22 Crank angle sensor r/min
24 Vehicle speed km/h
44 Ignition advance km/h
81 Long-term fuel compensation (cylinder 1, 4) %
82 Short-term fuel compensation (cylinder 1, 4) %
83 Long-term fuel compensation (cylinder 2, 3) %
84 Short-term fuel compensation (cylinder 2, 3) %
(cylinder 1, 4) Closed loop CL
(cylinder 2, 3) Closed loop CL
87 Calculation load value %
8A Throttle position sensor (main) %
− Diagnosis code during data recording -
NOTE: If malfunctions have been detected in
multiple systems, store one malfunction only, which
has been detected first.
TROUBLESHOOTING
DRIVE CYCLE
The following five drive cycle patterns are performed on the diagnosis codes monitored during the vehicle
driving. The vehicle driving requires the patterns to identify the fault. In other words, doing such a drive allows
to regenerate any kind of trouble which involves illuminating the engine warming lamp (check engine lamp)
and to verify the repair procedure has eliminated the trouble [the engine warming lamp (check engine lamp) is
no longer illuminated].
CAUTION
Two technicians should always be in the vehicle when carrying out a test drive.
NOTE: Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the
diagnosis code if it has been output.
DRIVE CYCLE PATTERN LIST
Procedure Monitor item Diagnosis code
1 Catalytic converter monitor P0421, P0431
2 Oxygen sensor (front) monitor P0130, P0150
3 Other monitor P0135, P0136, P0141,
P0155, P0156, P0161,
P0201, P0202, P0203,
P0204, P0300, P0301,
P0302, P0303, P0304,
P0325, P0501, P0551,
P0638
TROUBLESHOOTING
Procedure 1
Catalytic converter monitor
Diagnosis P0421, P0431
code No.
Drive cycle One trip monitor [from start to ignition switch to "LOCK" (OFF) position] will be completed
pattern while traveling with the following drive cycle pattern. It will take 16 minutes or more.
6 minutes or more
90 km/h or more 10 minutes or more

(3)
(4) 55 - 80 km/h
Vehicle
speed (2) (5,6)
Stopping and braking

permitted
(1) (7)
Time
Engine Start Ignition switch :

"LOCK" (OFF)
position
AK301815 AB
Inspection • Atmospheric temperature: −10°C or more

condition
Test 1. Engine: start
procedure 2. Accelerate until the vehicle speed is 90 km/h or more.
3. Travel for 6 minutes or more while keeping the vehicle speed at 90 km/h or more.
4. Decelerate until the vehicle speed is within 80 km/h or less.
5. While traveling at 55 − 80 km/h for 10 minutes or more, fully close the throttle at least
once in 2 minutes and decelerate for 10 seconds or more.
• Do not repeat deceleration too often.
• Vehicle speed may go below 55 km/h after the deceleration.
• Stopping and braking are permitted. (If stopped or drive at 55 km/h or less for more
than 5 minutes the monitoring may be stopped. In this case please restart monitoring
from the beginning.)
6. After completing the above deceleration, bring the vehicle speed back to 55 − 80 km/h
and keep it in the range until starting the deceleration again.
• Repeat the above deceleration at least 5 times.
7. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.
TROUBLESHOOTING
Procedure 2
Oxygen sensor (front) monitor
Diagnosis P0130, P0150
code No.
16 minutes or more
55 - 80 km/h
(3)
Vehicle
speed (2) Stopping and braking
permitted
(1) (4)
Time

"LOCK" (OFF)
position
AK301816AB
Inspection • Engine coolant temperature: After engine warm up

conditions • Atmospheric temperature: −10°C or more
procedure 2. Accelerate until the vehicle speed is 55 − 80 km/h.
3. While keeping the acceleator pedal opening degree constant, keep the vehicle speed at
55 − 80km/h and travel for 16 minutes or more.
• Stopping and braking during this operation are permitted.
4. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.
TROUBLESHOOTING
Procedure 3
Other monitor
Diagnosis P0135, P0136, P0141, P0155, P0156, P0161, P0201, P0202, P0203, P0204, P0300,
code No. P0301, P0302, P0303, P0304, P0325, P0501, P0551, P0638
16 minutes or more
55 km/h or more
(3)
Vehicle (2) 5 minutes or more

speed Engine: Idling
Transmission: Neutral
(1) (4) (5)

Time

"LOCK" (OFF)
position
AK301817AB
Inspection • Engine coolant temperature: After engine warm up

conditions • Atmospheric temperature: −10°C or more
procedure 2. Accelerate until the vehicle speed is 55 km/h.
3. While keeping the acceleator pedal opening degree constant, keep the vehicle speed at
55 km/h and travel for 16 minutes or more.
4. Return the vehicle to the shop.
5. After stopping the vehicle, continue idling for 5 minutes, and then turn the ignition switch
to "LOCK" (OFF) position.
READINESS TEST STATUS In addition, if diagnosis codes are erased or the

The engine-ECU <M/T> or engine-A/T-ECU <A/T> battery cable is disconnected, this history will also be
monitors the following main diagnosis items, judges erased (the memory will be reset).
if these items are in good condition or not, and the • Catalyst: P0421, P0431
stores its history. this history can be read out by • Oxygen sensor: P0130, P0136, P0150, P0156
using MUT-II/III. (If the ECU has judged a item • Oxygen sensor heater: P0135, P0141, P0155,
before, the MUT-II/III displays "Complete"). P0161
TROUBLESHOOTING
FAIL-SAFE FUNCTION REFERENCE TABLE

When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by
means of the pre-set control logic to maintain safe conditions for driving.

Air flow sensor Uses the throttle position sensor signal and engine speed signal (crankshaft
position sensor signal) for basic injector drive time and basic ignition timing from
the pre-set mapping.
Intake air temperature Controls as if the intake air temperature is 25°C°.
sensor
Barometric pressure Controls as if the barometric pressure is 101 kPa.
sensor
Throttle position sensor • Controls the throttle valve position through the use of the throttle position sensor
(main) (sub) signal.
• Renders the amount of accelerator pedal travel as being approximately one-half
the normal opening angle.
• Prohibits the operation of the engine speed feedback control.
• Cuts off fuel when the engine speed exceeds 3,000 r/min.
• Suppresses the engine output by stopping the electronically controlled throttle
valve system if the throttle position sensor (sub) is also malfunctioning.
Throttle position sensor • Controls the throttle valve position through the use of the throttle position sensor
(sub) (main) signal.
• Renders the amount of accelerator pedal travel as being approximately one-half
the normal opening angle.
valve system if the throttle position sensor (main) is also malfunctioning.
Accelerator pedal • Detects the amount of the accelerator pedal travel through the use of the
position sensor (main) accelerator pedal position sensor (sub) signal, but rendering it only as being
approximately one-half the normal opening angle.
valve system if the accelerator pedal position sensor (sub) is also
malfunctioning.
Accelerator pedal • Detects the amount of the accelerator pedal travel through the use of the
position sensor (sub) accelerator pedal position sensor (main) signal, but rendering it only as being
approximately one-half the normal opening angle.
valve system if the accelerator pedal position sensor (main) is also
malfunctioning.
Engine coolant Controls as if the engine coolant temperature is 80°C°. (This control will be
temperature sensor continued until the ignition switch is turned to the "LOCK" (OFF) position even
though the sensor signal returns to normal.)
Camshaft position Injects fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
sensor ignition switch is turned to the "ON" position, the No. 1 cylinder top dead center is
not detected at all.)
Oxygen sensor <front> Air/fuel ratio closed loop control is not performed.
Oxygen sensor <rear> Performs the closed loop control of the air/fuel ratio by using only the signal of the
oxygen sensor (front) installed on the front side of the catalytic converter.
TROUBLESHOOTING

Detonation sensor Switches the ignition timing from ignition timing for high octane to ignition timing for
standard octane fuel.
Ignition coil Cuts off the fuel supply to cylinders with an abnormal ignition.
(incorporating power
transistor)
Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works
as a normal alternator)
Misfiring If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be
shut down.
Throttle valve position • Suppresses the engine output by stopping the electronically controlled throttle
feedback valve system.
Throttle valve control • Suppresses the engine output by stopping the electronically controlled throttle
servo valve system.
Engine-ECU <M/T> or • Suppresses the engine output by stopping the electronically controlled throttle
engine-A/T-ECU <A/T> valve system.
main processor • Prohibits the operation of the engine speed feedback control.
Communication • Renders the amount of accelerator pedal travel as being approximately one-half
between powertrain the normal opening angle.
control module main • Prohibits the operation of the engine speed feedback control.
processor and system • Cuts off fuel when the engine speed exceeds 3,000 r/min.
LSI
Intake air monitor • Suppresses the engine output by stopping the electronically controlled throttle
valve system.
• Prohibits the operation of engine speed feedback.
Oil control valve • Do not switch to high-speed cam.
• Cut off fuel when the engine speed exceeds 5,000 r/min.
TROUBLESHOOTING
INSPECTION CHART FOR DIAGNOSIS CODE

M1131151000776

P0100 Air flow sensor system P.13B-23
P0105 Manifold absolute pressure sensor system P.13B-28
P0110 Intake air temperature sensor system P.13B-37
P0115 Engine coolant temperature sensor system P.13B-44
P0122* Throttle position sensor (main) circuit low input P.13B-51
P0123* Throttle position sensor (main) circuit high input P.13B-55
P0125* Feedback system monitor P.13B-57
P0130 Cylinder 1, 4 oxygen sensor (front) system P.13B-64
P0135 Cylinder 1, 4 oxygen sensor (front) heater system P.13B-70
P0136 Cylinder 1, 4 oxygen sensor (rear) system P.13B-76
P0141 Cylinder 1, 4 oxygen sensor (rear) heater system P.13B-83
P0150 Cylinder 2, 3 oxygen sensor (front) system P.13B-90
P0155 Cylinder 2, 3 oxygen sensor (front) heater system P.13B-97
P0156 Cylinder 2, 3 oxygen sensor (rear) system P.13B-104
P0161 Cylinder 2, 3 oxygen sensor (rear) heater system P.13B-111
P0170 Abnormal fuel system (cylinder 1,4) P.13B-118
P0173 Abnormal fuel system (cylinder 2,3) P.13B-121
P0201 No.1 injector system P.13B-125
P0222* Throttle position sensor (sub) circuit low input P.13B-145
P0223* Throttle position sensor (sub) circuit high input P.13B-149
P0300* Random/multiple cylinder misfire detected P.13B-152
P0301* No.1 cylinder misfire detected P.13B-154
P0325 Detonation sensor system P.13B-166
P0335 Crank angle sensor system P.13B-169
P0340 Camshaft position sensor system P.13B-179
P0403 Exhaust gas recirculation control system P.13B-188
P0421 Warm Up Catalyst Malfunction (cylinder 1,4) P.13B-194
P0431 Warm Up Catalyst Malfunction (cylinder 2,3) P.13B-195
P0443 Purge control solenoid valve system P.13B-196
P0500 Vehicle speed sensor system <M/T> P.13B-201
TROUBLESHOOTING

P0505 Idle speed control (ISC) system P.13B-204
P0513 Immobilizer malfunction P.13B-205
P0551* Power steering fluid pressure switch system P.13B-207
P0606* Engine-ECU <M/T> or engine-A/T-ECU <A/T> main processor P.13B-213
malfunction
P0622 Alternator FR terminal system P.13B-214
P0638* Throttle valve control servo circuit range/performance problem P.13B-218
P0642* Throttle position sensor power supply P.13B-221
P0657* Throttle valve control servo relay circuit malfunction P.13B-222
P0705 Inhibitor switch system • A/T DTC No. 27 (Inhibitor switch P.23A-53,
system: open circuit) P.23A-61
• A/T DTC No. 28 (Inhibitor switch
system: short circuit)
P0710 A/T fluid temperature • A/T DTC No. 15 (A/T fluid temperature P.23A-19,
sensor system sensor system: open circuit) P.23A-25
• A/T DTC No. 16 A/T (fluid temperature
sensor system: short circuit)
P0715* Input shaft speed sensor • A/T DTC No. 22 (Input shaft speed P.23A-28
system sensor system)
P0720* Output shaft speed • A/T DTC No. 23 (Output shaft speed P.23A-37
sensor system sensor system)
P0740* Torque converter clutch • A/T DTC No. 36 (Torque converter P.23A-82
solenoid valve system clutch solenoid valve system)
P0750* Low-reverse solenoid • A/T DTC No. 31 (Low-reverse solenoid P.23A-65
valve system valve system)
P0755* Underdrive solenoid valve • A/T DTC No. 32 (Underdrive solenoid P.23A-70
system valve system)
P0760* Second solenoid valve • A/T DTC No. 33 (Second solenoid P.23A-74
P0765* Overdrive solenoid valve • A/T DTC No. 34 (Overdrive solenoid P.23A-78
P1010 Oil control valve circuit P.13B-229
P1602* Communication malfunction (between engine-ECU <M/T> or P.13B-234
engine-A/T-ECU <A/T> main processor and system LSI)
P1603* Battery backup circuit malfunction P.13B-235
P1751* A/T control relay system • A/T DTC No. 54 (A/T control relay P.23A-89
system)
P2100* Throttle valve control servo circuit (open) P.13B-238
P2101* Throttle valve control servo magneto malfunction P.13B-242
P2102* Throttle valve control servo circuit (shorted low) P.13B-245
P2103* Throttle valve control servo circuit (shorted high) P.13B-248
P2121* Accelerator pedal position sensor (main) circuit range/performance P.13B-251
problem
TROUBLESHOOTING

P2122* Accelerator pedal position sensor (main) circuit low input P.13B-254
P2123* Accelerator pedal position sensor (main) circuit high input P.13B-259
P2126* Accelerator pedal position sensor (sub) circuit range/performance P.13B-262
problem
P2127* Accelerator pedal position sensor (sub) circuit low input P.13B-265
P2128* Accelerator pedal position sensor (sub) circuit high input P.13B-269
P2135* Throttle position sensor (main and sub) range/performance problem P.13B-272
P2138* Accelerator pedal position sensor (main and sub) range/performance P.13B-274
problem
P2173* Abnormal intake air amount P.13B-280
NOTE: .
• Do not replace the engine-ECU <M/T> or engine-A/T-ECU <A/T> until a through terminal check reveals
there are no short/open circuit.
• Check that the engine-ECU <M/T> or engine-A/T-ECU <A/T> earth circuit is normal before checking for
the cause of the problem.
• After the engine-ECU <M/T> or engine-A/T-ECU <A/T> has detected a malfunction, a diagnosis code is
recorded the next time the engine is started and the same malfunction is re-detected. However, for items
marked with "*", the diagnosis code is recorded on the first detection of the malfunction.
TROUBLESHOOTING

DIAGNOSIS CODES
Code No. P0100: Air Flow Sensor System
Air flow sensor circuit
Battery
W-B W-B
4 3
B-17X
1 2 Engine
control
3 4 relay
1 2
R
4
J/C (2)
C-17
12
R
2
B-08
Heat Air flow
sensitizing sensor
1 2 3 4
resistance
3 4
BR
11
J/C (1)
W-R
C-16
6
BR
C-141 63 96 C-142
(MU803804) (MU803805)
6162 6364 9192 939495
656667686970717273 96979899100 101102103 104
747576777879808182 105106 107108109 110111112
8384 858687 8889 113114 115116117 118119120
Engine-ECU <M/T>
Engine-A/T-ECM <A/T>
Wire colour code

AK304118AB
TROUBLESHOOTING
OPERATION YES : Intermittent malfunction (Refer to GROUP

• Power is supplied by the engine control relay 00 − How to Use
(terminal No. 1) to the air flow sensor (terminal Troubleshooting/Inspection Service Points
No. 2), and the air flow sensor (terminal No. 4) is P.00-6).
grounded through the Engine-ECU <M/T> or NO : Go to Step 2 .
Engine-A/T-ECU <A/T> (terminal No. 96).
• The air flow sensor (terminal No. 3) outputs a
sensor signal, which is input into the Engine-ECU
connector
<M/T> or Engine-A/T-ECU <A/T> (terminal No.
63). Connector: B-08
FUNCTION
B-08 (B)
• The air flow sensor outputs amperage that varies
in accordance with the intake air volume.
• The Engine-ECU <M/T> or Engine-A/T-ECU
<A/T> uses the amperage output by the air flow
sensor and the engine speed signal in order to 4 3 2 1
determine the basic injection duration of the Harness
injector. side connector AK303649 AB

Check Conditions
NO : Repair.
• After 3 seconds have passed since the ignition
switch was turned to "ON" position.
STEP 3. Perform voltage measurement at B-08 air
Judgment Criteria
flow sensor connector.
• Air flow sensor output voltage has continued to
be 0.2 V or lower for 2 seconds. Connector: B-17X
Or B-17X
• Air flow sensor output voltage has continued to Relay box’s
be 4.9 V or higher for 2 seconds. triangle marks
PROBABLE CAUSE
• Failed air flow sensor 2 1
• Open/short circuit in air flow sensor circuit or 4 3
loose connector contact Harness
• Failed engine-ECU <M/T> side connector AK304152 AB
• Failed engine-A/T-ECU <A/T> • Disconnect connector, and measure at harness
side.
DIAGNOSIS PROCEDURE • Ignition switch: ON
• Voltage between terminal No. 2 and earth.
STEP 1. MUT-II/III data list OK: System voltage
• Refer to Data list reference table P.13B-401.
a. Item 12: Air flow sensor YES : Go to Step 5 .
TROUBLESHOOTING
STEP 4. Connector check: B-17X engine control STEP 5. Check at B-08 air flow sensor connector.
relay connector Connector: B-08
Connector: B-17X
B-17X B-08 (B)
Relay box’s
triangle marks
2 1
4 3 2 1
4 3 Harness
side connector AK304152 AB
• Disconnect and measure at harness side.
• Resistance between terminal No. 4 and earth.
Connector: B-08
OK: 2 Ω or less
B-08 (B) Q: Is the check result normal?

NO : Go to Step 6 .

4 3 2 1
<M/T> connector or engine-A/T-ECU <A/T>
Harness
connector
Connector: C-142
YES : Check intermediate connector C-17, and <L. H. Drive Vehicle>
flow sensor connector and B-17X (terminal C-142 (GR)
No. 1) engine control relay connector.
• Check power supply line for
open/short circuit.
<R. H. Drive Vehicle>
NO : Repair.
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 7. Check harness between B-08 (terminal NO : Repair.
No. 4) air flow sensor connector and C-142
(terminal No. 96) engine-ECU <M/T> connector or
engine-A/T-ECU <A/T> connector. STEP 8. MUT-II/III data list
• Refer to Data List Reference Table P.13B-401.
Connector: B-08
B-08 (B)
00 − How to Use
P.00-6).
4 3 2 1 NO : Replace engine-ECU <M/T> or
Harness engine-A/T-ECU <A/T>.

Connector: C-142
<L. H. Drive Vehicle> connector.
Connector: C-141
<L. H. Drive Vehicle>
C-142 (GR)
C-141(GR)
C-142 (GR)

C-141 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

6463 62 61
AK304153 AB 7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
NOTE: Before checking harness, check intermediate Harness side connector
AK304154 AB
• Check earthing line for open circuit.
NO : Repair.
TROUBLESHOOTING
STEP 10. Check harness between B-08 (terminal STEP 11. Connector check: B-17X engine control
No. 3) air flow sensor connector and C-141 relay connector
(terminal No. 63) engine-ECU <M/T> connector or Connector: B-17X
engine-A/T-ECU <A/T> connector.
B-17X
Connector: B-08
Relay box’s
triangle marks
B-08 (B)
2 1
4 3
Harness
4 3 2 1 side connector AK304152 AB
Harness
side connector AK303649 AB Q: Is the check result normal?
NO : Repair.
Connector: C-141
No. 2) air flow sensor connector and B-17X
C-141(GR)
Connector: B-08
B-08 (B)
C-141 (GR)
4 3 2 1
Harness
6463 62 61 Connector: B-17X

7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483 B-17X
Harness side connector Relay box’s
triangle marks
AK304154 AB
• Check output line for open/short circuit and

2 1
damage.
4 3
YES : Go to Step 11 . Harness
NO : Repair.
• Check power supply line for damage.
NO : Repair.
TROUBLESHOOTING
STEP 13. MUT-II/III data list STEP 14. Replace air flow sensor.
• Refer to Data List Reference Table P.13B-401. • After replacing the air flow sensor, re-check the
a. Item 12: Air flow sensor trouble symptoms.
YES : Intermittent malfunction (Refer to GROUP YES : Replace the engine-ECU <M/T> or
00 − How to Use engine-A/T-ECU <A/T>.
Troubleshooting/Inspection Service Points NO : Check end.
P.00-6).
Code No. P0105: Manifold Absolute Pressure Sensor System
Manifold absolute pressure sensor circuit
B-103
(MU802723)
Manifold absolute
1 2 3 pressure sensor
3 1 2
Y-B L-B BR
97 101 96
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120
5V
Engine-ECU <M/T>
Engine-A/T-ECU <A/T>
Wire colour code

AK304119AB
OPERATION engine-A/T-ECU <A/T> (terminal No. 96) from the

• A power voltage of 5 V is applied to the manifold manifold absolute pressure sensor (terminal No.
absolute pressure sensor power terminal 2).
(terminal No. 3) from the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (terminal No. 97) and
earthed to the engine-ECU <M/T> or
TROUBLESHOOTING
• The sensor signal is inputted to the engine-ECU YES : Intermittent malfunction (Refer to GROUP
<M/T> or engine-A/T-ECU <A/T> (terminal No. 00 − How to Use
101) from the manifold absolute pressure sensor Troubleshooting/Inspection Service Points
output terminal (terminal No. 1). P.00-6).
NO : Go to Step 2 .
FUNCTION
• The manifold absolute pressure sensor converts
the manifold absolute pressure into a voltage STEP 2. Connector check: B-103 Manifold
signal and inputs the signal to the engine-ECU absolute pressure sensor connector
<M/T> or engine-A/T-ECU <A/T>. Connector: B-103
• In response to the signal, the engine-ECU <M/T>
or engine-A/T-ECU <A/T> corrects the fuel
injection amount, etc. C-103 (B)
TROUBLE JUDGMENT
Check Conditions
3 2 1
• 2 seconds later after the ignition switch has been
in "ON" position or the engine has started up Harness side
connector
• The battery voltage is 8 V or more. AK304038AB
Judgment Criteria Q: Is the check result normal?

• The sensor output voltage is 4.5V or more YES : Go to Step 3 .
(barometric pressure above 114kPa or NO : Repair.
equivalent) for 4 seconds.
Or
STEP 3. Perform voltage measurement at B-103
• The sensor output voltage is 0.2V or less
manifold absolute pressure sensor connector.
(barometric pressure below 53kPa or equivalent)
for 4 seconds. Connector: B-103
PROBABLE CAUSE
• Failed Manifold absolute pressure sensor C-103 (B)
• Open/short circuit in Manifold absolute pressure
• Failed engine-ECU <M/T>
• Failed engine-A/T-ECU <A/T> 3 2 1
Harness side
connector
DIAGNOSIS PROCEDURE AK304038AB
• Disconnect and measure at harness side.

STEP 1. MUT-II/III data list • Ignition switch: ON
• Refer to Data List Reference Table P.13B-401. • Voltage between terminal No. 3 and earth.
a. Item 32: Manifold absolute pressure sensor OK: 4.9 − 5.1 V
NO : Go to Step 4 .
TROUBLESHOOTING
STEP 4. Perform voltage measurement at C-142 STEP 5. Connector check: C-142 engine-ECU
engine-ECU <M/T> connector or engine-A/T-ECU <M/T> connector or engine-A/T-ECU <A/T>
<A/T> connector. connector
<L. H. Drive Vehicle> <L. H. Drive Vehicle>
C-142 (GR) C-142 (GR)
<R. H. Drive Vehicle> <R. H. Drive Vehicle>
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Measure engine-ECU <M/T> or engine-A/T-ECU

Connector: B-103
<A/T> terminal voltage.
• Ignition switch: ON
C-103 (B)
OK: 4.9 − 5.1 V
NO : Go to Step 6 . 3 2 1
Harness side
connector
AK304038AB

(terminal No. 3) manifold absolute pressure
97) engine-ECU <M/T> connector or
• Check power supply line for open
circuit.
NO : Repair.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 3) manifold absolute pressure sensor
connector connector and C-142 (terminal No. 97)
engine-ECU <M/T> connector or engine-A/T-ECU
Connector: C-142
<A/T> connector.
Connector: B-103
C-103 (B)
C-142 (GR)
3 2 1
Harness side
C-142 (GR) connector
AK304038AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB
Q: Is the check result normal? <R. H. Drive Vehicle>

NO : Repair. C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
• Check power supply line for short circuit.

NO : Repair.
STEP 8. MUT-II/III data list

a. Item No. 32: Manifold absolute pressure
sensor
TROUBLESHOOTING

00 − How to Use
connector
P.00-6).
NO : Replace engine-ECU <M/T> or Connector: C-142
engine-A/T-ECU <A/T>. <L. H. Drive Vehicle>

manifold absolute pressure sensor connector.
C-142 (GR)
Connector: B-103
C-103 (B) <R. H. Drive Vehicle>
C-142 (GR)
3 2 1
Harness side
connector
AK304038AB
• Disconnect and measure at harness side. 959493 92 91

104 103102 101100 99 98 97 96
• Ignition switch: ON 112111110 109108107 106105
• Resistance between terminal No. 2 and earth. 120119118 117116115 114113

OK: 2 Ω or less
AK304153 AB
NO : Go to Step 10 . YES : Go to Step 11 .
NO : Repair.
TROUBLESHOOTING
No. 2) manifold absolute pressure sensor
engine-ECU <M/T> connector or C-124 STEP 12. Perform voltage measurement at B-103
engine-A/T-ECU <A/T> connector. manifold absolute pressure sensor connector.
C-103 (B) C-103 (B)
3 2 1 3 2 1
connector connector
AK304038AB AK304038AB
• Use special tool test harness (MB991348) to

Connector: C-142 connect connector and measure at pick-up
<L. H. Drive Vehicle> harness.
OK: 4.9 − 5.1 V
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
• Check earthing line for open circuit and damage.

TROUBLESHOOTING
STEP 13. Connector check: C-142 engine-ECU STEP 14. Perform voltage measurement at B-103
<M/T> connector or engine-A/T-ECU <A/T> manifold absolute pressure sensor connector.
connector Connector: B-103
Connector: C-142
C-103 (B)
C-142 (GR) 3 2 1
Harness side
connector
AK304038AB
<R. H. Drive Vehicle> • Use special tool test harness (MB991348) to

C-142 (GR)
connect connector, and measure at pick-up
harness.
OK:
Altitude 0m: 3.7 − 4.3 V
959493 92 91
104 103102 101100 99 98 97 96
Altitude 600m: 3.4 − 4.0 V
112111110 109108107 106105 Altitude 1,200m: 3.2 − 3.8 V
120119118 117116115 114113
Altitude 1,800m: 2.9 − 3.5 V
Connector: B-103 NO : Go to Step 15 .

C-103 (B) <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-142
3 2 1
Harness side
connector
AK304038AB

YES : Check and repair harness between B-103 C-142 (GR)
(terminal No. 3) manifold absolute pressure
97) engine-ECU <M/T> connector or <R. H. Drive Vehicle>
• Check power supply line for damage. C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

TROUBLESHOOTING
YES : Go to Step 16 . YES : Replace manifold absolute pressure sensor.

NO : Repair. NO : Repair.
STEP 16. Check harness between B-103 (terminal STEP 17. Perform voltage measurement at C-142
No. 1) manifold absolute pressure sensor engine-ECU <M/T> connector or engine-A/T-ECU
connector and C-142 (terminal No. 101) <A/T> connector.
Connector: C-142
<A/T> connector.
Connector: B-103
C-103 (B)
C-142 (GR)
3 2 1
Harness side
connector C-142 (GR)
AK304038AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
C-142 (GR) 120119118 117116115 114113

AK304153 AB

C-142 (GR) • Ignition switch: ON
OK:
Altitude 0m: 3.7 − 4.3 V
Altitude 600m: 3.4 − 4.0 V
Altitude 1,200m: 3.2 − 3.8 V
959493 92 91
104 103102 101100 99 98 97 96 Altitude 1,800m: 2.9 − 3.5 V
112111110 109108107 106105
120119118 117116115 114113
AK304153 AB NO : Go to Step 18 .
• Check output line for short circuit and damage.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> <M/T> connector or engine-A/T-ECU <A/T>
connector connector
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
C-103 (B) C-103 (B)
3 2 1 3 2 1
connector connector
AK304038AB AK304038AB

YES : Check and repair check harness between YES : Go to Step 8 .
B-103 (terminal No. 1) manifold absolute NO : Repair.
(terminal No. 101) engine-ECU <M/T>
connector or engine-A/T-ECU <A/T>
connector.
• Check output line for open circuit and
damage.
NO : Repair.
TROUBLESHOOTING
Code No. P0110: Intake Air Temperature Sensor System
Intake air temperature sensor circuit
B-08
Intake air temperature sensor
(Integrated in air flow sensor)
1 2 3 4
4 1
BR
11
J/C/ (1)
C-16 Y-L
6
BR
96 99
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304120AB
OPERATION • The intake air temperature sensor is a kind of

• A power voltage of 5 V is applied to the intake air resistor, which has characteristics to reduce its
temperature sensor output terminal (terminal No. resistance as the intake air temperature rises.
1) of the air flow sensor connector from the Therefore, the sensor output voltage varies with
engine-ECU <M/T> or engine-A/T-ECU <A/T> the intake air temperature, and becomes lower as
(terminal No. 99). the intake air temperature rises.
• The power voltage is earthed to the engine-ECU
<M/T> or engine-A/T-ECU (terminal No. 96) from TROUBLE JUDGMENT
the air flow sensor (terminal No. 4). Check Conditions
FUNCTION
in "ON" position or the engine has started up.
• The intake air temperature sensor converts the
• The battery voltage is 8 V or more.
intake air temperature into a voltage and inputs
the voltage signal to the engine-ECU <M/T> or Judgment Criteria
engine-A/T-ECU <A/T>. • The sensor output voltage is 4.6V or more (intake
• In response to the signal, the engine-ECU <M/T> air temperature of below -45°C or equivalent) for
or engine-A/T-ECU <A/T> corrects the fuel 4 seconds.
injection amount, etc. Or
TROUBLESHOOTING
• The sensor output voltage is 0.2V or less (intake

air temperature of above 125°C or equivalent) for
4 seconds.
Connector: B-08
PROBABLE CAUSE
• Failed intake air temperature sensor
B-08 (B)
• Open/short circuit in intake air temperature
• Failed engine-A/T-ECU <A/T>
4 3 2 1
DIAGNOSIS PROCEDURE Harness
STEP 1. MUT-II/III data list • Disconnect connector, and measure at harness

• Refer to Data List Reference Table P.13B-401. side.
a. Item 13: Intake air temperature sensor • Voltage between terminal No. 4 and earth.
OK: At ambient temperature (atmospheric OK: 2 Ω or less
temperature) or equivalent. Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP NO : Go to Step 5 .
00 − How to Use
Troubleshooting/Inspection Service Points STEP 5. Connector check: C-142 engine-ECU
P.00-6). <M/T> connector or engine-A/T-ECU <A/T>
NO : Go to Step 2 . connector
Connector: C-142
STEP 2. Connector check: B-08 air flow sensor <L. H. Drive Vehicle>
connector
Connector: B-08
C-142 (GR)
B-08 (B)

4 3 2 1 C-142 (GR)
Harness

NO : Repair. 959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
STEP 3. Check intake air temperature sensor
itself.
AK304153 AB
• Check intake air temperature sensor itself (Refer
to P.13B-430).
NO : Replace air flow sensor.
TROUBLESHOOTING
engine-A/T-ECU <A/T> connector. STEP 7. MUT-II/III data list
Connector: B-08
a. Item No. 13: Intake air temperature sensor
OK: At ambient temperature (atmospheric
B-08 (B) temperature) or equivalent.
00 − How to Use
4 3 2 1 Troubleshooting/Inspection Service Points
Harness P.00-6).
side connector AK303649 AB NO : Replace engine-ECU <M/T> or
engine-A/T-ECU <A/T>.
Connector: C-142
Connector: B-08
C-142 (GR)
B-08 (B)
C-142 (GR)
4 3 2 1
Harness
• Disconnect connector, and measure at harness

side.
959493 92 91 • Ignition switch: ON
104 103102 101100 99 98 97 96
112111110 109108107 106105 • Voltage between terminal No. 1 and earth.
120119118 117116115 114113
Harness side connector OK: 4.5 − 4.9 V

AK304153 AB
YES : Replace engine-ECU <M/T> or
NO : Go to Step 9 .
TROUBLESHOOTING
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
B-08 (B) B-08 (B)
4 3 2 1 4 3 2 1
Harness Harness
side connector AK303649 AB side connector AK303649 AB

<A/T> terminal voltage. YES : Check and repair harness between B-08
• Disconnect B-08 air flow sensor connector. (terminal No. 1) air flow sensor connector
• Ignition switch: ON and C-142 (terminal No. 99) engine-ECU
• Voltage between terminal No. 99 and earth. <M/T> connector or engine-A/T-ECU <A/T>
OK: 4.5 − 4.9 V connector.
• Check output line for open circuit.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 1) air flow sensor connector and C-142
connector (terminal No. 99) engine-ECU <M/T> connector or
Connector: C-142 • Check output line for short circuit.
Connector: B-08
B-08 (B)
C-142 (GR)
<R. H. Drive Vehicle> 4 3 2 1

Harness
C-142 (GR) side connector AK303649 AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 13. Perform voltage measurement at B-08 STEP 14. Connector check: C-142 engine-ECU
air flow sensor connector. <M/T> connector or engine-A/T-ECU <A/T>
Connector: B-08
connector
Connector: C-142
B-08 (B) <L. H. Drive Vehicle>
C-142 (GR)
4 3 2 1
Harness
• Use special tool test harness (MB991709) to <R. H. Drive Vehicle>

connect only terminal No. 1 and No. 4, and then C-142 (GR)
measure at pick-up harness.
OK:
Ambient temperature at −20°C: 3.8 − 4.4 V
Ambient temperature at 0°C: 3.2 − 3.8 V 959493 92 91
104 103102 101100 99 98 97 96
Ambient temperature at 20°C: 2.3 − 2.9 V 112111110 109108107 106105
120119118 117116115 114113
Ambient temperature at 40°C: 1.5 − 2.1 V
AK304153 AB
NO : Go to Step 14 . NO : Repair.
TROUBLESHOOTING
Connector: B-08
B-08 (B)
4 3 2 1
Harness
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
• Check output line for damage.

TROUBLESHOOTING
Code No. P0115: Engine Coolant Temperature Sensor System
Engine coolant temperature sensor circuit
B-108
(MU802406)
Engine coolant
temperature sensor
1 2
2 1
BR Y-G
96 98
C-142
(MU803805)
Engine-ECU <M/T>
9192 939495
96979899100 101102103 104 Engine-A/T-ECU <A/T>
105106 107108109 110111112
113114 115116117 118119120 5V
Wire colour code

AK304121AB
OPERATION • The engine coolant temperature sensor is a kind

• A power voltage of 5 V is applied to the engine of resistor, which has characteristics to reduce its
coolant temperature sensor output terminal resistance as the engine coolant temperature
(terminal No. 1) from the engine-ECU <M/T> or rises. Therefore, the sensor output voltage varies
engine-A/T-ECU <A/T> (terminal No. 98). with the engine coolant temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the engine coolant
<M/T> or engine-A/T-ECU <A/T> (terminal No. temperature rises.
96) from the engine coolant temperature sensor
(terminal No. 2). TROUBLE JUDGMENT
Check Conditions
FUNCTION
• The engine coolant temperature sensor converts
in "ON" position or just after the engine has
the engine coolant temperature into a voltage
started up.
signal, and inputs the voltage to the engine-ECU
<M/T> or engine-A/T-ECU <A/T>. Judgment Criteria
• In response to the signal, the engine-ECU <M/T> • The sensor output voltage is 4.6V or more (water
or engine-A/T-ECU <A/T> controls the fuel temperature of below -45°C or equivalent) for 4
infection amount and the fast idle speed when the seconds.
engine is cold state. Or
TROUBLESHOOTING
• The sensor output voltage is 0.1V or less (water YES : Go to Step 3 .

temperature of above 140°C or equivalent) for 4 NO : Repair.
seconds.
Check Conditions STEP 3. Perform resistance measurement at
• After the engine has started up. B-108 engine coolant temperature sensor
connector.
Judgment Criteria
• The sensor output voltage rises 1.6V or more Connector: B-108
(engine coolant temperature below 40°C or 2 1
equivalent) from 1.6V or less (engine coolant Harness side
temperature above 40°C or equivalent). connector
PROBABLE CAUSE
• Failed engine coolant temperature sensor
B-108 (B)
• Open/short circuit in engine coolant temperature
• Failed engine-ECU <M/T> AK304156 AB
• Failed engine-A/T-ECU <A/T> • Disconnect connector, and measure at sensor
side.
DIAGNOSIS PROCEDURE • Resistance between terminal No. 1 and No. 2.
OK:
STEP 1. MUT-II/III data list Engine coolant temperature at −20°C: 14 − 17
• Refer to Data List Reference Table P.13B-401. kΩ
a. Item 21: Engine coolant temperature sensor Engine coolant temperature at 0°C: 5.1 − 6.5
OK: kΩ
Engine cold state: At ambient temperature Engine coolant temperature at 20°C: 2.1 − 2.7
(atmospheric temperature) or equivalent. kΩ
Engine hot state: At 80 − 120°C Engine coolant temperature at 40°C: 0.9 − 1.3
kΩ
Q: Is the check result normal? Engine coolant temperature at 60°C: 0.48 −
YES : Intermittent malfunction (Refer to GROUP 0.68 kΩ
00 − How to Use Engine coolant temperature at 80°C: 0.26 −
Troubleshooting/Inspection Service Points 0.36 kΩ
P.00-6).
NO : Replace engine coolant temperature
STEP 2. Connector check: B-108 engine coolant sensor.
temperature sensor connector
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK304156 AB

TROUBLESHOOTING
STEP 4. Perform voltage measurement at B-108 STEP 6. Check harness between B-108 (terminal
engine coolant temperature sensor connector. No. 2) engine coolant temperature sensor
Connector: B-108
2 1 engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
Harness side
connector Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK304156 AB
B-108 (B)
• Disconnect connector and measure at harness
side.
AK304156 AB
OK: 2 Ω or less
Connector: C-142
Q: Is the check result normal? <L. H. Drive Vehicle>
NO : Go to Step 5 .
STEP 5. Connector check: C-142 engine-ECU C-142 (GR)

connector
Connector: C-142 C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
NO : Repair.
TROUBLESHOOTING
STEP 7. MUT-II/III data list STEP 9. Perform voltage measurement at C-142

• Refer to Data List Reference Table P.13B-401. engine-ECU <M/T> connector or engine-A/T-ECU
a. Item 21: Engine coolant temperature sensor <A/T> connector.
OK: Connector: C-142
Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
Engine hot state: At 80 − 120 °C
YES : Intermittent malfunction (Refer to GROUP C-142 (GR)
00 − How to Use
P.00-6).
NO : Replace engine-ECU <M/T> or <R. H. Drive Vehicle>
engine-A/T-ECU <A/T>. C-142 (GR)

engine coolant temperature sensor connector.
Connector: B-108
2 1 959493 92 91
104 103102 101100 99 98 97 96
Harness side 112111110 109108107 106105
connector 120119118 117116115 114113

AK304153 AB
B-108 (B) Connector: B-108

2 1
AK304156 AB Harness side
connector
side.
• Voltage between terminal No. 1 and earth. B-108 (B)
OK: 4.5 − 4.9 V
AK304156 AB
YES : Go to Step 13 . • Measure engine-ECU <M/T> or engine-A/T-ECU
NO : Go to Step 9 . <A/T> terminal voltage.
• Disconnect B-108 engine coolant temperature
sensor.
OK: 4.5 − 4.9 V
TROUBLESHOOTING

(terminal No. 1) engine coolant temperature
connector
Connector: C-142 engine-A/T-ECU <A/T> connector.
<L. H. Drive Vehicle> • Check output line for open circuit.
NO : Repair.

C-142 (GR) <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-142
<R. H. Drive Vehicle> <L. H. Drive Vehicle>
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB
Connector: B-108
2 1
Harness side 959493 92 91
connector 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
B-108 (B)
NO : Repair.
TROUBLESHOOTING
No. 1) engine coolant temperature sensor
engine-ECU <M/T> connector or engine-A/T-ECU STEP 13. Perform voltage measurement at B-108
<A/T> connector engine coolant temperature sensor connector.
2 1 2 1
connector connector
B-108 (B) B-108 (B)
AK304156 AB AK304156 AB

Connector: C-142 connect connector, and measure at pick-up
<L. H. Drive Vehicle> harness.
OK:
C-142 (GR) Engine coolant temperature at −20°C: 3.9 − 4.5
V
Engine coolant temperature at 0°C: 3.2 − 3.8 V
Engine coolant temperature at 20°C: 2.3 − 2.9
V
C-142 (GR) Engine coolant temperature at 40°C: 1.3 − 1.9
V
V
V
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113 YES : Go to Step 7 .
AK304153 AB
• Check output line for short circuit.

TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 1) engine coolant temperature sensor
Connector: C-142
<A/T> connector.
Connector: B-108
2 1
Harness side
connector
C-142 (GR)
B-108 (B)
C-142 (GR) AK304156 AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0122: Throttle Position Sensor (Main) Circuit Low Input
Throttle position sensor (main) circuit
(main)
B-06 Hall IC
Electronically
1 2 3 4 5 6 controlled
throttle valve
5 4 3
R W B
106 115 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304122 AB
OPERATION • The Engine-ECU <M/T> or Engine-A/T-ECU

• A power voltage of 5 V is applied to the <A/T> controls the throttle valve position.
electronically controlled throttle valve (terminal
No. 5) from the engine-ECU <M/T> or TROUBLE JUDGMENT
Engine-A/T-ECU <A/T> (terminal No. 106). Check Conditions
• The power voltage is earthed to the engine-ECU • Ignition switch is in "ON" position.
<M/T> or engine-A/T-ECU <A/T> (terminal No.
105) from the electronically controlled throttle Judgment Criteria
valve (terminal No. 3). • Throttle position sensor (main) output voltage is
• The sensor signal is inputted to the engine-ECU 0.35 V or less for 0.5 second.
PROBABLE CAUSE
115) from the electronically controlled throttle
• Failed throttle position sensor (main)
valve output terminal (terminal No. 4).
• Open/short circuit in throttle position sensor
FUNCTION circuit or loose connector contact
• The throttle position sensor converts the throttle • Failed engine-ECU <M/T>
valve position into voltage and inputs it into the • Failed engine-A/T-ECU <A/T>
Engine-ECU <M/T> or Engine-A/T-ECU <A/T>.
TROUBLESHOOTING

NO : Go to Step 4 .

• Refer to Data List Reference Table P.13B-401. STEP 4. Connector check: C-142 engine-ECU
a. Item 79: Throttle position sensor (main) <M/T> connector or engine-A/T-ECU <A/T>
connector
YES : Intermittent malfunction (Refer to GROUP Connector: C-142
00 − How to Use <L. H. Drive Vehicle>
P.00-6).
NO : Go to Step 2 .
C-142 (GR)
STEP 2. Connector check: B-06 electronically

controlled throttle valve connector
Connector: B-06 <R. H. Drive Vehicle>
C-142 (GR)
B-06 (B) 959493 92 91

6 5 4 3 2 1 104 103102 101100 99 98 97 96
112111110 109108107 106105
Harness side connector AK304259 AB 120119118 117116115 114113

NO : Repair.
electronically controlled throttle valve connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1

side.
OK: 4.9 − 5.1 V
TROUBLESHOOTING
STEP 5. Check harness between B-06 (terminal STEP 6. MUT-II/III data list
No. 5) electronically controlled throttle valve • Refer to Data List Reference Table P.13B-401.
connector and C-142 (terminal No. 106) a. Item 79: Throttle position sensor (main)
engine-ECU <M/T> or engine-A/T-ECU <A/T>
connector. YES : Intermittent malfunction (Refer to GROUP
Connector: B-06 00 − How to Use
P.00-6).
NO : Replace engine-ECU <M/T> or
B-06 (B) STEP 7. Connector check: C-142 engine-ECU

6 5 4 3 2 1 <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)

C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
959493 92 91
112111110 109108107 106105
104 103102 101100 99 98 97 96
120119118 117116115 114113
112111110 109108107 106105
120119118 117116115 114113 Harness side connector
AK304153 AB
• Check power supply line for open/short circuit. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
No. 5) electronically controlled throttle valve No. 4) electronically controlled throttle valve
connector and C-142 (terminal No. 106) connector and C-142 (terminal No. 115)
engine-ECU <M/T> connector or engine-A/T-ECU engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector. <A/T> connector.
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Check power supply line for damage. • Check output line for open/short circuit and
damage.
NO : Repair.
STEP 10. Replace the electronically controlled

throttle valve
• After replacing the electronically controlled
throttle valve, re-check the trouble symptoms.
YES : Check end.
TROUBLESHOOTING
Code No. P0123: Throttle Position Sensor (Main) Circuit High Input
Throttle position sensor (main) circuit
(main)
B-06 Hall IC
Electronically
throttle valve
5 4 3
R W B
106 115 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304122 AB

engine-A/T-ECU <A/T> (terminal No. 106). Check Conditions
valve (terminal No. 3). • Throttle position sensor (main) output voltage is
• The sensor signal is inputted to the engine-ECU 4.8 V or more for 0.5 second.
PROBABLE CAUSE
• Failed throttle position sensor (main)
• Open/short circuit in throttle position sensor
TROUBLESHOOTING

NO : Go to Step 4 .

a. Item 79: Throttle position sensor (main) <M/T> connector or engine-A/T-ECU <A/T>
connector
P.00-6).
NO : Go to Step 2 .
C-142 (GR)

C-142 (GR)
B-06 (B) 959493 92 91

6 5 4 3 2 1 104 103102 101100 99 98 97 96
112111110 109108107 106105

NO : Repair.
STEP 3. Perform resistance measurement at B-06
Connector: B-06
B-06 (B)
6 5 4 3 2 1

side.
OK: 2 Ω or less
TROUBLESHOOTING
No. 3) electronically controlled throttle valve
engine-ECU <M/T> connector or engine-A/T-ECU STEP 6. MUT-II/III data list
<A/T> connector. • Refer to Data List Reference Table P.13B-401.
a. Item 79: Throttle position sensor (main)
Connector: B-06
00 − How to Use
P.00-6).
B-06 (B) engine-A/T-ECU <A/T>.
6 5 4 3 2 1
throttle valve
Connector: C-142
<L. H. Drive Vehicle> throttle valve, re-check the trouble symptoms.
YES : Check end.
NO : Replace the engine-ECU <M/T> or
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

Code No. P0125: Feedback System Monitor
OPERATION Refer to Code No. P0204 No. 4 Injector System

• Refer to Code No. P0201 No. 1 Injector System P.13B-140.
P.13B-125. • Refer to Code No. P0130 Cylinder 1, 4 Oxygen
Refer to Code No. P0202 No. 2 Injector System Sensor (Front) Circuit P.13B-64.
P.13B-130. • Refer to P0150 Cylinder 2, 3 Oxygen Sensor
Refer to Code No. P0203 No. 3 Injector System (Front) Circuit P.13B-70.
P.13B-135.
TROUBLESHOOTING
FUNCTION YES : Inspection chart for diagnosis code (Refer

• The engine-ECU <M/T> or engine-A/T-ECU to P.13B-20).
<A/T> effects air-fuel ratio feedback control in NO : Go to Step 2 .
accordance with the signals from the oxygen
sensor (front). STEP 2.MUT-II/III data list
• If the oxygen sensor (front) has deteriorated, • Refer to Data List Reference Table P.13B-401.
corrections will be made by the oxygen sensor
(rear).
b. Item 21: Engine coolant temperature sensor
• Diagnosis code P0125 becomes stored in
memory if a failure is detected in the above c. Item 59: Cylinder 1, 4 oxygen sensor (front)
air/fuel ratio feedback control system. d. Item 69: Cylinder 2, 3 oxygen sensor (rear)
Check Conditions NO : Perform the diagnosis code classified check
• The engine coolant temperature approximately. procedure for the sensor that has shown an
82°C or more. abnormal data valve (Refer to Inspection
• Within the range of air-fuel ratio feedback Chart for Diagnosis Code P.13B-20).
operation.
• Not in low speed operation. STEP 3: MUT-II/III data list
Judgment Criteria • Refer to Data List Reference Table P.13B-401.
• The oxygen sensor output voltage is not deviated a. Item 25: Barometric pressure sensor
from 0.5 V for 30 seconds. Q: Are the check results normal?
PROBABLE CAUSE NO : Replace engine-ECU <M/T> or
• Failed oxygen sensor (front) engine-A/T-ECU <A/T>.
• Harness damage in oxygen sensor (front) circuit
• Failed oxygen sensor (rear) STEP 4.Check for intake of air from intake hose
NOTE: When the oxygen sensor (front) begins to and inlet manifold.
deteriorate, the oxygen sensor output voltage will Q: Is the check result normal?
deviate from the voltage when the sensor was new YES : Go to Step 5 .
(normally 0.5 volt at stoichiometric ratio). This NO : Repair.
deviation will be corrected by the oxygen sensor
(rear).If the oxygen sensor (rear) responds poorly STEP 5.Check for leakage of exhaust emission
because it has deteriorated, it will improperly correct from exhaust manifold.
the oxygen sensor (front). Thus, even when closed
loop control is being effected, the fluctuation of the Q: Is the check result normal?
oxygen sensor (front) output voltage decreases,
NO : Repair.
without intersecting with 0.5 volt. As a result, there is
a possibility of diagnosis code P0125 becoming
registered. STEP 6.Check throttle body (throttle valve
• Failed fuel system portion) for contamination.
• Failed exhaust system
• Failed engine-ECU <M/T> YES : Go to Step 7 .
• Failed engine-A/T-ECU <A/T> NO : Clean throttle body (throttle valve portion)
(Refer to P.13B-425).
DIAGNOSIS PROCEDURE
STEP 1. MUT-II/III diagnosis code

Q: Is any other diagnosis code than P0170 or P0173
output?
TROUBLESHOOTING
STEP 7. Connector check: B-39 cylinder 1, 4 NO : Replace cylinder 1, 4 oxygen sensor (front).
oxygen sensor (front) connector, C-142
<A/T> connector. STEP 9. Check harness between B-39 (terminal
No. 4) cylinder 1, 4 oxygen sensor (front)
Connector: B-39
<A/T> connector.
Connector: B-39
2 1
Cylinder 1, 4 oxygen
4 3 sensor (front)
B-39 (GR)
2 1
Connector: C-142 Cylinder 1, 4 oxygen
4 3 sensor (front)
B-39 (GR)
Connector: C-142
C-142 (GR) <L. H. Drive Vehicle>
<R. H. Drive Vehicle> C-142 (GR)

C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB 959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105


STEP8. Check cylinder 1, 4 oxygen sensor (front)
itself.
• Check cylinder 1, 4 oxygen sensor (front) itself
NO : Repair.
TROUBLESHOOTING
STEP 10. Connector check: B-112 cylinder 2, 3 STEP 11. Check cylinder 2, 3 oxygen sensor
oxygen sensor (front) connector, C-142 (front) itself.
engine-ECU <M/T> connector or engine-A/T-ECU • Check cylinder 2, 3 oxygen sensor (front) itself
<A/T> connector. (Refer to P.13B-432).
NO : Replace cylinder 2, 3 oxygen sensor (front).
sensor (front)
2 1
4 3
Harness
side connector B-112 (GR)
AK304264 AB
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 12. Check harness between B-112 (terminal STEP 13. Connector check: Injector connector
No. 4) cylinder 2, 3 oxygen sensor (front) Connectors: B-01, B-02, B-04, B-05
B-05 (GR)
engine-ECU <M/T> connector or engine-A/T-ECU B-01 (GR) B-02 (GR) B-04 (GR)
<A/T> connector.
Connector: B-112
M
2 1
Harness
sensor (front) a. B-01 (No.1 injector connector)
b. B-02 (No.2 injector connector)
c. B-04 (No.3 injector connector)
d. B-05 (No.4 injector connector)
NO : Repair.

• Check Injector itself (Refer to P.13B-435).
2 1
Harness NO : Replace injector.
AK304264 AB
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 15. Connector check: B-17X engine control STEP 16. Check harness between B-17X engine
relay connector and C-139 engine-ECU <M/T> control relay connector and injector connector.
connector or engine-A/T-ECU <A/T> connector. Connector: B-17X
Connector: B-17X B-17X
B-17X Relay box’s
Relay box’s triangle marks
triangle marks
2 1
2 1 4 3
4 3 Harness
Connectors: B-01, B-02, B-04, B-05
Connector: C-139 B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR)
C-139 (GR)
M
2 1
Harness
<R. H. Drive Vehicle> a. Check harness between B-17X (terminal No. 1)

C-139 (GR)
b. Check harness between B-17X (terminal No. 1)
c. Check harness between B-17X (terminal No. 1)
4 3 2 1
13 12 1110 9 8 7 6 5 engine control relay connector and B-04 (terminal
2019 18 17 16 15 14
2726 2524 23 22 21 No. 1) No. 3 injector connector.
Harness side connector d. Check harness between B-17X (terminal No. 1)
AK304262 AB
Q: Is the check result normal? • Check power supply line for damage.
NO : Repair.
TROUBLESHOOTING
NO : Repair.
STEP 17. Check harness between injector
connector and C-134 engine-ECU connector.
STEP 18. Fuel pressure measurement.
• Fuel pressure measurement (Refer to
B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR) P.13B-426).
YES : Repair.
M
2 1
Harness
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
Code No. P0130: Cylinder 1, 4 Oxygen Sensor (Front) System
Cylinder 1, 4 oxygen sensor circuit (front)
B-39
MU802665
1 2 sensor (front)
3 4
1 3 2 4
R G
To engine-ECU <M/T>
To engine-A/T-ECM <A/T>
B
7
9
J/C (2)
J/C (1)
C-17
C-16
1
6
B
BR
96 109
Engine-ECU <M/T>
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120
Wire colour code

AK304123 AC
OPERATION FUNCTION
• The sensor signal is inputted to the engine-ECU • The cylinder 1, 4 oxygen sensor (front) converts
<M/T> or engine-A/T-ECU <A/T> (terminal No. the concentration of oxygen in the exhaust
109) from the cylinder 1, 4 oxygen sensor (front) emission into a voltage and inputs the signal to
output terminal (terminal No. 4). the engine-ECU <M/T> or engine-A/T-ECU
• The cylinder 1, 4 oxygen sensor (front) (terminal <A/T>.
No. 2) is earthed with engine-ECU <M/T> or • When the air-fuel ratio is richer than the
engine-A/T-ECU <A/T> (terminal No. 96). theoretical air-fuel ratio, the cylinder 1, 4 oxygen
sensor (front) outputs a voltage of about 1 V.
When it is leaner than the theoretical air-fuel
ratio, it outputs a voltage of about 0 V.
TROUBLESHOOTING
• In response to the signal, the engine-ECU <M/T> YES : Intermittent malfunction (Refer to GROUP
or engine-A/T-ECU <A/T> controls the fuel 00 − How to Use
infection amount so that the air-fuel ratio can be Troubleshooting/Inspection Service Points
equivalent to the theoretical air-fuel ratio. P.00-6).
NO : Go to Step 2 .
TROUBLE JUDGMENT
Check Conditions STEP 2. Connector check: B-39 cylinder 1, 4
• Above 3 minutes later after the engine has oxygen sensor (front) connector
started up.
• The engine coolant temperature is approx. 82°C Connector: B-39
or higher.
• The engine speed is 1200 r/min or more.
• The monitoring time is 5 seconds.
Judgment Criteria
• When the cylinder 1, 4 oxygen sensor (front) 2 1
output voltage is 0.2 V or less and a power Cylinder 1, 4 oxygen
4 3 sensor (front)
voltage of 5 V is applied to the cylinder 1, 4 B-39 (GR)
oxygen sensor (front) in the engine-ECU <M/T> Harness side connector AK304260 AB
or engine-A/T-ECU <A/T>, the sensor output
voltage is 4.5V or more. Q: Is the check result normal?
• To be monitored once per driving cycle. YES : Go to Step 3 .
NO : Repair.
Check Conditions
• The engine speed is 1200 − 3000 r/min.
• The engine coolant temperature is approx. 60°C STEP 3. Perform voltage measurement at B-39
or higher. cylinder 1, 4 oxygen sensor (front) connector.
• Volumetric efficiency is 20 − 60 %. Connector: B-39
• During the air-fuel ratio feedback control
Judgment Criteria
• When the cylinder 1, 4 oxygen sensor (front)
output frequency is 6 or less for 10 seconds on
the average.
2 1
PROBABLE CAUSE 4 3 sensor (front)
B-39 (GR)
• Failed cylinder 1, 4 oxygen sensor (front)
• Open/short circuit in cylinder 1, 4 oxygen sensor AK304260 AB
(front) circuit or loose connector contact • Disconnect connector, and measure at harness
• Failed engine-ECU <M/T> side.
• Failed engine-A/T-ECU <A/T> • Resistance between terminal No. 2 and earth.
OK: 2 Ω or less
DIAGNOSIS PROCEDURE
STEP 1. MUT-II/III data list NO : Go to Step 4 .
a. Item 11: Cylinder 1, 4 oxygen sensor (front)
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 2) cylinder 1, 4 oxygen sensor (front)
Connector: C-142
<A/T> connector.
Connector: B-39
C-142 (GR)
2 1
<R. H. Drive Vehicle> 4 3 sensor (front)
B-39 (GR)
C-142 (GR) Harness side connector AK304260 AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 6. MUT-II/III data list STEP 9. Connector check: C-142 engine-ECU

• Refer to Data List Reference Table P.13B-401. <M/T> connector or engine-A/T-ECU <A/T>
a. Item 11: Cylinder 1, 4 oxygen sensor (front) connector
Q: Is the check result normal? Connector: C-142
00 − How to Use
P.00-6).
C-142 (GR)

cylinder 1, 4 oxygen sensor (front) connector.
Connector: B-39 C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
2 1
Cylinder 1, 4 oxygen 112111110 109108107 106105
4 3 sensor (front) 120119118 117116115 114113
B-39 (GR)
Harness side connector AK304260 AB AK304153 AB

connect connector, and measure at pick-up Connector: B-39
harness.
• Engine: After warm-up
• Transmission: Neutral <M/T> or P range <A/T>.
OK:
When the engine is 2,500 r/min, the output 2 1
voltage should repeat 0 to 0.8 V alternately. 4 3 sensor (front)
B-39 (GR)

(terminal No. 4) Cylinder 1, 4 oxygen sensor
STEP 8. Check cylinder 1, 4 oxygen sensor (front) connector and C-142 (terminal No.
(front) itself. 109) engine-ECU <M/T> connector or
• Check cylinder 1, 4 oxygen sensor (front) itself engine-A/T-ECU <A/T> connector.
(Refer to P.13B-432). • Check output line for damage.
TROUBLESHOOTING
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

Connector: B-39
• Transmission: Neutral <M/T> or P range <A/T>
OK:
When the engine is 2,500 r/min, the output
2 1
voltage should repeat 0 to 0.8 V alternately. Cylinder 1, 4 oxygen
4 3 sensor (front)
B-39 (GR)
engine-ECU <M/T> connector or
NO : Repair.
TROUBLESHOOTING

connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0135: Cylinder 1, 4 Oxygen Sensor (Front) Heater System
Cylinder 1, 4 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4 3 Cylinder 1, 4 oxygen sensor (front)

B-17X B-39
Engine MU802665
1 2 control
relay
3 4
1 2
1 2 3 4
1 3 2 4
R
To engine-ECU <M/T>
P-L
25
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304124AC
TROUBLESHOOTING

• Power is supplied to the heater power terminal
(terminal No. 1) of the Cylinder 1, 4 oxygen
sensor (front) connector from the engine control STEP 1. Connector check: B-39 cylinder 1, 4
relay (terminal No. 1). oxygen sensor (front) connector
• The heater (terminal No. 3) of the Cylinder 1, 4 Connector: B-39
oxygen sensor (front) connector is controlled by
the power transistor in the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (terminal No. 25).
FUNCTION
• The power supply to the cylinder 1, 4 oxygen
2 1
sensor (front) heater is controlled by the ON/OFF Cylinder 1, 4 oxygen
4 3 sensor (front)
control of the power transistor in the engine-ECU B-39 (GR)
<M/T> or engine-A/T-ECU <A/T>. Harness side connector AK304260 AB
• Heating the cylinder 1, 4 oxygen sensor (front)
heater enables the cylinder 1, 4 oxygen sensor Q: Is the check result normal?
(front) to provide good response even when the YES : Go to Step 2 .
exhaust emission temperature is low. NO : Repair.
TROUBLE JUDGMENT
Check Conditions cylinder 1, 4 oxygen sensor (front) connector.
• 60 seconds have elapsed since the previous
Connector: B-39
monitoring started.
• Engine coolant temperature is 20°C or higher.
• While cylinder 1, 4 oxygen sensor (front) heater is
on.
• Battery positive voltage is 11 − 16 V.
Judgment Criteria 2 1
• Cylinder 1, 4 oxygen sensor (front) heater current Cylinder 1, 4 oxygen
4 3 sensor (front)
has continued to be 0.16 A or lower, or 7.5 A or B-39 (GR)
higher for 4 seconds. Harness side connector AK304260 AB
• Disconnect connector, and measure at sensor

PROBABLE CAUSE
side.
• Failed cylinder 1, 4 oxygen sensor (front) heater
• Resistance between terminal No. 1 and No. 3.
• Open/short circuit in cylinder 1, 4 oxygen sensor
(front) circuit or loose connector contact OK: 4.5 − 8.0 Ω
• Failed engine-ECU <M/T> Q: Is the check result normal?
• Failed engine-A/T-ECU <A/T> YES : Go to Step 3 .
TROUBLESHOOTING

(terminal No. 1) cylinder 1, 4 oxygen sensor
(front) connector and B-17X (terminal No. 1)
Connector: B-39 engine control relay connector.
open/short circuit.
NO : Repair.
STEP 5. Perform voltage measurement at C-139

4 3 sensor (front) <A/T> connector.
B-39 (GR)
Harness side connector AK304260 AB Connector: C-139
• Disconnect connector, and measure at harness <L. H. Drive Vehicle>
side.
C-139 (GR)
OK: System voltage
NO : Go to Step 4 . <R. H. Drive Vehicle>

C-139 (GR)
relay connector
Connector: B-17X
B-17X
Relay box’s 4 3 2 1
13 12 1110 9 8 7 6 5
triangle marks 2019 18 17 16 15 14
2726 2524 23 22 21
2 1
AK304262 AB
4 3
Harness
Connector: B-39 • Voltage between terminal No. 25 and earth.
OK: System voltage
NO : Go to Step 6 .
2 1
4 3 sensor (front)
B-39 (GR)

TROUBLESHOOTING
Connector: C-139
<A/T> connector.
Connector: B-39
C-139 (GR)
2 1
<R. H. Drive Vehicle> 4 3 sensor (front)
B-39 (GR)
C-139 (GR)
Connector: C-139
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21 C-139 (GR)
AK304262 AB

NO : Repair.
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Check earthing line for open/short circuit.

NO : Repair.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 1)cylinder 1, 4 oxygen sensor (front)
connector connector and B-17X (terminal No. 1) engine
Connector: C-139
Connector: B-39
C-139 (GR)
2 1
4 3 sensor (front)
B-39 (GR)
C-139 (GR) Connector: B-17X

B-17X
Relay box’s
triangle marks
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2 1
2726 2524 23 22 21
AK304262 AB Harness
Q: Is the check result normal? • Check power supply line for damage.
NO : Repair.
TROUBLESHOOTING
engine-ECU <M/T> connector or engine-A/T-ECU STEP 11. Check the trouble symptoms.
<A/T> connector. Q: Does trouble symptom persist?
Connector: B-39 YES : Replace engine-ECU <M/T> or
00 − How to Use
P.00-6).
2 1
4 3 sensor (front)
B-39 (GR)
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Check earthing line for damage.

TROUBLESHOOTING
Code No. P0136: Cylinder 1, 4 Oxygen Sensor (Rear) System
Cylinder 1, 4 oxygen sensor (rear) circuit
B-38
MU802605
1 2 sensor (rear)
3 4
1 3 2 4
BR Y
To engine-ECU <M/T>
B
8
10
J/C (2)
J/C (1)
C-17
C-16
1
6
B
BR
96 117
Engine-ECU <M/T>
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120
Wire colour code

AK304125 AC
OPERATION FUNCTION
• The sensor signal is inputted to the engine-ECU • The cylinder 1, 4 oxygen sensor (rear) converts
117) from the cylinder 1, 4 oxygen sensor (rear) emission into a voltage and inputs the signal to
• The cylinder 1, 4 oxygen sensor (rear) (terminal <A/T>.
sensor (rear) outputs a voltage of about 1 V.
TROUBLESHOOTING
• Based on this signal, the Engine-ECU <M/T> or DIAGNOSIS PROCEDURE

Engine-A/T-ECU <A/T> corrects the deviation in
the signal that is output by the cylinder 1, 4
oxygen sensor (rear). STEP 1. MUT-II/III data list
TROUBLE JUDGMENT a. Item 59: Cylinder 1, 4 oxygen sensor (rear)
Check Conditions Q: Is the check result normal?
• Above 3 minutes later after the engine has YES : Intermittent malfunction (Refer to GROUP
started up. 00 − How to Use
• The engine coolant temperature is approx. 82°C Troubleshooting/Inspection Service Points
or higher. P.00-6).
• The engine speed is 1200 r/min or more. NO : Go to Step 2 .
Judgment Criteria STEP 2. Connector check: B-38 cylinder 1, 4
• When the cylinder 1, 4 oxygen sensor (rear) oxygen sensor (rear) connector
output voltage is 0.2V or less and a power
Connector: B-38
voltage of 5V is applied to the cylinder 1, 4
oxygen sensor (rear) in the engine-ECU <M/T>
voltage is 4.5V or more.
• To be monitored once per driving cycle. Cylinder 1, 4 oxygen
sensor (rear)
Check Conditions
• 2 seconds later after lack of circuit continuity is
detected.
• When the front oxygen sensor is normally
operated.
Judgment Criteria
• When the air-fuel ratio is rich, the cylinder 1, 4
oxygen sensor (front) output voltage is 0.5 V or
more.
• The cylinder 1, 4 oxygen sensor (rear) output
voltage is less than 0.1 V.
• The maximum and maximum of the cylinder 1, 4 2 1
oxygen sensor (rear) output is 0.078 V or less. 4 3 B-38 (B)
Harness
PROBABLE CAUSE side connector AK304263 AB
• Failed cylinder 1, 4 oxygen sensor (rear)

• Open/short circuit in cylinder 1, 4 oxygen sensor Q: Is the check result normal?
(rear) circuit or loose connector contact
NO : Repair.
TROUBLESHOOTING
STEP 3. Perform voltage measurement at B-38 NO : Go to Step 4 .
cylinder 1, 4 oxygen sensor (rear) connector.
Connector: B-38
connector
Connector: C-142
sensor (rear) <L. H. Drive Vehicle>
C-142 (GR)
C-142 (GR)
2 1
4 3 B-38 (B)
Harness
side connector AK304263 AB 959493 92 91
104 103102 101100 99 98 97 96
• Disconnect connector, and measure at harness 112111110

120119118
109108107
117116115
106105
114113
side. Harness side connector
• Resistance between terminal No. 2 and earth. AK304153 AB
OK: 2 Ω or less
NO : Repair.
TROUBLESHOOTING
No. 2) cylinder 1, 4 oxygen sensor (rear)
a. Item 59: Cylinder 1, 4 oxygen sensor (rear)
Connector: B-38
00 − How to Use
Cylinder 1, 4 oxygen P.00-6).
sensor (rear) NO : Replace engine-ECU <M/T> or

Connector: B-38
2 1 sensor (rear)
4 3 B-38 (B)
Harness
Connector: C-142
C-142 (GR)
2 1
4 3 B-38 (B)
<R. H. Drive Vehicle> Harness
C-142 (GR)
• Use special tool test harness (MD998464) to
harness.
104 103102 101100 99 98 97 96
112111110 109108107 106105 OK:
120119118 117116115 114113

voltage should repeat 0 to 0.8 V alternately
AK304153 AB
NOTE: Before checking harness, check intermediate YES : Go to Step 10 .
connector C-16, and repair if necessary. NO : Go to Step 8 .
• Check earthing line for open circuit.
TROUBLESHOOTING
STEP 8. Check Cylinder 1, 4 oxygen sensor (rear) STEP 9. Connector check: C-142 engine-ECU
itself. <M/T> connector or engine-A/T-ECU <A/T>
• Check cylinder 1, 4 oxygen sensor (rear) itself connector
Connector: C-142
NO : Replace cylinder 1, 4 oxygen (rear) sensor.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
Connector: B-38
sensor (rear)
2 1
4 3 B-38 (B)
Harness

TROUBLESHOOTING

(rear) connector and C-142 (terminal No.
connector
engine-A/T-ECU <A/T> connector. Connector: C-142
• Check output line for damage. <L. H. Drive Vehicle>
NO : Repair.

engine-ECU <M/T> connector or engine-A/T-ECU C-142 (GR)
<A/T> connector.
Connector: B-38
C-142 (GR)
sensor (rear)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
Connector: B-38
2 1
4 3 B-38 (B)
Harness sensor (rear)

OK:
voltage should repeat 0 to 0.8 V alternately.
NO : Go to Step 11 . 4 3 B-38 (B)
Harness

TROUBLESHOOTING

connector
• Check output line for open circuit. <L. H. Drive Vehicle>
NO : Repair.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0141: Cylinder 1, 4 Oxygen Sensor (Rear) Heater System
Cylinder 1,4 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4 3 Cylinder 1, 4 oxygen sensor (rear)

B-17X
Engine B-38
1 2 control MU802605
relay
3 4
1 2
1 2 3 4
1 3 2 4
R
To engine-ECU <M/T>
V-W
24
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304126 AC
TROUBLESHOOTING
OPERATION • Open/short circuit in cylinder 1, 4 oxygen sensor

• Power is supplied to the heater power terminal (rear) circuit or loose connector contact
(terminal No. 1) of the cylinder 1, 4 oxygen • Failed engine-ECU <M/T>
sensor (rear) connector from the engine control • Failed engine-A/T-ECU <A/T>
• The heater (terminal No. 3) of the cylinder 1, 4 DIAGNOSIS PROCEDURE
oxygen sensor (rear) connector is controlled by
the power transistor in the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (terminal No. 24). STEP 1. Connector check: B-38 cylinder 1, 4
oxygen sensor (rear) connector
FUNCTION Connector: B-38
sensor (rear) heater is controlled by the ON/OFF
control of the power transistor in the engine-ECU
<M/T> or engine-A/T-ECU <A/T>.
• Heating the cylinder 1, 4 oxygen sensor (rear) Cylinder 1, 4 oxygen
heater enables the cylinder 1, 4 oxygen sensor sensor (rear)
(rear) to provide good response even when the
exhaust emission temperature is low.
TROUBLE JUDGMENT
Check Conditions
monitoring started.
• While cylinder 1, 4 oxygen sensor (rear) heater is
on.
• Battery positive voltage is 11 − 16 V. 2 1
Judgment Criteria 4 3 B-38 (B)
• Cylinder 1, 4 oxygen sensor (rear) heater Harness
currents have continued to be 0.16 A or lower, or side connector AK304263 AB
5.0 A or higher for 4 seconds.

• Failed cylinder 1, 4 oxygen sensor (rear) heater NO : Repair.
TROUBLESHOOTING
STEP 2. Perform resistance measurement at B-38 STEP 3. Perform voltage measurement at B-38
cylinder 1, 4 oxygen sensor (rear) connector. cylinder 1, 4 oxygen sensor (rear) connector.
Cylinder 1, 4 oxygen Cylinder 1, 4 oxygen

sensor (rear) sensor (rear)
2 1 2 1
4 3 B-38 (B) 4 3 B-38 (B)
Harness Harness
• Disconnect connector, and measure at sensor • Disconnect connector, and measure at harness
side. side.
• Resistance between terminal No. 1 and No. 3. • Ignition switch: ON
OK: 11 − 18 Ω • Voltage between terminal No. 1 and earth.
OK: System voltage
NO : Replace cylinder 1, 4 oxygen sensor (rear). YES : Go to Step 5 .
NO : Go to Step 4 .
TROUBLESHOOTING

relay connector
(rear) connector and B-17X (terminal No. 1)
Connector: B-17X engine control relay connector.
B-17X • Check power supply line for
open/short circuit.
Relay box’s
triangle marks NO : Repair.
2 1 STEP 5. Perform voltage measurement at C-139

4 3
<A/T> connector.
Harness
side connector AK304152 AB Connector: C-139
Connector: B-38
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1
4 3 B-38 (B) AK304262 AB
Harness • Measure engine-ECU <M/T> or engine-A/T-ECU

OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 3) cylinder 1, 4 oxygen sensor (rear)
Connector: C-139
<A/T> connector.
Connector: B-38
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1
AK304262 AB
4 3 B-38 (B)
Harness
Q: Is the check result normal? side connector AK304263 AB
NO : Repair.
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
Connector: C-139
Connector: B-38
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1
4 3 B-38 (B)
AK304262 AB
Harness
YES : Go to Step 9 . Connector: B-17X
NO : Repair.
B-17X
Relay box’s
triangle marks
2 1
4 3
Harness

NO : Repair.
TROUBLESHOOTING
00 − How to Use
Cylinder 1, 4 oxygen P.00-6).
sensor (rear)
2 1
4 3 B-38 (B)
Harness
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
Code No. P0150: Cylinder 2, 3 Oxygen Sensor (Front) System
Cylinder 2, 3 oxygen sensor (front) circuit
B-112
MU802665
1 2 sensor (front)
3 4
1 3 2 4
B W
To engine-ECU <M/T>
B
2
7
J/C (2)
J/C (1)
C-17
C-16
1
6
B
BR
96 108
Engine-ECU <M/T>
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120
Wire colour code

AK304123 AB
OPERATION • The front cylinder 2, 3 oxygen sensor (front)

• The sensor signal is inputted to the engine-ECU (terminal No. 2) is earthed with engine-ECU
<M/T> or engine-A/T-ECU <A/T> (terminal No. <M/T> or engine-A/T-ECU <A/T> (terminal No.
108) from the cylinder 2, 3 oxygen sensor (front) 96).
output terminal (terminal No. 4).
TROUBLESHOOTING
FUNCTION PROBABLE CAUSE

• The cylinder 2, 3 oxygen sensor (front) converts • Failed cylinder 2, 3 oxygen sensor (front)
the concentration of oxygen in the exhaust • Open/short circuit in cylinder 2, 3 oxygen sensor
emission into a voltage and inputs the signal to (front) circuit or loose connector contact
the engine-ECU <M/T> or engine-A/T-ECU • Failed engine-ECU <M/T>
<A/T>. • Failed engine-A/T-ECU <A/T>
• When the air-fuel ratio is richer than the
theoretical air-fuel ratio, the cylinder 2, 3 oxygen DIAGNOSIS PROCEDURE
sensor (front) outputs a voltage of about 1 V.
ratio, it outputs a voltage of about 0 V. STEP 1. MUT-II/III data list
or engine-A/T-ECU <A/T> controls the fuel a. Item 39: Cylinder 2, 3 oxygen sensor (front)
infection amount so that the air-fuel ratio can be Q: Is the check result normal?
equivalent to the theoretical air-fuel ratio. YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
TROUBLE JUDGMENT Troubleshooting/Inspection Service Points
Check Conditions P.00-6).
• Above 3 minutes later after the engine has NO : Go to Step 2 .
started up.
• The engine coolant temperature is approx. 82°C STEP 2. Connector check: B-112 cylinder 2, 3
or higher. oxygen sensor (front) connector
• The engine speed is 1200 r/min or more.
• The monitoring time is 5 seconds. Connector: B-112
Judgment Criteria
• When the cylinder 2, 3 oxygen sensor (front)
output voltage is 0.2V or less and a power
voltage of 5 V is applied to the cylinder 2, 3
oxygen sensor (front) in the engine-ECU <M/T> Cylinder 2, 3 oxygen
sensor (front)
• To be monitored once per driving cycle.
Check Conditions
• The engine speed is 1200 − 3000 r/min.
• The engine coolant temperature is approx. 60°C
or higher.
• Volumetric efficiency is 20 − 60 %.
• During the air-fuel ratio feedback control.
Judgment Criteria 2 1
• When the cylinder 2, 3 oxygen sensor (front) 4 3
output frequency is 6 or less for 10 seconds on
the average Harness
AK304264 AB

NO : Repair.
TROUBLESHOOTING
Connector: B-112
connector
Connector: C-142
Cylinder 2, 3 oxygen <L. H. Drive Vehicle>

sensor (front)
C-142 (GR)
C-142 (GR)
2 1
4 3
Harness
AK304264 AB 959493 92 91
104 103102 101100 99 98 97 96
120119118
109108107
117116115
106105
114113
AK304153 AB
OK: 2 Ω or less
NO : Repair.
TROUBLESHOOTING
Connector: B-112
00 − How to Use
P.00-6).
sensor (front) NO : Replace engine-ECU <M/T> or

Connector: B-112
2 1
4 3 sensor (front)
Harness
AK304264 AB
Connector: C-142
C-142 (GR)
2 1
4 3
AK304264 AB
C-142 (GR)
harness.
104 103102 101100 99 98 97 96
112111110 109108107 106105 OK:
120119118 117116115 114113

AK304153 AB
TROUBLESHOOTING
STEP 8. Check cylinder 2, 3 oxygen sensor STEP 9. Connector check: C-142 engine-ECU
(front) itself <M/T> connector or engine-A/T-ECU <A/T>
• Check cylinder 2, 3 oxygen sensor (front) itself connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
Connector: B-112
sensor (front)
2 1
4 3
Harness
AK304264 AB

TROUBLESHOOTING

(front) connector and C-142 (terminal No.
connector
NO : Repair.

<A/T> connector.
Connector: C-142
<L. H. Drive Vehicle> <R. H. Drive Vehicle>
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB
Connector: B-112
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB sensor (front)
OK:
NO : Go to Step 11 . 4 3
Harness
AK304264 AB

TROUBLESHOOTING

(front) connector and C-142 (terminal No.
connector
NO : Repair.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0155: Cylinder 2, 3 Oxygen Sensor (Front) Heater System
Cylinder 2, 3 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4 3 Cylinder 2, 3 oxygen sensor (front)

B-17X
B-112
Engine MU802665
1 2 control
relay
3 4
1 2
1 2 3 4
1 3 2 4
R
To engine-ECU <M/T>
Y-R
10
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304124 AB
OPERATION • The heater (terminal No. 3) of the cylinder 2, 3

• Power is supplied to the heater power terminal oxygen sensor (front) connector is controlled by
(terminal No. 1) of the cylinder 2, 3 oxygen the power transistor in the engine-ECU <M/T> or
sensor (front) connector from the engine control engine-A/T-ECU <A/T> (terminal No. 10).
TROUBLESHOOTING

sensor (front) heater is controlled by the ON/OFF
control of the power transistor in the engine-ECU STEP 1. Connector check: B-112 cylinder 2, 3
<M/T> or engine-A/T-ECU <A/T>. oxygen sensor (front) connector
• Heating the cylinder 2, 3 oxygen sensor (front) Connector: B-112
heater enables the cylinder 2, 3 oxygen sensor
(front) to provide good response even when the
TROUBLE JUDGMENT
Check Conditions sensor (front)
monitoring started.
• While cylinder 2, 3 oxygen sensor (front) heater is
on.
Judgment Criteria
• Cylinder 2, 3 oxygen sensor (front) heater
currents has continued to be 0.16 A or lower, or
7.5 A or higher for 4 seconds. 2 1
PROBABLE CAUSE 4 3
• Failed oxygen sensor heater Harness
B-112 (GR)
• Open/short circuit in cylinder 2, 3 oxygen sensor side connector AK304264 AB
(front) circuit or loose connector contact

• Failed engine-A/T-ECU <A/T> NO : Repair.
TROUBLESHOOTING
STEP 2. Perform resistance measurement at STEP 3. Perform voltage measurement at B-112

B-112 cylinder 2, 3 oxygen sensor (front) cylinder 2, 3 oxygen sensor (front) connector.
connector. Connector: B-112
Connector: B-112
Cylinder 2, 3 oxygen sensor (front)
sensor (front)
2 1
2 1 4 3
4 3 Harness
Harness AK304264 AB
AK304264 AB
• Disconnect connector, and measure at sensor side.
side. • Ignition switch: ON
• Resistance between terminal No. 1 and No. 3. • Voltage between terminal No. 1 and earth.
OK: 4.5 − 8.0 Ω OK: System voltage
NO : Replace cylinder 2, 3 oxygen sensor (front). NO : Go to Step 4 .
TROUBLESHOOTING

relay connector
(front) connector and B-17X (terminal No. 1)
open/short circuit.
Relay box’s

4 3
<A/T>.
Harness
Connector: B-112
C-139 (GR)
sensor (front)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1 Harness side connector
4 3 AK304262 AB

AK304264 AB
OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
Connector: C-139
<A/T> connector.
Connector: B-112
C-139 (GR)
sensor (front)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB 4 3
Harness
Q: Is the check result normal? side connector B-112 (GR)
AK304264 AB
NO : Repair.
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
Connector: C-139
Connector: B-112
C-139 (GR)
sensor (front)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21 2 1
AK304262 AB
Harness
AK304264 AB
NO : Repair.
B-17X
Relay box’s
triangle marks
2 1
4 3
Harness

NO : Repair.
TROUBLESHOOTING
00 − How to Use
P.00-6).
sensor (front)
2 1
4 3
Harness
AK304264 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
Cylinder 2, 3 oxygen sensor (rear) circuit
B-38
MU802605
1 2 sensor (rear)
3 4
1 3 2 4
P Y
To engine-ECU <M/T>
B
3
10
J/C (2)
J/C (1)
C-17
C-16
1
6
B
BR
96 116
Engine-ECU <M/T>
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120
Wire colour code

AK304125 AB
OPERATION FUNCTION
• The sensor signal is inputted to the engine-ECU • The cylinder 2, 3 oxygen sensor (rear) converts
116) from the cylinder 2, 3 oxygen sensor (rear) emission into a voltage and inputs the signal to
• The cylinder 2, 3 oxygen sensor (rear) (terminal <A/T>.
sensor (rear) outputs a voltage of about 1 V.
TROUBLESHOOTING
• Based on this signal, the Engine-ECU <M/T> or DIAGNOSIS PROCEDURE

Engine-A/T-ECU <A/T> corrects the deviation in
the signal that is output by the cylinder 2, 3
oxygen sensor (front). STEP 1. MUT-II/III data list
TROUBLE JUDGMENT a. Item 69: Cylinder 2, 3 oxygen sensor (rear)
• Above 3 minutes later after the engine has YES : Intermittent malfunction (Refer to GROUP
started up. 00 − How to Use
• The engine coolant temperature is approx. 82°C Troubleshooting/Inspection Service Points
or higher. P.00-6).
• The engine speed is 1200 r/min or more. NO : Go to Step 2 .
Judgment Criteria STEP 2. Connector check: B-113 cylinder 2, 3
• When the cylinder 2, 3 oxygen sensor (rear) oxygen sensor (rear) connector
output voltage is 0.2V or less and a power Connector: B-113
voltage of 5V is applied to the cylinder 2, 3
oxygen sensor (rear) in the engine-ECU <M/T>
• To be monitored once per driving cycle.
Check Conditions
• 2 seconds later after lack of circuit continuity is Cylinder 2, 3 oxygen
sensor (rear)
detected.
• When the cylinder 2, 3 oxygen sensor (rear) is
normally operated.
Judgment Criteria
• When the air-fuel ratio is rich, the cylinder 1, 4
oxygen sensor (front) output voltage is 0.5 V or B-113 (B)
more.
• The cylinder 1, 4 oxygen sensor (rear) output
voltage is less than 0.1 V.
2 1
• The maximum and maximum of the cylinder 1, 4
oxygen sensor (rear) output is 0.078 V or less. 4 3
Harness
PROBABLE CAUSE side connector AK304265 AB

• Open/short circuit in cylinder 2, 3 oxygen sensor Q: Is the check result normal?
(rear) circuit or loose connector contact NO : Repair.
TROUBLESHOOTING
Connector: B-113
connector
Connector: C-142
sensor (rear)
C-142 (GR)

B-113 (B)
C-142 (GR)
2 1
4 3
Harness
side connector AK304265 AB 959493 92 91
104 103102 101100 99 98 97 96
120119118
109108107
117116115
106105
114113
AK304153 AB
OK: 2 Ω or less
NO : Repair.
TROUBLESHOOTING
a. Item 69: Cylinder 2, 3 oxygen sensor (rear)
Connector: B-113
00 − How to Use
P.00-6).
Cylinder 2, 3 oxygen engine-A/T-ECU <A/T>.
sensor (rear)

Connector: B-113
B-113 (B)
2 1
4 3
Harness sensor (rear)
Connector: C-142
B-113 (B)
C-142 (GR)
2 1
4 3
C-142 (GR)
• Use special tool test harness (MD998464) to
harness.
104 103102 101100 99 98 97 96
112111110 109108107 106105 OK:
120119118 117116115 114113

AK304153 AB
TROUBLESHOOTING
STEP 8. Check cylinder 2, 3 oxygen sensor (rear) STEP 9. Connector check: C-142 engine-ECU
itself <M/T> connector or engine-A/T-ECU <A/T>
• Check cylinder 2, 3 oxygen sensor (rear) itself connector
Connector: C-142
NO : Replace cylinder 2, 3 oxygen sensor (rear).
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
Connector: B-113
sensor (rear)
B-113 (B)
2 1
4 3
Harness

TROUBLESHOOTING

connector
NO : Repair.

<A/T> connector.
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB
Connector: B-113
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
• Measure engine-ECU <M/T> or engine-A/T-ECU sensor (rear)
OK:
When the engine is 2,500 r/min, the output B-113 (B)
NO : Go to Step 11 . 4 3
Harness

TROUBLESHOOTING

connector
NO : Repair.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Cylinder 1,4 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4 3 Cylinder 1, 4 oxygen sensor (rear)

B-17X
Engine B-38
1 2 control MU802605
relay
3 4
1 2
1 2 3 4
1 3 2 4
R
To engine-ECU <M/T>
V-W
24
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304126 AC
OPERATION • The heater (terminal No. 3) of the cylinder 2, 3

• Power is supplied to the heater power terminal oxygen sensor (rear) connector is controlled by
(terminal No. 1) of the cylinder 2, 3 oxygen the power transistor in the engine-ECU <M/T> or
sensor (rear) connector from the engine control engine-A/T-ECU <A/T> (terminal No. 18).
TROUBLESHOOTING

sensor (rear) heater is controlled by the ON/OFF
control of the power transistor in the engine-ECU STEP 1. Connector check: B-113 cylinder 2, 3
<M/T> or engine-A/T-ECU <A/T>. oxygen sensor (rear) connector
• Heating the cylinder 2, 3 oxygen sensor (rear) Connector: B-113
heater enables the cylinder 2, 3 oxygen sensor
(rear) to provide good response even when the
TROUBLE JUDGMENT
Check Conditions
• 60 seconds have elapsed since the previous Cylinder 2, 3 oxygen
sensor (rear)
monitoring started.
• While cylinder 2, 3 oxygen sensor (rear) heater is
on.
Judgment Criteria B-113 (B)
• Cylinder 2, 3 oxygen sensor (rear) heater
currents have continued to be 0.16 A or lower, or
5.0 A or higher for 4 seconds.
2 1
PROBABLE CAUSE 4 3
• Failed cylinder 2, 3 oxygen sensor (rear) heater Harness
• Open/short circuit in cylinder 2, 3 oxygen sensor side connector AK304265 AB
(rear) circuit or loose connector contact

TROUBLESHOOTING
STEP 2. Perform resistance measurement at B-38 STEP 3. Perform voltage measurement at B-113
cylinder 2, 3 oxygen sensor (rear) connector. cylinder 2, 3 oxygen sensor (rear) connector.
Cylinder 2, 3 oxygen Cylinder 2, 3 oxygen

sensor (rear) sensor (rear)
B-113 (B) B-113 (B)
2 1 2 1
4 3 4 3
Harness Harness
• Disconnect connector, and measure at sensor • Disconnect connector, and measure at harness
side. side.
• Resistance between terminal No. 1 and No. 3. • Ignition switch: ON
OK: 11 − 18 Ω • Voltage between terminal No. 1 and earth.
OK: System voltage
NO : Replace cylinder 2, 3 oxygen sensor (rear). YES : Go to Step 5 .
NO : Go to Step 4 .
TROUBLESHOOTING

relay connector
(rear) connector and B-17X (terminal No. 1)
open/short circuit.
Relay box’s

4 3
<A/T>.
Harness
Connector: B-113
C-139 (GR)
sensor (rear) <R. H. Drive Vehicle>
C-139 (GR)
B-113 (B)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21

4 3 AK304262 AB

OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
Connector: C-139
<A/T> connector.
Connector: B-113
C-139 (GR)
<R. H. Drive Vehicle> sensor (rear)
C-139 (GR)
B-113 (B)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1
AK304262 AB 4 3
Harness
NO : Repair.
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
NO : Repair.
TROUBLESHOOTING
Connector: C-139
Connector: B-113
C-139 (GR)
sensor (rear)
C-139 (GR)
B-113 (B)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1
4 3
AK304262 AB
Harness
NO : Repair.
B-17X
Relay box’s
triangle marks
2 1
4 3
Harness

NO : Repair.
TROUBLESHOOTING
00 − How to Use
P.00-6).
sensor (rear)
B-113 (B)
2 1
4 3
Harness
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
Code No. P0170: Abnormal Fuel System (Cylinder 1,4)
OPERATION
• Refer to Code No. P0201: No. 1 Injector System • Refer to Data List Reference Table P.13B-401.
P.13B-125. a. Item 12: Air flow sensor
• Refer to Code No. P0204: No. 4 Injector System
b. Item 13: Intake air temperature sensor
P.13B-140.
c. Item 21: Engine coolant temperature sensor
FUNCTION d. Item 95: Manifold absolute pressure sensor
• If the fuel system goes out of order, the fuel Q: Are the check results normal?
correction valve will become larger. YES : Go to Step 3 .
• The engine-ECU <M/T> or engine-A/T-ECU NO : Perform the diagnosis code classified check
<A/T> checks whether the fuel trim value is within procedure for the sensor that has shown an
a specified range. abnormal data value (Refer to Inspection
Chart for Diagnosis Code P.13B-20).
TROUBLE JUDGMENT
Check Conditions
STEP 3: MUT-II/III data list
• In learning the air-fuel ratio. • Refer to Data List Reference Table P.13B-401.
Judgment Criteria a. Item 25: Barometric pressure sensor
• Long-term fuel trim has continued to be +12.5 %
or higher for 10 seconds. YES : Go to Step 4 .
Or NO : Replace engine-ECU <M/T> or
• Long-term fuel trim has continued to be -12.5 % engine-A/T-ECU <A/T>.
or higher for 10 seconds.
PROBABLE CAUSE STEP 4. Check throttle body (throttle valve

• Failed intake air temperature sensor portion) for contamination.
• Failed air flow sensor Q: Is the check result normal?
• Failed purge control solenoid valve YES : Go to Step 5 .
• Failed injector NO : Clean throttle body (throttle valve portion)
• Air drawn in from gaps in gasket, seals, etc. (Refer to P.13B-425).
• Failed manifold absolute pressure sensor
• Failed barometric pressure sensor STEP 5. Check for intake of air from intake hose
• Exhaust leak and inlet manifold.
• Incorrect fuel pressure Q: Is the check result normal?
DIAGNOSIS PROCEDURE STEP 6. Check for leakage of exhaust emission

STEP 1. MUT-II/III diagnosis code Q: Is the check result normal?
Q: Is any other diagnosis code than P0170 output?
YES : Inspection chart for diagnosis code (Refer NO : Repair.
to P.13B-20).
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 7. Connector Check: Injector connector STEP 9. Connector check: B-17X engine control
Connectors: B-01, B-05
relay connector and C-139 engine-ECU <M/T>
connector or engine-A/T-ECU <A/T> connector
B-05 (GR)
B-01 (GR) Connector: B-17X
B-17X
Relay box’s
triangle marks
M
2 1 2 1
Harness
side connector AK304261 AG 4 3
a. B-01 (No. 1 injector connector). Harness

b. B-05 (No. 4 injector connector).
Q: Are the check results normal? Connector: C-139
NO : Replace.

• Check Injector itself (Refer to P.13B-435). C-139 (GR)

C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Replace.
TROUBLESHOOTING
control relay connector and injector connector. connector and C-139 engine-ECU <M/T>
connector or engine-A/T-ECU <A/T> connector.
B-05 (GR) Connectors: B-01, B-05

B-01 (GR)
B-05 (GR)
B-01 (GR)
M
2 1 M
Harness 2 1
side connector AK304261 AG
Harness
side connector AK304261 AG
Connector: B-17X
B-17X Connector: C-139
Relay box’s <L. H. Drive Vehicle>
triangle marks
2 1
C-139 (GR)
4 3
Harness
a. Check harness between B-17X (terminal No. 1) <R. H. Drive Vehicle>

C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
Q: Are the check results normal? 2019 18 17 16 15 14
YES : Go to Step 11 . 2726 2524 23 22 21
NO : Replace. Harness side connector
AK304262 AB

NO : Replace.
TROUBLESHOOTING
STEP 12. Check purge control solenoid valve STEP 13. Fuel pressure measurement.
itself. • Fuel pressure measurement (Refer to
• Check purge control solenoid valve itself (Refer P.13B-426).
to GROUP 17 − Emission Control System −
Evaporative Emission Control System− Purge Q: Is the check result normal?
Control Solenoid Valve P.17-20).
Code No. P0173: Abnormal Fuel System (cylinder 2, 3)

• Refer to Code No. P0202 No. 2 Injector System
P.13B-130.
• Refer to Code No. P0203 No. 3 Injector System STEP 1. MUT-II/III diagnosis code
P.13B-135. Q: Is any other diagnosis code than P0173 output?
FUNCTION to P.13B-20).
• If the fuel system goes out of order, the fuel NO : Go to Step 2 .
correction valve will become larger.
• The engine-ECU <M/T> or engine-A/T-ECU
<A/T> checks whether the fuel trim value is within • Refer to Data List Reference Table P.13B-401.
a specified range.
TROUBLE JUDGMENT b. Item 13: Intake air temperature sensor
Check Conditions
d. Item 95: Manifold absolute sensor
• In learning the air-fuel ratio.
Judgment Criteria
• Long-term fuel trim has continued to be +12.5 % NO : Perform the diagnosis code classified check
or higher for 10 seconds. procedure for the sensor that has shown an
Or abnormal data value (Refer to Inspection
• Long-term fuel trim has continued to be -12.5 % Chart for Diagnosis Code P.13B-20).
or higher for 10 seconds.
PROBABLE CAUSE STEP 3: MUT-II/III data list

• Failed intake air temperature sensor • Refer to Data List Reference Table P.13B-401.
• Failed air flow sensor a. Item 25: Barometric pressure sensor
• Failed purge control solenoid valve
• Failed injector Q: Are the check results normal?
• Air drawn in from gaps in gasket, seals, etc. NO : Replace engine-ECU <M/T> or
• Failed engine coolant temperature sensor engine-A/T-ECU <A/T>.
• Failed manifold absolute pressure sensor
• Failed barometric pressure sensor
• Exhaust leak STEP 4. Check throttle body (throttle valve
• Incorrect fuel pressure portion) for contamination.
• Failed engine-A/T-ECU <A/T> YES : Go to Step 5 .
TROUBLESHOOTING
STEP 5. Check for intake of air from intake hose STEP 9. Connector check: B-17X engine control
and inlet manifold. relay connector and C-139 engine-ECU <M/T>
NO : Repair.
B-17X
Relay box’s
STEP 6. Check for leakage of exhaust emission triangle marks
NO : Repair.
Harness
STEP 7. Connector Check: Injector connector

Connector: B-113
B-02 (GR) B-04 (GR)
M sensor (rear)
2 1
Harness
side connector AK304261 AH
a. B-02 (No. 2 injector connector).

b. B-04 (No. 3 injector connector).
Q: Are the check results normal? B-113 (B)
NO : Replace.
2 1
STEP 8. Check injector itself. 4 3
• Check Injector itself (Refer to P.13B-435).
Harness
NO : Replace injector. Q: Is the check result normal?
NO : Replace.
TROUBLESHOOTING
control relay connector and injector connector. connector and C-139 engine-ECU <M/T>
B-02 (GR) B-04 (GR)
B-02 (GR) B-04 (GR)
M
2 1 M
Harness 2 1
Harness
Connector: B-17X
triangle marks
2 1
C-139 (GR)
4 3
Harness
a. Check harness between B-17X (terminal No. 1) <R. H. Drive Vehicle>

C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
Q: Are the check results normal? 2019 18 17 16 15 14
YES : Go to Step 11 . 2726 2524 23 22 21
NO : Replace. Harness side connector
AK304262 AB

NO : Replace.
TROUBLESHOOTING
STEP 12. Check purge control solenoid valve STEP 13. Fuel pressure measurement.
itself. • Fuel pressure measurement (Refer to
• Check purge control solenoid valve itself (Refer P.13B-426).
Evaporative Emission Control System − Purge Q: Is the check result normal?
Control Solenoid Valve P.17-20).
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R R R R

No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
1 2 1 2 1 2 1 2
2 2 2 2
O W-G R-W R-B
1 5 14 21
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304127 AB
TROUBLESHOOTING
OPERATION
STEP 2. Connector check: B-01 No. 1 injector
• Power is supplied to the injector (terminal No. 1)
connector
• The engine-ECU <M/T> or engine-A/T-ECU Connector: B-01
<A/T> (terminal No. 1) makes the power
transistor in the unit be in "ON" position, and that B-01 (GR)
makes currents go on the injector (terminal No.
2).
FUNCTION
M
• The engine-ECU <M/T> or engine-A/T-ECU 2 1
<A/T> controls the power supply interval of the Harness
injector. side connector AK304261 AC
• The fuel injection amount of the injector depends
on the power supply interval. Q: Is the check result normal?
TROUBLE JUDGMENT NO : Repair.
Check Conditions
• While engine is running. STEP 3. Check No. 1 injector itself.
• Check No. 1 Injector itself (Refer to P.13B-435).
Judgment Criteria
• Injector coil surge voltage (battery positive Q: Is the check result normal?
voltage + 2 V) has not been detected for 2 YES : Go to Step 4 .
seconds. NO : Replace No. 1 injector.
PROBABLE CAUSE STEP 4. Perform voltage measurement at B-01

• Failed No. 1 injector No. 1 injector connector.
• Open/short circuit in injector circuit or loose
connector contact Connector: B-01
B-01 (GR)
DIAGNOSIS PROCEDURE
STEP 1. MUT-II/III actuator test M

2 1
• Refer to Actuator Test Reference Table List Harness
P.13B-410. side connector AK304261 AC
a. Item 01: No. 1 injector • Disconnect connector, and measure at harness

OK: Idling state varies. side.
YES : Intermittent malfunction (Refer to GROUP • Voltage between terminal No. 1 and earth.
00 − How to Use OK: System voltage
Troubleshooting/Inspection Service Points Q: Is the check result normal?
P.00-6). YES : Go to Step 6 .
NO : Go to Step 2 . NO : Go to Step 5 .
TROUBLESHOOTING
STEP 5. Connector check: B-17X engine control STEP 6. Connector check: B-17X engine control
relay connector relay connector
Connector: B-17X Connector: B-17X
B-17X B-17X
Relay box’s Relay box’s
2 1 2 1
4 3 4 3
Harness Harness

B-01 (GR) NO : Repair.
STEP 7. Check harness between B-17X (terminal

No. 1) engine control relay connector and B-01
M (terminal No. 1) No. 1 injector connector.
2 1
Connector: B-17X
Harness
side connector AK304261 AC B-17X
Relay box’s
Q: Is the check result normal? triangle marks
connector and B-01 (terminal No. 1) No. 1 2 1
injector connector. 4 3
• Check power supply line for Harness
open/short circuit. side connector AK304152 AB
NO : Repair.
Connector: B-01
B-01 (GR)
M
2 1
Harness
side connector AK304261 AC

NO : Repair.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 2) No. 1 injector connector and C-139
Connector: C-139
Connector: B-01
B-01 (GR)
C-139 (GR)
M
2 1
C-139 (GR) Connector: C-139

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

damage.
NO : Repair.
TROUBLESHOOTING

STEP 10. Perform signal wave pattern
00 − How to Use
measurement at C-139 engine-ECU <M/T>
P.00-6).
(Using an oscilloscope).
Connector: C-139 engine-A/T-ECU <A/T>.
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Engine: Idling
OK: Waveforms should be display on
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R R R R

No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
1 2 1 2 1 2 1 2
2 2 2 2
O W-G R-W R-B
1 5 14 21
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304127 AB
TROUBLESHOOTING
OPERATION
connector
<A/T> connector (terminal No. 5) makes the
B-02 (GR)
and that makes currents go on the injector
(terminal No. 2).
FUNCTION
M
injector. side connector AK304261 AD
Check Conditions
Judgment Criteria

• Open/short circuit in No. 2 injector circuit or loose
• Failed engine-ECU <M/T> B-02 (GR)
DIAGNOSIS PROCEDURE

2 1
P.13B-410. side connector AK304261 AD

TROUBLESHOOTING
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness

B-02 (GR) NO : Repair.

2 1
Connector: B-17X
Harness
side connector AK304261 AD B-17X
Relay box’s
open/short circuit and damage. side connector AK304152 AB
NO : Repair.
Connector: B-02
B-02 (GR)
M
2 1
Harness
side connector AK304261 AD

NO : Repair.
TROUBLESHOOTING
Connector: C-139
Connector: B-02
B-02 (GR)
C-139 (GR)
M
2 1

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

damage.
NO : Repair.
TROUBLESHOOTING

00 − How to Use
P.00-6).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Engine: Idling
OK: Waveform should be display on
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R R R R

No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
1 2 1 2 1 2 1 2
2 2 2 2
O W-G R-W R-B
1 5 14 21
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304127 AB
TROUBLESHOOTING
OPERATION
connector
<A/T> (terminal No. 14) makes the power B-04 GR)
transistor in the unit be in "ON" position, and that
2).
FUNCTION
M
injector. side connector AK304261 AE
Check Conditions
Judgment Criteria

• Failed engine-ECU<M/T> B-04 GR)
• Failed engine-A/T-ECU<A/T>
DIAGNOSIS PROCEDURE

2 1
• Refer to Actuator test reference table list Harness
P.13B-410. side connector AK304261 AE

TROUBLESHOOTING
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness

B-04 GR) NO : Repair.

2 1
Connector: B-17X
Harness
side connector AK304261 AE B-17X
Relay box’s
open/short circuit. side connector AK304152 AB
NO : Repair.
Connector: B-04
B-04 GR)
M
2 1
Harness
side connector AK304261 AE

NO : Repair.
TROUBLESHOOTING
Connector: C-139
Connector: B-04
B-04 GR)
C-139 (GR)
M
2 1

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
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AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

damage.
NO : Repair.
TROUBLESHOOTING

00 − How to Use
P.00-6).
(Using on oscilloscope).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Engine: Idling
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R R R R

No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
1 2 1 2 1 2 1 2
2 2 2 2
O W-G R-W R-B
1 5 14 21
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304127 AB
TROUBLESHOOTING
OPERATION
connector
<A/T> (terminal No. 21) makes the power B-05 (GR)
2).
FUNCTION
M
<A/T> connector controls the power supply Harness
interval of the injector. side connector AK304261 AF
Check Conditions
• Check No. 4 Injector (Refer to P.13B-435) itself.
Judgment Criteria

• Failed engine-ECU <M/T> B-05 (GR)
DIAGNOSIS PROCEDURE

2 1
P.13B-410. side connector AK304261 AF

TROUBLESHOOTING
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness

YES : Go to Step 7.
B-05 (GR)
NO : Repair.

2 1
Connector: B-17X
Harness
side connector AK304261 AF B-17X
Relay box’s
open/short circuit and damage. side connector AK304152 AB
NO : Repair.
Connector: B-05
B-05 (GR)
M
2 1
Harness
side connector AK304261 AF

NO : Repair.
TROUBLESHOOTING
Connector: C-139
Connector: B-05
B-05 (GR)
C-139 (GR)
M
2 1

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
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AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

damage.
NO : Repair.
TROUBLESHOOTING

00 − How to Use
P.00-6).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
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AK304262 AB
• Engine: Idling
TROUBLESHOOTING
Code No. P0222: Throttle Position Sensor (Sub) Circuit Low Input
Throttle position sensor (sub) circuit
(sub)
B-06 Hall IC Electronically
controlled
1 2 3 4 5 6 throttle valve
5 6 3
R G B
106 113 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304122AC

valve (terminal No. 3). • Throttle position sensor (sub) output voltage is
• The sensor signal is inputted to the engine-ECU 2.25 V or less for 0.5 second.
PROBABLE CAUSE
• Failed throttle position sensor (sub)
• Open/short circuit in throttle position sensor (sub)
TROUBLESHOOTING

NO : Go to Step 4 .

• Refer to Data list reference table P.13B-401. STEP 4. Connector check: C-142 engine-ECU
a. Item 14: Throttle position sensor (sub) <M/T> connector or engine-A/T-ECU <A/T>
connector
P.00-6).
NO : Go to Step 2 .
C-142 (GR)

C-142 (GR)
B-06 (B) 959493 92 91

6 5 4 3 2 1 104 103102 101100 99 98 97 96
112111110 109108107 106105

NO : Repair.
Connector: B-06
B-06 (B)
6 5 4 3 2 1

side.
OK: 4.9 − 5.1 V
TROUBLESHOOTING
No. 5) electronically controlled throttle valve • Refer to Data List Reference Table P.13B-401.
connector and C-142 (terminal No. 106) a. Item 79: Throttle position sensor (main)
<A/T> connector. YES : Intermittent malfunction (Refer to GROUP
Connector: B-06 00 − How to Use
P.00-6).
B-06 (B) STEP 7. Connector check: C-142 engine-ECU

6 5 4 3 2 1 <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)

C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
959493 92 91
112111110 109108107 106105
104 103102 101100 99 98 97 96
120119118 117116115 114113
112111110 109108107 106105
AK304153 AB
• Check power supply line for open/short circuit. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Check power supply line for damage. • Check output line for open/short circuit and
damage.
NO : Repair.

throttle valve
throttle valve, re-check the trouble symptoms.
YES : Check end.
TROUBLESHOOTING
Code No. P0223: Throttle Position Sensor (Sub) Circuit High Input
Throttle position sensor (sub) circuit
(sub)
B-06 Hall IC Electronically
controlled
5 6 3
R G B
106 113 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304122AC

valve (terminal No. 3). • Throttle position sensor (sub) output voltage is
• The sensor signal is inputted to the engine-ECU 4.8 V or more for 0.5 second.
PROBABLE CAUSE
• Failed throttle position sensor (sub)
• Open/short circuit in throttle position sensor (sub)
TROUBLESHOOTING

NO : Go to Step 4 .

a. Item 14: Throttle position sensor (sub) <M/T> connector or engine-A/T-ECU <A/T>
connector
P.00-6).
NO : Go to Step 2 .
C-142 (GR)

C-142 (GR)
B-06 (B) 959493 92 91

6 5 4 3 2 1 104 103102 101100 99 98 97 96
112111110 109108107 106105

NO : Repair.
Connector: B-06
B-06 (B)
6 5 4 3 2 1

side.
OK: 2 Ω or less
TROUBLESHOOTING
a. Item 14: Throttle position sensor (sub)
Connector: B-06
00 − How to Use
P.00-6).
B-06 (B) engine-A/T-ECU <A/T>.
6 5 4 3 2 1
throttle valve
Connector: C-142
<L. H. Drive Vehicle> throttle valve, re-check the trouble symptoms.
YES : Check end.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

TROUBLESHOOTING
Code No. P0300: Random/Multiple Cylinder Misfire Detected

• Refer to Code No. P0201: No. 1 injector system • Ignition system related part(s) failed
P.13B-125. • Failed crank angle sensor
• Refer to Code No. P0202: No. 2 injector system • Incorrect air-fuel ratio
P.13B-130. • Low compression pressure
• Refer to Code No. P0203: No. 3 injector system • Failed engine coolant temperature sensor
P.13B-135. • Skipping of timing belt teeth.
• Refer to Code No. P0204: No. 4 injector system • EGR system and EGR valve failed
P.13B-140.
FUNCTION
• If a misfire occurs while the engine is running, the DIAGNOSIS PROCEDURE
engine speed changes for an instant.
STEP 1.MUT-II/III data list
<A/T> checks for such changes in engine speed. • Item 22: Crank angle sensor
TROUBLE JUDGMENT OK: Keep the engine speed constant to make
the pulse width of output waveform
Check Conditions constant.
• Engine speed is 500 − 6,500 r/min.
• Engine coolant temperature is −10°C or higher. Q: Is the check result normal?
• Barometric pressure is 76 kPa or higher. YES : Go to Step 2 .
• Volumetric efficiency is between 30% and 55 %. NO : Check crank angle sensor system (Refer to
• Adaptive learning is complete for the vane which Code No. P0335 P.13B-169).
generates a crankshaft position signal.
• While the engine is running, excluding gear STEP 2. MUT-II/III data list
shifting, deceleration, sudden • Refer to Data list reference table P.13B-401.
acceleration/deceleration and A/C compressor a. Item 21: Engine coolant temperature sensor
switching. b. Item 81: Long-term fuel compensation
• The throttle deviation is −0.06 V/10 ms to +0.06 c. Item 82: Short-term fuel compensation
V/10 ms.
Judgment Criteria (change in the angular YES : Go to Step 3 .
acceleration of the crankshaft is used for NO : Perform the diagnosis code classified check
misfire detection). procedure for the sensor that has shown an
• Misfire has occurred more frequently than the abnormal data valve (Refer to Inspection
limit during the last 200 revolutions (when the Chart for Diagnosis Code P.13B-20).
catalyst temperature has been 950°C or higher).
Or
• Misfire has occurred 15 times or more in the last STEP 3. Check ignition coil spark.
1,000 revolutions (that has been equivalent to Q: Is the check result normal?
approximately 1.5 times the emission standard). YES : Go to Step 4 .
Inspection Procedure 31 P.13B-386).
TROUBLESHOOTING
STEP 4. Connector check: Injector connector NO : Repair.
B-05 (GR) STEP 7. Check for intake of air from intake hose
B-01 (GR) B-02 (GR) B-04 (GR)
and inlet manifold.
NO : Repair.
M
2 1
Harness STEP 8. Check for skipped timing belt teeth.
a. B-01 (No. 1 injector connector) YES : Go to Step 9 .
b. B-02 (No. 2 injector connector) NO : Repair.
c. B-04 (No. 3 injector connector)
d. B-05 (No. 4 injector connector) STEP 9. Check EGR valve (stepper motor) itself.
• Check EGR valve (stepper motor) itself [Refer to
YES : Go to Step 5 . GROUP 17 − Exhaust Gas Recirculation (EGR)
NO : Repair. System − EGR Valve (Stepper Motor) Check
<4G69> P.17-25].
STEP 5. Check injector itself. Q: Is the check result normal?

• Check Injector itself (Refer to P.13B-435). YES : Go to Step 10.
NO : Replace EGR valve (stepper motor)
NO : Replace injector. STEP 10. Check the trouble symptoms.
STEP 6. Fuel pressure measurement. YES : Replace engine-ECU <M/T> or
• Fuel pressure measurement (Refer to Fuel engine-A/T-ECU <A/T>.
Pressure Test P.13B-426) NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
Q: Is the check result normal? Troubleshooting/Inspection Service
PointsP.00-6).
TROUBLESHOOTING
Code No. P0301: No. 1 Cylinder Misfire Detected
OPERATION • Low compression pressure

• Refer to Code No. P0201: No. 1 Injector System • Failed engine-ECU <M/T>
P.13B-125. • Failed engine-A/T-ECU <A/T>

• If a misfire occurs while the engine is running, the
• The engine-ECU <M/T> or engine-A/T-ECU STEP 1.Check ignition coil spark.
<A/T> checks for such changes in engine speed. Q: Is the check result normal?
TROUBLE JUDGMENT NO : Check ignition circuit system (Refer to
Check Conditions Inspection procedure 31 P.13B-386)
• Engine coolant temperature is −10°C or higher. STEP 2.Connector check: B-01 No. 1 injector
• Barometric pressure is 76 kPa or higher. connector
• Volumetric efficiency is between 30% and 55 %.
Connector: B-01
• Adaptive learning is complete for the vane which
generates a crankshaft position signal. B-01 (GR)
• While the engine is running, excluding gear
shifting, deceleration, sudden
acceleration/deceleration and A/C compressor
switching.
• The throttle deviation is −0.06 V/10 ms to +0.06 M
V/10 ms. 2 1
Harness
Judgment Criteria (change in the angular side connector AK304261 AC
acceleration of the crankshaft is used for
misfire detection). Q: Is the check result normal?
• Misfire has occurred more frequently than the YES : Go to Step 3 .
limit during the last 200 revolutions (when the NO : Repair.
Or STEP 3.Check No. 1 injector itself.
• Misfire has occurred 15 times or more in the last • Check Injector itself (Refer to P.13B-435).
1,000 revolutions (that has been equivalent to
approximately 1.5 times the emission standard). Q: Is the check result normal?
NO : Replace No. 1 injector.
PROBABLE CAUSE
• Ignition system related part(s) failed
TROUBLESHOOTING
STEP 4.Connector check: B-17X engine control NO : Repair.
STEP 5.Check harness between B-17X (terminal
Connector: B-17X
B-17X (terminal No. 1) No. 1 injector connector.
Relay box’s
triangle marks Connector: B-17X
B-17X
2 1 Relay box’s
triangle marks
4 3
Harness 2 1
4 3
Connector: C-139 Harness
Connector: B-01
B-01 (GR)
C-139 (GR)
<R. H. Drive Vehicle> M

2 1
Harness
C-139 (GR) side connector AK304261 AC

4 3 2 1
13 12 1110 9 8 7 6 5 NO : Repair.
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TROUBLESHOOTING
STEP 6. Check harness between B-01(terminal NO : Repair.
No. 2) No. 1 injector connector and C-139
engine-A/T-ECU <A/T> connector STEP 7. Fuel pressure measurement.
• Fuel pressure measurement (Refer to fuel
Connector: B-01
pressure test P.13B-426).
YES : Go to Step 8
NO : Repair.
M
2 1
Harness YES : Replace engine-ECU <M/T> or
Connector: C-139
00 − How to Use
<L. H. Drive Vehicle> Troubleshooting/Inspection Service Points
P.00-6).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
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AK304262 AB

TROUBLESHOOTING

• Refer to Code No. P0202 No. 2 Injector System • Failed engine-ECU <M/T>

• The engine-ECU <M/T> or engine-A/T-ECU STEP 1. Check ignition coil spark.
Check Conditions Inspection Procedure 31 P.13B-386).
• Engine coolant temperature is −10°C or higher. STEP 2. Check connector: B-02 No. 2 injector
Connector: B-02
switching.
V/10 ms. 2 1
Harness
Judgment Criteria (change in the angular side connector AK304261 AD
Or STEP 3. Check No. 2 injector itself.
PROBABLE CAUSE
TROUBLESHOOTING
STEP 4. Connector check: B-17X engine control NO : Repair.
Connector: B-17X
No. 1) engine control relay connector and
B-17X B-02(terminal No. 1) No. 2 injector connector.
Relay box’s
B-17X
2 1 Relay box’s
triangle marks
4 3
Harness 2 1
4 3
Connector: B-02
B-02 (GR)
C-139 (GR)

2 1
Harness
C-139 (GR) side connector AK304261 AD

4 3 2 1
13 12 1110 9 8 7 6 5 NO : Repair.
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TROUBLESHOOTING
Connector: B-02
pressure test P.13B-426)
NO : Repair.
M
2 1
Connector: C-139
00 − How to Use
P.00-6).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
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AK304262 AB

TROUBLESHOOTING

P.13B-135. • Failed engine-A/T-ECU

• The engine-ECU <M/T> or engine-A/T-ECU STEP 1. Check ignition coil spark.
• Engine coolant temperature is −10°C or higher. STEP 2. Connector check: B-04 No. 3 injector
Connector: B-04
generates a crankshaft position signal. B-04 GR)
switching.
V/10 ms. 2 1
Harness
Judgment Criteria (change in the angular side connector AK304261 AE
PROBABLE CAUSE
TROUBLESHOOTING
Connector: B-17X
Relay box’s
B-17X
2 1 Relay box’s
triangle marks
4 3
Harness 2 1
4 3
Connector: B-04
B-04 GR)
C-139 (GR)

2 1
Harness
C-139 (GR) side connector AK304261 AE

4 3 2 1
13 12 1110 9 8 7 6 5 NO : Repair.
2019 18 17 16 15 14
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AK304262 AB

TROUBLESHOOTING
Connector: B-04
pressure test P.13B-426)
B-04 GR)
NO : Repair.
M
2 1
Connector: C-139
00 − How to Use
P.00-6).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING


• The engine-ECU <M/T> or engine-A/T-ECU STEP 1. Check the ignition coil spark.
TROUBLE JUDGMENT NO : Check ignition Circuit System (Refer to
• Engine coolant temperature is −10°C or higher. STEP 2. Connector check: B-05 No. 4 injector
Connector: B-05
switching.
V/10 ms. 2 1
Harness
Judgment Criteria (change in the angular side connector AK304261 AF
PROBABLE CAUSE
TROUBLESHOOTING
Connector: B-17X
Relay box’s
B-17X
2 1 Relay box’s
triangle marks
4 3
Harness 2 1
4 3
Connector: B-05
B-05 (GR)
C-139 (GR)

2 1
Harness
C-139 (GR) side connector AK304261 AF

4 3 2 1
13 12 1110 9 8 7 6 5 NO : Repair.
2019 18 17 16 15 14
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AK304262 AB

TROUBLESHOOTING
engine-A/T-ECU <A/T> connector. STEP 7. Fuel pressure measurement.
• Fuel pressure measurement (Refer to Fuel
Connector: B-05
Pressure Test P.13B-426)
B-05 (GR)
NO : Repair.
M
2 1
Connector: C-139
00 − How to Use
<L. H. Drive Vehicle> Troubleshooting/Inspection Service
PointsP.00-6).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
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AK304262 AB

TROUBLESHOOTING
Code No. P0325: Detonation Sensor System
Detonation sensor circuit
C-141
(MU803804)
6162 6364 Engine-ECU <M/T>
656667686970717273 Engine-A/T-ECU <A/T>
747576777879808182
8384 858687 8889
89
B B
B-102
MU802661
2 1 1 2
Detonation sensor
Wire colour code

AK304128 AB

• The sensor signal is inputted to the engine-ECU
Check Conditions
• After 2 seconds have passed since the engine
89) from the detonation sensor (terminal No. 1).
starting sequence was completed.
FUNCTION • Engine speed is 2,500 r/min or higher.
• The detonation sensor detects the vibration of the Judgment Criteria
cylinder block caused by detonation waves, and • Change of detonation sensor output voltage
inputs a signal to the engine-ECU <M/T> or (detonation sensor peak voltage in each 1/2 turn
engine-A/T-ECU <A/T>. of the crankshaft) has not been 0.06 V or more in
• In response to the signal, the engine-ECU <M/T> the last consecutive 200 periods.
or engine-A/T-ECU <A/T> provides controls to
retard the ignition timing when the detonation PROBABLE CAUSE
occurs. • Failed detonation sensor
• Open/short circuit in detonation sensor circuit or
TROUBLESHOOTING

• Failed engine-A/T-ECU <A/T> NO : Check and repair harness between B-102
(terminal No. 2) detonation sensor
DIAGNOSIS PROCEDURE connector and body earth.
• Check earthing line for open circuit
and damage.
STEP 1. Connector check: B-102 detonation
sensor connector
Connector: B-102
Connector: C-141
B-102 (GR) <L. H. Drive Vehicle>
2 1 Detonation sensor C-141(GR)

Harness

YES : Go to Step 2 . C-141 (GR)
NO : Repair.
STEP 2. Perform resistance measurement at

B-102 detonation sensor connector.
Connector: B-102
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
B-102 (GR) Harness side connector
AK304154 AB

2 1 Detonation sensor YES : Go to Step 4 .
Harness NO : Repair.

side.
OK: 2 Ω or less
TROUBLESHOOTING
No. 1) detonation sensor connector and C-141
engine-A/T-ECU <A/T> connector. STEP 5. Check the trouble symptoms.
Connector: B-102 Q: Does trouble symptom persist?
00 − How to Use
B-102 (GR)
P.00-6).
2 1 Detonation sensor STEP 6. Replace detonation sensor.

Harness • After replacing the detonation sensor, re-check
Connector: C-141 Q: Does trouble symptom persist?

NO : Check end.
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

damage.
TROUBLESHOOTING
Code No. P0335: Crank Angle Sensor System
Crank angle sensor circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
relay
3 4
1 2
R
1 B-29
B-29 1 B-29-1
(MU802064)
Crank
1 2 3 angle
sensor
B-29-1
1 2 3
3 2
3 2
B-W
18
J/C (1)
G-R
C-16
17
B-W
88 70
C-141
(MU803804)
6162 6364
656667686970717273
747576777879808182
8384 858687 8889
5V
Engine-ECU <M/T>
Wire colour code

AK304129 AB
OPERATION (terminal No. 1) and is earthed to the engine-ECU

• Power is supplied to the crank angle sensor <M/T> or engine-A/T-ECU <A/T> (terminal No.
(terminal No. 1) from the engine control relay 88) from the crank angle sensor (terminal No. 3).
TROUBLESHOOTING
• A power voltage of 5 V is applied to the crank

STEP 2. Connector check: B-29 crank angle
angle sensor output terminal (terminal No. 2)
sensor intermediate connector
from the engine-ECU <M/T> or engine-A/T-ECU
<A/T> (terminal No. 70). Connector: B-29
FUNCTION
• The crank angle sensor detects the crank angle
(position) and inputs a pulse signal to the B-29 (GR)
engine-ECU <M/T> or engine-A/T-ECU <A/T>.
or engine-A/T-ECU <A/T> controls the injector, 3 2 1
etc. Harness
TROUBLE JUDGMENT
• While engine is being cranked.
NO : Repair.
Judgment Criteria
• Crank angle sensor output voltage has not been
changed (no pulse signal has been input) for 2
crank angle sensor intermediate connector.
seconds.
Connector: B-29
PROBABLE CAUSE
• Failed crank angle sensor
• Open/short circuit in crank angle sensor circuit or
loose connector contact B-29 (GR)
3 2 1
DIAGNOSIS PROCEDURE Harness
STEP 1. MUT-II/III data list • Disconnect connector, and measure at harness

• Refer to Data List Reference Table P.13B-401. side.
a. Item 22: Crank angle sensor • Ignition switch: ON
Q: Is the check result normal? OK: 4.9 − 5.1 V
00 − How to Use Q: Is the check result normal?
P.00-6). NO : Go to Step 4 .
NO : Go to Step 2 .
TROUBLESHOOTING
engine-ECU connector. <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-141
<L. H. Drive Vehicle> Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR) <R. H. Drive Vehicle>
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574 6463 62 61
8988 87 86 85 8483 7372 7170 69 6867 6665
82 818079 78 7776 7574
Harness side connector 8988 87 86 85 8483
AK304154 AB Harness side connector

AK304154 AB
Connector: B-29
Connector: B-29
B-29 (GR)
B-29 (GR)
3 2 1
Harness 3 2 1
Harness
• Disconnect B-29 crank angle sensor intermediate YES : Check and repair harness between B-29
connector. (terminal No. 2) crank angle sensor
• Ignition switch: ON intermediate connector and C-141 (terminal
• Voltage between terminal No. 70 and earth. No. 70) engine-ECU <M/T> connector or
OK: 4.9 − 5.1 V engine-A/T-ECU <A/T> connector.
NO : Go to Step 6 .
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 2) crank angle sensor intermediate connector
connector and C-141 (terminal No. 70) engine-ECU <M/T>
Connector: C-141
Connector: B-29
C-141(GR) B-29 (GR)
3 2 1
Connector: C-141
6463 62 61
7372 7170 69 6867 6665 C-141(GR)
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
Q: Is the check result normal? C-141 (GR)
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.

a. Item 22: Crank angle sensor
00 − How to Use
P.00-6).
TROUBLESHOOTING

crank angle sensor intermediate connector.
intermediate connector and B-17X (terminal
Connector: B-29 No. 1) engine control relay connector.
open/short circuit.
NO : Repair.
B-29 (GR)

B-29 crank angle sensor intermediate connector.
3 2 1
Harness Connector: B-29

side.
• Ignition switch: ON B-29 (GR)
OK: System voltage
3 2 1
Q: Is the check result normal? Harness
YES : Go to Step 11 . side connector AK304267 AB
NO : Go to Step 10 . • Disconnect connector, and measure at harness
side.
STEP 10. Connector check: B-17X engine control • Resistance between terminal No. 3 and earth.
relay connector OK: 2 Ω or less
Connector: B-17X Q: Is the check result normal?
B-17X YES : Go to Step 14 .
Relay box’s
triangle marks
2 1
4 3
Harness
Connector: B-29
B-29 (GR)
3 2 1
Harness

TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 3) crank angle sensor intermediate connector
Connector: C-141
Connector: B-29
C-141(GR) B-29 (GR)
3 2 1
Connector: C-141
6463 62 61
7372 7170 69 6867 6665 C-141(GR)
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
STEP 14. Perform output wave pattern NO : Repair.
measurement at B-29 crank angle sensor
intermediate connector (Using an oscilloscope).
Connector: B-29
No. 1) crank angle sensor intermediate connector
and B-17X (terminal No. 1) engine control relay
connector.
B-29 (GR) Connector: B-29
3 2 1
Harness B-29 (GR)

connect connector, and measure at pick-up 3 2 1
harness. Harness
• Engine: Idling
Connector: B-17X
B-17X
Relay box’s
Inspection procedure using an oscilloscope triangle marks
(Refer to P.13B-418), its maximum value
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in 2 1
waveform. 4 3
Q: Is the check result normal? Harness

NO : Go to Step 15 . • Check power supply line for damage.

STEP 15. Connector check: B-17X engine control YES : Go to Step 17 .
relay connector NO : Repair.
Connector: B-17X
B-17X
Relay box’s
triangle marks
2 1
4 3
Harness

TROUBLESHOOTING
<M/T> connectors or engine-A/T-ECU <A/T> No. 2) crank angle sensor intermediate connector
Connector: C-141
Connector: B-29
C-141(GR) B-29 (GR)
3 2 1
Connector: C-141
6463 62 61
7372 7170 69 6867 6665 C-141(GR)
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
STEP 19. Check harness between B-29 (terminal STEP 20. Connector check: B-29-1 crank angle
No. 3) crank angle sensor intermediate connector sensor connector
and C-141 (terminal No. 88) engine-ECU <M/T> Connector: B-29-1
Connector: B-29
B-29-1 (B)
B-29 (GR)
3 2 1
Harness
3 2 1 side connector AK304268 AB
Harness
NO : Repair.
Connector: C-141
STEP 21. Check harness between B-29 crank
angle sensor intermediate connector and B-29-1
crank angle sensor connector.
C-141(GR)
Connector: B-29

C-141 (GR) B-29 (GR)
3 2 1
Harness
6463 62 61 Connector: B-29-1

7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB B-29-1 (B)
• Check earthing line for damage. 3 2 1
Harness
NO : Repair. • Check power supply line open/short circuit and
damage.
• Check output line open/short circuit and damage.
• Check earthing line for open/short circuit and
damage.
NO : Replace the timing belt cover.
TROUBLESHOOTING
STEP 22. Check the crankshaft sensing blade. STEP 23: MUT-II/III data list
YES : Go to Step 23 . a. Item 22: Crank angle sensor
NO : Replace the crankshaft sensing blade. Q: Is the check result normal?
00 − How to Use
P.00-6).
NO : Replace crank angle sensor.
TROUBLESHOOTING
Code No. P0340: Camshaft Position Sensor System
Camshaft position sensor circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
relay
3 4
1 2
R
3
B-106
MU802337 Camshaft
position
sensor
1 2 3
1 2
B-W
19
J/C (1)
L-Y
C-16
17
B-W
88 71
C-141
(MU803804)
6162 6364
656667686970717273
747576777879808182
8384 858687 8889 5V
Engine-ECU <M/T>
Wire colour code

AK304130 AB
TROUBLESHOOTING
OPERATION YES : Go to Step 2 .

• Power is supplied to the camshaft position sensor NO : Repair.
(terminal No. 3) from the engine control relay
(terminal No. 1) and is earthed to the engine-ECU
<M/T> or engine-A/T-ECU <A/T> (terminal No. camshaft position sensor connector.
88) from the camshaft position sensor (terminal
No. 1). Connector: B-106
• A power voltage of 5 V is applied to the camshaft
position sensor output terminal (terminal No. 2)
from the engine-ECU <M/T> or engine-A/T-ECU B-106 (B)
<A/T> (terminal No. 71).
FUNCTION 3 2 1
• The camshaft position sensor detects the top Harness
dead center on the compression stroke of the No. side connector
1 cylinder and inputs a pulse signal to the AK304269 AB
engine-ECU <M/T> or engine-A/T-ECU <A/T>. • Disconnect connector, and measure at harness

side.
TROUBLE JUDGMENT
Check Conditions • Voltage between terminal No. 3 and earth.
• Engine speed is 50 r/min or higher. OK: System voltage
• Camshaft position sensor output voltage has not YES : Go to Step 4 .
been changed (no pulse signal is has been input) NO : Go to Step 3 .
for 2 seconds.
PROBABLE CAUSE STEP 3. Connector check: B-17X engine control

• Failed camshaft position sensor relay connector
• Open/short circuit in camshaft position sensor Connector: B-17X
circuit or loose connector contact
B-17X
• Failed engine-A/T-ECU <A/T> Relay box’s
triangle marks
DIAGNOSIS PROCEDURE
2 1
4 3
STEP 1. Connector check: B-106 camshaft
position sensor connector Harness
Connector: B-106
Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
3 2 1
Harness
side connector Harness
AK304269 AB side connector
AK304269 AB
TROUBLESHOOTING

<A/T> connector.
• Check power supply line for Connector: C-141
open/short circuit. <L. H. Drive Vehicle>
NO : Repair.

camshaft position sensor connector. C-141(GR)
Connector: B-106

B-106 (B) C-141 (GR)
3 2 1
Harness
side connector
AK304269 AB
6463 62 61
7372 7170 69 6867 6665
• Disconnect connector, and measure at harness 82 818079 78 7776 7574
side. 8988 87 86 85 8483
• Ignition switch: ON Harness side connector

• Voltage between terminal No. 2 and earth. AK304154 AB
OK: 4.9 − 5.1 V

Connector: B-106
NO : Go to Step 5 . B-106 (B)
3 2 1
Harness
side connector
AK304269 AB

• Disconnect B-106 camshaft position sensor
connector.
OK: 4.9 − 5.1 V
NO : Go to Step 7 .
TROUBLESHOOTING

connector
NO : Repair.

C-141(GR) <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-141
<R. H. Drive Vehicle> <L. H. Drive Vehicle>
C-141 (GR)
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483 C-141 (GR)
AK304154 AB
Connector: B-106
6463 62 61
7372 7170 69 6867 6665
B-106 (B) 82 818079 78 7776 7574
8988 87 86 85 8483
3 2 1 AK304154 AB
Harness
side connector Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
STEP 8. Check harness between B-106 (terminal STEP 10. Perform resistance measurement at
No. 2) camshaft position sensor connector and B-106 camshaft position sensor connector.
C-141 (terminal No. 71) engine-ECU <M/T> Connector: B-106
Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
Harness
3 2 1 side connector
AK304269 AB
Harness
side connector • Disconnect connector, and measure at harness
AK304269 AB
side.
Connector: C-141
OK: 2 Ω or less
C-141(GR)
connector
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
Harness side connector <R. H. Drive Vehicle>
AK304154 AB C-141 (GR)
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
STEP 9. Check the trouble symptoms. 82 818079 78 7776 7574
8988 87 86 85 8483
Q: Does trouble symptom persist? Harness side connector
AK304154 AB
00 − How to Use YES : Go to Step 12 .
P.00-6).
TROUBLESHOOTING
STEP 12. Check harness between B-106 (terminal STEP 13. Perform output wave pattern
No. 1) camshaft position sensor connector and measurement at B-106 camshaft position sensor
C-141 (terminal No. 88) engine-ECU <M/T> connector (Using an oscilloscope).
connector or engine-A/T-ECU <A/T> connector. Connector: B-106
Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
3 2 1 Harness
AK304269 AB
Connector: C-141 harness.
<L. H. Drive Vehicle> • Engine: Idling
C-141(GR)
(Refer to P.13B-418), its maximum value
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in
C-141 (GR)
waveform.

6463 62 61
7372 7170 69 6867 6665
relay connector.
82 818079 78 7776 7574
8988 87 86 85 8483 Connector: B-17X
Harness side connector B-17X
AK304154 AB
Relay box’s
triangle marks
• Check earthing line for open circuit and damage. 2 1

YES : Go to Step 9 . Harness
NO : Repair. side connector AK304152 AB

NO : Repair.
TROUBLESHOOTING
No. 3) camshaft position sensor connector and <M/T> connectors or engine-A/T-ECU <A/T>
B-17X (terminal No. 1) engine control relay connector
connector.
Connector: C-141
Connector: B-106
B-106 (B)
C-141(GR)
3 2 1
Harness
side connector <R. H. Drive Vehicle>
AK304269 AB C-141 (GR)
Connector: B-17X
B-17X
Relay box’s
triangle marks
6463 62 61
7372 7170 69 6867 6665
2 1 82 818079 78 7776 7574
8988 87 86 85 8483
Harness AK304154 AB
• Check power supply line for damage. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
No. 2) camshaft position sensor connector and No. 1) camshaft position sensor connector and
C-141 (terminal No. 71) engine-ECU <M/T> C-141 (terminal No. 88) engine-ECU <M/T>
connector or engine-A/T-ECU <A/T> connector. connector or engine-A/T-ECU <A/T> connector.
B-106 (B) B-106 (B)
3 2 1 3 2 1
Harness Harness
side connector side connector
AK304269 AB AK304269 AB

C-141(GR) C-141(GR)

C-141 (GR) C-141 (GR)
6463 62 61 6463 62 61
7372 7170 69 6867 6665 7372 7170 69 6867 6665
82 818079 78 7776 7574 82 818079 78 7776 7574
8988 87 86 85 8483 8988 87 86 85 8483
AK304154 AB AK304154 AB
• Check output line for damage. NOTE: Before checking harness, check intermediate
Q: Is the check result normal? connector C-16, and repair if necessary.
YES : Go to Step 18 . • Check earthing line for damage.
NO : Repair.
NO : Repair.
TROUBLESHOOTING
STEP 19. Check camshaft position sensing STEP 20. Check the trouble symptoms.
cylinder. Q: Does trouble symptom persist?
Q: Is the check result normal? YES : Replace camshaft position sensor.
YES : Go to Step 20 . NO : Intermittent malfunction (Refer to GROUP
NO : Replace camshaft position sensing cylinder. 00 − How to Use
P.00-6).
TROUBLESHOOTING
Code No. P0403: Exhaust Gas Recirculation Control System
EGR valve circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R
R R
2 5
B-105
(MU802056)
Exhaust gas
recirculation
1 2 3 (EGR) valve
4 5 6
1 3 4 6
L-B Y L-Y L-R
3 12 19 26
C-139
(MU803802)
1 2 3 4
Engine-ECU <M/T>
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK304131AB
TROUBLESHOOTING

• Power is supplied to the EGR valve (terminal No. NO : Repair.
2 and No. 5) from the engine control relay
(terminal No. 1).
STEP 2. Check EGR valve itself.
• The engine-ECU <M/T> or engine-A/T-ECU • Check EGR control solenoid valve itself [Refer to
<A/T> (terminal No. 3, No. 12, No. 19 and No. 26) GROUP 17 − Emission Control System −
makes the power transistor in the unit be in "ON", Exhaust Gas Recirculation (EGR) System − EGR
and that makes currents go on the EGR valve Valve (stepper motor) Check <4G69> P.17-25.
(terminal No. 1, No. 3, No. 4 and No. 6).
FUNCTION YES : Go to Step 3 .
• Based on the signal from engine-ECU <M/T> or NO : Replace EGR valve (stepper motor).
engine-A/T-ECU <A/T>, the EGR valve (stepper
motor) controls the EGR rate. STEP 3. Perform voltage measurement at B-102
EGR valve connector.
TROUBLE JUDGMENT
Connector: B-105
Check Conditions
• Battery positive voltage is 10.3 V or higher.
Judgment Criteria
• The EGR valve motor coil surge voltage (battery
positive voltage +2 V) is not detected for 3 B-105 (GR)
seconds. 3 2 1
6 5 4
PROBABLE CAUSE
Harness
• Failed EGR valve side connector AK304270 AB
• Open/short circuit in EGR valve circuit or loose
connector contact
side.
• Voltage between terminal No. 2, No. 5 and earth.
DIAGNOSIS PROCEDURE OK: System voltage
STEP 1. Connector check: B-105 EGR valve NO : Go to Step 4 .
connector
Connector: B-105
B-105 (GR)
3 2 1
6 5 4
Harness

TROUBLESHOOTING
STEP 4. Connector check: B-17X engine control STEP 5. Perform voltage measurement at C-139
relay connector engine-ECU connector or engine-A/T-ECU <A/T>.
Connector: B-17X Connector: C-139
B-17X <L. H. Drive Vehicle>
Relay box’s
triangle marks
C-139 (GR)
2 1
4 3
Harness
Connector: B-105
C-139 (GR)
B-105 (GR) 4 3 2 1
3 2 1 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
6 5 4 2726 2524 23 22 21
Harness Harness side connector

AK304262 AB
Q: Is the check result normal? • Disconnect connector, and measure at harness

YES : Check and repair harness between B-105 side.
(terminal No. 2, No. 5) EGR valve connector • Ignition switch: ON
and B-17X (terminal No. 1) engine control • Voltage between terminal No. 3, No. 12, No. 19,
relay connector. No. 26 and earth.
• Check power supply line for OK: System voltage
open/short circuit.
NO : Go to Step 6 .
TROUBLESHOOTING

EGR valve and C-139 engine-ECU <M/T>
Connector: C-139 connector
<L. H. Drive Vehicle> a. Check harness between B-105
(terminal No. 1) EGR valve and
<M/T> connector or engine-A/T-ECU
C-139 (GR) <A/T> connector
b. Check harness between B-105
<R. H. Drive Vehicle> <M/T> connector or engine-A/T-ECU
<A/T> connector
c. Check harness between B-105
C-139 (GR)
<A/T> connector
4 3 2 1
13 12 1110 9 8 7 6 5 d. Check harness between B-105
2019 18 17 16 15 14
2726 2524 23 22 21
Harness side connector C-139 (terminal No. 26) engine-ECU
AK304262 AB
<A/T> connector
Connector: B-105
open/short circuit.
NO : Repair.
B-105 (GR)
3 2 1
6 5 4
Harness

TROUBLESHOOTING
STEP 7. Connector check: C-139 engine-ECU NO : Repair.
connector
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING

STEP 8. Check harness between B-105 EGR YES : Go to Step 9 .
valve and C-139 engine-ECU <M/T> or NO : Repair.
Connector: B-105
No. 2, No. 5) EGR valve connector and B-17X
Connector: B-105
B-105 (GR)
3 2 1
6 5 4
Harness
side connector AK304270 AB B-105 (GR)
3 2 1
Connector: C-139 6 5 4
<L. H. Drive Vehicle> Harness
Connector: B-17X
C-139 (GR) B-17X
Relay box’s
triangle marks
<R. H. Drive Vehicle> 2 1

4 3
C-139 (GR) Harness

4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16
2726 2524 23
15
22
14
21
NO : Repair.
AK304262 AB

EGR valve and C-139 (terminal No. 3)
engine-A/T-ECU <A/T> connector
TROUBLESHOOTING
Code No. P0421: Warm Up Catalyst Malfunction (cylinder 1,4)

• The signal from the cylinder 1, 4 oxygen sensor
(rear) differs from the cylinder 1, 4 oxygen sensor
(front). That is because the catalytic converter STEP 1. Check for leakage of exhaust emission
purifies exhaust gas. When the catalytic from exhaust manifold.
converter has deteriorated, the signal from the Q: Is the check result normal?
cylinder 1, 4 oxygen sensor (front) becomes YES : Go to Step 2 .
similar to the cylinder 1, 4 oxygen sensor (rear). NO : Repair.
<A/T> compares the output of the cylinder 1, 4
oxygen sensor signals (front and rear). • Refer to Data List Reference Table P.13B-401.
TROUBLE JUDGMENT a. Item 11: Cylinder 1, 4 oxygen sensor (front)
b. Item 59: Cylinder 1, 4 oxygen sensor (rear)
Check Conditions
• Engine speed is 3,000 r/min or lower. Q: Is the check result normal?
• The accelerator pedal is open. YES : Go to Step 3 .
• Air flow sensor output is 8 gm/s or higher.
• 3 seconds or more elapsed after the procedure for the sensor that has shown an
abovementioned conditions were satisfied. abnormal data valve (Refer to Inspection
• Intake air temperature is −10°C or higher after the Chart for Diagnosis Code P.13B-20).
engine is started.
• Barometric pressure is 76 kPa or higher. STEP 3. MUT-II/III data list
• Under the closed loop air/fuel ratio control. a. Item 11: Cylinder 1, 4 oxygen sensor (front)
• Vehicle speed is 1.5 km/h or higher. OK: 0 − 0.4 and 0.6 − 1.0 volt should alternate
• For 10 seconds per cycle, the engine-ECU 15 times or more within 10 seconds (engine
<M/T> or engine-A/T-ECU <A/T> monitors 7 speed at 2,000 r/min).
cycles of this condition during the drive cycle.
• Short-term fuel trim is between −25 % or higher Q: Is the check result normal?
and +25 % or lower. YES : Go to Step 4 .
• The cumulative air flow sensor output is 2,931 g NO : Replace the cylinder 1, 4 oxygen sensor
or higher. (front).
Judgment Criteria
• The cylinder 1, 4 oxygen sensor (rear) signal STEP 4. Replace the cylinder 1, 4 oxygen sensor
frequency divided by cylinder 1, 4 oxygen sensor (rear).
(front) signal frequency is 0.8 or more. • After replacing the cylinder 1, 4 oxygen sensor
(rear), re-check the trouble symptoms.
• Catalytic converter deteriorated YES : Check end.
• Failed cylinder 1, 4 oxygen sensor (front) NO : Go to Step 5 .
• Failed engine-A/T-ECU <A/T> STEP 5. Replace the catalytic converter (cylinder
1, 4).
• After replacing the catalytic converter (cylinder 1,
4), re-check the trouble symptoms.
YES : Replacing engine-ECU <M/T> or
NO : Check end.
TROUBLESHOOTING
Code No. P0431: Warm Up Catalyst Malfunction (Cylinder 2, 3)

• The signal from the cylinder 2, 3 oxygen sensor
(rear) differs from the cylinder 2, 3 oxygen sensor
(front). That is because the catalytic converter STEP 1. Check for leakage of exhaust emission
purifies exhaust gas. When the catalytic from exhaust manifold.
converter has deteriorated, the signal from the Q: Is the check result normal?
cylinder 2, 3 oxygen sensor (front) becomes YES : Go to Step 2 .
similar to the cylinder 2, 3 oxygen sensor (rear). NO : Repair.
<A/T> compares the output of the cylinder 2, 3
oxygen sensor signals (front and rear). • Refer to Data List Reference Table P.13B-401.
TROUBLE JUDGMENT a. Item 39: Cylinder 2, 3 oxygen sensor (front)
b. Item 69: Cylinder 2, 3 oxygen sensor (rear)
Check Conditions
• Engine speed is 3,000 r/min or lower. Q: Is the check result normal?
• The accelerator pedal is open. YES : Go to Step 3 .
• Air flow sensor output is 8 gm/s or higher.
• 3 seconds or more elapsed after the procedure for the sensor that has shown an
abovementioned conditions were satisfied. abnormal data valve (Refer to Inspection
• Intake air temperature is −10°C or higher after the Chart for Diagnosis Code P.13B-20).
engine is started.
• Barometric pressure is 76 kPa or higher. STEP 3. MUT-II/III data list
• Under the closed loop air/fuel ratio control. a. Item 39: Cylinder 2, 3 oxygen sensor (front)
• Vehicle speed is 1.5 km/h or higher. OK: 0 − 0.4 and 0.6 − 1.0 volt should alternate
• For 10 seconds per cycle, the engine-ECU 15 times or more within 10 seconds (engine
<M/T> engine-A/T-ECU <A/T> monitors 7 cycles speed at 2,000 r/min).
of this condition during the drive cycle.
• Short-term fuel trim is between −25 % or higher Q: Is the check result normal?
and +25 % or lower. YES : Go to Step 4 .
• The cumulative air flow sensor output is 2,931 g NO : Replace the cylinder 2, 3 oxygen sensor
or higher. (front).
Judgment Criteria
• The cylinder 2, 3 oxygen sensor (rear) signal STEP 4. Replace the cylinder 2, 3 oxygen sensor
frequency divided by cylinder 2, 3 oxygen sensor (rear).
(front) signal frequency is 0.8 or more. • After replacing the cylinder 2, 3 oxygen sensor
(rear), re-check the trouble symptoms.
• Catalytic converter deteriorated YES : Check end.
• Failed cylinder 2, 3 oxygen sensor (front) NO : Go to Step 5 .
• Failed engine-A/T-ECU <A/T> STEP 5. Replace the catalytic converter (cylinder
2, 3).
• After replacing the catalytic converter (cylinder 2,
3), re-check the trouble symptoms.
YES : Replacing engine-ECU <M/T> or
NO : Check end.
TROUBLESHOOTING
Code No. P0443: Purge Control Solenoid Valve System
Purge control solenoid valve circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
2
B-101 Purge
MU802779 control
solenoid
1 2 valve
1
BR
23
C-139
(MU803802)
1 2 3 4
Engine-ECU <M/T>
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK304132 AB
TROUBLESHOOTING
OPERATION YES : Intermittent malfunction (Refer to GROUP

• Power is supplied to the purge control solenoid 00 − How to Use
valve (terminal No. 2) from the engine control Troubleshooting/Inspection Service Points
relay (terminal No. 1). P.00-6).
• The engine-ECU <M/T> or engine-A/T-ECU NO : Go to Step 2 .
STEP 2. Connector check: B-101 purge control
makes currents go on the purge control solenoid
solenoid valve connector
valve (terminal No. 1).
Connector: B-101
FUNCTION
• In response to a signal from the engine-ECU
<M/T> or engine-A/T-ECU <A/T>, the purge
control solenoid valve controls the flow rate of the
purge air to be introduced into the surge tank.
TROUBLE JUDGMENT 2 1 B-101 (B)

Check Conditions Harness
• Ignition switch is in "ON" position. side connector AK304271 AB
• Battery positive voltage is 10 V or higher.

Judgment Criteria YES : Go to Step 3 .
• The surge voltage (system voltage +2 V) of NO : Repair.
solenoid coil is not detected when the purge
control solenoid valve is turned in OFF position
STEP 3: Perform resistance measurement at
from ON.
B-101 purge control solenoid valve connector.
PROBABLE CAUSE Connector: B-101
• Failed purge control solenoid valve
• Open/short circuit in purge control solenoid value
DIAGNOSIS PROCEDURE 2 1 B-101 (B)

Harness
STEP 1. MUT-II/III actuator test
• Item 08: Purge control solenoid valve • Disconnect connector, and measure at solenoid
valve side.
valve vibrates
OK: 30 − 34 Ω (at 20°C)
TROUBLESHOOTING

purge control solenoid valve connector.
Connector: B-101 engine control relay connector.
• Check power line for open/short
circuit.
NO : Repair.

B-101 (B)
<A/T> connector.
Harness
• Disconnect connector, and measure at harness <L. H. Drive Vehicle>
side.
C-139 (GR)
OK: System voltage
NO : Go to Step 5 . <R. H. Drive Vehicle>

C-139 (GR)
relay connector
Connector: B-17X
B-17X
Relay box’s 4 3 2 1
13 12 1110 9 8 7 6 5
triangle marks 2019 18 17 16 15 14
2726 2524 23 22 21
2 1
AK304262 AB
4 3
Harness
side.
Connector: B-101 • Voltage between terminal No. 23 and earth.
OK: System voltage
NO : Go to Step 7 .
2 1 B-101 (B)
Harness

TROUBLESHOOTING

connector
• Check output line for open/short
circuit.
NO : Repair.
C-139 (GR)
connector
<R. H. Drive Vehicle> Connector: C-139

C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
C-139 (GR)
Connector: B-101
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1 B-101 (B) AK304262 AB
Harness
TROUBLESHOOTING
No. 1) purge control solenoid valve connector No. 2) purge control solenoid valve connector
and C-139 (terminal No. 23) engine-ECU <M/T> and B-17X (terminal No. 1) engine control relay
connector or engine-A/T-ECU <A/T> connector. connector.
2 1 B-101 (B) 2 1 B-101 (B)

Harness Harness
Connector: C-139 Connector: B-17X
<L. H. Drive Vehicle> B-17X

Relay box’s
triangle marks
C-139 (GR)
2 1
4 3
Harness
• Check power line for damage.
C-139 (GR) Q: Is the check result normal?

NO : Repair.
4 3 2 1 STEP 11. MUT-II/III actuator test

13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
• Item 08: purge control solenoid valve
2726 2524 23 22 21
valve vibrates
AK304262 AB
• Check output line for damage. YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
YES : Go to Step 10 . Troubleshooting/Inspection Service Points
NO : Repair. P.00-6).
TROUBLESHOOTING
Code No. P0500: Vehicle Speed Sensor System <M/T>
Vehicle speed sensor circuit
Ignition switch Engine-ECU

C-141
C-303 (MU803804)
R LOCK
1 2 3 6162 6364
4 5 6 ST ACC 656667686970717273
IG1 IG2 747576777879808182
8384 858687 8889
2
L-B 86
C-203
6
W-L
2 J/B
7.5A Meter and gauge
C-202
11
B-W C-105
22
C-106
3
W-L
B-W
1 3
B-115
1 2 3 Vehicle speed sensor
2
B 6
J/C (2)
C-17
1
B
Wire colour code

AK304535 AB
TROUBLESHOOTING

• A power voltage of 5 V is applied to the vehicle NO : Check the speedometer (Refer to GROUP
speed sensor (terminal No. 3) from the 54A −Combination Meter Assembly −
engine-ECU (terminal No. 79). On-vehicle Service − Speedmeter Check
P.54A-68).
FUNCTION
• The vehicle speed sensor converts the vehicle STEP 2.MUT-II/III data list
speed to the voltage, and then input it into the • Refer to Data list reference table P.13B-401.
engine-ECU a. Item 24: Vehicle speed sensor
Check Conditions NO : Intermittent malfunction (Refer to GROUP
• 2 seconds later after the engine has started up. 00 - How to Use Troubleshooting/Inspection
• Engine speed: 2,500 r/min or more. Service Points P.00-6).
• Idle switch: OFF
• Under the high load operation. STEP 3.Check connector: C-141 engine-ECU
Judgment Criterion connector
• The sensor output voltage remains unchanged
Connector: C-141
PROBABLE CAUSE
• Failed Vehicle speed sensor
• Open/short circuit in vehicle speed sensor circuit
or loose connector contact C-141 (GR)
• Failed engine-ECU
DIAGNOSIS PROCEDURE
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
STEP 1.Check the speedometer

NO : Repair.
TROUBLESHOOTING
STEP 4.Check harness between C-141 (terminal NO : Repair.
No. 79) engine-ECU connector and B-115
(terminal No. 3) Vehicle speed sensor connector.
STEP 5.Check the trouble symptoms.
Connector: C-141
YES : Replacing engine-ECU.
00 - How to Use Troubleshooting/Inspection
Service Points P.00-6).
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304536 AB
Connector: B-115
C-115 (B)
3 2 1
Harness side
connector
AK304537AB

• Check output line for open circuit and damage.
TROUBLESHOOTING
DTC P0505: Idle Speed Control (ISC) System
FUNCTION Judgment Criteria

• The amount of air taken in during idling is • The actual idle speed is lower than the target idle
regulated by the opening and closing of the speed by 100 r/min or more for 10 seconds.
throttle valve.
• The engine-ECU <M/T> or engine-A/T-ECU PROBABLE CAUSE
<A/T> checks the difference between the actual • Throttle valve area is dirty.
engine speed and the target engine speed. • Intake system vacuum leak.
TROUBLE JUDGMENT • Failed engine-A/T-ECU <A/T>
Check Conditions
• The vehicle speed has reached 1.5 km/h or more STEP 1: MUT-II/III diagnosis code
at least once.
• During the closed-loop idle speed control.
Judgment Criteria to P.13B-20.)
• The actual idle speed is higher than the target NO : Go to Step 2 .
Check Conditions STEP 2: Check throttle body (throttle valve
• The vehicle speed has reached 1.5 km/h or more portion) for contamination.
at least once. Q: Is the check result normal?
• During the closed-loop idle speed control. YES : Go to Step 3 .
• The highest ambient temperature at the last drive NO : Clean throttle body (throttle valve portion)
is 45°C or less. (Refer to P.13B-425).
• The engine coolant temperature is approx. 77°C
or higher.
• The battery voltage is 10 V or more. STEP 3. Check air intake from intake hose and
• The intake air temperature is -10°C or higher. inlet manifold.
Judgment Criteria
• The actual idle speed is higher than the target NO : Repair.
Check Conditions
• During the closed-loop idle speed control
• The engine coolant temperature is approx. 77°C Q: Does trouble symptom persist?
or higher. YES : Replace engine-ECU <M/T> or
• The battery voltage is 10 V or more. engine-A/T-ECU <A/T>.
• The power steering switch is in OFF position.
• The charging efficiency is 40 % or less. 00 − How to Use
• The intake air temperature is -10°C or higher. Troubleshooting/Inspection Service Points
P.00-6).
TROUBLESHOOTING
Code No. P0513: Immobilizer Malfunction
Immobilizer-ECU circuit
Signal
transmission Immobilizer-ECU
circuit
C-304-1 3
1 2 C-304
7 3 4 5 6 7 (MU801547)
V
C-104
11
V
65
C-141
(MU803804)
656667686970717273 Engijne-A/T-ECU <A/T>
747576777879808182
8384 858687 8889
Wire colour code

AK304151AB

• The signals are sent and received between
Check Condition
• Ignition switch is in "ON" position.
(terminal No. 65) and immobilizer-ECU (terminal
No. 7). Judgment Criterion
• When the communication error between
FUNCTION engine-ECU <M/T> or engine-A/T-ECU <A/T>
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> and the immobilizer-ECU continues for 2 seconds
sends or receives the control signals to or from or more.
immobilizer-ECU to certify the ignition key.
NOTE: . PROBABLE CAUSE
• If the registered ignition keys are close each • Open/short circuit in immobilizer system circuit or
other when starting the engine, radio loose connector contact
interference may cause this code to be • Failed immobilizer-ECU
displayed. • Failed engine-ECU <M/T>
• This code may be displayed when registering • Failed engine-A/T-ECU <A/T>
the key encrypted code.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Check harness between C-304 (terminal

No. 3) immobilizer-ECU connector and C-141
STEP 1. Connector check: C-304 (terminal No. 65) engine-ECU <M/T> connector or
immobilizer-ECU connector and C-141 engine-A/T-ECU <A/T> connector.
engine-ECU <M/T> connector or engine-A/T-ECU Connector: C-304
<A/T> connector.
Connector: C-304
C-304
C-304 2 1
76543
Harness
2 1 side connector AK304272 AB
76543
Harness
Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR)
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
6463 62 61
7372 7170 69 6867 6665 Harness side connector
82 818079 78 7776 7574
8988 87 86 85 8483 AK304154 AB

AK304154 AB
YES : Go to Step 2 . damage.
NO : Repair.
TROUBLESHOOTING
STEP 3. Check the trouble symptoms. STEP 4. After replacing the immobilizer-ECU,
re-check the trouble symptoms.
NO : Intermittent malfunction (Refer to GROUP YES : Replace engine-ECU <M/T> or
00 − How to Use engine-A/T-ECU <A/T>.
Troubleshooting/Inspection Service Points NO : Check end.
P.00-6).
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-140
(MU803803)
3132 33 34 Engine-ECU <M/T>
353637383940 41 42 43 Engine-A/T-ECU <A/T>
444546474849 50 51
5253 545556 57 58
47
Y
B-19
1
Y
B-37
(MU801215) 1
1 Power steering fluid

OFF pressure switch
ON
Wire colour code

AK304134 AB
CONDITION FUNCTION
• The battery voltage is applied to the power • It is detected whether a load is applied on the
steering fluid pressure switch (terminal No. 1) power steering fluid pump by steering or not, and
from the engine-ECU <M/T> or engine-A/T-ECU the signal is inputted to the engine-ECU <M/T> or
<A/T> (terminal No. 47). engine-A/T-ECU <A/T>. When the power
steering fluid pressure switch "ON" signal (a large
load on the power steering fluid pump) is
inputted, the engine-ECU <M/T> or
engine-A/T-ECU <A/T> provides the idle-up
control.
TROUBLESHOOTING

NO : Repair.
Check Conditions
• Drive the vehicle of 50 km/h or more for 4 STEP 2. Perform voltage measurement at B-37
seconds or more. Stop the vehicle (of 1.5 km/h or power steering fluid pressure switch connector.
less). Repeat 10 times or more. Connector: B-37
Judgment Criteria
• Power steering pressure switch continues to be
in "ON".
PROBABLE CAUSE
• Failed power steering fluid pressure switch
B-37 (B)
• Open/short circuit in power steering fluid
pressure switch circuit or loose connector contact 1
• Failed engine-ECU <M/T> Harness side connector AK304273 AB
• Failed engine-A/T-ECU <A/T> • Disconnect connector, and measure at harness
side.
STEP 1. Connector check: B-37 power steering OK: System voltage
fluid pressure switch connector Q: Is the check result normal?
Connector: B-37 YES : Go to Step 8 .
NO : Go to Step 3 .
B-37 (B)
1

TROUBLESHOOTING
C-140 (GR) C-140 (GR)
C-140 (GR) C-140 (GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK304274 AB AK304274 AB

Connector: B-37
OK: System voltage
YES : Go to Step 4 . B-37 (B)
NO : Go to Step 5 .
1

(terminal No. 1) power steering fluid
pressure switch connector and C-140
connector.
NO : Repair.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 1) power steering fluid pressure switch
Connector: C-140
<A/T> connector.
Connector: B-37
C-140 (GR)
B-37 (B)
<R. H. Drive Vehicle> 1

34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
C-140 (GR)
AK304274 AB

NO : Repair.
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

NO : Repair.
TROUBLESHOOTING
STEP 7. MUT-II/III data List NO : Go to Step 9 .
a. Item 27: Power steering fluid pressure switch
Q: Is the check result normal? <M/T> connector or engine-A/T-ECU <A/T>
connector
00 − How to Use
Troubleshooting/Inspection Service Points Connector: C-140
P.00-6). <L. H. Drive Vehicle>
C-140 (GR)
<A/T> connector.
Connector: C-140 <R. H. Drive Vehicle>
C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
<R. H. Drive Vehicle> Harness side connector
AK304274 AB

NO : Repair.
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

• Engine: Idling
OK:
System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
TROUBLESHOOTING
YES : Replace power steering fluid pressure

switch.
No. 1) power steering fluid pressure switch NO : Repair.
<A/T> connector. STEP 11. Connector check: C-140 engine-ECU
Connector: B-37
connector
Connector: C-140
B-37 (B)
C-140 (GR)
1

C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

NO : Repair.
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

TROUBLESHOOTING
DTC P0606: Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Main Processor Malfunction
• Failed the engine-A/T-ECU <A/T>

FUNCTION
• System LSI checks the engine-ECU <M/T> or DIAGNOSIS
engine-A/T-ECU <A/T> for abnormal conditions.
TROUBLE JUDGMENT STEP 1. Check the trouble symptoms.

Check Conditions Q: Does trouble symptom persist?
• Ignition switch is "ON" position. YES : Replace engine-ECU <M/T> or
Judgement Criteria NO : Intermittent malfunction (Refer to GROUP
• No surveillance pulse signals is input for 0.5 00 − How to Use
second. Troubleshooting/Inspection Service Points
P.00-6).
PROBABLE CAUSE
• Failed the engine-ECU <M/T>
TROUBLESHOOTING
Code No. P0622: Alternator FR Terminal System
Alternator circuit
C-141
(MU803804)
656667686970717273 Engine-A/T-ECU <A/T>
747576777879808182
8384 858687 8889
86
Y-B
B-19
2
Y-B
B-30
(MU802046) 4
1 2 3 4
IC voltage
regulator Alternator
Wire colour code

AK304135 AB

• The energized state of the alternator field coil is
Check Condition
inputted from the alternator (terminal No. 4) to the
• Engine speed is 50 r/min or higher.
(terminal No. 86). Judgment Criterion
• Input voltage from the alternator FR terminal has
FUNCTION continued to be approximately battery positive
• A signal of the power supply duty ratio for the voltage for 20 seconds.
alternator field coil is inputted to the engine-ECU
<M/T> or engine-A/T-ECU <A/T>. PROBABLE CAUSE
• In response to the signal, the engine-ECU <M/T> • Failed alternator
or engine-A/T-ECU <A/T> detects the alternator • Open/short circuit in alternator FR terminal circuit
output current and controls the idling speed or loose connector
according to the output current (electric load). • Failed engine-ECU <M/T>
TROUBLESHOOTING

NO : Go to Step 3 .
STEP 1. Connector check: B-30 alternator

connector STEP 3. Connector check: C-141 engine-ECU
Connector: B-30 connector.
Connector: C-141
B-30 (GR)
4 3 2 1 C-141(GR)
Harness side

NO : Repair.

alternator connector.
Connector: B-30
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
B-30 (GR)
AK304154 AB

4 3 2 1 YES : Go to Step 4 .
• Disconnect connector, and measure at male

connector side.
OK: System voltage
TROUBLESHOOTING

No. 1) alternator connector and C-141 (terminal NO : Intermittent malfunction (Refer to GROUP
No. 86) engine-ECU <M/T> connector or 00 − How to Use
engine-A/T-ECU <A/T> connector. Troubleshooting/Inspection Service Points
Connector: B-30 P.00-6).

B-30 (GR) engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
Connector: C-141
4 3 2 1
Harness side
Connector: C-141
C-141(GR)

C-141(GR) C-141 (GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
6463 62 61
7372 7170 69 6867 6665 • Measure engine-ECU <M/T> or engine-A/T-ECU
82 818079 78 7776 7574
8988 87 86 85 8483
Harness side connector • Engine: Idle after warm-up
AK304154 AB
• Radiator fan: Inactive
• Check output line for open/short circuit. • Voltage between terminal No. 86 and earth.
Q: Is the check result normal? OK: Switching the headlamps to ON from
YES : Go to Step 5 . OFF causes the voltage to fall.
NO : Repair.
STEP 5. Check the trouble symptoms. NO : Go to Step 5 .
TROUBLESHOOTING
No. 4) alternator connector and C-141 (terminal
No. 86) engine-ECU <M/T> connector or
engine-A/T-ECU <A/T> connector. STEP 8. Check trouble symptom.
Connector: C-141 Q: Same symptoms regenerated?
<L. H. Drive Vehicle> NO : Intermittent malfunction (Refer to Group 00
− How to Use troubleshooting/Inspection
Service Points P.00-6).
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
Connector: B-30
B-30 (GR)
4 3 2 1
Harness side

TROUBLESHOOTING
DTC P0638: Throttle Valve Control Servo Circuit Range/Performance Problem
Judgement Criteria
OPERATION • Difference between throttle position sensor
• Refer to P2101 − Throttle valve control servo (main) output voltage and target throttle position
circuit P.13B-242. sensor (main) voltage is 1 V or higher for 4
seconds.
FUNCTION
• engine-ECU <M/T> or engine-A/T-ECU <A/T> PROBALE CAUSE
checks the electronic controlled throttle system • Failed throttle valve return spring.
for abnormal conditions. • Failed throttle valve operation.
• Failed throttle valve control servo.
TROUBLE JUDGMENT • Open/short circuit in throttle valve control servo
Check Conditions connector contact.
• Battery positive voltage is 8.3 V or higher. • Failed engine-ECU <M/T>.
• Throttle position sensor (main) output voltage is • Failed engine-A/T-ECU <A/T>.
0.35 − 4.8 V.
• Drop of throttle position sensor (main) output DIAGNOSIS
voltage per 100 milliseconds is 0.04 V or more.
Judgement Criteria STEP 1. MUT-II/III data list
• Throttle position sensor (main) output voltage has • Refer to Data list reference table P.13B-401.
continued to be above 0.5 V higher than the a. Item 9A: Throttle position sensor (main) mid
target throttle position sensor (main) voltage for opening learning value
0.5 second.
Check Conditions YES : Go to Step 2 .
• Battery positive voltage is 8.3 V or higher. NO : Replace throttle body assembly.
• Throttle position sensor (main) output voltage is
0.35 − 4.8 V. STEP 2. Check the throttle valve control servo
itself.
• Check the throttle valve control servo control
motor itself (Refer to P.13B-436)
TROUBLESHOOTING
STEP 3. Connector check: B-06 electronically STEP 4. Check harness between B-06 (terminal
controlled throttle valve connector and C-138 No. 1) electronically controlled throttle valve
engine-ECU <M/T> connector or engine-A/T-ECU connector and C-138 (terminal No. 133)
<A/T> connector engine-ECU <M/T> connector or engine-A/T-ECU
Connector: B-06
<A/T> connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1 B-06 (B)
6 5 4 3 2 1
Connector: C-138
C-138 (GR)
C-138 (GR)

C-138 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134 124 123 122121
146 145 144 143142 133 132 131 130 129128127126125
141 140 139 138 137136 135134
Harness side connector 146 145 144 143142

AK304275 AB
AK304275 AB
YES : Go to Step 4 . • Check output line for short circuit and damage.
NO : Repair.
TROUBLESHOOTING
00 − How to Use
P.00-6).
B-06 (B)
6 5 4 3 2 1
Connector: C-138
C-138 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

TROUBLESHOOTING
DTC P0642: Throttle Position Sensor Power Supply
PROBALE CAUSE
FUNCTION • Failed engine-ECU <M/T>
• engine-ECU <M/T> or engine-A/T-ECU <A/T> • Failed engine-A/T-ECU <A/T>
checks the throttle position sensor power voltage
for abnormal conditions. DIAGNOSIS
TROUBLE JUDGMENT
Check Conditions
• Battery positive voltage is 6.3 V or higher. Q: Does trouble symptom persist?
Judgement Criteria engine-A/T-ECU <A/T>.
• Throttle position sensor power voltage is 4.1 V or NO : Intermittent malfunction (Refer to GROUP
less for 0.5 second. 00 − How to Use
P.00-6).
TROUBLESHOOTING
DTC P0657: Throttle Valve Control Servo Relay Circuit Malfunction
Throttle valve control srvo relay circuit

Battery
W-B
A-14
5 (*1) or
16 (*2)
W-B
W-B
4 3
B-17X
Engine
1 2 control
relay
3 4
1 2
W-B R
4
R Y-G
J/C (2)
12
4 3
Throrrle B-14X
valve
control 1 2
servo
relay 3 4
To engine-ECU <M/T>
1 2
R-W L
132 15
C-138 C-139
(MU803801) (MU803802)
121122 123 124
Power source 1 2 3 4
125126127128129 130 131 132 133 5 6 7 8 9 10111213
134135 136137 138 139 140 141 14 15 16 1718 19 20
142143 144 145 146 21 22 232425 2627
NOTE
*1: L.H. drive vehicles Engine-ECU <M/T>
*2: R.H. drive vehicles Engine-A/T-ECU <A/T>
Wire colour code

AK304138 AB
TROUBLESHOOTING
OPERATION FUNCTION
• Battery voltage is applied to the Throttle valve • When the ignition switch ON signal is input into
control servo relay terminal (terminal No. 4). the engine-ECU <M/T> or engine-A/T-ECU
• Battery voltage is applied to the Throttle valve <A/T>, the engine-ECU <M/T> or
control servo relay terminal (terminal No. 3) from engine-A/T-ECU <A/T> turns ON the Throttle
the engine control relay (terminal No. 1). valve control servo.
• Engine-ECU <M/T> or engine-A/T-ECU <A/T>
(terminal No. 15) applies current to the throttle TROUBLE JUDGMENT
valve control servo relay coil by turning ON the Check Condition
power transistor in the unit in order to turn the • Ignition switch is in "ON" position.
relay ON.
• When the throttle valve control servo relay turns Judgement Criteria
ON, battery voltage is supplied by the throttle • The power line voltage of the electronic controlled
valve control servo relay (terminal No. 1) to the throttle system is 4.0 V or less for 1 second.
PROBALE CAUSE
(terminal No. 132).
• Failed throttle valve return spring
• Open/short circuit in throttle valve control servo
circuit or loose connector contact.
DIAGNOSIS
STEP 1. Connector check: B-14X throttle valve STEP 3. Perform voltage measurement at B-14X
control servo relay connector throttle valve control servo relay connector.

triangle marks B-14X triangle marks B-14X
2 1 2 1
4 3 4 3
Harness Harness
• Remove relay, and measure at relay box side.

YES : Go to Step 2 . • Voltage between terminal No. 4 and earth.
NO : Repair. OK: System voltage
STEP 2. Check throttle valve control servo relay YES : Go to Step 4 .
itself. NO : Check intermediate connector A-14, and
• Check throttle valve control servo relay (Refer to repair if necessary. If intermediate
P.13B-430). connector is normal, check and repair
Q: Is the check result normal? throttle valve control servo relay connector
YES : Go to Step 3 . and battery.
NO : Repair.
open/short circuit.
TROUBLESHOOTING

STEP 4. Perform voltage measurement at B-14X
throttle valve control servo relay connector.
Connector: B-14X harness between B-17X (terminal No. 1)
engine control relay connector and B-14X
(terminal No. 3) throttle valve control servo
Relay box’s
triangle marks B-14X relay connector.
open/short circuit.
2 1
NO : Repair.
4 3
Harness
• Remove relay, and measure at relay box side. connector.
• Voltage between terminal No. 3 and earth. Connector: C-139
OK: System voltage <L. H. Drive Vehicle>

NO : Go to Step 6 . C-139 (GR)

relay connector
Connector: B-17X
B-17X
Relay box’s C-139 (GR)
triangle marks
2 1
4 3 2 1
4 3 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
Harness 2726 2524 23 22 21
side connector AK304152 AB Harness side connector
AK304262 AB
Connector: B-14X
Connector: B-14X
Relay box’s
triangle marks B-14X
Relay box’s
2 1
4 3 2 1
Harness 4 3
Harness
side.
OK: System voltage
TROUBLESHOOTING

No. 1) throttle valve control servo relay
relay connector and C-139 (terminal No. 15)
<A/T> connector.
• Check earthing line for open/short
circuit. Connector: B-14X
NO : Go to Step 7 .
Relay box’s
<A/T> connector. 2 1
Connector: C-138 4 3
<L. H. Drive Vehicle> Harness

Connector: C-138
C-138 (GR)
C-138 (GR)
C-138 (GR)
124 123 122121
133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142

124 123 122121
133 132 131 130 129128127126125
AK304275 AB
141 140 139 138 137136 135134
146 145 144 143142
side.
AK304275 AB
OK: System voltage • Check output line for open/short circuit.
NO : Repair.
NO : Go to Step 8 .
TROUBLESHOOTING

No. 1) engine control relay connector and B-14X
relay connector and C-139 (terminal No. 15)
(terminal No. 3) throttle valve control servo relay
connector.
Connector: B-17X • Check earthing line for open/short
B-17X circuit.
NO : Repair.
Relay box’s
triangle marks
STEP 10. Connector check: C-138 and C-139
4 3
<A/T> connector
Harness Connectors: C-138, C-139
Connector: B-14X

C-138 (GR)
2 1
4 3
Harness
C-139 (GR)

<L. H. Drive Vehicle> 124 123 122121
133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
C-139 (GR) C-138 Harness side connector
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
<R. H. Drive Vehicle> C-139 Harness side connector
AK304277 AB
C-139 (GR)
00 − How to Use
4 3 2 1
13 12 1110 9 8 7 6 5 Troubleshooting/Inspection Service Points
2019 18 17 16 15 14
2726 2524 23 22 21 P.00-6).
AK304262 AB

TROUBLESHOOTING
STEP 11. Check and repair harness between STEP 12. Check and repair harness between
B-14X (terminal No. 4) throttle valve control servo B-14X (terminal No. 1) throttle valve control servo
relay connector and battery. relay connector and C-138 (terminal No. 132)
Connector: B-14X
<A/T> connector.
Connector: B-14X
Relay box’s
Relay box’s
2 1
4 3
2 1
Harness
side connector AK304276 AB 4 3
• Check power supply line for damage. Harness
Q: Is the harness connector in good condition?
YES : Go to Step 12 . Connector: C-138
00 − How to Use
P.00-6).
C-138 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

Q: Is the harness connector in good condition?
00 − How to Use
P.00-6).
TROUBLESHOOTING

Q: Does trouble symptom persist? NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
P.00-6).
TROUBLESHOOTING
Code No. P1010: Oil Control Valve Circuit
Engine oil control valve circuit
Battery
W-B
W-B
4 3
B-17X
1 2 Engine
control
3 4 relay
1 2
R
4
J/C (2)
C-17
11
R
B-104 1
MU802779
Oil control
1 2 valve
P-B
C-142 95
(MU803805)
9192 939495
96979899100 101102103 104 Engine-ECU <M/T>
105106 107108109 110111112 Engine-A/T-ECU <A/T>
113114 115116117 118119120
Wire colour code

AK304140AB
TROUBLESHOOTING

• Power is supplied to the oil control valve (terminal NO : Repair.
No. 1) from the engine control relay (terminal No.
1). STEP 2: Perform resistance measurement at
• The engine-ECU <M/T> or engine-A/T-ECU B-104 oil control valve connector.
transistor in the unit be in "ON" position, and that Connector: B-104
makes currents go on the oil control valve
(terminal No. 2).
FUNCTION
• The oil control valve switches the cams to
operate the MIVEC system in the low-speed or
high-speed mode in accordance with the signals 2 1 B-104 (B)
from the engine-ECU <M/T> or engine-A/T-ECU Harness
<A/T>. side connector AK304278 AB
• Disconnect connector, and measure at control

TROUBLE JUDGMENT
valve side.
Check Conditions • Resistance between terminal No. 1 and No. 2.
• Ignition switch is "ON" position OK: 6.9 − 7.9 Ω (at 20°C)
• Battery positive voltage is higher than 10 V.
• MIVEC operating in the low-speed mode. Q: Is the check result normal?
Judgment Criteria NO : Replace oil control valve.
• The engine-ECU terminal voltage of oil control
valve circuit is less than 1.5 V for 2 seconds.
PROBABLE CAUSE oil control valve connector.
• Failed purge oil control valve Connector: B-104
• Open/short circuit in oil control valve circuit or
DIAGNOSIS PROCEDURE
2 1 B-104 (B)
STEP 1. Connector check: B-104 oil control valve Harness

connector
Connector: B-104
side.
OK: System voltage
2 1 B-104 (B) NO : Go to Step 4 .
Harness

TROUBLESHOOTING
STEP 4. Connector check: B-17X engine control STEP 5. Perform voltage measurement at C-142
relay connector engine-ECU <M/T> connector or engine-A/T-ECU
Connector: B-17X
<A/T> connector.
triangle marks
2 1
C-142 (GR)
4 3
Harness

Connector: B-104
C-142 (GR)
B-104 (B) 959493 92 91

2 1 104 103102 101100 99 98 97 96
112111110 109108107 106105
Harness 120119118 117116115 114113
AK304153 AB
YES : Check intermediate connector C-17, and • Disconnect connector, and measure at harness
repair if necessary. If intermediate side.
connector is normal, check and repair • Ignition switch: ON
harness between B-104 (terminal No. 1) oil • Voltage between terminal No. 95 and earth.
control valve connector and B-17X (terminal OK: System voltage
No. 1) engine control relay connector.
• Check power line for open/short Q: Is the check result normal?
circuit. YES : Go to Step 7 .
NO : Repair. NO : Go to Step 6 .
TROUBLESHOOTING

(terminal No. 2) oil control valve connector
connector
Connector: C-142 connector.
<L. H. Drive Vehicle> • Check output line for open/short
circuit.
NO : Repair.
C-142 (GR) STEP 7. Connector check: C-142 engine-ECU

connector
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113 <R. H. Drive Vehicle>
C-142 (GR)
AK304153 AB
Connector: B-104
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

2 1 B-104 (B) AK304153 AB
Harness
TROUBLESHOOTING
No. 2) oil control valve connector and C-142 No. 2) oil control valve connector and B-17X
(terminal No. 95) engine-ECU <M/T> connector or (terminal No. 2) engine control relay connector.
Connector: B-104
Connector: B-104
2 1 B-104 (B)
2 1 B-104 (B)
Harness
Connector: B-17X
Connector: C-142 B-17X
<L. H. Drive Vehicle> Relay box’s
triangle marks
2 1
C-142 (GR)
4 3
Harness
<R. H. Drive Vehicle> • Check power supply line for damage.

NO : Repair.

959493 92 91 Q: Does trouble symptom persist?
104 103102 101100 99 98 97 96
112111110 109108107 106105 YES : Replace engine-ECU <M/T> or
120119118 117116115 114113
Harness side connector NO : Intermittent malfunction (Refer to GROUP
AK304153 AB 00 − How to Use
• Check output line for damage. Troubleshooting/Inspection Service Points
P.00-6).
NO : Repair.
TROUBLESHOOTING
DTC P1602: Communication Malfunction (between Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Main
Processor and System LSI)
PROBALE CAUSE
FUNCTION • Failed engine-ECU <M/T>
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> • Failed engine-A/T-ECU <A/T>
checks the communication status for abnormal
conditions. DIAGNOSIS
TROUBLE JUDGMENT
Check Conditions
• Ignition switch is "ON" position. Q: Does trouble symptom persist?
Judgement Criteria engine-A/T-ECU <A/T>.
• Engine-ECU detects an error in communication NO : Intermittent malfunction (Refer to GROUP
with the throttle actuator control module for 0.07 00 − How to Use
second. Troubleshooting/Inspection Service Points
P.00-6).
TROUBLESHOOTING
Code No. P1603: Battery Backup Circuit Malfunction
Battery backup circuit
Battery
Relay 9
box 20A
W-B
A-14
5 (*1) or
16 (*2)
W-B
58
C-140
(MU803803)
3132 33 34
Battery Engine-ECU <M/T>
35363738394041 42 43 backup Engine-A/T-ECU <A/T>
444546474849 50 51
5253 545556 57 58
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
AK304139AB
OPERATION FUNCTION
• Power is directly supplied to the engine-ECU • The engine-ECU <M/T> or engine-A/T-ECU
<M/T> or engine-A/T-ECU <A/T> (terminal No. <A/T> is check the open circuit of battery backup
58) from the battery. line.
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 2. Perform voltage measurement at C-140

Check Condition engine-ECU <M/T> connector or engine-A/T-ECU
• After engine starting sequence is completed. <A/T> connector.
• Battery positive voltage is 10 V or higher.
Connector: C-140
Judgment Criterion
• Battery backup line voltage is 6 V or lower for 2
seconds.
PROBABLE CAUSE C-140 (GR)

• Open/short circuit in battery backup line circuit or
DIAGNOSIS PROCEDURE
C-140 (GR)
• Temporarily place the ignition switch in "LOCK"
(OFF) position, and 10 seconds after that, place it 34 33 32 31
in "ON" position again. 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
Q: Is the diagnosis code P1603 set?
AK304274 AB
00 − How to use Troubleshooting/Inspection
Service Points P.00-6). • Disconnect connector, and measure at harness
side.
OK: System voltage
harness between battery and C-140
connector.
open/short circuit.
TROUBLESHOOTING
STEP 3. Check harness between battery and
NO : Repair.
C-140 (terminal No. 58) engine-ECU <M/T>
NOTE: Before checking harness, check intermediate STEP 4. Connector check: C-140 engine-ECU
connector A-14, and repair if necessary. <M/T> connector or engine-A/T-ECU <A/T>
connector.
Connector: B-17X
Connector: C-140
B-17X
Relay box’s
triangle marks
2 1 C-140 (GR)
4 3
Harness
Connector: C-140
C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352

AK304274 AB

C-140 (GR) YES : Go to Step 5 .
NO : Repair.
34 33 32 31
43 42 4140 39 38 37 36 35 STEP 5. Check the trouble symptoms.
51 50 49 4847 46 4544
58 57 5655 54 5352 Q: Does trouble symptom persist?
Harness side connector YES : Replace engine-ECU <M/T> or
AK304274 AB NO : Intermittent malfunction (Refer to GROUP
• Check earthing line for damage. 00 − How to Use
Troubleshooting/Inspection Service
PointsP.00-6).
TROUBLESHOOTING
DTC P2100: Throttle Valve Control Servo Circuit (open)
Throttle valve control servo circuit
B-06 Electronically
controlled
1 2
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
125126127128129 130 131 132 133
134135 136137 138 139 140 141
GND GND 142143 144 145 146

B
Wire colour code

AK304136 AB
FUNCTION
OPERATION • Engine-ECU <M/T> or engine-A/T-ECU <A/T>
• Controls the current that is applied from the varies the direction and the amperage of the
engine-ECU <M/T> or engine-A/T-ECU <A/T> current that is applied to the throttle valve control
(terminals No. 133, No. 141) to the electronically servo in order to control the opening of the
controlled throttle valve (terminals No. 1, No. 2). throttle valve.
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 2. Perform resistance measurement at B-06

Check Condition electronically controlled throttle valve connector.
• Battery positive voltage is 8.3 V or higher.
Connector: B-06
Judgement Criteria
• Throttle actuator control motor current is 0.1 A or
less for 0.72 second.
PROBABLE CAUSE
• Failed throttle valve control servo.
• Open/short circuit in throttle valve control servo B-06 (B)
circuit or lose connector contact. 6 5 4 3 2 1
• Disconnect connector, and measure at
electronically controlled throttle valve side.
DIAGNOSIS PROCEDURE • Resistance between terminal No. 1 and No. 2.
OK: 0.3 − 80 kΩ (at 20 °C)
Connector: B-06 NO : Replace throttle body assembly.

connector
Connector: C-138
B-06 (B)
6 5 4 3 2 1

NO : Repair.
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

NO : Repair.
TROUBLESHOOTING
STEP 4. Perform voltage measurement at C-138 STEP 5. Check harness between B-06 (terminal
engine-ECU <M/T> connector or engine-A/T-ECU No. 1) electronically controlled throttle valve
<A/T> connector. connector and C-138 (terminal No. 133)
Connector: C-138
<A/T> connector.
Connector: B-06
C-138 (GR)
B-06 (B)
6 5 4 3 2 1
Connector: C-138
124 123 122121
133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142

C-138 (GR)
AK304275 AB

side.
• Voltage between terminal No. 144 and earth or C-138 (GR)
terminal No. 145 and earth.
OK: 2 Ω or less
YES : Go to Step 5 . 124 123 122121
NO : Check harness between C-138 (terminal 133 132 131 130 129128127126125
141 140 139 138 137136 135134
No. 144 or No. 145) engine-ECU <M/T> or 146 145 144 143142
engine-A/T-ECU <A/T> and earth. Harness side connector
AK304275 AB

NO : Repair.
TROUBLESHOOTING
NO : Repair.
<A/T> connector. Q: Is the check result normal?
00 − How to Use
P.00-6).
B-06 (B)
6 5 4 3 2 1
Connector: C-138
C-138 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

TROUBLESHOOTING
DTC P2101: Throttle Valve Control Servo Magneto Malfunction
B-06 Electronically
controlled
1 2
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU <M/T>
125126127128129 130 131 132 133 Engine-A/T-ECU <A/T>
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK304137AB
TROUBLE JUDGMENT
OPERATION Check Condition
• Controls the current that is applied from the • Battery positive voltage is 8.3 V or higher.
(terminals No. 133, No. 141) to the electronically Judgement Criteria
controlled throttle valve (terminals No. 1, No. 2). • The coil temperature of the throttle actuator
control motor is 180°C or higher for 0.8 second.
FUNCTION
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> PROBABLE CAUSE
check whether the throttle valve control servo • Failed throttle valve control servo.
magneto failed. • Open/short circuit in throttle valve control servo
circuit or lose connector contact.
TROUBLESHOOTING

NO : Replace throttle body assembly.

controlled throttle valve connector STEP 3. Connector check: C-138 engine-ECU
Connector: B-06 connector
Connector: C-138
B-06 (B)
6 5 4 3 2 1 C-138 (GR)


124 123 122121
Connector: B-06 133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

6 5 4 3 2 1 NO : Repair.

OK: 0.3 − 80 kΩ (at 20 °C)
TROUBLESHOOTING
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-138 (GR) C-138 (GR)
C-138 (GR) C-138 (GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142
AK304275 AB AK304275 AB
• Check output line for short circuit and damage. • Check output line for short circuit and damage.

00 − How to Use
P.00-6).
TROUBLESHOOTING
DTC P2102: Throttle Valve Control Servo Circuit (Shorted Low)
B-06 Electronically
controlled
1 2
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU <M/T>
125126127128129 130 131 132 133 Engine-A/T-ECU <A/T>
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK304137AB
TROUBLE JUDGMENT
engine-ECU <M/T> or engine-A/T-ECU
controlled throttle valve (terminals No. 1, No. 2). • Throttle valve control servo current is 12 A or
higher for 0.8 second.
FUNCTION
varies the direction and the amperage of the • Failed throttle valve control servo.
current that is applied to the throttle valve control • Short circuit in throttle valve control servo circuit
servo in order to control the opening of the or lose connector contact.
throttle valve. • Failed engine-ECU <M/T>
TROUBLESHOOTING

NO : Replace throttle body assembly.

Connector: C-138
B-06 (B)
6 5 4 3 2 1 C-138 (GR)


124 123 122121
Connector: B-06 133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

6 5 4 3 2 1 NO : Repair.

OK: 0.3 − 80 Ω (at 20 °C)
TROUBLESHOOTING
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-138 (GR) C-138 (GR)
C-138 (GR) C-138 (GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142
AK304275 AB AK304275 AB
• Check output line for short circuit. • Check output line for short circuit.

00 − How to Use
P.00-6).
TROUBLESHOOTING
DTC P2103: Throttle Valve Control Servo Circuit (Shorted High)
B-06 Electronically
controlled
1 2
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU <M/T>
125126127128129 130 131 132 133 Engine-A/T-ECU <A/T>
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK304137AB
TROUBLE JUDGMENT
engine-ECU <M/T> or engine-A/T-ECU
controlled throttle valve (terminals No. 1, No. 2). • Throttle actuator control motor current is 8 A or
higher for 0.8 second.
FUNCTION
varies the direction and the amperage of the • Failed throttle valve control servo.
current that is applied to the throttle valve control • Short circuit in throttle valve control servo circuit
servo in order to control the opening of the or loose connector contact.
throttle valve. • Failed engine-ECU <M/T>
TROUBLESHOOTING

NO : Replace the throttle body assembly.

Connector: C-138
B-06 (B)
6 5 4 3 2 1 C-138 (GR)


124 123 122121
Connector: B-06 133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

6 5 4 3 2 1 NO : Repair.

OK: 0.3 − 80 Ω (at 20 °C)
TROUBLESHOOTING
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-138 (GR) C-138 (GR)
C-138 (GR) C-138 (GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142
AK304275 AB AK304275 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
Code No. P2121: Accelerator Pedal Position Sensor (Main) Circuit Range/Performance Problem

• Refer to P2122 accelerator pedal position sensor NO : Repair.
(main) circuit P.13B-394.
• Refer to inspection procedure 32 accelerator STEP 2. Check accelerator pedal position sensor
pedal position switch circuit P.13B-394. itself.
• Check accelerator pedal position sensor itself
FUNCTION
checks the accelerator pedal position sensor Q: Is the check result normal?
(main) output signal characteristics for abnormal YES : Go to Step 3 .
conditions. NO : Replace accelerator pedal position sensor.
TROUBLE JUDGMENT
Check Condition B-116 accelerator pedal position sensor
• Ignition switch is in "ON" position connector.
• Closed throttle position switch: ON
Connector: B-116
• Accelerator pedal position sensor (sub) output
voltage is 1.88 V or less. B-116 (GR)
Judgment Criteria
• Accelerator pedal position sensor (main) output
voltage is 1.88 V or higher for 1 second.
PROBABLE CAUSE
• Failed accelerator pedal position sensor 8 7 6 5 4 3 2 1
• Open/short circuit in accelerator pedal position Harness side connector AK304279 AB
• Failed accelerator pedal position switch
side.
• Open/short circuit in accelerator pedal position
switch circuit or loose connector contact
• Failed engine-ECU <M/T> OK: 2 Ω or less
• Failed engine-A/T-ECU <A/T> Q: Is the check result normal?
DIAGNOSIS PROCEDURE NO : Go to Step 4 .
STEP 1. Connector check: B-116 accelerator

pedal position sensor connector
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1

TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 1) accelerator pedal position sensor
Connector: C-142 <A/T> connector.
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.

00 − How to Use Trouble
shooting/Inspection Service Points P.00-6).
TROUBLESHOOTING
STEP 7. Check accelerator pedal position switch STEP 9. Check harness between B-116 (terminal
itself. No. 4) accelerator pedal position sensor
• Check accelerator pedal position switch itself connector and C-140 (terminal No. 38)
(Refer to P.13B-432). engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
YES : Go to Step 8 . Connector: B-116
NO : Replace accelerator pedal position sensor.
B-116 (GR)
connector
Connector: C-140
<L. H. Drive Vehicle> 8 7 6 5 4 3 2 1
Connector: C-140
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 C-140 (GR)
58 57 5655 54 5352

34 33 32 31
AK304274 AB
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
NO : Repair.
AK304274 AB

NO : Repair.
TROUBLESHOOTING
Code No. P2122: Accelerator Pedal Position Sensor (Main) Circuit Low Input
Accelerator pedal position sensor (main) circuit
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(main)
2 3 1
L-W GR BR-W
92 114 91
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304133AB
OPERATION • The sensor signal is inputted to the engine-ECU

• A power voltage of 5 V is applied to the <M/T> or engine-A/T-ECU <A/T> (terminal No.
accelerator pedal position sensor (terminal No. 2) 114) from the accelerator pedal position sensor
from the engine-ECU <M/T> or engine-A/T-ECU output terminal (terminal No. 3).
• The power voltage is earthed to the engine-ECU FUNCTION
<M/T> or engine-A/T-ECU <A/T> (terminal No. • The accelerator pedal position sensor (main)
91) from the accelerator pedal position sensor outputs voltage which corresponds to the
(terminal No. 1). accelerator pedal depression.
<A/T> checks whether the voltage is within a
specified range.
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 2. Connector check: B-116 accelerator

Check Condition pedal position sensor connector
Connector: B-116
Judgment Criteria
• Accelerator pedal position sensor (main) output B-116 (GR)
voltage is 0.2 volt or less for 0.3 second.
PROBABLE CAUSE
• Failed accelerator pedal position sensor
sensor circuit or loose connector contact 8 7 6 5 4 3 2 1
NO : Repair.

STEP 3. Check accelerator pedal position sensor
itself.
a. Item 78: Accelerator pedal position sensor
(main)
00 − How to Use NO : Replace accelerator pedal position sensor.
P.00-6).
NO : Go to Step 2 . STEP 4. Perform voltage measurement at B-116
accelerator pedal position sensor connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
TROUBLESHOOTING
Connector: C-142
connector.
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 7. MUT-II/III data list STEP 9. Check harness between B-116 (terminal
• Refer to Data List Reference Table P.13B-401. No. 2) accelerator pedal position sensor
a. Item 78: Accelerator pedal position sensor connector and C-142 (terminal No. 92)
(main) engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
YES : Intermittent malfunction (Refer to GROUP Connector: B-116
00 − How to Use
Troubleshooting/Inspection Service Points B-116 (GR)
P.00-6).
STEP 8. Connector check: C-142 engine-ECU 8 7 6 5 4 3 2 1

<M/T> connector or engine-A/T-ECU <A/T> Harness side connector AK304279 AB
connector
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

NO : Repair.
TROUBLESHOOTING

No. 3) accelerator pedal position sensor
<A/T> connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P2123: Accelerator Pedal Position Sensor (Main) Circuit High Input
Accelerator pedal position sensor (main) circuit
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(main)
2 3 1
L-W GR BR-W
92 114 91
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304133AB

<M/T> or engine-A/T-ECU <A/T> (terminal No. • The accelerator pedal position sensor (main)
specified range.
TROUBLESHOOTING

NO : Repair.
Check Condition
• Accelerator pedal position sensor (sub) output STEP 3. Check accelerator pedal position sensor
voltage is 0.2 - 2.5 V. itself.
Judgment Criteria (Refer to P.13B-431).
voltage is 4.5 V or higher for is 1 second. Q: Is the check result normal?
PROBABLE CAUSE NO : Replace accelerator pedal position sensor.
• Open/short circuit in accelerator pedal position STEP 4. Perform resistance measurement at
sensor circuit or loose connector contact B-116 accelerator pedal position sensor
• Failed engine-ECU <M/T> connector.
Connector: B-116
DIAGNOSIS PROCEDURE
B-116 (GR)

(main)
8 7 6 5 4 3 2 1
00 − How to Use • Disconnect connector, and measure at harness
Troubleshooting/Inspection Service Points side.
P.00-6). • Resistance between terminal No. 1 and earth.
NO : Go to Step 2 . OK: 2 Ω or less
STEP 2. Connector check: B-116 accelerator YES : Go to Step 5 .
pedal position sensor connector NO : Go to Step 6 .
Connector: B-116
B-116 (GR) • Refer to Data list reference table P.13B-401.
(main)
8 7 6 5 4 3 2 1
00 − How to Use
AK304279 AB
P.00-6).
Q: Is the check result normal? NO : Replace engine-ECU <M/T> or
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P2126: Accelerator Pedal Position Sensor (Sub) Circuit Range/Performance Problem

• Refer to Code No. P2127 Accelerator Pedal NO : Repair.
Circuit Position Sensor (sub) Circuit P.13B-265.
• Refer to Inspection Procedure 32: Accelerator STEP 2. Check accelerator pedal position sensor
Pedal Position Switch Circuit P.13B-394. itself.
FUNCTION
checks the accelerator pedal position sensor Q: Is the check result normal?
(sub) output signal characteristics for abnormal YES : Go to Step 3 .
conditions. NO : Replace accelerator pedal position sensor.
TROUBLE JUDGMENT
Check Condition B-116 accelerator pedal position sensor
• Ignition switch is in "ON" position connector.
• Closed throttle position switch: ON
Connector: B-116
• Accelerator pedal position sensor (main) failure is
detected. B-116 (GR)
Judgment Criteria
voltage is 2.5 V or higher for 1 second.
PROBABLE CAUSE
• Failed accelerator pedal position sensor 8 7 6 5 4 3 2 1
• Open/short circuit in accelerator pedal position Harness side connector AK304279 AB
• Failed accelerator pedal position switch
side.
switch circuit or loose connector contact
• Failed engine-ECU <M/T> OK: 2 Ω or less

Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1

TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
NO : Repair.
00 − How to Use Trouble connector and C-140 (terminal No. 38)
shooting/Inspection Service Points P.00-6). engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
STEP 7. Check accelerator pedal position switch Connector: B-116

itself.
B-116 (GR)
• Check accelerator pedal position switch itself
8 7 6 5 4 3 2 1
STEP 8. Connector check: C-140 engine-ECU Harness side connector AK304279 AB

connector Connector: C-140
Connector: C-140
C-140 (GR)
C-140 (GR)
C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
34 33 32 31 58 57 5655 54 5352
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 Harness side connector
58 57 5655 54 5352
AK304274 AB
NO : Repair.
TROUBLESHOOTING
Code No. P2127: Accelerator Pedal Position Sensor (Sub) Circuit Low Input
Accelerator pedal position sensor (sub) circuit
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(sub)
8 6 7
Y-R L B
97 107 96
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304133AC

<M/T> or engine-A/T-ECU <A/T> (terminal No. • The accelerator pedal position sensor (sub)
specified range.
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 4. Perform voltage measurement at B-116

Check Condition accelerator pedal position sensor connector.
• Ignition switch is in "ON" position
Connector: B-116
Judgment Criteria
• Accelerator pedal position sensor (sub) output B-116 (GR)
voltage is 0.2 volt or less for 1 second.
PROBABLE CAUSE
sensor circuit or loose connector contact 8 7 6 5 4 3 2 1
side.
STEP 1. MUT-II/III data list OK: 4.9 − 5.1 V
a. Item 77: Accelerator pedal position sensor YES : Go to Step 8 .
(sub) NO : Go to Step 5 .
YES : Intermittent malfunction (Refer to GROUP STEP 5. Connector check: C-142 engine-ECU
00 − How to Use <M/T> connector or engine-A/T-ECU <A/T>
Troubleshooting/Inspection Service Points connector
P.00-6).
NO : Go to Step 2 . Connector: C-142
B-116 (GR)
C-142 (GR)
8 7 6 5 4 3 2 1

959493 92 91
YES : Go to Step 3 . 104 103102 101100 99 98 97 96
NO : Repair. 112111110
120119118
109108107
117116115
106105
114113

STEP 3. Check accelerator pedal position sensor AK304153 AB
itself.
• Check accelerator pedal position sensor itself Q: Is the check result normal?
(Refer to P.13B-431). YES : Go to Step 6 .
NO : Repair.
TROUBLESHOOTING
No. 8) accelerator pedal position sensor • Refer to Data List Reference Table P.13B-401.
connector and C-142 (terminal No. 97) a. Item 77: Accelerator pedal position sensor
engine-ECU <M/T> or engine-A/T-ECU <A/T> (sub)
connector.
Connector: B-116 YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
B-116 (GR) Troubleshooting/Inspection Service Points
P.00-6).
8 7 6 5 4 3 2 1 STEP 8. Connector check: C-142 engine-ECU

connector
C-142 (GR) C-142 (GR)

C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Check power supply line for open/short circuit.

NO : Repair.
TROUBLESHOOTING
No. 8) accelerator pedal position sensor No. 6) accelerator pedal position sensor
B-116 (GR) B-116 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Check power supply line for damage. • Check earthing line for damage.
TROUBLESHOOTING
Code No. P2128: Accelerator Pedal Position Sensor (Sub) Circuit High Input
Accelerator pedal position sensor (sub) circuit
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(sub)
8 6 7
Y-R L B
97 107 96
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304133AC

<M/T> or engine-A/T-ECU <A/T> (terminal No. • The accelerator pedal position sensor (sub)
specified range.
TROUBLESHOOTING

NO : Repair.
Check Condition
• Accelerator pedal position sensor (main) output STEP 3. Check accelerator pedal position sensor
voltage is 0.2 − 2.5 V. itself.
Judgment Criteria (Refer to P.13B-431).
voltage is 4.5 V or higher for 1 second. Q: Is the check result normal?
PROBABLE CAUSE NO : Replace accelerator pedal position sensor.
• Open/short circuit in accelerator pedal position STEP 4. Perform resistance measurement at
sensor circuit or loose connector contact B-116 accelerator pedal position sensor
• Failed engine-ECU <M/T> connector.
Connector: B-116
DIAGNOSIS PROCEDURE
B-116 (GR)

(sub)
8 7 6 5 4 3 2 1
00 − How to Use • Disconnect connector, and measure at harness
Troubleshooting/Inspection Service Points side.
P.00-6). • Resistance between terminal No. 7 and earth.
NO : Go to Step 2 . OK: 2 Ω or less
STEP 2. Connector check: B-116 accelerator YES : Go to Step 5 .
pedal position sensor connector NO : Go to Step 6 .
Connector: B-116
B-116 (GR) • Refer to Data list reference table P.13B-401.
(sub)
8 7 6 5 4 3 2 1
00 − How to Use
AK304279 AB
P.00-6).
Q: Is the check result normal? NO : Replace engine-ECU <M/T> or
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P2135: Throttle Position Sensor (Main and Sub) Range/Performance Problem

• Refer to Code No. P0122: Throttle Position
Sensor (main) Circuit Low Input P.13B-51.
• Refer to Code No. P0222: Throttle Position STEP 1. Connector check: C-142 engine-ECU
Sensor (sub) Circuit Low Input P.13B-145. <M/T> connector or engine-A/T-ECU <A/T>
connector and B-06 electronically controlled
FUNCTION throttle valve connector
• engine-ECU <M/T> or engine-A/T-ECU <A/T>
Connector: C-142
checks the throttle position sensor output signal
characteristics for abnormal conditions. <L. H. Drive Vehicle>
TROUBLE JUDGMENT
Check Condition
C-142 (GR)
• Throttle position sensor (main) output voltage is
0.35 − 2.5 V.
• Throttle position sensor (sub) output voltage is <R. H. Drive Vehicle>
2.25 − 4.8 V
C-142 (GR)
Judgment Criteria
• Using the formula given below, the voltage of 0.3
V or higher is obtained for 0.5 second: V* − V** −
2V
V*: throttle position sensor (main) output voltage
V**: throttle position sensor (sub) output voltage. 959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
PROBABLE CAUSE 120119118 117116115 114113
• Failed throttle position sensor Harness side connector

• Open/short circuit in throttle position sensor AK304153 AB

Connector: B-06
B-06 (B)
6 5 4 3 2 1

NO : Repair.
TROUBLESHOOTING
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
STEP 4. Replace throttle body assembly.

• After throttle body assembly is replaced, re-check
for trouble symptom.
Q: Does trouble system persist?
NO : Check end.
TROUBLESHOOTING
Code No. P2138: Accelerator Pedal Position Sensor (Main and Sub) Range/Performance Problem

• Refer to Code No. P2122: Accelerator Pedal
Position Sensor (main) Circuit Low Input
P.13B-254.
pedal position connector
• Refer to Code No. P2127: Accelerator Pedal
Position Sensor (sub) Circuit Low Input Connector: B-116
P.13B-265.
B-116 (GR)
FUNCTION
checks the accelerator pedal position sensor
output signal characteristics for abnormal
conditions.
8 7 6 5 4 3 2 1
TROUBLE JUDGMENT Harness side connector AK304279 AB
Check Condition
• Ignition switch is in "ON" position
NO : Repair.
voltage is 0.2 − 4.5 V.
voltage is 0.2 − 4.5 V. STEP 2. Check accelerator pedal position sensor
itself.
Judgment Criteria • Check accelerator pedal position sensor itself
• Accelerator pedal position sensor (sub) output (Refer to P.13B-431).
voltage minus Accelerator pedal position sensor
(main) output voltage is 1 volt or higher for 1 Q: Is the check result normal?
second. YES : Go to Step 3 .
• Accelerator pedal position sensor (main) output NO : Replace accelerator pedal position sensor.
voltage minus Accelerator pedal position sensor
(sub) output voltage is 1 volt or higher for 0.2 STEP 3. Perform resistance measurement at
seconds. B-116 accelerator pedal position sensor
connector.
PROBABLE CAUSE
• Failed accelerator pedal position sensor Connector: B-116
sensor circuit or loose connector contact B-116 (GR)
8 7 6 5 4 3 2 1

side.
OK: 2 Ω or less
NO : Go to Step 4 .
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 6. Check the trouble symptoms STEP 8. Connector check: C-142 engine-ECU
YES : Replace engine-ECU <M/T> or connector
engine-A/T-ECU <A/T>. Connector: C-142
00 − How to Use
P.00-6).
C-142 (GR)
B-116 accelerator pedal position sensor
connector.
Connector: B-116
C-142 (GR)
B-116 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
8 7 6 5 4 3 2 1
120119118 117116115 114113
Harness side connector AK304279 AB Harness side connector
• Disconnect connector, and measure at harness AK304153 AB
side.
• Resistance between terminal No. 7 and earth. Q: Is the check result normal?
OK: 2 Ω or less NO : Repair.
NO : Go to Step 8 .
TROUBLESHOOTING
engine-ECU <M/T> connector or engine-A/T-ECU STEP 10. Connector check: C-142 engine-ECU
<A/T> connector. <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: B-116
Connector: C-142
B-116 (GR)
C-142 (GR)
8 7 6 5 4 3 2 1

Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
<R. H. Drive Vehicle> Harness side connector

AK304153 AB
C-142 (GR)

NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

TROUBLESHOOTING
B-116 (GR) B-116 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Check power supply line for damage. • Check power supply line for damage.
TROUBLESHOOTING
B-116 (GR) B-116 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Check output line for damage. • Check output line for damage.
TROUBLESHOOTING
DTC P2173: Abnormal Intake Air Amount
FUNCTION DIAGNOSIS
decides the allowable intake air amount in
accordance with the engine speed and the target STEP 1. MUT-II/III diagnosis code
opening angle of throttle valve. Q: Diagnosis code set?
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> YES : Inspection chart for diagnosis code (Refer
checks whether the actual intake air amount is to P.13B-20).
more than the allowable intake air amount. NO : Go to Step 2 .
TROUBLE JUDGMENT
STEP 2. Replace the air flow sensor.
Check Conditions • After replacing the air flow sensor, re-check the
• While engine is running. trouble symptoms.
• The actual intake air amount is more than the YES : Go to Step 3 .
allowable in take air amount for 1.5 seconds. NO : Check end.
TROUBLESHOOTING HINTS (The most likely

STEP 3. Replace the throttle body assembly.
causes for this code to be set are: )
• After replacing the throttle body assembly,
• Failed air flow sensor.
re-check the trouble symptoms.
• Throttle valve faulty operation.
• Failed throttle position sensor Q: Is the check result normal?
• Failed engine-ECU <M/T> YES : Replacing engine-ECU <M/T> or
• Failed engine-A/T-ECU <A/T> engine-A/T-ECU <A/T>.
NO : Check end.
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1131151500812

procedure
No.
Communication Communication with all system is not possible 1
with MUT-II/III is Communication with engine-ECU <M/T> or engine-A/T-ECU <A/T> only 2
impossible is not possible
Engine warning The engine warning lamp does not illuminate right after the ignition switch 3
lamp is turned the "ON" position
The engine warning lamp remains illuminating and never goes out 4
Starting Starting impossible The starter is impossible to operate. 5 <M/T>,
(No initial combustion) 6 <A/T>
Starting impossible The starter is operative and cranks 7
(Starter operative but no initial the engine, but none of initial
combustion) combustion is in the cylinders and
the engine is not started.
Starting impossible The initial combustion occurs, but 8
(Initial combustion but no complete the engine stalls soon due to the
combustion) incomplete combustion.
Improper starting It is long cranking to start the engine.
(Long time to start)
Improper idling Unstable idling The engine speed is not constant 9
(Rough idling, hunting) and changeable during the idling.
Usually, the judgment can be based
on the movement of the tachometer
pointer, also on the vibration
transmitted to the steering wheel, sift
lever, vehicle body and so on.
Improper idling speed The proper idling speed is not
satisfied.
Engine stalled during idling The engine stalls during the idling in
(Die out) no relation to the vehicle movement.
Engine stalls The engine stalls when starting the The engine stalls during the 10
car operation, or when the accelerator
(Pass out) pedal is depressed from the idling.
The engine stalls when The engine stalls at the deceleration. 11
decelerating
TROUBLESHOOTING

procedure
No.
Driving Engine does not revolve up The engine speed is not higher when 12
the accelerator pedal is depressed.
Hesitation, sag The response of vehicle speed 13
(engine speed) is delayed when the
accelerator pedal is depressed, or
the vehicle speed (engine speed) is
temporarily dropped during the
acceleration. These phenomena are
called "hesitation" and the serious
hesitation is called "sag".
Poor acceleration The engine cannot obtain the
acceleration corresponding to the
degree of throttle opening although
the engine is smooth at the constant
speed.
Stumble The engine speed increase is
delayed when the accelerator pedal
is initially depressed at the starting.
Surge The vehicle body is repeated to
vibrate jollity in the forward and
backward directions at the constant
speed or acceleration.
when accelerating the acceleration.
when decelerating the deceleration.
Knocking Sharp sound like a hammer striking 16
on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
Ignition timing offset The basic ignition timing is deviated 17
from the datum value.
Stopping Run on (Dieseling) The engine continues to run after the 18
ignition switch is in "LOCK (OFF)"
position.
Exhaust gas Odor, white smoke, black smoke, The exhaust gas is extremely rank 19
high-concentration CO/HC during odor, white smoke or black smoke.
idling The concentration of CO & HC is
high during the idling.
Charging Battery rundown The battery is soon rundown or the 20
performance charging ability of battery is small.
TROUBLESHOOTING

procedure
No.
Cooling Overheating The temperature of engine cooling 21
performance water is extremely high.
Abnormal rotation of fan Motor The fan motor is abnormally rotated 22
when the ignition switch is in "ON"
position in no relation to the engine
cooling water temperature.
A/C performance Poor A/C Performance The temperature of air cooling from 23
A/C is not efficient or very far from
the target temperature.
PROBLEM SYMPTOMS TABLE
procedure page
No.
1 Communication with all system is not possible P.13B-285
2 Communication with engine-ECU <M/T> or engine-A/T-ECU <A/T> only is not P.13B-288
possible
3 The engine warning lamp does not illuminate right after the ignition switch is P.13B-291
turned the "ON" position
4 The engine warning lamp remains illuminating and never goes out P.13B-298
5 Starting impossible (No initial combustion) <M/T> P.13B-301
6 Starting impossible (No initial combustion) <A/T> P.13B-306
7 Starting impossible (Starter operative but no initial combustion) P.13B-312
8 Starting impossible (Initial combustion but no complete combustion) P.13B-314
Starting impossible (Long time to start)
9 Unstable idling (Rough idling, hunting) P.13B-316
Improper idling speed (Too high or too low)
Engine stalls during idling (Die out)
10 The engine stalls when starting the car (pass out) P.13B-320
11 The engine stalls when decelerating P.13B-321
12 Engine does not revolve up P.13B-322
13 Hesitation, sag P.13B-323
Poor acceleration
Stumble
Surge
14 The feeling of impact or vibration when accelerating P.13B-324
15 The feeling of impact or vibration when decelerating P.13B-325
16 Knocking P.13B-325
17 Ignition timing offset P.13B-326
18 Run on (Dieseling) P.13B-327
TROUBLESHOOTING

procedure page
No.
19 Odor, white smoke, black smoke, high-concentration CO/HC during idling P.13B-328
20 Battery rundown P.13B-330
21 Overheating P.13B-333
22 Abnormal rotation of fan motor P.13B-334
23 Poor A/C performance P.13B-337
24 Engine-ECU <M/T> or engine-A/T-ECU <A/T> power supply, engine control P.13B-338
relay, ignition switch-IG1 system
25 Fuel pump system P.13B-344
26 Fan control relay system P.13B-352
27 A/C switch system P.13B-359
28 A/C compressor relay system P.13B-364
29 A/C load signal system P.13B-371
30 A/C pressure sensor system P.13B-376
31 Ignition circuit system P.13B-386
32 Accelerator pedal position switch circuit system P.13B-394
TROUBLESHOOTING
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is Not Possible
Diagnosis connector circuit
Fusible link (1)
R C-116
15 (*1) or
A-14
14 (*2)
R
C-122
2 (*2)
R
C-204
1
15 J/B
15A
12
C-205
W-R
C-24
MU803797 16
1 2 3 4 5 6 7 8
Diagnosis connector
9 10 1112 13 14 1516
4 5
B B
NOTE
Wire colour code
AK304141 AB
TROUBLESHOOTING

• Battery voltage is applied to diagnosis connector NO : Repair.
(terminal No.16).
• Diagnosis connector (terminals No. 4 and 5) are STEP 2: Perform resistance measurement at C-24
earthed to the vehicle body. diagnosis connector.
COMMENT ON TROUBLE SYMPTOM Connector: C-24
• Failure is possibly caused by failed power supply <L. H. drive vehicle>
circuit or failed earthing circuit of diagnosis
connector.
PROBABLE CAUSE
• Failed diagnosis connector C-24 (B)
• Open/short circuit in diagnosis connector circuit
• Failed MUT-II/III 1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
DIAGNOSIS PROCEDURE <R. H. drive vehicle> Harness side
NOTE: . connector
*1
: L.H. drive vehicles
STEP 1: Check connector: C-24 diagnosis C-24 (B)

connector
Connector: C-24
<L. H. drive vehicle> AK304280 AB

side.
• Resistance between terminal No. 4 and earth,
also between terminal No. 5 and earth.
C-24 (B)
OK: 2 Ω or less
9 10 1112 13 14 1516 YES : Go to Step 3 .
<R. H. drive vehicle> Harness side NO : Check and repair harness between C-24
connector (terminal No. 4) diagnosis connector and
body earth, also between C-24 (terminal No.
5) diagnosis connector and body earth.
• Check earthing line for open circuit
and damage.
C-24 (B)
AK304280 AB

TROUBLESHOOTING
STEP 3: Perform voltage measurement at C-24 STEP 4: Replace MUT-II/III

diagnosis connector. • After replacing the MUT-II/III, re-check the trouble
symptoms.
Connector: C-24
<L. H. drive vehicle> Q: Does trouble symptom persist?
NO : Check end

C-24 (B)
No. 16) diagnosis connector and battery.
Connector: C-24
1 2 3 4 5 6 7 8
<L. H. drive vehicle>
9 10 1112 13 14 1516
<R. H. drive vehicle> Harness side
connector
C-24 (B)
C-24 (B) 1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
connector
AK304280 AB
• Disconnect connector, and measure at the

harness side.
C-24 (B)
OK: System voltage
NO : Check intermediate connectors C-116*1, AK304280 AB
A-14*2 C-122*2, C-204 and C-205 and repair NOTE: Before checking harness, check intermediate
if necessary. If connectors are normal, connectors C116*1, A-14*2, C-122*2, C-204 and
check and repair harness between C-24 C-205, and repair if necessary.
(terminal No. 16) diagnosis connector and • Check power supply line for damage.
battery.
• Check power supply line for Q: Is the check result normal?
open/short circuit. YES : Check and repair harness between C-24
(terminal No. 4 and No. 5) diagnosis
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 2: Communication with Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Only is

Not Possible.
Diagnosis connector circuit
C-141
(MU803804)
656667686970717273
747576777879808182 Engine-A/T-ECM <A/T>
8384 858687 8889
74
O-W
C-04 (*1)
C-105
5
31 32 33 34 35 36 37 38 39 40 41
O-L 42 43 44 45 46 47 48 49 50 51 52
37
G G
Combination mater CPU C-04 (*2)
36 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
O-W 32 (*1) or
20 (*2)
J/C (3)
C-02
29 (*1) or
18 (*2)
O-L
C-24 7
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
NOTE
Wire colour code
AK304142 AB

• There is data communication between diagnosis • Open/short circuit in engine-ECU <M/T> or
connector output terminal (terminal No. 7) and engine-A/T-ECU <A/T> power circuit
engine-ECU <M/T> (terminal No. 74). • Between engine-ECU <M/T> or engine-A/T-ECU
<A/T> and diagnosis connector for short circuit
COMMENT ON TROUBLE SYMPTOM • Failed combination meter
• Failure is possibly caused by failed power supply • Failed engine-ECU <M/T>
circuit or failed earthing circuit of engine-ECU • Failed engine-A/T-ECU <A/T>
<M/T> or engine-A/T-ECU <A/T>.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3: Check harness between C-24 (terminal

No. 7) diagnosis connector and C-141 (terminal
STEP 1: Check engine warning lamp. No. 74) engine-ECU <M/T> connector or
• Ignition switch: OFF → ON engine-A/T-ECU <A/T> connector.
Q: Is lamp illuminating for few seconds? Connector: C-24
YES : Go to Step 2 . <L. H. drive vehicle>
NO : Check engine-ECU <M/T> or
engine-A/T-ECU <A/T> power supply,
engine control relay and ignition switch IG1
system (Refer to Inspection Procedure 24
P.13B-338). C-24 (B)
1 2 3 4 5 6 7 8
STEP 2: Connector check: C-141 engine-ECU 9 10 1112 13 14 1516
connector connector
Connector: C-141
C-24 (B)
C-141(GR)
AK304280 AB

C-141 (GR)
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
C-141 (GR)
AK304154 AB

NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
NOTE: Before Checking harness, check

intermediate connectors C-02, C-04 and C-105 and
repair if necessary.
• Check communication line for open/short circuit
and damage.
TROUBLESHOOTING
STEP 5: Check the trouble symptom.
NO : Repair.
STEP 4: Replace the combination meter
• After replacing the combination meter, re-check NO : Intermittent malfunction (Refer to GROUP
the trouble symptoms. 00 − How to Use
Q: Is the check result normal? Troubleshooting/Inspection Service Points
YES : Go to Step 5 . P.00-6).
NO : Check end.
TROUBLESHOOTING
Inspection Procedure 3: The Engine Warning Lamp Does Not Illuminate Right after the Ignition Switch
is Turned the "ON" Position
Combination meter circuit
Ignition switch
C-303 R LOCK
1 2 3 ST ACC
4 5 6 IG1 IG2
L-B
C-203
6
2
J/B
7.5A
25
C-205 C-04 (*1)
B-W
C-04
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
Combination meter
G G
C-05 (*1)
C-04 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
G G C-05
14
R-W
C-05 (*2)
1 2 3 4 5 6 7 8 9 10 11 7
12 13 14 15 16 17 18 19 20 2122 C-105
R-W
C-139
1 2 3 4 Engine-ECU <M/T>
5 6 7 8 9 10111213 Engine-A/T-ECM <A/T>
NOTE 14 15 16 1718 19 20
*1: L.H. drive vehicles 21 22 232425 2627
Wire colour code

AK304143 AB
TROUBLESHOOTING
OPERATION STEP 2: Check engine warning lamp for

• Battery voltage is applied to engine warning lamp burnt-out bulb.
of combination meter connector (terminal No. 42)
from ignition switch. Q: Is the check result normal?
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> YES : Go to Step 3 .
(terminal No. 7) makes power transistor in unit be NO : Replace engine warning lamp.
in "ON" position, and that makes currents go on
engine warning lamp of combination meter STEP 3: Connector check: C-04 combination
connector (terminal No. 14). meter connector
COMMENTS ON TROUBLE SYMPTOM Connector: C-04
• Engine-ECU <M/T> engine-A/T-ECU <A/T> turns C-04
on engine warning lamp for 5 seconds to check
for burnt-out bulb immediately after ignition
switch is turned to ON.
• If engine warning lamp is not lit just after turning
ignition switch to "ON" position, failure is possibly
caused by burn-out bulb, open/short circuit or
other faults.
PROBABLE CAUSE <L. H. Drive Vehicles>

• Engine warming lamp bulb burnt out
• Failed ignition switch 41 40 39 38 37 36 35 34 33 32 31
• Open/short circuit in engine warning lamp circuit 52 51 50 49 48 47 46 45 44 43 42
for or loose connector contact
G G
<R. H. Drive Vehicles>
DIAGNOSIS PROCEDURE
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 4342
STEP 1: Check engine start-up.
Q: Is engine started?
NO : Check engine-ECU <M/T> engine-A/T-ECU

<A/T> power supply, engine control relay
and ignition switch IG1 system (Refer to
NO : Repair.
TROUBLESHOOTING
STEP 4: Perform voltage measurement at C-04 STEP 5: Connector check: C-303 ignition switch
combination meter connector. connector
C-04
C-303
3 2 1
6 5 4
<L. H. Drive Vehicles>

Connector: C-04
41 40 39 38 37 36 35 34 33 32 31 C-04
52 51 50 49 48 47 46 45 44 43 42
G G
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 4342
AK304333 AB
41 40 39 38 37 36 35 34 33 32 31
• Disconnect connector, and measure at the 52 51 50 49 48 47 46 45 44 43 42
harness side. G G
OK: System voltage <R. H. Drive Vehicles>
Q: Is the check result normal? 41 40 39 38 37 36 35 34 33 32 31

YES : Go to Step 6 . 52 51 50 49 48 47 46 45 44 4342
NO : Go to Step 5 .
AK304333 AB

No. 42) combination meter connector and
connector.
open/short circuit.
NO : Repair
TROUBLESHOOTING
STEP 6: Connector check: C-139 engine-ECU STEP 7: Perform voltage measurement at C-139
<M/T> connector or engine-A/T-ECU <A/T> engine-ECU <M/T> connector or engine-A/T-ECU
connector <A/T> connector.
C-139 (GR) C-139 (GR)
C-139 (GR) C-139 (GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK304262 AB AK304262 AB

YES : Go to Step 7 . harness side.
NO : Repair. • Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING

STEP 8: Check connector: C-05 combination
meter connector
Connector: C-05 harness between C-05 (terminal No. 14)
C-05 (L) (terminal No. 7) engine-ECU <M/T>
connector.
circuit.
NO : Repair
STEP 9: Connector check: C-303 ignition switch

connector
Connector: C-303
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G
C-303
3 2 1
11 10 9 8 7 6 5 4 3 2 1 6 5 4
22 21 20 19 18 17 16 15 14 13 12

NO : Repair.
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
STEP 10: Check harness between C-04 (terminal NO : Repair.
No. 42) combination connector and C-303
Connector: C-04
connector
C-05 (L)

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G G 11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G
<R. H. Drive Vehicles> Harness side connector
41 40 39 38 37 36 35 34 33 32 31 <R. H. Drive Vehicles>

52 51 50 49 48 47 46 45 44 4342
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
AK304333 AB

Connector: C-303
AK304335 AB
C-303 Q: Is the check result normal?

NO : Repair.
3 2 1
6 5 4

connectors C-203 and C-205, and repair if
necessary.
TROUBLESHOOTING

No. 14) combination connector and C-139 NO : Repair.
Connector: C-05
C-05 (L)
00 − How to Use
P.00-6).
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12

AK304335 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and Never Goes Out
Combination meter circuit
Ignition switch
C-303 R LOCK
1 2 3 ST ACC
4 5 6 IG1 IG2
L-B
C-203
6
2
J/B
7.5A
25
C-205 C-04 (*1)
B-W
C-04
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
Combination meter
G G
C-05 (*1)
C-04 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
G G C-05
14
R-W
C-05 (*2)
1 2 3 4 5 6 7 8 9 10 11 7
12 13 14 15 16 17 18 19 20 2122 C-105
R-W
C-139
5 6 7 8 9 10111213 Engine-A/T-ECM <A/T>
NOTE 14 15 16 1718 19 20
*1: L.H. drive vehicles 21 22 232425 2627
Wire colour code

AK304143 AB
TROUBLESHOOTING
OPERATION STEP 2: Connector check: C-139 engine-ECU

• Battery voltage is applied to engine warning lamp <M/T> connector or engine-A/T-ECU <A/T>
of combination meter connector (terminal No. 42)
from ignition switch. Connector: C-139
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> <L. H. Drive Vehicle>
(terminal No. 7) makes power transistor in unit be
in "ON" position, and that makes currents go on
engine warning lamp (terminal No. 14).
C-139 (GR)
COMMENT ON TROUBLE SYMPTOM
has detected failed sensor or failed actuator. Or
failure is possibly caused by short circuit or other <R. H. Drive Vehicle>
faults.
PROBABLE CAUSE C-139 (GR)

• Short circuit in between engine warning lamp and
circuit.
• Failed engine-ECU <A/T>
4 3 2 1
• Failed engine-A/T-ECU <A/T> 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
DIAGNOSIS PROCEDURE Harness side connector
AK304262 AB
STEP 1: MUT-II/III diagnosis code

Q: Diagnosis code set? YES : Go to Step 3 .
YES : Inspection chart for diagnosis code (Refer NO : Repair
to P.13B-20.)
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 3: Perform voltage measurement at C-139 OK: System voltage

engine-ECU <M/T> connector or engine-A/T-ECU Q: Is the check result normal?
<A/T> connector. YES : Go to Step 4 .
NO : Check intermediate connector C-105, and
Connector: C-139 repair if necessary. If intermediate
<L. H. Drive Vehicle> connector is normal, check and repair
C-139 (GR) connector or engine-A/T-ECU <A/T>.

C-139 (GR) engine-A/T-ECU <A/T>.
00 − How to Use
4 3 2 1 P.00-6).
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
Connector: C-05
C-05 (L)
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12

AK304335 AB

harness side.
TROUBLESHOOTING
Inspection Procedure 5: Starting Impossible (No Initial Combustion) <M/T>
Stating impossible (no initial combustion) <M/T>
Ignition switch
C-303
R LOCK
1 2 3
ST ACC
IG1 IG2 4 5 6
Battery
5
B-Y
C-106
16
B-Y
B-L
B-19
4 B-Y
C-140
51 (MU803083)
B-R 3132 33 34
35363738394041 42 43
444546474849 50 51
5253 545556 57 58
1 1
1 Engine-ECU
1
ON
OFF
B-26
B-25 M
(MU801211)
Starter
Wire colour code

AK304155 AB
COMMENT ON TROUBLE SYMPTOM PROBABLE CAUSE

• Failure is possibly caused by failed starter itself • Failed battery
or failed related circuit. • Failed starter motor
• Open/short circuit in starter associated circuit or
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 4: Perform voltage measurement at C-140

Connector: C-140
• Measure battery voltage at cranking.
OK: 8 V or higher
NO : Check battery (Refer to GROUP 54A − C-140 (GR)
Battery − On-vehicle Service − Battery Test
P.54A-6).
34 33 32 31
STEP 2: MUT-II/III data list 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
• Item 18: Cranking signal 58 57 5655 54 5352
OK: Harness side connector
AK304455 AB
OFF (Ignition switch: ON) • Disconnect connector, and measure at the
Q: Is the check result normal? harness side.
YES : Go to Step 8 . • Ignition switch: ST
NO : Go to Step 3 . • Voltage between terminal No. 51 and earth.
OK: System voltage
STEP 3: Connector check: C-140 engine-ECU Q: Is the check result normal?
NO : Go to Step 5 .
Connector: C-140

connector
Connector: C-303
C-140 (GR)
C-303
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 3 2 1
58 57 5655 54 5352
Harness side connector 6 5 4
AK304455 AB

NO : Repair.
NO : Repair.
TROUBLESHOOTING
STEP 6: Check ignition switch. STEP 7: Connector check: C-303 ignition switch
Connector: C-140
Connector: C-303
C-303
C-140 (GR)
3 2 1
6 5 4
34 33 32 31
43 42 4140 39 38 37 36 35 Harness side connector AK304334 AB
51 50 49 4847 46 4544
58 57 5655 54 5352
Harness side connector Connector: B-26
AK304455 AB
Connector: C-303
B-26(B)
C-303
1
3 2 1
6 5 4
Harness side connector AK304334 AB YES : Check intermediate connectors C-106 and
B-19, and repair if necessary. If intermediate
• Check ignition switch (Refer to GROUP 54A −
Ignition Switch − Ignition Switch − Inspection
P.54A-35). ignition switch connector and B-26 (terminal
Q: Is the check result normal? No. 1) starter connector.
YES : Check intermediate connectors C-106 and • Check output line for short circuit.
B-19, and repair if necessary. If intermediate NO : Repair.
STEP 8: Check connector: B-26 starter connector
engine-ECU connector and C-303 (terminal
No. 5) ignition switch connector. Connector: B-26
open/short circuit.
B-26(B)
1

NO : Repair.
TROUBLESHOOTING
YES : Check intermediate connectors B-19 and

STEP 9: Perform voltage measurement at B-26
starter connector.
Connector: B-26 and repair harness between C-303 (terminal
No. 5) ignition switch connector and B-26
damage.
B-26(B) NO : Repair.
1 STEP 11: Connector check: B-25 starter

connector
• Disconnect connector, and measure at the Connector: B-25

harness side.
• Ignition switch: ST
OK: System voltage
Q: Is the check result normal? B-25
YES : Go to Step 11 . 1
STEP 10: Connector check: C-303 ignition switch Q: Is the check result normal?
Connector: C-303 NO : Repair.

C-303
starter connector.
Connector: B-25
3 2 1
6 5 4
Connector: B-26 B-25

1

B-26(B) harness side.
1 OK: System voltage
Q: Is the check result normal? NO : Check and repair harness between B-25
battery.
open/short circuit.
TROUBLESHOOTING
NO : Repair.
No. 5) ignition switch connector and B-26
STEP 14: Check harness between B-25 (terminal
Connector: C-303
No. 1) starter connector and battery.
Connector: B-25
C-303
3 2 1
6 5 4 B-25
Harness side connector 1
AK304334 AB
Connector: B-26 Harness side connector AK304337 AB

1

connectors B-19 and C-106, and repair if necessary.
TROUBLESHOOTING
Inspection Procedure 6: Starting Impossible (No Initial Combustion) <A/T>
Stating impossible (no initial combustion) <A/T>
Ignition switch
C-303
R LOCK
1 2 3
ST ACC
IG1 IG2 4 5 6
Battery
5
B-Y
C-106
16
B-Y
10 B-35
(MU802355)
1 2 3 4 5 6
7 8 9 10
B-L 9
B-R
B-Y
B-19 C-140
4 51 (MU803803)
3132 33 34
B-R 35363738394041 42 43
444546474849 50 51
5253 545556 57 58
1 1
Engine-A/T-ECU
1 ON
OFF
1
M
B-25 B-26
(MU801215)
Starter
Wire colour code

AK304329 AB
COMMENT ON TROUBLE SYMPTOM • Failed inhibitor switch

• Failure is possibly caused by failed starter itself • Failed starter motor
or failed related circuit. • Open/short circuit in starter associated circuit or
PROBABLE CAUSE
• Failed battery
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 4: Perform voltage measurement at C-140

engine-A/T-ECU connector.
Connector: C-140
OK: 8 V or higher
NO : Check battery (Refer to GROUP 54A − C-140 (GR)
Battery-On-vehicle Service − Battery Test
P.54A-6).

• Item 18: Cranking signal
OK:
ON (Ignition switch: ST) C-140 (GR)
Q: Is the check result normal? 34 33 32 31
YES : Go to Step 11 . 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
NO : Go to Step 3 . 58 57 5655 54 5352

STEP 3: Connector check: C-140 engine-A/T-ECU AK304274 AB
connector
Connector: C-140 harness side.
<L. H. Drive Vehicle> • Ignition switch: ST
OK: System voltage
C-140 (GR)
NO : Go to Step 5 .
<R. H. Drive Vehicle> STEP 5: Connector check: B-35 inhibitor switch

connector
Connector: B-35
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352 B-35 (B)
Harness side connector 6 5 4 3 2 1
10 9 8 7
AK304274 AB

NO : Repair.
NO : Repair.
TROUBLESHOOTING
STEP 6: Perform voltage measurement at B-35 STEP 8: Check ignition switch

inhibitor switch connector
Connector: B-35
Connector: B-35
B-35 (B)
B-35 (B) 6 5 4 3 2 1
6 5 4 3 2 1 10 9 8 7
Connector: C-303
harness side.
• Ignition switch: ST C-303
OK: System voltage
NO : Go to Step 7 .
STEP 7: Connector check: C-303 ignition switch • Check ignition switch (Refer to GROUP 54A −
connector Ignition switch − Ignition Switch − Inspection
P.54A-35).
Connector: C-303
YES : Check intermediate connector C-106 and
C-303 repair if necessary. If intermediate
harness between B-35 (terminal No. 10)
inhibitor switch connector and C-303
3 2 1 (terminal No. 5) ignition switch connector.
6 5 4 • Check power supply line for
Harness side connector AK304334 AB open/short circuit.
NO : Repair.
TROUBLESHOOTING
STEP 9: Check inhibitor switch. STEP 10: Connector check: B-35 inhibitor switch
Connector: B-35
Connector: B-35
B-35 (B)
6 5 4 3 2 1 B-35 (B)
10 9 8 7 6 5 4 3 2 1
AK304338 AB
Connector: C-140
Connector: B-26
C-140 (GR)
B-26(B)
1

C-140 (GR) YES : Check intermediate connectors B-19, and
34 33 32 31 harness between B-35 (terminal No. 9)
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 inhibitor switch connector and B-26
58 57 5655 54 5352 (terminal No. 1) starter connector.
Harness side connector • Check output line for short circuit.
NO : Repair.
AK304274 AB
• Check ignition switch (Refer to GROUP 23A − On

STEP 11: Check connector: B-26 starter
− vehicle Service − A/T Control Component
connector
Check − Inhibitor Switch Check P.23A-149).
Connector: B-26
YES : Check intermediate connectors B-19, and
B-26(B)
(terminal No. 51) engine-A/T-ECU
connector. 1
• Check power supply line for Harness side connector AK304336 AB
open/short circuit.
NO : Repair.
TROUBLESHOOTING
YES : Check intermediate connectors B-19, and

starter connector.
Connector: B-26 harness between B-35 (terminal No. 9)
inhibitor switch connector and B-26
damage.
1 STEP 14: Connector check: B-25 starter

connector
• Disconnect connector, and measure at the Connector: B-25

harness side.
• Ignition switch: ST
OK: System voltage
Q: Is the check result normal? B-25
YES : Go to Step 14 . 1
STEP 13: Connector check: B-35 inhibitor switch Q: Is the check result normal?
Connector: B-35 NO : Repair.

starter connector.
Connector: B-25
B-35 (B)
6 5 4 3 2 1
10 9 8 7
Connector: B-26 B-25

1

B-26(B) harness side.
1 OK: System voltage
Q: Is the check result normal? NO : Check and repair harness between B-25
battery.
open/short circuit.
TROUBLESHOOTING
NO : Repair.
No. 9) inhibitor switch connector and B-26
Connector: B-35
No. 1) starter connector and battery.
Connector: B-25
B-35 (B)
6 5 4 3 2 1
10 9 8 7 B-25
Harness side connector 1
AK304338 AB
Connector: B-26 Harness side connector AK304337 AB

1

connectors B-19 and repair if necessary.
TROUBLESHOOTING
Inspection Procedure 7: Starting Impossible (Starter Operative but No Initial Combustion)
COMMENT ON TROUBLE SYMPTOM STEP 3: MUT-II/III diagnosis code

• Failure is possibly caused by failed ignition
circuit, failed fuel feed or other faults. Q: Diagnosis code set?
PROBABLE CAUSE to P.13B-20)
• Failed battery NO : Go to Step 4 .
• Timing belt broken
• Failed idle speed control STEP 4: MUT-II/III actuator test
• Throttle valve fouled around • Item 07: Fuel pump
• Failed ignition system
OK: Operating sound of fuel pump can be
• Failed fuel system
heard.
• Failed immobilizer system
• Failed inhibitor-switch <A/T> Q: Is the check result normal?
• Failed engine-A/T-ECU <A/T> NO : Check fuel pump system (Refer to
Inspection Procedure 25 P.13B-344)
DIAGNOSIS PROCEDURE
NOTE: . STEP 5. Check timing belt for breakage.
*1: L.H. drive vehicles • Engine: Cranking
*2
: R.H. drive vehicles OK: Camshaft rotates.
NO : Replace timing belt.
OK: 8 V or higher
STEP 6. Check throttle body (throttle valve)
Q: Is the check result normal? contamination.
YES : Go to STEP 2 .
NO : Check battery (Refer to GROUP 54 − Q: Is the check result normal?
Battery − On-vehicle Service − Battery Test YES : Go to Step 7 .
P.54A-6).
STEP 2: Check engine warning lamp for burnt out

bulb. STEP 7: MUT-II/III data list
• Item 18: Cranking signal
OK:
NO : Check engine-ECU <M/T> or
engine-A/T-ECU <A/T> power supply,
engine control relay and ignition switch IG1 Q: Is the check result normal?
system (Refer to Inspection Procedure 24 YES : Go to Step 10 .
P.13B-338). NO : Go to Step 8 <M/T> , Go to Step 9 <A/T> .
TROUBLESHOOTING
STEP 8: Connector check: C-140 engine-ECU STEP 9: Connector check: C-140 engine-A/T-ECU
connector connector
C-140 (GR) C-140 (GR)
34 33 32 31 <R. H. Drive Vehicle>

43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304455 AB C-140 (GR)
Connector: C-303
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
C-303 58 57 5655 54 5352
AK304274 AB
3 2 1
6 5 4 Connector: C-303
C-303
YES : Check intermediate connectors B-19 and
intermediate connectors are normal, check 3 2 1
and repair harness between C-303 (terminal 6 5 4
• Check output line for open/short Q: Is the check result normal?
circuit. YES : Check intermediate connectors B-19, and
NO : Repair. repair if necessary. If intermediate
(terminal No. 51) engine-A/T-ECU
connector.
circuit.
NO : Repair.
TROUBLESHOOTING
STEP 10: MUT-II/III data list STEP 12: Check ignition coil spark.
a. Item 22: Crank angle sensor YES : Go to Step 13 .
Q: Is the check result normal? NO : Check ignition circuit system (Refer to
YES : Go to Step 11 . Inspection Procedure 31)
NO : Check crank angle sensor system (Refer to
Code No. P0335 P.13B-169). STEP 13: Fuel pressure measurement.
• Fuel pressure measurement (Refer to
STEP 11: Check injector for operating sound. P.13B-426).
• Check injector for operating sound (Refer to
P.13B-435). YES : Go to Step 14 .
Q: Can operating sound be heard? NO : Repair.
STEP 14: Replace engine-ECU <M/T> or
cylinder. engine-A/T-ECU <A/T>
(Refer to Code No. P0201: No. 1 injector • After replacing the engine-ECU <M/T> or
system P.13B-125.) engine-A/T-ECU <A/T>, re-check the trouble
(Refer to Code No. P0202: No. 2 injector symptoms.
system P.13B-130.)
(Refer to Code No. P0203: No. 3 injector Q: Does trouble symptom persist?
system P.13B-135.) YES : Check for foreign matters (water, kerosene,
(Refer to Code No. P0204: No. 4 injector etc.) in fuel and replace if necessary.
NO : Check end.
system P.13B-140.)
Inspection Procedure 8: Starting Impossible (Initial Combustion But No Complete Combustion),

Improper Starting (Long Time to Start)
COMMENT ON TROUBLE SYMPTOM YES : After warm-up engine, idle for about 10
• Failure is possibly caused by poor ignition, minutes.
incorrect air-fuel ratio at cranking, improper fuel NO : Go to Step 2 .
pressure or other faults.
PROBABLE CAUSE
• Failed battery
• Failed ignition system OK: 8 V or higher
• Failed fuel system Q: Is the check result normal?
• Air-fuel ratio control YES : Go to Step 3 .
• Failed idle speed control system NO : Check battery (Refer to GROUP 54 −
• Failed intake system Battery − On-vehicle Service − Battery Test
• Failed exhaust gas cleaning system P.54A-6).
• Throttle valve fouled around
• Timing belt not in place
STEP 3: MUT-II/III diagnosis code
• Compression pressure improper
• Failed engine-ECU <M/T> Q: Diagnosis code set?
• Failed engine-A/T-ECU <A/T> YES : Inspection chart for diagnosis codes (Refer
to P.13B-20)
STEP 1: Check battery condition.

Q: Have the battery terminal been disconnected?
TROUBLESHOOTING
cylinder.
a. Item 12: Air flow sensor (Refer to Code No. P0201: No.1 Injector
b. Item 13: Intake air temperature sensor System P.13B-125.)
c. Item 21: Engine coolant temperature sensor (Refer to Code No. P0202: No.2 Injector
Q: Are the check results normal? System P.13B-130.)
YES : Go to Step 5 . (Refer to Code No. P0203: No.3 Injector
NO : Perform the diagnosis code classified check System P.13B-135.)
procedure for the sensor that has shown an (Refer to Code No. P0204: No.4 Injector
abnormal data value (Refer to Inspection System P.13B-140.)
STEP 5: MUT-II/III data list Q: Is the check result normal?
• Refer to Data list reference table P.13B-401. YES : Go to Step 11 .
a. Item 25: Barometric pressure sensor NO : Align timing marks.
YES : Go to Step 6 . STEP 11: Check ignition coil spark.
STEP 6: Check throttle body (throttle valve) Inspection Procedure 31 P.13B-386).
contamination.
Q: Is the check result normal? STEP 12: Check spray condition of injector.
YES : Go to Step 7 . • Check each injector for spray condition (Refer to
NO : Clean throttle body (throttle valve portion) P.13B-435).
STEP 7: MUT-II/III actuator test NO : Replace injector.
• Item 07: Fuel pump
OK: Operating sound of fuel pump can be STEP 13: Check compression pressure.
heard. • Check compression pressure (Refer to GROUP
Q: Is the check result normal? 11C − On-vehicle Service − Compression
YES : Go to Step 8 . Pressure Check P.11C-15).
NO : Check fuel pump system (Refer to
Inspection Procedure 25 P.13B-344). YES : Go to Step 14 .
NO : Repair.
STEP 8: Check air intake from intake hose and
inlet manifold. STEP 14: Check EGR valve (stepper motor) itself.
Q: Is the check result normal? • Check EGR valve (stepper motor) itself [Refer to
YES : Go to Step 9 . GROUP 17 − Emission Control System −
NO : Repair. Exhaust Gas Recirculation (EGR) System − EGR
Valve (stepper motor) Check <4G69> P.17-25].
STEP 9: Check injector for operating sound. Q: Is the check result normal?
• Check injector for operating sound at engine YES : Go to Step 15 .
cranking (Refer to P.13B-435). NO : Replace EGR valve (stepper motor).
TROUBLESHOOTING

STEP 15: Replace engine-ECU <M/T> or
engine-A/T-ECU <A/T>. NO : Check end.
• After replacing the engine-ECU <M/T> or
engine-A/T-ECU <A/T>, re-check the trouble
symptoms.
Inspection Procedure 9: Unstable Idling (Rough Idling, Hunting), Improper Idling Speed (Too High or
too Low), Engine Stalls during Idling (Die Out)
COMMENT ON TROUBLE SYMPTOM STEP 3: MUT-II/III data list

• Probable causes can be widely found in ignition • Refer to Data List Reference Table P.13B-401.
system, air-fuel ratio control system, idle speed
control system, fuel system, etc. A sudden
engine stall is possibly caused by poor connector b. Item 13: Intake air temperature sensor
contact. c. Item 14: Throttle position sensor (sub)
d. Item 21: Engine coolant temperature sensor
PROBABLE CAUSE e. Item 77: Accelerator pedal position sensor
• Failed ignition system (sub)
• Failed fuel system f. Item 78: Accelerator pedal position sensor
• Failed air-fuel ratio control system (main)
• Failed idle speed control system
g. Item 79: Throttle position sensor (main)
• Failed intake/exhaust system
• Failed emission gas cleaning system Q: Are the check results normal?
• Throttle valve body fouled YES : Go to Step 4 .
• Timing belt out of place NO : Perform the diagnosis code classified check
• Compression pressure improper procedure for the sensor that has shown an
• Failed engine-ECU <M/T> abnormal data value (Refer to Inspection
• Failed engine-A/T-ECU <A/T> Chart for Diagnosis Code P.13B-20).
DIAGNOSIS PROCEDURE STEP 4: MUT-II/III data list

STEP 1: Check battery condition. a. Item 25: Barometric pressure sensor
Q: Has the battery terminal been disconnected? Q: Are the check results normal?
YES : After warm-up engine, idle for about 10 YES : Go to Step 5 .
minutes.
NO : Go to Step 2 . engine-A/T-ECU <A/T>.
STEP 2: MUT-II/III diagnosis code STEP 5: MUT-II/III data list

Q: Diagnosis code set? a. Item 27: Power steering fluid pressure switch
to P.13B-20). Q: Is the check result normal?
NO : Check power steering fluid pressure switch
circuit (Refer to Code No. P0551
P.13B-207).
TROUBLESHOOTING
STEP 6: Check throttle body (throttle valve)
contamination.
Q: Is the check result normal? abnormal data value (Refer to Inspection
YES : Go to Step 7 . Chart for Diagnosis Code P.13B-20).
STEP 7: Check air intake from intake hose and <A/T> connector.
inlet manifold.
Connector: C-140
YES : Go to Step 8 . <L. H. Drive Vehicle>
NO : Repair.
STEP 8: Check injector for operating sound. C-140 (GR)

P.13B-435).
YES : Go to Step 9 . <R. H. Drive Vehicle>
cylinder.
(Refer to Code No. P0201: No. 1 Injector
C-140 (GR)
System P.13B-125.)
System P.13B-130.) 34 33 32 31
(Refer to Code No. P0203: No. 3 Injector 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
System P.13B-135.) 58 57 5655 54 5352
(Refer to Code No. P0204: No. 4 Injector Harness side connector
System P.13B-140.)
AK304274 AB

STEP 9: Check timing marks of timing belt.
Q: Is the check result normal? • Engine: Idling after warm-up
YES : Go to Step 10 . • Transmission: Neutral <M/T> or P range <A/T>
NO : Align timing marks. • Radiator fan: Not operating
STEP 10. MUT-II/III data list OK: Switching the headlamps to ON from
• Refer to Data List Reference Table P.13B-401. OFF causes the voltage to increase.
a. Item 11: Cylinder 1, 4 oxygen sensor (front) Q: Is the check result normal?
b. Item 39: Cylinder 2, 3 oxygen sensor (front) YES : Go to Step 15 .
c. Item 59: Cylinder 1, 4 oxygen sensor (rear) NO : Go to Step 12 .
d. Item 69: Cylinder 2, 3 oxygen sensor (rear)
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 45) engine-ECU <M/T> connector or
connector and B-30 alternator connector engine-A/T-ECU <A/T> connector and B-30
(terminal No. 1) alternator connector.
Connector: C-140
C-140 (GR)
C-140 (GR)

C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 34 33 32 31
58 57 5655 54 5352 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544

AK304274 AB
AK304274 AB
Connector: B-30
Connector: B-30
B-30 (GR)
B-30 (GR)
4 3 2 1
Harness side 4 3 2 1
connector AK304037AB Harness side
NO : Repair. connector B-19, and repair if necessary.
damage.
NO : Repair.
TROUBLESHOOTING
STEP 14. Replace alternator NO : Check A/C load signal system (Refer to
• After alternator is replaced, re-check for trouble
symptom.
YES : Replace engine-ECU <M/T> or STEP 16. Check ignition coil spark.
engine-A/T-ECU <A/T>. Q: Is the check result normal?
NO : Check end. YES : Go to Step 17 .
<A/T> connector. STEP 17. Check injector for spray condition.
• Check each injector for spray condition (Refer to
Connector: C-141
P.13B-435).
C-141(GR)
• Check compression pressure (Refer to GROUP
11A − On-vehicle Service − Compression
<R. H. Drive Vehicle> Pressure Check P.11C-15).
C-141 (GR)
NO : Repair.

6463 62 61 itself.
7372 7170 69 6867 6665 • Check purge control solenoid valve itself (Refer
82 818079 78 7776 7574
8988 87 86 85 8483 to GROUP 17 − Emission Control System −
Harness side connector Evaporative Emission Control System− Purge
AK304154 AB Control Solenoid Valve Check P.17-20)
• Measure engine-ECU <M/T> or engine-A/T-ECU Q: Is the check result normal?
<A/T> terminal voltage. YES : Go to Step 20 .
• Engine: Idling NO : Replace purge control solenoid valve.
• A/C switch: ON (A/C compressor ON)
• Voltage between terminal No. 78 and earth. STEP 20. Check EGR valve (stepper motor) itself.
OK: • Check EGR valve (stepper motor) itself [Refer to
1 V or less (with outside air temperature GROUP 17 − Emission Control System −
sensor ambient temperature at 18°C or Exhaust Gas Recirculation (EGR) System − EGR
higher and A/C set for maximum air flow at Valve (Stepper Motor) Check <4G69> P.17-25].
minimum temperature)
System voltage (with A/C set for minimum air YES : Go to Step 21 .
flow at room temperature) NO : Replace EGR valve (stepper motor).
TROUBLESHOOTING
STEP 21. MUT-II/III actuator test STEP 22. Replace engine-ECU <M/T> or
• Item 07: Fuel pump engine-A/T-ECU <A/T>.
OK: Operating sounds of fuel pump can be • After engine-ECU <M/T> or engine-A/T-ECU
heard. <A/T> is replaced, re-check for trouble symptom.
Q: Is the check result normal? Q: Does trouble system persist?
YES : Go to Step 22 . YES : Check for foreign matters (water, kerosene,
NO : Check fuel pump system (Refer to etc.) in fuel and replace if necessary.
inspection Procedure 25 P.13B-344). NO : Check end.
Inspection Procedure 10: The Engine Stalls when Starting the Car (Pass Out)
COMMENT ON TROUBLE SYMPTOM YES : Go to Step 3 .

• Engine stall on starting is possibly caused by NO : Perform the diagnosis code classified check
misfire due to failed spark plug, improper air-fuel procedure for the sensor that has shown an
ratio at accelerator pedal depression or other abnormal data value (Refer to Inspection
faults. Chart for Diagnosis Code P.13B-20).
PROBABLE CAUSE
STEP 3. Check EGR valve (stepper motor) itself.
• Failed intake system
GROUP 17 − Emission Control System −
• Failed emission gas cleaning system
Exhaust Gas Recirculation (EGR) System − EGR
Valve (Stepper Motor) Check <4G69> P.17-25].
NO : Replace EGR valve (stepper motor).

STEP 4. Check air intake from intake hose and
Q: Diagnosis code set? inlet manifold.
NO : Repair.

• Refer to Data list reference table P.13B-401. STEP 5. Check ignition coil spark.
a. Item 14: Throttle position sensor (sub) Q: Is the check result normal?
b. Item 77: Accelerator pedal position sensor YES : Replace engine-ECU <M/T> or
(sub) engine-A/T-ECU <A/T>.
c. Item 78: Accelerator pedal position sensor
(main) Inspection Procedure 31 P.13B-386).
d. Item 79: Throttle position sensor (main)
TROUBLESHOOTING
Inspection Procedure 11. The Engine Stalls when Decelerating

• Engine stall on deceleration is possibly caused by NO : Perform the diagnosis code classified check
insufficient air intake, improper air-fuel ratio due procedure for the sensor that has shown an
to failed exhaust gas recirculation system or abnormal data value (Refer to Inspection
other faults. Chart for Diagnosis Code P.13B-20).
PROBABLE CAUSE
STEP 3. Check EGR valve (stepper motor) itself.
• Failed idle speed control system
GROUP 17 − Emission Control System −
• Failed emission control system
Exhaust Gas Recirculation (EGR) System − EGR
• Throttle valve fouled
DIAGNOSIS PROCEDURE NO : Replace EGR valve (stepper motor).
STEP 1. MUT-II/III diagnosis code STEP 4. Check throttle body (throttle valve
portion) for contamination.
to P.13B-20). YES : Go to Step 5 .
NO : Go to Step 2 . NO : Clean throttle body (throttle valve portion)

• Refer to Data list reference table P.13B-401. STEP 5. Check ignition coil spark.
a. Item 14: Throttle position sensor (sub) Q: Is the check result normal?
b. Item 77: Accelerator pedal position sensor YES : Replace engine-ECU <M/T> or
(sub) engine-A/T-ECU <A/T>.
c. Item 78: Accelerator pedal position sensor
(main) Inspection Procedure 31 P.13B-386).
d. Item 79: Throttle position sensor (main)
TROUBLESHOOTING
Inspection Procedure 12: Engine Does Not Revole Up
COMMENT ON TROUBLE SYMPTOM STEP 2. MUT-II/III data list

• Failure is possibly caused by failed fuel system, • Refer to Data list reference table P.13B-401.
throttle valve opening control system ignition
system or other faults.
b. Item 77: Accelerator pedal position sensor
PROBABLE CAUSE (sub)
• Failed ignition system c. Item 78: Accelerator pedal position sensor
• Failed fuel system (main)
• Failed throttle valve opening control system d. Item 79: Throttle position sensor (main)
DIAGNOSIS PROCEDURE procedure for the sensor that has shown an
STEP 1. MUT-II/III diagnosis code Chart for Diagnosis Code P.13B-20).
YES : Inspection chart for diagnosis code (Refer STEP 3. Check ignition coil spark.
STEP 4. Fuel pressure measurement.

• Fuel pressure measurement P.13B-426).
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 13: Hesitation, Sag, Poor Acceleration, Stumble, Surge

• Failure is possibly caused by failed ignition • Refer to Data list reference table P.13B-401.
system, improper air-fuel ratio, throttle valve
a. Idem 13: Intake air temperature sensor
opening control system improper compression
pressure or other faults. b. Item 14: Throttle position sensor (sub)
PROBABLE CAUSE d. Item 77: Accelerator pedal position sensor
• Failed air-fuel ratio control system (sub)
• Failed ignition system e. Item 78: Accelerator pedal position sensor
• Failed fuel system (main)
• Failed intake and exhaust system f. Item 79: Throttle position sensor (main)
• Failed emission control system
• Failed throttle valve opening control system Q: Are the check results normal?
• Throttle valve fouled YES : Go to Step 4 .
• Improper compression pressure
• Failed engine-ECU <M/T> Procedure for the sensor that has shown an
• Failed engine-A/T-ECU <A/T> abnormal data value (Refer to Inspection
DIAGNOSIS PROCEDURE
a. Item 25: Barometric pressure sensor
YES : Inspection chart for diagnosis code (Refer Q: Are the check results normal?
to P.13B-20).
NO : Go to Step 2 .
STEP 2. Check injector for operating sound.

itself.
P.13B-435).
• Check purge control solenoid valve itself (Refer
Q: Can operating sound be heard? to GROUP 17 − Emission Control System −
YES : Go to Step 3 . Evaporative Emission Control System− Purge
NO : Check the injector system of the defective Control Solenoid Valve Check P.17-20).
cylinder.
System P.13B-125).
System P.13B-130).
(Refer to Code No. P0203: No. 3 Injector STEP 6. Check EGR valve (stepper motor) itself.
System P.13B-135). • Check EGR valve (stepper motor) itself [Refer to
(Refer to Code No. P0204: No. 4 Injector GROUP 17 − Emission Control System −
System P.13B-140). Exhaust Gas Recirculation (EGR) System − EGR
NO : Replace EGR valve (stepper motor).
TROUBLESHOOTING
STEP 7. MUT-II/III data list STEP 9. Check throttle body (throttle valve
• Refer to Data List Reference Table P.13B-401. portion) for contamination.
a. Item 11: Cylinder 1, 4 oxygen sensor (front) Q: Is the check result normal?
b. Item 39: Cylinder 2, 3 oxygen sensor (front) YES : Go to Step 10 .
c. Item 59: Cylinder 1, 4 oxygen sensor (rear) NO : Clean throttle body (throttle valve portion)
d. Item 69: Cylinder 2, 3 oxygen sensor (rear) (Refer to P.13B-425).
YES : Go to Step 8 . STEP 10. Measure fuel pressure.
NO : Perform the diagnosis code classified check • Measure fuel pressure (Refer to P.13B-426).
Procedure for the sensor that has shown an Q: Is the check result normal?
abnormal data value (Refer to Inspection YES : Go to Step 11 .
Chart for Diagnosis Code P.13B-20). NO : Repair.
STEP 8. Check ignition coil spark. STEP 11. Check compression pressure.
Q: Is the check result normal? • Check compression pressure (Refer to GROUP
YES : Go to Step 9 . 11C − On-vehicle Service − Compression
NO : Check ignition circuit system (Refer to Pressure Check P.11C-15).
Inspection Procedure 31 P.13B-386). Q: Is the check result normal?
NO : Repair.
Inspection Procedure 14. The Feeling of Impact or Vibration when Accelerating

• Failure is possibly caused by failed ignition leak • Refer to Data List Reference Table P.13B-401.
with rise in spark plug-required voltage at
acceleration, throttle valve opening control
system. b. Item 77: Accelerator pedal position sensor
(sub)
PROBABLE CAUSE c. Item 78: Accelerator pedal position sensor
• Failed throttle valve opening control system
DIAGNOSIS PROCEDURE

to P.13B-20).
NO : Go to Step 2 .
TROUBLESHOOTING
Inspection Procedure 19: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC during
Idling

• Failure is possibly caused by improper air-fuel NO : Check for offset ignition timing (Refer to
ratio, deteriorated catalyst, failed ignition system, Inspection Procedure 17 P.13B-326).
failed fuel system, failed compression pressure or
other faults. STEP 4. MUT-II/III data list
PROBABLE CAUSE
• Incorrect air/fuel ratio a. Item 12: Air flow sensor
• Failed ignition system b. Item 13: Intake air temperature sensor
• Failed fuel system c. Item 21: Engine coolant temperature sensor
• Failed intake and exhaust system Q: Are the check results normal?
• Failed emission control system YES : Go to Step 5 .
• Failed compression pressure NO : Perform the diagnosis code classified check
• Failed catalytic converter Procedure for the sensor that has shown an
• Failed engine-ECU <M/T> abnormal data value (Refer to Inspection
• Failed engine-A/T-ECU <A/T> Chart for Diagnosis Code P.13B-20).
DIAGNOSIS PROCEDURE
STEP 1. MUT-II/III diagnosis code a. Item 25: Barometric pressure sensor
Q: Diagnosis code set? Q: Are the check results normal?
YES : Inspection chart for diagnosis code (Refer YES : Go to Step 6 .
to P.13B-20). NO : Replace engine-ECU <M/T> or
NO : Go to Step 2 . engine-A/T-ECU <A/T>.
STEP 2. Check injector for operating sound. STEP 6. Check air intake from intake hose and
• Check injector for operating sound (Refer to inlet manifold.
P.13B-435). Q: Is the check result normal?
Q: Can operating sound be heard? YES : Go to Step 7 .
cylinder. STEP 7. Check for emission leakage from
(Refer to, Code No. P0201: No. 1 injector exhaust manifold.
systemP.13B-125)
(Refer to, Code No. P0202: No. 2 injector Q: Is the check result normal?
systemP.13B-130) YES : Go to Step 8 .
(Refer to, Code No. P0203: No. 3 injector NO : Repair.
systemP.13B-135)
(Refer to, Code No. P0204: No. 4 injector STEP 8. Check throttle body (throttle valve
systemP.13B-140) portion) for contamination.
STEP 3. Check ignition timing. YES : Go to Step 9 .
• Check ignition timing. (Refer to GROUP 11C − NO : Clean throttle body (throttle valve portion)
On-vehicle Service − Ignition Timing Check (Refer to P.13B-425).
P.11C-13).
TROUBLESHOOTING
NO : Replace positive crankcase ventilation
valve.
b. Item 39: Cylinder 2, 3 oxygen sensor (front)
c. Item 59: Cylinder 1, 4 oxygen sensor (rear)
d. Item 69: Cylinder 2, 3 oxygen sensor (rear) Q: Is the check result normal?
Q: Is the check result normal? NO : Replace spark plug.
Procedure for the sensor that has shown an STEP 15. Check ignition coil itself.
abnormal data value (Refer to Inspection • Check ignition coil itself (Refer to GROUP 16 −
Chart for Diagnosis Code P.13B-20). Ignition System − On-vehicle Service − Ignition
Coil Check <4G69> P.16-33).
STEP 10. Check Purge control solenoid valve Q: Is the check result normal?
itself. YES : Go to Step 16 .
• Check purge control solenoid valve itself (Refer NO : Replace ignition coil.
Evaporative Emission Control System − Purge STEP 16. Check compression pressure.
Control Solenoid Valve Check P.17-20). • Check compression pressure (Refer to GROUP
Q: Is the check result normal? 11C − On-vehicle Service − Compression
YES : Go to Step 11 . Pressure Check P.11C-15).
NO : Replace purge control solenoid valve. Q: Is the check result normal?
STEP 11. Check EGR valve (stepper motor) itself. NO : Repair.
GROUP 17 − Emission Control System − STEP 17. Check injector for spraying condition.
Exhaust Gas Recirculation (EGR) System − EGR • Check each injector for spray condition (Refer to
Valve (Stepper Motor) Check <4G69> P.17-25]. P.13B-435).
NO : Replace EGR valve (stepper motor). NO : Replace injector.
STEP 12. Measure fuel pressure. STEP 18. Replace catalytic converter.
• Measure fuel pressure (Refer to P.13B-426). • After replacing the catalytic converter, re-check
Q: Is the check result normal? the trouble symptoms.
YES : Go to Step 13 . Q: Does trouble symptom persist?
NO : Repair. YES : Replace engine-ECU <M/T> or
STEP 13. Check positive crankcase ventilation NO : Check end
valve itself.
• Check positive crankcase ventilation valve itself
(Refer to GROUP 17 − Emission Control System
− crankcase Emission Control System − Positive
Crankcase Ventilation (PCV) Valve Check
P.17-16).
TROUBLESHOOTING
Inspection Procedure 20: Battery Run Down
COMMENT ON TROUBLE SYMPTOM STEP 3. Perform voltage measurement at B-30

• Failure is possibly caused by failed alternator, alternator connector.
failed generation control circuit or other faults.
Connector: B-30
PROBABLE CAUSE
• Failed battery
• Alternator G terminal short-circuited
• Failed alternator B-30 (GR)
4 3 2 1
STEP 1. Check battery voltage. • Disconnect connector, and measure at harness

• Measure battery voltage during cranking. side.
OK: 8 V or more
OK: System voltage
NO : Check battery (Refer to GROUP 54A − Q: Is the check result normal?
Battery − On-vehicle Service − Battery Test YES : Go to Step 5 .
P.54A-6). NO : Go to Step 4 .
STEP 2. Connector check: B-30 alternator STEP 4. Connector check: C-303 ignition switch
connector connector
Connector: B-30 Connector: C-303
C-303
B-30 (GR)
3 2 1
4 3 2 1 6 5 4
Harness side
connector Harness side connector AK304334 AB
AK304037AB
Q: Is the check result normal? Connector: B-30

NO : Repair.
B-30 (GR)
4 3 2 1
Harness side

TROUBLESHOOTING
YES : Check intermediate connectors B-19, C-04, YES : Go to Step 6 .

C-05, C-105, C-203 and C-205, and repair if NO : Repair.
normal, check and repair harness between STEP 6. Perform voltage measurement at C-140
B-30 (terminal No. 3) alternator connector engine-ECU <M/T> connector or engine-A/T-ECU
and C-303 (terminal No. 2) ignition switch <A/T> connector
connector.
• Check power supply line for Connector: C-140
open/short circuit. <L. H. Drive Vehicle>
NO : Repair.

<M/T> connector or engine-A/T-ECU <A/T> C-140 (GR)
connector
Connector: C-140
C-140 (GR) C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
<R. H. Drive Vehicle> 58 57 5655 54 5352
AK304274 AB
C-140 (GR)
side.
34 33 32 31
43 42 4140 39 38 37 36 35 • Voltage between terminal No. 45 and earth.
51 50 49 4847 46 4544
58 57 5655 54 5352 OK: System voltage
NO : Go to Step 7 .
TROUBLESHOOTING
STEP 7. Check harness between C-140 (terminal STEP 8. Perform voltage measurement at C-140
No. 45) engine-ECU <M/T> or engine-A/T-ECU engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> and B-30 (terminal No. 1) alternator <A/T> connector.
connector.
Connector: C-140
Connector: C-140 <L. H. Drive Vehicle>
C-140 (GR)
C-140 (GR)

C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
34 33 32 31 51 50 49 4847 46 4544
43 42 4140 39 38 37 36 35 58 57 5655 54 5352
51 50 49 4847 46 4544
58 57 5655 54 5352 Harness side connector
AK304274 AB
AK304274 AB
Connector: B-30
• Engine: Idling after warm-up
• Radiator fan: Inactive
B-30 (GR) • Voltage between terminal No. 45 and earth.
OFF causes the voltage to increase.
4 3 2 1 Q: Is the check result normal?
Harness side YES : Go to Step 9 .
connector AK304037AB NO : Replace alternator.
• Check output line for open/short circuit.
Q: Is the check result normal? STEP 9. Check the trouble symptoms.
YES : replace alternator. Q: Does trouble symptom persist?
NO : Repair. YES : Replace engine-ECU <M/T> or
00 − How to Use
P.00-6).
TROUBLESHOOTING
Inspection Procedure 21: Overheating
COMMENT ON TROUBLE SYMPTOM STEP 3. MUT-II/III actuator test

• Failure is possibly caused by failed engine • Item 21: Fan controller
cooling system, failed fan controller, failed engine
coolant temperature sensor or other faults. OK: Fan motor rotating
• Insufficient or deteriorated engine coolant NO : Check fan control relay system (Refer to
• Failed fan controller Inspection Procedure 26 P.13B-352).
• Failed thermostat
• Failed water pump
• Item 21: Engine coolant temperature sensor
• Failed radiator core
• Failed engine-ECU <M/T> OK:
• Failed engine-A/T-ECU <A/T> Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
DIAGNOSIS PROCEDURE Engine hot state: At 80 − 120°C
NO : Check engine coolant temperature sensor
Q: Diagnosis code set? system (Refer to Code No. P0115
YES : Inspection chart for diagnosis code (Refer P.13B-44).
to P.13B-20).
NO : Go to Step 2 .
STEP 5. Check thermostat.
• Check thermostat (Refer to GROUP 14 −
STEP 2. Check engine coolant Thermostat − Thermostat Inspection P.14-22).
NOTE: If engine coolant level falls too early, check
for leaky spots, and repair if necessary.
• Check engine coolant (Refer to GROUP 14 − NO : Replace thermostat.
On-vehicle Service − Engine Coolant Leak Check
P.14-17).
STEP 6. Check water pump.
Q: Is the check result normal? • Check water pump.
NO : Replace or add engine coolant. Q: Is the check result normal?
YES : Replace radiator.
NO : Replace water pump.
TROUBLESHOOTING
Inspection Procedure 22: Abnormal Rotation of Fan Motor
Fan controller (Radiator fan, A/C condensor fan) Circuit
5V
A-20
(MU802322)
1 2 3 Fan controller
L-W
7
A-14
L-W
17
C-139
5 6 7 8 9 10111213 Engine-A/T-ECM <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK304144 AB

• The control (duty) signal is inputted to the fan • Failed fan controller
controller (terminal No. 2) from the engine-ECU • Open/short circuit in fan controller circuit or loose
<M/T> or engine-A/T-ECU <A/T> (terminal No. connector contact
17). • Failed engine-ECU <M/T>
FUNCTION
<A/T> inputs a duty signal suitable for the engine
coolant temperature, vehicle speed and A/C
switch position to the fan controller. In response
to the signal, the fan controller controls the
rotating speeds of the radiator fan and A/C
condenser fan (The fan speed becomes higher
as the average voltage of the terminal comes
nearer to 5V).
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Check at C-139 engine-ECU <M/T>

Connector: C-139
<M/T> connector or engine-ECU <A/T> or
engine-ECU <L. H. Drive Vehicle>
Connector: C-139
C-139 (GR)
C-139 (GR)
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
4 3 2 1
13 12 1110 9 8 7 6 5 AK304262 AB
2019 18 17 16 15 14
2726 2524 23 22 21
side.
AK304262 AB • Ignition switch: ON
• Short-circuit terminal No. 17 to earth.
YES : Go to Step 2 . OK: Fan motor stops rotating.
NO : Go to Step 4 .

00 − How to Use
P.00-6).
TROUBLESHOOTING
NO : Repair.
engine-ECU <M/T> connector.
Connector: C-139 STEP 6. Check harness between A-20 (terminal
<L. H. Drive Vehicle> No. 2) fan controller connector and C-139
(terminal No. 17) engine-ECU <M/T> connector.
Connector: A-20
C-139 (GR)
A-20 (GR)
3 2 1
C-139 (GR) Harness side
Connector: C-139
4 3 2 1 <L. H. Drive Vehicle>
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
C-139 (GR)

side.
OK: 4.9 − 5.1 V
C-139 (GR)
YES : Replace fan controller.
NO : Go to Step 5 .
4 3 2 1
STEP 5. Connector check: A-20 fan controller 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
connector 2726 2524 23 22 21
Connector: A-20
AK304262 AB

A-20 (GR) • Check output line for open circuit.
3 2 1 YES : Replace fan controller.
NO : Repair.
Harness side

TROUBLESHOOTING
Inspection Procedure 23: Poor A/C Performance

• Failure is possibly caused by short /overcharged NO : Check A/C switch (Refer to Inspection
A/C refrigerant, failed A/C control system, failed Procedure 27 P.13B-359).
fan control system or other faults.
PROBABLE CAUSE
• Item 49: A/C relay
• Short or overcharged A/C refrigerant
• Failed A/C compressor relay a. Engine: Running at idle
• Failed fan controller b. A/C set temperature:
• Failed A/C-ECU Maximum Cool when temperature in cabin is
• Failed engine-ECU <M/T> 25°C or more.
• Failed engine-A/T-ECU <A/T> Maximum Hot when temperature in cabin is
25°C or less.
DIAGNOSIS PROCEDURE OK:
ON (when A/C is ON)
Q: Diagnosis code set? YES : Check A/C system (Refer to GROUP 55A −
Troubleshooting check chart for trouble
to P.13B-20).
symptoms P.55A-4).
NO : Go to Step 2 .
NO : Check A/C compressor relay (Refer to
STEP 2. A/C compressor magnet clutch
operation check.
STEP 5. Check charged amount of A/C
• Engine: Idling
refrigerant.
• A/C set temperature:
• Check charged amount of A/C refrigerant (Refer
to GROUP 55A − On-vehicle Service − Sight
25°C or more
Glass Refrigerant Level Test P.55A-51).
Maximum Hot when temperature in cabin is 25°C
or less Q: Is the check result normal?
OK:
NO : Adjust charged amount of A/C refrigerant.
Magnet clutch active (when A/C is ON)
Magnet clutch inactive (when A/C is OFF)
• Item 21: Fan controller
NO : Go to Step 3 . OK: Fan motor rotates.
STEP 3. MUT-II/III data list YES : Check A/C load signal system (Refer to
• Item 28: A/C switch Inspection Procedure 29 P.13B-371).
NO : Check fan control relay system (Refer to
a. Engine: Idling
b. A/C set temperature:
25°C or more
25°C or less
OK:
ON (when A/C is ON)
TROUBLESHOOTING
Inspection Procedure 24: Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Power Supply, Engine Control
Relay, Ignition Switch-IG1 System
Power supply and ignition switch-IG circuit
Battery
9
Relay box
20A Ignition switch
LOCK C-303
R
ST ACC 123
W-B 456
IG1 IG2
A-14
5 (*1) 2
6 (*2)
L-B
C-203
W-B
W-B 8
J/B
7.5A
4 3
B-17X 1
Engine C-202
1 2 control
relay
3 4
L-B
1 2
4 C-106
10
J/C (2) Y-G W-B
C-17
9 10 L-B
R R
34 43 57 58 50
C-140 Engine-ECU <M/T>

3132 33 34 Power Battery Engine-A/T-ECM <A/T>
353637383940 41 42 43 source backup NOTE
444546474849 50 51 *1: L.H. drive vehicles
5253 545556 57 58
Wire colour code

AK304145 AB
TROUBLESHOOTING
OPERATION STEP 2. Connector check: B-17X engine control

• The battery voltage is applied to the engine relay connector
control relay (terminal No. 3 and 4).
• The engine-ECU <M/T> or engine-A/T-ECU Connector: B-17X
<A/T> (terminal No. 57) makes the power B-17X
transistor in the unit be in "ON" position and Relay box’s
makes currents go on the engine control relay triangle marks
coil, and that makes the relay be in "ON" position.
• When the engine control relay is in "ON" position,
2 1
the battery voltage is supplied to the engine-ECU
<M/T> or engine-A/T-ECU <A/T> (terminal No. 4 3
34 and No. 43), the sensor and the actuator from Harness
the engine control relay (terminal No. 1). side connector AK304152 AB
FUNCTION Q: Is the check result normal?

• When the ignition switch ON signal is input to the YES : Go to Step 3 .
engine-ECU <M/T> or engine-A/T-ECU <A/T>, NO : Repair.
the engine-ECU <M/T> or engine-A/T-ECU
<A/T> places the engine control relay in the ON STEP 3. Check engine control relay.
position. Accordingly, the battery voltage is • Check engine control relay (Refer to P.13B-429).
supplied to the engine-ECU <M/T> or
engine-A/T-ECU <A/T>, sensor and actuator. YES : Go to Step 4 .
NO : Replace engine control relay.
PROBABLE CAUSE
• Failed engine control relay
• Open/short circuit in engine control relay circuit or STEP 4. Perform voltage measurement at B-17X
loose connector contact engine control relay connector.
Connector: B-17X
B-17X
DIAGNOSIS PROCEDURE Relay box’s
triangle marks
STEP 1. Check battery voltage.

2 1
• Measure battery voltage during cranking.
4 3
OK: 8 V or more
Harness
NO : Check battery (Refer to GROUP 54A − • Remove relay, and measure at relay box side.
Battery − On-vehicle Service − Battery test • Voltage between terminal No. 3 and earth, also
P.54A-6).
OK: System voltage
harness between B-17X (terminal No. 3 and
terminal No. 4) engine control relay
connector and battery.
open/short circuit.
TROUBLESHOOTING
YES : Check and repair C-140 engine-ECU <M/T>

connector.
<A/T> connector. NO : Go to Step 6 .
Connector: C-140
<L. H. Drive Vehicle> STEP 6. Connector check: C-140 engine-ECU
connector

C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
C-140 (GR)
AK304274 AB
34 33 32 31
• Measure engine-ECU <M/T> or engine-A/T-ECU 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
<A/T> terminal voltage. 58 57 5655 54 5352

• Voltage between terminal No. 34 and earth, also
AK304274 AB
NO : Repair.
TROUBLESHOOTING
STEP 7. Perform voltage measurement at C-140 STEP 8. Connector check: C-303 ignition switch
engine-ECU <M/T> connector or engine-A/T-ECU connector
<A/T> connector.
Connector: C-303
Connector: C-140
<L. H. Drive Vehicle> C-303
C-140 (GR) 3 2 1
6 5 4

NO : Repair.
C-140 (GR)
STEP 9. Check ignition switch.
• Check ignition switch (Refer to GROUP 54A −
34 33 32 31 Ignition Switch − Ignition Switch − Inspection
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 P.54A-35).
58 57 5655 54 5352

YES : Check intermediate connector C-106,
AK304274 AB
C-202 and C-203, and repair if necessary. If
• Measure engine-ECU <M/T> or engine-A/T-ECU intermediate connector is normal, check and
<A/T> terminal voltage. repair harness between C-303 (terminal No.
• Ignition switch: ON 2) ignition switch connector and C-140
• Voltage between terminal No. 50 and earth. (terminal No. 50) engine-ECU <M/T>
OK: System voltage connector or engine-A/T-ECU <A/T>
connector.
Q: Is the check result normal? • Check output line for open/short
circuit and damage.
NO : Go to Step 8 .
TROUBLESHOOTING
STEP 10. Perform voltage measurement at C-140 NO : Check and repair harness between B-17X
engine-ECU <M/T> connector or engine-A/T-ECU (terminal No. 2) engine control relay
<A/T> connector. connector and C-140 (terminal No. 57)
Connector: C-140 engine-ECU <M/T> connector or
circuit.
C-140 (GR) STEP 11. Check harness between B-17X (terminal

No. 3 and No. 4) engine control relay connector
and battery.
<R. H. Drive Vehicle> Connector: B-17X

B-17X
Relay box’s
triangle marks
C-140 (GR)
2 1
34 33 32 31 4 3
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 Harness
58 57 5655 54 5352
AK304274 AB
Connector: B-17X
B-17X Q: Is the check result normal?
Relay box’s NO : Repair.
triangle marks
2 1
4 3
Harness

• Ignition switch: OFF
OK: System voltage
TROUBLESHOOTING
No. 2) ignition switch connector and C-140 No. 33 and No. 42) engine-ECU <M/T> connector
(terminal No. 50) engine-ECU <M/T> connector or or engine-A/T-ECU <A/T> connector and body
engine-A/T-ECU <A/T> connector. earth.
B-17X
C-303 Relay box’s

triangle marks
2 1
3 2 1
4 3
6 5 4
Harness
Harness side connector AK304334 AB side connector AK304152 AB

C-140 (GR) C-140 (GR)
C-140 (GR) C-140 (GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK304274 AB AK304274 AB
NOTE: Before checking harness, check intermediate • Check earthing line for damage.
connectors C-106, C-202 and C-203 and repair if Q: Is the check result normal?
necessary. YES : Replace engine-ECU <M/T> or
• Check output line for damage. engine-A/T-ECU <A/T>
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 25: Fuel Pump System
Fuel pump and gauge unit (main) circuit
Battery
C-303
W R LOCK
123 Ignition switch
456 ST ACC
IG1 IG2
24
Reray box
15A 2
W
L-B
C-116
41
W
C-202 C-203
2 6
4 3 1 3 8
7.5A
C-215 C-213
1 2 1 2 OFF ON OFF ON J/B
Fuel Fuel
3 4 3 4 pump 1 2 pump 4 2
relay (1) relay (2)
C-215 C-213
C-205 11 C-209 1 C-205

14
B-L
D-24 6
B
G
B-L
Fuel pump
and gauge 5
unit (main)
D-16
(MU802058) M
C-106
1 2 3 8
4 5 4
B
D-24 4
G
B
16
C-139
1 2 3 4
5 6 7 8 9 10111213 Engine-ECU <M/T>
14 15 16 1718 19 20 Engine-A/T-ECM <A/T>
21 22 232425 2627
Wire colour code

AK304146 AB
TROUBLESHOOTING

• The battery voltage is applied to the fuel pump NO : Repair.
relay (1) (terminal No. 3) form the ignition switch
and is earthed to the vehicle body from the fuel STEP 2. Check fuel pump relay.
pump relay (1) (terminal No. 2). • Fuel pump relay, continuity check (Refer to
• The battery voltage is applied to the fuel pump
P.13B-430).
relay (1) (terminal No. 4) and to the fuel pump
relay (2) (terminal No. 1) from the fuel pump relay Q: Is the check result normal?
(1) (terminal No. 1). YES : Go to Step 3 .
• The battery voltage is applied to the fuel pump NO : Replace fuel pump relay.
relay (2) (terminal No. 3) from the ignition switch.
The engine-ECU <M/T> or engine-A/T-ECU STEP 3. Perform resistance measurement at
(terminal No. 16) makes the power transistor in C-215 fuel pump relay (1) connector.
the unit be in "ON" position and makes currents
Connectors: C-215
go on the fuel pump relay (2) coil, and that makes
the relay be in "ON" position.
• When the fuel pump relay (2) is in "ON" position, Junction block’s
the battery voltage is supplied to the fuel pump triangle marks C-215
(low pressure) from the fuel pump relay (2)
(terminal No. 4).
2 1
FUNCTION 4 3
• When the ignition switch ON signal is input to the Harness side
engine-ECU <M/T> or engine-A/T-ECU <A/T>,
the engine-ECU <M/T> or engine-A/T-ECU • Remove relay, and measure at junction block
<A/T> places the fuel pump relay in the "ON" side.
position. Accordingly, the battery voltage is • Resistance between terminal No. 2 and earth.
supplied to the fuel pump. OK: 2 Ω or less
• Failed fuel pump relay YES : Go to Step 4 .
• Failed fuel pump NO : Check intermediate connector C-205, and
• Open/short circuit in fuel pump drive circuit or repair if necessary. If intermediate
loose connector contact connector is normal, check and repair
• Failed engine-ECU <M/T> harness between C-215 (terminal No. 2)
• Failed engine-A/T-ECU <A/T> fuel pump relay (1) connector and body
earth.
DIAGNOSIS PROCEDURE • Check earthing line for open circuit
and damage.
STEP 1. Connector check: C-215 fuel pump relay

(1) connector and C-213 fuel pump relay (2)
connector
Connectors: C-213, C-215
Junction block’s
triangle marks C-215
C-213
2 1
4 3
Harness side

TROUBLESHOOTING

fuel pump relay (1) connector.
Connectors: C-215 harness between C-215 (terminal No. 3)
fuel pump relay (1) connector and C-303
Junction block’s
triangle marks • Check power supply line for open
C-215
circuit and damage.
NO : Repair.
2 1
4 3
Harness side
• Remove relay, and measure at junction block Connectors: C-215

side.
• Ignition switch: ON Junction block’s
• Voltage between terminal No. 3 and earth. triangle marks C-215
OK: System voltage
STEP 5. Connector check: C-303 ignition switch • Remove relay, and measure at junction block
connector side.
Connector: C-303
OK: System voltage
C-303 YES : Go to Step 7 .
3 2 1
6 5 4
Harness side connector AK304334 AB battery.
Connectors: C-215 open/short circuit.
Junction block’s
2 1
4 3
Harness side

TROUBLESHOOTING

Connectors: C-213 harness between C-303 (terminal No. 2)
ignition switch connector and C-213
(terminal No. 3) fuel pump relay (2)
Junction block’s
triangle marks connector.
• Check power supply line for open
C-213 circuit.
2 1 NO : Repair.
4 3
Harness side
connector AK304339 AD
• Remove relay, and measure at junction block connector
side.
• Ignition switch: ON Connector: C-139
• Voltage between terminal No. 3 and earth. <L. H. Drive Vehicle>
OK: System voltage
NO : Go to Step 8 .

connector <R. H. Drive Vehicle>
Connector: C-303
C-139 (GR)
C-303
4 3 2 1
13 12 1110 9 8 7 6 5
3 2 1 2019 18 17 16 15 14
2726 2524 23 22 21
6 5 4
AK304262 AB
Connectors: C-213
NO : Repair.
Junction block’s
triangle marks
C-213
2 1
4 3
Harness side

TROUBLESHOOTING
STEP 10. Perform voltage measurement at C-139 STEP 11. Connector check: D-16 fuel pump
engine-ECU <M/T> connector or engine-A/T-ECU connector
<A/T> connector. Connector: D-16
Connector: C-139
D-16 (GR)
C-139 (GR) 3 2 1
5 4
Harness side

NO : Repair.
C-139 (GR)
STEP 12. Perform voltage measurement at D-16

fuel pump connector.
4 3 2 1
13 12 1110 9 8 7 6 5 Connector: D-16
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
Connectors: C-213 D-16 (GR)

3 2 1
5 4
Junction block’s Harness side
triangle marks connector AK203431AC

C-213
2 1 side.
4 3 • Ignition switch: ON
Harness side • Using a jumper wire, connect C-139 (terminal No.
connector AK304339 AD 16) engine-ECU <M/T> connector or
engine-A/T-ECU <A/T> connector and earth.
side.
• Ignition switch: ON OK: System voltage
• Voltage between terminal No. 16 and earth. Q: Is the check result normal?
OK: System voltage YES : Go to Step 15 .
C-139 (terminal No. 16) engine-ECU <M/T>
connector.
circuit.
TROUBLESHOOTING

No. 1) fuel pump relay (1) connector and C-213 NO : Repair.
D-16 fuel pump connector.
Junction block’s
triangle marks Connector: D-16
C-215
C-213
2 1
4 3
Harness side D-16 (GR)
3 2 1
• Check power supply line for open/short circuit. 5 4
Harness side
Q: Is the check result normal? connector AK203431AC
YES : Go to Step 14
NO : Repair.
side.
STEP 14. Check harness between C-213 (terminal OK: 2 Ω or less
No. 4) fuel pump relay (2) connector and D-16
(terminal No. 5) fuel pump connector. Q: Is the check result normal?
Connectors: C-213 NO : Check intermediate connector D-24, and
Junction block’s
triangle marks harness between D-16 (terminal No. 4) fuel
pump connector and body earth.
C-213 • Check earthing line for open circuit
2 1 and damage.
4 3
Harness side
connector AK304339 AD STEP 16. Connector check: C-303 ignition switch
connector
Connector: D-16
Connector: C-303
C-303
D-16 (GR)
3 2 1
5 4 3 2 1
Harness side 6 5 4
connector AK203431AC Harness side connector AK304334 AB

connectors D-209 and D-24, and repair if necessary. Q: Is the check result normal?
NO : Repair.
damage.
TROUBLESHOOTING
STEP 17. Check harness between C-303 (terminal NO : Repair.
Connector: C-303
No. 1) fuel pump relay (1) connector and C-213
C-303 Connectors: C-213, C-215
Junction block’s
3 2 1 triangle marks C-215
6 5 4
C-213
Harness side connector AK304334 AB 2 1
4 3
Connectors: C-215 Harness side
Junction block’s • Check power supply line for damage.

2 1 NO : Repair.
4 3
Harness side STEP 20. Check harness between C-303 (terminal
NOTE: Before checking harness, check intermediate (terminal No. 3) fuel pump relay (2) connector.
connector C-203, and repair if necessary. Connector: C-303
C-303
NO : Repair.
STEP 18. Check harness between battery and 3 2 1

C-215 (terminal No. 4) fuel pump relay (1) 6 5 4
connector. Harness side connector AK304334 AB
Connectors: C-215
Connectors: C-213
Junction block’s
triangle marks C-215 Junction block’s
triangle marks
2 1 C-213
4 3 2 1
4 3
Harness side
connector AK304339 AC Harness side
• Check power supply line for damage. Q: Is the check result normal?
TROUBLESHOOTING
No. 4) fuel pump relay (2) connector and D-16 No. 2) fuel pump relay (2) connector and C-139
(terminal No. 5) fuel pump connector. (terminal No. 16) engine-ECU <M/T> connector or
Connectors: C-213
Connectors: C-213
Junction block’s
triangle marks Junction block’s
triangle marks
C-213
2 1
C-213
4 3 2 1
Harness side 4 3
connector AK304339 AD Harness side
CONNECTOR: C-303
Connector: C-139
C-303
3 2 1
6 5 4 C-139 (GR)
Harness side
connector
AK300304 AB
NOTE: Before checking harness, check intermediate <R. H. Drive Vehicle>

connectors D-24 and C-209, and repair if necessary.
C-139 (GR)
YES : Replace fuel pump.
NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

necessary.
YES : Replace fuel pump
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 26: Fan Control Relay System
Fan control relay Circuit
Battery
9
20A
W-B A-14
5 (*1)
16 (*2)
W-B
W-B
4 3
B-17X

3 4
1 2
Engine control system R
4 To engine-ECU <M/T>
Fusible link (2) J/C (2)
C-17
5
R
L-W A-14
11
R
4 1
A-10X
2 Fan control relay
1 3
4
2 3
B
L
A-20
(MU802322) NOTE
Smoothing Fan controller
circuit *1: L.H. drive vehicles
1 2 3 *2: R.H. drive vehicles
Wire colour code

AK304147 AB
TROUBLESHOOTING

• The battery voltage is applied to the fan control NO : Replace fan control relay.
relay (terminal No. 1) from the engine control
relay (terminal No. 1) and is earthed to the STEP 3. Perform resistance measurement at
vehicle body from the fan control relay (terminal A-10X fan control relay connector.
No. 3).
• The battery voltage is applied to the fan control Connector: A-10X
• When the fan control relay is in "ON" position, the
battery voltage is supplied to the fan controller A-10X
(terminal No. 3) from the fan control relay
(terminal No. 2).
2
3 1
FUNCTION 4
• When the engine control relay is in "ON" position, Harness
the fan control relay is also simultaneously placed side connector AK304340 AB
in "ON" position. Accordingly, the battery voltage • Remove relay and measure at relay box side.
is supplied to the fan controller. • Resistance between terminal No. 3 and earth.
PROBABLE CAUSE OK: 2 Ω or less
• Failed fan control relay Q: Is the check result normal?
• Failed fan controller YES : Go to Step 4 .
• Failed radiator fan motor NO : Check and repair harness between A-10X
• Failed condenser fan motor (terminal No. 3) fan control relay connector
• Open/short circuit in fan control relay circuit or and body earth.
loose connector contact • Check earthing line for open circuit
• Failed engine-ECU <M/T> and damage.
STEP 4. Perform voltage measurement at A-10X
DIAGNOSIS PROCEDURE fan control relay connector.
Connector: A-10X
STEP 1. Connector check: A-10X fan control
relay connector
Connector: A-10X A-10X
2
A-10X 3 1
4
Harness
2 side connector AK304340 AB
3 1
4 • Remove relay and measure at relay box side.
Harness • Ignition switch: ON
side connector AK304340 AB • Voltage between terminal No. 1 and earth.
Q: Is the check result normal? OK: System voltage
NO : Go to Step 5 .
STEP 2. Check fan control relay.
• Check fan control relay (Refer to GROUP 14 −
On−vehicle Service − Fan Control Relay
Continuity Check P.14-19).
TROUBLESHOOTING
STEP 5. Connector check: B-17X engine control NO : Check and repair harness between battery
relay connector and A-10X (terminal No. 4) fan control relay
Connector: B-17X connector.
open/short circuit.
Relay box’s
triangle marks
STEP 7. Connector check: A-20 fan controller
2 1 connector
4 3 Connector: A-20
Harness
Connector: A-10X
A-20 (GR)
A-10X 3 2 1
Harness side
2
3 1
4
Harness
side connector AK304340 AB NO : Repair.

YES : Check intermediate connectors A-14 and STEP 8. Perform voltage measurement at A-20
C-17, and repair if necessary. If intermediate fan controller connector.
connectors are normal, check and repair Connector: A-20
engine control relay connector and A-10X
• Check power supply line for A-20 (GR)
open/short circuit.
NO : Repair.
3 2 1
STEP 6. Perform voltage measurement at A-10X Harness side
fan control relay connector.
Connector: A-10X
side.
A-10X OK: System voltage
2 YES : Go to Step 12 .
3 1
4
NO : Go to Step 9 .
Harness

• Voltage between terminal No. 4 and earth
OK: System voltage
TROUBLESHOOTING
STEP 9. Check harness between A-10X (terminal NO : Repair.
No. 2) fan control relay connector and A-20
(terminal No. 3) fan controller connector.
Connector: A-10X
No. 1) engine control relay connector and A-10X
Connector: B-17X
A-10X
B-17X
Relay box’s
2 triangle marks
3 1
4
Harness 2 1
4 3
Connector: A-20 Harness
Connector: A-10X
A-20 (GR)
A-10X
3 2 1
Harness side
connector AK203423 AC 2
3 1
• Check output line for open/short circuit. 4
Harness
NO : Repair. NOTE: Before checking harness, check intermediate
connectors A-14 and C-17, and repair if necessary.
relay connector Q: Is the check result normal?
YES : Check and repair harness between A-10X
Connector: B-17X (terminal No. 3) fan control relay connector
B-17X and body earth.
Relay box’s • Check earthing line for damage.
2 1
4 3
Harness

TROUBLESHOOTING
STEP 12. Connector check: C-139 engine-ECU STEP 13. Fan motor drive test.
Connector: C-139
connector
Connector: C-139
C-139 (GR)
C-139 (GR)

C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
4 3 2 1
2019 18 17 16 15 14
2726 2524 23 22 21 AK304262 AB
• Disconnect C-139 engine-ECU <M/T> connector
AK304262 AB
or engine-A/T-ECU <A/T> connector.
YES : Go to Step 13 . OK: Fan motor rotates.
NO : Repair.

• Item 21: Fan controller
OK: Fan motor rotates.
00 − How to Use
P.00-6).
TROUBLESHOOTING
STEP 15. Perform voltage measurement at C-139 STEP 16. Check harness between A-10X
engine-ECU <M/T> connector or engine-A/T-ECU (terminal No. 4) fan control relay connector and
<A/T> connector. battery.
Connector: C-139 Connector: A-10X
A-10X
C-139 (GR)
2
3 1
4
Harness

NO : Repair.
4 3 2 1 STEP 17. Check harness between A-10X

13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 (terminal No. 2) fan control relay connector and
2726 2524 23 22 21
A-20 (terminal No. 3) fan controller connector.
Connector: A-10X
AK304262 AB

side. A-10X
OK: 4.9 − 5.1 V 2
3 1
4
Harness
Connector: A-20
A-20 (GR)
3 2 1
Harness side

NO : Repair.
TROUBLESHOOTING

STEP 18. Check harness between A-20 (terminal
NO : Repair.
No. 2) fan controller connector and C-139
Connector: A-20
A-20 (GR)
3 2 1
Harness side
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
Inspection Procedure 27: A/C Switch System
A/C Switch circuit

C-06
(MU801584)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A/C-ECU
C-26
(MU801584)
21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36
C-06
4 <Manual A/C>
G-B C-26
34 <Auto A/C>
C-104
7
G-B
69
C-141
(M(U803804)
6162 6364
656667686970717273 Engine-ECU <M/T>
747576777879808182 Engine-A/T-ECM <A/T>
8384 858687 8889
Wire colour code

AK304148 AB

• The battery voltage is applied to the engine-ECU • Failed A/C
<M/T> or engine-A/T-ECU <A/T> (terminal No. • Failed A/C system
69) from the A/C- (terminal No. 4) <Manual A/C> • Open/short circuit in A/C circuit or loose
or A/C-ECU (terminal No. 34) <Auto A/C>. connector contact
FUNCTION • Failed engine-A/T-ECU <A/T>
• When the A/C switch is in "ON" position, A/C
switch ON signal is inputted to the engine-ECU
<M/T> or engine-A/T-ECU <A/T> from the
A/C-ECU. In response to the signal, the
controls the A/C compressor relay.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Perform voltage measurement at C-06

A/C-ECU <Manual A/C> connector or C-26
STEP 1. Perform voltage measurement at C-141 A/C-ECU <Auto A/C> connector.
engine-ECU <M/T> connector or engine-A/T-ECU Connector: C-06
<A/T> connector. <Manual A/C>
Connector: C-141
C-06 (B)
10 9 8 7 6 5 4 3 2 1
C-141(GR) 20 19 18 17 16 15 14 13 12 11
AK304341 AB
Connector: C-26
<R. H. Drive Vehicle> <Auto A/C>
C-141 (GR)
C-26 (B)
28 27 26 25 24 23 22 21
6463 62 61 36 35 34 33 32 31 30 29
7372 7170 69 6867 6665
82 818079 78 7776 7574 Harness side connector AK304342 AB
8988 87 86 85 8483
Harness side connector • Measure A/C-ECU terminal voltage.
AK304154 AB • Engine: Idling
• A/C set temperature:
• Measure engine-ECU <M/T> or engine-A/T-ECU Maximum Cool when temperature in cabin is
<A/T> terminal voltage. 25°C or more
• Engine: Running at idle Maximum Hot when temperature in cabin is 25°C
• A/C set temperature: or less
Maximum Cool when temperature in cabin is • Voltage between terminal No. 4 and earth
25°C or more <Manual A/C>
Maximum Hot when temperature in cabin is 25°C • Voltage between terminal No. 34 and earth <Auto
or less A/C>
OK: System voltage
OK:
System voltage (when A/C is ON) Q: Is the check result normal?
0.5 V or less (when A/C is OFF) YES : Go to Step 5 .
NO : Go to Step 3 .
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 3. Connector check: C-06 A/C-ECU STEP 4. Check harness between C-06 (terminal
<Manual A/C> connector or C-26 A/C-ECU <Auto No. 4) A/C-ECU <Manual A/C> connector or C-26
A/C> connector and C-141 engine-ECU <M/T> (terminal No. 34) A/C-ECU <Auto A/C> connector
connector or engine-A/T-ECU <A/T> connector and C-141 (terminal No. 69) engine-ECU <M/T>
Connector: C-06
<Manual A/C> Connector: C-06
<Manual A/C>
C-06 (B)
C-06 (B)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side connector 20 19 18 17 16 15 14 13 12 11
AK304341 AB
AK304341 AB
Connector: C-26
<Auto A/C> Connector: C-26
<Auto A/C>
C-26 (B)
C-26 (B)
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21
Harness side connector AK304342 AB 36 35 34 33 32 31 30 29
Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574 6463 62 61
8988 87 86 85 8483 7372 7170 69 6867 6665
82 818079 78 7776 7574
AK304154 AB Harness side connector

AK304154 AB
NO : Repair. connector C-104, and repair if necessary.
TROUBLESHOOTING
YES : Check A/C system (Refer to GROUP 55A − YES : Check intermediate connector C-104, and
Troubleshooting − Check Chart for Trouble repair if necessary. If intermediate
Symptoms P.55A-4). connector is normal, check and repair
NO : Repair. harness between C-06 (terminal No. 4)
<Manual A/C> or C-26 (terminal No. 34)
<Auto A/C> A/C-ECU connector and C-141
STEP 5. Connector check: C-06 A/C-ECU
<Manual A/C> connector or C-26 A/C-ECU <Auto
A/C> connector and C-141 engine-ECU <M/T>
connector.
<Manual A/C>

C-06 (B) connector
Connector: C-141
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 <L. H. Drive Vehicle>
AK304341 AB
Connector: C-26
<Auto A/C> C-141(GR)
C-26 (B)

C-141 (GR)
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Connector: C-141
6463 62 61
<L. H. Drive Vehicle> 7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
C-141(GR)
NO : Repair.
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

TROUBLESHOOTING

00 − How to Use
• Item 28: A/C switch
a. Engine: Idling
P.00-6).
b. A/C set temperature: NO : Replace engine-ECU <M/T> or
Maximum Cool when temperature in cabin is engine-A/T-ECU <A/T>.
25°C or more.
25°C or less.
OK:
ON (when A/C is ON)
TROUBLESHOOTING
Inspection Procedure 28: A/C Compressor Relay System
A/C compressor relay Circuit
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
4
L-R
C-203
2
Battery
W 5 J/B
7.5A
10 C-205
Relay box 16 <Manual A/C>
10A C-202
L-R 13 <Auto A/C>
B-R
A-14 C-106
9 11
B-R L-R
4 3
B-18X
1 2 A/C compressor relay

3 4
1 2
A/C-ECU
B-W G
1 8
Engine-ECU <M/T>
Engine-A/T-ECM <A/T>
A/C compressor
assembly A/C refrigerant
temperature
switch C-139
B-27 (MU803802)
MU802653
1 2 3 4
5 6 7 8 9 10111213
1 14 15 16 1718 19 20
Magnetic 21 22 232425 2627
clutch
Wire colour code

AK304149 AB
TROUBLESHOOTING

• The battery voltage is applied to the A/C
compressor relay (terminal No. 4).
• The battery voltage is applied to the A/C STEP 1. Connector check: B-18X A/C
compressor relay (terminal No. 3) from the compressor relay connector
ignition switch. The engine-ECU <M/T> or Connector: B-18X
engine-A/T-ECU <A/T> (terminal No. 8) makes B-18X
the power transistor in the unit be in "ON"
Relay box’s
position and makes currents go on the A/C triangle marks
compressor relay coil, and that makes the relay
be in "ON" position.
• When the A/C compressor is in "ON" position, the 2 1
battery voltage is supplied to the A/C compressor 4 3
(terminal No. 1) from the A/C compressor relay Harness
assembly (terminal No. 1). side connector AK304343 AB
FUNCTION Q: Is the check result normal?

• When the A/C switch "ON" signal is input to the YES : Go to Step 2 .
engine-ECU <M/T> or engine-A/T-ECU <A/T>, NO : Repair.
the engine-ECU <M/T> or engine-A/T-ECU
<A/T> places the A/C compressor relay in the STEP 2. A/C compressor relay check.
"ON" position. Accordingly, the battery voltage • Check A/C compressor relay (Refer to GROUP
supplied to the A/C compressor operates the 55A − On-vehicle Service P.55A-57).
magnet clutch.
• Failed A/C compressor relay NO : Replace A/C compressor relay.
• Failed A/C compressor magnet clutch
• Open/short circuit in A/C compressor relay circuit STEP 3. Perform voltage measurement at B-18X
or loose connector contact A/C compressor relay connector.
• Failed engine-A/T-ECU <A/T> Connector: B-18X
B-18X
Relay box’s
triangle marks
2 1
4 3
Harness

OK: System voltage
NO : Go to Step 4 .
TROUBLESHOOTING
STEP 4. Connector check: C-303 ignition switch STEP 5. Perform voltage measurement at B-18X
connector A/C compressor relay connector.
B-18X
C-303 Relay box’s

triangle marks
2 1
3 2 1
4 3
6 5 4
Harness
Harness side connector AK304334 AB side connector AK304343 AB

Connector: B-18X
B-18X
OK: System voltage
Relay box’s
triangle marks Q: Is the check result normal?
2 1
4 3 connector is normal, check and repair
Harness harness between B-18X (terminal No. 4)
side connector AK304343 AB A/C compressor relay connector and
battery.
Q: Is the check result normal? • Check power supply line for
YES : Check intermediate connectors C-106,
open/short circuit.
C-202 <Auto A/C>, C-203 and C-205
<Manual A/C>, and repair if necessary. If
intermediate connectors are normal, check STEP 6. Connector check: B-27 A/C compressor
and repair harness between B-18X (terminal assembly connector
No. 3) A/C compressor relay connector and Connector: B-27
C-303 (terminal No. 4) ignition switch Harness 1
connector. side connector
open/short circuit.
NO : Repair.
B-27(B)
AK304344 AB

NO : Repair.
TROUBLESHOOTING
STEP 7. Perform voltage measurement at B-27 STEP 8. Perform voltage measurement at C-139
A/C compressor assembly connector. engine-ECU <M/T> connector or engine-A/T-ECU
Connector: B-27
<A/T> connector.
Harness 1
Connector: C-139
side connector
B-27(B) C-139 (GR)
AK304344 AB

Connector: B-18X
B-18X

triangle marks
2 1
4 3 2 1
4 3 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
Harness 2726 2524 23 22 21
side connector AK304343 AB Harness side connector
• Disconnect connector, and measure at harness AK304262 AB
side. • Disconnect connector, and measure at harness
• Remove B-18X (terminal No. 1 and No. 4) A/C side.
compressor relay and short-circuit of harness • Ignition switch: ON
side connector. • Voltage between terminal No. 8 and earth.
• Voltage between terminal No. 1 and earth. OK: System voltage
(terminal No. 1) A/C compressor assembly
connector and B-18X (terminal No. 1) A/C
compressor relay connector.
circuit.
TROUBLESHOOTING
STEP 9. Connector check: C-139 engine-ECU STEP 10. Check harness between B-18X
<M/T> connector or engine-A/T-ECU <A/T> (terminal No. 2) A/C compressor relay connector
Connector: C-139
Connector: B-18X
B-18X
Relay box’s
triangle marks
C-139 (GR)
2 1
4 3

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
STEP 11. MUT-II/III data list NO : Repair.
• Item 49: A/C relay
a. Engine: Idling
b. A/C set temperature: STEP 13. Check harness between B-18X
Maximum Cool when temperature in cabin is (terminal No. 2) A/C compressor relay connector
25°C or more and C-139 (terminal No. 8) engine-ECU <M/T>
Maximum Hot when temperature in cabin is connector or engine-A/T-ECU <A/T> connector.
25°C or less Connector: B-18X
OK: B-18X
ON (when A/C is ON) Relay box’s
OFF (when A/C is OFF) triangle marks

YES : Intermittent malfunction (Refer to GROUP 2 1
00 − How to Use
4 3
Harness
P.00-6). side connector AK304343 AB
Connector: C-139
connector
C-139 (GR)
Connector: C-139
C-139 (GR)
C-139 (GR)

4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
C-139 (GR) 2726 2524 23 22 21
AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 Q: Is the check result normal?
2726 2524 23 22 21
Harness side connector NO : Repair.
AK304262 AB

TROUBLESHOOTING
STEP 14. Connector check: C-303 ignition switch STEP 16. Check harness between battery and
connector B-18X (terminal No. 4) A/C compressor relay
connector.
Connector: C-303
Connector: B-18X
B-18X
C-303
Relay box’s
triangle marks
3 2 1 2 1
6 5 4
4 3
Harness side connector AK304334 AB Harness
NO : Repair. connector A-14, and repair if necessary.
STEP 15. Check harness between C-303 (terminal Q: Is the check result normal?
No. 4) ignition switch connector and B-18X YES : Go to Step 17 .
(terminal No. 3) A/C compressor relay connector. NO : Repair.
Connector: C-303
(terminal No. 1) A/C compressor relay connector
C-303 and B-27 (terminal No. 1) A/C compressor
assembly connector.
Connector: B-18X
3 2 1 B-18X
6 5 4 Relay box’s
Harness side connector triangle marks
AK304334 AB
Connector: B-18X 2 1
B-18X 4 3
Relay box’s Harness
triangle marks side connector AK304343 AB
Connector: B-27
2 1 1
Harness
4 3 side connector
Harness

B-27(B)
connectors C-106, C-202 <Auto A/C>, C-203 and
C-205 <Manual A/C>, and repair if necessary.
AK304344 AB
YES : Go to Step 16 . • Check output line for damage.
YES : Replace A/C compressor magnet clutch.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 29: A/C Load Signal System
A/C Load Signal System

C-06
(MU801584)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A/C-ECU
C-26
(MU801584)
21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36
C-06
5 <Manual A/C>
L-W C-26
32 <Auto A/C>
C-104
6
L-W
78
C-141
(M(U803804)
6162 6364
656667686970717273 Engine-ECU <M/T>
747576777879808182 Engine-A/T-ECM <A/T>
8384 858687 8889
Wire colour code

AK304150 AB

• The A/C load signal is inputted to the • Failed A/C-ECU
engine-ECU <M/T> or engine-A/T-ECU <A/T> • Open/short circuit in A/C load signal circuit or
(terminal No. 78) from the A/C-ECU (terminal No. loose connector contact
5). <Manual A/C> or (terminal No. 32) <Auto • Failed engine-ECU <M/T>
A/C> • Failed engine-A/T-ECU <A/T>
FUNCTION
• The magnitude of the A/C compressor load is
detected and input to the engine-ECU <M/T> or
engine-A/T-ECU <A/T>. The engine-ECU <M/T>
or engine-A/T-ECU <A/T> provides A/C idle up
control according to the A/C compressor load
condition.
TROUBLESHOOTING

NO : Go to Step 4 .

engine-ECU <M/T> connector or engine-A/T-ECU STEP 2. Connector check: C-141 engine-ECU
<A/T>. <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-141
Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665 6463 62 61
82 818079 78 7776 7574 7372 7170 69 6867 6665
8988 87 86 85 8483 82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
AK304154 AB
<A/T> terminal voltage. Q: Is the check result normal?
• Engine: Idling YES : Go to Step 3 .
• A/C switch: ON (A/C compressor in driven state) NO : Repair.
OK: STEP 3. Check the trouble symptoms.
1 V or less (when the temperate around the
atmospheric air temperature sensor is 18°C
or more, and the A/C is set to the lowest
temperature and the maximum air flow rate) NO : Intermittent malfunction (Refer to GROUP
System voltage (when the A/C is set to the 00 − How to Use
temperature in the cabin and the minimum Troubleshooting/Inspection Service Points
air flow rate)
P.00-6).
TROUBLESHOOTING
STEP 4. Connector check: C-141 engine-ECU STEP 5. Perform voltage measurement at C-06
<M/T> connector or engine-A/T-ECU <A/T> A/C-ECU <Manual A/C> connector or C-26
connector A/C-ECU <Auto A/C> connector.
<Manual A/C>
C-141(GR) C-06 (B)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
AK304341 AB
C-141 (GR)
Connector: C-26
<Auto A/C>
C-26 (B)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
AK304154 AB
• Measure A/C-ECU terminal voltage.
Q: Is the check result normal? • Engine: Idling
YES : Go to Step 5 . • A/C set temperature:
NO : Repair. Maximum Cool when temperature in cabin is
25°C or more
Maximum Hot when temperature in cabin is 25°C
or less
<Manual A/C>
• Voltage between terminal No. 32 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
STEP 6. Connector Check: C-06 A/C-ECU STEP 7. Check harness between C-06 (terminal
<Manual A/C> connector or C-26 A/C-ECU <Auto No. 5) or C-26 (terminal No. 32) A/C-ECU
A/C> connector connector and C-141 (terminal No. 78)
Connector: C-06
<Manual A/C> <A/T> connector.
Connector: C-06
<Manual A/C>
C-06 (B)
10 9 8 7 6 5 4 3 2 1
C-06 (B)
20 19 18 17 16 15 14 13 12 11
AK304341 AB 10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Connector: C-26 AK304341 AB
<Auto A/C>
C-26 (B) Connector: C-26

<Auto A/C>
C-26 (B)
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Harness side connector AK304342 AB 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
NO : Repair.
Connector: C-141
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

TROUBLESHOOTING
YES : Check A/C system (Refer to GROUP 55A − YES : Check intermediate connector C-104, and
Troubleshooting − Check Chart for Trouble repair if necessary. If intermediate
Symptoms P.55A-4). connector is normal, check and repair
NO : Repair. harness between C-06 (terminal No. 5) or
C-26 (terminal No. 32) A/C-ECU connector
STEP 8. Check connector: C-06 A/C-ECU and C-141 (terminal No. 78) engine-ECU
connector <Manual A/C> or C-26 A/C-ECU <M/T> connector or engine-A/T-ECU <A/T>
connector <Auto A/C> connector.
<Manual A/C>
C-06 (B)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
AK304341 AB
Connector: C-26
<Auto A/C>
C-26 (B)
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
Inspection Procedure 30: A/C Pressure Sensor System
A/C Pressure sensor circuit
A-02
(MU802509) A/C Pressure sensor
1 2 3
3 1 2
G-Y BR G-R
C-116
17 5
A-14 BR G-R
17
C-105 C-104
21 4
G-Y
A/C-ECU
BR G-R
97 96 118
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304330AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the A/C • The A/C pressure sensor detects the A/C
pressure sensor power terminal (terminal No. 3) refrigerant pressure and inputs the pressure
from the engine-ECU <M/T> or engine-A/T-ECU signal to the engine-ECU <M/T> or
<A/T> (terminal No. 97) and is earthed to the engine-A/T-ECU <A/T>. The engine-ECU uses
engine-ECU <M/T> or engine-A/T-ECU <A/T> the signal for ON/OFF control of the magnet
(terminal No. 96) from the A/C pressure sensor clutch of the A/C compressor.
(terminal No. 1).
• The sensor signal is inputted to the engine-ECU PROBABLE CAUSE
<M/T> or engine-A/T-ECU <A/T> (terminal No. • Failed A/C pressure sensor
118) from the A/C pressure sensor output • Open/short circuit in A/C pressure sensor circuit
terminal (terminal No. 2). or loose connector contact
• Failed engine-A/T <A/T>
TROUBLESHOOTING

NO : Go to Step 3 .
STEP 1. Connector check: A-02 A/C pressure

sensor connector STEP 3. Perform voltage measurement at C-142
Connector: A-02 <A/T> connector.
A-02 (B)
Connector: C-142
C-142 (GR)
3 2 1

STEP 2. Perform voltage measurement at A-02

A/C pressure sensor connector.
Connector: A-02
A-02 (B) 959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

3 2 1 • Ignition switch: ON
• Disconnect connector, and measure at harness OK: 4.9 − 5.1 V
side. Q: Is the check result normal?
• Ignition switch: ON YES : Go to Step 4 .
• Voltage between terminal No. 3 and earth. NO : Go to Step 5 .
OK: 4.9 − 5.1 V
TROUBLESHOOTING

connector
Connector: C-142 pressure sensor connector and C-142
<L. H. Drive Vehicle> (terminal No. 97) engine-ECU <M/T>
connector.
• Check power line for open circuit.
NO : Repair.
C-142 (GR)

connector
C-142 (GR)
Connector: C-142
959493 92 91 C-142 (GR)

104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB <R. H. Drive Vehicle>
C-142 (GR)
Connector: A-02
A-02 (B)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
Harness side connector AK304345 AB AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 6. Check harness between A-02 (terminal STEP 8. Perform resistance measurement at A-02
No. 3) A/C pressure sensor connector and C-142 A/C pressure sensor connector.
Connector: A-02
engine-A/T-ECU <A/T> connector. A-02 (B)
Connector: A-02
A-02 (B)
3 2 1
3 2 1
side.
• Resistance between terminal No. 1 and earth
Connector: C-142
OK: 2 Ω or less
NO : Go to Step 9 .
C-142 (GR)
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
Harness side connector <R. H. Drive Vehicle>

AK304153 AB
C-142 (GR)
• Check power line for short circuit.
YES : Go to Step 7 . 959493 92 91
NO : Repair. 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
YES : Replace engine-ECU <M/T> or Q: Is the check result normal?
engine-A/T-ECU <A/T>. YES : Go to Step 10 .
NO : Intermittent malfunction (Refer to GROUP NO : Repair.
00 − How to Use
P.00-6).
TROUBLESHOOTING
STEP 10. Check harness between A-02 (terminal NO : Repair.
No. 1) A/C pressure sensor connector and C-142
engine-A/T-ECU <A/T> connector. STEP 11. Perform voltage measurement at A-02
Connector: A-02
A-02 (B)
Connector: A-02
A-02 (B)
3 2 1
Harness side connector 3 2 1
AK304345 AB
Connector: C-142 • Use special tool test harness (MB991348) to

<L. H. Drive Vehicle> connect connector, and measure at pick-up
harness.
C-142 (GR) OK: 4.9 − 5.1 V
<R. H. Drive Vehicle> NO : Go to Step 12 .
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

necessary.
• Check earthing line for open circuit or damage.
TROUBLESHOOTING

connector
Connector: C-142 pressure sensor connector and C-142
<L. H. Drive Vehicle> (terminal No. 97) engine-ECU <M/T>
connector.
• Check power line for damage.
NO : Repair.
C-142 (GR)

Connector: A-02
C-142 (GR) A-02 (B)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105 3 2 1
120119118 117116115 114113
Harness side connector Harness side connector AK304345 AB
AK304153 AB • Use special tool test harness (MB991348) to

Connector: A-02 harness.
A-02 (B)
OK: 0.5 or less
3 2 1

TROUBLESHOOTING

connector
Connector: C-142 No. 1) A/C pressure sensor connector and
<L. H. Drive Vehicle> C-137 (terminal No. 96) engine-ECU <M/T>
connector.
NO : Repair.
C-142 (GR)

Connector: A-02
C-142 (GR) A-02 (B)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105 3 2 1
120119118 117116115 114113
Harness side connector Harness side connector AK304345 AB
AK304153 AB • Use special tool test harness (MB991348) to

Connector: A-02 harness.
A-02 (B)
• Engine: Running at idle
• A/C switch: ON
OK:
2.2 V or more (When A/C is "MAX, COOL"
condition)
3 2 1 1.8 V or less (When A/C is "MAX, HOT"
Harness side connector condition)
AK304345 AB

TROUBLESHOOTING
STEP 16. Connector check: C-142 engine-ECU STEP 17. Check harness between A-02 (terminal
<M/T> connector or engine-A/T-ECU <A/T> No. 2) A/C pressure sensor connector and C-142
connector (terminal No. 118) engine-ECU <M/T> or
Connector: C-142
<L. H. Drive Vehicle> Connector: A-02
A-02 (B)
C-142 (GR)
3 2 1
C-142 (GR)
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
C-142 (GR)
120119118 117116115 114113

AK304153 AB
C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

necessary.
• Check output line for open circuit and damage.
YES : Replace A/C pressure sensor.
NO : Repair.
TROUBLESHOOTING
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

Connector: A-02
<A/T> terminal voltage. A-02 (B)
• Engine: Running at idle
• A/C switch: ON
OK:
2.2 V or more (When A/C is "MAX, COOL"
condition)
1.8 V or more (When A/C is "MAX, HOT" 3 2 1
condition) Harness side connector AK304345 AB

connector.
• Check power line for short circuit and
damage.
NO : Repair.
TROUBLESHOOTING
NO : Repair.
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

TROUBLESHOOTING
Inspection Procedure 31: Ignition Circuit System
Ignition circuit
Ignition switch
C-303
R LOCK
ST 1 2 3
ACC 4 5 6
IG1 IG2
2
L-B
C-203
6
J/B 1
W 10A
C-116 (*1)
26 10
C-205
W
A-14 (*1)
16
C-124 (*2)
1
B-110 B-111 B-117 B-118

(MU801211) (MU801211) (MU801211) (MU801211)
W W W W W
1 2 3 1 2 3 1 2 3 1 2 3
Ignition coil 1 1 Ignition coil 2 1 Ignition coil 3 1 Ignition coil 4 1 1
B-107
3 2 3 2 3 2 3 2 Capacitor
B Spark B Spark B Spark B Spark

plug plug plug Y-L plug
Y-B
B-L W-L
NOTE
31 32 35 52
C-140
(MU803803)
3132 33 34
35363738394041 42 43
444546474849 50 51
5253 545556 57 58
Engine-ECU <M/T>
Wire colour code
AK304331 AB
TROUBLESHOOTING
OPERATION STEP 2. Connector check: B-110, B-111, B-117

• The battery voltage is applied to the ignition coil and B-118 ignition coil connectors
(terminal No. 1) from the ignition switch and is
earthed to the vehicle body from the ignition coil Connectors: B-110, B-111, B-117, B118
(terminal No. 2). B-118 (B)
B-117 (B)
• A power voltage of 12 V is applied to the ignition
B-111 (B)
coil output terminal (terminal No. 3) from the
engine-ECU <M/T> or engine-A/T-ECU <A/T> B-110 (B)
(terminal No. 31, No. 32, No. 35 and No. 52).
3 2 1
FUNCTION Harness side
• When the engine-ECU <M/T> or engine-A/T-ECU connector
<A/T> makes the power transistor in the unit be AK304346 AB
in "OFF" position, the battery voltage in the unit is
applied to the power transistor unit, and that Q: Is the check result normal?
makes the power transistor unit be in "ON" YES : Go to Step 3 .
position. The engine-ECU <M/T> or NO : Repair.
engine-A/T-ECU <A/T> makes the power
transistor in the unit be in "ON", and that makes STEP 3. Check ignition coil itself.
the power transistor unit be in "OFF" position. • Check ignition coil itself (Refer to GROUP 16 −
• In response to the signal from the engine-ECU Ignition System − On-vehicle Service − Ignition
<M/T> or engine-A/T-ECU <A/T>, the power coil check <4G69> P.16-33).
transistor unit is in "ON" position. The primary
current is going to the ignition coil. When the YES : Go to Step 4 .
power transistor unit is in "OFF" position, the NO : Replace ignition coil.
primary current is interrupted and high voltage is
generated in the secondary coil.
STEP 4. Perform voltage measurement at B-110,
PROBABLE CAUSE B-111, B-117 and B-118 ignition coil connectors.
• Failed ignition coil
Connectors: B-110, B-111, B-117, B118
• Failed spark plug
B-118 (B)
• Failed spark plug cable B-117 (B)
• Open/short circuit in ignition primary circuit or B-111 (B)
B-110 (B)
3 2 1
connector
NOTE: . AK304346 AB
*1
: L.H. drive vehicle • Disconnect connector, and measure at harness
*2: R.H. drive vehicle side.
OK: System voltage
NO : Replace spark plug. YES : Go to Step 6 .
NO : Go to Step 5 .
TROUBLESHOOTING
YES : Check intermediate connectors A-14*1,

connector C-116*1, C-124*2, C-203 and C-205, and
Connector: C-303 connectors are normal, check and repair
harness between ignition switch connector
and ignition coil connector
C-303
a. Check and repair harness between
3 2 1 No. 1 ignition coil connector
6 5 4 b. Check and repair harness between
Harness side connector C-303 (terminal No. 2) ignition switch
AK304334 AB
Connectors: B-110, B-111, B-117, B118 No. 2 ignition coil connector
B-118 (B) c. Check and repair harness between
B-117 (B) C-303 (terminal No. 2) ignition switch
B-111 (B) connector and B-117 (terminal No. 1)
B-110 (B) No. 3 ignition coil connector
d. Check and repair harness between
3 2 1
Harness side connector and B-118 (terminal No. 1)
connector No. 4 ignition coil connector
AK304346 AB • Check power supply line for
open/short circuit.
STEP 6. Perform voltage measurement at B-110,

B-111, B-117 and B-118 ignition coil connectors.
Connectors: B-110, B-111, B-117, B118
B-118 (B)
B-117 (B)
B-111 (B)
B-110 (B)
3 2 1
Harness side
connector
AK304346 AB

side.
• Engine: Cranking
OK: 0.5 − 4.0 V
NO : Go to Step 7 .
TROUBLESHOOTING
STEP 7. Perform voltage measurement at C-140 NO : Go to Step 9 .
<A/T>.
Connector: C-140 <M/T> connector or engine-A/T-ECU <A/T>
<L. H. Drive Vehicle> connector
Connector: C-140
C-140 (GR)
C-140 (GR)

C-140 (GR)
34 33 32 31 C-140 (GR)
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352

43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
AK304274 AB
58 57 5655 54 5352

Connectors: B-110, B-111, B-117, B118
B-118 (B) AK304274 AB
B-117 (B)
B-111 (B) Connectors: B-110, B-111, B-117, B118
B-110 (B) B-118 (B)
B-117 (B)
B-111 (B)
3 2 1
B-110 (B)
Harness side
connector
AK304346 AB
3 2 1
• Measure engine-ECU <M/T> or engine-A/T-ECU Harness side
connector
AK304346 AB
• Disconnect B-110, B-111, B-117 and B-118
ignition coil connectors. Q: Is the check result normal?
• Engine: Cranking
a. Voltage between terminal No. 31 and earth
(No. 1 Ignition coil).
b. Voltage between terminal No. 32 and earth
c. Voltage between terminal No. 35 and earth
d. Voltage between terminal No. 52 and earth
OK: 0.5 − 4.0 V
TROUBLESHOOTING
YES : Check and repair harness between ignition

coil connector and engine-ECU <M/T>
connector
connector
a. Check and repair harness between Connector: C-140
B-110 (terminal No. 3) No. 1 ignition <L. H. Drive Vehicle>
coil connector and C-140 (terminal
No. 31) engine-ECU <M/T> or
b. Check and repair harness between C-140 (GR)
B-111 (terminal No. 3) No. 2 ignition
engine-A/T-ECU <A/T> connector. <R. H. Drive Vehicle>
c. Check and repair harness between
B-117 (terminal No. 3) No. 3 ignition
C-140 (GR)
d. Check and repair harness between 34 33 32 31
B-118 (terminal No. 3) No. 4 ignition 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
coil connector and C-140 (terminal 58 57 5655 54 5352
No. 52) engine-ECU <M/T> or Harness side connector

AK304274 AB
NO : Repair.
NO : Repair.
TROUBLESHOOTING

STEP 10. Check harness between ignition coil YES : Go to Step 11 .
connector and engine-ECU <M/T> connector or NO : Repair.
Connector: C-140 STEP 11. Check the trouble symptoms.
C-140 (GR)
00 − How to Use
P.00-6).
B-110, B-111, B-117 and B-118 ignition coil
connectors.
C-140 (GR)
Connector: A-02
A-02 (B)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB
3 2 1
Connector: A-02
A-02 (B) Harness side connector AK304345 AB

side.
OK: 2 Ω or less
3 2 1 YES : Go to Step 13.
Harness side connector NO : Check and repair harness between ignition
AK304345 AB
coil connector and body earth
a. Check and repair harness between B-110 a. Check and repair harness between
(terminal No. 3) No. 1 ignition coil connector and B-110 (terminal No. 2) No. 1 ignition
C-140 (terminal No. 31) engine-ECU <M/T> or coil connector and body earth
engine-A/T-ECU <A/T> connector. b. Check and repair harness between
b. Check and repair harness between B-111 B-111 (terminal No. 2) No. 2 ignition
(terminal No. 3) No. 2 ignition coil connector and coil connector and body earth
C-140 (terminal No. 32) engine-ECU <M/T> or c. Check and repair harness between
engine-A/T-ECU <A/T> connector. B-117 (terminal No. 2) No. 3 ignition
c. Check and repair harness between B-117 coil connector and body earth
(terminal No. 3) No. 3 ignition coil connector and d. Check and repair harness between
C-140 (terminal No. 35) engine-ECU <M/T> or B-118 (terminal No. 2) No. 4 ignition
engine-A/T-ECU <A/T> connector. coil connector and body earth
d. Check and repair harness between B-118 • Check earthing line for open
(terminal No. 3) No. 4 ignition coil connector and circuit and damage.
C-140 (terminal No. 52) engine-ECU <M/T> or
TROUBLESHOOTING
STEP 13. Check harness between ignition switch NO : Repair.
connector and ignition coil connector.
Connector: C-303
C-303
3 2 1
6 5 4
Connector: A-02
A-02 (B)
3 2 1
a. Check and repair harness between C-303

(terminal No. 2) ignition switch connector and
B-110 (terminal No. 1) No. 1 ignition coil
connector
b. Check and repair harness between C-303
connector
c. Check and repair harness between C-303
connector
d. Check and repair harness between C-303
connector
connectors A-14*1, C-116*1, C-124*2, C-203 and
C-205, and repair if necessary.
TROUBLESHOOTING

STEP 14. Check harness between ignition coil
connector and engine-ECU <M/T> connector or NO : Repair.
Connector: A-02
A-02 (B)
3 2 1
Connector: C-140
C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB
a. Check and repair harness between B-110

(terminal No. 3) No. 1 ignition coil connector and
b. Check and repair harness between B-111
(terminal No. 3) No. 2 gnition coil connector and
c. Check and repair harness between B-117
d. Check and repair harness between B-118
TROUBLESHOOTING
Inspection Procedure 32: Accelerator Pedal Position Switch Circuit System
Accelerator pedal position switch circuit
B-116
(MU802073)
OFF Accelerator pedal
1 2 3 4 5 6 7 8 ON position sensor
4 5
BR-G B
38 96
C-140 C-142
(MU803803) (MU803805)
3132 33 34 9192 939495
35363738394041 42 43 96979899100 101102103 104
444546474849 50 51 105106 107108109 110111112
5253 545556 57 58 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code
AK304332 AB
OPERATION • Engine-ECU <M/T> or engine-A/T-ECU <A/T>

• A power voltage of 5 V is applied to the uses the signal that is input by the accelerator
accelerator pedal position switch output terminal pedal position switch for determining the
(terminal No. 4) from the engine-ECU <M/T> or abnormal characteristics of the accelerator pedal
engine-A/T-ECU <A/T> (terminal No. 38). position sensor (sub).
• The power voltage is earthed to the engine-ECU
<M/T> or engine-A/T-ECU <A/T> (terminal No. PROBABLE CAUSE
92) from the Accelerator pedal position switch • Failed accelerator pedal position switch.
(terminal No. 5). • Open/short circuit in accelerator pedal position
switch circuit or loose connector contact.
COMMENT ON TROUBLE SYMPTOM • Failed engine-ECU <M/T>
• Accelerator pedal position switch turns OFF • Failed engine-A/T-ECU <A/T>
when amount of travel of the accelerator pedal
exceeds the prescribed value.
TROUBLESHOOTING

NO : Go to Step 4 .

pedal position sensor connector STEP 4. Perform voltage measurement at C-140
Connector: B-116 <A/T> connector.
B-116 (GR) Connector: C-140

C-140 (GR)
8 7 6 5 4 3 2 1

NO : Repair.
C-140 (GR)
STEP 2. Check accelerator pedal position switch
itself
• Check accelerator pedal position switch itself
34 33 32 31
(Refer to P.13B-432). 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
Q: Is the check result normal? 58 57 5655 54 5352

AK304274 AB
STEP 3. Perform voltage measurement at B-116 Connector: B-116

accelerator pedal position sensor connector.
B-116 (GR)
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 • Measure engine-ECU <M/T> or engine-A/T-ECU

Harness side connector AK304279 AB <A/T> terminal voltage.
• Disconnect B-116 accelerator pedal position
sensor
side.
OK: 4.9 − 5.1 V
OK: 4.9 − 5.1 V
NO : Go to Step 6 .
TROUBLESHOOTING

(terminal No. 4) accelerator pedal position
Connector: C-140 38) engine-ECU <M/T> connector or
NO : Repair.
C-140 (GR) STEP 6. Connector check: C-140 engine-ECU

connector

C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB
B-116 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB
8 7 6 5 4 3 2 1
TROUBLESHOOTING
STEP 7. Check harness between B-116 (terminal STEP 8. Perform voltage measurement at B-116
No. 4) accelerator pedal position sensor accelerator pedal position sensor connector.
Connector: B-116
<A/T> connector. B-116 (GR)
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1
side.
OK: 2 Ω or less
Connector: C-140
<L. H. Drive Vehicle> Q: Is the check result normal?
NO : Go to Step 9 .
C-140 (GR)
connector
<R. H. Drive Vehicle> Q: Is the check result normal?
Connector: C-142
C-140 (GR)
34 33 32 31 C-142 (GR)
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352

AK304274 AB
C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
NO : Repair.
TROUBLESHOOTING

No. 5) accelerator pedal position sensor NO : Repair.
<A/T> connector. STEP 11. Perform voltage measurement at C-140
Connector: B-116
<A/T> connector
B-116 (GR) Connector: C-140
C-140 (GR)
8 7 6 5 4 3 2 1

C-140 (GR)
C-142 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
C-142 (GR)
AK304274 AB

959493 92 91
104 103102 101100 99 98 97 96 OK:
112111110 109108107 106105
120119118 117116115 114113
0 − 1 V (Release the accelerator pedal)
Harness side connector 4 V or more (Depress the accelerator pedal)
• Check earthing line for open circuit and damage. YES : Replace engine-ECU <M/T> or
TROUBLESHOOTING
Connector: C-140
<A/T> connector.
Connector: B-116
B-116 (GR)
C-140 (GR)

8 7 6 5 4 3 2 1

34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
C-140 (GR)
AK304274 AB

NO : Repair.
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

NO : Repair.
TROUBLESHOOTING
YES : Check harness between B-116 (terminal

connector
<L. H. Drive Vehicle> • Check earthing line for damage.
NO : Repair.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1

TROUBLESHOOTING
Data List Reference Table

M1131152000928
Item Inspection Inspection condition Normal condition Inspection Reference

No. item procedure page
No.
11 Cylinder 1,4 Engine: After Excessive deceleration 200 mV or less Code No. P.13B-64
oxygen warm-up (leaner by from 4,000 r/min P0130
sensor deceleration, richer At excessive 600 − 1,000 mV
(front) by acceleration) acceleration
warm-up (using 2,500 r/min ⇔ 600 − 1,000
check air-fuel ratio
as well as control
status by
engine-ECU <M/T>
or engine-A/T-ECU
<A/T>.
12 Air flow • Engine coolant Idle operation 2.0 − 6.0 gm/s − −
sensor *1 temperature: 85 2,500 r/min 6.0 − 16.0 gm/s
− 95°C
Acceleration According to
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral <M/T>,
"P" range <A/T>
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13B-37
temperature "ON" or engine −20°C P0110
sensor running
Intake air temperature: 0°C
0°C
20°C
40°C
80°C
TROUBLESHOOTING

No.
14 Throttle • Remove the Fully close the throttle 2,200 − 2,800 Code No. P.13B-145
position intake air hose valve with your finger mV P0222, P.13B-149
sensor (sub) at the throttle Fully open the throttle 4,600 mV or P0223
*4 body valve with your finger more
• Disconnect the
throttle position
sensor, and the
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the
use of the
special tool:
MB991658.
• Ignition switch:
ON
16 Power Ignition switch: "ON" System voltage Procedure P.13B-338
supply No. 24
voltage
18 Cranking Ignition switch: Engine: Stopped OFF Procedure P.13B-338
signal "ON" Engine: Cranking ON No. 24
(ignition
switch-ST)
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13B-44
coolant "ON" or engine −20°C P0115
temperature running
Coolant temperature: 0°C
sensor 0°C
20°C
40°C
80°C
22 Crank angle • Engine: Compare engine speed Matched Code No. P.13B-169
sensor Cranking on tachometer with the P0335
• Tachometer: value displayed on
Connected MUT-II/III
Engine: Idle Coolant temperature: 1,275 − 1,475
operation −20°C r/min
Coolant temperature: 1,220 − 1,420
0°C r/min
20°C r/min
Coolant temperature: 930 − 1,130
40°C r/min
Coolant temperature: 600 − 800 r/min
80°C
TROUBLESHOOTING

No.
25 Barometric Ignition switch: Altitude: 0m 101 kPa − −
pressure "ON" Altitude: 600m 95 kPa
sensor
26 Accelerator Ignition switch: Release the accelerator ON Procedure P.13B-394
pedal "ON" pedal No. 32
position Depress the accelerator OFF
switch pedal
27 Power Engine: Idle Steering wheel: Not OFF Code No. P.13B-207
steering fluid operation operated P0551
pressure Steering wheel: ON
switch Operated
28 A/C switch Engine: Idle AC switch: OFF OFF Procedure P.13B-359
AC A/C OFF No. 27
switch: compressor is
ON not driven
A/C ON
compressor is
driven
37 Volumetric • Engine coolant Idle operation 13 − 33 % − −
efficiency temperature: 85 2,500 r/min 12 − 32 %
− 95°C
Excessive acceleration According to
• Lamps, electric
acceleration,
cooling fan and
volumetric
all accessories:
efficiency is
OFF
increased.
• Transmission:
Neutral <M/T>,
"P" range <A/T>
39 Cylinder 2,3 Engine: After Excessive deceleration 200 mV or less Code No. P.13B-90
oxygen warm-up (leaner by from 4,000 r/m P0150
sensor deceleration, richer At excessive 600 − 1,000 ms
(front) acceleration) acceleration
warm-up (using 2,500 r/min ⇔ 600 − 1,000
as well as control
status by
engine-ECU
TROUBLESHOOTING

No.
41 Injectors *2 Engine: Cranking Coolant temperature: 60.5 − 80.5 ms − −
0°C (all cylinders in
simultaneous injecting
operation)
Coolant temperature: 23.7 − 33.7 ms
20°C
Coolant temperature: 7.2 − 13.2 ms
80°C
Injectors*3 • Engine coolant Idle operation 1.0 − 2.2 ms
temperature: 80 2,500 r/min 1.0 − 3.1 ms
− 95°C
Excessive acceleration Increased
• Lamps, electric
cooling fan and
all accessories:
OFF
• Transmission:
Neutral <M/T>,
"P" range <A/T>
44 Ignition • Engine: After Idle operation 2 − 18°BTDC Procedure P.13B-386
advance warm-up 2,500 r/min 22 − 42°BTDC No. 31
• Install timing
light (for use to
measure actual
ignition timing)
49 A/C relay Engine: After A/C switch: OFF OFF Procedure P.13B-364
warm-up, idle A/C A/C OFF No. 28
operation after switch: compressor is
warm-up ON not driven
A/C ON
compressor is
driven
59 Cylinder 1,4 Engine: After At excessive 0 mV or less ⇔ Code No. P.13B-76
Oxygen warm-up acceleration 600 − 1,000 mV P0136
Sensor (altered)
(rear)
68 EGR valve • Engine coolant Idling 2 − 8 STEP Code No. P.13B-188
temperature: 85 2,500 r/min 2 − 8 STEP P0403
− 95°C
• Lights and all
accessories:
"OFF"
• Transmission:
Neutral <M/T>,
"P" range <A/T>
69 Cylinder 2,3 Engine: After At excessive 0 mV or less ⇔ Code No. P.13B-104
oxygen warm-up acceleration 600 − 1,000 mV P0156
sensor (altered)
(rear)
TROUBLESHOOTING

No.
77 Accelerator Ignition switch: ON Release the accelerator 335 − 935 mV Code No. P.13B-262
pedal pedal P2126, P.13B-265
position Depress the accelerator Increases in P2127, P.13B-269
sensor (sub) pedal gradually response to the P2128
pedal
depression
stroke
Depress the accelerator 4,000 mV or
pedal fully more
78 Accelerator Ignition switch: ON Release the accelerator 335 − 935 mV Code No. P.13B-251
pedal pedal P2121, P.13B-254
position Depress the accelerator Increases in P2122, P.13B-259
sensor pedal gradually response to the P2123
(main) pedal
depression
stroke
Depress the accelerator 4,000 mV or
pedal fully more
79 Throttle • Remove the Fully close the throttle 300 − 700 mV Code No. P.13B-51
position intake air hose valve with your finger P0122, P.13B-55
sensor at the throttle Fully open the throttle 4,000 mV or P0123
(main) body valve with your finger more
• Disconnect the
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the
use of the
special tool:
MB991658.
ON
No load 520 − 620 mV
• Shift lever: "N" → "D" <A/ T> 540 − 640 mV
TROUBLESHOOTING

No.
95 Manifold Ignition switch: ON Altitude: 0 m 101 kPa Code No. P.13B-28
absolute Altitude: 600 m 95 kPa P0105
pressure
sensor Altitude: 1,200 m 88 kPa
Altitude: 1,800 m 81 kPa
• Engine coolant Idle operation 16 − 36 kPa
temperature: 85 When engine is Increased
− 95°C suddenly raced
• Lights and all
accessories:
"OFF"
• Transmission:
Neutral <M/T>,
"P" range <A/ T>
9A Throttle Ignition switch: ON 600 − 1,200 mV Code No. P.13B-51
position P0122, P.13B-55
sensor P0123
(main) mid
opening
learning
value
12 Air flow • Engine coolant Idle operation 2.0 − 6.0 gm/s − −
*5 sensor temperature: 85 2,500 r/min 8.0 − 16.0 gm/s
− 95°C
Acceleration According to
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral <M/T>,
"P" range <A/T>
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13B-37
*5 temperature "ON" or engine −20°C P0110
sensor running
0°C
20°C
40°C
Intake air temperature: 80° C
80°C
TROUBLESHOOTING

No.
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13B-44
*5 coolant "ON" or engine −20°C P0115
temperature running
sensor 0°C
20°C
40°C
80°C
22 Crank angle • Engine: Compare engine speed Matched − −
*5 sensor Cranking on tachometer with the
• Tachometer: value displayed on
Connected MUT-II/III
Engine: Idle Coolant temperature: 1,275 − 1,475
operation −20°C r/min
0°C r/min
20°C r/min
Coolant temperature: 930 − 1,130
40°C r/min
Coolant temperature: 600 − 800 r/min
80°C
24 Vehicle Drive 40 km/h Approximately − −
*5 speed 40 km/h
sensor
44 Ignition • Engine: After Idle operation 2 − 18 deg − −
*5 advance warm-up 2,500 r/min 22 − 42 deg
• Install timing
light (for use to
measure actual
ignition timing)
81 Long-term Engine: After warm-up, 2,500 r/min without −12.5 − 12.5 % Code No. P.13B-118
*5 fuel any load (during closed loop) P0170
compensati
on cylinder
1, 4
82 Shot-term Engine: After warm-up, 2,500 r/min without −25 − 25 % Code No. P.13B-118
compensati
on cylinder
1, 4
TROUBLESHOOTING

No.
83 Long-term Engine: After warm-up, 2,500 r/min without −12.5 − 12.5 % Code No. P.13B-121
compensati
on cylinder
2, 3
84 Short-term Engine: After warm-up, 2,500 r/min without −25 − 25 % Code No. P.13B-121
compensati
on cylinder
2, 3
87 Calculation Engine: After Idle operation 13 − 33 % − −
*5 losd value warm-up 2,500 r/min 10 − 30 %
88 Fuel control Engine: After 2,500 r/min Closed loop − −
cylinder 1, 4 condition
89 Fuel control Engine: After 2,500 r/min Closed loop − −
cylinder 2, 3 condition
8A Throttle • Remove the Fully close the throttle 0−5% Code No. P.13B-51
*5 position intake air hose valve with your finger P0122, P.13B-55
sensor at the throttle Fully open the throttle 88 % or more P0123
(main) *4 body valve with your finger
• Disconnect the
throttle position
sensor, and then
connect terminal
numbers No. 3,
and No. 4, No. 5
and No. 6 with
the use of the
special tool:
MB991658.
ON
A1 Cylinder 1,4 Engine: After Excessive deceleration 0.2 V or less ⇔ Code No. P.13B-64
*5 oxygen warm-up (leaner by from 4,000 r/min 0.6 − 1 V P0130
sensor deceleration, richer (altered)
(front) by acceleration)
Engine: After Idle operation 0.4 V or less ⇔
warm-up (using 2,500 r/min 0.6 − 1 V
as well as control
status by
engine-ECU <M/T>
or engine-A/T-ECU
<A/T>)
TROUBLESHOOTING

No.
A2 Cylinder 1,4 Engine: After At excessive 0 V or less ⇔ Code No. P.13B-76
*5 oxygen warm-up acceleration 0.6 − 1 V P0136
sensor (altered)
(rear)
A3 Cylinder 2,3 Engine: After Excessive deceleration 0.2 V or less ⇔ Code No. P.13B-90
*5 oxygen warm-up (leaner by from 4,000 r/min 0.6 − 1 V P0150
sensor deceleration, richer (altered)
(front) by acceleration)
Engine: After Idle operation 0.4 V or less ⇔
warm-up (using 2,500 r/min 0.6 − 1V
as well as control
status by
engine-ECU <M/T>
or engine-A/T-ECU
<A/T>)
A4 Cylinder 2,3 Engine: After At excessive 0 V or less ⇔ Code No. P.13B-104
*5 oxygen warm-up acceleration 0.6 − 1 V P0156
sensor (altered)
(rear)
CAUTION
When shifting the select lever to D range, the brakes should be applied so that the vehicle does not
move forward
NOTE: *1: On the new vehicle (mileage: 500 km or less), air flow sensor output frequency may be higher by
approx. 10%.
NOTE: *2: Injector drive time ranges shown are when power voltage is 11 V and the cranking speed is 250
r/min. or less.
NOTE: *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approx. 10%.
NOTE: *4: After the inspection has been completed, disconnect the throttle actuator control motor connector,
and then use the MUT-II/III to delete the diagnosis code that was recorded during the inspection.
NOTE: *5: When service data in check mode is selected, the data is not displayed.
TROUBLESHOOTING
Actuator Test Reference Table

M1131152500558
Item Inspection Drive content Inspection conditions Normal Code No. Reference
No. item condition /Inspection page
procedure
No.
01 Injector Cut off No. 1 Engine: After warm-up, Engine is Code No. P.13B-125
injector idle operation (Cut off changed P0201
02 Cut off No. 2 injectors sequentially to (becomes Code No. P.13B-130
injector check for a cylinder that unstable or P0202
does not change engine in stalled)
03 Cut off No. 3 idle status. Code No. P.13B-135
injector P0203
04 Cut off No. 4 Code No. P.13B-140
injector P0204
07 Fuel pump Drive fuel pump Ignition Check for Operating Procedure P.13B-344
to circulate fuel switch: "ON" pump noise audible No. 25
operating
noise near
fuel tank
08 Purge Switch solenoid Ignition switch: "OFF" When the valve Code No. P.13B-196
control valve from OFF is actuated, P0443
solenoid to ON operating noise
valve is audible
17 Basic ignition Switch • Engine: Idle operation 5° BTDC − −
timing engine-ECU • Install timing light
<M/T> or
engine-A/T-ECU
<A/T> to ignition
timing adjusting
mode
21 Fan Actuate fan • Ignition switch: "ON" Fan motor is Procedure P.13B-334
controller motor • A/C switch: ON rotated No. 22
22 Oil control Oil control valve Ignition switch: "ON" Clicks when oil Code No. P.13B-229
valve turns from OFF control valve is P1010
the ON driven
34 Throttle Stop the throttle Ignition switch: "ON" Throttle valve Code No. P.13B-238
valve control valve control is open P2100, P.13B-242
servo servo P2101, P.13B-245
P2102,
P.13B-248
P2103
TROUBLESHOOTING
CHECK AT THE ECU TERMINALS NOTE: .

M1131153500238 1. Make the voltage measurement with the
TERMINAL VOLTAGE CHECK CHART engine-ECU <M/T> or engine-A/T-ECU <A/T>
connector connected.
Needle-nosed wire probe 2. You may find it convenient to pull out the
to make it easier to reach the connector
terminals.
3. The checks can be carried out off the order
given in the chart.
CAUTION
Short-circuiting the positive (+) probe between a
AK201749AB connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU <M/T> or
1. Connect a needle-nosed wire probe to a voltmeter
engine-A/T-ECU <A/T> or all of them. Be careful
probe.
to prevent this!
2. Insert the needle-nosed wire probe into each of
3. If voltmeter shows any division from standard
the engine-ECU <M/T> or engine-A/T-ECU <A/T>
value, check the corresponding sensor, actuator
connector terminals from the wire side, and
and related electrical wiring, then repair or
measure the voltage while referring to the check
replace.
chart.
voltmeter to confirm that the repair has corrected
the problem.
TROUBLESHOOTING
Engine-ECU <M/T> or engine-A/T-ECU <A/T> Connector Terminal Arrangement

Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Connector
C-139 C-140 C-141 C-142 C-138
121 125 134

122 126 135
123 132 140

124 133 141
31
32
33
34
61
62
63
64
91
92
93
94
95
1
2
3
4
127
128 136
129 137
130 138
131 139
100
101
102
103
104 112 120

10
71
11
12
13
35
36
37
38
39
40
41
42
43
65
66
67
68
69
70
72
73
96
97
98
99
5
6
7
8
9
105 113
106 114
107 115
108 116
109 117
110 118
111 119
44
45
46
47
48
49
50
51
74
75
76
78
79
80
81
82
77
14
15
16
17
18
19
20
142
143
144
145
146
83
84
85
86
87
88
89
52
53
54
55
56
57
58
21
22
23
24
25
26
27
AK303309 AB

No.
1 No. 1 injector While engine is idling after having warmed From 9 − 13 V*,
5 No. 2 injector up, suddenly depress the accelerator pedal. momentarily drops slightly
14 No. 3 injector
21 No. 4 injector
3 EGR valve (A) Ignition switch: Immediately after turning ON 5 − 8 V* (fluctuates for
12 EGR valve (B) approximately 3 seconds)
19 EGR valve (C)
26 EGR valve (D)
7 Engine warning lamp Ignition switch: "LOCK" (OFF) → "ON" 1 V or less → System
voltage (After several
8 A/C relay • Engine: Idle speed System voltage → 1 V or
• A/C switch: OFF → ON (A/C compressor less
is operating)
10 Cylinder 2,3 oxygen Engine: Idling after warming up 9 − 11 V
sensor heater (front) Engine: 5,000 r/min System voltage
15 Throttle valve control Ignition switch: "ON" System voltage
servo relay Running at 3,500 r/min while engine is 1 V or less
16 Fuel pump relay Ignition switch: ON System voltage
Engine: Idle speed 1 V or less
17 Fan controller Radiator and condenser fan is not operating 0 − 0.3 V*
Radiator and condenser fan is operating 0.7 V* or more
18 Cylinder 2,3 oxygen Engine: Idling after warming up 1 V or less
sensor heater (rear) Engine: Racing System voltage
23 Purge control Ignition switch: "ON" Decreases Voltage
solenoid valve Running at 3,500 r/min while engine is 1 V or less
24 Cylinder 1,4 oxygen Engine: Idling after warming up 1 V or less
sensor heater (rear) Engine: 5,000 r/min System voltage
25 Cylinder 1,4 oxygen Engine: Idling after warming up 9 − 11 V
sensor heater (front) Engine: Racing System voltage
TROUBLESHOOTING

No.
31 Ignition coil − No. 1 Engine r/min: 3,000 r/min 0.3 − 3.0 V*
32 Ignition coil − No. 2
43
38 Accelerator pedal Ignition switch: "ON" Release the 0−1V
position switch accelerator pedal
Depress the 4 V or more
accelerator pedal
40 <M/T> Clutch pedal position Depress the clutch pedal System voltage
switch Release the clutch pedal 1 V or less
45 Alternator G terminal • Engine: Warm, idle (radiator fan: OFF) Voltage increases
• Headlamp: OFF → ON
• Stop lamp: OFF → ON
• Rear defogger switch: OFF → ON
47 Power steering fluid Engine: Idling after When steering wheel System voltage
pressure switch warming up is Stationary
When steering wheel 1 V or less
is turned
50 Ignition switch − IG Ignition switch: "ON" System voltage
51 Ignition switch − ST Engine: Cranking 8 V or more
57 Engine control relay Ignition switch: "LOCK" (OFF) System voltage
(Power supply) Ignition switch: "ON" 1 V or less
58 Backup power Ignition switch: "LOCK" (OFF) System voltage
supply
63 Air flow sensor Engine: Gradually increase the speed. Voltage increase in
response to revving
69 A/C switch Engine: Idle speed Turn the A/C switch 0.5 V or less
OFF
Turn the A/C switch System voltage
ON (A/C compressor
is operating)
70 Crank angle sensor Engine: Cranking 0.4 − 4.0 V
Engine: Idling 2.0 − 3.0 V
71 Camshaft position Engine: Cranking 2.0 − 4.8 V
sensor Engine: Idling 3.0 − 4.0 V
78 A/C load signal Refer to GROUP 55 − Troubleshooting (Inspection at the Automatic
compressor − ECU Terminal)
79 <M/T> Vehicle speed • Ignition switch: "ON" 0 ⇔ 5 V Changes
sensor • Move the vehicle forword slowly repeatedly
TROUBLESHOOTING

No.
86 Alternator FR • Engine: Warm, idle (radiator fan: OFF) Voltage decreases
terminal • Headlamp: OFF → ON
• Stop lamp: OFF → ON
• Rear defogger switch: OFF → ON
87 Tachometer signal Engine: 3,000 r/min 0.3 − 3.0 V
92 Power supply Ignition switch: "ON" 4.5 − 5.5 V
voltage applied to
accelerator pedal
position sensor
95 Oil control valve Ignition switch: "ON" System voltage
Engine: warming up, 4,000 r/min 4.0 − 10 V*
97 Sensor impressed Ignition switch: "ON" 4.9 − 5.1 V
voltage
98 Engine coolant Ignition switch: "ON" When engine coolant 3.9 − 4.5 V
temperature sensor temperature is −20°C
When engine coolant 3.2 − 3.8 V
temperature is 0°C
temperature is 20°C
99 Intake air Ignition switch: "ON" When intake air 3.8 − 4.4 V
temperature sensor temperature is −20°C
When intake air 3.2 − 3.8 V
temperature is 0°C
101 Manifold absolute Engine: idling 0.8 − 2.4 V
pressure sensor • Engine: idling Rises from 0.8 − 2.4 V
• Revving (momentary wide open throttle) suddenly
106 Power supply Ignition switch: "ON" 4.5 − 5.5 V
voltage applied to
throttle position
sensor
TROUBLESHOOTING

No.
107 Accelerator pedal Ignition switch: "ON" Release the 0.335 − 0.935 V
position sensor (sub) accelerator pedal
Depress the 4.0 V or more
accelerator pedal fully
108 Cylinder 2,3 oxygen Engine: Running at 2,500 r/min after warmed 0 ⇔ 0.8 V (Changes
sensor (front) up (Check using a digital type voltmeter) repeatedly)
109 Cylinder 1,4 oxygen Engine: Running at 2,500 r/min after warmed 0 ⇔ 0.8 V (Changes
sensor (front) up (Check using a digital type voltmeter) repeatedly)
113 Throttle position • Remove the intake Fully close the throttle 2.2 − 2.8 V
sensor (sub) air hose at the valve with your finger
throttle body Fully open the throttle 4.6 V or more
• Disconnect the valve with your finger
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the use
of the special tool
(MB991658).
"ON"
114 Accelerator pedal Ignition switch: "ON" Release the 0.335 − 0.935 V
position sensor accelerator pedal
(main) Depress the 4.0 V or more
accelerator pedal fully
115 Throttle position • Remove the intake Fully close the throttle 0.3 − 0.7 V
sensor (main) air hose at the valve with your finger
throttle body Fully open the throttle 4.0 V or more
• Disconnect the valve with your finger
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the use
of the special tool
(MB991658).
"ON"
116 Cylinder 2,3 oxygen Engine: Idling after warmed up (Check using 0 ⇔ 0.6 V (Changes
sensor (rear) a digital type voltmeter) repeatedly)
117 Cylinder 1,4 oxygen Engine: Idling after warmed up (Check using 0 ⇔ 0.6 V (Changes
sensor (rear) a digital type voltmeter) repeatedly)
TROUBLESHOOTING

No.
118 A/C pressure sensor • Engine: Idling When A/C is "MAX, 2.2 V or more
• A/C switch: ON COOL" condition
(when the load by
A/C is high)
When A/C is "MAX, 1.8 V or less
HOT" condition (when
the load by A/C is
low)
voltage applied to
throttle valve control
servo
133 Throttle valve control • Ignition switch: "ON" Decreases slightly
servo (+) • Accelerator pedal: fully opened → fully (approximately 2 V) from
closed battery voltage.
141 Throttle valve control • Ignition switch: "ON" Decreases slightly
servo (−) • Accelerator pedal: fully closed → fully (approximately 2 V) from
opened battery voltage.
NOTE: * :The average voltage is shown when an NOTE: .
analog voltmeter is used (because the average 1. When measuring resistance and checking
voltage might not be shown stably when digital continuity, a harness for checking contact pin
voltmeter is used). pressure should be used instead of inserting a
test probe.
CHECK CHART FOR RESISTANCE AND 2. Checking need not be carried out in the order
CONTINUITY BETWEEN TERMINALS given in the chart.
1. Turn the ignition switch to "LOCK" (OFF) position. CAUTION
2. Disconnect the engine-ECU <M/T> or If the terminals that should be checked are
engine-A/T-ECU <A/T> connector. mistaken, or if connector terminals are not
3. Measure the resistance and check for continuity correctly shorted to earth, damage may be
between the terminals of the engine-ECU <M/T> caused to the vehicle wiring, sensors,
or engine-A/T-ECU <A/T> harness-side connector engine-ECU <M/T> or engine-A/T-ECU <A/T>
while referring to the check chart. and/or ohmmeter. Be careful to prevent this!
4. If the ohmmeter shows any deviation from the
standard value, check the corresponding sensor,
actuator and related electrical wiring, and the
repair or replace.
ohmmeter to confirm that the repair or
replacement has corrected the problem.
TROUBLESHOOTING
Engine-ECU <M/T> or engine-A/T-ECU <A/T> Harness Side Connector Terminal

Arrangement
Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Harness Side Connector
C-138
124 133 141 C-142 C-141 C-140 C-139
123 132 140
122 126 135

121 125 134
34
33
32
31
64
63
62
61
95
94
93
92
91
4
3
2
1
131 139
130 138
129 137
128 136
127
104 112
103 110
102
101 109
100 108
10
71
11
13
12
43
42
41
40
39
38
37
36
35
73
72
70
69
68
67
66
65
99 107
98
97 106
96 105
6
5
8
7
9
111
51
50
49
48
47
46
45
44
82
81
80
79
78
76
75
74
77
20
19
18
17
16
15
14
146
145
144
143
142
120
119
118
117
116
115
114
113
89
88
87
86
85
84
83
58
57
56
55
54
53
52
27
26
25
24
23
22
21
AK303310 AB

No.
1 − 34 No. 1 injector 10.5 − 13.5 Ω (At 20°C)
5 − 34 No. 2 injector
3 − 34 EGR valve (A) 20 − 24 Ω (at 20°C)
12 − 34 EGR valve (B)
19 − 34 EGR valve (C)
26 − 34 EGR valve (D)
10 − 34 Cylinder 2,3 oxygen sensor heater 4.5 − 8.0 Ω (at 20°C)
(front)
25 − 34 Cylinder 1,4 oxygen sensor heater
(front)
18 − 34 Cylinder 2,3 oxygen sensor heater 11 − 18 Ω (at 20°C)
(rear)
24 − 34 Cylinder 1,4 oxygen sensor heater
(rear)
23 − 34 Purge control solenoid valve 30 − 34 Ω (At 20°C)
33 − Body ECU earth Continuity (2 Ω or less)
earth
42 − Body
earth
144 −
Body
earth
145 −
Body
earth
34 − 95 Oil control valve 6.9 − 7.9 Ω (at 20°C)
TROUBLESHOOTING

No.
96 − 98 Engine coolant temperature sensor 14 − 17 kΩ (When coolant temperature is −20°C)
5.1 − 6.5 kΩ (When coolant temperature is 0°C)
96 − 99 Intake air temperature sensor 13 − 17 kΩ (When intake air temperature is −20°C)
5.3 − 6.7 kΩ (When intake air temperature is 0°C)
133 − 141 Throttle actuator control motor 0.3 − 80 Ω (at 20°C)
INSPECTION PROCEDURE USING 1. Disconnect the camshaft position sensor

OSCILLOSCOPE connector and connect the special tool Test
M1131154500639 harness (MB991709) in between (All terminals
The output signals of the sensors and the conditions should be connected).
of the actuation signals of the actuators can be 2. Connect the oscilloscope special pattern pickup to
inspected visually by observing the waveforms on camshaft position sensor terminal No. 2.
the oscilloscope.
3. Disconnect the crank angle sensor intermediate
CAMSHAFT POSITION SENSOR AND connector and connect the special tool Test
CRANK ANGLE SENSOR harness (MB991658) in between.
Measurement Method 4. Connect the oscilloscope special patterns pickup
to crank angle sensor terminal No. 2.
Camshaft position
sensor connector Alternate Method (Test harness not available)
Special patterns
1 2 3 pick-up Oscilloscope
to engine-ECU <M/T> or engine-A/T-ECU <A/T>
terminal No. 71 (When checking the camshaft
position sensor signal wave pattern).
1 2 3 to engine-ECU <M/T> or engine-A/T-ECU <A/T>
Crank angle sensor
terminal No. 70 (When checking the crank angle
intermediate sensor signal wave pattern).
connector
AK304513AB
TROUBLESHOOTING

Pattern height Low
Engine speed Idle
2 engine revolutions
(V) (1 camshaft revolution)
No.1 TDC No.3 TDC No.4 TDC No.2 TDC

Crank angle
sensor output 5
wave pattern
5
Camshaft position
sensor output
wave pattern
0 Time
TDC: Top dead centre

AK304514 AB
Wave Pattern Observation Points Wave pattern characteristics

Check that cycle time T becomes shorter when the Rectangular wave pattern is output even when
engine speed increases. the engine is not started.
•

•
AK203244
AK304525
Example 2
Cause of problem
Example 1
Loose timing belt
Cause of problem Abnormality in sensor disk
Wave pattern is displaced to the left or right.
TROUBLESHOOTING
INJECTOR 2. Connect the oscilloscope special patterns pickup

Measurement Method to engine-ECU <M/T> or engine-A/T-ECU <A/T>
terminal No. 5 (When checking the No. 2
Oscilloscope cylinder).
1 2 terminal No. 14 (When checking the No. 3
cylinder).
Special 4. Connect the oscilloscope special patterns pickup
patterns
pickup to engine-ECU <M/T> or engine-A/T-ECU <A/T>
cylinder).
AK101807AC
1. Disconnect the injector connector, and then Standard Wave Pattern

connect the special tool Test harness set Observation conditions
(MB991658) in between (All terminals should be Function Special patterns
connected). Pattern height Variable
Variable knob Adjust while viewing the
to terminal No. 2 of the injector connector.
wave pattern
Alternate Method (Test harness not available) Pattern selector Display
1. Connect the oscilloscope special patterns pickup Engine Idle
cylinder).
Point A.
Standard wave pattern (V)
50
Solenoid back
electromotive force
(Approximately 7×10V)
Point B
Injector drive
time
Power
voltage
Time
0 Drive signal: ON Drive signal: OFF
AK301250AC
Wave Pattern Observation Points Contrast with standard wave Probable

Point A: Height of solenoid back electromotive force pattern cause
Solenoid coil back electromotive Short in the
force is low or doesnít appear at injector solenoid
all.
Point B: Injector drive time
TROUBLESHOOTING
•
1. Disconnect the ignition coil connector, and

in between (All terminals should be connected).
to terminal No. 3 of each ignition coil connector in
turn.

When idling
1. Connect the oscilloscope probe to engine-ECU
When racing AKX01605AE <M/T> or engine-A/T-ECU <A/T> terminal No. 31.
(When checking the number 1 cylinder.)
The injector drive time will be synchronized with the
MUT-II tester display. 2. Connect the oscilloscope probe to engine-ECU
• When the engine is suddenly raced, the drive <M/T> or engine-A/T-ECU <A/T> terminal No. 32.
time will be greatly extended at first, but the drive (When checking the number 2 cylinder.)
time will soon match the engine speed. 3. Connect the oscilloscope probe to engine-ECU
<M/T> or engine-A/T-ECU <A/T> terminal No. 35.
IGNITION COIL AND POWER (When checking the number 3 cylinder.)
TRANSISTOR 4. Connect the oscilloscope probe to engine-ECU
<M/T> or engine-A/T-ECU <A/T> terminal No. 52.
Measurement Method
(When checking the number 4 cylinder.)
Oscilloscope
1 2 3
Special
patterns
pickup
AK300345 AB
TROUBLESHOOTING

Pattern height Low
Engine Approximately. 1,200
r/min
(V) 2 engine revolutions

(1 camshaft revolution)
5˚ BTDC
TDC
Crank angle 10
sensor output
wave pattern
0
Ignition timing
Power transistor
control signal 10
wave pattern
0
OFF ON
Dwell section
TDC: Top dead centre AK203245AC
Wave Pattern Observation Points Example

Point: When the engine speed increases, verify that Wave pattern during engine cranking
the power transistor control signal (ignition timing) Cause of problem
advances. Open-circuit in ignition primary circuit
Examples of Abnormal Wave Patterns Wave pattern characteristics
•
Top-right part of the build-up section cannot be
seen, and voltage value is approximately 2 V
Normal wave pattern too low.
AK203246 AD
TROUBLESHOOTING
EGR VALVE (STEPPER MOTOR) Alternate Method (Test Harness not Available)
Measurement Method 1. Connect the oscilloscope probe to engine-ECU
<M/T> or engine-A/T-ECU <A/T> terminal No. 3,
Oscilloscope connection terminal No. 12, connection terminal
No. 19, and connection terminal No. 26
1 2 3 respectively.
4 5 6
Special Standard Wave Pattern
patterns
pickup Observation condition
Pattern height High
AK303311AB Pattern selector Display
1. Disconnect the EGR valve connector, and Engine Ignition switch: OFF →
connect the special tool test harness (MB991658) ON
in between.
2. Connect the oscilloscope probe to the EGR
valve-side connector terminal 1, terminal 3,
terminal 4 and terminal 6 respectively.
(V)
The wave pattern

appears for an
instant, but soon
40 disappears.
Point A
Induced electromotive force
from the motor turning
Point B
Coil reverse electromotive
20 force (Approximately. 40V)
Stepper
motor
control
signal
wave
pattern 0
Time
AK301251AB
Wave pattern Observation Points

Check that the standard wave pattern appears when Point B: Height of coil reverse electromotive force
the EGR control servo is operating. Contrast with standard wave Probable
Point A: Presence or absence of induced pattern cause
electromotive force from the motor turning. (Refer to
the abnormal wave pattern.) Coil reverse electromotive force Short in the
does not appear or is extremely coil
Contrast with standard wave Probable small.
pattern cause
Induced electromotive force does Motor is
not appear or is extremely small. malfunctioning
TROUBLESHOOTING

•
Open
circuit
side
Normal
side
AKX01609AF
AKX01608AE
Example 2
Example 1 Cause of problem
Cause of problem Open circuit in the line between the EGR valve
Sensor interface malfunction. (Motor is not and the engine-ECU <M/T> or
operating) engine-A/T-ECU <A/T>.
Wave pattern characteristics Wave pattern characteristics
Induced electromotive force from the motor Current is not supplied to the motor coil on the
turning dose not appear. open circuit side. (Voltage dose not drop to 0
V.)
Furthermore, the induced electromotive force
waveform at the normal side is slightly
different from the normal waveform.
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
THROTTLE BODY (THROTTLE VALVE
AREA) CLEANING
M1131001000484
1. Remove the air intake hose from the throttle body.
2. Remove the throttle body assembly.
CAUTION
• Do not spray the cleaning fluid directly to the
throttle valve. 16 PIN
MB991502
• Make sure the cleaning fluid does not enter
the motor from the bypass line. Also make AK303691AG
sure it does not enter the sensor through the

shaft.
3. Spray cleaning fluid on a clean cloth.
4. Wipe off the dirt around the throttle valve with the
cloth sprayed with cleaning fluid. 16-PIN
5. Install the throttle body assembly.
6. Attach the air intake hose.
ACCELERATOR PEDAL POSITION

SWITCH AND ACCELERATOR PEDAL
MB991911
POSITION SENSOR (APS) ADJUSTMENT
M1131053400041
MB991824
CAUTION
1. The accelerator pedal position sensor should
not be moved unnecessarily; it has been
precisely adjusted by the manufacture.
2. If the adjustment is disturbed for any reason,
readjust as follows.
MB991827 AK303690AB
1. Connect the MUT-II/III to the diagnosis connector.

ON-VEHICLE SERVICE
9. Remove the thickness gauge and then install the

Accelerator pedal 1 2 3 4 5 6 7 8 accelerator pedal position sensor assembly.
position sensor Equipment 10.Remove the MUT-II/III.
side connector
FUEL PRESSURE TEST
M1131001900562
1. Release residual pressure from the fuel pipe line
to prevent fuel gush out (Refer to P.13B-428).
CAUTION
AK303330AB Cover the hose connection with rags to prevent
splash of fuel that could be caused by some
residual pressure in the fuel pipe line.
Accelerator lever
Stopper (full
stop position)
A
AK303650AB
2. Remove the accelerator pedal position sensor AK303313AB
(main and sub) assembly mounting bolts, and

2. Disconnect the high-pressure fuel hose at the
then insert a thickness gauge with a thickness of
delivery pipe side.
0.60 mm in between the accelerator lever and the
fully-closed stopper (i.e. into area "A" shown in 3. Assemble the fuel pressure measurement tools
Fig). as follows.
3. Turn the ignition switch to the "ON" position
(without starting the engine). MB 991637
4. Loosen the accelerator pedal position sensor Gasket
mounting bolt, and then turn the accelerator pedal MD 998709
position sensor anti-clockwise as far as it will go.
Delivery
5. Check that the accelerator pedal position switch pipe MD 998742
turns on at this time. High-pressure
6. Turn the accelerator pedal position sensor fuel hose
clockwise until the point is found where the
AKX01458AG
accelerator pedal position switch turns off.
Securely tighten the accelerator pedal position <When using the fuel pressure gauge set (special
sensor mounting bolt at this point. tool)>
7. Check that the accelerator pedal position sensor a. Remove the union joint and bolt from the special
(main) output at this time is within the standard tool Adaptor hose (MD998709) and attach the
value range. special tool Hose adaptor (MD998742) to the
Standard value: 0.5 − 0.9 V adaptor hose.
8. Turn the ignition switch to the "LOCK" (OFF) b. Via a gasket, install the special tool Fuel pressure
position. gauge set (MB991637) into the special tool that
has already assembled as described in (a)
above.
ON-VEHICLE SERVICE
Fuel pressure CAUTION

gauge set To prevent damage to the MUT-II/III, always turn
O-ring or gasket the ignition switch to the "LOCK" (OFF) position
MD 998709 before connecting or disconnecting the MUT-II/III.
Delivery
5. Connect the MUT-II/III to the diagnosis connector.
pipe
MD 998742 6. Turn the ignition switch to "ON" position (But do
High-pressure not start the engine).
fuel hose 7. Select "Item No. 07" from the MUT-II/III Actuator
test to drive the fuel pump. Check that there are
AKX01457AF
no fuel leaks from any parts.
<When using the fuel pressure gauge> 8. Finish the actuator test or turn the ignition switch
a. Remove the union joint and bolt from special tool to "LOCK" (OFF) position.
Adaptor hose (MD998709) and attach the special 9. Start the engine and run at idle.
tool Hose adaptor (MD998742) to the adaptor 10.Measure fuel pressure while the engine is running
hose. at idle.
b. Via a suitable O-ring or gasket, install the fuel Standard value: Approximately. 324 kPa at
pressure gauge to the special tool that has cerb idle
already assembled as described in (a) above.
11.Check to see that fuel pressure at idle does not
4. Install the assembled fuel pressure measurement
drop even after the engine has been raced
tools between the fuel rail and fuel high-pressure
several times.
hose.
12.If any of fuel pressure measured in steps 10 to 11
is out of specification, troubleshoot and repair
• Fuel pressure too low Clogged fuel filter Replace fuel filter
• Fuel pressure drops after racing Fuel leaking to return side due to Replace fuel pressure regulator
poor fuel regulator valve seating or
settled spring
Low fuel pump delivery pressure Replace fuel pump
Fuel pressure too high Binding valve in fuel pressure Replace fuel pressure regulator
regulator
Clogged fuel return hose or pipe Clean or replace hose or pipe
13.Stop the engine and check change of fuel
pressure gauge reading. Normal if the reading
does not drop within 2 minutes. If it does, observe
the rate of drop and troubleshoot and repair
Fuel pressure drops gradually after Leaky injector Replace injector
engine is stopped Leaky fuel regulator valve seat Replace fuel pressure regulator
Fuel pressure drops sharply Check valve in fuel pump is held Replace fuel pump
immediately after engine is open
stopped
14.Release residual pressure from the fuel pipe line
ON-VEHICLE SERVICE
CAUTION 19.Disconnect the MUT-II/III.

Cover the hose connection with rags to prevent
splash of fuel that could be caused by some FUEL PUMP CONNECTOR
residual pressure in the fuel pipe line. DISCONNECTION (HOW TO REDUCE
15.Remove the fuel pressure gauge and special tool PRESSURIZED FUEL LINES)
M1131000900688
from the delivery pipe.
The service procedure is the same as the vehicles
16.Replace the O-ring at the end of the fuel high with 4G63 engine. (Refer to GROUP 13A -
pressure hose with a new one. Furthermore, On-vehicle Service P.13A-328).
apply engine oil to the new O-ring before
replacement. FUEL PUMP OPERATION CHECK
17.Fit the fuel high pressure hose over the delivery M1131002000766
pipe and tighten the bolt to specified toque. The service procedure is the same as the vehicles
with 4G63 engine. (Refer to GROUP 13A -
Tightening torque: 8.8 ± 1.9 N⋅m On-vehicle Service P.13A-328).
18.Check for any fuel leaks by following the
procedure in step 7.
COMPONENT LOCATION
M1131002100815
Name Symbol Name Symbol

Accelerator pedal position sensor (with A A/C relay I
accelerator pedal position switch)
A/C pressure sensor A Engine control relay I
Throttle valve control servo relay I
Crank angle sensor B Cylinder 1,4 oxygen sensor (front) J
Detonation sensor C Cylinder 1,4 oxygen sensor (rear) K
Manifold absolute pressure sensor C Ignition coil L
Purge control solenoid valve C Cylinder 2,3 oxygen sensor (rear) M
Injector D Cylinder 2,3 oxygen sensor (front) N
EGR valve E Inhibitor switch <A/T> O
Electronic-controled throttle valve F Power steering fluid pressure switch O
(Throttle position sensor and throttle Fuel pump relay (1) and (2) P
valve control servo)
Vehicle speed sensor <M/T> F Engine warning lamp Q
(check engine lamp)
Camshaft position sensor G Diagnosis connector R
Oil control valve G A/C switch S
Engine coolant temperature sensor G Engine-ECU <M/T> or engine-A/T-ECU T
Air flow sensor H <A/T> (with barometric pressure sensor)
(with intake air temperature sensor)
ON-VEHICLE SERVICE
A B C D E F G H I P Q R S T
T S R Q P
J K L M N O
AK303314 AB
ENGINE CONTROL RELAY CONTINUITY Tester Battery Voltage Normal State

CHECK Connection
M1131050000334 Terminal
Engine control relay Relay box’s 2−3 No Voltage Continuity
triangle marks
1−4 No Voltage No continuity
Voltage (Connect Continuity
1 2 positive (+) terminal of
battery to terminal No. 3
3 4
and negative (−)
Equipment terminal of battery to
side connector
terminal No. 2.)
AK303315 AB
ON-VEHICLE SERVICE
FUEL PUMP RELAY CONTINUITY CHECK INTAKE AIR TEMPERATURE SENSOR

M1131033000331
CHECK
Fuel pump relay(1) M1131002800535
Junction block’s
triangle marks Air flow sensor
1 2
3 4 Fuel pump relay(2)
Equipment 1 2 3 4
Equipment
side connector AK303318AB
Tester Battery Voltage Normal State
Connection 1. Disconnect the air flow sensor connector.
Terminal
2. Measure resistance between terminals No. 1 and
2-3 No Voltage Continuity No. 4.
1-4 No Voltage No continuity Standard value:
Voltage (Connect Continuity 13 − 17 kΩ (at −20°C)
positive (+) terminal of 5.3 − 6.7 kΩ (at 0°C)
battery to terminal No. 3 2.3 − 3.0 kΩ (at 20°C)
and negative (−) 1.0 − 1.5 kΩ (at 40°C)
terminal of battery to 0.56 − 0.76 kΩ (at 60°C)
terminal No. 2.) 0.30 − 0.45 kΩ (at 80°C)
3. Remove the air flow sensor
THROTTLE VALVE CONTROL SERVO
RELAY CONTINUITY CHECK
M1131053500026
Relay box’s
triangle marks
Intake air
1 2 temperature
sensor
3 4
Equipment AK203040 AD
Throttle valve control side connector
servo relay 4. Measure resistance while heating the sensor
AK303317AB
using a hair drier.
Tester Battery Voltage Normal State Normal condition:
Connection Temperature (°C) Resistance (kΩ)
Terminal
Higher Smaller
2−3 No Voltage Continuity
5. If the value deviates from the standard value or
1−4 No Voltage No continuity the resistance remains unchanged, replace the air
Voltage (Connect Continuity flow sensor assembly.
positive (+) terminal of 6. Install the air flow sensor and tighten it to the
battery to terminal No. 3 specified torque.
and negative (−)
terminal No. 2.)
ON-VEHICLE SERVICE
ENGINE COOLANT TEMPERATURE 4. Apply sealant to threaded portion.

SENSOR CHECK Specified sealant:
M1131003100506 3M NUT Locking Part No. 4171 or equivalent
CAUTION
5. Install the engine coolant temperature sensor and
Be careful not to touch the connector (resin
tighten it to the specified torque.
section) with the tool when removing and
installing. Tightening torque: 29 ± 10 N⋅m

SENSOR CHECK
M1130503400059
Engine coolant
temperature sensor
Accelerator pedal 1 2 3 4 5 6 7 8
position sensor Equipment
1 2 side connector
Equipment
side connector
AK303319 AB
1. Remove the engine coolant temperature sensor.
AK303330AB
1. Disconnect the accelerator pedal position sensor

connector.
2. Measure resistance between terminal No. 2 (main
power supply) and No. 1 (main earth) as well as
between terminal No. 8 (sub power supply) and
terminal No. 7 (sub earth) of the sensor
connector.
AKX01622
Standard valve: 3.5 − 6.5 kΩ
2. With temperature sensing portion of engine 3. Measure resistance between terminal No. 2 (main
coolant temperature sensor immersed in hot power supply) and No. 3 (main output) as well as
water, check resistance. between terminal No. 8 (sub power supply) and
Standard value: No. 6 (sub output) of the sensor connector.
14 − 17 kΩ (at −20°C) Normal condition:
5.1 − 6.5 kΩ (at 0°C) Depress the accelerator Resistance value
2.1 − 2.7 kΩ (at 20°C) pedal slowly. changes in accordance
0.9 − 1.3 kΩ (at 40°C) with the accelerator
0.48 − 0.68 kΩ (at 60°C) pedal depression
0.26 − 0.36 kΩ (at 80°C) smoothly.
3. If the resistance deviates from the standard value 4. If not within the standard value, or resistance
greatly, replace the sensor. value does not change smoothly, replace the
accelerator pedal position sensor.
NOTE: After replacement, adjust the accelerator
pedal position sensor. (Refer to P.13B-425.)
AKX01623AD
ON-VEHICLE SERVICE
ACCELERATOR PEDAL POSITION OXYGEN SENSOR CHECK

M1131005000679
SWITCH CHECK OXYGEN SENSOR (FRONT)
M1131052500045
Accelerator pedal 1 2 3 4 5 6 7 8 sensor (front)
position sensor Equipment
side connector
1 2
3 4
Equipment
Cylinder 1, 4 oxygen side connector
AK303330AB sensor (front) connector AK303320AB
1. Disconnect the accelerator pedal position sensor

connector.
2. Check continuity between terminal No. 4
(accelerator pedal position switch) and No. 5
(earth) of the connector.
Normal condition:
Accelerator pedal Continuity Cylinder 2, 3 oxygen
sensor (front)
Depressed No continuity
Released Continuity (0 Ω)
1 2
3. If defective, replace the accelerator pedal position 3 4
sensor.
Equipment
NOTE: After replacement, adjust the accelerator side connector
pedal position sensor. (Refer to P.13B-425.)
sensor (front) connector
AK303321 AB
1. Disconnect the oxygen sensor connector and

to the connector on the oxygen sensor side.
ON-VEHICLE SERVICE

No. 2 (black clip of special tool) and No. 4 (white
clip of special tool).
Oxygen
Red sensor 7. While repeatedly racing the engine, measure the
equipment oxygen sensor output voltage.
side connector
Blue Standard value:
sensor
AKX01624 AR
output
MB991316 voltage
When 0.6 − 1.0 V If you make the air-fuel
Oxygen
Red sensor normal oxygen sensor
equipment will output a voltage of
side connector
0.6 − 1.0 V.
Blue
CAUTION
• Be very careful when connecting the jumper
AKX01624 AF
wire; incorrect connection can damage the
MD998464
oxygen sensor.
2. Make sure that there is continuity (4.5 − 8.0 Ω at • Be careful the heater is broken when voltage
20°C) between terminal No. 1 (red clip of special of beyond 8V is applied to the oxygen sensor
tool) and No. 3 (blue clip of special tool) on the heater.
oxygen sensor connector. NOTE: If the sufficiently high temperature (of
3. If there is no continuity, replace the oxygen approximate 400°C or more) is not reached
sensor. although the oxygen sensor is normal, the output
4. Warm up the engine until engine coolant is 80°C voltage would be possibly low although the rich
or higher. air-fuel ratio. Therefore, if the output voltage is
low, use a jumper wire to connect the terminal No.
1 (red clip of special tool) and the terminal No. 3
engine speed of 4,500 r/min.
(blue clip of special tool) of the oxygen sensor
with a (+) terminal and (-) terminal of 8 V power
supply respectively, then check again.
Oxygen 8. If the sensor is defective, replace the oxygen
Black sensor sensor.
equipment
side connector NOTE: For removal and installation of the oxygen
White sensor, refer to GROUP 15 − Exhaust Manifold.
P.15-11.
AKX01624 AP
MB991316
ON-VEHICLE SERVICE
OXYGEN SENSOR (REAR)
Oxygen
Red sensor
equipment
side connector
Blue
sensor (rear)
AKX01624 AF
MD998464
1 2
2. Make sure that there is continuity (11 − 18 Ω at
3 4
20°C) between terminal No.1 (red clip of special
Equipment tool) and No. 3 (blue clip of special tool) on the
side connector
oxygen sensor connector.
3. If there is no continuity, replace the oxygen
sensor.
4. Warm up the engine until engine coolant is 80°C
or higher.
Cylinder 1, 4 oxygen engine speed of 4,500 r/min.
sensor (rear) connector
AK303322 AB
Oxygen
Black sensor
equipment
side connector
White
Cylinder 2, 3 oxygen MD998464

AKX01624 AS
sensor (rear)
No.2 (black clip of special tool) and No. 4 (white
1 2 clip of special tool).
Cylinder 2, 3 oxygen 3 4 7. While repeatedly racing the engine, measure the
sensor (rear) connector
Equipment oxygen sensor output voltage.
side connector
Standard value:
sensor
output
voltage
AK303323AB
When 0.6 − 1.0 V If you make the air-fuel
1. Disconnect the oxygen sensor connector and engine engine repeatedly, a
connect the special tool Test harness normal oxygen sensor
(MD998464) to the connector on the oxygen will output a voltage of
sensor side. 0.6 − 1.0 V.
ON-VEHICLE SERVICE
CAUTION MEASUREMENT OF RESISTANCE

• Be very careful when connecting the jumper BETWEEN TERMINALS
wire; incorrect connection can damage the 1. Disconnect the injector connector.
oxygen sensor.
2. Measure the resistance between terminals.
• Be careful the heater is broken when voltage
Standard value: 10.5 − 13.5 Ω (at 20°C)
of beyond 12 V is applied to the oxygen
sensor heater. 3. Connect the injector connector.
NOTE: If the sufficiently high temperature (of
approximate 400°C or more) is not reached CHECK THE INJECTION CONDITION
although the oxygen sensor is normal, the output 1. Carry out the procedure to prevent flow of the fuel
voltage would be possibly low although the rich (Refer to P.13B-428).
air-fuel ratio. Therefore, if the output voltage is CAUTION
low, use a jumper wire to connect the terminal Do not make fuel splash by covering fuel with
No.2 and the terminal No. 1 of the oxygen sensor waste and so on because the residual pressure is
with a (+) terminal and (-) terminal of 12 V power in the fuel pipeline.
supply respectively, then check again. 2. Remove the fuel high-pressure hose at the
8. If the sensor is defective, replace the oxygen delivery pipe side.
sensor.
NOTE: For removal and installation of the oxygen Tie up band
sensor, refer to GROUP 15 − Exhaust Pipe and
Main Muffler P.15-13.
MD998741
MB991976
INJECTOR CHECK
M1131005200509
CHECK THE OPERATION SOUND
Injector
Injector AK303686AC
3. Remove the injector.

4. Assemble Injector Test Set (MD998706) of the
special tool as shown in Fig.
1 2 a. Install the injector to the installation hose for the
Equipment injector and then fix it using Injector Holder
side connector (MB991976) of the special tool.
AK303324 AB
b. Install Injector Test Adaptor (MD998741) of the
1. Use a stethoscope to listen to the operation sound special tool to another hose connected with the
(clicking) of the injectors while the engine is idling installation hose for the injector.
or cranking. c. Fold, band and tie up the rest of hose completely
in order to prevent from fuel leakage because it is
CAUTION
not used.
Beware that the operation sounds of other
injectors can be heard even if the injector that is 5. Install Injector Test Set (MD998706) of the special
being inspected might not be operating. tool to the fuel high-pressure hose.
2. Verify that the operation sound increases with the 6. Connect the MUT-III to the diagnosis connector.
engine speed. 7. Turn the ignition switch to "ON" position (but do
NOTE: If the operating sound cannot be heard, not start the engine).
inspect the injector actuation circuit. 8. Select "Item No. 07" from MUT-III actuator test
and drive the fuel pump.
ON-VEHICLE SERVICE
High-pressure 1. Disconnect the electronically controlled throttle

fuel hose valve connector.
2. Measure the resistance between terminals No. 1
and No. 2 at the throttle valve control servo
connector.
Standard value: 0.3 − 80 Ω (at 20°C)
3. If resistance is outside the standard value, replace
MB991607
the throttle body assembly.
AK303687AC OIL CONTROL VALVE CHECK
M1131053200058
9. Connect Injector Test Harness (MB991607) of the OPERATION CHECK
special tool between the injector and battery, and
then actuate the injector.
10.Check the fuel spray condition. The condition can
1 2
be considered satisfactory unless it is extremely
poor. Equipment
side connector
11.Stop actuating the injector. Check leakage from
the injector nozzle. Turn the ignition switch to
"LOCK OFF" position and then disconnect
MUT-III.
Oil control valve
12.Actuate the injector until the fuel cannot flow. AK303326 AB
Draw the fuel out from the special tool.
13.Remove the special tool. 1. Disconnect the oil control valve connector.
14.If the fuel spray condition is extremely poor or if CAUTION
there is the fuel leakage from the injector nozzle, To prevent the coil from burning, keep the
replace the injector. duration of the voltage application as short as
15.Install the injector and fuel high-pressure hose. possible.
2. Apply battery voltage to the terminals of the
THROTTLE VALVE CONTROL SERVO connector at the oil control valve, and make sure
CHECK the oil control valve makes a clicking sound.
M1130532400037
OPERATION CHECK MEASUREMENT OF RESISTANCE

1. Remove the air intake hose from the throttle body. BETWEEN TERMINALS
2. Turn the ignition switch to "ON" position. 1. Disconnect the oil control valve connector.
3. Operate the accelerator pedal and confirm that 2. Measure the resistance between the terminals of
the throttle valve is opening and closing the connector at the oil control valve.
accordingly. Standard value: 6.9 − 7.9 Ω (at 20°C)
3. If resistance is outside the standard value, replace
CHECK THE COIL RESISTANCE
the oil control valve.
Electronically
Equipment throttle valve
side connector AK303325AB
INJECTOR
INJECTOR
M1131007100810

• Fuel Discharge Prevention (Refer to P.13B-428). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.15-4).
P.15-4). • Fuel Leakage Inspection.
11 ± 1 N·m
11 ± 1 N·m
3
N 87 5.0 ± 1.0 N·m
6 2
12
13 N 9
5
15 11
16
10
14
4 1
Apply engine oil to all

moving parts before
installation.
AC309314 AB
Removal steps INSTALLATION SERVICE POINT

1. PCV hose connection >>A<< FUEL INJECTOR ASSEMBLY/FUEL
2. Capacitor connector HIGH-PRESSURE HOSE INSTALLATION
3. Ignition coil connector
4. Injector connector CAUTION
5. EGR valve connector Do not let the engine oil get into the delivery pipe
6. Rocker cover bracket installation will be damaged.
bolts 1. Apply a drop of new engine oil to the O-ring.
>>A<< 7. Fuel high-pressure hose
2. Turn the fuel injector assembly to the right and left
connection
8. O-ring
to install to the fuel delivery pipe. Repeat for fuel
<<A>> 9. Fuel delivery pipe and fuel injector high-pressure hose. Be careful not to damage the
assembly O-ring. After installing, check that the item turns
10. Insulators smoothly.
>>A<< 11. Fuel injector assembly 3. If it dose not turn smoothly, the O-ring may be
12. Fuel delivery pipe trapped, remove the item, re-install it into the fuel
13. O-ring delivery pipe and check again.
14. Insulators
4. Tighten the fuel high-pressure hose to the
15. Grommets
16 Fuel injectors specified torque.
<<A>> FUEL DELIVERY PIPE AND FUEL
INJECTOR ASSEMBLY REMOVAL
CAUTION
Do not drop the injector.
Remove the fuel delivery pipe with the fuel injector
assembly attached to it.

M1131007700715
CAUTION
Do not loosen the fixing screws for the resin cover of throttle body assembly. If the screws are
loosened, the sensor incorporated in the resin cover becomes misaligned and the throttle body can
not work normally.
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
Service − Engine Coolant Replacement P.14-17). P.15-4).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Engine Coolant Supplying (Refer to GROUP 14,
P.15-4). On-vehicle Service − Engine Coolant Replacement
P.14-17).
5N
19 ± 3 N·m
1
AC304161AE
1. Throttle position sensor connector >>A<< THROTTLE BODY GASKET
2. Water return hose connection INSTALLATION
3. Water feed hose connection
4. Throttle body assembly CAUTION
>>A<< 5. Throttle body gasket Poor idling etc. may result if the throttle body
gasket is installed incorrectly.
Projection
AC304212AC
ENGINE ECU AND ENGINE-A/T-ECU
Install the throttle body gasket as its protrusion is in

the direction shown.

M1131022500042
<L.H. drive vehicles>

CAUTION
Always register the ignition key(s) when the engine-ECU <M/T> or the engine-A/T-ECU <A/T> is
replaced.(Refer to GROUP 54A, On-vehicle Service - Immobilizer ID Code Registration P.54A-24).
Cowl Side Trim (RH) Removal and Installation (Refer to
GROUP 52A, Instrument Panel Assembly P.52A-2).
3
5.0 ± 1.0 N·m
1 9.0 ± 2.0 N·m
AC309335AB
REMOVAL STEPS REMOVAL STEPS (Continued)

1. Engine-ECU connector <M/T> or 2. Engine-ECU <M/T> or
Engine-A/T-ECU connector <A/T> Engine-A/T-ECU <A/T>
3. Engine-ECU bracket <M/T> or
Engine-A/T-ECU bracket <A/T>
<R.H. drive vehicles>

CAUTION
Register the ignition key ID when the engine-A/T-ECU is replaced (Refer to GROUP 54A, On-vehicle
Service - Immobilizer ID Cood Registration P.54A-24).
Instrument panel console side cover (LH) Removal and
Installation (Refer to GROUP 52A, Instrument Panel
Assembly P.52A-8).
9.0 ± 2.0 N·m

5.0 ± 1.0 N·m
3
1
9.0 ± 2.0 N·m

AC309336AB

1. Side cover trim bracket 3. Engine-A/T-ECU
2. Engine-A/T-ECU connector 3. Engine-ECU bracket
13C-1
GROUP 13C
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION . . . . . . . . 13C-2 FUEL TANK GAUGE UNIT REPLACEMENT

<4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-5
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13C-2
FUEL TANK . . . . . . . . . . . . . . . . . . . . 13C-7
ON-VEHICLE SERVICE. . . . . . . . . . . 13C-2 REMOVAL AND INSTALLATION <4G63> . 13C-7
FUEL PUMP OPERATION CHECK . . . . . . 13C-2 REMOVAL AND INSTALLATION <4G69> . 13C-11
FUEL GAUGE UNIT CHECK . . . . . . . . . . . 13C-2 FUEL PUMP ASSEMBLY DISASSEMBLY
AND REASSEMBLY <2WD> . . . . . . . . . . . 13C-14
FUEL PUMP ASSEMBLY <2WD>,
FUEL TANK PUMP AND GAUGE ASSEMBLY
FUEL TANK PUMP AND GAUGE ASSEMBLY
<4WD> REPLACEMENT . . . . . . . . . . . . . . 13C-2 DISASSEMBLY AND REASSEMBLY
<4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-15
FUEL TANK GAUGE UNIT REPLACEMENT
<2WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-4 FUEL TANK GAUGE UNIT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 13C-16
13C-2 FUEL SUPPLY
GENERAL INFORMATION
GENERAL INFORMATION
M1135000100457
• The fuel tank is located under the floor of the rear • A fuel pump assembly <2WD>, fuel pump and
seats to provide increased protection and a more gauge assembly <4WD> including fuel pump,
luggage space. fuel filter, reservoir and fuel gauge unit, has been
• A fuel tank safety valve assembly has been adopted to lighten weight and improve
adopted to prevent fuel from leaking out in case serviceability.
of a collision.
SEALANT
M1135005200039

Service hole cover and floor pan <2WD> 3M! 8513 Grommets windshield sealer (Black)
ON-VEHICLE SERVICE
FUEL PUMP OPERATION CHECK 2. Remove the service hole cover mounting screws
M1135001000174 and remove the service hole cover.
<4G63>: Refer to GROUP 13A - On-vehicle Service,
Fuel Pump Operation Check P.13A-328. Fuel pump assembly <2WD>
<4G69>: Refer to GROUP 13B - On-vehicle Service, or fuel tank pump and gauge assembly <4WD>
Fuel Pump Operation Check P.13B-428. connector
FUEL GAUGE UNIT CHECK

M1135003100371 Fuel suction
Refer to GROUP 54A − Combination Meter, tube <4WD>
On-vehicle Service, Fuel Gauge Unit Check
P.54A-69 <2WD>, P.54A-70 <4WD>.

<4WD> REPLACEMENT
M1135004900336
GROUP 52A − Rear seat assembly P.52A-36).
Service hole cover
Fuel return hose

<4G63> Fuel high-pressure
hose
AC309286AB
3. Disconnect the fuel pump assembly <2WD> or

fuel tank pump and gauge assembly <4WD>
AC102784 AB
FUEL SUPPLY 13C-3
ON-VEHICLE SERVICE
CAUTION CAUTION
Fuel tank pump and
gauge assembly
Corresponding side
Service hole
Float
3 mm
Quick connector
AC107193AC AC300047AC
For 4WD: Pay attention not to damage the float After connecting the fuel high-pressure hose or
when removing and installing fuel tank pump and fuel pump suction tube <4WD>, slightly pull it to
gauge assembly through the service hole. ensure that it is installed securely. Also confirm
4. Remove the mounting nuts and fuel pump bracket that there is a play approximately 3 mm.
plate, and remove the fuel pump assembly Fuel pump assembly <2WD>
<2WD>, fuel tank pump and gauge assembly or fuel tank pump and gauge assembly <4WD>
<4WD> from the service hole. connector
5. Install the fuel pump assembly <2WD>, fuel tank
pump and gauge assembly <4WD> to the fuel
Fuel suction
tank through the service hole.
tube <4WD>
Fuel pump braket plate
2.5 ± 0.4 N·m
AC107194AC
6. Install the fuel pump bracket plate to the fuel tank

and tighten the mounting nuts to the specified Fuel return hose
<4G63> Fuel high-pressure
torque. hose
Tightening torque: 2.5 ± 0.4 N⋅m AC309286AB
7. Connect the fuel pump assembly <2WD> or fuel

tank pump and gauge assembly <4WD>
Service hole cover
AC102784 AB
13C-4 FUEL SUPPLY
ON-VEHICLE SERVICE
8. Tighten the service hole cover mounting screws CAUTION

and install the service hole cover. Fuel tank gauge unit
9. Install the rear seat cushion assembly. (Refer to
GROUP 52A − Rear seat assembly P.52A-36).

REPLACEMENT <2WD> Gauge unit
M1135001400398
GROUP 52A − Rear Seat Assembly P.52A-36).
Flat-tipped screwdriver Service hole AC107188AD

the float of the fuel tank gauge unit when
withdrawing it from the service hole.
hole.
CAUTION
Service hole cover AC107600AC
2. Pry off the service hole cover using a flat-tipped
screwdriver, etc.
Gauge unit
Service hole AC107188AE

harness connector AC107601AC inserting it from the service hole.
3. Disconnect the fuel tank gauge unit harness 2.5 ± 0.4 N·m
connector.
AC107602 AC

through the service hole, and tighten the mounting
nuts to the specified torque.
FUEL SUPPLY 13C-5
ON-VEHICLE SERVICE
Fuel tank gauge unit Service hole cover

harness connector AC107601AC AC107603AC
6. Connect the fuel tank gauge unit harness 2. Remove the service hole cover mounting screws
connector. and remove the service hole cover.
Service hole cover

Floor pan Fuel tank gauge

unit harness
connector
AC100961AD AC107189AC
7. Apply the specified sealant to the contact surfaces 3. Disconnect the fuel tank gauge unit harness
of the service hole cover and the floor pan, and connector and fuel pump suction tube.
install the service hole cover. CAUTION
Specified sealant: 3M! 8513 Grommets
Windshield Sealer (Black)
GROUP 52A − Rear Seat Assembly P.52A-36). Gauge unit
REPLACEMENT <4WD> Service hole
M1135001400406
GROUP 52A − Rear Seat Assembly P.52A-36). Float
AC107190AD

withdrawing it from the service hole.
hole.
13C-6 FUEL SUPPLY
ON-VEHICLE SERVICE
CAUTION CAUTION
Main pipe nozzle or

fuel main pipe
Gauge unit
Fuel tank gauge unit fuel pump suction tube
Service hole
3 mm
Float Quick connector
AC107190 AE AC300047AB
Pay attention not to damage the gauge unit and After connecting the fuel high-pressure hose or
the float of the fuel tank gauge unit when fuel pump suction tube, slightly pull it to ensure
inserting it from the service hole. that it is installed securely. Also confirm that
2.5 ± 0.4 N·m
Fuel tank gauge

unit harness
AC107618AC
connector
AC107189AC
through the service hole, and tighten the mounting 6. Connect the fuel tank pump gauge unit harness
nuts to the specified torque. connector and fuel suction tube.
Tightening torque: 2.5 ± 0.4 N⋅m Service hole cover
AC107603AC
7. Tighten the service hole cover mounting screws

GROUP 52A − Rear Seat Assembly P.52A-36).
FUEL SUPPLY 13C-7
FUEL TANK
FUEL TANK
REMOVAL AND INSTALLATION <4G63>
M1135001900520

• Draining Fuel • Propeller Shaft Installation <4WD> (Refer to GROUP 25,
• Fuel Pump Connector Disconnection (How to Reduce Propeller Shaft P.25-3).
Fuel Pressure) (Refer to GROUP 13A − On-vehicle • Centre Exhaust Pipe Installation (Refer to GROUP 15,
Service P.13A-328). Exhaust Pipe and Main Muffler P.15-13).
• Centre Exhaust Pipe Removal (Refer to GROUP 15, • Refilling Fuel
Exhaust Pipe and Main Muffler P.15-13). • Checking for Fuel Leaks
• Propeller Shaft Removal <4WD> (Refer to GROUP 25,
Propeller Shaft P.25-3).
<2WD>
8
2.5 ± 0.4 N·m
21
11
8 2.5 ± 0.4 N·m 12
5
15 13
13 15 13
17 22
18 N
2.5 ± 0.4 N·m 4 3
20 N 19
20 N 19
9 2.5 ± 0.4 N·m 13 24 2
14 13
25
1
23
6
26 ± 4 N·m
26 ± 4 N·m 7
AC212356 AB
13C-8 FUEL SUPPLY
FUEL TANK
<4WD>
8
2.5 ± 0.4 N·m
2.5 ± 0.4 N·m 21

16 11
8 12
2.5 ± 0.4 N·m 13 5
15
13 15 13
22
17 N 18 2.5 ± 0.4 N·m
4 3
13 20 N
20 N 19 14 19
13 2
24
10
25 1
23
26 ± 4 N·m 7 AC212516AB

steps steps (Continued)
1. Fuel filler hose connection <Fuel >>A<< 11. Fuel high-pressure hose
filler neck side> 12. Fuel return hose
2. Fuel filler neck breather hose 13. Fuel tank hose
connection <Fuel filler neck side> 14. Fuel tank vapour hose 2way valve
3. Main pipe connection 15. Fuel vapour pipe
4. Return pipe >>A<< 16. Fuel pump suction tube <4WD>
5. Fuel vapour pipe <> 17. Fuel tank gauge unit
6. Parking brake cable clamp 18. Gasket
connection <RH side> 19. Fuel tank safety valve
7. Wiring harness clamp connection 20. Gasket
8. Fuel tank gauge unit assembly, fuel 21. Fuel pump bracket plate
pump assembly <2WD>, fuel tank <> 22. Fuel pump assembly <2WD>, fuel
pomp and gauge assembly <4WD> tank pump and gauge assembly
connector connection <4WD>
<<A>> • Rear differential support member 23. Fuel filler hose
installation nuts and bolts <4WD> 24. Fuel filler neck breather hose
(Refer to GROUP 27B − Rear 25. Fuel tank
Differential Carrier Assembly
P.27B-16).
9. Fuel tank assembly <2WD>
<<A>> 10. Fuel tank assembly <4WD>
FUEL SUPPLY 13C-9
FUEL TANK
<FUEL FILLER NECK>
30
27
28
29
1
26
AC300410AB
Fuel filler neck removal steps Fuel filler neck removal steps
13C-10 FUEL SUPPLY
FUEL TANK

<<A>> REAR DIFFERENTIAL SUPPORT Support the fuel tank assembly securely so that
MEMBER INSTALLATION NUTS AND BOLTS it does not fall off from the transmission jack.
<4WD>/FUEL TANK ASSEMBLY <4WD> 3. Tilt the fuel tank assembly to disconnect the
REMOVAL connectors.
Rear differential
Fuel tank assembly Towards front Rear differential
carrier assembly of vehicle carrier assembly
Tilt
Towards front
Lower
Fuel tank assembly AC300043AB
1. Remove the rear differential support member 4. Remove the fuel tank assembly to the direction
installation nuts and bolts, and then tilt the rear shown, being careful not to strike it against the
differential carrier assembly (Refer to GROUP rear differential carrier assembly.
27B − Rear Differential Carrier Assembly
P.27B-16). <> FUEL TANK GAUGE UNIT/FUEL PUMP
ASSEMBLY <2WD>, FUEL TANK PUMP AND
GAUGE ASSEMBLY <4WD> REMOVAL
CAUTION
the float.
Fuel tank assembly INSTALLATION SERVICE POINS

Transaxle jack AC107196 AD >>A<< FUEL PUMP SUCTION TUBE <4WD>/FUEL
HIGH-PRESSURE HOSE INSTALLATION
2. Raise and support the fuel tank assembly with a
transmission jack, and remove the mounting nuts CAUTION
and bolts.
Towards front
of vehicle Rear differential Corresponding side
3 mm
Quick connector
AC300047AC
Tilt
AC300040AB After connecting the fuel high-pressure hose or
fuel pump suction tube <4WD>, slightly pull it to
ensure that it is installed securely. Also confirm
that there is a play approximately 3 mm.
FUEL SUPPLY 13C-11
FUEL TANK

M1135001900542

• Draining Fuel • Propeller Shaft Installation (Refer to GROUP 25,
• Fuel Pump Connector Disconnection (How to Reduce Propeller Shaft P.25-3).
Fuel Pressure) (Refer to GROUP 13B − On-vehicle • Centre Exhaust Pipe Installation (Refer to GROUP 15,
Service P.13B-428). Exhaust Pipe and Main Muffler P.15-13).
• Centre Exhaust Pipe Removal (Refer to GROUP 15, • Refilling Fuel
Exhaust Pipe and Main Muffler P.15-13). • Checking for Fuel Leaks
• Propeller Shaft Removal (Refer to GROUP 25, Propeller
Shaft P.25-3).
7
2.5 ± 0.4 N·m
2.5 ± 0.4 N·m 18

13
9
7
4
2.5 ± 0.4 N·m 10
12
10 12 10 19
N 15 2.5 ± 0.4 N·m
14 3
10 17 N 16
17 N 16 11
10 2
21
8
22 1
20
26 ± 4 N·m
6 AC309122AB

1. Fuel filler hose connection <Fuel <<A>> • Rear differential support member
filler neck side> installation nuts and bolts (Refer to
2. Fuel filler neck breather hose GROUP 27B − Rear Differential
connection <Fuel filler neck side> Carrier Assembly P.27B-16).
3. Main pipe connection <<A>> 8. Fuel tank assembly
4. Fuel vapour pipe >>A<< 9. Fuel high-pressure hose
5. Parking brake cable clamp 10. Fuel tank hose
connection <RH side> 11. Fuel tank vapour hose 2way valve
6. Wiring harness clamp connection 12. Fuel vapour pipe
7. Fuel tank gauge unit assembly, fuel >>A<< 13. Fuel pump suction tube
tank pomp and gauge assembly <> 14. Fuel tank gauge unit
connector connection 15. Gasket
16. Fuel tank safety valve
13C-12 FUEL SUPPLY
FUEL TANK
Fuel tank assembly removal

steps (Continued)
17. Gasket
18. Fuel pump bracket plate
<> 19. Fuel tank pump and gauge
assembly
20. Fuel filler hose
21. Fuel filler neck breather hose
22. Fuel tank
<FUEL FILLER NECK>
27
24
25
26
1
23
AC300410AC
Fuel filler neck removal steps Fuel filler neck removal steps
FUEL SUPPLY 13C-13
FUEL TANK

<<A>> REAR DIFFERENTIAL SUPPORT Support the fuel tank assembly securely so that
MEMBER INSTALLATION NUTS AND it does not fall off from the transmission jack.
BOLTS/FUEL TANK ASSEMBLY REMOVAL 3. Tilt the fuel tank assembly to disconnect the
Rear differential connectors.
Fuel tank assembly
carrier assembly
Towards front Rear differential
of vehicle carrier assembly
Tilt
Towards front
Lower
Fuel tank assembly AC300043AB
1. Remove the rear differential support member
installation nuts and bolts, and then tilt the rear 4. Remove the fuel tank assembly to the direction
differential carrier assembly (Refer to GROUP shown, being careful not to strike it against the
27B − Rear Differential Carrier Assembly rear differential carrier assembly.
P.27B-16).
<> FUEL TANK GAUGE UNIT/FUEL TANK
PUMP AND GAUGE ASSEMBLY REMOVAL
CAUTION
the float.
Fuel tank assembly INSTALLATION SERVICE POINS

Transaxle jack AC107196 AD >>A<< FUEL PUMP SUCTION TUBE <4WD>/FUEL
HIGH-PRESSURE HOSE INSTALLATION
2. Raise and support the fuel tank assembly with a
transmission jack, and remove the mounting nuts CAUTION
and bolts.
Towards front
of vehicle Rear differential Corresponding side
fuel pump suction tube
3 mm
Quick connector
AC300047AE
Tilt
AC300040AB After connecting the fuel high-pressure hose or
fuel pump suction tube, slightly pull it to ensure
that it is installed securely. Also confirm that
13C-14 FUEL SUPPLY
FUEL TANK
FUEL PUMP ASSEMBLY DISASSEMBLY

AND REASSEMBLY <2WD>
M1135004600380
3
2
10
1N
N5 8
6
N5 4
9
11 7
AC309295 AB
Disassembly steps Disassembly steps (Continued)

1. Gasket >>A<< 10. Fuel tank grommet
2. Fuel tank pump connector 11. Fuel tank filter assembly
connection
3. Fuel pump bracket REASSEMBLY SERVICE POINT
4. Fuel pump hose >>A<< FUEL TANK GROMMET/O-RING
>>A<< 5. O-ring INSTALLATION
6. Fuel pump tube
7. Fuel pump bracket
8. Fuel tank pump
9. Fuel tank pump cushion
FUEL SUPPLY 13C-15
FUEL TANK
FUEL TANK PUMP AND GAUGE

ASSEMBLY DISASSEMBLY AND
REASSEMBLY <4WD>
M1135004600391
<4G63> <4G69>
5 5
4
14 4
2 1N 2 1N 14
3 N 10
12 3 N 10
8 9 6
N 10
12
6 N 10
7 13
13
11
15 15 11
AC309123 AC309123
AC309296 AB

1. Gasket 11. Fuel pump bracket
2. Fuel tank gauge unit connector 12. Fuel tank pump
connection 13. Fuel tank pump cushion
3. Fuel tank gauge unit >>A<< 14. Fuel tank grommet
4. Fuel tank pump connector 15. Fuel tank filter assembly
connection
5. Fuel pump bracket REASSEMBLY SERVICE POINT
6. Fuel pump hose >>A<< FUEL TANK GROMMET/O-RING
7. Fuel tank assist pump <4G63> INSTALLATION
8. Fuel pump tube <4G63>
9. Fuel pump pressure regulator
<4G69>
>>A<< 10. O-ring
13C-16 FUEL SUPPLY
FUEL TANK
FUEL TANK GAUGE UNIT DISASSEMBLY AND REASSEMBLY

M1135051100068
<2WD> <4WD>
3
3
1
1
2
AC102461 AD

1. Gasket 2. Fuel in tank filter <4WD>
3. Fuel tank gauge unit
14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . . 14-2 FAN CONTROL RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
SERVICE SPECIFICATION . . . . . . . . 14-2 RADIATOR FAN MOTOR CHECK . . . . . . . 14-20
LUBRICANT. . . . . . . . . . . . . . . . . . . . 14-2 THERMOSTAT . . . . . . . . . . . . . . . . . . 14-20

SEALANT. . . . . . . . . . . . . . . . . . . . . . 14-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-22
SPECIAL TOOL . . . . . . . . . . . . . . . . . 14-3 WATER PUMP . . . . . . . . . . . . . . . . . . 14-23

REMOVAL AND INSTALLATION <4G36> . 14-23
TROUBLESHOOTING . . . . . . . . . . . . 14-3 REMOVAL AND INSTALLATION <4G69> . 14-24
ON-VEHICLE SERVICE. . . . . . . . . . . 14-17 WATER HOSE AND WATER PIPE . . 14-25

ENGINE COOLANT LEAK CHECK . . . . . . 14-17 REMOVAL AND INSTALLATION <4G63> . 14-25
RADIATOR CAP VALVE OPENING REMOVAL AND INSTALLATION <4G69> . 14-27
PRESSURE CHECK. . . . . . . . . . . . . . . . . . 14-17 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-28
ENGINE COOLANT REPLACEMENT . . . . 14-17
CONCENTRATION MEASUREMENT . . . . 14-18 RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-29
FAN CONTROLLER CHECK . . . . . . . . . . . 14-18 REMOVAL AND INSTALLATION . . . . . . . . 14-29
14-2 ENGINE COOLING
GENERAL INFORMATION
GENERAL INFORMATION
M1141000100434
The cooling system is designed to keep every part of temperature, the thermostat opens to circulate the
the engine at appropriate temperature in whatever coolant through the radiator as well so that the heat
condition the engine may be operated. The cooling absorbed by the coolant may be radiated into the air.
method is of the water-cooled, pressure forced The water pump is of the centrifugal type and is
circulation type in which the water pump pressurizes driven by the drive belt from the crankshaft. The
coolant and circulates it throughout the engine. If the radiator is the corrugated fin, down flow type.
coolant temperature exceeds the prescribed
Item Specification
Radiator Performance kJ/h 4G63 194,000
4G69 237,600
Built-in A/T Performance kJ/h 4G69 5,700
oil cooler
M1141000300461

Fan controller V A/C OFF 1 or less -
A/C ON Repeat -
8.2 ± 2.6
System voltage ± 2.6
Range of coolant antifreeze concentration of radiator % 30 − 60 -
Thermostat Valve opening temperature of thermostat °C 82 ± 1.5 -
Full-opening temperature of thermostat °C 95 -
Valve lift mm 8.5 or more -
LUBRICANT
M1141000400394
Item Specified coolant Quantity L

Engine coolant DIAQUEEN SUPER LONG LIFE COOLANT or an 7.0
(including condense equivalent
tank)
SEALANT
M1141000500391

Thermostat case, Water outlet fitting MITSUBISHI GENUINE Part No.MD970389 or equivalent
Thermostat case assembly bolt 3M Stud Locking 4170 or equivalent
Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent
ENGINE COOLING 14-3
SPECIAL TOOL
SPECIAL TOOL
M1141000600291

MB991871 LLC changer Coolant refilling
MB991871
MB991223 Harness set Making voltage and

A A: MB991219 A: Test harness resistance measurement
B: MB991220 B: LED harness during troubleshooting
C: MB991221 C: LED harness A: Connector pin contact
D: MB991222 adapter pressure inspection
B D: Probe B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester
connection
MB991223 AC
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE
SYMPTOMS
M1141005600412
Trouble symptom Inspection Reference page

procedure No.
Radiator fan and condenser fan do not operate 1 P.14-4
Radiator fan and condenser fan do not change speed or stop 2 P.14-12
Radiator fan does not operate 3 P.14-15
Condenser fan does not operate 4 P.14-16
14-4 ENGINE COOLING
TROUBLESHOOTING

TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1: Radiator Fan and Condenser Fan do not Operate
Radiator Fan and Condenser Fan Drive Circut
ENGINE-ECU <M/T>OR
ENGINE-A/T-ECU <A/T> FUSIBLE
LINK No.2
ENGINE CONTROL
RELAY
FAN CONTROL
RELAY
FAN
CONTROLLER
NOTE
4G63
4G69
Wire colour code

B : Black LG : Light green
G : Green L : Blue
W : White Y : Yellow
SB : Sky blue BR : Brown
CONDENSER RADIATOR O : Orange GR : Gray
FAN MOTOR FAN MOTOR R : Red P : Pink V : Violet
AC309494AB

CIRCUIT OPERATION <A/T> controls the fan controller to activate the
• The fan controller is powered from fusible link radiator fan motor and the condenser fan motor.
No.2.
• The engine-ECU <M/T> or engine-A/T-ECU TECHNICAL DESCRIPTION
<A/T> uses input signals from the A/C switch, the • The cause could be a malfunction of the fan
water temperature sensor unit and the vehicle controller power supply or earth circuit.
speed sensor <M/T> or the output shaft speed
sensor <A/T> to control the speed of the radiator
fan motor and the condenser fan motor.
ENGINE COOLING 14-5
TROUBLESHOOTING
• If the communication line wiring harness between (2) Turn the ignition switch to the "ON" position.
the fan controller and the engine-ECU <M/T> or
engine-A/T-ECU <A/T> is short-circuited to earth,
the radiator fan motor and the condenser fan
Connector A-20
motor will not rotate. (Conponent side)
• The cause could also be a malfunction of input
3 2 1
signal from the A/C switch, the water temperature
sensor unit and the vehicle speed sensor <M/T>
or the output shaft speed sensor <A/T> to the
• The cause could also be a malfunction of the fan
AC201418 AF
controller or the engine-ECU <M/T> or
engine-A/T-ECU <A/T>. (3) Measure the voltage between fan controller
connector A-20 terminal 3 and body earth.
TROUBLESHOOTING HINTS • The voltage should measure system voltage.
• Malfunction of fusible link No.2 (4) Turn the ignition switch to the "LOCK" (OFF)
• Malfunction of fan control relay position.
• Malfunction of cooling fan motor (5) Connect fan controller connector A-20.
• Malfunction of fan controller Q: Is the measured voltage system voltage?
• Malfunction of engine-ECU <M/T> or YES : Go to Step 17.
engine-A/T-ECU <A/T> NO : Go to Step 3.
• Damaged wiring harness or connector
STEP 3. Check the fan controller connector A-20.

DIAGNOSIS
Connector: A-20
STEP 1. Check the radiator fan motor.

Refer to P.14-20.
A-20
Q: Is the radiator fan motor in good condition?
YES : Go to Step 2. 3 2 1
NO : Replace the radiator fan motor (Refer to

P.14-29). Then go to Step 24.
AC301902 AB
STEP 2. Measure the power supply voltage at fan
controller connector A-20. Q: Is the connector in good condition?
Connector: A-20 YES : Go to Step 4.
NO : Repair or replace the connector. Then go to
Step 24.
A-20
STEP 4. Check the fusible link No.2.
3 2 1
Relay box
AC301902 AB
(1) Disconnect fan controller connector A-20 and

measure wiring harness side connector.
Fusible link
No.2 AC309505 AB
Q: Is the fusible link No.2 in good condition?

14-6 ENGINE COOLING
TROUBLESHOOTING
YES : Go to Step 5.
NO : Replace the fusible link No.2. Then go to STEP 6. Check the fan control relay connector
Step 24. A-10X.
Connector: A-10X
Relay box
STEP 5. Measure the power supply voltage at fan
control relay connector A-10X.
Fan control relay
Connector: A-10X
Relay box
A-10X
Fan control relay
AC309505 AC
A-10X Q: Is the connector in good condition?

YES : Go to Step 7.
AC309505 AC
NO : Repair the connector or replace the relay
box. Then go to Step 24.
(1) Disconnect fan control relay connector A-10X
(remove the fan control relay) and measure relay
box side connector. STEP 7. Check the harness wire between fusible
(2) Turn the ignition switch to the "ON" position. link No.2 and fan control relay connector A-10X
terminal 4.
A-10X Connector
(Relay box side) Relay box
AC303511AD
Fusible link
No.2 AC309505 AB
(3) Measure the voltage between fan control relay
connector A-10X terminal 4 and body earth. Connector: A-10X
Relay box
• The voltage should measure system voltage.
position.
Fan control relay
(5) Connect fan control relay connector A-10X
(install the fan control relay).
Q: Is the measured voltage system voltage? A-10X
YES : Go to Step 8.
NO : Go to Step 6.
AC309505 AC
Q: Is the harness wire in good condition?

YES : An intermittent malfunction is suspected
(Refer to GROUP 00 - How to use
troubleshooting P.00-6).
NO : Repair the damaged harness wire. Then go
to Step 24.
ENGINE COOLING 14-7
TROUBLESHOOTING
YES : Go to Step 11.

STEP 8. Check the fan control relay. NO : Repair the damaged harness wire. Then go
Refer to P.14-19.
to Step 24.
Q: Is the fan control relay in good condition?
YES : Go to Step 9.
NO : Replace the fan control relay. Then go to STEP 11. Measure the terminal voltage at fan
Step 24. control relay connector A-10X.
Connector: A-10X
Relay box
STEP 9. Check the fan control relay connector
A-10X.
Fan control relay
Connector: A-10X
Relay box
A-10X
Fan control relay
AC309505 AC
A-10X (1) Disconnect fan control relay connector A-10X

(remove the fan control relay) and measure relay
box side connector.
AC309505 AC
(2) Turn the ignition switch to the "ON" position.
Q: Is the connector in good condition?
YES : Go to Step 10. A-10X Connector
NO : Repair the connector or replace the relay (Relay box side)
box. Then go to Step 24.
STEP 10. Check the harness wire between fan

control relay connector A-10X terminal 2 and fan
controller connector A-20 terminal 3.
Connector: A-10X
Relay box AC303517AC
(3) Measure the voltage between fan control relay

Fan control relay
connector A-10X terminal 1 and body earth.
• The voltage should measure system voltage.
position.
A-10X (5) Connect fan control relay connector A-10X
AC309505 AC Q: Is the measured voltage system voltage?
Connector: A-20
NO : Go to Step 12.
A-20
3 2 1
AC301902 AB

14-8 ENGINE COOLING
TROUBLESHOOTING

STEP 12. Check the J/C No.2 C-17, intermediate NO : Repair or replace the connector. Then go to
connector A-14 and fan control relay connector Step 24.
A-10X.
Connector: C-17 <L.H drive vehicles>
STEP 13. Check the harness wire between J/C
No.2 C-17 terminal 5 and fan control relay
connector A-10X terminal 1.
Connector: C-17 <L.H drive vehicles>
C-17
C-17
C-17
AC309507AB
Connector: C-17 <R.H drive vehicles>

C-17
AC309507AB
C-17 Connector: C-17 <R.H drive vehicles>
C-17 C-17
AC309508AB
Connector: A-14 C-17
AC309508AB
A-14(GR) Connector: A-10X

Relay box
A-14(GR)
Fan control relay
AC309506AB
Connector: A-10X A-10X

Relay box
AC309505 AC
Fan control relay

Q: Are these harness wires in good condition?
A-10X troubleshooting P.00-6).
AC309505 AC
to Step 24.
Q: Are there connectors in good condition?

ENGINE COOLING 14-9
TROUBLESHOOTING

STEP 14. Check the continuity between fan NO : Repair the connector or replace the relay
control relay connector A-10X and body earth. box. Then go to Step 24.
Connector: A-10X
Relay box
STEP 16. Check the harness wire between fan
control relay connector A-10X terminal 3 and
Fan control relay body earth.
Connector: A-10X
Relay box
A-10X
Fan control relay

AC309505 AC
(1) Disconnect fan control relay connector A-10X

(remove the fan control relay) and measure relay A-10X
box side connector.
AC309505 AC
A-10X Connector
(Relay box side) Q: Is the harness wire in good condition?
to Step 24.
AC303533AC
STEP 17. Check the continuity between fan
(2) Measure the resistance between fan control relay controller connector A-20 and body earth.
connector A-10X terminal 3 and body earth. Connector: A-20
• Continuity exists.
(3) Connect fan control relay connector A-10X
A-20
Q: Does the continuity exists?
YES : An intermittent malfunction is suspected 3 2 1

NO : Go to Step 15.
AC301902 AB
STEP 15. Check the fan control relay connector (1) Disconnect fan controller connector A-20 and
A-10X. measure wiring harness side connector.
Connector: A-10X
Relay box
A-20 Connector
(Wiring harness side)
Fan control relay
A-10X
AC309505 AC AC303534 AC
(2) Measure the resistance between fan controller

Q: Is the connector in good condition?
14-10 ENGINE COOLING
TROUBLESHOOTING
connector A-20 terminal 1 and body earth. STEP 20. Check the fan controller connector
• Continuity exists.
A-20, intermediate connector A-14 and
(3) Connect fan controller connector A-20. engine-ECU connector or engine-A/T-ECU
Q: Dose the continuity exists? connector C-134 <4G63> or C-139 <4G69>.
Connector: A-20
NO : Go to Step 18.
STEP 18. Check the fan controller connector

A-20. A-20
3 2 1
Connector: A-20
A-20 AC301902 AB
3 2 1
Connector: A-14
AC301902 AB A-14(GR)
Q: Is the connector in good condition? A-14(GR)

Step 24.
AC309506AB
STEP 19. Check the harness wire between fan Connectors: C-134 , C-139
controller connector A-20 terminal 1 and body
earth. <L.H. drive vehicles>
Connector: A-20
C-134
C-139
A-20
3 2 1
AC301902 AB C-139

YES : An intermittent malfunction is suspected C-134 Harness side
C-139(GR) Harness side
: 4G63
to Step 24.
: 4G69
AC309503 AB
Q: Are these connectors in good condition?

Step 24.
ENGINE COOLING 14-11
TROUBLESHOOTING
STEP 21. Check the harness wire between fan STEP 22. Check the fan controller.
controller connector A-20 terminal 2 and Connectors: C-134 , C-139
engine-ECU or engine-A/T-ECU connector C-134
terminal 21 <4G63> or C-139 terminal 17 <4G69>. <L.H. drive vehicles>
Connector: A-20
C-134
C-139
A-20
3 2 1
AC301902 AB
C-139
Connectors: C-134 , C-139

C-134 Harness side

C-134 : 4G63
C-139 : 4G69
AC309503 AB
(1) Disconnect engine-ECU connector or

engine-A/T-ECU connector C-134 <4G63> or
<R.H. drive vehicles> C-139 <4G69>.
C-134 connector <4G63>

C-139
(Harness side connector: ECU side view)
C-134 Harness side

: 4G63
: 4G69
AC309503 AB AC309522 AB
(2) Pull out connector terminal pin 21 <4G63> or 17

YES : Go to Step 22. <4G69> to disconnect connector.
NO : Repair the damaged harness wire. Then go (3) Reconnect the connector with connector terminal
to Step 24. pin still removed.
(5) Check for the cooling fan operation.
• The cooling fan rotates. (with connector
terminal pin 21 <4G63> or 17 <4G69>
disconnected)
• The cooling fan stops. (When connector
terminal pin 21 <4G63> or 17 <4G69> is
connected to the body earth.)
(6) Turn the ignition switch to the "OFF" position.
TROUBLESHOOTING
(7) Disconnect engine-ECU connector or YES : Inspection chart for diagnosis code (Refer
engine-A/T-ECU connector C-134 <4G63> or to GROUP 13A - Trouble shooting
C-139 <4G69>, and push in connector terminal P.13A-16) <4G63> or Inspection chart for
pin 21 <4G63> or 17 <4G69> to disconnect diagnosis code (Refer to GROUP 13B -
connector. Trouble shooting P.13B-20) <4G69>.
(8) Reconnect the connector with connector terminal NO : Replace the engine-ECU <M/T> or
pin still installed. engine-A/T-ECU <A/T> (Refer to GROUP
13A, Engine-ECU P.13A-343) <4G63> or
Q: Does the cooling fan rotate? And when the
(Refer to GROUP 13B, Engine-ECU and
connector terminal pin is connected to the body
earth, does the cooling fan stop? Engine-A/T-ECU P.13B-439) <4G69>. Then
YES : Go to Step 23. go to Step 24.
NO : Replace the fan controller (Refer to
P.14-29). Then go to Step 24. STEP 24. Check the symptoms.
Q: Does the radiator fan motor and the condenser fan
STEP 23. MUT-II/III self-diag code motor operate correctly?
Check if an MPI system self-diag code is set. (Refer YES : This symptoms is complete.
to GROUP 13A - Trouble shooting P.13A-9) <4G63> NO : Return to Step 1.
or (Refer to GROUP 13B - Trouble shooting
P.13B-10) <4G69>.
INSPECTION PROCEDURE 2: Radiator Fan and Condenser Fan do not Change Speed or Stop
Radiator Fan and Condenser Fan Drive Circuit DIAGNOSIS

Refer to P.14-4.
TECHNICAL DESCRIPTION STEP 1. Check the fan control relay.

• The cause could be a malfunction of the fan Refer to P.14-19.
controller power supply or earth circuit. Q: Is the fan control relay in good condition?
• If the communication line wiring harness between YES : Go to Step 2.
the fan controller and the engine-ECU <M/T> or NO : Replace the fan control relay. Then go to
engine-A/T-ECU <A/T> is short-circuited to earth, Step 8.
the radiator fan motor and the condenser fan
motor will not rotate.
• The cause could also be a malfunction of input STEP 2. Check the fan control relay connector
signal from the A/C switch, the water temperature A-10X.
sensor unit and the vehicle speed sensor <M/T> Connector: A-10X
Relay box
or the output shaft speed sensor <A/T> to the
• The cause could also be a malfunction of the fan Fan control relay
controller or the engine-ECU <M/T> or
TROUBLESHOOTING HINTS A-10X

• Malfunction of fusible link No.2
• Malfunction of fan control relay AC309505 AC
• Malfunction of cooling fan motor
• Malfunction of fan controller Q: Is the connector in good condition?
• Malfunction of engine-ECU <M/T> or YES : Go to Step 3.
engine-A/T-ECU <A/T> NO : Repair the connector or replace the relay
• Damaged wiring harness or connector box. Then go to Step 8.
TROUBLESHOOTING
STEP 3. Check the harness wire between fan STEP 4. Check the fan controller connector A-20,
control relay connector A-10X terminal 2 and fan intermediate connector A-14 and engine-ECU
controller connector A-20 terminal 3. connector or engine-A/T-ECU connector C-134
Connector: A-10X
<4G63> or C-139 <4G69>.
Relay box
Connector: A-20
Fan control relay
A-20
3 2 1
A-10X
AC309505 AC
AC301902 AB
Connector: A-20
Connector: A-14
A-20
3 2 1 A-14(GR)
A-14(GR)
AC301902 AB
AC309506AB
YES : Go to Step 4. Connectors: C-134 , C-139
to Step 8. <L.H. drive vehicles>
C-134
C-139
C-139
C-134 Harness side

: 4G63
: 4G69
AC309503 AB
Q: Are these connectors in good condition?

YES : Go to Step 5.
Step 8.
TROUBLESHOOTING
STEP 5. Check the harness wire between fan STEP 6. Check the fan controller.
controller connector A-20 terminal 2 and Connectors: C-134 , C-139
engine-ECU connector or engine-A/T-ECU
connector C-134 terminal 21 <4G63> or C-139 <L.H. drive vehicles>
terminal 17 <4G69>.
Connector: A-20
C-134
C-139
A-20
3 2 1
C-139
AC301902 AB
Connectors: C-134 , C-139 C-134 Harness side

: 4G63
C-134 : 4G69
C-139 AC309503 AB
(1) Disconnect engine-ECU connector or

engine-A/T-ECU connector C-134 <4G63> or
C-139 <4G69>.

C-139
C-134 Harness side


: 4G63
AC309522 AB
: 4G69
AC309503 AB
(2) Pull out connector terminal pin 21 <4G63> or 17
<4G69> to disconnect connector.
YES : Go to Step 6. (3) Reconnect the connector with connector terminal
NO : Repair the damaged harness wire. Then go pin still removed.
to Step 8. (4) Turn the ignition switch to the "ON" position.
(5) Check for the cooling fan operation.
• The cooling fan rotates. (with connector
terminal pin 21 <4G63> or 17 <4G69>
disconnected)
• The cooling fan stops. (When connector
terminal pin21 <4G63> or 17 <4G69> is
connected to the body earth.)
(6) Turn the ignition switch to the "OFF" position.
TROUBLESHOOTING
(7) Disconnect engine-ECU connector or YES : Inspection chart for diagnosis code (Refer
engine-A/T-ECU connector C-134 <4G63> or to GROUP 13A - Trouble shooting
C-139 <4G69>, and push in connector terminal P.13A-16) <4G63> or Inspection chart for
pin 21 <4G63> or 17 <4G69> to disconnect diagnosis code (Refer to GROUP 13B -
connector. Trouble shooting P.13B-20) <4G69>.
(8) Reconnect the connector with connector terminal NO : Replace the engine-ECU <M/T> or
pin still installed. engine-A/T-ECU <A/T> (Refer to GROUP
13A P.13A-343) <4G63> or (Refer to
Q: Does the cooling fan rotate? And when the
GROUP 13B, Engine-ECU and
connector terminal pin is connected to the body
earth, does the cooling fan stop? Engine-A/T-ECU P.13B-439) <4G69>. Then
YES : Go to Step 7. go to Step 8.
NO : Replace the fan controller (Refer to
P.14-29). Then go to Step 8. STEP 8. Check the symptoms.
Q: Does the radiator fan motor and the condenser fan
STEP 7. MUT-II/III self-diag code motor operate correctly?
Check if an MPI system self-diag code is set. (Refer YES : This symptoms is complete.
to GROUP 13A - Trouble shooting P.13A-9) <4G63> NO : Return to Step 1.
or (Refer to GROUP 13B - Trouble shooting
P.13B-10) <4G69>.
INSPECTION PROCEDURE 3: Radiator Fan does not Operate
Radiator Fan and Condenser Fan Drive Circuit YES : Go to Step 2.

Refer to P.14-4. NO : Replace the radiator fan motor (Refer to
TECHNICAL DESCRIPTION
The cause could be a malfunction of the radiator fan
motor or an open circuit between the fan controller STEP 2. Check the fan controller.
and the radiator fan motor. Refer to P.14-18.
Q: Is the fan controller in good condition?
TROUBLESHOOTING HINTS YES : Go to Step 3.
Malfunction of radiator fan motor NO : Replace the fan controller (Refer to
DIAGNOSIS
STEP 3. Check the symptoms.
STEP 1. Check the radiator fan motor.
Refer to P.14-20. Q: Do the radiator fan operate?
YES : This symptoms is complete.
Q: Is the radiator fan motor in good condition? NO : Return to Step 1.
TROUBLESHOOTING
INSPECTION PROCEDURE 4: Condenser Fan does not Operate
Radiator Fan and Condenser Fan Drive Circuit YES : Go to Step 2.

Refer to P.14-4. NO : Replace the condenser fan motor, then go
to Step 3.
TECHNICAL DESCRIPTION
The cause could be a malfunction of the condenser
fan motor or fan controller. STEP 2. Check the fan controller.
Refer to P.14-18.
TROUBLESHOOTING HINTS Q: Is the fan controller in good condition?
• Malfunction of condenser fan motor YES : Go to Step 3.
• Malfunction of fan controller NO : Replace the fan controller (Refer to
DIAGNOSIS
STEP 3. Check the symptoms.
STEP 1. Check the condenser fan motor. Q: Do the condenser fan operate?
Condenser fan motor check. (Refer to GROUP 55, YES : This symptoms is complete.
Condenser and Condenser Fan Motor P.55A-76). NO : Return to Step 1.
Q: Is the condenser fan motor in good condition?
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK 2. Increase the pressure until the indicator of the
M1141001000355 gauge stops moving.
WARNING Minimum limit: 83 kPa
When pressure testing the cooling system, Standard value: 93 − 123 kPa
slowly release cooling system pressure to
3. Replace the radiator cap if the reading does not
avoid getting burned by hot coolant.
remain at or above the limit.
CAUTION
• Be sure to completely clean away any ENGINE COOLANT REPLACEMENT
moisture from the places checked. M1141001200520
• When the tester is taken out, be careful not to WARNING

spill any coolant. When removing the radiator cap, use care to
• Be careful when installing and removing the avoid contact with hot coolant or steam.
tester and when testing not to deform the Place a shop towel over the cap and turn the
filler neck of the radiator. cap counterclockwise a little to let the
pressure escape through the vinyl tube.
After relieving the steam pressure, remove
Cap adapter the cap by slowly turning it
counterclockwise.
Adapter
1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug
and removing the radiator cap.
<2WD>
ACX01844 AC
1. Check that the coolant level is up to the filler neck.

Install a radiator tester and apply 160 kPa
pressure, and then check for leakage from the
radiator hose or connections.
Intake manifold
2. If there is leakage, repair or replace the Cylinder block
appropriate part. drain plug
AC200630AD
RADIATOR CAP VALVE OPENING <4WD>

PRESSURE CHECK
M1141001300431
NOTE: Be sure that the cap is clean before
testing. Rust or other foreign material on the cap
seal will cause an improper reading. 30 ± 3 N·m
Water return tube assembly

Cap adapter
AC301654 AC
2. Drain the water in the water jacket by unplugging

the drain plug of the cylinder block. On 4WD,
drain engine coolant from the water return tube
assembly of the transfer.
AC211643 AB
3. Remove the reserve tank and drain the coolant.
1. Use a cap adapter to attach the cap to the tester.

ON-VEHICLE SERVICE
4. Drain the coolant then clean the path of the 9. Reinstall the radiator cap.
coolant by injecting water into the radiator from 10.Start the engine and let it warm up until the
the radiator cap area. thermostat opens.
11.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
12.Remove the radiator cap after the engine has
Cylinder block
become cold, and pour in coolant up to the brim.
drain plug
Reinstall the cap.
CAUTION
Do not overfill the reserve tank.
13.Add coolant to the reserve tank between the
AC304677 AE
"FULL" and "LOW" mark if necessary.
5. Apply the designated sealant to the screw area of CONCENTRATION MEASUREMENT

the cylinder block drain plug, and then tighten to M1141001100426
the standard torque. Measure the temperature and specific gravity of the
engine coolant to check the antifreeze concentration.
Specified sealant: 3M Nut Locking Part
No.4171 or equivalent Standard value: 30 − 60 % (allowable
Tightening torque: 44 ± 5 N⋅m concentration range)
Recommended antifreeze: DIAQUEEN SUPER
6. Securely tighten the drain plug of the radiator. LONG LIFE COOLANT or equivalent
7. Assemble the reserve tank.
CAUTION
CAUTION If the concentration of the anti-freeze is below 30
Do not use alcohol or methanol anti-freeze or any %, the anti-corrosion property will be adversely
engine coolants mixed with alcohol or methanol affected. In addition, if the concentration is
anti-freeze. The use of an improper anti-freeze above 60 %, both the anti-freezing and engine
can cause corrosion of the aluminium cooling properties will decrease, affecting the
components. engine adversely. For these reasons, be sure to
maintain the concentration level within the
specified range.
MB991871
FAN CONTROLLER CHECK
M1141007400083
Air hose
AC200579AC
3 2 1
8. By referring to the section on coolant, select an
appropriate concentration for safe operating
Fan controller
temperature within the range of 30 to 60 %. Use
special tool LLC changer (MB991871) to refill the AC103011AD
coolant. A convenient mixture is a 50 % water and
50 % antifreeze solution (freezing point: −31°C). 1. Remove the fan controller connector.
Recommended antifreeze: DIAQUEEN SUPER 2. Turn the ignition switch to the "ON" position, and
LONG LIFE COOLANT or equivalent measure the voltage between the harness-side
Quantity: 7.0 L connector terminals.
NOTE: For how to use special tool MB991871, Standard value: System voltage
refer to its manufacturerís instructions.
ON-VEHICLE SERVICE
Fan controller FAN CONTROL RELAY CONTINUITY

CHECK
M1141006200332
Fan control relay
1 2
AC103010 AD
3. Connect the fan controller connector, and

disconnect the condenser fan motor connector.
4. Ensure that the A/C switch is off, and start the AC308060
engine and run it at idle.

5. Measure the voltage between the fan
controller-side connector terminals.
Standard value: 1V or less 2 4
2
1 3
WARNING
4 3 1
Stay clear of the fan when the fan starts
running.
6. Turn the A/C switch to the "ON" position.
AC309492 AB
7. Measure the voltage between the fan
controller-side connector terminals while the fan is Battery Terminal No.to Continuity test
running. The voltage should repeat the values voltage be connected to results
below. tester
Standard value:
Not applied 4−2 Open circuit
8.2 ± 2.6 V
System voltage ± 2.6 V Connect 4−2 Less than 2 ohms
terminal
8. If the voltage does not repeatedly change as
No.1 and
indicated, replace the fan controller.
battery (−)
terminal.
Connect
terminal
No.3 and
battery (+)
terminal.
THERMOSTAT
RADIATOR FAN MOTOR CHECK 1. Remove the radiator fan motor connector.
M1141007100112
2. Check to see that the fan motor of the radiator
turns when applying battery power between the
2 1 connector terminals of the radiator fan motor. Also
check to see that there is no abnormal sound
coming from the radiator fan motor at this time.
3. If the radiator fan motor is defective, replace it.
Radiator
fan motor
AC103006AE
THERMOSTAT
M1141002400516

• Engine Coolant Draining and Refilling (Refer to P.14-17).
• Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner P.15-3<4G63>, P.15-4<4G69>).
• Battery Removal and Installation
<4G63>
1
13 ± 2 N·m
2 4
3 AC301429 AB

1. Engine coolant temperature gauge <<A>> >B<< 3. Radiator lower hose connection
unit connector 4. Water inlet fitting
2. Engine coolant temperature sensor >>A<< 5. Thermostat
connector
THERMOSTAT
<4G69>
11 ± 1 N·m
2
3
11 ± 1 N·m
5
2
4 13 ± 2 N·m
1
AC309324AB

<<A>> >>B<< 1. Radiator lower hose connection >>A<< THERMOSTAT INSTALLATION
2. Control wiring harness connection
3. Control wiring harness connection CAUTION
bracket Make absolutely sure that no oil adheres to the
4. Water inlet fitting rubber ring of the thermostat. Also do not fold or
>>A<< 5. Thermostat scratch the rubber ring during installation.

Jiggle valve
<<A>> RADIATOR LOWER HOSE
DISCONNECTION
Rubber ring
AC000279 AB
Install the thermostat so that the jiggle valve is facing

Mating marks
straight up. Be careful not to fold or scratch the
rubber ring.
AC200641AC
Make mating marks on the radiator hose and the

hose clamp. Disconnect the radiator hose.
THERMOSTAT
>>B<< RADIATOR LOWER HOSE CONNECTION 1. Immerse the thermostat in water, and heat the
water while stirring. Check the thermostat valve
Projection opening temperature.
Standard value:
Valve opening temperature: 82 ± 1.5°C
Water inlet fitting Mating marks
AC200642 AE
1. Insert each hose as far as the projection of the

Valve lift
water inlet fitting.
2. Align the mating marks on the radiator hose and
ACX00401AC
hose clamp, and then connect the radiator hose.
2. Check that the amount of valve lift is at the
INSPECTION standard value when the water is at the
M1141002500472
THERMOSTAT CHECK full-opening temperature.
NOTE: Measure the valve height when the
thermostat is fully closed, and use this
measurement to compare the valve height when
the thermostat is fully open.
Standard value:
Full-opening temperature: 95°C
Amount of valve lift: 8.5 mm or more
ACX00400AB
WATER PUMP
WATER PUMP
M1141002700551

• Engine Coolant Draining (Refer to P.14-17). • Timing Belt Installation (Refer to GROUP 11A, Timing Belt
• Timing Belt Removal (Refer to GROUP 11A, Timing Belt P.11A-39).
P.11A-39). • Engine Coolant Refilling (Refer to P.14-17).
N4
2
1
22 ± 4 N·m Bolt specifications

8 × 70 8 × 22
2
3N 8 × 14
23 ± 3 N·m 14 ± 1 N·m 8 × 25
8 × 22
Screw diameter × length mm
AC301467AB

1. Alternator brace >>A<< O-RING INSTALLATION
2. Water pump
3. Water pump gasket Water pump
>>A<< 4. O-ring
O-ring
Water inlet pipe

AC103005AD
Fit the O-ring to the groove in the water inlet pipe.

Then lubricate the O-ring and the inside of the water
pump with water, and then insert the pipe to the
water pump.
WATER PUMP

M1141002700540

• Engine Coolant Draining (Refer to P.14-17). • Timing Belt Installation (Refer to GROUP 11C, Timing Belt
• Timing Belt Removal (Refer to GROUP 11C, Timing Belt P.11C-36).
P.11C-36). • Engine Coolant Refilling (Refer to P.14-17).
N3
Bolt specifications
8 × 55 8 × 22
N2
1
1
8 × 14
8 × 55
Screw diameter × length mm 8 × 22
14 ± 1 N·m
AC309459 AB

1. Water pump >>A<< O-RING INSTALLATION
2. Water pump gasket
>>A<< 3. O-ring Water pump
O-ring
Water inlet pipe

AC103005AD
Fit the O-ring to the groove in the water inlet pipe.

Then lubricate the O-ring and the inside of the water
pump with water, and then insert the pipe to the
water pump.
WATER HOSE AND WATER PIPE

M1141003300556

• Engine Coolant Draining and Supplying (Refer to
P.14-17).
15, Air Cleaner P.15-3).
• Thermostat Removal and Installation (Refer to P.14-20).
N 9
8 N 9 13 ± 2 N·m
13 ± 2 N·m
2
23 ± 4 N·m
1 5
5
Ø3 mm
2 Ø3 mm
Sealant: Mitsubishi Genuine Part No. MD970839 or equivalent

AC301428 AB

<<A>> >>C<< 1. Radiator upper hose connection 6. Heater hose connection
>>B<< 2. Water outlet fitting 7. Transfer water return hose
3. Water hose connection <4WD>
4. Water hose 8. Water inlet pipe assembly
>>B<< 5. Thermostat case assembly >>A<< 9. O-ring

<<A>> RADIATOR UPPER HOSE >>B<< THERMOSTAT CASE ASSEMBLY/WATER
DISCONNECTION OUTLET FITTING INSTALLATION
1. Use a gasket scraper or wire brush to completely
eliminate all gasket material on the gasket
mounting surface.
2. Apply a bead of the specified sealant.
Specified Sealant: MITSUBISHI GENUINE
PART No.MD970389 or equivalent
3. With the sealant still wet (within 15 minutes after
Mating marks
the sealant is applied), install the thermostat case
or water outlet fitting. Do not apply the sealant in
AC200641AC
an area more than the required.
After making mating marks on the radiator hose and
hose clamp, disconnect the radiator hose. >>C<< RADIATOR UPPER HOSE CONNECTION
INSTALLATION SERVICE POINTS Projection

>>A<< O-RING INSTALLATION
CAUTION
Water pump or thermostat case
Water inlet pipe, Mating marks

water outlet fitting
O-ring or radiator AC200642 AC
1. Insert each hose as far as the projection of the

water outlet fitting.
Water inlet pipe 2. Align the mating marks on the radiator hose and
AC200644 AC
Do not allow engine oil or other grease to adhere
to the O-ring
Insert the O-ring to the water pipe, and coat the outer
portion of the O-ring with water or engine coolant.

M1141003300567

• Engine Coolant Draining and Supplying (Refer to
P.14-17).
15, Air Cleaner P.15-4).
• Thermostat Removal and Installation (Refer to P.14-20).
N 14
24 ± 4 N·m
11
13 ± 2 N·m
13
5
9
14 N
12 10
8
6
24 ± 4 N·m
7 5.0 ± 1.0 N·m

4
1 3 2
13 ± 2 N·m
11 ± 1 N·m
AC309470 AB
Removal steps REMOVAL SERVICE POINT

<<A>> >>C<< 1. Radiator upper hose connection <<A>> RADIATOR UPPER HOSE
2. Radiator hose clamp DISCONNECTION
3. Control wiring harness connection
bracket
>>B<< 4. Water outlet fitting
5. Heater hose connection
6. Water return hose
7. Engine coolant temperature gauge
unit
>>B<< 8. Thermostat case assembly
9. Heater hose connection Mating marks
10. Harness clamp
11. Water feed hose
AC200641AC
12. Transfer water return hose
connection After making mating marks on the radiator hose and
13. Water inlet pipe assembly hose clamp, disconnect the radiator hose.
>>A<< 14. O-ring
INSTALLATION SERVICE POINTS Thermostat case assembly

Water pump or thermostat case
O-ring
AC303724AE
Water inlet pipe 3. Apply sealant to the thread of the thermostat case
AC200644 AC
assembly bolts as shown.
CAUTION Specified Sealant: 3M Stud Locking 4170 or
Do not allow engine oil or other grease to adhere equivalent
to the O-ring 4. With the sealant still wet (within 15 minutes after
Insert the O-ring to the water pipe, and coat the outer the sealant is applied), install the thermostat case.
portion of the O-ring with water or engine coolant. Do not apply the sealant in an area more than the
required.
>>B<< THERMOSTAT CASE ASSEMBLY/WATER
OUTLET FITTING INSTALLATION >>C<< RADIATOR UPPER HOSE CONNECTION
1. Use a gasket scraper or wire brush to completely
eliminate all gasket material on the gasket
Projection
mounting surface.
Water outlet Thermostat case

fitting assembly

or radiator AC200642 AC
Ø3 mm 1. Insert each hose as far as the projection of the

AC305204 AF
water outlet fitting.
2. Apply a bead of the sealant to the cylinder head hose clamp, and then connect the radiator hose.
mating surface of the thermostat case as shown.
Specified Sealant: Mitsubishi Genuine Part INSPECTION
M1141003400274
No.MD970389 or equivalent
WATER PIPE AND HOSE CHECK
Check the water pipe and hose for cracks, damage
and clogs. Replace them if necessary.
RADIATOR
RADIATOR
M1141001500565

• Engine Coolant Draining (Refer to P.14-17). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.15-3<4G63>, P.15-4<4G69>).
P.15-3<4G63>, P.15-4<4G69>). • Engine Coolant Refilling and Level Check (Refer to
P.14-17).
<4G63>
12 ± 2 N·m
12 ± 2 N·m
3 9
9
4 10
5 7 12
6
11 N 2 1
11
8
14
16
13 15
AC309199AB
Radiator removal steps Radiator removal steps

1. Drain plug 12. Fan controller
2. O-ring 13. Cooling fan assembly
3. Radiator cap Radiator fan motor removal
4. Rubber hose steps
5. Reserve tank assembly 4. Rubber hose
6. Fan controller connector 6. Fan controller connector
<<A>> >>A<< 7. Radiator upper hose <<A>> >>A<< 7. Radiator upper hose
<<A>> >>A<< 8. Radiator lower hose 13. Cooling fan assembly
9. Upper insulator 14. Radiator fan
10. Radiator assembly 15. Radiator fan motor
11. Lower insulator 16. Shroud assembly
RADIATOR
<4G69>
12 ± 2 N·m
12 ± 2 N·m 11
3
11
12
4
7
5 16
6
2N 1
18
13
19 5.0 ± 1.0 N·m 10 15
5.0 ± 1.0 N·m
14
8
5.0 ± 1.0 N·m 20
22
21
9 17
5.0 ± 1.0 N·m AC309197 AB
Radiator removal steps Radiator fan motor removal

1. Drain plug steps (Continued)
2. O-ring 16. Fan controller
3. Radiator cap 17. Radiator fan assembly
4. Rubber hose 20. Radiator fan
5. Reserve tank assembly 21. Radiator fan motor
6. Fan controller connector 22. Shroud assembly
<<A>> >>A<< 7. Radiator upper hose
<<A>> >>A<< 8. Radiator lower hose REMOVAL SERVICE POINT
9. Radiator hose clamp <<A>> RADIATOR UPPER HOSE/RADIATOR
10. Transmission fluid cooler hose LOWER HOSE DISCONNECTION
connection
11. Upper insulator
12. Radiator assembly
13. Lower insulator
14. Transmission fluid cooler hose
15. Condenser fan assembly
16. Fan controller
17. Radiator fan assembly
18. Oil cooler hose Mating marks
19. Oil cooler tube assembly
Radiator fan motor removal
AC200641AC
steps
4. Rubber hose Make mating marks on the radiator hose and the
6. Fan controller connector hose clamp. Disconnect the radiator hose.
<<A>> >>A<< 7. Radiator upper hose
15. Condenser fan assembly
RADIATOR
INSTALLATION SERVICE POINT 1. Insert each hose as far as the projection of the
>>A<< RADIATOR LOWER HOSE/RADIATOR water inlet fitting.
UPPER HOSE CONNECTION 2. Align the mating marks on the radiator hose and
Projection

or radiator AC200642 AC
NOTES
15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATION . . . . . . . . 15-2 REMOVAL AND INSTALLATION <4G63> . 15-5

SERVICE SPECIFICATION . . . . . . . . 15-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-9
SEALANT. . . . . . . . . . . . . . . . . . . . . . 15-2 EXHAUST MANIFOLD . . . . . . . . . . . . 15-10

SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-2 REMOVAL AND INSTALLATION <4G69> . 15-11
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-12
AIR CLEANER . . . . . . . . . . . . . . . . . . 15-3
REMOVAL AND INSTALLATION <4G63> . 15-3 EXHAUST PIPE AND MAIN
REMOVAL AND INSTALLATION <4G69> . 15-4 MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-13
INTAKE MANIFOLD . . . . . . . . . . . . . 15-5
15-2 INTAKE AND EXHAUST
GENERAL INFORMATION
GENERAL INFORMATION
M1151000100468
The exhaust pipe is divided into three parts.
M1151000300484

Manifold distortion of the installation surface mm 0.15 or less 0.20
SEALANT
M1151000500217

Thermostat case MITSUBISHI GENUINE Part No.MD970389 or equivalent
Thermostat case assembly bolt 3M Stud Locking 4170 or equivalent
SPECIAL TOOL
M1151000600441

MD998770 Oxygen sensor wrench Removal and installation of
oxygen sensor
INTAKE AND EXHAUST 15-3
AIR CLEANER
AIR CLEANER
M1151002100550
CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
• Avoid any shock or load to these parts when removing and installing them.
• When installing, securely set the air cleaner cover and the resonator clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws
3.9 ± 1.0 N·m

6
11
12
1* 5
Clamp 3.9 ± 1.0 N·m
8.8 ± 1.0 N·m

N 9
3*
8.8 ± 1.0 N·m
8
4* 10*
2* 7
11 ± 1 N·m
8.8 ± 1.0 N·m
13 22 ± 4 N·m
AC203703 AB

1. Resonator 8. Air flow sensor assembly
2. Air cleaner element 9. Gasket
3. Air duct 10. Air cleaner cover
4. Air cleaner body 11. Resonator
5. Air flow sensor connector 12. Air intake hose
6. Breather hose connection 13. Air cleaner bracket
7. Air cleaner cover and air flow sensor
assembly
AIR CLEANER

M1151002100561
CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
• Avoid any shock or load to these parts when removing and installing them.
• When installing, securely set the air cleaner cover and the resonator clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws
9 3.0 ± 0.5 N·m

3.0 ± 0.5 N·m
4.0 ± 1.0 N·m

1.6 ± 0.6 N·m
1* 3.9 ± 1.0 N·m
5
6
Clamp 3.9 ± 1.0 N·m

8.8 ± 1.0 N·m 7
3
10
8*
2*
11 ± 1 N·m 4*
8.8 ± 1.0 N·m
11 22 ± 4 N·m
AC304211AC

1. Resonator 7. Air flow sensor assembly
2. Air cleaner element 8. Air cleaner cover
3. Air duct 9. Resonator
4. Air cleaner body 10. Air intake hose
5. Air flow sensor connector 11. Air cleaner bracket
6. Breather hose connection
INTAKE MANIFOLD
INTAKE MANIFOLD
M1151003000879

• Fuel Line Pressure Reduction [Refer to GROUP 13A, • Fuel Delivery Pipe and Fuel Injector assembly Installation
On-vehicle Service − Fuel Pump Connector (Refer to GROUP 13A, Injector P.13A-338).
Disconnection (How to Reduce Pressurized Fuel Lines) • Throttle Body Installation (Refer to GROUP 13A, Throttle
P.13A-328.] Body P.13A-340).
• Throttle Body Removal (Refer to GROUP 13A, Throttle • Accelerator Cable Adjustment (Refer to GROUP 17,
Body P.13A-340). On-vehicle Service − Accelerator Cable Check and
• Fuel Delivery Pipe and Fuel Injector assembly Removal Adjustment P.17-5).
(Refer to GROUP 13A, Injector P.13A-338). • Fuel Leak Check
2
1 5.0 ± 1.0 N·m
3
5.0 ± 1.0 N·m
4
5
11 ± 1 N·m
10 6
13 ± 1 N·m
7
N9
(Engine oil) AC301313 AB

1. Purge control solenoid valve 5. Earth cable connection
connector 6. Emission control equipment hose
2. EGR control solenoid valve 7. PCV hose
connector 8. Oil level gauge and guide
3. Detonation sensor connector 9. O-ring
4. Accelerator cable connection 10. Detonation sensor connector clamp
INTAKE MANIFOLD
11 ± 1 N·m
11
9.0 ± 1.0 N·m

14
20 ± 2 N·m 36 ± 6 N·m
20 ± 2 N·m
16
36 ± 6 N·m
12
36 ± 6 N·m 13 N
17 N
20 ± 2 N·m
15
31 ± 3 N·m
AC301314 AB

11. Vacuum hose and pipe assembly 15. Intake manifold stay
12. EGR valve 16. Intake manifold assembly
13. EGR valve gasket 17. Intake manifold gasket
14. Brake booster vacuum hose
connection
INTAKE MANIFOLD

M1151003000880

• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Delivery Pipe and Injector Assembly Installation (Refer to
On-vehicle Service − Fuel Pump Connector GROUP 13B, Injector P.13B-437).
Disconnection (How to Reduce Pressurized Fuel Lines) • Throttle Body Installation (Refer to GROUP 13B, Throttle
P.13B-428]. Body P.13B-438).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Air Cleaner Cover and Air Intake Hose Installation (Refer
Service − Engine Coolant Replacement P.14-17). to P.15-4).
• Air Cleaner Cover and Air Intake Hose Removal (Refer to • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
P.15-4). Service − Engine Coolant Replacement P.14-17).
• Throttle Body Removal (Refer to GROUP 13B, Throttle
Body P.13B-438).
• Delivery Pipe and Injector Assembly Removal (Refer to
GROUP 13B, Injector P.13B-437).
<R.H. drive vehicle> <L.H. drive vehicle>

4
4 6 3
5
20 17
6 21
3
11 ± 1 N·m 5 19
7 24 ± 3 N·m
8 1
5.0 ± 1.0 N·m 24 ± 4 N·m
27
18
2N
24 22 N
29 12 9
11
28 N
10
13
11 ± 1 N·m
23 24 ± 3 N·m
14 20 ± 2 N·m
26
25
13 ± 1 N·m
15
N 16
31 ± 3 N·m
(Engine oil)
AC309416AB

1. EGR valve 6. Brake booster vacuum pipe
>>C<< 2. EGR valve gasket 7. Brake booster vacuum hose
3. Capacitor connector 8. Evaporative emission vacuum hose
4. Brake booster vacuum hose connection
5. Capacitor
INTAKE MANIFOLD
Removal steps (Continued) INSTALLATION SERVICE POINTS

9. Manifold absolute pressure sensor
>>A<< THERMOSTAT CASE ASSEMBLY
connector
10. Detonation sensor connector
INSTALLATION
11. Evaporative emission purge solenoid 1. Use a gasket scraper or wire brush to completely
valve connector eliminate all gasket material on the gasket
12. Harness clamp mounting surface.
13. Detonation sensor connector clamp
14. Harness clamp Thermostat case assembly
15. Oil level gauge and guide
16. O-ring
17. Harness clamp
<<A>> >>B<< 18. Radiator lower hose connection
19. Heater water hose connection
20. Engine coolant temperature gauge
unit connector
Ø3 mm
>>A<< 21. Thermostat housing assembly
22. O-ring AC305212 AD
23. Detonation sensor harness clamp
24. Manifold absolute pressure sensor 2. Apply a bead of the sealant to the cylinder head
25. Harness clamp mating surface of the thermostat case assembly
26. Intake manifold stay as shown.
27. Intake manifold
Specified Sealant: MITSUBISHI GENUINE
28. Intake manifold gasket
29. Evaporative emission purge solenoid PART No.MD970389 or equivalent
valve, evaporative emission vacuum Thermostat case assembly
hose and pipe assembly

<<A>> RADIATOR LOWER HOSE
DISCONNECTION
AC303724AE
3. Apply sealant to the thread of the thermostat case

assembly bolts as shown.
Mating marks Specified Sealant: 3M Stud Locking 4170 or
equivalent
AC200641AC 4. With the sealant still wet (within 15 minutes after
Make mating marks on the radiator hose and the the sealant is applied), install the thermostat case
hose clamp. Disconnect the radiator hose. assembly. Do not apply the sealant in an area
more than the required.
INTAKE MANIFOLD
>>B<< RADIATOR LOWER HOSE CONNECTION >>C<< EGR VALVE GASKET INSTALLATION
Projection
Notched
part
Water inlet fitting Mating marks Gasket

Notched
AC200642 AE part AC302358AE
1. Insert each hose as far as the projection of the Install the EGR valve gasket as shown in the
water inlet fitting. illustration.
INSPECTION
hose clamp, and then connect the radiator hose. M1151003100553
Check the following points; replace the part if a
problem is found.
Intake Manifold Check
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet
port, or clogging of the exhaust gas recirculation
passages.
3. Using a straight edge and feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1151003300717
8N
7 29 ± 3 N·m
14 ± 1 N·m 1
6 44 ± 5 N·m
29 ± 3 N·m
49 ± 5 N·m 14 ± 1 N·m
35 ± 6 N·m
5 2
44 ± 5 N·m
4N
49 ± 10 N·m
3 AC301312 AB
Removal steps Use special tool oxygen sensor wrench (MD998770)

<<A>> >>A<< 1. Oxygen sensor to remove the oxygen sensor.
2. Exhaust manifold cover
3. Front exhaust pipe connection INSTALLATION SERVICE POINT
4. Exhaust pipe gasket
>>A<< OXYGEN SENSOR INSTALLATION
5. Exhaust manifold bracket
6. Engine hanger
7. Exhaust manifold
8. Exhaust manifold gasket
MD998770
<<A>> OXYGEN SENSOR REMOVAL
Oxygen sensor
MD998770
AC212566AB
Use special tool oxygen sensor wrench (MD998770)

to install the oxygen sensor.
Oxygen sensor
AC212566AB
EXHAUST MANIFOLD

M1151003300728
14 ± 1 N·m
1
1
44 ± 5 N·m
14 ± 1 N·m
44 ± 5 N·m
N 5
4
49 ± 5 N·m
3
35 ± 6 N·m
44 ± 5 N·m AC309280AC
Removal steps Use special tool oxygen sensor wrench (MD998770)

<<A>> >>A<< 1. Oxygen sensor to remove the oxygen sensor.
2. Exhaust manifold cover
• Front exhaust pipe (Refer to P.15-13.) INSTALLATION SERVICE POINT
3. Exhaust manifold bracket B >>A<< OXYGEN SENSOR INSTALLATION
4. Exhaust manifold
5. Exhaust manifold gasket
6. Exhaust manifold bracket A
MD998770
Oxygen sensor
MD998770
AC212566AB

Oxygen sensor
AC212566AB
EXHAUST MANIFOLD
INSPECTION 2. Using a straight edge and a feeler gauge, check

M1151003400480 for distortion of the cylinder head installation
Check the following points; replace the part if a surface.
problem is found.
Exhaust Manifold Check Limit: 0.20 mm
1. Check for damage or cracking of any part.
EXHAUST PIPE AND MAIN MUFFLER

M1151008700367
<4G63>
13 ± 2 N·m
6
13 ± 2 N·m
7
1
13 ± 2 N·m 9 6
13 ± 2 N·m
11 N 12
4 N 5
2 45 ± 5 N·m
8N 59 ± 10 N·m
10 N
49 ± 10 N·m
49 ± 10 N·m
AC301054 AC
<4G69>
13 ± 2 N·m
6
13 ± 2 N·m
7
13 ± 2 N·m 1
13 ± 2 N·m 9 6
12 N 10 5N
N 11 4
2 45 ± 5 N·m
N 8 59 ± 10 N·m
3 3 49 ± 10 N·m
49 ± 10 N·m
AC309215 AB
44 ± 5 N·m 44 ± 5 N·m
Exhaust main muffler removal Centre exhaust pipe removal
1. Exhaust main muffler 8. Exhaust pipe gasket
5. Exhaust pipe gasket 9. Hanger
6. Hanger Front exhaust pipe removal
7. Exhaust pipe damper steps
Centre exhaust pipe removal • Centre under cover (front) (Refer to
steps GROUP 51, Under Cover P.51-19).
2. Centre exhaust pipe <<A>> >>A<< 3. Oxygen sensor <4G69>
5. Exhaust pipe gasket 4. Front exhaust pipe
Front exhaust pipe removal Use special tool oxygen sensor wrench (MD998770)
steps (Continued) to remove the oxygen sensor.
12. Hanger INSTALLATION SERVICE POINT
REMOVAL SERVICE POINT >>A<< OXYGEN SENSOR INSTALLATION
MD998770
MD998770
Oxygen sensor
Oxygen sensor AC212566AB
AC212566AB
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . . 16-3 REMOVAL AND INSTALLATION <4G69> 16-15

DISASSEMBLY AND REASSEMBLY . . 16-16
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-18
GENERAL INFORMATION . . . . . . 16-3
SERVICE SPECIFICATIONS. . . . . 16-4

STARTING SYSTEM . . . . . . . . 16-20
SPECIAL TOOLS. . . . . . . . . . . . . . 16-5

ON-VEHICLE SERVICE. . . . . . . . . 16-6 SERVICE SPECIFICATIONS . . . . . 16-21

ALTERNATOR OUTPUT LINE VOLTAGE
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-6 STARTER MOTOR ASSEMBLY . . 16-22
OUTPUT CURRENT TEST . . . . . . . . . . 16-7 REMOVAL AND INSTALLATION <4G63> 16-22
REGULATED VOLTAGE TEST . . . . . . . 16-9 REMOVAL AND INSTALLATION <4G69> 16-23
WAVEFORM CHECK USING AN STARTER MOTOR ASSEMBLY
OSCILLOSCOPE. . . . . . . . . . . . . . . . . . 16-10 INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-24
DISASSEMBLY AND REASSEMBLY . . 16-26
ALTERNATOR ASSEMBLY . . . . . 16-13 INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-27
REMOVAL AND INSTALLATION <4G63> 16-13 Continued on next page
16-2
IGNITION SYSTEM . . . . . . . . . . 16-30 DETONATION SENSOR CHECK . . . . . 16-36

IGNITION SECONDARY VOLTAGE
WAVEFORM CHECK USING AN OSCILLOSCOPE
GENERAL INFORMATION . . . . . . 16-30 <4G63>. . . . . . . . . . . . . . . . . . . . . . . . . . 16-36
SERVICE SPECIFICATIONS. . . . . 16-32 IGNITION COIL. . . . . . . . . . . . . . . . 16-40

REMOVAL AND INSTALLATION <4G63> 16-40
SPECIAL TOOL . . . . . . . . . . . . . . . 16-32 REMOVAL AND INSTALLATION <4G69> 16-41
ON-VEHICLE SERVICE. . . . . . . . . 16-33 CAMSHAFT POSITION SENSOR . 16-41

IGNITION COIL (WITH BUILT-IN POWER REMOVAL AND INSTALLATION. . . . . . 16-41
TRANSISTOR) CHECK <4G63> . . . . . . 16-33
IGNITION COIL (WITH BUILT-IN POWER CRANKSHAFT POSITION SENSOR 16-42
TRANSISTOR) CHECK <4G69> . . . . . . 16-33 REMOVAL AND INSTALLATION <4G63> 16-42
RESISTIVE CORD CHECK <4G63> . . . 16-34 REMOVAL AND INSTALLATION <4G69> 16-43
SPARK PLUG CHECK AND CLEANING
<4G63> . . . . . . . . . . . . . . . . . . . . . . . . . 16-35
SPARK PLUG CHECK AND CLEANING
DETONATION SENSOR . . . . . . . . 16-44
<4G69> . . . . . . . . . . . . . . . . . . . . . . . . . 16-35 REMOVAL AND INSTALLATION <4G63> 16-44
CAMSHAFT POSITION SENSOR CHECK 16-36 REMOVAL AND INSTALLATION <4G69> 16-45
CRANK ANGLE SENSOR CHECK . . . . 16-36
ENGINE ELECTRICAL 16-3
CHARGING SYSTEM
CHARGING SYSTEM
GENERAL INFORMATION
M1161000100373
The charging system uses the alternator output to The average output voltage fluctuates slightly with
keep the battery charged at a constant level under the alternator load condition.
various electrical loads. When the ignition switch is turned on, current flows in
OPERATION the field coil and initial excitation of the field coil
occurs.
Voltage When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field
Approximately current increases and it falls as the field current
14.4 V
decreases. When the battery voltage (alternator "S"
terminal voltage) reaches a regulated voltage of
approximately 14.4 V, the field current is cut off.
Time When the battery voltage drops below the regulated
AKX00183 AC
voltage, the voltage regulator regulates the output
Rotation of the excited field coil generates AC voltage to a constant level by controlling the field
voltage in the stator. current.
This alternating current is rectified through diodes to In addition, when the field current is constant, the
DC voltage having a waveform shown in the alternator output voltage rises as the engine speed
illustration. increases.
SYSTEM DIAGRAM
<4G63>
Alternator
Stator coil
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
G
Field coil S
L
+
FR Ignition switch
Battery
Voltage regulator Charge warning light
AK100054 AG
16-4 ENGINE ELECTRICAL
CHARGING SYSTEM
<4G69>
Alternator
Stator
coil
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
Field coil
G
S
+
L
FR Ignition
switch Battery
Charging
Voltage regulator warning
light –
AK301529 AC
ALTERNATOR SPECIFICATIONS
Item 4G63 4G69
Type Battery voltage sensing Battery voltage sensing
Rated output V/A 12/100 12/110
Voltage regulator Electronic built-in type Electronic built-in type
M1161000300377

Alternator output line voltage drop (at 30 A) V − maximum 0.3
Regulated voltage ambient −20°C 14.2 − 15.4 −
temperature at voltage regulator V 20°C 13.9 − 14.9 −
60°C 13.4 − 14.6 −
80°C 13.1 − 14.5 −
Output current − 70 % of normal output current
CHARGING SYSTEM
SPECIAL TOOLS
M1161000600301

MB991502 MUT-II sub assembly Checking the idle speed
B991502
MB991955 MUT-III sub assembly Checking the idle speed

A A: MB991824 A: Vehicle
B: MB991827 communication
C: MB991910 interface (V.C.I.)
D: MB991911 B: MUT-III USB cable
MB991824 E: MB991825 C: MUT-III main harness
B F: MB991826 A (Vehicles with CAN
communication
system)
D: MUT-III main harness
MB991827 B (Vehicles without
CAN communication
C
system)
DO NOT USED E: MUT-III measurement
adapter
F: MUT-III trigger
MB991910
harness
D
MB991911
MB991825
MB991826
MB991955
MB991519 Alternator test harness Checking the alternator

("S" terminal voltage)
CHARGING SYSTEM
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

M1161000900380
Ammeter (clamp-type)
Alternator
Voltmeter (digital-type)
Battery
"B" terninal
AK203361AD
This test determines whether the wiring from the 5. Connect a digital-type voltmeter between the
alternator "B" terminal to the battery (+) terminal alternator "B" terminal and the battery (+)
(including the fusible line) is in a good condition or terminal. [Connect the (+) lead of the voltmeter to
not. the "B" terminal and the connect the (-) lead of the
1. Always be sure to check the following before the voltmeter to the battery (+) cable].
test. 6. Reconnect the negative battery cable.
• Alternator installation 7. Connect the MUT-II/III
• Drive belt tension
8. Leave the hood open.
(Refer to P.11A-8, GROUP 11A − On-Vehicle
Service.) <4G63> 9. Start the engine.
(Refer to P.11C-8, GROUP 11C − On-Vehicle 10.With the engine running at 2,500 r/min, turn the
Service.) <4G69> headlamps and other lamps on and off to adjust
• Fusible link the alternator load so that the value displayed on
• Abnormal noise from the alternator while the the ammeter is slightly above 30 A.
engine is running Adjust the engine speed by gradually decreasing
2. Turn the ignition switch to the "LOCK" (OFF) it until the value displayed on the ammeter is 30
position. A. Take a reading of the value displayed on the
3. Disconnect the negative battery cable. voltmeter at this time.
4. Connect a clamp-type DC test ammeter with a Limit: maximum 0.3 V
range of 0 − 150 A to the alternator "B" terminal NOTE: When the alternator output is high and the
output wire. value displayed on the ammeter does not
NOTE: The way of disconnecting the alternator decrease until 30 A, set the value to 40 A. Read
output wire and of connecting the ammeter is the value displayed on the voltmeter at this time.
possibly not found the problem that the output When the value range is 40 A, the limit is
current is dropping due to the insufficient maximum 0.4 V.
connection between terminal "B" and the output
wire.
CHARGING SYSTEM
11.If the value displayed on the voltmeter is above 12.After the test, run the engine at idle.
the limit value, there is probably a malfunction in 13.Turn off all lamps.
the alternator output wire, so check the wiring 14.Turn the ignition switch to the "LOCK" (OFF)
between the alternator "B" terminal and the position.
battery (+) terminal (including fusible link).
15.Remove the MUT-II/III.
If a terminal is not sufficiently tight or if the 16.Disconnect the negative battery cable.
harness has become discolored due to
overheating, repair and then test again. 17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.
OUTPUT CURRENT TEST

M1161001000409
Load
Ammeter
Voltmeter (clamp-type)
– +
Ignition switch Charging indicator
B
FR
L
S
G
Alternator
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
Battery
AK304240 AB
This test determines whether the alternator output (Refer to P.11A-8, GROUP 11A − On-Vehicle
current is normal. Service.) <4G63>
1. Before the test, always be sure to check the (Refer to P.11C-8, GROUP 11C − On-Vehicle
following. Service.) <4G69>
• Alternator installation • Fusible link
• Battery (Refer to P.54A-6, GROUP 54A − Battery • Abnormal noise from the alternator while the
− On-Vehicle Service.) engine is running.
NOTE: The battery should be slightly discharged. 2. Turn the ignition switch to the "LOCK" (OFF)
The load needed by a fully-charged battery is position.
insufficient for an accurate test. 3. Disconnect the negative battery cable.
• Drive belt tension
CHARGING SYSTEM
CAUTION Limit: 70 % of normal current output

Never use clips but tighten bolts and nuts to NOTE: .
connect the line. Otherwise loose connections • For the nominal current output, refer to the
(e.g. using clips) will lead to a serious accident Alternator Specifications.
because of high current. • Because the current from the battery will soon
4. Connect a clamp-type DC test ammeter with a drop after the engine is started, the above step
range of 0 − 150 A to the alternator "B" terminal should be carried out as quickly as possible in
output wire. order to obtain the maximum current output
value.
NOTE: The way of disconnecting the alternator
• The current output value will depend on the
output wire and of connecting the ammeter is
electrical load and the temperature of the
possibly not found the problem that the output
alternator body.
current is dropping due to the insufficient
• If the electrical load is small while testing, the
specified level of current may not be output
wire.
even though the alternator is normal. In such
5. Connect a voltmeter with a range of 0 − 20 V cases, increase the electrical load by leaving
between the alternator "B" terminal and the earth the headlamps turned on for some time to
[Connect the (+) lead of the voltmeter to the "B" discharge the battery or by using the lighting
terminal, and then connect the (-) lead of the system in another vehicle, and then test again.
voltmeter to the earth]. • The specified level of current also may not be
6. Connect the negative battery cable. output if the temperature of the alternator body
7. Connect the MUT-II/III or the ambient temperature is too high. In such
8. Leave the hood open. cases, cool the alternator and then test again.
9. Check that the reading on the voltmeter is equal 12.The reading on the ammeter should be above the
to the battery voltage. limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
NOTE: If the voltage is 0 V, the cause is probably
the alternator from the engine and check the
an open circuit in the wire or fusible link between
alternator.
the alternator "B" terminal and the battery (+)
terminal. 13.Run the engine at idle after the test.
10.Turn the light switch on to turn on headlamps and 14.Turn the ignition switch to the "LOCK" (OFF)
then start the engine. position.
11.Immediately after setting the headlamps to high 15.Remove the MUT-II/III.
beam and turning the heater blower switch to the 16.Disconnect the negative battery cable.
high revolution position, increase the engine 17.Disconnect the ammeter and voltmeter.
speed to 2,500 r/min and read the maximum 18.Connect the negative battery cable.
current output value displayed on the ammeter.
CHARGING SYSTEM
REGULATED VOLTAGE TEST

M1161001100398
Load
Ammeter (clamp-type)
Ignition switch Charging indicator
MB991519 Black
B
FR
L Alternator
S
G
Blue
Red Yellow
Battery
Engine-ECU
<M/T> or
Engine-A/T-
ECU <A/T>
Voltmeter (digital-type)
AK304241AB
This test determines whether the voltage regulator 4. Use the special tool Alternator test harness
correctly controlling the alternator output voltage. (MB991519) to connect a digital voltmeter
1. Always be sure to check the following before the between the alternator "S" terminal and earth
test. [Connect the (+) lead of the voltmeter to the "S"
• Alternator installation terminal, and then connect the (-) lead of the
• Check that the battery installed in the vehicle is voltmeter to a secure earth or to the battery (-)
fully charged. terminal].
(Refer to P.54A-4, GROUP 54A − Battery − 5. Connect a clamp-type DC test ammeter with a
On-Vehicle Service.) range of 0 − 150 A to the alternator "B" terminal
• Drive belt tension output wire.
(Refer to P.11A-8, GROUP 11A − On-Vehicle NOTE: The way of disconnecting the alternator
Service.)<4G63>
output wire and of connecting the ammeter is
(Refer to P.11C-8, GROUP 11C − On-Vehicle possibly not found the problem that the output
Service.)<4G69> current is dropping due to the insufficient
• Fusible link
• Abnormal noise from the alternator while the wire.
engine is running
6. Reconnect the negative battery cable.
position. 7. Connect the MUT-II/III
3. Disconnect the negative battery cable. 8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "S" terminal and the battery (+)
terminal.
CHARGING SYSTEM
9. Turn all lamps and accessories off. 14.After the test, lower the engine speed to the idle
10.Start the engine. speed.
11.Increase the engine speed to 2,500 r/min. 15.Turn the ignition switch to the "LOCK" (OFF)
12.Read the value displayed on the voltmeter when position.
the alternator output current alternator becomes 16.Remove the MUT-II/III.
10 A or less. 17.Disconnect the negative battery cable.
13.If the voltage reading conforms to the value in the 18.Disconnect the ammeter and voltmeter.
voltage regulation, then the voltage regulator is 19.Connect the alternator output wire to the
operating normally. alternator "B" terminal.
If the voltage is not within the standard value, 20.Remove the special tool, and return the connector
there is a malfunction of the voltage regulator or of to the original condition.
the alternator. 21.Connect the negative battery cable.
Voltage Regulation Table
Standard value:
Inspection terminal Voltage regulator ambient Voltage V
temperature °C
Terminal "S" −20 14.2 − 15.4
20 13.9 − 14.9
60 13.4 − 14.6
80 13.1 − 14.5
WAVEFORM CHECK USING AN OSCILLOSCOPE

M1161001200179
MEASUREMENT METHOD Connect the oscilloscope special patterns pick-up to

the alternator "B" terminal.
Alternator
CH1
"B" terminal AK100002 AC

CHARGING SYSTEM
STANDARD WAVEFORM
Observation Conditions
Function Special pattern
Pattern height Variable
Variable knob Adjust while viewing the waveform.
Pattern selector Raster
Engine speed Curb idle speed
(V)
0.4
0.2
Voltage at
alternator 0
"B" terminal
–0.2
–0.4
Time
AKX00189AG
NOTE: when the voltage waveform reaches an excessively

high value (approximately 2 V or higher at idle), it
often indicates an open circuit due to a brown fuse
between alternator "B" terminal and battery, but not a
defective alternator.
AKX00190
The voltage waveform of the alternator "B" terminal

can undulate as shown in the illustration. This
waveform is produced when the regulator operates
according to fluctuations in the alternator load
(current), and is normal for the alternator. In addition,
CHARGING SYSTEM
EXAMPLE OF ABNORMAL WAVEFORMS

NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveform Problem cause

Example 1 Open diode
AKX00191
Example 2 Short in diode
AKX00192
Example 3 Broken wire in

stator coil
AKX00193
Example 4 Short in stator

coil
AKX00194
CHARGING SYSTEM
ALTERNATOR ASSEMBLY
M1161001400667

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Installation (Refer to GROUP 11A, Crankshaft
P.51-19). Pulley P.11A-16).
• Drive Belt Removal (Refer to GROUP 11A, Crankshaft • Drive Belt Tension Adjustment (Refer to GROUP 11A,
Pulley P.11A-16). On-vehicle Service P.11A-8).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
1 7
11 ± 1 N·m
13 ± 1 N·m
44 ± 10 N·m
12 ± 2 N·m 9
N2
4 22 ± 4 N·m
(Engine oil) 23 ± 3 N·m
6
8.8 ± 1.0 N·m
AC301643 AB

1. Oil level gauge and guide <<A>> 5. Harness connector
2. O-ring 6. Water pump pulley
3. Detonation sensor harness 7. Alternator connector
connector and clamp 8. Alternator brace
4. Power steering oil pressure hose <> 9. Alternator assembly
clamp
CHARGING SYSTEM
REMOVAL SERVICE POINT Move the lock lever of the ABS-ECU connector as
<<A>> HARNESS CONNECTOR shown in the illustration, and then disconnect the
DISCONNECTION harness connector.
Lock lever <> ALTERNATOR ASSEMBLY REMOVAL

Remove the alternator assembly from above the
vehicle.
AC200022AE
CHARGING SYSTEM

M1161001400678

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Installation (Refer to GROUP 11C, Crankshaft
P.51-19). Pulley P.11C-17).
• Drive Belt Removal (Refer to GROUP 11C, Crankshaft • Drive Belt Tension Check (Refer to GROUP 11C,
Pulley P.11C-17). On-vehicle Service P.11C-8).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
1
11 ± 1 N·m
5
14 ± 3 N·m
4
3
49 ± 9 N·m
49 ± 9 N·m
8
11 ± 1 N·m
49 ± 9 N·m
7 6
44 ± 10 N·m AC309557AB

1. A/C compressor assembly • Timing belt lower cover (Refer to
connector GROUP 11C, Timing Belt
2. A/C compressor assembly P.11C-36).
connector clamp 8. Alternator mounting bracket
3. Alternator connector
4. Alternator terminal REMOVAL SERVICE POINT
5. Connector bracket <<A>> ALTERNATOR ASSEMBLY REMOVAL
6. Harness bracket
Remove the alternator assembly from above the
<<A>> 7. Alternator assembly
vehicle.
CHARGING SYSTEM
DISASSEMBLY AND REASSEMBLY

M1161001600199
1
4
3
5
7 6
12
10
9
8
14
13
11
AK202845 AB

<<A>> 1. Front bracket assembly <<C>> 8. Stator
<> 2. Alternator pulley 9. Plate
>>B<< 3. Rotor <<C>> >>A<< 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Rubber packing
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
CHARGING SYSTEM
DISASSEMBLY SERVICE POINTS CAUTION

<<A>>FRONT BRACKET ASSEMBLY REMOVAL • Use a 180 − 250 W soldering iron, and finish
unsoldering within four seconds. Diodes will
be damaged by heat if unsoldering time is too
long.
• Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the
regulator assembly, undo the soldered points on
AK202718 the rectifier assembly.
CAUTION REASSEMBLY SERVICE POINTS

Do not insert the screwdriver blades too deep.
Doing so could damage the stator coil. >>A<<REGULATOR ASSEMBLY INSTALLATION
Insert the blades of screwdrivers between the front
bracket assembly and stator core, and pry and
separate them with the screwdrivers.
Wire
<>ALTERNATOR PULLEY REMOVAL
AK202779 AB
Rear bracket
Brush
AK202714
CAUTION Wire
Perform operation carefully not to damage the
rotor.
Clamp the rotor in a vise with the pulley facing up to
AK202830 AB
remove the pulley.
After installing the regulator assembly, insert a piece
<<C>>STATOR / REGULATOR ASSEMBLY of wire through the hole in the rear bracket while
REMOVAL pressing the brush to keep the brush against
movement.
Rectifier Solder
assembly NOTE: Holding the brush with the wire facilities
installation of the rotor.
Solder
AK202778 AB
CHARGING SYSTEM
>>B<<ROTOR INSTALLATION 3. If continuity is present, replace the rotor.
STATOR
Wire
AK202779 AB
Remove the brush holding wire after the rotor has

been installed. AK202716
INSPECTION 1. Check the continuity between coil leads.

M1161001700129
If there is no continuity, replace the stator.
ROTOR
AK202717
AK202735
2. Check the continuity between coil and core.

1. Measure the resistance between the two slip rings
of the rotor coil to check the continuity between If there is no continuity, replace the stator.
them.
RECTIFIER ASSEBMLY
Replace the rotor if the resistance is not within the
standard value range.
Standard value: 3 − 5 Ω
2. Check the continuity between the slip rings and
core.
AK202803
1. Check the condition of the (+) heat sink by

checking continuity between the (+) heat sink and
each of the stator coil lead connecting terminals.
AK202736 If continuity is present for both terminals, the
diode is shorted. Replace the rectifier assembly.
CHARGING SYSTEM
BRUSH
Protrusion
length
AK202802
2. Check the condition of the (−) heat sink by

AK202808 AB
checking continuity between the (−) heat sink and
each of the stator coil lead connecting terminals. 1. Measure the length of the protrusion of the brush.
If continuity is present in both directions, the diode Replace the brush if the protrusion length is
is shorted. Replace the rectifier assembly. shorter than the limit.
Limit: 2 mm minimum
2. Unsolder the lead of the brush. The brush will
come out, becoming ready for removal.
Solder
AK202804
3. Check the condition of the diode trio by testing

continuity of each of the three diodes using a
circuit tester connected to both sides of the diode. AK202834 AB
Connect in a polarity and then reverse the polarity 3. Install a new brush by pushing it into the holder as
for each test. shown in the drawing and soldering the lead.
If continuity exists or no continuity exists for both
polarities, the diode is defective. Replace the
rectifier assembly if any of the diodes is defective.
STARTING SYSTEM
STARTING SYSTEM
GENERAL INFORMATION
M1162000100268
If the ignition switch is turned to the "START" When the ignition switch is returned to the "ON"
position, current flows in the pull-in and holding coils position after starting the engine, the starter clutch is
provided inside magnetic switch, attracting the disengaged from the ring gear.
plunger, When the plunger is attracted, the lever An overrunning clutch is provided between the pinion
connected to the plunger is actuated to engage the and the armature shaft, to prevent damage to the
starter clutch. starter.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
SYSTEM DIAGRAM
Holding coil Plunger
Pull-in coil
Lever
B Overrunning clutch
Ignition switch M
Pinion gear
S
+ Armature
Battery
Brush
Yoke
AK202970 AB
STARTING SYSTEM
STARTER MOTOR SPECIFICATIONS

Item Specification
Type Reduction drive with planetary gear
Rated output kW/V 1.4/12
Number of pinion teeth 8
M1162000300079

Pinion gap mm 0.5 − 2.0 −
Commutator run-out mm 0.05 0.1
Commutator diameter mm 29.4 28.8
Undercut depth mm 0.5 0.2
STARTING SYSTEM
STARTER MOTOR ASSEMBLY

M1162001000725

• Resonator and Air Intake Duct Removal and Installation
(Refer to GROUP 15, Air Cleaner P.15-3).
• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-19).
18 ± 3 N·m
4 9.0 ± 2.0 N·m
3
30 ± 3 N·m
1
49 ± 9 N·m
AC301550 AB

1. Starter cover <<A>> STARTER ASSEMBLY REMOVAL
2. Starter connector Remove the starter assembly from above the
3. Clutch release cylinder connecting
vehicle.
bolts
4. Clutch hose clamp
<<A>> 5. Starter assembly
6. Starter cover bracket
STARTING SYSTEM

M1162001000639

• Air Duct Removal and Installation (Refer to GROUP 15,
Air Cleaner P.15-4).
• Exhaust Manifold Heat Protector Removal and Installation
(Refer to GROUP 15, Exhaust Manifold P.15-11).
30 ± 3 N·m
2
3
12 ± 2 N·m 1
6 49 ± 9 N·m 9.0 ± 2.0 N·m
AC305106 AC

1. Starter cover <<A>> STARTER ASSEMBLY REMOVAL
2. Harness clamp Remove the starter assembly from above the
3. Starter connector
vehicle.
4. Starter terminal
<<A>> 5. Starter assembly
6. Starter cover bracket
STARTING SYSTEM
STARTER MOTOR ASSEMBLY INSPECTION

M1162001100227
PINION GAP ADJUSTMENT
MAGNETIC SWITCH PULL-IN TEST
Switch
S
M S
B
battery
M
B
Battery
Starter Wire
motor
Starter Wire
motor
AKX01238 AF
AKX01242 AE
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch. 1. Disconnect the field coil wire from the M-terminal
2. Connect a 12-volt battery between the S-terminal of the magnetic switch.
and M-terminal. CAUTION
CAUTION This test must be performed quickly (in less than
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal
3. Set the switch to "ON", and the pinion will move and M-terminal.
out. 3. If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.
Stopper MAGNETIC SWITCH HOLD-IN TEST
S
M
Pinion B
Battery
Pinion gap
AKX00198 AC
Starter Wire
4. Check the pinion-to-stopper clearance (pinion motor
gap) with a feeler gauge.
AKX01244AE
Standard value: 0.5 − 2.0 mm
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal
and body.
3. Manually pull out the pinion as far as the pinion
stopper position.
AKX00199
4. If the pinion remains out, everything is in order. If
5. If the pinion gap is out of specification, adjust by the pinion moves in, the hold-in circuit is open.
adding or removing gasket(s) between the Replace the magnetic switch.
magnetic switch and front bracket.
STARTING SYSTEM
FREE RUNNING TEST Current: maximum 95 Amps
Ammeter
A MAGNETIC SWITCH RETURN TEST
S
Carbon-pile
rheostat
M B
S
Battery
Starter V M
motor Voltmeter B
Battery
AKX01246 AE Starter Wire

motor
1. Place the starter motor in a vise equipped with
soft jaws and connect a fully-charged 12-volt AKX01248 AE
battery to the starter motor as follows: 1. Disconnect the field coil wire from the M-terminal
2. Connect a test ammeter (100-ampere scale) and of the magnetic switch.
carbon pile rheostat in series between the positive
CAUTION
battery terminal and starter motor terminal.
This test must be performed quickly (in less than
3. Connect a voltmeter (15-volt scale) across the 10 seconds) to prevent the coil from burning.
starter motor.
2. Connect a 12-volt battery between the M-terminal
4. Rotate the rheostat to full-resistance position.
and body.
5. Connect the battery cable from the negative
battery terminal to the starter motor body. WARNING
6. Adjust the rheostat until the battery positive
Be careful not to get your fingers caught
voltage shown on the voltmeter is 11 V. when pulling out the pinion.
7. Confirm that the maximum amperage is within the 3. Pull the pinion out and release. If the pinion
specifications and that the starter motor turns quickly returns to its original position, everything is
smoothly and freely. operating properly. If it doesn't, replace the
magnetic switch.
STARTING SYSTEM

M1162001200224
12
15 13
10
11
14
2 20
5.8 ± 1.6 N·m 19

18 5.8 ± 1.6 N·m
1 17 3.4 ± 1.0 N·m
4
16
3
21
7 5
9
AK304532 AB

1. Screw 12. Packing B
<<A>> 2. Magnetic switch 13. Plate
3. Screw 14. Planetary gear
4. Bolt 15. Lever
5. Rear bracket <> >>A<< 16. Snap ring
6. Brush holder <> >>A<< 17. Stop ring
7. Rear bearing 18. Overrunning clutch
8. Armature 19. Internal gear
9. Yoke assembly 20. Planetary gear shaft
10. Ball 21. Front bracket
11. Packing A
STARTING SYSTEM
DISASSEMBLY SERVICE POINTS STARTER MOTOR PARTS CLEANING

<<A>> MAGNETIC SWITCH REMOVAL Never clean in a solvent such starter motor parts as
the magnetic switch, brush holder, and armature.
B terminal S terminal If they are soaked in a solvent, their insulation
could be impaired. When these parts require
cleaning, wipe off contamination with cloth.
Field coil
M terminal lead 1. Never soak the drive unit in a solvent. If it is
washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.
AK202890 AB
REASSEMBLY SERVICE POINTS
CAUTION >>A<< STOP RING/SNAP RING INSTALLATION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the
magnetic switch.
<> SNAP RING/STOP RING REMOVAL

Overrunning Stop ring
Socket wrench clutch
Stop ring
Stop ring Pinion Gear

Snap ring AK202911 AB
Overrunning
clutch Use a suitable puller to pull the stop ring until it gets
over the snap ring.
INSPECTION
AK202790 AB M1162001300179
COMMUTATOR
1. Apply a long socket wrench of an appropriate size
to the stop ring and strike the wrench to drive out
the stop ring toward the pinion gear side.
Snap ring
Snap ring
pliers Pinion gear
Overrunnning
clutch
AK202712
1. Support the armature with a pair of V block and

AK202791 AB turn it to measure the runout of the surface not
rubbed by the brushes using a dial gauge.
2. Remove the snap ring with snap ring pliers, then
remove the stop ring and overrunning clutch.
Limit: 0.1 mm
STARTING SYSTEM
Push the brush into the brush holder to make sure

that the spring is working on the brush.
If the spring is not working, replace the brush holder.
OVERRUNNING CLUTCH
AK202715
Free
2. Measure the diameter of the commutator.
Limit: 28.8 mm Lock
AK202710 AB
Undercut 1. Make sure that the pinion cannot be turned

Segment
counterclockwise and can be turned clockwise
Mica
freely.
2. Check the pinion for abnormal ware and damage.
BRUSHES
AK202711 AB
3. Measure the depth of the undercut between

segments.
Brush
Standard value: 0.5 mm height
Limit: 0.2 mm
BRUSH HOLDER
AK202846 AB
1. Check the commutator contacting surface of each

brush for abnormal roughness. Also check the
height of the brush. Replace the brush holder if
the height is lower than the limit.
Limit: 7.0 mm
2. When the contact surface of the brush is rectified
or the brush holder is replaced, recondition the
AK202897
contact surface with sandpaper wrapped around
the commutator.
STARTING SYSTEM
ARMATURE COIL MAGNETIC SWITCH

1. Check the armature coil for short circuit as
follows:
A
Growler
M terminal
AK202891 AB
1. Coil open circuit test

AK202733 AB
• Check that there is continuity between the M
2. Set the armature in a growler. terminal and body A.
• If there is no continuity, replace the magnetic
CAUTION
switch.
Clean the surface of the armature thoroughly
before performing the test.
3. While holding a thin strip of iron against the B terminal
armature in parallel with its axis, turn the armature
slowly. The armature is normal if the iron strip is
not attracted to the armature or it does not vibrate.
M terminal
AK202892 AB
2. Contact fusion check

• Check that there is no continuity between the B
terminal and M terminal.
• If there is continuity, replace the magnetic switch.
AK202734
4. Check the insulation between commutator B terminal

segments and armature coils. The armature coils
are properly insulated if no continuity is present.
M terminal
AK202893 AB
3. Switch contact check

• Push the indicated end of the magnetic switch
with a strong force to close the internal contacts.
AK202713 Without releasing the switch end, check that
there is continuity between the B terminal and M
5. Check continuity between a segment and another. terminal.
There is no open circuit in the tested coil if there is • If there is no continuity, replace the magnetic
continuity. switch.
IGNITION SYSTEM
IGNITION SYSTEM
GENERAL INFORMATION
M1163000100335
<4G63> The engine-ECU <M/T> or engine-A/T-ECU <A/T>

This system is equipped with two ignition coils (A and turns the two power transistors inside the ignition
B) with built-in power transistors for the No. 1 and coils alternately on and off. This causes the primary
No. 4 cylinders and the No. 2 and No. 3 cylinders currents in the ignition coils to be alternately
respectively. interrupted and allowed to flow to fire the cylinders in
Interruption of the primary current flowing in the the order 1-3-4-2.
primary side of ignition coil A generates a high The engine-ECU <M/T> or engine-A/T-ECU <A/T>
voltage in the secondary side of ignition coil A. The determines which ignition coil should be controlled
high voltage thus generated is applied to the spark by means of the signals from the camshaft position
plugs of No. 1 and No. 4 cylinders to generate sensor which is incorporated in the camshaft and
sparks. At the time that the sparks are generated at from the crank angle sensor which is incorporated in
both spark plugs, if one cylinder is at the the crankshaft. It also detects the crankshaft position
compression stroke, the other cylinder is at the in order to provide ignition at the most appropriate
exhaust stroke, so that ignition of the compressed timing in response to the engine operation
air/fuel mixture occurs only for the cylinder which is conditions. It also detects the crankshaft position in
at the compression stroke. order to provide ignition at the most appropriate
In the same way, when the primary current flowing in timing in response to the engine operation
ignition coil B is interrupted, the high voltage thus conditions.
generated is applied to the spark plugs of No. 2 and When the engine is cold or operated at high
No. 3 cylinders. altitudes, the ignition timing is slightly advanced to
provide optimum performance.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce
output torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM
Air flow sensor
Intake air temperatur

sensor
Ignition
Engine coolant switch
Ignition coil B Ignition coil A
temperature sensor
Engine-ECU
Camshaft position
<M/T> or
sensor
Engine-A/T-
ECU <A/T>
Crank angle sensor Battery
Barometric pressure
sonsor Spark plug
Detonatoin sensor
Cylinder No. 2 3 4 1
Ignition switch-ST
AK101074 AF
IGNITION SYSTEM
IGNITION COIL SPECIFICATION

Item Specification
Type Molded 2-coil
SPARK PLUG SPECIFICATIONS

Item Specification
NGK IGR6A11
<4G69> The engine-ECU <M/T> or engine-A/T-ECU <A/T>

This system is equipped with four ignition coils with determines which ignition coil should be controlled
built-in power transistors for each of the cylinders. by means of the signals from the camshaft position
Interruption of the primary current flowing in the sensor and the crank angle sensor. It also detects
primary side of an ignition coil generates a high the crankshaft position, in order to provide ignition at
voltage in the secondary side of ignition coil. The the most appropriate timing in response to the
high voltage thus generated is applied to the spark engine operation conditions.
plugs to generate sparks. The engine-ECU <M/T> or When the engine is cold or running at high altitudes,
engine-A/T-ECU <A/T> turns the power transistors the ignition timing is slightly advanced to provide
inside the ignition coils alternately on and off.This optimum performance. Furthermore, if knocking
causes the primary currents in the ignition coils to be occurs, the ignition timing is gradually retarded until
alternately interrupted and allowed to flow to fire the knocking ceases.
cylinders in the order 1-3-4-2.
SYSTEM DIAGRAM
Ignition
Air flow sensor switch
Battery
Barometric pressure
sonsor
Intake air temperatur
sensor
Engine coolant
temperature sensor
Engine-ECU
Accelerator pedal <M/T> or
position sensor Engine-A/T-
Camshaft position ECU <A/T>
sensor
Ignition coil
Crank angle sensor
Ignition switch-ST
Detonatoin sensor
Vehicle speed signal
Inhibitor switch
Spark plug
Cylinder No. 2 3 4 1
AK303631 AB
IGNITION SYSTEM
IGNITION COIL SPECIFICATION

Item Specification
Type Molded 4-coil
SPARK PLUG SPECIFICATIONS

Item Specification
NGK LZFR6AI
M1163000300209
IGNITION COIL <4G63>

Item Standard value
Secondary coil resistance kΩ 8.5 − 11.5
SPARK PLUG
Spark plug gap mm 4G63 1.0 − 1.1 1.3
4G69 0.7 − 0.8 1.2
RESISTIVE CORD <4G63>

Resistance kΩ − Maximum 19
SPECIAL TOOL
M1163000600200

MD998773 Detonation sensor Detonation sensor
wrench removal and installation
IGNITION SYSTEM
ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK <4G63>

M1163001200409
Check by the following procedure, and replace if PRIMARY COIL AND POWER
there is a malfunction. TRANSISTOR CONTINUITY CHECK
SECONDARY COIL RESISTANCE CHECK NOTE: .
•
+ –
1.5 V
– + 1 2 3
AKX01264 AK202356 AE
Measure the resistance between the high-voltage An analogue-type circuit tester should be used.
terminals of the ignition coil. • Connect the negative (-) prove of the circuit tester
Standard value: 8.5 − 11.5 kΩ to terminal No. 1.
CAUTION
This test must be performed quickly (in less
than 10 seconds) to prevent coil from burning
and power transistor from breakage.
Connect and disconnect 1.5 V battery between
terminal No. 2 and No. 3, and observe the ohmmeter
whether there is continuity or not.
1.5 V power supply Continuity between 1 −
between 2 − 3 2
When current is flowing Continuity
When current is not
flowing No continuity
IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK <4G69>

M1163001200391
Check by the following procedure, and replace if 3. Connect the ignition coil connector.
there is a malfunction. 4. Earth the side electrode of the spark plug and
SECONDARY COIL RESISTANCE CHECK crank the engine.
NOTE: It is impossible to check the secondary coil 5. Check that spark is produced between the
through the continuity check as a diode is integrated electrodes of the spark plug.
in the secondary coil circuit of this ignition coil. 6. If no spark plug is produced, replace the ignition
Accordingly, check the secondary coil in the following coil with a new one and recheck.
procedure. 7. If spark is produced with the new ignition coil,
1. Disconnect the ignition coil connector. replace the old one as it is faulty. If no spark is
2. Remove the ignition coil and install a new spark produced again, the ignition circuit is suspected
plug to the ignition coil. as faulty. Check the ignition circuit.
IGNITION SYSTEM
PRIMARY COIL AND POWER CAUTION

TRANSISTOR CONTINUITY CHECK This test must be performed quickly (in less
NOTE: . than 10 seconds) to prevent coil from burning
•
and power transistor from breakage.
Connect and disconnect 4.5 − 9.0 V battery between
+ – terminal No. 2 and No. 3, and observe the ohmmeter
whether there is continuity or not.
4.5 – 9 V
4.5 − 9 V power supply Continuity between 1 −
– + 1 2 3
between 2 − 3 2
When current is flowing Continuity
When current is not
flowing No continuity
AK202356 AD
An analogue-type circuit tester should be used.

• Connect the negative (-) prove of the circuit tester
to terminal No. 1.
RESISTIVE CORD CHECK <4G63>

M1163001400146
Measure the resistance of the all spark plug cables.
1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Maximum 19 kΩ
AKX00382
IGNITION SYSTEM
SPARK PLUG CHECK AND CLEANING <4G63>

M1163004300405
CAUTION 3. Check the plug gap and replace if the limit is

When pulling off the spark plug cable from the exceeded.
plug always hold the cable cap, not the cable. Standard value: 1.0 − 1.1 mm
1. Remove the spark plug cables. Limit: 1.3 mm
2. Remove the spark plugs. CAUTION
CAUTION Be careful not to allow foreign matter in
• Do not attempt to adjust the gap of the iridium cylinders.
plug. 4. Clean the engine plug holes.
• Always use a plug cleaner and finish cleaning 5. Install the spark plugs.
within 20 seconds. Do not use wire brushes.
Otherwise, the iridium and platinum tip may
be damaged.
Iridium tip
Platinum tip
AKX01327AD
SPARK PLUG CHECK AND CLEANING<4G69>

M1163004300416
1. Remove the spark plugs. 2. Check the plug gap and replace if the limit is
CAUTION exceeded.
• Do not attempt to adjust the gap of the iridium Standard value: 0.7 − 0.8 mm
plug. Limit: 1.2 mm
• Always use a plug cleaner and finish cleaning CAUTION
within 20 seconds. Do not use wire brushes. Be careful not to allow foreign matter in
Otherwise, the iridium tip may be damaged. cylinders.
3. Clean the engine plug holes.
4. Install the spark plugs.
Iridium tip
AKX00383 AN
IGNITION SYSTEM
CAMSHAFT POSITION SENSOR CHECK

M1163004400264
Check the camshaft position sensor circuit if (Refer to P.13B-179, GROUP 13B − Troubleshooting
self-diagnosis code, No. P0340 is shown. − Inspection procedure for diagnosis code.) <4G69>
(Refer to P.13A-142, GROUP 13A − Troubleshooting
− Inspection procedure for diagnosis code.) <4G63>
CRANK ANGLE SENSOR CHECK

M1163004500324
Check the crank angle sensor circuit if self-diagnosis (Refer to P.13B-169 GROUP 13B − Troubleshooting
code, No. P0335 is shown. − Inspection procedure for diagnosis code.) <4G69>
(Refer to P.13A-131 GROUP 13A − Troubleshooting
DETONATION SENSOR CHECK

M1163002900058
Check the detonation sensor circuit if self-diagnosis (Refer to P.13B-166, GROUP 13B − Troubleshooting
code, No. P0325 is shown. − Inspection procedure for diagnosis code.) <4G69>
(Refer to P.13A-127, GROUP 13A − Troubleshooting
IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE

<4G63>
M1163001700233
MEASUREMENT METHOD 2. Clamp the spark plug cable with the trigger
1. Clamp the secondary pickup around the spark pickup.
plug cable. NOTE: Clamp the trigger pickup to the same
NOTE: . spark plug cable clamped by the secondary
• The peak ignition voltage will be reversed pickup.
when the spark plug cables No. 2 and No. 4,
or No. 1 and No. 3 cylinders are clamped.
• Because of the two-cylinder simultaneous
ignition system, the waveforms for two
cylinders in each group appear during
waveform observation (No. 1 cylinder - No. 4
cylinder, No. 2 cylinder - No. 3 cylinder).
However, waveform observation is only
applicable for the cylinder with the spark plug
cable clamped by the secondary pickup.
• Identifying which cylinder waveform is
displayed can be difficult. For reference,
remember that the waveform of the cylinder
attached to the secondary pickup will be
displayed as stable.
IGNITION SYSTEM
STANDARD WAVEFORM
Observation Conditions
Function Secondary
Pattern height High (or Low)
Pattern selector Raster
Engine revolutions Curb idle speed
Spark line (point A)

kV
Ignition voltage
(point D)
Secondary
ignition voltage
wave pattern
Wave dampling reduction section (point B)
Dwell section
Point C
Time
AKX00278AD
IGNITION SYSTEM
Observation Conditions (The only change from above condition is the pattern selector.)
kV
NO. 2 cylinder
NO. 1 cylinder NO. 3 cylinder NO. 4 cylinder ignition noise
ignition noise
Secondary ignition
voltage wave pattern Time
0
2 Newtral section
AKX01275 AC
WAVEFORM OBSERVATION POINTS

Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).
Spark line Plug gap Condition of Compression Concentration Ignition Spark plug
electrode force of air mixture timing cable
Length Long Small Normal Low Rich Advanced Leak
Short Large Large wear High Lean Retarded High
resistance
Height High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
Slope Large Plug is fouled − − − −
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil and condenser
3 or more Normal
Except above Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations Coil
5 − 6 or higher Normal
Except above Abnormal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentration Ignition Spark plug
voltage electrode force of air mixture timing cable
High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
IGNITION SYSTEM
EXAMPLES OF ABNORMAL Example 3

WAVEFORMS • Wave characteristics
Spark line is low and long, and is sloping.
However, there is almost no spark line
distortion.
• Cause of problem
Spark plug gap is fouled.
AKX00280
Example 1
• Wave characteristics
Spark line is high and short.
AKX00283
Spark plug gap is too large.
Example 4
Spark line is high and short.
Difficult to distinguish between this and abnormal
waveform example 1.
Spark plug cable is nearly falling off (Causing a
dual ignition).
AKX00281
Example 2
Spark line is low and long, and is sloping.
Also, the second half of the spark line is distorted.
This could be a result of misfiring.
Spark plug gap is too small. AKX00284
Example 5
No waves in wave damping section.
Layer short in ignition coil.
AKX00282
IGNITION SYSTEM
IGNITION COIL
M1163004000493
10 ± 2 N·m
3.0 ± 0.5 N·m
1 2
4
4
3
2
3
5
25 ± 4 N·m
AC301786 AB

1. Rocker cover centre cover 4. Ignition coil
2. Ignition coil connector 5. Spark plug
3. Spark plug cable
IGNITION SYSTEM

M1163004000501

Resonator Removal and Installation (Refer to GROUP 15,
10 ± 2 N·m
2
1
25 ± 5 N·m
AC305115AD

1. Ignition coil connectors 2. Ignition coils
3. Spark plugs
CAMSHAFT POSITION SENSOR

M1163003400517
<4G63>
2
1
3N
8.8 ± 1.0 N·m
AC301556 AB

1. Camshaft position sensor 2. Camshaft position sensor
connector connection 3. O-ring
IGNITION SYSTEM
<4G69>
11 ± 1 N·m
2
AC304319
AC302233
3N AC305127 AC

1. Camshaft position sensor 2. Camshaft position sensor
connector connection 3. O-ring
CRANKSHAFT POSITION SENSOR

M1163003500514
3.0 ± 0.5 N·m
22 ± 4 N·m
6
1
8.8 ± 1.0 N·m
2
8 22 ± 4 N·m
4
3
7
8.8 ± 1.0 N·m
49 ± 9 N·m 5 49 ± 9 N·m
AC301612
IGNITION SYSTEM

1. Power steering pressure switch <<A>> POWER STEERING OIL PUMP ASSEMBLY
connector REMOVAL
2. A/C compressor connector
Remove the power steering oil pump assembly from
3. A/C compressor connector clamp
<<A>> 4. Power steering oil pump assembly
the bracket with the hose attached.
5. Power steering oil pump bracket NOTE: Place the removed power steering oil pump
6. Rocker cover centre cover assembly in a place where it will not be a hindrance
7. Crankshaft position sensor when removing and installing and secure it with a
8. Crankshaft position sensor cord or wire.
connector bracket

M1163003500525

Timing Belt Lower Cover Removal and Installation (Refer to
GROUP 11C, Timing Belt P.11C-36).
2
1
8.5 ± 0.5 N·m

AC305391 AD
Removal steps
1. Timing belt lower cover bracket
2. Crankshaft position sensor
IGNITION SYSTEM
DETONATION SENSOR
M1163002800631
CAUTION
Do not drop or hit the detonation sensor against other components. Internal damage may result, and
the detonation sensor will need to be replaced.
<Intake side>
2
23 ± 2 N·m
AC301657AB
Removal steps Use special tool detonation sensor wrench

1. Detonation sensor connector (MD998773) to remove the detonation sensor.
connection
<<A>> >>A<< 2. Detonation sensor INSTALLATION SERVICE POINT
REMOVAL SERVICE POINT >>A<< DETONATION SENSOR INSTALLATION
<<A>> DETONATION SENSOR REMOVAL Detonation

sensor
Detonation
sensor
MD998773
MD998773 AC100807 AC
AC100807 AC
Use special tool detonation sensor wrench
(MD998773) to tighten the detonation sensor to the
specified torque.
IGNITION SYSTEM

M1163002800642
CAUTION
Do not drop or hit the detonation sensor against other components. Internal damage may result, and
the detonation sensor will need to be replaced.
Air Cleaner Removal and Installation (Refer to GROUP 15,
23 ± 2 N·m
1
5
11 ± 1 N·m
31 ± 3 N·m
3
AC302234
AC305130 AD

1. Detonation sensor connector 4. Intake manifold stay
connection <<A>> >>A<< 5. Detonation sensor
2. Detonation sensor clamp 6. Detonation sensor connector
3. Harness clamp bracket
IGNITION SYSTEM
REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> DETONATION SENSOR REMOVAL >>A<< DETONATION SENSOR INSTALLATION
Detonation Detonation
sensor sensor
MD998773 MD998773
AC100807 AC AC100807 AC
Use special tool detonation sensor wrench Use special tool detonation sensor wrench
(MD998773) to remove the detonation sensor. (MD998773) to tighten the detonation sensor to the
specified torque.
17-1
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL . . . . . . . . . . 17-3 ADJUSTMENT <4G63> . . . . . . . . . . . . . 17-5

ACCELERATOR CABLE CHECK AND
ADJUSTMENT <4G69> . . . . . . . . . . . . . 17-5
ACCELERATOR CABLE AND PEDAL
SERVICE SPECIFICATIONS. . . . . 17-3 <4G63> . . . . . . . . . . . . . . . . . . . . . . 17-6
REMOVAL AND INSTALLATION. . . . . . 17-6
TROUBLESHOOTING . . . . . . . . . . 17-3
INTRODUCTION TO ENGINE CONTROL ACCELERATOR CABLE AND PEDAL
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . 17-3
<4G69> . . . . . . . . . . . . . . . . . . . . . . 17-7
ENGINE CONTROL SYSTEM DIAGNOSTIC REMOVAL AND INSTALLATION. . . . . . 17-7
TROUBLESHOOTING STRATEGY . . . 17-3
SYMPTOM CHART . . . . . . . . . . . . . . . . 17-3
SYMPTOM PROCEDURES . . . . . . . . . 17-3 ACCELERATOR PEDAL POSITION
SENSOR <4G69> . . . . . . . . . . . . . . 17-9
ON-VEHICLE SERVICE. . . . . . . . . 17-5 REMOVAL AND INSTALLATION. . . . . . 17-9
ACCELERATOR CABLE CHECK AND Continued on next page
17-2
EMISSION CONTROL <MPI> . . 17-10 GENERAL INFORMATION (EVAPORATIVE

EMISSION CONTROL SYSTEM) . . . . . 17-17
COMPONENT LOCATION (EVAPORATIVE
GENERAL INFORMATION . . . . . . 17-10 EMISSION CONTROL SYSTEM) . . . . . 17-18
PURGE CONTROL SYSTEM CHECK. . 17-18
EMISSION CONTROL DEVICE PURGE PORT VACUUM CHECK . . . . . 17-19
REFERENCE PURGE CONTROL SOLENOID VALVE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
TABLE . . . . . . . . . . . . . . . . . . . . . . 17-10
CANISTER REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . 17-21
EXHAUST GAS RECIRCULATION (EGR)
SPECIAL TOOL . . . . . . . . . . . . . . . 17-11 SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-22
GENERAL INFORMATION
VACUUM HOSE. . . . . . . . . . . . . . . 17-12 (EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-22
VACUUM HOSE PIPING DIAGRAM . . . 17-12 COMPONENT LOCATION
VACUUM CIRCUIT DIAGRAM . . . . . . . 17-13 (EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-23
VACUUM HOSE CHECK. . . . . . . . . . . . 17-14 EGR SYSTEM CHECK <4G63> . . . . . . 17-24
VACUUM HOSE INSTALLATION . . . . . 17-14 EGR PORT VACUUM CHECK<4G63> . 17-24
EGR VALVE CHECK <4G63> . . . . . . . . 17-24
EGR CONTROL SOLENOID VALVE
CRANKCASE EMISSION CONTROL CHECK <4G63> . . . . . . . . . . . . . . . . . . . 17-25
SYSTEM. . . . . . . . . . . . . . . . . . . . . 17-15 EGR VALVE (STEPPER MOTOR)
GENERAL INFORMATION (CRANKCASE CHECK <4G69> . . . . . . . . . . . . . . . . . . . 17-25
EMISSION CONTROL SYSTEM) . . . . . 17-15 EXHAUST GAS RECIRCULATION (EGR)
COMPONENT LOCATION (CRANKCASE VALVE REMOVAL AND INSTALLATION
EMISSION CONTROL SYSTEM) . . . . . 17-15 <4G63>. . . . . . . . . . . . . . . . . . . . . . . . . . 17-27
POSITIVE CRANKCASE VENTILATION EXHAUST GAS RECIRCULATION (EGR)
SYSTEM CHECK. . . . . . . . . . . . . . . . . . 17-16 VALVE REMOVAL AND INSTALLATION
POSITIVE CRANKCASE VENTILATION <4G69>. . . . . . . . . . . . . . . . . . . . . . . . . . 17-28
(PCV) VALVE CHECK . . . . . . . . . . . . . . 17-16
CATALYTIC CONVERTER . . . . . . 17-29
EVAPORATIVE EMISSION CONTROL REMOVAL AND INSTALLATION. . . . . . 17-29
SYSTEM. . . . . . . . . . . . . . . . . . . . . 17-17
ENGINE AND EMISSION CONTROL 17-3
ENGINE CONTROL
ENGINE CONTROL
GENERAL INFORMATION SERVICE SPECIFICATIONS
M1171000100329 M1171000300099
A cable-type accelerator mechanical
suspended-type pedal has been adopted.
Accelerator cable play mm 1.0 − 2.0
Engine idle speed r/min 4G63 750 ± 50
4G69 700 ± 100
TROUBLESHOOTING If you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find an
INTRODUCTION TO ENGINE CONTROL engine control system fault.
1. Gather information from the customer.
SYSTEM DIAGNOSIS
M1171002000287 2. Verify that the condition described by the
If there is a malfunction in the engine control system, customer exists.
the accelerator cable, accelerator pedal or throttle
3. Find the malfunction by following the Symptom
lever may be faulty.
Chart.
ENGINE CONTROL SYSTEM 4. Verify that the malfunction is eliminated.
DIAGNOSTIC TROUBLESHOOTING SYMPTOM CHART
STRATEGY M1171002200322
M1171002100314
Use these steps to plan your diagnostic strategy.
SYMPTOM INSPECTION PROCEDURE REFERENCE PAGE
Throttle valve will not fully open or close <4G63> 1 P.17-3
Throttle valve will not fully open or close <4G69> 2 P.17-4
Accelerator pedal operation is not smooth (over 3 P.17-4
acceleration)
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Throttle Valve will not Fully Open or Close <4G63>
DIAGNOSIS YES : Go to Step 3 .

NO : Cleaning the throttle body (Refer to GROUP
13A, On-vehicle Service P.13A-324), or
STEP 1. Check the accelerator cable adjustment. replace the throttle body assembly (Refer to
Q: Is the accelerator cable properly adjusted? GROUP 13A, Throttle Body P.13A-340).
YES : Go to Step 2 . Then go to Step 3 .
NO : Adjust the accelerator cable (Refer to
P.17-5). Then go to Step 3 . STEP 3. Retest the system.
Q: Does the throttle valve fully open and close?
STEP 2. Check the throttle valve. YES : The procedure is complete.
Check that the throttle lever of the throttle body NO : Return to Step 1 .
assembly moves smoothly by moving it by hand.
Q: Does the throttle lever of the throttle body
assembly move smoothly?
17-4 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
INSPECTION PROCEDURE 2: Throttle Valve will not Fully Open or Close <4G69>
DIAGNOSIS STEP 3. Check the accelerator pedal position

sensor assembly.
STEP 1. Check the accelerator cable adjustment. Refer to GROUP 13B, On-vehicle Service
P.13B-431.
Q: Is the accelerator cable properly adjusted?
YES : Go to Step 2 . Q: Is the accelerator pedal position sensor assembly
NO : Adjust the accelerator cable (Refer to normally?
P.17-5). Then go to Step 5 . YES : Go to Step 4 .
NO : Replace the accelerator pedal position
sensor assembly (Refer to P.17-9). Then go
STEP 2. Check the accelerator pedal position to Step 5 .
sensor assembly.
Check that the lever of the accelerator pedal position
sensor assembly moves smoothly by moving it by STEP 4. Check the Throttle valve (Throttle valve
hand. control servo).
Refer to GROUP 13B, On-vehicle Service P.13B-436
Q: Dose the lever of the accelerator pedal position
sensor assembly move smoothly? Q: Is the throttle valve control servo normally?
NO : Replace the accelerator pedal position NO : Cleaning the throttle body (Refer to GROUP
sensor assembly (Refer to P.17-9). Then go 13B, On-vehicle Service P.13B-425), or
to Step 5 . replace the throttle body assembly (Refer to
GROUP 13B, Throttle Body P.13B-438).
Then go to Step 5 .
STEP 5. Retest the system.

Q: Does the throttle valve fully open and close?
YES : The procedure is complete.
NO : Return to Step 1 .
INSPECTION PROCEDURE 3: Accelerator Pedal Operation is not Smooth (Over Acceleration)
DIAGNOSIS STEP 3. Check the accelerator cable lubricant.

Q: Is the accelerator cable lubricated sufficiently?
STEP 1. Check the accelerator pedal. YES : Go to Step 4 .
NO : Refill or replace the lubricant. Then go to
Q: Is the accelerator pedal loose?
YES : Tighten the fasteners. Then go to Step 4 . Step 4 .
NO : Go to Step 2 .
STEP 2. Check the accelerator cable wiring. Q: Does the accelerator pedal work normally?
Q: Is the accelerator cable routing bent sharply?
YES : Correct the cable routing Then go to Step 4 NO : Return to Step 1 .
.
NO : Go to Step 3 .
ENGINE CONTROL
ON-VEHICLE SERVICE (3) After adjusting, check that the throttle lever is
touching the stopper.
ACCELERATOR CABLE CHECK AND
ADJUSTMENT <4G63> ACCELERATOR CABLE CHECK AND
M1171000900347 ADJUSTMENT <4G69>
1. Turn A/C and lights OFF. Inspect and adjust at no M1171000900358
load. 1. Turn A/C and lights OFF. Inspect and adjust at no

2. Warm engine until stabilized at idle. load.
3. Confirm idle speed is at standard value. 2. Warm engine until stabilized at idle.
3. Confirm idle speed is at standard value.
Standard value: 750 ± 50 r/min
Standard value: 700 ± 100 r/min
4. Stop engine. [ignition switch: LOCK (OFF)
position]. 4. Stop engine. [ignition switch: LOCK (OFF)
5. Confirm there are no sharp bends in the position].
accelerator cable. 5. Confirm there are no sharp bends in the
6. Check the inner cable for correct slack. accelerator cable.
6. Check the inner cable for correct slack.
Accelerator pedal
Adjusting bolt position sensor
Plate Adjusting nut
Lock nut
Accelerator cable AC212490 AC Accelerator cable

AC304671 AE
7. If there is too much slack or no slack, adjust play
by the following procedures. 7. If there is too much slack or no slack, adjust play
(1) Loosen the adjusting bolts to release the by the following procedures.
cable. (1) Loosen the lock nut and adjusting nut to
(2) Move the plate until the inner cable play is at release the cable.
the standard value, and then tighten the (2) Tighten the adjusting nut until the inner cable
adjusting bolts. play is at the standard value, and then tighten
the lock nut.
ENGINE CONTROL

<4G63>
M1171001200404
Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-5).
3
5.0 ± 1.0 N·m
12 ± 2 N·m
10
1 9 4
7
5N
7
11
6 N 12 8
13
AC309483AB
Accelerator cable assembly Accelerator pedal assembly

removal steps removal steps (Continued)
1. Inner cable connection (Accelerator 10. Accelerator pedal bracket
pedal side) 11. Accelerator arm
2. Inner cable connection (Throttle body >>A<< 12. Accelerator pedal pad
side) 13. Accelerator pedal stopper
3. Accelerator cable assembly
Accelerator pedal assembly INSTALLATION SERVICE POINT
removal steps >>A<< PEDAL PAD INSTALLATION
1. Inner cable connection (Accelerator
pedal side) CAUTION
4. Accelerator pedal assembly To prevent damages to the Pedal Pad, warm the
5. Push-on spring nut thumb area of the Pedal Pad with a dryer, etc.
6. Accelerator arm and accelerator prior to assembling it.
pedal pad assembly NOTE: If it is difficult to assemble, apply soapy water
7. Bushing to the thumb area to enhance the assembling
8. Spring
process.
9. Stopper
ENGINE CONTROL

<4G69>
M1171001200415

4
2
3
12 ± 2 N·m
11
1
10 5
8
6N
8
12
7 N 13 9
14
AC309484AB

1. Inner cable connection (Accelerator 6. Push-on spring nut
pedal side) 7. Accelerator arm and accelerator
2. Inner cable connection (Accelerator pedal pad assembly
pedal position sensor side) 8. Bushing
3. Accelerator cable assembly 9. Spring
4. Accelerator cable bracket 10. Stopper
Accelerator pedal assembly 11. Accelerator pedal bracket
removal steps 12. Accelerator arm
1. Inner cable connection (Accelerator >>A<< 13. Accelerator pedal pad
pedal side) 14. Accelerator pedal stopper
5. Accelerator pedal assembly
ENGINE CONTROL

Adjusting the Accelerator Cable (Refer to P.17-5.)
4
2
3
5
12 ± 2 N·m
11
12 9
13
8
N7 14 N
6
10
9
15
AC309485 AB

1. Inner cable connection (Accelerator 11. Stopper
pedal side) 12. Accelerator pedal bracket
2. Inner cable connection (Accelerator 13. Accelerator arm
pedal position sensor side) >>A<< 14. Accelerator pedal pad
3. Accelerator cable assembly 15. Accelerator pedal stopper
4. Accelerator cable bracket
5. Accelerator cable clip INSTALLATION SERVICE POINT
Accelerator pedal assembly >>A<< PEDAL PAD INSTALLATION
removal steps
1. Inner cable connection (Accelerator CAUTION
pedal side) To prevent damages to the Pedal Pad, warm the
6. Accelerator pedal assembly thumb area of the Pedal Pad with a dryer, etc.
7. Push-on spring nut prior to assembling it.
8. Accelerator arm and accelerator NOTE: If it is difficult to assemble, apply soapy water
pedal pad assembly to the thumb area to enhance the assembling
9. Bushing
process.
10. Spring
ENGINE CONTROL

SENSOR <4G69>
M1171001800053
12 ± 1 N·m
3
2 1
5.0 ± 1.0 N·m

4
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m

5 AC305408AC

1. Inner cable connection (Accelerator 4. Accelerator pedal position sensor
pedal position sensor side) bracket
2. Accelerator pedal position sensor 5. Accelerator pedal position sensor
connector bracket support
3. Accelerator pedal position sensor
assembly
EMISSION CONTROL <MPI>

GENERAL INFORMATION • Crankcase emission control system
M1173000100466 • Evaporative emission control system
The emission control system consists of the following • Exhaust emission control system
subsystems:
Items Name Specification
Crankcase emission control Positive crankcase ventilation Variable flow type
system (PCV) valve (Purpose: HC reduction)
Evaporative emission control Canister Equipped
system Purge control solenoid valve Duty cycle type solenoid valve
(Purpose: HC reduction)
Exhaust emission control system Air-fuel ratio control device - MPI Oxygen sensor feedback type
system (Purpose: CO, HC, NOx reduction)
Exhaust gas recirculation system Equipped
<4G63>
• EGR valve Single type
• EGR control solenoid valve Duty cycle type solenoid valve
(Purpose: NOx reduction)
Exhaust gas recirculation system Equipped
<4G69>
• EGR valve Steeper motor type
(Purpose: NOx reduction)
Catalytic converter Monolith type
(Purpose: CO, HC, NOx reduction)
EMISSION CONTROL DEVICE

REFERENCE TABLE
M1173006600157
Related parts Crankcase Evaporative Air/fuel ratio Catalytic Exhaust gas

emission emission control converter recirculation
control control system system
system system
PCV valve ×
Purge control solenoid valve ×
MPI system component × ×
Catalytic converter ×
EGR valve <4G63> ×
EGR control solenoid valve ×
<4G63>
EGR valve (Steeper moter) ×
<4G69>
M1173000300363

Purge control solenoid valve coil resistance (at 20°C) Ω 30 − 34
EGR control solenoid valve coil resistance (at 20°C) Ω 29 − 35
<4G63>
EGR valve coil resistance (at 20°C) Ω <4G69> 20 − 24
SPECIAL TOOL
M1173000600201

MD991658 Test harness EGR valve (Steeper moter)
CHECK
MB991658
MD998770 Oxygen sensor wrench Removal and installation of

oxygen sensor
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
M1173000900439
<4G63>
Air cleaner
Air
Fuel pressure
To regulator From
fuel tank fuel pump
PCV valve
EGR valve
Oxygen sensor Canister
(front)
EGR control
solenoid valve Purge control
Catalytic solenoid valve
converter
Catalytic
converter
AK204364AB
<4G69>
Air cleaner

Air
From
fuel pump
PCV valve
Canister
EGR valve
(Stepper motor) Purge control
Catalytic
converter solenoid valve
Catalytic
converter
Cylinder 1, 4 oxygen sensor (rear)

Cylinder 2, 3 oxygen sensor (rear)
AK302694 AB
VACUUM CIRCUIT DIAGRAM

M1173007100285
<4G63>
Intake manifold Throttle body
To From
combustion air
chamber cleaner
B W
R
Fuel
pressure
regulator
G
Y B Canister
Vacuum hose colour EGR
B: Black control
G: Green solenoid B
R: Red valve Purge
W: White EGR
valve control
Y: Yellow solenoid
valve
AK201210 AC
<4G69>
Intake manifold Throttle body
To From
combustion air
chamber cleaner
B Canister
Purge B B
control
solenoid
Vacuum hose colour valve
B: Black
AK302823 AB
VACUUM HOSE CHECK VACUUM HOSE INSTALLATION

M1173007300160 M1173007200118
1. Using the piping diagram as a guide, check to be 1. When connecting the vacuum hoses, they should
sure that the vacuum hoses are correctly be securely inserted onto the nipples.
connected. 2. Connect the hoses correctly, using the vacuum
2. Check the connection condition of the vacuum hose piping diagram as a guide.
hoses, (removed, loose, etc.) and check to be
sure that there are no bends or damage.
CRANKCASE EMISSION CONTROL The air becomes mixed with the blow-by gases
inside the crankcase.
SYSTEM The blow-by gas inside the crankcase is drawn into
the intake manifold through the positive crankcase
GENERAL INFORMATION (CRANKCASE ventilation (PCV) valve.
EMISSION CONTROL SYSTEM) The PCV valve lifts the plunger according to the
M1173005000334
intake manifold vacuum so as to regulate the flow of
The crankcase emission control system prevents
blow-by gas properly.
blow-by gases from escaping inside the crankcase
In other words, the blow-by gas flow is regulated
into the atmosphere.
during low load engine operation to maintain engine
Fresh air is sent from the air cleaner into the
stability, while the flow is increased during high load
crankcase through the breather hose.
operation to improve the ventilation performance.
SYSTEM DIAGRAM
Air cleaner
Air
Ventilation hose Breather hose
PCV valve
AK204365AB
COMPONENT LOCATION (CRANKCASE <4G69>

EMISSION CONTROL SYSTEM)
M1173007400242
<4G63>
PCV valve
AK302826 AB
PCV valve
AK204366AD
POSITIVE CRANKCASE VENTILATION 6. If vacuum is not felt, clean the PCV valve or
SYSTEM CHECK replace it.
M1173001100221
1. Remove the ventilation hose from the PCV valve. POSITIVE CRANKCASE VENTILATION
2. Remove the PCV valve from the rocker cover. (PCV) VALVE CHECK
M1173001200217
3. Reinstall the PCV valve at the ventilation hose.
4. Start the engine and run at idle.
PCV valve
PCV valve AK300022 AC
AK300021AC 1. Insert a thin rod into the PCV valve from the side
shown in the illustration (rocker cover installation
5. Place a finger at the opening of the PCV valve side), and move the rod back and forth to check
and check that vacuum of the intake manifold is that the plunger moves.
felt. 2. If the plunger does not move, there is a clogging
NOTE: At this moment, the plunger in the PCV in the PCV valve. In this case, clean or replace
valve moves back and forth. the PCV valve.
EVAPORATIVE EMISSION CONTROL When driving the vehicle, fuel vapours stored in the
canister flow through the gurge control solenoid
SYSTEM valve and purge port and go into the intake manifold
to be sent to the combustion chamber.
GENERAL INFORMATION (EVAPORATIVE When the engine coolant temperature is low or when
EMISSION CONTROL SYSTEM) the intake air quantity is small (when the engine is at
M1173005100427
idle, for example), the engine control unit turns the
The evaporative emission control system prevents
purge solenoid off to shut off the fuel vapour flow to
fuel vapours generated in the fuel tank from escaping
the intake manifold.
into the atmosphere.
This does not only insure the driveability when the
Fuel vapours from the fuel tank flow through the fuel
engine is cold or running under low load but also
tank pressure control valve and vapour pipe/hose to
stabilize the emission level.
be stored temporarily in the canister.
SYSTEM DIAGRAM
<4G63>
Throttle body
Engine-ECU
Canister
From
fuel Air flow sensor
tank
OFF
Engine coolant
temperature sensor
Purge
control
ON Solenoid
Control Intake air
valve temperature sensor
relay
Barometric pressure
sensor
Battery
AK204367AB
<4G69>
Intake manifold
Engine-ECU <M/T> or
Canister Air flow sensor

From
fuel
tank Engine coolant
OFF temperature sensor
Purge
control Intake air
ON Solenoid Control temperature sensor
valve relay
Barometric pressure sensor
(with engine-ECU <M/T>
or engine-A/T-ECU <A/T>)
Battery
AK302829AB
COMPONENT LOCATION (EVAPORATIVE PURGE CONTROL SYSTEM CHECK

M1173001400318
EMISSION CONTROL SYSTEM) <4G63>
M1173007500238
<4G63>
Vacuum hose
Plug
Purge control
solenoid valve
AK201217 AD AK201220AC
<4G69> 1. Disconnect the vacuum hose (red stripe) from

throttle body and connect it to a hand vacuum
pump.
2. Plug the nipple from which the vacuum hose was
removed.
3. When the engine is cold or hot, apply a vacuum of
53 kPa, and check the condition of the vacuum.
Purge control
solenoid valve
AK302830 AB
When engine is cold When engine is hot

(Engine coolant temperature: 40°C or less) (Engine coolant temperature: 80°C or higher)
Engine condition Normal condition Engine condition Normal condition
At idle Vacuum is maintained. At idle Vacuum is maintained.
3,000 r/min 3,000 r/min (within 3 Vacuum will leak.
minutes after engine
When engine is hot starts)
(Engine coolant temperature: 80°C or higher)
Engine condition Normal condition
PURGE PORT VACUUM CHECK
At idle Vacuum is maintained. M1173001500188
3,000 r/min (within 3 Vacuum will leak. <4G63>

minutes after engine Vacuum hose
starts)
<4G69>
Plug
Plug
AK201225 AD
1. Disconnect the vacuum hose (red stripe) from the

Vacuum hose throttle body and connect a hand vacuum pump to
the nipple.
AK302831AB 2. Plug the vacuum hose (red stripe).
1. Disconnect the vacuum hose (between purge
control solenoid valve and intake maniford) from
purge control solenoid valve and connect a hand
vacuum pump to the nipple.
2. Plug the vacuum hose. Vac-
uum
3. When the engine is cold or hot, apply a vacuum of
53 kPa, and check the condition of the vacuum.
When engine is cold Engine speed (r/min)
(Engine coolant temperature: 40°C or less) AK100011AC
Engine condition Normal condition
At idle Vacuum is maintained.
4. Check that a fairly constant negative pressure is
3,000 r/min
generated regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
<4G69>
A
Vacuum hose
Plug
Battery
AK100012 AC
AK302833 AB
1. Disconnect the vacuum hose (between purge

control solenoid valve and intake manifold) from
the purge control solenoid valve and connect it to
a hand vacuum pump.
2. Plug the nipple from which the vacuum hose was
removed.
AK100013
1. Disconnect the vacuum hose from the solenoid

Vac- valve.
uum 2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
Engine speed (r/min)
4. Check airtightness by applying a vacuum with
AK100011AC
voltage applied directly from the battery to the
3. Start the engine. purge control solenoid valve and without applying
voltage.
generated regardless of the engine speed. Battery voltage Normal condition
5. If no negative pressure is generated, the port is Applied Vacuum leaks
probably blocked and should be cleaned. Not applied Vacuum maintained
PURGE CONTROL SOLENOID VALVE 5. Measure the resistance between the terminals of
the solenoid valve.
CHECK
M1173001700234 Standard value: 30 − 34 Ω (at 20°C)
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.
CANISTER REMOVAL AND INSTALLATION

M1173004200175

Air cleaner cover and air intake hose removal and installation
(4G63: Refer to GROUP 15 - Air cleaner P.15-3) (4G69:
Refer to GROUP 15 - Air cleaner P.15-4).
3
2
4 1
5 8
AC212494 AB

1. Purge hose connection 6. Canister
2. Vapour hose 7. Fuel high-pressure hose clamp
3. Vent connector <4G63>
4. Vapour hose 8. Canister bracket
5. Hose clamp
EXHAUST GAS RECIRCULATION The EGR flow rate is controlled by the EGR valve so
as not to decrease the driveability.
(EGR) SYSTEM
OPERATION
GENERAL INFORMATION (EGR SYSTEM)
M1173005200349 The EGR valve is being closed and does not
The exhaust gas recirculation (EGR) system lowers recirculate exhaust gases under one of the following
the nitrogen oxide (NOx) emission level. conditions.
When the air/fuel mixture combustion temperature is Otherwise, the EGR valve is opened and recirculates
high, a large quantity of nitrogen oxides (NOx) is exhaust gases.
generated in the combustion chamber. • The engine coolant temperature is low.
Therefore, this system recirculates part of emission • The engine is at idle.
gas from the exhaust port of the cylinder head to the • The throttle valve is widely opened.
combustion chamber through the intake manifold to
decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.
SYSTEM DIAGRAM
<4G63>
EGR
control
Solenoid
valve
OFF
Engine-ECU
EGR valve
ON Barometric pressure
sensor
Air flow sensor

Control
relay
Engine coolant
temperature sensor
Battery Crank angle sensor
AK204368 AB
<4G69>
Air flow sensor
Engine coolant
EGR valve temperature sensor
(stepper motor)
Control
relay
Crank angle sensor
Battery
Throttle position sensor
Engine-ECU <M/T> or
Engine-A/T-ECU <A/T> AK204431AC
COMPONENT LOCATION (EGR SYSTEM) <4G63>

M1173007600246
EGR valve
<4G63>
AK303696AB
EGR control
solenoid valve
AK201234AD <4G69>
EGR valve
(stepper motor)
AK302840AB
EGR SYSTEM CHECK <4G63> EGR PORT VACUUM CHECK<4G63>

M1173002600360 M1173002900178
Three-way terminal
white stripe
Green stripe
EGR valve AK200375AE AK201247 AC
1. Disconnect the vacuum hose (Green stripe) from 1. Disconnect the vacuum hose (White stripe) from
the EGR valve, and then connect a hand vacuum the throttle body EGR vacuum nipple and connect
pump via the three-way terminal. a hand vacuum pump to the nipple.
2. When the engine is hot or cold, check the 2. Plug the vacuum hose (White stripe).
condition of vacuum by racing the engine.
When engine is cold
(Engine coolant temperature: 20°C or less)
Throttle valve Normal vacuum condition
Open quickly No vacuum will generate (the Vac-
uum
same as barometric pressure.)
When engine is hot
(Engine coolant temperature: 80°C or higher) Engine speed (r/min)
Throttle valve Normal vacuum condition AK100011AC
Open quickly It will momentarily rise over 13 3. Start the engine.

kPa
3. Disconnect the three-way terminal. generated regardless of the engine speed.
Green stripe 5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
EGR VALVE CHECK <4G63>

M1173002800234
1. Remove the EGR valve and inspect for sticking,
carbon deposits, etc. If found, clean with a
suitable solvent so that the valve seats correctly.
2. Connect a hand vacuum pump to the EGR valve.
EGR valve AK200376 AC 3. Apply 67 kPa of vacuum, and check that the
vacuum is maintained.
4. Connect the hand vacuum pump to the EGR
valve nipple.
5. Check whether the engine stalls or the idling is
unstable when a vacuum of 30 kPa or higher is
applied during idling.
AKX00348
4. Apply a vacuum and check the passage of air by Battery B nipple Normal condition
blowing through one side of the EGR passage. voltage condition
Vacuum Passage of air Not applied Open Vacuum
5.3 kPa or less Air is not blown out maintained
27 kPa or more Air is blown out Applied Open Vacuum leaks
5. Replace the gasket, and tighten to the specified Closed Vacuum
torque. maintained
Tightening torque: 20 ± 2 N⋅m 5. Measure the resistance between the terminals of
the solenoid valve.
EGR CONTROL SOLENOID VALVE Standard value: 29 − 35 Ω (at 20°C)
CHECK <4G63>
M1173003100261
EGR VALVE (STEPPER MOTOR) CHECK
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
<4G69>
M1173050200134
original position. Checking the Operation Sound
A
Battery
EGR valve
AK201251AB (stepper motor)
AK302877AB
1. Check that the operation sound of the stepper

motor can be heard from the EGR valve when the
ignition switch is turned ON (without starting the
engine).
2. If the operation sound cannot be heard, inspect
the drive circuit of the stepper motor.
NOTE: If the circuit is normal, either the stepper
motor or the engine-ECU <M/T> or engine-A/T-ECU
AK304447
<A/T> may have failed.
1. Disconnect the vacuum hose from the solenoid Checking the Coil Resistance
valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
4. Check air tightness by applying a vacuum with
voltage applied directly from the battery to the 1 2 3
4 5 6
EGR control solenoid valve and without applying
voltage. 1 2 3
4 5 6
AK200805 AC
1. Remove the EGR valve.

2. Measure the resistance between terminal No. 2 4. Connect terminals No. 1 and No. 3 to the negative
and either terminal No. 1 or terminal No. 3 of the (-) terminal of the battery, in order to test whether
connector at the EGR valve. the stepper motor vibrates (with a slight shudder),
Standard value: 20 − 24 Ω (at 20°C) indicating that the stepper motor is operating.
3. Measure the resistance between terminal No. 5 CAUTION
and either terminal No. 6 or terminal No. 4 of the Connecting battery voltage to the EGR valve for a
connector at the EGR valve. long term could damage the coil.
Standard value: 20 − 24 Ω (at 20°C)
4. Using a new gasket, install the EGR valve by
tightening its mounting bolts to the specified
torque.
Tightening Torque: 24 ± 4 N⋅m
Operation Check
MB991658 Battery
AK304039 AB
5. Connect the positive (+) terminal of the battery to

terminal No. 5.
6. Connect terminals No. 4 and No. 6 to the negative
1 2 3 (-) terminal of the battery, in order to test whether
4 5 6
the stepper motor vibrates (with a slight shudder),
indicating that the stepper motor is operating.
EGR valve
AK203698 AC
7. If a vibration can be felt during the test, the
stepper motor is normal.
1. Remove the EGR valve. 8. Using a new gasket, install the EGR valve by
2. Attach a test wiring harness (special tool tightening its mounting bolts to the specified
MB991658) to the connector at the EGR valve. torque.
Cleaning the EGR Valve

CAUTION
Do not use a solvent or detergent, which could
enter the motor and cause it to malfunction.
MB991658 1. Remove the EGR valve and check that the EGR
Battery valve is not stuck or clogged with carbon deposits.
Use a wire brush to clean the valve if necessary.
AK302886 AB
2. Using a new gasket, install the EGR valve by
CAUTION tightening its mounting bolts to the specified
Connecting battery voltage to the EGR valve for a torque.
long term could damage the coil. Tightening torque: 24 ± 3 N⋅m
3. Connect the positive (+) terminal of the battery to
terminal No. 2.
EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL AND INSTALLATION

<4G63>
M1173010500249

Air cleaner cover and air intake hose removal and installation
(Refer to GROUP 15 - Air cleaner P.15-3).
1
2 20 ± 2 N·m
3N
AC301219 AB

1. Vacuum hose connection 2. EGR valve
3. EGR valve gasket
EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL AND INSTALLATION

<4G69>
M1173010500250

Resonator removal and installation (Refer to GROUP 15 - Air
cleaner P.15-4).
1 24 ± 3 N·m
3N
AC302329AE
Removal steps INSTAIIATION SERVICE POINT

1. EGR valve connector >>A<< EGR PIPE B GASKET INSTALLATION
2. EGR valve
>>A<< 3. EGR valve gasket
Notched
part
Gasket
Notched
part AC302358AE
Install the EGR valve gasket as shown in the

illustration.
CATALYTIC CONVERTER
M1173003900449
<4G63-2WD> 44 ± 5 N·m
49 ± 10 N·m 1 2
N5
3N 59 ± 10 N·m
6
AC212564 AC
<4G63-4WD>
44 ± 5 N·m
2
1
N 5
4
3N 59 ± 10 N·m
6
49 ± 10 N·m
AC212565 AD
<4G69>
2
N 5
4
3N 59 ± 10 N·m
6
49 ± 10 N·m
AC309495 AB

<<A>> >>A<< 1. Oxygen sensor <4G63> 4. Front exhaust pipe connection
2. Center exhaust pipe connection 5. Exhaust pipe gasket
3. Exhaust pipe gasket 6. Catalytic converter

<<A>> OXYGEN SENSOR REMOVAL >>A<< OXYGEN SENSOR INSTALLATION
MD998770 MD998770
Oxygen sensor Oxygen sensor
AC212566AB AC212566AB
Use special tool oxygen sensor wrench (MD998770) Use special tool oxygen sensor wrench (MD998770)
to remove the oxygen sensor. to install the oxygen sensor.
21A-1
GROUP 21A
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . . 21A-2 CLUTCH PEDAL. . . . . . . . . . . . . . . . . 21A-5

REMOVAL AND INSTALLATION . . . . . . . . 21A-5
SERVICE SPECIFICATIONS. . . . . . . 21A-2
CLUTCH CONTROL . . . . . . . . . . . . . . 21A-6
LUBRICANTS . . . . . . . . . . . . . . . . . . 21A-2 REMOVAL AND INSTALLATION . . . . . . . . 21A-6
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-7
ON-VEHICLE SERVICE. . . . . . . . . . . 21A-3 DISASSEMBLY AND REASSEMBLY . . . . . 21A-7
CLUTCH PEDAL CHECK AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-8
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21A-3
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-4
21A-2 CLUTCH
GENERAL INFORMATION
GENERAL INFORMATION
M1211000100201
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control. The
clutch shares a brake fluid reservoir with the brake
system.
M1211000300197
Item Standard value

Clutch pedal height mm 208.4 ± 2
Clutch pedal clevis pin play mm 1−3
Clutch pedal free play mm 4 − 13
Distance between the clutch pedal and the clutch pedal 105 or more
stopper when the clutch pedal is released mm
LUBRICANTS
M1211000400150
Item Specified lubricant Quantity

Clutch fluid Brake Fluid DOT 3 or DOT 4 As required
Pushrod assembly Rubber grease As required
Boot Rubber grease As required
Release cylinder push rod MITSUBISHI genuine grease Part As required
No.0101011
CLUTCH 21A-3
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND CAUTION
ADJUSTMENT Do not push in the master cylinder pushrod at
M1211000900218 this time, otherwise the clutch will not operate
Clutch pedal height properly.
3. If the clutch pedal height and clutch pedal clevis
pin play are not within the standard value, loosen
the setting nut to adjust the clutch pedal height
and clevis pin play to the standard value.
A
Clutch pedal free play
Clutch pedal stopper
AC100354 AB
1. Measure the clutch pedal height.

Standard value (A): 208.4 ± 2 mm
C
Clutch pedal clevis pin play
AC100355 AC
Distance between the clutch pedal and the

clutch pedal stopper when the clutch is dis-
engaged
B D
AC100355 AB
2. Measure the clutch pedal clevis pin play. Clutch pedal

Standard value (B): 1 − 3 mm stopper AC100357 AB
4. After completing the adjustments, confirm that the

Setting nut clutch pedal free play (measured at the face of the
pedal pad) and the distance between the clutch
pedal (the face of the pedal pad) and the clutch
pedal stopper when the clutch is disengaged are
within the standard value ranges.
Standard value (C): 4 − 13 mm
Clutch pedal
Standard value (D): 105 mm or more
13 ± 2 N·m
AC100356 AB
5. If the clutch pedal free play and the distance
between the clutch pedal and the clutch pedal
stopper when the clutch is disengaged do not
agree with the standard values, it is probably the
result of either air in the hydraulic system or a
faulty master cylinder, release cylinder or clutch.
Bleed the air, or disassemble and inspect the
master cylinder, release cylinder or clutch.
21A-4 CLUTCH
ON-VEHICLE SERVICE
CLUTCH BLEEDING 6. Check that the brake fluid reservoir level stays
M1211001400164 between "MAX" and "MIN" marks throughout the
Clutch master cylinder bleeding clutch bleeding process.
CAUTION
Use the specified brake fluid. Do not mix brake Clutch release cylinder bleeding
fluids. CAUTION
Specified fluid: Brake fluid DOT 3 or DOT 4 Use the specified brake fluid. Do not mix brake
1. Disconnect the brake tube clamp and remove the fluids.
brake master cylinder with the brake tubes Specified fluid: Brake fluid DOT 3 or DOT 4
connected. 1. Remove the under cover.
2. Remove the brake fluid reservoir with the hoses
connected.
AC301000AB
AC301530AB 2. Connect a hose with a bottle to the bleeder screw.

3. Open the bleed nipple.
3. Connect a hose with a bottle to the bleeder screw. 4. Depress the clutch pedal slowly. Open the bleeder
4. Open the bleed nipple. screw to let air and brake fluid out. Close the
5. Depress the clutch pedal slowly. Open the bleeder bleeder screw. Release the clutch pedal. Repeat
screw to let air and brake fluid out. Close the until only brake fluid and no air comes out.
bleeder screw. Release the clutch pedal. Repeat 5. Check that the brake fluid reservoir level stays
until only brake fluid and no air comes out. between "MAX" and "MIN" marks throughout the
clutch bleeding process.
CLUTCH 21A-5
CLUTCH PEDAL
CLUTCH PEDAL
M1211001600179
• Clutch Pedal Adjustment (Refer to P.21A-3).
7
1
4
3 5
12 ± 2 N·m
6
AC301004 AB

• Instrument panel under cover 4. Clutch pedal assembly mounting
(Refer to GROUP 52A, Instrument bolt
panel P.52A-2). 5. Pedal pad
1. Snap pin 6. Pedal stopper
2. Clevis pin 7. Clutch pedal assembly
3. Clutch master cylinder mounting
nut
21A-6 CLUTCH
CLUTCH CONTROL
CLUTCH CONTROL
M1211001900211

Clutch Fluid Draining • Clutch Fluid Supplying
• Clutch Line Bleeding (Refer to P.21A-4).
• Clutch Pedal Adjustment (Refer to P.21A-3).
Release fork 15 ± 1 N·m
10, 12
Release cylinder
14 push rod
1
Specified grease:
MITSUBISHI genuine grease 4
PART No. 0101011 12 ± 2 N·m
30 ± 4 N·m
10
2
14
N 3 8 12 ± 2 N·m
6 5 7
9
18 ± 3 N·m
14
12
11
13
12
18 ± 3 N·m
AC308104 AB
Clutch master cylinder removal Clutch release cylinder removal

steps steps
1. Clevis pin assembly 10. Clutch pipe <4G63-2WD>
2. Eye bolt 11. Clutch pipe and clutch orifice
3. Gasket assembly <4G63-4WD, 4G69>
4. Reservoir hose 12. Clutch pipe <4G63-4WD, 4G69>
5. Clevis pin and pushrod assembly 13. Clutch orifice assembly
connecting part <4G63-4WD, 4G69>
<<A>> 6. Clutch master cylinder 14. Clutch release cylinder
7. Sealer Clutch line removal steps
8. Retainer plate 9. Clutch hose
10. Clutch pipe <4G63-2WD>
12. Clutch pipe <4G63-4WD, 4G69>
CLUTCH 21A-7
CLUTCH CONTROL
REMOVAL SERVICE POINT 3. Remove the clutch master cylinder.

<<A>> CLUTCH MASTER CYLINDER REMOVAL
INSPECTION
1. Disconnect the brake tube clamp and remove the M1211002000136
brake master cylinder with the brake tubes • Check the master cylinder or clutch hose for fluid
connected. leakage.
2. Remove the brake fluid reservoir with the hoses • Check the clutch hose or tube for cracks or
connected. clogging.

M1211002100199
CLUTCH MASTER CYLINDER
CAUTION
Do not disassemble the piston assembly.
13 ± 2 N·m
6
7
3
4N
1 N
2N
8 5
4 2
1
2
3
4
Clutch fluid:
Piston repair kit Brake fluid DOT3 OR DOT4 Grease: Rubber grease
AC309450 AB

1. Piston stopper ring 5. Spring pin
2. Piston assembly 6. Nipple
>>A<< 3. Pushrod assembly 7. Seal
4. Boot 8. Master cylinder body
21A-8 CLUTCH
CLUTCH CONTROL
REASSEMBLY SERVICE POINT >>A<< PUSHROD ASSEMBLY INSTALLATION

Set the length of the pushrod assembly to the
dimension shown to make the adjustment of the
clutch pedal easier.
INSPECTION
M1211002200130
• Check inside the cylinder body for rust and scars.
• Check the piston cup for wear and deformation.
• Check the piston for rust and scars.
103 ± 0.5 mm • Check the pipe connection for clogging.
AC001144 AG
21B-1
GROUP 21B
CLUTCH
OVERHAUL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 21B-2 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 21B-5

DISASSEMBLY AND REASSEMBLY . . . . . 21B-5
GENERAL SPECIFICATIONS . . . . . . 21B-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21B-7
SERVICE SPECIFICATIONS. . . . . . . 21B-4 CLUTCH RELEASE CYLINDER . . . . 21B-9

TORQUE SPECIFICATIONS . . . . . . . 21B-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21B-10
LUBRICANTS . . . . . . . . . . . . . . . . . . 21B-4
21B-2 CLUTCH OVERHAUL

M1212002400074

Scope of Service Explanations
This manual describes service procedures performed after removal of the transmission from the vehicle.
For removal of the transmission from the vehicle, installation of the transmission in the vehicle, and on-vehicle inspection
and service of the transmission, please use the separate Workshop Manuals prepared for the vehicle.
How to Read Explanations
Service steps
(1) A component part drawing is shown at the beginning of each section to enable the technician to ascertain the installed conditi-
on of the component parts.
(2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such,
and tightening torques are shown.
·Removal steps:
The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence.
·Installation steps:
Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse.
·Disassembly steps:
The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence.
·Reassembly steps:
Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.
Classification of Service Points

Key service points, service standards, and instructions <<A>>: Outward-pointing brackets denote removal service points
for using special tools are collated as service points and or disassembly service points.
explained in detail. >>A<<: Inward-pointing brackets denote installation service points
or reassembly service points.
Lubricant and Sealant Symbols

Every location where a lubricant or sealant must be ap- . . . . . . . . . . Grease
plied or added is indicated using a relevant symbol in the
component part drawing and/or on the page after the . . . . . . . . . . Sealant or form-in-place gasket (FIPG)
component part drawing.
. . . . . . . . . . Brake fluid
. . . . . . . . . . Gear oil
Inspection
If an inspection reveals a defect or fault, effect a repair and, if necessary, replace relevant parts.
AK300001
CLUTCH OVERHAUL 21B-3
Section title Page number
OVERHAUL CONTROL HOUSING 22-43

CONTROL HOUSING
Denotes non-reusable part.
6
9
7 3
11
12
5
13
4
8
10
14
Tightening torque
2
1
AK302747AB
22.3 ± 0.3 N·m
Disassembly steps Disassembly steps
1. Spring washer >>D<< 6. Spring pin
2. Stopper bracket 7. Stopper body
<<A>> >>E<< 3. Lock pin 8. Spring
4. Interlock plate 9. Control shaft
5. Control finger
Procedures and cautions for removal, instal-

lation, disassembly, and reassembly are ex- DISASSEMBLY SERVICE POINTS
plained under this category of heading.
<<A>> LOCK PIN REMOVAL
Drive out the lock pin from the direction shown.
Lock pin
The alphabetical character in this category of

heading matches that of the relevant removal
Control
finger steps, installation steps, disassembly steps,
AK204273 AB
or installation steps.
AK302746
M1212000200182
Item Specification
Combined engine 4G63-D4-MPI 4G69-S4-MIVEC
Clutch operating method Hydraulic type
Clutch disc type Single dry disc type
Clutch disc size OD × ID mm 230 × 155
Clutch cover type Diaphragm spring type
Clutch cover setting load N 4,320 5,200
M1212000300156
Item Limit
Diaphragm spring end height difference 0.5 mm
Clutch disc facing rivet sink Minimum 0.3 mm
Release cylinder I.D. to piston O.D. 0.15 mm
M1212001800154
Part N⋅m
Clutch fluid line bracket bolt 18 ± 3
Clutch tube flare nut 15 ± 1
Clutch orifice mounting bolt <W5M42> 18 ± 3
Union bolt 22 ± 2
Clutch release cylinder mounting bolt 18 ± 3
Clutch cover mounting bolt 18 ± 3
Fulcrum 35 ± 6
Air bleeder 17 ± 1
LUBRICANTS
M1212000400120
Item Specified lubricant

Release fork and release bearing contact surface MITSUBISHI genuine grease Part
Release fork and fulcrum contact surface Number 0101011 or equivalent
Release fork and release cylinder pushrod contact surface
Clutch disc splines
Piston and piston cup Brake fluid DOT3 or DOT4
Release cylinder inner surface
CLUTCH
CLUTCH
M1212001000169
<F5M42>
18 ± 3 N·m
1
2
3
35 ± 6 N·m
15 14
9 12
10
4
13 5
11 22 ± 2 N·m
7 6
15 ± 1 N·m
18 ± 3 N·m
18 ± 3 N·m
8
AK302748AC

1. Clutch fluid line bracket >>B<< 10. Clutch disc
2. Insulator 11. Return clip
3. Washer 12. Clutch release bearing
4. Clutch tube <<A>> >>A<< 13. Release fork
5. Union bolt 14. Release fork boot
6. Union 15. Fulcrum
7. Gasket
8. Clutch release cylinder
>>B<< 9. Clutch cover
CLUTCH
<W5M42>
18 ± 3 N·m
1
2
3
18 ± 3 N·m
35 ± 6 N·m
12 18 4
15
13 17
7
6
16
14 8 22 ± 2 N·m
10
9
15 ± 1 N·m 5
18 ± 3 N·m
11
18 ± 3 N·m
AK302278 AC

1. Clutch fluid line bracket 11. Clutch release cylinder
2. Insulator >>B<< 12. Clutch cover
3. Washer >>B<< 13. Clutch disc
4. Clutch tube 14. Return clip
5. Clutch tube 15. Clutch release bearing
6. Tube clip <<A>> >>A<< 16. Release fork
7. Clutch orifice 17. Release fork boot
8. Union bolt 18. Fulcrum
9. Union
10. Gasket
CLUTCH
REMOVAL SERVICE POINT 1. Apply Mitsubishi genuine grease part number

<<A>> RELEASE FORK REMOVAL 0101011 or equivalent to the illustrated positions
of the release fork.
2. Install the release fork to the fulcrum.
>>B<< CLUTCH DISC AND CLUTCH COVER

INSTALLATION
Fulcrum
Flywheel
Clutch disc
Clip
Clutch disc
guide
Release fork
AK204409AB
Move the release fork in the direction shown to

remove the clip from the fulcrum. Clutch cover
INSTALLATION SERVICE POINTS AK204214 AB
>>A<< RELEASE FORK INSTALLATION

1. Apply Mitsubishi genuine grease part number
0101011 or equivalent to the clutch disc splines
and rub it in the splines with a brush.
2. Using the clutch disc guide to position the clutch
Apply grease
disc on the flywheel.
3. Install the clutch cover onto the flywheel.
INSPECTION
M1212001100100
CLUTCH COVER
Apply grease
1. Check the diaphragm spring end for wear and
uneven height. Replace if wear is evident or
height difference exceeds the limit.
Limit: 0.5 mm
2. Check the pressure plate surface for wear, cracks
and discoloration.
3. Check the rivets of the strap plate for looseness. If
loose, replace the clutch cover.
Apply grease
AK204410AB
CLUTCH
CLUTCH DISC 3. Check the torsion spring for play and damage. If
CAUTION defective, replace the clutch disc.
Don't clean the clutch disc in a cleaning solvent. 4. Place the clutch disc on the input shaft and check
1. Check the facing for loose rivets, uneven contact, for sliding condition and play in the rotating
evidence of seizure, or deposited oils and direction. If poor sliding condition is evident,
greases. If defective, replace the clutch disc. clean, reassemble, and recheck.
NOTE: If contaminated with grease or oil, If excessive play is evident, replace the clutch
determine the source of the contaminant and disc and/or input shaft.
repair it.
CLUTCH RELEASE BEARING
CAUTION
Rivet sink Release bearing is packed with grease.
Therefore, do not wash it in a cleaning solvent.
1. Check for seizure, damage, noise or
Torsion spring binding/rough rotation.
2. Check for wear on the surface which contacts with
the diaphragm spring.
3. Check for wear on the surface which contacts with
AK300248AB the release fork. If abnormally worn, replace.
2. Measure the rivet sink. Replace the clutch disc if it RELEASE FORK
is below the limit. If the surface which contacts with the bearing is
Minimum limit: 0.3 mm abnormally worn, replace.
CLUTCH RELEASE CYLINDER

M1212001500119
3 2
5
4 1
9
17 ± 1 N·m
7
AK204216AB
Disassembly steps DISASSEMBLY SERVICE POINT

1. Push rod <<A>> PISTON ASSEMBLY REMOVAL
2. Boot
<<A>> >>A<< 3. Piston assembly
4. Piston cup
5. Piston
6. Conical spring
7. Cap
8. Air bleeder
9. Release cylinder
AKX00765
1. Cover with a shop towel to prevent the piston from

popping out.
CAUTION
Apply compressed air slowly to prevent brake
fluid from splashing.
2. Apply the compressed air into the tube mounting
hole to remove the piston assembly.
REASSEMBLY SERVICE POINT 1. Apply brake fluid DOT3 or DOT4 to the piston cup
>>A<< PISTON ASSEMBLY INSTALLATION and inner surface of the release cylinder.
2. Insert the piston assembly into the release
cylinder.
INSPECTION
M1212001600150
RELEASE CYLINDER
1. Check the bore of the release cylinder for rust,
scratches or damage.
2. Using a cylinder gauge, measure the inside
diameter of the release cylinder at about there
AK204411AB
positions (the deepest, middle and brim
positions).
If the clearance from the outside diameter of the
piston exceeds the limit, replace the release
cylinder as an assembly.
AK204412AB
22A-1
GROUP 22A
MANUAL
TRANSMISSION (FF)
CONTENTS
GENERAL INFORMATION . . . . . . . . 22A-2 TRANSMISSION OIL REPLACEMENT. . . . 22A-8

TRANSFER OIL CHECK . . . . . . . . . . . . . . . 22A-8
LUBRICANT. . . . . . . . . . . . . . . . . . . . 22A-2 TRANSFER OIL REPLACEMENT . . . . . . . 22A-8
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22A-3 TRANSMISSION CONTROL*. . . . . . . 22A-9

TROUBLESHOOTING . . . . . . . . . . . . 22A-4 SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . 22A-12
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 22A-4 DISASSEMBLY AND REASSEMBLY . . . . . 22A-12
TROUBLESHOOTING STRATEGY . . . . . . 22A-4
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 22A-4 TRANSFER ASSEMBLY . . . . . . . . . . 22A-13
SYMPTOM PROCEDURES . . . . . . . . . . . . 22A-4 REMOVAL AND INSTALLATION . . . . . . . . 22A-13
ON-VEHICLE SERVICE. . . . . . . . . . . 22A-8 TRANSMISSION ASSEMBLY . . . . . . 22A-15

TRANSMISSION OIL LEVEL CHECK . . . . 22A-8 REMOVAL AND INSTALLATION . . . . . . . . 22A-15
WANINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
• Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
paassenger (from rendering the SRS inoperative).
• Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.
• MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any
SRS-related component.
NOTE
The SRS includes the following components: SRS air bag control unit, SRS warning light, front impact sensors, air bag module,
clock spring, and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection
with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).
22A-2 MANUAL TRANSMISSION (FF)
GENERAL INFORMATION
GENERAL INFORMATION
M1221000100677
The manual transmission come in two models, namely, F5M42 and W5M42.
Item Specification
Transmission model F5M42 (2WD) W5M42 (4WD)
Engine model 4G63-DOHC-MPI 4G69-SOHC-MIVE
C
Transmission type 5-speed forward, 1-speed reverse constant mesh
Transmission gear ratio 1st 3.583
2nd 1.947
3rd 1.379
4th 1.030
5th 0.820
Reverse 3.363
Final reduction ration (Differential gear ratio) 4.625 4.687 4.352
Speedmeter gear ratio 27/36
LUBRICANT
M1221000400203
Item Specified lubricant Quantity L

Transmission oil Gear oil API classification GL-4 SAE 75W-85W or 75W-90 2WD 2.2
4WD 2.3
Transfer oil <4WD> Hypoid gear oil API classification GL-5 SAE90 0.55
MANUAL TRANSMISSION (FF) 22A-3
SPECIAL TOOLS
SPECIAL TOOLS
M1221000600672

MB991453 Engine hanger When the engine hanger is used:
assembly Supporting the engine assembly
during removal and installation of the
transmission assembly
B991453 NOTE: Special tool MB991454 is a
part of engine hanger attachment set
MB991454 Engine hanger MB991453.
balancer
B991454
B991527
MB991895

Slide bracket (HI) A: MB991929 A: Joint (50) ×2
B: MB991930 B: Joint (90) ×2
E C: MB991931 C: Joint (140) ×2
D: MB991932 D: Foot (standard) ×4
F E: MB991933 E: Foot (short) ×2
A F: MB991934 F: Chain and hook
D
assembly
B
C
B991928
TROUBLESHOOTING
TROUBLESHOOTING
INTRODUCTION TROUBLESHOOTING STRATEGY
M1221006900660 M1221007000585
The manual transmission can exhibit any of the Use these steps to plan your diagnostic strategy. If
following symptoms: noise or vibration is generated, you follow them carefully, you will be sure that you
oil leaks, shifting gears is hard or troublesome, or the have exhausted most of the possible ways to find a
transmission jumps out of gear. manual transmission fault.
The causes of these symptoms could come from: 1. Gather information from the customer.
incorrect mounting, the oil level may be low, or a 2. Verify that the condition described by the
component of the transmission may be faulty. customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1221007100571
SYMPTOM INSPECTION REFERENCE

PROCEDURE PAGE
Noise, Vibration 1 P.22A-4
Oil Leaks 2 P.22A-5
Hard Shifting 3 P.22A-6
Jumps Out of Gear 4 P.22A-7
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Noise, Vibration
DIAGNOSIS STEP 3. Check that the oil level is up to the lower

edge of the filler plug hole.
STEP 1. Check the idle speed.
Q: Does the idle speed meet the standard values?
YES : Go to Step 2 . Filler plug hole
NO : Refer to GROUP 11A <4G63
Engine>P.11A-11 , or GROUP 11C <4G69
Engine>P.11C-14 , On-vehicle Service −
Kerb Idle Speed Check.
Transmission oil Filler plug
STEP 2. Check whether the transaxle and engine AC102278AO
mount is loose or damaged.
Q: Are the transaxle and engine mount loose or Q: Is the oil level up to the lower edge of the filler plug
damaged? hole?
YES : Tighten or replace the part. Then go to Step YES : Go to Step 4 .
7. NO : Refill gear oil API classification GL-4 SAE
NO : Go to Step 3 . 75W−85W or 75W−90. Then go to Step 7 .
TROUBLESHOOTING
STEP 4. Check for the specified oil. STEP 6. Disassemble the transmission. Check
Q: Is the specified oil gear oil API classification GL-4
the gears for wear and damage.
SAE 75W−85W or 75W−90? Q: Are the gears worn or damaged?
YES : Go to Step 5 . YES : Replace the gears. Go to Step 7 .
NO : If in doubt, replace the oil. Refer to P.22A-8. NO : Go to Step 7 .
Then go to Step 7 .
STEP 7. Retest the systems.
STEP 5. Remove the transmission. Check the
Q: Is the noise or vibration still there?
end play of the input and output shafts. YES : Return to Step 1 .
Q: Does the end play of the input and output shafts NO : The procedure is complete.
meet the standard value?
NO : Adjust the end play of the input and output
shafts. Then go to Step 7 .
INSPECTION PROCEDURE 2: Oil Leaks
DIAGNOSIS YES : Remove the transmission. Check the input

shaft oil seal, and replace if necessary.
Then go to Step 4 .
STEP 1. Visual check. NO : Go to Step 3 .
Raise the vehicle, and check for oil leaks. If oil leak is
difficult to locate, steam clean the transmission and
drive the vehicle for at 10 minutes. Then check the STEP 3. Check the oil seal or O-ring for damage.
leak again. Q: Is the oil seal or O-ring damaged?
YES : Replace the oil seal or the O-ring. Then go
Q: Is the oil leak(s) found?
YES : Go to Step 2 . to Step 4 .
NO : Check for the oil leaks around the engine. NO : Go to Step 4 .
Then go to Step 4 .
STEP 2. Visual check at the clutch housing. Q: Is the oil still leaking?
YES : Return to Step 1 .
Q: Do oil leaks appear around the joint between the
NO : The procedure is complete.
engine and the clutch housing?
TROUBLESHOOTING
INSPECTION PROCEDURE 3: Hard Shifting

NO : Repair or replace the control housing. Refer
to GROUP 22B, Transmission P.22B-43.
STEP 1. Check the transmission control Then go to Step 7 .
Q: Are the shift cable and the select cable in good
condition? STEP 5. Check for poor meshing of worn
synchronizer ring and gear cone.
NO : Repair or replace the shift cable and the
select cable. Refer to P.22A-8. Then go to Q: Is poor meshing or worn synchronizer ring and
Step 7 . gear cone found?
YES : Repair or replace the synchronizer ring and
gear cone. Then go to Step 7 .
STEP 2. Check the transmission oil. NO : Go to Step 6 .
Q: Is the oil dirty?
YES : Replace the oil. Refer to P.22A-8. Then go
STEP 6. Check the synchronizer spring for
to Step 7
weakness.
NO : Go to Step 3 .
Q: Is the synchronizer spring weak?
YES : Replace the synchronizer spring. Then go
STEP 3. Check the clutch system. to Step 7 .
Q: Is the clutch system normal? NO : Go to Step 7 .
NO : Repair or replace the clutch system. Refer
to P.22A-8. Then go to Step 7 .
Q: Is the shifting of the gears still hard?
STEP 4. Remove and disassemble the NO : The procedure is complete.
transmission. Check the control housing.
Q: Is the control housing in good condition?
TROUBLESHOOTING
INSPECTION PROCEDURE 4: Jumps Out of Gear

NO : Repair or replace the control housing. Refer
to GROUP 22B, Transmission P.22B-14.
STEP 1. Check the transmission control Then go to Step 6 .
Q: Are the shift cable and the select cable in good
condition? STEP 4. Check the gear shift forks for wear.
NO : Repair or replace the shift cable and the Q: Is the gear shift forks worn?
select cable. Refer to P.22A-8. Then go to YES : Replace the gear shift fork. Refer to
Step 6 . GROUP 22B, Transmission P.22B-14. Then
go to Step 6 .
NO : Go to Step 5 .
STEP 2. Remove and disassemble the
transmission. Check the poppet spring for
breakage. STEP 5. Check the clearance.
Q: Is the poppet spring broken? Q: Is the clearance between the synchronizer hub and
YES : Replace the poppet spring. Refer to sleeve excessive?
GROUP 22B, Transmission P.22B-14. Then YES : Replace the synchronizer hub or sleeve.
go to Step 6 . Refer to GROUP 22B, Input Shaft
NO : Go to Step 3 . P.22B-25, Output Shaft P.22B-32. Then go
to Step 6.
NO : Go to Step 6 .
STEP 3. Check the control housing.
Q: Is the control housing in good condition?
Q: Does the transmission still jump out of gear?
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
TRANSMISSION OIL LEVEL CHECK TRANSFER OIL CHECK
M1221000900479 M1221001100108
Filler plug hole Filler plug hole
Transmission oil Filler plug Transfer oil Filler plug
AC210553 AB AC210553AC
1. Remove the filler plug. 1. Remove the filler plug.

2. Check that the oil level is up to the lower edge of 2. Check that the oil level is up to the lower edge of
the filler plug hole. the filler plug hole.
3. Check that the oil is not noticeably dirty. 3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque. 4. Tighten the filler plug to the specified torque.
Tightening torque: 32 ± 2 N⋅m Tightening torque: 32 ± 2 N⋅m
TRANSMISSION OIL REPLACEMENT TRANSFER OIL REPLACEMENT

M1221001000402 M1221001200086
Filler plug
Filler plug
Drain plug Drain plug
AC210554 AB AC210555 AB
1. Remove the filler plug. 1. Remove the filler plug.

2. Remove the drain plug and drain the oil. 2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque. 3. Tighten the drain plug to the specified torque.
Tightening torque: 32 ± 2 N⋅m Tightening torque: 32 ± 2 N⋅m
4. Fill with gear oil API classification GL-4 SAE 4. Fill with hypoid gear oil API classification GL-5
75W-85W or 75W-90 until the level comes to the SAE90 until the level comes to the lower portion
lower portion of filler plug hole. of filler plug hole.
Quantity: 2.2 L <2WD> Quantity: 0.55 L
Quantity: 2.3 L <4WD> 5. Tighten the filler plug to the specified torque.
5. Tighten the filler plug to the specified torque. Tightening torque: 32 ± 2 N⋅m
TRANSMISSION CONTROL
M1221003800578
WARNING
Be careful not to subject the SRS-ECU to any shocks during removal and installation of the
shift cable and select cable assembly.
• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15, Air Cleaner P.15-3<4G63>, P.15-4<4G69>).
• Battery and Battery Tray Removal and Installation.
11
7
9 12 ± 2 N·m
10
N 8 3 4
7 1
5
2
6
12 ± 2 N·m
12
AC309478AB
Gearshift cable and select cable Gearshift cable and select cable
assembly removal steps assembly removal steps
1. Gearshift lever knob <<A>> >>A<< 10. Gearshift cable connection
2. Sleeve (Transmission side)
• Front floor console (Refer to >>A<< 11. Gearshift cable and select cable
GROUP 52A P.52A-14). assembly
3. Select cable connection (Gearshift Gearshift lever assembly
lever side) removal steps
>>B<< 4. Gearshift cable clip 1. Gearshift lever knob
5. Gearshift cable connection 2. Sleeve
(Gearshift lever side) • Front floor console (Refer to
• SRS-ECU (Refer to GROUP 52B GROUP 52A P.52A-14).
P.52B-178). 3. Select cable connection (Gearshift
6. Console side cover bracket lever side)
7. Snap pin >>B<< 4. Gearshift cable clip
<<A>> >>A<< 8. Gearshift link clip 5. Gearshift cable connection
<<A>> >>A<< 9. Select cable connection (Gearshift lever side)
(Transmission side) 12. Gearshift lever assembly
REMOVAL SERVICE POINTS 1. Set the transmission side shift lever and the
<<A>> GEARSHIFT LINK CLIP/SELECT CABLE passenger compartment side shift lever to the
CONNECTION (TRANSMISSION SIDE)/GEAR neutral position.
SHIFT CABLE CONNECTION (TRANSMISSION 2. Install the painted part of the shift cable end
SIDE) REMOVAL (transmission side) and painted part of the select
cable (transmission side) facing the snap pin.
Gearshift cable,
Claws Select cable CAUTION
New gearshift
link clip
Gearshift link clip Cable bracket

AC210556 AB
Push up the claws of the gearshift link clip using a

screwdriver, etc., and then remove the gearshift link
clip from the bracket together with the cables. Shift cable, Select cable

>>A<< GEARSHIFT CABLE AND SELECT CABLE
ASSEMBLY/GEARSHIFT CABLE CONNECTION
(TRANSMISSION SIDE)/SELECT CABLE
CONECTION (TRANSMISSION SIDE)/GEARSHIFT
LINK CLIP INSTALLATION
Select lever
AC210558 AB
Insert thoroughly the gearshift link clip, shift

cable and select cable until they click in place.
3. After installing the new gearshift link clip to the
cable bracket of the transmission, install the shift
cable and select cable to the cable bracket.
NOTE: The clip is reversible.
Neutral position AC210557AB
4. Move the shift lever to all positions and check that
the operation is smooth.
>>B<< GEAR SHIFT CABLE CLIP INSTALLATION
9.5 mm
5 - 8 mm
AC210560 AB
AC210559AB
2. Engage the gearshift cable clip with the shift cable
1. Make sure that there is no excessive play at the hook securely, and push the gearshift cable clip
shift cable end gearshift cable clip. If there is with your thumbs until it clicks in place.
excessive play or the gearshift cable clip is 3. Install the shift cable to the shift lever.
disengaged from the shift cable end, check the
clip opening gap. If the gap is more than 9.5 mm,
squeeze the gearshift cable clip until the relaxed
gap reaches 5 to 8 mm.
SHIFT LEVER ASSEMBLY

M1221004000207
7
8
14 ± 2 N·m
8
4 3
3 2
1
5
10 ± 1 N·m
11 10
9
AC309326AB

1. Gearshift link bolt 7. Gearshift lever
2. Gearshift select lever 8. Gearshift link bushing
3. Gearshift link bushing 9. Gearshift lever bracket distance
4. Gearshift lever spring piece
5. Gearshift link collar 10. Gearshift link bushing
6. Bolt 11. Gearshift lever bracket
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
M1221003200059
CAUTION
*: Indicates parts which should be temporarily tightened, and then fully tightened after installing the
engine into the vehicle.
• Front Under Cover Removal and Installation (Refer to
GROUP 51, Front Bumper P.51-3).
• Side Under Cover Removal and Installation (Refer to
• Engine Coolant Draining and Supplying (Refer to GROUP
14, On-vehicle Service P.14-17).
• Transfer Oil Draining and Supplying (Refer to P.22A-8).
• Drive Shaft, Output Shaft Removal and Installation (Refer
to GROUP 26 P.26-15).
• Front Exhaust Pipe Removal and Installation (Refer to
GROUP 15, Exhaust Pipe and Main Muffler P.15-13).
• Propeller Shaft Removal and Installation (Refer to
GROUP 25 P.25-3).
10
3 9.0 ± 2.0 N·m

69 ± 10 N·m
8N 7
N 4 30 ± 3 N·m
69 ± 10 N·m
52 ± 7 N·m*
5
9.0 ± 2.0 N·m
N 2
52 ± 7 N·m* 1
30 ± 3 N·m
6
69 ± 10 N·m
69 ± 10 N·m
AC210286AC

1. Water return tube assembly 3. Water feed tube assembly
2. Gasket 4. Gasket
TRANSFER ASSEMBLY
Removal steps (Continued) REMOVAL SERVICE POINT

5. Rear roll stopper connection bolt
<<A>> TRANSFER ASSEMBLY REMOVAL
6. Centre member assembly
<<A>> 7. Transfer assembly
8. O-ring
9. Water return hose
10. Water feed hose
Engine and
Transmission
assembly
Transfer assembly
AC207772 AC
With the engine mount and transmission assembly

towards the front of the vehicle, and remove the
transfer assembly from between the engine block
and crossmember.
TRANSMISSION ASSEMBLY
M1221002700318
CAUTION
*: Indicates parts which should be temporarily tightened, and then fully tightened after installing the
engine into the vehicle.
• Air Cleaner assembly, Air Cleaner Bracket Removal and
Installation (Refer to GROUP 15, Air Cleaner
P.15-3<4G63>, P.15-4<4G69>).
• Battery and Battery Tray Removal and Installation.
• Front Under Cover Removal and Installation (Refer to
• Side Under Cover Removal and Installation (Refer to
• Transfer Oil Draining and Supplying <4WD> (Refer to
P.22A-8).
• Drive Shaft Removal and Installation (Refer to GROUP 26
P.26-15).
• Output Shaft Removal and Installation <4WD> (Refer to
GROUP 26 P.26-15).
• Propeller Shaft Removal and Installation <4WD> (Refer to
GROUP 25 P.25-3).
18 ± 3 N·m
18 ± 3 N·m
6
5
5
18 ± 3 N·m
4
1
3
7
70 ± 10 N·m
<2WD>
70 ± 10 N·m
8 <4WD>
7
70 ± 10 N·m
AC210287AB

1. Transmission harness clamp • Transfer assembly (Refer to
2. Back-up lamp switch connector P.22A-13).
3. Vehicle speed sensor connector 7. Rear roll mount bracket
4. Clutch release cylinder and clutch 8. Rear roll mount adapter bracket
oil pipe <4WD>
5. Snap pin <<A>> • Engine and transmission
6. Cable bracket and cable assembly assembly supporting
<Transmission side>
47 ± 7 N·m* 48 ± 5 N·m
48 ± 5 N·m 9
82 ± 7 N·m*
48 ± 5 N·m
9
48 ± 5 N·m
9
11
12
10 11 48 ± 5 N·m
15
<4WD> 13 44 ± 10 N·m
16
14
22 ± 4 N·m
9.0 ± 1.0 N·m
<2WD>
14 26 ± 5 N·m
9.0 ± 1.0 N·m

AC210288 AB

9. Transmission assembly upper part <> • Engine assembly supporting
coupling bolts <<C>> • Clutch release bearing connection
• Starter coupling bolts (Refer to >>A<< 13. Transmission housing front lower
GROUP 16 P.16-22<4G63>, cove stay <4WD>
P.16-23<4G69> ). 14. Flywheel housing front lower
<<A>> 10. Transmission mounting assembly cover
>>B<< 11. Transmission mounting stopper 15. Transmission assembly lower part
12. Transmission mounting coupling bolts
16. Transmission assembly

Front side
<<A>> ENGINE AND TRANSMISSION ASSEMBLY Slide
SUPPORTING/TRANSMISSION MOUNT bracket
ASSEMBLY REMOVAL (HI)
Joint (90)
Engine and transmission assembly (MB991930)
Joint (50) Foot (Standard)

(MB991929) (MB991932)
Garage jack Foot (Standard)
(MB991932) AC212277AD
2. <Engine hanger (special tool MB991928) is used>

(1) Assemble the engine hanger (special tool
MB991928). Set following parts to the base
AC210384 AB
hanger.
While supporting the engine and transmission • Slide bracket (HI)
assembly with a garage jack, remove the • Foot (standard) (MB991932)
transmission mount assembly. • Joint (90) (MB991930)
• Joint (50) (MB991929)
<> ENGINE ASSEMBLY SUPPORT
AC210400AB
AC210400AB
MB991928 Slide bracket (HI)
MB991895 MB991929
MB991527
MB991934
MB991930
MB991932
MB991932
MB991454
MB991454 MB991527 AC210392AF
AC210388 AB
(2) Set the engine hanger (special tool
1. <Engine hanger (special tool MB991895) is used> MB991928) to the strut mounting nuts and the
radiator support upper insulator mounting
(1) Set special tool MB991895 to the strut
bolts, which are located in the engine
mounting nuts and the radiator support upper
compartment, as shown.
insulator mounting bolts, which are located in
the engine compartment, as shown. NOTE: Adjust the engine hanger balance by
(2) Set special tools MB991454 to hold the sliding the slide bracket (HI).
engine/transmission assembly. (3) Set special tools MB991454 to hold the
engine/transmission assembly.
<<C>> CLUTCH RELEASE BEARING CAUTION

SEPARATION Be sure to push the release fork in the direction
CAUTION A before inserting a screwdriver.
3. Separate the release bearing from the wedge
B A collar by prying with the screwdriver (turning the
Release fork screwdriver grip 90°).
NOTE: The release fork is forced to move fully in
the direction B by the return spring as soon as it is
separated from the wedge collar.
Service hole
>>A<< TRANSMISSION HOUSING FRONT
LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cove stay
as below.
Wedge collar 1. Tighten the engine-side bolts to the specified
torque.
2. Tighten the transmission-side bolts to the
specified torque.
Release bearing
AC210561AC
>>B<< TRANSMISSION MOUNTING STOPPER
If it is hard to turn the screwdriver (to pry off the INSTALLATION
release bearing), remove the screwdriver once
Engine side
and repeat the below procedure after pushing the Transmission
release fork fully in the direction a two or three Arrow mounting stopper
times. Forcibly prying can cause the release
bearing to be damaged.
1. Remove the cover from the service hole in the Transmission
clutch housing. mounting
2. While pushing the release fork by hand in the
direction A, insert a flap-tip screwdriver between
the release bearing and the wedge collar. AC210408 AC
Install the transmission mounting stopper so that the

arrow points as shown in the illustration.
22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . . 22B-2 REVERSE IDLER GEAR . . . . . . . . . . 22B-40

GENERAL SPECIFICATIONS . . . . . . 22B-5
SPEEDOMETER GEAR . . . . . . . . . . . 22B-41
SERVICE SPECIFICATIONS. . . . . . . 22B-5 DISASSEMBLY AND REASSEMBLY . . . . . 22B-41
SNAP RING, SPACER AND THRUST SELECT LEVER . . . . . . . . . . . . . . . . . 22B-42

PLATE FOR ADJUSTMENT . . . . . . . 22B-6 DISASSEMBLY AND REASSEMBLY . . . . . 22B-42
TORQUE SPECIFICATIONS . . . . . . . 22B-8 CONTROL HOUSING . . . . . . . . . . . . . 22B-43

SEALANTS AND ADHESIVES . . . . . 22B-9
CLUTCH HOUSING . . . . . . . . . . . . . . 22B-45
LUBRICANTS . . . . . . . . . . . . . . . . . . 22B-10 DISASSEMBLY AND REASSEMBLY . . . . . 22B-45
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22B-10 TRANSMISSION CASE . . . . . . . . . . . 22B-48

TRANSMISSION . . . . . . . . . . . . . . . . 22B-14
DISASSEMBLY AND REASSEMBLY. . . . . 22B-14 DIFFERENTIAL. . . . . . . . . . . . . . . . . . 22B-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-24 DISASSEMBLY AND REASSEMBLY . . . . . 22B-50
INPUT SHAFT . . . . . . . . . . . . . . . . . . 22B-25 CENTER DIFFERENTIAL. . . . . . . . . . 22B-53

DISASSEMBLY AND REASSEMBLY. . . . . 22B-25 DISASSEMBLY AND REASSEMBLY . . . . . 22B-53
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-30
TRANSFER . . . . . . . . . . . . . . . . . . . . . 22B-56
OUTPUT SHAFT . . . . . . . . . . . . . . . . 22B-32 DISASSEMBLY AND REASSEMBLY . . . . . 22B-56
DISASSEMBLY AND REASSEMBLY. . . . . 22B-32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-38
22B-2 MANUAL TRANSMISSION OVERHAUL
GENERAL INFORMATION
GENERAL INFORMATION
M1222000100153
MANUAL TRANSMISSION MODELS
Transmission model Combined engine Vehicle model
F5M42-2-Y4B1 4G63-D4-MPI CU2W
W5M42-1-Z4B1 4G63-D4-MPI CU2W
W5M42-1-V4B1 4G93-S4-MIVEC CU5W
MANUAL TRANSMISSION OVERHAUL 22B-3
GENERAL INFORMATION
SECTIONAL VIEW
<F5M42>
AK302709
GENERAL INFORMATION
<W5M42>
AK302711
M1222000200202
TRANSMISSION MODEL TABLE

Transmission Speedomerter Final gear Vehicle model Engine model Transfer
model gear ratio ratio gear ratio
F5M42-2-Y4B1 27/36 4.625 CU2W 4G63-D4-MPI −
W5M42-1-Z4B1 27/36 4.687 CU2W 4G63-D4-MPI 0.3018
W5M42-1-V4B1 27/36 4.352 CU5W 4G93-S4-MIVEC 0.3018
GEAR RATIO TABLE
F5M42-2-Y4B1 W5M42-1-Z4B1 W5M42-1-V4B1
1st 3.583
2nd 1.947
3rd 1.379
4th 1.030
5th 0.820
Reverse 3.363
M1222000300179
Item Standard value Minimum limit

Differential case preload 0.05 − 0.11 mm −
Input shaft front bearing end play 0 − 0.12 mm −
Input shaft 5th speed gear end play 0 − 0.09 mm −
Input shaft rear bearing end play 0 − 0.12 mm −
Synchronizer ring back surface to gear clearance − 0.5 mm
Output shaft front bearing end play 0 − 0.12 mm −
Output shaft 3rd speed gear end play 0 − 0.09 mm −
Output shaft rear bearing end play 0 − 0.09 mm −
Backlash between differential gear and pinion <F5M42> 0 − 0.15 mm −
Backlash between center differential gear and pinion 0.025 − 0.150 mm −
<W5M42>
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
SNAP RING, SPACER AND THRUST PLATE FOR

ADJUSTMENT
M1222012000186
SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M42>

Thickness mm Identification symbol Thickness mm Identification symbol
0.71 71 1.01 01
0.74 74 1.04 04
0.77 77 1.07 07
0.80 80 1.10 J
0.83 83 1.13 D
0.86 86 1.16 K
0.89 89 1.19 L
0.92 92 1.22 G
0.95 95 1.25 M
0.98 98
SPACER (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD) <W5M42>
0.74 74 1.04 04
0.77 77 1.07 07
0.80 80 1.10 J
0.83 83 1.13 D
0.86 86 1.16 K
0.89 89 1.19 L
0.92 92 1.22 G
0.95 95 1.25 M
0.98 98 1.28 N
1.01 01 1.31 E
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING END PLAY)
2.24 None 2.38 Brown
2.31 Blue
THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY)
2.82 0 2.98 6
2.86 2 3.02 7
2.90 3 3.06 8
2.94 5 3.10 9
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY AND OUTPUT SHAFT
FRONT BEARING END PLAY)
1.43 Green (2) 1.59 Yellow (2)
1.51 White (2)
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY)
2.81 Green 2.97 Orange
2.85 White 3.01 Red
2.89 Yellow 3.05 Pink
2.93 Black 3.09 Blue
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY)
2.31 Black (2) 2.55 Yellow
2.35 None 2.59 Black
2.39 Blue 2.63 Orange
2.43 Brown 2.67 Blue
2.47 Green 2.71 Brown
2.51 White
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION)
<F5M42>
0.75 − 0.82 − 1.05 − 1.12 −
0.83 − 0.92 − 1.09 − 1.16 −
0.93 − 1.00 − 1.15 − 1.22 −
1.01 − 1.08 −
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN CENTER DIFFERENTIAL SIDE GEAR AND
PINION) <W5M42>
0.48 − 0.55 − 0.74 − 0.81 −
0.56 − 0.65 − 0.82 − 0.89 −
0.66 − 0.73 −
M1222012100138
Part N⋅m
Transfer - clutch housing mounting bolt <W5M42> 69 ± 10
Roll stopper bracket mounting bolt 70 ± 10
Shift cable bracket mounting bolt 18 ± 3
Select lever mounting bolt 18 ± 3
Speedometer gear mounting bolt 3.9 ± 1.0
Backup light switch 32 ± 2
Poppet spring 32 ± 2
Harness bracket bolt 18 ± 3
Harness bracket bolt <Except 2.4L model> 3.9 ± 1.0
Interlock plate bolt 30 ± 3
Control housing mounting bolt 18 ± 3
Under cover mounting bolt 6.9 ± 0.9
Reverse idler gear shaft mounting bolt 48 ± 6
Clutch housing-transaxle case mounting bolt 44 ± 5
Front bearing retainer mounting bolt 18 ± 3
Select lever mounting nut 11 ± 1
Stopper bracket mounting bolt 21.7 ± 0.3
Clutch release bearing retainer mounting bolt 9.8 ± 0.2
Differential drive gear mounting bolt 132 ± 5
Transfer cover mounting bolt <W5M42> 23 ± 3
SEALANTS AND ADHESIVES
SEALANTS AND ADHESIVES

M1222000500106

Clutch housing-transaxle case mating surface MITSUBISHI Genuine sealant part No. MD997740 or
Under cover-transaxle case mating surface equivalent
Control housing-transaxle case mating surface
Air breather 3M SUPER WEATHERSTRIP No.8001 or equivalent
Differential drive gear bolt 3M STUD Locking No.4170 or equivalent
FORM-IN-PLACE GASKET (FIPG) Surface Preparation
This transmission has several areas where the Thoroughly remove all substances deposited on the
form-in-place gasket (FIPG) is used for sealing. To FIPG application surface, using a gasket scraper.
ensure that the FIPG fully serves its purpose, it is Make sure that the FIPG application surface is flat
necessary to observe some precautions when and smooth. Also make sure that the surface is free
applying it. Bead size, continuity and location are of from oils, greases and foreign substances. Do not fail
paramount importance. to remove old FIPG that may remain in the fastener
Too thin a bead could cause leaks. Too thick a bead, fitting holes.
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To FIPG Application
prevent leaks or blocking of passages, therefore, it is Applied FIPG bead should be of the specified size
absolutely necessary to apply the FIPG evenly and free of any break. FIPG can be wiped away
without a break, while observing the correct bead unless it has completely hardened. Install the mating
size. parts in position while the FIPG is still wet (in less
FIPG hardens as it reacts with the moisture in the than 10 minutes after application). Do not allow FIPG
atmospheric air, and it is usually used for sealing to spread beyond the sealing areas during
metallic flange areas. installation. Avoid operating the transmission or
letting oils or water come in contact with the sealed
Disassembly area before a time sufficient for FIPG to harden
Parts sealed with a FIPG can be easily removed (approximately one hour) has passed.
without need for the use of a special method. In FIPG application method may vary from location to
some cases, however, the FIPG in joints may have to location. Follow the instruction for each particular
be broken by tapping parts with a mallet or similar case described later in this manual.
tool.
LUBRICANTS
LUBRICANTS
M1222000400132
TRANSMISSION
Each O-ring Hypoid gear oil SAE 75W-90 or 75W-85W conforming to
Each oil seal API classification GL-4
Select lever shoe MITSUBISHI genuine grease part No.0101011 or
Input shaft front oil seal equivalent
TRANSFER
Each O-ring Hypoid gear oil API classification GL-5 SAE 90
Each oil seal
SPECIAL TOOLS
M1222000600181
Tool Number Name Application

MB990935 Installer adapter Installation of differential case
taper roller bearing outer race
<F5M42> and center differential
case rear taper roller bearing
outer race <W5M42>
MB990938 Handle Use with Installer adapter
B990938
MB990927 Installer adapter Installation of sealing cap
MD998801 Bearing remover Installation and removal of

gears, bearings and sleeves
MD998812 Installer cap Use with Installer and Installer

adapter
SPECIAL TOOLS

MD998813 Installer-100 Use with Installer cap and
Installer adapter
MD998816 Installer adapter (30) Installation of input shaft front

bearing
MD998825 Installer adapter (52) Installation of 1st-2nd speed

synchronizer hub, 3rd-4th
speed synchronizer hub and 1st
speed gear sleeve
MD998824 Installer adapter (50) Installation of 4th speed gear

sleeve, 5th speed gear and
thrust plate stopper
MD998818 Installer adapter (38) Installation of input shaft rear

bearing, roller bearing inner
race, reverse gear sleeve and
output shaft rear ball bearing
MD998917 Bearing remover Installation and removal of

gears, bearing and sleeves
MD998814 Installer-200 Use with Installer cap and

Installer adapter
MD998822 Installer adapter (46) Installation of 2nd speed gear

sleeve and 3rd speed gear
SPECIAL TOOLS

MD998819 Installer adapter (40) Installation of 5th-reverse
speed synchronizer hub, 4th
speed gear and 5th speed gear
sleeve
MD999566 Claw Removal of taper roller bearing

outer race
MD998772 Valve spring Removal of output shaft front

compressor roller bearing outer race
MD998346 Bearing outer race Removal of output shaft front

remover roller bearing outer race
MB990934 Installer adapter Installation of output shaft front

roller bearing outer race
MB991550 Bearing outer race Installation of center differential

installer case front taper roller bearing
outer race <W5M42>
MD998325 Differential oil seal Installation of differential oil seal

installer
MB990926 Installer adapter Installation of clutch housing

input shaft oil seal
SPECIAL TOOLS

MD998823 Installer adapter (48) Installation of differential case
taper roller bearing <F5M42>
and center differential case rear
taper roller bearing <W5M42>
MB990930 Installer adapter Removal of center differential

case front taper roller bearing
bearing <W5M42>
MD998830 Installer adapter (66) Installation of center differential

case front taper roller bearing
<W5M42>
MB990937 Installer adapter Installation of transfer oil seal

<W5M42>
MD998800 Oil seal adapter Installation of transfer oil seal

<W5M42>
MB990887 Ring Installation of transfer oil seal

<W5M42>
MB990891 Bushing remover Using with ring

installer base
MB990936 Installer adapter Installation of transfer oil seal

<W5M42>
TRANSMISSION
TRANSMISSION
M1222001000193
<F5M42>
4
18 ± 3 N·m 32 ± 2 N·m
3
3.9 ± 1.0 N·m 6
8
3.9 ± 1.0 N·m
7
11
18 ± 3 N·m
9
70 ± 10 N·m 5 10
1
70 ± 10 N·m
AK203151AC

1. Roll stopper bracket, front 8. Poppet spring
2. Roll stopper bracket, rear 9. Gasket
3. Shift cable bracket 10. Harness bracket
>>J<< 4. Select lever 11. Harness bracket
>>I<< 5. Speedometer gear
6. Backup light switch
7. Gasket
TRANSMISSION
14
Apply gear oil to all 18 ± 3 N·m
moving parts before
installation.
30 ± 3 N·m
15 12
20
13
44 ± 5 N·m
21
23
22
18
17
24 19
25 48 ± 6 N·m
16
6.9 ± 0.9 N·m
AK204218AC

12. Interlock plate bolt <<A>> >>F<< 20. Sealing cap
13. Gasket <> >>E<< 21. Transaxle case
>>H<< 14. Control housing >>D<< 22. Outer race
15. Neutral return spring >>D<< 23. Spacer
>>G<< 16. Under cover 24. Magnet holder
17. Reverse idler gear shaft bolt 25. Magnet
18. Gasket
19. Reverse idler gear assembly
TRANSMISSION
Apply gear oil to all 30

moving parts before
installation. 27 29
26
28
38 32
34
31 33
39
36
37
18 ± 3 N·m
35
AK204219AB

>>C<< 26. Spring pin <<C>> >>B<< 34. 5th speed-reverse shift fork
27. 1st-2nd speed shift rail 35. Front bearing retainer
28. 1st-2nd speed shift fork <<D>> >>A<< 36. Input shaft
>>C<< 29. Spring pin <<D>> >>A<< 37. Output shaft
>>C<< 30. Spring pin 38. Differential
<<C>> >>B<< 31. 3rd-4th speed shift rail 39. Clutch housing
<<C>> >>B<< 32. 3rd-4th speed shift fork
<<C>> >>B<< 33. 5th speed-reverse shift rail
TRANSMISSION
<W5M42>
18 ± 3 N·m
7 32 ± 2 N·m
6
3.9 ± 1.0 N·m 9
11
3.9 ± 1.0 N·m
4 14
10
18 ± 3 N·m
5
8 13 12
70 ± 10 N·m
70 ± 10 N·m
3
69 ± 10 N·m
AK204184AB

1. Transfer 10. Gasket
2. O-ring 11. Poppet spring
3. Roll stopper bracket, front 12. Gasket
4. Roll stopper bracket, rear 13. Harness bracket
5. Roll stopper bracket, adaptor 14. Harness bracket <Except 2.4L
6. Shift cable bracket model>
>>J<< 7. Select lever
>>I<< 8. Speedometer gear
9. Backup light switch
TRANSMISSION
14
Apply gear oil to all 18 ± 3 N·m
moving parts before
installation.
30 ± 3 N·m
15 12
20
13
44 ± 5 N·m
21
23
22
18
17
24 19
25 48 ± 6 N·m
16
6.9 ± 0.9 N·m
AK204218AC

15. Interlock plate bolt <<A>> >>F<< 23. Sealing cap
16. Gasket <> >>E<< 24. Transaxle case
>>H<< 17. Control housing >>D<< 25. Outer race
18. Neutral return spring >>D<< 26. Spacer
>>G<< 19. Under cover 27. Magnet holder
20. Reverse idler gear shaft bolt 28. Magnet
21. Gasket
22. Reverse idler gear assembly
TRANSMISSION
33
Apply gear oil to all
moving parts before 30 32
installation.
29
31
41 35
37
34 36
42
39
40
18 ± 3 N·m
38
AK204189AB

>>C<< 29. Spring pin <<C>> >>B<< 36. 5th speed-reverse shift rail
30. 1st-2nd speed shift rail <<C>> >>B<< 37. 5th speed-reverse shift fork
31. 1st-2nd speed shift fork 38. Front bearing retainer
>>C<< 32. Spring pin <<D>> >>A<< 39. Input shaft
>>C<< 33. Spring pin <<D>> >>A<< 40. Output shaft
<<C>> >>B<< 34. 3rd-4th speed shift rail 41. Differential
<<C>> >>B<< 35. 3rd-4th speed shift fork 42. Clutch housing
TRANSMISSION
DISASSEMBLY SERVICE POINTS <<C>> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH

<<A>> SEALING CAP REMOVAL SPEED SHIFT FORK/5TH SPEED-REVERSE
SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK
REMOVAL
1. Shift the 3rd-4th speed shift fork and 5th
Sealing cap speed-reverse shift fork in the direction shown.
3rd-4th
speed
shift fork
5th speed
AK204301 AB reverse
shift fork
1. Drive a screwdriver into the center of the sealing
cap.
2. Bend the screwdriver back to remove the sealing AK204222 AB
cap.
2. Pull up on the 3rd-4th speed shift rail and 5th
speed-reverse shift rail and take them out of the
<> TRANSAXLE CASE REMOVAL
hole in the clutch housing.
1. Remove all sixteen bolts securing the transaxle
case to the clutch housing.
5th speed-
reverse
3rd-4th speed shift rail
shift rail
Snap ring AK204223 AB
AK204226 AB 3. Slide the 3rd-4th speed shift rail and 5th

speed-reverse shift rail in the direction shown and
2. Use snap ring pliers to expand the indicated snap remove them together with the shift forks.
ring. The snap ring will release the grooved ball
bearing, and the output shaft assembly will fall
<<D>> INPUT SHAFT AND OUTPUT SHAFT
under its own weight.
REMOVAL
CAUTION
Do not use a scraper or chisel to remove the Input shaft
transaxle case.
3. Remove the transaxle case from the clutch
housing by gently prying on opposite sides at the Output shaft
same time.
AK204224 AB
Remove the input and output shafts together.

TRANSMISSION
ADJUSTMENT BEFORE REASSEMBLY REASSEMBLY SERVICE POINTS

SPACER SELECTION FOR DIFFERENTIAL CASE >>A<< OUTPUT SHAFT/INPUT SHAFT
PRELOAD ADJUSTMENT INSTALLATION
Solders Input shaft
Output shaft
AK204227 AB AK204224 AB
1. Put solders (1.6 mm diameter, about 10 mm long) Install the input and output shafts together.
in the illustrated positions of the transaxle case.
2. Install the taper bearing outer race and differential >>B<< 5TH SPEED-REVERSE SHIFT FORK/5TH
assembly into the transaxle case. SPEED-REVERSE SHIFT RAIL/3RD-4TH SPEED
SHIFT FORK/3RD-4TH SPEED SHIFT RAIL
NOTE: If necessary, replace the differential case INSTALLATION
and taper bearing before carrying out these
adjustments.
3rd-4th speed
3. Install the clutch housing and tighten the bolts to synchronizer
the specified torque. sleeve

5th speed-
4. Remove the clutch housing, and then remove the reverse
differential assembly. synchronizer
sleeve
5. Remove the outer race and take out crushed
solders.
AK204229AB
1. Shift the 3rd-4th speed synchronizer sleeve and

5th speed-reverse synchronizer sleeve in the
direction shown.
3rd-4th speed shift rail
3rd-4th speed
5th speed- shift fork
AKX00953 reverse
shift fork 5th speed-
6. Measure the thickness of the crushed solder with reverse
shift rail
a micrometer and select a spacer that will provide
the standard preload value.
AK204230 AB
Standard value: 0.05 − 0.11 mm preload
2. Assemble the 3rd-4th speed shift rail and fork,
and the 5th speed-reverse shift rail and fork.
TRANSMISSION
• Installer adapter (MB990935)

• Handle (MB990938)
5th speed-
reverse
shift rail >>E<< TRANSAXLE CASE INSTALLATION
3rd-4th speed
shift rail CAUTION
Squeeze sealant evenly onto the transaxle
housing. Do not leave gaps or excess amounts,
otherwise oil leaks are likely.
AK204223 AC
3. While fitting each shift fork in the groove of

synchronizer sleeve, slide the shift rails in the
direction shown and install.
4. Insert the 3rd-4th speed shift rail and 5th
speed-reverse shift rail into the rail hole in the
clutch housing.
AK204232AB
>>C<< SPRING PIN INSTALLATION
1. Align the pin holes in the shift rail and shift fork. 1. Apply a 2 mm diameter bead of sealant
(Mitsubishi Genuine Part number MD997740 or
Shift fork
Shift rail 2.5 mm equivalent) as illustrated onto the transaxle case.
NOTE: Be sure to install the transaxle case onto
the transaxle housing while the sealant is still wet
(within 15 minutes).
Spring pin
AK204302 AC
2. Insert the new spring pin. Push it in as shown so

that the slit and center axis of the rail are aligned.
Snap ring
>>D<< SPACER AND OUTER RACE

AK204226 AB
INSTALLATION
1. Install the spacer selected in the section 2. Align the transaxle case and expand the snap
"ADJUSTMENT BEFORE REASSEMBLY." ring. After the case is on far enough for the snap
ring to ride on the bearing, release the snap ring.
Push down on the transaxle case, twisting it from
side to side until the case contacts the housing.
MB990938
3. Tighten the transaxle case mounting bolts to the
specified torque.
4. Place the transaxle upside down and let the snap
MB990935 ring fit in the groove by the output shaft's own
weight.
AK204231 AB
NOTE: After installation, keep the sealed area
2. Using special tools, press the outer race into the away from oil for approximately one hour.
transaxle case.
TRANSMISSION
>>F<< SEALING CAP INSTALLATION 1. Apply a 2 mm diameter bead of sealant

(Mitsubishi Genuine Part number MD997740 or
MB990938 equivalent) as illustrated onto the under cover.
NOTE: Be sure to install the under cover to the
case quickly while the sealant is still wet (within 15
MB990927 minutes).
2. Install the under cover to the transaxle case and
tighten the bolts to specified torque.
AK204234 AB
away from oil for approximately one hour.
1. Using special tools, press install the sealing cap
onto the case. >>H<< CONTROL HOUSING INSTALLATION
• Installer adapter (MB990927) CAUTION
• Handle (MB990938) Squeeze sealant onto the case. Do not leave
gaps or excess amounts, otherwise oil leaks are
Sealing cap likely.
AK204233 AB
2. Evenly press the sealing cap so it is fully seated

AK204236AB
and not at an angle.
1. Apply a 0.2 mm diameter bead of sealant
>>G<< UNDER COVER INSTALLATION (Mitsubishi Genuine Part number MD997740 or
CAUTION equivalent) as llustrated onto the control housing.
Squeeze sealant onto the case. Do not leave NOTE: Be sure to install the housig to the case
gaps or excess amounts, otherwise oil leaks are quickly while the sealant is still wet (within 15
likely. minutes).
2. Install the control housing to the transaxle case
and tighten the bolts to specified torque.
away from the oil for approximately one hour.
AK204235AB
TRANSMISSION
>>I<< SPEEDOMETER GEAR INSTALLATION 1. Apply grease (Mitsubishi Genuine Part number
0101011 or equivalent) to the control shaft sliding
O-ring
portion of the select lever shoe.
2. Install the select lever and tighten the bolts to
specified torque.
INSPECTION
M1222001100101
BACKUP LIGHT SWITCH
AK204237 AB
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or

75W-85W conforming to API classification GL-4)
to the O-ring of the speedometer gear. Install into
the transaxle housing.
2. Tighten the bolt to specified torque.
AKX00952
>>J<< SELECT LEVER INSTALLATION
Check for continuity between terminals.
Control shaft
SWITCH CONDITION CONTINUITY
Select lever Pressed Open
shoe
Released Conductive
AK204238 AB
INPUT SHAFT
INPUT SHAFT
M1222001600173
9
Apply gear oil to all 10
moving parts before 11
installation.
12
14
13
15
16
18 19 2
20 4
6
7
1
8
16 3
17
AK204391AB

>>M<< 1. Snap ring >>G<< 11. Synchronizer sleeve
<<A>> >>L<< 2. Ball bearing >>F<< 12. 3rd-4th speed synchronizer hub
<> >>K<< 3. Thrust plate stopper >>E<< 13. Synchronizer ring
>>J<< 4. Thrust plate >>D<< 14. Synchronizer spring
<<C>> >>I<< 5. 5th speed gear 15. 3rd speed gear
6. 4th speed gear 16. Needle roller bearing
7. Needle roller bearing >>C<< 17. Snap ring
<<D>> >>H<< 8. 4th speed gear sleeve <<E>> >>B<< 18. Ball bearing
>>E<< 9. Synchronizer ring >>A<< 19. Oil seal
>>D<< 10. Synchronizer spring 20. Input shaft
INPUT SHAFT
DISASSEMBLY SERVICE POINTS 1. Using special tool Bearing remover (MD998801),

<<A>> BALL BEARING REMOVAL support the 5th speed gear, and then set them on
the press.
2. Push down on the input shaft with the press and
remove the 5th speed gear.
MD998801
<<D>> 4TH SPEED GEAR SLEEVE REMOVAL
MD998801
AK204239 AB
1. Using special tool Bearing remover (MD998801),

support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and AK204241 AB
remove the ball bearing.
<> THRUST PLATE STOPPER REMOVAL support the 3rd speed gear, and then set them on
the press.
remove the 4th speed gear sleeve.
<<E>> BALL BEARING REMOVAL
MD998801
AK204293AB
Using a screwdriver, pry up at the position shown in

the illustration and remove the thrust plate stopper.
<<C>> 5TH SPEED GEAR REMOVAL

AK204242 AB

MD998801 support the ball bearing, and then set them on the
press.
AK204240 AB
INPUT SHAFT
REASSEMBLY SERVICE POINTS 1. Install the thickest snap ring that can be fitted in
>>A<< OIL SEAL INSTALLATION the snap ring groove of input shaft.
2. Make sure that the front bearing end play meets
the standard value.
Oil seal 3.5 mm Standard value: 0 − 0.12 mm
>>D<< SYNCHRONIZER SPRING INSTALLATION
AK204243 AC
Install the oil seal into the end of the input shaft as
shown.
>>B<< BALL BEARING INSTALLATION SYNCHRONIZER

Synchrnizer
SPRING
spring AK204263AB
MD998812 Install the synchronizer spring onto the synchronizer

ring as shown.
MD998813
MD998801 MD998816 >>E<< SYNCHRONIZER RING INSTALLATION

CAUTION
There are 3rd speed and 4th speed synchronizer
rings, if the wrong one is installed it will effect
the shift feeling.
AK204244AC
1. Using special tool Bearing remover (MD998801), Notch

support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, press install the ball bearing
with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998816)
AK204312 AB
>>C<< SNAP RING INSTALLATION

1. Ascertain whether or not there are identification
notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2. Install the synchronizer ring so that it completely
fits over the machined cone of the gear.
Snap ring
AK204245 AB
INPUT SHAFT
>>F<< 3RD-4TH SPEED SYNCHRONIZER HUB 1. Check the installation direction of the
INSTALLATION synchronizer sleeve, and install it onto the 3rd-4th
Installation speed synchronizer hub.
direction
Projecting portion
Groove AK204295 AB
Deep grooves AK204199AB

support the 2nd speed gear portion of the input 2. Install the synchronizer sleeve so that the areas
shaft, and then set them on the press. with teeth that have raised tips (three areas total)
2. Make sure that the synchronizer ring has been are aligned with the areas on the synchronizer
perfectly matched to the 3rd speed gear cone. hub that have deep grooves between the teeth
3. Check the installation direction of the 3rd-4th (three areas total).
speed synchronizer hub, and put it on the input
shaft. >>H<< 4TH SPEED GEAR SLEEVE
INSTALLATION
MD998812
MD998812
MD998813
MD998813
MD998801 MD998825
MD998824
MD998801
AK204246 AC
AK204247 AC
4. Using special tools, press install the 3rd-4th
speed synchronizer hub with the press. 1. Using special tool Bearing remover (MD998801),
• Installer cap (MD998812) support the 2nd speed gear portion of the input
• Installer-100 (MD998813) shaft, and then set them on the press.
• Installer adapter (MD998825) 2. Using special tools, install the 4th speed gear
5. Make sure that the synchronizer ring can rotate sleeve with the press.
freely. • Installer cap (MD998812)
>>G<< SYNCHRONIZER SLEEVE INSTALLATION • Installer adapter (MD998824)
Identification
groove
Installation
direction
AK204296AC
INPUT SHAFT
>>I<< 5TH SPEED GEAR INSTALLATION Install the thrust plate stopper by pressing special
tools, by hand. Make sure that it is not tilted.
MD998812 • Installer-100 (MD998813)
MD998813 • Installer adapter (MD998824)
MD998801 MD998824
>>L<< BALL BEARING INSTALLATION
MD998812
MD998818
AK204248 AB
MD998801
support the 2nd speed gear portion of the input
2. Using special tools, install the 5th speed gear onto
the input shaft with the press. AK204250 AC
• Installer-100 (MD998813) 1. Using special tool Bearing remover (MD998801),
• Installer adapter (MD998824) support the 2nd speed gear portion of the input
>>J<< THRUST PLATE INSTALLATION 2. Using special tools, install the ball bearing onto
the input shaft with the press.
Surface stamped
with identification • Installer cap (MD998812)
mark • Installer adapter (MD998818)
>>M<< SNAP RING INSTALLATION
Thrust plate
AK204249AB
1. Install the thickest thrust plates that can be fitted

Snap ring
in the groove of the input shaft. Install the thrust
plate so the surface stamped with the
identification mark is facing up.
AK204251 AB
2. Make sure that the 5th speed gear end play meets
the standard value. 1. Install the thickest snap ring that can be fitted in
Standard value: 0 − 0.09 mm the groove of the input shaft.
2. Make sure that the rear bearing end play meets
the standard value.
>>K<< THRUST PLATE STOPPER INSTALLATION
Standard value: 0 − 0.12 mm
MD998812
MD998813
MD998824
AK204294 AB
INPUT SHAFT
INSPECTION 1. Check the clutch gear teeth for damage and

M1222001700095 broken.
INPUT SHAFT
2. Check internal surface for damage, wear and
broken threads.
A
Gear Synchronizer
ring
AK204201AB
1. Check the outside diameter of the needle bearing AK204307 AB
mounting portion for damage, abnormal wear and

3. Force the synchronizer ring toward the clutch gear
seizure.
and check clearance "A". If "A" is less than the
2. Check the splines for damage and wear. limit, replace the synchronizer ring.
3. Check that the helical gear teeth surfaces are not Minimum limit: 0.5 mm
damaged or worn.
NEEDLE ROLLER BEARING SYNCHRONIZER SLEEVE AND HUB

1. Combine the needle roller bearing with the input Sleeve
shaft or bearing sleeve and gear, and check that it
rotates smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.
SYNCHRONIZER RING
Hub
AK204217 AB
1. Combine the synchronizer sleeve and hub, and

check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
SYNCHRONIZER SPRING
AK204298AB
Check that the spring is not sagging, deformed or
broken.
INPUT SHAFT
1. Check that the helical and clutch gear tooth

SPEED GEARS surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
3. Check that the gear inside diameter and front and
rear surfaces are not damaged and worn.
AK204299AB
OUTPUT SHAFT
OUTPUT SHAFT
M1222002200156
20
22
24
moving parts before
installation. 26
19 18
27
29 21
23 4
25
1
28
30 5
32 31
33 13
36 3 2
12
6
35 15 7
34 17 4
8
9
14 10 11
16 13
AK204392AB

>>Q<< 1. Snap ring 18. 2nd speed gear
<<A>> >>P<< 2. Ball bearing 19. Needle roller bearing
<> >>O<< 3. Reverse gear sleeve <<E>> >>G<< 20. 2nd speed gear sleeve
4. Needle roller bearing 21. Inner synchronizer ring
5. Reverse gear 22. Synchronizer cone
>>M<< 6. Synchronizer ring 23. Outer synchronizer ring
>>L<< 7. Synchronizer spring >>D<< 24. Synchronizer spring
>>F<< 8. Synchronizer sleeve >>F<< 25. Synchronizer sleeve
<<C>> >>N<< 9. 5th speed-reverse synchronizer >>E<< 26. 1st-2nd speed synchronizer hub
hub 27. Outer synchronizer ring
>>M<< 10. Synchronizer ring >>D<< 28. Synchronizer spring
>>L<< 11. Synchronizer spring 29. Inner synchronizer ring
12. 5th speed gear 30. Synchronizer cone
13. Needle roller bearing 31. 1st speed gear
>>K<< 14. 5th speed gear sleeve 32. Needle roller bearing
>>J<< 15. 4th speed gear <<F>> >>C<< 33. 1st speed gear sleeve
>>I<< 16. Snap ring >>B<< 34. Snap ring
<<D>> >>H<< 17. 3rd speed gear
OUTPUT SHAFT
Disassembly steps (Continued) <<C>> 5TH SPEED-REVERSE SYNCHRONIZER

<<G>> >>A<< 35. Roller bearing inner race HUB REMOVAL
36. Output shaft
Synchronizer hub
DISASSEMBLY SERVICE POINTS
MD998801
<<A>> BALL BEARING REMOVAL
Ball bearing
MD998917
AK204254 AB

support the 4th speed gear, and then set them on
AK204252 AC
the press.
2. Push down on the output shaft with the press and
1. Using special tool Bearing remover (MD998917), remove the 5th speed-reverse synchronizer hub.
support the ball bearing, and then set them on the
press. <<D>> 3RD SPEED GEAR REMOVAL
2. Push down on the output shaft with the press, and
<> REVERSE GEAR BEARING SLEEVE 3rd speed gear

MD998917
REMOVAL
Reverse gear
MD998801 bearing sleeve
AK204255 AB

support the 2nd speed gear, and then set them on
the press.
AK204253 AB 2. Push down on the output shaft with the press and
remove the 3rd speed gear.
support the reverse gear, and then set them on <<E>> 2ND SPEED GEAR SLEEVE REMOVAL
the press.
2. Push down on the output shaft with the press and
remove the reverse gear bearing sleeve.
2nd speed gear sleeve
MD998917
AK204256 AC

support the 1st speed gear, and then set them on
the press.
OUTPUT SHAFT
2. Push down on the output shaft with the press and REASSEMBLY SERVICE POINTS
remove the 2nd speed gear sleeve. >>A<< ROLLER BEARING INNER RACE
INSTALLATION
<<F>> 1ST SPEED GEAR SLEEVE REMOVAL
MD998812
MD998801 MD998818
1st speed gear sleeve Roller bearing

inner race
MD998801
AK204260 AB
AK204257 AC
1. Using special tool Bearing remover (MD998801), support the output shaft gear, and then set them
support the 1st speed gear sleeve, and then set on the press.
them on the press. 2. Using special tools, install the roller bearing inner
2. Push down on the output shaft with the press and race with the press.
remove the 1st speed gear sleeve. • Installer cap (MD998812)
<<G>> ROLLER BEARING INNER RACE
REMOVAL >>B<< SNAP RING INSTALLATION
Roller bearing
inner race
MD998917
Snap ring
AK204258 AB AK204261 AB
1. Using special tool Bearing remover (MD998917), 1. Install the thickest snap ring that can be fitted in
support the roller bearing inner race, and then set the groove of output shaft.
them on the press. 2. Make sure that the front bearing inner race end
2. Push down on the output shaft with the press and play meets the standard value.
remove the roller bearing inner race. Standard value: 0 − 0.12 mm
>>C<<1ST SPEED GEAR SLEEVE INSTALLATION

1. Set the output shaft on the press support stand.
OUTPUT SHAFT
MD998812 MD998812
MD998814 MD998814
1st speed 1st-2nd speed
gear sleeve synchronizer
hub MD998825
MD998825
AK204262 AC AK204265 AC
2. Using special tools, install the 1st speed gear 3. Using special tools, install the 1st-2nd speed
sleeve with the press. synchronizer hub with the press.
• Installer cap (MD998812) • Installer cap (MD998812)
• Installer-200 (MD998814) • Installer-200 (MD998814)
• Installer adapter (MD998825) • Installer adapter (MD998825)
4. Make sure that the outer synchronizer ring on the
>>D<< SYNCHRONIZER SPRING INSTALLATION 1st speed gear side can rotate freely.
>>F<< SYNCHRONIZER SLEEVE INSTALLATION

Identification
groove
Synchronizer spring Installation

direction
AK204316AC
Install the synchronizer spring onto the outer

synchronizer ring AK204296AC
as shown.
1. Check that the synchronizer sleeve is in the
correct direction for installation, and install it on
>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB the 1st-2nd speed synchronizer hub.
INSTALLATION
1. Set the output shaft on the press support stand. Projecting portion
Installation direction
Deep grooves AK204199AB
AK204305 AC 2. Install the synchronizer sleeve so that the areas

with teeth that have raised tips (three areas total)
2. Check that the 1st-2nd speed synchronizer hub is are aligned with the areas on the synchronizer
in the correct installation direction, and put it on hub that have deep grooves between the teeth
the output shaft. (three areas total).
OUTPUT SHAFT
>>G<< 2ND SPEED GEAR SLEEVE >>I<< SNAP RING INSTALLATION

INSTALLATION
MD998812
MD998813
Snap ring
MD998822
AK204268AB
1. Install the thickest snap ring that can be fitted in

AK204266 AC
the groove of output shaft.
2. Using special tools, install the 2nd speed sleeve 2. Make sure that the 3rd speed gear end play
onto the output shaft with the press. meets the standard value.
• Installer cap (MD998812) Standard value: 0 − 0.09 mm
>>J<< 4TH SPEED GEAR INSTALLATION
>>H<< 3RD SPEED GEAR INSTALLATION
1. Check that the 2nd speed gear and the outer
synchronizer ring have been properly installed. MD998812
Also, make sure the claws on the synchronizer MD998813
cone (four places) are correctly fitted into the
4th speed gear MD998819
holes in the 2nd speed gear (four places).
MD998812
MD998814 AK204269 AB
3rd speed gear 2. Using special tools, install the 4th speed gear onto
MD998822
the output shaft with the press.
AK204267 AB • Installer adapter (MD998819)
2. Using special tools, install the 3rd speed gear
onto the output shaft with the press. >>K<< 5TH SPEED GEAR SLEEVE
• Installer cap (MD998812) INSTALLATION
• Installer adapter (MD998822) MD998812
3. Make sure that the 2nd speed gear and the outer MD998813
synchronizer ring can rotate freely. 5th speed
gear sleeve MD998819
AK204300 AB
Using special tools, install the 5th speed gear sleeve

onto the output shaft with the press.
OUTPUT SHAFT
>>L<< SYNCHRONIZER SPRING INSTALLATION
AK204306 AB
3. Check that the 5th speed-reverse synchronizer

hub is oriented correctly for installation, and fit it
SYNCHRONIZER
Synchrnizer
SPRING
spring on the output shaft.
AK204263AB
Install the synchronizer spring onto the synchronizer

ring as shown. MD998812
MD998813
MD998819
>>M<< SYNCHRONIZER RING INSTALLATION
CAUTION Synchronizer hub
There is a 5th speed synchronizer ring and a
reverse synchronizer ring. Be careful not to
confuse the two when installing, as a mistake can
effect the shift feeling. AK204228 AB
4. Using special tools, press install the 5th

speed-reverse synchronizer hub with the press.
Notch
5. Make sure that the synchronizer ring on the 5th
speed gear side can rotate freely.
AK204393AB >>O<< REVERSE GEAR SLEEVE INSTALLATION

1. Make sure the synchronizer ring, reverse gear
1. Check for the presence of identification notches and needle roller bearing have been correctly
on the synchronizer ring. installed.
No notches: 5th speed synchronizer ring
Three notches: Reverse synchronizer ring MD998812
MD998818
2. Install the synchronizer ring so that it fits
Reverse
completely over the machined cone of the gear. gear Reverse gear
sleeve
>>N<< 5TH SPEED-REVERSE SYNCHRONIZER
HUB INSTALLATION
2. Make sure that the synchronizer ring is fitted AK204270 AB
correctly on the cone of the 5th speed gear.
2. Using special tools, press fit the reverse gear
sleeve. Make sure that the reverse gear and the
synchronizer ring can rotate freely during the
pressing process.
OUTPUT SHAFT
• Installer adapter (MD998818) 1. Check the splines for damage and wear.
2. Check that the helical gear teeth surfaces are not
>>P<< BALL BEARING INSTALLATION damaged or worn.
1. Check the installation direction of the ball bearing.
NEEDLE ROLLER BEARING
MD998812 1. Combine the needle roller bearing with the
MD998818 bearing sleeve and gear, and check that it rotates
smoothly without noise or play.
Ball bearing 2. Check the needle roller bearing cage for
deformation.
SYNCHRONIZER RING
AK204271 AC
2. Using special tools, install the ball bearing with the

press.
>>Q<< SNAP RING INSTALLATION

AK204298AB
1. Check if the clutch gear teeth are damaged or

broken.
2. Check internal surface for damage, wear and
broken threads.
Snap ring
A
Gear Synchronizer
AK204272 AC
ring
1. Install the thickest snap ring that can be fitted in

the groove of output shaft.
2. Make sure that the rear bearing end play meets
the standard value.
AK204307 AB
INSPECTION 3. Force the synchronizer ring toward the clutch gear

M1222002300131
OUTPUT SHAFT and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
Minimum limit: 0.5 mm
AK204310AB
OUTPUT SHAFT
OUTER SYNCHRONIZER RING/INNER 1. Combine the synchronizer sleeve and hub, and
SYNCHRONIZER RING/SYNCHRONIZER CONE check that they slide smoothly.
<FOR 1ST, 2ND SPEED> 2. Check that the sleeve is free from damage at its
CAUTION inside splines ends.
When replacing, replace the outer ring, inner ring
and cone as a set. SYNCHRONIZER SPRING
AK204395AB AK204314AB
1. Check that the clutch gear tooth surfaces and Check that the spring is not sagging, deformed or
cone surfaces are not damaged or broken. broken.
Gear A SPEED GEARS
Outer ring
Cone
Inner ring
AK203130AD
2. Install the outer ring, inner ring and cone, force AK204299AB
them toward the gear, and check clearance "A". If
"A" is less than the limit, replace them as a set. 1. Check that the helical and clutch gear tooth
surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
SYNCHRONIZER SLEEVE AND HUB
3. Check that the gear inside diameter and front and
Sleeve rear surfaces are not damaged and worn.
Hub
AK204217 AB
REVERSE IDLER GEAR
REVERSE IDLER GEAR

M1222012500136
Apply gear oil to

all moving parts
before installation.
3
4
AK302745AC
Disassembly steps REASSEMBLY SERVICE POINT

1. Snap ring >>A<< FRICTION DAMPER INSTALLATION
2. Thrust washer
3. Reverse idler gear
21.5 ± 0.2 mm
4. Needle roller bearing
>>A<< 5. Friction damper
6. Reverse idler gear shaft
AK302712AB
After apply gear oil to the outside and inside

circumferences of the friction damper, install it using
the special tool in position as shown in Fig.
SPEEDOMETER GEAR
SPEEDOMETER GEAR
M1222003400089

moving parts before
installation.
AK204397AB

1. E-clip 3. O-ring
2. Speedometer driven gear 4. Sleeve
SELECT LEVER
SELECT LEVER
M1222012800074
7 1
8
2 11 ± 1 N·m
9 3
10
AK204398AB

1. Dust cover >>A<< DUST COVER AND SELECT LEVER
2. Nut BUSHING INSTALLATION
3. Spring washer
4. Washer Select lever
>>A<< 5. Select lever bushing bushing
6. Select lever shoe
7. Select lever
>>A<< 8. Select lever bushing
>>A<< 9. Dust cover
10. Select lever shaft
Dust cover
AK204311 AB
Make sure the dust cover and select lever bushing

installation direction is correct, and the distinguished
parts are correctly assembled as shown.
CONTROL HOUSING
CONTROL HOUSING
M1222013100153
6
9
7 3
11
12
5
13
4
8
10
14
2
1
22.3 ± 0.3 N·m
AK302747 AC

1. Spring washer <<A>> LOCK PIN REMOVAL
2. Stopper bracket
<<A>> >>E<< 3 Lock pin
4. Interlock plate
5. Control finger
Lock pin
>>D<< 6. Spring pin
7. Stopper body
8. Spring
9. Control shaft
>>C<< 10. Air breather Control finger
11. Control shaft boot
>>B<< 12. Oil seal
AK204273 AB
>>A<< 13. Needle bearing
14. Control housing Drive out the lock pin from the direction shown.
CONTROL HOUSING
REASSEMBLY SERVICE POINTS 1. Apply sealant (3M SUPER WEATHERSTRIP No.

>>A<< NEEDLE BEARING INSTALLATION 8001 or equivalent) to the inserting portion of air
breather.
Control housing
Needle bearing
Model number Emboss
stamped side mark
0 – 0.5 mm
AK204176AC
AK204220 AB
Press fit the needle bearing into the control housing
side as shown. 2. Install the air breather so that the embossed mark
Make sure that the side with the model number is in the direction shown in the figure.
stamped on it faces the end of the control housing as
shown. >>D<< SPRING PIN INSTALLATION
>>B<< OIL SEAL INSTALLATION Control shaft

Stopper body
Slit
Spring pin
AK204177AB
AK204303AB
Drive in the spring pin so that the slit is in the
direction shown in the figure.
Apply gear oil (Hypoid gear oil SAE 75W-90 or
75W-85W conforming to API classification GL-4) to >>E<< LOCK PIN INSTALLATION
the oil seal lip area.
>>C<< AIR BREATHER INSTALLATION
AK204273 AC
Drive the lock pin in from the direction shown in the

figure.
AK204274AB
CLUTCH HOUSING
CLUTCH HOUSING
M1222003700176
4
6
7
3 5
1
9.8 ± 2.0 N·m
AK204400AC
Disassembly steps DISASSEMBLY SERVICE POINTS

1. Clutch release bearing retainer <<A>> OUTER RACE REMOVAL
>>E<< 2. Oil seal
>>D<< 3 Oil seal <F5M42>
<<A>> >>C<< 4. Outer race
<> >>B<< 5. Outer race
>>A<< 6. Bushing
7. Clutch housing
MD999566
AK204276 AB
Using special tool Claw (MD999566), remove the

outer race from the clutch housing.
CLUTCH HOUSING
<> OUTER RACE REMOVAL >>B<< OUTER RACE INSTALLATION
MD998772 MD998346
Model number
stamped side
AK204277AB AK204279 AB
1. Set special tools as indicated in the figure. 1. Check the installation direction of the outer race.
• Valve spring compressor (MD998772) Install the outer race so the side with the model
• Bearing outer race remover (MD998346) number stamping can be seen.
2. Turn the nut on special tool Bearing outer race
remover (MD998346) to pull up on the tool and
take out the outer race. MB990938
MB990934
>>A<< BUSHING INSTALLATION

AK204280 AB
2. Using special tools, press fit the outer race into

Seam of bushing Air vent the clutch housing.
>>C<< OUTER RACE INSTALLATION

1. Check the installation direction of the outer race.
AK204278 AB
1. Press fit the bushing so the seam is away from

the air vent. MB990938
1 mm
MB990935 <F5M42>
MB991550 <W5M42>
AK204281 AC
2. Using special tools, press fit the outer race into

the clutch housing.
AK204291 AC • Handle (MB990938)
2. Be sure the bushing is fully seated as shown. It • Bearing outer race installer (MB991550)
must be 1 mm below the housing surface.
CLUTCH HOUSING
>>D<<OIL SEAL INSTALLATION >>E<< OIL SEAL INSTALLATION
AK204282AB AK204284AC
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 1. Pack grease (MITSUBISHI genuine grease part
75W-85W conforming to API classification GL-4) No.0101011 or equivalent).
to the oil seal lip.
MB990938
MD998325
MB990926
AK204285 AB
AK204283 AB
2. Using special tools, press fit the oil seal into the
2. Using special tool Differential oil seal installer clutch housing.
(MD998325), press fit the oil seal into the clutch • Handle (MB990938)
housing. • Installer adapter (MB990926)
TRANSMISSION CASE
TRANSMISSION CASE
M1222013400079
1
2
4 3 6
AK204407AB
Disassembly steps REASSEMBLY SERVICE POINTS

>>C<< 1. Oil seal >>A<< BUSHING INSTALLATION
>>B<< 2. Needle bearing
3. Oil guide
4. Snap ring
>>A<< 5. Bushing Seam of bushing
6. Transaxle
Air vent
AK204292 AB
1. Press fit the bushing so the seam is away from

the air vent.
TRANSMISSION CASE
>>C<<OIL SEAL INSTALLATION
3 mm
AK204304 AC
2. Be sure the bushing is fully seated as shown. It

AK204286AB
must be 3 mm below the housing surface.
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or
>>B<< NEEDLE BEARING INSTALLATION 75W-85W conforming to API classification GL-4).
1. Check the installation direction of the needle
bearing.
MD998325
Model number
stamped side
AK204288 AB
2. Using special tool Differential oil seal installer

AK204287 AB
(MD998325), press fit the oil seal into the
2. Press fit the needle bearing until it is flush with the transaxle case.
case.
DIFFERENTIAL
DIFFERENTIAL
M1222002500146
<F5M42>

2
moving parts before
installation.
3
6 8
5
4
8
132 ± 5 N·m
7 1
5
2
6
AK204408AB

>>D<< 1. Differential drive gear <<A>> TAPER ROLLER BEARING REMOVAL
<<A>> >>C<< 2. Taper roller bearing
>>B<< 3. Lock pin
>>A<< 4. Pinion shaft MD998801
>>A<< 5. Pinion
>>A<< 6. Washer
>>A<< 7. Side gear
>>A<< 8. Spacer
9. Differential case
AK204289 AB

support the taper roller bearing, and then set them
on the press.
DIFFERENTIAL
2. Push down on the differential case with the press Standard value: 0 − 0.15 mm
and remove the bearing. 5. If the backlash is out of specification, select a
spacer that should get the back lash with in the
standard value and re-measure the backlash.
REASSEMBLY SERVICE POINTS NOTE: Repeat until the backlash on both sides
>>A<< SPACER/SIDE are equal.
GEAR/WASHER/PINION/PINION SHAFT
INSTALLATION >>B<< LOCK PIN INSTALLATION
Differential case
Lock pin
Pinion shaft
AKX00768
AK204290 AB
1. After a spacer has been mounted on the back Install the lock pin so that it will be oriented in the
surface of the side gear, install the side gear in the direction shown.
differential case.
NOTE: When a new side gear is to be installed, >>C<< TAPER ROLLER BEARING INSTALLATION
mount a medium thickness spacer.
2. Set the washer on the back of each pinion, and
MD998812
put both pinions simultaneously in mesh with the Taper roller
side gears. While rotating them, install them in MD998823 bearing
position.
AK204319 AC
Using special tools, install the taper roller bearing

with the press.
AKX00770
>>D<< DIFFERENTIAL DRIVE GEAR

3. Insert the pinion shaft.
INSTALLATION
AKX00766
AK204320AB
4. Measure the backlash between the side gear and

pinion.
DIFFERENTIAL
1. Apply sealant (3M STUD Locking No.4170 or 2. Tighten to the specified torque in the illustrated
equivalent) to the entire threaded portion of the sequence.
bolt. Tightening torque: 132 ± 5 N⋅m
3 1
5 8
7
6
2
4
AK204221 AC
CENTER DIFFERENTIAL
CENTER DIFFERENTIAL
M1222002800051
<W5M42>
1
3
moving parts before
installation.
2
5
11 12
6
7
12 132 ± 5 N·m
4
17
9
14 10
12
13 12 11
8
16 9
15
AK204225AB

>>D<< 1. Center differential drive gear <<A>> TAPER ROLLER BEARING REMOVAL
>>C<< 2. Center differential flange
<<A>> >>B<< 3. Taper roller bearing
>>C<< 4. Snap ring
>>C<< 5. Front output shaft
MD998917
>>C<< 6. Spacer
>>C<< 7. Side gear
>>C<< 8. Lock pin
>>C<< 9. Pinion shaft
>>C<< 10. Pinion shaft holder
>>C<< 11. Pinions
>>C<< 12. Washers
AK204264AB
>>C<< 13. Side gear
>>C<< 14. Spacer 1. Support the taper roller bearing with special tool
<> >>A<< 15. Taper roller bearing
bearing remover (MD998917), and then set them
16. Speed meter drive gear
on the press.
CENTER DIFFERENTIAL
2. Push down on the differential case with the press Using special tools, install the taper roller bearing
to remove the bearing. with the press.
<> TAPER ROLLER BEARING REMOVAL • Installer adapter (MD998823)
>>C<< SPACER, SIDE GEAR, WASHER, PINION

AND PINION SHAFT, PINION SHAFT HOLDER,
MD998917 MB990930 LOCK PIN, FRONT OUTPUT SHAFT, SNAP RING,
CENTER DIFFERENTIAL FLANGE,
INSTALLATION
AK204275AB
1. Support the taper roller bearing with special tools,

and then set them on the press.
• Bearing remover (MD998917)
2. Push down on the differential case with the press AK204315
to remove the bearing.
1. Mount a spacer on the back surface of the side
REASSEMBLY SERVICE POINTS gear, and then install the side gear in the
differential case.
>>A<< TAPER ROLLER BEARING INSTALLATION
NOTE: When a new side gear is to be installed,
use a medium thickness spacer (0.93 to 1.00
MD998812 mm).
MD998830
2. Place the washers on the back of the pinions, and
simultaneously mesh the four pieces with the side
gears. Place them into position while rotating
them. Then, install the pinion shaft holder.
3. Insert the pinion shaft.
AK204297AB Differential case

Lock pin
Using special tools, install the taper roller bearing Pinion shaft
with the press.
>>B<< TAPER ROLLER BEARING INSTALLATION

AK204317AC
MD998823 MD998812 4. Install the lock pin so that it will be oriented in the
direction shown.
5. Install the front output shaft on the side gear, and
install the snap ring.
6. Mount a spacer on the back surface of the side
gear, and then install the side gear in the
differential case.
AK204308AB
NOTE: When a new side gear is to be installed,
use a medium thickness spacer.
CENTER DIFFERENTIAL
7. Install the center differential flange by aligning the >>D<< CENTER DIFFERENTIAL DRIVE GEAR
matching marks, and temporarily tighten the four INSTALLATION
machine screws.
AK204320AB
AK204389
1. Apply sealant (3M STUD Locking No.4170 or
8. Measure the backlash between the side gear and equivalent) to the entire threaded portion of the
pinion. bolt.
1 10
9. If the backlash is out of the standard value, select 3
8
a spacer and re-measure the backlash. 5 6
NOTE: Adjust until the backlash on both sides are
equal. 7 4
9 2
AK204318AB
2. Tighten to the specified torque in the illustrated

sequence.
TRANSFER
TRANSFER
M1222004000084
1
2
5
6 3
7
11
8
9 Apply gear oil to all

moving parts before
installation.
10
23 ± 3 N·m AK204413AB
Disassembly steps >>B<< OIL SEAL INSTALLATION

1. Dust seal guide 1. Apply gear oil (Hypoid gear oil API classification
>>E<< 2. Oil seal GL-5 SAE 90).
>>D<< 3. Oil seal
>>A<< 4. O-ring MB990938
>>A<< 5. O-ring MB990937
>>A<< 6. O-ring
>>C<< 7. Oil seal
>>B<< 8. Oil seal
>>A<< 9. O-ring
10. Transfer cover
11. Transfer
REASSEMBLY SERVICE POINTS AK204414AB

Install a O-ring to the transfer, and apply gear oil 2. Using special tools, press fit the oil seal into the
(Hypoid gear oil API classification GL-5 SAE 90) to transfer cover.
the O-ring. • Installer adapter (MB990937)
TRANSFER
>>C<< OIL SEAL INSTALLATION MB990891

1. Apply gear oil (Hypoid gear oil API classification
MB990887
GL-5 SAE 90).
MD998800
AK204416 AB
2. Using special tools, press fit the oil seal into the
transfer.
• Ring (MB990887)
AK204415AB
• Bushing remover installer base (MB990891)
2. Using special tool oil seal installer (MD998800),
press fit the oil seal into the transfer cover. >>E<< OIL SEAL INSTALLATION
>>D<< OIL SEAL INSTALLATION GL-5 SAE 90).
GL-5 SAE 90).
MB990933
AK204417AB
2. Using special tool installer adapter (MB990933),

press fit the oil seal into the transfer.
NOTES
23A-1
GROUP 23A
AUTOMATIC
TRANSMISSION
CONTENTS
SERVICE SPECIFICATIONS. . . . . . . 23A-3 INSPECTION CHART FOR TROUBLE

SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 23A-101
LUBRICANTS . . . . . . . . . . . . . . . . . . 23A-3 SYMPTOM PROCEDURES . . . . . . . . . . . . 23A-102
DATA LIST REFERENCE TABLE . . . . . . . . 23A-133
SPECIAL TOOLS. . . . . . . . . . . . . . . . 23A-4 ACTUATOR TEST JUDGMENT VALUE . . . 23A-135
INVECS-II CANCEL COMMAND. . . . . . . . . 23A-136
TROUBLESHOOTING <A/T> . . . . . . 23A-7 CHECK AT ENGINE-A/T-ECU
STANDARD FLOW OF DIAGNOSIS TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . 23A-136
TROUBLESHOOTING . . . . . . . . . . . . . . . . 23A-7 OSCILLOSCOPE INSPECTION
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 23A-7 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 23A-139
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . 23A-9

TROUBLESHOOTING A/T KEY
SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . 23A-15
INTERLOCK AND SHIFT LOCK
DAMPER CLUTCH CONTROL. . . . . . . . . . 23A-16
MECHANISMS . . . . . . . . . . . . . . . . . . 23A-140
INSPECTION CHART FOR DIAGNOSIS
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-18 TROUBLE SYMPTOM CHART . . . . . . . . . . 23A-140
DIAGNOSTIC TROUBLE CODE SYMPTOM PROCEDURES . . . . . . . . . . . . 23A-141
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 23A-19 Continued on next page
WARNING
NOTE
23A-2
ON-VEHICLE SERVICE. . . . . . . . . . . 23A-143 KEY INTERLOCK AND SHIFT LOCK

MECHANISM CHECK . . . . . . . . . . . . . . . . . 23A-159
ESSENTIAL SERVICE . . . . . . . . . . . . . . . . 23A-143
AUTOMATIC TRANSMISSION FLUID (ATF)
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-143 TRANSMISSION CONTROL*. . . . . . . 23A-161
AUTOMATIC TRANSMISSION FLUID (ATF) REMOVAL AND INSTALLATION
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 23A-144 <VEHICES WITH LHD> . . . . . . . . . . . . . . . 23A-161
AUTOMATIC TRANSMISSION FLUID COOLER REMOVAL AND INSTALLATION
LINE FLUSHING . . . . . . . . . . . . . . . . . . . . . 23A-145 <VEHICLES WITH RHD> . . . . . . . . . . . . . . 23A-163
INHIBITOR SWITCH CONTINUITY DISASSEMBLY AND REASSEMBLY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-145 <VEHICLES WITH LHD> . . . . . . . . . . . . . . 23A-165
INHIBITOR SWITCH AND CONTROL CABLE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23A-166
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 23A-146 SELECTOR LEVER ASSEMBLY
TRANSFER OIL LEVEL CHECK . . . . . . . . 23A-146 <VEHICLES WITH RHD> . . . . . . . . . . . . . . 23A-166
TRANSFER OIL REPLACEMENT . . . . . . . 23A-147 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23A-167
A/T CONTROL COMPONENT LOCATION 23A-148
A/T CONTROL COMPONENT CHECK . . . 23A-149 A/T KEY INTERLOCK AND SHIFT LOCK
INHIBITOR SWITCH CHECK . . . . . . . . . . . 23A-149
MECHANISMS*. . . . . . . . . . . . . . . . . . 23A-168
CRANK ANGLE SENSOR CHECK. . . . . . . 23A-149 REMOVAL AND INSTALLATION
<VEHICLES WITH LHD> . . . . . . . . . . . . . . 23A-168
STOP LAMP SWITCH CHECK. . . . . . . . . . 23A-149
A/T CONTROL RELAY CHECK . . . . . . . . . 23A-149 <VEHICLES WITH RHD> . . . . . . . . . . . . . . 23A-170
A/T CONTROL SOLENOID VALVE
ASSEMBLY CHECK . . . . . . . . . . . . . . . . . . 23A-149
TRANSMISSION ASSEMBLY . . . . . . 23A-172
A/T FLUID TEMPERATURE SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-150
TORQUE CONVERTER STALL TEST . . . . 23A-151
TRANSFER ASSEMBLY . . . . . . . . . . 23A-176
HYDRAULIC PRESSURE TESTS . . . . . . . 23A-152
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . 23A-157
LINE PRESSURE ADJUSTMENT . . . . . . . 23A-158
A/T FLUID COOLER. . . . . . . . . . . . . . 23A-178
SELECTOR LEVER OPERATION
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-158
AUTOMATIC TRANSMISSION (FF) 23A-3
M1231000300393
Item Standard value

A/T fluid temperature sensor resistance kΩ At 0°C 16.7 − 20.5
At 20°C 7.3 − 8.9
At 40°C 3.4 − 4.2
At 60°C 1.9 − 2.2
At 80°C 1.0 − 1.2
At 100°C 0.57 − 0.69
Damper clutch control (DCC) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Low & reverse (LR) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Second (2ND) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Underdrive (UD) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Overdrive (OD) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Stall speed r/min 2,300 − 2,800
Line pressure MPa 1,01 − 1,05
LUBRICANTS
M1231000400453
Item Specified lubricants Capacity L

A/T fluid DIA QUEEN ATF SP III 8.1
Transfer oil Hypoid gear oil API classification GL-5 SAE 90 0.55
23A-4 AUTOMATIC TRANSMISSION (FF)
SPECIAL TOOLS
SPECIAL TOOLS
M1231000600480
Tools No. Name Application

MB991955 MUT-III sub-assembly SWS communication line check
A
A: MB991824 A: Vehicle (ECU check and service data)
B: MB991827 Communication
C: MB991910 Interface (V. C. I.)
MB991824
D: MB991911 B: MUT-III USB cable
E: MB991825 C: MUT-III main
B F: MB991826 harness A (Vehicles
with CAN
communication
MB991827 system)
D: MUT-III main
C
harness B (Vehicles
DO NOT USED without CAN
communication
MB991910 system)
E: MUT-III
D
measurement
adapter
F: MUT-III trigger
MB991911 harness
MB991825
MB991826
MB991955
MB991502 MUT-II sub assembly Diagnosis code checking
B991502
MB991529 Diagnosis code

checking harness
MB991529
MD991658 Test harness Voltage measurement
MB991658
SPECIAL TOOLS

MD998330 Oil pressure gauge (3.0 Hydraulic pressure measurement
(including MPa)
MD998331)
AC103525
MD998332 Adapter Oil pressure gauge connection
MD998900
MB990767 End yoke holder Fixing of the hub
B990767
MB991897 Ball joint remover Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113)is also
AC106827 used to disconnect knuckle and tie
rod end ball joint.
A MB990241 Axle shaft puller • Drive shaft removal
A:MB990242 A: Puller shaft • Hub assembly removal
B
B:MB990244 B: Puller bar
MB990241AB
A
A:MB991017 A, B: Front hub remover Wheel bearing temporarily fixing
B:MB990998 and installer NOTE: Use MB991000 (a part of
C:MB991000 C: Spacer MB990998) for spacer
B
C
MB991017
MB991721 Sliding hammer Output shaft removal

SPECIAL TOOLS

MB991454 Engine hanger balancer When the engine hanger is used:
Supporting the engine assembly
during removal and installation of
the transmission assembly
B991454
NOTE: Special tool MB991454 is a
part of engine hanger attachment
MB991527 Hanger
set MB991453.
B991527
Z203830

Slide bracket (HI) A: MB991929 A: Joint (50) × 2
B: MB991930 B: Joint (90) × 2
E C: MB991931 C: Joint (140) × 2
D: MB991932 D: Foot (standard) × 4
F E: MB991933 E: Foot (short) × 2
A
D F: MB991934 F: Chain and hook
B assembly
C
B991928
TROUBLESHOOTING <A/T>
STANDARD FLOW OF DIAGNOSIS
TROUBLESHOOTING
M1231013500450
Ask about trouble symptoms
NG
Check the A/T fluid Replace the A/T fluid
OK
Check the trouble symptoms

Communicationwith
Communication withthe
the
MUT-II/III
MUT-II not not possible
possible
Reading of a diagnosis code To INSPECTION CHART FOR
TROUBLE SYMPTOMS
Diagnosis code output No diagnosis code output
exists
Erase of a diagnosis code Check the trouble symptoms
Inhibitor switch, TPS check
Abnormality exists (no diagnosis code output)

Road test
Abnormality exists No abnormality
(diagnostic trouble
code output) Recheck diagnosis codes
Diagnosis code output No diagnosis code output
exists
To INSPECTION CHART FOR To INSPECTION CHART FOR

DIAGNOSIS CODES TROUBLE SYMPTOMS
Check for the cause

Found Not found
Repair INTERMITTENT MALFUNCTIONS

(Refer to GROUP 00 - Points to NG
Note for Intermittent Malfunction)
OK
NG OK
Confirmation test (road test) Completed
AC212495 AB
DIAGNOSIS FUNCTION If there is a problem with any of the A/T system, the
M1231019000215 N range lamp will flash at a rate of approximately
N RANGE LAMP SYSTEM 1Hz.
If the N range lamp is flashing at a rate of
approximately 1 Hz, check the diagnosis output.
N range lamp flashing item
• Input shaft speed sensor system
• Output shaft speed sensor system
• Solenoid valve system
• Non-synchronization at various shift ranges
• A/T control relay system
AC300319AD
NOTE: If the A/T fluid warning lamp is illuminating, METHOD OF ERASING THE DIAGNOSIS
the A/T fluid temperature is high. (It flushes when the CODE
fluid is approximately 125°C or more and goes off
Use the MUT-II/III to erase the diagnosis code.
when the fluid is approximately 115°C or less.)
(Refer to GROUP 00 − How to Use
Troubleshooting/Inspection Service Points P.00-6.)
METHOD OF READING THE DIAGNOSIS
CODE
Use the MUT-II/III to read the diagnosis code. (Refer
to GROUP 00 − How to Use
Troubleshooting/Inspection Service Points P.00-6.)
ROAD TEST
M1231007800463
Procedure Pre-test/operation Test/operation Judgment value Check item Diagnosis Inspection

conditions code No. procedure if
there is an
abnormality
1 Ignition switch: Ignition switch Data List No.54 A/T 54 A/T control
LOCK (OFF) (1) ON (1) System voltage control relay
position [V] relay system
2 Ignition switch: Selector lever Data List No.61 Inhibitor 27, 28 Inhibitor
ON position (1) P switch switch
Engine: (1) P (2) R system
Stopped (2) R (3) N
Selector lever (3) N (4) D
position: P (4) D
Selector lever Data List No.67 Select − Sport mode
position (1) OFF switch switch
(1) D (2) ON system
(2) Select the sport (3) ON
mode (4) ON
(3) Upshift and hold Data List No.68 Upshift
the selector lever (1) OFF switch
in that position (2) OFF
(2nd gear) (3) ON
(4) Downshift and (4) OFF
hold the selector
lever in that Data List No.69 Downshift
position (1st gear) (1) OFF switch
(2) OFF
(3) OFF
(4) ON
Shift indicator lamp Shift
(1) Only D indicator
illuminates lamp
(2) Only 1
illuminates
(3) Only 2
illuminates
(4) Only 1
illuminates
Accelerator pedal Data List No.11 TPS 11, 12, 14 TPS
(1) Fully closed (1) 300 − 700 mV system
(2) Depressed (2) Gradually
(3) Fully opened increases from
(1)
(3) 4,000 mV or
more
Brake pedal Data List No.26 Stop lamp 26 Stop lamp
(1) Depressed (1) ON switch switch
(2) Released (2) OFF system

there is an
abnormality
3 Ignition switch: Starting test at P or Starting should be Starting − Starting not

START N position possible possible/n possible
ot
possible
4 Driving after Drive for 15 minutes Data List No.15 A/T fluid 15, 16 A/T fluid
engine has or more until the A/T Gradually rises to 70 temperatu temperatur
warmed up fluid temperature − 80 °C re sensor e sensor
rises to 70 − 80 °C. system

there is an
abnormality
5 Engine: idle Brake pedal (re-test) Data List No.26 Stop lamp 26 Stop lamp
Selector lever (1) Depressed (1) ON switch switch
position: N (2) Released (2) OFF system
A/Cswitch Data List No.65 A/C − A/C
(1) ON (1) ON compress compressor
(2) OFF (2) OFF or relay relay
system
Accelerator pedal Data List No.21 Crank 21 Crank
(1) Fully closed (1) The engine angle angle
(2) Depressed speed displayed sensor sensor
on the tachometer system
is identical to the
engine speed
displayed on
MUT-II/III.
(2) Gradually
increases from
(1)
Selector lever No abnormal shock Malfunctio − Engine
position during shifting n when stalls during
(1) N to D Within 2 seconds of starting off shifting
(2) N to R time lag N to D
−
shocks,
large time
lag
− N to R
shocks,
large time
lag
− N to D, N to
R shocks,
large time
lag
Driving − Does not
not move
possible forward
− Does not
reverse
− Does not
move
(forward or
reverse)

there is an
abnormality
6 Selector lever Selector lever Data List No.63 Shift − −

position: Sport position and vehicle (2) 1st position
mode (Must be speed (Each (3) 2nd
done on a level condition should be (4) 3rd
and straight maintained for 10 (5) 4th
road.) seconds or more.) Data List No.31 LR 31 LR solenoid
(1) Engine idling in (2) 0 % solenoid valve
1st gear (vehicle (3) 100 % valve duty system
stopped) (4) 100 % %
(2) Driving at (5) 100 %
constant speed of
10 km/h in 1st Data List No.32 UD 32 UD
gear (2) 0 % solenoid solenoid
(3) Driving at (3) 0 % valve duty valve
constant speed of (4) 0 % % system
20 km/h in 2nd (5) 100 %
gear Data List No.33 2NDsolen 33 2ND
(4) Driving at (2) 100 % oid valve solenoid
constant speed of (3) 0 % duty % valve
30 km/h in 3rd (4) 100 % system
gear (5) 0 %
(5) Driving at Data List No.34 OD 34 OD
constant speed of (2) 100 % solenoid solenoid
50 km/h in 4th (3) 100 % valve duty valve
gear (4) 0 % % system
(5) 0 %
Data List No.29 Vehicle − Vehicle
(1) 0 km/h speed speed
(4) 50 km/h signal signal
system
Data List No.22 Input shaft 22 Input shaft
(4) 1,600 − 1,900 speed speed
r/min sensor sensor
system
Data List No.23 Output 23 Output
(4) 1,600 − 1,900 shaft shaft speed
r/min speed sensor
sensor system

there is an
abnormality
7 Selector lever Selector lever Data List No.36 DCC 36, 52 DCC
position: Sport position and vehicle (1) 70 − 99.6 % solenoid solenoid
mode (Must be speed (2) 70 − 99.6 % to valve duty valve
done on a level (1) Driving at 0% % system
and straight constant speed Data List No.52 DCC
road.) 60 km/h in 3rd (1) −10 − 10 r/min amount of
gear (2) The value slippage
(2) Driving at 60 changes from (1)
km/h in 3rd gear,
then fully close
the accelerator
pedal
8 Suspends the (1) Accelerate to 4th Data List No.11, 23 Problem − Shocks,
INVECS-II range at a TPS The shifting points during engine
function using output of 1.5 V correspond with the shifting racing
MUT-II/III (opening angle MUT-II/III display Incorrect − All points
Selector lever 20%). and the TPS voltage shift points
position: D (2) Slowly (opening angle) and − Some
(Must be done decelerate and output shaft speed, points
on a level and stop. which are described No shifting − No
straight road) (3) Accelerate to 4th in the standard shift diagnosis
range at a TPS pattern. codes
output of 2.5 V 22 Input shaft
(opening angle speed
50%). sensor
system
23 Output
shaft speed
sensor
system

there is an
abnormality
8 Suspends the (1) Accelerate from Data List No.63 No shifting 31 LR solenoid
INVECS-II 1st gear to 4th (1) 1st → 2nd → 3rd from 1st to valve
function using gear. → 4th 2nd, or no system
MUT-II/III (2) Downshift to 3rd (2) 4th → 3rd shifting 33 2ND
Selector lever gear at speed of (3) 3rd → 2nd from 2nd solenoid
position: D 50 km/h in 4th (4) 2nd → 1st to 1st valve
(Must be done gear. system
on a level and (3) Downshift to 2nd
straight road) gear at speed of 41 1ST without
30 km/h in 3rd completion
gear. of shifting
(4) Downshift to 1st 42 2ND
gear at speed of without
20 km/h in 2nd completion
gear. of shifting
No shifting 33 2ND
from 2nd solenoid
to 3rd, or valve
no shifting system
from 3rd 34 OD
to 2nd solenoid
valve
system
42 2ND
without
completion
of shifting
43 3RD
without
completion
of shifting
No shifting 32 UD
from 3rd solenoid
to 4th, or valve
no shifting system
from 4th to 33 2ND
3rd solenoid
valve
system
43 3RD
without
completion
of shifting
44 4TH without
completion
of shifting

there is an
abnormality
9 Selector lever Selector lever The ration of data list No shifting 22 Input shaft
position: N position and vehicle No.22 and No.23 speed
(Must be done speed should be the same sensor
on a level and (1) Select R and as the transmission system
straight road) drive at 10 km/h ratio when reversing 23 Output
shaft speed
sensor
system
46 Reverse
without
completion
of shifting
SHIFT PATTERN
M1231028400192
UPSHIFT PATTERN
Throttle Throttle
opening Opening (%)
voltage (V)
4.5 100
4.0 1 2 2 3 3 4
2 3
movement
3.0 range
50
2.0 3 4
movement
range
1.0
0.5 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000
Output shaft speed r/min
0 50 100 150 200

Vehicle speed km/h
AC309445 AB
DOWNSHIFT PATTERN
Throttle
opening Throttle
voltage (V) opening (%)
4.5 100
4.0
1 2 2 3 3 4
3.0
50
2.0
1 3 2 3 3 4
1.0 (Sport mode) (Sport mode) (Sport mode)
0.5 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000

0 50 100 150 200

Vehicle speed km/h
AC309446AB
DAMPER CLUTCH CONTROL

M1231021300064
In 4th range
Throttle
opening Throttle
4.5
100
4.0
3.0 Damper clutch

disengaged Damper clutch engaged
50
2.0
1.0
0.5 0
1,000 2,000 3,000 4,000 5,000 6,000 7,000
0 50 100 150
Vehicle speed km/h AC309497 AC
In 3rd range
Throttle
opening Throttle
4.5 100
4.0
Damper clutch disengaged

3.0
50
Damper clutch engaged
2.0
1.0
0.5 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
0 50 100 150
Vehicle speed km/h
AC309498AB

CODE
M1231007900385
A/T MPI Diagnosis item Reference page

diagnosis diagnosis
code No. code No.
15 P0710 A/T fluid temperature sensor system P.23A-19
16 P.23A-25
21 − Crank angle sensor system Refer to GROUP
13B,
TroubleshootingP.13
B-169.
22 P0715 Input shaft speed sensor system P.23A-28
23 P0720 Output shaft speed sensor system P.23A-37
26 − Stop lamp switch system P.23A-48
27 P0705 Inhibitor switch system P.23A-53
28 P.23A-61
31 P0750 LR solenoid valve system P.23A-65
32 P0755 UD solenoid valve system P.23A-70
33 P0760 2ND solenoid valve system P.23A-74
34 P0765 OD solenoid valve system P.23A-78
36 P0740 DCC solenoid valve system P.23A-82
41 − 1st gear ratio does not meet the specification P.23A-86
42 − 2nd gear ratio does not meet the specification P.23A-86
43 − 3rd gear ratio does not meet the specification P.23A-86
44 − 4th gear ratio does not meet the specification P.23A-86
46 − Reverse gear ratio does not meet the specification P.23A-86
52 − DCC solenoid valve system P.23A-88
54 P1751 A/T control relay system P.23A-89
56 − N range lamp system P.23A-96
NOTE: The MPI diagnostic trouble codes are the codes which are set when item "MPI" is selected on
MUT-II/III. However, the codes above indicate failure in the automatic transmission.
DIAGNOSTIC TROUBLE CODE

PROCEDURES
Code No.15: A/T fluid temperature sensor system
A/T fluid temperature sensor system circuit
A/T CONTROL
A/T SOLENOID
FLUID VALVE ASSEMBLY
TEMPERATURE
SENSOR
ENGINE-
A/T-ECU
Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
AC309562 AC
OPERATION Possible causes

• The A/T fluid temperature sensor converts the • Malfunction of the A/T fluid temperature sensor
automatic fluid temperature to voltage, and send • Damaged harness wires and connectors
the information to the engine-A/T-ECU. • Malfunction of the engine-A/T-ECU
• The A/T fluid temperature rises, the resistance
decreases. Thus, the sensor output voltage DIAGNOSIS
depends on the automatic fluid temperature. As
the A/T fluid temperature rises, the output voltage
will decrease. STEP 1. MUT-II/III data list
Item 15: A/T fluid temperature sensor (Refer to Data
diagnosis code set conditions List Table P.23A-133).
If the A/T fluid temperature sensor output voltage is Q: Is the check result normal?
4.5 volts or more after driving for 10 minutes or more, YES : Intermittent malfunction (Refer to GROUP
there is an open circuit in the A/T fluid temperature 00 − How to Cope with Intermittent
sensor and diagnosis code 15 is set. Malfunction P.00-6).
NO : Go to Step 2.
STEP 2. Measure the resistance at A/T control STEP 4. Measure the resistance at A/T control
solenoid valve assembly connector B-34. solenoid valve assembly connector B-34.
Sensor side Harness side

B-34 (GR) B-34 (GR)
AC309511AC AC309511AB
Disconnect the connector, and measure the Disconnect the connector, and measure the
resistance between terminal 1 and 2 at the sensor resistance between terminal 2 and earth at the wiring
side. harness side.
OK: OK: 2 Ω or less
• 16.7 − 20.5 kΩ (at 0°C)
• 7.3 − 8.9 kΩ (at 20°C) YES : Go to Step 9.
• 3.4 − 4.2 kΩ (at 40°C) NO : Go to Step 5.
• 1.9 − 2.2 kΩ (at 60°C)
• 1.0 − 1.2 kΩ (at 80°C)
• 0.57 − 0.69 kΩ (at 100°C) STEP 5. Measure the voltage at engine-A/T-ECU
connector C-142.
Q: Is the check result normal? (1) Connect A/T control solenoid valve assembly
YES : Go to Step 3.
connector B-34.
NO : Replace the A/T fluid temperature sensor.
(2) Turn the ignition switch to the ON position.
Connector: C-142 <LHD>
STEP 3. Connector check: B-34 A/T control
solenoid valve assembly Engine-A/T-ECU
Connector: B-34
Harness side C-142 (GR)

B-34 (GR)
Connector: C-142 <RHD>

Engine-A/T-ECU
AC309511AB
C-142 (GR)
Check for the contact with terminals.
YES : Go to Step 4.
95 94 93 92 91
NO : Repair the defective connector. 104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113
Harness side
AC309479 AF
(3) Measure the voltage between engine-A/T-ECU

connector C-142 terminal No.96 and earth.
OK: 0.5 V or less
YES : Go to Step 8.
NO : Go to Step 6. STEP 8. Connector check: C-142 engine-A/T-ECU
connector
STEP 6. Connector check: C-142 engine-A/T-ECU
connector Engine-A/T-ECU
Engine-A/T-ECU
C-142 (GR)
C-142 (GR)

Engine-A/T-ECU
Connector: C-142 <RHD> C-142 (GR)

Engine-A/T-ECU
C-142 (GR)
95 94 93 92 91
104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113
95 94 93 92 91
Harness side
104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105 AC309479 AF
120 119 118 117 116 115 114 113
Harness side Check for the contact with terminals.
AC309479 AF Q: Is the check result normal?
Check for the contact with terminals. NO : Repair the defective connector.
YES : Go to Step 7.
NO : Repair the defective connector. STEP 9. Measure the voltage at A/T control
solenoid valve assembly connector B-34.
Connector: B-34
Harness side
List Table P.23A-133.) B-34 (GR)
00 − How to Cope with Intermittent
Malfunction P.00-6).
NO : Replace the engine-A/T-ECU.
AC309511AB
(1) Disconnect the connector, and measure the

voltage between terminal 1 and earth at the
wiring harness side.
OK: 4.5 − 4.9 V
YES : Go to Step 7.
NO : Go to Step 10.

STEP 10. Measure the voltage at engine-A/T-ECU NO : Go to Step 11.
connector C-142.
(1) Connect A/T control solenoid valve assembly
connector B-34. STEP 11. Connector check: C-142
(2) Turn the ignition switch to the ON position. engine-A/T-ECU connector
Connector: C-142 <LHD> Connector: C-142 <LHD>
Engine-A/T-ECU Engine-A/T-ECU
C-142 (GR) C-142 (GR)
Connector: C-142 <RHD> Connector: C-142 <RHD>

C-142 (GR) C-142 (GR)
95 94 93 92 91 95 94 93 92 91
104 103 102 101 100 99 98 97 96 104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105 112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113 120 119 118 117 116 115 114 113
AC309479 AF AC309479 AF
(3) Measure the voltage between engine-A/T-ECU Check for the contact with terminals.
connector C-142 terminal No.119 and earth. Q: Is the check result normal?
OK: YES : Go to Step 7.
• 3.8 − 4.0 V (at 20°C) NO : Repair the defective connector.
• 3.2 − 3.4 V (at 40°C)
• 1.7 − 1.9 V (at 80°C)
STEP 12. Connector check: C-142 STEP 13. Check the harness between A/T control
engine-A/T-ECU connector solenoid valve assembly connector B-34 terminal
No.1 and engine-A/T-ECU connector C-142
terminal No.119.
Engine-A/T-ECU Connector: B-34
Harness side
C-142 (GR) B-34 (GR)

Engine-A/T-ECU
AC309511AB
C-142 (GR) Connector: C-142 <LHD>
Engine-A/T-ECU
95 94 93 92 91
104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113 C-142 (GR)
Harness side
AC309479 AF

Q: Is the check result normal? Engine-A/T-ECU
NO : Repair the defective connector.
C-142 (GR)
95 94 93 92 91
104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113
Harness side
AC309479 AF
Check the output line for short-circuited or open

circuit.
YES : Go to Step 7.
NO : Repair the wiring harness.
YES : Go to Step 7.
STEP 14. Check the harness between A/T control NO : Repair the wiring harness.
solenoid valve assembly connector B-34 terminal
terminal No.96.
Connector: B-34
Harness side
B-34 (GR)
AC309511AB
Engine-A/T-ECU
C-142 (GR)

Engine-A/T-ECU
C-142 (GR)
95 94 93 92 91
104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113
Harness side
AC309479 AF
Check the earth line for open circuit.

Code No.16: A/T fluid temperature sensor system (short circuit)
A/T FLUID TEMPERATURE SENSOR SYSTEM

STEP 3. Measure the voltage at A/T control
CIRCUIT
Refer to P.23A-19.
Connector: B-34
OPERATION
Refer to P.23A-19. Sensor side
B-34 (GR)
DIAGNOSIS CODE SET CONDITION
If the A/T fluid temperature sensor output voltage has
been approximately 0 V for at least one second
(indicating abnormally high oil temperature), it
indicates that the A/T fluid temperature sensor circuit
is shorted and diagnosis code No.16 will be set. AC309511AC
POSSIBLE CAUSES (1) Disconnect the connector, and measure the

• Malfunction of the A/T fluid temperature sensor voltage between terminal 1 and earth at the
• Damaged harness wires and connectors wiring harness side.
• Malfunction of the engine-A/T-ECU (2) Turn the ignition switch to the ON position.
OK: 4.5 − 4.9 V
DIAGNOSIS
YES : Go to Step 4.
STEP 1. MUT-II/III data list NO : Go to Step 6.
List Table P.23A-133). STEP 4. Measure the resistance at A/T control
Q: Is the check result normal? solenoid valve assembly connector B-34.
YES : Intermittent malfunction (Refer to GROUP Connector: B-34
Malfunction P.00-6). Sensor side
NO : Go to Step 2. B-34 (GR)

solenoid valve assembly
Connector: B-34
AC309511AC
Sensor side
B-34 (GR) Disconnect the connector, and measure the
resistance between terminal 1 and 2 at the sensor
side.
OK:
• 16.7 − 20.5 kΩ (at 0°C)
• 7.3 − 8.9 kΩ (at 20°C)
AC309511AC • 3.4 − 4.2 kΩ (at 40°C)
Check for the contact with terminals. • 1.9 − 2.2 kΩ (at 60°C)
• 1.0 − 1.2 kΩ (at 80°C)
Q: Is the check result normal? • 0.57 − 0.69 kΩ (at 100°C)
YES : Go to Step 3.
NO : Repair the defective connector. Q: Is the check result normal?
YES : Go to Step 5.
NO : Replace the A/T fluid temperature sensor.
STEP 5. MUT-II/III data list connector C-142 terminal No.119 and earth.
Item 15: A/T fluid temperature sensor (Refer to Data OK:
List Table P.23A-133). • 3.8 − 4.0 V (at 20°C)
• 3.2 − 3.4 V (at 40°C)
Q: Is the check result normal? • 1.7 − 1.9 V (at 80°C)
00 − How to Cope with Intermittent Q: Is the check result normal?
Malfunction P.00-6). YES : Go to Step 5.
NO : Replace the engine-A/T-ECU. NO : Go to Step 7.
STEP 6. Measure the voltage at engine-A/T-ECU STEP 7. Connector check: C-142 engine-A/T-ECU
connector C-142. connector
(1) Connect A/T control solenoid valve assembly Connector: C-142 <LHD>
connector B-34.
(2) Turn the ignition switch to the ON position. Engine-A/T-ECU
Engine-A/T-ECU C-142 (GR)
C-142 (GR)
Engine-A/T-ECU

Engine-A/T-ECU
C-142 (GR)
95 94 93 92 91
104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113
Harness side
95 94 93 92 91
104 103 102 101 100 99 98 97 96 AC309479 AF
112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113
Harness side
AC309479 AF
YES : Go to Step 8.
(3) Measure the voltage between engine-A/T-ECU NO : Repair the defective connector.
YES : Go to Step 5.
STEP 8. Check the harness between A/T control NO : Repair the wiring harness.
terminal No.119.
Connector: B-34
Harness side
B-34 (GR)
AC309511AB
Engine-A/T-ECU
C-142 (GR)

Engine-A/T-ECU
C-142 (GR)
95 94 93 92 91
104 103 102 101 100 99 98 97 96
112 111 110 109 108 107 106 105
120 119 118 117 116 115 114 113
Harness side
AC309479 AF

circuit.
Code No.22: Input shaft speed sensor system
Input shaft speed sensor system circuit
IGNITION
SWITCH (IG1)
INPUT SHAFT
SPEED SENSOR
ENGINE-
A/T-ECU
Wire colour code

AC309564AC
OPERATION
STEP 3. Measure the resistance at input shaft
The input shaft speed sensor detects the speed of
speed sensor connector B-36.
the underdrive clutch retainer, and sends the
information to the engine-A/T-ECU as a pulse signal. Connector: B-36
diagnosis code set conditions Harness side

The diagnosis code No. 22 will be set if the input
shaft speed sensor does not send a pulse signal for
B-36 (B)
one second or more while the 3rd gears are engaged
and the vehicle speed is 40 km/h or more (the output
shaft speed sensor speed is 1000 r/min or more).
If the code No. 22 is set four times, the transmission
will be fixed in 3rd gear as a fail-safe measure. AC309512 AB
However, the transmission can be downshifted to Disconnect the connector, and measure the
2nd gear by operating the selector lever. resistance between terminal 1 and earth at the wiring
Possible causes harness side.
• Malfunction of input shaft speed sensor OK: 2 Ω or less
• Malfunction of underdrive clutch retainer Q: Is the check result normal?
• Damaged harness wires and connectors YES : Go to Step 9.
• Malfunction of the engine-A/T-ECU NO : Go to Step 4.
DIAGNOSIS
STEP 4. Measure the voltage at engine-A/T-ECU
connector C-141.
STEP 1. MUT-II/III data list (1) Connect input shaft speed sensor connector
Item 22: Input shaft speed sensor (Refer to data list B-36.
reference table P.23A-133). (2) Turn the ignition switch to the ON position.
Q: Is the check result normal? Connector: C-141 <LHD>
00 − How to Cope with Intermittent Engine-A/T-ECU
NO : Go to Step 2.
C-141 (GR)
STEP 2. Connector check: B-36 input shaft speed
sensor connector
Connector: B-36
Engine-A/T-ECU
Harness side
C-141 (GR)
B-36 (B)
AC309512 AB
Harness side
AC309479 AE
YES : Go to Step 3. (3) Measure the voltage between engine-A/T-ECU
NO : Repair the defective connector. connector C-141 terminal No.88 and earth.
OK: 0.5 V or less
YES : Go to Step 7.
NO : Go to Step 5. STEP 7. Connector check: C-141 engine-A/T-ECU
connector, C-16 J/C (1)
STEP 5. Connector check: C-141 engine-A/T-ECU
Engine-A/T-ECU
C-141 (GR)
C-141 (GR)

Engine-A/T-ECU

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE
Harness side Connector: C-16

<RHD>
AC309479 AE

YES : Go to Step 6.
C-16 (L)
Item 22: Input shaft speed sensor (Refer to data list AC308735BH
reference table P.23A-133).

Connector: C-16
Q: Is the check result normal? <LHD>
C-16 (L)
AC308718 BA

YES : Go to Step 8.
YES : Go to Step 6.
STEP 8. Check the harness between input shaft NO : Repair the wiring harness.
speed sensor connector B-36 terminal No.1 and
engine-A/T-ECU connector C-141 terminal No.88.
Connector: B-36 STEP 9. Measure the voltage at input shaft speed
sensor connector B-36.
Harness side Connector: B-36
Harness side
B-36 (B)
B-36 (B)
AC309512 AB
Connector: C-141 <LHD> AC309512 AB
Engine-A/T-ECU (1) Disconnect the connector, and measure the

C-141 (GR)
OK: System voltage
NO : Go to Step 10.
Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE

STEP 10. Connectors check: C-202 J/B Connector: C-16

<RHD>
connector, C-106 intermediate connector, C-16
J/C (1)
Connector: C-202
<RHD>
C-202
C-16 (L)
AC308735BH
6 5 4 3 2 1 Connector: C-16
14 13 12 11 10 9 8 7
<LHD>
Harness side
AC308772 AL
Connector: C-202
<LHD>
C-202
C-16 (L)
AC308718 BA
6 5 4 3 2 1
14 13 12 11 10 9 8 7 Check for the contact with terminals.
AC308720 AM YES : Go to Step 11.
Connector: C-106
<RHD>
1 2
3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
C-106 (GR)
AC308735AX
Connector: C-106
<LHD>
1 2
3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
C-106 (GR)
AC308718AS
STEP 11. Check the harness between input shaft STEP 12. Measure the voltage at input shaft
speed sensor connector B-36 terminal No.3 and speed sensor connector B-36.
junction block connector C-202 terminal No.12. Connector: B-36
Connector: B-36
Harness side
Harness side
B-36 (B)
B-36 (B)
AC309512 AB
AC309512 AB
Connector: C-202 voltage between terminal 2 and earth at the
<RHD> wiring harness side.
C-202
OK: 4.5 − 4.9 V
NO : Go to Step 13.
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side STEP 13. Measure the voltage at engine-A/T-ECU

AC308772 AL
connector C-141.
Connector: C-202 (1) Disconnect input shaft speed sensor connector
<LHD> B-36.
C-202
Engine-A/T-ECU
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side C-141 (GR)

AC308720 AM
Check the power supply line for short or open circuit.

YES : Go to Step 6. Connector: C-141 <RHD>
NO : Repair the wiring harness. Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE

OK: 4.5 − 4.9 V

NO : Go to Step 14. STEP 15. Check the harness between input shaft
speed sensor connector B-36 terminal No.2 and
STEP 14. Connector check: C-141 Connector: B-36
engine-A/T-ECU connector
Connector: C-141 <LHD> Harness side
Engine-A/T-ECU
B-36 (B)
C-141 (GR)
AC309512 AB

C-141 (GR)
C-141 (GR)

Harness side
Engine-A/T-ECU
AC309479 AE
Check for the contact with terminals. C-141 (GR)

Harness side
AC309479 AE
Check the output line for short circuit.

YES : Go to Step 6.
STEP 16. Connector check: C-141 STEP 17. Check the harness between input shaft
engine-A/T-ECU connector speed sensor connector B-36 terminal No.2 and
Connector: B-36
Engine-A/T-ECU
Harness side
C-141 (GR)
B-36 (B)

AC309512 AB
Engine-A/T-ECU
C-141 (GR)
Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE
Check for the contact with terminals. Connector: C-141 <RHD>

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE
Check the output line for open circuit.

YES : Go to Step 6.
STEP 18. Measure the output wave pattern of the STEP 19. Connector check: C-141
input shaft speed sensor at engine-A/T-ECU engine-A/T-ECU connector
connector C-141 (using an oscilloscope). Connector: C-141 <LHD>
(1) Shift the selector lever to the D range.
(2) Accelerate the vehicle to approximately 50 km/h Engine-A/T-ECU
(shift range; 3rd).
C-141 (GR)
Engine-A/T-ECU
C-141 (GR) Connector: C-141 <RHD>

Engine-A/T-ECU
C-141 (GR)
Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE

AC309479 AE
(3) Connect an oscilloscope, and measure the
voltage between engine-A/T-ECU connector
C-141 terminal No.64 and earth. STEP 20. Replace the input shaft speed sensor
and then recheck the diagnosis code.
OK: A wave pattern such as the one
(1) Replace the input shaft speed sensor.
shown on P.23A-139 (Check Procedure
(2) Test drive the vehicle.
Using an Oscilloscope) should be output,
(3) Check if the diagnosis code is set.
and the maximum value should be 4.8 V
or more and the minimum value should Q: Is diagnosis code 22 set?
be 0.8 V or less. There should be no noise YES : Go to Step 21.
in the output wave pattern. NO : The inspection is complete.

YES : Go to Step 6. STEP 21. Underdrive clutch retainer inspection
NO : Go to Step 19. Visually check the underdrive clutch retainer for
damage.
YES : Eliminate the cause of the noise.
NO : Replace the underdrive clutch retainer.
Code No.23: Output shaft speed sensor system
Output shaft speed sensor system circuit
IGNITION
SWITCH (IG1)
OUTPUT SHAFT
SPEED SENSOR
ENGINE-
A/T-ECU
Wire colour code

AC309574AC
OPERATION
STEP 2. Connector check: B-33 output shaft
The output shaft speed sensor detects the speed of
speed sensor connector
the transfer drive gear, and sends the information to
the engine-A/T-ECU as a pulse signal. Connector: B-33
diagnosis code set conditions Harness side

If the output pulse from the output shaft speed
sensor has been lost for one second or more while
B-33 (GR)
the vehicle is being driven, it is judged that there is
an open circuit or short circuit in the output shaft
speed sensor, and diagnosis code 23 is set.
If the code No. 23 is set four times, the transmission
will be fixed in 3rd gear as a fail-safe measure. AC309512 AD
However, the transmission can be downshifted to Check for the contact with terminals.
2nd gear by operating the selector lever.
Possible causes YES : Go to Step 3.
• Malfunction of output shaft speed sensor NO : Repair the defective connector.
• Malfunction of transfer drive gear or driven gear
• Damaged harness wires and connectors STEP 3. Measure the resistance at output shaft
• Malfunction of the engine-A/T-ECU speed sensor connector B-33.
Connector: B-33
DIAGNOSIS
Harness side
Item 23: Output shaft speed sensor (Refer to data list
B-33 (GR)
AC309512 AD
NO : Go to Step 2. Disconnect the connector, and measure the
resistance between terminal 1 and earth at the wiring
harness side.
OK: 2 Ω or less
YES : Go to Step 9.
NO : Go to Step 4.
STEP 4. Measure the voltage at engine-A/T-ECU STEP 5. Connector check: C-141 engine-A/T-ECU
connector C-141. connector
(1) Connect output shaft speed sensor connector Connector: C-141 <LHD>
B-33.
(2) Turn the ignition switch to the "ON" position. Engine-A/T-ECU
Engine-A/T-ECU C-141 (GR)
C-141 (GR)
Engine-A/T-ECU

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE
Harness side Check for the contact with terminals.

AC309479 AE Q: Is the check result normal?
YES : Go to Step 6.
(3) Measure the voltage between engine-A/T-ECU NO : Repair the defective connector.
OK: 0.5 V or less
Q: Is the check result normal? Item 23: Output shaft speed sensor (Refer to data list
YES : Go to Step 7. reference table P.23A-133).
NO : Go to Step 5.
YES : Go to Step 8.
STEP 7. Connector check: C-141 engine-A/T-ECU NO : Repair the defective connector.
connector, C-16 J/C (1)
STEP 8. Check the harness between output shaft
Engine-A/T-ECU speed sensor connector B-33 terminal No.1 and
Connector: B-33
C-141 (GR)
Harness side
B-33 (GR)
Engine-A/T-ECU
C-141 (GR) AC309512 AD
Engine-A/T-ECU
Harness side
AC309479 AE
C-141 (GR)
Connector: C-16
<RHD>

Engine-A/T-ECU
C-141 (GR)
C-16 (L)
AC308735BH
Connector: C-16
<LHD> Harness side
AC309479 AE

YES : Go to Step 6.
C-16 (L)
AC308718 BA

STEP 9. Measure the voltage at output shaft voltage between terminal 3 and earth at the
speed sensor connector B-33. wiring harness side.
Connector: B-33
OK: System voltage
NO : Go to Step 10.
B-33 (GR)
AC309512 AD

STEP 10. Connectors check: C-202 J/B Connector: C-16

<RHD>
connector, C-106 intermediate connector, C-16
J/C (1)
Connector: C-202
<RHD>
C-202
C-16 (L)
AC308735BH
6 5 4 3 2 1 Connector: C-16
14 13 12 11 10 9 8 7
<LHD>
Harness side
AC308772 AL
Connector: C-202
<LHD>
C-202
C-16 (L)
AC308718 BA
6 5 4 3 2 1
Connector: C-106
<RHD>
1 2
3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
C-106 (GR)
AC308735AX
Connector: C-106
<LHD>
1 2
3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
C-106 (GR)
AC308718AS
YES : Go to Step 6.
STEP 11. Check the harness between output NO : Repair the wiring harness.
shaft speed sensor connector B-33 terminal No.3
and junction block connector C-202 terminal
No.12. STEP 12. Measure the voltage at output shaft
Connector: B-33 speed sensor connector B-33.
Connector: B-33
Harness side
Harness side
B-33 (GR)
B-33 (GR)
AC309512 AD
AC309512 AD
Connector: C-202
<RHD> (1) Disconnect the connector, and measure the
C-202
OK: 4.5 − 4.9 V
6 5 4 3 2 1 YES : Go to Step 18.
14 13 12 11 10 9 8 7
NO : Go to Step 13.
Harness side
AC308772 AL
Connector: C-202
<LHD>
C-202
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side
AC308720 AM


connector C-141.
(1) Disconnect output shaft speed sensor connector
B-33. STEP 14. Connector check: C-141
(2) Turn the ignition switch to the "ON" position. engine-A/T-ECU connector
C-141 (GR) C-141 (GR)

C-141 (GR) C-141 (GR)
AC309479 AE AC309479 AE
OK: 4.5 − 4.9 V YES : Go to Step 15.
YES : Go to Step 6.
STEP 15. Check the harness between output NO : Repair the wiring harness.
shaft speed sensor connector B-33 terminal No.2
and engine-A/T-ECU connector C-141 terminal
No.73. STEP 16. Connector check: C-141
Connector: B-33 engine-A/T-ECU connector
Harness side
Engine-A/T-ECU
B-33 (GR)
C-141 (GR)
AC309512 AD

Engine-A/T-ECU
Engine-A/T-ECU
C-141 (GR)
C-141 (GR)
Harness side
Engine-A/T-ECU AC309479 AE

C-141 (GR)
Harness side
AC309479 AE

STEP 17. Check the harness between output STEP 18. Measure the output wave pattern of the
shaft speed sensor connector B-33 terminal No.2 output shaft speed sensor at engine-A/T-ECU
and engine-A/T-ECU connector C-141 terminal connector C-141 (using an oscilloscope).
No.73. (1) Shift the selector lever to the D range.
Connector: B-33 (2) Accelerate the vehicle to approximately 50 km/h
(shift range; 3rd.)
Harness side Connector: C-141 <LHD>
Engine-A/T-ECU
B-33 (GR)
C-141 (GR)
AC309512 AD

C-141 (GR)
C-141 (GR)

Harness side
Engine-A/T-ECU
AC309479 AE
C-141 (GR) (3) Connect an oscilloscope, and measure the

voltage between engine-A/T-ECU connector
C-141 terminal No.73 and earth.
OK: A wave pattern such as the one
shown on P.23A-139 (Check Procedure
Using an Oscilloscope) should be output,
Harness side and the maximum value should be 4.8 V
AC309479 AE or more and the minimum value should
be 0.8 V or less. There should be no noise
Check the output line for open circuit.
in the output wave pattern.
YES : Go to Step 6. Q: Is the check result normal?
YES : Go to Step 6.
NO : Go to Step 19.

STEP 19. Connector check: C-141 NO : Repair the defective connector.
engine-A/T-ECU connector
STEP 20. Replace the output shaft speed sensor
Engine-A/T-ECU and then recheck the diagnosis code.
(1) Replace the output shaft speed sensor.
(3) Check if the diagnosis code is set.
C-141 (GR)
Q: Is diagnosis code 23 set?
NO : The inspection is complete.

Engine-A/T-ECU STEP 21. Check the transfer drive gear and
driven gear.
C-141 (GR) Visually check the transfer drive gear and driven
gear for damage.
NO : Replace the transfer drive gear and driven
gear.
Harness side
AC309479 AE

Code No.26: Stop lamp switch system
Stop lamp switch system circuit
BATTERY
RELAY
BOX
STOP LAMP
SWITCH
Wire colour code ENGINE-

B : Black LG : Light green A/T-ECU
G : Green L : Blue
W : White Y : Yellow
SB : Sky blue BR : Brown
O : Orange GR : Gray
R : Red P : Pink V : Violet
AC309565AB

The stop lamp switch judges whether the brake • Malfunction of brake pedal
pedal is depressed or released, and sends the • Malfunction of stop lamp switch
information to the engine-A/T-ECU. • Damaged harness wires and connectors
• Malfunction of the engine-A/T-ECU
diagnosis code set conditions
If the stop lamp remains on for consecutively five
minutes or more while the vehicle is being driven or
all the stop lamp bulbs are blown, it is judged that
there is a short or open circuit in the stop lamp switch
and diagnosis code 26 is set.
DIAGNOSIS STEP 6. Measure the voltage at stop lamp switch

connector C-101.
STEP 1. Check that the stop lamps illuminate and Connector: C-101
extinguish normally.
The stop lamps should illuminate when the brake
pedal is depressed, and extinguish when released.
2 1
Q: Is the check result normal?? 4 3
YES : Go to Step 7. Harness side
NO : Go to Step 2.
STEP 2. Check the brake pedal height. Brake pedal

AC309520AB
Refer to GROUP 35A − On-vehicle Service, Brake
Pedal Check and Adjustment. (Refer to P.35A-4.) Disconnect the connector, and measure the voltage
between terminal No.2 and earth at the harness side.
YES : Go to Step 3. OK: System voltage
NO : Adjust the brake pedal height. Q: Is the check result normal?
YES : Go to Step 7.
NO : Go to Step 12.
STEP 3. Check the stop lamp switch.
Refer to GROUP 35A − Brake Pedal and Stop Lamp
Switch Continuity Check. (Refer to P.35A-14.) STEP 7. Measure the voltage at engine-A/T-ECU
Q: Is the check result normal? connector C-140.
YES : Go to Step 4. (1) Connect stop lamp switch connector C-101.
NO : Replace the stop lamp switch. Connector: C-140 <LHD>
Engine-A/T-ECU
STEP 4. MUT-II/lll data list
Item 26: Stop lamp switch (Refer to data list
reference table P.23A-133.)
C-140 (GR)
Malfunction P.00-6.)
NO : Go to Step 5. Connector: C-140 <RHD>
Engine-A/T-ECU
C-140 (GR)
STEP 5. Connector check: C-101 stop lamp
switch connector
Connector: C-101
34 33 3231
43 42 41403938373635
51 50 494847464544
58 57 565554 5352
2 1
4 3 Harness side
Harness side
AC309479AD

Brake pedal
AC309520AB
OK:
Check for the contact with terminals. Brake pedal depressed: System voltage
Brake pedal not depressed: 1 V or less
NO : Repair the defective connector. YES : Go to Step 8.
NO : Go to Step 10.
YES : Go to Step 9.
STEP 8. Connector check: C-140 engine-A/T-ECU NO : Repair the defective connector.
connector
STEP 9. MUT-II/lll data list
Engine-A/T-ECU Item 26: Stop lamp switch (Refer to data list
reference table P.23A-133.)
C-140 (GR) YES : Intermittent malfunction (Refer to GROUP

Engine-A/T-ECU
C-140 (GR)
34 33 3231
43 42 41403938373635
51 50 494847464544
58 57 565554 5352
Harness side
AC309479AD

Q: Is the check result normal??
STEP 10. Connectors check: C-104 intermediate Connector: C-140 <LHD>

connector, C-16 J/C (1), C-140 engine-A/T-ECU
Connector: C-104
<RHD>
C-140 (GR)

C-104 (B)
1 2 3 4 5 6 7 Engine-A/T-ECU
8 9 10 11 12 13 14 15 16 C-140 (GR)
AC308735AV
Connector: C-104
<LHD>
34 33 3231
43 42 41403938373635
51 50 494847464544
58 57 565554 5352
Harness side
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 AC309479AD
C-104 (B)
AC308718 AQ
Connector: C-16 NO : Repair the defective connector.
<RHD>
C-16 (L)
AC308735BH
Connector: C-16
<LHD>
C-16 (L)
AC308718 BA
STEP 11. Check the harness between stop lamp STEP 12. Connector check: C-116 intermediate
switch connector C-101 terminal No.1 and connector
engine-A/T-ECU connector C-140 terminal No.39. Connector: C-116 <RHD>
Connector: C-101
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 1617 18 1920 21
22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 4243
2 1
4 3
Harness side
C-116
AC308735 BD
Brake pedal
AC309520AB
Engine-A/T-ECU
C-140 (GR) 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 1617 18 1920 21 C-116
22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 4243
AC308716 AY
Connector: C-140 <RHD> Check for the contact with terminals.

Engine-A/T-ECU
C-140 (GR)
STEP 13. Check the harness between stop lamp

34 33 3231 switch connector C-101 terminal No.2 and
43 42 41403938373635
51 50 494847464544 battery.
58 57 565554 5352
Harness side Connector: C-101
AC309479AD
Check the output line for short or open circuit.

2 1
YES : Go to Step 9. Harness side
Brake pedal
AC309520AB

YES : Go to Step 9.
Code No.27: Inhibitor switch system
Inhibitor switch system circuit <RHD>
IGNITION
SWITCH (IG1)
INHIBITOR
SWITCH
SHIFT
SWITCH
ASSENBLY
SHIFT SELECT
SWITCH SWITCH
COMBINATION
METER
ENGINE-
A/T-ECU
Wire colour code

BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet AC309572 AC
Inhibitor switch system circuit <LHD>
IGNITION
SWITCH (IG1)
INHIBITOR
SWITCH
SHIFT
SWITCH
ASSENBLY
SHIFT SELECT
SWITCH SWITCH
COMBINATION
METER
ENGINE-
A/T-ECU
Wire colour code

AC309566AB
OPERATION
The inhibitor switch detects the selector lever
position (P, R, N or D) which the driver has selected,
and sends the information to the engine-A/T-ECU.
DIAGNOSIS CODE SET CONDITIONS YES : Intermittent malfunction (Refer to GROUP

If the inhibitor switch has not been sending any 00 − How to Cope with Intermittent
signal for at least 30 seconds, an open circuit may be Malfunction P.00-6).
present and dianosis code No.27 will be set. NO <none of the selector lever positions are
displayed on MUT II/III> : Go to Step 2.
POSSIBLE CAUSES NO <only one of the selector lever positions is not
• Malfunction of the inhibitor switch displayed on MUT II/III> : Go to Step 6.
• Damaged harness wires and connectors
STEP 2. Check the inhibitor switch.
Refer to P.23A-145.
DIAGNOSIS
YES : Go to Step 3.
STEP 1. MUT-II/III data list NO : Replace the inhibitor switch.
Item 61: Inhibitor switch P.23A-133 (Refer to data list
reference table).
STEP 3. Connector check: B-35 Inhibitor switch Connector: C-106

connector, C-202 J/B connector, C-106 <LHD>
intermediate connector, C-16 J/C (1) 1 2
3 4 5 6
Connector: B-35 7 8 9 10 11 12
16
13 14 15 17 18 19
C-106 (GR)
B-35 (B)
AC308718AS
Harness side
Connector: C-16
<LHD>
AC103395AN
Connector: C-202
<RHD>
C-202
C-16 (L)
AC308718 BA
6 5 4 3 2 1 Connector: C-16
14 13 12 11 10 9 8 7
<RHD>
Harness side
AC308772 AL
Connector: C-202
<LHD>
C-202
C-16 (L)
AC308735BH
6 5 4 3 2 1
Connector: C-106
<RHD>
1 2
3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
C-106 (GR)
AC308735AX
STEP 4. Check the harness between inhibitor STEP 6. Check the inhibitor switch.
switch connector B-35 terminal No.8 and J/B Refer to P.23A-145.
connector C-202 terminal No.12. Q: Is the check result normal?
Connector: B-35 YES : Go to Step 7.
NO : Replace the inhibitor switch.
STEP 7. Connector check: B-35 inhibitor switch

B-35 (B) connector, C-141 engine-A/T-ECU connector
Connector: B-35
Harness side
AC103395AN
B-35 (B)
Connector: C-202
<RHD>
Harness side
C-202
AC103395AN

6 5 4 3 2 1
14 13 12 11 10 9 8 7 Engine-A/T-ECU
Harness side
AC308772 AL

<LHD>
C-202

Engine-A/T-ECU
6 5 4 3 2 1
14 13 12 11 10 9 8 7
C-141 (GR)
Harness side
AC308720 AM
Check the power supply line for open circuit.

YES : Go to Step 5.
NO : Repair the wiring harness. Harness side
AC309479 AE
STEP 5. MUT-II/III data list Check for the contact with terminals.
reference table). Q: Is the check result normal?
YES : Go to Step 8.
Q: Is the check result normal? NO : Repair the defective connector.
STEP 8. Check the harness between inhibitor STEP 9. Connector check: C-105 intermediate
switch connector B-35 terminal No.3, 7, 4, 1 and connector, C-02 J/C (3), C-05 combination meter
engine-A/T-ECU connector C-141 terminal No.66, connector
67, 75, 76. Connector: C-105
<RHD>
Connector: B-35
B-35 (B)
1 2 3 4 5 6 7 8 9 C-105
Harness side 10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW
AC103395AN
Connector: C-105
<LHD>
Engine-A/T-ECU 1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
C-141 (GR)
C-105
AC308718 AR

Engine-A/T-ECU <RHD>
C-141 (GR) C-05 (L)

C-02
Harness side
C-02
AC309479 AE
1 2 3 4 5 6 7 8 9 1011
Check the output line for open circuit. 121314 1516 171819 202122
232425 2627 282930 313233

YES : Go to Step 9.
NO : Repair the wiring harness. C-05
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
Harness side
AC308770 AI
Connectors: C-02, C-05 STEP 10. Check the harness between inhibitor
<LHD> switch connector B-35 terminal No.3, 7, 4 and
C-05 (L)
C-02 combination meter connector C-05 terminal
No.4, 3, 2.
Connector: B-35
B-35 (B)
C-02
1 2 3 4 5 6 7 8 9 1011 Harness side
121314 1516 171819 202122
232425 2627 282930 313233
AC103395AN

<RHD>
1110 9 8 7 6 5 4 3 2 1
2221201918171615141312
C-05 (L)
G G
11 10 9 8 7 6 5 4 3 2 1
Harness side 22 21 20 19 18 17 16 15 14 13 12
AC308717 AV
Harness side
YES : Go to Step 10. AC308769AW
Connector: C-05 C-05 (L)
<LHD>
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
G G
Harness side AC308716 AT

STEP 11. Connector check: C-129 <RHD>, C-143 STEP 12. Check the harness between inhibitor
<LHD> shift switch assembly connector, C-105 switch connector B-35 terminal No.1 and shift
intermediate connector <RHD> switch assembly connector C-129 <RHD>, C-143
Connector: C-129 <LHD> terminal No.1.
<RHD>
Connector: B-35
B-35 (B)
Harness side C-129
Harness side
AC308735BI
AC103395AN
Connector: C-143
<LHD> Connector: C-129
<RHD>
Harness side
Harness side C-129

C-143
AC308718 BD
AC308735BI
Connector: C-105
<RHD> Connector: C-143
<LHD>
C-105 Harness side

1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW
C-143
Check for the contact with terminals. AC308718 BD

Code No.28: Inhibitor switch system
INHIBITOR SWITCH SYSTEM CIRCUIT

STEP 2. Connector check: B-35 Inhibitor switch
Refer to P.23A-53.
connector, C-141 engine-A/T-ECU connector
OPERATION Connector: B-35
Refer to P.23A-53.
DIAGNOSIS CODE SET CONDITIONS

If the inhibitor switch has been sending multiple
signals for at least 30 seconds, the circuit may be B-35 (B)
open and diagnosis code No.28 will be set.
Harness side
POSSIBLE CAUSES
• Malfunction of the inhibitor switch
AC103395AN
• Malfunction of the engine-A/T-ECU Connector: C-141 <LHD>
DIAGNOSIS Engine-A/T-ECU
STEP 1. Check the inhibitor switch.

Refer to P.23A-145. C-141 (GR)

YES : Go to Step 2.
NO : Replace the inhibitor switch.
Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE

YES : Go to Step 3.
STEP 3. Check the harness between inhibitor STEP 4. Connector check: C-105 intermediate
switch connector B-35 terminal No.3, 7, 4, 1 and connector, C-02 J/C (3), C-05 combination meter
engine-A/T-ECU connector C-141 terminal No.66, connector
67, 75, 76. Connector: C-105
<RHD>
Connector: B-35
B-35 (B)
1 2 3 4 5 6 7 8 9 C-105
Harness side 10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW
AC103395AN
Connector: C-105
<LHD>
Engine-A/T-ECU 1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
C-141 (GR)
C-105
AC308718 AR

C-141 (GR) C-05 (L)

C-02
Harness side
C-02
AC309479 AE
1 2 3 4 5 6 7 8 9 1011
Check the output line for short circuit. 121314 1516 171819 202122
232425 2627 282930 313233

YES : Go to Step 4.
NO : Repair the wiring harness. C-05
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
Harness side
AC308770 AI
Connectors: C-02, C-05 STEP 5. Check the harness between inhibitor

<LHD> switch connector B-35 terminal No.3, 7, 4 and
C-05 (L)
C-02 combination meter connector C-05 terminal
No.4, 3, 2.
Connector: B-35
B-35 (B)
C-02
1 2 3 4 5 6 7 8 9 1011 Harness side
121314 1516 171819 202122
232425 2627 282930 313233
AC103395AN

<RHD>
1110 9 8 7 6 5 4 3 2 1
2221201918171615141312
C-05 (L)
G G
11 10 9 8 7 6 5 4 3 2 1
Harness side 22 21 20 19 18 17 16 15 14 13 12
AC308717 AV
Harness side
YES : Go to Step 5. AC308769AW
<LHD>
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
G G

YES : Go to Step 6.
STEP 6. Connector check: C-129 <RHD>, C-143 STEP 7. Check the harness between inhibitor
<LHD> shift switch assembly connector, C-105 switch connector B-35 terminal No.1 and shift
intermediate connector <RHD> switch assembly connector C-129 <RHD>, C-143
Connector: C-129 <LHD> terminal No.1.
<RHD>
Connector: B-35
B-35 (B)
Harness side C-129
Harness side
AC308735BI
AC103395AN
Connector: C-143
<RHD>
Harness side
Harness side C-129

C-143
AC308718 BD
AC308735BI
Connector: C-105
<LHD>
C-105 Harness side

1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW
C-143
Check for the contact with terminals. AC308718 BD


reference table).
Code No.31: Low-reverse solenoid valve system
Solenoid valve system circuit
BATTERY
RELAY
BOX
A/T
CONTROL
RELAY
A/T CONTROL
SOLENOID
VALVE ASSEMBLY
UNDERDRIVE SECOND OVERDRIVE TORQUE LOW AND

SOLENOID SOLENOID SOLENOID CONVERTER REVERSE
VALVE VALVE VALVE CLUTCH SOLENOID
CONTROL VALVE
SOLENOID
VALVE
ENGINE-
A/T-ECU
Wire colour code

AC309567AB
OPERATION diagnosis code set conditions

• Solenoid valve closes or opens according to the If the drive terminal voltage of the low-reverse
signals from the engine-A/T-ECU. solenoid valve is 3.0 V or less, it is judged that there
• The engine-A/T-ECU energizes or deenergizes is a short circuit or open circuit in the low-reverse
solenoid valve, based on input signals such as solenoid valve, and diagnosis code 31 is set.
throttle position sensor opening angle, inhibitor If diagnosis code 31 is output 4 times, the
switch, etc. transmission is fixed in 3rd as a fail-safe measure.

• Malfunction of low-reverse solenoid valve NO : Repair the defective connector.
STEP 4. Measure the resistance at A/T control
DIAGNOSIS
Connector: B-34
STEP 1. MUT-II/III diagnosis code Sensor side

B-34 (GR)
YES : Go to Step 9.
NO : Go to Step 2.

Item 01: Low-reverse solenoid valve AC309511AC
OK: Operating sound can be heard.
Disconnect the connector, and measure the
Q: Is the check result normal? resistance between terminal No.6 and No.10 at the
YES : Intermittent malfunction (Refer to GROUP solenoid valve side.
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
NO : Go to Step 3. Q: Is the check result normal?
YES : Go to Step 5.
NO : Check the low-reverse solenoid valve and
STEP 3. Connector check: B-34 A/T control solenoid valve harness.
solenoid valve assembly connector
Connector: B-34
Harness side
B-34 (GR)
AC309511AB

YES : Go to Step 8.
connector C-138.
connector B-34. STEP 6. Connector check: C-138 engine-A/T-ECU
(2) Turn the ignition switch to the ON position. connector
C-138 (GR) C-138 (GR)

C-138 (GR) C-138 (GR)
124 123 122 121 124 123 122 121

133 132 131 130 129128 127126 125 133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134 141 140 139 138 137136 135 134
146 145 144 143 142 146 145 144 143 142

AC309479AC AC309479AC
OK: System voltage YES : Go to Step 7.

STEP 7. Check the harness between A/T control
No.6 and engine-A/T-ECU connector C-138 NO : Replace the engine-A/T-ECU.
terminal No.128.
Connector: B-34
Harness side
Harness side
B-34 (GR)
AC309511AB

AC309511AB
Engine-A/T-ECU
C-138 (GR) YES : Go to Step 10.

Connector: C-138 <RHD> solenoid valve assembly connector B-34.
C-138 (GR)
Sensor side
B-34 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309511AC
AC309479AC
resistance between terminal No.6 and No.10 at the
Q: Is the check result normal? solenoid valve side.
YES : Go to Step 8.
STEP 8. MUT-II/III actuator test NO : Check the solenoid valve harness.
• Item 01: Low-reverse solenoid valve
STEP 11. Connector check: B-16X A/T control STEP 12. Check the harness between A/T control
relay connector solenoid valve assembly connector B-34 terminal
Connector: B-16X
No.10 and A/T control relay connector B-16X
Front of terminal No.1.
vehicle
Relay box Connector: B-34
side
Harness side
B-34 (GR)
AC309525AB

AC309511AB
YES : Go to Step 12. Connector: B-16X Front of
NO : Repair the defective connector. vehicle
Relay box
side
AC309525AB

YES : Go to Step 8.
Code No.32: Underdrive solenoid valve system
SOLENOID VALVE SYSTEM CIRCUIT

Refer to P.23A-65.
• Solenoid valve closes or opens according to the
signals from the engine-A/T-ECU. Harness side
• The engine-A/T-ECU energizes or deenergizes B-34 (GR)
solenoid valve, based on input signals such as
throttle position sensor opening angle, inhibitor
switch, etc.

If the drive terminal voltage of the underdrive AC309511AB
solenoid valve is 3.0 V or less, it is judged that there
is a short-circuit or open circuit in the solenoid valve, Check for the contact with terminals.
and diagnosis code 32 is output. Q: Is the check result normal?
If diagnosis code 32 is output 4 times, the YES : Go to Step 4.
transmission is fixed in 3rd as a fail-safe measure. NO : Repair the defective connector.
Possible causes
• Malfunction of underdrive solenoid valve STEP 4. Measure the resistance at A/T control
• Damaged harness wires and connectors solenoid valve assembly connector B-34.
• Malfunction of the engine-A/T-ECU Connector: B-34
DIAGNOSIS Sensor side

B-34 (GR)

Q: Are diagnosis codes 33 and 34 set?
YES : Go to Step 9.
NO : Go to Step 2.
AC309511AC
STEP 2. MUT-II/III actuator test Disconnect the connector, and measure the
Item 02: Underdrive solenoid valve resistance between terminal No.3 and No.9 at the
OK: Operating sound can be heard. solenoid valve side.
00 − How to Cope with Intermittent YES : Go to Step 5.
Malfunction P.00-6.) NO : Check the underdrive solenoid valve.
NO : Go to Step 3.
connector C-138.
connector B-34.
(2) Turn the ignition switch to the ON position. STEP 6. Connector check: C-138 engine-A/T-ECU
Connector: C-138 <LHD> connector
Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
C-138 (GR)

Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134 124 123 122 121
146 145 144 143 142 133 132 131 130 129128 127126 125
Harness side 141 140 139 138 137136 135 134
146 145 144 143 142
AC309479AC Harness side
(3) Measure the voltage between engine-A/T-ECU AC309479AC
connector C-138 terminal No.137 and earth. Check for the contact with terminals.
OK: 6−9 V
Q: Is the check result normal? YES : Go to Step 7.
YES : Go to Step 8. NO : Repair the defective connector.
NO : Go to Step 6.

terminal No.137.
Connector: B-34
Harness side
Harness side
B-34 (GR)
AC309511AB

AC309511AB
Engine-A/T-ECU

C-138 (GR)
Sensor side
B-34 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309511AC
AC309479AC
YES : Go to Step 8.
Item 02: Underdrive solenoid valve
Connector: B-16X
vehicle
side
Harness side
B-34 (GR)
AC309525AB

AC309511AB
Relay box
side
AC309525AB

YES : Go to Step 8.
Code No.33: Second solenoid valve system

Refer to P.23A-65.
switch, etc.

If the drive terminal voltage of the second solenoid AC309511AB
valve is 3.0 V or less, it is judged that there is a short
circuit or open circuit in the second solenoid valve, Check for the contact with terminals.
Possible causes
• Malfunction of second solenoid valve STEP 4. Measure the resistance at A/T control

B-34 (GR)
STEP 1. MUT-II/III diagnosis code.

Q: Are diagnosis code 32 and 34 set?
YES : Go to Step 9.
NO : Go to Step 2.
AC309511AC
Item 03: Second solenoid valve resistance between terminal No.4 and No.9 at the
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C))
Malfunction P.00-6.) NO : Check the second solenoid valve and
NO : Go to Step 3. solenoid valve harness.

connector C-138.
connector B-34.
Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
C-138 (GR)

Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134 124 123 122 121
146 145 144 143 142 133 132 131 130 129128 127126 125
Harness side 141 140 139 138 137136 135 134
146 145 144 143 142
OK: 6−9 V
NO : Go to Step 6.

terminal No.136.
Connector: B-34
Harness side
Harness side
B-34 (GR)
AC309511AB

AC309511AB
Engine-A/T-ECU

C-138 (GR)
Sensor side
B-34 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309511AC
AC309479AC
YES : Go to Step 8.
Item 03: Second solenoid valve
Connector: B-16X
vehicle
side
Harness side
B-34 (GR)
AC309525AB

AC309511AB
Relay box
side
AC309525AB

YES : Go to Step 8.
Code No.34: Overdrive solenoid valve system

Refer to P.23A-65.
switch, etc.

If the drive terminal voltage of the overdrive solenoid AC309511AB
valve is 3.0 V or less, it is judged that there is a short
circuit or open circuit in the overdrive solenoid valve, Check for the contact with terminals.
Possible causes
• Malfunction of overdrive solenoid valve STEP 4. Measure the resistance at A/T control

B-34 (GR)

Q: Are diagnosis codes 32 and 33 set?
YES : Go to Step 9.
NO : Go to Step 2.
AC309511AC
Item 04: Overdrive solenoid valve resistance between terminal No.5 and No.9 at the
Malfunction P.00-6.) NO : Check the overdrive solenoid valve and
NO : Go to Step 3. solenoid valve harness.

connector C-138.
connector B-34.
Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
C-138 (GR)

Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134 124 123 122 121
146 145 144 143 142 133 132 131 130 129128 127126 125
Harness side 141 140 139 138 137136 135 134
146 145 144 143 142
OK: 6−9 V
NO : Go to Step 6.

terminal No.138.
Connector: B-34
Harness side
Harness side
B-34 (GR)
AC309511AB

AC309511AB
Engine-A/T-ECU

C-138 (GR)
Sensor side
B-34 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309511AC
AC309479AC
YES : Go to Step 8.
Item 04: Overdrive solenoid valve
Connector: B-16X
vehicle
side
Harness side
B-34 (GR)
AC309525AB

AC309511AB
Relay box
side
AC309525AB

YES : Go to Step 8.
Code No.36: DCC solenoid valve system

Refer to P.23A-65.
switch, etc.

If the drive terminal voltage of the torque converter AC309511AB
control clutch solenoid valve is 3.0 V or less, it is
judged that there is a short circuit or open circuit in Check for the contact with terminals.
the torque converter control clutch solenoid valve, Q: Is the check result normal?
and diagnosis code 36 is output. YES : Go to Step 4.
If diagnosis code 36 is output 4 times, the NO : Repair the defective connector.
transmission is fixed in 3rd as a fail-safe measure.
Possible causes STEP 4. Measure the resistance at A/T control

• Malfunction of damper clutch solenoid valve solenoid valve assembly connector B-34.
• Damaged harness wires and connectors Connector: B-34
Sensor side
DIAGNOSIS B-34 (GR)

YES : Go to Step 9.
NO : Go to Step 2. AC309511AC

STEP 2. MUT-II/III actuator test resistance between terminal No.7 and No.10 at the
Item 06: Damper clutch solenoid valve solenoid valve side.
OK: Operating sound can be heard. OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
YES : Intermittent malfunction (Refer to GROUP YES : Go to Step 5.
00 − How to Cope with Intermittent NO : Check the damper clutch solenoid valve and
Malfunction P.00-6.) solenoid valve harness.
NO : Go to Step 3.
connector C-138.
connector B-34.
Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
C-138 (GR)

Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134 124 123 122 121
146 145 144 143 142 133 132 131 130 129128 127126 125
Harness side 141 140 139 138 137136 135 134
146 145 144 143 142
OK: 6−9 V
NO : Go to Step 6.

terminal No.130.
Connector: B-34
Harness side
Harness side
B-34 (GR)
AC309511AB

AC309511AB
Engine-A/T-ECU

C-138 (GR)
Sensor side
B-34 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309511AC
AC309479AC
YES : Go to Step 8.
Item 06: Damper clutch solenoid valve
Connector: B-16X
vehicle
side
Harness side
B-34 (GR)
AC309525AB

AC309511AB
Relay box
side
AC309525AB

YES : Go to Step 8.
Code No.41 (1st), 42 (2nd), 43 (3rd), 44 (4th), 46 (reverse): Gear incorrect ratio
OPERATION DIAGNOSIS
The engine-A/T-ECU detects the current gear/speed
according to the output signals from the input and
output shaft speed sensor. STEP 1. MUT-II/III diagnosis code
Either of diagnosis codes 41, 42, 43, 44 or 46 is
diagnosis code set conditions output, the input shaft speed sensor or output shaft
If the output from the output shaft speed sensor speed sensor is defective.
multiplied by the gear ratio is not the same as the Q: Are diagnosis codes 22 or 23 output?
output from the input shaft speed sensor after YES <diagnosis code 22 is output> : Refer to
completing of shifting, the corresponding diagnosis diagnosis code 22 input shaft speed sensor
code is output. system P.23A-28.
If each diagnosis code is output 4 times, the YES <diagnosis code 23 is output> : Refer to
transmission is fixed in 3rd as a fail-safe measure. diagnosis code 23 output shaft speed
sensor system P.23A-37.
Possible causes NO : Go to Step 2.
• Malfunction of input shaft speed sensor
• Malfunction of output shaft speed sensor
• Damaged harness wires and connectors STEP 2. MUT-II/III diagnosis code
• Malfunction of the engine-A/T-ECU Either of diagnosis codes 41, 42, 43, 44 or 46 is
• Malfunction of solenoid valve output, the corresponding solenoid valve is defective.
• Malfunction of underdrive clutch retainer Q: Is either of diagnosis code 31, 32, 33, 34 output?
• Malfunction of valve body YES <diagnosis code 31 is output> : Refer to
• Malfunction of transfer drive gear or driven gear diagnosis code 31: Low-reverse solenoid
• Malfunction of low-reverse brake system (for valve system P.23A-65.
diagnosis codes 41, 46) YES <diagnosis code 32 is output> : Refer to
• Malfunction of underdrive clutch system (for diagnosis code 32: Underdrive solenoid
diagnosis codes 41, 42, 43) valve system P.23A-70.
• Malfunction of second brake system (for YES <diagnosis code 33 is output> : Refer to
diagnosis codes 42, 44) diagnosis code 33: Second solenoid valve
• Malfunction of overdrive clutch system (for system P.23A-74.
diagnosis codes 43, 44) YES <diagnosis code 34 is output> : Refer to
• Malfunction of reverse clutch system (for diagnosis code 34: Overdrive solenoid valve
diagnosis code 46) system P.23A-78.
• Malfunction of one-way clutch system (for NO : Go to Step 3.
diagnosis code 41)
STEP 3. Hydraulic pressure test (3) Check the diagnosis code.

Each hydraulic pressure of the elements below, Q: Is the diagnosis code set?
which diagnosis codes indicate, should be within the YES : Go to Step 7.
standard value. NO : The inspection is complete.
• diagnosis code 41: Underdrive clutch,
low-reverse brake STEP 6. Replace the engine-A/T-ECU and then
• diagnosis code 42: Underdrive clutch, second recheck the diagnosis code.
brake (1) Replace the engine-A/T-ECU.
• diagnosis code 43: Underdrive clutch, overdrive (2) Test drive the vehicle.
clutch (3) Check the diagnosis code.
• diagnosis code 44: Overdrive clutch, second
brake Q: Is the diagnosis code set?
YES : Go to Step 7.
• diagnosis code 46: Reverse clutch, low-reverse
brake
OK: Refer to Hydraulic Pressure Test
P.23A-152. STEP 7. Check the A/T internal clutch and brake,
and then recheck the diagnosis code.
Q: Is the check result normal? (1) Check the following clutches or brakes according
YES : Go to Step 6.
to the output diagnosis codes, replace if
NO <some hydraulic pressures are abnormal> :
necessary.
Go to Step 5. • If diagnosis code 41, 42, 43 are output
NO <all hydraulic pressure are abnormal> : Go to
individually or in a group, replace the
Step 4.
underdrive clutch.
• If diagnosis code 43, 44 are output
STEP 4. Adjust the line pressure and recheck the individually or in a group, replace the
diagnosis code. overdrive clutch.
(1) Adjust the line pressure (Refer to P.23A-158). • If diagnosis code 46 is output, replace the
(2) Test drive the vehicle. reverse clutch.
(3) Check the diagnosis code. • If diagnosis code 41, 46 are output
individually or in a group, replace the
Q: Is the diagnosis code set?
YES : Go to Step 5. low-reverse brake.
NO : The inspection is complete. • If diagnosis code 42, 44 are output
individually or in a group, replace the second
brake.
STEP 5. Disassemble, clean and assemble the • If diagnosis code 41 is output, replace the
valve body and recheck the diagnosis code. one-way clutch.
(1) Check the mounting bolts for looseness, and the (2) Test drive the vehicle.
O-ring, solenoid valve and valve body for (3) Check the diagnosis code.
damage.
Replace the valve body assembly if the damages Q: Is the diagnosis code set?
are thought to be irreparable.
Code No.52: Damper clutch system
OPERATION YES : Go to Step 6.

The engine-A/T-ECU engages and disengages the NO : Go to Step 4.
damper clutch (incorporated in the torque converter)
by operating the DCC solenoid valve in response to
STEP 4. Hydraulic pressure test
driving conditions. Measure the torque converter hydraulic pressure.
(Refer to P.23A-152.)
If the damper clutch solenoid valve drive duty ratio is OK: Refer to Hydraulic Pressure Test
100% for a continuous period of 4 seconds or more P.23A-152.
when the damper clutch starts operating, diagnosis Q: Is the check result normal?
code 52 is output. YES : Go to Step 6.
NO : Go to Step 5.
Possible causes
• Damaged harness wires and connectors STEP 5. Adjust the line pressure and recheck the
• Malfunction of the engine-A/T-ECU diagnosis code.
• Malfunction of damper clutch solenoid valve (1) Adjust the line pressure (Refer to P.23A-158).
• Malfunction of valve body assembly (2) Test drive the vehicle.
• Malfunction of torque converter (3) Check the diagnosis code.
Q: Is the diagnosis code set?
DIAGNOSIS YES : Go to Step 7.

If diagnosis code 52 is output, the input shaft speed STEP 6. Replace the engine-A/T-ECU and then
sensor may be defective. recheck the diagnosis code.
(1) Replace the engine-A/T-ECU.
YES : Refer to diagnosis code 22: Input shaft (2) Test drive the vehicle.
speed sensor system P.23A-28. (3) Check the diagnosis code.
NO : Go to Step 2. Q: Is the diagnosis code set?
YES : Go to Step 7.
If diagnosis code 52 is output, the damper clutch
solenoid valve may be defective. STEP 7. Disassemble, clean and assemble the
valve body and recheck the diagnosis code.
YES : Refer to diagnosis code 36: Damper clutch (1) Check the mounting bolts for looseness, and the
solenoid valve system P.23A-82. O-ring, solenoid valve and valve body for
NO : Go to Step 3. damage.
Replace the valve body assembly if the damages
STEP 3. MUT-II/III data list (2) Test drive the vehicle.
• Item 36: Damper clutch solenoid valve duty ratio (3) Check the diagnosis code.
(Refer to data list reference table P.23A-133).
• Item 52: Damper clutch slip amount (Refer to Q: Is the diagnosis code set?
YES : Check the torque converter and replace it if
data list reference table P.23A-133).
necessary.
Q: Is the check result normal? NO : The inspection is complete.
Code No.54: A/T control relay system
A/T control system circuit
IGNITION
SWITCH (IG1) BATTERY
RELAY
BOX
A/T
CONTROL
RELAY
ENGINE-
A/T-ECU
SOLENOID
VALVE POWER
SOURCE
Wire colour code

AC309568AC
OPERATION If code No. 54 is set, the transmission will be held in

If a fail-safe operation is activated, the A/T control 3rd gear.
relay shuts off the power supply to the solenoid valve
in accordance with the signal from the Possible causes
engine-A/T-ECU. • Malfunction of A/T control relay
diagnosis code set conditions • Malfunction of the engine-A/T-ECU
Code No. 54 will be set if the A/T control voltage is
less than 7 V after the ignition switch is turned on.
DIAGNOSIS STEP 4. Measure the voltage at A/T control relay

connector B-16X.
STEP 1. MUT-II/III data list Connector: B-16X Front of
Item 54: Relay voltage (Refer to data list reference vehicle
table P.23A-133.) Relay box
side
NO : Go to Step 2.
AC309525AB
STEP 2. Check the A/T control relay connector
Refer to P.23A-149. Disconnect the A/T control relay, and measure the
voltage between terminal No.4 and earth at the relay
Q: Is the check result normal? box side.
YES : Go to Step 3.
NO : Replace the A/T control relay. OK: System voltage
YES : Go to Step 8.
STEP 3. Connector check: B-16X A/T control
NO : Go to Step 5.
relay connector
Connector: B-16X Front of
vehicle STEP 5. Connector check: A-14 intermediate
connector
Relay box
side Connector: A-14 <RHD>
AC309525AB A-14 (GR)

Q: Is the check result normal? AC308686 AG
YES : Go to Step 4.
NO : Repair the defective connector. Connector: A-14 <LHD>
A-14(GR)
AC308679AG

YES : Go to Step 6.
YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 − How to
relay connector B-16X terminal No.4 and battery.
Cope with Intermittent Malfunction P.00-6).
Connector: B-16X Front of NO : Replace the engine-A/T-ECU.
vehicle
Relay box
side STEP 8. Measure the voltage at the A/T control
relay connector B-16X.
Connector: B-16X Front of
vehicle
Relay box
AC309525AB side

YES : Go to Step 7.
AC309525AB
STEP 7. MUT-II/III data list (2) Disconnect the A/T control relay, and measure
Item 54: Relay voltage (Refer to data list reference the voltage between terminal No.3 and earth at
table P.23A-133.) the relay box side.
Q: Is the check result normal? OK: System voltage
NO : Go to Step 9.
STEP 9. Connectors check: C-16 J/C (1), C-106 Connector: C-202

intermediate connector, C-202 J/B connector <RHD>
C-202
<RHD>
6 5 4 3 2 1
C-16 (L) 14 13 12 11 10 9 8 7
Harness side
AC308772 AL
C-106 (GR)
Connector: C-202
<LHD>
C-16 C-202
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
Haness side
6 5 4 3 2 1
14 13 12 11 10 9 8 7
C-106
Harness side
1 2
3 4 5 6
AC308720 AM
7 8 9 10 11 12
16
13 14 15 17 18 19 Check for the contact with terminals.
AC308736 AX Q: Is the check result normal?
Connectors: C-16, C-106 NO : Repair the defective connector.
<LHD>
C-106 (GR)
C-16 (L)
C-16
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
Harness side
C-106
1 2
3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
AC308719 AU
YES : Go to Step 7.
STEP 10. Check the wiring harness between A/T NO : Repair the wiring harness.
control relay connector B-16X terminal No.3 and
junction block connector C-202 terminal No.12.
Connector: B-16X Front of connector C-138.
vehicle
(1) Install the A/T control relay.
Relay box
side (2) Turn the ignition switch to the ON position.
Engine-A/T-ECU
AC309525AB
C-138 (GR)
Connector: C-202
<RHD>
C-202
Engine-A/T-ECU
C-138 (GR)
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side
AC308772 AL 124 123 122 121
133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
Connector: C-202
146 145 144 143 142
<LHD>
Harness side
AC309479AC
C-202
connector C-138 terminal No.123, No.124 and
earth.
6 5 4 3 2 1
14 13 12 11 10 9 8 7 OK: System voltage
Harness side
AC308720 AM
Check the power supply line for short or open circuit. NO : Go to Step 12.
engine-A/T-ECU connector relay connector B-16X terminal No.1 and
Connector: C-138 <LHD> engine-A/T-ECU connector C-138 terminal
No.123, 124.
Engine-A/T-ECU Connector: B-16X Front of
vehicle
Relay box
C-138 (GR) side

Engine-A/T-ECU
C-138 (GR) AC309525AB
Engine-A/T-ECU
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
C-138 (GR)
Harness side
AC309479AC

YES : Go to Step 13. C-138 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309479AC

YES : Go to Step 7.
engine-A/T-ECU connector relay connector B-16X terminal No.2 and
Connector: C-138 <LHD> engine-A/T-ECU connector C-138 terminal
No.127.
Engine-A/T-ECU Connector: B-16X Front of
vehicle
Relay box
C-138 (GR) side

Engine-A/T-ECU
C-138 (GR) AC309525AB
Engine-A/T-ECU
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
C-138 (GR)
Harness side
AC309479AC

YES : Go to Step 15. C-138 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309479AC

YES : Go to Step 7.
Code No.56: N range lamp system
N range lamp system circuit
INHIBITOR
SWITCH
ENGINE-
A/T-ECU
COMBINATION
METER
Wire colour code

B : Black LG : Light green G : Green L : Blue
W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Gray R : Red P : Pink V : Violet
AC309569AC
OPERATION YES <diagnosis code 27 is set> : Refer to

If a fail-safe operation is activated during driving, the diagnosis code 27: Inhibitor switch system
engine-A/T-ECU flashes the N range lamp at a P.23A-53.
frequency of 1 Hz to inform the driver. YES <diagnosis code 28 is set> : Refer to
diagnosis code 28: Inhibitor switch system
diagnosis code set conditions P.23A-61.
If the N range signal is OFF after the N range lamp NO : Go to Step 2.
illuminates (ON), it is judged that there is a
short-circuit to earth or open circuit in the N range
lamp, and code No. 56 is output. STEP 2. Check the N range lamp.
Possible causes (2) Shift the selector lever to the N position.
• Malfunction of the combination meter
Q: Does the N range lamp illuminate?
• Damaged harness wires and connectors YES : Go to Step 10.
• Malfunction of the engine-A/T-ECU NO : Go to Step 3.
DIAGNOSIS
STEP 3. Check the N range lamp valve.
(1) Remove the combination meter. (Refer to
STEP 1. MUT-II/III diagnosis code. GROUP 54A − Combination Meter Assembly
Either of diagnosis codes 27 or 28 is set, inhibtor Removal and Installation P.54A-72.)
switch is defective. (2) Check the N range lamp valve.
Q: Are diagnosis codes 27 or 28 output? Q: Is the check result normal?
YES : Go to Step 4.
NO : Replace the valve.
STEP 4. Connector check: C-05 combination STEP 5. Measure the resistance at combination
meter connector meter connector C-05.
<RHD> <RHD>
C-05 (L) C-05 (L)

11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 22 21 20 19 18 17 16 15 14 13 12
AC308769AW AC308769AW
Connector: C-05 C-05 (L) Connector: C-05 C-05 (L)

<LHD> <LHD>
11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12 22 21 20 19 18 17 16 1514 13 12
G G G G

Check for the contact with terminals. Disconnect the connector, and measure the
resistance between terminal 12 and earth at the
YES : Go to Step 5. wiring harness side.
NO : Repair the defective connector. OK: 2 Ω or less
YES : Go to Step 7.
NO : Go to Step 6.
STEP 6. Check the harness between combination STEP 7. Measure the voltage at combination
meter connector C-05 terminal No.12 and body meter connector C-05.
earth. Connector: C-05
<RHD>
C-05 (L)
C-05 (L) 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
Harness side
Harness side
AC308769AW
AC308769AW
Connector: C-05 C-05 (L) <LHD>
<LHD>
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12 G G
G G Harness side AC308716 AT

Check the earth line for open circuit or short-circuit. voltage between terminal 2 and earth at the
YES : Go to Step 10. (2) Turn the ignition switch to the ON position.
NO : Repair the wiring harness. (3) Shift the selector lever to the N position.
OK: System voltage
YES : Check the combination meter, and replace if
necessary.
NO : Go to Step 8.
STEP 8. Connector check: C-105 intermediate STEP 9. Check the harness between combination
connector meter connector C-05 terminal No.2 and inhibitor
Connector: C-105 switch connector B-35 terminal No.4.
<RHD>
C-05 (L)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
1 2 3 4 5 6 7 8 9 C-105 Harness side

10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW
AC308769AW
Connector: C-105
<LHD> Connector: C-05 C-05 (L)
<LHD>
1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
C-105
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
G G
AC308718 AR
Q: Is the check result normal? Connector: B-35
YES : Go to Step 9.
B-35 (B)
Harness side
AC103395AN

circuit.
YES : Replace the engine-A/T-ECU.

STEP 10. Connector check: C-141 engine NO : Repair the defective connector.
A/T-ECU connector
Engine-A/T-ECU
C-141 (GR)

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE


SYMPTOMS
M1231008000318
Trouble symptom Inspection Reference page

procedure No.
Communication with the MUT-II/III is not possible 1 Refer to GROUP
13B,
Troubleshooting
P.13B-288.
Driving not possible Starting not possible 2 P.23A-102
Does not move forward 3 P.23A-103
Does not reverse 4 P.23A-104
Does not move (forward or reverse) 5 P.23A-105
Malfunction when Engine stalls during shifting 6 P.23A-106
starting off N to D shocks, large time lag 7 P.23A-107
N to R shocks, large time lag 8 P.23A-108
N to D, N to R shocks, large time lag 9 P.23A-109
Problem during Shocks, engine racing 10 P.23A-110
shifting
Incorrect shift points All points 11 P.23A-111
Some points 12 P.23A-112
No shifting No diagnosis codes 13 P.23A-112
Problem during Poor acceleration 14 P.23A-113
driving Vibration 15 P.23A-113
Shift switch assembly system 16 P.23A-114
Abnormal shift indicator display 17 P.23A-128
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 2: Engine does not start
COMMENTS ON TROUBLE SYMPTOM YES : Go to Step 3.

If the engine does not start when the selector lever is NO : Adjust the positions of the transmission
in P or N position, the cause is probably a control cable and inhibitor switch (Refer to
malfunction of inhibitor switch system, transmission P.23A-146).
control cable, engine system, torque converter or oil
pump.
STEP 3. Engine system check
POSSIBLE CAUSES Q: Is the check result normal?
• Malfunction of inhibitor switch YES : Go to Step 4.
• Malfunction of transmission control cable NO : Repair the engine system.
• Malfunction of engine system
• Malfunction of torque converter
STEP 4. Engine-A/T-ECU replacement
• Malfunction of oil pump
(3) Verify that the condition described by the
DIAGNOSIS customer exists.
Q: Does a malfunction take place again?
STEP 1. MUT-II/III diagnosis code YES : Go to Step 5.
Either of diagnosis codes 27 or 28 is set, inhibtor NO : The inspection is complete.
switch is defective.
Q: Are diagnosis codes 27 or 28 output? STEP 5. Torque converter check
YES <diagnosis code 27 is set> : Refer to Check for damaged drive plate, incorrect installation
diagnosis code 27: Inhibitor switch system in the input shaft (inserted at an angle) or damaged
P.23A-53. splines.
YES <diagnosis code 28 is set> : Refer to
diagnosis code 28: Inhibitor switch system YES : Check the oil pump for incorrect installation,
P.23A-61. damage and etc., and replace the oil pump
NO : Go to Step 2. assembly if necessary (The oil pump cannot
be disassembled).
STEP 2. Transmission control cable check NO : If repair is possible, repair the damaged
Check the transmission control cable and inhibitor part. If repair is not possible because the
switch for installation condition. splines on the drive plate or torque
converter are damaged, replace it.
INSPECTION PROCEDURE 3: Does not move forward

If the vehicle does not move forward when the NO : Replace the engine-A/T-ECU.
selector lever is shifted sport mode 1, or 2 range
while the engine is idling, the cause is probably
abnormal line pressure or a malfunction of the Measure the hydraulic pressure of the underdrive
underdrive clutch or valve body. clutch when the selector lever is at the L range
(Refer to P.23A-152).
POSSIBLE CAUSES
• Malfunction of underdrive solenoid valve OK: Refer to P.23A-152.
• Malfunction of inhibitor switch Q: Is the check result normal?
• Abnormal line pressure YES : Go to Step 7.
• Malfunction of the underdrive clutch NO : Go to Step 5.
• Malfunction of valve body
DIAGNOSIS
STEP 1. MUT-II/III actuator test customer exists.
Item 02: Underdrive solenoid valve Q: Does a malfunction take place again?
OK: Operating sound can be heard. YES : Go to Step 6.
YES : Go to Step 2.
NO : Replace the underdrive solenoid valve. STEP 6. Valve body disassembly clean and
assembly
STEP 2. MUT-II/III diagnosis code (1) Check the bolts for looseness and the O-ring,
Either of diagnosis codes 27 or 28 is set, inhibtor solenoid valve and valve body for damage.
switch is defective. Replace the valve body assembly if the damages
Q: Are diagnosis codes 27 or 28 output? (2) Test drive the vehicle.
customer exists.
P.23A-53.
YES <diagnosis code 28 is set> : Refer to Q: Does a malfunction take place again?
YES : Go to Step 7.
P.23A-61.
NO : Go to Step 3.
STEP 7. Underdrive clutch check
(1) Check the facing for seizure and the piston seal
STEP 3. Underdrive solenoid valve check
ring for damage and interference with the
retainer.
(2) Shift the selector lever from N to D range.
(3) Confirm the operating sound of the underdrive
solenoid valve.
customer exists.
Q: Is the check result normal? YES : The inspection is complete.
NO : Repair or replace the underdrive clutch.
INSPECTION PROCEDURE 4: Does not move backward

If the vehicle does not move backward when the NO : Go to Step 3.
selector lever is shifted to R range while the engine is
idling, the cause is probably abnormal pressure of
the reverse clutch and low-reverse brake or a
malfunction of the reverse clutch, low-reverse brake, (2) Test drive the vehicle.
or valve body.
Possible causes customer exists.
• Abnormal reverse clutch pressure Q: Does a malfunction take place again?
• Abnormal low-reverse brake pressure YES : Go to Step 4.
• Malfunction of low-reverse solenoid valve NO : The inspection is complete.
• Malfunction of the reverse clutch
• Malfunction of low-reverse brake STEP 4. Valve body disassembly clean and
• Malfunction of valve body assembly
• Malfunction of the engine-A/T-ECU (1) Check the bolts for looseness and the O-ring,
solenoid valve and valve body for damage.
DIAGNOSIS Replace the valve body assembly if the damages
STEP 1. MUT-II/III actuator test (2) Test drive the vehicle.
Item 01: Low-reverse solenoid valve (3) Verify that the condition described by the
customer exists.
YES : Go to Step 2. NO : The inspection is complete.
NO : Replace the low-reverse solenoid valve.
STEP 5. Reverse clutch and low-reverse brake

check
Measure the hydraulic pressure for reverse clutch
Check the facing for seizure and the piston seal ring
and low-reverse brake when the selector lever is at
for damage and interference with the retainer.
the R range (Refer to P.23A-152).
OK: Refer to P.23A-152. Q: Is the check result normal?
YES : The inspection is complete.
Q: Is the check result normal? NO : Repair or replace the reverse clutch and
low-reverse brake.
INSPECTION PROCEDURE 5: Does not move (forward or backward)
COMMENTS ON TROUBLE SYMPTOM are thought to be irreparable.

If the vehicle does not move forward or backward (2) Test drive the vehicle.
when the selector lever is shifted to any position (3) Verify that the condition described by the
while the engine is idling, the cause is probably an customer exists.
abnormal line pressure, a malfunction of the power
train components, oil pump or valve body. YES : Go to Step 3.
Possible causes
• Abnormal line pressure
• Malfunction of valve body STEP 3. Torque converter check
• Malfunction of torque converter Check for damaged drive plate, incorrect installation
• Malfunction of oil pump in the input shaft (inserted at an angle) or damaged
• Malfunction of each element splines.
• Malfunction of power train components
YES : Check the oil pump for incorrect installation,
DIAGNOSIS damage and etc., and replace the oil pump
assembly if necessary (The oil pump cannot
be disassembled.)
Measure the hydraulic pressure of each element NO : If repair is possible, repair the damaged
when the selector lever is in L, 2nd or reverse (Refer part. If repair is not possible because the
to P.23A-152). splines on the drive plate or torque
OK: Refer to P.23A-152.
YES : Go to Step 4.
STEP 4. Power train components check
Disassemble the transmission and check the input
NO : Go to Step 2.
shaft, planetary carrier, output shaft differential and
each element, etc.
STEP 2. Valve body disassembly clean and
assembly YES : The inspection is complete.
(1) Check the bolts for looseness and the O-ring, NO : Repair or replace each power train
solenoid valve and valve body for damage. components.
INSPECTION PROCEDURE 6: Engine stalls during shifting
COMMENTS ON TROUBLE SYMPTOM solenoid valve and valve body for damage.
If the engine stalls when the selector lever is shifted Replace the valve body assembly if the damages
from N to D or R range while the engine is idling, the are thought to be irreparable.
cause is probably a malfunction of the engine (2) Test drive the vehicle.
system, damper clutch solenoid valve, valve body or (3) Verify that the condition described by the
torque converter (damper clutch). customer exists.
Possible causes Q: Does a malfunction take place again?
YES : Go to Step 3.
• Malfunction of damper clutch solenoid valve
• Malfunction of torque converter (damper clutch) STEP 3. Torque converter check
• Malfunction of the engine-A/T-ECU Check for damaged drive plate, incorrect installation
in the input shaft (inserted at an angle), damaged
DIAGNOSIS splines or damper clutch sealing.
YES : Go to Step 4.
Item 06: Damper clutch solenoid valve NO : If repair is possible, repair the damaged
part. If repair is not possible because the
OK: Operating sound can be heard. splines on the drive plate or torque
Q: Is the check result normal? converter are damaged, replace it.
YES : Go to Step 2.
NO : Replace the damper clutch solenoid valve.
STEP 2. Valve body disassembly clean and YES : Replace the engine-A/T-ECU.
assembly NO : Repair the engine system.
(1) Check the bolts for looseness and the O-ring,
INSPECTION PROCEDURE 7: Shift shock when shifting from N to D and long delay
COMMENTS ON TROUBLE SYMPTOM

If abnormal shock or delay of two seconds or more Measure the hydraulic pressure for underdrive clutch
occurs when the selector lever is shifted from N to D when the selector lever is shifted from N to D range
range while the engine is idling, the cause is (Refer to P.23A-152).
probably abnormal underdrive clutch pressure or a
malfunction of the underdrive clutch, valve body or OK: Refer to P.23A-152.
throttle position sensor. Q: Is the check result normal?
YES : Go to Step 9.
Possible causes NO : Go to Step 8.
• Malfunction of underdrive solenoid valve
• Abnormal underdrive clutch pressure STEP 6. Check when shift shock occurs.
• Malfunction of throttle position sensor Q: Does the shift shock always occur?
• Malfunction of the underdrive clutch YES : Go to Step 8.
• Malfunction of valve body NO : Go to Step 7.
DIAGNOSIS Item 11: Throttle position sensor (Refer to data list
STEP 1. MUT-II/III actuator test Q: Is the check result normal?
Item 02: Underdrive solenoid valve YES : Go to Step 8.
OK: Operating sound can be heard. NO : Check the throttle position sensor system
(Refer to GROUP 13B, Troubleshooting
Q: Is the check result normal? P.13B-20).
YES : Go to Step 2.
NO : Replace the underdrive solenoid valve.
STEP 8. Valve body disassembly clean and
assembly
Item 01: Input shaft speed sensor (Refer to data list (1) Check the bolts for looseness and the O-ring,
reference table P.23A-133). solenoid valve and valve body for damage.
Q: Is the check result normal? are thought to be irreparable.
YES : Go to Step 3. (2) Test drive the vehicle.
NO : Refer to diagnosis code 22: Input shaft
speed sensor system P.23A-28. customer exists.
STEP 3. MUT-II/III data list YES : Go to Step 9.
Item 32: Underdrive solenoid valve duty ratio. NO : The inspection is complete.
YES : Go to Step 4. STEP 9. Underdrive clutch check
NO : Replace the engine-A/T-ECU. Check the facing for seizure and the piston seal ring
STEP 4. Check when shift shock occurs. Q: Is the check result normal?
Q: Does the shift shock occur when the vehicle starts YES : The inspection is complete.
moving? NO : Repair or replace the underdrive clutch.
YES : Go to Step 6.
NO : Go to Step 5.
INSPECTION PROCEDURE 8: Shift shock when shifting from N to R and long delay

If abnormal shock or delay of two seconds or more Either of diagnosis codes 27 or 28 is set, inhibtor
occurs when the selector lever is shifted from N to R switch is defective.
range while the engine is idling, the cause is
probably abnormal pressure in reverse clutch and Q: Are diagnosis codes 27 or 28 output?
low-reverse clutch or a malfunction of the reverse YES <diagnosis code 27 is set> : Refer to
clutch, low-reverse brake, valve body or throttle diagnosis code 27: Inhibitor switch system
position sensor. P.23A-53.
POSSIBLE CAUSES diagnosis code 28: Inhibitor switch system
• Malfunction of low-reverse solenoid valve P.23A-61.
• Malfunction of input shaft speed sensor NO : Go to Step 4.
• Malfunction of the inhibitor switch
• Abnormal reverse clutch pressure
• Abnormal low-reverse brake pressure STEP 4. MUT-II/III data list
Item 31: Low-reverse solenoid valve duty ratio (Refer
• Malfunction of throttle position sensor
to data list reference table P.23A-133).
• Malfunction of the reverse clutch
• Malfunction of low-reverse brake Q: Is the check result normal?
• Malfunction of valve body YES : Go to Step 5.
• Malfunction of the engine-A/T-ECU NO : Replace the engine-A/T-ECU.
DIAGNOSIS STEP 5. Check when shift shock occurs.

Q: Does the shift shock occur when the vehicle starts
STEP 1. MUT-II/III actuator test moving?
Item 01: Low-reverse solenoid valve YES : Go to Step 7.
NO : Go to Step 6.
YES : Go to Step 2. STEP 6. Hydraulic pressure test
NO : Replace the low-reverse solenoid valve. Measure the hydraulic pressure for reverse clutch
and low-reverse clutch when the selector lever is
shifted from N to R range (Refer to P.23A-152).
Item 22: Input shaft speed sensor (Refer to data list
reference table P.23A-133). Q: Is the check result normal?
Q: Is the check result normal? NO : Go to Step 9.
YES : Go to Step 3.
NO : Refer to diagnosis code 22: Input shaft
speed sensor system P.23A-28. STEP 7. Check when shift shock occurs.
Q: Does the shift shock always occur?
YES : Go to Step 9.
NO : Go to Step 8.
STEP 8. MUT-II/III data list (2) Test drive the vehicle.

Item 11: Throttle position sensor (Refer to data list (3) Verify that the condition described by the
reference table P.23A-133). customer exists.
YES : Go to Step 9.
NO : Check the throttle position sensor system
(Refer to GROUP 13B, Troubleshooting
P.13B-20). STEP 10. Reverse clutch and low-reverse brake
check
STEP 9. Valve body disassembly clean and for damage and interference with the retainer.
assembly
(1) Check the bolts for looseness and the O-ring, Q: Is the check result normal?
solenoid valve and valve body for damage. YES : The inspection is complete.
Replace the valve body assembly if the damages NO : Repair or replace the reverse clutch and
are thought to be irreparable. low-reverse brake.
INSPECTION PROCEDURE 9: Shift shock when shifting from N to D, N to R and long delay

STEP 2. Line pressure adjustment
If abnormal shock or delay of two seconds or more (1) Adjust the line pressure (Refer to P.23A-158).
occurs when the selector lever is shifted from N to D
range and from N to R range while the engine is
idling, the cause is probably abnormal line pressure
customer exists.
or a malfunction of the oil pump, valve body.
• Abnormal line pressure NO : The inspection is complete.
• Malfunction of throttle position sensor
• Malfunction of oil pump
STEP 3. Check when shift shock occurs.
• Malfunction of the engine-A/T-ECU Q: Does the shift shock occur when the vehicle starts
moving?
YES : Go to Step 4.
DIAGNOSIS
NO : Replace the oil pump assembly (Oil pump
cannot be repaired).
Measure the hydraulic pressure of each element
STEP 4. Check when shift shock occurs.
when the selector lever is in L, 2nd or reverse (Refer
to P.23A-152). Q: Does the shift shock always occur?
YES : Go to Step 7.
NO : Go to Step 5.
YES : Go to Step 3.
NO : Go to Step 2.
STEP 5. MUT-II/III data list customer exists.

Item 11: Throttle position sensor (Refer to data list Q: Does a malfunction take place again?
reference table P.23A-133). YES : Go to Step 7.
YES : Go to Step 6.
NO : Check the throttle position sensor system STEP 7. Valve body disassembly clean and
(Refer to GROUP 13B, Troubleshooting assembly
P.13B-20). Check the bolts for looseness and the O-ring,
STEP 6. Engine-A/T-ECU replacement Q: Is the check result normal?
(1) Replace the engine-A/T-ECU. YES : The inspection is complete.
(2) Test drive the vehicle. NO : Replace the valve body assembly if the
(3) Verify that the condition described by the damages are thought to be irreparable.
INSPECTION PROCEDURE 10: Shift shock and slipping

If shift shock when driving are due to upshifting or NO : Replace the defective solenoid valve.
downshifting and the transmission speed become
higher than the engine speed, the cause is probably
abnormal line pressure or a malfunction of a solenoid • Item 63: Shift position (Refer to data list reference
valve, oil pump, valve body or of a brake or clutch. table P.23A-133).
• Item 31, 32, 33, 34: Each solenoid valve duty
Possible causes
ratio (Refer to data list reference table
• Malfunction of each solenoid valve
• Abnormal line pressure P.23A-133).
• Malfunction of valve body Q: Is the check result normal?
• Malfunction of oil pump YES : Go to Step 3.
• Malfunction of each brake or each clutch NO : Replace the engine-A/T-ECU.
DIAGNOSIS Check all hydraulic pressures within the standard
value.
STEP 1. MUT-II/III actuator test OK: Refer to P.23A-152.
• Item 01: Low-reverse solenoid valve
• Item 02: Underdrive solenoid valve YES : Go to Step 6.
• Item 03: Second solenoid valve NO : Go to Step 4.
• Item 04: Overdrive solenoid valve
STEP 4. Line pressure adjustment (3) Verify that the condition described by the
(1) Adjust the line pressure (Refer to P.23A-158). customer exists.
(2) Test drive the vehicle. Q: Does a malfunction take place again?
(3) Verify that the condition described by the YES : Check the oil pump for incorrect installation,
customer exists. damage and etc., and replace the oil pump
assembly if necessary (The oil pump cannot
YES : Go to Step 5.
be disassembled).
STEP 5. Valve body disassembly clean and STEP 6. Each clutch and brake check
assembly
(1) Check the bolts for looseness and the O-ring,
solenoid valve and valve body for damage. Q: Is the check result normal?
Replace the valve body assembly if the damages YES : The inspection is complete.
are thought to be irreparable. NO : Repair or replace each clutch and brake.
INSPECTION PROCEDURE 11: Does not shift properly (all points)

If all shift points are early or late while driving, the Item 11: Throttle position sensor (Refer to data list
cause is probably a malfunction of the output shaft reference table P.23A-133).
speed sensor, throttle position sensor, or
engine-A/T-ECU. Q: Is the check result normal?
YES : Go to Step 3.
Possible causes NO : Check the throttle position sensor system
• Malfunction of output shaft speed sensor (Refer to GROUP 13B, Troubleshooting
• Malfunction of throttle position sensor P.13B-20).
DIAGNOSIS
(1) Item 14: INVECS-II cancel command
(2) Test drive the vehicle (Refer to Road Test,
STEP 1. MUT-II/III data list Inspection procedure 8 P.23A-9).
Item 02: Output shaft speed sensor (Refer to data list (3) Check that the gear shifting corresponds to the
reference table P.23A-133). standard shift line of the shift pattern diagram.
YES : Go to Step 2. YES : The inspection is complete.
NO : Refer to diagnosis code 23: Output shaft NO : Replace the engine-A/T-ECU.
speed sensor system P.23A-37.
INSPECTION PROCEDURE 12: Does not shift properly (some point)
COMMENTS ON TROUBLE SYMPTOM YES : The symptom is due to characteristics of the

If some of the shift points are early or late when INVECS-II system, but is not abnormal.
driving, the cause is probably a malfunction of valve NO : Go to Step 2.
body, or it is due to the characteristics of the
INVECS-II system but is not an abnormality.
Possible causes (1) Item 14: INVECS-II cancel command
• Malfunction of valve body (2) Test drive the vehicle (Refer to Road Test,
Inspection procedure 8 P.23A-9).
(3) Check that the gear shifting corresponds to the
DIAGNOSIS standard shift line of the shift pattern diagram.
YES : The inspection is complete.
STEP 1. Check when the shift points early or late. NO : Replace the engine-A/T-ECU.
Q: Are the shift points early or late only when A/T fluid
is −20°C or less, or 125°C or more?
INSPECTION PROCEDURE 13: Does not shift (no diagnosis code)

The gear shifting does not occur while driving. If no NO : Replace the engine-A/T-ECU.
diagnosis codes are set, the cause is probably a
malfunction of the shift switch assembly or STEP 2. MUT-II/III data list
engine-A/T-ECU . Item 67: Select switch (Refer to Data List Reference
Table P.23A-133).
POSSIBLE CAUSES
• Malfunction of Shift switch assembly Q: Is the check result normal?
• Malfunction of the engine-A/T-ECU YES : Replace the engine-A/T-ECU.
NO : INSPECTION PROCEDURE 16: Shift
DIAGNOSIS switch assembly system check (Refer to
P.23A-114).

Item 54: A/T control relay (Refer to Data List
Reference Table P.23A-133).
INSPECTION PROCEDURE 14: Poor acceleration

If acceleration is poor when downshifting occurs NO : Repair the engine system.
while driving, the cause is probably a malfunction of
the engine system.
Possible causes (1) Replace the engine-A/T-ECU.
• Malfunction of engine system (2) Test drive the vehicle.
• Malfunction of the engine-A/T-ECU (3) Verify that the condition described by the
customer exists.
DIAGNOSIS Q: Does a malfunction take place again?
YES : Go to Step 1.
INSPECTION PROCEDURE 15: Vibration

If vibration occurs when driving at constant speed or
when acceleration in high range, the cause is
probably an abnormal torque converter pressure, or
a malfunction of the engine system, damper clutch
customer exists.
solenoid valve, valve body or torque converter.
• Malfunction of damper clutch solenoid valve NO : The inspection is complete.
• Abnormal torque converter pressure
STEP 4. Torque converter check
• Malfunction of valve body Check for damaged drive plate, incorrect installation
• Malfunction of torque converter in the input shaft (inserted at an angle), damaged
• Malfunction of the engine-A/T-ECU splines or damper clutch sealing.
DIAGNOSIS Q: Is the check result normal?

YES : Go to Step 5.
NO : If repair is possible, repair the damaged
STEP 1. Check when the vibration occurs. part. If repair is not possible because the
splines on the drive plate or torque
Q: Does the vibration occur when the damper clutch
is operating?
YES : Go to Step 3.
NO : Go to Step 2. STEP 5. Valve body disassembly clean and
assembly
STEP 2. Engine system check Check the bolts for looseness and the O-ring,
YES : The inspection is complete. Q: Is the check result normal?
NO : Repair the engine system. YES : The inspection is complete.
NO : Replace the valve body assembly if the
damages are thought to be irreparable.
INSPECTION PROCEDURE 16: Shift switch assembly system
Shift switch system circuit <RHD>
IGNITION
SWITCH (IG1)
INHIBITOR
SWITCH
SHIFT
SWITCH
ASSEMBLY SHIFT SELECT
SWITCH SWITCH
ENGINE- COMBINATION
A/T-ECU METER
Wire colour code

BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet AC309573AB
Shift switch system circuit <LHD>
IGNITION
SWITCH (IG1)
INHIBITOR
SWITCH
SHIFT
SWITCH
ASSEMBLY SHIFT SELECT
SWITCH SWITCH
ENGINE- COMBINATION
A/T-ECU METER
Wire colour code

AC309570AC

The shift switch assembly detects the shift range • Malfunction of shift switch assembly
(sport mode) which the driver has selected, and • Damaged harness wires and connectors
sends the information to the engine-A/T-ECU. • Malfunction of the engine-A/T-ECU

The cause is probably a malfunction of the shift
switch and engine-A/T-ECU.
DIAGNOSIS STEP 2. MUT-II/III data list

• Item 67: Select switch
STEP 1. MUT-II/III diagnosis code • Item 68: Upshift switch
Either of diagnosis codes 27 or 28 is set, inhibtor • Item 69: Downshift switch
switch is defective. Check the above data list (Refer to data list reference
table P.23A-133).
Q: Are diagnosis codes 27 or 28 output?
YES <diagnosis code 27 is set> : Refer to Q: Is the check result normal?
diagnosis code 27: Inhibitor switch system YES : Intermittent malfunction (Refer to GROUP
P.23A-53. 00 − How to Cope with Intermittent
YES <diagnosis code 28 is set> : Refer to Malfunction P.00-6).
diagnosis code 28: Inhibitor switch system NO <"NG" for all items> : Go to Step 3.
NO <"NG" for items 68 and 69> : Go to Step 5.
P.23A-61.
NO <"NG" for item 67> : Go to Step 10.
NO : Go to Step 2.
STEP 3. Connectors check: C-129 <RHD>, C-143 Connector: C-105

<RHD>
<LHD> shift switch assembly connector, C-141
engine-A/T-ECU connector, C-105 intermediate
connector <RHD>
Connector: C-129
<RHD>
1 2 3 4 5 6 7 8 9 C-105
10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW

Harness side C-129
YES : Go to Step 4.
AC308735BI NO : Repair the defective connector.
Connector: C-143
<LHD> STEP 4. MUT-II/III data list
• Item 68: Upshift switch
• Item 69: Downshift switch
Harness side
Check the above data list (Refer to data list reference
table P.23A-133).
C-143
AC308718 BD 00 − How to Cope with Intermittent
Connector: C-141 <LHD> NO : Replace the engine-A/T-ECU.
Engine-A/T-ECU
STEP 5. Check the shift switch assembly.
Refer to P.23A-167 <RHD> or P.23A-166 <LHD>.
YES : Go to Step 6.
NO : Replace the shift switch assembly.

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE
STEP 6. Connector check: C-129 <RHD>, C-143 STEP 7. Measure the voltage at shift switch
<LHD> shift switch assembly connector assembly connector C-129 <RHD>, C-143 <LHD>
Connector: C-129 (1) Disconnect the connector, and measure the
<RHD> voltage between terminal 3 and earth at the
Connector: C-129
<RHD>
Harness side C-129
AC308735BI
Harness side C-129
Connector: C-143
<LHD>
AC308735BI
Connector: C-143
<LHD>
Harness side
Harness side
C-143
AC308718 BD

AC308718 BD
YES : Go to Step 7.
NO : Repair the defective connector. (2) Ignition switch: ON
OK: System voltage
YES : Go to Step 4.
NO : Go to Step 8.
STEP 8. Connectors check: C-202 J/B connector, STEP 9. Check the harness between shift switch
C-16 J/C (1) assembly connector C-129 <RHD>, C-143 <LHD>
Connector: C-202 terminal No.3 and J/B connector C-202 terminal
<RHD> No.12.
<RHD>
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side Harness side C-129

AC308772 AL
Connector: C-202
AC308735BI
<LHD>
Connector: C-143
C-202 <LHD>
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side
Harness side
AC308720 AM
Connector: C-16 C-143

AC308718 BD
<RHD>
Connector: C-202
<RHD>
C-202
C-16 (L)
AC308735BH 6 5 4 3 2 1
14 13 12 11 10 9 8 7
Connector: C-16 Harness side

AC308772 AL
<LHD>
Connector: C-202
<LHD>
C-202
C-16 (L)
6 5 4 3 2 1
AC308718 BA 14 13 12 11 10 9 8 7
Check for the contact with terminals. Harness side

AC308720 AM
YES : Go to Step 9. Check the power supply line for short or open circuit.
NO : Repair the defective connector. Q: Is the check result normal?
YES : Go to Step 4.
STEP 10. Check the shift switch assembly. STEP 12. Measure the voltage at shift switch
Refer to P.23A-167 <RHD> or P.23A-166 <LHD>. assembly connector C-129 <RHD>, C-143 <LHD>
YES : Go to Step 11. voltage between terminal 1 and earth at the
NO : Replace the shift switch assembly. wiring harness side.
Connector: C-129
<RHD>
STEP 11. Connector check: C-129 <RHD>, C-143
<LHD> shift switch assembly connector
Connector: C-129
<RHD>
Harness side C-129
AC308735BI
Harness side C-129

Connector: C-143
<LHD>
AC308735BI
Connector: C-143
<LHD>
Harness side
Harness side C-143

AC308718 BD
(2) Selector lever position: D

(3) Ignition switch: ON
C-143 OK: System voltage
AC308718 BD
Check for the contact with terminals. Q: Is the check result normal?
Q: Is the check result normal? NO <RHD> : Go to Step 17.
NO <LHD> : Go to Step 18.
STEP 13. Connectors check: C-141 STEP 14. Check the harness between shift switch
engine-A/T-ECU connector, C-105 intermediate assembly connector C-129 <RHD>, C-143 <LHD>
connector <RHD> terminal No.4 and engine-A/T-ECU connector
C-141 terminal No.85.
Connector: C-129
C-141 (GR)
Harness side C-129

AC308735BI
Engine-A/T-ECU
Connector: C-143
C-141 (GR) <LHD>
Harness side
Harness side
AC309479 AE
C-143
AC308718 BD
Connector: C-105
<RHD> Connector: C-141 <LHD>
Engine-A/T-ECU
C-141 (GR)
1 2 3 4 5 6 7 8 9 C-105
10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW
Check for the contact with terminals. Connector: C-141 <RHD>

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE

circuit.
STEP 15. Connector check: C-05 combination STEP 16. Checkt the harness between shift
meter connector, C-106 intermediate connector switch assembly connector C-129 <RHD>, C-143
<LHD> <LHD> terminal No.2 and combination meter
Connector: C-05 connector C-05 terminal No.1.
<RHD>
C-05 (L)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
Harness side
Harness side C-129
AC308769AW
AC308735BI
<LHD>
11 10 9 8 7 6 5 4 3 2 1 Harness side
22 21 20 19 18 17 16 1514 13 12
G G

C-143
AC308718 BD
Connector: C-106
<RHD>
1 2
3 4 5 6 C-05 (L)
7 8 9 10 11 12
16
13 14 15 17 18 19 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
C-106 (GR) Harness side
AC308718AS
Check for the contact with terminals. AC308769AW
Q: Is the check result normal? Connector: C-05 C-05 (L)

YES : Go to Step 16. <LHD>
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
G G

circuit.
YES : Go to Step 4.
STEP 17. Connector check: C-105 intermediate STEP 18. Check the harness between shift switch
connector assembly connector C-129 <RHD>, C-143 <LHD>
Connector: C-105 terminal No.1 and inhibitor switch connector
<RHD> B-35 terminal No.1.
Connector: C-129
<RHD>
1 2 3 4 5 6 7 8 9 C-105
10 11 12 13 1415 16 1718 19 20 21 22
Harness side C-129

AC308735AW
Connector: C-105
AC308735BI
<LHD>
Connector: C-143
1 2 3 4 5 6 7 8 9
<LHD>
10 11 12 13 1415 16 1718 19 20 21 22
C-105
Harness side
AC308718 AR
Check for the contact with terminals. C-143

AC308718 BD
YES : Go to Step 18. Connector: B-35
B-35 (B)
Harness side
AC103395AN

YES : Go to Step 4.
STEP 19. Check the shift switch assembly.


<RHD>
connector <RHD>
Connector: C-129
<RHD>
1 2 3 4 5 6 7 8 9 C-105
10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW

Harness side C-129
Connector: C-143
<LHD>
Harness side
C-143
AC308718 BD
Engine-A/T-ECU
C-141 (GR)

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE
YES : Go to Step 4.
STEP 21. Check the harness between shift switch NO : Repair the wiring harness.
assembly connector C-129 <RHD>, C-143 <LHD>
terminal No.6 and engine-A/T-ECU connector
C-141 terminal No.77. STEP 22. Check the shift switch assembly.
Connector: C-129
<RHD> Q: Is the check result normal?
Harness side C-129
AC308735BI
Connector: C-143
<LHD>
Harness side
C-143
AC308718 BD
Engine-A/T-ECU
C-141 (GR)

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE

circuit.

<RHD>
connector <RHD>
Connector: C-129
<RHD>
1 2 3 4 5 6 7 8 9 C-105
10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW

Harness side C-129
Connector: C-143
<LHD>
Harness side
C-143
AC308718 BD
Engine-A/T-ECU
C-141 (GR)

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE
YES : Go to Step 4.
STEP 24. Check the harness between shift switch NO : Repair the wiring harness.
assembly connector C-129 <RHD>, C-143 <LHD>
terminal No.5 and engine-A/T-ECU connector
C-141 terminal No.68.
Connector: C-129
<RHD>
Harness side C-129
AC308735BI
Connector: C-143
<LHD>
Harness side
C-143
AC308718 BD
Engine-A/T-ECU
C-141 (GR)

Engine-A/T-ECU
C-141 (GR)
Harness side
AC309479 AE

circuit.
INSPECTION PROCEDURE 17: Abnormal shift indicator display
Shift indicator display system circuit
COMBINATION
METER
CONTROL CIRCUIT
ENGINE-
A/T-ECU
Wire colour code

AC309571AB
OPERATION DIAGNOSIS
The engine-A/T-ECU detects the shift range (sport
mode) which the driver has selected, and sends the
information to the combination meter. STEP 1. MUT-II/III data list
COMMENTS ON TROUBLE SYMPTOM • Item 68: Upshift switch
The cause is probably a malfunction of the shift • Item 69: Downshift switch
switch assembly, combination meter and Check the above data list P.23A-133. (Refer to data
engine-A/T-ECU. list reference table.)
Possible causes
YES : Go to Step 2.
• Malfunction of shift switch assembly NO : Refer to inspection procedure 16: shift
• Malfunction of the combination meter switch assembly system P.23A-114.
connector C-138.
(1) Confirm the shift range by using the Actuator test
on the MUT-II/III, and measure the voltage at the
ECU terminals. STEP 3. Connectors check: C-138

Connector: C-138 <LHD> engine-A/T-ECU connector, C-105 intermediate
connector, C-04 combination connector
Engine-A/T-ECU
Engine-A/T-ECU
C-138 (GR)
C-138 (GR)

Engine-A/T-ECU
C-138 (GR)
Engine-A/T-ECU
C-138 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
124 123 122 121
Harness side 133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
AC309479AC 146 145 144 143 142
(2) Ignition switch: ON Harness side

AC309479AC
Item Gear Measured terminals
No. shift Between Between Between Connector: C-105
position terminal terminal terminal <RHD>
134 and 125 and 121 and
earth earth earth
09 3rd 8 − 10 V 8 − 10 V 1 V or
less
10 4th 1 V or 1 V or 8 − 10 V 1 2 3 4 5 6 7 8 9 C-105
less less 10 11 12 13 1415 16 1718 19 20 21 22
Q: Is the check result normal? AC308735AW

YES : Go to Step 4.
NO : Go to Step 3. Connector: C-105
<LHD>
1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
C-105
AC308718 AR
Connector: C-04 STEP 4. Measure the voltage at combination

<RHD>
meter connector C-04.
C-04 (1) Remove the combination meter.
Connector: C-04
41 40 39 38 37 36 35 34 33 32 31 <RHD>
52 51 50 49 48 47 46 45 44 43 42
C-04
Harness side
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
AC308769AV
Harness side
Connector: C-04
<LHD> C-04
AC308769AV
Connector: C-04
<LHD> C-04
Harness side AC308716 AS

Harness side
YES : Replace the engine-A/T-ECU. AC308716 AS
NO : Repair the defective connector. (2) Confirm the shift range by using the Actuator test
on the MUT-II/III, and measure the voltage at the
combination meter harness-side connector
terminals.
(3) Ignition switch: ON
Item Gear Measured terminals
No. shift Between Between Between
position terminal terminal terminal
50 and 51 and 52 and
earth earth earth
09 3rd 8 − 10 V 8 − 10 V 1 V or
less
10 4th 1 V or 1 V or 8 − 10 V
less less
YES : Go to Step 7.
NO : Go to Step 5.
STEP 5. Connectors check: C-04 combination Connector: C-138 <LHD>

meter connector, C-105 intermediate connector,
C-138 engine-A/T-ECU connector Engine-A/T-ECU
Connector: C-04
<RHD>
C-138 (GR)
C-04
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
Harness side Connector: C-138 <RHD>

Engine-A/T-ECU
C-138 (GR)
AC308769AV
Connector: C-04
<LHD> C-04
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309479AC

YES : Go to Step 6.
Connector: C-105 NO : Repair the defective connector.
<RHD>
1 2 3 4 5 6 7 8 9 C-105
10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW
Connector: C-105
<LHD>
1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
C-105
AC308718 AR
YES : Replace the engine-A/T-ECU.

STEP 6. Check the harness between combination NO : Repair the wiring harness.
meter connector C-04 terminal No.50, 51, 52 and
engine-A/T-ECU connector C-138 terminal
No.134, 125, 121. STEP 7. Connector check: C-04 combination
Connector: C-04 meter connector
<RHD>
C-04
C-04
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
Harness side
Harness side
AC308769AV
AC308769AV
Connector: C-04
<LHD> C-04
Connector: C-04
<LHD> C-04

Engine-A/T-ECU Q: Is the check result normal?
YES : Replace the combination meter.
C-138 (GR)

Engine-A/T-ECU
C-138 (GR)
124 123 122 121

133 132 131 130 129128 127126 125
141 140 139 138 137136 135 134
146 145 144 143 142
Harness side
AC309479AC

circuit.
DATA LIST REFERENCE TABLE

M1231008100371
Data list Check item Inspection conditions Normal condition

No.
11 TPS Ignition switch: ON Accelerator pedal: Fully 300 − 700 mV
Engine: Stopped closed
Accelerator pedal: Gradually increases
Depressed from the above value.
Accelerator pedal: Fully 4,000 mV or more
open
15 A/T fluid temperature Driving after engine has warmed up Gradually increases.
sensor
21 Crank angle sensor Engine: Idling Compare the engine Identical
Selector lever speeds displayed on the
position: P tachometer and the
MUT-II/III.
22 Input shaft speed Driving at a constant speed of 50 km/h in 3rd 1,800 − 2,100 r/min
sensor
23 Output shaft speed Driving at a constant speed of 50 km/h in 3rd 1,800 − 2,100 r/min
sensor
26 Stop lamp switch Brake pedal: Depressed ON
Brake pedal: Released OFF
29 Vehicle speed signal Idling in 1st (Vehicle stopped) 0 km/h
Driving at a constant speed of 50 km/h in 3rd 50 km/h
31 LR solenoid valve Driving at a constant speed of 10 km/h in 1st 0%
duty ratio Driving at a constant speed of 20 km/h in 2nd 100 %
Driving at a constant speed of 30 km/h in 3rd 100 %
Driving at a constant speed of 50 km/h in 4th 100 %
32 UD solenoid valve Driving at a constant speed of 10 km/h in 1st 0%
duty ratio Driving at a constant speed of 20 km/h in 2nd 0%
Driving at a constant speed of 30 km/h in 3rd 0%
Driving at a constant speed of 50 km/h in 4th 100 %
33 2ND solenoid valve Driving at a constant speed of 10 km/h in 1st 100 %
duty ratio Driving at a constant speed of 20 km/h in 2nd 0%
Driving at a constant speed of 30 km/h in 3rd 100 %
Driving at a constant speed of 50 km/h in 4th 0%
34 OD solenoid valve Driving at a constant speed of 10 km/h in 1st 100 %
duty ratio Driving at a constant speed of 20 km/h in 2nd 100 %
Driving at a constant speed of 30 km/h in 3rd 0%
Driving at a constant speed of 50 km/h in 4th 0%
36 DCC solenoid valve Driving at a constant speed 60 km/h in 3rd gear 70 − 99.6 %
duty ratio Driving at 60 km/h in 3rd gear, then fully close 70 − 99.6 % to 0 %
the accelerator pedal

No.
52 Damper clutch Driving at a constant speed 60 km/h in 3rd gear −10 to 10 r/min
amount of slippage Driving at 60 km/h in 3rd gear, then fully close The value changes
the accelerator pedal from the above value.
54 A/T control relay Ignition switch: ON System voltage
output voltage
57 Engine load Engine: Idling Accelerator pedal: fully Data changes
(volumetric Selector lever closed to depressed
efficiency) position: N, P
61 Inhibitor switch Ignition switch: ON Selector lever position: P P
Engine: Stopped Selector lever position: R R
Selector lever position: N N
Selector lever position: D D
63 Shift position Selector lever Driving at a constant 1st
position: Sport mode speed of 10 km/h in 1st
Driving at a constant 2nd
speed of 20 km/h in 2nd
Driving at a constant 3rd
speed of 50 km/h in 3th
Driving at a constant 4th
speed of 60 km/h in 4th
Selector lever Driving at a constant P, N
position: P speed of 5 km/h in reverse
Selector lever Driving at a constant REV
position: R speed of 5 km/h in reverse
Selector lever Driving at a constant P, N
position: N speed of 5 km/h in reverse
65 A/C compressor Engine: Idling A/C switch: ON ON
relay A/C switch: OFF OFF
67 Select switch Ignition switch: ON Selector lever position: D OFF
Engine: Stopped Selector lever position: ON
Select sport mode
Selector lever position: ON
Upshift and hold the
selector lever
Downshift and hold the
selector lever

No.
68 Upshift switch Ignition switch: ON Selector lever position: D OFF
Engine: Stopped Selector lever position: OFF
Select sport mode
selector lever
Selector lever position: OFF
selector lever
69 Downshift switch Ignition switch: ON Selector lever position: D OFF
Engine: Stopped Selector lever position: OFF
Select sport mode
Selector lever position: OFF
selector lever
selector lever
ACTUATOR TEST JUDGMENT VALUE

M1231008200345
Item No. Inspection item Test description Inspection Normal status

condition
01 LR solenoid valve Actuate solenoid valve Ignition switch: ON When solenoid valve is
02 UD solenoid valve indicated by MUT-II/III Selector lever actuated, operating
for 5 seconds at duty position: P sound is audible.
03 2ND solenoid valve ratio of 50%. Engine: Stopped
04 OD solenoid valve Other remaining Accelerator pedal:
06 DCC solenoid valve solenoid valve are not Released
ON.
07 1st indicator lamp Illuminate shift Shift indicator is
08 2nd indicator lamp indicator indicated by displayed.
MUT-II/III for 3
09 3rd indicator lamp seconds
10 4th indicator lamp
12 A/T control relay A/T control relay is Data list No.54
OFF for three During test: 0 V
seconds. Normal: System voltage
(V)
INVECS-II CANCEL COMMAND

M1231009500327
Item No. Item Contents NOTE

14 INVECS-II Stop the INVECS-II control and Use this procedure when carrying out road
changes gear according to the test procedure 8.
standard shift pattern. If the ignition switch is turned from OFF to
ON to OFF, this function restores the
INVECS-II control.
CHECK AT ENGINE-A/T-ECU TERMINALS

M1231008400350
C-139 C-140 C-141 C-142 C-138
1 2 3 4 31 32 33 34 61 62 63 64 91 92 93 94 95 121122 123 124

5 6 7 8 9 10 11 12 13 35 36 37 38 39 40 41 42 43 65 66 67 68 69 70 71 72 73 96 97 98 99 100101102103 104 125126127128129 130 131 132 133
14 15 16 17 18 19 20 44 45 46 47 48 49 50 51 74 75 76 77 78 79 80 81 82 105106 107108109 110111112 134135 136137 138 139 140 141
21 22 23 24 25 26 27 52 53 54 55 56 57 58 83 84 85 86 87 88 89 113114 115116117 118119120 142143 144 145 146
AC201888AI
Terminal Check item Inspection condition Standard value

No.
39 Stoplight switch • Ignition switch: ON System voltage
• Brake pedal: Depressed
• Ignition switch: ON 1 V or less
• Brake pedal: Released
64 Input shaft speed • Measure between terminals 64 and 88 Refer to P.23A-139,
sensor with an oscilloscope. Inspection Procedure
• Engine: 2,000 r/min Using an Oscilloscope.
• Selector lever position: Sport mode
(3rd gear)
66 Inhibitor awitch: P • Ignition switch: ON System voltage
• Selector lever position: P
• Selector lever position: Other than
above
67 Inhibitor awitch: R • Ignition switch: ON System voltage
• Selector lever position: R
above
68 Shift switch (Down) • Ignition switch: ON System voltage
• Selector lever operation: Downshift and
hold the selector lever
• Selector lever operation: Other than
above
70 Crankshaft position Engine: Idling 1.5 − 2.5 V
sensor

No.
73 Output shaft speed • Measure between terminals 73 and 88 Refer to P.23A-139,
sensor with an oscilloscope. Inspection Procedure
(3rd gear)
75 Inhibitor awitch: N • Ignition switch: ON System voltage
• Selector lever position: N
above
76 Inhibitor switch: D • Ignition switch: ON System voltage
• Selector lever position: D
above
77 Shift switch (Up) • Ignition switch: ON System voltage
• Selector lever operation: Upshift and
hold the selector lever
• Selector lever operation: Other than
above
79 Vehicle speed signal • Measure between terminals 79 and Refer to P.23A-139,
ground with an oscilloscope. Inspection Procedure
(3rd gear)
85 Select switch • Ignition switch: ON System voltage
above
119 A/T fluid temperature A/T fluid temperature: 20°C 3.8 − 4.0 V
sensor A/T fluid temperature: 40°C 3.2 − 3.4 V
A/T fluid temperature: 80°C 1.7 − 1.9 V
121 Shift indicator C Measure the voltage when 1st 1 V or less
each shift range is displayed 2nd 1 V or less
by using actuator function
(item No.07 to 10) on the 3rd 1 V or less
scan tool (MUT-II/III). 4th 8 − 10 V
123 Solenoid valve power Ignition switch: LOCK (OFF) 1 V or less
supply Ignition switch: ON System voltage
124 Solenoid valve power Ignition switch: LOCK (OFF) 1 V or less
supply Ignition switch: ON System voltage

No.
125 Shift indicator B Measure the voltage when 1st 1 V or less
each shift range is displayed 2nd 8 − 10 V
(item No.07 to 10) on the 3rd 8 − 10 V
scan tool (MUT-II/III). 4th 1 V or less
127 A/T control relay Always 1 V or less
128 LR solenoid valve • Engine: Idling System voltage
• Engine: Idling 6−9V
(2nd gear)
130 DCC clutch solenoid • Engine: Idling System voltage
valve • Selector lever position: P
131 Ground Always 1 V or less
134 Shift indicator A Measure the voltage when 1st 8 − 10 V
each shift range is displayed 2nd 1 V or less
(item No.07 to 10) on the 3rd 8 − 10 V
scan tool (MUT-II/III). 4th 1 V or less
135 A/T fluid temperature Ignition switch: LOCK (OFF) to ON 1 V or less to System
warning light voltage (after several
136 2ND solenoid valve • Engine: Idling System voltage
(2nd gear)
137 UD solenoid valve • Engine: Idling System voltage
(1st gear)
138 OD solenoid valve • Engine: Idling System voltage
(3rd gear)
139 Ground Always 1 V or less
OSCILLOSCOPE INSPECTION
PROCEDURE
M1231008500357
Terminal Check item Inspection conditions Normal

No. condition
(Waveform
sample)
70 Crank angle sensor Selector lever position: P Engine: Idling (vehicle Waveform A
stopped)
79 Vehicle speed signal Selector lever position: Driving at constant Waveform B
64 Input shaft speed sensor Sport mode (3rd gear) speed of 50 km/h in 3rd Waveform C
gear ( 1,400 − 1,700
73 Output shaft speed r/min)
sensor
128 LR solenoid valve • Ignition switch: ON Force drive each Waveform D
137 UD solenoid valve • Selector lever solenoid valve (Actuator
position: P test)
136 2ND solenoid valve • Engine: Stopped
138 OD solenoid valve • Throttle (Accelerator)
130 DCC solenoid valve opening voltage: 1 V
or less
Waveform sample
Waveform C Waveform D
Waveform A Waveform B (V)
(V)
(V) (V) 5 60
5 12
40
20
0 0
0 0
(ms) (ms) (ms) (ms)
AC001872AC AC001872 AG AC001874AC AC001875 AC
TROUBLESHOOTING <A/T KEY INTERLOCK AND SHIFT LOCK MECHANISMS>
TROUBLESHOOTING <A/T KEY INTERLOCK AND SHIFT

LOCK MECHANISMS>
TROUBLE SYMPTOM CHART
M1232001800468
Symptom Inspection Reference

procedure page
number
When the ignition key is at a position other than the LOCK (OFF) position, 1 P.23A-141
the selector lever can be moved from the P to the R position even though
the brake pedal is not depressed.
When the ignition key is at a position other than the LOCK (OFF) position, 2 P.23A-141
the selector lever cannot be moved from the P to the R position even
though the brake pedal is being depressed.
The ignition key is at the LOCK (OFF) position, but the selector lever can 3 P.23A-141
be moved from the P to the R position when the brake pedal is
depressed.
The selector lever cannot be easily moved from the P to the R position. 4 P.23A-141
The selector lever cannot be moved from the R to the P position. 5 P.23A-142
The ignition key cannot be turned to the LOCK (OFF) position when the 6 P.23A-142
selector lever is at the P position.
The ignition key can be turned to the LOCK (OFF) position when the 7 P.23A-142
selector lever is at a position other than the P position.
The buzzer does not sound when the selector lever is at the R position.* − −
NOTE: The R (reverse) position warning function is controlled by the Smart Wiring System (SWS). The
troubleshooting for * refers to GROUP 54B - SWS troubleshooting.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: When the ignition key is at a position other than the LOCK (OFF)
position, the selector lever can be moved from the P to the R position even though the brake pedal is
not depressed.
COMMENTS ON TROUBLE SYMPTOM • Malfunction of shift lock cable

The cause is probably a malfunction of the selector
lever assembly lock cam or shift lock cable. DIAGNOSIS
Check by referring to the possible causes.
Possible causes
• Malfunction of lock cam
INSPECTION PROCEDURE 2: When the ignition key is at a position other than the LOCK (OFF)
position, the selector lever cannot be moved from the P to the R position even though the brake pedal
is being depressed.
COMMENTS ON TROUBLE SYMPTOM • Malfunction of transmission control cable

The cause is probably a malfunction of the selector • Malfunction of shift lock cable
lever assembly, transmission control cable, shift lock • Malfunction of key interlock cable
cable, key interlock cable or ignition key cylinder lock • Malfunction of lock bar
bar.
DIAGNOSIS
Possible causes Check by referring to the possible causes.
• Malfunction of selector lever assembly
INSPECTION PROCEDURE 3: The ignition key is at the LOCK (OFF) position, but the selector lever
can be moved from the P to the R position when the brake pedal is depressed.
COMMENTS ON TROUBLE SYMPTOM • Malfunction of lock bar

The cause is probably a malfunction of the key
interlock cable or ignition key cylinder lock bar. DIAGNOSIS
Possible causes
• Malfunction of key interlock cable
INSPECTION PROCEDURE 4: The selector lever cannot be easily moved from the P to the R position.

The cause is probably a malfunction of the selector • Malfunction of shift lock cable
lever assembly, transmission control cable, shift lock • Malfunction of key interlock cable
cable, key interlock cable or ignition key cylinder lock • Malfunction of lock bar
bar.
DIAGNOSIS
Possible causes Check by referring to the possible causes.
INSPECTION PROCEDURE 5: The selector lever cannot be moved from the R to the P position.

The cause is probably a malfunction of the selector
lever assembly or transmission control cable. DIAGNOSIS
Possible causes
INSPECTION PROCEDURE 6: The ignition key cannot be turned to the LOCK (OFF) position when the
selector lever is at the P position.
COMMENTS ON TROUBLE SYMPTOM • Malfunction of key interlock cable

The cause is probably a malfunction of the selector • Malfunction of lock bar
lever assembly, key interlock cable or ignition key
cylinder lock bar. DIAGNOSIS
Possible causes
INSPECTION PROCEDURE 7: The ignition key can be turned to the LOCK (OFF) position when the
selector lever is at a position other than the P position.
COMMENTS ON TROUBLE SYMPTOM • Malfunction of lock bar

The cause is probably a malfunction of the key
interlock cable or ignition key cylinder lock bar. DIAGNOSIS
Possible causes
• Malfunction of key interlock cable
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ESSENTIAL SERVICE NOTE: If the A/T fluid has a burnt smell, or if it has
become very contaminated or dirty, it means that
AUTOMATIC TRANSMISSION FLUID the A/T fluid has become contaminated by minute
particles form bushings (metal) or worn parts. In
(ATF) CHECK such a case, the transmission needs to be
M1231000900340
CAUTION overhauled and the A/T fluid cooler line needs to

When replacing the transmission with a new one, be flushed out.
overhauling the existing transmission, or driving
in a harsh condition, the A/T fluid cooler line
should always be flushed out and A/T fluid
should be replaced with a new one.
1. Drive the vehicle until the A/T fluid temperature
reaches the normal temperature (70 − 80 °C)
NOTE: Measure A/T Fluid temperature using
MUT-II/III.
NOTE: AC005861
Fluid level [mm]
10
5. Check that the A/T fluid level is between the HOT
0 marks on the oil level gauge. If the A/T fluid level
is too low, add more A/T fluid until the level
-10
reaches between the HOT marks.
-20 Automatic transmission fluid: DIA QUEEN
Fluid level ATF SP III
-30
40 60 80 NOTE: If the A/T fluid level is too low, the oil pump
Fluid temperature [ ] AC002477AF draws air into the system along with the A/T fluid,
and air bubbles will thus from in the fluid circuit.
Check the oil level referring to the characteristics
This will cause a drop in fluid pressure and cause
chart shown at left if it takes some time to reach
the shift points to change and the clutches and
the normal operation temperature of A/T fluid (70
brakes to slip.
− 80 °C). If the A/T fluid level is too high, the gear will churn
2. Park the vehicle on a level surface. the A/T fluid and cause bubbles to develop, which
3. Move the selector lever to all positions to fully can then cause the same problems as when the
charge the torque converter and the fluid lines A/T fluid is too low.
with A/T fluid, and then move the selector lever to In either case, the air bubbles can cause
the N position. overheating and oxidation of the A/T fluid, and
4. After wiping away any dirt from around the oil also prevent the valves, clutches and brakes from
level gauge, pull out the oil level gauge and check operating normally. In addition, if bubbles develop
the level of A/T fluid. in the A/T fluid, the A/T fluid can overflow from the
transmission vent holes and be mistaken for
leaks.
6. Securely re-insert the oil level gauge.
ON-VEHICLE SERVICE
AUTOMATIC TRANSMISSION FLUID 4. Install the drain plug with a gasket in between,
(ATF) REPLACEMENT and tighten it to the specified torque.
M1231001000339 Tightening torque: 32 ± 2 N⋅m
CAUTION
Before replacing the transmission with a new CAUTION
one, overhauling the existing transmission, or Stop pouring in the A/T fluid once 5.5 L has been
connecting the cooler pipe to the transmission, poured in.
the A/T fluid cooler line should always be flushed 5. Pour in new A/T fluid through the oil filler tube.
out. Amount to add: Approx. 2.0 L
In you have an A/T fluid changer, use the A/T fluid
6. Repeat the operation in step 2.
changer to flush the A/T fluid. If you do not have an
A/T fluid changer, follow the procedure given below. 7. Pour in new A/T fluid through the oil filler tube.
Amount to add: Approx. 3.5 L
NOTE: Carry out steps 2 and 7 so that at least 8.0
L has been discharged from the cooler hose. After
this, discharge a small quantity of A/T fluid and
check for contamination. If the A/T fluid is
contaminated, repeat steps 6 and 7.
AC103690AB
1. Remove the hose shown in the illustration which

allows the A/T fluid to flow from the A/T fluid
cooler (built into the radiator) to the transmission.
CAUTION
The engine should be stopped within one minute AC103690AB
of it being started. If the A/T fluid has all been
discharged before this, stop the engine at that 8. Connect the hose which was disconnected in step
point. 1, and then securely re-insert the oil level gauge.
2. Start the engine and discharge the A/T fluid. 9. Start the engine, and let it run at idle for 1 − 2
minutes.
Driving conditions: N range, idling
10.Move the selector lever to all positions once, and
Discharge amount: Approx. 3.5 L then return it to the N position.
AC103691AB AC005861
3. Remove the drain plug at the bottom of the 11.Check that the A/T fluid level on the oil level
transmission case to drain out the remaining A/T gauge is at the COLD mark. if it is not up to this
fluid. mark, add more A/T fluid.
Discharge amount: Approx. 2.0 L
ON-VEHICLE SERVICE
12.Drive the vehicle until the A/T Fluid temperature CAUTION

reaches the normal temperature (70 − 80 °C), and The engine should be stopped within one minute
then re check the A/T fluid level. of it being started. If the A/T fluid has all been
NOTE: The COLD mark is for reference only; the discharged before this, stop the engine at that
HOT marks should be used as the standard for point.
judgment. 2. Start the engine and discharge the A/T fluid.
NOTE: A/T fluid temperature using MUT-II/III.
Driving conditions: N range, idling
NOTE:
Discharge amount: Approx. 3.5 L
Fluid level [mm]
10 CAUTION
0 Stop pouring in the A/T fluid once 3.5 L has been
poured in.
-10
3. Pour in new A/T fluid through the oil filler tube.
-20 Amount to add: Approx. 3.5 L
Fluid level
-30 4. Repeat the operation in step 2 and 3.
40 60 80
NOTE: Carry out steps 2 and 3 so that at least 8.0
Fluid temperature [ ] AC002477AF
L has been discharged from the cooler hose. After
Check the oil level referring to the characteristics this, discharge a small quantity of A/T fluid and
chart shown at left if it takes some time until check for contamination. If the A/T fluid is
reaching the normal operation temperature of A/T contaminated, repeat steps 2 and 3.
fluid (70 − 80 °C.) 5. Carry out the procedure in "Automatic
13.When A/T fluid is under the specified level, top up Transmission Fluid (ATF) Replacement" from step
A/T fluid. When A/T fluid is over the specified 2 onwards.
level, drain the excessive A/T fluid from the drain
plug to adjust A/T fluid level to the specified level. INHIBITOR SWITCH CONTINUITY CHECK
M1231001400586
14.Securely insert the oil level gauge into the oil filler
tube.
AUTOMATIC TRANSMISSION FLUID Inhibitor switch

COOLER LINE FLUSHING
M1231013000381
CAUTION
If replacing the transmission with a new one, if
overhauling the existing transmission, or if the
A/T fluid has deteriorated or is contaminated, the
AC103395AE
A/T fluid cooler line must always be flushed out.
D
N
R
AC103690AB P AC304824AC
1. Remove the hose shown in the illustration which

allows the A/T fluid to flow from the A/T fluid
cooler (built into the radiator) to the transmission.
ON-VEHICLE SERVICE
Item Terminal No. Resistance CAUTION

P 3 − 8, 9 − 10 Less than 2 Ω Be careful not let the inhibitor switch body slip
out of place.
R 7−8
5. Tighten the inhibitor switch body mounting bolt to
N 4 − 8, 9 − 10 the specified torque.
D 1−8 Tightening torque: 11 ± 1 N⋅m
NOTE: The inhibitor switch has 7 positions, but only
four positions [P, R, N and D]are used.
Transmission
INHIBITOR SWITCH AND CONTROL control cable
CABLE ADJUSTMENT
M1231010300316 Adjusting nut
1. Move the selector lever to the N position.
2. Loosen the adjusting nut, and set the manual
control lever upper and lower to the free condition.
3. Move the manual control lever lower to the neutral AC103395AL
position.
6. Gently push the transmission control cable in the
direction as shown in the illustration at left, and
11 ± 1 N·m tighten the adjusting nut the specified torque.
Mounting bolts
7. Check that the selector lever is at the N position.
8. Check that the transmission shifts to the correct
range corresponding to the position of the selector
lever, and that it functions correctly in that range.
A
A TRANSFER OIL LEVEL CHECK
Manual M1231001100132
control lever
Section A-A
Oil filler plug hole
Hole in end Manual
control lever
Hole in
flange
Inhibitor
switch body
Oil filler plug
Transfer oil
AC001893AD AC103664AE
4. Loosen the inhibitor switch body mounting bolt, 1. Remove the filler plug.
and then turn the inhibitor switch to adjust so that 2. Check that the oil level is up to the lower edge of
the hole at the end of the manual control lever and the filler plug hole.
the hole in the inhibitor switch body flange 3. Check that the oil is not noticeably dirty.
(section A − A in the illustration at left) are aligned.
4. Tighten the filler plug to the specified torque.
NOTE: The inhibitor switch body can be aligned
by hand, because the manual control lever end is
as wide as the switch body flange. Alternatively,
the inhibitor switch can also be aligned by
inserting a 5-mm bar in the holes of the manual
control lever end and the inhibitor switch body
flange.
ON-VEHICLE SERVICE
TRANSFER OIL REPLACEMENT 1. Remove the drain plug and discharge the oil.
M1231001200139
2. Tighten the drain plug to the specified torque.
Filler plug Tightening torque: 32 ± 2 N⋅m
3. Remove the oil filer plug and pour in oil until it
reaches the bottom the oil filer plug hole.
Cross
member Specified oil: Hypoid gear oil API
classification GL-5 SAE 90
Quantity: 0.55 L
Drain plug
4. Tighten the filler plug to the specified torque.
AC101739AF
ON-VEHICLE SERVICE
A/T CONTROL COMPONENT LOCATION

M1231008600398
Name Symbol Name symbol

A/C compressor relay C Inhibitor switch F
A/T control relay C Input shaft speed sensor E
A/T control solenoid valve assembly G Output shaft speed sensor B
A/T fluid temperature sensor G Shift switch assembly K
Crank angle sensor D Stop lamp switch H
Diagnosis connector J Throttle position sensor (TPS) A
Engine-A/T-ECU L
A B C
D E F G
<LHD> <RHD>
H J K L L K J H AC309369AB
ON-VEHICLE SERVICE
A/T CONTROL COMPONENT CHECK A/T CONTROL SOLENOID VALVE

ASSEMBLY CHECK
INHIBITOR SWITCH CHECK M1231009400308
M1231001400597 1. Use the MUT-II/III to measure the ATF
Refer to P.23A-145. temperature and check that the ATF temperature
is 20°C.
CRANK ANGLE SENSOR CHECK
M1231009000399
Refer to GROUP 13B − Troubleshooting, Inspection
Procedure using an Oscilloscope P.13B-418.
STOP LAMP SWITCH CHECK

M1231010100118
Refer to GROUP 35A − Brake pedal, Inspection
P.35A-14.
A/T CONTROL RELAY CHECK

M1231009300282 AC202402 AB
2. Disconnect the A/T control solenoid valve

A/T control relay
assembly connector.
3. Measure the resistance between the solenoid
valve terminals.
4. Check that the measured values are within the
standard values at items 1 and 3.
Standard value:
Name Terminal Resistance
AC103000AH No. value
1. Removal the A/T control relay. Damper clutch control 7 − 10 2.7 − 3.4 Ω
solenoid valve (A/T fluid
Low-reverse solenoid valve 6 − 10 temperatur
e 20°C)
Second solenoid valve 4−9
1 2 Underdrive solenoid valve 3−9
3 4 Overdrive solenoid valve 5−9
5. If within the standard value, check the power
supply and the earth circuits.
6. If not within the standard value, drain the ATF and
AC100115AQ remove the valve body cover.
2. Use the jumper leads to connect A/T control relay
terminal 2 to the negative battery terminal and OD UD
terminal 3 to the positive battery terminal. solenoid solenoid
valve valve
3. Check the continuity between A/T control relay
connector terminals 1 and 4 while alternately 2ND
solenoid
connecting and disconnecting the jumper leads LR valve
from the battery terminals. solenoid
valve DCC
solenoid
Jumper leads Continuity between valve
terminals 1 and 4 AC002219 CO
Connected Less than 2 Ω
7. Disconnect the solenoid valve connectors.
Disconnected Open circuit
4. If there is a malfunction, replace the A/T control
relay.
ON-VEHICLE SERVICE
2. Remove the A/T fluid temperature sensor.
AC002289 ATF
AC103441AB
8. Measure the resistance between terminals 1 and
2 at each solenoid valve side. 3. Measure the resistance between A/T control
Standard value: 2.7 − 3.4 Ω (A/T fluid solenoid valve assembly connector terminals 1
temperature 20°C) and 2.
9. If not within the standard value, replace the Standard value:
solenoid valve. Fluid temperature Resistance value (Ω)
10.If within the standard value, check the harness (°C)
wire between A/T control solenoid valve assembly
0 16.7 − 20.5
connector and each solenoid valve connector. If a
problem is not found at the steps above, check 20 7.3 − 8.9
the solenoid valve O-rings and replace if 40 3.4 − 4.2
necessary.
60 1.9 − 2.2
A/T FLUID TEMPERATURE SENSOR 80 1.0 − 1.2
CHECK 100 0.57 − 0.69
M1231004500281
1. Drain the ATF and remove the valve body cover. NOTE: The A/T fluid temperature warning lamp
on the combination meter flashes when the
temperature reaches approximately 125 °C or
higher and then stops flashing when the
temperature drops below approximately 115°C.
4. If the A/T fluid temperature sensor resistance and
the temperature when the N range indicator is
A/T fluid flashing or switched off are outside the standard
temperature
sensor value ranges, replace the A/T fluid temperature
sensor.
AC002219CF
ON-VEHICLE SERVICE
TORQUE CONVERTER STALL TEST 3. Pull the parking brake lever to apply the parking
M1231005400403 brake and depress the brake pedal fully.
One-way CAUTION
Reverse clutch
clutch Torque • Do not keep the throttle fully open for any
Low-reverse converter longer than 5 seconds.
Underdrive
brake clutch • If you repeat the stall test when the A/T fluid
temperature is greater than 80°C, move the
selector lever to the "N" position and let the
engine run at approximately 1,000 r/min for at
least one minute. Wait until the A/T fluid
temperature returns to 80°C or less.
5. Move the selector lever to the D position, fully
depress the accelerator pedal and quickly take a
reading of the maximum engine speed at this
time.
Standard stalling engine speed: 2, 300 − 2,
Overdrive
clutch
800 r/min
Second brake 6. Move the selector lever to the R position and
repeat the test described above.
AC001824AC
Standard stalling engine speed: 2, 300 − 2,
800 r/min
The purpose of this test is to measure the maximum
engine speed when the torque converter stalls in D TORQUE CONVERTER STALL TEST
or R ranges in order to check the torque converter JUDGMENT RESULTS
(Stator and one-way clutch operation) and the
1. Stall speed is too high in both D and R ranges
holding performance of the clutches and brakes
• Malfunction of the torque converter (Slippage
which are built into the transmission.
on the splines of the torque converter and the
WARNING input shaft)
For safety, the front and rear of the vehicle • Low line pressure
should be kept clear of other people while • Low-reverse brake slippage and malfunction
this test is being carried out. of the one-way clutch
1. Check the A/T fluid level, the A/T fluid 2. Stall speed is too high in D range only
temperature and the engine coolant temperature. • Underdrive clutch slippage
• A/T fluid level: HOT position on oil level gauge 3. Stall speed is too high in R range only
• A/T fluid temperature: 70 − 80°C • Reverse clutch slippage
• Engine coolant temperature: 80 − 100°C 4. Stall speed is too low in both D and R ranges
NOTE: The A/T fluid temperature is measured • Malfunction of the torque converter (Slippage
with MUT-II/III. of the one-way clutch)
2. Place wheel locks on both the left and right front • Low line pressure
wheels. • Poor engine output
ON-VEHICLE SERVICE
HYDRAULIC PRESSURE TESTS 3. Connect the special tools (oil pressure gauge (3.0
M1231005500433 MPa) [MD998330] and adapters [MD998332,
CAUTION MD998900]) to each pressure discharge port.
The transmission fluid temperature should be NOTE: .
between 70 − 80°C during the test. • 2ND: Second brake pressure port
1. Check the transmission fluid level, temperature • UD: Underdrive clutch pressure port
and engine coolant temperature. • LR: Low-reverse brake pressure port
• Transmission fluid level: HOT mark on the • DR: Torque converter release pressure port
dipstick • DA: Torque converter apply pressure port
• Transmission fluid temperature: 70 − 80°C • RV: Reverse clutch pressure port
• Engine coolant temperature: 80 − 100°C • OD: Overdrive clutch pressure port
2. Raise the vehicle so that the wheels are free to 4. Restart the engine.
turn. 5. Check that there are no leaks around the special
<Under side view> tool port adapters.
MD998330 6. Measure the hydraulic pressure at each port
under the conditions given in the standard
MD998332 hydraulic pressure table, and check that the
measured values are within the standard value
ranges.
7. If the pressure is not within the standard value,
Valve body cover stop the engine and refer to the hydraulic
pressure test diagnosis table.
AC006150AC 8. Remove the O-ring from the port plug and replace
it.
MD998330 9. Remove the special tool, and install the plugs to
the hydraulic pressure ports.
Valve body cover 10.Start the engine and check that there are no leaks
around the plugs.
MD998332
AC006149AC
MD998330
MD998900
Valve body
cover AC006151AC
ON-VEHICLE SERVICE
STANDARD HYDRAULIC PRESSURE

TABLE
Measurement condition Standard hydraulic pressure MPa
Selecto Shift Engine Underdriv Reverse Overdrive Low- Second Torque
r lever position speed e clutch clutch clutch reverse brake converter
positio (r/min) pressure pressure pressure brake pressure pressure
n [UD] [RV] [OD] pressure [2ND] [DR]
[LR]
P − 2,500 − − − 0.31 − 0.39 − 0.22 − 0.36
R Reverse 2,500 − 1.27 − 1.77 − 1.27 − 1.77 − 0.50 − 0.70
N − 2,500 − − − 0.31 − 0.39 − 0.22 − 0.36
Sport 1st gear 2,500 0.95 − 1.06 − − 0.95 − 1.06 − 0.50 − 0.70
mode
2nd gear 2,500 0.95 − 1.06 − − − 1.01 − 1.05 0.50 − 0.70
3rd gear 2,500 0.78 − 0.88 − 0.78 − 0.88 − − −
4th gear 2,500 − − 0.78 − 0.88 − 0.78 − 0.88 −
NOTE: When the torque converter pressure is measured, the engine speed should be 1,500 r/min or less.
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom Probable cause
All hydraulic pressures are high. Malfunction of the regulator valve
All hydraulic pressures are low. Malfunction of the oil pump
Clogged internal oil filter
Clogged oil cooler
Malfunction of the regulator valve
Malfunction of the relief valve
Incorrect valve body installation
Improperly installed solenoid valves
Damaged solenoid valve O-rings
Hydraulic pressure is abnormal in reverse Malfunction of the regulator valve
gear only. Clogged orifice
Hydraulic pressure is abnormal in 3rd or 4th Malfunction of the overdrive solenoid valve
gear only. Malfunction of the overdrive pressure control valve
Malfunction of the regulator valve
Malfunction of the switch valve
Clogged orifice
ON-VEHICLE SERVICE

Only underdrive clutch hydraulic pressure is Malfunction of the oil seal K
abnormal. Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of the check ball
Clogged orifice
Malfunction of the accumulator for underdrive clutch
Only reverse clutch hydraulic pressure is Malfunction of the oil seal A
abnormal. Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Only overdrive clutch hydraulic pressure is Malfunction of the oil seal D
abnormal. Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Clogged orifice
Malfunction of the accumulator for overdrive clutch
Only low-reverse brake hydraulic pressure is Malfunction of the oil seal I
abnormal. Malfunction of the oil seal J
Malfunction of the low-reverse solenoid valve
Malfunction of the low-reverse pressure control valve
Malfunction of the switch valve
Malfunction of the fail safe valve A
Malfunction of all the check balls
Clogged orifice
Malfunction of the accumulator for low-reverse brake
ON-VEHICLE SERVICE

Only second brake hydraulic pressure is Malfunction of the oil seal G
abnormal. Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Malfunction of the accumulator for second brake
Only torque converter pressure is abnormal. Clogged oil cooler
Malfunction of the oil seal N
Malfunction of the damper clutch control solenoid
Malfunction of the damper clutch pressure control valve
Clogged orifice
Pressure applied to element which should not Incorrect transmission control cable adjustment
receive pressure. Malfunction of the manual valve
ON-VEHICLE SERVICE
OIL SEAL LAYOUT
H I J K L M N
E F G
B
A
AC103760
ON-VEHICLE SERVICE
HYDRAULIC CIRCUIT
M1231008800370
1 2 3 4 5
6 7 8
9
10
11 12
13
15
14 17 18 19
16
21 22 23 24
20
26 27
25
30
28 31 32
29
AK202328 AD
1. Reverse clutch 17. Second pressure control valve

2. Low-reverse brake 18. Underdrive pressure control valve
3. Second brake 19. Overdrive pressure control valve
4. Underdrive clutch 20. Damper clutch control solenoid valve
5. Overdrive clutch 21. Low-reverse solenoid valve
6. Low-reverse accumulator 22. Second solenoid valve
7. Second accumulator 23. Underdrive solenoid valve
8. Underdrive accumulator 24. Overdrive solenoid valve
9. Overdrive accumulator 25. Damper clutch pressure control valve
10. Damper clutch 26. Regulator valve
11. Fail-safe valve A 27. Manual valve
12. Fail-safe valve B 28. Oil filter
13. Damper clutch control valve 29. Oil pan
14. Cooler 30. Oil pump
15. Switch valve 31. Relief valve
16. Low-reverse pressure control valve 32. Oil strainer
ON-VEHICLE SERVICE
LINE PRESSURE ADJUSTMENT SELECTOR LEVER OPERATION CHECK

M1231001700402 M1231001300460
1. Drain the transmission fluid.
<LHD>
NOTE: The hydraulic pressure test must be P
performed before attempting any adjustments. R
N
2. Remove the valve body cover. D
<RHD> P
R
N
Adjusting D
screw
AC006153AC : Operation when the ignition switch is turned to

a position other than LOCK (OFF), the brake
pedal is depressed and the pushbutton is kept
3. Turn the adjusting screw shown in the illustration pressed.
to adjust the line pressure to the standard value.
: Operation when the pushbutton is not pressed.
The pressure increases when the screw is turned
counterclockwise. : Operation when the pushbutton is kept pressed.
NOTE: When adjusting the line pressure, adjust
to the middle of the standard value range. AC309372AB
Standard value: 1.01 − 1.05 MPa (Change in 1. Apply the parking brake, and check that the
pressure for a single full of the adjusting selector lever moves smoothly and accurately to
screw: 0.035 MPa) each position.
4. Install the valve body cover, and then pour in the 2. Check that the engine starts when the selector
specified amount of ATF. lever is in the N or P position, and that it does not
5. Repeat the hydraulic pressure test (Refer to start when the selector lever is in any other
P.23A-152.) Readjust the line pressure if position.
necessary. 3. Start the engine, release the parking brake, and
check that the vehicle moves forward when the
selector lever is moved from N position to the D
position or to 1st or 2nd gear in Sport mode, and
that the vehicle reverses when the selector lever
is moved to the R position.
4. Stop the engine.
5. Turn the ignition switch to the ON position, and
check that the backup lamp illuminates when the
selector lever is shifted from the P position to the
R position.
NOTE: The A/T mis-operation prevention
mechanism prevents movement of the selector
lever from the P position if the ignition switch is in
a position other than LOCK (OFF) position and
the brake pedal is not depressed.
ON-VEHICLE SERVICE
KEY INTERLOCK AND SHIFT LOCK

MECHANISM CHECK
M1232003100238
1. Carry out the following check.
Key interlock side
Inspection Inspection conditions Check details (normal condition)
procedure
1 Brake pedal: Ignition key position: The selector lever push button cannot be
Depressed LOCK (OFF) or pulled out pushed, and the selector lever should not
be moved from P position.
2 Ignition key position: The selector lever push button can be
Other than above pushed, and the selector lever can be
moved from P position.
3 Selector lever position: Other than P position The ignition key cannot turned to LOCK
(OFF) position.
4 Selector lever position: P position The ignition key can be turned to LOCK
(OFF) position.
shift lock side
Inspection Inspection conditions Check details (normal condition)
procedure
1 Ignition switch Brake pedal: The selector lever push button can be pushed, and the
position: ACC Depressed selector lever can be moved from P position.
2 Brake pedal: The selector lever push button cannot be pushed, and
Not depressed the selector lever should not be moved from P position.
3 The selector lever push button can be pushed, and the
selector lever can be moved from R position to P
position.
2. If the above operations do not occur correctly, View A
adjust the shift lock cable unit by the following
Lock guide
procedure. Lock released
(1) Remove the front floor console (Refer to Locked
GROUP 52A − Floor Console Assembly
P.52A-14) <LHD>.
Remove the instrument panel center console
(Refer to GROUP 52A − Instrument Panel
Assembly P.52A-8) <RHD>. Key interlock cable
(2) Move the selector lever to P position.
Lever
(3) Turn the ignition key to LOCK (OFF) position. Cap
B
A
Shift lock cable
C
Fixing bolt Shift lock
cable unit
AC000004 AC
ON-VEHICLE SERVICE
(4) Loosen the shift lock cable unit fixing bolt, and NOTE: The lock position at this time (the
then while pushing the lever in direction of B amount by which the cap is pushed) represents
and the unit in direction of C, tighten the fixing the amount of adjustment for the key interlock
bolt to the specified torque. cable. If the key interlock cable does not
Tightening torque: 12 ± 2 N⋅m operate correctly, adjust the lock position.
3. After adjusting, check the operation once more. If
(5) Lift the lock guide to unlock the key
the operation is still incorrect, replace the shift
interlocking cable.
lock unit. (Refer to P.23A-168 <vehicles with
(6) While pushing the cap of the key interlock LHD> or P.23A-170 <vehicles with RHD>)
cable in the direction of B, lower the lock guide
to lock the cable.
<VEHICES WITH LHD>
M1231006600400
CAUTION
When removing and installing the transmission control cable and shift lock cable unit, be careful not
to hit the SRS-ECU.
• Front Floor Console Removal. (Refer to GROUP 52A −
Floor Console Assembly P.52A-14.)
5.0 ± 1.0 N·m

2
12 ± 2 N·m
12 ± 2 N·m
12 ± 2 N·m
6
5
3 AC300157AC
Transmission control cable Transmission control cable

• Air cleaner assembly (Refer to • SRS-ECU (Refer to GROUP 52B,
GROUP 15 P.15-4.) SRS control unit P.52B-178.)
• Battery and battery tray 6. Transmission control cable
>>B<< 1. Transmission control cable assembly
assembly connection Selector lever assembly
(transmission side) removal steps
>>A<< 2. Shift lock cable unit connection >>A<< 2. Shift lock cable unit connection
3. Transmission control cable 3. Transmission control cable
assembly connection (selector assembly connection (selector
lever assembly side) lever assembly side)
4. Harness connector 4. Harness connector
5. Selector lever assembly 5. Selector lever assembly

>>A<< SHIFT LOCK CABLE UNIT INSTALLATION >>B<< TRANSMISSION CONTROL CABLE
1. Selector lever to P position. (TRANSMISSION SIDE) INSTALLATION
2. Turn the ignition key to LOCK (OFF) position. 1. Place the selector lever and manual control lever
in the N position.
Lock cam
Adjusting nut
Shift lock
cable unit
12 ± 2 N·m
Manual control lever

AC203163AC
AC103395AO
3. Install the shift lock cable unit rod to the selector

2. Place the cable stud into the manual control lever
lever assembly lock cam, and tighten the shift lock
cable unit installation bolt to the specified torque. slot and install the nut loosely. Gently push the
transmission control cable into the manual control
Tightening torque: 5.0 ± 1.0 N⋅m lever slot until the cable is taut. Tighten the nut to
4. Check the selector lever operation. (Refer to the specified torque.
P.23A-158) Tightening torque: 12 ± 2 N⋅m

<VEHICLES WITH RHD>
M1231006600411
CAUTION
When removing and installing the transmission control cable and shift lock cable unit, be careful not
to hit the SRS-ECU.
• Instrument Panel Centre Console Removal and
Installation (Refer to GROUP 52A − Instrument Panel
assembly P.52A-8.)
1 6
5
AC103060AC
Selector lever assembly and Selector lever assembly and

transmission control cable transmission control cable
• Footrest • Air cleaner (Refer to GROUP 15 -
>>B<< 1. Transmission control cable Air cleaner P.15-4.)
connection (Transmission side) • Battery and Battery tray
>>A<< 2. Shift lock cable unit connection • SRS-ECU (Refer to GROUP 52B -
3. Transmission control cable SRS air bag control unit
connection (shift lever side) P.52B-178.)
4. Shift switch connector 6. Transmission control cable
5. Selector lever assembly assembly
INSTALLATION SERVICE POINTS 3. Check the operation of the selector lever. (Refer
>>A<< SHIFT LOCK CABLE UNIT INSTALLATION to P.23A-158.)
1. Shift the selector lever to the P position and turn
the ignition switch to the LOCK (OFF) position. >>B<< TRANSMISSION CONTROL CABLE
(TRANSMISSION SIDE) INSTALLATION
Lock cam 1. Shift the selector lever and manual control lever to
Bolts the N position.
Adjusting nut
Rod
AC103391AC 12 ± 2 N·m
2. After installing the rod of the shift lock cable unit to Manual control lever
the lock cam of the selector lever assembly, AC103395AO
tighten the bolts of the shift lock cable unit to the
specified torque. 2. Gently push the transmission control cable in the
Tightening torque: 5.0 ± 1.0 N⋅m direction of the arrow to tighten the adjusting nut

<VEHICLES WITH LHD>
M1231006800404
1.8 ± 0.2 N·m

3
7
8
9
5.0 ± 1.0 N·m
5
10
4
11 5.0 ± 1.0 N·m
1.8 ± 0.2 N·m
N
6
12
13
AC300171AB

1. Shift knob 8. Plunger
2. Sleeve 9. Spring
3. Indicator panel assembly 10. Universal joint
4. Shift switch assembly 11. Cable arm
5. Detente spring 12. Lock cam
6. Shaft 13. Base bracket
7. Lever assembly
INSPECTION SHIFT SWITCH ASSEMBLY CONTINUITY CHECK

M1231006900207 Switch position Terminal NO.
ON ON
Select switch ON 1−4
OFF Shift switch
Shift switch (up)
(down)
OFF 1−2
Shift switch (up) ON 3−6
OFF −
OFF
ON
Shift switch (down) ON 3−5
1 2
OFF −
Select 3 4 5 6
switch
AC200593 AB
SELECTOR LEVER ASSEMBLY <VEHICLES WITH RHD>

M1231006800415
DISASSEMBLY AND REASSENBLY
1.5 ± 0.5 N·m
1.5 ± 0.5 N·m
AC103059

<<A>> • Pre-disassembly check 3. Indicator panel
1. Selector lever knob 4. Shift switch assembly
2. Sleeve 5. Lock cam
6. Selector lever sub assembly
DISASSEMBLY SERVICE POINT INSPECTION

M1231006900218
<<A>> PRE-DISASEMBLY CHECK
Shift switch (up)
A ON
OFF
ON
OFF OFF
1 2 ON
3456
Shift switch
(down)
Shift switch
assembly Select switch
Shift switch AC103390AC
assembly AC103620AC
If the collision energy absorbing mechanism has Switch position Terminal NO.
already operated and the part A in the illustration is Select switch ON 1−4
deformed, replace the selector lever assembly. OFF 1−2
Shift switch (up) ON 3−6
OFF −
Shift switch (down) ON 3−5
OFF −
A/T KEY INTERLOCK AND SHIFT LOCK MECHANISMS

<VEHICLES WITH LHD>
M1232001200507
CAUTION
When removing and installing the shift lock cable unit, be careful not to hit the SRS-ECU.
• Instrument Lower Panel Removal (Refer to GROUP 52A, • Instrument Lower Panel Installation (Refer to GROUP
Instrument Panel Assembly P.52A-2.) 52A, Instrument Panel Assembly P.52A-2.)
• Lower Column Cover Removal (Refer to GROUP 37, • Lower Column Cover Installation (Refer to GROUP 37,
Steering Shaft P.37A-18.) Steering Shaft P.37A-18.)
• Key Interlock and Shift Lock Mechanism Check (Refer to
P.23A-159.)
5
3 5.0 ± 1.0 N·m
N 4 2
6
1
AC202709AI
Shift lock cable unit removal Shift lock cable unit removal
1. Cover 5. Shift lock cable connection (brake
2. Slider pedal side)
3. Key interlock cable connection >>A<< 6. Shift lock cable unit
(steering lock cylinder side)
4. Split pin
INSTALLATION SERVICE POINT 3. Install the shift lock cable unit rod to the selector
>>A<< SHIFT LOCK CABLE UNIT (SELECTOR lever assembly lock cam, and tighten the shift lock
LEVER SIDE) INSTALLATION cable unit installation bolt to the specified torque.
1. Selector lever to P position. Tightening torque: 5.0 ± 1.0 N⋅m
2. Turn the ignition switch to LOCK (OFF) position. 4. Check the selector lever operation.(Refer to
P.23A-158)
Lock cam
Shift lock
cable unit
AC203163AC

<VEHICLES WITH RHD>
M1232001200518
CAUTION
When removing and installing the shift lock cable unit, be careful not to hit it against the SRS-ECU.
• Selector Lever Assembly Removal and Installation (Refer
to P.23A-163.)
• Instrument Lower Panel Removal and Installation (Refer
to GROUP 52A − Instrument Panel P.52A-8.)
• Lower Column Cover Removal and Installation (Refer to
GROUP 37A − Steering Shaft P.37A-18.)
• Key Interlock and Shift Lock Mechanisms Check <after
installation only> (Refer to P.23A-159.)
5.0 ± 1.0 N·m
AC103061 AB

<<A>> >>B<< 1. Key interlock cable connection 2. Shift lock cable connection (brake
(steering lock cylinder side) pedal side)
• Footrest >>A<< 3. Shift lock cable unit
REMOVAL SERVICE POINT 2. After installing the rod of the shift lock cable unit to
<<A>> KEY INTERLOCK CABLE (STEERING the lock cam of the selector lever assembly,
LOCK CYLINDER SIDE) REMOVAL tighten the bolts of the shift lock cable unit to the
Turn the ignition switch to the ACC position and then specified torque.
pull the key interlock cable out from the ignition key Tightening torque: 5.0 ± 1.0 N⋅m
cylinder. 3. Check the operation of the selector lever. (Refer
to P.23A-158.)
>>A<< SHIFT LOCK CABLE UNIT INSTALLATION >>B<< KEY INTERLOCK CABLE (STEERING
1. Shift the selector lever to the P position and turn LOCK CYLINDER SIDE) INSTALLATION
the ignition switch to the LOCK (OFF) position. Turn the ignition switch to the ACC position and then
install the key interlock cable to the ignition key
Lock cam cylinder.
Bolts
Rod
AC103391AC
M1231005700556
CAUTION
*
: Indicates parts which should be temporarily tightened, and then fully tightened after placing the
vehicle on the earth and loading the full weight of the engine on the vehicle body.
• Front Under Cover and Side Under Cover Removal (Refer • Front Under Cover and Side Under Cover Installation
to GROUP 51, Under Cover P.51-19.) (Refer to GROUP 51, Under Cover P.51-19.)
• A/T Fluid Draining (Refer to P.23A-144.) • A/T Fluid Supplying (Refer to P.23A-144.)
• Transfer Oil Draining (Refer to P.23A-147.) • Transfer Oil Supplying (Refer to P.23A-147.)
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-13.) Exhaust Pipe and Main Muffler P.15-13.)
• Propeller Shaft Removal (Refer to GROUP 25 P.25-3.) • Propeller Shaft Installation (Refer to GROUP 25 P.25-3.)
• Air Cleaner Assembly Removal (Refer to GROUP 15 • Air Cleaner Assembly Installation (Refer to GROUP 15
P.15-4.) P.15-4.)
• Battery and Battery Tray Removal. • Battery and Battery Tray Installation.
• Selector Lever Operation Check (Refer to P.23A-158.)
GROUP 33A, On-vehicle Service P.33-6.)
48 ± 6 N·m
12 ± 2 N·m 10
1
3 4
5
2 6
8
9
30 ± 3 N·m
AC309373AB

>>D<< 1. Adjusting nut 7. A/T fluid cooler hose (radiator
>>D<< 2. Transmission control cable side)
3. Inhibitor switch connector 8. A/T fluid cooler hose (A/T fluid
4. A/T control solenoid valve cooler side)
assembly connector • Drive shaft and output shaft
5. Input shaft speed sensor (Refer to GROUP 26, Drive Shaft
connector Assembly P.26-15.)
6. Output shaft speed sensor 9. Starter motor installation bolt
connector <<A>> 10. Transmission upper connecting
bolts
48 ± 6 N·m
18
49 ± 3 N·m
58 ± 7 N·m* 13
83 ± 12 N·m*
12 11
44 ± 10 N·m
19
16 22 ± 4 N·m
17 9.0 ± 1.0 N·m
15 16
14 90 ± 10 N·m
AC309374AB
Removal steps <> DRIVE PLATE BOLTS REMOVAL

>>C<< 11. Transmission stay 1. Turn the crank shaft so that it is positioned to
12. Bell housing cover allow the drive plate bolt to be unscrewed.
<> 13. Torque converter and drive plate 2. Push in the torque converter into the transmission
coupling bolts
side and make a point to ensure that the torque
• Transfer assembly (Refer to
converter does not remain on the engine side.
P.23A-176.)
14. Rear roll stopper bracket
<<C>> 15. Transmission mounting assembly <<C>> TRANSMISSION MOUNT BRACKET
>>B<< 16. Transmission mounting stopper ASSEMBLY REMOVAL
17. Transmission mounting Engine and transmission assembly
<<D>> • Engine assembly supporting
• Support the transmission
• Support the transmission with a
transmission jack Garage jack
18. Transmission lower part coupling
bolts
>>A<< 19. Transmission assembly

AC210384 AB
<<A>> TRANSMISSION UPPER CONNECTING
BOLTS While supporting the engine and transmission
Do not fully unscrew the bolts from the transmission assembly with a garage jack, remove the
assembly. Only loosen the bolts. transmission mount bracket assembly.
<<D>> ENGINE ASSEMBLY SUPPORTING
AC210400AB
AC210400AB
MB991928 Slide bracket (HI)
MB991895 MB991929
MB991527
MB991934
MB991930
MB991932
MB991932
MB991454
MB991454 MB991527 AC210392 AB
AC210388 AB
(2) Set the engine hanger (special tool
1. <Engine hanger (special tool MB991895) is used> MB991928) to the strut mounting nuts and the
(1) Set special tool MB991895 to the strut radiator support upper insulator mounting
mounting nuts and the radiator support upper bolts, which are located in the engine
insulator mounting bolts, which are located in compartment, as shown.
the engine compartment, as shown. NOTE: Adjust the engine hanger balance by
(2) Set special tools MB991454 to hold the sliding the slide bracket (HI).
engine/transmission assembly. (3) Set special tools MB991454 to hold the
engine/transmission assembly.
Front side
Slide
bracket INSTALLATION SERVICE POINTS
(HI) >>A<< TRANSMISSION ASSEMBLY
Joint (90)
(MB991930) INSTALLATION
Joint (50) Foot (Standard)

(MB991929) (MB991932)
Foot (Standard) Approximately
(MB991932) 12.2 mm
AC212277AB
2. <Engine hanger (special tool MB991928) is used>

(1) Assemble the engine hanger (special tool Torque converter
MB991928). Set following parts to the base
hanger.
AC209056AE
• Slide bracket (HI)
• Foot (standard) (MB991932) Engage the torque converter into the transmission
• Joint (90) (MB991930) side securely, and then assemble the transmission
• Joint (50) (MB991929) assembly on the engine.
>>B<< TRANSMISSION MOUNT STOPPER Tightening torque: 44 ± 10 N⋅m

INSTALLATION
>>D<< ADJUSTING NUT/TRANSMISSION
Engine side Transmission CONTROL CABLE INSTALLATION
mount stopper 1. Place the selector lever and manual control lever
Transmission in the N position.
mount bracket
Adjusting nut
AC005916 AB
Install the transmission mount stopper so that the 12 ± 2 N·m

arrow mark points as shown in the illustration.
Manual control lever
>>C<< TRANSMISSION STAY INSTALLATION
AC103395AO
Install the transmission stay as below.
1. Tighten the engine-side bolts to the specified 2. Place the cable stud into the manual control lever
torque. slot and install the nut loosely. Gently push the
Tightening torque: 22 ± 4 N⋅m transmission control cable into the manual control
lever slot until the cable is taut. Tighten the nut to
2. Tighten the transmission-side bolts to the
specified torque.
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
M1231006000204
CAUTION
*
: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.
• Under Cover Removal and Installation
• A/T fluid Draining and Supplying (Refer to GROUP 23A,
On-vehicle Service P.23A-144).
• Transfer Oil Draining and Supplying (Refer to GROUP
23A, On-vehicle Service P.23A-147).
• Drive Shaft, Output Shaft Removal and Installation (Refer
to GROUP 26 P.26-15).
• Propeller Shaft Removal and Installation (Refer to
GROUP 25P.25-3).
10
3 9.0 ± 2.0 N·m

69 ± 10 N·m
8N 7
<LHD>
N 4 30 ± 3 N·m
5 5 69 ± 10 N·m
52 ± 7 N·m*
52 ± 7 N·m*
9.0 ± 2.0 N·m

N 2
1
52 ± 7 N·m*
30 ± 3 N·m
6
69 ± 10 N·m
69 ± 10 N·m
AC309352AB

1. Water return tube assembly 6. Centre member assembly
2. Gasket <<A>> 7. Transfer assembly
3. Water feed tube assembly 8. O-ring
4. Gasket 9. Water return hose
5. Rear roll stopper connection bolt 10. Water feed hose
TRANSFER ASSEMBLY

<<A>> TRANSFER ASSEMBLY REMOVAL After pulling out the transfer assembly, upon
returning the transmission assembly to the
original position be careful not to damage the
Cross member
bush parts of the roll stopper.
Use a tyre lever, etc. to slide the transmission
assembly to the front of the vehicle, create a
clearance between the transmission assembly and
crossmember, and then pull out the transfer
assembly from that clearance.
Engine transmission
assembly
AC103630AD
A/T FLUID COOLER
A/T FLUID COOLER

M1231028600099

• Front Under Cover (LH) Removal and Installation (Refer
to GROUP 51, Under Cover P.51-19.)
• Splash Shield Mounting Clips (LH) Removal and
Installation (Refer to GROUP 51, Front Bumper P.51-3.)
• A/T Fluid Supplying (Refer to P.23A-144.)
12 ± 2 N·m
7
6
7 6
1
3
4
5
2
12 ± 2 N·m AC309337AB

1. Cooler hose assembly 5. A/T fluid cooler
2. A/T fluid cooler and bracket 6. Bush
3. Bracket A 7. Collar
4. Bracket B
25-1
GROUP 25
PROPELLER SHAFT
CONTENTS
GENERAL INFORMATION . . . . . . . . 25-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . 25-2
SERVICE SPECIFICATIONS. . . . . . . 25-2 PROPELLER SHAFT . . . . . . . . . . . . . 25-3

LUBRICANTS . . . . . . . . . . . . . . . . . . 25-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 25-4
DISASSEMBLY AND REASSEMBLY . . . . . 25-5
SEALANT. . . . . . . . . . . . . . . . . . . . . . 25-2
25-2 PROPELLER SHAFT
GENERAL INFORMATION
GENERAL INFORMATION
M1251000100175
For 4WD vehicles, a 3 way split 4-joint type propeller
shaft with centre bearing is used.
M1251000300180

Propeller shaft run-out mm − 0.6
Clearance between snap ring and snap ring groove mm 0.02 − 0.06 −
LUBRICANTS
M1251000400217

Front propeller shaft sleeve yoke Hypoid gear oil SAE 75W-90 or 75W-85W or As required
80W conforming to API GL-4
DOJ assembly Repair kit grease 95 ± 5 g
SEALANT
M1251000500106

Rubber packings for DOJ assembly 3M Stud Locking 4170 or equivalent
SPECIAL TOOLS
M1251000600170

MB990840 Universal joint remover Disassembly and
and installer reassembly of universal
joint
MB990840
MD998801 Bearing remover Removal of centre

bearing assembly
AC106983
PROPELLER SHAFT 25-3
PROPELLER SHAFT
PROPELLER SHAFT
M1251001000223
4
Gear Oil:
3
4 Hypoid gear oil SAE 75W-90 or 75W-85W
or 80W conforming to API GL-4
3
3 3
N2
N 2 1
30 ± 4 N·m 13 ± 2 N·m
5
1 54 ± 5 N·m 30 ± 4 N·m
13 ± 2 N·m
AC203945 AD
Removal steps CAUTION

1. Heat protector Be careful not to bend the joint portion when
2. Self locking nut removing the propeller shaft because this will
3. Insulator damage to the joint boot.
4. Spacer
<<A>> >>A<< 5. Propeller shaft assembly Joint boot
Rag
<<A>> PROPELLER SHAFT ASSEMBLY
REMOVAL
1. Make mating marks on the differential companion
flange and the propeller shaft assembly.
Rear propeller
Joint assembly shaft
AC101255 AD
2. Insert a rag so as to avoid boot damage, and

remove the propeller shaft assembly in a straight
and level manner.
PROPELLER SHAFT
INSTALLATION SERVICE POINT Differential

Propeller shaft
>>A<< PROPELLER SHAFT ASSEMBLY assembly companion flange
INSTALLATION
CAUTION
•
Marking Marking
Oil seal
AC300150AC
2. When installing a new rear propeller shaft

assembly, align the mark on the propeller shaft
tube with the mark at the side of the differential
Transfer AC101431 AC companion flange.
Do not damage the oil seal lips on the transfer
case. INSPECTION
M1251001100167
• Remove oil and grease from the threads of • Check the sleeve yoke and centre yoke for wear,
the mounting bolts and nuts before damage or cracks.
tightening, or they will loosen. • Check the propeller shaft for bends, twisting or
• Be careful not to bend the joint portion when damage.
removing the propeller shaft, because this • Check the universal joint for smooth operation in
will damage the joint boot. all directions.
• Check the centre bearing for smooth movement.
1. If reusing the propeller shaft, align the mating
marks of differential companion flange and PROPELLER SHAFT RUNOUT
propeller shaft assembly to install.
ACX00643AB
Limit: 0.6 mm
PROPELLER SHAFT

M1251001200238
1N 187 ± 29 N·m 8
6N
1N N 2
4 2N
9
7 19 N
N 15
3
5 17 N
3 10 N 14 N
12
18
187 ± 29 N·m 16
11
34 ± 5 N·m
13
20
17 18 15 19 18 15
17 16 17
14 14
2
3
1
DOJ kit DOJ boot kit Universal joint kit
AC203968 AD

<<A>> >>G<< 1. Snap ring <<C>> >>E<< 7. Centre yoke
<> >>F<< 2. Journal bearing <<D>> >>E<< 8. Centre bearing assembly
>>F<< 3. Journal <<D>> 9. Bolt
4. Sleeve yoke >>D<< 10. Self locking nut
5. Front propeller shaft >>D<< 11. Companion flange
>>E<< 6. Self locking nut <<D>> >>D<< 12. Centre bearing assembly
PROPELLER SHAFT
Disassembly steps (Continued)

13. Centre propeller shaft
14. Snap ring
>>C<< 15. Boot band
<<E>> >>B<< 16. DOJ assembly
17. Rubber packing
<<F>> >>A<< 18. DOJ boot
19. Washer
20. Rear propeller shaft
PROPELLER SHAFT
Lubrication and Adhesive Points
Rubber
mount
CAUTION
Do not refill or apply grease excessively.
Otherwise, faulty fitting of bearing caps and
errors in the selection of snap rings may
result.
Repair kit grease: Adhesive: 3M Stud Locking 4170 or

Quantity: 95 ± 5 g equivalent
AC203969 AC
PROPELLER SHAFT

<<A>> SNAP RING REMOVAL <<C>> CENTRE YOKE REMOVAL
Mating marks
Mating marks
ACX00645 AD AC003847AD
Make mating marks on the flange yoke and propeller Make mating marks on the centre yoke and centre
shaft. Then, remove the snap rings. propeller shaft, and then remove the centre yoke.
<> JOURNAL BEARING REMOVAL <<D>>CENTRE BEARING ASSEMBLY/BOLT

REMOVAL
CAUTION
Do not tap the journal bearings to remove them, 1. Make mating marks on the centre propeller shaft,
as this will upset the balance of the propeller DOJ assembly and companion flange, and then
shaft. remove the bolt.
Centre bearing
MB990840 assembly
MD998801
MB990840 AC101273 AD
2. Use special tool bearing remover (MD998801) to

MB990840
remove the centre bearing assembly from the
centre propeller shaft.
MB990840
<<E>>DOJ ASSEMBLY REMOVAL
MB990840 DOJ assembly

ACX00646AC
1. Use special tool universal joint remover and

installer (MB990840) to press in the journal
bearing on one side, and take out the journal DOJ boot
bearing on the opposite side. AC101274 AC
2. Insert special tool into the other side and press

the journal to remove the first journal bearing that 1. Remove the DOJ boot from the DOJ assembly.
was pushed.
PROPELLER SHAFT
>>B<< DOJ ASSEMBLY INSTALLATION
Outer race
Inner
race
Outer race
Inner
race Circlip
Cage
Ball Circlip
AC101275 AC Cage
AC101277AC
2. Make mating marks on the outer race, cage and
inner race, and then remove the circlip, outer race 1. Apply a thin coat of the specified grease to the
and ball. ball grooves of the inner and outer races.
NOTE: Note the positions of the balls so that they Specified grease: Repair kit grease
can be reinstalled in their original positions. 2. Assemble the DOJ assembly as follows:
Cage (1) Assemble the outer race, cage, balls, and
Inner race
inner race with their mating marks aligned.
(2) Install the circlip.
Puller AC101276 AC
3. Remove the inner race with cage from the centre

propeller shaft assembly by using a puller
(commercially available). AC101278 AC
4. Wipe off the grease and clean the outer race, 3. Apply specified grease to the DOJ assembly.
inner race, cage and balls.
Specified grease: Repair kit grease
<<F>> DOJ BOOT REMOVAL Amount to use: 95 ± 5 g
When the DOJ boot is reused, tape the spline part on
the rear propeller shaft and then remove the DOJ
Rubber packing
boot.

>>A<< DOJ BOOT INSTALLATION
1. Install the boot band.
2. Wrap a plastic tape around the spline part on the DOJ assembly
centre propeller shaft and then install the DOJ
boot. AC101279 AF
4. Apply a thin coat of specified adhesive to the

groove side of DOJ assembly (shown by arrows in
the figure) and install the rubber packing.
Specified adhesive: 3M Stud Locking 4170 or
equivalent
5. Set the groove side of DOJ assembly (for
packing) toward the DOJ boot side and install
them.
PROPELLER SHAFT
Socket wrench
>>D<< CENTRE BEARING
ASSEMBLY/COMPANION
FLANGE/SELF-LOCKING NUT INSTALLATION
Centre bearing
assembly Companion flange
Self-locking
AC101280 AC nut
6. Lining up the mating marks on the DOJ assembly

and the centre propeller shaft and using the
socket wrench, install the DOJ assembly to the
AC101283 AD
1. Set the centre bearing assembly in the direction
Bolt shown in the figure and install it to the centre
propeller shaft.
2. Install, lining up the mating marks on the
companion flange and the centre propeller shaft.
3. While tightening the self-locking nut, install the
centre bearing assembly with the companion
flange.
DOJ boot >>E<<CENTRE BEARING ASSEMBLY/CENTRE
AC101281AF
YOKE/SELF-LOCKING NUT INSTALLATION
7. Using the bolt, align the bolt holes of the DOJ boot
and the DOJ assembly and install DOJ boot to the
DOJ assembly. Centre
Dust seal
8. Install the rubber packing of the companion flange yoke Rubber
mount
side in the same manner as described in (4) Self-
above. locking
nut
>>C<< BOOT BAND INSTALLATION
CAUTION
•
AC101284 AD
Mark
1. Set the centre bearing assembly in the direction

shown in the figure and install it to the centre
propeller shaft.
Boot
2. Align the mating marks on the centre yoke and the
Vent plug
3. While tightening the self-locking nut, install the
centre bearing assembly with the centre yoke.
AC107071AB
Clamp the boot by holding down the lever at a

position nearly opposite to the vent groove
provided in the DOJ boot (at arrow marked
position on boot).
• Be sure to remove grease, if present, from
around the vent groove. Grease obstructs the
ventilation air passage.
PROPELLER SHAFT
>>F<< JOURNAL/JOURNAL BEARING 3. Use the special tool to press the opposite side
INSTALLATION journal bearing into the yoke.
CAUTION 4. Align the mating marks on the centre yoke and
rear propeller shaft, and install the propeller shaft
journal bearings in the same manner as described
in (1) and (2) above.
>>G<< SNAP RING INSTALLATION

1. Install a snap ring to one side of the journal.
MB990840
AC101285AC
Do not apply grease excessively. Too much

grease can result in errors in the selection of Snap ring
snap rings.
1. Apply multi-purpose grease to the following
universal joint kit.
ACX00649AE
• Shaft and journal grease cup
• Dust seal lip 2. Use special tool universal joint remover and
• Needle roller bearing installer (MB990840) at the opposite side of the
CAUTION installed snap ring to press in the journal bearing
Be careful when pressing the journal bearings. If toward the snap ring.
they are pressed at an angle, the inside of the CAUTION
journal bearings will be damaged. Always use snap rings of equal thickness on
both sides.
MB990840
Groove for
snap ring
Snap ring
ACX00647AC
ACX00650AC
2. Use special tool universal joint remover and
installer (MB990840) to press the journal bearing 3. Install the snap ring on the opposite side, and
into the centre yoke, sleeve yoke or flange yoke measure the clearance of the snap ring groove
until the snap ring groove is fully visible. with a feeler gauge.
Standard value (A): 0.02 − 0.06 mm
4. If the clearance exceeds the standard value,
MB990840
adjust by changing the thickness of the snap ring.
Thickness mm Identification colour
1.28 −
MB990840 1.31 Yellow
1.34 Blue
ACX00648AC
1.37 Purple
1.40 Brown
NOTES
26-1
GROUP 26
FRONT AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . 26-2 FRONT AXLE HUB ASSEMBLY . . . . 26-9

SERVICE SPECIFICATIONS. . . . . . . 26-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-11
LUBRICANTS . . . . . . . . . . . . . . . . . . 26-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-14
SPECIAL TOOLS. . . . . . . . . . . . . . . . 26-4 DRIVE SHAFT ASSEMBLY . . . . . . . . 26-15

ON-VEHICLE SERVICE. . . . . . . . . . . 26-8 DISASSEMBLY AND REASSEMBLY . . . . . 26-20
WHEEL BEARING AXIAL PLAY CHECK . . 26-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-25
HUB BOLT REPLACEMENT . . . . . . . . . . . 26-8 BJ BOOT (RESIN BOOT) REPLACEMENT 26-26
26-2 FRONT AXLE
GENERAL INFORMATION
GENERAL INFORMATION
M1261000100392
The front axle consists of front hubs, knuckles, wheel • Due to the use of the inner shaft and bracket
bearings and drive shafts, and it has the following assembly, the right and left drive shafts are
features: approximately the same in length. This reduces
• The wheel bearing is a double-row angular noise, vibration and torque steer.<2WD>
contact ball bearing which incorporates the oil • Due to the use of the output shaft, the right and
seals and is highly resistant to a thrust load. left drive shafts are approximately the same in
• The driveshaft incorporates BJ-PTJ type constant length. This reduces noise, vibration and torque
velocity joints with high transmission efficiency for steer.<4WD>
low vibration and noise. • ABS rotor for detecting the wheel speed is
• The dynamic damper has been mounted on the press-fitted to the BJ outer wheel.
left driveshaft <2WD, 4WD> and on the right NOTE: .
driveshaft <4WD> to reduce differential gear • PTJ: Pillow Tripod Joint
noise. • BJ: Birfield Joint
SPECIFICATIONS
Item 2WD 4WD
Wheel bearing Type Double-row angular contact ball bearing
Bearing (OD x ID) mm 80 x 40 80 x 40
Driveshaft Joint type Outer BJ BJ
Inner PTJ PTJ
Length (joint to joint) × LH 383.5 × 24 361 × 22
diameter mm RH 474.5 × 24 455 × 22
CONSTRUCTION DIAGRAM
<2WD>
Strut assembly
PTJ (LH)
Knuckle Drive shaft (LH)

Bracket assembly Drive shaft (RH)
Front hub
Dynamic damper PTJ (RH)

(LH only)
BJ Inner shaft
ABS rotor
Wheel bearing
AC106952 AD
FRONT AXLE 26-3
<4WD> Strut assembly

Output shaft
PTJ (LH)
Knuckle Drive shaft (LH)

Drive shaft (RH)
Front hub
Dynamic damper
(RH)
Dynamic damper
(LH) PTJ (RH)
BJ
ABS rotor
Output shaft
Wheel bearing
AC308113 AB
M1261000300352

Wheel bearing axial play mm − 0.05
Hub starting torque N⋅m − 1.8
Protruding length of stabilizer link mm 9.4 ± 0.4 −
Setting of PTJ boot length mm 2WD 90 ± 3 −
4WD 85 ± 3 −
Opening dimension of the When the BJ boot band 2.9 −
special tool (MB991561) mm (small) is crimped
When the BJ boot band 2.9 −
(large) is crimped
Crimped width of the BJ boot band mm 2.4 − 2.8 −
26-4 FRONT AXLE
LUBRICANTS
LUBRICANTS
M1261000400445

PTJ boot grease Repair kit grease 2WD 215 ± 10 g
4WD 150 ± 10 g
BJ boot grease Repair kit grease 2WD 120 ± 10 g
4WD 85 ± 10 g
Dust seal inner grease Repair kit grease 14 − 20 g
Dust seal outer grease Repair kit grease 8 − 12 g
SPECIAL TOOLS
M1261000600353

MB990767 End yoke holder Fixing of the hub
B990767
MB991618 Hub bolt remover Removal of the hub bolt
MB991618
disconnection
(MB990635 or MB991113)is also used
to disconnect knuckle and tie rod end
AC106827
ball joint.
A MB990241 Axle shaft puller Removal of the drive shaft
A: MB990242 A: Puller shaft
B B: MB990244 B: Puller bar
MB990241AB
MB991354 Puller body
MB991354
FRONT AXLE 26-5
SPECIAL TOOLS

MB991056 or Knuckle arm • Removal of the hub
MB991355 bridge • Removal of the wheel bearing
MB991721 Sliding hammer Removal of the output shaft <4WD>
A A: MB991017 A, B: Front hub • Removal of the hub

B: MB990998 remover and • Provisional holding of the wheel
C: MB991000 installer bearing
B C: Spacer • Measurement of hub starting torque
C • Measurement of wheel bearing axial
AC100320AB
play
NOTE: MB991000, which belongs to
MB990998, should be used as a
spacer.
MB990685 Torque wrench Measurement of hub starting torque
MB990326 Preload socket
MB990326
MB990810 Side bearing • Removal of the centre bearing

puller bracket
• Removal of the wheel bearing inner
race (outside)
MB990810
MB991172 Inner shaft Press-fitting of the inner shaft

installer base
26-6 FRONT AXLE
SPECIAL TOOLS

MB991248 or Inner shaft Removal of the inner shaft
MB998801 remover
MB991248
MB991460 Plug Prevention of transmission fluid drain

and of entry of foreign objects
MB991561 Boot band BJ boot (resin boot) band installation

crimping tool
MB991561
MB990925 Bearing and oil • Removal of the wheel bearing

seal installer set • Removal and installation of the
centre bearing
• Press-fitting of the dust seal outer,
inner
MB990925
MB990890 Rear suspension • Installation of the wheel bearing

bushing base • Press-fitting of the dust seal outer,
inner
MB990890
MB990883 Rear suspension Installation of the wheel bearing

bushing arbor
MB990883
FRONT AXLE 26-7
SPECIAL TOOLS
Tool Type Tool number O D mm
MB990925
A MB990926 39.0
MB990927 45.0
MB990928 49.5
MB990929 51.0
MB990930 54.0
A
Installer adapter MB990931 57.0
MB990932 61.0
C Brass bar MB990933 63.5
MB990934 67.5
B
MB990935 71.5
Bar (snap-in type) MB990936 75.5
MB990937 79.0
B MB990938 −
C MB990939 −
Tool box
ACX02372 AC
26-8 FRONT AXLE
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
M1261000900213
1. Remove the caliper assembly and suspend it with MB991618 MB990767
a wire.
2. Remove the brake disc from the front hub.
AC102439 AC
3. Use the following special tools to remove the hub

bolts.
• End yoke holder (MB990767)
AC102438
• Hub bolt remover (MB991618)
3. Attach a dial gauge as shown in the illustration,

and then measure the axial play while moving the MB990767
hub in the axial direction.
Plain
Limit: 0.05 mm washer
4. If axial play exceeds the limit, disassemble the
front hub assembly and check the parts.
5. Install the brake disc, caliper assembly and
tighten the caliper assembly mounting bolts to the
AC102440AC
specified torque 100 ± 10 N⋅m.
4. Install the plain washer to the new hub bolt, and
HUB BOLT REPLACEMENT install the bolt with a nut.
M1261001000279
1. Remove the caliper assembly and suspend it with 5. Install the brake disc, caliper assembly and
wire so that it does not fall. tighten the caliper assembly mounting bolts to the
2. Remove the brake disc. specified torque 100 ± 10 N⋅m.
FRONT AXLE 26-9
FRONT AXLE HUB ASSEMBLY

M1261001700416
CAUTION
• Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when
removing or installing the drive shaft. Otherwise the ABS rotors will be damaged.
• Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing
work.
• Check the dust cover for cracks or damage by pushing it
with your finger.
N 6
25 ± 5 N·m
7 12 13 10 N
167 ± 9 N·m
1
8
3
245 ± 29 N·m
11
5
4N
39 ± 5 N·m 9
100 ± 10 N·m
108 ± 10 N·m
2
AC107173 AB

1. Front ABS sensor 8. Stabilizer link assembly
<<A>> 2. Caliper assembly 9. Lower arm ball joint connection
3. Brake disc <<C>> 10. Self-locking nut (tie rod end
<> >>B<< 4. Drive shaft nut connection)
>>B<< 5. Washer <<D>> 11. Drive shaft
>>A<< 6. Self-locking nut (stabilizer bar 12. Nut (hub and knuckle to strut
connection) connection)
>>A<< 7. Stabilizer rubber 13. Hub and knuckle
26-10 FRONT AXLE

<<A>> CALIPER ASSEMBLY REMOVAL Bolt
Secure the removed caliper assembly with wire, etc.
Parallel
<> DRIVE SHAFT NUT REMOVAL
CAUTION Knob Correct
Do not apply pressure to wheel bearing by the
vehicle weight to avoid possible damage when
drive shaft nut is loosened.
Wrong AC106821AD
2. Turn the bolt and knob as necessary to make the

jaws of special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the
figure.
MB990767 3. Tighten the bolt with a wrench to disconnect the
tie rod end.
AC102462 AC
Use special tool end yoke holder (MB990767) to fix <<D>> DRIVE SHAFT REMOVAL
the hub and remove the drive shaft nut.
<<C>> SELF-LOCKING NUT (TIE ROD END

CONNECTION) REMOVAL MB990767
CAUTION
• Do not remove the nut from ball joint. Loosen
it and use the special tool to avoid possible MB990244
damage to ball joint threads. (Three)
• Hang the special tool with cord to prevent it MB990242 MB991354
from falling. AC102550 AC
Cord 1. Use the following special tools to push out the

drive shaft from the hub and knuckle.
• Puller shaft (MB990242)
• Puller bar (MB990244)
MB991897
• Puller body (MB991354)
Nut
Bolt
Ball joint AC208247AD
1. Install special tool ball joint remover (MB991897)

Drive shaft
as shown in the figure.
AC102551AC
2. Withdraw the drive shaft from the hub by pulling

the bottom of the hub and knuckle towards you.
3. Hang the drive shaft on the vehicle body with a
rope.
FRONT AXLE 26-11
INSTALLATION SERVICE POINT >>B<< WASHER/ DRIVE SHAFT NUT

>>A<< SELF-LOCKING NUT (STABILIZER BAR INSTALLATION
CONNECTION) INSTALLATION CAUTION
Before securely tightening the drive shaft nuts,
make sure there is no load on the wheel
A bearings. Otherwise the wheel bearings will be
damaged.
Washer
AC107031AB
AC107031
Tighten the self-locking nut so that the protruding

length of the stabilizer link protruding part meets its MB990767
standard value (A).
AC102465AD
Standard value (A): 9.4 ± 0.4 mm
1. Be sure to install the drive shaft washer in the
specified direction.
2. Using special tool end yoke holder (MB990767),
tighten the drive shaft nut to the specified torque.
INSPECTION
M1261001800220
• Check the hub for cracks and spline for wear.
• Check the knuckle for cracks.
• Check for defective bearing.
NOTE: If the meshing of the wheel bearing outer
race and the knuckle, or of the wheel bearing
inner race and the hub, is loose, replace the
bearing or damaged parts.
26-12 FRONT AXLE

M1261001900186
N 1 2
N 4
3
AC101684 AD
Disassembly steps Use the following special tools to pull out the hub
1. Snap ring from the knuckle.
<<A>> 2. Hub • Knuckle arm bridge (MB991056 or MB991355)
3. Dust cover • Front hub remover and Installer (MB991017)
<> 4. Wheel bearing • Spacer (MB991000)
5. Knuckle
Assembly steps
<> WHEEL BEARING REMOVAL
5. Knuckle
>>A<< 4. Wheel bearing Inner race
1. Snap ring (outside)
3. Dust cover
2. Hub
>>B<< • Hub starting torque check
>>C<< • Wheel bearing axial play check

<<A>> HUB REMOVAL Outer oil seal
CAUTION AC102508 AC
When the hub has been removed, always replace

1. Crush the oil seal in two places so that the tabs of
the wheel bearing with a new part because wheel
the special tool will be caught on the wheel
bearing frictional surface will be damaged when
bearing inner race (outside).
removing the hub.
MB991017 MB991056 or
MB991355
Tighten the nut

with the bolt
secured
MB991000
AC100130AB
FRONT AXLE 26-13
CAUTION CAUTION
When removing the inner race (outside) from the Press the outer race when pressing-in the wheel
hub, be careful not to let the hub drop. bearing. Otherwise the wheel bearing will be
damaged.
MB990810
MB990883
MB990890
Inner race
(outside) AC102509 AC
AC102511 AC
2. Remove the wheel bearing inner race (outside)
from the front hub by using special tool side 3. Press-in the bearing by using the following special
bearing puller (MB990810). tools.
• Rear suspension bushing arbor (MB990833)
MB990938 • Rear suspension bushing base (MB990890)
Inner race >>B<< HUB STARTING TORQUE CHECK

(outside) MB990935
MB991017
MB991000
MB991056 or MB991355 AC102510 AC
245 ± 29 N·m
3. Install the inner race (outside) that was removed Tighten the nut
from the hub to the wheel bearing, and then use with the bolt secured
the following special tools to remove the wheel
AC210929AC
bearing.
• Installer bar (MB990938) 1. Tighten the following special tools to the specified
• Installer adapter (MB990935) torque, and then press-in the hub into the knuckle.
• Knuckle arm bridge (MB991056 or MB991355) • Front hub remover and installer (MB991017)
• Spacer (MB991000)
REASSEMBLY SERVICE POINTS 2. Rotate the hub in order to seat the bearing.
>>A<< WHEEL BEARING INSTALLATION
1. Fill the wheel bearing with multipurpose grease. MB990685
2. Apply a thin coating of multipurpose grease to the
knuckle and bearing contact surfaces.
MB990326
AC100136 AB
3. Measure the hub starting torque by using the

following special tools.
• Torque wrench (MB990685)
• Preload socket (MB990326)
Limit: 1.8 N⋅m
26-14 FRONT AXLE
4. The starting torque must be within the limit and 1. Measure to determine whether the wheel bearing
the hub rotation must be smooth. axial play is within the limit or not by using the
following special tools.
>>C<< WHEEL BEARING AXIAL PLAY CHECK • Front hub remover and installer (MB991017)
MB991000
Limit: 0.05 mm
2. If the play is not within the limit range while the nut
245 ± 29 N·m is tightened to 245 ± 29 N⋅m, the bearing, hub
Tighten the nut and/or knuckle have probably not been installed
with the bolt
secured correctly. Replace the bearing and re-install.
INSPECTION
MB991017 M1261002000067
• Check the front hub and brake disc mounting
AC100137AB
surfaces for galling and contamination.
• Check the knuckle inner surface for galling and
cracks.
FRONT AXLE 26-15
DRIVE SHAFT ASSEMBLY

M1261003500474
CAUTION
• Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing
work.
Pre-installation Operation Post-installation Operation

• Transmission Fluid Draining (Refer to GROUP • Front Exhaust Pipe Installation (Refer to
22A and 23A, On-vehicle Service − GROUP 15, Exhaust Pipe and Muffler
Transmission Oil Replacement P.22A-8, P.15-13).
P.23A-144). • Check the Ball Joint Dust Cover for cracks or
• Transfer Oil Draining <4WD> damage by pushing it with your finger.
(Refer to GROUP 22A and 23A, On-vehicle • Transfer Oil Filling<4WD> (Refer to GROUP
Service − Transfer Oil Replacement P.22A-8, 22A and 23A, On-vehicle Service − Transfer Oil
P.23A-147). Replacement P.22A-8, P.23A-147).
• Front Exhaust Pipe Removal (Refer to GROUP • Transmission Fluid Filling (Refer to GROUP
15, Exhaust Pipe and Muffler P.15-13). 22A and 23A, On-vehicle Service −
Transmission Oil Replacement P.22A-8,
P.23A-144).
<2WD>
N 14 N6
<LH> 7 25 ± 5 N·m
11
41 ± 4 N·m
5
10 N
4
<RH> 3
7
2
8 1N
12
9
245 ± 29 N·m
39 ± 5 N·m 108 ± 10 N·m
AC107141AB
26-16 FRONT AXLE
<4WD>
6N
N 14 5 25 ± 5 N·m
4
7
10 N
3
13
N 14
11 2
1N
8
9
245 ± 29 N·m
39 ± 5 N·m
108 ± 10 N·m
AC107142 AB
Removal steps REMOVAL SERVICE POINTS

<<A>> >>C<< 1. Drive shaft nut <<A>> DRIVE SHAFT NUT REMOVAL
>>C<< 2. Washer
3. Front ABS sensor CAUTION
4. Front ABS sensor bracket Do not apply pressure to the wheel bearing by
5. Brake hose bracket the vehicle weight to avoid possible damage
>>B<< 6. Self-locking nut when the drive shaft nut is loosened.
7. Stabilizer rubber
8. Stabilizer link assembly
9. Lower arm ball joint connection
<> 10. Self-locking nut (tie rod end
connection)
<<C>> >>A<< 11. Drive shaft
<<C>> >>A<< 12. Drive shaft and inner shaft
assembly <2WD-RH>
<<D>> >>A<< 13. Output shaft <4WD>
14. Circlip MB990767
AC102462 AC
Use special tool end yoke holder (MB990767) to fix

the hub and remove the drive shaft nut.
FRONT AXLE 26-17
<> SELF-LOCKING NUT (TIE ROD END <<C>> DRIVE SHAFT/DRIVE SHAFT AND INNER
CONNECTION) REMOVAL SHAFT ASSEMBLY <2WD-RH> REMOVAL
CAUTION
it and use special tool to avoid possible
MB990767
damage to ball joint threads.
• Hang special tool with cord to prevent it from
falling.
MB990244
Cord
(Three)
MB990242 MB991354
AC102550 AC
Nut MB991897 1. Use the following special tools to push out the
drive shaft or the drive shaft and inner shaft
assembly from the hub.
• Puller shaft (MB990242)
Bolt • Puller bar (MB990244)
• Puller body (MB991354)
Bolt
Parallel Drive shaft
Knob Correct
AC102551AC
Wrong AC106821AD 2. Remove the drive shaft from the hub by pulling
the bottom of the brake disc towards you.
hand and confirm that the jaws are still parallel. CAUTION
NOTE: When adjusting the jaws in parallel, make • Do not pull on the drive shaft; doing so will
sure the knob is in the position shown in the damage the PTJ; be sure to use the pry bar.
figure. • When pulling the drive shaft out from the
transmission, be careful that the spline part of
3. Tighten the bolt with a wrench to disconnect the
the drive shaft does not damage the oil seal.
tie rod end.
Transmission
PTJ assembly
Pry bar
AC100141AF
26-18 FRONT AXLE
3. Insert a pry bar between the transmission case

and the drive shaft, and then pry and remove the <<D>> OUTPUT SHAFT <4WD> REMOVAL
drive shaft from the transmission. CAUTION
When pulling the output shaft out from the
Bracket assembly transmission, be careful that the spline part of
the output shaft does not damage the oil seal.
MB991721
AC102553 AC
4. If the inner shaft is hard to remove from the Output shaft

transmission, strike the bracket assembly lightly
AC102556 AC
with a plastic hammer and remove the inner shaft.
Use special tool sliding hammer (MB991721) to
remove the output shaft.

>>A<< OUTPUT SHAFT <4WD>/DRIVE
SHAFT/DRIVE SHAFT AND INNER SHAFT
ASSEMBLY <2WD-RH> INSTALLATION
CAUTION
MB991460 When installing the output shaft, the drive shaft
AC102554 AC or the drive shaft and inner shaft assembly, be
careful that the spline part of the output shaft, the
5. Use special tool plug (MB991460) to prevent the drive shaft or the drive shaft and inner shaft
entry of foreign material into the transmission assembly do not damage the oil seal.
case.
CAUTION >>B<< SELF-LOCKING NUT INSTALLATION
A
MB991000
MB991017
AC102555 AC AC107031AB
AC107031
Do not apply pressure to the wheel bearing by Tighten the self-locking nut so that the protruding
the vehicle weight to avoid possible damage length of the stabilizer link protruding part meets its
when the drive shaft is removed. If, however, standard value (A).
vehicle weight must be applied to the bearing in Standard value (A): 9.4 ± 0.4 mm
moving the vehicle, temporarily secure the wheel
bearing by using the following special tools.
• Front hub remover and installer (MB991017)
FRONT AXLE 26-19
>>C<< WASHER/DRIVE SHAFT NUT 1. Be sure to install the drive shaft washer in the
INSTALLATION specified direction.
CAUTION
Washer Before securely tightening the drive shaft nuts,
bearings. Otherwise the wheel bearing will be
damaged.
2. Using special tool end yoke holder (MB990767),
tighten the drive shaft nut to the specified torque.
MB990767 Tightening torque: 245 ± 29 N⋅m
AC102465AD
26-20 FRONT AXLE

M1261003700531
CAUTION
• Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly
and reassembly.
• Never disassemble the BJ assembly except when replacing the BJ boot.
18
12 8 20
10 21
9 19
2 N 1N
15
14 <2WD-RH>
13 N
4
Bearing dust seal repair kit
3
12 N
12 <2WD-LH>
8 17
16
<4WD> 6
8N 5
4 12 N 11 6
10
4 9N
11 12 N 7
10
9
Bracket assembly repair kit
20 21 Grease
2 1 2 1 15 for PTJ Grease
15 19
2 1 for BJ
14
13
13 4
12
12 16 13 12
PTJ boot repair kit PTJ repair kit BJ boot repair kit
AC101959 AD

>>G<< 1. PTJ boot band (large) >>D<< 9. Dust seal inner <2WD-RH>
>>G<< 2. PTJ boot band (small) <<C>> >>C<< 10. Centre bearing <2WD-RH>
3. PTJ case and inner shaft assembly 11. Centre bearing bracket <2WD-RH>
<2WD-RH> 12. Circlip
<<A>> >>F<< 4. PTJ case 13. Snap ring
<> >>E<< 5. Inner shaft <2WD-RH> <<A>> >>B<< 14. Spider assembly
6. Dust cover <2WD-RH> <<D>> >>A<< 15. PTJ boot
7. Bracket assembly <2WD-RH> >>A<< 16. Damper band
>>D<< 8. Dust sear outer <2WD-RH> >>A<< 17. Dynamic damper
FRONT AXLE 26-21
Disassembly steps (Continued) NOTE: .

18. BJ assembly • PTJ: Pillow Tripod Joint
19. BJ boot band (small) • BJ: Birfield Joint
20. BJ boot band (large)
21. BJ boot
26-22 FRONT AXLE
LUBRICATION POINTS
Grease: repair kit grease Grease: repair kit grease

Amount used: Amount used:
<2WD>: 120 ± 10 g <2WD>: 215 ± 10 g
<4WD>: 85 ± 10 g <4WD>: 150 ± 10 g Grease: repair kit grease
Amount used:
CAUTION CAUTION Dust seal inner: 14 - 20 g
Dust seal outer: 8 - 12 g
The drive shaft joint uses special The drive shaft joint uses special
grease. Do not mix old and new or grease. Do not mix old and new or
different types of grease. different types of grease.
AC107123 AF
FRONT AXLE 26-23
DISASSEMBLY SERVICE POINTS <<C>> CENTRE BEARING <2WD-RH> REMOVAL

<<A>> PTJ CASE/SPIDER ASSEMBLY REMOVAL
MB990938
CAUTION MB990930
Do not disassemble the spider assembly.
1. Wipe off grease from the spider assembly and the
inside of the PTJ case.
2. Always clean the spider assembly when the
grease contains water or foreign material.
Centre bearing bracket
<> INNER SHAFT <2WD-RH> REMOVAL AC102652 AD
Use the following special tools to remove the centre

Bar
bearing from the centre bearing bracket.
MB991248 • Bar (MB990938)
or • Installer adapter (MB990930)
PTJ case MD998801
<<D>> PTJ BOOT REMOVAL
1. Wipe off grease from the shaft spline.
2. When reusing the PTJ boot, wrap plastic tape
around the shaft spline to avoid damaging the
boot.

Bar
>>A<< DYNAMIC DAMPER/DAMPER BAND/PTJ
BOOT INSTALLATION
PTJ case CAUTION
There should be no grease adhered to the rubber
part of the dynamic damper.
MB991248
or
MD998801 L
AC102878 AD
1. Use special tool inner shaft remover (MB991248

or MD998801) to remove the inner shaft assembly
from the PTJ case.
MB990810
AC101695AC
1. Install the dynamic damper in the position (L)

shown in the figure .
L: 237 ± 3 mm <2WD>
L: 231 ± 3 mm <4WD-LH>, 222 ± 3 mm
<4WD-RH>
AC101694 AC 2. Secure the damper bands.
2. Use special tool side bearing puller (MB990810) 3. Wrap plastic tape around the shaft spline, and
to remove the centre bearing bracket from the then install the PTJ boot band (small) and PTJ
inner shaft. boot.
26-24 FRONT AXLE
>>B<< SPIDER ASSEMBLY INSTALLATION Specified grease: Repair kit grease

CAUTION Amount used (Dust seal inner): 14 − 20 g
• The drive shaft joint use special grease. Do Amount used (Dust seal outer): 8 − 12 g
not mix old and new or different types of
grease.
MB990890
• If the spider assembly has been cleaned, take
special care to apply the specified grease.
1. Apply the specified grease furnished in the repair Dust seal
kit to the spider assembly between the spider axle inner
and the roller.
AC101696 AC
Chamfered
MB990938
side
MB990934
Dust seal
outer
MB990890
AC102654AC
2. Install the spider assembly to the shaft from the AC101697AC

direction of the spline chamfered side.
2. Use the following special tools to press the dust
>>C<< CENTRE BEARING <2WD-RH> seals into the centre bearing bracket until they are
INSTALLATION
flush with each other.
• Rear suspension bushing base (MB990890)
MB990938
• Bar (MB990938)
MB990932 • Installer adapter (MB990934)
3. Apply repair kit grease to the lip of each dust seal.
>>E<< INNER SHAFT <2WD-RH> INSTALLATION
Centre bearing bracket Inner shaft

AC102655 AD
Use the following special tools to press-fit the centre

bearing into the centre bearing bracket.
• Bar (MB990938)
MB991172
>>D<< DUST SEAL INNER <2WD-RH> /DUST
AC101698 AC
SEAL OUTER <2WD-RH> INSTALLATION
CAUTION 1. Use special tool inner shaft installer base
When applying grease, make sure that it does not (MB991172) to hold the centre bearing inner race,
adhere to anything outside the lip. and then press-in the inner shaft.
1. Apply the specified grease to the rear surface of
all dust seals.
FRONT AXLE 26-25
>>G<< PTJ BOOT BAND (SMALL)/PTJ BOOT

BAND (LARGE) INSTALLATION
Inner shaft
PTJ case
AC101699 AD
A
2. Apply repair kit grease to the inner shaft spline, AC102657AC

then press fit it into the PTJ case.
Set the PTJ boot bands at the specified distance in
NOTE: When press-fitting the inner shaft into the
order to adjust the amount of air inside the PTJ boot,
PTJ case, apply a thin coat of repair kit grease to
and then tighten the PTJ boot band (small), PTJ boot
the dust seal outer lip part and the outside edge of
band (large) securely.
the PTJ axial part.
Standard value (A):
<2WD>: 90 ± 3 mm
>>F<< PTJ CASE INSTALLATION
<4WD>: 85 ± 3 mm
CAUTION
The drive shaft joint use special grease. Do not INSPECTION
mix old and new or different types of grease. M1261003800129
• Check the drive shaft for damage, bending or
corrosion.
• Check the inner shaft for damage, bending or
corrosion.
• Check the output shaft for damage, bending or
corrosion.
• Check the drive shaft spline part for wear or
damage.
• Check the inner shaft spline part for wear or
damage.
AC102656 AC • Check the output shaft spline part for wear or
After applying the specified grease to the PTJ case, damage.
insert the drive shaft and apply grease one more • Check the spider assembly for roller rotation,
time. wear or corrosion.
Specified grease: Repair kit grease • Check the groove inside PTJ case for wear or
Amount to use <2WD>: 215 ± 10 g corrosion.
Amount to use <4WD>: 150 ± 10 g • Check the dynamic damper for damage or
cracking.
NOTE: The grease in the repair kit should be divided
• Check the boots for deterioration, damage or
in half for use, respectively, at the joint and inside the
cracking.
boot.
• Check the centre bearing for seizure,
discolouration or roughness of rolling surface.
• Check the dust cover for damage or
deterioration.
26-26 FRONT AXLE
BJ BOOT (RESIN BOOT) REPLACEMENT NOTE: The adjusting bolt should not be turned
M1261005200338 more than once.
Boot
Boot band
(small)
AC102658 Projection AC102661AC
1. Remove the boot bands (large and small).

6. Position the BJ boot band (small) so that there is
NOTE: The boot bands cannot be re-used. even clearance at either end (A and B).
2. Remove the BJ boot. CAUTION
3. Wrap a plastic tape around the shaft spline, and • Secure the drive shaft in an upright position
assemble the boot band and BJ boot. and clamp part of the boot band to be crimped
securely in the jaws of special tool.
• Crimp the boot band until special tool
touches the stopper.
AC102659
4. Align the centre groove on the BJ boot small end

with the shaft groove. MB991561
AC102663 AC
MB991561
7. Use the special tool to crimp the boot band
Stopper (small).
W
C
Adjusting bolt
AC102660 AC
5. Turn the adjusting bolt on special tool boot band

crimping tool (MB991561) so that the size of the
AC102662 AD
opening (W) is at the standard value.
Standard value (W): 2.9 mm 8. Check that the crimping amount (C) of the boot
• <If it is larger than 2.9 mm> Tighten the band is at the standard value.
adjusting bolt. Standard value (C): 2.4 − 2.8 mm
• <If it is smaller than 2.9 mm> Loosen the <If the crimping amount is larger than 2.8 mm
adjusting bolt. >
NOTE: The value of W will change by Readjust the value of (W) in step 5 according to
approximately 0.7 mm for each turn of the the following formula, and then repeat the
adjusting bolt. operation in step 7.
FRONT AXLE 26-27
W = 5.5 mm − C
Projection
Example: If C = 2.9 mm, then W = 2.6 mm.
<If the crimping amount is smaller than 2.4
mm > D
Remove the BJ boot band, readjust the value of
(W) in step 5 according to the following Boot band
(large)
formula, and then repeat the operations in
steps 6 and 7 using a new BJ boot band.
Boot E
W = 5.5 mm − C
Example: If C = 2.3 mm, then W = 3.2 mm. AC102665AC
9. Check that the boot band is not sticking out past
the place where it has been installed. If the boot 13.Position the BJ boot band (large) so that there is
band is sticking out, remove it and then repeat even clearance at either end (D and E).
steps 6 to 8, using a new boot band. 14.Use the special tool to crimp the BJ boot band
(large) in the same way as in step 7.
CAUTION
The drive shaft joint uses special grease. Do not
mix old and new or different types of grease.
10.Fill the inside of the boot with the specified
amount of the specified grease.
Amount to use <2WD>: 120 ± 10 g
Amount to use <4WD>: 85 ± 10 g
F
AC102666 AD
15.Check that the crimping amount (F) of the boot

band is at the standard value.
Standard value (F): 2.4 − 2.8 mm
<If the crimping amount is larger than 2.8 mm
>
Readjust the value of (W) in step 12 according
AC102664 AC
to the following formula, and then repeat the
operation in step 14.
11.Align the centre groove on the BJ boot big end W = 5.8 mm − F
with the BJ case groove. Example: If F = 2.9 mm, then W = 2.9 mm.
12.Follow the same procedure as in step 5 to adjust <If the crimping amount is smaller than 2.4
the size of the opening (W) on the special tool so mm >
that it is at the standard value. Remove the BJ boot band, readjust the value of
(W) in step 12 according to the following
Standard value (W): 2.9 mm
formula, and then repeat the operations in
steps 13 and 14 using a new BJ boot band.
W = 5.8 mm − F
Example: If F = 2.3 mm, then W = 3.5 mm.
16.Check that the boot band is not sticking out past
the place where it has been installed. If the boot
band is sticking out, remove it and then repeat
steps 13 to 15, using a new boot band.
NOTES
27A-1
GROUP 27A
REAR AXLE <2WD>

CONTENTS
GENERAL INFORMATION . . . . . . . . 27A-2 ON-VEHICLE SERVICE . . . . . . . . . . . 27A-4

WHEEL BEARING AXIAL PLAY CHECK . . 27A-4
SERVICE SPECIFICATIONS. . . . . . . 27A-2 REAR HUB ROTARY-SLIDING RESISTANCE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27A-4
SEALANT. . . . . . . . . . . . . . . . . . . . . . 27A-2 HUB BOLT REPLACEMENT. . . . . . . . . . . . 27A-4
SPECIAL TOOLS. . . . . . . . . . . . . . . . 27A-3 REAR AXLE HUB ASSEMBLY . . . . . 27A-5

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27A-6
27A-2 REAR AXLE <2WD>
GENERAL INFORMATION
GENERAL INFORMATION
M1271000100348
The rear axle has the following features: • ABS rotor for detecting the wheel speeds is
• The wheel bearing is a unit ball bearing press-fitted to the rear hub in vehicles with ABS.
(double-row angular contact ball bearing) which
incorporates the oil seals and is highly resistant
to a thrust load.
Oil seal
Rear hub
Trailing arm spindle
Wheel bearing
ABS rotor
AC300617AB
M1271000300427
Item Limit
Wheel bearing axial play mm 0.05
Rear hub rotary-sliding resistance N 19
SEALANT
M1271000500249

Hub cap 3M ATD Part No.8663 or equivalent Semi-drying sealant
REAR AXLE <2WD> 27A-3
SPECIAL TOOLS
SPECIAL TOOLS
M1271000600439

MB990767 End yoke holder Hub fixing
B990767
MB991618 Hub bolt remover Hub bolt removal
MB991618
MD998801 Remover Removal of ABS rotor
MD998812 Installer cap
MD998813 Installer 100
MD998815 Installer adapter

ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK 3. Wind a rope around the hub bolt and turn the hub
M1271000900377 by pulling at a 90° angle with a spring balance.
1. Remove the caliper assembly, and suspend the Measure to determine whether or not the
caliper assembly with a wire and remove the rotary-sliding resistance of the rear hub is at the
brake disc. limit value.
Limit: 19 N
4. If limit value is exceeded, loosen the self-locking
nut and then tighten it to the specified torque and
check the rear hub rotary sliding resistance again.
5. Replace the rear hub assembly if an adjustment
cannot be made to within the limit.
AC206092AC HUB BOLT REPLACEMENT

M1271001000214
2. Check the bearing's axial play. Place a dial gauge 1. Remove the caliper assembly, and suspend the
against the hub surface; then move the hub in the caliper assembly with a wire and remove the
axial direction and check whether or not there is brake disc.
axial play.
Limit: 0.05 mm
3. If the play exceeds the limit, the self-locking nut MB991618
should be tightened to the specified torque and
check the axial play again.
4. Replace the rear hub assembly if an adjustment
cannot be made to within the limit. MB990767
AC301662 AB
REAR HUB ROTARY-SLIDING
RESISTANCE CHECK 2. Use the following special tools to remove the hub
M1271001100222 bolts.
1. Remove the caliper assembly, and suspend the • End yoke holder (MB990767)
caliper assembly with a wire and remove the • Hub bolt remover (MB991618)
brake disc. NOTE: To retain a space for removing the hub
2. Turn the hub a few times to seat the bearing. bolts, remove them near the retainer spring
mounting position.
Plain
washer
AC201814 MB990767
AC301663 AB
3. Install the plain washer to the new hub bolt, and

install the bolt with a nut.
REAR AXLE <2WD> 27A-5
REAR AXLE HUB ASSEMBLY

M1271002000347
CAUTION
• Care must be taken not to scratch or damage the teeth of the ABS rotor. The ABS rotor must never
be dropped. If the teeth of the ABS rotor are chipped, resulting in a deformation of the ABS rotor,
it will not be able to accurately detect the wheel rotation speed, and the system will not function
normally.
• The rear hub assembly should not be dismantled. When removing the rear hub assembly, the
wheel bearing inner race may be left at the spindle side. In this case, always replace the rear hub
assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play.
60 ± 5 N·m
6
2
175 ± 25 N·m
7 4N
3
3 5
Semi-drying sealant:
3M ATD Part No. 8663 or
equivalent
AC301185 AB
Removal steps <> SELF-LOCKING NUT REMOVAL

<<A>> 1. Caliper assembly CAUTION
2. Brake disc
3. Hub cap
<> >>B<< 4. Self-locking nut
5. Rear hub assembly
<<C>> >>A<< 6. ABS rotor
7. Hub bolt

<<A>> CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, etc.
AC301112 AB
Do not apply the vehicle weight to the wheel

bearing while loosening the self-locking nut, or
the wheel bearing will be damaged.
<<C>> ABS ROTOR REMOVAL INSTALLATION SERVICE POINTS

>>A<< ABS ROTOR INSTALLATION
CAUTION
MD998812
When installing, take care not to deform the ABS
rotor.
MD998813 Iron piece

ABS rotor
ABS rotor Rear hub

assembly
MD998815
MD998801
Iron piece
AC102209AC
Press-fit the ABS rotor to the rear hub assembly.
>>B<< SELF-LOCKING NUT INSTALLATION

Rear hub assembly CAUTION
AC210936 AC
Use the following special tools to press out ABS rotor

175 ± 25 N·m
from the rear hub assembly.
• Remover (MD998801)
• Installer100 (MD998813)
AC301113 AB
Before securely tightening the self-locking nuts,

bearings. Otherwise the wheel bearing will be
damaged.
Tighten the self-locking nut to the specified torque.
INSPECTION
M1271002100225
• Check the rear hub assembly for crack or
damage.
• Check the oil seal of the rear hub assembly for
crack or damage.
• Check the ABS rotor for chipped teeth.
27B-1
GROUP 27B
REAR AXLE <4WD>

CONTENTS
GENERAL INFORMATION . . . . . . . . 27B-2 REAR AXLE HUB ASSEMBLY . . . . . 27B-8

SERVICE SPECIFICATIONS. . . . . . . 27B-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27B-9
LUBRICANTS . . . . . . . . . . . . . . . . . . 27B-3 DRIVE SHAFT ASSEMBLY . . . . . . . . 27B-10

SEALANT AND ADHESIVE. . . . . . . . 27B-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27B-12
SPECIAL TOOLS. . . . . . . . . . . . . . . . 27B-4
DIFFERENTIAL CARRIER
ON-VEHICLE SERVICE. . . . . . . . . . . 27B-7 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 27B-16
REAR AXLE TOTAL BACKLASH CHECK . 27B-7 REMOVAL AND INSTALLATION . . . . . . . . 27B-16
GEAR OIL LEVEL CHECK . . . . . . . . . . . . . 27B-7 DIFFERENTIAL SUPPORT MEMBER
WHEEL BEARING AXIAL PLAY CHECK . . 27B-7 BUSHING REPLACEMENT . . . . . . . . . . . . 27B-17
DIFFERENTIAL CARRIER OIL SEAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27B-19
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 27B-8 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27B-25
27B-2 REAR AXLE <4WD>
GENERAL INFORMATION
GENERAL INFORMATION
M1271000100359
The rear axle has the following features. • ABS rotor for detecting the wheel speed are
• The wheel bearing is a double-row angular press-fitted to the BJ outer wheel.
contact ball bearing which incorporates the oil NOTE: .
seals and is highly resistant to a thrust load. • TJ: Tripod Joint
• The drive shaft has BJ-TJ constant velocity joints. • BJ: Birfield Joint
• A smaller BJ side boot is used.
SPECIFICATIONS
Item Specification
Wheel bearing Type Double-row angular contact ball
bearing
Bearing (OD x ID) mm 70 × 40
Drive shaft Type Outer BJ
Inner TJ
Length (joint to joint) × LH 481 × 22
outer diameter mm RH 571 × 22
Differential carrier
TJ
BJ Rear hub
Drive shaft
ABS rotor
AC300622 AB
REAR AXLE <4WD> 27B-3
M1271000300535

Rear axle total backlash mm − 5
Wheel bearing rotation starting torque N⋅m − 1.0
Wheel bearing axial play mm − 0.05
TJ boot assembly dimension mm 80 ± 3 −
Drive gear backlash mm 0.11 − 0.16 −
Drive gear runout mm − 0.05
Differential gear backlash mm 0 − 0.076 0.2
Drive pinion Without oil seal 0.9 − 1.2 −
turning torque
With Companion flange (oil seal 1.0 − 1.3 −
N⋅m oil seal contacting area) with anti-rust
agent
Companion flange (oil seal 0.5 − 0.6 −
contacting area) with gear oil
applied
LUBRICANTS
M1271000400253

Rear differential gear oil Hypoid gear oil API classification GL-5 or higher 0.55 L
Above 10°C: SAE 90
Below 10°C: SAE 80W
Drive shaft BJ joint Repair kit grease 75 ± 10 g
Drive shaft TJ joint Repair kit grease 110 ± 10 g
SEALANT AND ADHESIVE

M1271000500227
Item Specified sealant and adhesive Remark

Differential cover 3M ATD Part No. 8661 or equivalent Semi-drying sealant
Drive gear and differential case 3M Stud Locking 4170 or equivalent Anaerobic sealant
mounting part
SPECIAL TOOLS
SPECIAL TOOLS
M1271000600440

MB991115 Oil seal installer Press-fitting of the differential
carrier oil seal
(Use together with MB990938)
MB990767 End yoke holder Rear axle hub fixing
B990767
A MB990241 Axle shaft puller Removal of the drive shaft

A: MB990242 A: Puller shaft
B
B: MB990244 B: Puller bar
MB990241AB
MB991354 Puller body
MB991354
A A: MB991017 A, B: Front hub • Provisional holding of the

B: MB990998 remover and wheel bearing
C: MB991000 installer • Measurement of wheel
B C: Spacer bearing rotation starting
C
AC100320AB torque
• Measurement of wheel
bearing end play
NOTE: MB991000, which
belongs to MB990998,
should be used as a spacer.
MB990883 Rear suspension Removal and installation of the
bushing arbor differential support member
bushing
MB990883
MB990884 Mount bushing

arbor
SPECIAL TOOLS

MB990909 Working base Supporting of the differential
carrier
MB990909
MB991116 Working base

adapter
MB990810 Side bearing puller • Removal of the side bearing

inner race
• Removal of the companion
flange
MB990810
MB990850 End yoke holder Companion flange fixing
MB990850
MB990339 Bearing puller Removal of drive pinion rear

bearing inner race
MB990339
MB990374 Pinion bearing

remover
MB990835 Drive pinion setting Adjustment of the drive pinion

A: MB990836 gauge set height
B: MB990392 A: Drive pinion
gauge assembly
B
A B: Cylinder gauge
MB990326 Preload socket • Measurement of the wheel

bearing rotation starting
torque
• Measurement of the drive
MB990326 pinion turning torque
MB990685 Torque wrench

SPECIAL TOOLS

MB990728 Bearing installer Press-fitting of the drive pinion
rear bearing inner race
MB990728
MB990031 or MB990699 Oil seal installer Press-fitting of the drive pinion

oil seal
MB990031
MB990925 Bearing and oil • Press-fitting of differential

A A: MB990926 − MB990937 seal installer set carrier oil seal
C B: MB990938 A: Installer adapter (Use together with
C: MB990939 B: Bar MB991115)
B MB990925 C: Brass bar • Inspection of final drive gear
tooth contact
• Removal and installation of
drive pinion front/rear bearing
outer race
For details of each installer,
refer to GROUP 26 − Special
ToolsP.26-4.
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK GEAR OIL LEVEL CHECK
M1271001200218 M1272001200211
1. Park the vehicle on a flat, level surface.
2. Move the transmission gearshift lever to the
neutral position. Apply the parking brake and jack
Gear oil
up the vehicle.
Mating marks
Upper
limit
Lower
limit 8 mm
AC102739 AD
Check that gear oil level is not 8 mm below the

bottom of filler plug hole.
Specified gear oil:
AC301509AB Hypoid gear oil API classification GL-5 or
higher
3. Turn the propeller shaft clockwise as far as it will
Above 10°C: SAE 90
go. Make the mating marks on the companion
Below 10°C: SAE 80W
flange and on the differential carrier.
WHEEL BEARING AXIAL PLAY CHECK
M1271000900388
1. Remove the caliper assembly, and suspend the
caliper assembly with a wire and remove the
brake disc.
AC301510AB
4. Turn the propeller shaft counterclockwise as far

as it will go, and measure the amount of distance
between the mating marks.
Limit: 5 mm AC206092AC
5. If the backlash exceeds the limit value, remove
2. Fit the dial gauge as shown in the diagram and
the differential carrier assembly and check the
move the hub in the axial direction to measure the
following.
play.
• Final drive gear backlash (Refer toP.27B-19.)
• Differential gear backlash (Refer to P.27B-19.) Limit: 0.05 mm
3. If the play exceeds the limit, the drive shaft nut
should be tightened to the specified torque and
check the axial play again.
4. Replace the wheel bearing if adjustment cannot
be made to within the limit. (Refer to GROUP
34−Trailing ArmP.34-13.)
DIFFERENTIAL CARRIER OIL SEAL 3. Use the following special tools to press-fit a new
REPLACEMENT oil seal.
M1272001300111 • Installer bar (MB990938)
1. Remove the drive shaft from the differential • Oil seal installer (MB991115)
carrier. (Refer to P.27B-10). 4. Apply multi-purpose grease to the oil seal lip and
2. Remove the differential carrier oil seal. drive shaft oil seal seating area.
5. Replace the drive shaft circlip with a new one, and
install the drive shaft to the differential carrier.
MB990938 (Refer to P.27B-10).
MB991115
AC102740 AC

M1271002000358
AC301904 AB
Removal steps
1. Rear hub assembly (Refer to GROUP
34, Trailing arm assembly P.34-13).
2. Hub bolt
INSPECTION 3. Measure the wheel bearing rotation starting

M1271002100236 torque by using the following special tools.
WHEEL BEARING ROTATION STARTING • Preload socket (MB990326)
TORQUE AND AXIAL PLAY CHECK • Torque wrench (MB990685)
Limit: 1.0 N⋅m
4. The rotation starting torque must be within the
245 ± 29 N·m limit and wheel bearing must rotate smoothly.
MB991017
MB991000
Wheel bearing
AC102720 AC
1. Tighten the following special tools to the specified

torque.
• Spacer (MB991000) AC301906

5. Measure to determine whether the wheel bearing
2. Rotate the rear hub in order to seat the bearing. axial play is within the specified limit or not.
Limit: 0.05 mm
6. If the play is not within the limit range while the nut
is tightened to 245 ± 29 N⋅m, the bearing, trailing
MB990685
arm and/or rear hub have probably not been
installed correctly. Replace the bearing and
re-install.
MB990326
AC301905AB

M1271003300147
CAUTION
• Be careful not to strike the pole piece at the tip of the rear ABS sensor with tools during servicing
work.
Pre-installation Operation Post-installation Operation

• Differential Gear Oil Draining (Refer to • Differential Gear Oil Filling (Refer to P.27B-7).
P.27B-7). • Rear Wheel Alignment Check and Adjustment
(Refer to GROUP 34, On-vehicle Service −
Rear Wheel Alignment Check and Adjustment
P.34-7).
245 ± 29 N·m
N 3 1N
AC201825 AB

<<A>> >>B<< 1. Drive shaft nut ⋅• Control link and trailing arm
⋅• Rear ABS sensor (Refer to GROUP connection (Refer to GROUP 34,
35B, Wheel Speed Sensor P.35B-67). Trailing arm assembly P.34-13).
⋅• Lower arm and trailing arm <> >>A<< 2. Drive shaft
connection (Refer to Group 34, 3. Circlip
Trailing arm assembly P.34-13).

<<A>> DRIVE SHAFT NUT REMOVAL • Do not pull on the drive shaft; doing so will
CAUTION damage the TJ; be sure to use the pry bar.
• When pulling the drive shaft out from the
differential carrier, be careful that the spline
part of the drive shaft does not damage the oil
seal.
Differential carrier
MB990767
AC201826AC
Do not apply pressure to wheel bearing by the TJ assembly

vehicle weight to avoid possible damage to
Pry bar
wheel bearing before tightening drive shaft nut AC102552 AE
fully.
Use special tool end yoke holder (MB990767) to fix 2. Remove the drive shaft from the differential carrier
the hub and remove the drive shaft nut. by using a pry bar.
<> DRIVE SHAFT REMOVAL
MB990242 245 ± 29 N·m

(MB990241)
MB990767
MB991017
MB990244
(MB990241) MB991000
Wheel bearing
(Three)
MB991354 AC102720 AC
AC201827 AC
CAUTION
1. Use the following special tools to push out the Do not apply pressure to the wheel bearing by
drive shaft from the hub. the vehicle weight to avoid possible damage
• Puller shaft (MB990242) when the drive shaft is removed. If, however,
• Puller bar (MB990244) vehicle weight must be applied to the bearing in
• Puller body (MB991354) moving the vehicle, temporarily secure the wheel
• End yoke holder (MB990767) bearing by using the following special tools.
INSTALLATION SERVICE POINTS 1. Assemble the drive shaft washer in the illustrated
>>A<< DRIVE SHAFT INSTALLATION direction.
CAUTION 2. Tighten the drive shaft nut to the torque
When installing the drive shaft, be careful that specification with special tool end yoke holder
the spline part of the drive shaft does not (MB990767).
damage the oil seal.
INSPECTION
M1271003400069
>>B<< DRIVE SHAFT NUT INSTALLATION • Check the drive shaft for damage, bending or
CAUTION corrosion.
Do not apply pressure to wheel bearing by the • Check the drive shaft spline part for wear or
vehicle weight to avoid possible damage to damage.
wheel bearing before tightening drive shaft nut • Check the boots for deterioration, damage or
fully. cracking.
• Check the dust cover for damage or
deterioration.
245 ± 29 N·m
Washer
MB990767
AC201828 AC

M1271003500185
CAUTION
• Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly
and reassembly.
• Never disassemble the BJ assembly except when replacing the BJ boot.
5N 1N
7
N4
2N
8N
3 10
6
11
N9
4 5 4
1 3
6
9 8 7
10 1
11
2
2 5
BJ repair kit TJ repair kit
4 5 1 4
5 7
2 8
1
10
2
Grease for TJ Grease for BJ
BJ boot repair kit TJ boot repair kit
AC201162 AB

>>C<< 1. TJ boot band (large) <> >>A<< 7. TJ boot
>>C<< 2. TJ boot band (small) 8. BJ boot band (large)
<<A>> >>B<< 3. TJ case 9. BJ boot band (small)
4. Circlip <> >>A<< 10. BJ boot
5. Snap ring 11. BJ assembly
<<A>> >>B<< 6. Spider assembly
LUIBRICATION POINTS

Amount used: 110 ± 10 g Amount used: 75 ± 10 g
CAUTION CAUTION
The drive shaft joint uses special The drive shaft joint uses special
grease. Do not mix old and new or grease. Do not mix old and new or
different types of grease. different types of grease.
AC212165 AC

<<A>> TJ CASE/SPIDER ASSEMBLY REMOVAL
Chamfered
CAUTION side
Do not disassemble the spider assembly.
1. Wipe off grease from the TJ case and spider
assembly.
2. If there is water or foreign material in the wiped
grease, be sure to clean the spider assembly.
AC102654AC
<> TJ BOOT/BJ BOOT REMOVAL
2. Install the spider assembly to the shaft from the
direction of the spline chamfered side.
Plastic tape
ACX02368AB
1. Wipe off grease from the shaft spline part. AC102656 AC

2. Wrap plastic tape around the spline part on the TJ
3. After applying the specified grease to the TJ case,
side of the drive shaft so that TJ and BJ boots are
insert the driveshaft and apply grease one more
not damaged when they are removed.
time.
REASSEMBLY SERVICE POINTS Specified grease: Repair kit grease
Used amount: 110 ± 10 g
>>A<< BJ BOOT/TJ BOOT INSTALLATION
Wrap plastic tape around the spline part on the TJ NOTE: The grease in the repair kit should be
side of the drive shaft, and then install BJ and TJ divided in half for use, respectively, at the joint
boots. and inside the boot.
>>B<< SPIDER ASSEMBLY/TJ CASE >>C<< TJ BOOT BAND (SMALL)/TJ BOOT BAND
INSTALLATION (LARGE) INSTALLATION
CAUTION
• The drive shaft joint use special grease. Do
not mix old and new or different types of
grease.
• If the spider assembly has been cleaned, take
special care to apply the specified grease.
1. Apply the specified grease furnished in the repair
A
kit to the spider assembly between the spider axle
and the roller.
AC102657AC
Set the TJ boot bands at the specified distance in
order to adjust the amount of air inside the TJ boot,
and then tighten the TJ boot band (large) and TJ
boot band (small) securely.
Standard value (A): 80 ± 3 mm
DIFFERENTIAL CARRIER ASSEMBLY

M1272002000254

• Main Muffler and Centre Exhaust Pipe Removal (Refer to • Drive Shaft Installation (Refer to P.27B-10).
GROUP 15, Exhaust Pipe and Muffler P.15-13). • Differential Gear Oil Filling (Refer to P.27B-7).
• Differential Gear Oil Draining • Main Muffler and Centre Exhaust Pipe Installation (Refer
• Drive Shaft Removal (Refer to P.27B-10). to GROUP 15, Exhaust Pipe and Muffler P.15-13).
• Rear Wheel Alignment Check and Adjustment (Refer to
GROUP 34, On-vehicle Service−Rear Wheel Alignment
6
7 90 ± 10 N·m
N 5
4 90 ± 10 N·m
13
N
3
2N
44 ± 9 N·m
1 49 ± 9 N·m
11
12
10
32 ± 2 N·m
N
9
64 ± 4 N·m 90 ± 10 N·m
70 ± 10 N·m
AC304071AC

<<A>> >>B<< 1. Propeller shaft connection 7. Differential support arm
2. Self-locking nut >>A<< 8. Breather hose assembly
3. Dynamic damper 9. Differential mount bracket bolt
4. Differential support arm connecting 10. Lower stopper
bolt 11. Upper stopper
5. Self-locking nut 12. Differential mount bracket
6. Rear differential support weiht 13. Differential carrier assembly

<<A>> PROPELLER SHAFT DISCONNECTION >>B<< PROPELLER SHAFT INSTALLATION
Align the mating marks of differential companion
Propeller shaft Differential flange and propeller shaft assembly.
assembly companion flange
DIFFERENTIAL SUPPORT MEMBER
BUSHING REPLACEMENT
M1272001400077
Marking
<DIFFERENTIAL MOUNT BRACKET>
Marking
MB990883
Differential
AC300150AC mount bracket
1. Make mating marks on the differential companion Bushing

flange and the propeller shaft assembly.
2. Suspend the removed propeller shaft from the
body with a wire to prevent bending.

>>A<< BREATHER HOSE ASSEMBLY Iron piece
INSTALLATION Hollow
portion
CAUTION
Be careful not to apply grease, water or soapy
water to the hose inlet.
Breather hose assembly
Pad
Vent plug AC107255 AB
1. Use special tool rear suspension bushing arbor

(MB990883) to remove or install the bushing.
2. Press-fit the bushing with its hollow portion facing
in the direction shown.
Drive shaft
Differential case AC211428AD 3. Press-fit the bushing until the bushing outer case
Fully insert the breather hose into the vent plug. end face is flush with the differential mount
Install the breather hose pad as shown in the bracket.
illustration.
<DIFFERENTIAL SUPPORT ARM> 1. Use special tool mont bushing arbor (MB990984)
to remove or install the bushing.
MB990984
2. Press-fit the bushing with its marks facing in the
Differential
support arm direction shown.
Bushing
3. Press-fit the bushing until the bushing outer case
end face is flush with the differential support arm.
Iron piece
LH side
Bushing
Marks
45˚
RH side
Bushing
Marks
AC107256AB
DISASSEMBLY
M1272002200203
8
6N
9 10 18 17 14 1516 13 12 19
5
17 1
11 18 2N
10
9 16 15
11
9
28
34 32 27
25 26
24 22
31
23
20 N 33 N
4N
30
3
29 N
21
AC301212AB

• Inspection before disassembly (Refer 18. Side gear spacer
to P.27B-20). 19. Differential case
1. Filler plug <<E>> 20. Self-locking nut
2. Gasket 21. Washer
3. Drain plug <<F>> 22. Drive pinion assembly
4. Packing <<F>> 23. Companion flange
5. Differential cover 24. Drive pinion front shim (For adjusting
6. Vent plug preload of drive pinion)
7. Bearing cap 25. Drive pinion spacer
<<A>> 8. Differential case assembly <<G>> 26. Drive pinion rear bearing inner race
<<A>> 9. Differential side bearing spacer 27. Drive pinion rear shim (for adjusting
<<A>> 10. Differential side bearing outer race drive pinion height)
<> 11. Differential side bearing inner race 28. Drive pinion
<<C>> 12. Drive gear <<H>> 29. Oil seal
<<D>> 13. Lock pin <<H>> 30. Drive pinion front bearing inner race
14. Pinion shaft <<H>> 31. Drive pinion front bearing outer race
15. Pinion gear <> 32. Drive pinion rear bearing outer race
16. Pinion washer 33. Oil seal
17. Side gear 34. Differential carrier
INSPECTION BEFORE DISASSEMBLY DRIVE GEAR RUNOUT

1. Remove the cover.
MB990909
and
MB991116
AC102886
AC102883 AC 1. Measure the drive gear runout at the shoulder on

2. Hold the following special tools in a vise, and the reverse side of the drive gear.
install the differential carrier assembly to the Limit: 0.05 mm
special tool. 2. When runout exceeds the limit value, check for
• Working base (MB990909) foreign material between drive gear rear side and
• Working base adapter (MB991116) differential case, or for loose drive gear
installation bolts.
FINAL DRIVE GEAR BACKLASH 3. When step (2) gives normal results, reposition the
drive gear and differential case and remeasure.
4. If adjustment is impossible, replace the differential
case, or replace the drive gear and pinion as a
set.
DIFFERENTIAL GEAR BACKLASH
Wedge
AC102884
1. With the drive pinion locked in place, use a dial

gauge to measure the drive gear backlash in four
or more places on the drive gear. Side gear
Side gear spacer
spacer
2. If the backlash is not within the standard value, AC102885 AC
adjust the final drive gear backlash (Refer to
P.27B-25). 1. Insert a wedge between the side gear and the
3. After the adjustment, inspect the final drive gear pinion shaft to lock the side gear.
tooth contact. 2. While locking the side gear with the wedge,
measure the differential gear backlash with a dial
indicator on the pinion gear.
Use the measurement procedure for the other
pinion gear.
Limit: 0.2 mm
3. If the backlash exceeds the limit value, adjust it by
replacing the side gear spacers.
4. If adjustment is not possible, replace the side
gears and pinion gears as a set.
FINAL DRIVE GEAR TOOTH CONTACT CAUTION

Check the tooth contact of drive gear by following the If the drive gear is rotated too much, the tooth
steps below. contact pattern will become unclear and difficult
to check.
MB990939
AC102887
1. Apply a thin, uniform coat of machine blue to both AC102888 AC
surfaces of the drive gear teeth. 2. Insert special tool brass bar (MB990939) between
the differential carrier and the differential case,
and then rotate the companion flange by hand
(once in the normal direction, and then once in the
reverse direction) while applying a load to the
drive gear so that the revolution torque
(approximately 2.5 − 3.0 N⋅m) is applied to the
drive pinion.
3. Check the tooth contact condition of the drive gear
and drive pinion.
Standard tooth contact pattern Problem Solution

1. Narrow tooth side Tooth contact pattern resulting
1 4
2. Drive-side tooth surface (the side from excessive pinion 2
applying power during forward movement) height
3. Wide tooth side 3
4. Coast-side tooth surface (the side 1 4 AC107261AB
2
applying power during reverse movement)
Increase the thickness of
the drive pinion rear shim,
3 and position the drive pinion
AC107260 AB
2 1 closer to the centre of the
4 The drive pinion is positioned too drive gear. Also, for
far from the centre of the drive backlash adjustment,
gear. position the drive gear
farther from the drive
pinion.
3
Tooth contact pattern resulting
2
ACX01039 AF
from insufficient pinion 1 4
height.
3
2 1 AC107263 AB
4
Decrease the thickness of
the drive pinion rear shim,
3
AC107262 AB
and position the drive pinion
farther from the centre of
The drive pinion is positioned too the drive gear. Also, for
close to the centre of the drive backlash adjustment,
gear. position the drive gear
closer to the drive pinion.
NOTE: Check the tooth contact pattern to confirm pattern. If, even after adjustments have been
that the adjustments of the pinion height and made, the correct tooth contact pattern cannot be
backlash have been done properly. Continue to obtained, it means that the drive gear and the
adjust the pinion height and backlash until the drive pinion have become worn beyond the
tooth contact pattern resembles the standard allowable limit. Replace the gear set.
DISASSEMBLY SERVICE POINTS <<C>> DRIVE GEAR REMOVAL

<<A>> DIFFERENTIAL CASE
ASSEMBLY/DIFFERENTIAL SIDE BEARING
SPACER/DIFFERENTIAL SIDE BEARING OUTER
RACE REMOVAL
CAUTION
When taking out the differential case assembly, Mating
be careful not to drop and damage the differential marks
side bearing spacers and differential side
bearing outer races.
AC102891 AC
1. Make the mating marks to the differential case

and the drive gear.
2. Loosen the drive gear attaching bolts in a
diagonal sequence to remove the drive gear.
<<D>> LOCK PIN REMOVAL
AC102889
Use the wooden handle of a hammer to remove the

differential case assembly, differential side bearing
spacers and differential side bearing outer races.
NOTE: Keep the right and left side bearings and side
bearing spacers separate, so that they do not
become mixed during reassembly.
AC102892
<> DIFFERENTIAL SIDE BEARING INNER Drive out the lock pin with a punch.
RACE REMOVAL
<<E>> SELF-LOCKING NUT REMOVAL
MB990810
Socket
wrench MB990850
AC107274 AB
Use special tool side bearing puller (MB990810) to AC102893AC

pull out the side bearing inner races.
Use special tool end yoke holder (MB990850) to hold
NOTE: There are two notches provided (at the the companion flange, and then remove the
differential case side) for the claw part of the special companion flange self-locking nut.
tools; use special tool at that position.
<<F>> DRIVE PINION ASSEMBLY/COMPANION • Bearing puller (MB990339)

FLANGE REMOVAL • Pinion bearing remover (MB990374)
CAUTION
The mating mark made on the companion flange <<H>> OIL SEAL/DRIVE PINION FRONT
must not be on the coupling surface of the BEARING INNER RACE/DRIVE PINION FRONT
companion flange and the front propeller shaft. BEARING OUTER RACE REMOVAL
1. Make mating marks on the drive pinion and MB990939
companion flange.
MB990810
Drive pinion
front bearing Drive pinion
outer race front bearing
Oil seal
inner race
Companion AC102896 AC
flange
Use special tool bras bar (MB990939) to remove the
AC102894 AD oil seal, drive pinion front bearing inner race, and
drive pinion front bearing outer race.
2. Use special tool side bearing puller (MB990810)
to pull out the companion flange. <> DRIVE PINION REAR BEARING OUTER
RACE REMOVAL
<<G>> DRIVE PINION REAR BEARING INNER
RACE REMOVAL
MB990939
MB990339
Drive pinion
rear bearing
outer race
AC102897AC
MB990374 Use special tool brass bar (MB990939) to remove
AC102895AD
the drive pinion rear bearing outer race.
Use the following special tools to pull out the drive
pinion rear bearing inner race.
REASSEMBLY
M1272002300288
23 27 29 N
5
15 26 25 17 18 21 20 19 22 23 16
36 ± 5 N·m
34
Final drive gear set
18
49 ± 9 N·m
24 17
33 N
37 ± 2 N·m 30
25
19 20
28 24
26
5
1 6
3
8 7
84 ± 4 N·m
9 10
4
13 37 ± 2 N·m
20
17
15 N 18
2N
31 N
11 17
32 18
12 N 20
14 64 ± 4 N·m
Differential gear set
186 ± 29 N·m
AC301213 AB
Reassembly steps Reassembly steps (Continued)
1. Differential carrier >>F<< • Differential gear backlash adjustment
>>A<< 2. Oil seal 17. Side gear spacer
>>B<< 3. Drive pinion rear bearing outer race 18. Side gear
>>C<< 4. Drive pinion front bearing outer race 19. Pinion washer
>>D<< • Drive pinion height adjustment 20. Pinion gear
5. Drive pinion 21. Pinion shaft
6. Drive pinion rear shim (for adjusting >>G<< 22. Lock pin
drive pinion height) >>H<< 23. Drive gear
7. Drive pinion rear bearing inner race >>I<< 24. Differential side bearing inner race
8. Drive pinion spacer 25. Differential side bearing outer race
>>E<< • Drive pinion turning torque 26. Differential side bearing spacer
adjustment 27. Differential case assembly
9. Drive pinion front shim (for adjusting >>J<< 28. Bearing cap
drive pinion turning torque) 29. Vent plug
10. Drive pinion assembly 30. Differential cover
11. Drive pinion front bearing inner race 31. Packing
>>E<< 12. Oil seal 32. Drain plug
13. Companion flange 33. Gasket
14. Washer 34. Filler plug
15. Self-locking nut >>J<< • Final drive gear backlash adjustment
Lubrication and Adhesive Points
2 – 3 mm
Vent plug
(bead diameter)
Adhesive: Semi-driying sealant:

3M Stud Locking 4170 or 3M ATD Part No.8661 or equivalent
equivalent
AC301214AB
REASSEMBLY SERVICE POINTS • Oil seal installer (MB991115)

>>A<< OIL SEAL PRESS-FITTING
>>B<< DRIVE PINION REAR BEARING OUTER
RACE PRESS-FITTING
MB990938
MB990938
MB990935
MB991115
AC102740 AC
Use the following special tools to press-fit a new oil

AC102907AD
seal.
Use the following special tools to press-fit the drive CAUTION

pinion rear bearing outer race. There should be no gear oil adhered to the
• Installer bar (MB990938) bearing.
>>C<< DRIVE PINION FRONT BEARING OUTER MB990836

RACE PRESS-FITTING
MB990938
MB990932
AC102910 AD
MB990685
MB990326
AC102908 AD
Use the following special tools to press-fit the drive

pinion front bearing outer race.
>>D<< DRIVE PINION HEIGHT ADJUSTMENT

AC102911 AC
Adjust the drive pinion height by the following
procedures: 3. Tighten the nut of special tool a little at a time,
1. Apply multipurpose grease to the washer of while measuring the turning torque of the drive
special tool drive pinion gauge asseembly pinion by using the following special tools. Then
(MB990836). confirm that the turning torque (without the drive
pinion oil seal) is at the standard value.
• Preload socket (MB990326)
• Torque wrench (MB990685)
Standard value:
Bearing division Turning torque
New 0.9 − 1.2 N⋅m
MB990836 NOTE: Because the special tool preload socket
(MB990326) cannot be turned one turn, turn it
AC102909 AC several times within the range that it can be
turned; then, after fitting to the bearing, measure
2. Install special tool, drive pinion front and rear the turning torque.
bearing inner races to the differential carrier as
4. Clean the side bearing seat of the differential
shown in the illustration.
carrier and bearing caps.
10.Calculate thickness (F) of the required drive

Notch
MB990392 pinion rear shim by the following formula. Select a
shim which most closely matches this thickness.
F = A + B + C − 1/2D − 86.00 mm
MB990728
A Drive pinion
rear shim
MB990836 Thickness
gauge AC102912 AD
5. Place the following special tools in the side

bearing seat of the differential carrier, and position MB990728
the notch as shown in the illustration. Then install
the bearing caps. ACX02432 AD
• Cylinder gauge (MB990392)

11.Fit the selected drive pinion rear shim(s) to the
• Drive pinion gauge assembly (MB990836)
drive pinion, and press-fit the drive pinion rear
6. Use a thickness gauge to measure the clearance bearing inner race by using special tool bearing
(A) between special tools. installer (MB990728).
7. Remove the bearing caps and special tools.
>>E<< DRIVE PINION TURNING TORQUE
ADJUSTMENT/OIL SEAL INSTALLATION
C
Adjust the drive pinion turning torque by the following
procedures:
1. Insert the drive pinion into the differential carrier,
and then install the following parts in sequence
from the carrier rear side: drive pinion spacer,
B drive pinion front shim , drive pinion front bearing
inner race and companion flange.
AC102913 AC NOTE: Do not install the oil seal.
8. Use a micrometer to measure the shown
dimensions (B, C) of special tools.
MB990850
D
Cylinder gauge
AC201179 AB
2. Tighten the companion flange self-locking nut to

AC102914 AC the specified torque while holding the companion
flange with special tool end yoke holder
9. Install the bearing cap, and then use a cylinder
(MB990850).
gauge to measure the inside diameter (D) of the
bearing cap. Tightening torque: 186 ± 29 N⋅m
CAUTION Height of drive pinion Identification colour

There should be no gear oil adhered to the spacer (A) mm
bearing. 57.08 Red
MB990326 57.72 −
MB990685
MB990031
or
MB990699
ACX01062AD
3. Use the following special tools MB990685 and ACX01064AG

MB990326 to measure the drive pinion turning
torque (without the drive pinion oil seal). 5. Remove the companion flange and drive pinion
• Preload socket (MB990326) again. Then insert the drive pinion front bearing
• Torque wrench (MB990685) inner race into the differential carrier. Use special
Standard value: tool oil seal installer (MB990031 or MB990699) to
press-fit the drive pinion oil seal.
Bearing division Turning torque
New 0.9 − 1.2 N⋅m
MB990850
4. If the drive pinion turning torque is not within the
standard value, adjust the turning torque by
replacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTE:
AC201179 AB
6. Install the drive pinion assembly and companion

flange with the mating marks properly aligned.
A
Identifi-
Tighten the companion flange self-locking nut to
cation the specified torque while holding the companion
colour flange with special tool.
ACX01063 AE Tightening torque: 186 ± 29 N⋅m
When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of
shims to a minimum by selecting the drive pinion
spacers.
Select the drive pinion spacer from the following
two types.
NOTE: Do not assemble the lock pin yet.

MB990326
MB990685 Wedge
Side gear
Side gear spacer
ACX01062AD spacer
AC102885 AC
7. Use special tools to measure the drive pinion
turning torque (with drive pinion oil seal) to verify 3. Insert a wedge between the side gear and the
that the drive pinion turning torque complies with pinion shaft to lock the side gear.
the standard value. 4. While locking the side gear with the wedge,
Standard value: measure the differential gear backlash with a dial
indicator on the pinion gear.
Bearing Companion flange Turning torque
division lubrication Measure by the same procedure for the other
pinion gear.
New None (with anti-rust 1.0 − 1.3 N⋅m
agent) Standard value: 0 − 0.076 mm
Limit: 0.2 mm
Gear oil applied 0.5 − 0.6 N⋅m
5. If the backlash exceeds the limit value, adjust it by
8. If the turning torque is not within the standard replacing the side gear spacers.
value, check the tightening torque of the
companion flange self-locking nut, and the 6. If adjustment is not possible, replace the side
installation of the oil seal. gears and pinion gears as a set.
7. Check that the backlash is within the limit value
>>F<< DIFFERENTIAL GEAR BACKLASH and that the differential gear turns smoothly.
ADJUSTMENT
Adjust the differential gear backlash by the following >>G<< LOCK PIN INSTALLATION
procedure: 1. Align the pinion shaft lock pin hole with the
differential case lock pin hole, and drive in the lock
pin.
ACX01066
1. Assemble the side gears, side gear spacers, ACX02429AC

pinion gears, and pinion washers into the
differential case. 2. Stake the lock pin with a punch on both sides.
2. Temporarily install the pinion shaft.
>>H<< DRIVE GEAR INSTALLATION Use special tool bearing installer (MB990728) to
1. Clean the drive gear attaching bolts. press-fit the differential side bearing inner races into
the differential case.
>>J<< BEARING CAP INSTALLATION/FINAL

DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the final drive gear backlash by the following
procedure:
1. Assemble the differential case with the side
bearing outer race to the differential carrier.
Tap ACX01068 AD
2. Remove the adhesive adhered to the threaded

holes of the drive gear by turning the tap (M10 x
1.25). Clean the threaded holes by applying
compressed air.
ACX01071AD
2. Press the differential case to one side to measure

the clearance of the side bearing outer race and
the differential carrier.
3. Select two pairs of side bearing spacers.
Determine the thickness by adding 1/2 of the
ACX02430 AB clearance to the pre-load 0.05mm.
3. Apply the specifed sealant to the threaded holes MB990810

of the drive gear.
Specified sealant: 3M stud locking 4170 or
equivalent Socket
4. Install the drive gear onto the differential case with wrench
the mating marks properly aligned. Tighten the
drive gear attching bolts to the specified torque in
a diagonal sequence.
Tightening torque: 84 ± 4 N⋅m AC107274 AB
4. Remove the side bearing by using special tool

>>I<< DIFFERENTIAL SIDE BEARING INNER side bearing puller (MB990810).
RACE INSTALLATION NOTE: Hook the claws of special tool with the
Piece of
side bearing inner race by using the notches (two
Piece of metal areas) of the differential case side.
metal 5. Assemble the selected side bearing spacers to
each side.
MB990728
AC102942 AC
When the backlash is small

Piece of
Piece of metal
Decreased Increased
metal
MB990728
Increased Decreased
When the backlash is large

AC102942 AC AC107626 AB
6. Use special tool bearing installer (MB990728) to 9. If the backlash is not within the standard value,
press-fit the side bearing inner race into the move the side bearing spacer as shown in the
differential case. After installing the outer race, illustration to adjust the backlash.
assemble the differential case to the differential NOTE: The increment of side bearing spacer
carrier. must be the same as the decreased amount.
7. Align the mating marks of differential carrier and 10.Inspect the tooth condition at the final drive gear
the bearing cap with each other and tighten the and replace if required. (Refer to P.27B-19).
bearing cap attaching bolts to the specified
torque.
AC102886
11.Measure the drive gear runout.

AC102884
Limit: 0.05 mm
12.If drive gear runout exceeds the limit, remove the
8. Measure the final drive gear backlash at four
differential case and then the drive gears, moving
points or more on the circumference of the drive
them to different positions and reinstall them.
gear.
13.If adjustment is not possible, replace the
differential case or drive gear and drive pinion as
a set.
31-1
GROUP 31
WHEEL AND TYRE

CONTENTS
GENERAL INFORMATION . . . . . . . . 31-2 ON-VEHICLE SERVICE . . . . . . . . . . . 31-8

TYRE INFLATION PRESSURE CHECK . . . 31-8
SERVICE SPECIFICATIONS. . . . . . . 31-2 TYRE WEAR CHECK . . . . . . . . . . . . . . . . . 31-8
WHEEL RUNOUT CHECK . . . . . . . . . . . . . 31-8
TROUBLESHOOTING . . . . . . . . . . . . 31-3
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 31-3 WHEEL AND TYRE . . . . . . . . . . . . . . 31-8
WHEEL BALANCE ACCURACY . . . . . . . . 31-4 INSTALLATION SERVICE POINT . . . . . . . 31-8
31-2 WHEEL AND TYRE
GENERAL INFORMATION
GENERAL INFORMATION
M1311000100101
The wheels and tyres of the following specifications SPECIFICATIONS
have been established.
Road wheel and tyre

Item Comfort Sport
Wheel Type Steel type or Aluminium type* Aluminium type or Steel type*
Size 16 × 6JJ 16 × 6JJ
Amount of wheel offset mm 46 46
PCD mm 114.3 114.3
Tyre Size 215/60R16 95H 215/60R16 95H
Spare wheel and tyre
Item LHD RHD
Spare Type Steel type Steel type
wheel Size 16 × 4T or 16 × 6JJ* 16 × 6JJ
Amount of wheel offset mm 40 or 46* 46
PCD mm 114.3 114.3
Spare tyre Size T135/90D16 102M or 215/60R16 95H
215/60R16 95H*
NOTE: The * mark indicates optional item.
NOTE: PCD (Pitch Circle Diameter) indicates the pitch circle diameter of the wheel installation holes.
M1311000300365
ITEM LIMIT
Tread depth of tyre mm Minimum 1.6
Wheel runout Radial runout mm 1.0 or less
<Aluminium wheel> Lateral runout mm 1.0 or less
Wheel runout Radial runout mm 1.2 or less
<Steel wheel> Lateral runout mm 1.2 or less
WHEEL AND TYRE 31-3
TROUBLESHOOTING
TROUBLESHOOTING
DIAGNOSIS
M1311000700363
Symptom Probable cause Remedy Reference page

Rapid wear Under-inflation Adjust the tyre For tyre inflation
at shoulders or lack of pressure. pressure, refer to
rotation the label on the
driver's side centre
pillar.
ACX00923AB
ACX00924 AB
Rapid wear Over-inflation

at centre or lack of
rotation
ACX00925AB
ACX00926AB
Cracked Under-inflation Adjust the tyre For tyre inflation

treads pressure. pressure, refer to
the label on the
driver's side centre
pillar.
ACX00927AB
31-4 WHEEL AND TYRE
TROUBLESHOOTING
Symptom Probable cause Remedy Reference page

Wear on one Excessive Check the camber. Refer to GROUP
side camber 33A, On-vehicle
service − Front
wheel alignment
check and
ACX00928 AB
adjustment P.33-6.
ACX00929 AB
Feathered Incorrect toe-in Adjust the toe-in.

edge
ACX00930AB
ACX00931AB
Bald spots Unbalanced Balance the wheels. P.31-4

wheel
ACX00932AB
ACX00933 AB
Scalloped Lack of rotation of tyres or worn Rotate the tyres, and Refer to GROUP
wear or out-of-alignment suspension check the front 33A, On-vehicle
suspension service − Front
alignment. wheel alignment
check and
ACX00934
adjustment P.33-6.
WHEEL BALANCE ACCURACY 2. Off-the-car wheel balancers must be calibrated

M1311001700300 periodically to ensure good balancing results. An
PURPOSE inaccurately calibrated balancer could cause
This section contains tips and procedures for unnecessary replacement of tyres, shocks,
achieving accurate wheel balance. Steering wheel suspension components, or steering components.
vibration and/or body shake can result if any of these Check your balancer's calibration approximately
procedures are not carefully observed. every 100 balances. Your wheel balancer's
1. Wheels and tyres must be properly mounted on a instruction manual should include calibration
balancer in order to achieve correct balance. procedures. If the calibration procedures specifically
Centering the wheel on the shaft of the balancer is for your balancer are missing, use the generic steps
essential for proper mounting. in this section for zero calibration, static balance, and
dynamic balance checks. The wheel balancer
calibration checks are also described in the flowchart
(Refer to P.31-7).
WHEEL AND TYRE 31-5
TROUBLESHOOTING
PROCEDURE <Balancing Tips> 3. Install a wheel mounting cone. The appropriate

1. Confirm that the balancer's cone and the wheel size cone for this vehicle is 67.0 mm.
mounting cone are undamaged and free of dirt 4. Before balancing the wheel, remove any wheel
and rust. weights from both sides. Also check both sides for
2. On this vehicle, the wheel's centre hole on the any damage.
hub side has a chamfered edge. Use a 5. When installing wheel weights, hammer them at a
back-mounting cone on your wheel balancer to straight (not diagonal) angle.
centre the wheel on the balancer shaft.
Clamping cup
Hub/shaft assembly
Wing nut
Spring plate
Wheel mounting cone AC000041AB
Standard passenger car wheel
<Confirming Proper Balance> 2. Turn the wheel again 180° against the balancer's
1. After balancing the wheel, loosen the wing nut hub. If the wheel becomes out-of-balance each
and turn the wheel 180° against the balancer's time it is turned against the balancer's hub, the
hub. Then re-tighten the wing nut and check the wheel balancer may require calibration.
balance again. Repeat wheel balance if
necessary.
31-6 WHEEL AND TYRE
TROUBLESHOOTING
<Wheel Balancer Calibration Checks> 4. <<Static Balance Check>>

1. Mount an undamaged original-equipment alloy Attach a 5g weight to the outer rim. Recheck the
rim and tyre assembly (wheel) onto your balancer. The balancer should detect 5 ± 2g of
off-the-car wheel balancer. Balance the wheel. imbalance 170 to 190° away from the 5g weight.
2. <<Zero Calibration Check>> • If the imbalance is within specification, the static
balance calibration is correct. Go to Step 5 to
Loosen the balancer wing nut, rotate the wheel a
half-turn (180°), and retighten the nut. Recheck check the dynamic balance.
• If the imbalance is out of specification, the
the balance.
• If the imbalance is 5g or less, the zero calibration balancer requires calibration. Contact the
is OK. Rebalance the wheel, then go to Step 4 to balancer manufacturer for calibration by their
repair representative.
check static balance.
• If the imbalance is more than 5g, go to Step 3. 5. <<Dynamic Balance Check>>
3. Loosen the balancer wing nut, rotate the wheel Attach a 5g weight to the inner rim at 180°
1/4 turn (90°), and retighten the nut. Recheck the opposite the 5g weight that was added in Step 4.
wheel balance. Recheck the balance. The balancer should detect
• If the imbalance is 5g or less, the wheel may not 5 ± 2g of imbalance 170 to 190° away from both
be centred on the balancer, or the balancing the inner and outer 5g weights.
cones, the cup, and/or wing nut are damaged, • If the imbalance is within specification, the
dirty, or inappropriate for the wheel. You may dynamic balance calibration is correct. The
need to refer to the balancer manufacturer's balancer calibration checks are complete.
instructions to verify the correct attachments. • If the imbalance is out of specification, the
After making the necessary corrections, recheck balancer requires calibration. Contact the
the wheel balance. If OK, then go to Step 4. balancer manufacturer for calibration by their
• If the imbalance is more than 5g, the balancer repair representative.
requires calibration. Contact the balancer
manufacturer for calibration by their repair
representative.
WHEEL AND TYRE 31-7
TROUBLESHOOTING
WHEEL BALANCER CALIBRATION

CHECKING FLOW CHART
Balance wheel.
ZERO CALIBRATION
Rotate wheel 1/2 turn. CHECK
Imbalance = 5g or less Imbalance = more than 5g
Rebalance wheel.
Rotate wheel 1/4 turn.
Imbalance = 5g or less Imbalance = more than 5g
Verify wheel is properly centered.

Verify cones, cup, and wing nut are clean,
undamaged, and appropriate for wheel.
Make necessary corrections, then recheck
wheel balance.
Attach a 5g weight to the outer rim. STATIC BALANCE

Is the imbalance 5 ± 2g at 170 – 190˚ CHECK
away from the 5g weight?
YES NO
DYNAMIC BALANCE
Attach a 5g weight to the inner rim at 180˚
CHECK
opposite the weight on the outer rim.
Is the imbalance 5 ± 2g at 170 – 190˚
away from both 5g weights?
YES NO
Balancer does not require Balancer requires calibration.

calibration. Contact balancer manufacturer.
AC000040 AB
31-8 WHEEL AND TYRE
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK WHEEL RUNOUT CHECK
M1311000900293 M1311001100427
NOTE: For information on tyre inflation pressure,
refer to the label attached to the centre pillar on the
driver's side.
Radial
TYRE WEAR CHECK
M1311001000301
Measure the tread depth of the tyres.
If the remaining tread depth is less than the minimum
limit, replace the tyre. Lateral
ACX00651AB
NOTE: When the tread depth of the tyres is reduced Jack up the vehicle so that the wheels are clear of
to 1.6 mm or less, wear indicators will appear. the floor. While slowly turning the wheel, measure
wheel runout with a dial indicator.
Limit:
Item Steel wheel Aluminium
wheel
Radial runout mm 1.2 1.0
Lateral runout 1.2 1.0
mm
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE

INSTALLATION SERVICE POINT Tightening torque: 98 ± 10 N⋅m
M1311001300261
Tighten the wheel nuts to the specified torque.
32-1
GROUP 32
POWER PLANT
MOUNT
CONTENTS
GENERAL INFORMATION . . . . . . . . 32-2 REMOVAL AND INSTALLATION . . . . . . . . 32-8

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 32-9
SERVICE SPECIFICATION . . . . . . . . 32-4
ENGINE ROLL STOPPER,
SPECIAL TOOL . . . . . . . . . . . . . . . . . 32-4 CENTREMEMBER <4G63> . . . . . . . . 32-10
ENGINE MOUNTING . . . . . . . . . . . . . 32-5 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 32-11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 32-5 ENGINE ROLL STOPPER,
CENTREMEMBER <4G69> . . . . . . . . 32-12
TRANSMISSION MOUNTING <M/T> 32-6 REMOVAL AND INSTALLATION . . . . . . . . 32-12
REMOVAL AND INSTALLATION . . . . . . . . 32-6 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 32-13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 32-7
CROSSMEMBER . . . . . . . . . . . . . . . . 32-14
TRANSMISSION MOUNTING <A/T>. 32-8 REMOVAL AND INSTALLATION . . . . . . . . 32-14
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 32-18
32-2 POWER PLANT MOUNT
GENERAL INFORMATION
GENERAL INFORMATION
M1321000100414
The inertia axial mount system has been adopted for • The liquid-filled transmission mount body side
the engine mount system. bracket improves riding comfort by its refined
• On vehicles with 4G63 or 4G69-A/T engine, insulator.
pressurized liquid-filled longitudinally installed • Installation of engine rear roll stopper bracket or
cylindrical engine front mounting bracket is engine roll stopper rod assembly in the upper
adopted to reduce vibration during acceleration area limits engine rolling. Further more, large
and cornering. diameter insulator reduces idle vibration.
• On vehicles with 4G69-M/T engine, liquid-filled
cylindrical engine front mounting bracket is
adopted to reduce vibration during acceleration
and cornering.
<4G63>
Engine front mounting bracket
Transmission mounting
body side bracket
AC301341
<2WD> <4WD> Engine roll stopper

rod assembly
Engine rear roll
stopper bracket
Engine roll stopper bracket
Engine roll stopper

rod bracket
Centremember
AC107318
AC301640 AD
POWER PLANT MOUNT 32-3
GENERAL INFORMATION
<4G69>
<M/T>
Engine front mounting
bracket
<A/T>
Engine front mounting <M/T>
bracket Transmission mounting
body side bracket <A/T>
Transmission mounting
body side bracket
AC309245
<M/T> <A/T-L.H. drive vehicles>

Engine roll stopper Engine roll stopper
rod assembly rod assembly
Engine roll stopper

rod bracket
<M/T>
Engine roll stopper
bracket Engine roll stopper
rod bracket
<A/T-R.H. drive vehicles>
Engine rear roll
stopper bracket
Centremember
<A/T>
Engine roll stopper
bracket
AC309246
AC309368 AC
M1321000300377
Item Standard value

Protruding length of stabilizer link thread part mm 9.4 ± 0.4
SPECIAL TOOL
M1321000600420

disconnection
(MB990635 or MB991113) is also
available to disconnect knuckle and
AC106827
tie rod end ball joint.
ENGINE MOUNTING
ENGINE MOUNTING
M1321001100547
CAUTION
*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
• Raise the engine and transmission assembly until its • Accelerator Pedal Position Sensor Installation (Refer to
weight is not applied to the insulator, and support it GROUP 17, Accelerator Pedal Position Sensor P.17-9)
securely. <4G69>.
• Accelerator Pedal Position Sensor Removal (Refer to • Accelerator Cable Check and Adjustment (Refer to
GROUP 17, Accelerator Pedal Position Sensor P.17-9) GROUP 17, On-vehicle Service P.17-5) <4G69>.
<4G69>.
<M/T> <A/T>
12 ± 2 N·m
12 ± 2 N·m 44 ± 10 N·m
44 ± 10 N·m
1
1
2N
2N 44 ± 10 N·m 45 ± 5 N·m
44 ± 10 N·m
70 ± 4 N·m
3
AC309428
3
AC309429
AC309430 AB
Removal steps Tightening torque: 70 ± 4 N⋅m

1. Pressure hose clamp
>>A<< 2. Self-locking nut INSPECTION
M1321001200209
3. Engine front mounting bracket
• Check the engine front mounting bracket for
INSTALLATION SERVICE POINT cracks or damage.
>>A<< SELF-LOCKING NUT INSTALLATION
CAUTION
Do not tighten the self-locking nuts while the
engine is hot.
Tighten the self-locking nuts to the specified torque
while the engine is cold.
TRANSMISSION MOUNTING <M/T>

M1321001400485
CAUTION
• Raise the engine and transmission assembly until its • Engine Rear Roll Stopper rod assembly or Engine Rear
weight is not applied to the insulator, and support it Roll Stopper Bracket Installation <4G63-4WD> (Refer to
securely. P.32-10).
• Air Cleaner Removal (4G63: Refer to GROUP 15, Air • Engine Rear Roll Stopper rod assembly or Engine Rear
Cleaner P.15-3), (4G69: Refer to GROUP 15, Air Cleaner Roll Stopper Bracket Installation <4G69-L.H. drive
P.15-4). vehicles> (Refer to P.32-12).
• Centremember and Engine Roll Stopper Bracket Removal • Centremember and Engine Roll Stopper Bracket
<4G63-2WD> (Refer to P.32-10). Installation <4G63-2WD> (Refer to P.32-10).
• Engine Rear Roll Stopper rod assembly or Engine Rear • Air Cleaner Installation (4G63: Refer to GROUP 15, Air
Roll Stopper Bracket Removal <4G63-4WD> (Refer to Cleaner P.15-3), (4G69: Refer to GROUP 15, Air Cleaner
P.32-10). P.15-4).
• Engine Rear Roll Stopper rod assembly or Engine Rear
Roll Stopper Bracket Removal <4G69-L.H. drive
vehicles> (Refer to P.32-12).
82 ± 7 N·m
47 ± 7 N·m
1 2
AC301677 AB
Removal steps
1. Transmission mounting body side
bracket
>>A<< 2. Transmission mounting stopper
INSTALLATION SERVICE POINT Install the transmission mounting stopper so that its
>>A<< TRANSMISSION MOUNTING STOPPER arrow points upward.
INSTALLATION
INSPECTION
M1321001500169
Engine side Transmission
mounting
• Check the transmission mounting body side
stopper bracket insulator for cracks, separation or
Transmission
mounting body deformation.
side bracket
AC200645 AF
TRANSMISSION MOUNTING <A/T>

M1321001400496
CAUTION
• Raise the engine and transmission assembly until its • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
weight is not applied to the insulator, and support it P.15-4).
securely. • Battery and Battery Tray Installation.
• Battery and Battery Tray Removal.
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-4).
82 ± 7 N·m
3
47 ± 7 N·m
23 ± 3 N·m
1 2
AC107606 AC
1. Control wiring harness bracket 2. Transmission mounting body side
bracket
>>A<< 3. Transmission mounting stopper
INSTALLATION SERVICE POINT Install the transmission mounting stopper so that its
>>A<< TRANSMISSION MOUNTING STOPPER arrow points upward.
INSTALLATION
INSPECTION
M1321001500170
Engine side Transmission
mounting
• Check the transmission mounting body side
stopper bracket insulator for cracks, separation or
Transmission
mounting body deformation.
side bracket
AC200645 AF
ENGINE ROLL STOPPER, CENTREMEMBER <4G63>

M1321002300339
CAUTION
<2WD> <4WD>
11 45 ± 5 N·m
11 ± 1 N·m 7
8 9 10 52 ± 7 N·m
5
6
45 ± 5 N·m
52 ± 7 N·m
5
52 ± 7 N·m 13
12
70 ± 10 N·m
14
45 ± 5 N·m
52 ± 7 N·m
4 2 1
3
69 ± 10 N·m
69 ± 10 N·m
AC309561 AB
Engine roll stopper bracket and Engine rear roll stopper bracket
centremember removal steps removal steps <2WD>
• Under cover (Refer to GROUP 51, 5. Engine rear roll stopper bracket
Under cover P.51-19). connecting bolt
1. Engine roll stopper bracket 6. Engine rear roll stopper bracket
connecting bolt mounting bolt
2. Centremember and engine roll 7. Engine rear roll stopper bracket
stopper bracket assembly and mount bracket assembly
3. Centremember 8. Clamp bracket
>>A<< 4. Engine roll stopper bracket 9. Rear roll mount bracket
10. Engine rear roll stopper bracket
Engine roll stopper rod and INSTALLATION SERVICE POINT

bracket removal steps <4WD>
>>A<< ENGINE ROLL STOPPER BRACKET
• Front exhaust pipe (Refer to
GROUP 15, Exhaust pipe P.15-13).
INSTALLATION
5. Engine roll stopper rod connecting
bolt
11. Engine roll stopper rod assembly
12. Engine roll stopper rod bracket and Hole
crossmember assembly (Refer to
P.32-14).
13. Engine roll stopper rod bracket
14. Crossmember assembly
Front of vehicle AC208360 AC
Install the engine roll stopper bracket so that its hole

points towards the front side of the vehicle.
INSPECTION
M1321002400057
• Check the roll stopper for cracks, separation or
deformation.
• Check the centremember for cracks or damage.

M1321002300340
CAUTION
<R.H. drive vehicles> <L.H. drive vehicles>

10
45 ± 5 N·m
45 ± 5 N·m
52 ± 7 N·m
9
52 ± 7 N·m
52 ± 7 N·m
7
5 6 12
8 11
13
<M/T>
45 ± 5 N·m <A/T>
45 ± 5 N·m
52 ± 7 N·m 1 52 ± 7 N·m
4 2
3
3 4
2
69 ± 10 N·m
69 ± 10 N·m AC309432 AB
Front roll stopper and Engine rear roll stopper bracket

centermember removal steps removal steps <R.H. drive
• Under cover (Refer to GROUP 51, vehicles>
Under cover P.51-19). • Front exhaust pipe (Refer to
1. Engine roll stopper bracket GROUP 15, Exhaust pipe P.15-13).
connecting bolt 5. Engine rear roll stopper bracket
2. Centremember and engine roll connecting bolt
stopper bracket assembly 6. Engine rear roll stopper bracket
3. Centremember and crossmember assembly (Refer
>>A<< 4. Engine roll stopper bracket to P.32-14).
Engine rear roll stopper bracket

removal steps <R.H. drive
vehicles> (Continued)
7. Engine rear roll stopper bracket
Engine roll stopper rod and
bracket removal steps <L.H.
drive vehicles>
• Front exhaust pipe (Refer to
GROUP 15, Exhaust pipe P.15-13).
9. Engine roll stopper rod connecting
bolt
10. Engine roll stopper rod assembly
11. Engine roll stopper rod bracket and
crossmember assembly (Refer to
P.32-14).
12. Engine roll stopper rod bracket
INSTALLATION SERVICE POINT Install the engine roll stopper bracket so that its hole
>>A<< ENGINE ROLL STOPPER BRACKET points towards the front side of the vehicle.
INSTALLATION
INSPECTION
M1321002400068
<M/T>
• Check the roll stopper for cracks, separation or
deformation.
• Check the centremember for cracks or damage.
Hole
Front of vehicle AC208360
<A/T>
Hole
Front of vehicle AC101615

AC309431 AB
CROSSMEMBER
CROSSMEMBER
M1321003200410
CAUTION
• Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so that they are
facing straight forward, and remove the ignition key. If you fail to do this, the SRS clock spring will
be damaged, causing the SRS air bag to be inoperative and serious injury.
• *1: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
• *2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in the unladen condition.
• Steering Wheel Air Bag Module Assembly Removal • Centremember Installation (4G63: Refer to P.32-10),
(Refer to GROUP 37, Steering Wheel P.37A-16). (4G69: Refer to P.32-12).
• Power Steering Fluid Draining (Refer to GROUP 37A, • Front Exhaust Pipe Installation (Refer to GROUP 15,
On-vehicle Service P.37A-11). Exhaust Pipe and Main Muffler P.15-13).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Steering Wheel Air Bag Module Assembly Installation
Exhaust Pipe and Main Muffler P.15-13). (Refer to 37, Steering Wheel P.37A-16).
• Centremember Removal (4G63: Refer to P.32-10), • Power Steering Fluid Supplying (Refer to GROUP 37A,
(4G69: Refer to P.32-12). On-vehicle Service P.37A-11).
• Power Steering Fluid Line Bleeding (Refer to GROUP
37A, On-vehicle Service P.37A-12).
• Press the dust cover with a finger to check whether the
dust cover cracked or damaged.
• Checking Steering Wheel Position with Wheels Straight
Ahead.
GROUP 37A, On-vehicle Service P.37A-9).
CROSSMEMBER

<2WD> 45 ± 5 N·m ¹
12 ± 2 N·m
13 9
70 ± 10 N·m 70 ± 10 N·m 10
18 ± 2 N·m
5.0 ± 1.0 N·m

52 ± 7 N·m ¹
16 5 57 ± 7 N·m
<4WD>
7
14 6
45 ± 5 N·m ¹
25 ± 5 N·m
52 ± 7 N·m ¹
N 8
12 11 N
19
21 ± 4 N·m
15
52 ± 7 N·m ¹ 21 ± 4 N·m
18
17 2N
108 ± 10 N·m
3
4
20
186 ± 10 N·m ² 1
39 ± 5 N·m
167 ± 9 N·m
49 ± 10 N·m AC309433 AB

1. Lower arm and knuckle connection 15. Engine roll stopper rod assembly
>>B<< 2. Self-locking nut <4WD>
3. Stabilizer link assembly <> • Crossmenber, engine rear roll
4. Lower arm assembly stopper bracket, stabilizer bar and
5. Return hose connection steering gear and linkage assembly
6. Eye bolt <2WD>
7. Pressure hose connection <> • Crossmenber, engine roll stopper
8. Gasket rod bracket, stabilizer bar and
9. Shaft cover steering gear and linkage assembly
10. Steering shaft assembly and gear <4WD>
box connecting bolt 16. Engine rear roll stopper bracket
11. Self-locking nut <2WD>
<<A>> 12. Tie rod end and knuckle connection 17. Engine roll stopper rod bracket
13. Engine rear roll stopper bracket <4WD>
connecting bolt <2WD> >>A<< 18. Stabilizer bar
14. Engine roll stopper rod connecting 19. Steering gear and linkage
bolt <4WD> 20. Crossmember
CROSSMEMBER

9
57 ± 7 N·m
5 10
N 8 18 ± 2 N·m
6
5.0 ± 1.0 N·m
7 70 ± 10 N·m
45 ± 5 N·m ¹
52 ± 7 N·m ¹ 16 25 ± 5 N·m
12
21 ± 4 N·m 11 N
15
21 ± 4 N·m
13
14
2N
108 ± 10 N·m
3
4
17
186 ± 10 N·m ² 1
39 ± 5 N·m
167 ± 9 N·m
49 ± 10 N·m AC309434 AB

1. Lower arm and knuckle connection <<A>> 12. Tie rod end and knuckle connection
>>B<< 2. Self-locking nut 13. Engine rear roll stopper bracket
3. Stabilizer link assembly connecting bolt
4. Lower arm assembly <> • Crossmenber, engine read roll
5. Return hose connection stopper bracket, stabilizer bar and
6. Eye bolt steering ger and linkage assembly
7. Pressure hose connection 14. Engine rear roll stopper bracket
8. Gasket >>A<< 15. Stabilizer bar
9. Shaft cover 16. Steering gear and linkage
10. Steering shaft assembly and gear 17. Crossmember
box connecting bolt
11. Self-locking nut
CROSSMEMBER
REMOVAL SERVICE POINTS 2. Turn the bolt and knob as necessary to make the
<<A>> TIE ROD END AND KNUCKLE jaws of the special tool ball joint remover
DISCONNECTION (MB991897) parallel, tighten the bolt by hand and
confirm that the jaws are still parallel.
CAUTION
• Do not remove the nut from ball joint. Loosen NOTE: When adjusting the jaws in parallel, make
it and use special tool ball joint remover sure the knob is in the position shown in the
(MB991897) to avoid possible damage to ball figure.
joint threads. 3. Tighten the bolt with a wrench to disconnect the
• Hang special tool ball joint remover tie rod end.
(MB991897) with a cord to prevent it from
falling. <> CROSSMEMBER, ENGINE REAR ROLL
STOPPER BRACKET, ENGINE ROLL STOPPER
Cord ROD BRACKET, STABILIZER BAR AND
STEERING GEAR AND LINKAGE ASSEMBLY
REMOVAL
Nut MB991897
Bolt
1. Install the special tool ball joint remover

(MB991897) as shown in the figure. Transmission jack
AC200018AC
Bolt Retain the crossmember with a transmission jack,

and then remove the crossmember mounting bolt.
Parallel
Knob Good
Bad AC106821AB
CROSSMEMBER
INSTALLATION SERVICE POINTS >>B<< SELF-LOCKING NUT INSTALLATION

>>A<< STABILIZER BAR/BUSHING/FIXTURE
INSTALLATION A
Outside of Approximately
vehicle 10 mm
Identification
mark
AC107031AB
AC107031
Bushing (LH) Fixture (LH)
Tighten the self-locking nut until the stabilizer link
AC006141AD thread part protruding length meets the standard
Align the stabilizer bar identification mark with the value.
right end of the bushing (LH). Standard value (A): 9.4 ± 0.4 mm
INSPECTION
M1321003300224
• Check the crossmember for cracks and damage.
33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . . 33-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-7

SERVICE SPECIFICATIONS. . . . . . . 33-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-10
LUBRICANT. . . . . . . . . . . . . . . . . . . . 33-3 LOWER ARM . . . . . . . . . . . . . . . . . . . 33-11

SPECIAL TOOLS. . . . . . . . . . . . . . . . 33-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-12
BALL JOINT DUST COVER
ON-VEHICLE SERVICE. . . . . . . . . . . 33-6 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-12
FRONT WHEEL ALIGNMENT CHECK AND LOWER ARM REAR BUSHING
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 33-6 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-13
LOWER ARM BALL JOINT AXIAL PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-7 STABILIZER BAR. . . . . . . . . . . . . . . . 33-14
BALL JOINT DUST COVER CHECK . . . . . 33-7 REMOVAL AND INSTALLATION . . . . . . . . 33-14
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-16
STRUT ASSEMBLY. . . . . . . . . . . . . . 33-7 STABILIZER LINK BALL JOINT DUST
REMOVAL AND INSTALLATION . . . . . . . . 33-7 COVER REPLACEMENT . . . . . . . . . . . . . . 33-16
33-2 FRONT SUSPENSION
GENERAL INFORMATION
GENERAL INFORMATION
M1332000100292
The front suspension is a McPherson strut with coil CONSTRUCTION DIAGRAM
spring. The shock absorber is gas-filled hydraulic
double-acting type.
Stiffener plate
Coil spring
Stabilizer bar
Strut assembly
Crossmember
Lower arm AC301358AB
SPECIFICATIONS
COIL SPRING
Item 2WD 4WD
Wire diameter mm 14 14
Average diameter mm 160 160
Free length mm 300 305
FRONT SUSPENSION 33-3
M1332000300326
Item Standard value

Toe-in At the centre of tyre tread mm 1±2
Toe-angle (per wheel) 0°03' ± 05'
Toe-out angle on turns (inner wheel when outer wheel at 20°) 22°00' ± 1°30'
Steering angle Inner wheel 34°50' ± 1°30'
Outer wheel (reference) 29°20'
Camber -0°10' ± 30'*
Caster 3°15' ± 30'*
Kingpin inclination 12°25' ± 1°30'
Side slip mm (per 1m) 0±3
Lower arm ball joint starting torque N⋅m 0 − 3.9
Protruding length of stabilizer link thread part mm 9.4 ± 0.4
Stabilizer link ball joint turning torque N⋅m 0.5 − 1.5
NOTE: *: difference between right and left wheels
must be less than 30'
LUBRICANT
M1332000400130

Lower arm ball joint Lip portion of dust cover Multipurpose grease SAE J310, As required
Inside of dust cover NLGI No.2 or equivalent
Stabilizer link ball joint Inside of dust cover
SPECIAL TOOLS
SPECIAL TOOLS
M1332000600275

MB991004 Wheel alignment gauge Wheel alignment
attachment measurement <Vehicles
with aluminium wheels>
MB991004
A: MB991237 A: Spring compressor Coil spring compression

B: MB991238 body
A B: Arm set
B MB991237
A MB991680 Wrench set Strut assembly

B A: MB991681 A: Wrench disassembly and
B: MB991682 B: Socket reassembly
MB991680
MB991006 Preload socket Lower arm ball joint

starting torque check
MB991006
MB990800 Ball joint remover and Lower arm ball joint dust
installer cover installation
MB990800
SPECIAL TOOLS

MB990883 Rear suspension bushing Lower arm bushing
arbor removal and press-fitting
MB990883
MB990972 Torsion bar bushing

remover base
MB990971
MB990887 Ring
MB990890 Rear suspension bushing

base
MB990890
MB990326 Preload socket Stabilizer link ball joint

turning torque check
MB990326
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND Conduct this test on the left turn as well as on the
right turn.
ADJUSTMENT
M1331000900400 Standard value:
Measure wheel alignment with alignment equipment
on a level surface. The front suspension, steering Item Specification
system, wheels, and tires should be serviced to Toe-out angle on turns (inner 22°00' ± 1°30'
normal condition before measuring wheel alignment. wheel when outer wheel at 20°)
TOE-IN
Standard value: CAMBER, CASTER AND KINGPIN INCLINATION
at the centre of tyre tread: 1 ± 2 mm
Standard value:
Toe angle (per wheel): 0°03' ± 05'
Item Specification
Jam nut
Camber -0°10' ± 30'*
Clip Caster 3°15' ± 30'*
Kingpin inclination 12°25' ± 1°30'
NOTE: *: difference between right and left wheels
must be less than 30'
NOTE: Camber and caster are preset at the factory
and cannot be adjusted.
AC006074 AB
CAUTION
1. Adjust the toe-in by undoing the clip and jam nut, Never subject the wheel bearings to the vehicle
and turning the left and right tie rod turnbuckles by load when the driveshaft nuts are loosened.
the same amount (in opposite directions). NOTE:
NOTE: The toe will move out as the left
MB991004
turnbuckle is turned toward the front of the vehicle
and the right turnbuckle is turned toward the rear
of the vehicle.
2. Install the clip and tighten the jam nut to the
specified torque.
3. Confirm that the toe-in is at the standard value.
AC001079 AB
4. Use a turning radius gauge to check that the
steering angle is at the standard value. For vehicles with aluminium wheels, attach the
STEERING ANGLE camber/caster/kingpin gauge to the driveshaft by
Standard value: using special tool wheel alignment gauge attachment
(MB991004). Tighten the special tool to the same
Item Specification torque 245 ± 29 N⋅m as the driveshaft nut.
Inner wheels 34°50' ± 1°30'
SIDE SLIP
Outer wheels (reference) 29°20' Measure the side slip with a side slip tester.
Standard value: 0 ± 3 mm (per 1 m)
TOE-OUT ANGLE ON TURNS
To check the steering linkage, especially after the
vehicle has been involved in an accident or if an
accident is presumed, it is advisable to check the
toe-out angle on turns in addition to the wheel
alignment.
STRUT ASSEMBLY
LOWER ARM BALL JOINT AXIAL PLAY BALL JOINT DUST COVER CHECK
M1332008600309
CHECK 1. Press the dust cover with your finger to check that
M1332011300063
1. Raise the vehicle. there are no cracks or damage in the dust cover.
2. Remove the stabilizer link from the lower arm. 2. If the dust cover is cracked or damaged, replace
the lower arm assembly.
3. Move the lower arm up and down with your hands
to check for an excessive play in the axial NOTE: If the dust cover is cracked or damaged, it
direction of the ball joint. If there is an excessive is possible that there may also be damage to the
play, replace the lower arm assembly. ball joint.
STRUT ASSEMBLY
M1332001100400

• Washer Tank Assembly Removal (Refer to GROUP 51, • Washer Tank Assembly Installation (Refer to GROUP 51,
Windshield Wiper and Washer P.51-25). <Pre-removal of Windshield Wiper and Washer P.51-25).
the strut assembly (RH)> <Post-installation of the strut assembly (RH)>
• Front Wheel Alignment Adjustment (Refer to P.33-6).
N 4
5
44 ± 5 N·m
1
2 7
167 ± 9 N·m
AC202820 AB
Removal steps INSPECTION

1. Front ABS sensor harness bracket M1332001200236
2. Brake hose bracket • Check for oil leaks from the strut assembly.
3. Knuckle connection • Check the strut assembly for damage or
4. Strut mounting nut deformation.
5. Insulator clip
6. Stiffener plate
7. Strut assembly
STRUT ASSEMBLY

M1332001300277
60 ± 10 N·m
1
3
8
4
7
9
6
10
AC301222 AB

<<A>> >>A<< 1. Self-locking nut 6. Dust cover
2. Strut insulator assembly 7. Bump stopper
3. Bearing 8. Coil spring
4. Upper spring seat 9. Lower spring pad
5. Upper spring pad <> 10. Strut assembly
STRUT ASSEMBLY
DISASSEMBLY SERVICE POINTS <> STRUT ASSEMBLY DISPOSAL

<<A>> SELF-LOCKING NUT REMOVAL WARNING
CAUTION Wear goggles when drilling to protect your
• Install special tool arm set (MB991238) evenly, eyes from flying metal debris.
and so that the maximum length will be
attained within the installation range.
• Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237), otherwise the special tool will
break.
MB991238 MB991237 AC001087
The gas must be discharged from the strut assembly

before discarding it. Place the strut assembly
horizontally with its piston rod extended. Then drill a
hole of approximately 3 mm in diameter at the
location shown in the illustration and discharge the
AC001085 AB gas.
1. Use following special tools to compress the coil REASSEMBLY SERVICE POINT
spring.
>>A<< SELF-LOCKING NUT INSTALLATION
• MB991237: Spring Compressor Body
• MB991238: Arm Set 1. Ensure that the bearing is seated correctly.
CAUTION
WARNING Do not use an impact wrench to tighten the bolt
Do not use an impact wrench to remove the of special tool spring compressor body
self-locking nut. Vibration of the impact (MB991237), otherwise the special tool will break.
wrench will cause special tools (MB991237
and MB991238) to slip and cause personal
injury. MB991238 MB991237
MB991682
MB991681
AC001085 AB
2. Install following special tools to the strut assembly

same as its removal.
AC006091 AB • MB991237: Spring Compressor Body
• MB991238: Arm Set
2. Use following special tools to secure the strut, and
then remove the self-locking nut. 3. While the coil spring is being compressed by the
• MB991681: Wrench special tools, temporarily tighten the self-locking
• MB991682: Socket nut.
STRUT ASSEMBLY
CAUTION
Do not use an impact wrench to tighten the
self-locking nut, otherwise the self-locking nut
Rod will be damaged.
MB991682
MB991681
AC006091 AB
4. Align the hole in the strut assembly lower spring

seat with the hole in the upper spring seat.
NOTE: Using a rod as shown facilitates the AC006091 AB
alignment.
5. Align both ends of the coil spring with the grooves 6. Using following special tools, tighten the
in the spring seat, and then loosen the special self-locking nut to 60 ± 10 N⋅m.
tools. • MB991681: Wrench
• MB991682: Socket
INSPECTION
M1332001400177
• Check the bearing for wear or rust.
• Check the rubber parts for damage or
deterioration.
• Check the spring for deformation, deterioration or
damage.
• Check the shock absorber for deformation.
LOWER ARM
LOWER ARM
M1332001600308
CAUTION
*
: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in an unladen condition.
• Check the dust cover for cracks or damage by pushing it
with your finger.
P.33-6).
AC107030 N 2
Specified grease :
Multipurpose grease SAE J310,
NLGI No.2 or equivalent
186 ± 10 N·m*
5
6
167 ± 9 N·m
39 ± 5 N·m AC107017
5 1 108 ± 10 N·m
AC200961 AB

1. Lower arm and knuckle connection 5. Lower arm and crossmember
>>A<< 2. Self-locking nut connection
3. Stabilizer rubber 6. Lower arm assembly
4. Stabilizer link assembly
LOWER ARM
INSTALLATION SERVICE POINT 2. If the dust cover is cracked or damaged, replace

>>A<< SELF-LOCKING NUT INSTALLATION the lower arm assembly.
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint. When it is
A damaged during service work, replace the dust
cover.
BALL JOINT DUST COVER

REPLACEMENT
M1332008200259
If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
AC107031AB
AC107031
1. Remove the dust cover.
Tighten the self-locking nut until the stabilizer link 2. Apply specified grease to the lip and the inside of
thread part protruding length meets the standard a new dust cover.
value.
• Specified grease: Multipurpose grease
Standard value (A): 9.4 ± 0.4 mm SAE J310, NLGI No.2 or equivalent
• Grease amount for the inside the dust
INSPECTION cover (reference): 8 − 10g
M1332001700264
• Check the bushing for wear and deterioration.
• Check the lower arm for bend or breakage.
• Check all bolts for condition and straightness. MB990800
LOWER ARM BALL JOINT STARTING TORQUE
CHECK Dust cover
MB991006
AC006135 AB
3. Using special tool ball Joint remover and installer

(MB990800), drive in the dust cover until it is fully
seated.
AC001091 AB
1. After shaking the ball joint stud several times, use Dust cover 22 mm
special tool preload socket (MB991006) to
measure the starting torque of the ball joint.
Standard value: 0 − 3.9 N⋅m
2. If the measured value is not within the standard
value, or if the ball joint is difficult to turn or does
not turn smoothly, replace the lower arm
AC107030 AB
assembly.
4. Position the dust cover as shown in the
LOWER ARM BALL JOINT DUST COVER CHECK illustration. Make sure that there is no abnormal
1. Check the dust cover for cracks or damage by bulge or pressure applied on the dust cover.
pushing it with your finger. 5. Check the dust cover for cracks or damage by
pushing it with your finger.
LOWER ARM
LOWER ARM REAR BUSHING 1. Use following special tools to drive out the
REPLACEMENT bushing.
M1332008100337 • MB990883: Rear Suspension Bushing Arbor
• MB990972: Torsion Bar Bushing Remover Base
Bushing
• MB990887: Ring
• MB990890: Rear Suspension Bushing Base
MB990883
MB990972
Lower arm
assembly
Outer tube
AC107098 AB
Replace the bushing as follows:

MB990887
MB990890
MB990883
Lower arm assembly
30˚
MB990972
Lower arm
assembly
Projection
AC006138 AC
MB990887 2. Position the bushing so that its projection is as

shown, and then use the special tools to press in
the bushing.
MB990890
3. Press the bushing until its outer tube is flush with
the lower arm assembly surface.
AC006137 AC
STABILIZER BAR
STABILIZER BAR
M1332004000350
CAUTION
• Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Service
PrecautionsP.52B-4 and Air Bag Module and Clock SpringP.52B-179. Also, put the front wheels in
straight-ahead position. Failure to do so may damage the SRS clock spring and render the SRS air
bag inoperative, which results serious driver injury.
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
• Side Under Cover and Centre Under Cover Removal • Front Exhaust Pipe Installation (Refer to GROUP 15,
(Refer to GROUP 51, Under Cover P.51-19). Exhaust Pipe and Main Muffler P.15-13).
• Steering Wheel and Air Bag Module Assembly Removal • Centre Member Installation (Refer to GROUP 32, Engine
(Refer to GROUP 37A, Steering Wheel P.37A-16). Roll Stopper, Centre Member P.32-12).
• Clock Spring Removal (Refer to GROUP 52B, Air Bag • Clock Spring Installation (Refer to GROUP 52B, Air Bag
Modules and Clock Spring P.52B-179). Modules and Clock Spring P.52B-179).
• Centre Member Removal (Refer to GROUP 32, Engine • Steering Wheel and Air Bag Module Assembly Installation
Roll Stopper, Centre Member P.32-10). (Refer to GROUP 37A, Steering Wheel P.37A-16).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Check the dust covers for cracks or damage by pushing it
Exhaust Pipe and Main Muffler P.15-13). with your finger.
Ahead
P.33-6).
• Side Under Cover and Centre Under Cover Installation
(Refer to GROUP 51, Under Cover P.51-19).
STABILIZER BAR
9 18 ± 2 N·m
3
4
AC107102
Specified grease:
Multipurpose grease SAE J310, 21 ± 4 N·m
5
11
6
1 7
8
10
9
2
49 ± 10 N·m
52 ± 7 N·m*
167 ± 9 N·m
39 ± 5 N·m
AC107023
167 ± 9 N·m
AC200962 AB
Removal steps
1. Power steering hose clamp
2. Rear roll stopper connecting
bolt Piece of wood
3. Steering shaft cover
4. Steering gear and joint
connecting bolt
<<A>> >>A<< 5. Fixture
<<A>> >>A<< 6. Bushing
>>B<< 7. Self-locking nut Transmission
8. Stabilizer rubber jack AC102600 AD
<<A>> 9. Stabilizer link
10. Stabilizer rubber 1. Use a transmission jack to hold the crossmember,
<<A>> >>A<< 11. Stabilizer bar and then remove the crossmember mounting nuts
and bolts.
<<A>> FIXTURE/BUSHING/STABILIZER Be careful not to lower the crossmember
LINK/STABILIZER BAR REMOVAL excessively, otherwise the power steering return
Carry out the following operations to ensure working hose bracket may deform.
space in order to remove the fixtures, the bushings,
2. Lower the crossmember until the fixtures, the
the stabilizer links and the stabilizer bar.
bushings, the stabilizer links and the stabilizer bar
can be removed.
STABILIZER BAR
INSTALLATION SERVICE POINTS 1. After shaking the ball joint stud several times,
>>A<< STABILIZER BAR/BUSHING/FIXTURE install the nut to the stud and use special tool
INSTALLATION preload socket (MB990326) to measure the
turning torque of the ball joint.
Outside of Approximately
vehicle 10 mm Standard value: 0.5 − 1.5 N⋅m
2. When the measured value exceeds the standard
Identification
mark value, replace the stabilizer link.
3. When the measured value is lower than the
standard value, check that the ball joint turns
smoothly without excessive play. If so, it is
Bushing (LH) Fixture (LH) possible to re-use that ball joint.
AC006141AD STABILIZER LINK BALL JOINT DUST COVER

Align the stabilizer bar identification mark with the CHECK
right end of the bushing (LH). 1. Check the dust cover for cracks or damage by
>>B<< SELF-LOCKING NUT INSTALLATION 2. If the dust cover is cracked or damaged, replace
the stabilizer link.
NOTE: Cracks or damage of the dust cover may
A cause damage to the ball joint. When it is
damaged during service work, replace the dust
cover (Refer to P.33-16).
STABILIZER LINK BALL JOINT DUST

COVER REPLACEMENT
M1332008300104
Only when the dust cover is damaged accidentally
AC107031AB
AC107031
during service work, replace the dust cover as
Tighten the self-locking nut until the stabilizer link follows:
thread part protruding length meets the standard
value.
Standard value (A): 9.4 ± 0.4 mm
INSPECTION
M1332002000246
• Check the bushings for wear and deterioration.
• Check the stabilizer bar for deterioration or
damage.
Clip ring
• Check all bolts for condition and straightness.
AC006188AB
STABILIZER LINK BALL JOINT TURNING
TORQUE CHECK 1. Remove the clip ring and the dust cover.
2. Apply specified grease to the inside of a new dust
MB990326 cover.
Specified grease: Multipurpose grease SAE
J310, NLGI No.2 or equivalent
3. Wrap plastic tape around the stabilizer link stud,
and then install the dust cover to the stabilizer
link.
4. Secure the dust cover by the clip ring.
AC001129 AB
5. Check the dust cover for cracks or damage by
pushing it with finger.
34-1
GROUP 34
REAR SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . . 34-2 TRAILING ARM ASSEMBLY . . . . . . . 34-11

REMOVAL AND INSTALLATION <2WD>. . 34-11
SERVICE SPECIFICATIONS. . . . . . . 34-3 REMOVAL AND INSTALLATION <4WD>. . 34-13
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-16
LUBRICANT. . . . . . . . . . . . . . . . . . . . 34-3 TRAILING ARM BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-17
SPECIAL TOOLS. . . . . . . . . . . . . . . . 34-4
SHOCK ABSORBER ASSEMBLY . . . 34-18
ON-VEHICLE SERVICE. . . . . . . . . . . 34-7 REMOVAL AND INSTALLATION . . . . . . . . 34-18
REAR WHEEL ALIGNMENT CHECK AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-19
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 34-7 DISASSEMBLY AND REASSEMBLY . . . . . 34-20
LOWER ARM PILLOW BALL BUSHING AXIAL
PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . 34-8 STABILIZER BAR. . . . . . . . . . . . . . . . 34-23
STABILIZER LINK BALL JOINT DUST COVER
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 34-8
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-24
CONTROL LINK, UPPER ARM AND LOWER STABILIZER LINK BALL JOINT DUST
COVER REPLACEMENT . . . . . . . . . . . . . . 34-24
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 34-8
REAR SUSPENSION
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 34-9 CROSSMEMBER . . . . . . . . . . . . . . . . 34-25
LOWER ARM BUSHING AND LOWER ARM REMOVAL AND INSTALLATION . . . . . . . . 34-25
PILLOW BALL BUSHING REPLACEMENT 34-10
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-25
34-2 REAR SUSPENSION
GENERAL INFORMATION
GENERAL INFORMATION
M1341000100416
A trailing arm type multi-link suspension has been
adopted as the rear suspension. The shock absorber
is a hydraulic, cylindrical double-acting type.
Rear suspension
crossmember
Shock absorber
Stabilizer bar
Bump rubber
Upper arm
Coil spring
Control link Lower arm
Trailing arm bracket

Trailing arm AC301439AB
SPECIFICATION
COIL SPRING
Item 2WD 4WD
Wire diameter mm 11 11
Average diameter mm 91 91
Free length mm 342 350
REAR SUSPENSION 34-3
M1341000300379
Item Standard value

Toe-in At the centre of tyre tread mm 3±2
Toe-angle (per wheel) 0°08' ± 05'
Camber −0°40' ± 30' (Difference between right and left within 30')
Thrust angle 0°00' ± 09'
Control link pillow ball bushing starting torque 0.5 − 3.0
N⋅m
Upper arm pillow ball bushing starting torque N⋅m 0.5 − 3.0
Lower arm pillow ball bushing starting torque N⋅m 0.5 − 3.0
Stabilizer link ball joint turning torque N⋅m 1.7 − 3.1
LUBRICANT
M1341000400161

Stabilizer link ball joint (inside of dust cover) Multipurpose grease SAE J310, NLGI No.2 As required
or equivalent
SPECIAL TOOLS
SPECIAL TOOLS
M1341000600369

attachment measurement
<2WD-vehicles with
aluminium wheels>
MB991004

attachment measurement
<4WD-vehicles with
aluminium wheels>
MB991004
MB990326 Preload socket • Pillow ball bushing

starting torque check
• Stabilizer link ball
joint turning torque
check
MB990326
MB991447 Bushing remover and Lower arm bushing

installer removal and press-fitting
MB991448 Bushing remover and

installer base

installer supporter
B MB990957 Lower arm bushing Lower arm pillow ball

A A: MB990969 remover and installer bushing removal and
B: MB990971 A: Guide press-fitting
B: Base
MB990957
MB990996 Lower arm bushing arbor
B990996
SPECIAL TOOLS

MB990767 End yoke holder Rear axle hub fixing
B990767
MB990241 Axle shaft puller Drive shaft removal

A A: MB990243 A: Puller body <4WD>
B: MB990244 B: Puller bar
C: MB990242 C: Puller shaft
B C
MB990241
MB991354 Puller body • Removal of the drive

shaft <4WD>
• Rear hub assembly
removal <4WD>
MB991354
A A: MB991017 A, B: Front hub remover Provisional holding of

B: MB990998 and installer the wheel bearing
C: MB991000 C: Spacer <4WD>
B
C
AC100320AB
B MB990590 Rear axle shaft oil seal Rear hub assembly

A: MB990212 remover removal <4WD>
B: MB990211 A: Adapter
B: Sliding hammer
A MB990590
MB990560 Bearing remover Wheel bearing inner

race removal <4WD>
MB990560
MB990934 Adapter Wheel bearing removal

<4WD>
MB990938 Bar
B990938
SPECIAL TOOLS

MB991400 Rear wheel bearing and • Wheel bearing
hub installer press-fitting <4WD>
• Rear hub assembly
press-fitting <4WD>
MB991400
MB991401 Rear wheel bearing and Wheel bearing

hub installer base press-fitting <4WD>
MB991401
MB991411 Rear wheel bearing and Rear hub assembly

hub installer press-fitting <4WD>
MB991411
MB991444 Bushing remover and Trailing arm bushing

installer arbor removal and press-fitting
B991444

installer base
A: MB991237 A: Spring compressor Coil spring removal and

B: MB991239 body installation
B: Arm set
A
B MB991237
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
REAR WHEEL ALIGNMENT CHECK AND NOTE:
<4WD-vehicles with aluminium wheels>
ADJUSTMENT MB991004
M1341011000349
Measure wheel alignment with an alignment
equipment on level earth.
The rear suspension, wheels, and tyres should be
serviced to the normal condition prior to wheel
alignment measurement.
CAMBER
Standard value: -0° 40' ± 30' (Left/right AC001079 AE
deviation within 30')
For 4WD-vehicles with aluminium wheels, attach the
NOTE: Camber is preset at the factory and cannot
camber/caster/kingpin gauge to the driveshaft by
be adjusted.
using special tool wheel alignment gauge attachment
CAUTION (MB991004). Tighten the special tool to the same
Never subject the wheel bearings to the vehicle torque 245 ± 29 N⋅m as the driveshaft nut.
load when the trailing arm spindle self-locking
nuts (2WD), the driveshaft nuts (4WD), or the TOE-IN
special tool wheel alignment gauge attachment
Standard value:
(MB991004 or MB991014) are loosened.
At the centre of tyre tread: 3 ± 2 mm
NOTE: Toe angle (per wheel): 0°08' ± 05'
<2WD-vehicles with aluminium wheels>
If toe-in is not within the standard value, adjust by
MB991014
following procedures.
CAUTION
To prevent bushings from breakage, the toe
adjusting bolt should be temporarily tightened,
and then fully tightened with the vehicle on the
ground in the unladen condition.
AC001079 AD
<Control link front view> <Control link rear view>
For 2WD-vehicles with aluminium wheels, attach the
camber/caster/kingpin gauge to the trailing arm
spindle by using special tool wheel alignment gauge
attachment (MB991014). Tighten the special tool to
the same torque 175 ± 25 N⋅m as the trailing arm
spindle self-locking nut. Toe adjusting bolt 120 ± 10 N·m
Control link Control link

AC107070 AC
Carry out adjustment by turning the toe adjusting bolt

(control link mounting bolt which is located on the
inner side of the body).
NOTE: .
• LH: Clockwise viewed from the front → Toe-in
• RH: Clockwise viewed from the front → Toe-out
• Turning the toe adjusting bolt by one groove of
the scale, toe can be changed approximately 2.6
mm (single side toe angle equivalent to 16').
CONTROL LINK, UPPER ARM AND LOWER ARM
LOWER ARM PILLOW BALL BUSHING 4. After inspection, install the stabilizer link and
AXIAL PLAY CHECK shock absorber to the lower arm assembly (Refer
M1341016900046 to P.34-8).
1. Raise the vehicle.
2. Remove the stabilizer link and shock absorber STABILIZER LINK BALL JOINT DUST
from the lower arm assembly. COVER INSPECTION
M1341012800252
3. Move the lower arm up and down with your hands
1. Check dust covers for cracks or damage by
to check for an excessive play in the axial
direction of the pillow ball bushing. If there is an
excessive play, replace the lower arm pillow ball 2. If a dust cover is cracked or damaged, replace the
bushing (Refer to P.34-10). stabilizer link.
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint.

M1341004800161
CAUTION
*
the ground in an unladen condition.
P.34-7).
120 ± 10 N·m* 39± 5 N·m

95 ± 15 N·m*
3
5
2
120 ± 10 N·m* 90 ± 10 N·m*
6
120 ± 10 N·m*
1
95 ± 15 N·m* 95 ± 15 N·m*
4
AC107089 AC
Control link and upper arm Lower arm removal steps

removal steps 3. Stabilizer link connection
<<A>> >>A<< 1. Control link <> 4. Lower arm and trailing arm
>>A<< 2. Upper arm connection
5. Shock absorber connection
6. Lower arm
REMOVAL SERVICE POINTS • Check all bolts for condition and straightness.
<<A>> CONTROL LINK REMOVAL CONTROL LINK/UPPER ARM/LOWER ARM
PILLOW BALL BUSHING STARTING TORQUE
CHECK
Mating mark Control link pillow ball bushing
Upper arm pillow ball bushing

AC107125 AB
After making a mating mark on the toe-in adjusting

bolt, remove the control link.
<> LOWER ARM AND TRAILING ARM

DISCONNECTION
Lower arm pillow ball bushing
AC107127AC
Check each pillow ball bushing as follows.

Piece of wood 1. Insert the mounting bolt to the pillow ball bushing.
In the opposite direction, insert a washer, then
install the mounting nut.
AC107126 AB
After supporting the lower arm with a jack, separate

the lower arm and the trailing arm. MB990326
INSTALLATION SERVICE POINT

>>A<< UPPER ARM/CONTROL LINK
INSTALLATION
Identification colour
AC102498 AC
Upper arm
2. After rotating the inner sleeve (contained washer)
several times, measure the starting torque of the
Control link pillow ball bushing using special tool preload
socket (MB990326).
Standard value: 0.5 − 3.0 N⋅m
Trailing arm AC300343AB 3. If the measured value exceeds the standard
Install the upper arm/control link as shown so that its value, replace the control link, the upper arm, or
identification colour faces the trailing arm. the lower arm pillow ball bushing.
4. If the measured value is lower than the standard
INSPECTION value, check that the pillow ball bushing turns
M1341004900146
smoothly without excessive play. If there is no
• Check the bushings for wear and deterioration. excessive play and it turns smoothly, the pillow
• Check the control link, upper arm and lower arm ball bushing can be reused.
for bending or breakage.
LOWER ARM BUSHING AND LOWER Use following special tools to drive out and press fit
the bushing.
ARM PILLOW BALL BUSHING
• MB991447: Bushing Remover and Installer
REPLACEMENT • MB991448: Bushing Remover and Installer Base
M1341011800196
• MB991449: Bushing Remover and Installer
Supporter
Lower arm pillow After press fitting, the space between the edges of
ball bushing
the bushing outer sleeve and of the lower arm should
be 1.5 mm.
Lower arm bushing

LOWER ARM PILLOW BALL BUSHING
REPLACEMENT
MB990996
AC107128AC
Replace the lower arm bushing and lower arm pillow 3 mm

ball bushing as follows.
Lower arm
LOWER ARM BUSHING REPLACEMENT
CAUTION MB990969
Because the outside of both edges of the MB990971
bushing are different, be careful not to mistake AC102522AC
the direction.
Use following special tools to drive out and press fit
Driving Out the bushing.
• MB990957: Lower Arm Bushing Remover and
MB991447 Installer
• MB990969: Guide
Lower arm • MB990971: Base
MB991449 • MB990996: Lower Arm Bushing Arbor
After press fitting, the space between the edges of
MB991448 the bushing outer sleeve and of the lower arm should
be 3 mm.
AC006168 AC
Press-Fitting
1.5 mm
MB991447
Lower arm
MB991449
MB991448
AC006169 AC
TRAILING ARM ASSEMBLY

M1341002200323
CAUTION
*
the ground in the unladen condition.
• Brake Fluid Draining • Rear Hub Assembly Installation (Refer to GROUP 27A,
• Rear ABS Sensor Removal (Refer to GROUP 35B, ABS Rear Axle Hub Assembly P.27A-5).
Sensor P.35B-67). • Rear Brake Caliper Assembly Installation (Refer to
• Rear Brake Caliper Assembly Removal (Refer to GROUP GROUP 35A, Rear Disc Brake Assembly P.35A-24).
35A, Rear Disc Brake Assembly P.35A-24). • Rear ABS Sensor Installation (Refer to GROUP 35B, ABS
• Rear Hub Assembly Removal (Refer to GROUP 27A, Sensor P.35B-67).
Rear Axle Hub Assembly P.27A-5). • Brake Fluid Supplying and Bleeding (Refer to GROUP
35A, On-vehicle Service − Bleeding P.35A-7).
P.34-7).
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service − Parking Brake Lever Stroke
6 120 ± 10 N·m*
90 ± 10 N·m* 15 ± 2 N·m
120 ± 10 N·m*
10
9 11
5 2
39 ± 5 N·m
4
63 ± 7 N·m
3 8
95 ± 15 N·m*
95 ± 15 N·m
1
7
AC301223AB

1. Parking brake cable connection 5. Control link and trailing arm
(Refer to GROUP 36, Parking connection
Brake Cable P.36-9). 6. Upper arm and trailing arm
2. Brake hose and trailing arm connection
connection <<A>> 7. Lower arm and trailing arm
3. Lower arm and stabilizer link connection
connection 8. Rear parking brake assembly
4. Lower arm and shock absorber 9. Trailing arm and trailing arm
connection bracket connecting bolt
Removal steps (Continued) REMOVAL SERVICE POINT

10. Trailing arm
<<A>> LOWER ARM AND TRAILING ARM
11. Trailing arm bracket
DISCONNECTION
Piece of wood
AC107126 AB

the lower arm and trailing arm connection.

M1341002200334
CAUTION
*
• Brake Fluid Draining • Rear ABS Sensor Installation (Refer to GROUP 35B, ABS
• Rear ABS Sensor Removal (Refer to GROUP 35B, ABS Sensor P.35B-67).
Sensor P.35B-67). • Brake Fluid Supplying and Bleeding (Refer to GROUP
35A, On-vehicle Service − Bleeding P.35A-7).
P.34-7).
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service − Parking Brake Lever Stroke
4 120 ± 10 N·m*
120 ± 10 N·m*
15 ± 2 N·m 60 ± 5 N·m
90 ± 10 N·m*
9 17 3
14 7
N 16
1
12 11
39 ± 5 N·m 6
5 15
95 ± 15 N·m 10 N
95 ± 15 N·m*
63 ± 7 N·m
8 13
245 ± 29 N·m
2 AC300347AB

1. Brake hose and trailing arm 9. Trailing arm and trailing arm
connection bracket connecting bolt
2. Parking brake cable <> >>C<< 10. Drive shaft nut
3. Rear brake caliper assembly 11. Brake disc
4. Upper arm and trailing arm <<C>> • Drive shaft connection
connection <<D>> >>B<< 12. Rear hub assembly
5. Lower arm and stabilizer link 13. Rear parking brake assembly
connection 14. Trailing arm bracket
6. Lower arm and shock absorber 15. Snap ring
connection <<E>> >>A<< 16. Wheel bearing
7. Control link and trailing arm 17. Trailing arm
connection
<<A>> 8. Lower arm and trailing arm
connection
REMOVAL SERVICE POINTS Use special tool end yoke holder (MB990767) to fix
<<A>> LOWER ARM AND TRAILING ARM the rear axle hub, and then remove the drive shaft
DISCONNECTION nut.
<<C>> DRIVE SHAFT DISCONNECTION
MB990242
(MB990241)
MB990244
(MB990241)
MB990767
(Three)
Piece of wood
MB991354
AC107126 AB
AC102719 AC
the lower arm and trailing arm connection. 1. Use following special tools to push out the drive
shaft from the hub.
<> DRIVE SHAFT NUT REMOVAL • MB990241: Axle Shaft Puller
CAUTION • MB990242: Puller Shaft
Do not apply pressure to the wheel bearing by • MB990244: Puller Bar
the vehicle weight to avoid possible damage to • MB990767: End Yoke Holder
the wheel bearing before tightening the drive • MB991354: Puller Body
shaft nut fully. 2. Hang the drive shaft on the vehicle body with a
rope.
MB990767
CAUTION
245 ± 29 N·m
AC102718 AC
MB991017
MB991000
Wheel bearing
AC102720 AC
Do not apply pressure to the wheel bearing by

the vehicle weight to avoid possible damage
when the drive shaft is removed. If, however,
vehicle weight must be applied to the bearing in
moving the vehicle, temporarily secure the wheel
MB990767 bearing by using special tools front hub remover
AC201826AC and installer, and spacer (MB991000 and
MB991017).
<<D>> REAR HUB ASSEMBLY REMOVAL

CAUTION MB990938
Replace the wheel bearing with a new part MB990934
because wheel bearing frictional surface will be
Trailing arm
damaged when removing the hub.
MB990211
AC103550AC
2. Use following special tools to remove the wheel

bearing from the trailing arm.
MB991354 • MB990934: Adapter
MB990244 (Three) • MB990938: Bar
AC203557AC
Use following special tools to pull out the rear hub INSTALLATION SERVICE POINTS
assembly. >>A<< WHEEL BEARING INSTALLATION
• MB990211: Sliding Hammer
• MB990241: Axle Shaft Puller
• MB990244: Puller Bar MB991400
• MB991354: Puller Body
Wheel bearing
<<E>> WHEEL BEARING REMOVAL
Wheel bearing Trailing arm
inner race Socket
(outside)
MB991401
Rear hub
MB990560 assembly
AC103549 AC
1. Use special tool bearing remover (MB990560) to

remove the wheel bearing inner race (outside)
from the rear hub assembly.
AC103551 AC
Use following special tools to press-in the wheel

bearing.
• MB991400: Rear Wheel Bearing and Hub
Installer
• MB991401: Rear Wheel Bearing and Hub
Installer Base
>>B<< REAR HUB ASSEMBLY INSTALLATION • MB991411: Rear Wheel Bearing and Hub
CAUTION Installer
If the wheel bearing inner race has been pushed
out, set the wheel bearing to the trailing arm >>C<< DRIVE SHAFT NUT INSTALLATION
again before installing the rear hub assembly. CAUTION
Do not apply pressure to the wheel bearing by
the vehicle weight to avoid possible damage to
MB991400 the wheel bearing before tightening the drive
shaft nut fully.
Rear hub assembly 245 ± 29 N·m
MB990767
Trailing arm
Washer
MB991411
AC102721 AC
1. Assemble the drive shaft washer in the illustrated

direction.
2. Use special tool end yoke holder (MB990767) to
fix the rear axle hub, and the tighten the drive
shaft nut fully.
AC103682 AC
INSPECTION
Use following special tools to press-in the rear hub M1341002300171
assembly. • Check the bushings for wear and deterioration.
• MB991400: Rear Wheel Bearing and Hub • Check the trailing arm for bending or damage.
Installer
TRAILING ARM BUSHING 2. Set the installation direction and installation

REPLACEMENT location of the trailing arm bushing.
M1341011300209 (1) Place the long projection end of the trailing
Driving Out arm bushing inner pipe towards the inside of
MB991444 the vehicle.
(2) Make sure that the hollow of the trailing arm
bushing is located as shown in the illustration.
Trailing arm
Press-Fitting
MB991444
16.2 ± 0.5 mm
MB991445 Trailing arm
AC102542AD
1. Use following special tools to drive out the trailing

arm bushing.
MB991445
• MB991444: Bushing Remover and Installer Arbor
• MB991445: Bushing Remover and Installer Base AC102542AE
3. Using the special tools, press the trailing arm

bushing into the position shown.
Parallel
AC102539 AC
SHOCK ABSORBER ASSEMBLY

M1341002500335
CAUTION
*
3
44 ± 5 N·m
39± 5 N·m
1
5
95 ± 15 N·m*
95 ± 15 N·m*
2
AC107092 AB

1. Stabilizer link connection 4. Shock absorber and lower arm
<<A>> 2. Lower arm and trailing arm connecting bolt
connection >>A<< 5. Shock absorber assembly
3. Shock absorber mounting nut

<<A>> LOWER ARM AND TRAILING ARM >>A<< SHOCK ABSORBER ASSEMBLY
DISCONNECTION INSTALLATION
Rear of
the vehicle
Spring seat
Piece of wood stepped section
AC304795 AB
AC107126 AB
Install the spring seat stepped section so that it
After supporting the lower arm with a jack, separate points towards the rear side of the vehicle.
the lower arm and trailing arm connection.
INSPECTION
M1341002600149
• Check the rubber parts for cracks and wear.
• Check the shock absorber for malfunctions, oil
leakage, or abnormal noise.

M1341005300318
7 25 ± 5 N·m
1
11
2
8
5
3
9
12
4
13 10 6
AC209952AC

<<A>> >>D<< 1. Self-locking nut <<A>> SELF-LOCKING NUT REMOVAL
2. Washer
3. Upper bushing B CAUTION
>>C<< 4. Bracket assembly • To hold the coil spring securely, install
5. Collar special tool arm set (MB991239) evenly, and
6. Upper bushing A so that the space between both arms of the
7. Plate special tool will be maximum within the
8. Bump rubber installation range.
>>A<< 9. Upper spring pad • Do not use an impact wrench to tighten the
10. Dust cover
bolt of special tool spring compressor body
>>B<< 11. Coil spring
>>A<< (MB991237). It will break the special tool.
12. Lower spring pad
<> 13. Shock absorber
MB991237
MB991239
AC001070 AB
1. Use following special tools to compress the coil

spring.
• MB991239: Arm Set
WARNING REASSEMBLY SERVICE POINTS

Do not use an impact wrench to remove the >>A<< UPPER SPRING PAD/LOWER SPRING
self-locking nut. Vibration of the impact PAD INSTALLATION
wrench will cause special tools (MB991237
and MB991239) to slip and cause personal
injury. Spring upper pad
stepped section
Piston rod
AC304801AC
<UPPER SPRING PAD>

Align the stepped section of the spring upper pad
AC102268AC with the upper end of the coil spring, and install the
spring upper pad.
2. While holding the piston rod, remove the
self-locking nut.
Spring lower pad
<> SHOCK ABSORBER DISPOSAL
WARNING
Wear goggles when drilling to protect your
eyes from flying metal debris. Stepped section
Spring seat
AC304800 AB
<LOWER SPRING PAD>

Align the stepped section of the spring lower pad
with the stepped section of the spring seat of the
shock absorber, and install the spring lower pad.
AC102270 AC
>>B<< COIL SPRING INSTALLATION
CAUTION
The gas must be discharged from the shock
Do not use an impact wrench to tighten the bolt
absorber before discarding it. Place the shock
of special tool spring compressor body
absorber horizontally with its piston rod extended.
(MB991237). It will break the special tool.
Then drill a hole of approximately 3 mm in diameter
at the location shown in the illustration and discharge
the gas. MB991237
MB991239
AC001070 AB
1. Use following special tools to compress the coil

spring, and install it to the lower spring pad.
• MB991239: Arm Set Install the rear shock absorber insulator so that the
2. Align the end of the coil spring with the stepped axis of the lower bushing inner pipe of the shock
section of the lower spring pad. absorber and the line between the rear shock
absorber insulator mounting bolts are straight when
>>C<< BRACKET ASSEMBLY INSTALLATION looking from above.
>>D<< SELF-LOCKING NUT INSTALLATION

Lower bushing inner pipe
1. Temporarily tighten the self-locking nut.
CAUTION
Do not use an impact wrench to tighten the
self-locking nut, otherwise the self-locking nut
Rear shock absorber will be damaged.
insulator mounting bolt
2. Remove the special tools, and then tighten the
self-locking nut to 25 ± 5 N⋅m.
Lower bushing
inner pipe
AC304802 AB
STABILIZER BAR
STABILIZER BAR
M1341003000236
• Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.
2 4 <2WD>
3
39 ± 5 N·m 12 ± 2 N·m
4 <4WD>
12 ± 2 N·m
2
39 ± 5 N·m
1 3
39 ± 5 N·m
Specified grease:
Multipurpose grease SAE J310,
AC301224AB

1. Stabilizer link >>A<< 3. Bushing
>>A<< 2. Fixture >>A<< 4. Stabilizer bar
STABILIZER BAR
INSTALLATION SERVICE POINT 3. If the measured value is lower than the standard
>>A<< STABILIZER BAR/BUSHING/FIXTURE value, check that the ball joint turns smoothly
INSTALLATION without excessive play. If so, it is possible to
re-use that ball joint.
Outside of vehicle
STABILIZER LINK BALL JOINT DUST COVER
CHECK
2. If the dust cover is cracked or damaged, replace
the stabilizer link.
Bushing (LH) Stopper
NOTE: Cracks or damage of the dust cover may
Fixture (LH) cause damage to the ball joint. When it is
AC200960AC
damaged during service work, replace the dust
Install the stabilizer bar, the bushings and the fixtures cover (Refer to P.34-24).
so that the stoppers come inboard of the bushings.
STABILIZER LINK BALL JOINT DUST
INSPECTION
M1341001400272 COVER REPLACEMENT
M1341010900220
• Check the bushings for wear and deterioration. Only when the dust cover is damaged accidentally
• Check the stabilizer bar for deterioration or during service work, replace the dust cover as
damage. follows:
• Check all bolts for condition and straightness.
STABILIZER LINK BALL JOINT TURNING
TORQUE CHECK
MB990326
Clip ring
AC006188AB
1. Remove the clip ring and the dust cover.

AC001129 AB 2. Apply specified grease to the inside of a new dust
cover.
1. After shaking the ball joint stud several times,
install the nut to the stud and use special tool Specified grease: Multipurpose grease SAE
preload socket (MB990326) to measure the J310, NLGI No.2 or equivalent
turning torque of the ball joint. 3. Wrap plastic tape around the stabilizer link stud,
Standard value: 1.7 − 3.1 N⋅m and then install the dust cover to the stabilizer
link.
2. If the measured value exceeds the standard
value, replace the stabilizer link. 4. Secure the dust cover by the clip ring.
pushing it with finger.
REAR SUSPENSION CROSSMEMBER
REAR SUSPENSION CROSSMEMBER

M1341006800219

• Main Muffler, Centre Exhaust Pipe Removal (Refer to • Fuel Filler Neck Protector Installation (Refer to GROUP
GROUP 15, Exhaust pipe and Main Muffler P.15-13). 13B, Fuel Tank P.13C-11).
• Control Link, Upper Arm, Lower Arm Removal (Refer to • Stabilizer Bar Installation (Refer to P.34-23).
P.34-8). • Control Link, Upper Arm, Lower Arm Installation (Refer to
• Stabilizer Bar Removal (Refer to P.34-23). P.34-8).
• Fuel Filler Neck Protector Removal (Refer to GROUP • Main Muffler, Centre Exhaust Pipe Installation (Refer to
13B, Fuel Tank P.13C-7). GROUP 15, Exhaust pipe and Main Muffler P.15-13).
P.34-7).
5 90 ± 10 N·m
3 2
N
90 ± 10 N·m
1
44 ± 9 N·m
95 ± 15 N·m
AC107129 AB

1. Dynamic damper <4WD> M1341006900067
2. Differential support arm connecting • Check the crossmember for cracks or

bolt <4WD> deformation.
3. Rear suspension crossmember • Check all bolts for condition and straightness.
4. Differential support arm <4WD>
5. Plug
NOTES
35A-1
GROUP 35A
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL INFORMATION . . . . . . . . 35A-2 BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A-13

SERVICE SPECIFICATIONS. . . . . . . 35A-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-14
LUBRICANTS . . . . . . . . . . . . . . . . . . 35A-3 MASTER CYLINDER ASSEMBLY

AND BRAKE BOOSTER . . . . . . . . . . 35A-15
SEALANT. . . . . . . . . . . . . . . . . . . . . . 35A-3 REMOVAL AND INSTALLATION . . . . . . . . 35A-15
MASTER CYLINDER . . . . . . . . . . . . . . . . . 35A-18
SPECIAL TOOLS. . . . . . . . . . . . . . . . 35A-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-18
ON-VEHICLE SERVICE. . . . . . . . . . . 35A-4 FRONT DISC BRAKE ASSEMBLY . . 35A-19

BRAKE PEDAL CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 35A-19
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 35A-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-20
BRAKE BOOSTER OPERATING TEST . . . 35A-6 DISASSEMBLY AND REASSEMBLY . . . . . 35A-21
CHECK VALVE OPERATION CHECK . . . . 35A-6 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-23
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 35A-7
BRAKE FLUID LEVEL SENSOR CHECK. . 35A-7 REAR DISC BRAKE ASSEMBLY . . . 35A-24
DISC BRAKE PAD CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 35A-24
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 35A-7
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-25
DISC BRAKE ROTOR CHECK. . . . . . . . . . 35A-10
DISASSEMBLY AND REASSEMBLY . . . . . 35A-26
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-28
35A-2 BASIC BRAKE SYSTEM
GENERAL INFORMATION
GENERAL INFORMATION
M1351000100406
The brake system offers high dependability and
durability along with improved braking performance
and brake sensitivity.
CONFIGURATION DIAGRAM
Brake booster
Hydraulic unit
(Integrated with ABS-ECU)
Rear disc brake

Parking brake
Master cylinder
Front disc brake

AC300584 AC
SPECIFICATIONS
Item Specification
Master cylinder Type Tandem type
I.D. mm 25.4
Brake booster Type Vacuum type, tandem
Effective dia. of power cylinder mm 205 + 230
Boosting ratio 7.5
Rear wheel hydraulic control method Electronic brake-force distribution (EBD)
Front brakes Type Floating caliper, 2 piston, ventilated disc
Disc effective diameter × thickness mm 246 × 24
Wheel cylinder I.D. mm 42.9
Clearance adjustment Automatic
Rear disc brakes Type Floating caliper, 1 piston, solid disc
Disc effective dia. × thickness mm 226 × 10
Wheel cylinder I.D. mm 38.1
Clearance adjustment Automatic
BASIC BRAKE SYSTEM 35A-3
M1351000300530

Brake pedal height mm L.H. drive vehicles 150 − 153 −
R.H. drive vehicles 176.2 − 179.2 −
Brake pedal free play mm 3−8 −
Brake pedal to floor board clearance mm 100 or more −
Disc brake pad thickness mm 10.0 2.0
Disc brake disc thickness mm Front 24.0 22.4
Rear 10.0 8.4
Disc brake disc run-out mm Front − 0.04
Rear − 0.05
Disc brake drag force N Front/Rear 68 or less −
Wheel bearing axial play mm Front/Rear − 0.05
Brake booster push rod protruding length mm (When applying 10.15 − 10.40 −
negative pressure of 66.7 kPa to the brake booster)
LUBRICANTS
M1351000400377

Brake fluid DOT3 or DOT4
Guide pin Repair kit grease
Lock pin
Guide pin boot inner surface
Lock pin boot inner surface
Piston boot mounting grooves
Brake piston boot inner surface
Guide pin bush inner surface
SEALANT
M1351000500385

Fitting thread part 3M ATD Part No.8661 or equivalent Semi-drying sealant
SPECIAL TOOLS
SPECIAL TOOLS
M1351000600326

MB991568 Push rod adjusting Adjustment of the brake booster
socket push rod protrusion amount
MB990964 Brake tool set Pushing-in of the disc brake

A A: MB990520 A: Disc brake piston
B
piston expander
MB990964
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND (2) Remove the brake booster (Refer to
ADJUSTMENT P.35A-15).
M1351000900479
NOTE: With the master cylinder and brake
BRAKE PEDAL HEIGHT pipe connected, remove the brake booster
1. Turn up the carpet, etc. under the brake pedal. only.
Clevis
A
AC200515 AC AC006217AD
2. Measure the brake pedal height as illustrated. (3) Adjust the brake pedal height by turning the
clevis.
Standard value (A):
150 − 153 mm <L.H. drive vehicles> NOTE: When the clevis is turned 180°, the
176.2 − 179.2 mm <R.H. drive vehicles> pedal height is changed approximately 2.4
[From the surface of dash panel to the face mm.
of pedal pad] (4) Install the brake booster (Refer to P.35A-15).
(5) Measure the brake pedal height, and ensure
3. If the brake pedal height is not within the standard
that the measured value is within the standard
value, follow the procedure below.
value. When it is out of the standard value,
(1) Disconnect the stop lamp switch connector.
repeat Step (2) - (5).
ON-VEHICLE SERVICE

position, depress the brake pedal two or three
times. After eliminating the vacuum in the brake
Stopper booster, press the pedal down by hand, and
confirm that the amount of movement before
resistance is met (free play) is within the standard
value range.
Standard value: 3 − 8 mm
2. If the brake pedal play is not within the standard
value, check the following, and adjust or replace if
Stopper necessary:
• Excessive play between the brake pedal and the
clevis pin, or between the clevis pin and the
brake booster operating rod
• Brake pedal height
• Installation position of the stop lamp switch, etc.
CLEARANCE BETWEEN BRAKE PEDAL

1.0 - 1.5 mm AND FLOOR BOARD
1. Turn up the carpet, etc. under the brake pedal.
AC309282 AC
(6) Screw in the stop lamp switch until its thread

contacts the stopper, and fix the stop lamp
switch by turning it approximately one quarter
of a turn clockwise.
(7) Check that the clearance between the stop
lamp switch and the stopper is as shown.
CAUTION
C
Check that the stop lamp does not illuminate
when the brake pedal is not depressed. AC107452AC
(8) Connect the connector at the stop lamp
switch. 2. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the
4. Return the carpet, etc.
clearance between the brake pedal and the floor
board.
BRAKE PEDAL FREE PLAY
Standard value (C): 100 mm or more
[From the surface of floor board to the face
of pedal pad]
3. If the clearance is outside the standard value,
check for air trapped in the brake line, thickness of
the disc brake pad, clearance between the lining
and the drum and dragging in the parking brake.
And then adjust and replace defective parts as
B required.
AC200011AC
4. Return the carpet etc. to its original position.
ON-VEHICLE SERVICE
BRAKE BOOSTER OPERATING TEST (3) With the engine running, step on the brake
M1351001000327 pedal and then stop the engine. Hold the
1. For simple checking of the brake booster pedal depressed for 30 seconds. If the pedal
operation, carry out the following tests: height does not change, the booster is in good
Good No good condition, if the pedal rises, the booster is
defective.
2. If the above three tests are okay, the booster is

OK. If one of the above three tests is not okay, the
check valve, vacuum hose, or booster is
defective. Check the check valve (Refer to
P.35A-6), vacuum hose for leaks, high volume
engine vacuum applied to booster. Repair or
AC000870 AE replace as necessary. If these are OK, replace the
(1) Run the engine for one or two minutes, and booster and repeat this test starting at Step 1.
then stop it. If the pedal depresses fully the
first time but gradually becomes higher when CHECK VALVE OPERATION CHECK
M1351009000321
depressed succeeding times, the booster is
CAUTION
operating properly. If the pedal height remains
The check valve should not be removed from the
unchanged, the booster is defective. Go to
vacuum hose.
step 2.
1. Remove the vacuum hose (Refer to P.35A-15).
When engine When engine
is stopped is started CAUTION
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
Valve Spring
A B
Intake manifold
side
AC000871AE (does not hold)
Booster side
(2) With the engine stopped, step on the brake (holds)
pedal several times. Then step on the brake
pedal and start the engine. If the pedal moves
downward slightly, the booster is in good AC000873AE
condition. If there is no change, the booster is 2. Check the operation of the check valve by using a
defective. Go to step 3. vacuum pump.
Good No good Vacuum pump Accept/reject criteria
connection
Connection at the brake A negative pressure
booster side (A) (vacuum) is created and
held.
Connection at the intake A negative pressure
manifold side (B) (vacuum) is not created.
AC000872AE
ON-VEHICLE SERVICE
BLEEDING Start the engine and bleed the air in the sequence
M1351001400400 shown in the figure.
CAUTION
Use only brake fluid DOT 3 or DOT 4. Never mix BRAKE FLUID LEVEL SENSOR CHECK
M1351009100351
the specified brake fluid with other fluid as it will
influence the braking performance significantly.
MASTER CYLINDER BLEEDING

The master cylinder used has no check valve, so if
bleeding is carried out by the following procedure,
bleeding of air from the brake pipeline will become
easier (When brake fluid is not contained in the
master cylinder).
1. Fill the reserve tank with brake fluid. AC102357
2. Keep the brake pedal depressed.
The brake fluid level sensor is in good condition if
there is no continuity when the float surface is above
"MIN" and if there is continuity when the float surface
is below "MIN".
DISC BRAKE PAD CHECK AND

Outlet
REPLACEMENT
M1351002300343
NOTE:
Outlet When new When worn
AC301227AB
Pad
3. Have another person cover the master cylinder
outlet with a finger.
4. With the outlet still closed, release the brake
pedal.
5. Repeat steps 2 − 4 three or four times to fill the Wear indicator Brake
disc
inside of the master cylinder with brake fluid.
AC000879 AD
BRAKE LINE BLEEDING The brake pads have indicators that contact the
brake disc when the brake pad thickness becomes 2
mm, and emit a squealing sound to warn the driver.
4 1
2 3
AC301228AB
ON-VEHICLE SERVICE
CAUTION 1. Check the brake pad thickness through the caliper

• Whenever a pad must be replaced, replace body check port.
both LH and RH wheel pads as a set to Standard value: 10.0 mm
prevent the vehicle from pulling to one side Minimum limit: 2.0 mm
when braking.
• If there is a significant difference in the
CAUTION
thicknesses of the pads on the left and right
Do not wipe off the special grease that is on the
sides, check the sliding condition of the
lock pin or allow it to contaminate the lock pin.
piston and slide pins.
<Front>
<Front>
<Rear>
<Rear>
AC301229AC
AC301229AB
2. Remove the guide/lock pin bolt. Pivot the caliper

assembly and hold it with wires.
ON-VEHICLE SERVICE
4. In order to measure the brake drag force after pad

<Front>
3 installation, measure the rotary-sliding resistance
of the hub with the pads removed. For the front
2
brakes, refer to P.35A-19. For the rear brakes,
1 refer to P.35A-24.
5. Install the pads and caliper assembly, and then
check the brake drag force. For the front brakes,
5 refer to P.35A-19. For the rear brakes, refer to
P.35A-24.
3
<Rear>
3
2
4
1
3 AC301230AB
3. Remove the following parts from caliper support.

(1) Pad assembly or Pad and wear indicator
assembly
(2) Pad assembly
(3) Clip
(4) Inner shim
(5) Outer shim
ON-VEHICLE SERVICE
DISC BRAKE ROTOR CHECK

M1351002900367
CAUTION
Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following
conditions should be checked.
Inspection item Remark
Scratches, rust, saturated lining materials and wear • If the vehicle is not driven for a long period of
time, sections of the discs that are not in contact
with the pads will become rusty, causing noise
and shuddering.
• If grooves and scratches resulting from excessive
disc wear are not removed prior to installing a new
pad assembly, there will be inadequate contact
between the disc and the lining (pad) until the
pads conform to the disc.
Run-out Excessive run-out of the discs will increase the pedal
depression resistance due to piston kick-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause
pedal pulsation, shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing
will cause warping or distortion.
BRAKE DISC THICKNESS CHECK 1. Using a micrometer, measure disc thickness at
eight positions, approximately 45° apart and 10
mm in from the outer edge of the disc.
Standard value:
<Front> 24.0 mm
<Rear> 10.0 mm
Minimum limit:
<Front> 22.4 mm
<Rear> 8.4 mm
NOTE: Thickness variation (at least 8 positions)
ACX00668
should not be more than 0.015 mm.
ON-VEHICLE SERVICE
CAUTION
• After a new brake disc is installed, always BRAKE DISC RUN-OUT CHECK AND
grind the brake disc with on-the-car type CORRECTION
brake lathe. If this step is not carried out, the 1. Remove the brake caliper assembly, and then
brake disc run-out exceeds the specified hold it with wire.
value, resulting in judder. 2. Temporarily install the disc with the hub nut.
•
M12 Flat washer
ACX00669
3. Place a dial gauge approximately 5 mm from the

outer circumference of the brake disc, and
measure the run-out of the disc.
M12 Flat washer Limit:
<Front> 0.04 mm
<Rear> 0.05 mm
AC006226AD
When the on-the-car type lathe is used, first

install M12 flat washer on the stud bolt in the
brake disc side according to the figure, and
then install the adapter. If the adapter is
installed with M12 flat washer not seated, the
brake disc rotor may be deformed, resulting
in inaccurate grinding.
• Grind the brake disc with all wheel nuts
diagonally and equally tightened to the
specified torque 100 N⋅m. When all numbers
of wheel nuts are not used, or the tightening
torque is excessive or not equal, the brake
disc rotor or drum may be deformed,
resulting in judder.
2. If the disc thickness is less than the limits, replace
it with a new one. If thickness variation exceeds
the specification, turn rotor with an on-the-car type
brake lathe ("MAD, DL-8700PF" or equivalent). If
the calculated final thickness after turning the
rotor is less than the standard value, replace the
disc.
ON-VEHICLE SERVICE
Chalk marks CAUTION

• After a new brake disc is installed, always
grind the brake disc with on-the-car type
brake lathe. If this step is not carried out, the
brake disc run-out exceeds the specified
value, resulting in judder.
•
M12 Flat washer

AC201323AC
4. If the brake disc run-out exceeds the limit, correct

it as follows:
(1) Chalk phase marks on the wheel stud and the
brake disc, which run-out is excessive as
shown.
M12 Flat washer
AC102407
(2) Remove the brake disc. Then place a dial AC006226AD
gauge as shown, and measure the wheel When the on-the-car type lathe is used, first
bearing axial play by pushing and pulling the install M12 flat washer on the stud bolt in the
wheel hub. brake disc side according to the figure, and
Limit: 0.05 mm then install the adapter. If the adapter is
(3) If the axial play exceeds the limit, disassemble installed with M12 flat washer not seated, the
the hub and knuckle/trailing arm assembly to brake disc rotor may be deformed, resulting
check each part. in inaccurate grinding.
(4) If the axial play does not exceed the limit, • Grind the brake disc with all wheel nuts
dephase the brake disc and secure it. Then diagonally and equally tightened to the
recheck the brake disc run-out. specified torque 100 N⋅m. When all numbers
of wheel nuts are not used, or the tightening
torque is excessive or not equal, the brake
disc rotor or drum may be deformed,
resulting in judder.
5. If the run-out cannot be corrected by changing the
phase of the brake disc, replace the brake disc or
grind it with the on-the-car type brake lathe
("MAD, DL-8700PF" or equivalent).
BRAKE PEDAL
BRAKE PEDAL
M1351003400440
• Brake Pedal Adjustment (Refer to P.35A-4).
<M/T>
10
11
12 ± 2 N·m
12 ± 2 N·m
1
2
6 4
3 9
14 ± 3 N·m
AC301350AC
<A/T>
10
11
12 ± 2 N·m
7
8
12 ± 2 N·m 6
1
5 2
4
14 ± 3 N·m 3
9 AC309283AB
BRAKE PEDAL

1. Harness connector M1351003500180
2. Stop lamp switch STOP LAMP SWITCH CHECK

3. Adjuster
4. Pedal stopper
5. Snap pin
6. Pin assembly
7. Split pin <A/T>
No continuity Continuity
8. Shift lock cable connection <A/T>
9. Pedal pad
10. Reinforced bracket
11. Brake pedal and pedal support
member 4 mm
AC006235AB
1. Connect an ohmmeter between the stop lamp

switch connector terminals.
2. There should be no continuity between the
terminals when the plunger is pushed in as
shown. There should be continuity when it is
released.
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

M1351003700474

• Air Intake Hose and Air Cleaner Removal (Refer to • Brake Fluid Supplying and Air Bleeding (Refer to
GROUP 15, Air Cleaner P.15-3). <L.H. drive vehicles> P.35A-7).
• Brake Fluid Draining • Brake Pedal Adjustment (Refer to P.35A-4).
• Air Intake Hose and Air Cleaner Installation (Refer to
GROUP 15, Air Cleaner P.15-3). <L.H. drive vehicles>
2
12 ± 2 N·m
3
1
16
6 3M ATD Part No. 8661 or equivalent
5 11
4 7
15 ± 2 N·m 12
10
14 ± 3 N·m
13 15
10 ± 2 N·m 8
14
9 15 ± 2 N·m AC309375AB
AC309375
<L.H. drive vehicles> <R.H. drive vehicles>

2000 2400
16 ± 1 N·m
11
11
16
11
Master cylinder removal steps Master cylinder removal steps

1. Brake fluid level sensor connector 8. Brake pipe connection
<<A>> >>D<< 2. Reservoir protector <R.H. drive 9. Bracket <L.H. drive vehicles>
vehicles> 10. Master cylinder
3. Reservoir cap assembly Brake booster removal steps
4. Reservoir 1. Brake fluid level sensor connector
5. Brake fluid level sensor 8. Brake pipe connection
6. Reservoir hose <M/T> 9. Bracket <L.H. drive vehicles>
>>C<< 7. Reservoir hose 10. Master cylinder
Brake booster removal steps INSTALLATION SERVICE POINTS

>>B<< • Push rod protrusion amount check
>>A<< VACUUM HOSE CONNECTION
and adjustment
>>A<< 11. Vacuum hose (with built-in check
Insert vacuum hose with its paint mark facing
valve) upward.
12. Snap pin
13. Pin assembly
>>B<< PUSH ROD PROTRUSION AMOUNT
14. Brake booster CHECK AND ADJUSTMENT
15. Sealer
Fitting removal steps
>>A<< 11. Vacuum hose (with built-in check
valve)
16. Fitting
A
<<A>> RESERVOIR PROTECTOR REMOVAL
<R.H. DRIVE VEHICLES>
1
Measuring distance A
Reservoir protector 1 Block gauge

AC102457BD
1. Use the vacuum pump to measure dimension "A"

applying a negative pressure of 66.7 kPa to the
brake booster.
NOTE: When a negative pressure of 66.7 kPa is
Reservoir not applied to the brake booster, the push rod
AC309673AB protrusion amount (A) should be 8.85 - 9.10 mm.
Disengage the claw of arrow 1 and arrow 2 in
sequence, then remove the reservoir protector.
>>C<< RESERVOIR HOSE CONNECTION
Paint mark
Paint mark
Rod spline
Master cylinder
AC200460AC
Angle-nose pliers Insert the reservoir hose with its paint mark facing
front of the vehicle.
>>D<< RESERVOIR PROTECTOR INSTALLATION

<R.H. DRIVE VEHICLES>
Reservoir protector
MB991568
AC200306AC
2. If the protrusion amount is not within the standard

value range, adjust the push rod length by turning
the push rod. Use special tool push rod adjusting
socket (MB991568) to turn the push rod while Reservoir
holding the rod spline with angle-nose pliers. AC309675AB
Install the reservoir protector with its arrow mark

facing behind the vehicle.
MASTER CYLINDER
M1351004200320
N 4
1 2 5
6
3
5N Master cylinder kit
7
3 6N
6 5
Brake fluid: DOT 3 or DOT 4
AC102644 AE
Disassembly steps INSPECTION

1. Spring pin M1351004300253
2. Nipple • Check the inner surface of master cylinder body

3. Reservoir seal for rust or pitting.
4. Piston retainer • Check the primary and secondary pistons for
5. Primary piston assembly rust, scoring, wear or damage.
6. Secondary piston assembly
7. Master cylinder body
FRONT DISC BRAKE ASSEMBLY

M1351006000452
100 ± 10 N·m
30 ± 5 N·m 1
N 2
3
AC301353AB
Removal steps 1. In order to measure the brake drag torque,

• Brake fluid draining measure the hub torque with the pads removed by
1. Brake hose connection the following procedure.
2. Brake fluid line gasket (1) Use a spring balance to measure the hub
3. Front brake assembly torque in the forward direction.
4. Front brake disc
(2) Record hub torque with pads removed.
Installation steps
4. Front brake disc CAUTION
>>A<< 3. Front brake assembly Do not let any oil, grease or other contamination
2. Brake fluid line gasket get onto the friction surfaces of the pads and
1. Brake hose connection brake discs.
• Brake fluid supplying and air bleeding
(Refer to P.35A-7). 2. After re-installing the caliper support to the
>>B<< • Brake drag force check knuckle, install the pad clips and the pads to the
caliper support.
>>A<< FRONT BRAKE ASSEMBLY
INSTALLATION MB990520
AC301354 AB
Spring balance 3. Clean the piston and insert into cylinder with
special tool disc brake piston expander
AC000906AF
(MB990520).
4. Be careful that the piston boot does not become
caught, when lowering the caliper assembly and
installing the guide pin bolt.
>>B<< BRAKE DRAG FORCE CHECK (4) Use a spring balance to measure the hub
1. Check the brake drag force as follows. torque with pads installed in the same
(1) Start the engine and hold the brake pedal direction as earlier.
down for 5 seconds. (Pedal depression force: (5) Calculate the drag force of the disc brake
approximately 200 N) [difference between hub torque with pads
(2) Stop the engine. installed and hub torque with pads removed].
(3) Turn the brake disc forward 10 times. Standard value: 68 N or less
2. If the brake drag force exceeds the standard
value, disassemble and clean the piston. Check
for corrosion or worn piston seal, and check the
sliding condition of the lock pin and guide pin.
INSPECTION
M1351006100277
BRAKE DISC CHECK
Spring balance Disc wear (Refer to P.35A-10).
AC000908 AE
Disc run-out (Refer to P.35A-10).

M1351006200423
14
14
12
74 ± 10 N·m 11
1 2 14
5 Clip set
13
9
8 7
6 14
7.9 ± 0.9 N·m
74 ± 10 N·m
3 4
9
10 5 8
7 6
AC202238 AD
1
2 5 11 2
7 5
9 11 13 9
8 7
6
6
3
10 9 8 4 7
7 5
5 6 12
Grease
Caliper kit Pad set Shim set Caliper seal kit

1. Lock pin <> 9. Piston seal
2. Bushing 10. Caliper body
3. Guide pin 11. Pad and wear indicator assembly
4. Caliper support (including pad, clip, 12. Pad assembly
and shim) 13. Outer shim
5. Pin boot 14. Clip
6. Boot ring
<<A>> 7. Piston boot
<<A>> 8. Piston
LUBRICATION POINTS
Piston seal
Grease: Repair kit grease
! CAUTION
The piston seal inside the caliper seal
kit is coated with a special grease.
Do not wipe this grease off.
AC202239 AD
Grease: Repair kit grease Grease: Repair kit grease

DISASSEMBLY SERVICE POINTS 1. Remove the piston seal with your finger tip.
When disassembling the disc brakes, disassemble 2. Clean the piston surface and inner cylinder with
both sides (left and right) as a set. alcohol or brake fluid DOT 3 or DOT 4.
<<A>> PISTON BOOT/PISTON REMOVAL
CAUTION INSPECTION
M1351006300345
• Blow air little by little to remove the pistons. • Check the cylinder for wear, damage or rust.
The pistons will rush out if a force of air is • Check the piston surface for wear, damage or
applied suddenly. rust.
• If one piston has been removed completely, it • Check the caliper body or sleeve for wear.
will become impossible to remove the second • Check the pad for damage or adhesion of grease,
piston. check the backing metal for damage.
PAD WEAR CHECK
WARNING
• Always replace both brake pads on each
wheel as a set. Failure to do so will result
in uneven braking, which may cause
unreliable brake operation.
• If there is significant difference in the
thickness of the pads on the left and right
AC202257 sides, check the sliding condition of the
piston and slide pins.
Remove the pistons and the piston boots by pumping
in air from the brake hose connection. Be sure to use
the handle of a plastic hammer and adjust the height
of the two pistons so that the pistons protrude evenly.
<> PISTON SEAL REMOVAL

CAUTION
Do not use a flat-tipped screwdriver or similar
tool to remove the piston seal. These may
damage the inner side of the cylinder. ACX00690
1. Measure thickness at the thinnest and most worn

area of the pad.
2. Replace the pad assembly if pad thickness is less
than the limit value.
AC301355AB
REAR DISC BRAKE ASSEMBLY

M1351007000358
1 15 ± 2 N·m
60 ± 5 N·m
3
AC201830AC
Removal steps Use a spring balance to measure the hub torque

• Brake fluid draining in the forward direction. Record hub torque with
1. Brake hose connection pads removed.
2. Rear brake assembly
CAUTION
3. Rear brake disc
Installation steps
Do not let any oil, grease or other contamination
3. Rear brake disc get onto the friction surfaces of the pads and
>>A<< 2. Rear brake assembly brake discs.
1. Brake hose connection 2. After re-installing the caliper support to the
• Brake fluid supplying and air bleeding backing plate, install the pad clips and the pads to
(Refer to P.35A-7). the caliper support.
>>B<< • Brake drag force check

>>A<< REAR BRAKE ASSEMBLY INSTALLATION
MB990520
AC301357 AB
3. Clean the piston and insert into cylinder with

special tool disc brake piston expander
AC201814 (MB990520).
4. Be careful that the piston boot does not become
1. In order to measure the brake drag torque,
caught, when lowering the caliper assembly and
measure the hub torque with the pads removed by
installing the lock pin.
the following procedure.
>>B<< BRAKE DRAG FORCE CHECK (4) Use a spring balance to measure the hub
1. Check the brake drag force as follows. torque with pads installed in the same
(1) Start the engine and hold the brake pedal direction as earlier.
down for 5 seconds. (Pedal depression force: (5) Calculate the drag force of the disc brake
approximately 200 N) [difference between hub torque with pads
(2) Stop the engine. installed and hub torque with pads removed].
(3) Turn the brake disc forward 10 times. Standard value: 68 N or less
2. If the brake drag force exceeds the standard
value, disassemble and clean the piston. Check
for corrosion or worn piston seal, and check the
sliding condition of the lock pin and guide pin.
INSPECTION
M1351007100236
BRAKE DISC CHECK
Disc wear (Refer to P.35A-10).
Disc run-out (Refer to P.35A-10).
AC201815

M1351007200233
13 13
44 ± 5 N·m 12
14
3 7.9 ± 0.9 N·m
15
10
1 5
11 13
Clip set
7
44 ± 5 N·m
13
6
2 9 5
2
5 9
8
8
5 6
4
Grease
AC203578 AE Seal and boot repair kit
12
10 11 14 15
3 5
9
1 8
4
2
5 7 15
12
6 11
Grease
Brake caliper kit Pad set Shim set

1. Lock pin <> 9. Piston seal
2. Bushing 10. Caliper body
3. Guide pin 11. Pad and wear indicator assembly
4. Caliper support 12. Inner shim
5. Pin boot 13. Clip
6. Boot ring 14. Pad assembly
<<A>> 7. Piston 15. Outer shim
<<A>> 8. Piston boot
LUBRICATION POINTS
Piston seal
AC203550
! CAUTION
The piston seal inside the seal and boot
kit is coated with a special grease.
Do not wipe this grease off.

AC202232 AC
DISASSEMBLY SERVICE POINTS <> PISTON SEAL REMOVAL

When disassembling the disc brakes, disassemble CAUTION
both sides (left and right) as a set. Do not use a flat-tipped screwdriver or similar
<<A>> PISTON BOOT/PISTON REMOVAL tool to remove piston seal. These may damage
CAUTION the inner side of the cylinder.
Blow air little by little to remove the piston. The
piston will rush out if a force of air is applied
suddenly.
ACX00689
1. Remove the piston seal with your finger tip.

2. Clean the piston surface and inner cylinder with
ACX00697
alcohol or brake fluid DOT 3 or DOT 4.
Place a piece of wood, etc. against the caliper body
as shown. Blow compressed air through the brake INSPECTION
hose to remove the piston boot and piston. M1351007300229
Refer to P.35A-23.
35B-1
GROUP 35B
ANTI-SKID
BRAKING SYSTEM
(ABS)
CONTENTS
GENERAL INFORMATION . . . . . . . . 35B-2 ACTUATOR TEST REFERENCE TABLE . . 35B-56

CHECK AT ABS-ECU . . . . . . . . . . . . . . . . . 35B-56
SERVICE SPECIFICATIONS. . . . . . . 35B-3
ON-VEHICLE SERVICE . . . . . . . . . . . 35B-59
SPECIAL TOOLS. . . . . . . . . . . . . . . . 35B-4 ABS SENSOR OUTPUT VOLTAGE
MEASUREMENT. . . . . . . . . . . . . . . . . . . . . 35B-59
TROUBLESHOOTING . . . . . . . . . . . . 35B-5 HYDRAULIC UNIT CHECK . . . . . . . . . . . . . 35B-61
STANDARD FLOW OF DIAGNOSTIC IN THE EVENT OF A DISCHARGED
TROUBLESHOOTING . . . . . . . . . . . . . . . . 35B-5 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-63
NOTES WITH REGARD TO DIAGNOSIS . 35B-5
ABS WARNING LAMP INSPECTION. . . . . 35B-6 HYDRAULIC UNIT . . . . . . . . . . . . . . . 35B-64
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 35B-6 REMOVAL AND INSTALLATION . . . . . . . . 35B-64
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-8 ABS SENSOR. . . . . . . . . . . . . . . . . . . 35B-67
DIAGNOSTIC TROUBLE CODE REMOVAL AND INSTALLATION . . . . . . . . 35B-67
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 35B-9 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35B-68
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 35B-40 G-SENSOR . . . . . . . . . . . . . . . . . . . . . 35B-69
INSPECTION PROCEDURE FOR REMOVAL AND INSTALLATION . . . . . . . . 35B-69
TROUBLE SYMPTOMS . . . . . . . . . . . . . . . 35B-41
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35B-69
DATA LIST REFERENCE TABLE . . . . . . . 35B-55
35B-2 ANTI-SKID BRAKING SYSTEM (ABS)
GENERAL INFORMATION
GENERAL INFORMATION
M1352000100410
FEATURES EBD CONTROL
The 4ABS ensures directional stability and In ABS, electronic control is used so the rear wheel
controllability during hard braking. brake hydraulic pressure during braking is regulated
This ABS uses a 4-sensor 3-channel system that by rear wheel control solenoid valves in accordance
controls the right and left front wheels independently with the vehicle's rate of deceleration, and the front
of each other and controls the rear wheels and rear wheel slippage which are calculated from
simultaneously (select low control*). The basic the signals received from the various ABS sensors.
system is the same as that of former EBD control is a control system which provides a
COLT/LANCER. 4WD models are equipped with high level of control for both vehicle braking force
G-sensor. and vehicle stability. The system has the following
features:
NOTE: *Select low control: Control system that
• Because the system provides the optimum rear
compares the speeds of the right and left wheels and
wheel braking force regardless of vehicle load
performs the same fluid pressure control on both
conditions and the condition of the road surface,
wheels according to the speed of the wheel that is
the system reduces the required pedal
likely to be locked.
depression force, particularly when the vehicle is
The system has the following features:
heavily loaded or driven on road surfaces with
• EBD (Electronic Brake-force Distribution system)
high frictional coefficients.
control has been added to provide the ideal
• Because the duty placed on the front brakes is
braking force for the rear wheels.
reduced, the increases in pad temperature can
• Fail-safe function which ensures that safety is
be controlled during front brakes application to
maintained
improve the wear resistance characteristics of the
• Diagnostic function which provides improved
pad.
serviceability
• Control valves such as the proportioning valve
are no required.
SPECIFICATIONS
Item Specification
ABS control method 4-sensor, 3-channel
Number of ABS rotor teeth Front 43
Rear 43
ABS sensor Type Magnet coil type
Maximum gap between sensor and rotor 0.85 <Front>
mm <Non-adjustable> 0.89 <Rear (2WD)>
0.96 <Rear (4WD)>
ANTI-SKID BRAKING SYSTEM (ABS) 35B-3
ABS warning lamp
Hydraulic unit and

ABS-ECU
Diagnosis
connector
Stop lamp switch ABS sensor (rear)

G-sensor <4WD> ABS rotor (rear)
ABS rotor (front)
ABS sensor (front) AC301089AC
M1352000300544
Item Standard value

ABS sensor internal resistance kΩ 1.24 − 1.64
G-sensor output voltage <4WD> V Stationary vehicles 2.4 − 2.6
Arrow facing downward 3.4 − 3.6
SPECIAL TOOLS
SPECIAL TOOLS
M1352000600761

MB991502 MUT-II sub assembly Checking the ABS
(Diagnosis display using
the MUT-II)
B991502
MB991955 MUT-III sub-assembly Checking the ABS

A A: MB991824 A: Vehicle (Diagnosis display using
B: MB991827 Communication Interface the MUT-III)
C: MB991910 (V. C. I.) CAUTION
D: MB991911 B: MUT-III USB cable MUT-III main harness B
MB991824 E: MB991825 C: MUT-III main harness (MB991911) should be
B F: MB991826 A (Vehicles with CAN used. MUT-III main
communication system) harness A should not
D: MUT-III main harness be used for this vehicle.
B (Vehicles without CAN
MB991827 communication system)
E: MUT-III measurement
C
adapter
DO NOT USED F: MUT-III trigger harness
MB991910
MB991911
MB991825
MB991826
MB991955
MB991529 Diagnosis code check Checking the ABS

harness (Diagnosis display using
the ABS warning lamp)
MB991529
TROUBLESHOOTING

MB991348 Test harness set Checking the G-sensor
<4WD>
MB991348
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC
TROUBLESHOOTING
M1352011100511
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points P.00-6.
NOTES WITH REGARD TO DIAGNOSIS

M1352012600177
1. The ABS is a system which controls the brake
pressure by means of the operation of the ECU.
Accordingly, the following symptoms may occur at
times, but these are a sign of normal ABS
operation, and do not indicate a malfunction.
Phenomenon Explanation of phenomenon
When the engine starts, a knocking sound can be heard coming This sound occurs as a result of system
from the engine compartment. operation checking, and is not a
malfunction.
• Sound of the motor inside the ABS hydraulic unit operation. This is the sound of normal system
(whine) operation, and is not a malfunction.
• Sound is the generated along with vibration of the brake
pedal. (scraping)
• When ABS operates, sound is generated from the vehicle
chassis due to repeated brake application and release.
(Thump: suspension; squeak: tyres)
Shocks are felt if the brake pedal is depressed when driving at This is due to system operation checking
low speed. (starting-of check when the vehicle speed
reaches a certain number of km/h) and is
not a malfunction.
2. For road surfaces such as snow-covered roads 3. Diagnosis detection condition can vary depending
and gravel roads, the braking distance for on the diagnosis code. Make sure that checking
vehicles with ABS can sometimes be longer than requirements listed in the "Comment" are satisfied
that for other vehicles. Accordingly, advise the when checking the trouble symptom again.
customer to drive safely on such roads by
lowering the vehicle speed and not being too
overconfident.
TROUBLESHOOTING
ABS WARNING LAMP INSPECTION 4. If the illumination is other than the above, check
M1352012000197 the diagnosis codes.
DIAGNOSIS FUNCTION
M1352011200756
READING DIAGNOSIS CODES

When Using the MUT-II/III
Troubleshooting/Inspection Service Points P.00-6.
When Using the ABS Warning Lamp

position.
Approx. 3 s Approx. 3 s
Diagnosis connector
ABS Illuminated
warning
lamp Not
illuminated
START
Ignition MB991529
ON
switch 1 2 3 4 5 6 7 8
ACC 9 10 11 12 13 14 15 16
AC107528 AH
AC301359AB
2. Use special tool diagnosis code check harness
Check that the ABS warning lamp illuminates as (MB991529) to earth terminal number 1
follows. (diagnosis control terminal) of the diagnosis
1. When the ignition switch is turned to the "ON" connector.
position, the ABS warning lamp illuminates for 3. Turn the ignition switch to the "ON" position.
approximately 3 seconds and then switches off.
2. When the ignition switch is turned to the "START"
position, the ABS warning lamp remains
illuminated.
3. When the ignition switch is turned from the
"START" position back to the "ON" position, the
ABS warning lamp illuminates for approximately 3
seconds and then switches off.
NOTE: The ABS waning lamp may remain on until
the vehicle reaches a speed of several km/h. This ABS warning lamp
AC301437AB
is limited to cases where diagnosis code Nos. 21
to 24, 41 to 44, or 53 to 55 have been recorded 4. Read out a diagnosis code by observing how the
because of a previous problem occurring. In this warning lamp flashes.
case, the ABS-ECU keeps the warning lamp
illuminated until the problem corresponding to that
diagnosis code can be detected.
TROUBLESHOOTING
When the diagnosis code No.24 is set When no diagnosis code is set
0.5 sec. 0.25 sec.

1.5 secs.
0.5 sec.
Illuminated
Illuminated
Switched Switched
off off
Pause Tens Place Units
ACX01778 AD
time signal division signal
3 secs. 2 secs.
ACX01777 AD

Diagnosis connector
position.
6. Disconnect special tool diagnosis code check
harness (MB991529).
ERASING DIAGNOSIS CODES

When Using the MUT-II/III
MB991529
1 2 3 4 5 6 7 8
Troubleshooting/Inspection Service Points P.00-6. 9 10 11 12 13 14 15 16
AC107528 AH
When not Using the MUT-II/III
2. Use special tool diagnosis code check harness
NOTE: If the ABS-ECU functions have stopped due
(MB991529) to earth terminal number 1 of the
to the fail-safe function, the diagnosis code cannot
be erased.
position.
ON
Ignition switch
OFF(OFF)
ON
Stop lamp switch
OFF
ON
ABS warning lamp
OFF
3 sconds
ABS-ECU memory
Within Within Within
1 1
Within Within Within Within Within Within Within Within
1 1 1 1 1 1 1 1
1
3 sconds seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds
seconds
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Erasing of ABS-ECU
diagnosis codes complete.
AC000937AD
3. Depress the brake pedal and hold it. 6. Turn the ignition switch to the "LOCK" (OFF)
4. Turn the ignition switch to the "ON" position. position.
5. After turning the ignition switch to the "ON", 7. Disconnect special tool diagnosis code check
release the pedal within three seconds. Repeat harness (MB991529).
this process of pressing and releasing the brake
pedal 10 continuous times.
TROUBLESHOOTING

CODE
M1352011300708
Follow the inspection chart that is appropriate for the
diagnosis code.
Diagnosis code Inspection item Diagnostic content Reference page
No.
11 Front right ABS sensor Open circuit or short circuit P.35B-9
12 Front left ABS sensor
13 Rear right ABS sensor
14 Rear left ABS sensor
16 ABS-ECU power supply system ABS-ECU power supply P.35B-17
voltage below or above the
specified value. Not
displayed if the voltage
recovers.
21 Front right ABS sensor P.35B-19
22 Front left ABS sensor
23 Rear right ABS sensor
24 Rear left ABS sensor
32 G sensor system <4WD> P.35B-27
33 Stop lamp switch system P.35B-33
41 ABS front right solenoid valve P.35B-37
42 ABS front left solenoid valve
43 ABS rear right solenoid valve
44 ABS rear left solenoid valve
51 Valve relay problem (stays on) Replace the hydraulic
unit (Integrated with
ABS-ECU).
52 Valve relay problem (stays off) P.35B-37
53 Motor relay problem (stays off)
54 Motor relay problem (stays on) Replace the hydraulic
unit (Integrated with
ABS-ECU).
55 Motor system (seized pump motor) P.35B-37
63 • ABS-ECU abnormality Replace the hydraulic
• Improperly installed ABS-ECU <2WD> unit (Integrated with
ABS-ECU).
NOTE: diagnosis code No.16, 52, 63
.
• Code No.16 is cleared from the memory by turning the ignition switch to the "ACC" position. When the
system is properly reset, this code is also cleared from the memory.
• Code No.52 and 63 are cleared from the memory by turning the ignition switch to the "ACC" position.
TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE

PROCEDURES
Code No.11, 12, 13 and 14: ABS Sensor (Open Circuit or Short Circuit)
ABS Sensor Circuit
ABS SENSOR
(FRONT: LH) (FRONT: RH) (REAR: LH) (REAR: RH)
ABS-ECU
Wire colour code

AC301686AB
OPERATION • The ABS sensors transmit the frequency of the

• A toothed ABS rotor generates a voltage pulse as voltage pulses and the amount of voltage
it moves across the pickup field of each ABS generated by each pulse to the ABS-ECU.
sensor. • The hydraulic unit modulates the amount of
• The amount of voltage generated at each wheel braking force individually applied to each wheel
is determined by the clearance between the ABS cylinder.
rotor teeth and the ABS sensor, and by the speed
of rotation.
TROUBLESHOOTING

STEP 3. Resistance measurement at ABS-ECU
Diagnosis codes No.11, 12, 13 and 14 are set when
connector B-03.
signal is not input due to breakage of the wires of the
four ABS sensors. Connector: B-03
PROBABLE CAUSES
The most likely causes for these diagnosis codes to
set are:
B-03 (GR)
• Malfunction of the ABS sensor
• Malfunction of the hydraulic unit (integrated with
ABS-ECU)
DIAGNOSIS Harness side

Set MUT-II/III to data reading mode, and check the
data list items by driving the vehicle. AC301441AB
• Item 01: Front right ABS sensor
• Item 02: Front left ABS sensor (1) Disconnect ABS-ECU connector B-03 and
• Item 03: Rear right ABS sensor measure at the harness side.
• Item 04: Rear left ABS sensor
Connector B-03
OK: The reading on the speedometer nearly (harness side)
matches the indication on MUT-II/III, when
driving.
Q: Is the ABS sensor input normal?
YES : This malfunction is intermittent. Refer to
GROUP 00, How to Use
Troubleshooting/Inspection Service Points −
How to Cope With Intermittent Malfunction
AC301683 AB
P.00-6.
NO : Go to Step 2. (2) Measure the resistance between ABS-ECU
connector terminals 16 and 26, 9 and 10, 27 and
28, or 11 and 17.
STEP 2. Inspect the ABS sensor.
Refer to P.35B-68. Standard Value: 1.24 − 1.64 kΩ
Check items: Q: Is the resistance between terminals 16 and 26, 9

• ABS sensor internal resistance: 1.24 − 1.64 kΩ and 10, 27 and 28, or 11 and 17 within the standard
value?
• Insulation between the ABS sensor body and the When resistances between all terminals are within
connector terminals the standard value : Erase the diagnosis code
Q: Is the ABS sensor damaged? memory, and recheck if any diagnosis code
YES : Replace it and then go to Step 8. sets. If diagnosis code No.11, 12, 13 or 14
NO : Go to Step 3. sets, replace the hydraulic unit (integrated
with ABS-ECU). Then go to Step 8.
When resistance between terminals 16 and 26 is
not within the standard value : Go to Step 4.
When resistance between terminals 9 and 10 is not
within the standard value : Go to Step 5.
TROUBLESHOOTING
NOTE:
STEP 4. Check the harness wires between Connector: A-14 <LHD>
ABS-ECU connector B-03 (terminals 16 and 26)
and ABS sensor <front: LH> connector A-13
(terminals 1 and 2).
Connector: A-13
A-14(GR)
A-13 (B)
Harness side
AC308679AG
Connector: A-14
<RHD>
AC301443AB
Connector: B-03
A-14(GR)
B-03 (GR)
AC308686AH
After inspecting ABS-ECU connector B-03,

intermediate connector A-14 and ABS sensor <front:
LH> connector A-13, inspect the wire. If any of these
connectors is damaged, repair or replace it. Then go
Harness side
to Step 8.
Q: Is any harness wire between ABS-ECU connector
B-03 (terminals 16 and 26) and ABS sensor <front:
LH> connector A-13 (terminals 1 and 2) damaged?
AC301441AB YES : Repair it and go to Step 8.
NO : This malfunction is intermittent. Refer to
How to Cope with Intermittent
MalfunctionP.00-6.
TROUBLESHOOTING
NOTE:
STEP 5. Check the harness wires between
ABS-ECU connector B-03 (terminals 10 and 9) <LHD>
and ABS sensor <front: RH> connector A-31
Connector: A-31
A-31 (B)
Harness side C-104(B)

C-14
C-14
1 2 3
4 5 6 7 8 9
AC301444AB 10 11 12 13 14 15
Connector: B-03
C-104(B)
1 2
3 4 5 6
7 8 9 10 11 12
16
13 14 15 17 18 19
B-03 (GR)
AC308719 AI
Connector: C-14
<RHD>
Harness side
1 2 3 4
5 6 7 8 9 10
AC301441AB C-14
AC308769AY
Connector: C-104
<RHD>
C-104 (B)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
AC308735AV

intermediate connectors C-14 and C-104, and ABS
sensor <front: RH> connector A-31, inspect the wire.
If any of these connectors is damaged, repair or
replace it. Then go to Step 8.
TROUBLESHOOTING

RH> connector A-31 (terminals 1 and 2) damaged? ABS-ECU connector B-03 (terminals 28 and 27)
YES : Repair it and go to Step 8. and ABS sensor <rear: LH> connector D-22
NO : This malfunction is intermittent. Refer to (terminals 1 and 2).
GROUP 00, How to Use Connector: B-03
MalfunctionP.00-6.
B-03 (GR)
Harness side
AC301441AB
Connector: D-22
D-22 (B)
Harness side
AC301446AB
TROUBLESHOOTING
NOTE:
Connector: C-104 Connectors: C-104, C-117
<LHD> <RHD>
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
C-117
C-104 (B)
C-104(B)
AC308718 AQ
Connector: C-117
<LHD> C-104(B)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
C-117
1 2 3 111213
1 2 3 4 5 6 7 8 9 10 111213
4 5 6 7 8 9 10
14 1516 17 1819 20 2122 2324 25 14 1516 17 1819 20 2122 2324 25
26 27 28 29 30 31 38 26 27 28 29 30 31 38
32 33 34 35 36 37 C-117 32 33 34 35 36 37
AC308716 AV AC308736 AJ
Connector: D-24 Connector: D-24

<LHD> <RHD>
D-24
D-24
1 2 3
4 5 6 7 8 1 2 3
4 5 6 7 8
D-24 AC309649AB D-24 AC309650AB

intermediate connectors C-104, C-117 and D-24, and
ABS sensor <rear: LH> connector D-22, inspect the
wire. If any of these connectors is damaged, repair or
B-03 (terminals 28 and 27) and ABS sensor <rear:
LH> connector D-22 (terminals 1 and 2) damaged?
YES : Repair it and then go to Step 8.
MalfunctionP.00-6.
TROUBLESHOOTING
NOTE:
STEP 7. Check the harness wires between Connector: C-104
and ABS sensor <rear: RH> connector D-13
Connector: B-03
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
C-104 (B)
B-03 (GR)
AC308718 AQ
Connector: C-117
<LHD>
Harness side
1 2 3 4 5 6 7 8 9 10 111213
14 1516 17 1819 20 2122 2324 25
26 27 28 29 30 31 38
AC301441AB 32 33 34 35 36 37 C-117
AC308716 AV
Connector: D-13
Connector: D-24
<LHD>
D-24
D-13 (B) 1 2 3
4 5 6 7 8
Harness side
AC301445AB
D-24 AC309649AB
TROUBLESHOOTING

<RHD> B-03 (terminals 11 and 17) and ABS sensor <rear:
RH> connector D-13 (terminals 1 and 2) damaged?
NO : Go to Step 8.
C-117 STEP 8. Check whether the diagnosis code is

reset.
C-104(B)
Q: Is diagnosis code No.11, 12, 13 or 14 set?
YES : Start over at Step 1.
C-104(B)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
C-117
1 2 3 4 5 6 7 8 9 10 111213
14 1516 17 1819 20 2122 2324 25
26 27 28 29 30 31 38
32 33 34 35 36 37
AC308736 AJ
Connector: D-24
<RHD>
D-24
1 2 3
4 5 6 7 8
D-24 AC309650AB

ABS sensor <rear: RH> connector D-13, inspect the
TROUBLESHOOTING
Code No.16: ABS-ECU Power Supply System (ABS-ECU Power Supply Voltage or Valve Relay Power
Supply Voltage below or above the Specified Value)
ABS-ECU Power Supply Circuit

IGNITION
SWITCH (IG2)
ABS-ECU
POWER
SOURCE
Wire colour code

AC301687 AB
OPERATION DIAGNOSIS
The ABS-ECU power is supplied to the ABS-ECU
(terminal 20) from the ignition switch (IG2) through
STEP 1. Check the battery.
the multi-purpose fuse number 12 in the junction Refer to GROUP 54A, Battery − On-vehicle Service
block.
− Battery Test P.54A-6.
DIAGNOSIS CODE SET CONDITIONS Q: Is the battery damaged?
Output is provided when ABS-ECU power supply YES : Charge or replace the battery and then go
voltage drops below or rises above the specified to Step 4.
value. Output is not provided if the power supply NO : Go to Step 2.
voltage meets the specified voltage.
PROBABLE CAUSES STEP 2. Check the charging system.

The most likely causes for this diagnosis code to set Refer to GROUP 16, Charging System − On-vehicles
are: Service P.16-6.
• Malfunction of battery Q: Is the charging system damaged?
• Damaged wiring harness or connector YES : Repair the Charging System and then go to
• Malfunction of hydraulic unit and ABS-ECU Step 4.
NO : Go to Step 3.
TROUBLESHOOTING
STEP 3. Check the harness wire between Connectors: C-202, C-203

junction block connector C-203 terminal 2 and <RHD>
C-203
ABS-ECU connector B-03 terminal 20.
C-202
Connector: B-03
B-03 (GR)
C-202
Harness side
6 5 4 3 2 1
Harness side 14 13 12 11 10 9 8 7
C-203
Harness side
2 1
AC301441AB
6 5 4 3

AC308773 AO
<LHD>
C-203 NOTE:
Connector: C-106
<LHD>
1 2
3 4 5 6
C-202 7 8 9 10 11 12
13 14 15 16 17 18 19
C-106 (GR)
C-202
Harness side
AC308718AS
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Connector: C-106
<RHD>
C-203
Harness side
2 1
6 5 4 3 1 2
3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
AC308721 AN C-106 (GR)
AC308735AX

intermediate connector C-106, and junction block
connector C-202 and C-203, inspect the wire. If any
of these connectors is damaged, repair or replace it.
Then go to Step 4.
TROUBLESHOOTING
Q: Is the harness wire between junction block

STEP 4. Check whether the diagnosis code is
connector C-203 terminal 2 and ABS-ECU
connector B-03 terminal 20 damaged? reset.
YES : Repair it and go to Step 4. Q: Is diagnosis code No.16 set?
NO : Erase the diagnosis code memory, and YES : Start over at Step 1.
recheck if any diagnosis code sets. If NO : The procedure is complete.
diagnosis code No.16 sets, replace the
hydraulic unit (integrated with ABS-ECU)
and then go to Step 4 . If diagnosis code
No.16 is not set then an intermittent
malfunction is suspected. Refer to GROUP
00, How to Use Troubleshooting/Inspection
Service Points − How to Cope with
Intermittent Malfunction P.00-6.
Code No.21, 22, 23, 24: ABS Sensor
ABS Sensor Circuit
ABS SENSOR
(FRONT: LH) (FRONT: RH) (REAR: LH) (REAR: RH)
ABS-ECU
Wire colour code

AC301686AB
TROUBLESHOOTING
OPERATION DIAGNOSIS
• A toothed ABS rotor generates a voltage pulse as
it moves across the pickup field of each ABS
sensor. Set MUT-II/III to data reading mode, and check the
• The amount of voltage generated at each wheel data list items by driving the vehicle.
is determined by the clearance between the ABS • Item 01: Front right ABS sensor
rotor teeth and the ABS sensor, and by the speed • Item 02: Front left ABS sensor
of rotation. • Item 03: Rear right ABS sensor
• The ABS sensors transmit the frequency of the • Item 04: Rear left ABS sensor
voltage pulses and the amount of voltage
generated by each pulse to the ABS-ECU. OK: The reading on the speedometer nearly
• The hydraulic unit modulates the amount of matches the indication on MUT-II/III, when
braking force individually applied to each wheel driving.
cylinder. Q: Is the ABS sensor input normal?
DIAGNOSIS CODE SET CONDITIONS GROUP 00, How to Use
Diagnosis codes No.21, 22, 23 and 24 are set in the Troubleshooting/Inspection Service Points −
following cases: How to Cope With Intermittent Malfunction
• Open circuit is not found but no input is received P.00-6.
by one or more of the four ABS sensors at 10 NO : Go to Step 2.
km/h or more.
• ABS sensor output drops due to a malfunctioning
ABS sensor or warped ABS rotor. STEP 2. Check the ABS sensor installation.
Q: Is the ABS sensor bolted securely in place at the
PROBABLE CAUSES front knuckle <front> or the trailing arm <rear>?
The most likely causes for these diagnosis codes to YES : Go to Step 3.
set are: NO : Install it properly (Refer to P.35B-67) and go
• Malfunction of the ABS sensor to Step 11 .
ABS-ECU) STEP 3. Inspect the ABS sensor and ABS rotor.
Refer to P.35B-68.
• Malfunction of the ABS rotor
• Malfunction of the wheel bearing Check items:
• Excessive clearance between the ABS sensor • ABS sensor internal resistance: 1.24 − 1.64 kΩ
and ABS rotor • Insulation between the ABS sensor body and the
• Teeth lack or clogging of the ABS rotor connector terminals
• Toothed ABS rotor check
Q: Is the ABS sensor or ABS rotor damaged?
YES : Replace it and then go to Step 11.
NO : Go to Step 4.
TROUBLESHOOTING
When resistances between all terminals are within

STEP 4. Resistance measurement at the the standard value : Go to Step 9.
ABS-ECU connector B-03. When resistance between terminals 16 and 26 is
Connector: B-03 not within the standard value : Go to Step 5.
When resistance between terminals 9 and 10 is not
within the standard value : Go to Step 6.
B-03 (GR) When resistance between terminals 11 and 17 is

Harness side and ABS sensor <front: LH> connector A-13
Connector: A-13
AC301441AB A-13 (B)
(1) Disconnect ABS-ECU connector B-03 and Harness side

measure at the harness side.
Connector B-03
(harness side)
AC301443AB
Connector: B-03
AC301683 AB
B-03 (GR)
(2) Measure the resistance between ABS-ECU
connector terminals 16 and 26, 9 and 10, 11 and
17, or 27 and 28.
Standard Value: 1.24 − 1.64 kΩ
Harness side
Q: Is the resistance between terminals 16 and 26, 9
and 10, 27 and 28, or 11 and 17 within the standard
value?
AC301441AB
TROUBLESHOOTING
NOTE:
Connector: A-14 <LHD> STEP 6. Check the harness wires between
and ABS sensor <front: RH> connector A-31
Connector: A-31
A-14(GR)
A-31 (B)
Harness side
AC308679AG
Connector: A-14
<RHD>
AC301444AB
Connector: B-03
A-14(GR)
B-03 (GR)
AC308686AH

intermediate connector A-14 and ABS sensor <front:
LH> connector A-13, inspect the wire. If any of these
Harness side
to Step 11.
LH> connector A-13 (terminals 1 and 2) damaged?
YES : Repair it and go to Step 11. AC301441AB

P.00-6.
TROUBLESHOOTING
NOTE: Q: Is any harness wire between ABS-ECU connector

Connectors: C-14, C-104 B-03 (terminals 10 and 9) and ABS sensor <front:
<LHD> RH> connector A-31 (terminals 1 and 2) damaged?
YES : Repair it and go to Step 11.
P.00-6.
C-104(B)
C-14
C-14
1 2 3
and ABS sensor <rear: LH> connector D-22
4 5 6 7 8 9 (terminals 1 and 2).
10 11 12 13 14 15
Connector: B-03
C-104(B)
1 2
3 4 5 6
7 8 9 10 11 12
16
13 14 15 17 18 19
B-03 (GR)
AC308719 AI
Connector: C-14
<RHD>
Harness side
1 2 3 4
5 6 7 8 9 10
AC301441AB
C-14
Connector: D-22
AC308769AY
Connector: C-104
<RHD>
D-22 (B)
Harness side
C-104 (B) AC301446AB
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
AC308735AV

intermediate connectors C-14 and C-104, and ABS
sensor <front: RH> connector A-31, inspect the wire.
If any of these connectors is damaged, repair or
TROUBLESHOOTING
NOTE:
Connector: C-104 Connectors: C-104, C-117
<LHD> <RHD>
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
C-117
C-104 (B)
C-104(B)
AC308718 AQ
Connector: C-117
<LHD> C-104(B)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
C-117
1 2 3 111213
1 2 3 4 5 6 7 8 9 10 111213
4 5 6 7 8 9 10
14 1516 17 1819 20 2122 2324 25 14 1516 17 1819 20 2122 2324 25
26 27 28 29 30 31 38 26 27 28 29 30 31 38
32 33 34 35 36 37 C-117 32 33 34 35 36 37
AC308716 AV AC308736 AJ
Connector: D-24 Connector: D-24

<LHD> <RHD>
D-24
D-24
1 2 3
4 5 6 7 8 1 2 3
4 5 6 7 8
D-24 AC309649AB D-24 AC309650AB

ABS sensor <rear: LH> connector D-22, inspect the
B-03 (terminals 28 and 27) and ABS sensor <rear:
LH> connector D-22 (terminals 1 and 2) damaged?
P.00-6.
TROUBLESHOOTING
NOTE:
STEP 8. Check the harness wires between Connector: C-104
and ABS sensor <rear: RH> connector D-13
Connector: B-03
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
C-104 (B)
B-03 (GR)
AC308718 AQ
Connector: C-117
<LHD>
Harness side
1 2 3 4 5 6 7 8 9 10 111213
14 1516 17 1819 20 2122 2324 25
26 27 28 29 30 31 38
AC301441AB 32 33 34 35 36 37 C-117
AC308716 AV
Connector: D-13
Connector: D-24
<LHD>
D-24
D-13 (B) 1 2 3
4 5 6 7 8
Harness side
AC301445AB
D-24 AC309649AB
TROUBLESHOOTING

<RHD> B-03 (terminals 11 and 17) and ABS sensor <rear:
RH> connector D-13 (terminals 1 and 2) damaged?
NO : Go to Step 11.
C-117 STEP 9. Check the ABS sensor output voltage.

Refer to P.35B-59.
C-104(B)
Output Voltage:
• When measured with a voltmeter: 42 mV or more
• When measured with an oscilloscope (maximum
voltage): 200 mV or more
C-104(B)
1 2 3 4 5 6 7
Q: Does the voltage meet the specification?
8 9 10 11 12 13 14 15 16 YES : Erase the diagnosis code memory, and
recheck if any diagnosis code sets. If
C-117 diagnosis code No.21, 22, 23 or 24 sets,
1 2 3 4 5 6 7 8 9 10 111213 replace the hydraulic unit (integrated with
14 1516 17 1819 20 2122 2324 25 ABS-ECU). Then go to Step 11.
26 27 28 29 30 31 38
NO : Go to Step 10.
32 33 34 35 36 37
AC308736 AJ
STEP 10. Check the wheel bearing.
Connector: D-24 <Front>: Refer to GROUP 26, On-vehicle Service −
<RHD> Wheel Bearing Axial Play Check P.26-8.
<Rear (2WD)>: Refer to GROUP 27A, On-vehicle
Service − Wheel Bearing Axial Play Check P.27A-4.
D-24
<Rear (4WD)>: Refer to GROUP 27B, On-vehicle
1 2 3
4 5 6 7 8
Service − Wheel Bearing Axial Play Check P.27B-7.
NO : Replace it and then go to Step 11.
D-24 AC309650AB
After inspecting ABS-ECU connector B-03, STEP 11. Check whether the diagnosis code is
intermediate connectors C-104, C-117 and D-24, and reset.
ABS sensor <rear: RH> connector D-13, inspect the
wire. If any of these connectors is damaged, repair or Q: Is diagnosis codes No.21, 22, 23 or 24 set?
TROUBLESHOOTING
Code No.32 G-sensor System <4WD>
G-sensor Circuit <LHD>
IGNITION
SWITCH (IG2)
G SENSOR
ABS-ECU
Wire colour code

AC301688 AC
TROUBLESHOOTING
G-sensor Circuit <RHD>
IGNITION
SWITCH (IG2)
G SENSOR
ABS-ECU
Wire colour code

OPERATION • If the G-sensor output power does not change

The G-sensor detects the acceleration level in the (G-sensor output fastening).
forward/reverse direction of the vehicle, converts the
signals into voltage signals and then sends that PROBABLE CAUSES
signal to the ABS-ECU. The most likely causes for this diagnosis code to set
are:
DIAGNOSIS CODE SET CONDITIONS • Malfunction of the G-sensor
This code is set in the following case. • Damaged wiring harness or connector
• When the G-sensor output is 1.0V or lower or • Malfunction of the hydraulic unit (integrated with
4.0V or higher (disconnected G-sensor or ABS-ECU)
G-sensor short circuit)
TROUBLESHOOTING
DIAGNOSIS earth.
OK: System voltage
STEP 1. MUT-II/III data list Q: Is the check result normal?
Set MUT-II/III to data reading mode, and check the YES : Go to Step 4.
data list item. NO : Go to Step 3.
• Item 32: G-sensor
OK: STEP 3. Check the harness wire between
When vehicle is stationary (level): 2.4 − 2.6 V junction block connector C-202 terminal 8 and
When vehicle is being driven: 1.0 − 4.0 V G-sensor connector D-35 terminal 1.
Q: Is the G-sensor input normal? Connector: C-202
YES : This malfunctions is intermittent. Refer to <LHD>
Troubleshooting/Inspection Service Points − C-202
How to Cope with Intermittent Malfunction
P.00-6.
NO : Go to Step 2.
6 5 4 3 2 1
14 13 12 11 10 9 8 7
STEP 2. Voltage measurement at the G-sensor Harness side

connector D-35. AC308720 AM
Connector: D-35 Connector: C-202

<RHD>
C-202
Harness side
D-35 (B)
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC301440AB Harness side

AC308772 AL
(1) Disconnect G-sensor connector D-35, and check

Connector: D-35
at the harness side.
Harness side
Connector D-35
(harness side) D-35 (B)
AC301440AB
AC301684AB
(3) Measure the voltage between terminal 1 and

TROUBLESHOOTING
NOTE:
Connector: C-106 STEP 4. Resistance measurement at the
<LHD> G-sensor connector D-35.
Connector: D-35
C-106(GR)
1 2
3 4 5 6 Harness side
7 8 9 10 11 12
13 14 15 16 17 18 19
D-35 (B)
C-106(GR)
AC309654AB
Connector: C-13
AC301440AB
<RHD>
(1) Disconnect G-sensor connector D-35, and check
at the harness side.
1 2 3
4 5 6 7 8 9
10 11 12 13 14 15 Connector D-35
(harness side)
C-13(L)
AC308769AX
After inspecting the junction block connector C-202,

intermediate connector C-106 <L.H. drive vehicles>,
C-13 <R.H. drive vehilces>, and G-sensor connector
AC301684AC
D-35, inspect the wire. If any of these connector is
damaged, repair or replace it. Then go to Step 8. (2) Measure the resistance between terminal 3 and
earth.
connector C-202 terminal 8 and G-sensor OK: 2 Ω or less
connector D-35 terminal 1 damaged? Q: Is the check result normal?
YES : . Repair it and go to Step 8. YES : Go to Step 6.
NO : . This malfunctions is intermittent. Refer to NO : Go to Step 5.
P.00-6.
TROUBLESHOOTING
<R.H. drive vehicles> After inspecting the G-sensor

STEP 5. Check the harness wire between
connector D-35, intermediate connectors C-13,
G-sensor connector D-35 terminal 3 and
C-106, and ABS-ECU connector B-03, inspect the
wire. If any of these connector is damaged, repair or
Connector: D-35 replace it. Then go to Step 8.
Q: Is the harness wire between G-sensor connector
Harness side D-35 terminal 3 and ABS-ECU connector B-03
terminal 8 damaged?
D-35 (B) YES : Repair it and go to Step 8.
NO : Erase the diagnosis code memory, and
AC301440AB
and then go to Step 8 .
Connector: B-03
STEP 6. Check G-sensor output voltage.
B-03 (GR) Label
MB991348
Harness side
Connector: D-35
(Harness side)
AC301441AB
Label
NOTE:
Connector: C-13
<RHD>
1 2 3
4 5 6 7 8 9
10 11 12 13 14 15
AC103662AK
C-13(L) (1) Disconnect G-sensor connector D-35, and

connect special tool harness set (MB991348)
AC308769AX between the disconnected connectors.
Connector: C-106 (3) Measure the voltage between terminal 2 and
<RHD>
earth.
OK:
When vehicle is stationary (level): 2.4 −
1 2
2.6 V
3 4 5 6 When vehicle is being driven: 1.0 − 4.0 V
7 8 9 10 11 12
16
13 14 15 17 18 19
C-106 (GR) Q: Is G-sensor output voltage normal?
YES : Go to Step 7.
NO : Replace the G-sensor and go to Step 8.
AC308735AX
TROUBLESHOOTING
<R.H. drive vehicles> After inspecting the G-sensor

connector D-35, intermediate connectors C-13,
G-sensor connector D-35 terminal 2 and
C-106, and ABS-ECU connector B-03, inspect the
wire. If any of these connector is damaged, repair or
Connector: D-35 replace it. Then go to Step 8.
Q: Is the harness wire between G-sensor connector
Harness side D-35 terminal 2 and ABS-ECU connector B-03
terminal 15 damaged?
D-35 (B) YES : Repair it and go to Step 8.
NO : Erase the diagnosis code memory, and
AC301440AB
and then go to Step 8 .
Connector: B-03
reset.
Q: Is diagnosis code No.32 set?
B-03 (GR) YES : Start over at Step 1.
Harness side
AC301441AB
NOTE:
Connector: C-13
<RHD>
1 2 3
4 5 6 7 8 9
10 11 12 13 14 15
C-13(L)
AC308769AX
Connector: C-106
<RHD>
1 2
3 4 5 6
7 8 9 10 11 12
16
13 14 15 17 18 19
C-106 (GR)
AC308735AX
TROUBLESHOOTING
Code No.33 : Stop Lamp Switch System
Stop Lamp Switch Circuit
BATTERY
RELAY
BOX
STOP
LAMP
SWITCH
STOP LAMPS
ABS-ECU
NOTE
: 2000
: 2400
Wire colour code

OPERATION
The "ON" signal when the brake pedal is pressed or
the "OFF" signal when the brake pedal is released is
input to the ABS-ECU (terminal 3).
TROUBLESHOOTING

STEP 3. Check the stop lamp switch continuity.
Diagnosis code No.33 is set in the following cases:
(1) Remove the stop lamp switch (Refer to GROUP
• Stop lamp switch is not operating properly and 35A, Brake Pedal P.35A-13).
remains in ON state for more than 15 minutes.
• Stop lamp switch system harness is damaged
and no signal is input to ABS-ECU.
PROBABLE CAUSES
The most likely causes for this diagnosis code to set
are:
• Malfunction of the stop lamp switch
ABS-ECU)
DIAGNOSIS
No continuity Continuity
STEP 1. Check the stop lamp operation.
Q: Does the stop lamp come on and go out correctly?
YES : Go to Step 4.
NO : Go to Step 2.
STEP 2. Check the stop lamp switch installation 4 mm

condition. ACX00671AE
Q: Is the stop lamp switch installed properly? (2) Connect an ohmmeter to stop lamp switch
YES : Go to Step 3.
terminals 1 and 2, and check whether there is
NO : Repair it and then go to Step 7.
continuity when the plunger of the stop lamp
switch is pushed in and when it is released.
(3) The stop lamp switch is in good condition if there
is no continuity when the plunger is pushed in to
a depth of within 4 mm from the outer case edge
surface, and if there is continuity when it is
released.
Q: Is the stop lamp switch continuity correct?
YES : Check the stop lamp circuit and repair and
then go to Step 7.
NO : Replace the stop lamp switch and then go to
Step 7.
TROUBLESHOOTING
YES : Erase the diagnosis code memory, and

Set MUT-II/III to data reading mode, and check the
diagnosis code No.33 set, replace the
data list item.
hydraulic unit (integrated with ABS-ECU).
• Item 36: Stop lamp switch
Then go to Step 7.
OK: NO : Go to Step 6.
Brake pedal stepped down: ON
Brake pedal released: OFF
Q: Is the stop lamp switch input normal? ABS-ECU connector B-03 terminal 3 and stop
lamp switch connector C-101 terminal 1.
Troubleshooting/Inspection Service Points − Connector: B-03
P.00-6.
NO : Go to Step 5.
B-03 (GR)
STEP 5. Voltage measurement at the ABS-ECU
connector B-03.
Connector: B-03
Harness side
B-03 (GR)
AC301441AB
Connector: C-101
<LHD>
Harness side
C-101
AC301441AB
(1) Disconnect ABS-ECU connector B-03 and

measure at the harness side. Harness side AC308716 AW
(2) Depress the brake pedal to turn on the stop lamp
switch. Connector: C-101
<RHD>
Connector B-03
(harness side)
C-101 Harness side
AC308769BA
AC301683AC

earth.
OK: System voltage
TROUBLESHOOTING
NOTE: Q: Is the harness wire between ABS-ECU connector

Connectors: C-16, C-104 B-03 terminal 3 and stop lamp switch connector
<LHD> C-101 terminal 1 damaged?
C-104(B) P.00-6.
C-16(L)

C-16(L)
reset.
11 10 9 8 7 6 5 4 3 2 1
Q: Is diagnosis code No.33 set?
22 21 20 19 18 17 16 15 14 13 12 YES : Start over at Step 1.
C-104(B)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
AC308719 AJ

<RHD>
C-16(L)
C-104(B)
C-16(L)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
C-104(B)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
AC308736 AH

intermediate connectors C-16 and C-104, and stop
lamp switch connector C-101, inspect the wire. If any
of these connectors is damaged, repair or replace it.
Then go to Step 7.
TROUBLESHOOTING
Code No.41, 42, 43, and 44: ABS Solenoid Valve inside Hydraulic Unit (Open Circuit or Short Circuit)
Code No.52: Valve Relay Problem (Stays off)
Code No.53: Motor Relay Problem (Stays off)
Code No.55: Motor System (Seized Pump Motor)
Solenoid Valve and Motor power Supply Circuit

FUSIBLE
LINK 3
HYDRAULIC UNIT
MOTOR ABS SOLENOID

VALVES
SOLENOID
VALVE POWER MOTOR POWER
SOURCE SOURCE
ABS-ECU
Wire colour code

AC301690AB
OPERATION PROBABLE CAUSES

Power is continuously supplied to the ABS-ECU The most likely causes for these diagnosis codes to
through fusible link number 3 to operate the solenoid set are:
valve and motor. • Damaged wiring harness or connector
DIAGNOSIS CODE SET CONDITIONS ABS-ECU)
These codes are set if the power supply circuit of
solenoid valve or motor is open or shorted.
TROUBLESHOOTING
DIAGNOSIS YES : Erase the diagnosis code memory, and

diagnosis code No.41, 42, 43, 44, 52, 53, or
55 set, replace the hydraulic unit (integrated
connector B-03.
with ABS-ECU). Then go to Step 3. If
Connector: B-03 diagnosis code No.41, 42, 43, 44, 52, 53, or
55 is not set, an intermittent malfunction is
suspected. Refer to GROUP 00, How to
Use Troubleshooting/Inspection Service
B-03 (GR)
Points − How to Cope with Intermittent
Malfunction P.00-6.
NO : Go to Step 2.
STEP 2. Check the harness wires between fusible

Harness side link number 3 and ABS-ECU connector B-03
AC301441AB Fusible link

No.3
Connector B-03
(harness side)
AC208065AD
Connector: B-03
AC301683AD B-03 (GR)

earth, and 19 and earth.
OK: System voltage
AC301441AB
TROUBLESHOOTING
NOTE: Q: Is any harness wire between fusible link number 3

Connector: A-14 <LHD> and ABS-ECU connector B-03 (terminal 1 and 19)
damaged?
A-14(GR) Troubleshooting/Inspection Service Points −
P.00-6.
AC308679AG
Connector: A-14 reset.
<RHD>
Q: Is diagnosis code No.41, 42, 43, 44, 52, 53 or 55
set?
A-14(GR)
AC308686AH
After inspecting intermediate connector A-14,

inspect the wire. If the connector is damaged, repair
or replace it. Then go to Step 3.
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE NOTE: During ABS operation, the brake pedal may
vibrate a little or may not be able to be pressed. Such
SYMPTOMS
M1352011400664 conditions are due to intermittent changes in
NOTE: If steering movements are made when hydraulic pressure inside the brake line to prevent
driving at high speed, or when driving on road the wheels from locking. This is normal.
surfaces with low frictional resistance, or when
passing over bumps, the ABS may operate although
sudden braking is not being applied. Because of this,
when getting information from the customer, check if
the problem occurred while driving under such
conditions as these.
Trouble symptoms Inspection procedure No. Reference page
Communication between MUT-II/III and the whole − GROUP 13A,
system is not possible. Diagnosis P.13A-190
Communication between MUT-II/III and the 1 P.35B-41
ABS-ECU is not possible.
When the ignition switch is turned to the "ON" 2 P.35B-46
position (Engine stopped), the ABS warning lamp
does not illuminate.
The ABS warning lamp remains illuminated after the 3 P.35B-52
engine is started.
Faulty ABS operation 4 P.35B-55
TROUBLESHOOTING

TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1: Communication between MUT-II/III and the ABS-ECU is not Possible.
Diagnosis Connector Circuit
IGNITION
SWITCH (IG2)
ABS-ECU
POWER
SOURCE
NOTE DIAGNOSIS
: LHD CONNECTOR
: RHD FRONT SIDE
Wire colour code

TROUBLESHOOTING
OPERATION DIAGNOSIS
• The diagnostic output is made from the
ABS-ECU (terminal 13) to the diagnosis output
terminal (terminal 7) of the diagnosis connector.
connector B-03.
• When the diagnosis connector's diagnosis test
mode control terminal (terminal 1) is grounded, Connector: B-03
the ABS-ECU (terminal 4) will go into diagnosis
mode.
COMMENT ON TROUBLE SYMPTOM

B-03 (GR)
When communication with the MUT-II/III is not
possible, the cause is probably an open circuit in the
ABS-ECU power circuit or an open circuit in the
diagnostic output circuit.
PROBABLE CAUSES Harness side

The most likely causes for this case are:
• Blown fuse
• Malfunction of the hydraulic unit (Integrated with
AC301441AB
ABS-ECU)
(2) Start the engine.
Connector B-03
(harness side)
AC301683AE

earth.
OK: System voltage
YES : Go to Step 3.
NO : Go to Step 2.
TROUBLESHOOTING
NOTE:
STEP 2. Check the harness wire between Connector: C-106
junction block connector C-202 terminal 8 and <LHD>
1 2
Connector: B-03 3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
C-106 (GR)
B-03 (GR)
AC308718AS
Connector: C-106
<RHD>
Harness side
1 2
3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
AC301441AB C-106 (GR)
Connector: C-202
<LHD> AC308735AX
After inspecting ABS-ECU connector B-03, junction

C-202 block connector C-202 and intermediate connector
C-106, inspect the wire. If any of these connectors is
damaged, repair or replace it. Then go to Step 5.
6 5 4 3 2 1 Q: Is the harness wire between junction block
14 13 12 11 10 9 8 7
Harness side connector B-03 terminal 20 damaged?
AC308720 AM YES : Repair it and go to Step 5.
Connector: C-202 GROUP 00, How to Use
<RHD>
C-202 How to Cope With Intermittent Malfunction
P.00-6.
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side
AC308772 AL
TROUBLESHOOTING
STEP 3. Check the harness wires between Connectors: C-02, C-24 <RHD>
and diagnosis connector C-24 (terminals 1 and
7). C-02
Connector: B-03
B-03 (GR) C-24(B)
C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
Harness side
C-24 Harness side
AC301441AB
AC308770AH
Connectors: C-02, C-24 <LHD>
C-02
C-24(B)
C-02
C-24 Harness side
AC308717AT
TROUBLESHOOTING
NOTE: Q: Is any of the harness wires between ABS-ECU

Connectors: C-104, C-105 connector B-03 (terminals 4 and 13) and diagnosis
<LHD> connector C-24 (terminals 1 and 7) damaged?
NO : Go to Step 4.
C-105
C-104(B) and earth (No.9).
Connector: B-03
C-104(B)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
B-03 (GR)
C-105
1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
Harness side
AC308719 AK

<RHD> AC301441AB
C-105
C-104(B)
Relay box
Earth (No.9)
C-104(B)
AC208089AC
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
Q: Is any of the harness wires between ABS-ECU
connector B-03 (terminals 2 and 18) and earth
C-105 (No.9) damaged?
1 2 3 4 5 6 7 8 9 YES : Repair it and then go to Step 5.
10 11 12 13 1415 16 1718 19 20 21 22
NO : Check the troubleshooting condition. To
reproduce the troubleshooting state replace
the hydraulic unit (integrated with
AC308736 AI ABS-ECU).Then go to Step 5. If the state of
After inspecting ABS-ECU connector B-03, diagnosis failure is not reproduced then a intermittent
connector C-24, and intermediate connectors C-02, malfunction is suspected. Refer to GROUP
C-104 and C-105, inspect the wires. If any of these 00, How to Use Troubleshooting/Inspection
connectors is damaged, repair or replace it. Then go Service Points − How to Cope with
to Step 5. Intermittent Malfunction P.00-6.
TROUBLESHOOTING

STEP 5. Retest the system. NO : Start over at Step 1.
Q: Does the MUT-II/III communicate with the ABS
system?
INSPECTION PROCEDURE 2: When the Ignition Key is Turned to the "ON" position (Engine Stopped),
the ABS Warning Lamp does not Illuminate.
ABS Warning Lamp Circuit

IGNITION
SWITCH (IG1)
<LHD>
COMBINATION
METER
<RHD> <LHD>
CPU
<RHD>
ABS-ECU
Wire colour code

OPERATION lamp up when the transistor is turned OFF for this

• The ABS warning lamp is lit up by transistor circuit. This is how the ABS warning lamp lights
control in the ABS-ECU. However, the up even when the ABS-ECU connector is
relationship of the reverse circuit movement in connected improperly or if the ABS-ECU function
the combination meter will vary from usual in has terminated.
terms of transistor ON/OFF and ABS warning • The ABS-ECU also lights up the ABS warning
lamp ON/OFF, in that the ABS warning lamp will lamp during the initial check (approximately 3
seconds) when the ignition switch is turned to the
"ON" position in addition to when the system is
malfunctioning.
TROUBLESHOOTING
COMMENT ON TROUBLE SYMPTOM DIAGNOSIS

Possible causes include the combination meter
power circuit, disconnected earth circuit, dead lamp
STEP 1. Check the ABS warning lamp circuit at
bulb, or short circuited ABS warning lamp.
ABS-ECU connector B-03.
PROBABLE CAUSES Connector: B-03
The most likely causes for this case are:
• Blown fuse
• Burnt out ABS warning lamp bulb
B-03 (GR)
• Combination meter defect
ABS-ECU)
Harness side
AC301441AB
(1) Disconnect ABS-ECU connector B-03.

Q: Does the ABS warning lamp illuminate?
YES : To check and reproduce the state of
malfunction replace the hydraulic unit
(integrated with ABS-ECU). Then go to Step
7. If the malfunction is not reproduced, an
intermittent malfunction is suspected. Refer
to GROUP 00, How to Use
P.00-6.
NO : Go to Step 2.
TROUBLESHOOTING
STEP 3. Voltage measurement at the combination (2) Turn the ignition switch to the "ON" position.
meter connector C-04. <LHD>
Connector: C-04 Connector C-04
<LHD> C-04 (Junction block side)
AC301541FZ
<RHD>
Connector: C-04
Connector C-04
<RHD>
(Junction block side)
C-04
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
Harness side
AC301541GA
AC308769AV
(1) Disconnect connector C-04, and check at the earth.
harness side. OK: System voltage
YES : . Go to Step 5.
NO : . Go to Step 4.
TROUBLESHOOTING
STEP 4. Check the harness wire between Connectors: C-203, C-205

junction block connector C-203 terminal 6 and <RHD>
C-203
combination meter C-04 terminal 42.
Connector: C-04
<LHD> C-04
C-205
C-203
Harness side
2 1
Harness side AC308716 AS 6 5 4 3

<LHD> C-205
C-203 Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC308773 AP
C-205
NOTE: After inspecting junction block connectors
C-203 and C-205, and combination meter connector
C-04, inspect the wire. If any of these connectors is
C-203
Harness side damaged, repair or replace it. Then go to Step 7.
2 1
6 5 4 3
connector C-203 terminal 6 and combination meter
C-04 terminal 42 damaged?
YES : Repair the harness wire and go to Step 7.
C-205
Harness side NO : This malfunction is intermittent. Refer to
14 13 12 11 10 9 8 7 6 5 4 3 2 1 Troubleshooting/Inspection Service Points −
28 27 26 25 24 23 22 21 20 19 18 17 16 15
P.00-6.
AC308721 AO
Connector: C-04
<RHD>
C-04
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
Harness side
AC308769AV
TROUBLESHOOTING
STEP 5. Check the harness wire between the STEP 6. Check the harness wire between the
combination meter connector C-05 terminal 12 combination meter connector C-05 terminal 18
and earth (No.6). and ABS-ECU connector B-03 terminal 12.
Connector: C-05 C-05 (L) Connector: C-05 C-05 (L)
<LHD> <LHD>
11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12 22 21 20 19 18 17 16 1514 13 12
G G G G


<RHD> <RHD>
C-05 (L) C-05 (L)

11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 22 21 20 19 18 17 16 15 14 13 12
AC308769AW AC308769AW
Connector: B-03
Earth (No.6) B-03 (GR)
Junction
block AC208084AE
Harness side
Q: Is the harness wire between combination meter
connector C-05 terminal 12 and earth (No.6)
damaged?
NO : Go to Step 6. AC301441AB
TROUBLESHOOTING
NOTE: Q: Is the harness wire between the combination meter

Connector: C-105 connector C-05 terminal 18 and ABS-ECU
<LHD>
connector B-03 terminal 12 damaged?
1 2 3 4 5 6 7 8 9 NO : Replace the combination meter and go to
10 11 12 13 1415 16 1718 19 20 21 22
Step 7.

C-105
Q: Does the ABS warning lamp illuminate for 3
seconds when the ignition switch is turned to the
AC308718 AR
"ON" position with engine stopped or upon
Connector: C-105 start-up?
<RHD> YES : The procedure is complete.
NO : Start over at Step 1.
1 2 3 4 5 6 7 8 9 C-105
10 11 12 13 1415 16 1718 19 20 21 22
AC308735AW
After inspecting combination meter connector C-05,

ABS-ECU connector B-03 and intermediate
connector C-105, inspect the wire. If any of these
to Step 7.
TROUBLESHOOTING
INSPECTION PROCEDURE 3: The ABS Warning Lamp Remains Illuminated after the Engine is
Started.
NOTE: This diagnosis procedure is limited to cases where communication with the MUT-II/III is possible
(ABS-ECU power supply is normal) and no diagnosis code outputs.
ABS Warning Lamp Circuit

IGNITION
SWITCH (IG1)
<LHD>
COMBINATION
METER
<RHD> <LHD>
CPU
<RHD>
ABS-ECU
Wire colour code

OPERATION PROBABLE CAUSES

Refer to P.35B-46. The most likely causes for this case are:
COMMENT ON TROUBLE SYMPTOM • Malfunction of the hydraulic unit (integrated with
Disconnected ABS warning lamp output line of ABS-ECU)
ABS-ECU is suspected. • Malfunction of the combination meter
TROUBLESHOOTING
DIAGNOSIS (3) Turn the ignition switch to the "ON" position.

Q: Does the ABS warning lamp go off?
STEP 1. Check the ABS warning lamp circuit at YES : To check and reproduce the state of
ABS-ECU connector B-03. malfunction replace the hydraulic unit
(integrated with ABS-ECU). Then go to Step
Connector: B-03 3. If the malfunction is not reproduced, an
intermittent malfunction is suspected. Refer
to GROUP 00, How to Use
B-03 (GR) How to Cope With Intermittent Malfunction
P.00-6.
NO : Go to Step 2.
Harness side
AC301441AB
(1) Disconnect ABS-ECU connector B-03.
Connector B-03
(harness side)
AC301683AF
(2) Connect ABS-ECU connector B-03 terminal

number 12 to earth.
TROUBLESHOOTING
NOTE:
STEP 2. Check the harness wire between the Connector: C-105
combination meter connector C-05 terminal 18 <LHD>
and ABS-ECU connector B-03 terminal 12.
Connector: C-05 C-05 (L) 1 2 3 4 5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
<LHD>
C-105
11 10 9 8 7 6 5 4 3 2 1
AC308718 AR
22 21 20 19 18 17 16 1514 13 12
G G Connector: C-105
<RHD>
Connector: C-05
<RHD>
C-05 (L)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 1 2 3 4 5 6 7 8 9 C-105
10 11 12 13 1415 16 1718 19 20 21 22
Harness side AC308735AW
After inspecting combination meter connector C-05,

ABS-ECU connector B-03 and intermediate
AC308769AW
connector C-105, inspect the wire. If any of these
Connector: B-03
to Step 3.
Q: Is the harness wire between combination meter
connector B-03 terminal 12 damaged?
B-03 (GR) YES : Repair the harness wire and then go to Step
3.
NO : Replace the combination meter (printed
circuit board) and then go to Step 3.
Harness side
Q: Does the ABS warning lamp turn off in 3 seconds
after start-up?
AC301441AB NO : Start over at Step 1.
TROUBLESHOOTING
INSPECTION PROCEDURE 4: Faulty ABS Operation
COMMENT ON TROUBLE SYMPTOM DIAGNOSIS

The cause depends on driving and road surface Check the hydraulic unit (Refer to P.35B-61). If the
conditions, so diagnosis may be difficult. However, if hydraulic unit (integrated with ABS-ECU) is
no diagnosis code is set, carry out the following malfunctioning, replace it. Then check that the
inspection. malfunction symptom is eliminated.
PROBABLE CAUSES DATA LIST REFERENCE TABLE

The most likely cause for this case is: M1352011500661
• Malfunction of the hydraulic unit The following items can be read by the MUT-II/III
from the ABS-ECU input data.
When the system is normal.
Item Check item Checking requirements Normal valve
No.
11 Front-right ABS sensor Perform a test run Vehicle speeds
12 Front-left ABS sensor displayed on the
speedometer and
13 Rear-right ABS sensor MUT-II/III are
14 Rear-left ABS sensor identical.
21 ABS-ECU power supply voltage Ignition switch: ON 10 − 16 V
32 G-sensor <4WD> • Ignition switch: ON 2.4 − 2.6 V
• When vehicle is parked on a level
surface.
When vehicle is accelerated 4.0 − 1.0 V
When vehicle is decelerated 1.0 − 4.0 V
36 Stop lamp switch Depress the brake pedal. ON
Release the brake pedal. OFF
When the ABS-ECU shut off ABS operation.

When the diagnosis system stops the ABS-ECU, the
MUT-II/III display data will be unreliable.
TROUBLESHOOTING
ACTUATOR TEST REFERENCE TABLE No. Item

M1352011600679
The MUT-II/III activates the following actuators for 01 Solenoid valve for Solenoid valves
testing. front-left wheel and pump motors
NOTE: If the ABS-ECU runs down, actuator testing 02 Solenoid valve for in the hydraulic
cannot be carried out. front-right wheel unit (simple
inspection mode)
NOTE: Actuator testing is only possible when the 03 Solenoid valve for
vehicle is stationary. rear-left wheel
ACTUATOR TEST SPECIFICATIONS 04 Solenoid valve for
Activation pattern rear-right wheel
CHECK AT ABS-ECU
Start of End of M1352011800640
activation activation Use the following steps to remove the connector
Solenoid A cover and measure the terminal voltage.
valve
B 1s Lock lever
C 2s
0.05 s 0.01 s
Pump ON
motor OFF
NOTE
AC200022AE
A: Hydraulic pressure increases
B: Hydraulic pressure holds
C: Hydraulic pressure decreases 1. Move the lock lever of the ABS-ECU connector as
shown in the illustration, and then disconnect the
ABS-ECU connector.
AC100172 AG ABS-ECU connector
Connector cover
AC103604AC
TROUBLESHOOTING
TERMINAL VOLTAGE CHECK CHART 1. Measure the voltages between earth terminal (2)
or (18) and each respective terminal.
2. The terminal layouts are shown in the illustrations
below.
NOTE: Do not measure terminal voltage for
approximately three seconds after the ignition switch
is turned to the "ON" position. The ABS-ECU
performs the initial check during that period.
AC300659
Terminal No. Check item Checking requirements Normal condition

1 Solenoid valve power Always System voltage
supply
3 Stop lamp switch input Stop lamp switch: "ON" System voltage
Stop lamp switch: "OFF" Approximately 0 V
4 Diagnosis changeover When the MUT-II/III is connected Approximately 0 V
input When the MUT-II/III is not connected System voltage
8 G-sensor earth Always Approximately 0 V
<4WD>
12 ABS-ECU warning Ignition When the lamp is switched off Approximately 0 V
lamp transistor output switch: "ON" When the lamp is illuminated System voltage
13 MUT-II/III When the MUT-II/III is connected Serial
communication with
MUT-II/III
When the MUT-II/III is not connected Approximately 0 V
15 G-sensor input • Ignition switch: "ON" 2.4 − 2.6 V
<4WD> • Horizontal state of vehicle
19 Motor power supply Always System voltage
20 ABS-ECU power Ignition switch: "ON" System voltage
supply Ignition switch: "START" Approximately 0 V
TROUBLESHOOTING
RESISTANCE AND CONTINUITY BETWEEN 1. Turn the ignition switch to the "LOCK" (OFF)
HARNESS-SIDE CONNECTOR TERMINALS position and disconnect the ABS-ECU connectors
before checking resistance and continuity.
2. Check the resistance and continuity between the
terminals indicated in the table below.
3. The terminal layout is shown in the illustration.
AC300662
ABS-ECU terminal No. Signal Normal condition

9 − 10 Front-right ABS sensor 1.24 − 1.64 kΩ
11 − 17 Rear-right ABS sensor 1.24 − 1.64 kΩ
16 − 26 Front-left ABS sensor 1.24 − 1.64 kΩ
27 − 28 Rear-left ABS sensor 1.24 − 1.64 kΩ
2 − body earth Earth Less than 2 Ω
18 − body earth Earth Less than 2 Ω
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ABS SENSOR OUTPUT VOLTAGE 3. If the output voltage is lower than that given
MEASUREMENT above, the cause may be the following, so check
M1352001600485 or replace the ABS sensor if necessary.
Lift up the vehicle and release the parking brake. • ABS sensor pole piece-to-ABS rotor clearance
too large
• Faulty ABS sensor
WAVE PATTERN INSPECTION USING AN
OSCILLOSCOPE
After checking the connection of the ABS sensor
harness and the connector, take a reading of the
output voltage wave patterns for each ABS sensor
using an oscilloscope as follows.
Start the engine, the transmission shift lever to 1st
gear, and then spin the wheel.
NOTE:
11 10 9 8 7 6 5 4 3 2 1 When turned by hand

17 16 15 14 13 12
28 27 26 25 24 23 22 21 20 19 18
Harness connector
AC201294AH
1. Disconnect the ABS-ECU connector, and When idling (5 − 6 km/h), with 1st gear
measure the output voltage at the harness side
connector.
2. Manually turn the wheel to be measured 1/2 to 1
turn/second. Measure the output voltage with a
voltmeter or oscilloscope.
[10.0 ms/DIV IV/DIV]
Terminal No.
Front left Front right Rear left Rear right
16 9 27 11 AC000949 AF
26 10 28 17
.
Output voltage: • You can also take a reading of the wave pattern
42 mV or higher when measured using a by actually driving the vehicle in this condition.
multimeter • The output voltage will be lower when the wheel
120 mVP-P or higher when measured using a speed is lower, and will become higher as the
oscilloscope wheel speed becomes higher.
ON-VEHICLE SERVICE
POINTS IN WAVEFORM MEASUREMENT

Symptom Probable causes Remedy
Too small or zero waveform Faulty ABS sensor or excessive Replace ABS sensor
amplitude gap between it and the ABS rotor
Waveform amplitude fluctuates Axle hub eccentric or with large Replace hub assembly
excessively (This is no problem if runout
the minimum amplitude is 100 mV Faulty ABS-ECU earth Repair harness wires
or more)
Noisy or disturbed waveform Open circuit in ABS sensor Replace ABS sensor
Open circuit in harness Repair harness wire
Incorrectly mounted ABS sensor Mount ABS sensor correctly
ABS rotor with missing or Replace ABS rotor
damaged teeth
NOTE: The ABS sensor cable moves in relation to motion of the front or rear suspension. Therefore, it is
likely that it has an open circuit only when driving on rough roads but it functions normally when driving on
smooth roads. It is recommended to observe sensor output voltage waveform also under special conditions,
such as driving on a rough road.
ON-VEHICLE SERVICE
HYDRAULIC UNIT CHECK CAUTION

M1352001700620
To prevent damage to MUT-II/III, always turn the
CAUTION ignition switch to the "LOOK" (OFF) position
• The roller of the braking force tester and the before connecting or disconnecting the MUT-II/III.
tyre should be dry during testing.
<Using the MUT-II>
• When testing the front brakes, apply the
parking brake. When testing the rear brakes, Steering shaft
stop the front wheels with chocks.
1. Jack up the vehicle. Then support the vehicle with
rigid racks at the specified jack-up points or place
the front or rear wheels on the rollers of the
braking force tester. MUT-II
2. Release the parking brake, and feel the drag force

(drag torque) on each road wheel. When using AC300830 AC
the braking force tester, take a reading of the
brake drag force. <Using the MUT-III>
16-PIN
MB991911
MB991824
MB991827 AC308915 AC

position and set the MUT-II/III as shown in the
illustration.
4. After checking that the shift lever is in neutral,
start the engine.
5. Use the MUT-II/III to force-drive the actuator.
NOTE: The ABS system will switch to the
MUT-II/III mode and the ABS warning lamp will
illuminate.
NOTE: When the ABS has been interrupted by
the fail-safe function, the MUT-II/III actuator
testing cannot be used.
ON-VEHICLE SERVICE
Depressed
Pedal
operation MUT-II/III actuator test
Released (Item No.01, 02, 03, 04) start
Increase in pressure
Solenoid 2 seconds
valve Steady pressure
position
Reduction in pressure 1 seconds
Lock
Checking
the brake
force 3 seconds
Drag force when the
pedal is free Approx. 0.05 seconds
AC000954AH
6. Turn the wheel by hand and check the change in Front wheel 785 − 981 N
braking force when the brake pedal is depressed.
Rear wheel 588 − 784 N
When using the braking force tester, depress the
brake pedal until the braking force is at the 7. If the result of inspection is abnormal, repair
following values, and check that the braking force according to the Diagnosis Table below.
changes to the brake drag force inspected in step
2 when the actuator is force-driven. The result
should be as shown in the diagram above.
Diagnosis Table
MUT-II/III Operation Inspection result Judgme Probable cause Remedy
Display nt
01 FR VALBE • Depress brake pedal Brake force is Normal − −
02 FL VALBE to lock wheel. released for
03 RR VALBE • Using the MUT-II/III, three seconds
04 RL VALBE select the wheel to be after wheels
checked and force the have been
actuator to operate. locked.
• Turn the selected Wheel does not Abnor Clogged brake Check and clean
wheel manually to lock when brake mal line other than brake line
check the change of pedal is hydraulic unit
brake force. depressed. Clogged Replace
hydraulic circuit hydraulic unit
in hydraulic unit assembly
Brake force is Incorrect Connect correctly
not released hydraulic unit
brake tube
connection
Hydraulic unit Replace
solenoid valve hydraulic unit
not functioning assembly
correctly
8. After inspection, disconnect the MUT-II/III
immediately after turning the ignition switch to the
"LOCK" (OFF) position.
ON-VEHICLE SERVICE
IN THE EVENT OF A DISCHARGED

BATTERY
M1352003500495
WARNING
If the ABS is not operating, the vehicle
posture will be unstable during braking, Do
not drive the vehicle with the ABS-ECU
connector disconnected or with the ABS not
operating for any other reason.
If the engine is started using a booster cable when
the battery is completely flat, and the vehicle is then
driven without waiting for the battery to be recharged,
the engine may misfire and it may not be possible to
drive the vehicle. This is because the ABS consumes
a large amount of current when carrying out its initial
checks. If this happens, recharge the battery fully.
HYDRAULIC UNIT
HYDRAULIC UNIT
M1352008600516

NOTE: The ABS-ECU is integrated in the hydraulic unit.
• Brake Fluid Draining • Brake Fluid Filling
• Bake Line Bleeding (Refer to GROUP 35A, On-vehicle
Service − Bleeding P.35A-7.)
• Hydraulic Unit Check (Refer to P.35B-61.)
15 ± 2 N·m 2
3
1
25 ± 6 N·m 2
25 ± 6 N·m
25 ± 6 N·m
AC300471 AB

<<A>> 1. Harness connector <> 3. Hydraulic unit and ABS-ECU
>>A<< 2. Brake pipe connection 4. Hydraulic unit bracket assembly
HYDRAULIC UNIT

NOTE: The ABS-ECU is integrated in the hydraulic unit.
• Brake Fluid Draining • Brake Fluid Filling
• Air Cleaner Removal <2400> (Refer to GROUP 15, Air • Brake Line Bleeding (Refer to GROUP 35A, On-vehicle
Cleaner P.15-3.) Service − Bleeding P.35A-7.)
• Air Cleaner Installation <2400> (Refer to GROUP 15, Air
Cleaner P.15-3.)
• Hydraulic Unit Check (Refer to P.35B-61.)
15 ± 2 N·m
2
3
1
25 ± 6 N·m 2
25 ± 6 N·m
AC309655AB

<<A>> 1. Harness connector <> 3. Hydraulic unit and ABS-ECU
>>A<< 2. Brake pipe connection 4. Hydraulic unit bracket assembly
HYDRAULIC UNIT
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINT

<<A>> HARNESS CONNECTOR >>A<< BRAKE PIPE CONNECTION
DISCONNECTION
2 3
Lock lever 4
5
6
AC100240AD
AC200022AE
Connect the pipes to the hydraulic unit assembly as
Move the lock lever of the ABS-ECU connector as shown in the illustration.
shown in the illustration, and then disconnect the 1. From the master cylinder (secondary)
harness connector. 2. To the front brake (LH)
3. To the rear brake (RH)
<> HYDRAULIC UNIT AND ABS-ECU
4. To the rear brake (LH)
REMOVAL
5. To the front brake (RH)
WARNING
The hydraulic unit is heavy. Use care when 6. From the master cylinder (primary)
removing it.
CAUTION
• The hydraulic unit cannot be disassembled.
Never loosen its nuts or bolts.
• Do not drop or shock the hydraulic unit.
• Do not turn the hydraulic unit upside down or
lay it on its side.
ABS SENSOR
ABS SENSOR
M1352020700038
• ABS Sensor Output Voltage Measurement (Refer to
P.35B-59).
<Front> <Rear (2WD)>
4
<Rear (4WD)>
3
4 AC301105AB
Front ABS sensor removal steps REMOVAL SERVICE POINT

<<A>> 1. Front ABS sensor <<A>> FRONT ABS SENSOR/REAR ABS
2. Front ABS rotor (Refer to GROUP SENSOR REMOVAL
26, Driveshaft P.26-20).
Rear ABS sensor removal steps CAUTION
<<A>> 3. Rear ABS sensor
4. Rear ABS rotor (Refer to GROUP
27A, Rear Hub Assembly P.27A-5
for 2WD, or GROUP 27B,
Driveshaft P.27B-13 for 4WD).
<Front, Rear (4WD)> <Rear (2WD)>

AC100242 AE
Be careful when handling the projection at the tip

of the ABS sensor and the toothed edge of the
ABS rotor so as not to damage them by
contacting other parts.
ABS SENSOR
INSPECTION
M1352020800035
ABS SENSOR CHECK
1. Check whether any metallic foreign material has
adhered to the projection at the ABS sensor tip.
Remove any foreign material. Also check whether
the pole piece is damaged. Replace it with a new
one if it is damaged.
NOTE: The projection can become magnetized
due to the magnet inside the ABS sensor, causing ACX01120
foreign material to easily adhere to it. The

4. Remove all connections from the ABS sensor.
projection may not be able to correctly sense the The circuit should be open between terminals (1)
wheel rotation speed if foreign matter is on it or if it
and (2) and the body of the ABS sensor. If the
is damaged.
circuit is not open, replace with a new ABS
sensor.
<Front> <Rear>
5. Check the ABS sensor cable for breakage,
damage or disconnection. Replace with a new
one if a problem is found.
NOTE: When checking for cable damage, remove
the cable clamp part from the body and then
gently bend and pull the cable near the clamp.
TOOTHED ABS ROTOR CHECK

AC201428AD
2. Measure the resistance between the ABS sensor

terminals.
Standard value: 1.24 − 1.64 kΩ
3. If the internal resistance of the ABS sensor is not
within the standard value, replace it with a new
ABS sensor.
AC000965
Check whether the ABS rotor teeth are broken or

deformed. Replace the BJ assembly of the
driveshaft, or the ABS rotor (2WD-rear side),
respectively, if the teeth are damaged or deformed.
G-SENSOR
G-SENSOR
M1352010100251
CAUTION
Do not drop or apply a shock on the G-sensor.
• Rear Floor Console Assembly Removal and Installation
(Refer to GROUP 52A, Floor Console Assembly
P.52A-14).
G-sensor
AC200354AC
INSPECTION 1. Disconnect the G-sensor connector and connect

M1352018000065 special tool Test Harness Set (MB991348),
G-SENSOR CHECK between the disconnected connectors.
2. Turn the ignition switch to the "ON" position, and
then read the voltage between terminals number
Label 2 and number 3.
Standard Value: 2.4 − 2.6 V
MB991348
3. With special tool Test Harness Set (MB991348)
connected, rotate so that the arrow faces straight
down. Read output voltage between terminals
number 2 and number 3.
Connector: D-35 Standard Value: 1.0 − 4.0 V
(Harness side)
4. If the voltage deviates from the standard value,
make sure that nothing is wrong with the power
supply wire and earth wire and then replace the
Label G-sensor.
AC103662AJ
NOTES
36-1
GROUP 36
PARKING BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . . 36-2 REMOVAL AND INSTALLATION . . . . . . . . 36-7
SPECIFICATIONS . . . . . . . . . . . . . . . 36-3 PARKING BRAKE PEDAL

SERVICE SPECIFICATIONS . . . . . . . . . . . 36-3 <R.H. drive vehicles> . . . . . . . . . . . . 36-8
ON-VEHICLE SERVICE. . . . . . . . . . . 36-4
PARKING BRAKE LEVER STROKE CHECK AND
PARKING BRAKE CABLE. . . . . . . . . 36-9
ADJUSTMENT <L.H. drive vehicles> . . . . . 36-4 REMOVAL AND INSTALLATION
PARKING BRAKE PEDAL STROKE CHECK AND <L.H. drive vehicles> . . . . . . . . . . . . . . . . . . 36-9
ADJUSTMENT <R.H. drive vehicles>. . . . . 36-4 REMOVAL AND INSTALLATION
PARKING BRAKE SWITCH CHECK . . . . . 36-5 <R.H. drive vehicles> . . . . . . . . . . . . . . . . . 36-10
LINING RUNNING-IN . . . . . . . . . . . . . . . . . 36-6
PARKING BRAKE LINING AND
PARKING BRAKE LEVER DRUM . . . . . . . . . . . . . . . . . . . . . . . . . 36-12
<L.H. drive vehicles> . . . . . . . . . . . . 36-7 REMOVAL AND INSTALLATION . . . . . . . . 36-12
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 36-13
36-2 PARKING BRAKES
GENERAL INFORMATION
GENERAL INFORMATION
M1361000100388
<L.H. drive vehicles> <R.H. drive vehicles>
• The parking brake is of a mechanical rear-wheel • The parking brake is of a mechanical rear-wheel
acting type, and its operation utilises a parking acting type. The foot pedal is used to lock and
brake lever. release the parking brake for easier operation.
The pedal surface is labeled with "PUSH", "ON",
and "OFF," and users can easily understand the
pedal release mechanism.
<Vehicles with rear drum-in disc brakes>
Parking brake lever

AC202153
Parking brake cable
AC300160 AB
PARKING BRAKES 36-3
SPECIFICATIONS
Parking brake pedal assembly <Vehicles with rear drum-in disc brakes>
Front parking brake cable assembly
AC202153
Rear parking brake cable assembly
AC300158 AB
SPECIFICATIONS
M1361000300467

Parking brake lever stroke <L.H. drive vehicles> 4 − 5 notches −
Parking brake pedal stroke <R.H. drive vehicles> 1 − 2 notches −
Rear brake lining thickness mm 2.8 1.0
Rear drum inside diameter mm 168.0 169.0
36-4 PARKING BRAKES
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE CAUTION
CHECK AND ADJUSTMENT <L.H. drive If the parking brake lever stroke is below the
vehicles> standard value and the braking is too firm, the
M1361000900414 rear brakes may drag.
1. Pull the parking brake lever with a force of (4) Adjust the parking brake lever stroke to the
approximately 200 N and count the number of standard value by turning the adjusting nut.
notches. After the adjustment, ensure that there is no
Standard value: 4 − 5 notches free play between the adjusting nut and the
2. If the parking brake lever stroke is not the parking brake lever.
standard value, adjust as described below. (5) After the parking brake lever stroke is
(1) Remove the floor console assembly (Refer to adjusted, raise the rear of the vehicle. Release
GROUP 52A, Floor Console Assembly the parking brake, turn the rear wheels to
confirm that the rear brakes are not dragging.
P.52A-14).
Cable rod PARKING BRAKE PEDAL STROKE

CHECK AND ADJUSTMENT <R.H. drive
vehicles>
M1361001000102
1. Depress the parking brake pedal by
Adjusting nut approximately 200 N.
Standard value: 1 − 2 notches
2. If the parking brake pedal stroke is not within the
AC107239 AD
standard value, adjust as described below.
(2) Loosen the adjusting nut to move it to the

cable rod end so that the cable will be free.
Adjuster
AC202320AC
(3) Remove the rear brake adjusting hole plug.

Then insert a flat-tipped screwdriver to turn the
Cable rod Nut holder
adjuster to the arrow direction (to expand the
shoe) until the parking brake shoe makes
contact and the disc can no longer be turned.
Back off the adjuster to the opposite direction
by five notches. Adjusting nut
AC102699AE
(1) Loosen the adjusting nut to the end of the

cable rod in order to allow slack in the cables.
PARKING BRAKES 36-5
ON-VEHICLE SERVICE
Adjuster PARKING BRAKE SWITCH CHECK

M1361003300455
AC202320AC
(2) Remove the rear brake adjusting hole plug.

Then insert a flat-tipped screwdriver to turn the
adjuster to the arrow direction (to expand the
shoe) until the parking brake shoe makes
contact and the disc can no longer be turned.
Back off the adjuster to the opposite direction
by five notches.
CAUTION
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
(3) Adjust the parking brake pedal stroke to the
standard value by turning the adjusting nut. AC300397
After the adjustment, ensure that there is no
free play between the adjusting nut and the 1. Remove the floor console assembly. (Refer to
parking brake pedal. GROUP 52A, Floor Console
In addition, check that the adjusting nut is AaaemblyP.52A-14).
secured by the nut holder. 2. Check for continuity between the parking brake
(4) After the parking brake pedal stroke is switch terminal and the switch mounting bolt.
adjusted, raise the rear of the vehicle. Release When parking brake lever is pulled Less than 2
the parking brake, turn the rear wheels to ohms
confirm that the rear brakes are not dragging.
When parking brake lever is Open circuit
released
36-6 PARKING BRAKES
ON-VEHICLE SERVICE
<R.H. drive vehicles> <L.H. drive vehicles>

1. Adjust the parking brake lever stroke to the
specified value.
Specified value (Operation force: Approx.
200 N): 4 − 5 notches
2. Hook a spring balance onto the centre of the
parking brake lever grip and pull it with a force of
100 − 150 N in a direction perpendicular to the
handle.
3. Drive the vehicle at a constant speed of 35 − 50
km/h for 100 metres.
4. Release the parking brake and let the brakes cool
for 5 − 10 minutes.
5. Repeat the procedure in steps 2 to 4 four or five
times.

1. Adjust the parking brake pedal stroke to the
standard value.
Specified value (Operation force: Approx.
AC102700 200 N): 1 − 2 notches
Check for continuity between the parking brake 2. Depress the parking brake pedal by 100 to 150 N
switch terminal and the switch mounting bolt. (equivalent to approximately one notch).
When parking brake pedal is Less than 2 3. Drive the vehicle at a constant speed of 35 − 50
depressed ohms km/h for 100 metres.
4. Release the parking brake and let the brakes cool
When parking brake pedal is Open circuit
for 5 − 10 minutes.
released
5. Repeat the procedure in steps 2 to 4 four or five
times.
LINING RUNNING-IN
M1361001100303
CAUTION
Carry out running-in in a place with good
visibility, and pay careful attention to safety.
Carry out running-in by the following procedure when
replacing the parking brake linings or the rear brake
disc rotors, or when brake performance is
insufficient.
PARKING BRAKES 36-7
PARKING BRAKE LEVER <L.H. drive vehicles>
PARKING BRAKE LEVER <L.H. drive vehicles>

M1361001300396

Rear Floor Console Assembly Removal (Refer to GROUP • Parking Brake Lever Stroke Adjustment (Refer to P.36-4).
52A, Floor Console P.52A-14). • Rear Floor Console Assembly Installation (Refer to
GROUP 52A, Floor Console Assembly P.52A-14).
1
5
3
2
AC107292
AC107457AC
A Section A - A Section B - B
Ratchet pawl
B
AC107247 AC107249 AC107248
Removal steps
1. Adjusting nut
2. Parking brake switch connector
3. Parking brake cable connection
4. Parking brake lever assembly
5. Parking brake switch
36-8 PARKING BRAKES
PARKING BRAKE PEDAL <R.H. drive vehicles>
PARKING BRAKE PEDAL <R.H. drive vehicles>

M1361001600137

• Console side cover <driver's side> removal (Refer to • Foot duct <driver's side> installation (Refer to GROUP
GROUP 52A, Instrument Panel P.52A-8). 55A, Heater unit, Heater Core, Heater Blower Assembly
• Foot duct <driver's side> removal (Refer to GROUP 55A, and Evaporator Unit P.55A-63).
Heater unit, Heater Core, Heater Blower Assembly and • Console side cover <driver's side> installation (Refer to
Evaporator Unit P.55A-63). GROUP 52A, Instrument Panel P.52A-8).
• Parking Brake Pedal Stroke Adjustment (Refer to P.36-4).
7
3
8
2 4
AC103685 AC
Section A - A Section B - B
A
A
B
Removal steps
1. Adjusting nut
2. Nut holder
3. Parking brake pedal assembly
4. Sealer
5. Pedal pad
6. Parking brake switch
>>A<< 7. Tension spring
8. Stopper
9. Parking brake pedal assembly
PARKING BRAKES 36-9
PARKING BRAKE CABLE
INSTALLATION SERVICE POINT Apply grease to the mating surface of the tension
>>A<< TENSION SPRING INSTALLATION spring and pedal, and then install the spring as
shown.
AC300123AB
PARKING BRAKE CABLE

REMOVAL AND INSTALLATION <L.H.
drive vehicles>
M1361001900581

• Rear Floor Console Assembly Removal (Refer to GROUP • Parking Brake Lever Stroke adjustment (Refer to P.36-4).
52A, Floor Console P.52A-14). • Rear Floor Console Assembly Installation (Refer to
GROUP 52A, Floor Console Assembly P.52A-14).
6
3 2
5
1
4
AC202586AD

• Shoe and lining assembly (Refer to 2. Clip
P.36-12). 3. Protector B
• Loosen the adjusting nuts. 4. Parking brake cable connection
Turn up the driver's side carpet. 5. Protector C
•
6. Rear parking brake cable assembly
36-10 PARKING BRAKES
PARKING BRAKE CABLE

M1361001900592
<Front>
• Front scuff plate, rear scuff plate, cowl side trim, lower • Accelerator pedal stopper installation (Refer to GROUP
center pillar trim removal (Refer to GROUP 52A, Trims 17, Accelerator Cable and Pedal P.17-6 <2000>, P.17-7
P.52A-18). <2400>).
• Front seat assembly removal <driver's side> (Refer to • Foot duct <driverís side> installation (Refer to GROUP
GROUP 52A, Front Seat Assembly P.52A-29). 55A, Heater Unit, Heater Core, Blower Assembly and
• Rear seat cushion removal (Refer to GROUP 52A, Rear Evaporator Unit P.55A-63).
Seat P.52A-36). • Center console panel and center console installation
• Seat belt lower anchor bolt removal (Refer to GROUP (Refer to GROUP 52A, Instrument Panel Assembly
52A, Seat Belt P.52A-39). P.52A-8).
• Floor Console Assembly Removal (Refer to GROUP 52A, • Floor Console Assembly Installation (Refer to GROUP
Floor Console P.52A-14). 52A, Floor Console P.52A-14).
• Center console panel and center console removal (Refer • Seat belt lower anchor bolt removal (Refer to GROUP
to GROUP 52A, Instrument Panel Assembly P.52A-8). 52A, Seat Belt P.52A-39).
• Foot duct <driverís side> removal (Refer to GROUP 55A, • Rear seat cushion removal (Refer to GROUP 52A, Rear
Heater Unit, Heater Core, Blower Assembly and Seat P.52A-36).
Evaporator Unit P.55A-63). • Front seat assembly removal <driver's side> (Refer to
• Accelerator pedal stopper removal (Refer to GROUP 17, GROUP 52A, Front Seat Assembly P.52A-29).
Accelerator Cable and Pedal P.17-6 <2000>, P.17-7 • Front scuff plate, rear scuff plate, cowl side trim, lower
<2400>). center pillar trim removal (Refer to GROUP 52A, Trims
P.52A-18).
• Parking Brake pedal Stroke adjustment (Refer to P.36-4).
AC102716AD

• Turn up the driver's side carpet. 2. Nut holder
1. Adjusting nut 3. Equalizer
4. Front parking brake cable assembly
PARKING BRAKES 36-11
PARKING BRAKE CABLE
<Rear>
• Front scuff plate, rear scuff plate, cowl side trim, lower • Center console panel and center console installation
center pillar trim removal (Refer to GROUP 52A, Trims (Refer to GROUP 52A, Instrument Panel Assembly
P.52A-18). P.52A-8).
• Front seat assembly removal <driver's side> (Refer to • Floor Console Assembly Installation (Refer to GROUP
GROUP 52A, Front Seat Assembly P.52A-29). 52A, Floor Console Assembly P.52A-14).
• Rear seat cushion removal (Refer to GROUP 52A, Rear • Seat belt lower anchor bolt removal (Refer to GROUP
Seat Assembly P.52A-36). 52A, Seat Belt P.52A-39).
• Seat belt lower anchor bolt removal (Refer to GROUP • Rear seat cushion removal (Refer to GROUP 52A, Rear
52A, Seat Belt P.52A-39). Seat Assembly P.52A-36).
• Floor Console Assembly Removal (Refer to GROUP 52A, • Front seat assembly removal <driver's side> (Refer to
Floor Console Assembly P.52A-14). GROUP 52A, Front Seat Assembly P.52A-29).
• Center console panel and center console removal (Refer • Front scuff plate, rear scuff plate, cowl side trim, lower
to GROUP 52A, Instrument Panel Assembly P.52A-8). center pillar trim removal (Refer to GROUP 52A, Trims
P.52A-18).
• Parking Brake pedal Stroke adjustment (Refer to P.36-4).
6
3 2
5
1
4
AC202586AD

• Shoe and lining assembly (Refer to 2. Clip
P.36-12). 3. Protector B
• Loosen the adjusting nuts. 4. Parking brake cable connection
Turn up the driver's side carpet. 5. Protector C
•
6. Rear parking brake cable assembly
36-12 PARKING BRAKES
PARKING BRAKE LINING AND DRUM

M1361002500359
• Parking Brake Lever Stroke Check and Adjustment (Refer
to P.36-4).
• Lining Running-in (Refer to P.36-6).
• Floor Console Installation (Refer to GROUP 52A, Floor
Console Assembly P.52A-14).
12
15
13
5 60 ± 5 N·m
14 4 3
8 1
16 9
13
63 ± 7 N·m
11
6 2
10 7
AC300145AB
13 13
7
16
Brake grease: Multipurpose grease

<<A>> 1. Rear brake caliper assembly 11. Shoe hold-down spring
2. Rear brake disc 12. Shoe hold-down pin
>>B<< 3. Shoe-to-anchor spring 13. Shoe and lining assembly
>>B<< 4. Shoe-to-anchor spring 14. Clip
5. Shoe guide plate 15. Rear hub assembly (For 2WD, refer
6. Adjusting wheel spring to GROUP 27A, Rear Hub
>>A<< 7. Adjuster assembly Assembly P.27A-5. For 4WD, refer
8. Strut to GROUP 27B, Rear Hub
9. Strut-to-shoe spring Assembly P.27B-8).
10. Shoe hold-down cup 16. Backing plate
PARKING BRAKES 36-13
REMOVAL SERVICE POINT INSPECTION

M1361002600301
<<A>> REAR BRAKE CALIPER ASSEMBLY
REMOVAL
PARKING BRAKE LINING AND BRAKE
Remove the rear brake caliper assembly and support DRUM CHECK
it with wire or something similar.

>>A<< ADJUSTER ASSEMBLY INSTALLATION
ACX00708AB
1. Measure the thickness of the brake lining at

Shoe adjusting bolt
several places.
AC202301AC
Limit: 1.0 mm
Install the adjuster so that the shoe adjusting bolt for
the left hand wheel is attached towards the rear of 2. If the thickness of the brake lining is below the
the vehicle, and the shoe adjusting bolt for the right limit, replace the shoe and lining assemblies on
hand wheel is towards the front of the vehicle. both sides of the vehicle. Never replace only one
side.
>>B<< SHOE-TO-ANCHOR SPRING
INSTALLATION
Front of the vehicle
ACX00709
Blue paint Yellow paint 3. Measure the inside diameter of the brake disc in
AC202302AC
two places or more.
The shoe-to-anchor springs are not interchangeable Standard value: 168.0 mm
as their constants are different. The one with blue
Limit: 169.0 mm
paint mark should be install at the front of the vehicle,
and the other with yellow paint at the rear of the 4. If the inside diameter exceeds the limit, or if it is
vehicle, respectively. excessively worn on one side, replace the brake
NOTE: The illustration shows the left rear wheel. The disc.
right rear wheel is symmetrical to that.
NOTES
37-1
GROUP 37
00
11
POWER STEERING 12
13
14
CONTENTS
15
GENERAL INFORMATION . . . . . . . . 37!" STEERING COLUMN SHAFT ASSEMBLY
16
SHOCK ABSORBING MECHANISM CHECK 37!%'
SERVICE SPECIFICATIONS. . . . . . . 37!# 17
STEERING WHEEL*. . . . . . . . . . . . . . 37!'#
LUBRICANTS . . . . . . . . . . . . . . . . . . 37!$ REMOVAL AND INSTALLATION . . . . . . . . 37!%( 21
STEERING SHAFT* . . . . . . . . . . . . . . 37!'% 22
SEALANTS . . . . . . . . . . . . . . . . . . . . 37!$
REMOVAL AND INSTALLATION . . . . . . . . 37!%)
25
SPECIAL TOOLS. . . . . . . . . . . . . . . . 37!% DISASSEMBLY AND REASSEMBLY . . . . . 37!%"
26
ON-VEHICLE SERVICE. . . . . . . . . . . 37!& POWER STEERING GEAR BOX AND
STEERING WHEEL FREE PLAY CHECK . 37!" LINKAGE* . . . . . . . . . . . . . . . . . . . . . . 37!'( 27
REMOVAL AND INSTALLATION . . . . . . . . 37!%#
STEERING ANGLE CHECK . . . . . . . . . . . . 37!" 31
TIE ROD END BALL JOINT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37!'%
STARTING TORQUE CHECK . . . . . . . . . . 37!# DISASSEMBLY AND REASSEMBLY . . . . . 37!'' 32
STATIONARY STEERING EFFORT CHECK 37!$ TIE ROD END BALL JOINT
STEERING WHEEL RETURN TO DUST COVER REPLACEMENT . . . . . . . . . 37!(& 33
CENTRE CHECK . . . . . . . . . . . . . . . . . . . . 37!$
DRIVE BELT TENSION CHECK. . . . . . . . . 37!$ POWER STEERING OIL PUMP 34
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 37!#'
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37!$ 35
FLUID REPLACEMENT . . . . . . . . . . . . . . . 37!%& REMOVAL AND INSTALLATION . . . . . . . . 37!(%
POWER STEERING SYSTEM AIR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37!(' 36
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37!%& DISASSEMBLY AND REASSEMBLY . . . . . 37!((
OIL PUMP PRESSURE TEST . . . . . . . . . . 37!%% INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37!(* 37
POWER STEERING PRESSURE
42
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . 37!%% POWER STEERING HOSES . . . . . . . 37!#%
TIE ROD END BALL JOINT DUST REMOVAL AND INSTALLATION . . . . . . . . 37!() 51
COVER CHECK . . . . . . . . . . . . . . . . . . . . . 37!%'
52
54
WARNING 55
Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
passenger (from rendering the SRS inoperative).
Service or maintenance of any SRS component or SRS-related component must be performed only at an
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-
related component.
POWER STEERING
37-2 GENERAL INFORMATION
GENERAL INFORMATION
M1372000100326
FEATURES ! A vane type pump with a fluid flow rate control

Power steering has been adopted in all vehicles to system which change steering effort according to
make the steering system easier to handle. the engine speed is used.
! A 4-spoke steering wheel is used. ! The separate plastic resin oil reservoir is used to
! A steering column has a shock absorbing reduce weight and to make the fluid level
mechanism and a tilt steering mechanism. checking easier.
! Integral-type rack and pinion gear with high ! The cooler tube assembly is installed on the
rigidity and excellent response is used. power steering fluid line to improve the cooling
performance of the power steering fluid.
SPECIFICATIONS
Item Specification
Steering wheel Type 4-spoke type
Outside diameter mm 380
Maximum number of turns 2.7
Steering column Column mechanism Shock absorbing mechanism and Tilt
steering mechanism
Tilt up: 20 mm
Tilt down: 20 mm
Power steering type Integral type
Oil pump Type Vane pump
Basic discharge amount mL/rev. 9.6
Relief pressure MPa 8.8
Reservoir type Separate type (plastic)
Pressure switch Equipped
Steering gear Type Rack and pinion
Stroke ratio (Rack stroke/Steering wheel 51.45
maximum turning radius)
Rack stroke mm 141
POWER STEERING
37-3
Steering wheel
Steering column
Oil reservoir shaft assembly
Pressure hose
Suction hose assembly
Return hose
Oil pump assembly
Steering gear
Cooler tube assembly

AC300061 AB
M1372000300364

Steering wheel free With engine running " 30
play mm With engine stopped 10 or less "
Steering angle Inside wheel 34#50’ $ 1#30’ "
Outside wheel (reference) 29#20’ "
Toe-in At the centre of tyre tread mm 1$2 "
Toe-angle (per wheel) 0#03’ $ 05’ "
Tie rod end ball joint starting torque N%m 0.5 " 2.5 "
Tie rod swing resistance N [Tie rod swing torque N%m] 6 " 19 [1.5 " 4.9] "
Stationary steering effort N [Fluctuation allowance N] 29 or less [5.9 or less] "
Oil pump pressure Oil pump relief pressure 8.8 " 9.5 "
MPa (750 $ 100 r/min.) Pressure under no-load conditions 0.8 " 1.0 "
Steering gear retention hydraulic pressure 8.8 " 9.5 "
Oil pressure switch operating pressure OFF & ON 1.5 " 2.0 "
MPa ON & OFF 0.7 " 2.0 "
Steering gear total pinion torque N%m [Change in torque N%m] 0.7 " 1.6 [0.4 or less] "
Opening dimension of special tool boot band crimping tool 2.9 "
(MB991561) mm
Band crimped width mm 2.4 " 2.8 "
POWER STEERING
37-4 LUBRICANTS
LUBRICANTS
M1372000400338

Power steering fluid ATF DEXRON III or DEXRON II Approximately 1.0 L
Steering gear Bearing ATF DEXRON III or DEXRON II As required
O-ring and seal ring
Oil seal
Special tool (MB991213)
Pinion and valve assembly
seal ring part
Bellows Silicon grease As required
Tie rod end ball joint Multipurpose grease SAE J310, As required
Oil pump Friction surface of rotor vane, ATF DEXRON III or DEXRON II As required
cam ring and pump cover
O-ring
SEALANTS
M1372000500324

Steering shaft cover assembly bolt hole on the toeboard 3M ATD Part No.8513 or equivalent
Steering gear End plug 3M ATD Part No.8661, 8663 or
Rack support cover equivalent
POWER STEERING
SPECIAL TOOLS
37-5
SPECIAL TOOLS
M1372000600321

disconnection
AC106827
MB990326 Preload socket Tie rod end ball joint starting torque
check
MB990326
MB991548 Power steering oil Oil pump pressure test

pressure gauge
adapter (Pump
side)
MB991548
MB991549 Power steering oil

pressure gauge
adapter (Hose
side)
MB991549

pressure gauge
MB990662
MB990784 Ornament remover Cover removal
MB990784
MB990228 or Preload socket Steering gear total pinion torque

MB991006 check and adjustment
MB991006
POWER STEERING
37-6 SPECIAL TOOLS

MB991621 Rack support cover ! Rack support adjustment
wrench ! Rack support cover removal
MB991621
MB990925 Bearing and oil ! Oil seal and bearing installation

seal installer set ! MB990927, MB990938, MB990939
(For details, refer to GROUP 26,
Special Tools +,26!*).
MB990925
MB991120 Needle bearing Needle roller bearing removal

puller
MB991120
MB991199 Oil seal and Oil seal installation

bearing installer
MB991199
AB
MB991197 Bar (long type)
MB991197
MB991202 Oil seal and ! Needle bearing installation

bearing installer ! Lower bearing installation
MB991202
MB991213 Rack installer Rack installation
MB991212
MB991203 Oil seal and Oil seal and bearing installation

bearing installer
MB991203
POWER STEERING
ON-VEHICLE SERVICE
37-7
MB991317 Seal ring installer Seal ring installation
MB991317
MB990941 Torque tube Lower oil seal installation

bearing installer
MB990941
MB991561 Boot band crimping Bellows band installation

tool
MB991561
MB990776 Front axle base Tie rod end ball joint dust cover
installation
MB990776
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK 4. If the free play still exceeds the limit value, set the
M1372001000270 steering wheel straight ahead with the engine
1. With the engine running (hydraulic operation), set stopped. Load 5 N towards the steering wheel
the front wheels straight ahead. circumference and check the play.
Standard value (steering wheel play with the
engine stopped): 10 mm or less
5. If the play exceeds the standard value, remove the
steering gear (Refer to +,37!%#). and check the
total pinion torque (Refer to +,37!'').
STEERING ANGLE CHECK

M1372001100341
ACX01122 AB
2. Measure the play on the steering wheel

circumference before the wheels start to move
when slightly moving the steering wheel in both
directions.
Limit: 30 mm
3. When the play exceeds the limit, check for the
play on the steering shaft and steering linkage AC000756AB
connection. Correct or replace.

POWER STEERING
37-8 ON-VEHICLE SERVICE
1. Place the front wheel on a turning radius gauge TIE ROD END BALL JOINT STARTING
and measure the steering angle. TORQUE CHECK
Standard value: M1372001500275
CAUTION
Item Specification ! Do not remove the nut from ball joint. Loosen
Inside wheel 34#50’ $ 1#30’ it and use special tool to avoid possible
Outside wheel 29#20’ damage to the ball joint threads.
(reference) ! Hang special tool with cord to prevent it from
falling.
2. If the steering angle is not within the standard
value, adjust the toe-in as follows. Cord
Standard value:
at the centre of tyre tread: 1 $ 2 mm
Toe angle (per wheel): 0#03’ $ 05’
Nut MB991897
Jam nut
Clip
Bolt

AC006074 AB Bolt
3. Loosen the jam nut, and unclip the bellows.

Parallel
4. Adjust the toe-in by turning the left and right tie
rod turnbuckles by the same amount (in opposite
directions). Knob Good
NOTE: The toe will move out as the left

turnbuckle is turned toward the front of the vehicle
and the right turnbuckle is turned toward the rear Bad AC106821AB
of the vehicle.
5. Tighten the jam nut to the specified torque, and
tighten the bellows by the clip.
Tightening torque: 52 $ 2 N%m
6. Recheck the steering angle. sure the knob is in the position shown in the
figure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.
POWER STEERING
ON-VEHICLE SERVICE
37-9
Standard value:
MB990326 Steering effort: 29 N or less
Fluctuation allowance: 5.9 N or less
value, check and adjust the related parts.
STEERING WHEEL RETURN TO CENTRE

CHECK
M1372001800287
Conduct a road test:
ACX01129 AB
1. Make both gradual and sudden turns and check
4. Move the ball joint stud several times and install the steering wheel return.
the nut on the stud. Using special tool preload
socket (MB990326), measure the ball joint
starting torque.
Standard value: 0.5 " 2.5 N%m
70˚ 70˚
5. If the starting torque exceeds the standard value,
replace the tie rod end.
6. If the starting torque is under the standard value,
check the ball joint for axial play or ratcheting. If
no axial play or ratcheting, the ball joint can be re-
used.
ACX01130AB
CAUTION
Always use a new ball joint nut as it is a self- 2. At a vehicle speed of approximately 35 km/h, turn
locking nut. the steering wheel 90#, hold a few seconds, then
release. If the steering wheel then returns 70# or
7. Install the tie rod end to the knuckle, then tighten a
more, the return can be judged satisfactory.
new self-locking nut to the specified torque.
Tightening torque: 25 $ 5 N%m NOTE: There will be a momentary feeling or
"heaviness" when the wheel is turned quickly, but
STATIONARY STEERING EFFORT CHECK this is not abnormal (Oil pump discharge amount
M1372001700310
is especially apt to be insufficient during idling).
1. With the vehicle stopped on a flat and paved
surface, turn the steering wheel to the straight DRIVE BELT TENSION CHECK
ahead position. M1372001900240
2. Start the engine and set the engine idle speed. Refer to GROUP 11A, On-vehicle Service " Drive
Standard value: 750 $ 100 r/min Belt Tension Check +,11A!-.
FLUID LEVEL CHECK

M1372002000262
1. Park the vehicle on a flat, level surface.
2. Start the engine, and then turn the steering wheel
several times to raise the temperature of the fluid
to approximately 50 " 60#C.
3. With the engine running, turn the wheel all the
way to the left and right several times.
ACX01122 AB
3. Attach a spring balance to the outer

circumference of the steering wheel and measure
the steering force required to turn the steering
wheel from the straight ahead position to the left
and right (within a range of 1.5 turns). Also check
to be sure that there is no significant change in
the required steering effort.
POWER STEERING
2. Disconnect the ignition coil connectors (Refer to

Fluid level change: Within 5 mm
GROUP 16, Ignition Coil +,16!(').
CAUTION
Perform air bleeding only while cranking the
engine. If air bleeding is performed while the
engine is running, air could enter the fluid.
During air bleeding, refill the steering fluid
supply so that the level never falls below the
"MIN" mark on the oil reservoir.
While engine running While engine stopped
ACX01131AC 3. Turn the steering wheel all the way to the left and
right five or six times while using the starter motor
4. Check the fluid in the oil reservoir for foaming or
to crank the engine intermittently several times
milkiness. Check the difference of the fluid level
(for 15 to 20 seconds).
when the engine is stopped, and while it is
running. If the change of the fluid level is 5 mm or 4. Connect the ignition coil connectors (Refer to
more, air bleeding should be done. GROUP 16, Ignition Coil +,16!(').
5. Start the engine (idling).
FLUID REPLACEMENT 6. Turn the steering wheel to the left and right until
M1372002100311 there are no air bubbles in the oil reservoir.
1. Raise and support the front wheels. 7. Confirm that the fluid is not milky, and that the
level is between "MAX" and "MIN" marks.
Return hose
8. Confirm that there is very little change in the fluid
Return hose level when the steering wheel is turned left and
Vinyl hose right.
CAUTION
If the fluid level rises suddenly after the engine is
stopped, the air has not been completely bled. If
air bleeding is not complete, there will be
abnormal noises from the pump and the flow-
AC100369AB
control valve, and this condition could cause
2. Disconnect the return hose connection, and then reduce the life of the power steering
connect a vinyl hose to the return hose, and drain components.
the fluid into a container. Fluid level change: Within 5 mm
3. Disconnect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil +,16!(').
4. While operating the starter motor intermittently,
turn the steering wheel all the way to the left and
right several times to drain all of the fluid.
5. Connect the return hose securely, and then
secure with the clip.
6. Fill the oil reservoir with specified fluid up to the While engine running While engine stopped
lower position of the filler, and then bleed the air. ACX01131AC
Specified fluid: ATF DEXRON III or DEXRON 9. Confirm that the change in the fluid level is no
II more than 5 mm when the engine is stopped and
when it is running.
POWER STEERING SYSTEM AIR 10.If the change of the fluid level is 5 mm or more,
BLEEDING the air has not been completely bled from the
M1372002200318
system. The air bleeding procedure must be
Perform air bleeding procedure as necessary after
repeated.
replacing the steering gear or the steering fluid lines.
1. Raise and support the front wheels.
POWER STEERING
ON-VEHICLE SERVICE
37-11
OIL PUMP PRESSURE TEST 7. If it is not within the standard value, the probable
M1372002300296 cause is a malfunction of the oil line or steering
gear, so check these parts and repair as
Pressure necessary.
gauge Shut-off valve
Temperature (fully closed) 8. Turn the steering wheel all the way to the left or
gauge (MB990662)
right; then check whether or not the retention
hydraulic pressure is the standard value.
Standard value: 8.8 " 9.5 MPa
Oil reservoir
9. If not the standard value, overhaul the steering
Adapter gear. Remeasure fluid pressure.
(MB991548)
10. Remove the special tools, and then tighten the
pressure hose to the specified torque.
Oil 11. Bleed the system (Refer to +,37!%&).
pump
POWER STEERING PRESSURE SWITCH
CHECK
Adapter M1372007200302
(MB991549)
ACX01133 AB
1. Disconnect the pressure hose from the oil pump,

and then connect the following special tools.
! MB990662: Power Steering Oil Pressure Gauge
Adapter (Pump Side)
Adapter (Hose Side)
2. Bleed air, then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50
" 60#C.
3. Start the engine and idle it at 750 $ 100 r/min.
CAUTION
The pressure gauge shut-off valve must not
remain closed for more than 10 seconds.
4. Fully close the shut-off valve of the pressure
gauge and measure the oil pump relief pressure
to confirm that it is within the standard value 1. Disconnect the pressure hose from the oil pump,
range. Open it again immediately after checking and then connect the following special tools.
the pressure. ! MB990662: Power Steering Oil Pressure Gauge
Standard value: 8.8 " 9.5 MPa Adapter (Pump Side)
5. If it is not within the standard value, replace the oil ! MB991549: Power Steering Oil Pressure Gauge
pump. Adapter (Hose Side)
6. Check whether or not the hydraulic pressure is the 2. Bleed air, and then turn the steering wheel several
standard value when no-load conditions are times while the vehicle is not moving so that the
created by fully opening the shut-off valve of the temperature of the fluid rises to approximately 50
pressure gauge. " 60#C.
Standard value: 0.8 " 1.0 MPa 3. The engine should be idling.
POWER STEERING
4. Disconnect the connector for the oil pressure WARNING

switch, and place an ohmmeter at the switch. ! If the vehicle continues to be driven after
5. Gradually close the shut-off valve of the pressure the collision absorbing mechanism has
gauge and increase the hydraulic pressure, then operated, the steering column shaft may
check whether or not the hydraulic pressure that be damaged while it is in use.
activates the switch is the standard value.
! If there is a slack in the one-way capsule,
Standard value: 1.5 " 2.0 MPa do not attempt to repair it but replace the
6. Gradually open the shut-off valve and reduce the steering column shaft assembly.
hydraulic pressure; then check whether or not the
Inspection Procedure
hydraulic pressure that deactivates the switch is
the standard value. 1. Remove the lower and upper column covers.
Standard value: 0.7 " 2.0 MPa CAUTION
Do not release the tilt lever until the steering
7. Remove the special tools, and then tighten the column has been installed to complete this
pressure hose to the specified torque. inspection procedure.
Tightening torque: 57 $ 7 N%m 2. Ensure that the tilt lever is in the lock position.
8. Bleed the system (Refer to +,37!%&). NOTE: If not, place the tilt lever in the lock
position.
TIE ROD END BALL JOINT DUST COVER
3. Loosen the two upper steering column mounting
CHECK bolts by two turns.
M1372008600240
1. Press the dust cover with your finger to check
whether the dust cover is cracked or damaged.
the tie rod end.
Steering
NOTE: If the dust cover is cracked or damaged, column
mounting
the ball joint could be damaged. bolt
STEERING COLUMN SHAFT ASSEMBLY Steering

column
SHOCK ABSORBING MECHANISM assembly
CHECK
M1372013500067 One way capsule
If a collision accident occurs or severe impact is
applied on the steering wheel, the collision energy
absorbing mechanism may have operated. Once the
mechanism has operated, it will be inoperative even
it has suffered no apparent damage. Determine if the
steering column shaft can be reused by the following
procedure. If the collision energy absorbing
mechanism has already operated, replace the
AC209935 AC
steering column shaft assembly.
If any excessive radial free play on the steering 4. Hold the one-way capsules as shown, and then
wheel is found with the tilt lever in the lock position, try to lock them. If there is a slack in either of the
always check the steering shaft assembly. capsules, replace the steering column shaft
assembly.
NOTE: When installing a new steering column
shaft assembly, place the tilt lever in the lock
position, if it is not in place.
POWER STEERING
STEERING WHEEL
37-13
CAUTION
! Be careful that nothing is pinched between
the one-way capsules and the body.
! Do not release the tilt lever until the steering
column has been installed to complete this
inspection procedure.
5. If no problem is found during the inspection,
tighten the steering column mounting bolts to the
specified torque.
STEERING WHEEL
M1372011400150
WARNING
! Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions and Air Bag Module and Clock Spring !"52B#$.
! When removing and installing the steering wheel, do not let it bump against the air bag
module.
! Checking Steering Wheel Position with Wheels Straight
Ahead
Section A - A
2 Tab
2
1
Section B - B
Tab
1
A 50 ± 5 N·m
B
B 2
1 A
AC107402 AB
Removal steps NOTE: For air bag module removal, refer to GROUP
<<A>> 1. Cover 52B, Air Bag Module and Clock Spring !"52B#$%$.
<> 2. Steering wheel and air bag module
assembly
POWER STEERING
37-14 STEERING WHEEL
REMOVAL SERVICE POINTS <> STEERING WHEEL AND AIR BAG

<<A>> COVER REMOVAL MODULE ASSEMBLY REMOVAL
Clock spring
MB990784 connector
A
Steering
wheel AC006295 AB
AC006294 AB
Insert special tool ornament remover (MB990784) at 1. By sliding section A of the clock spring connector
the indicated position to remove the cover. shown in the illustration in the arrow direction,
NOTE: The special tool can be inserted through the disconnect the connector.
notch behind the area shown.
Hexagonal bit socket
AC102792 AC107462 AD
2. Loosen the bolt completely. Then, remove the

steering wheel and air bag module assembly.
NOTE: Use a hexagonal bit socket or a hexagonal
wrench having an effective length of 75 mm or
more in the hexagonal section and the diameter of
8 mm or more.
POWER STEERING
STEERING SHAFT
37-15
STEERING SHAFT
M1372011500094
WARNING
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions and Air Bag Module and Clock Spring !"52B#$.
! Steering Wheel and Air bag Module Assembly Removal ! Instrument Lower Panel Installation (Refer to GROUP
(Refer to +,37!%(). 52A, Instrument Panel +,52A!').
! Instrument Lower Panel Removal (Refer to GROUP 52A, ! Steering Wheel and Air bag Module Assembly Installation
Instrument Panel +,52A!'). (Refer to +,37!%().
Section A - A A
2 3
2
Tab
A
5
Section B - B
B B
Toe board
12 ± 2 N·m 1
B B 4
6
18 ± 2 N·m
6
Specified sealant:
3M ATD Part No.8513 or equivalent 5.0 ± 1.0 N·m
AC301263 AB
Removal steps Removal steps)*+,-./-0123

1. Lower column cover 4. Shaft cover
2. Upper column cover <<A>> >>A<< 5. Steering column shaft assembly
3. Clock spring and column switch 6. Cover assembly
assembly (Refer to GROUP 52B, Air
Bag Module and Clock Spring
+,52B!%*%).
POWER STEERING
37-16 STEERING SHAFT

<<A>> STEERING COLUMN SHAFT ASSEMBLY >>A<< STEERING COLUMN SHAFT ASSEMBLY
REMOVAL INSTALLATION
CAUTION CAUTION
The tilt lever should be held in the lock position ! When reusing the steering column, do not
until the steering column shaft is installed to the release the tilt lever until the steering column
vehicle. If the steering column is removed with shaft has been installed.
the tilt lever released, or the tilt lever is released ! When the steering column is replaced, do not
after the steering column shaft was removed release the tilt lever until it has been installed.
from the vehicle, the steering column can not be Do not remove the tilt lever fixing band until
reinstalled correctly. If the steering column is the installation has completed.
installed incorrectly, the collision energy ! When installing the steering column, do not
absorbing mechanism may be damaged. leave it fixed temporarily at only one point and
1. Ensure that the tilt lever is in the lock position, and make sure the column shaft is not shaken
remove the steering column mounting bolts. strongly. If you fail to do, the collision
absorbing mechanism at the column shaft
mounting location may be damaged.
Clip
4
Steering column 1 2
shaft
3
Tilt lever
AC210969 AD
2. Pinch the steering column shaft clip with pliers, AC209383 AD

and pull up the shaft towards the direction shown
Ensure that the tilt lever is in the lock position, and
to disengage the steering column shaft assembly.
install the steering column. Tighten the four bolts in
the order shown by hand, and then tighten them to
the specified torque in the order shown.
POWER STEERING
STEERING SHAFT
37-17
M1372011700087
4 3
AC210967AD
Disassembly steps Disassembly steps)*+,-./-0123

<<A>> >>A<< 1. Special bolt >>A<< 3. Steering lock cylinder assembly
>>A<< 2. Steering lock bracket 4. Steering column shaft assembly
DISASSEMBLY SERVICE POINT CAUTION

The steering lock bracket and bolts must be
Reverse screw tap
Special bolt replaced with new ones when the steering lock is
installed.
Steering lock
bracket 1. When installing the steering lock cylinder
assembly and steering lock bracket to the column
tube, temporarily install the steering lock in
alignment with the column boss.
Steering lock
cylinder ACX01138 AB
<<A>> SPECIAL BOLT REMOVAL

1. Drill in the special bolt a hole deep enough for the
tap to stand.
2. Remove the special bolt with a left-hand tap.
REASSEMBLY SERVICE POINT ACX01139 AB

>>A<< STEERING LOCK CYLINDER ASSEMBLY/
STEERING LOCK BRACKET/SPECIAL BOLT 2. After checking that the lock works properly, tighten
INSTALLATION the special bolts until the head twists off.
POWER STEERING
37-18 POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING GEAR BOX AND LINKAGE

M1372010900215
WARNING
Before removing the steering gear, refer to GROUP 52B, Service Precautions (!"52B#$) and
Air Bag Module and Clock Spring (!"52B#%&%). Centre the front wheels. Failure to do so may
damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
! Power Steering Fluid Draining (Refer to +,37!%&). ! Stabilizer Link Assembly and Lower Arm Assembly
! Front Exhaust Pipe Removal (Refer to GROUP 15, Installation (Refer to GROUP 33A, Lower Arm +,33!%%).
Exhaust Pipe and Main Muffler +,15!#). ! Centermember Installation (Refer to GROUP 32, Engine
! Centermember Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember +,32!-).
Roll Stopper and Centermember +,32!-). ! Front Exhaust Pipe Installation (Refer to GROUP 15,
! Steering Wheel and Air Bag Module Assembly Removal Exhaust Pipe and Main Muffler +,15!#).
(Refer to +,37!%(). ! Clock Spring Installation (Refer to GROUP 52B, Air Bag
! Clock Spring Removal (Refer to GROUP 52B, Air Bag Module and Clock Spring +,52B!%*%).
Module and Clock Spring +,52B!%*%). ! Steering Wheel and Air Bag Module Assembly Installation
! Stabilizer Link Assembly and Lower Arm Assembly (Refer to +,37!%().
Removal (Refer to GROUP 33A, Lower Arm +,33!%%). ! Check the dust cover for cracks or damage by pushing it
with your finger.
! Power Steering Fluid Supplying (Refer to +,37!%&).
! Power Steering Fluid Line Bleeding (Refer to +,37!%&).
! Checking Steering Wheel Position with Wheels Straight
Ahead.
! Front Wheel Alignment Adjustment (Refer to GROUP
33A, On-vehicle Service " Front Wheel Alignment Check
and Adjustment +,33!)).
POWER STEERING
37-19
4
2
12 ± 2 N·m 1
18 ± 2 N·m
11
12 ± 2 N·m 7 15 ± 3 N·m
9
5
70 ± 10 N·m 10
4
6 25 ± 5 N·m
7
8
70 ± 10 N·m
13
57 ± 7 N·m
18 ± 2 N·m
3
12
49 ± 10 N·m
167 ± 9 N·m
AC300496 AB

1. Shaft cover <> ! Crossmember assembly
2. Steering column shaft assembly and ! Rear roll stopper (Refer to GROUP 32,
steering gear connecting bolt Engine Roll Stopper and
<<A>> 3. Tie rod end and knuckle connection Centermember +,32!-).
! Rear roll stopper connecting bolt >>A<< 9. Joint cover grommet
(Refer to GROUP 32, Engine Roll 10. Steering extension
Stopper and Centermember +,32!-). 11. Return tube
4. Return hose connection 12. Crossmember
5. Return tube 13. Steering gear
6. O-ring
7. Pressure hose connection
8. Gasket
POWER STEERING
REMOVAL SERVICE POINTS 3. Tighten the bolt with a wrench to disconnect the
<<A>> TIE ROD END AND KNUCKLE tie rod end.
DISCONNECTION
<> CROSSMEMBER ASSEMBLY REMOVAL
CAUTION
! Do not remove the nut from ball joint. Loosen
Piece of wood
! Hang special tool with a cord to prevent it
from falling.
Cord
Transmission
jack AC102600 AD
Nut MB991897
1. Use a transmission jack to hold the crossmember,
and then remove the crossmember mounting nuts
and bolts.
Bolt 2. Lower the crossmember with the rear roll stopper,
Ball joint AC208247AD the stabilizer bar, the return tube, and the steering
1. Install the special tool ball joint remover gear.
(MB991897) as shown in the figure.
>>A<< JOINT COVER GROMMET INSTALLATION
Bolt
Joint cover
Parallel grommet
A
Knob Good B
Bad AC106821AB
Steering gear
2. Turn the bolt and knob as necessary to make the AC301284 AB
jaws of the special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel. Align the joint cover grommet notch (arrow A) with
the steering gear lug (arrow B), and then install the
NOTE: When adjusting the jaws in parallel, make steering joint cover to the steering gear.
figure.
POWER STEERING
37-21
INSPECTION TIE ROD SWING RESISTANCE CHECK
M1372011000204 1. Give 10 hard swings to the tie rod.
STEERING GEAR TOTAL PINION TORQUE
CHECK
CAUTION
When holding the steering gear in a vice, secure
its mounting positions. If it is secured in any
other place, the gear housing may become
deformed or damaged.
MB991006 AC000997
2. Measure the tie rod swing resistance [tie rod

swing torque] with a spring balance.
Standard value: 6 " 19 N [1.5 " 4.9 N%m]
value, replace the tie rod.
AC000996 AC 4. If the measured value is below the standard value,
the tie rod can be re-used if it swings smoothly
Using special tool preload socket (MB991006), rotate
without excessive play.
the pinion gear at the rate of one rotation in
approximately 4 to 6 seconds to check the total TIE ROD END BALL JOINT DUST COVER CHECK
pinion torque. 1. Check the dust cover for cracks or damage by
Standard value: 0.7 " 1.6 N%m pushing it with your finger.
[Change in torque: 0.4 N%m or less] 2. If the dust cover is cracked or damaged, replace
NOTE: When measuring, remove the bellows from the tie rod end (Refer to +,37!'').
the rack housing. Measure the pinion torque through NOTE: Cracks or damage of the dust cover may
the whole stroke of the rack. damage the ball joint. If it is damaged during
If the measured value is not within the standard service work, replace the dust cover (Refer to
range, first adjust the rack support cover, and then !"37#&').
check the total pinion torque again.
If the total pinion torque cannot be adjusted to within
the standard range by adjusting the rack support
cover, check the rack support cover, rack support
spring, rack support and replace any parts if
necessary.
POWER STEERING

M1372011100171
22 ± 4 N·m
Flare nut
3 13 ± 3 N·m
4 24 3
23
4 22
20 18
21
35 34 19 23
Repair kit grease
13 59 ± 10 N·m 21
19
1 36 12 4
52 ± 2 N·m 11 8
15 14 23 ± 2 N·m
2 33 -30˚ 8
17 11 35
16
6 25 ± 4 N·m 17 31 29 28
5 59 ± 10 N·m 32
7
9 Steering gear seal kit
8 11 26
10 27
88 ± 10 N·m
25 32
28
29
31
30
AC100244AC

>>O<< 1. Gear mounting rubber <> >>H<< 19. Lower oil seal
2. Gear housing mounting bushing <> 20. Pinion and valve assembly
3. Feed pipe <<C>> >>G<< 21. Seal ring
4. O-ring <<D>> >>F<< 22. Upper bearing
>>N<< 5. Jam nut <<D>> >>F<< 23. Upper oil seal
>>N<< 6. Tie rod end 24. Valve housing
7. Clip <<E>> >>E<< 25. Circlip
>>M<< 8. Bellows band <<F>> 26. Rack stopper
9. Bellows <<F>> >>D<< 27. Rack bushing
>>L<< 10. Tie rod <<F>> >>D<< 28. OIL SEAL
>>L<< 11. Tab washer <<F>> 29. O-ring
>>K<< ! Total pinion torque adjustment <<F>> >>C<< 30. Rack assembly
>>J<< 12. Jam nut <<C>> 31. Seal ring
<<A>> >>J<< 13. Rack support cover 32. O-ring
14. Support spring <<G>> >>B<< 33. Lower bearing
15. Rack support <<H>> >>B<< 34. Needle bearing
>>I<< 16. End plug <> >>A<< 35. Oil seal
17. Jam nut 36. Gear housing
18. Valve housing assembly
POWER STEERING
37-23
Fluid:
ATF DXRON III or Fluid: Fluid:
DEXRON II ATF DXRON III or ATF DXRON III or
DEXRON II DEXRON II
Grease:
Multipurpose grease
SAE J310, NLGI No.2
or equivalent Grease: Repair kit grease
Fluid:
ATF DXRON III or
DEXRON II
Sealant:
3M ATD Part No. 8661, 8663
or equivalent
AC200119 AC
Grease: Silicone grease
Fluid: Grease: Repair kit grease

ATF DXRON III or Fluid:
DEXRON II ATF DXRON III or DEXRON II
POWER STEERING
DISASSEMBLY SERVICE POINTS <<D>> UPPER BEARING/UPPER OIL SEAL

<<A>> RACK SUPPORT COVER REMOVAL REMOVAL
MB991621
Socket
ACX01145AC
AC103692 AB
Using a socket, remove the oil seal and the ball
Using special tool rack support cover wrench
bearing from the valve housing simultaneously.
(MB991621), remove the rack support cover from the
steering gear.
<<E>> CIRCLIP REMOVAL
<> LOWER OIL SEAL/PINION AND VALVE CAUTION
ASSEMBLY REMOVAL If the rack stopper is first turned counterclockwise,
the circlip will get caught in the slot in the housing
and the rack stopper will not turn.
Rack stopper
ACX01143 AB
Circlip
Using a plastic hammer, gently tap the pinion to ACX01146 AB
remove it.
1. Turn the rack stopper clockwise until the end of
<<C>> SEAL RING REMOVAL the circlip comes out of the slot in the rack
housing.
CAUTION
When cutting the seal ring, be careful not to 2. Turn the rack stopper counterclockwise to remove
damage the pinion and valve assembly or the the circlip.
rack.
<<F>> RACK STOPPER/RACK BUSHING/OIL
SEAL/O-RING/RACK ASSEMBLY REMOVAL
ACX01144 AB
Cut the seal ring and remove it from the pinion and
ACX01147 AB
valve assembly or the rack.
1. Pull out the rack slowly. Take out the rack stopper
and the rack bushing at the same time.
POWER STEERING
37-25
CAUTION
Do not damage the oil seal press fitting surface. <> OIL SEAL REMOVAL
CAUTION
Be careful not to damage the inner surface of the
rack cylinder of the gear housing.
Rack bushing
Gear housing
Pipe or similar tool
ACX01148 AB
2. Partially bend the oil seal and remove it from the Oil seal
rack bushing.
AC100259 AB
<<G>> LOWER BEARING REMOVAL Use a piece of pipe or similar tool to remove the oil
seal from the gear housing.
MB990939 REASSEMBLY SERVICE POINTS

Valve housing >>A<< OIL SEAL INSTALLATION
1. Apply a coating of ATF DEXRON III or DEXRON II
to the both sides of the oil seal.
Lower bearing
Gear housing MB991199

MB991197
ACX01149 AC
Use a brass bar or special tool brass bar

(MB990939) to remove the ball bearing from the gear
housing.
Oil seal
<<H>> NEEDLE BEARING REMOVAL
AC100260 AC
CAUTION
Do not open special tool excessively to prevent 2. Using the following special tools, press the oil seal
damaging housing interior. into the rack housing.
! MB991197: Bar (Long type)
! MB991199: Oil Seal and Bearing Installer
MB991120
>>B<< NEEDLE BEARING/LOWER BEARING
INSTALLATION
Valve housing Needle 1. Apply ATF DEXRON III or DEXRON II to housing,
bearing bearing and oil seal press fitting surface.
ACX01150 AB
Use special tool needle bearing puller (MB991120)

to remove the needle bearing from the rack housing.
POWER STEERING
CAUTION 4. Align the centre of the oil seal with the rack to
Press-fit straight. The valve housing is prevent the retainer spring from slipping. Slowly
aluminium, and may become deformed if press- insert the rack from power cylinder side.
fit on an angle.
>>D<< OIL SEAL/RACK BUSHING INSTALLATION
MB990938
Needle bearing
MB990938
MB991202
MB991202
MB990927
Lower
bearing Oil seal
O-ring
Rack
bushing
ACX01153 AE
ACX01156 AE
2. Press fit needle bearing with the following special
tools. 1. Apply ATF DEXRON III or DEXRON II to the outer
! MB990938: Bar (Snap-in type) surface of the oil seal. Using the special tool
! MB991202: Oil Seal and Bearing Installer installer adapter (MB990927), press in the oil seal
until it is flush with the bushing end face.
>>C<< RACK ASSEMBLY INSTALLATION
CAUTION Rack
Do not close the vent hole in the rack with
grease.
Vent hole
Vinyl tape
Rack bushing
AC100261AB
2. Apply ATF DEXRON III or DEXRON II to the oil

seal inner surface and the O-ring.
Seal ring and O-ring 3. Wrap the rack end with plastic tape, and push the
ACX01154 AB
rack bushing onto the rack.
1. Apply a coating of repair kit grease to the rack
teeth face. >>E<< CIRCLIP INSTALLATION
CAUTION
Insert the circlip to the rack stopper hole while
Oil seal turning the rack stopper clockwise.
Circlip Circlip
MB991213
ACX01155 AB
2. Cover rack serrations with special tool rack Slot

installer (MB991213). Slot
ACX01158 AB
3. Apply ATF DEXRON III or DEXRON II to special
tool, and to the outer surface of the seal ring and Insert the circlip to the rack stopper hole through
the O-ring. cylinder hole. Turn the rack stopper clockwise and
insert the circlip firmly.
POWER STEERING
37-27
>>H<< LOWER OIL SEAL INSTALLATION
>>F<< UPPER OIL SEAL/UPPER BEARING
INSTALLATION
CAUTION
Approximately
1 mm
MB990938 MB990941
MB990938 Oil
seal
Housing
MB991203
MB991203
Bearing
Oil seal
ACX01161 AC
ACX01159AC
To eliminate a seal malfunction at the valve
Apply a coating of ATF DEXRON III or DEXRON II to
housing alignment surface, the upper surface of
the outside of the upper oil seal/upper bearing. Using
the oil seal should project outward approximately
the following special tools, press the upper oil seal/
1 mm from the housing edge surface.
upper bearing into the valve housing.
Using special tool torque tube bearing installer
! MB990938: Bar (Snap-in type)
(MB990941), press the oil seal into the valve
housing.
>>G<< SEAL RING INSTALLATION

>>I<< END PLUG INSTALLATION
MB991317 End plug End plug
ACX01160 AB
ACX01162 AB
Because the seal rings expand after installation,
tighten after installing by using special tool seal ring 1. Apply specified sealant to the threaded part of the
installer (MB991317) to compress the rings, or press end plug.
down by hand. Specified sealant:
3M ATD Part No.8661, 8663 or equivalent
2. Secure the threaded portion of the end plug at two
places by using a punch.
>>J<< RACK SUPPORT COVER/JAM NUT

INSTALLATION
1. Position the rack at its centre.
2. Apply specified sealant to the threaded part of the
rack support cover.
Specified sealant:
3M ATD Part No.8661, 8663 or equivalent
POWER STEERING
2. If the total pinion torque or the change in torque is

outside the standard value, move the rack support
cover 0 " 30#, and adjust the pinion torque again.
>>L<< TAB WASHER/TIE ROD INSTALLATION
MB991621
AC100273 AC
3. Use special tool rack support cover wrench

(MB991621) to tighten the rack support cover to
23 $ 2 N%m.
4. Turn the rack support cover 30# counterclockwise.
5. Use the special tool to hold the rack support ACX01163 AB
cover, and then tighten the jam nut to 59 $ 10 After installing the tie rod to the rack, fold tab washer
N%m. end (two locations) to tie rod notch.
>>K<< TOTAL PINION TORQUE ADJUSTMENT >>M<< BELLOWS BAND INSTALLATION

CAUTION
! Be sure there is no ratcheting or catching MB991561
when operating the rack towards the shaft. Stopper
! Measure the total pinion torque through the
whole stroke of the rack. W
MB991006
Adjusting bolt
ACX01164 AB
1. Turn the adjusting bolt of special tool boot band

crimping tool (MB991561) to adjust the opening
dimension (W) to the standard value.
AC100274 AB NOTE: The dimension (W) is adjusted by
approximately 0.7 mm per one turn.
1. Using special tool preload socket (MB991006), NOTE: Do not turn the adjusting bolt more than
rotate the pinion shaft at the rate of one rotation in one turn.
four to six seconds to check the total pinion torque
and the change in torque. Standard value (W): 2.9 mm
<When more than 2.9 mm>: Screw in the
Standard value: adjusting bolt.
Total pinion torque: 0.7 " 1.6 N%m <When less than 2.9 mm>: Loosen the
[Change in torque: 0.4 N%m or less] adjusting bolt.
CAUTION
When adjusting, set at the highest value of the
NOTE: If the total pinion toque cannot be adjusted
to the standard value within the specified return
angle, check the rack support cover components
and replace any parts if necessary.
POWER STEERING
37-29
CAUTION
! Hold the rack housing, and use special tool to >>N<< TIE ROD END/JAM NUT INSTALLATION
crimp the bellows band securely.
! Crimp the bellows band until special tool Edge of bellows Jam nut
touches the stopper. assembly groove
MB991561
186 mm
AC001011 AH
Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the jam nut.
ACX01165 AB
NOTE: The jam nuts must be tightened securely only
2. Use special tool boot band crimping tool after the steering gear is installed to the vehicle and
(MB991561) to crimp the bellows band. toe-in is adjusted.
>>O<< GEAR MOUNTING RUBBER

INSTALLATION
A
220 mm
ACX01166 AB
3. Check that crimped width (A) is within the

standard value.
AC100275AB
Standard value (A): 2.4 " 2.8 mm
Install the gear mounting rubber to the rack housing
<When more than 2.8 mm>: Readjust the
so that the distance is as shown in the illustration.
dimension (W) of step (1) to the value
calculated by the following equation, and
repeat step (2).
W = 5.5 mm " A [Example: if (A) is 2.9 mm,
(W) is 2.6 mm.]
<When less than 2.4 mm>: Remove the
bellows band, readjust the dimension (W) of
step (1) to the value calculated by the
following equation, and use a new bellows
band to repeat steps (2) to (3).
W = 5.5 mm " A [Example: if (A) is 2.3 mm,
(W) is 3.2 mm.]
POWER STEERING

REPLACEMENT
M1372008200305
MB990776
AC001012AB
1. Apply specified grease to the lip and inside of the

dust cover.
Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
equivalent
2. Drive in the dust cover with special tool front axle
base (MB990776) until it is fully seated.
POWER STEERING
POWER STEERING OIL PUMP ASSEMBLY
37-31
M1372005200276

! Front Under Cover (RH) and Side Under Cover (RH) ! Power Steering Fluid Supplying and Bleeding (Refer to
Removal (Refer to GROUP 51, Under Cover +,51!%#). +,37!%&).
! Power Steering Fluid Draining (Refer to +,37!%&). ! Drive Belt Tension Check (Refer to GROUP 11A, On-
vehicle Service " Drive Belt Tension Check +,11A!-).
! Front Under Cover (RH) and Side Under Cover (RH)
Installation (Refer to GROUP 51, Under Cover +,51!%#).
57 ± 7 N·m 12 ± 2 N·m
3
4
1
2
49 ± 9 N·m
7
22 ± 4 N·m
22 ± 4 N·m
6
49 ± 9 N·m
AC200116 AB

1. Pressure switch connector <<A>> 5. Oil pump assembly
2. Drive belt 6. A/C compressor harness
>>A<< 3. Suction hose 7. Power steering pump bracket
4. Pressure hose

<<A>> OIL PUMP ASSEMBLY REMOVAL
With the engine lifted by the jack, remove the oil
pump assembly mounting bolt (lower side) at the
pulley side.
POWER STEERING
37-32 POWER STEERING OIL PUMP ASSEMBLY
INSTALLATION SERVICE POINT INSPECTION

M1372005300176
>>A<< SUCTION HOSE INSTALLATION ! Check the drive belt for cracks.
! Check the pulley for uneven rotation.
Suction hose
AC103338 AC
Install the suction hose so that the marking is

positioned as shown in the illustration.
POWER STEERING
37-33
M1372005400281
CAUTION
Never disassemble the terminal assembly. It cannot be reassembled.
11
4 28 ± 2 N·m
12
13
10
18 2
9
17 8
6
5
16 7
3
15 1
9.9 ± 2.1 N·m
14
28 ± 1 N·m
59 ± 9 N·m
: ATF DEXRON III or DEXRON II

AC100143 AE
13
13 8 4
10 5
2
11 7
3 3
3 9
18 6
15 10
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit

1. Pump cover >>A<< 10. O-ring
2. O-ring >>B<< 11. Oil seal
3. Snap ring 12. Terminal assembly
4. Pulley and shaft >>A<< 13. O-ring
5. Vanes 14. Plug assembly
>>C<< 6. Cam ring >>A<< 15. O-ring
7. Rotor 16. Flow control spring
8. Pin 17. Suction connector
9. Side plate >>A<< 18. O-ring
POWER STEERING
37-34 POWER STEERING OIL PUMP ASSEMBLY
REASSEMBLY SERVICE POINTS >>B<< OIL SEAL INSTALLATION

>>A<< O-RING INSTALLATION MB990938
Suction connector Plug assembly

MB991203
1 2
AC000752AB
Use following special tool to install the oil seal.

Terminal assembly Side plate ! MB990938: Bar (Snap-in type)
>>C<< CAM RING INSTALLATION

3 CAUTION
Be sure to install the cam ring in the correct
direction as shown.
4
5
AC100170 AB Side plate side Pump cover side
No. ID ' Width mm

1 15.8 ' 2.4
2 21.0 ' 1.9
3 14.8 ' 2.4
AC100171AB
4 3.8 ' 1.9
5 14.8 ' 1.9 Install the cam ring as shown in the illustration.
INSPECTION
M1372005500192
! Check the flow control valve of the pump body for
clogging.
! Check the pulley and shaft for wear or damage.
! Check the rotor and vane groove for "stepped"
wear.
! Check the contact surface of cam ring and vanes
for "stepped" wear.
! Check the vanes for damage.
POWER STEERING
POWER STEERING HOSES
37-35
M1372005700367

! Power Steering Fluid Draining and Refilling (Refer to
+,37!%&). and Bleeding (Refer to +,37!%&).
12 ± 2 N·m 7
5
6
4
1
2 12 ± 2 N·m
57 ± 7 N·m
12 12 ± 2 N·m
3 14
12 ± 2 N·m
12 ± 2 N·m
13 13
15
12 ± 2 N·m
12
11
57 ± 7 N·m 9
8 10
15 ± 3 N·m
12 ± 2 N·m
AC300498 AC

1. Oil reservoir ! Tie rod end and knuckle connection
>>F<< 2. Return hose (Refer to +,37!%#).
>>E<< 3. Suction hose ! Stabilizer link (Refer to GROUP 33A,
>>D<< 4. Return hose Stabilizer Bar +,33!%*).
>>C<< 5. Return hose >>A<< 9. Return hose
>>B<< 6. Return hose 10. Return tube
7. Return tube assembly 11. O-ring
! Front bumper assembly (Refer to 12. Eye bolt
GROUP 51, Front Bumper Assembly 13. Gasket
+,51!(). 14. Pressure hose assembly
8. Cooler tube assembly 15. Return tube
POWER STEERING
37-36 POWER STEERING HOSES

>>A<< RETURN HOSE INSTALLATION >>D<< RETURN HOSE INSTALLATION
Return hose
Return tube
Return hose AC100277AB AC100278 AC
Install the return hose so that the marking is Install the return hose so that the markings are
positioned as shown in the illustration. positioned as shown in the illustration.
>>B<< RETURN HOSE INSTALLATION
>>E<< SUCTION HOSE INSTALLATION
Return hose
Marking Suction hose
Return tube
AC201792 AC
AC103338 AC
Marking
Return hose
Cooler tube
assembly
>>F<< RETURN HOSE INSTALLATION
Marking
Return tube
AC201922 AC
Install the return hose so that the marking is

Return hose
>>C<< RETURN HOSE INSTALLATION
Cooler tube assembly Return tube AC201923 AC
Marking Install the return hose so that the markings are

Return hose
Marking AC201791 AC

37A-1
GROUP 37A
POWER STEERING
CONTENTS
GENERAL INFORMATION . . . . . . . . 37A-3 FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37A-11

FLUID REPLACEMENT . . . . . . . . . . . . . . . 37A-11
SERVICE SPECIFICATIONS. . . . . . . 37A-5 POWER STEERING SYSTEM AIR
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37A-12
LUBRICANTS . . . . . . . . . . . . . . . . . . 37A-5 OIL PUMP PRESSURE TEST . . . . . . . . . . 37A-13
POWER STEERING PRESSURE SWITCH
SEALANTS . . . . . . . . . . . . . . . . . . . . 37A-6 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A-14
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A-14
SPECIAL TOOLS. . . . . . . . . . . . . . . . 37A-6
STEERING COLUMN SHAFT ASSEMBLY SHOCK
ABSORBING MECHANISM CHECK. . . . . . 37A-15
ON-VEHICLE SERVICE. . . . . . . . . . . 37A-9
STEERING WHEEL FREE PLAY CHECK . 37A-9 STEERING WHEEL*. . . . . . . . . . . . . . 37A-16
STEERING ANGLE CHECK . . . . . . . . . . . . 37A-9
TIE ROD END BALL JOINT STARTING
TORQUE CHECK . . . . . . . . . . . . . . . . . . . . 37A-10
STEERING SHAFT* . . . . . . . . . . . . . . 37A-18
STATIONARY STEERING EFFORT
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A-10
DISASSEMBLY AND REASSEMBLY . . . . . 37A-20
STEERING WHEEL RETURN TO CENTRE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A-11 Continued on next page
DRIVE BELT TENSION CHECK. . . . . . . . . 37A-11
WARNING
NOTE
37A-2
POWER STEERING GEAR BOX AND REMOVAL AND INSTALLATION . . . . . . . . 37A-36

LINKAGE* . . . . . . . . . . . . . . . . . . . . . 37A-21 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37A-38
REMOVAL AND INSTALLATION . . . . . . . . 37A-21 DISASSEMBLY AND REASSEMBLY . . . . . 37A-39
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 37A-25 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37A-41
DISASSEMBLY AND REASSEMBLY. . . . . 37A-26
TIE ROD END BALL JOINT DUST COVER POWER STEERING HOSES . . . . . . . 37A-42
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 37A-35 REMOVAL AND INSTALLATION
<L.H. drive vehicles> . . . . . . . . . . . . . . . . . . 37A-42
POWER STEERING OIL PUMP REMOVAL AND INSTALLATION
ASSEMBLY . . . . . . . . . . . . . . . . . . . . 37A-36 <R.H. drive vehicles> . . . . . . . . . . . . . . . . . 37A-46
POWER STEERING 37A-3
GENERAL INFORMATION
GENERAL INFORMATION
M1372000100412
FEATURES • A vane type pump with a fluid flow rate control
Power steering has been adopted in all vehicles to system which change steering effort according to
make the steering system easier to handle. the engine speed is used.
• A 4-spoke steering wheel is used. • The separate plastic resin oil reservoir is used to
• A steering column has a shock absorbing reduce weight and to make the fluid level
mechanism and a tilt steering mechanism. checking easier.
• Integral-type rack and pinion gear with high • The cooler tube assembly is installed on the
rigidity and excellent response is used. power steering fluid line to improve the cooling
performance of the power steering fluid.
SPECIFICATIONS
Item Specification
Steering wheel Type 4-spoke type
Outside diameter mm 380
Maximum number of turns 2.7
Steering column Column mechanism Shock absorbing mechanism and Tilt
steering mechanism
Tilt up: 20 mm
Tilt down: 20 mm
Power steering type Integral type
Oil pump Type Vane pump
Basic discharge amount mL/rev. 9.6
Relief pressure MPa 8.8
Reservoir type Separate type (plastic)
Pressure switch Equipped
Steering gear Type Rack and pinion
Stroke ratio (Rack stroke/Steering wheel 51.45
maximum turning radius)
Rack stroke mm 141
37A-4 POWER STEERING
GENERAL INFORMATION
Steering wheel
Steering column
Oil reservoir shaft assembly
Pressure hose
Suction hose assembly
Return hose
Oil pump assembly
Steering gear
Cooler tube assembly

AC300061AB
M1372000300449

Steering wheel free With engine running − 30
play mm
With engine stopped 10 or less −
Steering angle Inside wheel 34°50' ± 1°30' −
Outside wheel (reference) 29°20' −
Toe-in At the centre of tyre tread mm 1±2 −
Toe-angle (per wheel) 0°03' ± 05' −
Tie rod end ball joint starting torque N⋅m 0.5 − 2.5 −
Tie rod swing resistance N [Tie rod swing torque N⋅m] 6 − 19 [1.5 − 4.9] −
Stationary steering effort N [Fluctuation allowance N] 29 or less [5.9 or less] −
Oil pump pressure Oil pump relief pressure 8.8 − 9.5 −
MPa (750 ± 100 r/min.)
Pressure under no-load conditions 0.8 − 1.0 −
Steering gear retention hydraulic pressure 8.8 − 9.5 −
Oil pressure switch operating pressure OFF → ON 1.5 − 2.0 −
MPa ON → OFF 0.7 − 2.0 −
Steering gear total pinion torque N⋅m [Change in torque N⋅m] 0.7 − 1.6 [0.4 or less] −
Opening dimension of special tool boot band crimping tool 2.9 −
(MB991561) mm
Band crimped width mm 2.4 − 2.8 −
LUBRICANTS
M1372000400413

Power steering fluid ATF DEXRON III or DEXRON II Approximately 1.0 L
Steering gear Bearing ATF DEXRON III or DEXRON II As required
O-ring and seal ring
Oil seal
Special tool (MB991213)
Pinion and valve assembly
seal ring part
Bellows Silicon grease As required
Tie rod end ball joint Multipurpose grease SAE J310, As required
Oil pump Friction surface of rotor vane, ATF DEXRON III or DEXRON II As required
cam ring and pump cover
O-ring
SEALANTS
SEALANTS
M1372000500421

Steering shaft cover assembly bolt hole on the toeboard 3M ATD Part No.8513 or equivalent
Steering gear End plug 3M ATD Part No.8661, 8663 or
Rack support cover equivalent
SPECIAL TOOLS
M1372000600440

disconnection
AC106827
MB990326 Preload socket Tie rod end ball joint starting torque
check
MB990326
MB991548 Power steering oil Oil pump pressure test

pressure gauge
adapter (Pump
side)
MB991548

pressure gauge
adapter (Hose
side)
MB991549

pressure gauge
MB990662
MB990784 Ornament remover Cover removal
MB990784
SPECIAL TOOLS

MB990228 or Preload socket Steering gear total pinion torque
MB991006 check and adjustment
MB991006
MB991621 Rack support cover • Rack support adjustment

wrench • Rack support cover removal
MB991621
MB990925 Bearing and oil • Oil seal and bearing installation

seal installer set • MB990927, MB990938, MB990939
(For details, refer to GROUP 26,
Special Tools P.26-4).
MB990925
MB991120 Needle bearing Needle roller bearing removal

puller
MB991120
MB991199 Oil seal and Oil seal installation

bearing installer
MB991199
AB
MB991197 Bar (long type)
MB991197
MB991202 Oil seal and • Needle bearing installation

bearing installer • Lower bearing installation
MB991202
MB991213 Rack installer Rack installation
MB991212
SPECIAL TOOLS

MB991203 Oil seal and Oil seal and bearing installation
bearing installer
MB991203
MB991317 Seal ring installer Seal ring installation
MB991317
MB990941 Torque tube Lower oil seal installation

bearing installer
MB990941
MB991561 Boot band crimping Bellows band installation

tool
MB991561
MB990776 Front axle base Tie rod end ball joint dust cover
installation
MB990776
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK 1. Place the front wheel on a turning radius gauge
M1372001000399 and measure the steering angle.
1. With the engine running (hydraulic operation), set
Standard value:
the front wheels straight ahead.
Item Specification
Inside wheel 34°50' ± 1°30'
Outside wheel 29°20'
(reference)
2. If the steering angle is not within the standard
value, adjust the toe-in as follows.
Standard value:
at the centre of tyre tread: 1 ± 2 mm
ACX01122AB Toe angle (per wheel): 0°03' ± 05'
2. Measure the play on the steering wheel Jam nut
circumference before the wheels start to move
when slightly moving the steering wheel in both Clip
directions.
Limit: 30 mm
3. When the play exceeds the limit, check for the
play on the steering shaft and steering linkage
connection. Correct or replace.
4. If the free play still exceeds the limit value, set the AC006074 AB
steering wheel straight ahead with the engine
stopped. Load 5 N towards the steering wheel 3. Loosen the jam nut, and unclip the bellows.
circumference and check the play. 4. Adjust the toe-in by turning the left and right tie
Standard value (steering wheel play with the rod turnbuckles by the same amount (in opposite
engine stopped): 10 mm or less directions).
5. If the play exceeds the standard value, remove NOTE: The toe will move out as the left turnbuckle
the steering gear (Refer to P.37A-21). and check is turned toward the front of the vehicle and the
the total pinion torque (Refer to P.37A-26). right turnbuckle is turned toward the rear of the
vehicle.
STEERING ANGLE CHECK 5. Tighten the jam nut to the specified torque, and
M1372001100448 tighten the bellows by the clip.
6. Recheck the steering angle.
AC000756AB
ON-VEHICLE SERVICE
TIE ROD END BALL JOINT STARTING 4. Move the ball joint stud several times and install
TORQUE CHECK the nut on the stud. Using special tool preload
M1372001500372 socket (MB990326), measure the ball joint
CAUTION starting torque.
• Do not remove the nut from ball joint. Loosen Standard value: 0.5 − 2.5 N⋅m
5. If the starting torque exceeds the standard value,
damage to the ball joint threads.
replace the tie rod end.
• Hang special tool with cord to prevent it from
6. If the starting torque is under the standard value,
falling.
check the ball joint for axial play or ratcheting. If
Cord no axial play or ratcheting, the ball joint can be
re-used.
CAUTION
Always use a new ball joint nut as it is a
Nut MB991897 self-locking nut.
7. Install the tie rod end to the knuckle, then tighten a
new self-locking nut to the specified torque.
Bolt Tightening torque: 25 ± 5 N⋅m
STATIONARY STEERING EFFORT CHECK
1. Install special tool ball joint remover (MB991897) M1372001700406
as shown in the figure. 1. With the vehicle stopped on a flat and paved
surface, turn the steering wheel to the straight
ahead position.
Bolt
2. Start the engine and set the engine idle speed.
Parallel Standard value: 750 ± 100 r/min
Knob Good
Bad AC106821AB

ACX01122AB
sure the knob is in the position shown in the 3. Attach a spring balance to the outer
figure. circumference of the steering wheel and measure
3. Tighten the bolt with a wrench to disconnect the the steering force required to turn the steering
tie rod end. wheel from the straight ahead position to the left
and right (within a range of 1.5 turns). Also check
MB990326 to be sure that there is no significant change in
the required steering effort.
Standard value:
Steering effort: 29 N or less
Fluctuation allowance: 5.9 N or less
value, check and adjust the related parts.
ACX01129 AB
ON-VEHICLE SERVICE
STEERING WHEEL RETURN TO CENTRE 4. Check the fluid in the oil reservoir for foaming or
CHECK milkiness. Check the difference of the fluid level
M1372001800384 when the engine is stopped, and while it is
Conduct a road test: running. If the change of the fluid level is 5 mm or
1. Make both gradual and sudden turns and check more, air bleeding should be done.
the steering wheel return.
FLUID REPLACEMENT
M1372002100418
70˚ 70˚ <2000>

Return hose
Return hose
ACX01130AB Vinyl hose
2. At a vehicle speed of approximately 35 km/h, turn

the steering wheel 90°, hold a few seconds, then
release. If the steering wheel then returns 70° or <2400>
more, the return can be judged satisfactory. Return hose
NOTE: There will be a momentary feeling or

"heaviness" when the wheel is turned quickly, but
this is not abnormal (Oil pump discharge amount
is especially apt to be insufficient during idling).
DRIVE BELT TENSION CHECK

M1372001900336
Refer to GROUP 11A, On-vehicle Service − Drive
Belt Tension Check <2000> P.11A-8. AC309079AC
Refer to GROUP 11C, On-vehicle Service − Drive
Belt Tension Check <2400> P.11C-8. 2. Disconnect the return hose connection, and then
connect a vinyl hose to the return hose, and drain
FLUID LEVEL CHECK the fluid into a container.
M1372002000358
1. Park the vehicle on a flat, level surface. 3. Disconnect the ignition coil connectors (Refer to
2. Start the engine, and then turn the steering wheel GROUP 16, Ignition Coil P.16-40 <2000>,
several times to raise the temperature of the fluid P.16-41 <2400>).
to approximately 50 − 60°C. 4. While operating the starter motor intermittently,
3. With the engine running, turn the wheel all the turn the steering wheel all the way to the left and
way to the left and right several times. right several times to drain all of the fluid.
5. Connect the return hose securely, and then
Fluid level change: Within 5 mm
secure with the clip.
6. Fill the oil reservoir with specified fluid up to the
lower position of the filler, and then bleed the air.
Specified fluid: ATF DEXRON III or DEXRON
II
While engine running While engine stopped

ACX01131AC
ON-VEHICLE SERVICE
POWER STEERING SYSTEM AIR 8. Confirm that there is very little change in the fluid
BLEEDING level when the steering wheel is turned left and
M1372002200404 right.
Perform air bleeding procedure as necessary after
CAUTION
replacing the steering gear or the steering fluid lines.
If the fluid level rises suddenly after the engine is
stopped, the air has not been completely bled. If
2. Disconnect the ignition coil connectors (Refer to air bleeding is not complete, there will be
GROUP 16, Ignition Coil P.16-40 <2000>, abnormal noises from the pump and the
P.16-41 <2400>). flow-control valve, and this condition could
CAUTION cause reduce the life of the power steering
Perform air bleeding only while cranking the components.
engine. If air bleeding is performed while the Fluid level change: Within 5 mm
engine is running, air could enter the fluid.
During air bleeding, refill the steering fluid
supply so that the level never falls below the
"MIN" mark on the oil reservoir.
3. Turn the steering wheel all the way to the left and
right five or six times while using the starter motor
to crank the engine intermittently several times
(for 15 to 20 seconds). While engine running While engine stopped
ACX01131AC
4. Connect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-40 <2000>, 9. Confirm that the change in the fluid level is no
P.16-41 <2400>). more than 5 mm when the engine is stopped and
5. Start the engine (idling). when it is running.
6. Turn the steering wheel to the left and right until 10.If the change of the fluid level is 5 mm or more,
there are no air bubbles in the oil reservoir. the air has not been completely bled from the
7. Confirm that the fluid is not milky, and that the system. The air bleeding procedure must be
level is between "MAX" and "MIN" marks. repeated.
ON-VEHICLE SERVICE
OIL PUMP PRESSURE TEST 3. Start the engine and idle it at 750 ± 100 r/min.
M1372002300382
CAUTION
The pressure gauge shut-off valve must not
Pressure remain closed for more than 10 seconds.
Temperature gauge Shut-off valve
gauge (MB990662) (fully closed) 4. Fully close the shut-off valve of the pressure
gauge and measure the oil pump relief pressure
to confirm that it is within the standard value
range. Open it again immediately after checking
Oil reservoir
the pressure.
Adapter
(MB991548) Standard value: 8.8 − 9.5 MPa
5. If it is not within the standard value, replace the oil
pump.
6. Check whether or not the hydraulic pressure is
Oil the standard value when no-load conditions are
pump created by fully opening the shut-off valve of the
pressure gauge.
Adapter Standard value: 0.8 − 1.0 MPa
(MB991549)
7. If it is not within the standard value, the probable
cause is a malfunction of the oil line or steering
gear, so check these parts and repair as
ACX01133 AB
necessary.
8. Turn the steering wheel all the way to the left or
1. Disconnect the pressure hose from the oil pump, right; then check whether or not the retention
and then connect the following special tools. hydraulic pressure is the standard value.
• MB990662: Power Steering Oil Pressure Gauge Standard value: 8.8 − 9.5 MPa
• MB991548: Power Steering Oil Pressure Gauge
Adapter (Pump Side) 9. If not the standard value, overhaul the steering
• MB991549: Power Steering Oil Pressure Gauge gear. Remeasure fluid pressure.
Adapter (Hose Side) 10. Remove the special tools, and then tighten the
2. Bleed air, then turn the steering wheel several pressure hose to the specified torque.
times while the vehicle is not moving so that the Tightening torque: 57 ± 7 N⋅m
temperature of the fluid rises to approximately 50 11. Bleed the system (Refer to P.37A-12).
− 60°C.
ON-VEHICLE SERVICE
POWER STEERING PRESSURE SWITCH 2. Bleed air, and then turn the steering wheel several
CHECK times while the vehicle is not moving so that the
M1372007200391 temperature of the fluid rises to approximately 50
− 60°C.
3. The engine should be idling.
Adapter Shut-off valve 4. Disconnect the connector for the oil pressure
(MB991548) switch, and place an ohmmeter at the switch.
Pressure gauge
Temperature (MB990662) 5. Gradually close the shut-off valve of the pressure
gauge gauge and increase the hydraulic pressure, then
check whether or not the hydraulic pressure that
activates the switch is the standard value.
Standard value: 1.5 − 2.0 MPa
6. Gradually open the shut-off valve and reduce the
hydraulic pressure; then check whether or not the
hydraulic pressure that deactivates the switch is
Oil the standard value.
pump
Standard value: 0.7 − 2.0 MPa
Oil reservoir
Adapter 7. Remove the special tools, and then tighten the
(MB991549) pressure hose to the specified torque.
8. Bleed the system (Refer to P.37A-12).
ACX01134 AB

1. Disconnect the pressure hose from the oil pump,
and then connect the following special tools.
CHECK
M1372008600336
• MB990662: Power Steering Oil Pressure Gauge 1. Press the dust cover with your finger to check
• MB991548: Power Steering Oil Pressure Gauge whether the dust cover is cracked or damaged.
Adapter (Pump Side) 2. If the dust cover is cracked or damaged, replace
• MB991549: Power Steering Oil Pressure Gauge the tie rod end.
Adapter (Hose Side)
NOTE: If the dust cover is cracked or damaged,
the ball joint could be damaged.
ON-VEHICLE SERVICE
STEERING COLUMN SHAFT ASSEMBLY

SHOCK ABSORBING MECHANISM
CHECK
M1372013500197
Steering
If a collision accident occurs or severe impact is column
applied on the steering wheel, the collision energy mounting
bolt
absorbing mechanism may have operated. Once the
mechanism has operated, it will be inoperative even Steering
it has suffered no apparent damage. Determine if the column
assembly
steering column shaft can be reused by the following
procedure. If the collision energy absorbing
mechanism has already operated, replace the One way capsule
steering column shaft assembly.
If any excessive radial free play on the steering
wheel is found with the tilt lever in the lock position,
always check the steering shaft assembly.
WARNING
• If the vehicle continues to be driven after
the collision absorbing mechanism has
AC209935 AC
operated, the steering column shaft may
be damaged while it is in use. 4. Hold the one-way capsules as shown, and then
• If there is a slack in the one-way capsule, try to lock them. If there is a slack in either of the
do not attempt to repair it but replace the capsules, replace the steering column shaft
steering column shaft assembly. assembly.
NOTE: When installing a new steering column
Inspection Procedure
shaft assembly, place the tilt lever in the lock
1. Remove the lower and upper column covers. position, if it is not in place.
CAUTION CAUTION
Do not release the tilt lever until the steering • Be careful that nothing is pinched between
column has been installed to complete this the one-way capsules and the body.
inspection procedure.
• Do not release the tilt lever until the steering
2. Ensure that the tilt lever is in the lock position. column has been installed to complete this
NOTE: If not, place the tilt lever in the lock inspection procedure.
position. 5. If no problem is found during the inspection,
3. Loosen the two upper steering column mounting tighten the steering column mounting bolts to the
bolts by two turns. specified torque.
STEERING WHEEL
STEERING WHEEL
M1372011400235
WARNING
• Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-4) and Air Bag Module and Clock Spring (P.52B-179).
• When removing and installing the steering wheel, do not let it bump against the air bag
module.
Ahead
Section A - A
2 Tab
2
1
Section B - B
Tab
1
A 50 ± 5 N·m
B
B 2
1 A
AC107402AB
Removal steps NOTE: For air bag module removal, refer to GROUP
<<A>> 1. Cover 52B, Air Bag Module and Clock Spring P.52B-179.
<> 2. Steering wheel and air bag module
assembly
STEERING WHEEL
REMOVAL SERVICE POINTS 1. By sliding section A of the clock spring connector

<<A>> COVER REMOVAL shown in the illustration in the arrow direction,
disconnect the connector.
MB990784 Hexagonal bit socket
AC006294 AB
AC102792 AC107462 AD
Insert special tool ornament remover (MB990784) at
the indicated position to remove the cover. 2. Loosen the bolt completely. Then, remove the
NOTE: The special tool can be inserted through the steering wheel and air bag module assembly.
notch behind the area shown. NOTE: Use a hexagonal bit socket or a hexagonal
wrench having an effective length of 75 mm or
<> STEERING WHEEL AND AIR BAG more in the hexagonal section and the diameter of
MODULE ASSEMBLY REMOVAL 8 mm or more.
Clock spring
connector
A
Steering
wheel AC006295 AB
STEERING SHAFT
STEERING SHAFT
M1372011500157
WARNING
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-4) and Air Bag Module and Clock Spring (P.52B-179).
• Steering Wheel and Air Bag Module Assembly Removal • Instrument Lower Panel Installation (Refer to GROUP
(Refer to P.37A-16). 52A, Instrument Panel <L.H. drive vehicles> P.52A-2,
• Instrument Lower Panel Removal (Refer to GROUP 52A, <R.H. drive vehicles> P.52A-8).
Instrument Panel <L.H. drive vehicles> P.52A-2, <R.H. • Steering Wheel and Air Bag Module Assembly Installation
drive vehicles> P.52A-8). (Refer to P.37A-16).
Section A - A A
2 3
2
Tab
A
5
Section B - B
B B
Toe board
12 ± 2 N·m 1
B B 4
6
18 ± 2 N·m
6
Specified sealant:
3M ATD Part No.8513 or equivalent 5.0 ± 1.0 N·m
AC301263 AB

1. Lower column cover 4. Shaft cover
2. Upper column cover <<A>> >>A<< 5. Steering column shaft assembly
3. Clock spring and column switch 6. Cover assembly
assembly (Refer to GROUP 52B, Air
Bag Module and Clock Spring
P.52B-179).
STEERING SHAFT

<<A>> STEERING COLUMN SHAFT ASSEMBLY >>A<< STEERING COLUMN SHAFT ASSEMBLY
CAUTION CAUTION
The tilt lever should be held in the lock position • When reusing the steering column, do not
until the steering column shaft is installed to the release the tilt lever until the steering column
vehicle. If the steering column is removed with shaft has been installed.
the tilt lever released, or the tilt lever is released • When the steering column is replaced, do not
after the steering column shaft was removed release the tilt lever until it has been installed.
from the vehicle, the steering column can not be Do not remove the tilt lever fixing band until
reinstalled correctly. If the steering column is the installation has completed.
installed incorrectly, the collision energy • When installing the steering column, do not
absorbing mechanism may be damaged. leave it fixed temporarily at only one point
1. Ensure that the tilt lever is in the lock position, and and make sure the column shaft is not shaken
remove the steering column mounting bolts. strongly. If you fail to do, the collision
absorbing mechanism at the column shaft
mounting location may be damaged.
Clip
4
Steering column 1 2
shaft
3
Tilt lever
AC210969AD
2. Pinch the steering column shaft clip with pliers, AC209383AD

and pull up the shaft towards the direction shown
Ensure that the tilt lever is in the lock position, and
to disengage the steering column shaft assembly.
install the steering column. Tighten the four bolts in
the order shown by hand, and then tighten them to
the specified torque in the order shown.
STEERING SHAFT

M1372011700128
4 3
AC210967AD

<<A>> >>A<< 1. Special bolt >>A<< STEERING LOCK CYLINDER
>>A<< 2. Steering lock bracket ASSEMBLY/STEERING LOCK
>>A<< 3. Steering lock cylinder assembly
BRACKET/SPECIAL BOLT INSTALLATION
4. Steering column shaft assembly
CAUTION
DISASSEMBLY SERVICE POINT The steering lock bracket and bolts must be
<<A>> SPECIAL BOLT REMOVAL replaced with new ones when the steering lock is
installed.
Reverse screw tap
Special bolt 1. When installing the steering lock cylinder
assembly and steering lock bracket to the column
Steering lock
bracket tube, temporarily install the steering lock in
alignment with the column boss.
Steering lock
cylinder ACX01138AB
1. Drill in the special bolt a hole deep enough for the

tap to stand.
2. Remove the special bolt with a left-hand tap.
ACX01139 AB
2. After checking that the lock works properly,

tighten the special bolts until the head twists off.

M1372010900282
WARNING
Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-4) and
Air Bag Module and Clock Spring (P.52B-179). Centre the front wheels. Failure to do so may
damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
• Power Steering Fluid Draining (Refer to P.37A-11). • Stabilizer Link Assembly and Lower Arm Assembly
• Front Exhaust Pipe Removal (Refer to GROUP 15, Installation (Refer to GROUP 33A, Lower Arm P.33-11).
Exhaust Pipe and Main Muffler P.15-13). • Centermember Installation (Refer to GROUP 32, Engine
• Centermember Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-10 <2000>,
Roll Stopper and Centermember P.32-10 <2000>, P.32-12 <2400>).
P.32-12 <2400>). • Front Exhaust Pipe Installation (Refer to GROUP 15,
• Steering Wheel and Air Bag Module Assembly Removal Exhaust Pipe and Main Muffler P.15-13).
(Refer to P.37A-16). • Clock Spring Installation (Refer to GROUP 52B, Air Bag
• Clock Spring Removal (Refer to GROUP 52B, Air Bag Module and Clock Spring P.52B-179).
Module and Clock Spring P.52B-179). • Steering Wheel and Air Bag Module Assembly Installation
• Stabilizer Link Assembly and Lower Arm Assembly (Refer to P.37A-16).
Removal (Refer to GROUP 33A, Lower Arm P.33-11). • Check the dust cover for cracks or damage by pushing it
with your finger.
• Power Steering Fluid Supplying (Refer to P.37A-11).
• Power Steering Fluid Line Bleeding (Refer to P.37A-12).
Ahead.
• Front Wheel Alignment Adjustment (Refer to GROUP
33A, On-vehicle Service − Front Wheel Alignment Check
and Adjustment P.33-6).

4
2
12 ± 2 N·m 1
18 ± 2 N·m
11
12 ± 2 N·m 7 15 ± 3 N·m
9
5
70 ± 10 N·m 10
4
6 25 ± 5 N·m
7
8
70 ± 10 N·m
13
57 ± 7 N·m
18 ± 2 N·m
3
12
49 ± 10 N·m
167 ± 9 N·m
AC300496AB

1. Shaft cover 8. Gasket
2. Steering column shaft assembly and <> • Crossmember assembly
steering gear connecting bolt • Rear roll stopper (Refer to GROUP 32,
<<A>> 3. Tie rod end and knuckle connection Engine Roll Stopper and
• Rear roll stopper connecting bolt Centermember P.32-10 <2000>,
(Refer to GROUP 32, Engine Roll P.32-12 <2400>.)
Stopper and Centermember P.32-10 >>A<< 9. Joint cover grommet
<2000>, P.32-12 <2400>.) 10. Steering extension
4. Return hose connection 11. Return tube
5. Return tube 12. Crossmember
6. O-ring 13. Steering gear
1 18 ± 2 N·m
2
5.0 ± 1.0 N·m

18 ± 2 N·m 7
57 ± 7 N·m 8
5 4
70 ± 10 N·m
25 ± 5 N·m
49 ± 10 N·m
167 ± 9 N·m
AC309390AC

1. Shaft cover <> • Crossmember assembly
2. Steering column shaft assembly and • Rear roll stopper (Refer to GROUP 32,
steering gear connecting bolt Engine Roll Stopper and
<<A>> 3. Tie rod end and knuckle connection Centermember P.32-10 <2000>,
• Rear roll stopper connecting bolt P.32-12 <2400>.)
(Refer to GROUP 32, Engine Roll 6. Crossmember
Stopper and Centermember P.32-10 >>A<< 7. Joint cover grommet
<2000>, P.32-12 <2400>.) 8. Steering extension
4. Return hose connection 9. Steering gear
REMOVAL SERVICE POINTS 3. Tighten the bolt with a wrench to disconnect the
<<A>> TIE ROD END AND KNUCKLE tie rod end.
DISCONNECTION
<> CROSSMEMBER ASSEMBLY REMOVAL
CAUTION
Piece of wood
• Hang special tool with a cord to prevent it
from falling.
Cord
Transmission
jack AC102600 AD
Nut MB991897
1. Use a transmission jack to hold the crossmember,
and then remove the crossmember mounting nuts
and bolts.
Bolt
2. Lower the crossmember with the rear roll stopper,
the stabilizer bar, the return tube, and the steering
1. Install the special tool ball joint remover gear.
(MB991897) as shown in the figure.
>>A<< JOINT COVER GROMMET INSTALLATION
Bolt
Joint cover
Parallel grommet
A
Knob Good B
Bad AC106821AB
Steering gear
2. Turn the bolt and knob as necessary to make the AC301284AB
jaws of the special tool parallel, tighten the bolt by
Align the joint cover grommet notch (arrow A) with
the steering gear lug (arrow B), and then install the
NOTE: When adjusting the jaws in parallel, make steering joint cover to the steering gear.
figure.
INSPECTION TIE ROD SWING RESISTANCE CHECK

M1372011000282 1. Give 10 hard swings to the tie rod.
STEERING GEAR TOTAL PINION TORQUE
CHECK
CAUTION
When holding the steering gear in a vice, secure
its mounting positions. If it is secured in any
other place, the gear housing may become
deformed or damaged.
MB991006 AC000997
2. Measure the tie rod swing resistance [tie rod

swing torque] with a spring balance.
Standard value: 6 − 19 N [1.5 − 4.9 N⋅m]
value, replace the tie rod.
AC000996 AC
4. If the measured value is below the standard value,
Using special tool preload socket (MB991006), rotate the tie rod can be re-used if it swings smoothly
the pinion gear at the rate of one rotation in without excessive play.
approximately 4 to 6 seconds to check the total
pinion torque. TIE ROD END BALL JOINT DUST COVER CHECK
Standard value: 0.7 − 1.6 N⋅m
[Change in torque: 0.4 N⋅m or less]
NOTE: When measuring, remove the bellows from
the tie rod end (Refer to P.37A-26).
the rack housing. Measure the pinion torque through
the whole stroke of the rack. NOTE: Cracks or damage of the dust cover may
If the measured value is not within the standard damage the ball joint. If it is damaged during
range, first adjust the rack support cover, and then service work, replace the dust cover (Refer to
check the total pinion torque again. P.37A-35).
If the total pinion torque cannot be adjusted to within
the standard range by adjusting the rack support
cover, check the rack support cover, rack support
spring, rack support and replace any parts if
necessary.

M1372011100256

22 ± 4 N·m
Flare nut
3 13 ± 3 N·m
4 24 3
23
4 22
20 18
21
35 34 19 23
Repair kit grease
13 59 ± 10 N·m 21
19
1 36 12 4
52 ± 2 N·m 11 8
15 14 23 ± 2 N·m
2 33 -30˚ 8
17 11 35
16
6 25 ± 4 N·m 17 31 29 28
5 59 ± 10 N·m 32
7
9 Steering gear seal kit
8 11 26
10 27
88 ± 10 N·m
25 32
28
29
31
30
AC100244AC

>>O<< 1. Gear mounting rubber <> 20. Pinion and valve assembly
2. Gear housing mounting bushing <<C>> >>G<< 21. Seal ring
3. Feed pipe <<D>> >>F<< 22. Upper bearing
4. O-ring <<D>> >>F<< 23. Upper oil seal
>>N<< 5. Jam nut 24. Valve housing
>>N<< 6. Tie rod end <<E>> >>E<< 25. Circlip
7. Clip <<F>> 26. Rack stopper
>>M<< 8. Bellows band <<F>> >>D<< 27. Rack bushing
9. Bellows <<F>> >>D<< 28. OIL SEAL
>>L<< 10. Tie rod <<F>> 29. O-ring
>>L<< 11. Tab washer <<F>> >>C<< 30. Rack assembly
>>K<< • Total pinion torque adjustment <<C>> 31. Seal ring
>>J<< 12. Jam nut 32. O-ring
<<A>> >>J<< 13. Rack support cover <<G>> >>B<< 33. Lower bearing
14. Support spring <<H>> >>B<< 34. Needle bearing
15. Rack support <> >>A<< 35. Oil seal
>>I<< 16. End plug 36. Gear housing
17. Jam nut
18. Valve housing assembly
<> >>H<< 19. Lower oil seal

22 ± 4 N·m Flare nut
24
4 13 ± 3 N·m 3
23
18 3
22
21
20 4 23 Repair kit grease

19 34 21
4
1 19
4
11 8
2
36 8 35
33 35 11
25 ± 4 N·m 17 31 29 28
32
17
15 12 Steering gear seal kit
16
14
59 ± 10 N·m 13 59 ± 10 N·m
23 ± 2 N·m -30˚
30
31 88 ± 10 N·m
29
32 27 26
11 52 ± 2 N·m
28 25 10
8
9 7
5
6
AC102865 AD

>>O<< 1. Gear mounting rubber 18. Valve housing assembly
2. Gear housing mounting bushing <> >>H<< 19. Lower oil seal
3. Feed pipe <> 20. Pinion and valve assembly
4. O-ring <<C>> >>G<< 21. Seal ring
>>N<< 5. Jam nut <<D>> >>F<< 22. Upper bearing
>>N<< 6. Tie rod end <<D>> >>F<< 23. Upper oil seal
7. Clip 24. Valve housing
>>M<< 8. Bellows band <<E>> >>E<< 25. Circlip
9. Bellows <<F>> 26. Rack stopper
>>L<< 10. Tie rod <<F>> >>D<< 27. Rack bushing
>>L<< 11. Tab washer <<F>> >>D<< 28. OIL SEAL
>>K<< • Total pinion torque adjustment <<F>> 29. O-ring
>>J<< 12. Jam nut <<F>> >>C<< 30. Rack assembly
<<A>> >>J<< 13. Rack support cover <<C>> 31. Seal ring
14. Support spring 32. O-ring
15. Rack support <<G>> >>B<< 33. Lower bearing
>>I<< 16. End plug <<H>> >>B<< 34. Needle bearing
17. Jam nut <> >>A<< 35. Oil seal
36. Gear housing
Fluid:
ATF DXRON III or Fluid: Fluid:
DEXRON II ATF DXRON III or ATF DXRON III or
DEXRON II DEXRON II
Grease:
Multipurpose grease
SAE J310, NLGI No.2
or equivalent Grease: Repair kit grease
Fluid:
ATF DXRON III or
DEXRON II
Sealant:
3M ATD Part No. 8661, 8663
or equivalent
AC200119 AC
Grease: Silicone grease
Fluid: Grease: Repair kit grease

ATF DXRON III or Fluid:
DEXRON II ATF DXRON III or DEXRON II
DISASSEMBLY SERVICE POINTS <<D>> UPPER BEARING/UPPER OIL SEAL

<<A>> RACK SUPPORT COVER REMOVAL REMOVAL
MB991621
Socket
ACX01145AC
AC103692 AB
Using a socket, remove the oil seal and the ball
Using special tool rack support cover wrench
bearing from the valve housing simultaneously.
(MB991621), remove the rack support cover from the
steering gear.
<<E>> CIRCLIP REMOVAL
<> LOWER OIL SEAL/PINION AND VALVE CAUTION
ASSEMBLY REMOVAL If the rack stopper is first turned
counterclockwise, the circlip will get caught in
the slot in the housing and the rack stopper will
not turn.
Rack stopper
ACX01143AB
Using a plastic hammer, gently tap the pinion to Circlip

remove it.
ACX01146 AB
<<C>> SEAL RING REMOVAL 1. Turn the rack stopper clockwise until the end of
CAUTION the circlip comes out of the slot in the rack
When cutting the seal ring, be careful not to housing.
damage the pinion and valve assembly or the 2. Turn the rack stopper counterclockwise to remove
rack. the circlip.
<<F>> RACK STOPPER/RACK BUSHING/OIL

SEAL/O-RING/RACK ASSEMBLY REMOVAL
ACX01144 AB
Cut the seal ring and remove it from the pinion and
valve assembly or the rack.
ACX01147 AB
1. Pull out the rack slowly. Take out the rack stopper Use special tool needle bearing puller (MB991120) to
and the rack bushing at the same time. remove the needle bearing from the rack housing.
CAUTION <> OIL SEAL REMOVAL

Do not damage the oil seal press fitting surface. CAUTION
Be careful not to damage the inner surface of the
rack cylinder of the gear housing.
Rack bushing
Gear housing
Pipe or similar tool
ACX01148 AB
Oil seal
2. Partially bend the oil seal and remove it from the AC100259 AB
rack bushing.
Use a piece of pipe or similar tool to remove the oil
seal from the gear housing.
<<G>> LOWER BEARING REMOVAL
MB990939 >>A<< OIL SEAL INSTALLATION
Valve housing 1. Apply a coating of ATF DEXRON III or DEXRON II
to the both sides of the oil seal.
Lower bearing
Gear housing MB991199
MB991197
ACX01149 AC
Use a brass bar or special tool brass bar

(MB990939) to remove the ball bearing from the gear
housing. Oil seal
AC100260 AC
<<H>> NEEDLE BEARING REMOVAL
CAUTION 2. Using the following special tools, press the oil seal
Do not open special tool excessively to prevent into the rack housing.
damaging housing interior. • MB991197: Bar (Long type)
• MB991199: Oil Seal and Bearing Installer
MB991120
Valve housing Needle

bearing
ACX01150 AB
>>B<< NEEDLE BEARING/LOWER BEARING 2. Cover rack serrations with special tool rack
INSTALLATION installer (MB991213).
1. Apply ATF DEXRON III or DEXRON II to housing, 3. Apply ATF DEXRON III or DEXRON II to special
bearing and oil seal press fitting surface. tool, and to the outer surface of the seal ring and
CAUTION the O-ring.
Press-fit straight. The valve housing is 4. Align the centre of the oil seal with the rack to
aluminium, and may become deformed if prevent the retainer spring from slipping. Slowly
press-fit on an angle. insert the rack from power cylinder side.
MB990938
Needle bearing >>D<< OIL SEAL/RACK BUSHING
MB990938
INSTALLATION
MB991202
MB991202
Lower
bearing
MB990927
Oil seal
ACX01153 AE
O-ring
Rack
2. Press fit needle bearing with the following special bushing
tools.
ACX01156 AE
• MB990938: Bar (Snap-in type)
• MB991202: Oil Seal and Bearing Installer 1. Apply ATF DEXRON III or DEXRON II to the outer
surface of the oil seal. Using the special tool
>>C<< RACK ASSEMBLY INSTALLATION installer adapter (MB990927), press in the oil seal
CAUTION until it is flush with the bushing end face.
Do not close the vent hole in the rack with
grease.
Rack
Vent hole
Vinyl tape
Rack bushing
AC100261AB
Seal ring and O-ring 2. Apply ATF DEXRON III or DEXRON II to the oil
ACX01154 AB
seal inner surface and the O-ring.
1. Apply a coating of repair kit grease to the rack 3. Wrap the rack end with plastic tape, and push the
teeth face. rack bushing onto the rack.
Oil seal
MB991213
ACX01155 AB
>>E<< CIRCLIP INSTALLATION Because the seal rings expand after installation,
CAUTION tighten after installing by using special tool seal ring
Insert the circlip to the rack stopper hole while installer (MB991317) to compress the rings, or press
turning the rack stopper clockwise. down by hand.
>>H<< LOWER OIL SEAL INSTALLATION

Circlip Circlip
CAUTION
Approximately
1 mm
MB990941
Oil
seal
Slot
Slot Housing
ACX01158 AB
Insert the circlip to the rack stopper hole through

cylinder hole. Turn the rack stopper clockwise and
ACX01161 AC
insert the circlip firmly.
To eliminate a seal malfunction at the valve
>>F<< UPPER OIL SEAL/UPPER BEARING housing alignment surface, the upper surface of
INSTALLATION the oil seal should project outward
approximately 1 mm from the housing edge
MB990938 surface.
MB990938 Using special tool torque tube bearing installer
(MB990941), press the oil seal into the valve
housing.
>>I<< END PLUG INSTALLATION

MB991203
MB991203
Bearing
Oil seal
ACX01159AC End plug End plug
Apply a coating of ATF DEXRON III or DEXRON II to

the outside of the upper oil seal/upper bearing. Using
the following special tools, press the upper oil
seal/upper bearing into the valve housing.
• MB990938: Bar (Snap-in type)
ACX01162 AB
>>G<< SEAL RING INSTALLATION 1. Apply specified sealant to the threaded part of the
end plug.
Specified sealant:
MB991317 3M ATD Part No.8661, 8663 or equivalent
2. Secure the threaded portion of the end plug at two
places by using a punch.
ACX01160 AB
>>J<< RACK SUPPORT COVER/JAM NUT CAUTION

INSTALLATION When adjusting, set at the highest value of the
1. Position the rack at its centre. standard value range.
2. Apply specified sealant to the threaded part of the NOTE: If the total pinion toque cannot be adjusted
rack support cover. to the standard value within the specified return
Specified sealant: angle, check the rack support cover components
3M ATD Part No.8661, 8663 or equivalent and replace any parts if necessary.
2. If the total pinion torque or the change in torque is
outside the standard value, move the rack support
cover 0 − 30°, and adjust the pinion torque again.
>>L<< TAB WASHER/TIE ROD INSTALLATION
MB991621
AC100273 AC
3. Use special tool rack support cover wrench

(MB991621) to tighten the rack support cover to
23 ± 2 N⋅m.
4. Turn the rack support cover 30° counterclockwise.
ACX01163 AB
5. Use the special tool to hold the rack support
cover, and then tighten the jam nut to 59 ± 10 After installing the tie rod to the rack, fold tab washer
N⋅m. end (two locations) to tie rod notch.
>>K<< TOTAL PINION TORQUE ADJUSTMENT >>M<< BELLOWS BAND INSTALLATION

CAUTION
MB991561
• Be sure there is no ratcheting or catching
when operating the rack towards the shaft. Stopper
• Measure the total pinion torque through the W

whole stroke of the rack.
MB991006
Adjusting bolt
ACX01164 AB
1. Turn the adjusting bolt of special tool boot band

crimping tool (MB991561) to adjust the opening
dimension (W) to the standard value.
NOTE: The dimension (W) is adjusted by
AC100274AB
approximately 0.7 mm per one turn.
1. Using special tool preload socket (MB991006), NOTE: Do not turn the adjusting bolt more than
rotate the pinion shaft at the rate of one rotation in one turn.
four to six seconds to check the total pinion torque Standard value (W): 2.9 mm
and the change in torque. <When more than 2.9 mm>: Screw in the
Standard value: adjusting bolt.
Total pinion torque: 0.7 − 1.6 N⋅m <When less than 2.9 mm>: Loosen the
[Change in torque: 0.4 N⋅m or less] adjusting bolt.
CAUTION <When less than 2.4 mm>: Remove the

• Hold the rack housing, and use special tool to bellows band, readjust the dimension (W) of
crimp the bellows band securely. step (1) to the value calculated by the
following equation, and use a new bellows
• Crimp the bellows band until special tool
band to repeat steps (2) to (3).
touches the stopper.
W = 5.5 mm − A [Example: if (A) is 2.3 mm,
(W) is 3.2 mm.]
MB991561
>>N<< TIE ROD END/JAM NUT INSTALLATION
Edge of bellows Jam nut

assembly groove
ACX01165 AB
2. Use special tool boot band crimping tool 186 mm

(MB991561) to crimp the bellows band.
AC001011 AH
Screw in the tie rod end to achieve the right and left
A length as illustrated. Lock with the jam nut.
NOTE: The jam nuts must be tightened securely only
after the steering gear is installed to the vehicle and
toe-in is adjusted.
>>O<< GEAR MOUNTING RUBBER

INSTALLATION
ACX01166 AB
3. Check that crimped width (A) is within the 220 mm

standard value.
<When more than 2.8 mm>: Readjust the
dimension (W) of step (1) to the value
calculated by the following equation, and
repeat step (2).
W = 5.5 mm − A [Example: if (A) is 2.9 mm,
(W) is 2.6 mm.] AC100275AB
Install the gear mounting rubber to the rack housing

so that the distance is as shown in the illustration.
TIE ROD END BALL JOINT DUST COVER 1. Apply specified grease to the lip and inside of the
REPLACEMENT dust cover.
M1372008200383 Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
equivalent
2. Drive in the dust cover with special tool front axle
base (MB990776) until it is fully seated.
MB990776
AC001012AB

M1372005200395

• Front Under Cover (RH) and Side Under Cover (RH) • Power Steering Fluid Supplying and Bleeding (Refer to
Removal (Refer to GROUP 51, Under Cover P.51-19). P.37A-12).
• Power Steering Fluid Draining (Refer to P.37A-11). • Drive Belt Tension Check (Refer to GROUP 11A,
On-vehicle Service − Drive Belt Tension Check P.11A-8
<2000>, Refer to GROUP 13A, On-vehicle Service - Drive
Belt Tensioner P.11C-8 <2400>).
• Front Under Cover (RH) and Side Under Cover (RH)
Installation (Refer to GROUP 51, Under Cover P.51-19).
<2000>
57 ± 7 N·m 12 ± 2 N·m
3
4
1
2
49 ± 9 N·m
7
22 ± 4 N·m
22 ± 4 N·m
6
49 ± 9 N·m
AC200116 AB

1. Pressure switch connector <<A>> 5. Oil pump assembly
2. Drive belt (Refer to GROUP 11A, 6. A/C compressor harness
Engine assembly P.11A-49.) 7. Power steering pump bracket
>>A<< 3. Suction hose
4. Pressure hose
<2400>
7
5 7
2
57 ± 7 N·m
N 6
13 ± 1 N·m
4 8
24 ± 4 N·m
1 24 ± 2 N·m
3
12
9N (Engine oil)
11
10
44 ± 10 N·m
24 ± 2 N·m
AC305528 AD

1. Drive belt (Refer to GROUP 11C, 10. Oil pump and bracket assembly
Engine assembly P.11C-47.) 11. Bracket
>>A<< 2. Suction hose <<A>> 12. Oil pump assembly
3. Pressure switch connector
4. Pressure hose REMOVAL SERVICE POINT
5. Power steering oil pressure sensor <<A>> OIL PUMP ASSEMBLY REMOVAL
harness clamp With the engine lifted by the jack, remove the oil
6. Control wiring harness clamp
pump assembly mounting bolt (lower side) at the
7. Battery wiring harness clamp
8. Engine oil dipstick and dipstick guide
pulley side.
9. O-ring
INSTALLATION SERVICE POINT Install the suction hose so that the marking is
>>A<< SUCTION HOSE INSTALLATION positioned as shown in the illustration.
<2000> INSPECTION
M1372005300240
Suction hose • Check the drive belt for cracks.
• Check the pulley for uneven rotation.
AC103338 AD
<2400>
Suction hose
Oil pump
AC302812 AE

M1372005400366
CAUTION
Never disassemble the terminal assembly. It cannot be reassembled.
<2000>
11
4 28 ± 2 N·m
12
13
10
18 2
9
17 8
6
5
7
16 3
15 1
9.9 ± 2.1 N·m
14
28 ± 1 N·m
59 ± 9 N·m

AC100143 AE
13
13 8 4
10 5
2
11 7
3 3
3 9
18 6
15 10
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit

1. Pump cover >>B<< 11. Oil seal
2. O-ring 12. Terminal assembly
3. Snap ring >>A<< 13. O-ring
4. Pulley and shaft 14. Plug assembly
5. Vanes >>A<< 15. O-ring
>>C<< 6. Cam ring 16. Flow control spring
7. Rotor 17. Suction connector
8. Pin >>A<< 18. O-ring
9. Side plate
>>A<< 10. O-ring
<2400>
12 ± 1 N·m
4
17
18
11
30 ± 5 N·m
13 12
10
2
16
7
15
14 3 1
59 ± 9 N·m 9
8
6
5 28 ± 1 N·m

AC305524
4 18
13
7
10
3 3
9
8 15
6 11 2
AC305525 5 AC305526
10 3 AC305527
Oil pump pulley and shaft kit Oil pump cartridge kit Oil pump seal kit
AC305771 AC
DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)

1. Pump cover >>A<< 10. O-ring
2. O-ring >>B<< 11. Oil seal
3. Snap ring 12. Terminal assembly
4. Pulley and shaft >>A<< 13. O-ring
5. Vanes 14. Plug assembly
>>C<< 6. Cam ring >>A<< 15. O-ring
7. Rotor 16. Flow control spring
8. Pin 17. Suction connector
9. Side plate >>A<< 18. O-ring
REASSEMBLY SERVICE POINTS >>B<< OIL SEAL INSTALLATION

>>A<< O-RING INSTALLATION MB990938
Suction connector Plug assembly

MB991203
1 2
AC000752AB
Use following special tool to install the oil seal.

Terminal assembly Side plate • MB990938: Bar (Snap-in type)
>>C<< CAM RING INSTALLATION

3 CAUTION
Be sure to install the cam ring in the correct
direction as shown.
4
5
AC100170 AB Side plate side Pump cover side
No. ID × Width mm
1 15.8 × 2.4
2 21.0 × 1.9
3 14.8 × 2.4
AC100171AB
4 3.8 × 1.9
5 14.8 × 1.9 Install the cam ring as shown in the illustration.
INSPECTION
M1372005500244
• Check the flow control valve of the pump body for
clogging.
• Check the pulley and shaft for wear or damage.
• Check the rotor and vane groove for "stepped"
wear.
• Check the contact surface of cam ring and vanes
for "stepped" wear.
• Check the vanes for damage.

REMOVAL AND INSTALLATION <L.H.
drive vehicles>
M1372005700497

• Power Steering Fluid Draining and Refilling (Refer to
P.37A-11). and Bleeding (Refer to P.37A-12).
<2000>
12 ± 2 N·m 7
5
6
4
1
2 12 ± 2 N·m
57 ± 7 N·m
12 12 ± 2 N·m
3 14
12 ± 2 N·m
12 ± 2 N·m
13 13
15
12 ± 2 N·m
12
11
57 ± 7 N·m 9
8 10
15 ± 3 N·m
12 ± 2 N·m
AC300498AC

1. Oil reservoir • Tie rod end and knuckle connection
>>F<< 2. Return hose (Refer to P.37A-21).
>>E<< 3. Suction hose • Stabilizer link (Refer to GROUP 33A,
>>D<< 4. Return hose Stabilizer Bar P.33-14).
• Front bumper assembly (Refer to 12. Eye bolt
P.51-3). 14. Pressure hose assembly
<2400>
12 ± 2 N·m 7
5
6
4
1
2 12 ± 2 N·m
57 ± 7 N·m
12
14
12 ± 2 N·m
12 ± 2 N·m
3
15
13 13
57 ± 7 N·m 11
12 9
8 10
15 ± 3 N·m
12 ± 2 N·m
AC309400AB
>>F<< 2. Return hose (Refer to P.37A-21).
>>D<< 4. Return hose Stabilizer Bar P.33-14).
• Front bumper assembly (Refer to 12. Eye bolt
P.51-3). 14. Pressure hose assembly
INSTALLATION SERVICE POINTS >>B<< RETURN HOSE INSTALLATION

>>A<< RETURN HOSE INSTALLATION Return hose
Marking
Return tube
AC201792 AC
Return hose AC100277AB
Install the return hose so that the marking is Marking

positioned as shown in the illustration. Return hose
Cooler tube
assembly
AC201922 AC

>>C<< RETURN HOSE INSTALLATION

Cooler tube assembly Return tube
Marking
Return hose
Marking AC201791 AC
>>E<< SUCTION HOSE INSTALLATION Install the suction hose so that the marking is
<2000>
Suction hose >>F<< RETURN HOSE INSTALLATION
Marking
Return tube
Return hose
AC103338 AE
<2400>
Suction hose AC201923 AC
Install the return hose so that the markings are

Oil pump positioned as shown in the illustration.
AC302812 AE
REMOVAL AND INSTALLATION <R.H.

drive vehicles>
M1372005700505

• Power Steering Fluid Draining and Refilling (Refer to
P.37A-11.) and Bleeding (Refer to P.37A-12.)
AC211765
AC309229
12 ± 2 N·m 7
5
6
1 2
4
3
10
12 ± 2 N·m
57 ± 7 N·m
9 11
57 ± 7 N·m
15 ± 3 N·m
9 12
13
10
12 ± 2 N·m
AC309399AB

>>F<< 2. Return hose (Refer to P.37A-21.)
>>D<< 4. Return hose Stabilizer Bar P.33-14.)
>>C<< 5. Return hose 9. Eye bolt
>>B<< 6. Return hose 10. Gasket
7. Return tube assembly >>A<< 11. Pressure hose assembly
• Front bumper assembly (Refer to 12. Return tube
GROUP 51, Front Bumper Assembly 13. O-ring
P.51-3.)
8. Cooler tube assembly
INSTALLATION SERVICE POINTS >>C<< RETURN HOSE INSTALLATION

>>A<< PRESSURE HOSE ASSEMBLY Cooler tube assembly Return tube
INSTALLATION
Marking
Plate
Return hose
Marking AC201791 AC

AC103574 AC
Install the pressure hose assembly so that its plate is >>D<< RETURN HOSE INSTALLATION
Apploximately
>>B<< RETURN HOSE INSTALLATION 30˚
Clip
Return hose
Marking
AC103339AD
Install the return hose so that the clip is positioned as

Return tube
AC201792 AC shown in the illustration.
>>E<< SUCTION HOSE INSTALLATION

Marking
Return hose Suction hose
Cooler tube
assembly Oil pump
AC201922 AC

AC302812 AF
>>F<< RETURN HOSE INSTALLATION Install the return hose so that the markings are
Marking
Return tube
Return hose
AC201923 AC
42-1
GROUP 42
BODY
CONTENTS
HOOD. . . . . . . . . . . . . . . . . . . . . 42-3 TAILGATE WINDOW GLASS . . . . 42-19

REMOVAL AND INSTALLATION. . . . . . 42-19
ON-VEHICLE SERVICE. . . . . . . . . 42-3
ADJUSTMENT OF CLEARANCE AROUND ROOF WINDOW GLASS . . . . . . . . 42-22
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3 REMOVAL AND INSTALLATION. . . . . . 42-22
ADJUSTMENT OF ALIGNMENT OF HOOD
STEPPED PORTION AND HOOD STRIKER 42-3
ADJUSTMENT OF HOOD HEIGHT . . . 42-3
DOOR . . . . . . . . . . . . . . . . . . . . 42-23
HOOD. . . . . . . . . . . . . . . . . . . . . . . 42-4 SERVICE SPECIFICATIONS . . . . . 42-23

REMOVAL AND INSTALLATION . . . . . 42-4
SEALANT . . . . . . . . . . . . . . . . . . . . 42-23
FENDER. . . . . . . . . . . . . . . . . . . 42-6
SPECIAL TOOLS . . . . . . . . . . . . . . 42-23
SPECIAL TOOL . . . . . . . . . . . . . . . 42-6

FENDER. . . . . . . . . . . . . . . . . . . . . 42-6
REMOVAL AND INSTALLATION . . . . . 42-6 ON-VEHICLE SERVICE . . . . . . . . . 42-25
DOOR FIT ADJUSTMENT . . . . . . . . . . . 42-25
DOOR WINDOW GLASS ADJUSTMENT 42-26
FUEL FILLER LID . . . . . . . . . . . 42-8 GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT. . . . . . . . . . . . . . . . 42-26
POWER WINDOW SAFETY MECHANISM
REMOVAL AND INSTALLATION . 42-8
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 42-26
POWER WINDOW OPERATING CURRENT
WINDOW GLASS . . . . . . . . . . . 42-9 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 42-27
POWER WINDOW RELAY CHECK. . . . 42-27
CIRCUIT BREAKER (INCORPORATED
ADHESIVE . . . . . . . . . . . . . . . . . . . 42-9 IN THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-27
SPECIAL TOOL . . . . . . . . . . . . . . . 42-9 POWER WINDOW CHECK . . . . . . . . . . 42-27
CENTRAL DOOR LOCKING SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-28
GENERAL . . . . . . . . . . . . . . . . . . . 42-9
DOOR OUTSIDE HANDLE PLAY CHECK 42-28
DOOR INSIDE HANDLE PLAY
WINDSHIELD. . . . . . . . . . . . . . . . . 42-11 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 42-28
Continued on next page
QUARTER WINDOW GLASS . . . . 42-16
42-2
DOOR ASSEMBLY . . . . . . . . . . . . 42-29 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-48

INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-30
KEYLESS ENTRY SYSTEM . . 42-49
DOOR GLASS AND REGULATOR 42-31
REMOVAL AND INSTALLATION . . . . . 42-31 SPECIAL TOOLS . . . . . . . . . . . . . . 42-49
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-32
DOOR HANDLE AND LATCH. . . . 42-34
REMOVAL AND INSTALLATION . . . . . 42-34 ON-VEHICLE SERVICE . . . . . . . . . 42-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-35 KEYLESS ENTRY SYSTEM CHECK. . . 42-50
KEYLESS ENTRY SYSTEM TIMER LOCK
WINDOW GLASS RUNCHANNEL FUNCTION INSPECTION . . . . . . . . . . . 42-50
HOW TO REPLACE THE TRANSMITTER
AND DOOR OPENING
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 42-50
WEATHERSTRIP. . . . . . . . . . . . . . 42-38
ENABLING/DISABLING
REMOVAL AND INSTALLATION . . . . . 42-38 THE ANSWERBACK FUNCTION . . . . . 42-51
HOW TO REGISTER SECRET CODE . 42-54
TAILGATE . . . . . . . . . . . . . . . . . 42-43
SUNROOF ASSEMBLY . . . . . . 42-57
SERVICE SPECIFICATIONS . . . . . 42-57
SEALANTS . . . . . . . . . . . . . . . . . . 42-43
SPECIAL TOOL . . . . . . . . . . . . . . . 42-43 CHECK CHART FOR TROUBLE
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . 42-57
ON-VEHICLE SERVICE . . . . . . . . . 42-71
WATER TEST . . . . . . . . . . . . . . . . . . . . 42-71
ON-VEHICLE SERVICE. . . . . . . . . 42-44
SUNROOF FIT ADJUSTMENT . . . . . . . 42-71
TAILGATE FIT ADJUSTMENT . . . . . . . 42-44
SUNROOF CHECK . . . . . . . . . . . . . . . . 42-71
TAILGATE HANDLE PLAY CHECK . . . 42-44
SUNROOF SAFETY FUNCTION CHECK 42-71
ADJUSTMENT OF TAILGATE HEIGHT 42-44
ROOF LID GLASS OPERATION CURRENT
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 42-72
TAILGATE . . . . . . . . . . . . . . . . . . . 42-45 SUNROOF INITIALIZATION . . . . . . . . . 42-72
SUNROOF ASSEMBLY . . . . . . . . . 42-73
TAILGATE HANDLE AND REMOVAL AND INSTALLATION. . . . . . 42-73
LATCH . . . . . . . . . . . . . . . . . . . . . . 42-47 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-74
REMOVAL AND INSTALLATION . . . . . 42-47 DISASSEMBLY AND ASSEMBLY . . . . . 42-75
BODY 42-3
HOOD
HOOD
ON-VEHICLE SERVICE ADJUSTMENT OF HOOD HEIGHT
M1421007400101
ADJUSTMENT OF CLEARANCE AROUND

HOOD A
M1421007200107
Y0215AU
Section A – A
Hood
AC103720
ADJUSTMENT OF ALIGNMENT OF HOOD

STEPPED PORTION AND HOOD 16.5 mm
STRIKER
M1421007300104
X0424CA
Hood bumper
AC005948AF
Rotate the hood bumper by using the arrow mark on

the hood bumper as a guide to adjust the hood
height. If the hood bumper is rotated just one turn,
the hood height changes by approximately 3 mm.
AC005947
42-4 BODY
HOOD
HOOD
M1421001600408
6
8 21 ± 4 N·m
11 ± 2 N·m
1 3
9
7
11 ± 2 N·m
6 5 3
6
1 4
1
2
9.0 ± 2.0 N·m
AC107422AC
Removal steps Hood and hood hinge removal steps

1. Hood bumper 5. Hood Insulator
Hood latch and hood lock release 6. Hood weatherstrip
cable removal steps • Washer hose (Refer to GROUP 51,
• Radiator grille (Refer to GROUP 51, Windshield washer P.51-25.)
Radiator grille P.51-10.) 7. Hood
2. Hood latch 8. Hood support rod
• Splash shield (Refer to P.42-6.) • Front deck garnish (Refer to GROUP
3. Hood lock release handle 51, Windshield wiper P.51-21.)
4. Hood lock release cable 9. Hood hinge
BODY 42-5
HOOD
Clip positions
7
5
Section A – A
7
A Clip
Note
: Clip positions
AC200023 AE
42-6 BODY
FENDER
FENDER
SPECIAL TOOL
M1421000600212

MB990784 Ornament remover Side turn-signal lamp removal
MB990784
FENDER
M1421001900380

• Front Bumper Removal and Installation (Refer to GROUP
51, Front Bumper P.51-3).
• Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper P.51-21).
3
2 4
Note
: Clip positions
AC309633 AB
Removal Steps Removal Steps (Continued)

• Side sill garnish (Refer to GROUP 51, <<A>> >>A<< 3. Side turn signal lamp
Garnish P.51-12). • Headlamp assembly (Refer to
1. Splash shield GROUP 54A, Headlamp P.54A-77).
2. Front pillar pad 4. Fender
BODY 42-7
FENDER
REMOVAL SERVICE POINT Use an appropriate tool such as special tool

<<A>> SIDE TURN SIGNAL LAMP REMOVAL Ornament remover MB990874 to pry out the tab from
the fender, and remove the side turn signal lamp.
: Front of vehicle
Side turn signal lamp >>A<< SIDE TURN SIGNAL LAMP INSTALLATION
Hook
Claw
A
Fender panel
A
Section A – A
MB990784 Fender panel
Fender panel
: Front of vehicle AC005719 AE
Engage the hook with the fender panel, and install

the side turn signal lamp.
Claw
AC101384 AE
42-8 BODY
FUEL FILLER LID
FUEL FILLER LID

M1421002500329

• Rear Seat Removal and Installation (Refer to GROUP
52A, Rear Seat P.52A-36).
• Front Seat Assembly (Driver's Seat Side) Removal and
Installation (Refer to GROUP 52A, Front Seat P.52A-29).
• Front Seat Belt Anchor Bolt (Driver's Side) Removal and
Installation (Refer to GROUP 52A, Front Seat Belt
P.52A-39).
• Front Scuff Plate (Driver's Side), Rear Scuff Plate
(Driver's Side), Centre Pillar Lower Trim (Driver's Side)
Removal and Installation (Refer to GROUP 52A, Trims
P.52A-18).
• Floor Console Removal and Installation (Refer to GROUP
52A, Floor Console P.52A-14).
4
Fuel filler lid height and clearance
adjustment
1 2 5.0 ± 1.0 N·m
AC107424 AC

1. Fuel filler lid panel assembly • Protector C (Refer to GROUP 36,
2. Clip Parking Brake Cable P.36-9 <LH
3. Fuel filler lid hook assembly drive vehicles>, P.36-10 <RH drive
4. Fuel filler lid lock release handle vehicles>).
• Quarter lower trim (Refer to 5. Fuel filler lid lock release cable
GROUP 52A, Trims P.52A-18).
BODY 42-9
WINDOW GLASS
WINDOW GLASS
ADHESIVE
M1422000500069
Item Specified adhesive

Windshield 3M ATD Part No.8609 Super Fast Urethane Auto Glass
Quarter window glass Sealant or equivalent
3M ATD Part No.8608 Super Fast Urethane Primer or
Tailgate window glass equivalent
Roof window glass
SPECIAL TOOL
M1422000600271

MB990480 Window glass holder Window glass removal and installation
MB990480
GENERAL
M1422000100436
The windshield, quarter window glass, tailgate
window glass and roof window glass are attached by
an urethane-base adhesive to the window frame.
This adhesive provides improved glass holding and
sealing, and also gives body openings a greater
structural strength.
ITEMS
Name Remark
Adhesive 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent
Spacers Available as service part
Dam Available as service part
Anti-rust solvent (or Tectyl For rust prevention
506T.Valvoline Oil Company)
Isopropyl alcohol For grease removal from bonded surface
Steel piano wire Dia. × length... 0.6mm × 1m For cutting adhesive
Glass adhesive knife For cutting adhesive
Adhesive gun For pressing-out adhesive
HANDLING OF AUTO WINDOW SEALER BODY PINCH-WELD FLANGE SERVICING

Keep the sealant in a cool place, not exposed to the Before servicing the body pinch-weld flange, remove
direct rays of the sun. Do not place any heavy article old adhesive completely. If the flange requires
on the sealant nor press it, otherwise it will become painting, bake it after painting is completed.
deformed. Avoid storing the sealant for more than 6
months, because it will lose its sealing effect.
42-10 BODY
WINDOW GLASS
WINDOW GLASS INSTALLATION
Window glass installation procedure
Body side Window glass side
Reusing the glass Replace the glass
Cleaning of adhesion surface Cleaning of adhesion surface

Cleaning of adhesion surface Completely cut off all of the residual
Cut off the residual adhesive until the Clean off any dirt adhering to the adhesion
adhesive. Clean the adhesive surface surface with isopropyl alcohol, and let dry
thickness is less than 2 mm. Clean the with isopropyl alcohol, and let dry for
adhesion surface with isopropyl alcohol, for 3 minutes or more.
3 minutes or more.
and let dry for 3 minutes or more.
Gluing of window dam and window spacer

Attaching of dual lock fastener
Glue the window dam and window spacer to the glass, following the standard position
Attach the dual lock fastener to set the
all the way around the inside edge of the glass.
positions for the glass to be installed.
Application of primer
Do not apply primer on residual adhesive as doing so may affect adhesion. apply enough primer on adhesion surface evenly taking
care not to apply it on the residual adhesive. after applying primer, let it dry for 3 minutes or more.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
Installing the glass

After applying the adhesive, lightly press the glass evenly so that it adheres
completely.
Cleaning
After removing excess adhesive from the body or glass with a spatula, etc.
Clean off with isopropyl alcohol.
Checking for water leaks

Carry out a shower test to check that no water leaks through.
AC306636 AD
BODY 42-11
WINDOW GLASS
WINDSHIELD
M1422001000409

• Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper P.51-21).
• Roof Drip Moulding Removal and Installation (Refer to
GROUP 51, Moulding P.51-15).
• Front Pillar Trim Removal and Installation (Refer to
4N
3N
2
4N
N5
1 N5
AC301503
Apply the primer and adhesive along the fictitious lines (seal line) Units: mm
between each of the marks. Seal line Section B – B Seal line
center center
Section A – A
A
15
2
A
Ceramic line B Primer

B
Primer
2 2 15
Section C – C
15
Mark
Seal line center
Seal line
C Primer
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
AC301615 AB

1. Harness connector (Refer to GROUP >>A<< 3. Windshield moulding
51, Wiper deicer P.51-43). >>A<< 4. Glass stopper
<<A>> >>B<< 2. Windshield >>A<< 5. Windshield spacer
42-12 BODY
WINDOW GLASS

<<A>> WINDSHIELD REMOVAL
1. To protect the body (paint surface), apply cloth
tape to all body areas around the installed
windshield.
2. Make mating marks on the windshield and body.
AC002060
Glass adhesive knife
ACX00474 AB
3. Using piano wire.

(1) Using a sharp-point drill, make a hole in the
windshield adhesive.
(2) Pass the piano wire from the inside of the AC207478 AD
vehicle through the hole.
Inserting the glass adhesive knife too deeply into
CAUTION windshield adhesive may damage windshield.
Do not let the piano wire touch the edge of the
windshield. 4. Using glass adhesive knife
(3) Pull the piano wire alternately from the inside Keep glass adhesive knife at right angles with the
and outside along the windshield to cut the windshield edge, and put the blade at windshield
adhesive. edge and surface. Then cut away adhesive along
the windshield edge.
MB990480
ACX00475AB
5. Use special tool window glass holder MB990480

to remove the windshield.
BODY 42-13
WINDOW GLASS
CAUTION 7. Finish the flange surfaces so that they are

•
smooth.
CAUTION
Allow the cleaned area to dry for at least three
minutes. Do not touch any surface that has been
cleaned.
8. When reusing the windshield, remove the
adhesive still adhering to the windshield, and
clean with isopropyl alcohol.
9. Clean the body side in the same way.
ACX00476 AB
Be careful not to remove more adhesive than is INSTALLATION SERVICE POINTS

necessary. >>A<< WINDSHIELD SPACER/GLASS
• Be careful also not to damage the paintwork STOPPER/WINDSHIELD MOULDING
on the body surface with the knife. If the INSTALLATION
paintwork is damaged, repair the damaged
CAUTION
area with repair paint or anti-rust agent.
Leave the degreased parts for 3 or more minutes
6. Use a knife to cut away the remaining adhesive so to dry well, before starting on the next step. Do
that the thickness is within 2 mm around the entire not touch the degreased parts.
circumference of the body flange.
1. Use isopropyl alcohol to degrease the inside and
outside of the windshield and the body flanges.
42-14 BODY
WINDOW GLASS
Glass stopper and windshield spacer installation position

Windshield end line
Seal line
18.1 mm
Glass stopper Windshield

Align the glass
stopper end with
the windshield mark. Ceramic line
Windshield center line Seal line
Windshield
spacer
Ceramic line
Ceramic line
65 mm
43.9 mm
43.9 mm
Windshield Seal line

center line
Windshield Align the windshield
spacer spacer end with the
Seal line ceramic notch.
AC300403AB
2. The inner side of the windshield is curved, CAUTION

therefore, make a point to assemble the glass • The primer strengthens the adhesive, so be
stopper and windshield spacer without any lifting sure to apply it evenly around the entire
and assemble in the position shown. circumference. However, a too thick
3. Install the windshield moulding. application will weaken the adhesive.
• Do not touch the coated surface.
>>B<< WINDSHIELD INSTALLATION
• Do not apply the primer on the remaining
1. When replacing the windshield, temporarily set adhesive because of weakening the adhesive.
the windshield against the body, and place a
mating mark on the windshield and body. 2. Soak a sponge in the primer, and apply evenly to
the windshield and the body in the specified
places.
3. Allow the windshield to dry for at least three
minutes after applying primer.
BODY 42-15
WINDOW GLASS
5. Align the mating marks on the windshield and the

body, and lightly press the windshield evenly so
that it adheres completely.
6. Use a spatula or similar tool to remove any
excessive adhesive. Clean the surface with
isopropyl alcohol. Avoid moving the vehicle until
10 mm the adhesive sets.
15 mm 7. Bond the windshield to the body, and install the
roof drip moulding quickly before the adhesive
ACX00480 AB cures. (Refer to GROUP51, Moulding P.51-15).
4. Fill a sealant gun with adhesive. Then apply the CAUTION
adhesive evenly around the windshield within 30 • Do not move the vehicle unless absolutely
minutes after applying the primer. necessary.
NOTE: Cut the tip of the sealant gun nozzle into a • When testing for water leakage, do not pinch
V shape to simplify adhesive application. the end of the hose to spray the water.
8. Wait 30 minutes or more, and then test for water
leakage.
42-16 BODY
WINDOW GLASS
QUARTER WINDOW GLASS

M1422002500292

• Quarter Trim Upper Removal and Installation (Refer to
2N
1
N3
N4
3N
Apply the primer and adhesive Units: mm
along the fictitious lines (seal line)
between each of the marks.
Ceramic line Seal line Align the tape
end with the quarter
C window glass mark.
A C
A Ceramic line
Seal line Mark
B
Section A – A Section B – B Section C – C
Seal line Primer
1 center Seal line 1
center Seal line
15 center
1
15
15
Primer
Primer
Adhesive tape: Double-sided tape [ 15 mm width, 15 mm length and 0.8 mm thickness ]
AC107211AB

<<A>> >>B<< 1. Quarter window glass assembly >>A<< 3. Clip
>>A<< 2. Dual lock fastener >>A<< 4. Gasket
BODY 42-17
WINDOW GLASS

MB990480
<<A>> QUARTER WINDOW GLASS REMOVAL
AC103605AD
4. Make mating marks on the quarter window glass

Cloth tape AC103600AD and body.
1. Apply cloth tape to protect the quarter window 5. Use special tool window glass holder MB990480
glass. to remove the quarter window glass.
CAUTION
AC002060
ACX00476 AB
2. Use glass adhesive knife to cut away adhesive.
• Be careful not to remove more adhesive than
CAUTION is necessary.
Glass adhesive knife • Be careful also not to damage the paintwork
on the body surface with the knife. If the
paintwork is damaged, repair the damaged
area with repair paint or anti-rust agent.
6. Use a knife to cut away the remaining adhesive so
that the thickness is within 2 mm around the entire
circumference of the body flange.
7. Finish the flange surfaces so that they are
AC301614AB smooth.
Inserting the adhesive knife too deeply into CAUTION

windshield adhesive may damage quarter Allow the cleaned area to dry for at least three
window glass. minutes. Do not touch any surface that has been
cleaned.
3. Keep the glass adhesive knife at right angles with
body flange (from inside the vehicle), and put the 8. When reusing the quarter window glass, remove
blade at body flange. Then cut away adhesive the adhesive still adhering to the quarter window
along the body flange. glass, and clean with isopropyl alcohol.
9. Clean the body side in the same way.
42-18 BODY
WINDOW GLASS
INSTALLATION SERVICE POINTS CAUTION

>>A<< GASKET/CLIP/DUAL LOCK FASTENER Leave the degreased parts for 3 or more minutes
INSTALLATION to dry well, before starting on the next step. Do
1. Carry out the following procedure to re-install not touch the degreased parts.
quarter window glass. 2. Use isopropyl alcohol to degrease the inside and
CAUTION outside of the quarter window glass and the body
Do not forget gasket. flanges.
(1) Fit clips into body.
Dual lock fastener

Cut off these convex parts
Body flange end line
AC107213AB
AC103606 AC
3. Assemble the dual lock fastener according to the
(2) Cut away clip fitting convex on quarter window standard location of the body flange.
glass. 4. Assemble the dual lock fastener to the quarter
NOTE: Convex gets broken when quarter window glass relative to the body flange dual lock
window glass is removed. fastener.
>>B<< QUARTER WINDOW GLASS

INSTALLATION
Install the quarter window glass using the same
procedure as for the windshield installation (Refer to
P.42-11).
BODY 42-19
WINDOW GLASS
TAILGATE WINDOW GLASS

M1422003700158

• Tailgate Trim Removal and Installation (Refer to GROUP
52A, Tailgate Trim P.52A-25).
• Rear Wiper Arm Assembly Removal and Installation
(Refer to GROUP 51, Rear Wiper and Washer P.51-30).
N3
N4
2N
Units: mm
Section A – A Section B – B
Apply the primer and adhesive Seal line
along the fictitious lines (seal line) center
between each of the marks. 1 Seal line center
A
15
A Primer
15
1
C
Ceramic line C
Primer
Section C – C
MARK Primer
Mark 1
Seal line
B
Seal line
B center
15
AC107209AB

• Harness connector >>A<< 2. Dual lock fastener
<<A>> >>B<< 1. Tailgate window glass >>A<< 3. Glass stopper
>>A<< 4. Window dam
42-20 BODY
WINDOW GLASS
REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS

<<A>> TAILGATE WINDOW GLASS REMOVAL >>A<< WINDOW DAM/GLASS STOPPER/DUAL
Remove the tailgate window glass using the same LOCK FASTENER INSTALLATION
procedure as for the windshield. (Refer to P.42-11). CAUTION
Leave the degreased parts for 3 or more minutes
to dry well, before starting on the next step. Do
not touch the degreased parts.
1. Use isopropyl alcohol to degrease the inside and
outside edges of the tailgate window glass and
the surface of the tailgate flange.
Glass stopper, window dam and dual lock fastener installation position
Glass end line

Install the window
dam along the glass Glass end line
end line.
Seal line
25.5 ± 0.5 mm
Align the window dam

end with the ceramic notch.
Seal line Ceramic line

Glass stopper
Align the glass stopper
Seal line and with the tailgate
window glass mark.
Window dam
Tailgate window glass
Dual lock fastener
Align the dual lock fastener and with

the tailgate window glass mark. Ceramic line
AC107210 AB
2. Assemble the window dam, glass stopper and

dual lock fastener to the tailgate window glass
location shown.
BODY 42-21
WINDOW GLASS
>>B<< TAILGATE WINDOW GLASS

INSTALLATION
Install the tailgate window glass in the same way as
Flange convex for the windshield installation (Refer to P.42-11).
at the tailgate flange
Dual lock fastener

AC107208AB
3. Assemble the dual lock fastener in alignment with

the protrusion of the tailgate flange.
42-22 BODY
WINDOW GLASS
ROOF WINDOW GLASS

M1422004300045
AC301504
Seal line
A Section A – A
A A A Seal line center
A A
A
A 6 mm 1
Primer
15 mm
Adhesive tape: Double-sided tape [ 6 mm width, 0.5 mm thickness ]
AC301821AB
Removal steps
• Frame assembly (Refer to GROUP
52A − Headlining P.52A-27).
<<A>> >>A<< 1. Roof window glass assembly
BODY 42-23
DOOR

<<A>> ROOF WINDOW GLASS ASSEMBLY >>A<< ROOF WINDOW GLASS ASSEMBLY
Remove by the same procedure as for the quarter Install by the same procedure as for the windshield
window glass (Refer to P.42-16). (Refer to P.42-11).
DOOR
M1423000300079
Item Standard value

Power window operation current (Power supply voltage 14.5 ± 0.5 V, at 25 °C) A 5±1
Door outside handle play mm Front door 2.6 ± 2.5
Rear door 1.3 ± 1.3
Door inside handle play mm Front door 10.4 ± 9.6
Rear door 10 ± 9.6
SEALANT
M1423000500073

Door waterproof film 3M ATD Part No.8633 or equivalent
SPECIAL TOOLS
M1423000600315

MB990480 Window glass holder Removal of power window regulator
and motor assembly
MB990480
MB990900 or Door hinge adjusting Door alignment

MB991164 wrench
MB990900
42-24 BODY
DOOR

MB990925 Bearing and oil seal Door striker adjustment
A
A: MB990939 installer set
A: Brass bar
MB990925AF
MB990211 Sliding hammer
MB990211
MB990241 Axle shaft puller

A: MB990243 A: Body puller
A
MB990241AE
A
MB991223 Harness set Terminal voltage measurement
A: MB991219 A: Test harness A: For checking connector pin contact
B: MB991220 B: LED harness pressure
C: MB991221 C: LED harness adapter B: For checking power supply circuit
B D: MB991222 D: Probe C: For checking power supply circuit
D: For connecting a locally sourced
tester
C
D
MB991223 AD
TROUBLESHOOTING
M1423000700345
The door system is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to GROUP
54B, Troubleshooting P.54B-15 or GROUP 54C,
Troubleshooting P.54C-4.
BODY 42-25
DOOR
ON-VEHICLE SERVICE
3. When the door is stiff to lock and unlock:
DOOR FIT ADJUSTMENT
M1423001100250
CAUTION
• Attach protection tape to the fender and door
edges where the hinge is installed.
• Do not rotate special tool door hinge
adjusting wrench MB991164 with a torque of
MB990939
over 98 N⋅m.
Temporary
bolt Striker
AC006109AB
(1) Adjustment by using the striker (toward the

inside of the vehicle and vertical direction)
MB990900
or Install an appropriate bolt instead of the striker
MB991164 mounting bolt, and use special tool brass bar
MB990939 and a hammer to tap the bolt to the
desired direction.
AC000592 AB
1. Use special tool door hinge adjusting wrench

MB990900 or MB991164 to loosen the hinge MB990211
MB990243
mounting bolts on the body side, and then adjust
the clearance around the door so that it is uniform
on all sides.
2. If a door is not flush with its surrounding panels,
loosen the door-side door hinge mounting bolts Striker
and obtain the flushness by moving the door. AC006110 AB
NOTE: (2) Adjustment by using the striker (toward the

Weld point Washer outside of the vehicle)
Use special tools sliding hammer MB990211
and body puller MB990243 to pull the striker
toward the outside of the vehicle.
Bolt
Shim
Striker
Weld point Washer
Door hinge AC206498 AE
If the door hinge mounting bolt washers are

welded, grind off the welding according to the
procedure below beforehand.
.
AC006111AB
1. Remove the door hinge (Refer to P.42-29).
2. Use a chisel or grinder to release the door (3) Adjustment by using shims (forward and
hinge mounting bolt washer, which is welded rearward)
to the door hinge. Increase or decrease the number of shims so
3. On completion, paint the affected area with a that the striker engages with the door latch
suitable touch-in brush to prevent corrosion. properly.
4. Install the door hinge (Refer to P.42-29).
42-26 BODY
DOOR
DOOR WINDOW GLASS ADJUSTMENT

M1423001000305 Runchannel Door
Check that the door glass moves while contacting sash
the door glass channel when it is raised and lowered
fully. If not, adjust the door window according to the
following procedures.
1. Remove the door trim assembly (Refer to GROUP
52A, Door trim P.52A-21). Lower
sash
2. Remove the waterproof film. (Refer to P.42-38).
<Front> <Rear> AC003777AB
4. If the door window glass does not move up and

down smoothly, check or repair the following
points.
• Check the installation condition of the
Adjusting runchannel.
Adjusting hole
hole • Repair any twisting in the door sash.
• Check the installation condition of the lower sash.
Y0238AU Y0239AU 5. If repair or adjustment is not possible, replace the
AC006112 AB
door assembly.
3. Loosen the door glass mounting screw via the
adjusting hole with the door window glass fully POWER WINDOW SAFETY MECHANISM
closed, then lower the window glass a little. CHECK
M1429001000314
4. Fully close the door window glass again and
tighten the door glass mounting screw firmly via
the adjusting hole.
GLASS SLIDING MECHANISM CHECK

AND ADJUSTMENT
M1429000900121
If the window glass automatically starts moving
downwards at the wrong time while it is being raised,
carry out the following adjustment or replacement
procedures. AC103294
1. Remove the door trim assembly. (Refer to
1. Place a wooden board about 10 mm thick as
GROUP 52A, Door trim P.52A-21).
shown. Then, raise the window glass.
2. Remove the waterproof film. (Refer to P.42-38).
2. Check that the window lowers by about 150 mm
3. Remove the window regulator assembly from the when the window clamps the board. If this doesnít
door window glass, and then raise and lower the happen, carry out troubleshooting. Refer to
door window glass by hand to check the operation GROUP 54B, Troubleshooting P.54B-15, refer to
force. GROUP 54C, Troubleshooting P.54C-4.
NOTE: Insert a cushion or similar object to NOTE: If the anti-trap function (safety
prevent damage to the glass if it should happen to mechanism) is activated consecutively three
fall down. times or more, make the power window switch
learn the fully closed position of the power window
(Refer to P.42-31).
BODY 42-27
DOOR
POWER WINDOW OPERATING CURRENT BATTERY TESTER SPECIFIED

CHECK VOLTAGE CONNECTION CONDITION
M1429001100247
Not applied 4−5 Open circuit
• Connect 4−5 Less than 2
terminal No.1 ohms
and the positive
battery
terminal.
• Connect
terminal No.3
and the
AC208065AC
negative
battery
1. Remove the power window fuse and connect an terminal.
ammeter as shown in the illustration.
2. When the power window switch is pressed to the CIRCUIT BREAKER (INCORPORATED IN
ìUPî position, a large amount of current flows at THE POWER WINDOW MOTOR)
the time the window starts to close and when it is
INSPECTION
fully closed, so measure the operation current in M1429001700108
the interval between these two points. 1. Pull the power window switch to the UP position
Standard value: 5 ± 1A (Power supply to fully close the door window glass, and keep
voltage 14.5 ± 0.5V, 25°C) pulling the switch for 10 additional seconds.
3. If the operation current is outside the standard 2. Release the power window switch from the UP
value, refer to P.42-26. position and immediately press it to the DOWN
position. The condition of the circuit breaker is
POWER WINDOW RELAY CHECK good if the door window glass starts to move
M1429001800235 downwards within 60 seconds.
Power window relay POWER WINDOW CHECK

M1429004400269
Check the system as described below. If the system
does not work, carry out troubleshooting. Refer to
GROUP 54B, Troubleshooting P.54B-15 or GROUP
54C, Troubleshooting P.54C-4.
• Operate the power window switch of each seat to
check that the power window works.
• Turn on the power window lock switch of the
AC207981
power window main switch, and operate the front
Junction block passenger's and rear power window sub switches
to check that the power windows do not work.
• Turn on the power window lock switch of the
power window main switch, and operate the
5 1 2 3
power window main switch to check that each
4 4 power window operates.
1 3 5
AC106844
AC300331AB
42-28 BODY
DOOR
CENTRAL DOOR LOCKING SYSTEM DOOR INSIDE HANDLE PLAY

INSPECTION ADJUSTMENT
M1427001100199 M1423001500270
Check that the central door locking system works by Section A – A
operating the key cylinder and the inside lock knob
(driver's door). Carry out troubleshooting if the A
A
system does not activate. Refer to GROUP 54B,
B
Troubleshooting P.54B-15, refer to GROUP 54C,
DOOR OUTSIDE HANDLE PLAY CHECK

M1423001600255
Y0705AU
AC006114 AB
1. Check that the door inside handle play is within

the standard value range.
A Standard value (B):
Front door: 10.4 ± 9.6 mm
Rear door: 10 ± 9.6 mm
2. If the door inside handle play is outside the
AC006113AB
3. Remove the door trim assembly (Refer to GROUP
1. Check that the door outside handle play is within 52A, Door trim P.52A-21).
the standard value range. 4. Remove the waterproof film (Refer to P.42-38).
Standard value (A):
Front door: 2.6 ± 2.5 mm Inner cable Clip
Rear door: 1.3 ± 1.3 mm
2. If the door outside handle play is not within the Outer cable end
standard value range, check the door outside
handle or the door latch assembly. Replace if
necessary.
Door inside handle

Inside handle rod AC100404 AB
5. Adjust the door inside handle play with the outer

cable end connecting the door inside handle and
inside lock cable.
BODY 42-29
DOOR
DOOR ASSEMBLY
M1423002200261
• Door Fit Adjustment (Refer to P.42-25).
<Front door>
4 7 8
27 ± 5 N·m
11 ± 2 N·m
5
21 ± 4 N·m 1
3 1 9
2 1.5 ± 0.5 N·m 4
9.0 ± 2.0 N·m <Rear door>
27 ± 5 N·m 11 ± 2 N·m
21 ± 4 N·m 6
27 ± 5 N·m
5, 6 5 8
7
21 ± 4 N·m
1
1.5 ± 0.5 N·m
2
27 ± 5 N·m
21 ± 4 N·m
3 1 9
6 9.0 ± 2.0 N·m
AC103073 AC
Removal Door assembly removal steps

1. Damper 5. Door upper hinge
Door assembly removal steps 6. Door lower hinge
• Scuff Plate and Cowl Side Trim (Refer Striker removal steps
to GROUP 52A, Trims P.52A-18). >>A<< 7. Striker
2. Harness connector 8. Striker shim
3. Door check connecting bolt Door switch removal
4. Door assembly 9. Door switch
42-30 BODY
DOOR
INSTALLATION SERVICE POINT INSPECTION

M1423006000300
>>A<< STRIKER INSTALLATION
DOOR SWITCH CHECK
Latch center
Striker center
+1.5 mm 2 3
1
-1.5 mm
Striker
Latch
AC006126AB
AC211414 AC
Align the centre of the striker and latch within ±1.5
mm, and install. SWITCH TESTER SPECIFIED
POSITION CONNECTION CONDITION
Released (ON) 1 − switch body, Less than 2
2 − switch body, ohms
3 − switch body
Depressed 1 − switch body, Open circuit
(OFF) 2 − switch body,
3 − switch body
BODY 42-31
DOOR
DOOR GLASS AND REGULATOR

M1429001300393

• Door Trim Assembly Removal (Refer to GROUP 52A, • Door Window Glass Adjustment (Refer to P.42-26).
Door Trim P.52A-21). • Waterproof Film Installation (Refer to P.42-38).
• Waterproof Film Removal (Refer to P.42-38). • Door Trim Assembly Installation (Refer to GROUP 52A,
Door Trim P.52A-21).
1
AC101370
<Front door> <Rear door>

4
3
3
AC300452 AB
Power window switch removal steps Door window regulator assembly

>>B<< • Post-installation operation check removal steps
1. Power window switch (Refer to >>B<< • Post-installation operation check
GROUP 52A, Door trim P.52A-21). <<A>> >>A<< 2. Window regulator assembly
<<A>> 3. Power window motor assembly
42-32 BODY
DOOR
Door window glass removal steps INSTALLATION SERVICE POINTS

• Window glass runchannel <Rear >>A<< WINDOW REGULATOR ASSEMBLY
door> (Refer to P.42-38).
INSTALLATION
• Lower sash <Rear door> (Refer to
P.42-38). <Front door>
• Door latch assembly <Rear door> 7
(Refer to P.42-34).
3
• Door beltline moulding (Refer to 4
P.42-38). 2
• Door beltline inner weatherstrip 1
(Refer to P.42-38).
4. Door window glass
6
5
<<A>> WINDOW REGULATOR <Rear door>
ASSEMBLY/POWER WINDOW MOTOR
ASSEMBLY REMOVAL
1. Remove the door window glass installation bolts.
1
CAUTION 6 4
If tinting film is adhered to the door window
glass, attach special tool window glass holder 3
MB990480 to the outside of the glass to prevent 2
the film from peeling off.
5
AC102851AC
MB990480
When installing the window regulator assembly,
tighten the bolts to the specified torque in the order
shown.
>>B<< Post-installation operation check

When the following procedures are carried out, make
the power window switch learn the fully closed
position of the power window. (Refer to P.42-32).
AC100009AB
• Power window regulator removal or replacement
2. Lift the door window glass, and attach special tool • Power window switch removal or replacement
window glass holder MB990480 to the glass as
shown to prevent the glass from falling. INSPECTION
M1429001400260
3. Remove the window regulator assembly and
power window motor assembly.
How to make the power window switch
learn the fully closed position of the
power window
How to make the power window switch learn the
fully closed position when the power window
switch is removed, or the power window
regulator assembly is removed or replaced
1. If the anti-trap function (safety mechanism) is
activated consecutively three times or more, the
fully closed position that the power window switch
has learned will be erased (initialized).
2. Operate the power window switch and fully open
the door window glass.
BODY 42-33
DOOR
CAUTION How to make the power window switch learn the

The anti-trap function does not work until the fully closed position when the power window
power window switch completes learning the switch is replaced with a new one
fully closed position (It is because the anti-trap CAUTION
function is reset). The anti-trap function does not work until the
3. Operate the power window switch and fully close power window switch completes learning the
the door window glass. The power window fully closed position (It is because the anti-trap
activates for 0.7 seconds and stops automatically function is reset).
when the power window switch is pressed once. Operate the power window main switch to fully close
Repeat this operation until the door window glass the door window glass by one-shot up action so that
fully closes and release the switch once. Then, the power window switch will complete learning
hold the power window switch to the fully closed (Initialization is not needed).
side again for one second so that the power NOTE: When the power window sub switch of each
window switch completes learning the fully closed seat is replaced, operate the power window main
position. switch to fully close the applicable power window by
NOTE: If the power window switch is operated to one-shot up action (It is because the power window
open the door window glass while the switch is sub switch does not have one-shot up/down
learning, learning will be cancelled. If this function).
happens, return to step 2.
42-34 BODY
DOOR
DOOR HANDLE AND LATCH

M1423004600306

• Door Trim Assembly Removal (Refer to GROUP 52A • Door Inside Handle Play Check (Refer to P.42-28).
Door Trim P.52A-21). • Door Outside Handle Play Check (Refer to P.42-28).
• Door Trim Assembly Installation (Refer to GROUP 52A,
Door Trim P.52A-21).
<Front door> <Rear door>
3
4
5.0 ± 1.0 N·m
3
5.0 ± 1.0 N·m
9.0 ± 2.0 N·m 7
6
9.0 ± 2.0 N·m
8
8 5
1
5
1
2 5.0 ± 1.0 N·m

5.0 ± 1.0 N·m 2
9 9
AC101531AD
Door handle and door latch assembly Door handle and door latch assembly
>>C<< 1. Door inside handle 6. Inside lock cable
• Waterproof film (Refer to P.42-38). 7. Inside lock rod
>>B<< 2. Lower sash 8. Inside handle rod
3. Door outside handle Door check removal steps
4. Door lock key cylinder • Waterproof film (Refer to P.42-38).
5. Door latch assembly >>A<< 9. Door check
BODY 42-35
DOOR
INSTALLATION SERVICE POINTS 2. Install the inside handle rod to the door inside
>>A<< DOOR CHECK INSTALLATION handle.
3. Install the door inside handle to the door.
INSPECTION
Identification mark M1423004700477
FRONT DOOR LOCK ACTUATOR CHECK

Front door
<Left side>
Lock Unlock
View A
ACX00541AB 1 2 3
4 5 6
Install the door check so that the identification mark
faces upwards.
Lever
ITEM IDENTIFICATION
MARK A
<Right side>
Front Door Left door 39L
Unlock Lock
Right door 39R
View B
Rear Door Left door 40L
1 2 3
Right door 40R 4 5 6
>>B<< LOWER SASH INSTALLATION

Securely insert the rear lower sash into the window Lever
rear sash.
B AC005657AD
>>C<< DOOR INSIDE HANDLE INSTALLATION
Actuator Operation Check <Left side>
Inner cable Clip LEVER BATTERY LEVER
POSITION CONNECTION OPERATION
Outer cable end At the • Connect terminal The lever
"LOCK" No.6 and the moves from the
position negative battery "LOCK"
terminal. position to the
• Connect terminal "UNLOCK"
Door inside handle No.4 and the position.
Inside handle rod AC100404 AB
positive battery
terminal.
1. Install the inside lock cable to the door inside
handle as follows: At the • Connect terminal The lever
"UNLOCK" No.4 and the moves from the
(1) Install the inner cable end in the inside lock
position negative battery "UNLOCK"
cable to the clip in the door inside handle.
(2) Turn the inside lock knob to the door lock • Connect terminal "LOCK"
position. No.6 and the position.
(3) Install the outer cable end to the door inside positive battery
handle securely. terminal.
(4) Install the clip to the inner cable.
42-36 BODY
DOOR
Actuator Switch Check <Left side (LH drive REAR DOOR LOCK ACTUATOR CHECK
vehicles)>
Rear door
LEVER TESTER SPECIFIED <Left side>
At the "LOCK" 1−3 Less than 2 Lock
position ohms View A
At the 1−2 Less than 2
1 2 3
"UNLOCK" ohms 4 5 6
position
Unlock
Actuator Operation Check <Right side> Lever
A
LEVER BATTERY LEVER <Right side>
POSITION CONNECTION OPERATION
At the • Connect terminal The lever Lock
"LOCK" No.4 and the moves from View B
position negative battery the "LOCK"
terminal. position to the 1 2 3
• Connect terminal "UNLOCK" 4 5 6
No.6 and the position. Unlock

positive battery Lever
B
AC005658 AD
terminal.
At the • Connect terminal The lever Actuator Operation Check <Left side>
"UNLOCK" No.6 and the moves from LEVER BATTERY LEVER
position negative battery the "UNLOCK" POSITION CONNECTION OPERATION
• Connect terminal "LOCK" At the • Connect terminal The lever
No.4 and the position. "LOCK" No.3 and the moves from
positive battery position negative battery the "LOCK"
terminal. terminal. position to the
Actuator Switch Check <Right side (RH drive No.2 and the position.
vehicles)> positive battery
LEVER TESTER SPECIFIED terminal.
POSITION CONNECTION CONDITION At the • Connect terminal The lever
At the "LOCK" 1−3 Less than 2 "UNLOCK" No.2 and the moves from
position ohms position negative battery the "UNLOCK"
At the 2−3 Less than 2 terminal. position to the
"UNLOCK" ohms • Connect terminal "LOCK"
position No.3 and the position.
positive battery
terminal.
BODY 42-37
DOOR
Actuator Operation Check <Right side> <Right side (LH drive vehicles)>
LEVER BATTERY LEVER SWITCH TESTER SPECIFIED
POSITION CONNECTION OPERATION POSITION CONNECTION CONDITION
At the • Connect terminal The lever LOCK 1−2 Less than 2
"LOCK" No.2 and the moves from ohms
position negative battery the "LOCK" NEUTRAL 1 − 2, 2 − 3 Open circuit
terminal. position to the (OFF)
No.3 and the position. UNLOCK 2−3 Less than 2
positive battery ohms
terminal. <Left side (RH drive vehicles)>
At the • Connect terminal The lever SWITCH TESTER SPECIFIED
"UNLOCK" No.3 and the moves from POSITION CONNECTION CONDITION
position negative battery the "UNLOCK" LOCK 2−3 Less than 2
terminal. position to the ohms
• Connect terminal "LOCK"
No.2 and the position. NEUTRAL 1 − 2, 2 − 3 Open circuit
positive battery (OFF)
terminal. UNLOCK 1−2 Less than 2
ohms
DOOR LOCK KEY CYLINDER SWITCH
CHECK
1 2 3
AC101318
42-38 BODY
DOOR
WINDOW GLASS RUNCHANNEL AND

DOOR OPENING WEATHERSTRIP
M1423003100375
<Front door>
5 4
: Sectional view
6 of clip position
7 A
3
A
Section A – A
2
7
1
Door
Note Sealant: 3M ATD Part No. 8633

: The convex position of the door or equivalent
AC103084 AC
Waterproof film removal steps Door beltline inner weatherstrip

• Door trim assembly (Refer to GROUP removal steps
52A, Door Trim P.52A-21). • Door trim assembly (Refer to GROUP
1. Pull handle bracket 52A, Door Trim P.52A-21).
2. Waterproof film 5. Door beltline inner weatherstrip
Door inner opening weatherstrip Door window glass runchannel
removal steps removal steps
• Cowl side trim (Refer to GROUP 52A, • Door trim assembly (Refer to GROUP
Trims P.52A-18). 52A, Door Trim P.52A-21).
3. Door inner opening weatherstrip 1. Pull handle bracket
(body side) 2. Waterproof film
Door outer opening weatherstrip 5. Door beltline inner weatherstrip
removal steps >>B<< 6. Door window glass runchannel
• Front door check mounting bolt (body Door beltline moulding removal steps
side) (Refer to P.42-29). • Door mirror assembly (Refer to
<<A>> >>C<< 4. Door outer opening weatherstrip GROUP 51, Door Mirror P.51-57).
7. Door beltline moulding
BODY 42-39
DOOR
DOUBLE-SIDED TAPE POSITION

B
B
b
A A
Clip hole
Clip hole
Door outer opening

weatherstrip
Section A – A Section B – B
Door outer opening

weatherstrip
Door outer opening

weatherstrip
Adhesive tape: Double-sided tape

a: 7 mm width, 100 mm length and 0.8 mm thickness,
b: 7 mm width, 130 mm length and 0.8 mm thickness
AC103492 AD
42-40 BODY
DOOR
<Rear door>
5 : Sectional view
8N 4 of clip position
7 A
6 3
A
2 Section A – A
Door
1
2
Note Sealant: 3M ATD Part No. 8633

: The convex position of the door or equivalent
AC103491AC
Waterproof film removal steps Door beltline inner weatherstrip

• Door trim assembly (Refer to GROUP removal steps
52A, Door Trim P.52A-21). • Door trim assembly (Refer to GROUP
1. Pull handle bracket 52A, Door Trim P.52A-21).
2. Waterproof film 5. Door beltline inner weatherstrip
Door inner opening weatherstrip Door window glass runchannel
removal steps removal steps
• Rear seat (Refer to GROUP 52A, • Door trim assembly (Refer to GROUP
Trims P.52A-18). 52A, Door Trim P.52A-21).
• Scuff plate (Refer to GROUP 52A, 1. Pull handle bracket
Trims P.52A-18). 2. Waterproof film
3. Door inner opening weatherstrip 5. Door beltline inner weatherstrip
(body side) 6. Door window glass runchannel
Door outer opening weatherstrip Door beltline moulding removal
removal steps 7. Door beltline moulding
• Rear door check mounting bolt (body Door tape removal steps
side) (Refer to P.42-29). • Door trim assembly (Refer to GROUP
<<A>> >>C<< 4. Door outer opening weatherstrip 52A, Door Trim P.52A-21).
>>A<< 8. Door tape
BODY 42-41
DOOR
DOUBLE-SIDED TAPE POSITION
20 mm
Clip hole B
a 7 mm
c
b
B
Clip hole
A A
d
Clip hole
Door outer opening

weatherstrip C
C
Clip hole
Section A – A
Door outer opening Section B – B Section C – C
weatherstrip Door outer opening Door outer opening
weatherstrip weatherstrip
Adhesive tape: Double-sided tape

a, d: 7 mm width and 0.8 mm thickness,
b: 7 mm width, 110 mm length and 0.8 mm thickness,
c: 7 mm width, 62 mm length and 0.8 mm thickness
AC103128AD
REMOVAL SERVICE POINT Make a fabricated tool as shown in the illustration to

<<A>> DOOR OUTER OPENING WEATHERSTRIP remove the door weatherstrip.
REMOVAL
15 mm Fabricated
tool
4 mm
8 mm
Thickness:
1 mm
ACX00555AB
42-42 BODY
DOOR
INSTALLATION SERVICE POINTS >>B<< DOOR WINDOW GLASS RUNCHANNEL

>>A<< DOOR TAPE <REAR DOOR> <FRONT DOOR> INSTALLATION
INSTALLATION Section A – A
Door panel
Door tape
Runchannel
Door mirror Notch

claw position
A A Door mirror
Door mirror A
claw position
Section A – A
Adjust the end of the
Door panel door tape to the corner
end of the door panel. A
Runchannel
AC103753 AC
Assemble the run channel cut-out area with the

Door tape AC106848AB
thumb of the door mirror.
Apply the door tape in the location shown in the >>C<< DOOR OUTER OPENING WEATHERSTRIP
Figure of the instructions. INSTALLATION
The clip colour identifies the left and right
weatherstrips so be sure to see the colours so as to
install correctly.
APPLICABLE SIDE IDENTIFICATION
COLOUR
Left door Natural (White)
Right door Pink
BODY 42-43
TAILGATE
TAILGATE
M1421000300244
Item Standard value

Tailgate handle play mm 2.3 to 5.9
SEALANTS
M1424000500076

Tailgate waterproof film 3M ATD Part No.8633 or equivalent
Tailgate hinge 3M ATD Part No.8531 Heavy drip check sealer, 3M
ATD Part No.8646 Automotive joint and seam sealer
or equivalent
SPECIAL TOOL
M1424000600158

MB991223 Harness set Terminal voltage measurement
A
A: MB991219 A: Test harness A: For checking connector pin
B: MB991220 B: LED harness contact pressure
C: MB991221 C: LED harness B: For checking power supply
D: MB991222 adapter circuit
B D: Probe C: For checking power supply
circuit
D: For connecting a locally
sourced tester
C
D
MB991223 AD
TROUBLESHOOTING
M1424000700229
The tailgate system is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to GROUP
54B, Troubleshooting P.54B-15 or GROUP 54C,
42-44 BODY
TAILGATE
ON-VEHICLE SERVICE TAILGATE HANDLE PLAY CHECK

M1424002400116
TAILGATE FIT ADJUSTMENT Section A – A

M1424000900148 Holder
1. If the striker and latch mesh badly, replace the
striker and striker installation bolts with A
replacement parts (striker: MR523105, striker
installation bolt: MU000474).
Rod
A B
AC103270 AC
1. Check the tailgate handle play.

Standard value (B): 2.3 − 5.9 mm
2. If it deviates from the standard value, remove the
lower tailgate trim (Refer to GROUP 52A, tailgate
AC203659 trim P.52A-25) and waterproof film (Refer to
P.42-45).
2. Move the replaced striker forward and backward
3. Remove the holder from the tailgate handle and
or to the left and right to adjust, after bolt the
adjust according to the tailgate latch rod and
striker temporarily.
tailgate handle connection position.
3. After adjusting, tighten the bolts to the specified
torque [24 ± 4 N⋅m]. ADJUSTMENT OF TAILGATE HEIGHT
M1424003500075
NOTE:
A
Grind here
AC203660AB
When the bolt head interferes with the rear end Section A – A
trim, rasp the interference area with a round file.
17.4mm
Bumper
Body
AC103269 AC
AC201556 Turn the tailgate bumper using the arrow of the

tailgate bumper as a guideline to adjust the height of
4. If uneven clearance is present between tailgate the tailgate. The bumper height is altered by
and body, reposition the hinge to adjust the approximately 3mm by turning the tailgate bumper
clearance. one rotation.
BODY 42-45
TAILGATE
TAILGATE
M1424001100156
CAUTION
• Do not disassemble or throw the tailgate gas spring into fire.
• Punch a hole in the gas spring before disposal to release the gas inside.
• Ensure the tailgate gas spring piston rod does not come into contact with foreign material.
• Tailgate Spoiler Assembly Removal (Refer to GROUP 51, • Tailgate Fit Adjustment (Refer to P.42-44).
Tailgate Spoiler P.51-17). • Rear Wiper Motor Installation (Refer to GROUP 51, Rear
• Tailgate Trim Assembly Removal (Refer to GROUP 52A, Wiper and Washer P.51-30).
Tailgate Trim P.52A-25). • Tailgate Trim Assembly Installation (Refer to GROUP
• Rear Wiper Motor Removal (Refer to GROUP 51, Rear 52A, Tailgate Trim P.52A-25).
Wiper and Washer P.51-30). • Tailgate Spoiler Assembly Installation (Refer to GROUP
51, Tailgate Spoiler P.51-17).
3
4 Sealant: 3M ATD Part No. 8633 or equivalent
9.0 ± 2.0 N·m 7 12 ± 2 N·m
9.0 ± 2.0 N·m 8
2
7
12 ± 2 N·m
3
6
12 ± 2 N·m
AC102859 AC
42-46 BODY
TAILGATE
Tailgate assembly removal steps INSTALLATION SERVICE POINTS

1. Bumper >>A<< TAILGATE OPENING WEATHERSTRIP
2. Rear washer hose INSTALLATION
3. Waterproof film
4. Tailgate wiring harness Tailgate opening
<<A>> 5. Tailgate gas spring weatherstrip
6. Tailgate assembly
• Headlining (Refer to GROUP 52A,
Headlining P.52A-27).
>>B<< 7. Tailgate hinge Positioning
Tailgate opening weatherstrip removal mark
>>A<< 8. Tailgate opening weatherstrip

AC103272AD
<<A>> TAILGATE GAS SPRING REMOVAL
Assemble so the tailgate opening weatherstrip
marking is at the centre of the body.
>>B<< TAILGATE HINGE INSTALLATION

Bolt
Tailgate hinge
Pin
AC103607AD
As shown in the Figure, slide the pin upward, then

remove the tailgate gas spring in the direction of the
arrow to unscrew the bolt. AC104148 AC
Apply the specified sealing agent to the tailgate

hinge assembly surface to assembly the tailgate
hinge.
Specified Adhesive: 3M ATD Part No.8531
Heavy drip check sealer, 3M ATD Part
No.8646 Automotive joint and seam sealer or
equivalent
BODY 42-47
TAILGATE
TAILGATE HANDLE AND LATCH

M1424001700147
Pre-removal Operation
• Tailgate Handle Play Check (Refer to P.42-44).
4
3
4
5.0 ± 1.0 N·m
2
5.0 ± 1.0 N·m

7
6
5
9.0 ± 2.0 N·m
22 ± 4 N·m
6
1
AC102861AC
Striker removal steps Tailgate latch removal steps

• Rear end trim (Refer to GROUP 52A, • Lower tailgate trim (Refer to GROUP
Trims P.52A-18). 52A, Tailgate Trim P.52A-25).
>>A<< 1. Striker • Waterproof film (Refer to P.42-45).
Tailgate handle and lock key cylinder 5. Bolt (earth)
removal steps 6. Tailgate latch assembly
• Lower tailgate trim (Refer to GROUP Tailgate lock actuator removal steps
52A, Tailgate Trim P.52A-25). • Lower tailgate trim (Refer to GROUP
• Waterproof film (Refer to P.42-45). 52A, Tailgate Trim P.52A-25).
2. Tailgate Lock Actuator Connection • Waterproof film (Refer to P.42-45).
3. Tailgate lock key cylinder 7. Tailgate lock actuator
4. Tailgate handle
42-48 BODY
TAILGATE
INSTALLATION SERVICE POINT LEVER BATTERY LEVER

>>A<< STRIKER INSTALLATION POSITION CONNECTION OPERATION
Latch center At the • Connect terminal The lever
Striker center "LOCK" No.2 and the moves from the
position negative battery "LOCK"
+1.5 mm terminal. position to the
No.3 and the position.
-1.5 mm positive battery
terminal.
Striker At the • Connect terminal The lever
Latch
AC006126AB "UNLOCK" No.3 and the moves from the
Assemble so the distance between the centre of the position negative battery "UNLOCK"
striker and centre of the latch is ±1.5mm or less. terminal. position to the
• Connect terminal "LOCK"
INSPECTION No.2 and the position.
M1424001200120
positive battery
TAILGATE LOCK ACTUATOR CHECK terminal.
TAILGATE LATCH CHECK <Vehicles for

Lever keyless entry system>
A Lock
Lever
View A Unlock 1
Lock
AC103292 AC Unlock
2
AC103291AD
LEVER TESTER SPECIFIED

At the "LOCK" 1 − 2 (Earth) Open circuit
position
At the Less than 2
"UNLOCK" ohms
position
BODY 42-49
KEYLESS ENTRY SYSTEM

SPECIAL TOOLS
M1428000600406

MB991502 MUT-II sub-assembly Encrypted code registration
B991502
MB991529 Diagnosis code check

harness
MB991529
MB991955 MUT-III sub-assembly Encrypted code registration

A A: MB991824 A: Vehicle CAUTION
B: MB991827 communication MUT-III main harness B
C: MB991910 interface (V.C.I.) (MB991911) should be used.
D: MB991911 B: MUT-III USB cable MUT-III main harness A should
MB991824
E: MB991825 C: MUT-III main not be used for this vehicle.
B F: MB991826 harness A
(applicable to
vehicles with CAN
communication)
MB991827 D: MUT-III main
harness B
C
(applicable to
DO NOT USED vehicles without
CAN
MB991910
communication)
E: MUT-III
D measurement
adapter
F: Trigger harness
MB991911
MB991825
MB991826
MB991955
42-50 BODY
TROUBLESHOOTING KEYLESS ENTRY SYSTEM TIMER LOCK

M1428000700351
The keyless entry system is controlled by the Smart FUNCTION INSPECTION
M1428004000172
Wiring System (SWS). For troubleshooting, refer to Push the transmitter unlock button and check to see
GROUP 54B, Troubleshooting P.54B-15 or GROUP that the doors and tailgate lock within 30 seconds. If
54C, Troubleshooting P.54C-4. it doesn't, then execute troubleshooting remedies.
Refer to GROUP 54B, Troubleshooting P.54B-15,
ON-VEHICLE SERVICE refer to GROUP 54C, Troubleshooting P.54C-4.
KEYLESS ENTRY SYSTEM CHECK HOW TO REPLACE THE TRANSMITTER

M1428001400126
Check the system as described below. If the system BATTERY
M1428000900236
does not work, carry out troubleshooting. Refer to
GROUP 54B, Troubleshooting P.54B-15, refer to CAUTION
GROUP 54C, Troubleshooting P.54C-4. Do not allow water or dust to enter the inside of
• Operate the transmitter to check that the doors the transmitter when it is open. Also, do not
and tailgate can be locked and unlocked. touch the precision electronic device.
• Operate the transmitter to check that the Battery
answerback function works in response to door
and tailgate locking/unlocking.
NOTE: .
• The adjustment function allows you to change
the answerback setting as follows. Prior to
that check, confirm which setting is activated. Claw
• The hazard warning lamps flash twice
when locked and once when unlocked.
Screw AC000509AB
The room lamp flashes twice when locked
and illuminates for 15 seconds when
1. Remove the set screw to remove the battery from
unlocked.
the transmitter.
• The hazard warning lamps do not flash
when locked and flash once when 2. Install a battery with its (+) side face-down.
unlocked. The room lamp flashes twice Battery required for replacement: Coin type
when locked and illuminates for 15 battery CR2032
seconds when unlocked. 3. Insert the claw first, and assemble the transmitter.
• The hazard warning lamps flash twice
4. Verify that the keyless entry system operates.
when locked and do not flash when
unlocked. The room lamp flashes twice
when locked and illuminates for 15
seconds when unlocked.
• The hazard warning lamps do not flash
when both locked and unlocked. The room
lamp flashes twice when locked and
illuminates for 15 seconds when unlocked.
BODY 42-51
ENABLING/DISABLING THE (4) Close the driver's side door.

ANSWERBACK FUNCTION (5) Keep the windshield washer switch on for at
M1428003200322 least ten seconds. Then the ETACS-ECU
If the keyless entry system locks or unlocks the buzzer will sound once.
doors, the room lamp flashes or illuminates, the 2. If the transmitter ìLOCKî button is pushed
hazard warning lamp flashes (hazard answerback consecutively twice (within two seconds), the
function). The hazard answerback function can be ETACS-ECU buzzer will sound, indicating that the
enabled or disabled according to the following hazard answerback function can be enabled or
procedure: disabled when the doors are locked.
• Enable the hazard answerback function
ENABLING/DISABLING THE HAZARD when the doors are locked: The
ANSWERBACK FUNCTION ETACS-ECU buzzer will sound once.
The hazard answerback function can be enabled or • Disable the hazard answerback function
disabled by one of the two following procedures. when the doors are locked: The
<When using the transmitter after diagnosis ETACS-ECU buzzer will sound twice.
connector (1) is earthed> 3. If the transmitter ìUNLOCKî button is pushed
1. Enter the hazard answerback customize mode by consecutively twice (within two seconds), the
performing one of the following steps. If the ETACS-ECU buzzer will sound, indicating that the
ETACS-ECU enters the customize mode, its hazard answerback function can be enabled or
buzzer will sound once. disabled when the doors are unlocked.
(1) Turn the ignition switch to ìLOCKî(OFF) • Enable the hazard answerback function
position. when the doors are unlocked: The
(2) Turn off the hazard warning lamp switch. ETACS-ECU buzzer will sound once.
CAUTION • Disable the hazard answerback function
Before connecting or disconnecting the earth, when the doors are unlocked: The
turn the ignition switch to the "LOCK" (OFF) ETACS-ECU buzzer will sound twice.
position. 4. Exit the hazard answerback customize mode by
Diagnosis observing one of the following steps.
connector (1) Disconnect diagnosis connector terminal (1)
form the earth.
(2) Turn the ignition switch to position other then
ìLOCKî(OFF), or remove the ignition key.
(3) Open the driver's side door,
(4) Any other warning buzzer output occurs.
MB991529
1 2 3 4 5 6 7 8 NOTE: If any operation is not done for at least three
9 10 11 12 13 14 15 16 minutes after the ETACS-ECU has entered the
AC107528 AC
customize mode, the hazard answerback customize
(3) Connect the diagnosis connector to the mode will be canceled automatically.
special tool diagnosis code check harness
MB991529.
42-52 BODY
<When the transmitter is used after connecting 2. If the transmitter ìLOCKî button is pushed
MUT-II to the diagnosis connector> consecutively twice (within two seconds), the
1. Enter the hazard answerback customize mode by ETACS-ECU buzzer will sound, indicating that the
performing one of the following steps. If the hazard answerback function can be enabled or
ETACS-ECU enters the customize mode, its disabled when the doors are locked.
buzzer will sound once. • Enable the hazard answerback function
(1) Turn the ignition switch to ìLOCKî(OFF) when the doors are locked: The
position. ETACS-ECU buzzer will sound once.
(2) Turn off the hazard warning lamp switch. • Disable the hazard answerback function
CAUTION when the doors are locked: The
Before connecting or disconnecting the MUT-II, ETACS-ECU buzzer will sound twice.
turn the ignition switch to the "LOCK" (OFF) 3. If the transmitter ìUNLOCKî button is pushed
position. consecutively twice (within two seconds), the
ETACS-ECU buzzer will sound, indicating that the
hazard answerback function can be enabled or
disabled when the doors are unlocked.
when the doors are unlocked: The
ETACS-ECU buzzer will sound once.
• Disable the hazard answerback function
16 Pin MB991502 ETACS-ECU buzzer will sound twice.
AC107200AC 4. Exit the hazard answerback customize mode by
observing one of the following steps.
connector. (1) Disconnect MUT-II from the diagnosis
connector.
(4) Close the driver's side door.
(5) Keep the windshield washer switch on for at
least ten seconds. Then the ETACS-ECU
buzzer will sound once. (3) Open the driver's side door,
NOTE: If any operation is not done for at least three
minutes after the ETACS-ECU has entered the
customize mode, the hazard answerback customize
mode will be canceled automatically.
BODY 42-53
<When the transmitter is used after connecting (5) Close the driver's side door.
special tool V. C. I. MB991824 to the diagnosis (6) Keep the windshield washer switch on for at
connector> least ten seconds. Then the ETACS-ECU
1. Enter the hazard answerback customize mode by buzzer will sound once.
performing one of the following steps. If the 2. If the transmitter ìLOCKî button is pushed
ETACS-ECU enters the customize mode, its consecutively twice (within two seconds), the
buzzer will sound once. ETACS-ECU buzzer will sound, indicating that the
(1) Turn the ignition switch to ìLOCKî(OFF) hazard answerback function can be enabled or
position. disabled when the doors are locked.
(2) Turn off the hazard warning lamp switch. • Enable the hazard answerback function
CAUTION when the doors are locked: The
Before connecting or disconnecting the V. C. I., ETACS-ECU buzzer will sound once.
turn the ignition switch to the "LOCK" (OFF) • Disable the hazard answerback function
position. when the doors are locked: The
ETACS-ECU buzzer will sound twice.
3. If the transmitter ìUNLOCKî button is pushed
consecutively twice (within two seconds), the
ETACS-ECU buzzer will sound, indicating that the
hazard answerback function can be enabled or
disabled when the doors are unlocked.
ETACS-ECU buzzer will sound once.
• Disable the hazard answerback function
16-Pin
ETACS-ECU buzzer will sound twice.
4. Exit the hazard answerback customize mode by
MB991911 observing one of the following steps.
(1) Disconnect V. C. I. from the diagnosis
connector.
MB991824
AC305321AC (3) Open the driver's side door.
(3) Connect the V. C. I. to the diagnosis
connector. NOTE: If any operation is not done for at least three
(4) Turn the V.C.I. power switch to the "ON" minutes after the ETACS-ECU has entered the
position. customize mode, the hazard answerback customize
mode will be canceled automatically.
42-54 BODY
HOW TO REGISTER SECRET CODE

M1428001000418
Ground connected
Each individual secret code is registered inside the
transmitter, and so it is necessary to resister these
codes with the EEPROM inside the receiver in the Within 10 seconds
following cases.
• When the transmitter or ETACS-ECU is replaced
1 2 3 4 5 6
• If more transmitters are to be used Hazard ON
• If it appears that a problem is occurring because warning
switch OFF
of faulty registration of a code.
ACX00571 AG
A maximum of four different codes can be stored in
the EEPROM memory (four different transmitters can 4. Press the hazard warning lamp switch six times
be used). When the code for the first transmitter is within 10 seconds.
registered, the previously registered codes for all
NOTE: Once the process is completed six times,
transmitters are cleared. Therefore, if you are using
then it will operate with all doors and tailgate lock
four transmitters or are adding more transmitters, the
and unlock operations once and then go to the
codes for all transmitters must be registered at the
save mode.
same time.
NOTE: The hazard warning lamp switch is turned
When special tool diagnosis code check on and off alternately whenever it is pushed.
harness MB991529 is used 5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will
1. Check that the doors lock normally when the key register the code.
is used.
6. Once the program is saved, it will operate once
2. Insert the ignition key. with the all doors and tailgate lock and unlock
CAUTION operations.
Before connecting or disconnecting the earth, 7. If you are using two or more transmitters or have
turn the ignition switch to the "LOCK" (OFF) added a second transmitter, the same registration
position. procedure should be carried out within one minute
Diagnosis after registering the code for the first transmitter.
connector 8. Registration mode will be canceled under the
following conditions:
• When the secret code for four transmitters has
been registered;
• When one minute has passed after registration
mode started;
MB991529 • When the diagnosis connector is disconnected
1 2 3 4 5 6 7 8
from earth
9 10 11 12 13 14 15 16
AC107528 AC • When the key is removed from the key cylinder;
9. After the registration is completed, remove the
3. Connect the diagnosis connector to the special
ignition key and close all the doors, and then
tool diagnosis code check harness MB991529.
check that the keyless entry system operates
NOTE: This will connect terminal (1) of the normally.
diagnosis connector to earth, and the system will
be in secret code registration standby mode.
BODY 42-55
When the MUT-II is used 7. If you are using two or more transmitters or have
1. Check that the doors lock normally when the key added a second transmitter, the same registration
is used. procedure should be carried out within one minute
2. Insert the ignition key. after registering the code for the first transmitter.
8. Registration mode will be canceled under the
CAUTION following conditions:
Before connecting or disconnecting the MUT-II, • When the secret code for four transmitters has
turn the ignition switch to the "LOCK" (OFF) been registered;
position. • When one minute has passed after registration
mode started;
• When the MUT-II is disconnected from the
diagnosis connector
• When the key is removed from the key cylinder;
9. After the registration is completed, remove the
ignition key and close all the doors, and then
check that the keyless entry system operates
normally.
16 Pin MB991502
AC107200AC When the special tool V. C. I. MB991824 is
used
1. Check that the doors lock normally when the key
is used.
MUT-II connected
2. Insert the ignition key.
CAUTION
Within 10 seconds
Before connecting or disconnecting the V. C. I.,
turn the ignition switch to the "LOCK" (OFF)
1 2 3 4 5 6 position.
Hazard ON
warning
switch OFF
ACX00571 AB
4. Press the hazard warning switch six times within

10 seconds.
NOTE: Once the process is completed six times,
then it will operate with all doors and tailgate lock
and unlock operations once and then go to the
save mode.
NOTE: The hazard warning lamp switch is turned 16-Pin
on and off alternately whenever it is pushed.
5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will MB991911
register the code.
6. Once the program is saved, it will operate once
with the all doors and tailgate lock and unlock
operations.
MB991824
AC305321AC
3. Connect the V. C. I. to the diagnosis connector.

42-56 BODY
Connect V. C. I. and turn 6. Once the program is saved, it will operate once
the V. C. I. power supply with the all doors and tailgate lock and unlock
switch ON.
operations.
7. If you are using two or more transmitters or have
Within 10 seconds
added a second transmitter, the same registration
procedure should be carried out within one minute
1 2 3 4 5 6 after registering the code for the first transmitter.
Hazard ON
warning 8. Registration mode will be canceled under the
switch OFF following conditions:
ACX00571 AJ • When the secret code for four transmitters has
been registered;
4. Within 10 seconds after turning the V.C.I. power • When one minute has passed after registration
switch to the "ON" position, press the hazard
mode started;
switch six times. • When the V. C. I. is disconnected from the
NOTE: Once the process is completed six times, diagnosis connector;
then it will operate with all doors and tailgate lock • When the key is removed from the key cylinder;
and unlock operations once and then go to the 9. After the registration is completed, remove the
save mode. ignition key and close all the doors, and then
NOTE: The hazard warning lamp switch is turned check that the keyless entry system operates
on and off alternately whenever it is pushed. normally.
5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will
register the code.
BODY 42-57
SUNROOF ASSEMBLY
SUNROOF ASSEMBLY
M1421000300255
Item Standard value

Roof lid glass operation current A (at 20 °C) 7 or less
TROUBLESHOOTING
CHECK CHART FOR TROUBLE
SYMPTOMS
M1426002000114
Symptom Inspection Reference

procedure page
number
Sunroof does not work at all. 1 P.42-58
Any of the sunroof switch positions is defective. 2 P.42-66
Sunroof anti-trap function does not work normally. 3 P.42-70
42-58 BODY
SUNROOF ASSEMBLY
INSPECTION PROCEDURE 1: The sunroof does not work at all.
CAUTION
Whenever the ECU is replaced, ensure that the
input and output signal circuits are normal.
Sunroof-ECU Power Supply Circuit <L.H. drive vehicles>
FUSIBLE IGNITION
LINK 5 SWITCH (IG2)
SUNROOF
MOTOR ASSEMBLY
CONTROL CIRCUIT
SUNROOF
SWITCH
Wire colour code

AC309237AB
BODY 42-59
SUNROOF ASSEMBLY
Sunroof-ECU Power Supply Circuit <R.H. drive vehicles>
FUSIBLE IGNITION
LINK 5 SWITCH (IG2)
SUNROOF
MOTOR ASSEMBLY
CONTROL CIRCUIT
SUNROOF
SWITCH
Wire colour code

AC309238AB
COMMENTS ON TROUBLE SYMPTOM Possible causes

If the sunroof does not work at all, these power • Malfunction of the sunroof switch
supply circuit(s), these earth circuit(s), sunroof switch • Malfunction of the sunroof motor assembly
or the sunroof motor assembly (sunroof-ECU) may (sunroof-ECU)
be defective. • Damaged harness wires and connectors
42-60 BODY
SUNROOF ASSEMBLY
Diagnostic procedure STEP 3. Measure the resistance at the D-06

sunroof switch connector.
STEP 1. Connector check: D-06 sunroof switch Connector: D-06 D-06(B)
connector <L.H. drive vehicles>
Connector: D-06 D-06(B)

<L.H. drive vehicles> Harness side
6 5 4 3 2 1
Harness side
6 5 4 3 2 1
AC301408 AJ
Connector: D-06 <R.H. drive vehicles>

AC301408 AJ
D-06(B)
Connector: D-06 <R.H. drive vehicles>
Harness side
D-06(B) 6 5 4 3 2 1
Harness side
6 5 4 3 2 1
AC309220AB
(1) Disconnect the connector, and measure at the

AC309220AB wiring harness side.
YES : Go to Step 2.
NO : Repair the connector.
STEP 2. Check the sunroof switch. 6 5 4 3 2 1

Refer to sunroof switch continuity check P.42-74.
YES : Go to Step 3. Connector D-06
(Harness side)
NO : Replace the sunroof switch. AC301721AB
(2) Continuity between D-06 sunroof switch

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*5283,1'(;

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HOW TO USE THIS MANUAL. . . . . . 00-2 SUPPLEMENTAL RESTRAINT

GENERAL DATA AND STANDARD PART/TIGHTENING-

PRECAUTIONS BEFORE SERVICE. 00-22

HOW TO USE THIS MANUAL

Symbols are used to show the locations for lubrication

For bolts and nuts which do

parts sets are

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Check trouble symptom.

Read the diagnosis code. Read the diagnosis code.

After taking note of the

Read the diagnosis codes.

2. SYSTEM OPERATION AND SYMPTOM 4. DIAGNOSIS CODE CHART

6. TROUBLE SYMPTOM CHART <Using the MUT-III>

8. SERVICE DATA REFERENCE TABLE

10. INSPECTION PROCEDURE BY USING AN

AC300830 AC Steering shaft

<Using the MUT-III>

<Using the MUT-III>

MB991827 AC308915 AC MB991824

Steering shaft HOW TO USE THE INSPECTION

Relevant circuit(s) of the component which

Start of diagnosis Describes

HARNESS CHECK IF INSPECTING WITH THE CONNECTOR

MEASURES TO TAKE AFTER REPLACING THE

<When Inspecting a Male Pin>

Check by inserting the multi-meter test probe from

IF INSPECTING WITH THE CONNECTOR

At this time, be careful not to short the connector

CONNECTOR INSPECTION SERVICE • Low connection pressure due to rusted terminals

CONNECTOR ENGAGEMENT INSPECTION

Harness wire breakage

Use the special tool inspection harness (MB991219)

MODEL CODE No. Item Content

CHASSIS NUMBER The chassis number is stamped on the toeboard

No. Item Content

1 Fixed figure J Asia

Front of the vehicle

GENERAL DATA AND SPECIFICATIONS

PRECAUTIONS BEFORE SERVICE

INITIALIZATION PROCEDURE FOR LEARNING PROCEDURE FOR IDLING IN

SERVICING ELECTRICAL SYSTEM PRE-INSPECTION CONDITION

APPLICATION OF ANTI-CORROSION If high-pressure car-washing equipment or steam

MUT-III USB cable

MUT-III main harness A

MUT-III main harness B

MUT-III measurement adapter

MUT-III trigger harness

CAUTION ENGINE OILS

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS warning lamp

Seat belt with pre-tensioner

Driver's air bag

Side air bag module

Side impact sensor

Side air bag module

287/$1'(5 *HQHUDO