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345 Mitsubishi 380 Workshop Service Manual 2005 2008 (Chassis DB)
345 Mitsubishi 380 Workshop Service Manual 2005 2008 (Chassis DB)
General . . . . . . . . . . . . . . . . . . . . . . . 00
380
Engine . . . . . . . . . . . . . . . . . . . . . . . . 11
WORKSHOP MANUAL
Engine Lubrication . . . . . . . . . . . . . . 12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Cooling . . . . . . . . . . . . . . . . . 14
Engine Electrical. . . . . . . . . . . . . . . . 16
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . 21
Manual Transmission . . . . . . . . . . . . 22
FOREWORD
This service manual is subdivided into various group
Automatic Transmission . . . . . . . . . 23
categories. Each section contains diagnostic,
disassembly, repair, and installation procedures, Front Axle . . . . . . . . . . . . . . . . . . . . . 26
along with complete specifications and tightening
references. Use of this manual will aid in properly Rear Axle . . . . . . . . . . . . . . . . . . . . . . 27
performing any service necessary to maintain or
restore the high levels of performance and reliability Wheel and Tyre . . . . . . . . . . . . . . . . . 31
designed into this Mitsubishi vehicle.
When reference is made in this manual to a brand Power Plant Mount . . . . . . . . . . . . . . 32
name, number, or specific tool, an equivalent product
may be used in place of the recommended item. All Front Suspension . . . . . . . . . . . . . . . 33
information, illustrations and specifications contained
in this manual are based on the latest product Rear Suspension . . . . . . . . . . . . . . . 34
information available at the time of publication
approval. The right is reserved to make changes at Service Brakes . . . . . . . . . . . . . . . . . 35
any time without notice.
Parking Brakes . . . . . . . . . . . . . . . . . 36
COPYRIGHT 2005
Steering . . . . . . . . . . . . . . . . . . . . . . . 37
SERVICE DIVISION Body. . . . . . . . . . . . . . . . . . . . . . . . . . 42
TONSLEY PARK
SOUTH AUSTRALIA Exterior . . . . . . . . . . . . . . . . . . . . . . . 51
Chassis Electrical . . . . . . . . . . . . . . . 54
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
GROUP 00E
GENERAL
<ELECTRICAL>
CONTENTS
AC000014 AB
CAUTION
Forcing the test probe into the terminal may open the ter-
minal, causing intermittent or poor contact and creating an
open circuit.
2. If the connector is disconnected for checking and the facing
part is the female pin side, use an appropriate male terminal
for checking the contact pressure of connector pins (like
MB991219 MB991219).
CAUTION
Do not simultaneously contact more than one terminal
AC000015 AB with the test probe. Contacting two or more terminals at
the same time may damage a circuit, possibly to the point
of starting an electrical fire.
3. If the facing part is the male pin side, either carefully touch
the test probe to the pin so it does not accidently contact
other pins, or use an appropriate female terminal.
HOW TO DIAGNOSE
HOW TO DIAGNOSE
M1001004300086
The most important point in troubleshooting is to
determine "Probable Cause." Once the probable
causes are determined, parts to be checked can be
limited to those associated with such probable
causes. The determination of the probable causes
must be based on a theory and be supported by facts
and must not be based on intuition only.
GENERAL <ELECTRICAL> 00E-3
HOW TO DIAGNOSE
TROUBLESHOOTING STEPS
M1001004400049
If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symp-
toms could become more complicated, resulting in failure to determine the causes correctly and making
incorrect repairs. The four steps below should be followed in troubleshooting.
INSPECTION
M1001004600139
1. Sight and sound checks
Check relay operation, blower motor rotation, light
CLICK illumination, etc. Listen for a "click" when some relay covers
are pushed down.
ACX00936 AB
2. Simple checks
For example, if a headlight does not come on and a faulty
fuse or poor grounding is suspected, replace the fuse with a
new one. Or use a jumper wire to ground the light to the
body. Determine which part(s) is/are responsible for the
problem.
ACX00937
INSPECTION INSTRUMENTS
M1001004700040
For inspection, use the following instruments:
CAUTION
Never use a test light for checking ECU-related circuits or
ECUs.
1. Test light
A test light consists of a 12V bulb and lead wires. It is used
to check voltages or short circuits.
ACX00939
ACX00940
CAUTION
Never use a jumper wire to connect a power supply
directly to a load.
3. Jumper wire
A jumper wire is used to close an open circuit.
ACX00941
4. Voltmeter
POWER LINE A voltmeter is used to measure the circuit voltage. Normally,
the positive (red lead) test probe is applied to the point of
BLACK LEAD WIRE voltage measurement and the negative (black lead) test
probe to the body ground. Use a digital voltmeter to check
for voltage drop before or after a component.
RED LEAD WIRE
GROUND
ACX00942 AB
GENERAL <ELECTRICAL> 00E-6
HOW TO DIAGNOSE
5. Ohmmeter
An ohmmeter is used to check continuity or measure
resistance of a switch or coil. If the measuring range has
been changed, the zero point must be adjusted before
measurement.
ACX00943
CHECKING FUSES
M1001005000044
A blade type fuse has test taps provided to allow checking of
the fuse itself without removing it from the fuse block. The fuse
FUSE BLOCK is okay if the test light comes on when its one lead is connected
to the test taps (one at a time) and the other lead is grounded.
Remember to turn the ignition switch to ON to ensure all cir-
cuits are live.
TEST TAPS
ACX00951AB
ACX00953 AB
GENERAL <ELECTRICAL> 00E-7
HOW TO DIAGNOSE
CHECKING SWITCHES
M1001004800144
In a circuit diagram, a switch is shown in the idle state.
1. Normally open or normally closed switch
NORMALLY OPEN (NO) TYPE
Switches are classified into those which open the circuit and
OFF ON those which close the circuit when off.
Switches are shown in their normal state unless specified
otherwise.
2. Switch connection
6 This figure illustrates a complex switch. The continuity
between terminals at each position is as indicated in the
table below.
SWITCH TESTER SPECIFIED
POSITION CONNECTION CONNECTION
OFF 1ST 2ND 3RD 4TH STAGE
OFF − −
1st stage 1−5−6 Continuity
5 4 3 2 1
2nd stage 1−4−6 Continuity
3rd stage 1−3−6 Continuity
4th stage 1−2−6 Continuity
ACX00945 AB
GENERAL <ELECTRICAL> 00E-8
HOW TO DIAGNOSE
CHECKING RELAYS
M1001004900152
POWER SUPPLY 1. By using a relay, a heavy current can be turned on and off by
a switch using much less current. For example, in the circuit
shown here, when the switch is turned on (closed), current
RELAY flows to the coil of the relay. Then, its contact is turned on
ON
(closed) and the light comes on. The current flowing through
OFF
the switch is much less than that for the light.
FUSE
SWITCH
LIGHT ON
OFF
ACX00948 AB
NORMALLY OPEN (NO) TYPE 2. When current flows through the coil of a relay, its core is
ENERGIZED STATE magnetized to attract the iron piece, closing (ON) the
COVER contact at the tip of the iron piece. When the coil current is
SPRING
turned off, the iron piece returns to its original position by a
COIL spring, opening the contact (OFF).
IRON
CORE
IRON
PIECE
CONTACT
AC308621 AB
NORMALLY OPEN (NO) TYPE 3. Relays may be classified as the normally open-type or the
DEENERGIZED STATE ENERGIZED STATE normally closed-type, depending on their contact
construction.
3 1 3 1 NOTE: The deenergised state means that no current is flow-
ing through the coil. The energised state means that current
is flowing through the coil.
(1) The normally open-type
4 2 4 2
CURRENT DOES CURRENT FLOWS When a normally open relay as illustrated here is
NOT FLOW checked, there should be no continuity between terminals
AC310636AB 3 and 4 when the relay is deenergised. There should be
continuity between terminals 3 and 4 when battery
NORMALLY CLOSED (NC) TYPE
voltage and ground are applied to terminals 1 and 2. The
DEENERGIZED STATE ENERGIZED STATE
relay condition is determined by this check.
NOTE: Check the relay in both situation which is
3 1 3 1
energised and is not energised.
(2) The normally closed-type
When a normally closed relay as illustrated here is
4 2 4 2 checked, there should be continuity between terminals 3
CURRENT FLOWS CURRENT DOES
NOT FLOW and 4 when the relay is deenergised. There should be no
AC310637 AB continuity between terminals 3 and 4 when battery
voltage and ground are applied to terminals 1 and 2. The
relay condition is determined by this check.
NOTE: Check the relay in both situation which is
energised and is not energised.
GENERAL <ELECTRICAL> 00E-9
HOW TO DIAGNOSE
BATTERY HANDLING
M1001005200048
WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
When checking or servicing does not require power from the
vehicle battery, be sure to disconnect the cable from the battery
(−) terminal. This will prevent problems that could be caused by
a short circuit. Disconnect the (−) battery terminal first and
reconnect it last.
AC000017
1. VOLTAGE CHECK
POWER SUPPLY (1) Ground one lead wire of the test light. If a voltmeter is
used instead of the test light, ground the grounding side
lead wire.
FUSE
(2) Connect the other lead wire of the test light to the power
side terminal of the switch connector. The test light
ON (2) should come on or the voltmeter should indicate a
voltage.
SWITCH
(3) Then, connect the test light or voltmeter to the motor
connector. The test light should not come on, or the
voltmeter should indicate no voltage. When the switch is
turned ON in this state, the test light should come on, or
OFF the voltmeter should indicate a voltage, with the motor
(3)
starting to run.
MOTOR (4) The circuit illustrated here is normal. If there is any
problem, such as the motor failing to run, check voltages
TEST LIGHT beginning at the connector nearest to the motor until the
(OR faulty part is identified.
(1) VOLTMETER)
2. SHORT-CIRCUIT CHECK
Because the fuse has blown, it is probable that there is a
ACX00956AB
short circuit. Follow the procedures below to narrow down
the short-circuit location.
STEP 1. Remove the blown fuse and connect the test light
across the fuse terminals (Circuit switch: OFF).
Q: Does the test light illuminate?
YES : Short-circuit exists between the fuse block and the
POWER SUPPLY
switch. Diagnose the harness between the fuse block
and the switch.
FUSE BLOCK
(REMOVE NO : Go to Step 2.
THE FUSE)
SHORT-CIRCUIT
TEST
LOCATION
LIGHT
SWITCH
OFF
ILLUMINATION
LIGHT
ACX00957 AB
GENERAL <ELECTRICAL> 00E-11
HOW TO DIAGNOSE
ON
SHORT-CIRCUIT
LOCATION
DISCONNECT
THE LOAD
ILLUMINATION
LIGHT
ACX00958 AB
POWER SUPPLY
FUSE BLOCK
(REMOVE
THE FUSE)
TEST
LIGHT
SWITCH
ON
DISCONNECT
THE LOAD
SHORT-CIRCUIT
LOCATION
ILLUMINATION
LIGHT
ACX00959 AB
GENERAL <ELECTRICAL> 00E-12
HOW TO DIAGNOSE
3. CONTINUITY CHECK
(1) When the switch is in the "OFF" position and the contact
SELF-POWERED TEST 1 4 points of terminals 1 and 2 are connected, the
LIGHT (OR OHMMETER) self-powered test light should illuminate or the ohmmeter
ON should read 0 ohm.
ON (2) When the switch is the "ON" position and the contact
OFF OFF
points of terminals 3 and 4 are connected, the
2 3 self-powered test light should come on or the ohmmeter
should read 0 ohm.
ACX00960 AB
HOME
00-1
GROUP 00
GENERAL
CONTENTS
Indicates the
section title.
Denotes tightening torque.
If there is no indication of
tightening torque, refer to
tightening torque. Indicates the Indicates the
group title. group number.
Component diagram
A diagram of the component parts is pro-
vided near the front of each section in order
to give the reader a better understanding of
the installed condition of component parts.
AC400266 AB
GENERAL 00-5
HOW TO USE THIS MANUAL
Operating procedures,
cautions, etc. on removal,
installation, disassembly and
assembly are described
AC400267AB
GENERAL 00-6
TROUBLESHOOTING GUIDELINES
TROUBLESHOOTING GUIDELINES
M1001008800340
CAUTION
If DTC P0202 has been set, TCL related DTC
U1120 is also set. After P0202 has been diag-
AIR
nosed, don't forget to erase DTC U1120. CLEANER
CONNECTOR: B-30
COVER
ENGINE
CONTROL
UNIT
B-30 (GR)
AK303102AB
16DB400A
CONNECTOR: B-17X
(2) For connector color, refer to GROUP 80A,
How to read configuration diagrams.
MFI RELAY
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3
00DB075A
GENERAL 00-10
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
(5)
(5) Explains
Explains about
abouttechnical
technicaldetails.
details. (6)
(6)Describes
Describesthe
theconditions
conditionsfor
forthat
thatDTC
DTC
being
beingset
set(stored).
(stored).
ECU (7)
(7)Describes
Describespossible
possible
cause(s)for
cause(s)forthat
thatDTC.
DTC.
(8)
(8)Start
Startofofthe
thediagnosis
diagnosisprocedure
procedure
ECU
for that DTC.
for that DTC.
A/T 7
DATA LINK
CONNECTOR
MB991910 7
MB991824
MPI 5
MB991827 00DB076A
(10)
(10) Provides
Providesthetheinspection
inspectionprocedure
procedure
for
for that
that DTC
DTCstep
stepby
bystep.
step.
AC210616 AB
00DB077A
ACX00863AE
CONNECTOR
AC001606AB
GENERAL 00-12
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
MB991219
ACX00865 AB
ACX00867 AB
GENERAL 00-13
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
VISUAL INSPECTION
• Connector is disconnected or improperly connected
CONNECTOR DISCONNECTED OR
IMPROPERLY CONNECTED
• Connector pins are pulled out
• Stretched an broken wires at terminal section
• Low contact pressure between male and female terminals
• Low connection pressure due to rusted terminals or foreign
matter lodged in terminals
ACX00868AC
ACX00869AB
.
GENERAL 00-14
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
ACX00870 AB
SIMULATION TESTS
NOTE: In case of difficulty in finding the cause of the intermit-
tent malfunction, the data recorder function in the
DIAGNOSTIC TOOL (MUT-III) is effective.
For these simulation tests, shake, then gently bend, pull, and
twist the wiring of each of these examples to duplicate the inter-
mittent malfunction.
• Shake the connector up-and-down, and right-and-left.
• Shake the wiring harness up-and-down, and right-and-left.
Especially, check the splice points of wiring harnesses care-
fully. Refer to GROUP 00E, Harness Connector Inspection
P.00E-2.
• Shake the part or sensor.
ACX00871 AB
GENERAL 00-16
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
LOAD
ACX00872 AB
AFFILIATED RESULTS
DTC’s P0513 P2138 TBA U1120 U1100 U1110
U1120 X - X - - -
U1100 - - - - - -
U1120 X X X X - X
U1110 - - - - - -
TBA - - - - - -
GENERAL 00-18
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
M1001000401028
VEHICLE IDENTIFICATION
NUMBER (VIN)
00DB078A
VEHICLE COMPLIANCE
PLATE
00DB092A
GENERAL 00-20
VEHICLE IDENTIFICATION
VEHICLE DATA
PLATE
00DB090A
EXPORT CODES
OPTION ITEM
CODE
X71 Fiji
X62 New Zealand
A18 Export Preparation (wax and brake bags)
X30 Brunei
00DB095A
GENERAL 00-22
PRECAUTIONS BEFORE SERVICE
00DB080A
WRITING PROCEDURE
Required Special Tools:
• Diagnostic Tool (MUT-III)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (BLUE)
CAUTION
To prevent damage to DIAGNOSTIC TOOL (MUT-III), always
DATA LINK turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR
before connecting or disconnecting.
1. Connect Diagnostic Tool to the data link connector.
2. Turn the ignition switch to the "ON" position.
3. Confirm DTC No.P0630 (EEPROM malfunction) is not
shown.
NOTE: When DTC No. P0630 (EEPROM malfunction) is
MB991910 shown, the VIN cannot be stored even if entered. Therefore,
the troubleshooting is performed when this DTC is shown.
MB991824 4. Select "Coding" form the menu screen.
5. Select "VIN writing" form the menu screen.
6. Enter the VIN.
7. After entry of the VIN, turn the ignition switch to the "LOCK"
(OFF) position. After ten seconds or more passed, turn to
the "ON" position again.
8. Confirm DTC No.P0630 (VIN malfunction) is not shown.
MB991827 00DB076A NOTE: When DTC No.P0630 (VIN malfunction) is shown,
enter the VIN again because that would be not appropriate.
GENERAL 00-24
PRECAUTIONS BEFORE SERVICE
WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
1. Note the following before proceeding with working on the
electrical system.
Never perform unauthorized modifications to any electrical
device or wiring. Such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result in
a fire in the vehicle.
CAUTION
• Before connecting or disconnecting the negative bat-
tery cable, be sure to turn the ignition switch to the
ACX00880AB "LOCK" (OFF) position and turn off the lights (If this is
not done, there is the possibility of semiconductor
parts being damaged).
• After completion of the work (and the negative battery
terminals is connected), warm up the engine and allow
it to idle for approximately 10 minutes under the condi-
tions described below in order to stabilize engine con-
trol conditions, and then check to be sure that the idle
is satisfactory.
• Engine coolant temperature: 85 to 95°C (185 to
203°F)
• Lights and all accessories: OFF
• Transaxle: "N" or "P" position
• Steering wheel: straight-forward position
2. When servicing the electrical system, disconnect the
negative cable terminal from the battery.
VEHICLE WASHING
M1001012000057
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
APPROXIMATELY spray nozzle at a distance of at least approximately 50 cm (20
50 cm (20 in) inches) from any plastic parts and all opening parts (doors, lug-
gage compartment, etc.).
ACX00881AF
GENERAL 00-25
PRECAUTIONS BEFORE SERVICE
CAUTION
Turn the ignition switch to the "LOCK" (OFF) position
before disconnecting or connecting the diagnostic tool
(MUT-III).
NOTE: MUT-III trigger harness is not necessary when pushing
V.C.I. ENTER key.
MB991826 AC2010881AD
GENERAL 00-26
TOWING AND HOISTING
CAUTION
This vehicle cannot be towed by a tow truck using
sling-type equipment (TYPE A) as illustrated; otherwise it
will damage the bumper and front end. If this vehicle is
towed, use wheel lift or flat bed equipment.
• If the transmission is malfunctioning or damaged,
transport the vehicle with the driving wheels on a car-
riage (TYPE C, D or E) as illustrated.
• If you tow the vehicles with an A/T with the driving
wheels on the ground (TYPE B) as illustrated, make
sure that the towing speed and distance given below
are never exceeded, causing damage to the transmis-
sion.
• Towing speed: 50km/h
• Towing distance: 30km
• For the towing speed and the towing distance, follow
the local driving laws and regulations.
00DB093A
00DB093A
SAFETY PRECAUTIONS
The following precautions should be taken when towing the
vehicle:
1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING
TO OR WRAPPING AROUND THE BUMPER.
2. Any loose, protruding, or damaged parts such as hoods,
doors, fenders, trim, etc. should be secured or removed
prior to moving the vehicle.
GENERAL 00-28
TOWING AND HOISTING
FLOOR JACK
CAUTION
• Never place a support at any point other than the speci-
fied one, or that point will be deformed.
••For lifting, put rubber or similar material between the
Under view
side sill and rigid rack, otherwise the side sill area will
be damaged.
SILL
COVER
Side view
00DB096A
GENERAL 00-29
TOWING AND HOISTING
NOTCH NOTCH
RUBBER
RUBBER
POST TYPE
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations.
GENERAL 00-30
TOWING AND HOISTING
CAUTION
• When service procedures require removing rear sus-
pension, fuel tank and spare tyre, place additional
weight on the rear end of vehicle, or anchor vehicle to
hoist to prevent tipping when the location of the center
of gravity changes.
• If the lifting support area contacts with the sill cover
Under view
(arrow area as shown in the illustration), the sill cover
will be damaged. Ensure that the lifting support does
not contact the sill cover.
SILL
COVER
Side view
00DB096A
AC307269AB
NOTCH NOTCH
GENERAL 00-31
GENERAL DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
<3.8L ENGINE>
ITEM 380, 380LS, 380LX 380VRX, 380GT
Vehicle Front track 1 1,570mm
dimension Overall width 2 1,840mm
mm
Front overhang 3 984mm 989mm
Wheelbase 4 2,750mm
Rear overhang 5 1103mm 1116mm
Overall length 6 4837mm 4855mm
Ground clearance 7 162mm
(unladen
Overall height 8 1480mm
(unladen)
Rear track 9 1,570mm
ITEM MANUAL TRANS. AUTOMATIC TRANS.
380 380 VRX 380 380 VRX 380 380 GT
LS/LX
Vehicle Kerb mass (without 1,625 1,630 1,665 1,670 1,660 1,700
weight kg optional parts)
Kerb mass (with full 1,642 1,652 1,682 1,692 1,698 1,700
optional parts)
Maximum gross vehicle 2,080 2,125
mass
Maximum axle mass 1,180
rating-front
Maximum axle mass 1,010
rating-rear
Ride Front ride height 410 Measured from lowest point of
height Rear ride height 393 fender (wheel arch) to the centre
(mm) of the wheel.
Seating 5
capacity
GENERAL 00-32
TIGHTENING TORQUE
TIGHTENING TORQUE
M1001001100555
Each torque value in the table is a standard value for 1. If toothed washers are inserted.
tightening under the following conditions. 2. If plastic parts are fastened.
1. Bolts, nuts and washers are all made of steel and 3. If bolts are tightened to plastic or die-cast
plated with zinc. inserted nuts.
2. The threads and bearing surface of bolts and 4. If self-tapping screws or self-locking nuts are
nuts are all in dry condition. used.
The values in the table are not applicable:
STANDARD BOLT AND NUT TIGHTENING TORQUE
THREAD SIZE STANDARD TIGHTENING TORQUE
NOMINAL BOLT PITCH HEAD MARK "4" HEAD MARK "7" HEAD MARK "8"
DIAMETER (mm) (mm)
M5 0.8 2.5 ± 0.5 N⋅m (23 ± 4 5.0 ± 1.0 N⋅m (44 ± 9 6.0 ± 1.0 N⋅m (53 ± 9
in-lb) in-lb) in-lb)
M6 1.0 5.0 ± 1.0 N⋅m (44 ± 9 8.5 ± 1.5 N⋅m (76 ± 13 10 ± 2 N⋅m (89 ± 17
in-lb) in-lb) in-lb)
M8 1.25 11 ± 2 N⋅m (98 ± 17 20 ± 4 N⋅m (15 ± 3 ft-lb) 24 ± 4 N⋅m (18 ± 3 ft-lb)
in-lb)
M10 1.25 23 ± 4 N⋅m (17 ± 3 ft-lb) 42 ± 8 N⋅m (31 ± 6 ft-lb) 53 ± 7 N⋅m (39 ± 5 ft-lb)
M12 1.25 42 ± 8 N⋅m (31 ± 6 ft-lb) 80 ± 10 N⋅m (59 ± 7 93 ± 12 N⋅m (68 ± 9
ft-lb) ft-lb)
M14 1.5 70 ± 10 N⋅m (52 ± 7 130 ± 20 N⋅m (96 ± 15 150 ± 20 N⋅m (111 ± 14
ft-lb) ft-lb) ft-lb)
M16 1.5 105 ± 15 N⋅m (78 ± 11 195 ± 25 N⋅m (144 ± 18 230 ± 30 N⋅m (170 ± 22
ft-lb) ft-lb) ft-lb)
M18 1.5 150 ± 20 N⋅m (111 ± 14 290 ± 40 N⋅m (214 ± 29 335 ± 45 N⋅m (247 ± 33
ft-lb) ft-lb) ft-lb)
GENERAL 00-33
TIGHTENING TORQUE
CAUTION
PETROL CONTAINING ALCOHOL
Tests have shown that laboratory animals Some petrol sold at service stations contain alcohol
develop skin cancer after prolonged contact with although they may not be so identified.
used engine oil. Accordingly, the potential exists Using fuels containing alcohol is not recommended
for humans to develop a number of skin disor- unless the nature of the blend can be determined as
ders, including cancer, from such exposure to being satisfactory, as follows.
used engine oil. Therefore, when changing Gasohol: A mixture of 10% ethanol and 90%
engine oil, be careful not to touch it as much as unleaded gasoline may be used in your vehicle. If
possible. Protective clothing and gloves, that driveability problems are experienced as a result of
cannot be penetrated by oil, should be worn. The using gasohol, it is recommended that the vehicle be
skin should be thoroughly washed with soap and operated on petrol.
water, or use waterless hand cleaner, to remove Methanol: Do not use petrol containing methanol
any used engine oil. Do not use petrol, thinners, (wood alcohol). Using this type of alcohol can result
or solvents. in vehicle performance deterioration and damage
critical parts in the fuel system components. Fuel
system damage and performance problems resulting
from the use of petrol containing methanol may not
be covered by the new vehicle warranty.
RECOMMENDED LUBRICANTS
LUBRICANT SPECIFICATION
Engine oil Engine oils conforming to ACEA A1, A2 or A3 and
AP1 SG or higher
AutomaticTransmission fluid Genuine Mitsubishi Motors ATF-SP III
Manual Transmission fluid Genuine Mitsubishi Motors MTF
Power steering fluid ATF DEXRON III or DEXRON II
Brakes fluid Conforming to DOT 3 or DOT 4
Engine coolant Genuine Mitsubishi Motors coolant
Refrigerant (air conditioning) HFC-134a
SELECTION OF COOLANT
.
COOLANT
Relationship between Coolant Concentration and Specific Gravity
CAUTION
• If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely
affected. In addition, if the concentration is above 50%, both the anti-freeze and engine cooling
properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain
the concentration level within the specified range.
• Do not use a mixture of different brands of anti-freeze.
MAINTENANCE SERVICE
1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTION, AND FUEL TANK FILLER TUBE
CAP) (CHECK FOR LEAKS)
M1001001600312
Check for damage or leakage in the fuel lines and connections.
AC305838AB
CAUTION
Iridium plugs are used. Use care not to damage the iridium
tips of the plugs. Do not adjust the spark plug gap.
1. Spark plugs must spark properly to assure proper engine
performance and reduce exhaust emission level. Therefore,
they should be replaced periodically with new ones( Refer to
Maintainence Schedule).
Spark plug type
IRIDIUM TIP
MAKER 3.8L ENGINE
AKX00383 AK BOSCH FR8DI30
<3.8L ENGINE>
For removal and installation procedures, refer to GROUP 11C,
Engine Mechanical <3.8L Engine> − Timing Belt − Removal
and Installation P.11A-46.
GENERAL 00-39
MAINTENANCE SERVICE
MB991910
MB991824
MB991668
01DB039A
GENERAL 00-40
MAINTENANCE SERVICE
CAUTION
• The temperature of the surface of the belt should be as
close as possible to underhood temperature.
• Do not let any contaminants such as water or oil get
onto the microphone.
• If strong gusts of wind blow against the microphone or
if there are any loud sources of noise nearby, the val-
ues measured by the microphone may not correspond
to actual values.
• If the microphone is touching the belt while the mea-
surement is being made, the values measured by the
microphone may not correspond to actual values.
• Do not take the measurement while the vehicle's engine
is running.
5. Hold special tool MB991668 (microphone) to the middle of
the drive belt between the pulleys (at the place indicated by
ALTERNATOR AIR the arrow), about 10 − 20 mm (0.4 − 0.8 inch) away from the
PULLEY CONDITIONING
COMPRESSOR rear surface of the belt and so that it is perpendicular to the
PULLEY belt (within an angle of ± 15 degree angle).
TENSIONER 6. Gently tap the middle of the belt between the pulleys (the
PULLEY place indicated by the arrow) with your finger as shown in
the illustration, and check that the vibration frequency of the
belt is within the standard value.
TAP LIGHTLY
Standard value:
WITH A FINGER
Part No. Vibration frequency Hz
10 – 20mm
CRANK (0.4 – 0.8in) MD368275 133 − 158
SHAFT
PULLEY MB991668 MN158101, MN187016 143 − 169
(MICROPHONE)
15° 15°
NOTE: Because the frequency depends on the belt material,
confirm Part No. shown on the reverse of the belt.
.
00DB081A
GENERAL 00-41
MAINTENANCE SERVICE
TENSIONER
PULLEY
CRANK
SHAFT AIR
PULLEY CONDITIONING
COMPRESSOR
PULLEY
TENSION
GAUGE
00DB082A
APPROXIMATELY AIR
98 N (22 lb) CONDITIONING
COMPRESSOR
CRANK PULLEY
SHAFT
PULLEY
00DB083A
GENERAL 00-42
MAINTENANCE SERVICE
.
GENERAL 00-43
MAINTENANCE SERVICE
MAXIMUM MINIMUM
AC205268 AB
AC000093 AG
FLUID LEVEL [mm (in)] NOTE: If it takes some amount of time until the transmission
10 (0.4) fluid reaches its normal operating temperature [70 − 80°C
(158 − 176°F)], check the transmission fluid level by refer-
0 (0)
ring to the left diagram.
– 10 (– 0.4) 2. Park the vehicle on a level surface.
– 20 (– 0.8) 3. Move the selector lever through all positions to fill the torque
DIPSTICK
converter and the hydraulic circuits with fluid, and then move
– 30 (– 1.2) the selector lever to the "N" position.
40 60 80
(104) (140) (176)
4. After wiping off any dirt around the dipstick, remove the
FLUID TEMPERATURE [˚C (˚F)] AC005860AB
dipstick and check the condition of the transmission fluid.
NOTE: If the transmission fluid smells as if it is burnt, it
means that the transmission fluid has been contaminated by
fine particles from the bushings and friction materials. Tran-
saxle overhaul and cooler line flushing may be necessary.
5. Check transmission fluid level is at the "HOT" mark on the
dipstick. If the transmission fluid level is less than this, add
DIAMOND ATF SP III until the level reaches the "HOT"
mark.
NOTE: If the transmission fluid level is too low, the oil pump
will draw in air along with the transmission fluid, which will
cause to form bubbles. If the transmission fluid level is too
high, rotating components inside the transaxle will churn the
fluid and air into a foamy liquid. Both conditions (level too
AC106828AB
low or too high) will cause the hydraulic pressure to drop,
which will result in late shifting and slipping of the clutches
and brakes.
NOTE: In either case, air bubbles can interfere with normal
valve, clutch, and brake operation. Also, foaming can cause
transmission fluid to escape from the transaxle vent where it
may be mistaken for a leak.
GENERAL 00-47
MAINTENANCE SERVICE
CHANGING COOLANT
1. Set the temperature control knob to the "HOT" position.
2. Run the engine until the engine coolant warms, and then
stop the engine.
WARNING
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise a lit-
tle to let the pressure escape through the vinyl tube.
After relieving the steam pressure, remove the cap by
slowly turning it counterclockwise.
3. Drain the water from the radiator, heater core and engine
after unplugging the radiator drain plug and removing the
radiator cap.
00-48 GENERAL
MAINTENANCE SERVICE
CYLINDER BLOCK
DRAIN PLUG
AC306132AB
CYLINDER BLOCK
DRAIN PLUG
AC306131AB
14.Remove the radiator cap after the engine has cooled, and
pour in coolant up to the brim. Reinstall the cap.
CAUTION
Do not overfill the radiator condenser tank assembly.
15.Add coolant to the radiator condenser tank assembly
between the "FULL" and "LOW" mark if necessary.
AC306483AB
00-50 GENERAL
MAINTENANCE SERVICE
AC100948 AB
AC000109 AB
GENERAL 00-51
MAINTENANCE SERVICE
SRS-ECU
24DB066A
<DRIVER'S SIDE>
3. Check the connector for damage and deformed terminals,
and check the harness for binding.
INFLATOR CASE
4. Check the air bag inflator case for dents, cracks or
deformation.
5. Check the harness (built into the steering wheel) and
connectors for damage, and check the terminals for
deformation.
CONNECTOR
<FRONT PASSENGER'S SIDE>
INFLATOR
CASE
CONNECTOR AC307662AB
AC307538AB
AIR BAG
MODULE
00DB094A
GENERAL 00-55
MAINTENANCE SERVICE
DANGER
The SRS may not activate if any of the above compo-
nents are not installed properly, which could result in
serious injury or death to the vehicle's driver and
front passenger.
11.Check the steering wheel for excessive free play.
Replace any part if it fails visual inspection (Refer to
GROUP 52B, Air Bag Module and Clock Spring P.52B-237).
AC206854 AB
WIRING HARNESS
1. Check the connector for poor connection.
DANGER
The SRS system may not operate if SRS harnesses or
connectors are damaged or improperly connected,
which could result in serious injury or death to the
vehicle's driver and front passenger.
2. Check the harness for binds, the connectors for damage,
and the terminals for deformation. Replace any connector or
harness that fails the visual inspection (Refer to GROUP
52B, SRS Precaution P.52B-16).
GENERAL 00-57
MAINTENANCE SERVICE
DATE LINK
CONNECTOR
SRS-ECU
CONNECTOR
FRONT IMPACT SENSOR FRONT IMPACT SENSOR AIR BAG MODULE CLOCK SPRING
CONNECTOR (RH) CONNECTOR (LH) CONNECTOR CONNECTOR
<DRIVER'S SIDE>
GROUP 11
ENGINE
CONTENTS
GROUP 11A
ENGINE
MECHANICAL
<3.8L ENGINE>
CONTENTS
GENERAL DESCRIPTION
M1111000100419
The 6G75 (3.8 L) engine is a six-cylinder engine. The
cylinder numbers are assigned as 1-3-5 for the right
bank and 2-4-6 for the left bank from the front of the
engine (timing belt side). This engine is fired in the
order of 1-2-3-4-5-6 cylinders.
ITEMS SPECIFICATIONS
Type V type, overhead camshaft
Number of cylinders 6
Bore mm (in) 95.0 (3.74)
Stroke mm (in) 90.0 (3.54)
Total displacement cm3 (cu. in) 3,828 (233.6)
Compression ratio 10.0
Firing order 1-2-3-4-5-6
Valve timing Intake valve Opens (BTDC) 9°
Closes (ABDC) 59°
Exhaust valve Opens (BBDC) 47°
Closes (ATDC) 21°
Lubrication system Pressure feed, full-flow filtration
Oil pump type Trochoid type
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ENGINE MECHANICAL <3.8L ENGINE> 11A-3
ENGINE DIAGNOSIS
ENGINE DIAGNOSIS
M1111000700273
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ENGINE MECHANICAL <3.8L ENGINE> 11A-4
SPECIAL TOOLS
SPECIAL TOOLS
M1111000600986
MB991825
MB991826
MB991958
B991668
MB991800
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ENGINE MECHANICAL <3.8L ENGINE> 11A-5
SPECIAL TOOLS
MB991802
B990767
D998443
D998713
B991559
D998781
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ENGINE MECHANICAL <3.8L ENGINE> 11A-6
SPECIAL TOOLS
D998767
AC204024
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ENGINE MECHANICAL <3.8L ENGINE> 11A-7
SPECIAL TOOLS
MB991895
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ENGINE MECHANICAL <3.8L ENGINE> 11A-8
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
M1111003100496
Refer to GROUP 00, Maintenance Service − Drive Belts
(Check Condition) P.00-40.
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ENGINE MECHANICAL <3.8L ENGINE> 11A-9
ON-VEHICLE SERVICE
CAUTION
To prevent damage to Diagnostic Tool (MUT-III) , always
DATA LINK turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR
before connecting or disconnecting.
2. Connect Diagnostic Tool (MUT-III) to the data link connector.
3. Start the engine.
4. Run the engine at idle for 2 minutes.
5. Select Diagnostic Tool (MUT-III) Data List for MPI and then
scroll to Item No.2 Crank Angle Sensor. Check that actual
MB991910 idle speed is within specification.
Idle speed: 680 - 750 r/min
MB991824
NOTE: The idle speed is controlled automatically by the
ENGINE-ECU and throttle valve system.
6. If the idle speed is outside the standard value, refer to
GROUP 13A, Multiport Fuel Injection (MPI) − Multiport Fuel
Injection (MPI) Diagnosis − Symptom Chart P.13A-21.
MB991827 00DB076A
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ENGINE MECHANICAL <3.8L ENGINE> 11A-10
ON-VEHICLE SERVICE
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ENGINE MECHANICAL <3.8L ENGINE> 11A-11
ON-VEHICLE SERVICE
MB991910
MB991824
MB991827 00DB076A
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ENGINE MECHANICAL <3.8L ENGINE> 11A-12
ON-VEHICLE SERVICE
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ENGINE MECHANICAL <3.8L ENGINE> 11A-13
ON-VEHICLE SERVICE
HIGH-
PRESSURE
CHAMBER
AKX00329AB
NOTE: If air mixed with oil enters the high pressure chamber
inside the lash adjuster from the above causes, air in the
high pressure chamber is compressed excessively while the
valve is opened, resulting in an abnormal noise when the
valve closes. This is the same phenomenon as that
observed when the valve clearance has become excessive.
The lash adjuster can resume normal function when air
entered the lash adjuster is removed.
2. Idle the engine for one to three minutes to warm it up.
AIR BLEEDING OPERATION PATTERN 3. Repeat the operation pattern, shown in left figure, at no load
OPEN THROTTLE CLOSE to check for abnormal noise. (Usually the abnormal noise is
VALVE GRADUALLY THROTTLE VALVE
eliminated after repetition of the operation 10 to 30 times. If,
APPROXI- however, no change is observed in the level of abnormal
MATELY noise after repeating the operation more than 30 times,
3,000 r/min
suspect that the abnormal noise is due to some other
IDLING 15 s 15 s factors.)
OPERATION
4. After elimination of abnormal noise, repeat the operation
ONCE shown in left figure five more times.
AKX00330 AB 5. Run the engine at idle for one to three minutes to make sure
that the abnormal noise has been eliminated.
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ENGINE MECHANICAL <3.8L ENGINE> 11A-14
ENGINE ASSEMBLY
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001000894
CAUTION
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Pre-removal Operation Post-installation Operation
• Under Cover Removal (Refer to GROUP 51, Under Cover • Right Bank Exhaust Manifold Installation (Refer to
P.51-13.) GROUP 15, Exhaust Manifold P.15-10.)
• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Radiator Grille Installation (Refer to GROUP 51, Radiator
On-vehicle Service − Fuel Pump Relay Disconnection Grille P.51-6.)
(How to Reduce Pressurized Fuel Lines) P.13A-663.] • Battery and Battery Tray Installation
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Strut Tower Bar Installation (Refer to GROUP 42, Strut
Service − Engine Coolant Replacement P.14-27.) Tower Bar P.42-12.)
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Ser- • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
vice − Engine Oil Replacement P.12-3.) P.15-4.)
• Hood Removal (Refer to GROUP 42, Hood P.42-8.) • Front Exhaust Pipe Installation (Refer to GROUP 15,
• Engine Control Unit (ECU) Removal (Refer to GROUP Exhaust Pipe and Main Muffler P.15-14.)
13B, Engine Control Unit (ECU) P.13A-675.) • Engine Control Unit (ECU) Installation (Refer to GROUP
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner 13B, Engine Control Unit (ECU) P.13A-675.)
P.15-4.) • Hood Installation (Refer to GROUP 42, Hood P.42-8.)
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Drive Belt Tension Check (Refer to P.11A-8.)
Exhaust Pipe and Main Muffler P.15-14.) • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-
• Strut Tower Bar Removal (Refer to GROUP 42, Strut vice − Engine Oil Replacement P.12-3.)
Tower Bar P.42-12.) • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Battery and Battery Tray Removal Service − Engine Coolant Replacement P.14-27.)
• Radiator Grille Removal (Refer to GROUP 51, Radiator • Fuel Leak Check
Grille P.51-6.) • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-13.)
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ENGINE MECHANICAL <3.8L ENGINE> 11A-15
ENGINE ASSEMBLY
(ENGINE OIL) 2
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ENGINE MECHANICAL <3.8L ENGINE> 11A-16
ENGINE ASSEMBLY
12 ± 2 N·m 12 ± 2 N·m
102 ± 22 in-lb 102 ± 22 in-lb
16
13
20
12
11
42 ± 7 N·m
31 ± 5 ft-lb
46 ± 8 N·m 8
34 ± 6 ft-lb
N 17
7
108 ± 10 N·m*
80 ± 9 ft-lb*
18
19 10
AC306783 AB
7. GENERATOR DRIVE BELT <<F>> • TRANSAXLE ASSEMBLY (REFER
8. POWER STEERING OIL PUMP TO GROUP 23A, TRANSAXLE
DRIVE BELT ASSEMBLY <F4A5A>P.23A-304 .)
9. A/C COMPRESSOR ASSEMBLY 14. ENGINE MOUNTING STAY
CONNECTOR 15. GROUNDING CABLE
<<C>> 10. A/C COMPRESSOR ASSEMBLY CONNECTION
11. POWER STEERING PRESSURE 16. POWER STEERING OIL
SWITCH CONNECTOR RESERVOIR
<<D>> 12. POWER STEERING OIL PUMP 17. SELF-LOCKING NUTS
13. POWER STEERING PRESSURE <<G>> >>B<< 18. ENGINE FRONT MOUNTING
HOSE CLAMP BRACKET BRACKET
<<E>> • RADIATOR (REFER TO GROUP 19. MOUNTING BOLT
14, RADIATOR P.14-32.) <<H>> >>A<< 20. ENGINE ASSEMBLY
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ENGINE MECHANICAL <3.8L ENGINE> 11A-17
ENGINE ASSEMBLY
STOPPER
AC304581AB
RETAINER
AC304582AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-18
ENGINE ASSEMBLY
AC306135AB
MB991454
AC306215AB
MB991454
AC306217AB
AC306687AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-19
ENGINE ASSEMBLY
AC306687AB
C D
AC306197AB
MB991895
(2) Set special tool MB991454 to hold the engine assembly.
MB991454
AC306215AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-20
ENGINE ASSEMBLY
<RH> <LH> (2) Set special tool MB991928 to the front fender assembling
A B bolts (A and B) and (C and D) as shown.
C D
AC306197AB
MB991928 (3) Set special tool MB991454 to hold the engine assembly.
NOTE: Adjust the engine hanger balance by sliding the
slide bracket (HI).
MB991454
AC306217AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-21
ENGINE ASSEMBLY
STOPPER
AC304583AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-22
CAMSHAFT OIL SEAL
4N
3
88 ± 10 N·m
65 ± 7 ft-lb
1 2N
AC205540AB
MD998715
ACX00301AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-23
CAMSHAFT OIL SEAL
FLAT-TIPPED
CAMSHAFT SCREWDRIVER
ACX00373AB
MD998713 MB991559
ACX00371AB
<RIGHT BANK>
MD998713
ACX00372 AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-24
CAMSHAFT OIL SEAL
MD998715
ACX00301AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-25
CAMSHAFT AND VALVE STEM SEAL
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
<LEFT BANK>
3 10 ± 2 N·m
89 ± 17 in-lb
2 31 ± 3 N·m 14 ± 1 N·m
23 ± 2 ft-lb 120 ± 13 in-lb
N 7
18*
19* 9 10
20* 13
N 21*
22* 22 ± 4 N·m
N8
14 16 ± 3 ft-lb
16
18*
N 17 19*
15 20*
88 ± 10 N·m
65 ± 7 ft-lb 21* N
22*
01DB043A
CAMSHAFT REMOVAL STEPS CAMSHAFT REMOVAL STEPS
• TIMING BELT (REFER TO 6. ROCKER COVER
P.11A-46.) 7. ROCKER COVER GASKET
• THERMOSTAT HOUSING (REFER 8. SPARK PLUG GUIDE OIL SEAL
TO GROUP 14, WATER HOSE <<A>> >>D<< 9. ROCKER ARM, SHAFT AND
AND WATER PIPE P.14-40.) LASH ADJUSTER ASSEMBLY
1. PCV HOSE CONNECTION (INTAKE SIDE)
2. PCV VALVE <<A>> >>D<< 10. ROCKER ARM, SHAFT AND
3. IGNITION COIL CONNECTOR LASH ADJUSTER ASSEMBLY
4. IGNITION COIL (EXHAUST SIDE)
5. ENGINE CONTROL WIRING 11. CAMSHAFT POSITION SENSOR
HARNESS CLAMP CONNECTOR
12. CAMSHAFT POSITION SENSOR
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ENGINE MECHANICAL <3.8L ENGINE> 11A-26
CAMSHAFT AND VALVE STEM SEAL
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ENGINE MECHANICAL <3.8L ENGINE> 11A-27
CAMSHAFT AND VALVE STEM SEAL
<RIGHT BANK>
4
10 ± 2 N·m
11
89 ± 17 in-lb
2
13 12
CAM SECTION AND
1 3 JOURNAL SECTION CYLINDER HEAD
5 31 ± 3 N·m
23 ± 2 ft-lb
19 ± 3 N·m
15* 14 ± 2 ft-lb
N 6 16*
17*
9 18* N
15* 19* 11
16* 12 N
17*
N 18* 8
19* 13
N7
N 14
10
88 ± 10 N·m
65 ± 7 ft-lb
AC307923AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-28
CAMSHAFT AND VALVE STEM SEAL
AC205280AB
MD998715
ACX00301AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-29
CAMSHAFT AND VALVE STEM SEAL
FLAT-TIPPED
CAMSHAFT SCREWDRIVER
ACX00373AB
MD998772
AC205277AB
<RIGHT BANK>
MD998772
AC205278AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-30
CAMSHAFT AND VALVE STEM SEAL
INSTALLATION POSITION
EXHAUST SIDE
RIGHTBANK
VALVE
VALVE
STEM
SEAL
VALVE
GUIDE
01DB052A
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ENGINE MECHANICAL <3.8L ENGINE> 11A-31
CAMSHAFT AND VALVE STEM SEAL
IDENTIFICATION
COLOR
AC107415AB
MD998772
AC205277AB
<RIGHT BANK>
MD998772
AC205278AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-32
CAMSHAFT AND VALVE STEM SEAL
AC205280AB
4. Check that notches in the each rocker shaft are facing the
NOTCH
direction shown in the illustration.
<RIGHTBANK>
FRONT
NOTCH
NOTCH
<LEFTBANK>
NOTCH AC204149AC
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ENGINE MECHANICAL <3.8L ENGINE> 11A-33
CAMSHAFT AND VALVE STEM SEAL
MD998713 MB991559
ACX00371AB
<RIGHT BANK>
MD998713
ACX00372 AB
MD998715
ACX00301AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-34
OIL PAN AND OIL SCREEN
ENGINE OIL
N 12
5
11
19 ± 3 N·m 14 ± 1 N·m
14 ± 2 ft-lb 120 ± 13 in-lb
30 ± 3 N·m
10 6N 23 ± 2 ft-lb
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ENGINE MECHANICAL <3.8L ENGINE> 11A-35
OIL PAN AND OIL SCREEN
49 ± 3 N·m
36 ± 2 ft-lb
AC206538 AB
AC206525 AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-36
OIL PAN AND OIL SCREEN
17 13
16 14
11 7 3 2 6 10 15
13, 14 AC206507 AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-37
OIL PAN AND OIL SCREEN
8 7
3
5
1
AC206508 AB
INSPECTION
M1112002600134
• Check the oil pan for cracks.
• Check the oil pan sealant-coated surface for damage and
deformation.
• Check the oil screen for cracked, clogged or damaged wire
net and pipe.
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ENGINE MECHANICAL <3.8L ENGINE> 11A-38
CRANKSHAFT OIL SEAL
ENGINE OIL
1 5
8.5 ± 0.5 N·m
76 ± 4 in-lb
2
6N
4
3
AC205520 AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-39
CRANKSHAFT OIL SEAL
MD998717
OIL SEAL ACX00363AB
CLEANING
CRANKSHAFT
SPROCKET CRANKSHAFT
SHADED PART : DEGREASE ACX01536AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-40
CRANKSHAFT OIL SEAL
74 ± 1 N·m
<A/T> 55 ± 1 ft-lb
4
7N
2 132 ± 5 N·m
<M/T>
AB
7
6 5
7N AC306784
ENGINE OIL
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ENGINE MECHANICAL <3.8L ENGINE> 11A-41
CRANKSHAFT OIL SEAL
MD998781
AC306686AB
ACX00356AB
MD998781
AC306686AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-42
CYLINDER HEAD GASKET
10 ± 2 N·m
89 ± 17 in-lb
10 ± 2 N·m
89 ± 17 in-lb
17
5
16
1
19 4 3.5 ± 0.5 N·m
31 ± 4 in-lb
18 <COLD ENGINE> 7
108 ± 5 N·m 6
3.5 ± 0.5 N·m 80 ± 3 ft-lb
31 ± 4 in-lb <COLD ENGINE>
0 N·m 2 108 ± 5 N·m
0 in-lb
3 80 ± 3 ft-lb
20 N8
108 ± 5 N·m
0 N·m
80 ± 3 ft-lb 9 0 in-lb
N 21
(ENGINE OIL)
108 ± 5 N·m
80 ± 3 ft-lb
41 ± 8 N·m
30 ± 6 ft-lb (ENGINE OIL)
22 ± 4 N·m
15 13 16 ± 3 ft-lb
22
N 23 10
14 N
12
11
14 ± 1 N·m 88 ± 10 N·m
120 ± 13 in-lb 65 ± 7 ft-lb
AC306788AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-43
CYLINDER HEAD GASKET
MD998715
ACX00301AB
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ENGINE MECHANICAL <3.8L ENGINE> 11A-44
CYLINDER HEAD GASKET
MD998051
AC205273
EXHAUST SIDE
3 7 6 2
RIGHT BANK
4 8 5 1
INTAKE SIDE
1 5 8 4
LEFT BANK
2 6 7 3
EXHAUST SIDE
AC206708 AB
ACX00349AB
TSB Revision
ENGINE MECHANICAL <3.8L ENGINE> 11A-45
CYLINDER HEAD GASKET
EXHAUST SIDE
6 2 3 7
RIGHT BANK
5 1 4 8
INTAKE SIDE
8 4 1 5 LEFT BANK
7 3 2 6
EXHAUST SIDE
AC206709 AB
MD998715
ACX00301AB
TSB Revision
11A-46 ENGINE MECHANICAL <3.8L ENGINE>
TIMING BELT
TIMING BELT
REMOVAL AND INSTALLATION
M1112004300775
36 ± 6 N·m
27 ± 4 ft-lb
11 ± 1 N·m 4
98 ± 8 in-lb
8
6 5
16
7
9 10 12
49 ± 9 N·m
11 ± 1 N·m 11
36 ± 7 ft-lb
98 ± 8 in-lb
14 ± 1 N·m
17 20
120 ± 13 in-lb
41 ± 8 N·m
14 ± 1 N·m 30 ± 6 ft-lb
120 ± 13 in-lb 23 ± 3 N·m
2 17 ± 2 ft-lb 19
14 ± 1 N·m 44 ± 10 N·m 18
120 ± 13 in-lb 33 ± 7 ft-lb
48 ± 6 N·m
11 ± 1 N·m 36 ± 4 ft-lb
98 ± 8 in-lb
15
(ENGINE OIL)
45 ± 5 N·m
1 34 ± 3 ft-lb
14
185 N·m 13
136 ft-lb
3 AC306787AB
TSB Revision
ENGINE MECHANICAL <3.8L ENGINE> 11A-47
TIMING BELT
MB991802
ACX01675AB
TSB Revision
11A-48 ENGINE MECHANICAL <3.8L ENGINE>
TIMING BELT
CENTER
BOLT
TENSION
PULLEY
TIMING MARK
AC206490AB
AC205272 AB
CAUTION
Never compress the pushrod too fast, or it may be dam-
PIN HOLE A
aged.
(2) Slowly compress the pushrod of the auto-tensioner until
pin hole A in the pushrod is aligned with pin hole B in the
cylinder.
(3) Insert the setting pin into the pin holes once they are
PIN HOLE B
aligned.
NOTE: If replacing the auto-tensioner, the pin will already
be inserted into the pin holes of the new part.
AC206607 AB
TSB Revision
ENGINE MECHANICAL <3.8L ENGINE> 11A-49
TIMING BELT
CAUTION
Do not remove the setting pin from the auto-tensioner.
(4) Install the auto-tensioner to the engine.
.
AC205274AB
MD998769
AC205275AB
TSB Revision
11A-50 ENGINE MECHANICAL <3.8L ENGINE>
TIMING BELT
CAUTION
When tightening the center bolt, be careful that the ten-
48 ± 6 N·m sioner pulley does not turn with the bolt.
36 ± 4 ft-lb
6. Loosen the center bolt of the tensioner pulley. Use special
tool MD998767 and a torque wrench to apply the tension
MD998767 torque to the timing belt as shown in the illustration. Then
tighten the center bolt to the specified torque.
4.4 N·m Standard value: 4.4 N⋅m (39 in-lb) <Timing belt ten-
TENSIO- 39 in-lb sion torque>
NER
Tightening torque: 48 ± 6 N⋅m (36 ± 4 ft-lb)
PULLEY
AC206418AB
7. Remove the setting pin that has been inserted into the
auto-tensioner.
SETTING PIN
8. Turn the crankshaft clockwise twice to align the timing
marks.
AC205276AB
AC206419AB
MB991802
ACX01675AB
TSB Revision
ENGINE MECHANICAL <3.8L ENGINE> 11A-51
TIMING BELT
INSPECTION
M1112004400437
AUTO-TENSIONER
ACX00536 AB
98 – 196 N 3. While holding the auto-tensioner with your hand, press the
(22 – 44 lb) MOVEMENT end of the pushrod against a metal surface (such as the
cylinder block) with a force of 98 − 196 N (22 − 44 pound)
and measure how far the pushrod is pushed in.
A B
Standard value: Within 1 mm (0.04 inch)
A: Length when no force is applied
AUTO- B: Length when force is applied
ROD
TENSIONER A − B: Movement in
4. If the measured value is out of the standard value, replace
AC206608AB
the auto-tensioner adjuster.
TSB Revision
11A-52 ENGINE MECHANICAL <3.8L ENGINE>
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1111003800387
ITEM SPECIFICATION
Camshaft and valve stem seal
Camshaft position sensing cylinder bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Camshaft position sensor support bolt 14 ± 1 N⋅m (120 ± 13 in-lb)
Camshaft position sensor bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Camshaft sprocket bolt 88 ± 10 N⋅m (65 ± 7 ft-lb)
Ignition coil bolt 10 ± 2 N⋅m (89 ± 17 in-lb)
PCV valve 10 ± 2 N⋅m (89 ± 17 in-lb)
Rocker cover bolt 3.5 ± 0.5 N⋅m (31 ± 4 in-lb)
Rocker shaft bolt 31 ± 3 N⋅m (23 ± 2 ft-lb)
Thrust case bolt 19 ± 3 N⋅m (14 ± 2 ft-lb)
Camshaft oil seal
Camshaft sprocket bolt 88 ± 10 N⋅m (65 ± 7 ft-lb)
Crankshaft oil seal
A/T drive plate bolt 74 ± 1 N⋅m (55 ± 1 ft-lb)
Crankshaft position sensor bolt 8.5 ± 0.5 N⋅m (76 ± 4 in-lb)
TSB Revision
ENGINE MECHANICAL <3.8L ENGINE> 11A-53
SPECIFICATIONS
ITEM SPECIFICATION
Power steering pressure hose clamp bracket bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Power steering oil reservoir connecting bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Oil pan and oil screen
Cover bolt 11 ± 0.5 N⋅m (93 ± 4 in-lb)
Engine oil dipstick bolt 14 ± 1 N⋅m (120 ± 13 in-lb)
Engine lower oil pan bolt 11 ± 1 N⋅m (97 ± 9 in-lb)
Engine oil pan drain plug 39 ± 5 N⋅m (29 ± 3 ft-lb)
Engine upper oil pan bolt 8.5 ± 3.5 N⋅m (76 ± 31 in-lb)
Engine upper oil pan to torque converter bolt 35 ± 5 N⋅m (26 ± 4 ft-lb)
Oil screen bolt 19 ± 3 N⋅m (14 ± 2 ft-lb)
Starter bolt 30 ± 3 N⋅m (23 ± 2 ft-lb)
Torque converter connecting bolt 49 ± 3 N⋅m (36 ± 2 ft-lb)
Timing belt
Auto-tensioner bolt 23 ± 3 N⋅m (17 ± 2 ft-lb)
Crankshaft pulley center bolt 185 N⋅m (136 ft-lb)
Engine mount stay bolt 36 ± 6 N⋅m (27 ± 4 ft-lb)
Engine support bracket bolt 45 ± 5 N⋅m (34 ± 3 ft-lb)
Harness bracket bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Tensioner arm bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Tensioner bracket bolt 41 ± 8 N⋅m (30 ± 6 ft-lb)
Tensioner pulley bolt 48 ± 6 N⋅m (36 ± 4 ft-lb)
Tensioner pulley nut 49 ± 9 N⋅m (36 ± 7 ft-lb)
Timing belt lower cover bolt (bolt, flange) M6 11 ± 1 N⋅m (98 ± 8 in-lb)
Timing belt lower cover bolt (bolt, washer assembled) M10 14 ± 1 N⋅m (120 ± 13 in-lb)
Timing belt upper cover bolt (bolt, flange) M6 11 ± 1 N⋅m (98 ± 8 in-lb)
M8 14 ± 1 N⋅m (120 ± 13 in-lb)
TSB Revision
11A-54 ENGINE MECHANICAL <3.8L ENGINE>
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1111000300747
SEALANTS
M1111000500365
TSB Revision
HOME
11B-1
GROUP 11B
ENGINE OVERHAUL
<3.8L ENGINE>
CONTENTS
SPECIAL TOOLS
M1113000600603
D998781
B990767
MD998715 MIT308239
Pin
D998767
D998713
44 ± 10 N·m
33 ± 7 ft-lb
6
24 ± 4 N·m
18 ± 3 ft-lb
41 ± 8 N·m
30 ± 6 ft-lb
5
49 ± 9 N·m
37 ± 6 ft-lb 3
1 49 ± 9 N·m
37 ± 6 ft-lb
4
13
49 ± 9 N·m
37 ± 6 ft-lb 14
12
41 ± 8 N·m 2
30 ± 6 ft-lb 10 15
9
5.0 ± 1.0 N·m 8
44 ± 9 in-lb
7 11
185 ± 5 N·m 14 ± 1 N·m
137 ± 3 ft-lb 49 ± 9 N·m
37 ± 6 ft-lb 122 ± 9 in-lb
16
AK203969AB
MD998781
AKX01329 AB
MD998781
AKX01329 AB
36 ± 6 N·m
27 ± 4 ft-lb 18 ± 2 N·m
5 13 ± 1 ft-lb
36 ± 6 N·m
27 ± 4 ft-lb 10
28 ± 4 N·m
21 ± 3 ft-lb
03DB138A
PROJECTION
03DB188A
CHAMBER
SOLENOID VALVE
01DB051A
ENGINE OVERHAUL <3.8L ENGINE> 11B-8
IGNITION SYSTEM
IGNITION SYSTEM
REMOVAL AND INSTALLATION
M1113001600145
10 ± 2 N·m
10 ± 2 N·m 89 ± 17 in-lb
89 ± 17 in-lb
1 11 ± 1 N·m
97 ± 9 in-lb
1 25 ± 5 N·m 3
18 ± 4 ft-lb
2 4
25 ± 5 N·m
18 ± 4 ft-lb
2
6
14 ± 1 N·m
124 ± 9 in-lb
5
22 ± 4 N·m
16 ± 3 ft-lb
AK302894AB
MD998781
AKX01329 AB
AKX01329 AB
AK000008
ENGINE OVERHAUL <3.8L ENGINE> 11B-10
TIMING BELT
TIMING BELT
REMOVAL AND INSTALLATION
M1113001900618
24 ± 3 N·m
17 ± 2 ft-lb
20
14 ± 1 N·m
19 122 ± 9 in-lb 21
88 ± 10 N·m
65 ± 7 ft-lb
19
6
7
23 ± 3 N·m 10
18 ± 2 ft-lb 9
18 11
14
44 ± 10 N·m
33 ± 7 ft-lb 12
44 ± 5 N·m
16 33 ± 4 ft-lb
8 17 13
15 1 5.0 ± 1.0 N·m
48 ± 6 N·m 44 ± 9 in-lb
35 ± 4 ft-lb 2 5
11 ± 1 N·m
95 ± 9 in-lb
(M6 BOLT) 8.5 ± 0.5 N·m
76 ± 4 in-lb
4 14 ± 1 N·m
122 ± 9 in-lb
(M8 BOLT)
45 ± 5 N·m
34 ± 3 ft-lb 14 ± 1 N·m
122 ± 9 in-lb
(M10 BOLT) 3
AK302895 AB
AK302434
MB990767
AK302435AB
AK302436AB
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-12
TIMING BELT
DEGREASE
CLEAN
OIL PUMP CASE
AK101687AC
3. Align the location of pin and pin hole, and then apply equal
force in the direction of the arrow.
CAUTION
Do not bend the sensing blade when installing sprocket.
4. Install the crankshaft sprocket to the crankshaft.
PIN HOLE
PIN AK201830AD
CAMSHAFT SPROCKET
AKX00640AB
AKX00654AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-14
TIMING BELT
WATER PUMP
PULLEY
CAMSHAFT SPROCKET
CAMSHAFT SPROCKET
TENSIONER PULLEY
IDLER PULLEY
AUTO-TENSIONER
TIMING MARK
CRANKSHAFT SPROCKET
AK204322 AB
8. Check to see that the timing marks of all the sprockets are in
alignment.
9. Rotate the crankshaft a quarter turn counterclockwise. Then
rotate it back clockwise to verify that all the timing marks are
aligned.
MD998769
AKX00728AB
ROD PROTRUSION
14.Check to see whether the metal wire inserted when the
auto-tensioner was installed can be removed without any
resistance.
If the metal wire can be removed without any resistance, it
means that the belt has a proper tension. Therefore, remove
the metal wire. In this condition, check that the rod
protrusion of the auto-tensioner is within the standard value.
Standard value: 4.8 − 6.0 mm (0.19 − 0.24 inch)
15.If the metal wire offers resistance when removed, repeat the
AK204327 AB
previous steps 10 through 13 until proper belt tension is
obtained.
.
AKX00667AB
INSPECTION
M1113002000458
.
TIMING BELT
Replace the belt if any of the following conditions exist.
1. Hardening of rubber backing.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
AKX00749
CRACKS
AKX00713AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-16
TIMING BELT
ABNORMAL WEAR
(RAGGED)
AKX00750AB
AKX00751AC
AKX00650
AUTO-TENSIONER
1. Check for oil leaks. If oil leaks are evident, replace the
auto-tensioner.
2. Check the rod end for wear or damage and replace the
auto-tensioner if necessary.
3. Measure the rod protrusion. If it is out of specification,
replace the auto-tensioner.
Standard value: 12 mm (0.5 inch)
12 mm (0.5 in)
AK204323AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-17
INTAKE MANIFOLD AND FUEL PARTS
AK204324 AB
1
12 ± 1 N·m
107 ± 8 in-lb
2
6
7
5
4
20 – 23 N·m
15 – 17 ft-lb 3
8 9
10 10
AK203973AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-18
INTAKE MANIFOLD AND FUEL PARTS
INJECTOR
AK302906AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-19
WATER PUMP & WATER HOSE
29 ± 10 N·m
22 ± 7 ft-lb
1
3 19 ± 1 N·m 19 ± 1 N·m
14 ± 1 ft-lb 14 ± 1 ft-lb
2 4
5
11 ± 1 N·m
95 ± 9 in-lb
7
19 ± 1 N·m
10 6 14 ± 1 ft-lb
8
7
9
42 ± 8 N·m
31 ± 6 ft-lb
(M10 BOLT)
12
24 ± 3 N·m 11 AK302897AB
17 ± 2 ft-lb
(M8 BOLT)
WATER INLET
PIPE AKX00711AB
TAB
AK302907AB
AKX00670AB
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-21
EXHAUST MANIFOLD
AKX00686
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113004900424
44 ± 5 N·m
33 ± 4 ft-lb
11 ± 1 N·m
95 ± 9 in-lb
2
14 ± 1 N·m
122 ± 9 in-lb 3 11 44 ± 5 N·m
33 ± 4 ft-lb
1
8
44 ± 5 N·m 7 9
33 ± 4 ft-lb 17 14 ± 1 N·m
122 ± 9 in-lb
75 ± 10 N·m
56 ± 7 ft-lb 35 ± 6 N·m
26 ± 4 ft-lb
44 ± 5 N·m
33 ± 4 ft-lb
16
4
15 12
44 ± 8 N·m
33 ± 5 ft-lb
5 44 ± 5 N·m
44 ± 8 N·m 33 ± 4 ft-lb
33 ± 5 ft-lb
14 10
44 ± 5 N·m
33 ± 4 ft-lb
13
19 ± 3 N·m
14 ± 2 ft-lb 01DB045A
44 ± 8 N·m
33 ± 5 ft-lb
ENGINE OVERHAUL <3.8L ENGINE> 11B-22
EXHAUST MANIFOLD
EXHAUST MANIFOLD
STAY LEFT "B"
01DB047A
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-23
ROCKER ARMS AND CAMSHAFT
5
3 3.5 ± 0.5 N·m
31 ± 4 in-lb
1 31 ± 3 N·m
23 ± 2 ft-lb
2
3.5 ± 0.5 N·m
31 ± 4 in-lb 12 4
8
6
17
16 7
15
16
15 20
16 13 ± 2 N·m
15 19 115 ± 7 in-lb
9 14
19
18 19
21 22
23
13 10
11 24
25
10
APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
01DB049A
ENGINE OVERHAUL <3.8L ENGINE> 11B-24
ROCKER ARMS AND CAMSHAFT
AKX00613AB
CAMSHAFT, LEFT
AK204034AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-25
ROCKER ARMS AND CAMSHAFT
AK204035AB
MD998443
LASH
ADJUSTER
AKX00715AB
OIL HOLE
AK202325 AC
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-26
ROCKER ARMS AND CAMSHAFT
AKX00615AB
MD998713
MB991559
AKX00639AB
INSPECTION
M1113005500463
.
ROCKER ARM
1. Check the roller surface and replace the rocker arm if
recesses, damage or heat seizure is observed.
2. Check roller rotation and replace the rocker arm if uneven
rotation or roller backlash of the roller is observed.
3. Check the inside diameter and replace the rocker arm if
damage or seizure is observed.
ROLLER TIP
AKX00723AB
CAMSHAFT
1. Check the camshaft bearing journals for damage and
binding. If the journals are binding, check the cylinder head
for damage. Also check the cylinder head for clogged oil
holes.
2. Check the tooth surface of the distributor drive gear teeth of
the camshaft and replace if abnormal wear is evident.
ENGINE OVERHAUL <3.8L ENGINE> 11B-27
ROCKER ARMS AND CAMSHAFT
3. Check the cam surface for abnormal wear and damage and
replace if necessary. Also measure the cam height and
replace if out of minimum limit.
Standard value:
Intake 37.39 mm (1.472 inches)
Exhaust 37.71 mm (1.485 inches)
Minimum limit:
Intake 36.89 mm (1.452 inches)
Exhaust 37.21 mm (1.465 inches)
AKX00685
LASH ADJUSTERS
CAUTION
• The lash adjusters are precision-engineered mecha-
OUTSIDE INSIDE FILLING nisms. Do not allow them to become contaminated by
CLEANING CLEANING DIESEL FUEL dirt or other foreign substances.
• Do not attempt to disassemble the lash adjusters.
• Use only fresh diesel fuel to clean the lash adjusters.
1. Prepare three containers and approximately 5 dm3 (30.5
quart) of diesel fuel. Into each container, pour enough diesel
A B C fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
AKX00625AB adjuster.
2. Place the lash adjuster in container A and clean its outside
surface.
NOTE: Use a nylon brush if deposits are hard to remove.
DIESEL
FUEL
AKX00626AB
CAUTION
The steel ball spring is extremely weak, so the lash
adjuster's functionality may be lost if the air bleed wire is
pushed in hard.
3. While gently pushing down the internal steel ball using wire
[0.5 mm (0.020 inch) in diameter] or special tool MD998442,
move the plunger through five to ten strokes until it slides
smoothly. In addition to eliminating stiffness in the plunger,
DIESEL FUEL this operation will remove dirty oil.
MD998442 NOTE: If the plunger remains stiff or the mechanism
AK202680 AE appears otherwise abnormal, replace the lash adjuster.
ENGINE OVERHAUL <3.8L ENGINE> 11B-28
ROCKER ARMS AND CAMSHAFT
MD998442
MD998442
DIESEL FUEL
MD998442
AK202682 AD
8. Stand the lash adjuster with its plunger at the top, then push
the plunger downward firmly until it moves through its
greatest possible stroke. Return the plunger slowly, then
release the steel ball and allow the pressure chamber to fill
with diesel fuel.
AK202683 AD
ENGINE OVERHAUL <3.8L ENGINE> 11B-29
CYLINDER HEAD AND VALVES
9. Remove the lash adjuster from the container, then stand the
lash adjuster with its plunger at the top. Push the plunger
firmly and check that it does not move.
NOTE: If the lash adjuster contracts or moves, repeat steps
7 through 9 again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts or moves after
performing these steps.
10.Stand the lash adjuster upright to prevent diesel fuel from
spilling out. Do not allow the lash adjuster to become
AKX00627 contaminated by dirt or other foreign matter. Install the lash
adjuster onto the engine as soon as possible.
→
INSTALLATION.
7 0 N·m
0 in-lb
13
→
14 9 108 ± 5 N·m
11
17 16 80 ± 4 ft-lb
3 19
21 10
15
12
18
22
20
8
AK304296AB
MD998051
AK302682AB
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-31
CYLINDER HEAD AND VALVES
AK100166AB
MD998772
AKX00617AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-32
CYLINDER HEAD AND VALVES
INTAKE EXHAUST
AK303630AB
CAUTION
Always use the special tool to install the valve stem seal.
MB991999 Improperly installed valve stem seals may leak oil.
2. Using special tool MB991999, install a new stem seal to the
valve guide.
AKX00618AC
STEM SEAL
SPRING SEAT
AKX00718 AB
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-33
CYLINDER HEAD AND VALVES
AK100166AB
MD998772
AKX00617AB
RIGHT
BANK
LEFT
BANK
AKX01452AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-34
CYLINDER HEAD AND VALVES
INSPECTION
M1113007000464
.
CYLINDER HEAD
1. Check the cylinder head gasket surface for flatness by using
a straightedge in the directions of A through G shown in the
illustration.
Standard value: 0.03 mm (0.0012 inch)
Limit: 0.2 mm (0.007 inch)
2. If the service limit is exceeded, correct to meet the
specification.
Grinding limit: *0.2 mm (0.007 inch)
AKX00733 3. *If the service limit is exceeded, correct to meet the
specification.
Cylinder head height (specification when new):
120 mm (4.7 inches)
.
VALVE
1. Check the valve face for correct contact. If incorrect, reface
using a valve refacer. The valve should make a uniform
contact with the seat at the center of the valve face.
2. If the margin exceeds the service minimum limit, replace the
VALVE SEAT
valve.
CONTACT Standard value:
MARGIN
<Intake> 1.0 mm (0.04 inch)
<Exhaust> 1.2 mm (0.05 inch)
AKX00619AB
Minimum limit:
<Intake> 0.5 mm (0.02 inch)
<Exhaust> 0.7 mm (0.03 inch)
3. Measure the valve's total length. If the measurement is less
than specified, replace the valve.
Standard value:
<Intake> 110.30 mm (4.343 inches)
<Exhaust> 112.11 mm (4.414 inches)
Minimum limit:
<Intake> 109.80 mm (4.323 inches)
<Exhaust> 111.61 mm (4.394 inches)
AKX00624
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-35
CYLINDER HEAD AND VALVES
VALVE SPRINGS
1. Measure the free height of the spring and, if it is smaller than
2˚ the minimum limit, replace the spring.
Standard value: 50.6 mm
Minimum limit: 49.6 mm
FREE 2. Measure the squareness of the spring and, if the limit is
HEIGHT exceeded, replace the spring.
Standard value: 2° or less
Limit: 4°
AKX00607AB
VALVE GUIDES
Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide, valve, or
both.
Standard value:
VALVE <Intake> 0.02 − 0.05 mm (0.0008 − 0.0019 inch)
GUIDE <Exhaust> 0.04 − 0.06 mm (0.0016 − 0.0023 inch)
Limit:
STEM OUTSIDE <Intake> 0.10 mm (0.003 inch)
DIAMETER
<Exhaust> 0.15 mm (0.005 inch)
GUIDE INSIDE DIAMETER AKX00714AB
VALVE SEAT
Assemble the valve, then measure the valve stem projection
VALVE STEM END
between the end of the valve stem and the spring seating sur-
face. If the measurement exceeds the specified limit, replace
VALVE STEM the valve seat.
PROJECTION
Standard value:
SPRING SEATING <Intake> 48.30 mm (1.902 inches)
SURFACE <Exhaust> 51.71 mm (2.036 inches)
Limit:
<Intake> 48.80 mm (1.921 inches)
AKX00695AB
<Exhaust> 52.21 mm (2.056 inches)
.
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-36
CYLINDER HEAD AND VALVES
AKX00610AB
AKX00727AB
20
21
23 22
14 ± 1 N·m 10 ± 2 N·m
122 ± 9 in-lb 87 ± 17 in-lb
7 8
41 ± 8 N·m 19
30 ± 6 ft-lb 6
19 ± 3 N·m 9.0 ± 2.0 N·m
14 ± 2 ft-lb 80 ± 17 in-lb
23 ± 3 N·m
17 16
18 ± 2 ft-lb
15
13
14 5
9
12 44 ± 5 N·m 9.0 ± 3.0 N·m
33 ± 4 ft-lb 80 ± 26 in-lb
11 ± 1 N·m 10 ± 2 N·m
95 ± 9 in-lb 87 ± 17 in-lb
10 4
2
10.8 ± 0.9 N·m
11 96 ± 7 in-lb
39 ± 5 N·m 1
14 ± 2 N·m 29 ± 4 ft-lb 9.0 ± 3.0 N·m
122 ± 17 in-lb 80 ± 26 in-lb
3
11 ± 1 N·m
95 ± 9 in-lb AK302971AC
ENGINE OVERHAUL <3.8L ENGINE> 11B-38
OIL PAN AND OIL PUMP
AK304454AB
4. Screw M10 bolts into the two bolt holes in the oil pan to
break the joint and remove the oil pan.
AKX00658
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-39
OIL PAN AND OIL PUMP
AKX00742AB
AKX00742AB
AKX00674AB
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-40
OIL PAN AND OIL PUMP
OIL SEAL
AKX00659 AB
3. Using special tool MD998717, press-fit the oil seal into the
oil pump case.
MD998717
AKX00660AB
AKX00688
ENGINE OVERHAUL <3.8L ENGINE> 11B-41
OIL PAN AND OIL PUMP
2. Tighten the engine oil pressure switch together with the oil
MD998054 filter bracket to the specified torque, using special tool
MD998054.
Tightening torque: 10 ± 2 N⋅m (87 ± 17 in-lb)
AK204037AB
AK304451AB
16 14
11 7 3 2 6 10 15
AK304450AB
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-42
OIL PAN AND OIL PUMP
AK302911AB
3
5
1 AK204036AB
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-43
OIL PAN AND OIL PUMP
OIL PAN
SIDE
AKX00726AB
INSPECTION
M1113008200171
.
OIL PUMP
1. Check the tip clearance.
Standard value: 0.06 − 0.18 mm (0.003 − 0.007 inch)
AKX00743
AKX00744
ENGINE OVERHAUL <3.8L ENGINE> 11B-44
PISTON AND CONNECTING ROD
AKX00745
13 4
14
3
2
AKX00734AB
AKX01397AB
11B-46 ENGINE OVERHAUL <3.8L ENGINE>
PISTON AND CONNECTING ROD
NOTE: The piston size mark shows on the top of the piston.
2. Set the snap ring into one side of the piston pin hole.
CAUTION
Apply ample coat of engine oil to the periphery of the pis-
ton pin and the hole of the connecting rod small end. The
clearance between the piston and the piston pin is a tight
fit at room temperature. Therefore, be sure to heat the pis-
ton before inserting the piston pin. Use care since the pis-
ton is hot after heating.
3. Heat the piston to approximately 70°C (158°F).
70˚C
(158˚F)
AKX01398 AB
4. With the front mark of the connecting rod and that of the
piston located on the same side, insert the piston pin.
FRONT MARK 74 5. Set the snap ring into the other side of the piston pin hole.
FRONT MARK
AK201080 AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-47
PISTON AND CONNECTING ROD
AKX00716
SPACER
SIDE RAIL
AK000196AB
CAUTION
Do not use any piston ring expander when installing the
SIDE RAIL END
side rail. It will break the side rail.
2. Install the upper side rail by hand.
To install the side rail, first fit one end of the rail into the
piston groove, then press the remaining portion into the
position. See illustration.
3. Install the lower side rail in the same procedure as described
in step 2.
4. Make sure that the side rails move smoothly in both
AKX00608AB
directions.
.
11B-48 ENGINE OVERHAUL <3.8L ENGINE>
PISTON AND CONNECTING ROD
NO.3
NO.6
NO.5
AKX00634AB
ENGINE OVERHAUL <3.8L ENGINE> 11B-49
PISTON AND CONNECTING ROD
IDENTIFICATION
COLOR
AKX00635AB
LOWER
NO.2 RING GAP SIDE RAIL
AND SPACER GAP
AKX00620AB
11B-50 ENGINE OVERHAUL <3.8L ENGINE>
PISTON AND CONNECTING ROD
FRONT MARK
AK201081AB
AKX00721
NOTCHES
AKX00735AB
2. Make sure that the connecting rod big end side clearance
meets the specification.
Standard value: 0.10 − 0.25 mm (0.004 − 0.009 inch)
Limit: 0.4 mm (0.02 inch)
AK201530
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-51
PISTON AND CONNECTING ROD
INSPECTION
M1113008500440
.
PISTON
Replace the piston if scratches or seizure is evident on its sur-
faces (especially the thrust surface). Replace the piston if it is
cracked.
.
PISTON PIN
1. Insert the piston pin into the piston pin hole with a thumb.
You should feel a slight resistance. Replace the piston pin if
it can be easily inserted or there is excessive play.
2. The piston and piston pin must be replaced as an assembly.
.
11B-52 ENGINE OVERHAUL <3.8L ENGINE>
PISTON AND CONNECTING ROD
PISTON RING
1. Check the piston ring for damage, excessive wear, and
breakage. Replace if defects are evident. If the piston has
been replaced with a new one, the piston rings must also be
replaced with new ones.
2. Check for clearance between the piston ring and ring
groove. If the limit is exceeded, replace the ring or piston, or
both.
Standard value:
Number 1: 0.03 − 0.07 mm (0.0012 − 0.0027 inch)
Number 2: 0.02 − 0.06 mm (0.0008 − 0.0023 inch)
Limit: 0.1 mm (0.003 inch)
AKX00612
3. Insert the piston ring into the cylinder bore. Force the ring
PUSH IN BY down with a piston, the piston crown being in contact with
PISTON the ring, to correctly position it at right angles to the cylinder
wall. Then, measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
Number 1: 0.25 − 0.40 mm (0.010 − 0.016 inch)
Number 2: 0.35 − 0.50 mm (0.014 − 0.020 inch)
PISTON Oil: 0.10 − 0.35 mm (0.004 − 0.014 inch)
PISTON RING RING GAP
AKX00719AB
Limit:
Number 1, Number 2: 0.8 mm (0.03 inch)
Oil: 1.0 mm (0.03 inch)
.
23 ± 2 N·m 3 5
17 ± 1 ft-lb
6
13 28 ± 2 N·m
21 ± 1 ft-lb
1
14
2
16
2.6 ± 0.2 N·m 11 ± 1 N·m
23 ± 1 in-lb 97 ± 9 in-lb
4
15
11 ± 1 N·m
97 ± 9 in-lb
11
12
10
1
3
AKX00649AB
FOR UPPER
FOR LOWER
AKX00623AB
THRUST
BEARING
AKX01393AB
.
11B-56 ENGINE OVERHAUL <3.8L ENGINE>
CRANKSHAFT AND CYLINDER BLOCK
BEARING CAP
CRANKSHAFT
CYLINDER BLOCK
AKX01395AB
1. Attach the bearing cap on the cylinder block as shown in the
illustration.
2. Tighten the bearing cap bolts to specified torque in the
sequence shown in the illustration.
Tightening torque: 74 ± 4 N⋅m (54 ± 3 ft-lb)
3. Check that the crankshaft rotates smoothly.
4. Check the end play. If it exceeds the limit value, replace the
thrust bearing.
Standard value: 0.05 − 0.25 mm (0.002 − 0.009 inch)
Limit: 0.3 mm (0.01 inch)
AK201528
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-57
CRANKSHAFT AND CYLINDER BLOCK
MD998718
OIL SEAL
CASE
AKX00693AB
INSPECTION
M1113008800322
.
AK101043AB
11B-58 ENGINE OVERHAUL <3.8L ENGINE>
CRANKSHAFT AND CYLINDER BLOCK
CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Use a flaw
detecting agent for the check. If defects are evident, correct
or replace.
2. Using a straightedge and feeler gauge, check the block top
surface for warpage. Make sure that the surface is free from
gasket chips and other foreign matter.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.003 inch)
3. If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: *0.2 mm (0.008 inch)
AKX00738
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):
227.9 − 228.1 mm (8.972 − 8.980 inches)
4. Check the cylinder walls for scratches and seizure. If defects
are evident, correct (bored to an oversize) or replace.
5. Using a cylinder gauge, measure the cylinder bore and
12 mm (0.47 in) cylindricality. If worn badly, correct by boring the cylinders to
CENTER an oversize and replace pistons and piston rings. Measure
BOTTOM at the points shown in the illustration.
Standard value:
Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)
AKX00739AB
.
ENGINE OVERHAUL <3.8L ENGINE> 11B-59
SPECIFICATIONS
BORING CYLINDER
1. Oversize pistons to be used should be determined on the
basis of the largest bore cylinder.
Piston size identification
SIZE IDENTIFICATION MARK
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1113023400688
ITEMS SPECIFICATIONS
Alternator and drive belt
Adjusting bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Crankshaft bolt 185 ± 5 N⋅m (137 ± 3 ft-lb)
Drive belt tensioner nut 49 ± 9 N⋅m (37 ± 6 ft-lb)
Alternator bolt 49 ± 9 N⋅m (37 ± 6 ft-lb)
Alternator bracket bolt 49 ± 9 N⋅m (37 ± 6 ft-lb)
Idler pulley nut 49 ± 9 N⋅m (37 ± 6 ft-lb)
11B-60 ENGINE OVERHAUL <3.8L ENGINE>
SPECIFICATIONS
ITEMS SPECIFICATIONS
Oil dipstick guide bolt 14 ± 1 N⋅m (122 ± 9 in-lb)
Power steering pump bracket bolt 41 ± 8 N⋅m (30 ± 6 ft-lb)
Power steering pump bracket stay bolt M8 24 ± 4 N⋅m (18 ± 3 ft-lb)
Power steering pump bracket stay bolt M10 44 ± 10 N⋅m (33 ± 7 ft-lb)
Tensioner bracket bolt (Flange bolt) 49 ± 9 N⋅m (37 ± 6 ft-lb)
Tensioner bracket bolt (Bolt, washer assembly) 41 ± 8 N⋅m (30 ± 6 ft-lb)
Intake manifold plenum and throttle body
Boost sensor bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Intake manifold plenum bolt 28 ± 4 N⋅m (21 ± 3 ft-lb)
Intake manifold plenum stay bolt M8 18 ± 2 N⋅m (13 ± 1 ft-lb)
Intake manifold plenum stay bolt M10 36 ± 6 N⋅m (27 ± 4 ft-lb)
Solenoid valve bolt 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Throttle body bolt 28 ± 4 N⋅m (21 ± 3 ft-lb)
Throttle body stay bolt 18 ± 2 N⋅m (13 ± 1 ft-lb)
Ignition system
Ignition coil bolt 10 ± 2 N⋅m (87 ± 17 in-lb)
Spark plugs 25 ± 5 N⋅m (18 ± 4 ft-lb)
Camshaft position sensor bolt 11 ± 1 N⋅m (95 ± 9 in-lb)
Camshaft position sensor support bolt 14 ± 1 N⋅m (122 ± 9 in-lb)
Camshaft position sensing cylinder bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Timing belt
Adjusting bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Auto-tensioner bolt 23 ± 3 N⋅m (18 ± 2 ft-lb)
Bracket bolt 24 ± 3 N⋅m (18 ± 2 ft-lb)
Camshaft sprocket bolt 88 ± 10 N⋅m (65 ± 7 ft-lb)
Crankshaft position sensor bolt 8.5 ± 0.5 N⋅m (76 ± 4 in-lb)
Engine support bracket bolt 45 ± 5 N⋅m (34 ± 4 ft-lb)
Idler pulley bolt 44 ± 5 N⋅m (33 ± 4 ft-lb)
Tensioner pulley bolt 48 ± 6 N⋅m (35 ± 4 ft-lb)
Tensioner arm bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Timing belt front cover bolt M6 11 ± 1 N⋅m (95 ± 9 in-lb)
Timing belt front cover bolt M8, M10 14 ± 1 N⋅m (122 ± 9 in-lb)
Timing belt rear cover bolt 14 ± 1 N⋅m (122 ± 9 in-lb)
Intake manifold and fuel parts
Injector and fuel rail bolt 12 ± 1 N⋅m (104 ± 9 in-lb)
Intake manifold nut 20 − 23 N⋅m (15 − 17 ft-lb)
Water pump and water pipes
Engine coolant temperature sensor 29 ± 10 N⋅m (22 ± 7 ft-lb)
Thermostat housing bolt M6 11 ± 1 N⋅m (95 ± 9 in-lb)
Thermostat housing bolt M8 19 ± 1 N⋅m (14 ± 1 ft-lb)
ENGINE OVERHAUL <3.8L ENGINE> 11B-61
SPECIFICATIONS
ITEMS SPECIFICATIONS
Water inlet fitting bolt 19 ± 1 N⋅m (14 ± 1 ft-lb)
Water pump bolt M8 24 ± 3 N⋅ (17 ± 2 ft-lb)
Water pump bolt M10 42 ± 8 N⋅m (31 ± 6 ft-lb)
Exhaust manifold
Connector bracket bolt 11 ± 1 N⋅m (95 ± 9 in-lb)
Engine hanger bolt 35 ± 6 N⋅m (26 ± 4 ft-lb)
Exhaust manifold nut 44 ± 5 N⋅m (33 ± 4 ft-lb)
Exhaust manifold stay bolt M8 19 ± 3 N⋅m (14 ± 2 ft-lb)
Exhaust manifold stay bolt M10 44 ± 8 N⋅m (33 ± 5 ft-lb)
Exhaust manifold stay bolt M12 75 ± 10 N⋅m (56 ± 7 ft-lb)
Heat protector bolt 14 ± 1 N⋅m (122 ± 9 in-lb)
Heated oxygen sensor 44 ± 5 N⋅m (33 ± 4 ft-lb)
Rocker arms and camshaft
Thrust case bolt 13 ± 2 N⋅m (115 ± 17 in-lb)
Positive crankcase ventilation valve 10 ± 2 N⋅m (87 ± 17 in-lb)
Rocker arms and shaft bolt 31 ± 3 N⋅m (23 ± 2 ft-lb)
Rocker cover bolt 3.5 ± 0.5 N⋅m (31 ± 4 in-lb)
Cylinder head and valve
Cylinder head bolt 108 ± 5 N⋅m (80 ± 4 ft-lb) → 0 N⋅m (0 in-lb)
→ 108 ± 5 N⋅m (80 ± 4 ft-lb)
Oil pan and oil pump
Baffle plate bolt 9.0 ± 2.0 N⋅m (80 ± 17 in-lb)
Cover bolt 10.8 ± 0.9 N⋅m (96 ± 7 in-lb)
Drain plug 39 ± 5 N⋅m (29 ± 4 ft-lb)
Engine oil pressure switch 10 ± 2 N⋅m (87 ± 17 in-lb)
Oil filter bracket bolt M8 23 ± 3 N⋅m (18 ± 2 ft-lb)
Oil filter bracket bolt M10 41 ± 8 N⋅m (30 ± 6 ft-lb)
Oil filter bracket cover bolt 11 ± 1 N⋅m (95 ± 9 in-lb)
Oil pan, lower bolt 11 ± 1 N⋅m (95 ± 9 in-lb)
Oil pan, upper bolt 9.0 ± 3.0 N⋅m (80 ± 26 in-lb)
Oil pump case bolt 14 ± 1 N⋅m (122 ± 9 in-lb)
Oil pump cover bolt 10 ± 2 N⋅m (87 ± 17 in-lb)
Oil screen bolt 19 ± 3 N⋅m (14 ± 2 ft-lb)
Relief plug 44 ± 5 N⋅m (33 ± 4 ft-lb)
Piston and connecting rod
Connecting rod cap nut 27 ± 2 N⋅m (20 ± 1 ft-lb) + 90° to 94°
Crankshaft and cylinder block
Bearing cap bolt 74 ± 4 N⋅m (54 ± 3 ft-lb)
Drive plate bolt A/T 74 ± 1 N⋅m (54 ± 1 ft-lb)
Flywheel bolts M/T 132 ± 5 N⋅m(97± 3 ft-lb
11B-62 ENGINE OVERHAUL <3.8L ENGINE>
SPECIFICATIONS
ITEMS SPECIFICATIONS
Knock sensor 23 ± 2 N⋅m (17 ± 1 ft-lb)
Knock sensor bracket bolt 28 ± 2 N⋅m (22 ± 1 ft-lb)
Oil seal case bolt 11 ± 1 N⋅m (95 ± 9 in-lb)
Rear plate bolt 11 ± 1 N⋅m (95 ± 9 in-lb)
GENERAL SPECIFICATIONS
M1113000200553
DESCRIPTIONS SPECIFICATIONS
Type 60° V, OHV, SOHC
Number of cylinders 6
Combustion chamber Pentroof type
Total displacement cm3 (cu in) 3,828 (233.6)
Cylinder bore mm (in) 95.0 (3.74)
Piston stroke mm (in) 90.0 (3.54)
Compression ratio 10.0
Valve timing Intake valve Opens (BTDC) 9°
Closes (ABDC) 59°
Exhaust valve Opens (BBDC) 47°
Closes (ATDC) 21°
Lubrication system Pressure feed, full-flow filtration
Oil pump type Trochoid type
ENGINE OVERHAUL <3.8L ENGINE> 11B-63
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1113000300516
GROUP 12
ENGINE
LUBRICATION
CONTENTS
GENERAL DESCRIPTION
M1121000100410
The lubrication method is a fully force-fed, full-flow filtration type.
ITEM SPECIFICATION
Oil pump type
3.8L Engine Trochoid type
Drive method Crankshaft
ENGINE OILS
WARNING
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains
potentially harmful contaminants which may cause skin cancer. Adequate means of skin pro-
tection and washing facilities must be provided.
• Where there is a risk of eye contact, eye protec-
.
SPECIAL TOOLS
M1121000600404
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MB991610 General service tool Removal and installation
Oil filter wrench of engine oil filter (when
using oil filter MD356000)
MB991610
ON-VEHICLE SERVICE
ENGINE OIL CHECK
M1121000900397
1. Pull out the oil dipstick slowly and check that the oil level is
within the marks on the oil dipstick.
GOOD 2. Check that the oil is not excessively dirty, that there is no
coolant or gasoline mixed in, and that it has sufficient
viscosity.
MAXIMUM MINIMUM
AC205268 AB
<3.8L ENGINE> 4. Install a new drain plug gasket so that it faces in the
direction shown in the illustration, and then tighten the drain
plug to the specified torque.
OIL PAN SIDE Tightening torque: 39 ± 5 N⋅m (29 ± 3 ft-lb)
5. Refill the specified quantity of oil.
Select engine oil of ther proper SAE viscosity number
39 ± 5 N·m according to the atmospheric temperature SAE
DRAIN PLUG 29 ± 3 ft-lb 0W-30, 5W-30 and 5W-40 engine oils can only be used
GASKET if they meet ACEA A3 and API SG (or higher) specififi-
AC305937AB
cations.
AC000093 AG
ENGINE LUBRICATION 12-5
ON-VEHICLE SERVICE
O-RING
ACX00396 AB
8. Install the drain plug and refill engine oil (Refer to Engine Oil
Replacement P.12-3).
9. Rev the engine a few times, and check to be sure that no
engine oil leaks at the oil filter.
ENGINE LUBRICATION 12-6
ON-VEHICLE SERVICE
MD998054
AKX00294 AB
AKX00295 AB
ENGINE LUBRICATION 12-7
SPECIFICATIONS
CAUTION
Do not start the engine within one hour after the engine
MD998054 engine oil pressure switch has been installed.
8. Use special tool MD998054 to tighten the engine oil
pressure switch to the specified torque.
Tightening torque:
<3.8L ENGINE> 10 ± 2 N⋅m (87 ± 17 in-lb)
AKX00294 AB
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1121002200305
ITEM SPECIFICATION
Engine oil filter
MD136466, MD322508 17 ± 3 N⋅m (13 ± 2 ft-lb)
Engine oil pan drain plug 39 ± 5 N⋅m (29 ± 3 ft-lb)
Engine oil pressure switch
3.8L Engine 10 ± 2 N⋅m (87 ± 17 in-lb)
SERVICE SPECIFICATIONS
M1121000300221
ITEM STANDARD VALUE
Engine oil pressure kPa (psi) at idle 29 (4.2) or more
at 3,500 r/min 294 − 686 (43 − 100)
SEALANT
M1121000500225
ITEM SPECIFIED SEALANT
Engine oil pressure switch 3M™ AAD Part No. 8672 or equivalent
LUBRICANT
M1121000400701
ITEM ENGINE OIL QUANTITY (litres)
Oil filter Engine oils conforming to ACEA A1, A2 or 0.3
A3 and API classification SG or higher.
Total quantity
3.8 L Engine 4.0
ENGINE LUBRICATION 12-8
SPECIFICATIONS
HOME
13-1
GROUP 13
FUEL
CONTENTS
GROUP 13A
MULTIPOINT FUEL
INJECTION (MPI)
CONTENTS
GENERAL DESCRIPTION
M1131000101908
. .
The Multipoint Fuel Injection System consists of sen- IDLE AIR CONTROL
sors which detect the engine conditions, the The idle speed is kept at the optimum speed by con-
ENGINE- ECU which controls the system based on trolling the amount of air that passes through the
signals from these sensors, and actuators which throttle valve in accordance with changes in idling
operate under the control of the ENGINE-ECU. conditions and engine load during idling.
The ENGINE-ECU carries out activities such as fuel The ENGINE-ECU drives the throttle actuator control
injection control, idle air control, and ignition timing motor to keep the engine running at the pre-set idle
control. target speed in accordance with the engine coolant
In addition, the ENGINE-ECU is equipped with a temperature and A/C and other electrical load. In
number of diagnostic test modes which simplify trou- addition, when the air conditioning switch is turned
bleshooting when a problem develops. off and on while the engine is idling, the throttle actu-
. ator control motor adjusts the throttle valve passes
FUEL INJECTION CONTROL through air amount according to the engine load con-
The injector drive times and injector timing are con- ditions to avoid fluctuations in the engine speed.
trolled so that the optimum air/fuel mixture is sup- .
INJECTOR
CAMSHAFT EVAPORATIVE
POSITION EMISSION
SENSOR PURGE SOLENOID
FUEL
LEFT BANK HEATED OXYGEN LEVEL
SENSOR (FRONT) SENSOR
LEFT BANK HEATED OXYGEN
GHT BANK SENSOR (REAR)
ATED FUEL PRESSURE
YGEN REGULATOR
NSOR
RONT)
NOTE: For the vacuum routing, refer to GROUP 17, Emission Control System − Vacuum Hoses − Vacuum
Hose Routing P.17-77.
MULTIPOINT FUEL INJECTION (MPI) 13A-5
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
MB991910
MB991824
MB991827 00DB076A
MULTIPOINT FUEL INJECTION (MPI) 13A-8
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
MB991910
MB991824
MB991827 00DB076A
MULTIPOINT FUEL INJECTION (MPI) 13A-9
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
ON-BOARD DIAGNOSTICS
The Engine-ECU monitors the input/output signals (some signals all the time and others under specified con-
ditions) of the ENGINE-ECU. When a malfunction continues for a specified time or longer after the irregular
signal is initially monitored, the ENGINE-ECU judges that a malfunction has occurred. After the
ENGINE-ECU first detects a malfunction, a diagnostic trouble code is recorded when the engine is restarted
and the same malfunction is re-detected. However, for items marked with a "*", a diagnostic trouble code is
recorded on the first detection of the malfunction. The diagnostic results can be read out with a diagnostic
tool. The diagnostic results are memorized even if the ignition key is turned off or battery terminals are dis-
connected. In addition, the diagnostic trouble code can also be erased by turning the ignition switch to ON
and sending the diagnostic trouble code erase signal from diagnostic tool to the ENGINE-ECU.
NOTE: If the sensor connector is disconnected with the ignition switch turned on, the diagnostic trouble code
is memorized. In this case, send the diagnostic trouble code erase signal to the ENGINE-ECU in order to
erase the diagnostic memory. The diagnostic items are all indicated sequentially from the smallest code num-
ber.
MULTIPOINT FUEL INJECTION (MPI) 13A-11
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
PROCEDURE 1
CATALYTIC CONVERTER MONITOR
DTC P0421, P0431
Drive cycle This monitor [from start to ignition switch "LOCK" (OFF) position] will be completed while
pattern driving the vehicle with the following drive cycle pattern. It will take 20 minutes. You must
complete this drive twice.
NOTE: Vehicle speed and throttle opening angle should be within the shaded range.
5 MINUTES OR MORE
72 - 97 km/h
ENGINE IGNITION
START SWITCH:
100 "LOCK"
(OFF)
CALCULATED
LOAD (%)
50
PROCEDURE 2
HEATED OXYGEN SENSOR MONITOR
DTC P0133, P0139, P0153, P0159.
Drive cycle This monitor [from start to ignition switch "LOCK" (OFF) position] will be completed while
pattern driving the vehicle with the following drive cycle pattern. It will take 5 minutes or more. You
must complete this drive twice.
97
2 MINUTES OR MORE
56 - 64 km/h
64 (3)
VEHICLE SPEED
km/h
32 (2) DURING MONITOR (4)
(1)
0
ENGINE IGNITION
START SWITCH: "LOCK"
100 (OFF)
CALCULATED
LOAD (%) 50
03DB262A
PROCEDURE 3
OTHER MONITOR (Main components, sensors and switches, wire breakage and short circuit)
DTC • Main components: P0106, P0107, P0108, P0134, P0154, P0300, P0301, P0302, P0303,
P0304, P0305, P0306, P0506, P0507
• Sensors and switches: P0101, P0102, P0103, P0111, P0112, P0113, P0116, P0117,
P0118, P0125, P0335, P0340, P0461.
• Wire breakage and short circuit: P0130, P0131, P0132, P0135, P0136, P0137, P0138,
P0140, P0150, P0151, P0152, P0155, P0156, P0157, P0158, P0160, P0161, P0201,
P0202, P0203, P0204, P0205, P0206, P0443.
Drive cycle This monitor [from start to ignition switch "LOCK" (OFF) position] will be completed while
pattern driving the vehicle with the following drive cycle pattern. It will take 10 minutes. You must
complete this drive twice.
NOTE: Drive according to the graph below.
5 MINUTES OR MORE
56 - 64 km/h
64
(3)
(4)
VEHICLE 32 ENGINE: IDLING
SPEED (2) TRANSMISSION: NEUTRAL
km/h 5 MINUTES
(1)
0
CALCULATED
LOAD (%) 50
03DB263A
CAUTION
During diagnosis, a DTC code associated with other systems may be set when the ignition switch is
turned on with connector(s) disconnected. On completion, confirm all systems for DTC(s). If DTC(s)
are set, erase them all.
NOTE: If the Check Engine Warning Lamp illuminates because of a malfunction of the Engine-ECU,
DTC - P0606 will be initialised. In this case, the ENGINE - ECU is the most probable cause. Refer to
DTC-P0606 in table for diagnosis.
DTC DIAGNOSTIC ITEM REFERENCE
PAGE
P0031 Heated oxygen sensor heater circuit low ( bank 1 sensor 1) P.13A-24
P0032 Heated oxygen sensor heater circuit high ( bank 1 sensor 1) P.13A-34
P0037 Heated oxygen sensor heater circuit low ( bank 1 sensor 2) P.13A-37
P0038 Heated oxygen sensor heater circuit high ( bank 1 sensor 2) P.13A-47
P0051 Heated oxygen sensor heater circuit low ( bank 2 sensor 1) P.13A-50
P0052 Heated oxygen sensor heater circuit high ( bank 2 sensor 1) P.13A-60
P0057 Heated oxygen sensor heater circuit low ( bank 2 sensor 2) P.13A-63
P0058 Heated oxygen sensor heater circuit high ( bank 2 sensor 2) P.13A-73
P0074 Ambient air temperature intermittant P.13A-76
P0101* Mass airflow circuit range/performance problem P.13A-78
P0102* Mass airflow circuit low input P.13A-81
P0103* Mass airflow circuit high input P.13A-87
P0106 Manifold absolute pressure circuit range/performance problem P.13A-92
P0107 Manifold absolute pressure circuit low input P.13A-101
P0108 Manifold absolute pressure circuit high input P.13A-109
P0112 Intake air temperature circuit low input P.13A-116
P0113 Intake air temperature circuit high input P.13A-120
P0116 Engine coolant temperature circuit range/performance problem P.13A-127
P0117 Engine coolant temperature circuit low input P.13A-134
P0118 Engine coolant temperature circuit high input P.13A-139
P0122* Throttle position sensor (main) circuit low input P.13A-148
P0123* Throttle position sensor (main) circuit high input P.13A-155
P0130 Heated oxygen sensor circuit (bank 1 sensor 1) P.13A-160
P0131 Heated oxygen sensor circuit low voltage (bank 1 sensor 1) P.13A-166
P0132 Heated oxygen sensor circuit high voltage (bank 1 sensor 1) P.13A-172
P0133 Heated oxygen sensor circuit slow response (bank 1 sensor 1) P.13A-177
P0134 Heated oxygen sensor circuit no activity detected (bank 1 sensor 1) P.13A-179
P0136 Heated oxygen sensor circuit (bank 1 sensor 2) P.13A-186
P0137 Heated oxygen sensor circuit low voltage (bank 1 sensor 2) P.13A-192
P0138 Heated oxygen sensor circuit high voltage (bank 1 sensor 2) P.13A-198
MULTIPOINT FUEL INJECTION (MPI) 13A-18
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
NOTE:
• Check that the ENGINE-ECU ground circuit is normal before checking for the cause of the problem.
• After the ENGINE-ECU detects a malfunction, a diagnostic trouble code is recorded the next time the
engine is started and the same malfunction is re-detected. However, for items marked with a "*", the diag-
nostic trouble code is recorded on the first detection of the malfunction.
• After the Check Engine Warning Lamp) illuminates, it will be switched off under the following conditions.
• When the ENGINE-ECU monitored the engine malfunction four times* and met set condition require-
ments, it detected no malfunction.
*: In this case, "one time" indicates from engine start to stop.
• For misfiring or a fuel trim malfunction, when driving conditions (engine speed, engine coolant temper-
ature, 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 sen-
sor mounted at the position second closest to the engine.
• Bank 1 indicates the right bank side cylinder, and Bank 2 indicates the left bank side cylinder.
MULTIPOINT FUEL INJECTION (MPI) 13A-21
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
SYMPTOM CHART
M1131151500726
CAUTION
During diagnosis, a DTC associated with other system may be set when the ignition switch is turned
on with connector(s) disconnected. On completion, confirm all systems for DTC(s). If DTC(s) are set,
erase them all.
CAUTION
Disconnecting the battery cables or removing the combination meter will erase the learned value of
the fuel gauge. To recover the learned value, input a vehicle speed (by actually driving the vehicle or
inputting a simulated vehicle speed), and stop the vehicle. This will complete the learning process.
.
NOTE: Check that the ENGINE-ECU ground circuit is normal before checking for the cause of the problem.
ITEMS SYMPTOM
At driving Hesitation Sag "Hesitation" is the delay in
VEHICLE
response of the vehicle speed SPEED
(engine speed). This occurs when HESITATION
the accelerator is depressed in INITIAL NORMAL
ACCELE-
order to accelerate from the speed RATOR
at which the vehicle is now PEDAL
DEPRE-
traveling, or a temporary drop in SSION
vehicle speed (engine speed)
during such acceleration. SAG
Serious hesitation is called "sag".
TIME
AKX01361
AKX01361AB
IDLING STUMBLE
TIME AKX01362
DTC P0031: Heated Oxygen Sensor Heater Circuit low (bank 1, sensor 1).
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3 16DB400A
AK303014 AB
THROTTLE BODY
B-09 (B)
AK303047 AB
. .
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-26
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-27
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
03DB200A
MULTIPOINT FUEL INJECTION (MPI) 13A-28
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-29
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB201A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-30
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-31
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-32
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-33
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
DTC P0032: Heated Oxygen Sensor Heater Circuit high (bank 1, sensor 1).
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3 16DB400A
AK303014 AB
THROTTLE BODY
B-09 (B)
AK303047 AB
. .
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: ENGINE-ECU Check Harness
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-36
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
DTC P0037: Heated Oxygen Sensor Heater Circuit low (bank 1, sensor 2).
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
16DB400A
4 3 4 3 4 3 4 3
CONNECTOR: B-08
B-17X
AK303014 AB
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
B-08 (GR)
AK303063AB
. .
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
MULTIPOINT FUEL INJECTION (MPI) 13A-39
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
MULTIPOINT FUEL INJECTION (MPI) 13A-40
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
03DB205A
MULTIPOINT FUEL INJECTION (MPI) 13A-41
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-42
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB206A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-43
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-44
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-45
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-08
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
MULTIPOINT FUEL INJECTION (MPI) 13A-46
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
DTC P0038: Heated Oxygen Sensor Heater Circuit high (bank 1, sensor 2).
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3 16DB400A
CONNECTOR: B-08
B-17X
AK303014 AB
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
B-08 (GR)
AK303063AB
. .
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-49
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
B-08 (GR)
AK303063AB
DTC P0051: Heated Oxygen Sensor Heater Circuit low (bank 2, sensor 1).
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3 16DB400A
CONNECTOR: B-25
B-17X
AK303014 AB
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
AK303070 AB
. .
Judgment Criteria
.
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-52
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-53
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
03DB210A
MULTIPOINT FUEL INJECTION (MPI) 13A-54
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-55
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB211A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-56
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-57
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-58
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-25
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-59
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
DTC P0052: Heated Oxygen Sensor Heater Circuit high (bank 2, sensor 1).
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3 16DB400A
CONNECTOR: B-25
B-17X
AK303014 AB
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
AK303070 AB
. .
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-62
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
DTC P0057: Heated Oxygen Sensor Heater Circuit low (bank 2, sensor 2).
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3 16DB400A
CONNECTOR: B-24
B-17X
AK303014 AB
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
. .
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-65
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-66
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
03DB229A
MULTIPOINT FUEL INJECTION (MPI) 13A-67
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-68
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB215A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-69
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-70 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-71
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-24
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
13A-72 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
DTC P0058: Heated Oxygen Sensor Heater Circuit high (bank 2, sensor 2).
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3 16DB400A
CONNECTOR: B-24
B-17X
AK303014 AB
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
. .
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
MULTIPOINT FUEL INJECTION (MPI) 13A-75
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
MFI RELAY
B-10 (GR)
03DB217A
MFI RELAY
FRONT OF VEHICLE
AIR
CLEANER 2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3
COVER
ENGINE B-17X
CONTROL
UNIT
AK303014 AB
16DB400A
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• No circuit - IC internal test. • Ambient air temperature is derived from the
Intake air temperature.
.
MB991827 00DB076A
CAUTION
CONNECTOR: B-17X
If DTC P0101 has been set, TCL related DTC
U1120 is also set. After P0101 has been diag-
nosed, don't forget to erase DTC U1120.
CONNECTOR: B-10
MFI RELAY
MASS
AIRFLOW
SENSOR
B-10 (GR)
MFI RELAY
FRONT OF VEHICLE
03DB217A
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3
AIR B-17X
CLEANER
AK303014 AB
COVER
ENGINE
CONTROL
UNIT
16DB400A
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• The mass airflow sensor power is supplied from • While the engine is running, the mass airflow
the MPI relay (terminal No. 4), and the ground is sensor outputs voltage which corresponds to the
provided on the ENGINE-ECU (terminal No. 11). mass airflow rate.
• 5-volt power is applied to the mass airflow sensor • The ENGINE-ECU checks whether the voltage
output terminal (terminal No. 4) from the output by the mass airflow sensor while the
ENGINE-ECU (terminal No. 11). engine is running is within a specified speed and
load range.
.
• Air flow sensor output is above upper threshold TROUBLESHOOTING HINTS (The most
(40.9-903.0 kg/h) for 4 seconds. likely causes for this code to be set are:)
• MIL is activated immediately.
• Mass airflow sensor failed.
• No limp home mode.
• Mass airflow sensor circuit harness damage, or
.
connector damage.
• Refer to component locations GROUP-70
• Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MFI RELAY
03DB217A
AIR
CLEANER
B-17X
AK303014 AB
16DB400A
CIRCUIT OPERATION
• The mass airflow sensor power is supplied from Judgement Criteria
the MPI relay (terminal No. 4), and the ground is • Air flow sensor output is below lower threshold
provided on the ENGINE-ECU (terminal No. 11). (0-283.0 kg/h) for 4 seconds.
• 5-volt power is applied to the mass airflow sensor • MIL is activated immediately.
output terminal (terminal No. 4) from the • No limp home mode.
ENGINE-ECU (terminal No. 11). .
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: ECU Check Harness
B-10 (GR)
03DB218A
MULTIPOINT FUEL INJECTION (MPI) 13A-83
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-10 HARNESS
CONNECTOR:
COMPONENT SIDE
03DB220A
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
13A-84 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB225A
MULTIPOINT FUEL INJECTION (MPI) 13A-85
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-10 (GR)
03DB218A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB218A
13A-86 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 10. Using diagnostic tool , check data list item AA:
Mass Airflow Sensor.
CAUTION
To prevent damage to diagnostic tool , always turn the
DATA LINK ignition switch to the "LOCK" (OFF) position before con-
CONNECTOR
necting or disconnecting diagnostic tool .
(1) Connect diagnostic tool to the data link connector.
(2) Start the engine and run at idle.
(3) Set diagnostic tool to the data reading mode for item AA,
Mass Airflow Sensor.
(4) Warm up the engine to normal operating temperature: 80°C
to 95°C (176°F to 203°F).
MB991910
• The standard value during idling should be approxi-
mately 4.7 g/sec.
MB991824
• When the engine is revved, the mass airflow rate should
increase according to the increase in engine speed.
(5) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the sensor operating properly?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points − How to
MB991827 00DB076A
Cope with Intermittent Malfunctions P.00-14.
NO : Then go to Step 11.
CAUTION
CONNECTOR: B-10
If DTC P0103 has been set, TCL related DTC
U1120 is also set. After P0103 has been diag- MASS
AIRFLOW
nosed, don't forget to erase DTC U1120. SENSOR
CONNECTOR: B-17X
B-10 (GR)
MFI RELAY
03DB217A
AIR
CLEANER
B-17X
AK303014 AB
16DB400A
CIRCUIT OPERATION
• The mass airflow sensor power is supplied from Judgement Criteria
the MPI relay (terminal No. 4), and the ground is • Air flow sensor output is above upper threshold
provided on the ENGINE-ECU (terminal No. 11). (40.9-903.0 kg/h) for 4 seconds.
• 5-volt power is applied to the mass airflow sensor • MIL is activated immediately.
output terminal (terminal No. 4) from the • No limp home mode.
ENGINE-ECU (terminal No. 11). .
DIAGNOSIS
Required Special Tool:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
B-10 (GR)
03DB218A
MULTIPOINT FUEL INJECTION (MPI) 13A-89
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
03DB218A
B-10 HARNESS
CONNECTOR:
COMPONENT SIDE
03DB219A
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-90 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-10 (GR)
03DB218A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-91
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
CONNECTOR: B-02
MANIFOLD
ABSOLUTE
PRESSURE AIR
INTAKE SENSOR CLEANER
MANIFOLD
03DB222A
16DB400A
. .
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: ECU Check Harness
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
03DB225A
MULTIPOINT FUEL INJECTION (MPI) 13A-95
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-96 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-97
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB242A
13A-98 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-99
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-02
MANIFOLD
ABSOLUTE
PRESSURE AIR
INTAKE SENSOR CLEANER
MANIFOLD
03DB222A
16DB400A
. .
• None
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are: )
Judgement Criteria • Manifold absolute pressure sensor failed.
• MAP sensor output voltage is below 0.2 V for 2 • Open or shorted manifold absolute pressure sen-
seconds. sor circuit, harness damage or connector dam-
• MIL is activated after 2 Drive cycles. age.
• No limp home mode (backed-up by AFS). • Refer to component locations GROUP-70
. • Refer to configuration diagrams GROUP-80
EOBD DRIVE CYCLE PATTERN • Refer to circuit diagrams GROUP-90
Refer to Diagnostic Function − EOBD Drive Cycle −
P.13A-11.
13A-102 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: ECU Check Harness
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB225A
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-104 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-106 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-108 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-02
MANIFOLD
ABSOLUTE
PRESSURE AIR
INTAKE SENSOR CLEANER
MANIFOLD
3 2 1 03DB223A
16DB400A
. .
• None
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are: )
Judgement Criteria • Refer to component locations GROUP-70
• MAP sensor output voltage is above 4.88 V for 2 • Refer to configuration diagrams GROUP-80
seconds. • Refer to circuit diagrams GROUP-90
.
• Manifold absolute pressure sensor failed.
EOBD DRIVE CYCLE PATTERN • Open manifold absolute pressure sensor circuit,
Refer to Diagnostic Function − EOBD Drive Cycle − or connector damage.
P.13A-11. • ENGINE-ECU failed.
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
13A-110 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AK303030 AB
13A-112 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-113
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-114 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
MB991910
MB991824
MB991827 00DB076A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-115
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
CONNECTOR: B-10
MASS AIR CLEANER
AIRFLOW
SENSOR
B-10 (GR)
B-21 (B)
B-22 (B)
03DB217A
AK303013 AB
• None
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are:)
Judgement Criteria • Intake air temperature sensor failed.
• Intake air temperature is below -38.3 degreeC for • Shorted intake air temperature sensor circuit, or
2 seconds. connector damage.
• MIL is activated after 2 Drive cycles. • Refer to component locations GROUP-70
• No limp home mode. • Refer to configuration diagrams GROUP-80
. • Refer to circuit diagrams GROUP-90
EOBD DRIVE CYCLE PATTERN
Refer to Diagnostic Function − EOBD Drive Cycle −
P.13A-11.
DIAGNOSIS
Required Special Tool:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPOINT FUEL INJECTION (MPI) 13A-117
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
B-10 (GR)
03DB218A
13A-118 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-10 (GR)
03DB218A
(2) Measure the resistance between intake air temperature
INTAKE AIR TEMPERATURE
sensor side connector terminal No. 1 and No. 3.
SENSOR CONNECTOR • There should be continuity. (0.30 − 16 kΩ)
Q: Is the measured resistance between 0.30 and 16 kΩ?
YES : Go to Step 4.
NO : Replace the Mass Airflow Sensor assembly. Then go
to Step 6.
03DB158A
B-10 (GR)
03DB218A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-119
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-10
MASS AIR CLEANER
AIRFLOW
SENSOR
B-10 (GR)
B-21 (B)
B-22 (B)
03DB217A
AK303013 AB
CIRCUIT OPERATION
increases when the resistance increases and
• Approximately 5 volts are applied to the intake air decreases when the resistance decreases.
temperature sensor output terminal (terminal No.
1) from the ENGINE-ECU (terminal No. 58) via .
• None.
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are:)
Judgement Criteria • Intake air temperature sensor failed.
• Intake air temperature is above 135 degreeC for • Open intake air temperature sensor circuit, or
2 seconds. connector damage.
• MIL is activated after 2 Drive cycles. • Refer to component locations GROUP-70
• No limp home mode. • Refer to configuration diagrams GROUP-80
.
• Refer to circuit diagrams GROUP-90
EOBD DRIVE CYCLE PATTERN
Refer to Diagnostic Function − EOBD Drive Cycle −
P.13A-11.
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: ECU Check Harness
MULTIPOINT FUEL INJECTION (MPI) 13A-121
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
B-10 (GR)
03DB218A
13A-122 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-10 (GR)
03DB218A
03DB158A
B-10 (GR)
03DB218A
03DB226A
MULTIPOINT FUEL INJECTION (MPI) 13A-123
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
16DB400A
B-20 HARNESS
CONNECTOR
03DB227A
16DB400A
13A-124 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
16DB400A
B-10 (GR)
03DB218A
03DB219A
MULTIPOINT FUEL INJECTION (MPI) 13A-125
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-10 (GR)
03DB218A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-126 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
CONNECTOR: B-104
AIR CLEANER
B-104 (B)
THROTTLE
ENGINE BODY B-21 (B)
COOLANT B-22 (B)
TEMPERATURE
SENSOR
AK303036AB
AK303013 AB
MB991827 00DB076A
AKX01622
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
13A-130 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
AK000235 AQ
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-131
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-132 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-133
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
CAUTION
If DTC P0117 has been set, TCL and air condi-
tioner related DTC U1120 is also set. After P0117
has been diagnosed, don't forget to erase DTC AIR
CLEANER
U1120.
THROTTLE
ENGINE BODY
COOLANT
TEMPERATURE
SENSOR
AK303036AB 16DB400A
MB991827 00DB076A
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
13A-136 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-137
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
AKX01622
CAUTION
If DTC P0118 has been set, TCL and air condi-
tioner related DTC U1120 is also set. After P0118
has been diagnosed, don't forget to erase DTC AIR
CLEANER
U1120.
THROTTLE
ENGINE BODY
COOLANT
TEMPERATURE
SENSOR
AK303036AB 16DB400A
MB991827 00DB076A
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
MULTIPOINT FUEL INJECTION (MPI) 13A-141
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
AK303039 AB
13A-142 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
16DB400A
03DB228A
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-143
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
AK303040 AB
13A-144 MULTIPOINT FUEL INJECTION (MPI)
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPOINT FUEL INJECTION (MPI) 13A-145
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
COMPONENT SIDE AK303037AB
AKX01622
MB991827 00DB076A
NEXT PAGE
PREVIOUS PAGE MULTIPORT FUEL INJECTION (MPI)
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
13A-148
13A
CAUTION
If DTC P0122 has been set, TCL related DTC
U1120 is also set. After P0122 has been diag-
AIR
nosed, don't forget to erase DTC U1120. CLEANER
CONNECTOR: B-06
COVER
ENGINE
CONTROL
UNIT
B-06 (B)
03DB180A
16DB400A
. .
27).
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB991658: Test Harness
WARNING
If the air intake duct is removed from the throttle body take great care to keep fingers away
from the throttle plate. The drive motor has very high torque and is capable of random move-
ment at any time. Do not under any circumstances activate the throttly plate by hand.
When removing the throttle body from the intake manifold disconnect the wiring first. During
replacement connect the wiring last.
Do not activate the throttle body using a DC suppy to test the motor,as permanent damage to
the throttle body will result.
B-06 (B)
03DB180A
B-06 (B)
03DB180A
(3) Measure the voltage between terminal No. 3 and ground.
THROTTLE ACTUATOR
CONTROL MOTOR • Voltage should be between 4.9 and 5.1 volts.
CONNECTOR (4) Turn the ignition switch to the "LOCK"(OFF) position.
Q: Is the measured voltage between 4.9 and 5.1 volts?
YES : Go to Step 6.
NO : Go to Step 4.
03DB195A
MULTIPORT FUEL INJECTION (MPI) 13A-151
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-152
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-153
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB180A
MULTIPORT FUEL INJECTION (MPI) 13A-154
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-155
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
CAUTION
If DTC P0123 has been set, TCL related DTC
U1120 is also set. After P0123 has been diag-
AIR
nosed, don't forget to erase DTC U1120. CLEANER
CONNECTOR: B-06
COVER
ENGINE
CONTROL
UNIT
B-06 (B)
03DB180A
16DB400A
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• A 5-volt power supply is applied on the throttle • The throttle position sensor (main) outputs volt-
position sensor (main) power terminal (terminal age which corresponds to the throttle valve open-
No. 3) from the ENGINE-ECU (terminal No. 10). ing angle.
The ground terminal (terminal No. 2) is grounded • The ENGINE-ECU checks whether the voltage is
with ENGINE-ECU (terminal No. 27). within a specified range.
.
WARNING
If the air intake duct is removed from the throttle body take great care to keep fingers away
from the throttle plate. The drive motor has very high torque and is capable of random move-
ment at any time. Do not under any circumstances activate the throttly plate by hand.
When removing the throttle body from the intake manifold disconnect the wiring first. During
replacement connect the wiring last.
Do not activate the throttle body using a DC suppy to test the motor,as permanent damage to
the throttle body will result.
B-06 (B)
03DB180A
MULTIPORT FUEL INJECTION (MPI) 13A-157
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-06 (B)
03DB180A
03DB197A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-158
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB180A
MULTIPORT FUEL INJECTION (MPI) 13A-159
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-160
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
THROTTLE BODY
AK303047 AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Check Conditions
tration in the exhaust gas is sent to the • Battery voltage < 11.02 volts
ENGINE-ECU (terminal No. 45) from the output • Engine coolant temperature is higher than 80°C.
terminal (terminal No. 1) of the right bank heated
Judgment Criteria
oxygen sensor (front).
• Idling.
• Terminal No. 2 of the right bank heated oxygen
• MIL is activated after 2 Drive cycles.
sensor (front) is grounded with ENGINE-ECU
• No limp home.
(terminal No. 44).
.
TECHNICAL DESCRIPTION
• The right bank heated oxygen sensor (front) Refer to Diagnostic Function − EOBD Drive Cycle −
detects the concentration of oxygen in the P.13A-11.
exhaust gas; it converts those data to voltage, .
and inputs the resulting signals to the TROUBLESHOOTING HINTS (The most
ENGINE-ECU. likely causes for this code to be set are: )
• When the right bank heated oxygen sensor • Right bank heated oxygen sensor (front) failed.
(front) begins to deteriorate, the heated oxygen • Short circuit in right bank heated oxygen sensor
sensor signal response becomes poor. (front) output line to heater circuit ground line.
• The ENGINE-ECU forcibly varies the air/fuel mix- • Wiring harness or connector damage.
ture to make it leaner and richer, and checks the • Refer to component locations GROUP-70
response speed of the right bank heated oxygen • Refer to configuration diagrams GROUP-80
sensor (front). In addition, the ENGINE-ECU also • Refer to circuit diagrams GROUP-90
checks for an open circuit in the right bank
heated oxygen sensor (front) output line. NOTE: To assist in diagnosis check the Freeze
Frame Data on diagnostic tool for records of engine
.
conditions when the DTC was detected.
MULTIPORT FUEL INJECTION (MPI) 13A-161
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: ENGINE-ECU Check Harness
16DB400A
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-164
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-165
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0131: Heated Oxygen Sensor Circuit Low Voltage (bank 1, sensor 1).
COVER
ENGINE
CONTROL
UNIT
THROTTLE BODY
16DB400A
B-09 (B)
AK303047 AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Check Conditions
tration in the exhaust gas is sent to the • Battery voltage < 11.02 volts
ENGINE-ECU (terminal No. 45) from the output • Engine coolant temperature is higher than 80°C.
terminal (terminal No. 1) of the right bank heated
oxygen sensor (front). Judgement Criteria
• Terminal No. 2 of the right bank heated oxygen • Internal Resistance of the Nernst - cell is equal or
sensor (front) is grounded with ENGINE-ECU greater than a modelled resistance based on the
(terminal No. 44). heating output of the O2-sensor and the mod-
elled exhasused gas temperature
.
• Idling.
TECHNICAL DESCRIPTION • MIL is activated after 2 Drive cycles.
• The right bank heated oxygen sensor (front) • No limp home.
detects the concentration of oxygen in the
exhaust gas; it converts those data to voltage,
.
and inputs the resulting signals to the EOBD DRIVE CYCLE PATTERN
ENGINE-ECU. Refer to Diagnostic Function − EOBD Drive Cycle −
• When the right bank heated oxygen sensor P.13A-11.
(front) begins to deteriorate, the heated oxygen .
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: ENGINE-ECU Check Harness
COVER
ENGINE
CONTROL
UNIT
16DB400A
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-170
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-171
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0132: Heated Oxygen Sensor Circuit High Voltage (bank 1, sensor 1).
COVER
ENGINE
CONTROL
UNIT
THROTTLE BODY
16DB400A
B-09 (B)
AK303047 AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Check Conditions
tration in the exhaust gas is sent to the • Battery voltage < 11.02 volts
ENGINE-ECU (terminal No. 45) from the output • Engine coolant temperature is higher than 80°C.
terminal (terminal No. 1) of the right bank heated
oxygen sensor (front). Judgment Criteria
• Terminal No. 2 of the right bank heated oxygen • Internal Resistance of the Nernst - cell is equal or
sensor (front) is grounded with ENGINE-ECU greater than a modelled resistance based on the
(terminal No. 44). heating output of the O2-sensor and the mod-
elled exhasused gas temperature.
.
• Idling.
TECHNICAL DESCRIPTION • MIL is activated after 2 Drive cycles.
• The right bank heated oxygen sensor (front) • No limp home.
detects the concentration of oxygen in the
exhaust gas; it converts those data to voltage,
.
and inputs the resulting signals to the EOBD DRIVE CYCLE PATTERN
ENGINE-ECU. Refer to Diagnosis Function − EOBD Drive Cycle −
• When the right bank heated oxygen sensor P.13A-11.
(front) begins to deteriorate, the heated oxygen .
DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-175
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-176
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0133: Heated Oxygen Sensor Circuit Slow Response (bank 1, sensor 1).
COVER
ENGINE
CONTROL
UNIT
THROTTLE BODY
AK303047 AB
. .
DTC P0134: Heated Oxygen Sensor Circuit No Activity Detected (bank 1, sensor 1).
.
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB199A
MULTIPORT FUEL INJECTION (MPI) 13A-182
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-183
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-184
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-185
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Judgment Criteria
tration in the exhaust gas is sent to the • Signal check.
ENGINE-ECU (terminal No. 60) from the output • MIL is activated after 2 Drive cycles.
terminal (terminal No. 1) of the right bank heated • No limp home.
oxygen sensor (rear). .
• Terminal No. 2 of the right bank heated oxygen EOBD DRIVE CYCLE PATTERN
sensor (rear) is grounded with ENGINE-ECU (ter- Refer to Diagnostic Function − EOBD Drive Cycle −
minal No. 59).
P.13A-11.
.
TECHNICAL DESCRIPTION .
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB203A
MULTIPORT FUEL INJECTION (MPI) 13A-189
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-190
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-191
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0137: Heated Oxygen Sensor Circuit Low Voltage (bank 1, sensor 2).
CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB
sensor (rear) is grounded with ENGINE-ECU (ter- EOBD DRIVE CYCLE PATTERN
minal No. 59).
Refer to Diagnostic Function − EOBD Drive Cycle −
.
P.13A-11.
TECHNICAL DESCRIPTION
• The output signal of the right bank heated oxygen
.
COVER
ENGINE
CONTROL
UNIT
16DB400A
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-196
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-197
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0138: Heated Oxygen Sensor Circuit High Voltage (bank 1, sensor 2).
CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB
sensor (rear) is grounded with ENGINE-ECU (ter- EOBD DRIVE CYCLE PATTERN
minal No. 59).
Refer to Diagnostic Function − EOBD Drive Cycle −
.
P.13A-11.
TECHNICAL DESCRIPTION
• The output signal of the right bank heated oxygen
.
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-201
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-202
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0139: Heated Oxygen Sensor Circuit Slow Response (bank 1, sensor 2).
CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Check Conditions
tration in the exhaust gas is sent to the • Engine speed between 1320 and 3200rpm.
ENGINE-ECU (terminal No. 60) from the output
Judgment Criteria
terminal (terminal No.1) of the right bank heated
• MIL is activated after 2 Drive cycles.
oxygen sensor (rear).
• No limp home.
• Terminal No. 2 of the right bank heated oxygen
sensor (rear) is grounded with ENGINE-ECU (ter- .
sensor (front) is compensated by the output sig- TROUBLESHOOTING HINTS (The most
nal of the right bank heated oxygen sensor (rear). likely causes for this code to be set are: )
• The ENGINE-ECU checks for an open circuit in • Right bank heated oxygen sensor (rear) deterio-
the right bank heated oxygen sensor (rear) output rated.
line. • Refer to component locations GROUP-70
. • Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPORT FUEL INJECTION (MPI) 13A-204
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0140: Heated Oxygen Sensor Circuit No Activity Detected (bank 1, sensor 2).
CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB
sensor (rear) is grounded with ENGINE-ECU (ter- EOBD DRIVE CYCLE PATTERN
minal No. 59).
Refer to Diagnostic Function − EOBD Drive Cycle −
• The ENGINE-ECU applies an offset voltage of
0.5 volt to terminal No. 2 of the right bank heated P.13A-11.
oxygen sensor (rear). .
.
TROUBLESHOOTING HINTS (The most
TECHNICAL DESCRIPTION likely causes for this code to be set are: )
• The output signal of the right bank heated oxygen • Right bank heated oxygen sensor (rear) failed.
sensor (front) is compensated by the output sig- • Open circuit in right bank heated oxygen sensor
nal of the right bank heated oxygen sensor (rear). (rear) output line.
• The ENGINE-ECU checks for the right bank • Open circuit in right bank heated oxygen sensor
heated oxygen sensor (rear) output voltage. (rear) sensor ground.
• Wiring harness or connector damage.
• Refer to component locations GROUP-70
.
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB203A
MULTIPORT FUEL INJECTION (MPI) 13A-208
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-209
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-210
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-211
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
CONNECTOR: B-25
AIR
CLEANER
AK303070 AB
. .
16DB400A
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-216
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-217
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0151: Heated Oxygen Sensor Circuit Low Voltage (bank 2, sensor 1).
CONNECTOR: B-25
AIR
CLEANER
AK303070 AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Check Conditions
tration in the exhaust gas is sent to the • Battery voltage < 11.02 volts
ENGINE-ECU (terminal No. 15) from the output • Engine coolant temperature is higher than 80°C.
terminal (terminal No. 1) of the left bank heated
oxygen sensor (front). Judgement Criteria
• Terminal No. 2 of the left bank heated oxygen • Internal Resistance of the Nernst - cell is equal or
sensor (front) is grounded with ENGINE-ECU greater than a modelled resistance based on the
(terminal No. 14). heating output of the O2-sensor and the mod-
elled exhasused gas temperature
.
• Idling.
TECHNICAL DESCRIPTION • MIL is activated after 2 Drive cycles.
• The left bank heated oxygen sensor (front) • No limp home.
detects the concentration of oxygen in the
exhaust gas; it converts those data to voltage,
.
and input the resulting signal to the EOBD DRIVE CYCLE PATTERN
ENGINE-ECU. Refer to Diagnostic Function − EOBD Drive Cycle −
• When the left bank heated oxygen sensor (front) P.13A-11.
begins to deteriorate, the heated oxygen sensor .
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: ENGINE-ECU Check Harness
16DB400A
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-222
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-223
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0152: Heated Oxygen Sensor Circuit High Voltage (bank 2, sensor 1).
CONNECTOR: B-25
AIR
CLEANER
AK303070 AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Check Conditions
tration in the exhaust gas is sent to the • Battery voltage < 11.02 volts
ENGINE-ECU (terminal No. 15) from the output • Engine coolant temperature is higher than 80°C.
terminal (terminal No. 1) of the left bank heated
oxygen sensor (front). Judgment Criteria
• Terminal No. 2 of the left bank heated oxygen • Internal Resistance of the Nernst - cell is equal or
sensor (front) is grounded with ENGINE-ECU greater than a modelled resistance based on the
(terminal No. 14). heating output of the O2-sensor and the mod-
elled exhasused gas temperature.
.
• Idling.
TECHNICAL DESCRIPTION • MIL is activated after 2 Drive cycles.
• The left bank heated oxygen sensor (front) • No limp home.
detects the concentration of oxygen in the
exhaust gas; it converts those data to voltage,
.
and input the resulting signals to the EOBD DRIVE CYCLE PATTERN
ENGINE-ECU. Refer to Diagnostic Function − EOBD Drive Cycle −
• When the left bank heated oxygen sensor (front) P.13A-11.
begins to deteriorate, the heated oxygen sensor .
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-227
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-228
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0153: Heated Oxygen Sensor Circuit Slow Response (bank 2, sensor 1).
CONNECTOR: B-25
AIR
CLEANER
AK303070 AB
. .
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
DTC P0154: Heated Oxygen Sensor Circuit No Activity Detected (bank 2, sensor 1)
.
16DB400A
03DB208A
MULTIPORT FUEL INJECTION (MPI) 13A-234
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-235
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-236
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-237
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
HEATED OXYGEN CONTROL
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Judgment Criteria
tration in the exhaust gas is sent to the • Signal check.
ENGINE-ECU (terminal No. 30) from the output • MIL is activated after 2 Drive cycles.
terminal (terminal No. 1) of the left bank heated • No limp home.
oxygen sensor (rear). .
• Terminal No. 2 of the left bank heated oxygen EOBD DRIVE CYCLE PATTERN
sensor (rear) is grounded with ENGINE-ECU (ter- Refer to Diagnostic Function − EOBD Drive Cycle −
minal No. 29).
P.13A-11.
.
TECHNICAL DESCRIPTION .
STEP 1. Using diagnostic tool, check data list item AF: Left
Bank Heated Oxygen Sensor Bank 2, Sensor 2 (left rear).
CAUTION
To prevent damage to diagnostic tool, always turn the igni-
DATA LINK tion switch to the "LOCK" (OFF) position before connect-
CONNECTOR
ing or disconnecting diagnostic tool .
(1) Connect diagnostic tool to the data link connector.
(2) Start the engine and run at idle.
(3) Set diagnostic tool to the data reading mode for item AF,
Heated Oxygen Sensor Bank 2, Sensor 2 (left rear).
• Warming up the engine. When the engine is revved, the
output voltage should alternate between 0 and 0.6 to 1.0
MB991910
volts.
(4) Turn the ignition switch to the "LOCK" (OFF) position.
MB991824
Q: Is the sensor operating properly?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points − How to
Cope with Intermittent Malfunctions P.00-14.
NO : Go to Step 2.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-240
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
16DB400A
03DB213A
MULTIPORT FUEL INJECTION (MPI) 13A-241
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-242
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-243
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
DTC P0157: Heated Oxygen Sensor Circuit Low Voltage (bank 2, sensor 2).
CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
HEATED OXYGEN CONTROL
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB
sensor (rear) is grounded with ENGINE-ECU (ter- EOBD DRIVE CYCLE PATTERN
minal No. 29).
Refer to Diagnostic Function − EOBD Drive Cycle −
.
P.13A-11.
TECHNICAL DESCRIPTION
• The output signal of the left bank heated oxygen
.
16DB400A
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-248
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-249
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0158: Heated Oxygen Sensor Circuit High Voltage (bank 2, sensor 2).
CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
HEATED OXYGEN CONTROL
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB
sensor (rear) is grounded with ENGINE-ECU (ter- EOBD DRIVE CYCLE PATTERN
minal No. 29).
Refer to Diagnostic Function − EOBD Drive Cycle −
.
Procedure 6 − Other Monitor P.13A-11.
TECHNICAL DESCRIPTION
• The output signal of the left bank heated oxygen
.
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-253
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-254
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0159: Heated Oxygen Sensor Circuit Slow Response (bank 2, sensor 2).
CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
HEATED OXYGEN CONTROL
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB
CIRCUIT OPERATION
• A voltage corresponding to the oxygen concen- Check Conditions
tration in the exhaust gas is sent to the • Engine speed between 1320 and 3200rpm.
ENGINE-ECU (terminal No. 30) from the output
Judgment Criteria
terminal (terminal No. 1) of the left bank heated
• MIL is activated after 2 Drive cycles.
oxygen sensor (rear).
• No limp home.
• Terminal No. 2 of the left bank heated oxygen
sensor (rear) is grounded with ENGINE-ECU (ter- .
sensor (front) is compensated by the output sig- TROUBLESHOOTING HINTS (The most
nal of the left bank heated oxygen sensor (rear). likely causes for this code to be set are: )
• The ENGINE-ECU checks for an open circuit in • Left bank heated oxygen sensor (rear) deterio-
the left bank heated oxygen sensor (rear) output rated.
line. • Refer to component locations GROUP-70
. • Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPORT FUEL INJECTION (MPI) 13A-256
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DTC P0160: Heated Oxygen Sensor Circuit No Activity (bank 2, sensor 2).
CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
HEATED OXYGEN CONTROL
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB
CIRCUIT OPERATION
• Engine start achieved.
• A voltage corresponding to the oxygen concen-
tration in the exhaust gas is sent to the Judgment Criteria
ENGINE-ECU (terminal No. 30) from the output • Signal check.
terminal (terminal No. 1) of the left bank heated • MIL is activated after 2 Drive cycles.
oxygen sensor (rear). • No limp home.
• Terminal No. 2 of the left bank heated oxygen .
sensor (rear) is grounded with ENGINE-ECU (ter- EOBD DRIVE CYCLE PATTERN
minal No. 29) .
Refer to Diagnostic Function − EOBD Drive Cycle −
• The ENGINE-ECUapplies an offset voltage of 0.5
volt to terminal No. 2 of the left bank heated oxy- P.13A-11.
gen sensor (rear). .
.
TROUBLESHOOTING HINTS (The most
TECHNICAL DESCRIPTION likely causes for this code to be set are: )
• The output signal of the heated left bank oxygen • Left bank heated oxygen sensor (rear) failed.
sensor (front) is compensated by the output sig- • Open circuit in left bank heated oxygen sensor
nal of the left bank heated oxygen sensor (rear). (rear) output line.
• The ENGINE-ECU checks for the left bank • Open circuit in left bank heated oxygen sensor
heated oxygen sensor (rear) output voltage. (rear) sensor ground.
• Wiring harness or connector damage.
• Refer to component locations GROUP-70
.
16DB400A
03DB213A
MULTIPORT FUEL INJECTION (MPI) 13A-260
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-261
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-262
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303079 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-263
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
NEXT PAGE
PREVIOUS PAGE MULTIPORT FUEL INJECTION (MFI)
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
13A-264
13A
• No limp home.
.
CIRCUIT OPERATION
• Multiplicative or Additive adaption performed by .
trim value becomes too large. TROUBLESHOOTING HINTS (The most likely
• The ECU checks whether the fuel trim value is causes for this code to be set are:)
within a specified range. • Injector (Number 1, 3, 5) malfunctioning.
• Incorrect fuel pressure.
• Air drawn in from gaps in gasket, seals, etc.
.
Judgment Criteria
.
• No limp home.
.
CIRCUIT OPERATION
• Multiplicative or Additive adaption performed by .
trim value becomes too large. TROUBLESHOOTING HINTS (The most likely
• The ECU checks whether the fuel trim value is causes for this code to be set are:)
within a specified range. • Injector (Number 2, 4, 6) malfunctioning.
• Incorrect fuel pressure.
• Air drawn in from gaps in gasket, seals, etc.
.
Judgment Criteria
.
B-01 (GR)
B-32 (B)
AK303097AB
AK303096AB
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
16DB400A
4 3 4 3 4 3 4 3
B-17X
AK303014 AB
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• Refer to DTC P0300 - Random/Multiple Misfire- • The amount of fuel injected by the injector is con-
trolled by the amount of continuity time the coil is
P.13A-330 and Misfire Cylinder 1- P.13A-334.
grounded by the ECU.
• The injector power is supplied from the MPI relay
• A surge voltage is generated when the injectors
(terminal No. 4).
are switched on/off.
• The ECU controls the injector by turning the
• The ECU monitors this surge voltage.
power transistor in the ECU "ON" and "OFF".
.
MB991827 00DB076A
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
MULTIPORT FUEL INJECTION (MFI) 13A-274
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AK303098 AB
HARNESS CONNECTOR:
COMPONENT SIDE
AK303099AB
MULTIPORT FUEL INJECTION (MFI) 13A-275
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-01 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303099AB
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AK203172 AB
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MFI) 13A-277
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-32
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
MULTIPORT FUEL INJECTION (MFI) 13A-278
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-279
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AK203300 AB
NORMAL WAVEFORM
(4) Measure the waveform.
• The waveform should show a normal pattern similar to
the illustration.
A:INJECTOR DRIVE TIME
(5) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
YES : It can be assumed that this malfunction is intermittent.
Refer to 00, How to Use Troubleshooting/Inspection
Service Points − How to Cope with Intermittent
A Malfunctions P.00-14.
AKX01557 AB
NO : Replace the ECU. Then go to Step 12.
CONNECTOR: B-30
AIR
CLEANER
B-30 (GR)
COVER
ENGINE
CONTROL
UNIT
AK303102AB
CONNECTOR: B-17X
16DB400A
MFI RELAY
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3
B-17X
AK303014 AB
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• Refer to DTC P0300 - Random/Multiple Misfire- • The amount of fuel injected by the injector is con-
trolled by the amount of continuity time the coil is
P.13A-330 and Misfire Cylinder 2- P.13A-336.
grounded by the ECU.
• The injector power is supplied from the MPI relay
• A surge voltage is generated when the injectors
(terminal No. 4).
are switched on/off.
• The ECU controls the injector by turning the
• The ECU monitors this surge voltage.
power transistor in the ECU "ON" and "OFF".
.
DTC SET CONDITIONS <Circuit continuity − open circuit and shorted low>
Check Conditions • Misfire present.
• Battery voltage is between 9.04 and 16.01vols.
• Engine speed is above 801 r/min.
.
TROUBLESHOOTING HINTS (The most • Shorted to battery, No.2 cylinder injector circuit.
likely causes for this code to be set are:) • Harness or connector damage.
• Refer to component locations GROUP-70
• No. 2 cylinder injector failed.
• Refer to configuration diagrams GROUP-80
• Open or shorted to ground No.2 cylinder injector
• Refer to circuit diagrams GROUP-90
circuit.
DIAGNOSIS
Required Special Tools:
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB991658: Test Harness
• MB992044: Power Plant ECU Check Harness
MB991827 00DB076A
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303103AB
MULTIPORT FUEL INJECTION (MFI) 13A-282
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303103AB
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303103AB
AK303104 AB
MULTIPORT FUEL INJECTION (MFI) 13A-283
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MFI) 13A-284
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-30
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303103AB
MULTIPORT FUEL INJECTION (MFI) 13A-285
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303103AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-286
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303103AB
AK302166 AB
NORMAL WAVEFORM
(4) Measure the waveform.
• The waveform should show a normal pattern similar to
the illustration.
A:INJECTOR DRIVE TIME
(5) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points − How to
A Cope with Intermittent Malfunctions P.00-14.
AKX01557 AB
NO : Replace the ECU. Then go to Step 10.
B-32 (B)
B-03 (GR)
AK303097AB
AK303106AB
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
FRONT OF VEHICLE
16DB400A
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3
B-17X
AK303014 AB
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• Refer to DTC P0300 - Random/Multiple Misfire- • The amount of fuel injected by the injector is con-
trolled by the amount of continuity time the coil is
P.13A-330 and Misfire Cylinder 3- P.13A-338.
grounded by the ECU.
• The injector power is supplied from the MPI relay
• A surge voltage is generated when the injectors
(terminal No. 4).
are switched on/off.
• The ECU controls the injector by turning the
• The ECU monitors this surge voltage.
power transistor in the ECU "ON" and "OFF".
.
DTC SET CONDITIONS <Circuit continuity − open circuit and shorted low>
Check Conditions • Misfire present.
• Battery voltage is between 9.04 and 16.01vols.
• Engine speed is above 801 r/min.
.
TROUBLESHOOTING HINTS (The most • Shorted to battery, No.3 cylinder injector circuit.
likely causes for this code to be set are:) • Harness or connector damage.
• Refer to component locations GROUP-70
• No. 3 cylinder injector failed.
• Refer to configuration diagrams GROUP-80
• Open or shorted to ground No.3 cylinder injector
• Refer to circuit diagrams GROUP-90
circuit.
DIAGNOSIS
Required Special Tools:
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB991658: Test Harness
• MB992044: Power Plant ECU Check Harness
MB991827 00DB076A
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
MULTIPORT FUEL INJECTION (MFI) 13A-289
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
(2) Measure the resistance between terminal No. 9 and No. 10.
B-32
INTERMEDIATE
• Resistance should be between 10.5 and 13.5 ohms.
CONNECTOR Q: Is the measured resistance between 10.5 and 13.5
ohms?
1 2 3 4 5
6 7 8 9 10 YES : Go to Step 6.
NO : Go to Step 4.
AK303107 AB
HARNESS CONNECTOR:
COMPONENT SIDE
AK303108AB
MULTIPORT FUEL INJECTION (MFI) 13A-290
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
M B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303108AB
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AK203172 AB
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MFI) 13A-292
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-32
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
MULTIPORT FUEL INJECTION (MFI) 13A-293
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-294
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AK203300 AB
NORMAL WAVEFORM
(4) Measure the waveform.
• The waveform should show a normal pattern similar to
the illustration.
A:INJECTOR DRIVE TIME
(5) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
YES : It can be assumed that this malfunction is intermittent.
Refer to 00E, How to Use Troubleshooting/Inspection
Service Points − How to Cope with Intermittent
A Malfunctions P.00-14.
AKX01557 AB
NO : Replace the ECU. Then go to Step 12.
CONNECTOR: B-27
AIR
CLEANER
COVER
ENGINE
B-27 (GR) CONTROL
UNIT
AK303109AB
CONNECTOR: B-17X
16DB400A
MFI RELAY
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3
B-17X
AK303014 AB
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• Refer to DTC P0300 - Random/Multiple Misfire- • The amount of fuel injected by the injector is con-
trolled by the amount of continuity time the coil is
P.13A-330 and Misfire Cylinder 4- P.13A-340.
grounded by the ECU.
• The injector power is supplied from the MPI relay
• A surge voltage is generated when the injectors
(terminal No. 4).
are switched on/off.
• The ECU controls the injector by turning the
• The ECU monitors this surge voltage.
power transistor in the ECU "ON" and "OFF".
.
DTC SET CONDITIONS <Circuit continuity − open circuit and shorted low>
Check Conditions • Misfire present.
• Battery voltage is between 9.04 and 16.01vols.
• Engine speed is above 801 r/min.
.
TROUBLESHOOTING HINTS (The most • Shorted to battery, No.4 cylinder injector circuit.
likely causes for this code to be set are:) • Harness or connector damage.
• Refer to component locations GROUP-70
• No.4 cylinder injector failed.
• Refer to configuration diagrams GROUP-80
• Open or shorted to ground No.4 cylinder injector
• Refer to circuit diagrams GROUP-90
circuit.
DIAGNOSIS
Required Special Tools:
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB991658: Test Harness Set
• MB992044: Power Plant ECU Check Harness
MB991827 00DB076A
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303110AB
MULTIPORT FUEL INJECTION (MFI) 13A-297
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303110AB
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303110AB
AK303111 AB
MULTIPORT FUEL INJECTION (MFI) 13A-298
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MFI) 13A-299
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-27
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303110AB
MULTIPORT FUEL INJECTION (MFI) 13A-300
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303110AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-301
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303110AB
AK302166 AB
NORMAL WAVEFORM
(4) Measure the waveform.
• The waveform should show a normal pattern similar to
the illustration.
A:INJECTOR DRIVE TIME
(5) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points − How to
A Cope with Intermittent Malfunctions P.00-14.
AKX01557 AB
NO : Replace the ECU. Then go to Step 10.
CONNECTOR: B-04
CONNECTOR: B-32
B-04 (GR)
B-32 (B)
AK303097AB
AK303112AB
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY
COVER
ENGINE
CONTROL
UNIT
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
16DB400A
4 3 4 3 4 3 4 3
B-17X
AK303014 AB
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• Refer to DTC P0300 - Random/Multiple Misfire- • The amount of fuel injected by the injector is con-
trolled by the amount of continuity time the coil is
P.13A-330 and Misfire Cylinder 5- P.13A-342.
grounded by the ECU.
• The injector power is supplied from the MPI relay
• A surge voltage is generated when the injectors
(terminal No. 4).
are switched on/off.
• The ECU controls the injector by turning the
• The ECU monitors this surge voltage.
power transistor in the ECU "ON" and "OFF".
.
DTC SET CONDITIONS <Circuit continuity − open circuit and shorted low>
Check Conditions • Misfire present.
• Battery voltage is between 9.04 and 16.01vols.
• Engine speed is above 801 r/min.
.
TROUBLESHOOTING HINTS (The most • Shorted to battery, No.5 cylinder injector circuit.
likely causes for this code to be set are:) • Harness or connector damage.
• Refer to component locations GROUP-70
• No. 5 cylinder injector failed.
• Refer to configuration diagrams GROUP-80
• Open or shorted to ground No.5 cylinder injector
• Refer to circuit diagrams GROUP-90
circuit.
DIAGNOSIS
Required Special Tools:
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB991658: Test Harness
• MB992044: Power Plant ECU Check Harness
MB991827 00DB076A
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
MULTIPORT FUEL INJECTION (MFI) 13A-304
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AK303113 AB
HARNESS CONNECTOR:
COMPONENT SIDE
AK303114AB
MULTIPORT FUEL INJECTION (MFI) 13A-305
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303114AB
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AK203172 AB
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MFI) 13A-307
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-32
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
MULTIPORT FUEL INJECTION (MFI) 13A-308
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-309
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
AK203300 AB
NORMAL WAVEFORM
(4) Measure the waveform.
• The waveform should show a normal pattern similar to
the illustration.
A:INJECTOR DRIVE TIME
(5) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points − How to
A Cope with Intermittent Malfunctions P.00-14.
AKX01557 AB
NO : Replace the ECU. Then go to Step 12.
CONNECTOR: B-26
AIR
B-26 (GR) CLEANER
COVER
ENGINE
CONTROL
UNIT
AK303115AB
CONNECTOR: B-17X
16DB400A
MFI RELAY
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3
B-17X
AK303014 AB
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• Refer to DTC P0300 - Random/Multiple Misfire- • The amount of fuel injected by the injector is con-
trolled by the amount of continuity time the coil is
P.13A-330 and Misfire Cylinder 6- P.13A-344.
grounded by the ECU.
• The injector power is supplied from the MPI relay
• A surge voltage is generated when the injectors
(terminal No. 4).
are switched on/off.
• The ECU controls the injector by turning the
• The ECU monitors this surge voltage.
power transistor in the ECU "ON" and "OFF".
.
DTC SET CONDITIONS <Circuit continuity − open circuit and shorted low>
Check Conditions • Misfire present.
• Battery voltage is between 9.04 and 16.01vols.
• Engine speed is above 801 r/min.
.
TROUBLESHOOTING HINTS (The most • Shorted to battery, No.6 cylinder injector circuit.
likely causes for this code to be set are:) • Harness or connector damage.
• Refer to component locations GROUP-70
• No. 6 cylinder injector failed.
• Refer to configuration diagrams GROUP-80
• Open or shorted to ground No.6 cylinder injector
• Refer to circuit diagrams GROUP-90
circuit.
DIAGNOSIS
Required Special Tools:
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB991658: Test Harness
• MB992044: Power Plant ECU Check Harness
MB991827 00DB076A
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303116AB
MULTIPORT FUEL INJECTION (MFI) 13A-312
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-26 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303116AB
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303116AB
AK303117 AB
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MFI) 13A-314
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
CONNECTOR: B-26
B-26 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303116AB
MULTIPORT FUEL INJECTION (MFI) 13A-315
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303116AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-316
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303116AB
AK302166 AB
NORMAL WAVEFORM
(4) Measure the waveform.
• The waveform should show a normal pattern similar to
the illustration.
A:INJECTOR DRIVE TIME
(5) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points − How to
A Cope with Intermittent Malfunctions P.00-14.
AKX01557 AB
NO : Replace the ECU. Then go to Step 10.
MB991827 00DB076A
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
16DB400A
. .
WARNING
If the air intake duct is removed from the throttle body take great care to keep fingers away
from the throttle plate. The drive motor has very high torque and is capable of random move-
ment at any time. Do not under any circumstances activate the throttly plate by hand.
When removing the throttle body from the intake manifold disconnect the wiring first. During
replacement connect the wiring last.
Do not activate the throttle body using a DC suppy to test the motor,as permanent damage to
the throttle body will result.
B-06 (B)
03DB180A
MULTIPORT FUEL INJECTION (MFI) 13A-320
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-321
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-322
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB180A
MULTIPORT FUEL INJECTION (MFI) 13A-323
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MFI) 13A-324
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
16DB400A
. .
WARNING
If the air intake duct is removed from the throttle body take great care to keep fingers away
from the throttle plate. The drive motor has very high torque and is capable of random move-
ment at any time. Do not under any circumstances activate the throttly plate by hand.
When removing the throttle body from the intake manifold disconnect the wiring first. During
replacement connect the wiring last.
Do not activate the throttle body using a DC suppy to test the motor,as permanent damage to
the throttle body will result.
B-06 (B)
03DB180A
MULTIPORT FUEL INJECTION (MFI) 13A-326
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-06 (B)
03DB180A
03DB195A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-327
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-328
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB180A
MULTIPORT FUEL INJECTION (MFI) 13A-329
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MFI) 13A-330
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
• Engine speed is beween idle and 6200 r/min. EOBD DRIVE CYCLE PATTERN
• Engine torque is above 0. Refer to Diagnostic Function − EOBD Drive Cycle
• Engine speed during start is above 530 r/min. P.13A-11.
• Ignition counter (starts when engine speed 530 .
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MFI) 13A-332
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
• A/C compressor switching is not active. <M/T> TROUBLESHOOTING HINTS (The most
• Clutch pedal is not pressed. <M/T>. likely causes for this code to be set are:)
Judgement Criteria (change in the angular accel- • Ignition system related part(s) failed.
eration of the crankshaft is used for misfire • Low compression pressure.
detection). • Refer to component locations GROUP-70
• MIL activated after 2 drive cycles. • Refer to configuration diagrams GROUP-80
• No Limp home. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• Engine speed is beween idle and 6200 r/min. EOBD DRIVE CYCLE PATTERN
• Engine torque is above 0. Refer to Diagnostic Function − EOBD Drive Cycle −
• Engine speed during start is above 530 r/min. P.13A-11.
• Ignition counter (starts when engine speed 530
.
• Engine speed is beween idle and 6200 r/min. EOBD DRIVE CYCLE PATTERN
• Engine torque is above 0. Refer to Diagnostic Function − EOBD Drive Cycle −
• Engine speed during start is above 530 r/min. P.13A-11.
• Ignition counter (starts when engine speed 530
.
• Engine speed is beween idle and 6200 r/min. EOBD DRIVE CYCLE PATTERN
• Engine torque is above 0. Refer to Diagnostic Function − EOBD Drive Cycle −
• Engine speed during start is above 530 r/min. P.13A-11.
• Ignition counter (starts when engine speed 530
.
• Engine speed is beween idle and 6200 r/min. EOBD DRIVE CYCLE PATTERN
• Engine torque is above 0. Refer to Diagnostic Function − EOBD Drive Cycle −
• Engine speed during start is above 530 r/min. P.13A-11.
• Ignition counter (starts when engine speed 530
.
• Engine speed is beween idle and 6200 r/min. EOBD DRIVE CYCLE PATTERN
• Engine torque is above 0. Refer to Diagnostic Function − EOBD Drive Cycle −
• Engine speed during start is above 530 r/min. P.13A-11.
• Ignition counter (starts when engine speed 530
.
CONNECTOR: B-120
AIR
CLEANER
COVER
KNOCK SENSOR
ENGINE
CONTROL
UNIT
B-120 (GR)
16DB400A
AK303118 AB
Judgment Criteria
.
DIAGNOSIS
Required Special Tools:
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303120 AB
MULTIPORT FUEL INJECTION (MFI) 13A-348
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303120 AB
AK303121 AB
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-349
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303120 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-350
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-351
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303120 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-352
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303120 AB
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MFI) 13A-354
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CONNECTOR: B-119
CRANKSHAFT AIR
POSITION CLEANER
SENSOR
COVER
ENGINE
CRANKSHAFT CONTROL
SPROCKET UNIT
B-119 (B)
16DB400A
AK303122 AB
. .
• Open or shorted crankshaft position sensor cir- • Refer to component locations GROUP-70
cuit. . • Refer to configuration diagrams GROUP-80
• Harness or connector damage. • Refer to circuit diagrams GROUP-90
MULTIPORT FUEL INJECTION (MFI) 13A-356
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
DIAGNOSIS
Required Special Tools:
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MD998478: Test Harness (3pin, triangle)
• MB992044: Power Plant ECU Check Harness
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MFI) 13A-357
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
AK102979AB
NORMAL WAVEFORM
(4) Check the waveform.
• The waveform should show a pattern similar to the illus-
tration.
5V (5) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
YES : Go to Step 3.
NO : Go to Step 5.
AK302211AB
MULTIPORT FUEL INJECTION (MFI) 13A-358
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MFI) 13A-359
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
MULTIPORT FUEL INJECTION (MFI) 13A-360
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
AK303125 AB
MULTIPORT FUEL INJECTION (MFI) 13A-361
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
16DB400A
03DB196A
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-362
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-363
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-364
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
AK303127AB
MULTIPORT FUEL INJECTION (MFI) 13A-365
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
16DB400A
CONNECTOR: B-119
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
MULTIPORT FUEL INJECTION (MFI) 13A-366
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
AK303128 AB
MULTIPORT FUEL INJECTION (MFI) 13A-367
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-368
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-369
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MFI) 13A-370
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303123 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
NEXT PAGE
PREVIOUS PAGE MULTIPORT FUEL INJECTION (MPI)
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
13A-372
13A
CONNECTOR: B-106
CAMSHAFT POSITION
SENSOR AIR
CLEANER
COVER
B-106 (B) ENGINE
CONTROL
UNIT
AK303129AB
16DB400A
. .
changed (no pulse signal is input) for 2 seconds. TROUBLESHOOTING HINTS (The most
• MIL activated immediately.
• Engine stalls.
likely causes for this code to be set are: )
• Camshaft position sensor failed.
.
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB232A
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
MULTIPORT FUEL INJECTION (MPI) 13A-375
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
AKX01421AF
MULTIPORT FUEL INJECTION (MPI) 13A-376
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
16DB400A
03DB191A
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-377
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-378
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
AK303134 AB
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-379
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
03DB192A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-380
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-381
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-106
CAMSHAFT POSITION
SENSOR
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
MULTIPORT FUEL INJECTION (MPI) 13A-382
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303130AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
. .
MB991827 00DB076A
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
DTC P0443: Evaporative Emission Control System Purge Control Valve Circuit.
CONNECTOR: B-17X
2 1
HARNESS
MFI RELAY CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3 AIR
CLEANER
B-17X
COVER
ENGINE
AK303014 AB CONTROL
UNIT
16DB400A
. .
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: Engine ECU Check Harness
MB991827 00DB076A
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
MULTIPORT FUEL INJECTION (MPI) 13A-391
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
(2)Measure the resistance between evaporative emission
EVAPORATIVE EMISSION purge solenoid side connector terminal No. 1 and No. 2.
PURGE SOLENOID
CONNECTOR Standard value: 16 ± 2 ohms [at 20°C]
1 2 Q: Is the measured resistance between 14 and 18 ohms [at
20°C]?
YES : Go to Step 4.
NO : Replace the evaporative emission purge solenoid.
Then go to Step 12.
AK202961 AB
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
AK303144 AB
MULTIPORT FUEL INJECTION (MPI) 13A-392
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MPI) 13A-393
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB194A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-394
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-395
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
MULTIPORT FUEL INJECTION (MPI) 13A-396
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
TECHNICAL DESCRIPTION
.
CIRCUIT OPERATION
• The fuel level sensor (main) output voltage is • The ENGINE-ECU detects the amount of fuel left
input into ENGINE- ECU via meter circuit. in the fuel tank with this signal.
• This input is used in conjunction with the Engine
.
Management System and does not indicate a
sensor or wiring fault.
.
NEXT PAGE
PREVIOUS PAGE MULTIPORT FUEL INJECTION (MPI)
MULTIPORT FUEL INJECTION (MPI) DIAG
13A-399
13A
A-13 (GR)
1 2 3 4 5 6 7
8 9 10 11
22DB018A
SPEED SENSOR
12 13 14 15 16 17
10DB083A
AIR
CLEANER
COVER C-214
ENGINE
CONTROL 1 2 3 4 5 6
UNIT
7 8 9 10 11 12 1314
C-215
1 2
3 4 5 6
16DB400A
10DB084A
MULTIPORT FUEL INJECTION (MPI) 13A-400
MULTIPORT FUEL INJECTION (MPI) DIAG
CONNECTOR: B-17X
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
. .
82 and 85) via the vehicle speed sensor connec- TROUBLESHOOTING HINTS (THE MOST
tor B-121 (terminals 1 and 2).
LIKELY CAUSES FOR THIS CODE TO BE
• The ENGINE-ECU detects the vehicle speed by
the signal input to terminal 85. SET ARE:)
• The vehicle speed sensor generates the pulse • Malfunction of the vehicle speed sensor (M/T)
signal as the teeth of the driven gear engages • Damaged harness or connector
with the vehicle speed sensor gear. Circuit drawings
. • Refer to circuit diagrams GROUP-90
DTC SET CONDITIONS • Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
Check Conditions
• M/T gear range position: 1, 2, 3, 4, 5 and reverse
• Engine speed: 1,000 r/min or more.
Judgement Criteria
• (P0500) will be set, and the check engine warn-
ing lamp will come on after 2 drive cycles.
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB992044: Engine-ECU Check Harness
MULTIPORT FUEL INJECTION (MPI) 13A-401
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-402
MULTIPORT FUEL INJECTION (MPI) DIAG
VEHICLE
SPEED SENSOR
B-121
03DB234A
03DB233A
MULTIPORT FUEL INJECTION (MPI) 13A-403
MULTIPORT FUEL INJECTION (MPI) DIAG
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MPI) 13A-404
MULTIPORT FUEL INJECTION (MPI) DIAG
10DB083A
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MPI) 13A-405
MULTIPORT FUEL INJECTION (MPI) DIAG
VEHICLE
SPEED SENSOR
B-121
03DB234A
03DB235A
10DB083A
MULTIPORT FUEL INJECTION (MPI) 13A-406
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB236A
MULTIPORT FUEL INJECTION (MPI) 13A-407
MULTIPORT FUEL INJECTION (MPI) DIAG
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
MULTIPORT FUEL INJECTION (MPI) 13A-408
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
MULTIPORT FUEL INJECTION (MPI) 13A-409
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
MULTIPORT FUEL INJECTION (MPI) 13A-410
MULTIPORT FUEL INJECTION (MPI) DIAG
10DB083A
MULTIPORT FUEL INJECTION (MPI) 13A-411
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
MULTIPORT FUEL INJECTION (MPI) 13A-412
MULTIPORT FUEL INJECTION (MPI) DIAG
VEHICLE
SPEED SENSOR
B-121
03DB234A
03DB237A
10DB083A
MULTIPORT FUEL INJECTION (MPI) 13A-413
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB238A
MULTIPORT FUEL INJECTION (MPI) 13A-414
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
MULTIPORT FUEL INJECTION (MPI) 13A-415
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
MULTIPORT FUEL INJECTION (MPI) 13A-416
MULTIPORT FUEL INJECTION (MPI) DIAG
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-417
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
OSCILLO-
SCOPE
03DB239A
NORMAL WAVEFORM
(5) Check the vehicle speed sensor waveform.
• The vehicle speed sensor waveform should show a pat-
(V)
tern similar to the illustration. The maximum value
5
should be 4.8 volts or more and the minimum value 0.8
volt or less. The output waveform should not contain
electrical noise.
(6) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
0
YES : It can be assumed that this malfunction is intermittent.
ACX02131 AD
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points − How to
Cope with Intermittent Malfunction P.00-14.
NO : Go to Step 22.
MULTIPORT FUEL INJECTION (MPI) 13A-418
MULTIPORT FUEL INJECTION (MPI) DIAG
22DB018A
SPEED SENSOR
MULTIPORT FUEL INJECTION (MPI) 13A-419
MULTIPORT FUEL INJECTION (MPI) DIAG
Judgment Criteria
.
P.13A-11.
Check Conditions
• Vehicle speed is 0 km/h. .
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-420
MULTIPORT FUEL INJECTION (MPI) DIAG
Judgment Criteria
.
P.13A-11.
Check Conditions
• Vehicle speed is 0 km/h. .
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-422
MULTIPORT FUEL INJECTION (MPI) DIAG
• No MIL
.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-424
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
Judgment Criteria
.
MB991827 00DB076A
Check Conditions
• Ignition switch is in "ON" position. • EPPROM defect in ENGINE-ECU.
• Incorrect ENGINE-ECU fitted.
Judgement Criteria • Refer to component locations GROUP-70
• Mismatch between software variant and trans- • Refer to configuration diagrams GROUP-80
misssion. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-427
MULTIPORT FUEL INJECTION (MPI) DIAG
. .
TECHNICAL DESCRIPTION
• Throttle actuator control module processor
checks the ENGINE-ECU for abnormal condi-
tions.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-428
MULTIPORT FUEL INJECTION (MPI) DIAG
. .
TECHNICAL DESCRIPTION
• The Vehicle Identification Number (VIN) is stored
in the ENGINE-ECU by the vehicle manufacturer.
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-429
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-430
MULTIPORT FUEL INJECTION (MPI) DIAG
CIRCUIT OPERATION
.
DTC SET CONDITIONS <Throttle Body: Error at Emergency Air Position Test>
Check Conditions • Battery voltage is higher than 10 volts.
• Vehicle speed is 0 km/h. • Time with ignition on (engine off) is more than
• Engine speed is below 300 r/min. 1310.7 seconds.
• Engine coolant temperature is between 5.3 and
Judgement Criteria
105 degreeC.
• Throttle angle at limp-home air position is below
• Intake air temperature is between 5.3 and 143.3
1.0697% or above 13.0785%.
degreeC.
.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-433
MULTIPORT FUEL INJECTION (MPI) DIAG
WARNING
If the air intake duct is removed from the throttle body take great care to keep fingers away
from the throttle plate. The drive motor has very high torque and is capable of random move-
ment at any time. Do not under any circumstances activate the throttly plate by hand.
When removing the throttle body from the intake manifold disconnect the wiring first. During
replacement connect the wiring last.
Do not activate the throttle body using a DC suppy to test the motor,as permanent damage to
the throttle body will result.
B-06 (B)
03DB180A
(2) Measure the resistance between throttle actuator control
motor side connector terminal No. 1 and No. 4.
THROTTLE ACTUATOR
CONTROL MOTOR Standard value: 1.5 ± 0.3 ohms [at 20°C]
CONNECTOR
Q: Is the measured resistance between the standard
value?
YES : Go to Step 3.
NO : Replace the throttle body assembly. Then go to Step
8.
03DB181A
B-06 (B)
03DB180A
MULTIPORT FUEL INJECTION (MPI) 13A-434
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-435
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-436
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MB991910
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-437
MULTIPORT FUEL INJECTION (MPI) DIAG
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
EOBD DRIVE CYCLE PATTERN Open or shorted battery backup line, harness
damage or connector damage.
None.
• ENGINE-ECU failed.
.
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB992044: Power Plant ENGINE-ECU Check Harness
MULTIPORT FUEL INJECTION (MPI) 13A-438
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-439
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB182A
MULTIPORT FUEL INJECTION (MPI) 13A-440
MULTIPORT FUEL INJECTION (MPI) DIAG
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB183A
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-442
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-443
MULTIPORT FUEL INJECTION (MPI) DIAG
• None
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are: )
Judgment Criteria • Right bank heated oxygen sensor deterio-
• Oxygen sensor slow response. rated/failed.
• MIL activated after 2 drive cycles. • Right bank side catalytic converter deteriorated.
• No Limp home. • Exhaust leak.
.
• Refer to component locations GROUP-70
EOBD DRIVE CYCLE PATTERN • Refer to configuration diagrams GROUP-80
Refer to Diagnostic Function − EOBD Drive Cycle − • Refer to circuit diagrams GROUP-90
P.13A-11.
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-445
MULTIPORT FUEL INJECTION (MPI) DIAG
• None.
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are: )
Judgment Criteria • Left bank heated oxygen sensor deterio-
• Oxygen sensor slow response. rated/failed.
• MIL activated after 2 drive cycles. • Left bank side catalytic converter deteriorated.
• No Limp home. • Exhaust leak.
.
• Refer to component locations GROUP-70
EOBD DRIVE CYCLE PATTERN • Refer to configuration diagrams GROUP-80
Refer to Diagnostic Function − EOBD Drive Cycle − • Refer to circuit diagrams GROUP-90
P.13A-11.
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-448
MULTIPORT FUEL INJECTION (MPI) DIAG
• None.
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are: )
Judgment Criteria • Right bank heated oxygen sensor deterio-
• Oxygen sensor slow response. rated/failed.
• MIL activated after 2 drive cycles. • Right bank side catalytic converter deteriorated.
• No Limp home. • Exhaust leak.
.
• Refer to component locations GROUP-70
EOBD DRIVE CYCLE PATTERN • Refer to configuration diagrams GROUP-80
Refer to Diagnostic Function − EOBD Drive Cycle − • Refer to circuit diagrams GROUP-90
P.13A-11.
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-451
MULTIPORT FUEL INJECTION (MPI) DIAG
• None.
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are: )
Judgment Criteria • Left bank heated oxygen sensor deterio-
• Oxygen sensor slow response. rated/failed.
• MIL activated after 2 drive cycles. • Left bank side catalytic converter deteriorated.
• No Limp home. • Exhaust leak.
.
• Refer to component locations GROUP-70
EOBD DRIVE CYCLE PATTERN • Refer to configuration diagrams GROUP-80
Refer to Diagnostic Function − EOBD Drive Cycle − • Refer to circuit diagrams GROUP-90
P.13A-11.
DIAGNOSIS
Required Special Tools:
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-454
MULTIPORT FUEL INJECTION (MPI) DIAG
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
CONNECTOR: A-14
A-14 (GR)
16DB400A
AK303190 AB
CIRCUIT OPERATION or
• Controls the current that is applied from the • Throttle power stage temperature is above
ENGINE-ECU (terminals No. 49, No. 50) to the 175°C.
throttle actuator control motor (terminals No. 1, • MIL activated immediately.
No. 4). • Fuel cut and engine speed limited.
.
TECHNICAL DESCRIPTION
.
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPORT FUEL INJECTION (MPI) 13A-456
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
B-06 (B)
03DB180A
03DB181A
MULTIPORT FUEL INJECTION (MPI) 13A-457
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-459
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-460
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MB991910
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-461
MULTIPORT FUEL INJECTION (MPI) DIAG
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
16DB400A
CIRCUIT OPERATION
requested position.
• Controls the current that is applied from the • MIL activated immediately.
ENGINE-ECU (terminals No. 49, No. 50) to the • Fuel cut and engine speed limited.
throttle actuator control motor (terminals No. 1,
No. 4). .
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPORT FUEL INJECTION (MPI) 13A-462
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
B-06 (B)
03DB180A
(2) Measure the resistance between throttle actuator control
THROTTLE ACTUATOR
motor side connector terminal No. 1 and No. 4.
CONTROL MOTOR Standard value: 1.5 ± 0.3 ohms [at 20°C (68°F)]
CONNECTOR
Q: Is the measured resistance between standard value?
YES : Go to Step 3.
NO : Replace the throttle body assembly. Then go to Step
7.
03DB181A
MULTIPORT FUEL INJECTION (MPI) 13A-463
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-464
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-465
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MB991910
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-466
MULTIPORT FUEL INJECTION (MPI) DIAG
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
16DB400A
Judgement Criteria
.
CIRCUIT OPERATION
• Maximum permissable PWM pulse duty factor is
• Controls the current that is applied from the above 80% for 0.6 sec.gement Criteria.
ENGINE-ECU (terminals No. 49, No. 50) to the • MIL activated immediately.
throttle actuator control motor (terminals No. 1, • Fuel cut and engine speed limited.
No. 4).
.
throttle actuator control motor in order to control TROUBLESHOOTING HINTS (The most
the opening of the throttle valve. likely causes for this code to be set are:)
.
• Throttle actuator control motor failed.
DTC SET CONDITIONS • Shorted throttle actuator control motor circuit,
harness damage or connector damage.
Check Condition • Refer to component locations GROUP-70
• Battery positive voltage is higher than 6.5 volts. • Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPORT FUEL INJECTION (MPI) 13A-467
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
B-06 (B)
03DB180A
(2) Measure the resistance between throttle actuator control
THROTTLE ACTUATOR motor side connector terminal No. 1 and No. 4.
CONTROL MOTOR
CONNECTOR
Standard value: 1.5 ± 0.3 ohms [at 20°C (68°F)]
Q: Is the measured resistance between standard value?
YES : Go to Step 3.
NO : Replace the throttle body assembly. Then go to Step
7.
03DB181A
MULTIPORT FUEL INJECTION (MPI) 13A-468
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-469
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-470
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MB991910
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-471
MULTIPORT FUEL INJECTION (MPI) DIAG
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
16DB400A
Judgement Criteria
.
CIRCUIT OPERATION
• Maximum permissable PWM pulse duty factor is
• Controls the current that is applied from the above 80% for 0.6 sec.gement Criteria.
ENGINE-ECU (terminals No. 49, No. 50) to the • MIL activated immediately.
throttle actuator control motor (terminals No. 1, • Fuel cut and engine speed limited.
No. 4).
.
throttle actuator control motor in order to control TROUBLESHOOTING HINTS (The most
the opening of the throttle valve. likely causes for this code to be set are:)
.
• Throttle actuator control motor failed.
DTC SET CONDITIONS • Shorted throttle actuator control motor circuit,
harness damage or connector damage.
Check Condition • Refer to component locations GROUP-70
• Battery positive voltage is higher than 6.5 volts. • Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPORT FUEL INJECTION (MPI) 13A-472
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
B-06 (B)
03DB180A
(2) Measure the resistance between throttle actuator control
THROTTLE ACTUATOR motor side connector terminal No. 1 and No. 4.
CONTROL MOTOR
CONNECTOR
Standard value: 1.5 ± 0.3 ohms [at 20°C (68°F)]
Q: Is the measured resistance between standard value?
YES : Go to Step 3.
NO : Replace the throttle body assembly. Then go to Step
7.
03DB181A
MULTIPORT FUEL INJECTION (MPI) 13A-473
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-474
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-475
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MB991910
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-476
MULTIPORT FUEL INJECTION (MPI) DIAG
DTC P2122: Accelerator Pedal Position Sensor (main) Circuit Low Input.
CONNECTOR: C-24
ACCELERATOR COVER
PERAL ENGINE
CONTROL
UNIT
AK303201 AB
16DB400A
. .
MB991827 00DB076A
ACCELERATOR
PERAL
6 5 4 3 2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303202 AB
MULTIPORT FUEL INJECTION (MPI) 13A-478
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
(3) Measure the voltage between terminal No. 5 and ground.
• Voltage should be between 4.9 and 5.1 volts.
C-24 HARNESS
CONNECTOR: (4) Turn the ignition switch to the "LOCK"(OFF) position.
COMPONENT SIDE
Q: Is the measured voltage between 4.9 and 5.1 volts?
6 5 4 3 2 1 YES : Go to Step 7.
NO : Go to Step 4.
03DB251A
MULTIPORT FUEL INJECTION (MPI) 13A-479
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-480
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-481
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-482
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-483
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-484
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL
16DB562A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-485
MULTIPORT FUEL INJECTION (MPI) DIAG
DTC P2123: Accelerator Pedal Position Sensor (main) Circuit High Input.
CONNECTOR: C-24
HARNESS
CONNECTOR:
COMPONENT SIDE
C-24 (B) AIR
CLEANER
COVER
ENGINE
CONTROL
ACCELERATOR UNIT
PEDAL POSITION
SENSOR
16DB400A
ACCELERATOR
PEDAL
16DB562A
. .
MB991827 00DB076A
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
MULTIPORT FUEL INJECTION (MPI) 13A-487
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
03DB252A
MULTIPORT FUEL INJECTION (MPI) 13A-488
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-489
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-490
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-491
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL
16DB562A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-492
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991910
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-493
MULTIPORT FUEL INJECTION (MPI) DIAG
DTC P2127: Accelerator Pedal Position Sensor (sub) Circuit Low Input.
CONNECTOR: C-24
HARNESS
CONNECTOR:
COMPONENT SIDE
C-24 (B)
AIR
CLEANER
COVER
ENGINE
CONTROL
ACCELERATOR UNIT
PEDAL POSITION
SENSOR
16DB400A
ACCELERATOR
PEDAL
16DB562A
. .
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
MULTIPORT FUEL INJECTION (MPI) 13A-495
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
03DB253A
MULTIPORT FUEL INJECTION (MPI) 13A-496
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-497
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-498
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-499
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-500
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-501
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL
16DB562A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-502
MULTIPORT FUEL INJECTION (MPI) DIAG
DTC P2128: Accelerator Pedal Position Sensor (Sub) Circuit High Input.
CONNECTOR: C-24
HARNESS
CONNECTOR:
COMPONENT SIDE
C-24 (B) AIR
CLEANER
COVER
ENGINE
CONTROL
ACCELERATOR UNIT
PEDAL POSITION
SENSOR
16DB400A
ACCELERATOR
PEDAL
16DB562A
. .
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
MULTIPORT FUEL INJECTION (MPI) 13A-504
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AK303204 AB
MULTIPORT FUEL INJECTION (MPI) 13A-505
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-506
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-507
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-508
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL
16DB562A
MB991910
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-510
MULTIPORT FUEL INJECTION (MPI) DIAG
DTC P2135: Throttle Position Sensor (Main and Sub) Range/Performance Problem
Check Conditions
.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-512
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-513
MULTIPORT FUEL INJECTION (MPI) DIAG
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB180A
MULTIPORT FUEL INJECTION (MPI) 13A-514
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-515
MULTIPORT FUEL INJECTION (MPI) DIAG
DTC P2138: Accelerator Pedal Position Sensor (main and sub) Circuit Range/Performance Problem
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPORT FUEL INJECTION (MPI) 13A-516
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
MULTIPORT FUEL INJECTION (MPI) 13A-517
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
03DB252A
MULTIPORT FUEL INJECTION (MPI) 13A-518
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-519
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-520
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AK303204 AB
MULTIPORT FUEL INJECTION (MPI) 13A-521
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-522
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-523
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-524
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-525
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-526
MULTIPORT FUEL INJECTION (MPI) DIAG
ACCELERATOR
PEDAL
16DB562A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-527
MULTIPORT FUEL INJECTION (MPI) DIAG
CAUTION
• If the ENGINE-ECU outputs DTC U1102, make
sure to diagnose the CAN bus line.
• Before replacing the ENGINE-ECU, make sure
that the communication circuit is operating
normally.
.
and the combination meter on the CAN bus line, EOBD DRIVE CYCLE PATTERN
a failure in the combination meter power supply None.
system, a failure in the combination meter, or a
failure in the ENGINE-ECU.
.
MB991827 00DB076A
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-529
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991910
MB991824
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-530
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-531
MULTIPORT FUEL INJECTION (MPI) DIAG
CAUTION CAUTION
• If the ENGINE-ECU output the DTC U1102,
make sure to diagnose the CAN bus line. ACC POSITION
ON POSITION
• Before replacing the ENGINE-ECU, make sure
RANGE
that the communication circuit is operating
LOCK (OFF) "A"
normally.
.
POSITION
DTC SET CONDITIONS START
POSITION
Check Conditions
• Battery positive voltage is 10 volts or higher.
• Engine is not cranked, or at least 3 seconds have AK204418 AB
passed since engine was cranked. When the ignition key is maintained within the
Judgement Criteria range "A" (i.e., the ignition switch IG2 is in OFF
• Unable to receive ABS-ECU signals through the position but the cranking does not start) for more
CAN bus line. than 1 second, ENGINE-ECU stores DTC U1102
(the past trouble).
.
the ABS power supply system. Refer to "How to TROUBLESHOOTING HINTS (The most
cope with past trouble" (Refer to GROUP 00, likely causes for this code to be set are:)
How to Use Troubleshooting/Inspection Service
• Refer to component locations GROUP-70
Points − How to Cope with Intermittent Malfunc-
• Refer to configuration diagrams GROUP-80
tions P.00-14).
• Refer to circuit diagrams GROUP-90
• CAN line harness damage or connector damage.
• ABS-ECU failed.
• ENGINE-ECU failed.
MULTIPORT FUEL INJECTION (MPI) 13A-532
MULTIPORT FUEL INJECTION (MPI) DIAG
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-533
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991910
MB991824
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-534
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-535
MULTIPORT FUEL INJECTION (MPI) DIAG
DTC SET CONDITIONS likely causes for this code to be set are:)
• CAN line harness damage or connector damage.
Check Conditions • ECU.
• None. • Refer to component locations GROUP-70
• Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-536
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-537
MULTIPORT FUEL INJECTION (MPI) DIAG
DTC SET CONDITIONS likely causes for this code to be set are:)
• CAN line harness damage or connector damage.
Check Conditions • TCU or transmission
• None. • Refer to component locations GROUP-70
Judgement Criteria • Refer to configuration diagrams GROUP-80
• MIL activated after 2 drive cycles. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-538
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-539
MULTIPORT FUEL INJECTION (MPI) DIAG
SYMPTOM PROCEDURES
JUNCTION
BLOCK C-211
DATA LINK
CONNECTOR
03DB187A 03DB172A
CONNECTOR: C-216 CONNECTOR: C-29
JUNCTION
BLOCK
C-29
C-216
03DB189A 03DB171A
. .
DIAGNOSIS
AK303229 AB
1 2 3 4 5 6 7 8
9 10 111213141516
D-125 HARNESS
CONNECTOR:
COMPONENT SIDE
AK303230 AB
MULTIPORT FUEL INJECTION (MPI) 13A-541
MULTIPORT FUEL INJECTION (MPI) DIAG
C-29
DATA LINK
CONNECTOR
03DB187A 03DB171A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
. .
DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
DATA LINK
CONNECTOR
03DB187A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-543
MULTIPORT FUEL INJECTION (MPI) DIAG
INSPECTION PROCEDURE 3: The Malfunction Indicator Lamp (Check Engine Lamp) Does Not
Illuminate Right after the Ignition Switch Is Turned to the "ON" Position.
COMMENT
• The combination meter causes the malfunction likely causes for this case:)
indicator lamp (Check Engine Lamp) to illuminate • Malfunction of the malfunction indicator lamp
for 20 seconds immediately after the ignition (Check Engine Lamp).
switch is turned to the "ON" position occurred. • Open or shorted malfunction indicator lamp
(Check Engine Lamp) circuit.
• Refer to component locations GROUP-70
.
16DB400A
INSPECTION PROCEDURE 4: The Malfunction Indicator Lamp (Check Engine Lamp) Remains
Illuminated and Never Goes Out.
COMMENT
• In cases such as the above, the cause is proba- likely causes for this case:)
bly that the ENGINE-ECU is detecting a problem • Shorted the malfunction indicator lamp (Check
in a sensor or actuator, or that one of the mal- Engine Lamp) circuit.
functions listed at next has probably occurred. • Refer to component locations GROUP-70
• Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
.
DIAGNOSIS
Required Special Tools:
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
MULTIPORT FUEL INJECTION (MPI) 13A-545
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
COMMENT
• Malfunction of the immobilizer system.
• In cases such as the above, the cause is proba- • Refer to component locations GROUP-70
bly no spark, fuel delivery, or fuel quality prob- • Refer to configuration diagrams GROUP-80
lems. In addition, foreign materials (water, • Refer to circuit diagrams GROUP-90
kerosene, etc.) may be mixed with the fuel.
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
• MB991348: Test Harness Set
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-548
MULTIPORT FUEL INJECTION (MPI) DIAG
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-549
MULTIPORT FUEL INJECTION (MPI) DIAG
B-26 (GR)
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303075AB
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
M B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303055AB
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
MULTIPORT FUEL INJECTION (MPI) 13A-551
MULTIPORT FUEL INJECTION (MPI) DIAG
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303075AB
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-552
MULTIPORT FUEL INJECTION (MPI) DIAG
03DB230A
MULTIPORT FUEL INJECTION (MPI) 13A-553
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-554
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-555
MULTIPORT FUEL INJECTION (MPI) DIAG
B-26 (GR)
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303075AB
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
M B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303055AB
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303075AB
MULTIPORT FUEL INJECTION (MPI) 13A-558
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) 13A-559
MULTIPORT FUEL INJECTION (MPI) DIAG
03DB230A
MULTIPORT FUEL INJECTION (MPI) 13A-560
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-561
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-562
MULTIPORT FUEL INJECTION (MPI) DIAG
B-26 (GR)
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303075AB
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
M B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303055AB
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE AK303053 AB
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE AK303075AB
MULTIPORT FUEL INJECTION (MPI) 13A-565
MULTIPORT FUEL INJECTION (MPI) DIAG
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB230A
MB991827 00DB076A
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) 13A-569
MULTIPORT FUEL INJECTION (MPI) DIAG
MB991824
MB991827 00DB076A
NEXT PAGE
PREVIOUS PAGE MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE>
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
13A-571
13A
COMMENT
• In such cases as the above, the cause is proba- likely causes for this case:)
bly that the intake air volume during idle is too • Malfunction of the electronic control throttle valve
great. system.
• Malfunction of the throttle body.
• Refer to component locations GROUP-70
.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-572
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-573
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COMMENT
• In cases such as the above, the cause is proba- likely causes for this case:)
bly that the intake air volume during idle is too • Malfunction of the electronic control throttle valve
small. system.
• Malfunction of the throttle body.
• Refer to component locations GROUP-70
.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-574
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
INSPECTION PROCEDURE 11: When the engine is cold, it stalls at idle (die out).
DIAGNOSIS
Required Special Tools:
• Diagnostic tool(MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MB991827 00DB076A
MB991827 00DB076A
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-577
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
INSPECTION PROCEDURE 12: When the Engine Is Hot, It Stalls at Idle (Die Out).
MB991824
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-579
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
INSPECTION PROCEDURE 13: The Engine Stalls when Accelerating (Pass Out).
COMMENT
• In case such as the above, the cause is probably likely causes for this case:)
misfiring due to a weak spark, or an inappropriate • Vacuum leak.
air/fuel mixture when the accelerator pedal is • Malfunction of the ignition system.
depressed. • Malfunction of emission control system.
• Refer to component locations GROUP-70
• Refer to configuration diagrams GROUP-80
.
MB991827 00DB076A
COMMENT
• The intake air volume may be insufficient due to a likely causes for this case:)
defective the electronic control throttle valve sys- • Malfunction of the electronic control throttle valve
tem. system.
• Refer to component locations GROUP-70
• Refer to configuration diagrams GROUP-80
.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-584
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-586
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-588
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COMMENT
• There may be an ignition leak accompanying the likely causes for this case:)
increase in the spark plug demand voltage during • Malfunction of the ignition system.
acceleration or the electronic control throttle • Malfunction of the electronic control throttle valve
valve system failed. system.
• Refer to component locations GROUP-70
• Refer to configuration diagrams GROUP-80
.
MB991827 00DB076A
COMMENT
• There may be a sudden change in air flow likely causes for this case:)
through the throttle valve, causing the vehicle to • Malfunction of the electronic control throttle valve
decelerate rapidly for an instant. system.
• Dirtiness around throttle valve.
• Refer to component locations GROUP-70
.
MB991827 AC305412AB
DIAGNOSIS
Required Special Tools:
• Diagnostic tool(MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-591
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-592
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-596
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
MB991827 00DB076A
COMMENT
• Incase such as the above, the cause is probably likely causes for this case:)
that the detonation control is defective or the heat • Defective knock sensor.
value of the spark plug is inappropriate. • Incorrect heat value of the spark plug.
• Refer to component locations GROUP-70
• Refer to configuration diagrams GROUP-80
.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-599
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE AK303120 AB
• Deteriorated catalyst.
.
MB991827 00DB076A
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-602
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
INSPECTION PROCEDURE 23: Purge Flow Test of the Evaporative Emission Canister Failure.
COMMENT
• The test fails when the purge line or purge port is likely causes for this case:)
clogged or if the evaporative emission purge • Malfunction of the evaporative emission purge
solenoid fails. solenoid.
• Evaporative emission canister is clogged.
• Refer to component locations GROUP-70
.
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-604
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
INSPECTION PROCEDURE 24: Power supply system and ignition switch - IG system.
• When the ignition switch is turned to the "ON" TROUBLESHOOTING HINTS (The most
position, the battery positive voltage is applied to likely causes for this code to be set are:)
the ECU (terminal No. 43). When the battery pos- • Malfunction of the ignition switch.
itive voltage is applied, the ECU turns the power • Malfunction of the MPI relay.
transistor in the ECU "ON" and grounds the MPI • Improper connector contact, open circuit or
relay coil. With this, the MPI relay turns "ON" and short-circuit harness wire.
the battery positive voltage is supplied to the • Disconnected ECU ground wire.
ECU (terminals No. 51, No. 64) from the MPI • Malfunction of the ECU.
relay (terminal No. 4). • Refer to component locations GROUP-70
• A battery positive voltage is constantly supplied • Refer to configuration diagrams GROUP-80
to the ECU (terminal No. 42) as the backup • Refer to circuit diagrams GROUP-90
power.
DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-605
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
(2) Check for continuity between the MPI relay terminals No. 2
and No. 3.
• There should be continuity. (approximately 70 ohms)
1 2 MFI RERAY
SIDE
3 4 CONNECTOR
AK204164 AB
(3) Use jumper wires to connect MPI relay terminal No. 2 to the
MFI RELAY SIDE
CONNECTOR positive battery terminal and terminal No. 3 to the negative
battery terminal.
1 2 (4) Check for continuity between the MPI relay terminals No. 1
3 4 and No. 4 while connecting and disconnecting the jumper
wire at the negative battery terminal.
• Should be less than 2 ohms. (Negative battery terminal
connected)
• Should be open loop. (Negative battery terminal discon-
AK203257 AB nected)
(5) Install the MPI relay.
Q: Is the measured resistance within the specified range?
YES : Go to Step 3.
NO : Replace the MPI relay. Then confirm that the
malfunction symptom is eliminated.
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-606
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-608
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(2) Check for the continuity between terminals (No. 04, No. 06)
B-21 HARNESS and ground.
CONNECTOR • Should be less than 2 ohms.
Q: Does continuity exist?
YES : Go to Step 8.
NO : Check harness connector A-14 at grounding
connector for damage, and repair or replace as
required. Refer to, GROUP 00E, Harness Connector
Inspection. If grounding connector is good condition,
03DB163A repair harness wire between ECU connector B-21
(terminal No. 04, No. 06) and ground because of open
circuit. Then confirm that the malfunction symptom is
eliminated.
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-611
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
HARNESS 2 1 UNIT
CONNECTOR 4 3
03DB166A
CONNECTOR: C-29
C-29
16DB400A
03DB171A
CONNECTOR: D-18
FUEL PUMP MODULE
(INCORPORATING FUEL
D-18 (GR) LEVEL SENSOR (MAIN)
3 2 1
C-215
5 4 03DB173A
HARNESS
CONNECTOR: CONNECTOR: C-308
COMPONENT SIDE
SERVICE
HOLE
03DB168A
03DB170A
CONNECTOR: C-211
JUNCTION
BLOCK C-211
C-214 03DB174A
03DB172A
.
HARNESS 2 1
CONNECTOR 4 3
03DB166A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-615
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
HARNESS 2 1
CONNECTOR 4 3
03DB166A
(2) Check for continuity between the each fuel pump relay
terminals No. 2 and No. 3.
FUEL PUMP • There should be continuity. (approximately 70 ohms)
RELAY SIDE
CONNECTOR
1 2
3 4
AK104052 AB
(3) Use jumper wires to connect each fuel pump relay terminal
FUEL PUMP No. 3 to the positive battery terminal and terminal No. 2 to
RELAY SIDE
CONNECTOR the negative battery terminal.
1 2 (4) Check for continuity between the each fuel pump relay
3 4 terminals No. 1 and No. 4 while connecting and
disconnecting the jumper wire at the negative battery
terminal.
• Should be less than 2 ohms. (Negative battery terminal
connected)
• Should be open loop. (Negative battery terminal discon-
AK104053 AB
nected)
(5) Install the fuel pump relay 1 and 2.
Q: Is the measured resistance normal?
YES : Go to Step 4.
NO : Replace the fuel pump relay 1 and/or 2. Then confirm
that the malfunction symptom is eliminated.
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-616
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
HARNESS 2 1
CONNECTOR 4 3
03DB166A
HARNESS 2 1
CONNECTOR 4 3
03DB166A
HARNESS 2 1
CONNECTOR 4 3
03DB166A
3 4
1 2
(1) Disconnect the connector C-208 and measure at the
harness side.
1 2
C-208
3 4
(2) Turn the ignition switch to the "ON" position.
HARNESS CONNECTOR:
COMPONENT SIDE
03DB167A
3 4
1 2
(1) Disconnect the connector C-208 and measure at the
harness side.
1 2
C-208
3 4
(2) Turn the ignition switch to the "ON" position.
HARNESS CONNECTOR:
COMPONENT SIDE
03DB167A
SERVICE
HOLE
03DB168A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-621
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
3 2 1
5 4
HARNESS
CONNECTOR:
COMPONENT SIDE
SERVICE
HOLE
03DB168A
AKX01439 AB
3 2 1
5 4
HARNESS
CONNECTOR:
COMPONENT SIDE
SERVICE
HOLE
03DB168A
3 4
4 3
2 1
1 2
Q: Is the harness wire in good condition?
YES : Go to Step 13.
4 3
2 1
1 2
3 4
C-208 C-208
NO : Repair it. Then confirm that the malfunction symptom
HARNESS CONNECTOR:
HARNESS CONNECTOR: is eliminated.
COMPONENT SIDECOMPONENT SIDE
03DB167A AK203272 AB
CONNECTOR: D-18
FUEL PUMP MODULE
(INCORPORATING FUEL
D-18 (GR) LEVEL SENSOR (MAIN)
3 2 1
5 4
HARNESS
CONNECTOR:
COMPONENT SIDE
SERVICE
HOLE
03DB168A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-623
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
INSPECTION PROCEDURE 26: Ignition Switch-ST System and Transmission Inhibitor Switch System
B-110 (B)
A-13(GR)
TRANSMISSION
RANGE SWITCH
AK303268AB AK303148 AB
CONNECTOR: C-29
AIR C-29
CLEANER
COVER
ENGINE
CONTROL
UNIT
03DB171A
CONNECTOR: C-308
16DB400A
C-308
03DB170A
6 5 4 3 2 1
10 9 8 7
TRANSMISSION
RANGE SWITCH
HARNESS
CONNECTOR:
COMPONENT SIDE AK303269AB
6 5 4 3 2 1
10 9 8 7
TRANSMISSION
RANGE SWITCH
HARNESS
CONNECTOR:
COMPONENT SIDE AK303269AB
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-627
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
6 5 4 3 2 1
10 9 8 7
TRANSMISSION
RANGE SWITCH
HARNESS
CONNECTOR:
COMPONENT SIDE AK303269AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-628
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-118 (GR)
B-117 (GR)
B-114 (GR)
C-215
03DB173A
AK303271AB
CONNECTOR: C-29
C-29
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT 03DB171A
CONNECTOR: A-13
A-13(GR)
16DB400A
CONNECTOR: C-211
JUNCTION
AK303148 AB
BLOCK C-211
CONNECTOR: B-32
B-32 (B)
03DB172A
CONNECTOR: C-308
AK303097AB
C-308
03DB170A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-629
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
CONNECTOR: B-111
B-111 (B)
AK303272AB
. .
B-118 (GR)
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-630
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-118 (GR)
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB
AK303273 AB
B-118 (GR)
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-632
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
B-118 (GR)
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-633
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
COMMENT
• When the A/C is "ON" the ECU turns "ON" the likely causes for this case: )
power transistor in the ECU. The ECU delays A/C • Malfunction of the A/C control system.
engagement momentarily while it increases idle • Improper connector contact, open circuit or
r/min. Then the A/C compressor clutch relay coil short-circuited harness wire.
will be energized. • Malfunction of the ECU.
With this, the A/C compressor clutch relay turns • Refer to component locations GROUP-70
"ON", and the A/C compressor clutch operates. • Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
.
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-635
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
DIAGNOSIS
MB991827 00DB076A
COVER
ENGINE
CONTROL
UNIT
16DB400A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-636
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
CAUTION
• When shifting the selector lever to D range, the brakes should be applied so that the vehicle does
not move forward.
• Driving tests always need two persons: one driver and one observer.
NOTE: Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates the
sensor mounted at the position second close to the engine.
NOTE: Bank 1 indicates the right bank cylinder, and bank 2 indicates the left bank cylinder
NOTE: *2: In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10%
longer than the standard time.
ITEM INSPECTION ITEM INSPECTION REQUIREMENT NORMAL CONDITION INSPECTION REFERENCE
NO. PROCEDURE PAGE
NO.
5 Intake air Ignition switch: Intake air −20°C Code No. P.13A-116,
temperature "ON" or with temperature is P0112, P.13A-120
sensor engine running −20°C P0113
Intake air 0°C
temperature is
0°C
Intake air 20°C
temperature is
20°C
Intake air 40°C
temperature is
40°C
Intake air 80°C
temperature is
80°C
6 Engine coolant Ignition switch: Engine coolant -20°C Code No. P.13A-127,
temperature "ON" or with temperature is P0116, P.13A-134,
sensor engine running −20°C P0117, P.13A-139
Engine coolant 0°C P0118
temperature is
0°C
Engine coolant 20°C
temperature is
20°C
Engine coolant 40°C
temperature is
40°C
Engine coolant 80°C
temperature is
80°C
10 Airflow sensor • Engine Engine idling 1348 − 1367 mV Code No. P.13A-78
coolant P0101, P.13A-81
temperature P0102, P.13A-87
80-95°C 2,500 rpm 1943 − 1983 mV P0103
• Accessories
off Engine revved Mass airflow rate
• Transmission increases in
in "P" response to revving
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-639
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
11 APS (main) Ignition switch: Release the 435 to 1035 mV Code No. P.13A-476,
"ON" accelerator P2122, P.13A-485
pedal P2123
Depress the Increases in
accelerator response to the
pedal gradually pedal depression
stroke
Depress the 4000 to 4824 mV
accelerator
pedal fully
12 APS (sub) Ignition switch: Release the 435 to 1035 mV Code No. P.13A-493,
"ON" accelerator P2127, P.13A-502
pedal P2128
Depress the Increases in
accelerator response to the
pedal gradually pedal depression
stroke
Depress the 4000 to 4824 mV
accelerator
pedal fully
13 TPS (main) Ignition switch: Release the 1035 to 1250 mV Code No. P.13A-148,
"ON" accelerator P0122, P.13A-155
pedal P0123 P.13A-510
Depress the Increases in P2135
accelerator response to the
pedal gradually pedal depression
stroke
Depress the 4000 to 4824 mV
accelerator
pedal fully
15 TPS (sub) Ignition switch: Release the 1035 to 1250 mV Code No. P.13A-318
"ON" accelerator P0222, P.13A-324
pedal P0223 P.13A-510
Depress the Increases in P2135
accelerator response to the
pedal gradually pedal depression
stroke
Depress the 4000 to 4824 mV
accelerator
pedal fully
16 Advance ignition • Engine: ENGINE ECU Varies depending - -
Running controlled on ECU
requirement
Cranking: No throttle -3 to -18 CA
Idling: No throttle 1 to 5 CA
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-640
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
AE Oxygen sensor Engine: When the 200mV or less Code No. P.13A-212,
bank 2, sensor 1 Warming up engine is P0150, P.13A-218,
(front) (air/fuel running at P0151, P.13A-224,
mixture is 4000 r/min, P0152, P.13A-229,
made leaner decelerate P0153, P.13A-231
when suddenly. P0154
decelerating,
and is made
richer when
revving.)
Engine: When engine 600 − 1,000mV
Warm is suddenly
revved.
Engine: Engine is idling Voltage alternates
Warming up 2,500 r/min quickly between
(the heated 400mV or less and
oxygen sensor 600 − 1,000mV.
signal is used
to check the
air/fuel mixture
ratio, and
control
condition is
also checked
by the ECU)
AF Oxygen sensor Engine: Revving Alternates slowly Code No. P.13A-238,
bank 2, sensor 2 warming up between 0 and 600 P0156, P.13A-244,
(rear) − 1,000mV. P0157, P.13A-250,
P0158, P.13A-255
P0159
BC Relative TPS Ignition Release the 12.5 − 16.5% Code No. P.13A-318
switch:"ON" accelerator P0222, P.13A-324
pedal P0223
BD TPS (sub) Ignition 0 − 100% Code No. P.13A-318
switch:"ON" P0222, P.13A-324
P0223
105 Fuel system Engine: 2,500 r/min Closed loop Code No. P.13A-179
status bank 1 warming up When engine Open loop − drive P0134
(right) is suddenly condition
revved
106 Fuel system Engine: 2,500 r/min Closed loop Code No. P.13A-231
status bank 2 warming up When engine Open loop − drive P0154
(left) is suddenly condition
revved
107 Clutch switch > 8V + OFF Code No. P.17-15
Pedal applied ON P0830
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-644
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
1 Injectors Cut fuel to Engine: warm up, idle (cut Idling Code No. P.13A-272
No.1 injector the fuel supply to each becomes P0201
2 Cut fuel to injector in turn and check unstable. Code No. P.13A-280
No.2 injector cylinders which don’t P0202
affect idling.)
3 Cut fuel to Code No. P.13A-287
No.3 injector P0203
4 Cut fuel to Code No. P.13A-295
No.4 injector P0204
5 Cut fuel to Code No. P.13A-302
No.5 injector P0205
6 Cut fuel to Code No. P.13A-310
No.6 injector P0206
10 Purge Solenoid Ignition switch: "ON" Clicks Code No. P.13A-389
control valve turns when P0443
solenoid from OFF to solenoid
valve ON. valve is
driven.
14 PWM Actuate fan • Ignition switch "ON" Fan motor Symptom P.14-3
Radiator motor • A/C switch "ON" is rotated chart
fan
16 A/C relay Activate A/C • Ignition switch "ON" Relay - -
relay • A/C switch "ON/OFF" operates
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-645
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
03DB159A
(B-20) - 42 Throttle position • Remove the Fully depress and release 1172 − 4043 mV
sensor (main) intake air hose accelerator pedal.
at the throttle WARNING
body. If the air intake duct is
• Ignition switch: removed from the
"ON"
throttle body take great
• Visually inspect
throttle plate for
care to keep fingers
full travel. away from the throttle
plate. The drive motor
has very high torque
and is capable of
random movement at
any time. Do not under
any circumstances
activate the throttle
plate by hand.
03DB160A
Measurement Method
1. Disconnect the all ECU connectors, and connect check
harness special tool (MB992044) between the separated
connectors.
2. Connect the oscilloscope to check harness terminal No. 38.
OSCILLOSCOPE (Check the camshaft position sensor signal wave pattern.)
B-20 HARNESS
CONNECTOR
03DB243A
5
CAMSHAFT
POSITION
SENSOR OUTPUT
WAVE PATTERN
(TIME)
0
03DB259A
AKX01597
Example 2
Cause of problem
• Loose timing belt.
• Abnormality in sensor disc.
Wave pattern characteristics
• Wave pattern is displaced to the left or right.
AKX01602
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-654
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
INJECTOR
Required Special Tools:
• MB991658: Test Harness
• MB992044: ECU Check Harness
.
Measurement Method 1
Perform a Power balance Test on all cylinders.
1. Connect MUT III to vehicle and go to Data item list.
DATA LINK 2. Scroll to Item No. 72, Absolute load value and lock. Also
CONNECTOR
lock Item No. 2, Crank angle sensor (engine speed).
3. Go to Actuator test and select Item No. 1, No.1 Injector.
4. Start engine and allow to idle.
5. Perform actuator test on each injecto from 1 to 6 and record
the engine load and speed during each actuator test.
6. Check recorded values for variations between cylinders. If
all injectors are operating correctly there should be minimal
MB991910
difference between load and engine speed values for all
cylinders.
MB991824
MB991827 00DB076A
Measurement Method 2
<Measure at the right bank (number 1, 3, 5 cylinders)>
1. Disconnect the intermediate connector B-32, and connect
B-32 INTERMEDIATE OSCILLOSCOPE
the test harness special tool (MB991658) between the
CONNECTOR
separated connector.
1 2 3 4 5 2. Connect the oscilloscope probe to each intermediate
6 7 8 9 10 connector B-32 terminal to analyze each cylinder:
MB991658
• Terminal No. 5 for the number 1 cylinder
• Terminal No. 10 for the number 3 cylinder
• Terminal No. 4 for the number 5 cylinder
<Measure at the right bank (number 2, 4, 6 cylinders)>
AK203300 AB 1. Disconnect the injector connector, and connect the test har-
ness special tool (MB991658) between the separated con-
OSCILLOSCOPE
INJECTOR nector. (All terminals should be connected.)
CONNECTOR
2. Connect the oscilloscope probe to injector connector termi-
1 2 MB991658 nal No. 2.
Alternate method (Measure at the ECU)
Disconnect the all ECU connectors, and connect check har-
ness special tool (MB992044) between the separated con-
nectors.
AK302166 AB
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-655
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
(V)
50 POINT A
POINT B:
INJECTOR DRIVE
TIME
POWER VOLTAGE
AKX01604 AB
WHEN IDLING
WHEN RACING AKX01605 AB
Measurement Method
1. Disconnect the all ECU connectors, and connect check har-
ness special tool (MB992044) between the separated con-
nectors.
POWER PLANT ECU
2. Connect the oscilloscope probe to each check harness con-
CHECK HARNESS OSCILLOSCOPE nector terminal to analyze each cylinder:
CONNECTOR • Terminal No. 151 for the number 1 cylinder.
• Terminal No. 150 for the number 2 cylinder.
• Terminal No. 144 for the number 3 cylinder.
• Terminal No. 148 for the number 4 cylinder.
• Terminal No. 143 for the number 5 cylinder.
• Terminal No. 134 for the number 6 cylinder.
Standard Wave Pattern
03DB246A Observation condition
Function Special pattern
Pattern height Low
Pattern selector Display
Engine r/min Idle speed
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-657
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
5˚BTDC
TDC
CRANKSHAFT
POSITION 5
SENSOR OUTPUT
WAVE PATTERN
0
IGNITION
IGNITION POWER TIMING
TRANSISTOR
CONTROL SIGNAL 10
WAVE PATTERN
TIME
0
OFF
ON
DWELL
SECTION
AK203308 AC
AK203246 AC
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-658
SPECIAL TOOLS
SPECIAL TOOLS
M1131000601293
MB991914
MB991825
MB991826
MB991958
MB991637
03DB257A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-660
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
COMPONENT LOCATION
• Refer to component locations GROUP70
WARNING
If the air intake duct is removed from the throttle
body take great care to keep fingers away from the
throttle plate. The drive motor has very high torque
and is capable of random movement at any time. Do
not under any circumstance activate the throttle plate
by hand.
When removing the throttle body from the intake
manifold disconnect the wiring first.During replace-
ment connect the wiring last.
Do not activate the throttle body using a DC supply to
test the motor, as permanent damage to the throttle
body will result.
1. Remove the throttle body.
CAUTION
• Do not spray the cleaning solvent directly to the throttle
valve.
• Make sure the cleaning solvent does not enter the
motor and the sensor through the shaft.
2. Spray cleaning solvent on a clean cloth.
3. Wipe off the dirt around the throttle valve with the cloth
sprayed with cleaning solvent.
4. Attach the throttle body.
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-661
ON-VEHICLE SERVICE
FUEL
HIGH-PRESSURE
HOSE
03DB145A
3. Disconnect the fuel high pressure hose at the fuel pipe side
FUEL by unclipping and rotating up the stopper then releasing the
HIGH-PRESSURE
HOSE quick release fitting. Remove the high pressure hose from
vehicle.
STOPPER
FUEL PIPE
03DB254A
03DB255A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-662
ON-VEHICLE SERVICE
03DB256A
WARNING
When removing the fuel pipe, etc., release fuel pres-
sure to prevent fuel spray.
1. Remove the rear seat cushion assembly (Refer to GROUP
52A, Rear Seat P.52A-55).
2. Remove the hole cover (LHS).
HOLE COVER
03DB150A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-664
ON-VEHICLE SERVICE
AC306490 AB
03DB150A
03DB150A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-665
ON-VEHICLE SERVICE
AC306490 AB
03DB150A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-666
ON-VEHICLE SERVICE
MPI RELAY
SIDE CONNECTOR
1 2
3 4
03DB258A
1 2
3 4
AK302122 AB
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-667
ON-VEHICLE SERVICE
CAUTION
Be careful not to touch the connector (resin section) with
the tool when removing and installing.
1. Drain engine coolant, then remove the engine coolant
temperature sensor.
2. With the temperature sensing portion of engine coolant
temperature sensor immersed in hot water, check the
resistance.
Standard value:
14 − 17 kΩ [at -20°C (-4°F)]
5.5 − 6.3 kΩ [at 0°C (32°F)]
2.35 − 2.65 kΩ [at 20°C (68°F)]
1.12 − 1.23 kΩ [at 40°C (104°F)]
0.573 − 0.618 kΩ [at 60°C (140°F)]
AKX01622 0.313 − 0.332 kΩ [at 80°C (176°F)]
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-668
ON-VEHICLE SERVICE
AKX01623 AB
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-669
ON-VEHICLE SERVICE
INJECTOR CHECK
M1131005200521
.
AK000126
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-671
ON-VEHICLE SERVICE
<Operation Inspection>
1. Disconnect the air intake hose from the throttle body.
2. Set the ignition switch to the "ON" position.
3. Operate the accelerator pedal and confirm that the throttle
valve is opening and closing accordingly.
WARNING
If the air intake duct is removed from the throttle body take great care to keep fingers away
from the throttle plate. The drive motor has very high torque and is capable of random move-
ment at any time. Do not under any circumstances activate the throttle plate by hand.
When removing the throttle body from the intake manifold disconnect the wiring first. During
replacement connect the wiring last.
Do not activate the throttle body using a DC suppy to test the motor,as permanent damage to
the throttle body will result.
.
03DB157A
INJECTOR
REMOVAL AND INSTALLATION
M1131007100768
12 ± 1 N·m
102 ± 13 in-lb 3
APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION. 10
6
9N
8
9N 11
7
8
1 7
5
36 ± 6 N·m
27 ± 4 ft-lb
03DB144A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. INJECTOR CONNECTOR 7. INSULATORS
2. ENGINE MOUNT STAY >>A<< 8. FUEL INJECTORS
>>A<< 3. FUEL HIGH-PRESSURE HOSE >>A<< 9. O-RING
CONNECTION (FUEL RAIL SIDE) 10. FUEL RAIL
5. BLOW-BY HOSE CONNECTION 11. INSULATORS
<<A>> 6. FUEL RAIL AND INJECTOR
ASSEMBLY
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-673
INJECTOR
CAUTION
Connect the fuel high-pressure hose, and then pull it gen-
tly in the direction of removal to check that the hose is
CONNECTOR
firmly connected.
Apply clean engine oil to the tips of the main pipe nozzle and
the fuel main pipe, and connect connector of the fuel high-pres-
sure hose to them.
WARNING
If the air intake duct is removed from the throttle body take great care to keep fingers away
from the throttle plate. The drive motor has very high torque and is capable of random move-
ment at any time. Do not under any circumstances activate the throttle plate by hand.
When removing the throttle body from the intake manifold disconnect the wiring first. During
replacement connect the wiring last.
Do not activate the throttle body using a DC suppy to test the motor,as permanent damage to
the throttle body will result.
Pre-removal Operation Post-installation Operation
• Air Intake Hose Removal (Refer to GROUP 15, Air • Air Intake Hose Installation (Refer to GROUP 15, Air
Cleaner P.15-4). Cleaner P.15-4).
3N
2
1
28 ± 4 N·m
21 ± 3 ft-lb
03DB155A
PROJECTION
03DB188A
CAUTION
Ensure Ignition key is turned "OFF" and battery terminals are disconnected prior to removal of the
ENGINE ECU.
NOTE: When replacing ENGINE-ECU with a new unit VIN Writing and Key Registration will be required.
3
4
03DB264A
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1131011600517
ITEM SPECIFICATION
Engine mount stay bolt 36 ± 6 N⋅m (27 ± 4 ft-lb)
Fuel rail and injector assembly bolt 12 ± 1 N⋅m (102 ± 13 in-lb)
Hole cover screw 1.5 ± 0.5 N⋅m (14 ± 4 in-lb)
Throttle body mounting bolt 28 ± 4 N⋅m (21 ± 3 ft-lb)
GENERAL SPECIFICATION(S)
M1131000200827
ITEMS SPECIFICATIONS
Throttle body Throttle bore mm 68
Throttle position sensor Potentiometer type
Throttle actuator control motor DC motor type, 2-stage gear train
Electronic Identification model No.
control unit
(ECU)
Sensors Mass airflow sensor Thermal flow meter type- hot film.
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor Thermistor type
Heated oxygen sensor "Planar" type sensor
Accelerator pedal position sensor Hall element type
Transmission range switch Contact switch type
Camshaft position sensor Hall element type
Crankshaft position sensor Magneto resistance element type
Knock sensor Piezoelectric type
Power steering pressure switch Contact switch type
Manifold absolute pressure sensor Piezo-resistive type
Actuators Multiport fuel injection (MPI) relay Contact switch type
Fuel pump relay Contact switch type
Throttle actuator control motor relay Contact switch type
Injector type and number Electromagnetic type, 6
Injector identification mark HDB305F
Evaporative emission purge solenoid Duty cycle type solenoid valve
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-677
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1131000300705
GROUP 13B
FUEL SUPPLY
CONTENTS
GENERAL DESCRIPTION
M1135000100435
• The fuel tank is located under the floor below the • A fuel pump module, including fuel pump, fuel fil-
rear seats. ter, reservoir and fuel level sensor, is used to
• A fuel cut-off valve is utilized to prevent fuel from lighten weight and improve serviceability.
leaking out in the event of a collision.
CONSTRUCTION DIAGRAM
FUEL RAIL
03DB142A
SYMPTOM PROCEDURES
DIAGNOSIS
Required Special Tools:
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
FUEL
HOSE
FUEL PIPE
AC307454AB
SPECIAL TOOLS
M1135000600300
MB991825
MB991826
MB991958
FUEL SUPPLY 13B-6
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
FUEL LEVEL SENSOR CHECK
M1135005300069
Refer to GROUP 54A - Combination Meter, On-vehicle Service,
Fuel Level Sensor Check P.54A-95.
03DB150A
FUEL PUMP MODULE 3. Disconnect the fuel pump module connector and fuel
CONNECTOR high-pressure hose.
FUEL HIGH-
PRESSURE HOSE
AC306090 AB
CAUTION
When withdrawing the fuel pump module from the fuel
tank, be careful not to damage the module unit and the
float.
FUEL PUMP
MODULE 4. Remove the mounting nuts and plate, and remove the fuel
FLOAT pump module from the fuel tank.
AC307207AB
FUEL SUPPLY 13B-7
ON-VEHICLE SERVICE
CAUTION
When installing the fuel pump module into the fuel tank, be
careful not to damage the module unit and the float.
FUEL PUMP
MODULE
FLOAT
AC307207AB
MATING MARKS
SUCTION HOSE AC306092AB
FUEL PUMP MODULE 7. Connect the fuel pump module connector and fuel
CONNECTOR high-pressure hose.
FUEL HIGH-
PRESSURE HOSE
AC306090 AB
03DB150A
FUEL SUPPLY 13B-8
FUEL TANK
FUEL TANK
REMOVAL AND INSTALLATION
M1135001900508
1 7
3
9 10
11 12 5
6
26 ± 5 N·m
19 ± 4 ft-lb
4
11
4 03DB147A
14
15
18
27
N 19 25
13
20
16 N
28
29 N
31
33 30
32
03DB146A
FUEL TANK REMOVAL STEPS FUEL TANK REMOVAL STEPS
>>C<< 13. FUEL HIGH-PRESSURE HOSE 27. FUEL FILLER HOSE
14. PLATE 28. FUEL SHUT-OFF VALVE
<<E>> >>B<< 15. FUEL PUMP MODULE 29. O-RING
16. PACKING 30. FUEL TANK PROTECTOR (A)
<<F>> >>A<< 18. FUEL LEVEL SENSOR (SUB) 31. FUEL TANK PROTECTOR (B)
19. PACKING 32. FUEL TANK CENTER
20. FUEL TANK LEVELING HOSE PROTECTOR
25. FUEL TANK VAPOR HOSE 33. FUEL TANK
FUEL SUPPLY 13B-10
FUEL TANK
34
39 N
35
36
38
37
03DB143A
03DB150A
FUEL SUPPLY 13B-11
FUEL TANK
FUEL HIGH-
PRESSURE HOSE
AC306090 AB
GROMMET
03DB149A
AC307207AB
Make alignment marks between the suction hose and the fuel
pump module and then disconnect the suction hose to remove
FUEL PUMP the fuel pump module.
MODULE
MATING MARKS
SUCTION HOSE AC306092AB
AC307206AB
FUEL SUPPLY 13B-13
FUEL TANK
AC307206AB
AC307207AB
1. Align the mark of the suction hose with that of the fuel pump
module, and then connect the suction hose to the fuel pump
FUEL PUMP module.
MODULE 2. Install the fuel pump module into the fuel tank while ensuring
that the suction hose is not kinked.
MATING MARKS
SUCTION HOSE AC306092AB
.
FUEL SUPPLY 13B-14
FUEL TANK
INSPECTION
M1135002000241
.
80°
CLOSED
AC005004A
03DB148A
FUEL SUPPLY 13B-15
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1135003900322
ITEM SPECIFICATIONS
Fuel tank band nut 26 ± 4 N⋅m (19 ± 3 ft-lb)
Hole cover screw 1.5 ± 0.5 N⋅m (14 ± 4 in-lb)
SERVICE SPECIFICATION
M1135000300257
GROUP 13C
TRACTION
CONTROL SYSTEM
(TCL)
CONTENTS
ABS/TCL-ECU . . . . . . . . . . . . . . . . . . 13C-49
REMOVAL AND INSTALLATION . . . . . . . . 13C-49
TRACTION CONTROL SYSTEM (TCL) 13C-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1136000100029
Traction Control systems are a significant safety fea- ing on how much torque reduction is required and
ture designed to prevent wheel spin during accelera- will continue to occur until the wheels are no longer
tion. This results in improved vehicle stability and spinning. During traction control operation the TCL
steer ability. When excessive wheel spin is detected, warning lamp will flash to inform the driver that the
the system will automatically reduce engine torque vehicle is under traction control. This will continue
via the engine management system. The Engine until traction control is finished.
ECU can reduce throttle position, cut fuel injection
CONSTRUCTION DIAGRAM
and retard ignition to one or more cylinders depend-
HYDRAULIC UNIT
ASSEMBLY
(BUILT-IN ABS/TCL-ECU)
ENGINE
ECU
WHEEL SPEED
WHEEL SPEED SENSOR SENSOR
DATA LINK
CONNECTOR
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
03DB140A
TRACTION CONTROL SYSTEM (TCL) 13C-3
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
TCL Diagnostic Trouble Code Detection will be displayed again after the DTC has been
Conditions erased, you should recreate the TCL DTC set condi-
tions. Depending on the detection timing and set
TCL diagnostic trouble codes (TCL DTCs) are set
conditions for the specific TCL DTC, you must either
under different conditions, depending on the mal-
drive the vehicle or turn the engine off and restart it.
function detected. Most TCL DTCs will only be set
To set the proper conditions for that DTC again, refer
during vehicle operation. Some TCL DTCs will also
to "TCL DTC SET CONDITIONS" for each TCL DTC
be set during the TCL self-check immediately after
that you are trying to reset.
the engine is started. When you check if an TCL DTC
TROUBLESHOOTING STRATEGY
M1136003100062
Use these steps to plan your diagnostic strategy. If 6. If there is a TCL DTC, record the number of the
you follow them carefully, you will check most of the code, then erase the code from vehicle memory
possible causes of a TCL problem. using the diagnostic tool MB991958 (MUT-III sub
1. Gather information from the customer. assembly). (Refer to P.13C-3, Diagnosis Function
2. Verify that the condition described by the − How to Read and Erase Diagnostic Trouble
customer exists. Codes).
3. Check the vehicle for any TCL DTC. (Refer to 7. Re-create the TCL DTC set conditions to see if
P.13C-3, Diagnosis Function − How to Read and the same TCL DTC will set again. (Refer to
Erase Diagnostic Trouble Codes). P.13C-3, Diagnosis Function − How to Read and
4. If you can verify the condition but no TCL DTCs Erase Diagnostic Trouble Codes).
are set, and the malfunction may be intermittent. • If the same TCL DTC sets again, perform the
(Refer to GROUP 00, How to Use diagnostic procedures for the set code. (Refer to
Troubleshooting/Inspection Service Points − How P.13C-8, Diagnostic Trouble Code Chart).
to Cope with Intermittent Malfunctions P.00-14). NOTE: If the ABS-8 ECU or the active wheel
5. If you can verify the condition but there is no TCL speed sensor are disconnected, or if the wir-
DTCs, or the system cannot communicate with ing is an open/ short circuit, the ABS 8 ECU
diagnostic tool MB991958 (MUT-III sub will shut off power supply to the respective
assembly), and find the fault. (Refer to P.13C-23, wheel speed sensor. All other wheel speed
Symptom Chart). sensors will operate normally. To restore the
power supply, the ignition switch must be
turned to the "OFF" position then to the "ON"
position again.
DIAGNOSIS FUNCTION
M1136003200025
CAUTION
To prevent damage to diagnostic tool MB991958, always
DATA LINK turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR before connecting or disconnecting diagnostic tool
MB991958.
1. Ensure that the ignition switch is at the "LOCK" (OFF)
position.
2. Start up the personal computer.
3. Connect special tool MB991827 to special tool MB991824
MB991910 and the personal computer.
4. Connect special tool MB991910 to special tool MB991824.
MB991824 5. Connect special tool MB991910 to the data link connector.
6. Turn the power switch of special tool MB991824 to the "ON"
position.
NOTE: When special tool MB991824 is energized, special
tool MB991824 indicator light will be illuminated in a green
color.
7. Start the MUT-III system on the personal computer.
MB991827 NOTE: Disconnect the diagnostic tool MB991958 is the
00DB076A
reverse of the connecting sequence, making sure that the
ignition switch is at the "LOCK" (OFF) position.
MB991827 00DB076A
TRACTION CONTROL SYSTEM (TCL) 13C-6
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
MB991827 00DB076A
TRACTION CONTROL SYSTEM (TCL) 13C-7
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
U1100 CAN Communications System Time Out Error Engine Related Data
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
TRACTION CONTROL SYSTEM (TCL) 13C-11
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
TRACTION CONTROL SYSTEM (TCL) 13C-12
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
MB991827 00DB076A
U1101 CAN Communications System Time Out Error A/T Related Data
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
TRACTION CONTROL SYSTEM (TCL) 13C-15
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
TRACTION CONTROL SYSTEM (TCL) 13C-16
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
MB991827 00DB076A
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
TRACTION CONTROL SYSTEM (TCL) 13C-20
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
DIAGNOSIS
Check whether the MPI system sets either of diagnostic trouble
codes P2138, P2122 or P2123, and repair if necessary. (Refer
to GROUP 13A, MPI Diagnosis − Diagnostic Function − How to
Read and Erase Diagnostic Trouble Code P.13A-6).
TRACTION CONTROL SYSTEM (TCL) 13C-23
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
SYMPTOM CHART
M1136003400029
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: When the Ignition Switch is Turned to the "ON" Position
(Engine Stopped), the "TCL OFF" Indicator Light does not Illuminate. INSPECTION
PROCEDURE 2: When the Ignition Switch is Turned to the "ON" Position (Engine
Stopped), the TCL Work Indicator Light dose not Illuminate. INSPECTION
PROCEDURE 3: The "TCL OFF" Indicator Light Remains Illuminated After the Engine
is Started. INSPECTION PROCEDURE 4: The TCL Work Indicator Light Remains
Illuminated After the Engine is Started.
TRACTION CONTROL SYSTEM (TCL) 13C-24
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
C-29
C-02
C-02 HARNESS
CONNECTOR:
COMPONENT SIDE
A-02 HARNESS CONNECTOR:
C-101 HARNESS
C-29 MALE SIDE CONNECTOR:
CONNECTOR COMPONENT SIDE
16DB402A 17DB046A
17DB047A
CIRCUIT OPERATION "TCL OFF" indicator light and TCL work indicator
• The TCL automatically goes to ON, when the light to the combination meter via the CAN com-
ignition is turned to the "ON" position. To deacti- munication.
vate the TCL, press the TCL switch. To reactivate • ABS/TCL-ECU operates the "TCL OFF" indicator
the TCL , press the TCL switch again. light and the TCL work indicator light for three
seconds after the ignition switch is turned "ON"
position for bulb check.
TRACTION CONTROL SYSTEM (TCL) 13C-25
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
NOTE: If you press the TCL switch to deactivate the NOTE: If the ABS-8 ECU or the active wheel
TCL and then keep the TCL switch pressed for about speed sensor are disconnected, or if the wiring is
10 seconds, an error prevention function will auto- an open/ short circuit, the ABS 8 ECU will shut
matically reactivate the TCL. If you then still wish to off power supply to the respective wheel speed
deactivate the TCL, press the TCL switch again to sensor. All other wheel speed sensors will oper-
deactivate it. ate normally. To restore the power supply, the
ignition switch must be turned to the "OFF" posi-
tion then to the "ON" position again.
.
TRACTION CONTROL SYSTEM (TCL) 13C-26
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
TRACTION CONTROL SYSTEM (TCL) 13C-27
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
MB991827 00DB076A
INSPECTION PROCEDURE 5: When the TCL Switch is Pushed On, TCL does not Cancel.
C-29
C-131(GR)
C-131 HARNESS
CONNECTOR:
COMPONENT SIDE
16DB402A 35DB115A
DIAGNOSIS
Required Special Tools:
• MB991223: Harness Set
• MB991219: Inspection Test Harness
TRACTION CONTROL SYSTEM (TCL) 13C-29
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
16DB402A
CONNECTOR: A-02
(2) Measure the resistance at the ABS/TCL-ECU wiring
harness-side connector A-02 using the Inspection test
harness MB991219 (by inserting probe) and body ground.
NOTE: The special tool (Inspection test harness)
MB991219 for connector pin contact pressure should be
used. The test probe should never be forcibly inserted, as it
may cause a defective contact.
TEST (3) Turn the ignition switch to the "OFF" position.
HARNESS
(MB991219)
(4) Measure the resistance by probing ABS/TCL-ECU
connector A-02 terminal 21 (using inspection test harness
MB991219) and ground.
NOTE: The special tool (Inspection test harness)
MB991219 for connector pin contact pressure should be
35DB119A
used. The test probe should never be forcibly inserted, as it
may cause a defective contact.
• When the TCL switch is not pressed, the resistance
should indicate an open circuit (more than 2 ohms).
• When the TCL switch is pressed, the resistance should
measure 2 ohms or less.
(5) Turn the ignition switch to the "LOCK" (OFF) position.
(6) Disconnect inspection test harness MB991219.
(7) Connect the ABS/TCL-ECU connector A-02.
Q: Is the resistance value more than 2 ohms when the TCL
switch is not pressed, and is the resistance value less
than 2 ohms when the TCL switch is pressed?
YES : Go to Step 6.
NO : Go to Step 2.
TRACTION CONTROL SYSTEM (TCL) 13C-30
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
16DB402A
C-29
C-131(GR)
C-131 HARNESS
CONNECTOR:
COMPONENT SIDE
35DB115A
TRACTION CONTROL SYSTEM (TCL) 13C-32
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
16DB402A
CONNECTOR: C-131
C-131(GR)
C-131 HARNESS
CONNECTOR:
COMPONENT SIDE
35DB116A
TRACTION CONTROL SYSTEM (TCL) 13C-33
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
C-131(GR)
C-131 HARNESS
CONNECTOR:
COMPONENT SIDE
35DB116A
COMBINATION METER
CONNECTOR
GROUND
TERMINAL
35DB117A
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
TRACTION CONTROL SYSTEM (TCL) 13C-35
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
16DB402A
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
11-12V FIGURE 1
OSCILLOSCOPE
Black Red
Ground
Terminals:
16, 9, 6, 8
Supply
Signal
WHEEL SPEED
SENSOR
35DB121A
TRACTION CONTROL SYSTEM (TCL) 13C-42
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
FIGURE 2
Wheel speed sensor connectors:
A-04, A-01, D-30, D-31
WHEEL SPEED
SENSOR
Supply
Signal
Terminals:
5, 10, 17, 19
Ground
Black Red
ABS-ECU
(A-02)
OSCILLOSCOPE
35DB122A
TRACTION CONTROL SYSTEM (TCL) 13C-44
TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
V
1.50
1.00
0.50
0.00
0 20 40 60 80 100
ms
35DB120A
SPECIAL TOOLS
M1136000600024
DO NOT USE
MB991914
MB991825
MB991826
MB991958
TRACTION CONTROL SYSTEM (TCL) 13C-46
SPECIAL TOOLS
D
MB991223 AD
TRACTION CONTROL SYSTEM (TCL) 13C-47
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
TCL INDICATOR LIGHT CHECK
M1136000900058
1. Check that the "TCL OFF" indicator light and the TCL work
indicator light illuminate for three seconds when the ignition
switch is turned to the "ON" position.
2. Check that the "TCL OFF" indicator light illuminates and
goes off in cycles each time the TCL switch is pushed after
starting the engine.
3. Check that the "TCL OFF" indicator light and the TCL work
indicator light do not illuminate, when driving at 30km/h
(37.5 mph) for more than 2 seconds.
4. If defective, repair it. (Refer to P.13C-23, TCL diagnosis −
Symptom Procedures − Inspection Procedure 1, 2, 3 and 4).
CAUTION
To prevent damage to diagnostic tool MB991958, always
DATA LINK turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR before connecting or disconnecting diagnostic tool
MB991958.
1. Connect diagnostic tool MB991958 to the data link
connector. (Refer to P.13C-3).
2. Turn the ignition switch to the "ON" position.
CAUTION
MB991910 The engine speed increases after the actuator test
because the actuator test continues for only three sec-
MB991824 onds. Therefore, release the accelerator pedal immedi-
ately.
3. Use diagnostic tool MB991958 to check the actuator test.
(Refer to P.13C-3).
• Item 09: Engine TCL Drive.
• When the accelerator pedal is depressed at the same
time that the button for actuator test item 09 displayed
on diagnostic tool MB991958 is pressed, the system
MB991827 00DB076A
prevents the engine speed from rising for three sec-
onds.
4. Turn the ignition switch to the "LOCK" (OFF) position.
5. Disconnect diagnostic tool MB991958.
6. If defective, repair it. (Refer to P.13C-34, TCL diagnosis −
Symptom Procedures − Inspection Procedure 6).
TCL SWITCH
REMOVAL AND INSTALLATION
M1136001600027
1
2
3
03DB141A
ABS/TCL-ECU
REMOVAL AND INSTALLATION
M1136005300017
Replace the hydraulic unit (integrated with ABS/TCL-ECU). (Refer to GROUP 35B, Hydraulic Unit P.35B-93).
13C-50 TRACTION CONTROL SYSTEM (TCL)
ABS/TCL-ECU
HOME
14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL DESCRIPTION
M1141000100401
• The cooling system is designed to keep every exceeds the prescribed temperature, the thermo-
part of the engine at appropriate temperature in stat opens to circulate the coolant through the
whatever condition the engine may be operated. radiator as well so that the heat absorbed by the
The cooling method is of the water-cooled, pres- coolant may be radiated into the air. The water
sure forced circulation type in which the water pump is of the centrifugal type and is driven by
pump pressurizes coolant and circulates it the drive belt from the crankshaft. The radiator is
throughout the engine. If the coolant temperature the corrugated fin, down flow type.
SPECIAL TOOL
M1141000600279
MB991871
SYMPTOM CHART
M1141005600393
SYMPTOM PROCEDURES
DIAGNOSIS
ACX01844 AB
DIAGNOSIS
CIRCUIT OPERATION signal from the A/C switch, the water temperature
• The fan controller is powered from fusible link sensor unit and the vehicle speed sensor <M/T>
No.2. or the output shaft speed sensor <A/T> to the
• The engine-ECU uses input signals from the A/C engine-ECU.
switch, the water temperature sensor unit and the • The cause could also be a malfunction of the fan
vehicle speed sensor <M/T> or the output shaft controller or the engine-ECU.
speed sensor <A/T> to control the speed of the
radiator fan motor and the condenser fan motor.
• The engine-ECU controls the fan controller to .
activate the radiator fan motor and the condenser TROUBLESHOOTING HINTS
fan motor. • Malfunction of fusible link No.2
• Malfunction of fan control relay
• Malfunction of cooling fan motor and fan control-
.
DIAGNOSIS
A-24
3 2 1
04DB008A
Connector A-24
(Component side)
3 2 1
04DB009A
(3) Measure the voltage between fan controller connector A-24
terminal 3 and body earth.
• The voltage should measure system voltage.
(4) Turn the ignition switch to the "LOCK" (OFF) position.
(5) Connect fan controller connector A-24.
Q: Is the measured voltage system voltage?
YES : Go to Step 17.
NO : Go to Step 2.
A-24
3 2 1
04DB008A
Relay box
Fusible link
No.2
Fan control
relay
04DB010A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
A-10X Connector
(Relay box side)
04DB013A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Relay box
Fusible link
No.2
Fan control
relay
04DB010A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Connector: A-24
A-24
3 2 1
04DB008A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
A-10X Connector
(Relay box side)
04DB014A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: A-13
A-13(GR)
AK303148 AB
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
A-13(GR)
AK303148 AB
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
A-10X Connector
(Relay box side)
04DB015A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
RELAY BOX
A-14
04DB019A
STEP 16. Check the harness wire between fan control relay
connector A-10X terminal 1 and body earth connector A-14
terminal 6.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
RELAY BOX
A-14
04DB019A
A-24
3 2 1
04DB008A
A-24 Connector
(Wiring harness side)
04DB016A
A-24
3 2 1
04DB008A
A-24
3 2 1
04DB008A
A-24
3 2 1
04DB008A
CONNECTOR: A-13
A-13(GR)
AK303148 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
A-24
3 2 1
04DB008A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
A-24
3 2 1
04DB008A
INSPECTION PROCEDURE 4: Radiator Fan and Condenser Fan do not Change Speed or Stop
Radiator Fan and Condenser Fan Drive signal from the A/C switch, the water temperature
Circuit sensor unit and the vehicle speed sensor <M/T>
Refer to 5. or the output shaft speed sensor <A/T> to the
.
engine-ECU.
TECHNICAL DESCRIPTION • The cause could also be a malfunction of the fan
• The cause could be a malfunction of the fan con- controller or the engine-ECU.
troller power supply or earth circuit. .
DIAGNOSIS
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Connector: A-24
A-24
3 2 1
04DB008A
A-24
3 2 1
04DB008A
CONNECTOR: A-13
A-13(GR)
AK303148 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
A-24
3 2 1
04DB008A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
A-24
3 2 1
04DB008A
DIAGNOSIS
Replace the radiator fan motor and fan controller assembly.
Q: Does the radiator fan operate correctly?
YES : There is no action to be taken?
NO : Repair the wiring harness between the fan controller
and the radiator fan motor.
DIAGNOSIS
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK
M1141001000333
WARNING
When pressure testing the cooling system, slowly
release cooling system pressure to avoid getting
burned by hot coolant.
CAUTION
• Be sure to completely clean away any moisture from
the places checked.
• When the tester is taken out, be careful not to spill any
coolant.
• Be careful when installing and removing the tester and
when testing not to deform the filler neck of the radia-
tor.
1. Check that the coolant level is up to the filler neck. Install a
CAP ADAPTER
radiator tester and apply 160 kPa (23 psi) pressure, and
then check for leakage from the radiator hose or
connections.
ADAPTER 2. If there is leakage, repair or replace the appropriate part.
ACX01844 AB
ENGINE COOLING 14-27
ON-VEHICLE SERVICE
ACX01845 AB
WARNING
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise a lit-
tle to let the pressure escape through the vinyl tube.
After relieving the steam pressure, remove the cap by
slowly turning it counterclockwise.
1. Drain the water from the radiator, heater core and engine
after unplugging the radiator drain plug and removing the
radiator cap.
ENGINE COOLING 14-28
ON-VEHICLE SERVICE
CYLINDER BLOCK
DRAIN PLUG
AC306132AB
CYLINDER BLOCK
DRAIN PLUG
AC306131AB
AC200625AD
5. Apply the designated sealant to the screw area of the
cylinder block drain plug, and then tighten to the standard
torque.
Specified sealant: 3M™ AAD Part No.8731 or equiva-
lent
Tightening torque:
39 ± 5 N⋅m
6. Securely tighten the radiator drain plug.
7. Assemble the radiator condenser tank assembly.
ENGINE COOLING 14-29
ON-VEHICLE SERVICE
CAUTION
• Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze can
cause corrosion of the aluminum components.
8. By referring to the section on coolant, select an appropriate
concentration for safe operating temperature within the
AIR HOSE
range of 30 to 60 %. Use special tool MB991871 to refill the
MB991871
coolant. A convenient mixture is a 50 % water and 50 %
antifreeze solution [freezing point: −31°C (−32.8 °F)].
Recommended antifreeze: Long Life Antifreeze
Coolant or an equivalent
Quantity:
8.7 Litres
AC306129 AB NOTE: For how to use special tool MB991871, refer to its
manufacturer’s instructions.
9. Reinstall the radiator cap.
10.Start the engine and let it warm up until the thermostat
opens.
11.After repeatedly revving the engine up to 3,000 r/min several
times, stop the engine.
12.Remove the radiator cap after the engine has cooled, and
pour in coolant up to the brim. Reinstall the cap.
CAUTION
Do not overfill the radiator condenser tank assembly.
13.Add coolant to the radiator condenser tank assembly
between the "FULL" and "LOW" mark if necessary.
Fan controller
3 2 1
04DB017A
Fan controller
1 2
04DB018A
2 4
2
1 3
4 1 3
AC307445AB
ENGINE COOLING 14-32
RADIATOR
RADIATOR
REMOVAL AND INSTALLATION
M1141001500521
22 ± 4 N·m
16 ± 3 ft-lb
7
10
16 15 14
8
8 17
9 2
11 ± 2 N·m
98 ± 17 in-lb 9
1
11
19
9 13
4 18
12 11
20
3
6 21
5
04DB007A
MATING MARKS
AC200641AB
THERMOSTAT
REMOVAL AND INSTALLATION
M1141002400475
13
14 18
16
13
10 20 17
11 2 22 ± 4 N·m
16 ± 3 ft-lb
04DB006A
23
22
19 ± 1 N·m
14 ± 1 ft-lb
21
AC306959AB
MATING MARKS
AC200641AB
RUBBER RING
AC000279 AB
INSPECTION
M1141002500450
.
Thermostat Check
1. Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value:
Valve opening temperature:
88 ± 1.5°C (190 ± 3°F)
ACX00400
WATER PUMP
REMOVAL AND INSTALLATION
M1141002700498
N3
4N BOLT SPECIFICATIONS
10 × 38
24 ± 3 N·m (0.4 × 1.5)
18 ± 2 ft-lb
8 × 25
(0.3 × 1.0)
8 × 25 8 × 20
(0.3 × 1.0) (0.3 × 0.8)
O-RING
WATER PIPE
AC200644 AB
ENGINE COOLING 14-40
WATER HOSE AND WATER PIPE
29 ± 10 N·m
N 9 22 ± 7 ft-lb
7
N 6
8 2
N 9
N 6 19 ± 1 N·m
14 ± 1 ft-lb
5 2
1 11 ± 1 N·m
19 ± 1 N·m 98 ± 8 in-lb
14 ± 1 ft-lb 04DB020A
MATING MARKS
AC200641AB
ENGINE COOLING 14-41
WATER HOSE AND WATER PIPE
WATER PIPE
AC200644 AB
AC208408AB
INSPECTION
M1141003400337
.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1141005000346
ITEM SPECIFICATION
Cylinder block drain plug 39 ± 5 N⋅m (29 ± 3 ft-lb)
Radiator
Front end structure bar bolt M8 × 10 11 ± 2 N⋅m (98 ± 17 in-lb)
M8 × 20 22 ± 4 N⋅m (16 ± 3 ft-lb)
Thermostat
Control harness bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Grounding bolt M6 9.0 ± 2.0 N⋅m (80 ± 17 in-lb)
M8 22 ± 4 N⋅m (16 ± 3 ft-lb)
Water inlet fitting bolt 19 ± 1 N⋅m (14 ± 1 ft-lb)
Water hose and water pipe
Engine coolant temperature sensor 29 ± 10 N⋅m
Thermostat housing bolt 19 ± 1 N⋅m (14 ± 1 ft-lb)
Water pump inlet pipe 11 ± 1 N⋅m (98 ± 8 ft-lb)
Water pump
Water pump bolt M8 42 ± 8 N⋅m (31 ± 6 ft-lb)
M10 24 ± 3 N⋅m (18 ± 2 ft-lb)
Water pump bracket bolt 24 ± 3 N⋅m (18 ± 2 ft-lb)
ENGINE COOLING 14-43
SPECIFICATIONS
SERVICE SPECIFICATION
M1141000300449
CAPACITIES
M1141005100138
SEALANTS
M1141000500368
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL DESCRIPTION
M1151000100446
The exhaust pipe is divided into four parts.
SYMPTOM PROCEDURES
SPECIAL TOOLS
M1151000600429
B991953
AIR CLEANER
REMOVAL AND INSTALLATION
M1151002100516
6
7
2 10
3
8.8 ± 1.0 N·m
78 ± 9 in-lb
5
8 4
12 ± 2 N·m
102 ± 22 in-lb
1
8.8 ± 1.0 N·m
78 ± 9 in-lb
10
.
9
CHAMBER
2
20 01DB051A
17 18 N
18 ± 2 N·m
13 ± 2 ft-lb
11 23
11 ± 1 N·m
36 ± 6 N·m
12 98 ± 8 in-lb
27 ± 4 ft-lb
41 ± 8 N·m 16
30 ± 6 ft-lb
15
36 ± 6 N·m
27 ± 4 ft-lb
05DB025A
INTAKE AND EXHAUST 15-6
INTAKE MANIFOLD PLENUM
MD998412
AC306688 AB
INTAKE AND EXHAUST 15-7
INTAKE MANIFOLD
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
M1151003000802
CONNECTOR
3
12 ± 1 N·m
102 ± 13 in-lb
6
MAIN PIPE NOZZLE OR
FUEL MAIN PIPE 11 ± 1 N·m
98 ± 8 in-lb
22 ± 1 N·m
1 16 ± 1 ft-lb
INTAKE 1
MANIFOLD 13
MOUNTING 36 ± 6 N·m 11
STAD 27 ± 4 ft-lb
CYLINDER 12 N
HEAD
2
5
ENGINE OIL
N 12
7
24 ± 3 N·m
18 ± 2 ft-lb
10
11 ± 1 N·m
98 ± 8 in-lb
14 ± 1 N·m 14 ± 1 N·m
120 ± 13 in-lb 120 ± 13 in-lb 9
05DB027A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. INJECTOR CONNECTOR 8. TIMING BELT FRONT UPPER
2. ENGINE MOUNTING STAY COVER, RIGHT
>>C<< 3. FUEL HIGH-PRESSURE HOSE 9. TIMING BELT FRONT UPPER
CONNECTION COVER, LEFT
5. BLOW-BY HOSE 10. WATER PUMP BRACKET
<<A>> 6. FUEL RAIL AND INJECTOR >>B<< 11. INTAKE MANIFOLD
7. PCV HOSE CONNECTION >>A<< 12. INTAKE MANIFOLD GASKET
13. CONTROL HARNESS CLAMP
INTAKE AND EXHAUST 15-8
INTAKE MANIFOLD
PROTRUSION
ACX02434 AC
.
INTAKE AND EXHAUST 15-9
INTAKE MANIFOLD
INSPECTION
M1151003100672
Check the following points; replace the part if a problem is
found.
.
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1151003301055
<LEFT BANK>
Pre-removal and Post-installation Operation
• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-13).
• Air Duct Removal and Installation (Refer to P.15-4).
1
14 ± 1 N·m
120 ± 13 in-lb
1 2
9 N
44 ± 5 N·m
33 ± 3 ft-lb
8
44 ± 8 N·m
33 ± 5 ft-lb
4
7
3
10 44 ± 5 N·m
19 ± 3 N·m
33 ± 3 ft-lb
14 ± 2 ft-lb
44 ± 8 N·m
44 ± 5 N·m
5 33 ± 5 ft-lb
33 ± 3 ft-lb
49 ± 9 N·m
37 ± 6 ft-lb
N 6
05DB028A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. LEFT HEATED OXYGEN SENSOR 6. FRONT EXHAUST PIPE GASKET
CONNECTOR 7. EXHAUST MANIFOLD STAY, LEFT
<<A>> >>A<< 2. LEFT BANK HEATED OXYGEN B
SENSOR (FRONT) 8. EXHAUST MANIFOLD
<<B>> >>B<< 3. LEFT BANK HEATED OXYGEN 9. EXHAUST MANIFOLD GASKET
SENSOR (REAR) 10. EXHAUST MANIFOLD STAY, LEFT
4. HEAT PROTECTOR A
5. FRONT EXHAUST PIPE
CONNECTING BOLTS
INTAKE AND EXHAUST 15-11
EXHAUST MANIFOLD
<RIGHT BANK>
Pre-removal and Post-installation Operation
• Air Cleaner Cover and Air Intake Duct Removal and
Installation (Refer to P.15-4).
• Battery Removal and Installation
• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-13).
• Front Exhaust Pipe, Center Exhaust Pipe Removal and
Installation (Refer to P.15-14).
• Strut Tower Bar Removal and Installation (Refer to
GROUP 42, Strut Tower Bar P.42-12).
• Engine Coolant Draining and Refilling (Refer to GROUP
14, On-vehicle Service − Engine Coolant Replacement
P.14-27).
14 ± 1 N·m
120 ± 13 in-lb
10 5
N 13
2 4
6
44 ± 5 N·m
33 ± 3 ft-lb
7
12 3
11
44 ± 5 N·m
33 ± 3 ft-lb
75 ± 10 N·m
55 ± 7 ft-lb
1
05DB029A
MD998770
ACX02426 AB
MB991953
AC301966AC
MD998770
ACX02426 AB
.
INTAKE AND EXHAUST 15-13
EXHAUST MANIFOLD
MB991953
AC301966AC
INSPECTION
M1151003400587
Check the following points; replace the part if a problem is
found.
.
MB991953
AC301966AC
INTAKE AND EXHAUST 15-15
EXHAUST PIPE AND MAIN MUFFLER
MB991953
AC301966AC
INTAKE AND EXHAUST 15-16
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1151006800506
ITEM SPECIFICATION
Air cleaner
Air cleaner bolt 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)
Air cleaner bracket bolt and nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Air cleaner resonator bolt 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)
Air intake hose clamp bolt 4.0 ± 0.9 N⋅m (35 ± 8 in-lb)
Airflow sensor nut 8.0 ± 1.0 N⋅m
Exhaust manifold <Left bank>
Exhaust manifold nut 44 ± 5 N⋅m (33 ± 3 ft-lb)
Front exhaust pipe bolt 49 ± 9 N⋅m (37 ± 6 ft-lb)
Exhaust manifold stay, left A bolt M8 19 ± 3 N⋅m (14 ± 2 ft-lb)
Exhaust manifold stay, left B bolt M10 44 ± 8 N⋅m (33 ± 5 ft-lb)
Heat protector bolt 14 ± 1 N⋅m (120 ± 13 in-lb)
Heated oxygen sensor 44 ± 5 N⋅m (33 ± 3 ft-lb)
Exhaust manifold <Right bank>
Exhaust manifold nut 44 ± 5 N⋅m (33 ± 3 ft-lb)
Exhaust manifold stay, right A bolt M12 75 ± 10 N⋅m (55 ± 7 ft-lb)
Exhaust manifold stay, right B bolt M10 44 ± 5 N⋅m (33 ± 3 ft-lb)
Heat protector bolt 14 ± 1 N⋅m (120 ± 13 in-lb)
Heated oxygen sensor 44 ± 5 N⋅m (33 ± 3 ft-lb)
Exhaust pipe and main muffler
Crossmember stay bolt 45 ± 5 N⋅m (34 ± 3 ft-lb)
Center exhaust pipe nut 49 ± 9 N⋅m (37 ± 6 ft-lb)
Front floor backbone brace bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Front no.1 exhaust pipe bolt 35 ± 4 N⋅m (26 ± 3 ft-lb)
Front no.1 exhaust pipe to front no.2 exhaust pipe bolt 49 ± 4 N⋅m (37 ± 3 ft-lb)
Front no.1 exhaust pipe to right bank exhaust manifold nut 49 ± 9 N⋅m (37 ± 6 ft-lb)
Front no.1 exhaust pipe to left bank exhaust manifold bolt 49 ± 9 N⋅m (37 ± 6 ft-lb)
Hanger bolt 12 ± 2 N⋅m (107 ± 17 in-lb)
Main muffler bolt 49 ± 4 N⋅m (37 ± 3 ft-lb)
Heat protector bolt 14 ± 1 N⋅m (120 ± 13 in-lb)
Intake manifold
Control harness clamp bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Engine mounting stay bolt 36 ± 6 N⋅m (27 ± 4 ft-lb)
Fuel rail and injector bolt 12 ± 1 N⋅m (102 ± 13 in-lb)
Intake manifold bolt 22 ± 1 N⋅m (16 ± 1 ft-lb)
Timing belt front upper cover bolt M6 11 ± 1 N⋅m (98 ± 8 in-lb)
M8 14 ± 1 N⋅m (120 ± 13 in-lb)
INTAKE AND EXHAUST 15-17
SPECIFICATIONS
ITEM SPECIFICATION
Water pump bracket bolt 24 ± 3 N⋅m (18 ± 2 ft-lb)
INTAKE AND EXHAUST 15-18
SPECIFICATIONS
ITEM SPECIFICATION
Intake manifold plenum
Evaporative emission purge solenoid bolt 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Harness bracket bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Intake manifold plenum bolt 18 ± 2 N⋅m (13 ± 2 ft-lb)
Intake manifold plenum stay bolt M8 18 ± 2 N⋅m (13 ± 2 ft-lb)
M10 36 ± 6 N⋅m (27 ± 4 ft-lb)
Manifold absolute pressure sensor bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Power steering pressure hose clamp nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Power steering pressure hose clamp bracket bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Power steering oil pump bracket connecting bolt 41 ± 8 N⋅m (30 ± 6 ft-lb)
SERVICE SPECIFICATION
M1151000300462
SEALANTS
M1151000500187
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM
GENERAL DESCRIPTION
M1161000100629
The charging system charges the battery with the
alternator output to keep the battery charged at a
constant level during varying electrical load.
OPERATION
When the ignition switch is turned on, current flows in
VOLTAGE the field coil and initial excitation of the field coil
occurs.
When the stator coil begins to generate power after
APPROXIMATELY
the engine is started, the field coil is excited by the
14.4 V output current of the stator coil.
The alternator output voltage rises as the field cur-
rent increases and it falls as the field current
decreases. When the battery positive voltage
TIME (alternator S terminal voltage) reaches a regulated
AKX00183 AB
voltage of approximately 14.4 V, the field current is
Rotation of the excited field coil generates AC volt- cut off. When the battery positive voltage drops
age in the stator. below the regulated voltage, the voltage regulator
This alternating current is rectified through diodes to regulates the output voltage to a constant level by
DC voltage having a waveform shown in the illustra- controlling the field current.
tion above. In addition, when the field current is constant, the
The average output voltage fluctuates slightly with alternator output voltage rises as the engine speed
the alternator load condition. increases.
<3.8L ENGINE>
ALTERNATOR
B
STATOR
COIL
FIELD COIL S
L +
IGNITION
ALTERNATOR SWITCH BATTERY
VOLTAGE REGULATOR
MALFUNCTION –
LIGHT
06DB028A
ENGINE ELECTRICAL 16-3
CHARGING SYSTEM
TROUBLESHOOTING HINTS
Alternator malfunction light dose not go on when the ignition
switch is turned to ON, before the engine starts.
• Check the bulb.
Alternator malfunction light dose not switch off after the engine
starts.
• Check the IC voltage regulator inside the
alternatoralternator.
Discharged or overcharged battery.
• Check the IC voltage regulator inside the alternator.
The alternator malfunction light illuminates dimly.
• Check the diode (inside the combination meter) for a
short-circuit.
TROUBLESHOOTING GUIDE
The charging system troubleshooting guide is shown in the fol-
lowing steps.
STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A,
Chassis Electrical − Battery − On-vehicle Service −
Battery Check P.54A-5.)
YES : Go to Step 2.
NO : Charge or replace the battery.
STEP 2.
Q: Is the alternator drive belt in good condition? (Refer to
GROUP 00, General − Maintenance Service − Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
YES : Go to Step 3.
NO : Adjust the belt tension or replace the belt.
STEP 3.
Q: Does the alternator malfunction light come on when the
ignition switch is turned on?
YES : Go to Step 4.
NO : • Check the ignition switch. (Refer to GROUP 54A,
Chassis Electrical − Ignition Switch − Ignition
Switch − Inspection P.54A-44.)
• Check for burnt-out alternator malfunction light.
• Check the alternator. (Refer to Charging System −
Alternator Assembly − Inspection P.16-17.)
• Check the alternator malfunction light-related
circuits.
ENGINE ELECTRICAL 16-4
CHARGING SYSTEM
STEP 4.
Q: Does the alternator malfunction light go out after
starting the engine?
YES : Go to Step 5.
NO : Check the alternator (Refer to Charging System −
Alternator Assembly − Inspection P.16-17.)
STEP 5.
Q: Is an oscilloscope available?
YES : Go to Step 6.
NO : Go to Step 7.
STEP 6.
Q: Does the oscilloscope show a normal wave pattern?
(Refer to Charging System − On-vehicle Service − Wave
Pattern Check Using an Oscilloscope P.16-11.)
YES : Go to Step 7.
NO : Check the alternator. (Refer to Charging System −
Alternator Assembly − Inspection P.16-17.)
STEP 7.
• Engine: 2,500 r/min
• Headlight: ON (high beam)
• Voltage between alternator terminal B and the positive bat-
tery terminal
OK: 0.5 V or less
• Voltage between the negative battery terminal and
alternator body
OK: 0.5 V or less
Q: Are the alternator output wire and ground wire in good
condition?
YES : Go to Step 8.
NO : Check the alternator output wire and ground wire.
STEP 8.
Q: Is the output current normal? (Refer to Charging
System − On-vehicle Service − Output Current Test
P.16-8.)
YES : Go to Step 9.
NO : Check the alternator (Refer to Charging System −
Alternator Assembly − Inspection P.16-17.)
ENGINE ELECTRICAL 16-5
CHARGING SYSTEM
STEP 9.
Q: Is the regulated voltage normal? (Refer to Charging
System − On-vehicle Service − Regulated Voltage Test
P.16-10.)
YES : Go to Step 10.
NO : Check the alternator (Refer to Charging System −
Alternator Assembly − Inspection P.16-17.)
STEP 10.
Q: Is the voltage drop in the alternator output wire normal?
YES : Alternator is normal. Check other systems.
NO : Check the output wire.
ENGINE ELECTRICAL 16-6
CHARGING SYSTEM
SPECIAL TOOL
M1161000600486
MB991825
MB991826
MB991958
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT WIRE VOLTAGE DROP TEST
M1161000900669
AMMETER
ALTERNATOR (CLAMP-TYPE)
VOLTMETER
(DIGITAL-TYPE)
BATTERY
"B" TERMINAL
06DB027A
Required Special Tool: 2. Turn the ignition switch to the "LOCK" (OFF)
: Diagnostic Tool (MUT-III) position.
• MB991824: V.C.I. 3. Disconnect the negative battery cable.
• MB991827: MUT-III USB Cable
4. Connect a clamp-type DC test ammeter with a
• MB991910: MUT-III Main Harness A
range of 0 − 100 A to the alternator "B" terminal
This test determines whether the wiring from the
output wire.
alternator "B" terminal to the positive battery terminal
(including the fusible link) is in good condition or not: NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is pos-
WARNING sibly not found the problem that the output current
Battery posts, terminals and related acces- is dropping due to the insufficient connection
sories contain lead and lead compounds. between terminal "B" and the output wire.
WASH HANDS AFTER HANDLING. 5. Connect a digital-type voltmeter between the
1. Always be sure to check the following before the alternator "B" terminal and the positive battery
test. terminal. (Connect the positive lead of the
• Alternator installation voltmeter to the "B" terminal, and then connect the
• Alternator drive belt tension (Refer to GROUP 00, negative lead of the voltmeter to the positive
General − Maintenance Service − Drive Belts battery cable.)
(For Alternator, Power Steering Pump and Air 6. Reconnect the negative battery cable.
Conditioning) (Check) P.00-39.)
7. Connect an engine tachometer or diagnostic tool.
• Fusible link
• Abnormal noise from the alternator while the 8. Leave the hood open.
engine is running. 9. Start the engine.
ENGINE ELECTRICAL 16-8
CHARGING SYSTEM
10.With the engine running at 2,500 r/min, turn the 11.If the value displayed on the voltmeter is above
headlights and other lights on and off to adjust the the limit value, there is probably a malfunction in
alternator load so that the value displayed on the the alternator output wire. Check the wiring
ammeter is slightly above 30 A. between the alternator "B" terminal and the
Read the voltmeter. Voltage reading at or below positive battery terminal (including fusible link).
limit value means voltage drop between alternator If a terminal is not sufficiently tight or if the
and battery is OK. harness has become discolored due to
Limit value: maximum 0.3 V overheating, repair and then test again.
NOTE: When the alternator output is high and the 12.After the test, run the engine at idle.
value displayed on the ammeter does not 13.Turn off all lights and turn the ignition switch to the
decrease to 30 A, set the value to 40 A. Read the "LOCK" (OFF) position.
value displayed on the voltmeter at this time. 14.Disconnect the engine tachometer or diagnostic
In this case the limit value becomes maximum 0.4 tool.
V. 15.Disconnect the negative battery cable.
Adjust the engine speed by gradually decreasing
16.Disconnect the ammeter and voltmeter.
it until the value displayed on the ammeter is 30
A. Take a reading of the value displayed on the 17.Connect the negative battery cable.
voltmeter at this time. 18.Run the engine for 10 minutes at an idle.
OUTPUT CURRENT TEST
M1161001000670
LOAD
AMMETER
VOLTMETER (CLAMP-TYPE)
– +
ALTERNATOR
MALFUNCTION
LIGHT
IGNITION
SWITCH
B
COMBINATION METER L
S
ALTERNATOR
BATTERY
06DB026A
ENGINE ELECTRICAL 16-9
CHARGING SYSTEM
Required Special Tool: 9. Check to be sure that the reading on the voltmeter
: Diagnostic Tool (MUT-III) is equal to the battery positive voltage.
• MB991824: V.C.I. NOTE: If the voltage is 0 V, the cause is probably
• MB991827: MUT-III USB Cable an open circuit in the wire or fusible link between
• MB991910: MUT-III Main Harness A the alternator "B" terminal and the battery positive
This test determines whether the alternator outputs terminal or malfunctioning voltmeter.
normal current. For best results, use a charging sys-
10.After turning on the headlights, start the engine.
tem tester. If not available, follow the steps below.
NOTE: Because the current from the battery will
WARNING
soon drop after the engine is started, step 11
Battery posts, terminals and related acces- should be carried out as quickly as possible in
sories contain lead and lead compounds. order to obtain the maximum current output value.
WASH HANDS AFTER HANDLING.
11.Immediately after setting the headlights to high
1. Before the test, always be sure to check the beam and turning the heater blower switch to the
following. highest position, increase the engine speed to
• Alternator installation 2,500 r/min and read the maximum current output
• Battery (Refer to GROUP 54A, Chassis Electrical value displayed on the ammeter.
− Battery − On-vehicle Service − Battery Check Limit value: 70 % of nominal current output
P.54A-5.)
NOTE: For the nominal current output, refer to the
NOTE: The battery to be used should be slightly Alternator Specifications.
discharged. The load in a fully-charged battery
NOTE: The current output value will depend on
will be insufficient and the test may not be able to
the electrical load and the temperature of the
be carried out correctly.
alternator body.
• Alternator drive belt tension (Refer to GROUP 00,
General − Maintenance Service − Drive Belts NOTE: If the electrical load is small while testing,
(For Alternator, Power Steering Pump and Air the specified level of current may not be output
Conditioning) (Check) P.00-39.) even though the alternator is normal. In such
• Fusible link cases, increase the electrical load by leaving the
• Abnormal noise from the alternator while the headlights turned on for some time to discharge
engine is running. the battery or by using the lighting system in
another vehicle, and then test again.
2. Turn the ignition switch to the "LOCK" (OFF)
position. NOTE: The specified level of current also may not
be output if the temperature of the alternator body
3. Disconnect the negative battery cable.
or the ambient temperature is too high. In such
WARNING cases, cool the alternator and then test again.
Never use clips to connect the wire. Loose 12.The reading on the ammeter should be above the
connections (for example, using clips) will limit value. If the reading is below the limit value
lead to a serious accident because of high and the alternator output wire is normal, remove
current. the alternator from the engine and check the
4. Connect a clamp-type DC test ammeter with a alternator.
range of 0 − 120 A to the alternator "B" terminal 13.Run the engine at idle speed after the test.
output wire. 14.Turn the ignition switch to the "LOCK" (OFF)
5. Connect a voltmeter with a range of 0 − 20 V position.
between the alternator "B" terminal and ground. 15.Disconnect the engine tachometer or diagnostic
(Connect the positive lead of the voltmeter to the tool.
"B" terminal, and then connect the negative lead 16.Disconnect the negative battery cable.
of the voltmeter to ground.) 17.Disconnect the ammeter and voltmeter .
6. Connect the negative battery cable. 18.Connect the negative battery cable.
7. Connect an engine tachometer or diagnostic tool. 19.Run the engine for 10 minutes at an idle.
8. Leave the hood open.
ENGINE ELECTRICAL 16-10
CHARGING SYSTEM
LOAD
ALTERNATOR AMMETER
MALFUNCTION (CLAMP-TYPE)
LIGHT
IGNITION MB998467
SWITCH
COMBINATION
METER
B
L
ALTERNATOR
S
RED
YELLOW
VOLTMETER (DIGITAL-TYPE)
BATTERY
06DB025A
Required Special Tools: 2. Turn the ignition switch to the "LOCK" (OFF)
• : Diagnostic Tool (MUT-III) position.
• MB991824: V.C.I. 3. Disconnect the negative battery cable.
• MB991827: MUT-III USB Cable
4. Use the special tool (Alternator harness
• MB991910: MUT-III Main Harness A
connector: MB998467) to connect a digital-type
• MB998467: Alternator Harness Connector
voltmeter between the alternator "S" terminal and
This test determines whether the voltage regulator is
ground. (Connect the positive lead of the
correctly controlling the alternator output voltage.
voltmeter to the "S" terminal, and then connect the
WARNING negative lead of the voltmeter to a secure ground
Battery posts, terminals and related acces- or to the negative battery terminal.)
sories contain lead and lead compounds. 5. Connect a clamp-type DC test ammeter with a
WASH HANDS AFTER HANDLING. range of 0 − 120 A to the alternator "B" terminal
1. Always be sure to check the following before the output wire.
test: 6. Reconnect the negative battery cable.
• Alternator installation 7. Connect an engine tachometer, or diagnostic tool.
• Check to be sure that the battery installed in the
8. Turn the ignition switch to the "ON" position and
vehicle is fully charged. (Refer to GROUP 54A,
check that the reading on the voltmeter is equal to
Chassis Electrical − Battery − On-vehicle Service
the battery positive voltage.
− Battery Check P.54A-5.)
NOTE: If the voltage is 0 V, the cause is probably
• Alternator drive belt tension (Refer to GROUP 00,
an open circuit in the wire or fusible link between
General − Maintenance Service − Drive Belts
the alternator "S" terminal and the battery positive
(For Alternator, Power Steering Pump and Air
terminal or malfunctioning voltmeter.
Conditioning) (Check) P.00-39.)
• Fusible link 9. Check to be sure that all lights and accessories
• Abnormal noise from the alternator while the are off.
engine is running. 10.Start the engine.
ENGINE ELECTRICAL 16-11
CHARGING SYSTEM
11.Increase the engine speed to 2,500 r/min. 14.After the test, lower the engine speed to idle.
12.Read the value displayed on the voltmeter when 15.Turn the ignition switch to the "LOCK" (OFF)
the current output by the alternator becomes 10 A position.
or less. 16.Disconnect the engine tachometer or diagnostic
13.If the voltage reading conforms to the value in the tool .
voltage regulation table, then the voltage regulator 17.Disconnect the negative battery cable.
is operating normally. 18.Disconnect the ammeter and voltmeter.
If the voltage is outside the standard value, there 19.Connect the negative battery cable.
is a malfunction of the voltage regulator or the 20.Run the engine for 10 minutes at an idle.
alternator (Refer to the following table).
VOLTAGE REGULATION TABLE
INSPECTION TERMINAL VOLTAGE REGULATOR STANDARD VALUE (V)
AMBIENT TEMPERATURE [°C
(°F)]
Terminal "S" −20 (−4) 14.2 − 15.4
20 (68) 13.9 − 14.9
60 (140) 13.4 − 14.5
80 (176) 13.1 − 14.2
MEASUREMENT METHOD
OSCILLOSCOPE Connect the oscilloscope special patterns pick-up to the
ALTERNATOR alternator "B" terminal.
PROBE
"B" TERMINAL
06DB029A
STANDARD WAVEFORM
Observation Conditions
FUNCTION SPECIAL PATTERNS
Pattern height Variable
Variable knob Adjust while viewing the wave
pattern
Pattern selector Raster
Engine revolutions Curb idle speed
ENGINE ELECTRICAL 16-12
CHARGING SYSTEM
(V)
0.4
0.2
VOLTAGE AT
GENERATOR 0
"B" TERMINAL
–0.2
–0.4
TIME
AKX00189 AB
AKX00190
ABNORMAL WAVEFORMS EXAMPLES
NOTE: The size of the waveform patterns can differ greatly,
depending on the adjustment of the variable knob on the oscil-
loscope.
NOTE: Identification of abnormal waveforms is easier when
there is a large output current (regulator is not operating).
(Waveforms can be observed when the headlights are illumi-
nated.)
NOTE: Check the conditions of the alternator malfunction light
(illuminated/not illuminated) also, and carry out a total check.
ABNORMAL WAVEFORMS
• Example 1
PROBABLE CAUSE: Open circuit in diode
AKX00191
ENGINE ELECTRICAL 16-13
CHARGING SYSTEM
• Example 2
PROBABLE CAUSE: Short-circuit in diode
AKX00192
• Example 3
PROBABLE CAUSE: Open circuit in stator coil
AKX00193
• Example 4
PROBABLE CAUSE: Short-circuit in stator coil
AKX00194
ENGINE ELECTRICAL 16-14
CHARGING SYSTEM
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION
M1161001400601
2
12 ± 2 N·m
102 ± 22 in-lb
5
49 ± 9 N·m
36 ± 7 ft-lb
3
1
4
06DB030A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. ALTERNATOR DRIVE BELT 3. A/C COMPRESSOR ASSEMBLY
2. ALTERNATOR CONNECTOR CONNECTOR
<<A>> 4. A/C COMPRESSOR ASSEMBLY
<<B>> 5. ALTERNATOR ASSEMBLY
1 4
4.4 ± 1.0 N·m
39 ± 9 in-lb 3
5
7 6
118 ± 19 N·m
87 ± 14 ft-lb
12
10
9
14
8
13
11
AKX00355
AKX00356
WIRE
REAR BRACKET
BRUSH
WIRE
AKX00358 AB
WIRE
AKX00359 AB
INSPECTION
M1161001700099
.
ROTOR CHECK
1. Check the continuity between the slip rings of the field coil. If
the resistance value is not within the standard value, replace
the rotor.
Standard value: approximately 2 − 5 Ω
AKX00360
ENGINE ELECTRICAL 16-18
CHARGING SYSTEM
2. Check the continuity between the slip ring and the core. If
there is continuity, replace the rotor.
AKX00361
STATOR CHECK
1. Check the continuity between the coil lead. If there is no
continuity, replace the stator.
AKX00362
2. Check the continuity between the coil and the core. If there
is continuity, replace the stator.
AKX00363
RECTIFIER CHECK
1. Check the continuity between the positive rectifier and the
stator coil lead connection terminal with a tester. If there is
continuity between the terminals, the diode is shorted, so
replace the rectifier.
AKX00364
ENGINE ELECTRICAL 16-19
CHARGING SYSTEM
AKX00365
AKX00366
BRUSH CHECK
1. Replace the brush if the brush protrusion length shown in
the illustration is below the minimum limit value.
Minimum limit: 2 mm (0.08 inch)
PROTRUSION
LENGTH
AKX00367AB
AKX00368 AB
16-20 ENGINE ELECTRICAL
STARTING SYSTEM
STARTING SYSTEM
GENERAL DESCRIPTION
M1162000100235
If the ignition switch is turned to the "START" posi- When the ignition switch is returned to the "ON" posi-
tion, current flows in the coil provided inside mag- tion after starting the engine, the starter clutch is dis-
netic switch, attracting the plunger. When the plunger engaged from the ring gear.
is attracted, the lever connected to the plunger is An overrunning clutch is provided between the pinion
actuated to engage the starter clutch. and the armature shaft, to prevent damage to the
On the other hand, attracting the plunger will turn on starter.
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
HOLDING
COIL
PLUNGER
PULL-IN COIL
LEVER
OVERRUNNING
B CLUTCH
IGNITION
SWITCH M
PINION GEAR
S
+ ARMATURE
BATTERY
BRUSH
YOKE
AK202970 AC
OPERATION
When the ignition switch is switched to the "ST" posi-
tion while the selector lever is at the "P" or "N" range,
the contact (magnetic switch) of the starter is
switched ON and the starter motor is activated.
ENGINE ELECTRICAL 16-21
STARTING SYSTEM
TROUBLESHOOTING HINTS
The starter motor does not operate at all.
WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
• Check the starter (coil).
• Check for poor contact at the battery terminals and
starter.
• Check the transmission range switch.
The starter motor doesn't stop
• Check the starter (magnetic switch).
TROUBLESHOOTING GUIDE
The starting system troubleshooting guide is shown in the fol-
lowing steps.
WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A,
Chassis Electrical − Battery − On-vehicle Service −
Battery Check P.54A-5.)
YES : Go to Step 2.
NO : Charge or replace the battery.
STEP 2.
• Disconnect the starter motor S (solenoid) terminal connec-
tor.
• Using a jumper wire, apply battery positive voltage to the
starter motor S (solenoid) terminal.
• Check the engine condition.
OK: Turns normally
Q: Dose the starter motor operate normally?
YES : • Check the ignition switch (Refer to GROUP 54A,
Chassis Electrical − Ignition Switch − Ignition
Switch − Inspection P.54A-44.)
• Check the transmission range switch. (Refer to
GROUP 23A, Automatic Transaxle − On-vehicle
Service − Essential Service − Transmission Range
Switch Check P.23A-294.)
• Check the wire between the battery and starter
motor S (solenoid) terminal.
NO : Go to Step 3.
16-22 ENGINE ELECTRICAL
STARTING SYSTEM
STEP 3.
• Check the cable between starter B (battery) terminal and
battery positive terminal for connection and continuity.
Q: Is the starter cable in good condition?
YES : Go to Step 4.
NO : Repair or replace the cable.
STEP 4.
• Check the connection and the continuity of the cable
between the starter motor body and the negative battery
terminal.
Q: Is the ground wire in good condition?
YES : Go to Step 5.
NO : Repair or replace the cable.
STEP 5.
Q: Is the starter motor in good condition? (Refer to Starting
System − Starter Motor Assembly − Inspection P.16-17.)
YES : Excessive rotational resistance of the engine.
NO : Replace the starter motor.
ENGINE ELECTRICAL 16-23
STARTING SYSTEM
3 30 ± 3 N·m
23 ± 2 ft-lb
1
12 ± 2 N·m
102 ± 22 in-lb 2
30 ± 3 N·m
23 ± 2 ft-lb 4.9 ± 1.0 N·m
4.9 ± 1.0 N·m 44 ± 8 in-lb
44 ± 8 in-lb
AC205798AB
INSPECTION
M1162001100197
.
AKX01239 AE
PINION
AKX00199
11
12
14
13
1
19
10
18
17
15 16
20
4
3
5
7
6
9
AK204336AB
OVERRUNNING
CLUTCH
AKX00370 AB
SNAP-RING 2. After removing the snap ring (by using snap-ring pliers),
SNAP RING PLIERS remove the stop ring and the overrunning clutch.
PINION GEAR
OVERRUNNING
CLUTCH
AKX00371AB
STOP
RING
OVERRUNNING
STOP RING CLUTCH
SNAP RING
AKX00372 AB
16-28 ENGINE ELECTRICAL
STARTING SYSTEM
INSPECTION
M1162001300102
.
COMMUTATOR CHECK
1. Place the armature on a pair of V-blocks, and check the
deflection by using a dial gauge.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.004 inch)
AKX00373
AKX00374
AKX00375 AB
BRUSH CHECK
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length. Replace the
brush holder if this measurement exceeds the limit.
Minimum limit:
7.0 mm (0.28 inch)
LIMIT LENGTH
2. If the contacting surface has been corrected or the brush
has been replaced, correct the contacting surface by
winding sandpaper around the commutator.
AK101390 AB
.
ENGINE ELECTRICAL 16-29
STARTING SYSTEM
AKX00378 AB
ARMATURE CHECK
1. Check that the armature coil is not grounded.
GROWLER
2. Place the armature in a growler.
3. Hold a thin steel blade parallel and just above while rotating
the armature slowly in the growler. A shorted armature will
cause a blade to vibrate and be attracted to the core.
Replace the shorted armature.
AKX00379 AB
AKX00380
AKX00381
16-30 ENGINE ELECTRICAL
IGNITION SYSTEM
IGNITION SYSTEM
GENERAL DESCRIPTION
M1163000100528
The ECU determines which ignition coil should be
This system is provided with six ignition coils with controlled by means of the signals from the camshaft
built-in ignition power transistors for each of the cylin- position sensor which is incorporated in the camshaft
ders. and from the crankshaft position sensor which is
Interruption of the primary current flowing in the pri- incorporated in the crankshaft.
mary side of ignition coil generates a high voltage in It also detects the crankshaft position to provide igni-
the secondary side of ignition coil. tion at the most appropriate timing in response to the
The engine control unit (ECU) controls the three engine operation conditions.
ignition power transistors to turn them alternately ON When the engine is cold or operated at high alti-
and OFF. This causes the primary currents in the tudes, the ignition timing is slightly advanced to pro-
ignition coils to be alternately interrupted and allowed vide optimum performance.
to flow to fire the cylinders in the order 1-2-3-4-5-6.
IGNITION
SWITCH BATTERY
06DB024A
SPECIAL TOOLS
M1163000600073
ON-VEHICLE SERVICE
SPARK PLUG
AKX00432 AB
2. Ground the spark plug outer electrode (body), and crank the
DEFECTIVE INSULATION engine.
DEFECTIVE
INSULATION Check that there is an electrical discharge between the
electrodes at this time.
AKX00277 AB
CAUTION
• Do not attempt to adjust the gap of the iridium plug.
• Cleaning of the iridium plug may result in damage to
the iridium tips. Therefore, if carbon deposits must be
removed, use a plug cleaner and complete cleaning
within 20 seconds to protect the electrode. Do not use a
wire brush.
Check the plug gap and replace if the limit is exceeded.
IRIDIUM TIP
Standard value: 0.7 − 0.8 mm (0.028 − 0.031 inch)
Limit: 1.2 mm (0.047 inch)
AKX00383 AK
IGNITION COIL
REMOVAL AND INSTALLATION
M1163004000448
10 ± 2 N·m 5
89 ± 17 in-lb
10 ± 2 N·m
1 89 ± 17 in-lb
6
25 ± 4 N·m 4
18 ± 3 ft-lb
3
25 ± 4 N·m
18 ± 3 ft-lb
AC306928 AB
1 11 ± 1 N·m
98 ± 8 in-lb
3N
06DB032A
KNOCK SENSOR
REMOVAL AND INSTALLATION
M1163002800589
23 ± 2 N·m
17 ± 1 ft-lb
AC307548 AB
REMOVAL
<<A>> >>A<< 1. KNOCK SENSOR
Required Special Tool:
MD998773: Knock Sensor Wrench
MD998773
ACX02082AB
ENGINE ELECTRICAL 16-37
IGNITION SYSTEM
MD998773
ACX02082AB
16-38 ENGINE ELECTRICAL
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1161002100506
ITEM SPECIFICATION
Charging system
Alternator bracket bolt 49 ± 9 N⋅m (36 ± 7 ft-lb)
Alternator bolt 49 ± 9 N⋅m (36 ± 7 ft-lb)
Alternator terminal nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Ignition system
Camshaft position sensor bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Crankshaft position sensor bolt 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Ignition coil bolt 10 ± 2 N⋅m (89 ± 17 in-lb)
Knock sensor 23 ± 2 N⋅m (17 ± 1 ft-lb)
Spark plug 25 ± 4 N⋅m (18 ± 3 ft-lb)
Starting system
Starter bolt 30 ± 3 N⋅m (23 ± 2 ft-lb)
Starter cover bolt 4.9 ± 1.0 N⋅m (44 ± 8 in-lb)
Starter terminal nut 12 ± 2 N⋅m (102 ± 22 in-lb)
GENERAL SPECIFICATIONS
M1161000200411
ITEMS SPECIFICATIONS
Alternator
Type Positive battery positive voltage sensing
Identification number −
Part No. MN180394
Rated output V/A 12/110
Voltage regulator Electronic built-in type
Starter Motor
Type Reduction drive with planetary gear
Identification number M000T31172
Part No. 1810A090
Rated output kW/V 1.2/12
Number of pinion teeth 8
Ignition Coil
Type Molded 6 coil
Spark Plugs
BOSCH FR8DI30
ENGINE ELECTRICAL 16-39
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1161000300322
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL
GENERAL DESCRIPTION
M1171000100437
For the accelerator system, an electronic throttle CONSTRUCTION DIAGRAM
actuator control system is utilised, eliminating the
accelerator cable.
ACCELERATOR PEDAL
ASSEMBLY[BUILT-IN ACCELERATOR
PEDAL POSITION SENSOR (APS)]
STOPPER
16DB405A
SYMPTOM CHART
M1171002200292
SYMPTOM PROCEDURES
COMMENT
The throttle body or accelerator pedal position (APP) LIKELY CAUSES FOR THIS CASE:)
sensor is suspected. • Malfunction of the throttle body.
• Malfunction of the accelerator pedal position
(APP) sensor.
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
COMMENT
The accelerator pedal, its installation condition or the LIKELY CAUSES FOR THIS CASE:)
accelerator pedal position (APP) sensor is sus- • Malfunction of the accelerator pedal.
pected. • Incorrectly installed accelerator pedal.
• Malfunction of the accelerator pedal position
.
(APP) sensor.
Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
SPECIAL TOOL
M1171000600045
MB991825
MB991826
MB991958
ENGINE AND EMISSION CONTROL 17-9
ENGINE CONTROL
ACCELERATOR PEDAL
REMOVAL AND INSTALLATION
M1171003000116
2
1
13 ± 2 N·m
111 ± 22 in-lb
AUTO-CRUISE CONTROL
GENERAL DESCRIPTION
M1172000100281
By using the auto-cruise control system, the driver NOTE: If engine speed reaches and exceeds 6000
can select and maintain a desired cruising speed r/min the Auto Cruise Control System will be can-
[between 40 km/h (25 mph) and 200 km/h (124 celled automatically.
mph)] without depressing the accelerator pedal.
CONSTRUCTION DIAGRAM
"CRUISE" INDICATOR
LIGHT
THROTTLE BODY
STOPLIGHT SWITCH (BUILT-IN THROTTLE
POSITION SENSOR
AND THROTTLE
ACTUATOR CONTROL
MOTOR)
AC20619
ENGINE
ECU
AUTO-CRUISE
CONTROL SWITCH
AC305702
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 AC30570
17DB039A
DIAGNOSTIC FUNCTION
M1172004900171
CAUTION
To prevent damage to Diagnostic Tool MB991958, always
DATA LINK turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR before connecting or disconnecting Diagnostic Tool
MB991958.
1. Ensure that the ignition switch is at the "LOCK" (OFF)
position.
2. Start up the personal computer.
3. Connect special tool MB991827 to special tool MB991824
MB991910 and the personal computer.
4. Connect special tool MB991910 to special tool MB991824.
MB991824 5. Connect special tool MB991910 to the data link connector.
6. Turn the power switch of special tool MB991824 to the "ON"
position.
NOTE: When special tool MB991824 is energized, special
tool MB991824 indicator lamp will be illuminated in green
color.
7. Start the MUT-III system on the personal computer.
MB991827 NOTE: Disconnecting Diagnostic Tool MB991958 is the
00DB076A
reverse of the connecting sequence, making sure that the
ignition switch is at the "LOCK" (OFF) position.
MB991827 00DB076A
CAUTION
To prevent damage to Diagnostic Tool MB991958, always
DATA LINK turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR before connecting or disconnecting Diagnostic Tool
MB991958.
1. Connect Diagnostic Tool MB991958 to the data link
connector.
2. Turn the ignition switch to the "ON" position.
3. Select the "CAN bus diagnosis" from the start-up screen.
4. When the vehicle information is displayed, confirm that it
MB991910 matches the vehicle whose CAN bus lines will be
diagnosed.
MB991824 • If the information is correct, go to step 8.
• If not, go to step 5.
5. Select the "view vehicle information" button.
6. Enter the vehicle information and select the "OK" button.
7. When the vehicle information is displayed, confirm again
that it matches the vehicle which is diagnosed CAN bus line.
• If they match, go to step 8.
• If not, go to step 5.
MB991827 00DB076A 8. Press the "OK" button.
9. When the optional equipment screen is displayed, choose
the one which the vehicle is fitted with, and then select the
"OK" button.
10.Turn the ignition switch to the "LOCK" (OFF) position.
11.Disconnect Diagnostic Tool MB991958.
DIAGNOSTIC TROUBLE CODE CHART
M1172002200295
Check according to the inspection chart that is
appropriate for the diagnostic trouble code.
DTC NO. INSPECTION ITEM REFERENCE PAGE
P0830 Clutch switch system P.17-15
P1564 Auto-cruise control switch system P.17-20
P1575 Cancel latch signal system P.17-34
P1571 Stoplamp switch system P.17-35
P1574 Engine ECU and its related components P.17-50
ENGINE AND EMISSION CONTROL 17-15
AUTO-CRUISE CONTROL
Judgement Criteria
.
TECHNICAL DESCRIPTION
• The ENGINE-ECU uses the clutch switch earth- • Clutch switch failed
ing as a signal that clutch pedal has been • Harness damage in clutch switch circuit, or con-
applied. nector damage.
• Refer to component locations GROUP-70
.
• Refer to configuration diagrams GROUP-80
DTC SET CONDITIONS • Refer to circuit diagrams GROUP-90
Check Conditions
• Vehicle speed is above 50 km/h.
DIAGNOSIS
Required Special Tools:
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: USB Cable
• MB991910: Main Harness A
ENGINE AND EMISSION CONTROL 17-16
AUTO-CRUISE CONTROL
03DB247A
CONNECTOR: C-30
C-07
C-07 HARNESS
CONNECTOR
COMPONENT SIDE
17DB052A
COVER
ENGINE
CONTROL
UNIT
16DB400A
03DB250A
CONNECTOR: C-30
C-07
C-07 HARNESS
CONNECTOR
COMPONENT SIDE
17DB052A
CONNECTOR: C-29
AIR
CLEANER C-29
COVER
ENGINE
CONTROL
UNIT
16DB400A
17DB041A
CLOCK
SPRING
C-302 (Y)
C-303 (GR)
C-306
C-306 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB040A
.
ENGINE AND EMISSION CONTROL 17-21
AUTO-CRUISE CONTROL
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991223: Harness Set
• MB992044: ENGINE-ECU Check Harness
ENGINE AND EMISSION CONTROL 17-22
AUTO-CRUISE CONTROL
C-302 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB042A
C-302 HARNESS (6) Measure the power supply voltage between auto-cruise
CONNECTOR: control switch connector C-302 terminal 2 and ground by
HARNESS SIDE backprobing.
(7) Turn the ignition switch to the "LOCK" (OFF) position.
1 2 3
Q: Is the measured voltage between 4.7 and 5.0 volts?
YES : Go to Step 9.
NO : Go to Step 3.
AC205053 AC
10DB133A
10DB133A
ENGINE AND EMISSION CONTROL 17-25
AUTO-CRUISE CONTROL
17DB041A
CLOCK
SPRING
C-302 (Y)
C-303 (GR)
C-306
C-306 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB040A
ENGINE AND EMISSION CONTROL 17-26
AUTO-CRUISE CONTROL
16DB400A
CONNECTOR: C-302
CLOCK
SPRING
C-302 (Y)
C-302 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB042A
C-302 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB042A
AC209264 AB
10DB133A
ENGINE AND EMISSION CONTROL 17-29
AUTO-CRUISE CONTROL
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-29
C-29
17DB041A
ENGINE AND EMISSION CONTROL 17-30
AUTO-CRUISE CONTROL
C-306 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB040A
10DB133A
CONNECTOR: C-302
CLOCK
SPRING
C-302 (Y)
C-302 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB042A
ENGINE AND EMISSION CONTROL 17-31
AUTO-CRUISE CONTROL
MB991827 00DB076A
ENGINE AND EMISSION CONTROL 17-34
AUTO-CRUISE CONTROL
DIAGNOSIS
Replace the Engine ECU.[Refer to GROUP 13A, Engine ECU
13A-675] . Then check that diagnostic trouble code P1575 is
not set.
ENGINE AND EMISSION CONTROL 17-35
AUTO-CRUISE CONTROL
CONNECTOR: C-30
AIR
CLEANER
COVER
ENGINE
CONTROL C-30
UNIT
C-30 HARNESS
16DB400A
CONNECTOR:
COMPONENT SIDE
17DB043A
• When the brake pedal is depressed, battery posi- TROUBLESHOOTING HINTS (THE MOST
tive voltage is applied to the ENGINE-ECU (B-21) LIKELY CAUSES FOR THIS CASE:)
(terminal 18). • Malfunction of the stoplamp switch.
• Damaged harness or connector.
• Malfunction of the ENGINE-ECU.
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic ToolDiagnostic Tool (MUT-III Sub
Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991223: Harness Set
• MB992044: ENGINE-ECU Check Harness
COVER
ENGINE
CONTROL
UNIT
10DB133A
10DB133A
CONNECTOR: C-30
17DB045A
ENGINE AND EMISSION CONTROL 17-39
AUTO-CRUISE CONTROL
16DB400A
CONNECTOR: C-30
17DB045A
ENGINE AND EMISSION CONTROL 17-40
AUTO-CRUISE CONTROL
17DB045A
C-30 HARNESS
(2) Measure the power supply voltage between stoplamp
CONNECTOR: switch connector C-30 terminal 2 and ground.
COMPONENT SIDE (3) Reconnect stoplamp switch connector C-30.
Q: Is the measured voltage battery positive voltage
(approximately 12 volts)?
YES : Go to Step 10.
NO : Go to Step 7.
AC305712AB
17DB045A
ENGINE AND EMISSION CONTROL 17-41
AUTO-CRUISE CONTROL
17DB045A
BATTERY
FUSE NUMBER 11
(HOUSING COLOR:
BLUE)
RELAY BOX
AC305713AB
RELAY BOX
AC305713AB
ENGINE AND EMISSION CONTROL 17-42
AUTO-CRUISE CONTROL
C-30
C-30 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB043A
ENGINE AND EMISSION CONTROL 17-43
AUTO-CRUISE CONTROL
17DB045A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
10DB133A
ENGINE AND EMISSION CONTROL 17-44
AUTO-CRUISE CONTROL
16DB400A
CONNECTOR: C-30
17DB045A
ENGINE AND EMISSION CONTROL 17-47
AUTO-CRUISE CONTROL
16DB400A
CONNECTOR: C-30
17DB045A
RELAY BOX
16DB401A
ENGINE AND EMISSION CONTROL 17-48
AUTO-CRUISE CONTROL
MB991827 00DB076A
ENGINE AND EMISSION CONTROL 17-50
AUTO-CRUISE CONTROL
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
ENGINE AND EMISSION CONTROL 17-51
AUTO-CRUISE CONTROL
MB991827 00DB076A
MB991827 00DB076A
ENGINE AND EMISSION CONTROL 17-53
AUTO-CRUISE CONTROL
SYMPTOM CHART
M1172002300366
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: When the Brake Pedal is Depressed, Auto-cruise Control System is not
Cancelled.
COMMENT
The stoplamp switch circuit is suspected. LIKELY CAUSES FOR THIS CASE:)
• Malfunction of the stoplamp switch.
• Damaged harness or connector.
.
DIAGNOSIS
Refer to P.17-35, Diagnostic Trouble Code Procedures − DTC
22: Stoplamp Switch System.
INSPECTION PROCEDURE 2: When the Selector Lever is Moved to "N" Range, Auto-cruise Control
System is not Cancelled.
COMMENT
The transmission inhibitor switch circuit is suspected. LIKELY CAUSES FOR THIS CASE:)
• Malfunction of the transmission inhibitor switch.
•
.
DIAGNOSIS
Refer to GROUP 23A, A/T Diagnosis − Diagnostic Trouble
Code Procedures − DTC 0705: Transmission Inhibitor Switch
System (Open/short Circuit) P.23A-97.
ENGINE AND EMISSION CONTROL 17-55
AUTO-CRUISE CONTROL
INSPECTION PROCEDURE 3: When the Auto-cruise Control "CANCEL" Switch is Set to ON,
Auto-cruise Control System is not Cancelled.
COMMENT
The cause is probably an open-circuit in the output in LIKELY CAUSES FOR THIS CASE:)
the circuit inside the "CANCEL" switch. • Malfunction of the auto-cruise control switch.
. Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
Replace the auto-cruise control switch. (Refer to P.17-75,
Auto-cruise Control).
INSPECTION PROCEDURE 4: When the Clutch Pedal is Depressed, Auto-cruise Control System is not
Cancelled.
COMMENT
The clutch switch circuit is suspected. LIKELY CAUSES FOR THIS CASE:)
• Malfunction of the clutch switch.
• Damaged harness or connector.
.
DIAGNOSIS
Refer to P.17-15, Diagnostic Trouble Code Procedures − DTC
0830: Clutch Switch System.
ENGINE AND EMISSION CONTROL 17-56
AUTO-CRUISE CONTROL
COMMENT
The fail-safe function is probably canceling LIKELY CAUSES FOR THIS CASE:)
auto-cruise control system. In this case, Diagnostic • Malfunction of the auto-cruise control switch.
Tool MB991958 can be used to retest each system • Malfunction of the stoplamp switch.
by checking the diagnostic trouble codes. The • Malfunction of the transmission inhibitor switch.
Diagnostic Tool can also be used to check if the cir- • Malfunction of the Engine ECU.
cuits of each input switch are normal or not by check- Circuit drawings
ing the input switch codes. • Refer to circuit diagrams GROUP-90
. • Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
ENGINE AND EMISSION CONTROL 17-57
AUTO-CRUISE CONTROL
INSPECTION PROCEDURE 6: Hunting (Repeated Acceleration and Deceleration) Occurs at the Set
Vehicle Speed.
COMMENT
The output shaft speed sensor signal or the throttle LIKELY CAUSES FOR THIS CASE:)
body is suspected. • Malfunction of the output shaft speed sensor.
• Malfunction of the throttle body.
•
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
ENGINE AND EMISSION CONTROL 17-61
AUTO-CRUISE CONTROL
MB991827 00DB076A
INSPECTION PROCEDURE 7: When "CRUISE" (MAIN) Switch is Turned "ON", "CRUISE" Indicator
Light Inside Combination Meter does not Illuminate. (However, Auto-cruise Control System is
Normal).
CONNECTOR: A-02
A-02 (GR)
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
16DB402A
C-101
C-29
C-02
C-02 HARNESS
CONNECTOR: C-211 HARNESS CONNECTOR:
COMPONENT SIDE COMPONENT SIDE
C-101 HARNESS
C-29 MALE SIDE CONNECTOR:
CONNECTOR COMPONENT SIDE C-215 HARNESS CONNECTOR:
COMPONENT SIDE
17DB046A 17DB047A
.
ENGINE AND EMISSION CONTROL 17-63
AUTO-CRUISE CONTROL
CIRCUIT OPERATION
.
TROUBLESHOOTING HINTS
The Engine ECU detects "CRUISE" (MAIN) switch • Malfunction of the combination meter.
"ON" signal to illuminate the "CRUISE" indicator • Damaged harness or connector.
lamp on the combination meter. • Malfunction of the Engine ECU.
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
ENGINE AND EMISSION CONTROL 17-64
AUTO-CRUISE CONTROL
MB991827 00DB076A
CAUTION
• When shifting the selector lever to "D" range, apply the brakes so that the vehicle does not move
forward.
• Driving tests always need two persons: one driver and one observer.
NOTE: *:After the inspection is completed, disconnect the throttle position sensor connector, and then delete
the diagnostic trouble code using use of Diagnostic Tool MB991958. (Refer to P.17-11).
94-PIN 60-PIN
CONNECTOR CONNECTOR
(ENGINE ECU CONNECTOR (ENGINE ECU CONNECTOR
B-21) B-20)
16DB403A
SPECIAL TOOLS
M1172000600509
MB991825
MB991826
MB991958
ENGINE AND EMISSION CONTROL 17-70
AUTO-CRUISE CONTROL
D
MB991223 AD
ON-VEHICLE SERVICE
AUTO-CRUISE
CONTROL SWITCH
AC305702
"CRUISE" INDICATOR
LIGHT
AC206195
16DB404A
SPEED-INCREASE SETTING
1. Set to the desired speed.
2. Push the auto-cruise control switch in the direction of the
arrow.
3. Check to be sure that acceleration continues while the
switch is held, and that after it is released the constant
speed at the time when it was released becomes the driving
speed.
NOTE: Acceleration can be continued even if the vehicle
speed has passed the high-speed limit [approximately 170
km/h ]. But the speed when the auto-cruise control switch is
ACX01172 AE
released will be recorded as the high-speed limit.
SPEED-REDUCTION SETTING
1. Set to the desired speed.
2. Push the auto-cruise control switch in the direction of the
arrow.
3. Check to be sure that deceleration continues while the
switch is pressed, and that after it is released the constant
speed at the time when it was released becomes the driving
speed.
NOTE: When the vehicle speed reaches the low limit
[approximately 40 km/h ] during deceleration, the
auto-cruise control will be cancelled.
ACX01172 AD
AC203822AB
STOPLIGHT SWITCH
1. Disconnect the connector.
2. Check for continuity between the terminals of the switch.
MEASUREMENT TERMINAL SPECIFIED
CONDITION CONNECTOR CONDITION
OF TESTER
When brake pedal 1 − 2 (for Less than 2 ohms
is depressed. stoplamp circuit)
3 − 4 (for Open circuit
auto-cruise
ACX01180 AB control circuit)
When brake pedal 1 − 2 (for Open circuit
is not depressed. stoplamp circuit)
3 − 4 (for Less than 2 ohms
auto-cruise
control circuit)
ENGINE AND EMISSION CONTROL 17-74
AUTO-CRUISE CONTROL
AUTO-CRUISE CONTROL
REMOVAL AND INSTALLATION
M1172001400467
WARNING
Before removal of the air bag module, refer to GROUP 52B, SRS Service Precautions
P.52B-16 and GROUP 52B, Air Bag Module and Clock Spring P.52B-237.
41 ± 8 N·m
1 30 ± 6 ft-lb
9
2
AC209672
7 4
8
AC305701
17DB048A
CONTROL SWITCH REMOVAL SENSOR REMOVAL STEPS
STEPS 6. TRANSMISSION INHIBITOR
1. AIR BAG MODULE <DRIVER’S SWITCH (REFER TO GROUP 23B,
SIDE> (REFER TO GROUP 52B, AIR AUTOMATIC TRANSMISSION)
BAG MODULES AND CLOCK 7. THROTTLE BODY (BUILT-IN
SPRING P.52B-237) THROTTLE POSITION SENSOR
2. STEERING WHEEL ASSEMBLY AND THROTTLE ACTUATOR
(REFER TO GROUP 37, STEERING CONTROL MOTOR) (REFER TO
WHEEL P.37-23) GROUP 13A, THROTTLE BODY
3. LOWER COVER CAP 13A-660)
4. AUTO-CRUISE CONTROL SWITCH 8. ACCELERATOR PEDAL (BUILT-IN
CONTROL UNIT REMOVAL ACCELERATOR PEDAL POSITION
5. Engine ECU [REFER TO GROUP SENSOR) (REFER TO GROUP 17,
13A, Engine ECU 13A-675] ACCELERATOR PEDAL P.17-9)
9. STOPLIGHT SWITCH (REFER TO
GROUP 35A, BRAKE PEDAL
P.35A-24)
ENGINE AND EMISSION CONTROL 17-76
EMISSION CONTROL
EMISSION CONTROL
GENERAL DESCRIPTION
M1173000100314
The emission control system consists of the fol- • Evaporative emission system
lowing subsystems: • Exhaust emission control system
• Positive crankcase ventilation system
DIAGNOSIS
M1173000700112
VACUUM HOSES
VACUUM HOSE ROUTING
M1173000900398
EVAPORATIVE EMISSION
VENTILATION SOLENOID
CHAMBER
INTAKE MANIFOLD
PLENUM
TO EVAPORATIVE EMISSION
CANISTER
THROTTLE
BODY
FRONT
AK301810
ENGINE AND EMISSION CONTROL 17-78
EMISSION CONTROL
TO
COMBUSTION FROM
CHAMBER AIRCLEANER
EVAPORATIVE EMISSION
PURGESOLENOID
(ON: OPEN)
CHAMBER
B
FUEL
TANK
EVAPORATIVE EMISSION
CANISTER
B: BLACK
07DB110A
SYSTEM DIAGRAM
VENTILATION HOSE
BREATHER HOSE
POSITIVE CRANKCASE
VENTILATION VALVE
07DB111A
ENGINE AND EMISSION CONTROL 17-80
EMISSION CONTROL
COMPONENT LOCATION
M1173007400189
07TE008A
POSITIVE CRANKCASE
VENTILATION VALVE
6EM0400
ENGINE AND EMISSION CONTROL 17-81
EMISSION CONTROL
SYSTEM DIAGRAM
EVAPORATIVE
EMISSION
PURGE
SOLENOID FUEL
ON: OPEN TANK
ENGINE
ECU
07DB112A
ENGINE AND EMISSION CONTROL 17-82
EMISSION CONTROL
COMPONENT LOCATION
M1173007500205
WHITE MARK
CHAMBER
SOLENOID VALVE
01DB051A
TO
COMBUSTION FROM
CHAMBER AIRCLEANER
OFF
EVAPORATIVE EMISSION
PURGESOLENOID
(ON: OPENED)
ON
CHAMBER
PURGE
PURGE HOSE FLOW
INDICATOR
(MB995061)
EVAPORATIVE EMISSION
CANISTER
07DB115A
ENGINE AND EMISSION CONTROL 17-83
EMISSION CONTROL
07DB114A
CATALYTIC CONVERTER
GENERAL DESCRIPTION (CATALYTIC CONVERTER)
M1173005300131
The three way catalytic converter, together with the When the mixture is controlled at stoichiometric
closed loop air-fuel ratio control based on the oxygen air-fuel ratio, the three way catalytic converter pro-
sensor signal, oxidizes carbon monoxides (CO) and vides the highest purification against the three con-
hydrocarbons (HC), also reduces nitrogen oxides stituents, namely, CO, HC and NOx.
(NOx).
ENGINE AND EMISSION CONTROL 17-85
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1173006400324
ITEM SPECIFICATION
Auto-cruise control system
Lower cover cap bolt 9.0 ± 2.0 N⋅m (80 ± 17 in-lb)
Steering wheel assembly nut 41 ± 8 N⋅m (30 ± 6 ft-lb)
Engine control system
Accelerator pedal assembly nut 13 ± 2 N⋅m (111 ± 22 in-lb)
SERVICE SPECIFICATIONS
M1173000300545
GROUP 21
CLUTCH
CONTENTS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A
GROUP 21A
CLUTCH
CONTENTS
GENERAL INFORMATION
M1211000100234
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.
SERVICE SPECIFICATIONS
M1211000300227
LUBRICANTS
M1211000400183
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND 2. Measure the clutch pedal height.
ADJUSTMENT Standard value (A): 183 − 186 mm
M1211000900285
1. Turn up the carpet, etc. under the clutch pedal. Clutch pedal clevis pin play
B
A
AC100355 AB
Locking nut
12 ± 2 N·m
Clearance
Clutch pedal 0.5 - 1.5 mm
08DB001A
08DB012A
1. Connect a hose with a bottle to the bleeder screw.
2. Open the bleed nipple.
3. Depress the clutch pedal slowly. Open the bleeder
screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
D
4. Check that the brake fluid reservoir level stays
between "MAX" and "MIN" marks throughout the
clutch bleeding process.
AC312891AB
CLUTCH 21A-4
CLUTCH PEDAL
CLUTCH PEDAL
REMOVAL AND INSTALLATION
M1211001600232
Post-installation Operation
Clutch Pedal Adjustment (Refer to P.21A-2).
12 ± 2 N·m
5
3
9
12 ± 2 N·m 1
4 2
8
08DB002A
CLUTCH CONTROL
REMOVAL AND INSTALLATION
M1211001900255
11, 15, 17
Release cylinder
13 push rod 4
Specified grease: 5 6
MITSUBISHI genuine grease
PART No. 0101011
1 7
2
12 ± 2 N·m
3
18 ± 3 N·m
11
9
12 ± 2 N·m
10
08DB003A
Clutch master cylinder removal Clutch master cylinder removal
steps steps (Continued)
1. Reservoir hose and brake fluid 5. Clutch master cylinder
reservoir connection 6. Sealer
2. Clutch damper 7. Reservoir hose
<<A>> >>A<< 3. Clutch pipe assembly Clutch release cylinder removal
• Brake master cylinder assembly steps
and brake booster (Refer to <<A>> >>A<< 8. Clutch tube assembly
GROUP 35A, Master cylinder 9. Clutch release cylinder
assembly and brake booster Clutch line removal steps
35A-26.) <<A>> >>A<< 10. Clutch hose bracket
4. Clevis pin <<A>> >>A<< 11. Clutch hose
CLUTCH 21A-6
CLUTCH CONTROL
Securing side
08DB008A
08DB009A
Holding the nut at the clutch hose side, loosen the
flare nut of the clutch pipe. 1. Temporarily tighten the clutch pipe flare nut by
hand, and then tighten it to the specified torque,
being careful that the clutch hose does not become
twisted.
2. After tightening the clutch pipe flare nut and eye
bolt, check to be sure there is no clutch fluid leak
INSPECTION
M1211002000158
• Check the master cylinder or clutch hose for fluid
leakage.
• Check the clutch hose or tube for cracks or
clogging.
• Check the pedal shaft bushing for wear.
• Check the pedal arm for bend or torsion.
CLUTCH 21A-7
CLUTCH CONTROL
12 ± 2 N·m
6
7 3
4 N
1N
2N
5
4 2
1
2
3
4
Clutch fluid:
Piston repair kit Brake fluid DOT3 OR DOT4 Grease: Rubber grease
08DB011A
Disassembly steps Disassembly steps (Continued)
1. Piston stopper ring 5. Spring pin
2. Piston assembly 6. Nipple
>>A<< 3. Pushrod assembly 7. Seal
4. Boot 8. Master cylinder body
CLUTCH 21A-8
CLUTCH CONTROL
REASSEMBLY SERVICE POINT Set the length of the pushrod assembly to the
dimension shown to make the adjustment of the
>>A<< PUSHROD ASSEMBLY
clutch pedal easier.
INSTALLATION
INSPECTION
M1211002200152
• Check inside the cylinder body for rust and scars.
• Check the piston for rust and scars.
• Check the pipe connection for clogging.
130.3 ± 0.5 mm
08DB010A
HOME
21B-1
GROUP 21B
CLUTCH
OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS
M1212000200461
Item Specification
Combined engine 6G75-S4-MPI
Clutch operating method Hydraulic type
Clutch disc type Single dry disc type
Clutch disc size O.D. x I.D. mm 240 x 160
Clutch cover type Diaphragm spring type
Clutch cover setting load N 6,800
Clutch release cylinder I.D. mm 20.64
SERVICE SPECIFICATIONS
M1212000300208
Item Limit
Diaphragm spring end height difference mm 0.5
Clutch disc facing rivet sink mm Minimum 0.3
Release cylinder I.D. to piston O.D. mm 0.15
TORQUE SPECIFICATIONS
M1212001800411
Item Specification
Clutch fluid line bracket bolt 18 ± 3 N⋅m
Clutch tube flare nut 15 ± 2 N⋅m
Clutch release cylinder union bolt 22 ± 2 N⋅m
Clutch release cylinder mounting bolt 18 ± 3 N⋅m
Clutch cover mounting bolt 18 ± 3 N⋅m
Release fork shaft locking bolt 9.8 ± 2.0 N⋅m
Clutch release cylinder air bleeder 11 ± 1 N⋅m
LUBRICANTS
M1212000400346
CLUTCH
REMOVAL AND INSTALLATION
M1212001000448
18 ± 3 N·m
9.8 ± 2.0 N·m
1 4
13
2
18 ± 3 N·m
3 14
10 15 ± 2 N·m
9
8
18 ± 3 N·m 6 7
22 ± 2 N·m
11 21 5
20
12 18
22
18
16
15
19
17
AK502050AB
Bushing AKX00755AD
Apply
grease
Apply
grease
AKX00757 AF
AKX00756AD
.
CLUTCH OVERHAUL 21B-5
CLUTCH
Clutch disc
guide
Clutch cover
AK204214 AB
Valve plate
AK201696AF
AK201696
INSPECTION
M1212001100315
.
CLUTCH COVER
1. Check the diaphragm spring end for wear and uneven
Diaphragm spring 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.
AK403603AB
.
CLUTCH OVERHAUL 21B-6
CLUTCH
CLUTCH DISC
CAUTION
Don't clean the clutch disc in a cleaning solvent.
1. Check the facing for loose rivets, uneven contact, evidence
of seizure, or deposited oils and greases. If defective,
replace the clutch disc.
2. Measure the rivet sink and replace the clutch disc if it is
below the limit.
Rivet sink Minimum limit: 0.3 mm
3. Check the torsion spring for play and damage. If defective,
replace the clutch disc.
Torsion spring
4. Combine the clutch disc with the input shaft and check for
sliding condition and play in the rotating direction. If poor
sliding condition is evident, clean, reassemble, and recheck.
AK300248AB
If excessive play is evident, replace the clutch disc and/or
input shaft.
.
RELEASE FORK
If the surface which contacts the bearing is abnormally worn,
replace.
.
8
11 ± 1 N·m
9
1
6
5 4
AK502008AB
AK305228AB
CLUTCH OVERHAUL 21B-8
CLUTCH RELEASE CYLINDER
AK201614
INSPECTION
M1212001600161
.
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 three 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.
Limit: 0.15 mm
HOME
22-1
GROUP 22
MANUAL
TRANSMISSION
CONTENTS
GROUP 22A
MANUAL
TRANSMISSION
CONTENTS
GENERAL INFORMATION
M1222000100379
LUBRICANTS
M1222000400358
SPECIAL TOOLS
M1222000600396
AC106827
09DB017
MANUAL TRANSMISSION 22A-3
SPECIAL TOOLS
ON-VEHICLE SERVICE
.
09DB018A
Drain plug
4. Remove filler plug and fill with specified oil until the oil level
reaches the lower portion of the filler plug hole.
Transmission oil:
09DB019A Genuine Mitsubishi MTF
Quantity:
2.8 (litres)
5. Replace and tighten the filler plug to specified torque.
Specified torque:
32 Nm
MANUAL TRANSMISSION 22A-4
TRANSMISSION CONTROL
TRANSMISSION CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation
CAUTION
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
15-4).
SRS
• Battery and Battery Tray Removal Be careful not to subject the SRS-ECU to any shocks
during removal and installation of the transmission
control cable and shift lever assembly.
6
12 ± 2 N·m
1
7
2
3 4
8
10
09DB020A
09DB021A
Neutral position
09DB022A
09DB034A
4. Install the shift and select cable ends onto tranmission side
SELECT CABLE lever pins, fit washers and snap pins.
5. Move the shift lever to all positions and check that the
operation is smooth.
SHIFT CABLE
09DB033A
.
MANUAL TRANSMISSION 22A-6
TRANSMISSION CONTROL
09DB031A
.
Mark on pin
SELECT CABLE
09DB032A
MANUAL TRANSMISSION 22A-7
TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
• Transmission Oil Draining (Refer to On-Vehicle Service) • Battery and Battery Tray Installation
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
15-4). 15-4).
• Battery and Battery Tray Removal • Under Cover Installation
• Under Cover Removal • Supplying Transmission Oil (Refer to On-Vehicle Service)
• Shift Lever Operation Check
• Speedometer Operation Check
1
30 ± 3 N·m
22 ± 2 ft-lb
6
2 5
3
22
83 ± 12 N·m* 30 ± 3 N·m
43 ± 5 ft-lb* 23 ± 2 ft-lb
83 ± 12 N·m* 21
61 ± 9 ft-lb*
30 ± 3 N·m
22 ± 2 ft-lb
21
8
7
8
09DB023A
48 ± 6 N·m*
65 ± 6 N·m 13 N 36 ± 4 ft-lb*
48 ± 4 ft-lb 20
11 10
11 ± 0.5 N·m
93 ± 4 in-lb
7N
19
13 N 15
29 ± 4 N·m
8 9 21 ± 3 ft-lb
226 ± 29 N·m
167 ± 21 ft-lb
12 21 18
69 ± 10 N·m*
18 N 51 ± 7 ft-lb*
90 ± 10 N·m
14 67 ± 7 ft-lb
58 ± 7 N·m*
43 ± 5 ft-lb* 17
16
83 ± 12 N·m
61 ± 9 ft-lb
83 ± 12 N·m
61 ± 9 ft-lb
09DB024A
09DB030A
09DB025A
09DB026A
DIAPHRAGM SPRING
Place
screwdriver
here
RELEASE
BEARING
RING
09DB027A
.
22A-10 MANUAL TRANSMISSION
TRANSMISSION ASSEMBLY
MOUNT
09DB035A
MB991527
MB991454
AC306198 AB
NUT MB991897
BOLT
BALL JOINT AC208247AC
PTJ ASSEMBLY
09DB028A
09DB029A
22A-12 MANUAL TRANSMISSION
TRANSMISSION ASSEMBLY
HOME
22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION
M1222000100379
SECTIONAL VIEW
AK502566
MANUAL TRANSMISSION OVERHAUL 22B-3
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
M1222000200495
SERVICE SPECIFICATIONS
M1222000300362
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING END PLAY)
Thickness mm Identification colour Thickness mm Identification colour
1.43 Green (2) 1.59 Yellow (2)
1.51 White (2)
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY)
Thickness mm Identification colour Thickness mm Identification colour
1.44 None 1.58 Brown
1.51 Blue
THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY)
Thickness mm Identification symbol Thickness mm Identification symbol
3.82 0 3.98 6
3.86 2 4.02 7
3.90 3 4.06 8
3.94 5 4.10 9
SPACER (FOR ADJUSTMENT OF OUTPUT SHAFT PRELOAD)
Thickness mm Identification symbol Thickness mm Identification symbol
0.86 86 1.19 L
0.89 89 1.22 G
0.92 92 1.25 M
0.95 95 1.28 N
0.98 98 1.31 E
1.01 01 1.34 O
1.04 04 1.37 P
1.07 07 1.40 None
1.10 J 1.43 Q
1.13 D 1.46 R
1.16 K
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY)
Thickness mm Identification colour Thickness mm Identification colour
1.36 Yellow 1.55 White
1.40 Green 1.58 Brown
1.44 None 1.63 Orange
1.48 Black 1.68 Blue
1.51 Blue
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY)
Thickness mm Identification colour Thickness mm Identification colour
2.81 None 2.97 Green
2.85 Blue 3.01 Black
2.89 Brown 3.05 White
2.93 Yellow 3.09 Orange
MANUAL TRANSMISSION OVERHAUL 22B-5
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
M1222012100387
Item Specifications
Roll stopper bracket mounting bolt 70 ± 10 N⋅m
Shift cable bracket mounting bolt 18 ± 3 N⋅m
Select lever mounting bolt 18 ± 3 N⋅m
Vehicle speed sensor mounting bolt 3.9 ± 1.0 N⋅m
Back-up lamp switch 32 ± 2 N⋅m
Poppet spring 32 ± 2 N⋅m
Interlock plate bolt 30 ± 3 N⋅m
Control housing mounting bolt 18 ± 3 N⋅m
Under cover mounting bolt 6.9 ± 0.9 N⋅m
Reverse idler gear shaft mounting bolt 48 ± 6 N⋅m
Clutch housing-transmission case mounting bolt 44 ± 5 N⋅m
Select lever mounting nut 11 ± 1 N⋅m
Stopper bracket mounting bolt 21.7 ± 0.3 N⋅m
Clutch release bearing retainer mounting bolt 9.8 ± 2.0 N⋅m
Differential drive gear mounting bolt 133 ± 4 N⋅m
MANUAL TRANSMISSION OVERHAUL 22B-6
SEALANTS
SEALANTS
M1222000500366
LUBRICANTS
M1222000400358
SPECIAL TOOLS
M1222000600396
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222001600355
12
14
Apply gear oil
to all moving 13
parts before 15
installation. 16
17
18 9
10
11
2
20
4
21
6
22 7
8 1
18 3
19 5
AKX00877AC
AK201631AD
AK201632
AK201633AE
AK201634AD
.
22B-12 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT
AK201635AD
AK204243 AC
AK201636 AD
Snap ring
AK201637AD
.
MANUAL TRANSMISSION OVERHAUL 22B-13
INPUT SHAFT
Synchronizer spring
AK201638AD
Synchronizer
spring
AKX00951AE
MD998825
AK201639 AD
.
22B-14 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT
Installation
direction
(3rd speed side)
AK400081AC
Teeth with
2. Install the synchronizer sleeve so that the areas with teeth
raised tips that have raised tips (three areas total) are aligned with the
areas on the synchronizer hub that have deep grooves
between the teeth (three areas total).
Deep grooves
between the teeth AKX00928AD
AK201640 AD
AK201641 AD
.
MANUAL TRANSMISSION OVERHAUL 22B-15
INPUT SHAFT
Thrust
plate AK201642AD
MD998825
AK201643 AD
AK201644 AD
AK201645AD
22B-16 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT
INSPECTION
M1222001700095
.
INPUT SHAFT
1. Check the outside diameter of the needle bearing mounting
portion for damage, abnormal wear and seizure.
2. Check the splines for damage and wear.
3. Check that the helical gear teeth surfaces are not damaged
or worn.
AK204201AB
SYNCHRONIZER RING
1. Check the clutch gear teeth for damage and broken.
2. Check internal surface for damage, wear and broken
threads.
AK204298AB
AK204307 AB
.
MANUAL TRANSMISSION OVERHAUL 22B-17
INPUT SHAFT
Hub
AK204217 AB
SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or broken.
.
SPEED GEARS
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.
3. Check that the gear inside diameter and front and rear
surfaces are not damaged and worn.
AK204299AB
22B-18 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222002200220
34 1
37
15 2
38 14
17 4
16
18 6 5
7
19
9 8
36 10
11
12
13
15
AK203133AD
AK201646 AD
AK201647 AD
AK201648 AD
.
22B-20 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
AK201649 AD
AK201650 AD
AK201651AD
AK201652 AD
MANUAL TRANSMISSION OVERHAUL 22B-21
OUTPUT SHAFT
AK204243 AC
AK201653 AD
AK201654 AD
Synchronizer spring
AK201638AD
.
22B-22 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
Installation
direction
Groove
AK302754AB
Installation
direction
AK302755AB
Teeth with
2. Install the synchronizer sleeve so that the areas with teeth
raised tips that have raised tips (three areas total) are aligned with the
areas on the synchronizer hub that have deep grooves
between the teeth (three areas total).
Deep grooves
between the teeth AKX00928AD
2. Using special tools, press install the 2nd speed sleeve onto
MD998812 the output shaft.
• Installer cap (MD998812)
MD998814 • Installer-200 (MD998814)
2nd speed • Installer adapter (MD998824)
gear sleeve
• Camshaft oil seal installer (MD998364)
MD998824
MD998364
AK201656 AD
AK201657 AD
AK201658AD
2. Using special tools, press install the 4th speed gear onto the
MD998812 output shaft.
MD998813 • Installer cap (MD998812)
4th speed
gear MD998821 • Installer-100 (MD998813)
• Installer adapter (MD998821)
• Camshaft oil seal installer (MD998364)
MD998364
AK201659 AD
MD998364
AK201660 AD
Installation
direction
Groove
AK302758AB
MANUAL TRANSMISSION OVERHAUL 22B-25
OUTPUT SHAFT
AK201661 AD
Installation
direction
(5th speed side)
AK400081AB
Teeth with
2. Install the synchronizer sleeve so that the areas with teeth
raised tips that have raised tips (three areas total) are aligned with the
areas on the synchronizer hub that have deep grooves
between the teeth (three areas total).
Deep grooves
between the teeth AKX00928AD
AK201662AD
.
22B-26 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
MD998364
AK201663 AD
AKX00934 AD
INSPECTION
M1222002300227
.
OUTPUT SHAFT
1. Check the splines for damage and wear.
2. Check that the helical gear teeth surfaces are not damaged
or worn.
AK204310AB
AK204298AB
AK204307 AB
AK204309AB
2. Install the outer ring, inner ring and cone, force them toward
Gear
the gear, and check clearance "A." If "A" is less than the
A limit, replace them as a set.
Minimum limit: 0.5 mm
Outer ring
Cone
Inner ring
AK204259 AB
.
22B-28 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
AK502785AB
2. Install the outer ring, inner ring and cone, force them toward
Gear A the gear, and check clearance "A." If "A" is less than the
limit, replace them as a set.
Outer ring
Minimum limit: 0.5 mm
Cone
Inner ring
AK203130AD
Hub
AK201697AD
SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or broken.
AKX00943
.
MANUAL TRANSMISSION OVERHAUL 22B-29
REVERSE IDLER GEAR
SPEED GEARS
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.
3. Check that the gear inside diameter and front and rear
surfaces are not damaged or worn.
AK204299AB
1
5
4
3
AK305225 AB
AK204397AB
SELECT LEVER
DISASSEMBLY AND REASSEMBLY
M1222012800193
7
1
8
2 11 ± 1 N·m
9 3
10
AK502136AB
Dust cover
AK204311 AB
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
M1222013100302
9 6
7 3
12
11 5
13
4
8
14
10
2
1
Lock pin
Control fing
AK204273 AB
0 – 0.5 mm
AK204176AC
AK204303AB
.
22B-34 MANUAL TRANSMISSION OVERHAUL
CONTROL HOUSING
AK204274AB
Emboss
mark
AK204220 AB
Slit
Spring pin
AK204177AB
AK204273 AC
MANUAL TRANSMISSION OVERHAUL 22B-35
CLUTCH HOUSING
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
M1222003700369
5*
Outer race
AK201665AD
AK201666 AD
AK201667 AD
Air vent
Seam of
bushing
AK201668 AD
MANUAL TRANSMISSION OVERHAUL 22B-37
CLUTCH HOUSING
1 mm
AK204291 AC
AK201669 AD
AK201670AD
AK204284AC
22B-38 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION CASE
2. Using special tools, press fit the oil seal into the clutch
housing.
MB990928 MB990938 • Handle (MB990938)
• Installer adapter (MB990928)
AK201671 AD
TRANSMISSION CASE
DISASSEMBLY AND REASSEMBLY
M1222013400303
2*
5*
4
6
3 AK203131AD
AK201672AD
3 mm
AK204304 AC
AK500016 AB
AK204287 AB
.
22B-40 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION CASE
1.5 mm
AK204286 AD
AK201673 AD
MANUAL TRANSMISSION OVERHAUL 22B-41
DIFFERENTIAL
DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
M1222002500254
6 8
5
4
8 133 ± 4 N·m
7 1
3
5
9
2
AK502153AB
AK305171AB
AK305230
AK305231
AK305229
.
MANUAL TRANSMISSION OVERHAUL 22B-43
DIFFERENTIAL
AK204290 AB
AK305199AB
AK500017AB
7 4
9 2
AK103662AC
22B-44 MANUAL TRANSMISSION OVERHAUL
DIFFERENTIAL
HOME
23-1
GROUP 23
AUTOMATIC
TRANSAXLE
CONTENTS
GROUP 23A
AUTOMATIC
TRANSMISSION
CONTENTS
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
passenger (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 (*).
AUTOMATIC TRANSMISSION 23A-2
SPECIAL TOOLS. . . . . . . . . . . . . . . . 23A-286 SELECTOR LEVER OPERATION
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-299
ON-VEHICLE SERVICE. . . . . . . . . . . 23A-289 TRANSMISSION CONTROL CABLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 23A-299
A/T CONTROL COMPONENT LAYOUT . . 23A-289
ESSENTIAL SERVICE . . . . . . . . . . . . . . . . 23A-291
TRANSMISSION CONTROL*. . . . . . . 23A-300
TRANSMISSION FLUID CHECK . . . . . . . . 23A-291
REMOVAL AND INSTALLATION . . . . . . . . 23A-300
TRANSMISSION FLUID CHANGE . . . . . . . 23A-292
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23A-301
OIL COOLER FLOW CHECK . . . . . . . . . . . 23A-294
DISASSEMBLY AND ASSEMBLY . . . . . . . 23A-302
TRANSMISSION RANGE SWITCH
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-294 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23A-303
TRANSMISSION RANGE SWITCH AND
CONTROL CABLE ADJUSTMENT. . . . . . . 23A-294 TRANSMISSION ASSEMBLY . . . . . . 23A-304
AUTOMATIC TRANSMISSION CONTROL REMOVAL AND INSTALLATION . . . . . . . . 23A-304
COMPONENT CHECK . . . . . . . . . . . . . . . . 23A-295
CRANKSHAFT POSITION SENSOR TRANSMISSION FLUID COOLER,
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-295 HOSE AND PIPE . . . . . . . . . . . . . . . . 23A-312
TRANSMISSION FLUID TEMPERATURE REMOVAL AND INSTALLATION . . . . . . . . 23A-312
SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 23A-296
TRANSMISSION RANGE SWITCH
SPECIFICATIONS . . . . . . . . . . . . . . . 23A-313
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-296
FASTENER TIGHTENING
STOPLIGHT SWITCH CHECK . . . . . . . . . . 23A-296
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 23A-313
A/T CONTROL RELAY CHECK . . . . . . . . . 23A-296
SERVICE SPECIFICATIONS . . . . . . . . . . . 23A-313
SOLENOID VALVE CHECK . . . . . . . . . . . . 23A-298
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 23A-314
AUTOMATIC TRANSMISSION 23A-3
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1231000100366
ITEM SPECIFICATION
Transmission model F5A5A-4-C5Z
Engine model 6G75-S4-MP
Torque converter Type 3-element, 1-stage, 2-phase type
Lock-up Provided
Stall torque ratio 1.71
Transmission type 5 forward speeds, 1 reverse speed, fully automatic
Transmission gear 1st 3.789
ratio 2nd 2.162
3rd 1.421
4th 1.000
5th 0.686
Reverse 3.117
Final reduction ratio (Differential gear ratio) 3.325
Clutch Multi-disc type 4 sets
Brake Multi-disc type 2 sets, band type 1 set
Manual control system P-R-N-D (4 position) + Sport mode (up, down)
Shift pattern control Electronic control
Hydraulic control during shifting Electronic control (Each clutch hydraulically independently
controlled)
Torque converter clutch control Electronic control
Transmission fluid Specified lubricants MITSUBISHI ELC4-SP III
Quantity (litres) 8.4
AUTOMATIC TRANSMISSION 23A-4
GENERAL DESCRIPTION
TRANSMISSION
The transmission is made up of the torque converter and gear train. A 3-element, 1-stage, 2-phase torque
converter with built-in torque converter clutch is used. The gear train is made up of four sets of multi-disc
clutches, two sets of multi-plate brakes, one band type brake, two set of one-way clutches and three sets of
planetary gears. The planetary gears are made up of sun gears, carriers, pinion gears and annulus gears.
.
DIR
OWC RED
10DB146A
.
P OK × − − − × − ×
R − − − × − × − ×
N OK − − − − × − ×
Sport 1st − − × − − ×* − ×
mode 2nd − − × − − − × ×
3rd − − × − × − − ×
4th − − × − × × − −
5th − − × × ×
×: Function element −: Not applicable
NOTE: * operates only when the vehicle is stationary [at approximately 10 km/h (6.2 mph) or less].
AUTOMATIC TRANSMISSION 23A-6
GENERAL DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12
13
14
15
17
16
18 AC305544
19
20 21 22 23
24
10DB147A
ELECTRONICALLY-CONTROLLED SYSTEM
.
INVECS-II
• When in drive ("D" range), the new automatic transmission
employs an innovative shift schedule to provide a high level
of comfort and "easy driving style" that matches all driving
conditions as well as the driver's driving style.
OPTIMUM SELECTION OF GEARS • INVECS-II features "Optimum Shift Control," which provides
shift timing the average driver perceives to be the optimum
timing under any road conditions. "Adaptive Shift Control"
WITHOUT WITH INVECS-II
adjusts shift timing to match the driving habits and prefer-
INVECS-II ALL DRIVING CONDITIONS ences of individual drivers.
LEVEL ROAD
AC000841AB
10DB155A
.
AUTOMATIC TRANSMISSION 23A-8
GENERAL DESCRIPTION
FEATURES
OPTIMUM SHIFT CONTROL
OPTIMUM CONTROL 1. The shift patterns found satisfying by the typical driver for all
MANUAL SHIFT ranges of driving are stored in the computer's memory. The
OPERATION computer uses this data to analyze road conditions and the
DATA OF A
ACCELERATOR driver's style of operation, and then outputs the optimal shift
NUMBER
POSITION
DRIVER'S
OPTIMUM
patterns stored in its memory to best match the conditions.
VEHICLE SPEED DECISION GEAR
ROAD SELECTION
CONDITION
FOOT BRAKE
AND DRIVING
OPERATION
COMPUTER AC000842 AB
COMPUTER
AC000843 AB
ADAPTIVE SHIFT CONTROL 2. If the computer determines from the driving pat-
terns that the driver is one who enjoys a relaxed,
1. The computer learns the driving habits and pref- unhurried style, it adjusts timing to execute
erences of each individual driver by processing up-shifts at a lower engine speed to provide a
driving data on engine output, tyre load, foot smooth, quiet ride. On the other hand, if the com-
brake operation, etc. It then uses this data to puter determines the driver to prefer a sporty ride,
adjust shift timing to best suit the driver's style. it adjusts timing to shift up at a higher engine
speed to provide more powerful response.
50 100
.
AUTOMATIC TRANSMISSION 23A-9
GENERAL DESCRIPTION
Select switch
<Vehicles with sport mode> Overdrive solenoid valve
Fail-safe operation
Fail-safe operation
(''N''range
("N" rangelight
lightflashing)
flashing)
<Vehicles with sport mode>
Serial communication
THROTTLE
OPENING (%) THICK LINE: STANDARD SHIFT PATTERN
THROTTLE
OPENING (%) THICK LINE: STANDARD SHIFT PATTERN
THROTTLE
OPENING (%)
100
LOCK-UP
DISENGAGED
4 5
4 5
50
PARTIAL
LOCK-UP
ZONE
ON/OFF
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
OUTPUT SHAFT SPEED r/min
4.0 4
3
PARTIAL 3 4
3.0 LOCK-UP 4 5
50 ZONE
DISENGAGED
2.0
1.0 LOCK-UP
0.5
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
OUTPUT SHAFT SPEED r/min
NG
Check the transmission fluid. Replace or replenish the
transmission fluid.
OK
Verify complaint. Communication with the scan tool
MB991958 (MUT-III sub assembly)
not possible
Read the diagnostic trouble code. Communication with the scan tool
MB991958 (MUT-III sub assembly)
not possible in Symptom Chart.
Diagnostic trouble code No diagnostic trouble code
displayed. displayed.
Erase the diagnostic trouble code. Check symptom.
AC210189 AB
NOTE: If a sensor is disconnected when the ignition The diagnostic items are displayed in numeric order.
switch is in the "ON" position, a diagnostic trouble
code is stored in memory. In this case, erase the
DTC using diagnostic tool.
CAUTION
To prevent damage to diagnostic tool MB991958, always
DATA LINK
turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR before connecting or disconnecting diagnostic tool
MB991958.
NOTE: If the battery voltage is low, diagnostic trouble codes
will not be set. Check the battery if diagnostic tool
MB991958 does not display.
1. Connect diagnostic tool MB991958 to the data link
connector.
MB991910
2. Turn the ignition switch to the "ON" position.
3. Select "Interactive Diagnosis" from the start-up screen.
MB991824
4. Select "System select."
5. Choose "ELC-A/T" from the "POWER TRAIN" tab.
6. Select "MITSUBISHI."
7. Select "Diagnostic Trouble Code."
8. If a DTC is set, it is shown.
9. Choose "Erase DTCs" to erase the DTC.
MB991827 00DB076A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-16
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
CAUTION
To prevent damage to diagnostic tool MB991958, always
DATA LINK
turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR before connecting or disconnecting diagnostic tool
MB991958.
1. Connect diagnostic tool MB991958 to the data link
connector.
2. Turn the ignition switch to the "ON" position.
3. Select "CAN bus diagnosis" from the start-up screen.
MB991910
4. When the vehicle information is displayed, confirm that it
matches the vehicle whose CAN bus lines will be
diagnosed.
MB991824
• If they match, go to step 8.
• If not, go to step 5.
5. Select the "view vehicle information" button.
6. Enter the vehicle information and select the "OK" button.
7. When the vehicle information is displayed, confirm again
that it matches the vehicle whose CAN bus lines will be
diagnosed.
MB991827 00DB076A • If they match, go to step 8.
• If not, go to step 5.
8. Select the "OK" button.
9. When the optional equipment screen is displayed, choose
the one which the vehicle is fitted with, and then select the
"OK" button.
HOW TO INITIALIZE A/T LEARNING VALUE
M1231022600121
FAIL-SAFE/BACKUP FUNCTION
M1231008300234
When a malfunction of a main sensor or actuator is The following table shows how the fail-safe/backup
detected by the A/T-ECU, the transmission is con- function affects vehicle driveability and operation.
trolled by pre-set control logic to maintain safe condi-
tions for driving.
MALFUNCTIONING ITEM JUDGEMENT CONTROL DEFAULT DURING MALFUNCTION
CONDITION
Input shaft speed sensor If no output pulse The diagnostic trouble code is recorded when the
from the input shaft malfunction occurs during 4 monitoring periods in
speed sensor is one drive cycle. When the judgment condition is
detected for one met, the transmission holds 3rd gear or 2nd gear,
second or more depending on speed, as a fail-safe.
when the vehicle
speed is 30 km/h (19
mph) or greater.
Output shaft speed sensor The output signal The diagnostic trouble code is recorded when the
from the output shaft malfunction occurs during 4 monitoring periods in
speed sensor is not one drive cycle. When the judgment condition is
present for one met, the transmission holds 3rd gear or 2nd gear,
second or more depending on speed, as a fail-safe.
while the vehicle is
driven.
Low-reverse solenoid valve Solenoid valve The diagnostic trouble code is recorded when the
Underdrive solenoid valve resistance is below malfunction occurs during 5 monitoring periods in
2.7 ohms for 0.32 one drive cycle. When the judgment condition is
Second solenoid valve seconds. met, the A/T control relay is turned off. The
Overdrive solenoid valve transmission will only operate in 3rd and reverse
Reduction (RED) solenoid valve gears until the system is repaired.
Damper control clutch (DCC)
solenoid valve
Incomplete shifting 1st The gear ratio value The diagnostic trouble code is recorded when the
2nd from the output shaft malfunction occurs during 5 monitoring periods in
speed sensor is not one drive cycle. When the judgment condition is
3rd the same as the met, the A/T control relay is turned off. The
4th output from the input transmission will only operate in 3rd and reverse
5th shaft speed sensor gears until the system is repaired.
for one second after
Reverse
shifting has been
completed.
A/T control relay A/T control relay The A/T control relay is switched off. The
voltage is less than transmission will only operate in 3rd and reverse
seven volts for 0.1 gears until the system is repaired.
second after the
ignition switch is
turned "ON."
Malfunction in the A/T-ECU Malfunction has The A/T control relay is switched off. The
occurred in the transmission will only operate in 3rd and reverse
A/T-ECU. gears until the system is repaired.
AUTOMATIC TRANSMISSION 23A-19
AUTOMATIC TRANSMISSION DIAGNOSIS
ROAD TEST
M1231007800407
Check using the following procedures.
STEP CONDITION TEST/OPERATION STANDARD INSPECTION INSPECTION
BEFORE ITEM PROCEDURE
TEST/OPERATION PAGE
1 Ignition switch: Ignition switch Data list No.8 A/T Control A/T Control
(LOCK) OFF (1) ON (1) Control Relay relay relay system
Voltage [V] output (P.23A-207).
voltage
2 Ignition switch: Transmission range Data list No.34 Transmissi Transmission
ON (1) P, (2) R, (3) N, (4) (1) P, (2) R, (3) N, (4) on range range switch
Engine: Stopped D D switch system
Transmission (P.23A-97,
range: P P.23A-119).
Transmission range Data list No.27 Select Shift switch
(1) D (1st gear) (1) OFF, (2) ON, (3) switch and assembly
(2) Select the sport ON, (4) ON Shift switch system
mode (1st gear) Data list No.28 (P.23A-252).
(3) Upshift and hold (1) OFF, (2) OFF, (3)
the selector lever in ON, (4) OFF
that position (2nd Data list No.29
gear) (1) OFF, (2) OFF, (3)
(4) Downshift and OFF, (4) ON
hold the selector
lever in that position
(1st gear)
Brake pedal Data list No.19 Stoplamp Stoplamp
(1) Depressed (1) ON switch switch system
(2) Released (2) OFF (P.23A-89).
3 Ignition switch: Cranking test with Cranking should be Cranking Engine does
ST lever in P or N range possible not crank
Engine: Stopped (P.23A-218).
4 Engine warming Drive for 15 minutes Data list No.7 Transmissi Transmission
up or more so that the Gradually rises to 70 on fluid fluid
transmission fluid − 90°C temperatur temperature
temperature e sensor sensor system
becomes 70 − 90°C (P.23A-36,
P.23A-47).
5 Engine: Idling Brake pedal (Retest) Data list No.19 Stoplamp Stoplamp
Transmission (1) Depressed (1) ON switch switch system
range: N (2) Released (2) OFF (P.23A-89).
Transmission range Should be no Malfunction Engine stalls
(1) N → D abnormal shift when when moving
(2) N → R shocks starting selector lever
Time delay when from N to D or
engaging should be N to R
within 2 seconds (P.23A-227).
AUTOMATIC TRANSMISSION 23A-20
AUTOMATIC TRANSMISSION DIAGNOSIS
CAUTION
• The throttle should not be fully open for any more than
five seconds.
• If you repeat the stall test when the transmission 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 transmission fluid temperature returns to 80°C
or less.
5. Move the selector lever to the "D" position. Fully depress the
accelerator pedal and read the maximum engine speed at
this time.
Standard value: Stall speed: 2,100 − 2,600 r/min
6. Move the selector lever to the "R" position. Fully depress the
accelerator pedal and read the maximum engine speed.
Standard value: Stall speed: 2,100 − 2,600 r/min
CAUTION
The transmission fluid temperature should be between 70
− 80°C during the test.
1. Check the transmission fluid level and temperature. Check
engine coolant temperature.
• Transmission fluid level: "HOT" mark on the dipstick
• Transmission fluid temperature: 70 − 80°C
• Engine coolant temperature: 80 − 100°C
2. Raise the vehicle so that the wheels are free to turn.
AUTOMATIC TRANSMISSION 23A-27
AUTOMATIC TRANSMISSION DIAGNOSIS
MD998330
TOPSIDE
DIR MD998900
PORT 10DB153A
RED PORT
TOPSIDE
MD998900
10DB154A
AUTOMATIC TRANSMISSION 23A-28
AUTOMATIC TRANSMISSION DIAGNOSIS
NOTE: When the torque converter pressure is measured, the engine speed should be 1,500 r/min or less.
M N
K L
E F G H I J
D
C
B
A
P Q R
O
S
T
10DB149A
AUTOMATIC TRANSMISSION 23A-32
AUTOMATIC TRANSMISSION DIAGNOSIS
HYDRAULIC CIRCUIT
M1231008800336
OVERVIEW
1 2 3 4 5 6 7
8
9 10
11
14 12
13
15 16 17 18 19
20 21 22 23 24 25
26 27 28
30 RND
P
31
32 33 29
10DB150A
34
CAUTION
During diagnosis, a DTC code associated with
other system may be set when the ignition switch
is turned on with connector(s) disconnected. On
completion, confirm all systems for DTC code(s).
If DTC code(s) are set, erase them all.
A/T DTC DIAGNOSIS ITEM REFERENCE
NO. PAGE
P0713 Transmission fluid temperature sensor system Open circuit P.23A-36
P0712 Short circuit P.23A-47
P0715 Input shaft speed sensor system Short circuit/open circuit P.23A-55
P0720 Output shaft speed sensor system Short circuit/open circuit P.23A-72
− Stoplamp switch system Short circuit P.23A-89
P0705 Transmission range switch system Open circuit P.23A-97
Short circuit P.23A-119
P0753 Low-reverse solenoid valve system Short circuit/open circuit P.23A-133
P0758 Underdrive solenoid valve system Short circuit/open circuit P.23A-144
P0763 Second solenoid valve system Short circuit/open circuit P.23A-154
P0768 Overdrive solenoid valve system Short circuit/open circuit P.23A-164
P0773 Reduction (RED) solenoid valve system Short circuit/open circuit P.23A-174
P0743 Damper clutch control (DCC) solenoid valve Short circuit/open circuit P.23A-185
system
P0731 1st gear incorrect ratio P.23A-196
P0732 2nd gear incorrect ratio P.23A-196
P0733 3rd gear incorrect ratio P.23A-196
P0734 4th gear incorrect ratio P.23A-196
P0735 5th gear incorrect ratio P.23A-196
P0736 Reverse gear incorrect ratio P.23A-196
P0741 Damper clutch control (DCC) system Defective system P.23A-201
P0742 Clutch stuck on P.23A-204
P1751 A/T control relay system Short circuit to ground/open P.23A-207
circuit
NOTE: The A/T diagnostic trouble codes are the codes which are set when item "A/T" is selected on
diagnostic tool MB991958 (MUT-III sub assembly). However, the some codes above indicate failure in the
MPI system.
AUTOMATIC TRANSMISSION 23A-35
AUTOMATIC TRANSMISSION DIAGNOSIS
SYMPTOM CHART
M1231008000277
CAUTION
During diagnosis, a DTC code associated with
other system may be set when the ignition switch
is turned on with connector(s) disconnected. On
completion, confirm all systems for DTC code(s).
If DTC code(s) are set, erase them all.
SYMPTOM INSPECTION REFERENCE
PROCEDURE NO. PAGE
Communication with diagnostic Communication with all systems - Group 13B
tool is not possible is impossible Symptom
Procedures
13A-539.
Communication with the - Group 13B
A/T-ECU only is impossible Symptom
Procedures
13A-541.
Driving impossible Engine does not start 1 P.23A-218
Does not move forward 2 P.23A-220
Does not move backward 3 P.23A-223
Does not move (forward and 4 P.23A-226
backward)
Malfunction when moving Engine stalls when moving 5 P.23A-227
selector into gear selector lever from "N" to "D" or
"N" to "R"
Shift shock when shifting from 6 P.23A-229
"N" to "D" and long delay
Shift shock when shifting from 7 P.23A-232
"N" to "R" and long delay
Shift shock when shifting from 8 P.23A-235
"N" to "D" and "N" to "R" and
long delay
Malfunction when shifting Shift shock and slipping 9 P.23A-236
Does not shift properly Early or late shifting in all gears 10 P.23A-239
Early or late shifting in some 11 P.23A-242
gears
Does not shift No diagnostic trouble codes 12 P.23A-244
Malfunction while driving Poor acceleration 13 P.23A-248
Vibration 14 P.23A-250
Shift switch assembly system 15 P.23A-252
Shift position indicator light system <Vehicles with sport mode> 16 P.23A-269
AUTOMATIC TRANSMISSION 23A-36
AUTOMATIC TRANSMISSION DIAGNOSIS
CONNECTOR: B-108
CONNECTORS: B-19, B-22
B-108 (GR)
AIR
CLEANER 1 2 3 4 5 6
7 8 9 10
COVER
A/T
CONTROL
UNIT TRANSMISSION
RANGE SWITCH
AC306322AC
16DB564A
CIRCUIT OPERATION
• The A/T-ECU connector B-22 (terminal 6) applies Check Conditions
5 volts to the transmission fluid temperature sen- • Engine speed: 1,000 r/min or more.
sor output terminal (terminal 1). • Output speed: 1,000 r/min or more.
• The transmission fluid temperature sensor circuit • Accumulated time in above condition: 10 min-
is grounded to the A/T-ECU connector B-22 (ter- utes.
minal 12).
Judgement Criteria
• When the transmission fluid temperature is cold,
• Transmission fluid temperature sensor voltage:
the transmission fluid temperature sensor resis-
4.5 volts or more. (1 second)
tance is high. When the transmission fluid tem-
perature is hot, the transmission fluid .
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
TRANSMISSION
RANGE SWITCH
AC306322AC
AC201006AE
AUTOMATIC TRANSMISSION 23A-40
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-42
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
B-108 HARNESS
CONNECTOR:
COMPONENT SIDE
AC209995AB
AUTOMATIC TRANSMISSION 23A-43
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
16DB564A
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-45
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB082A
AUTOMATIC TRANSMISSION 23A-46
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
16DB564A
AUTOMATIC TRANSMISSION 23A-47
AUTOMATIC TRANSMISSION DIAGNOSIS
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-50
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
AC201006AE
AUTOMATIC TRANSMISSION 23A-51
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
16DB564A
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-55
AUTOMATIC TRANSMISSION DIAGNOSIS
B-109 (GR)
A-13 (GR) 1 2 3
1 2 3 4 5 6 7
8 9 10 11
12 13 14 15 16 17
TRANSMISSION
RANGE SWITCH
10DB083A AC305354AC
COVER
A/T
CONTROL
UNIT
16DB564A
C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
C-215
1 2
3 4 5 6
10DB084A
.
AUTOMATIC TRANSMISSION 23A-56
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
TRANSMISSION
RANGE SWITCH
AC305354AC
AC210629AC
AUTOMATIC TRANSMISSION 23A-58
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB083A
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
TRANSMISSION
RANGE SWITCH
AC305354AC
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
AUTOMATIC TRANSMISSION 23A-59
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC305354AC
AC210631AC
AUTOMATIC TRANSMISSION 23A-60
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB086A
AUTOMATIC TRANSMISSION 23A-61
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC
AUTOMATIC TRANSMISSION 23A-62
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC
AUTOMATIC TRANSMISSION 23A-63
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC
AUTOMATIC TRANSMISSION 23A-64
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC
AUTOMATIC TRANSMISSION 23A-65
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC305354AC
AC210632 AD
AUTOMATIC TRANSMISSION 23A-66
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB086A
AUTOMATIC TRANSMISSION 23A-67
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC
AUTOMATIC TRANSMISSION 23A-68
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC
16DB564A
AUTOMATIC TRANSMISSION 23A-69
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
OSCILLO-
SCOPE
10DB088A
AUTOMATIC TRANSMISSION 23A-70
AUTOMATIC TRANSMISSION DIAGNOSIS
NORMAL WAVEFORM
(5) Check the input shaft speed sensor waveform.
• The input shaft speed sensor waveform should show a
(V)
pattern similar to the illustration. The maximum value
5
should be 4.8 volts or more and the minimum value 0.8
volt or less. The output waveform should not contain
electrical noise.
(6) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
0
YES : Go to Step 19.
ACX02131 AD
NO : Go to Step 17.
AC305354AD
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-72
AUTOMATIC TRANSMISSION DIAGNOSIS
A-13 (GR)
BATTERY
1 2 3 4 5 6 7
8 9 10 11 B-107 (GR)
12 13 14 15 16 17
1 2 3
10DB083A
AC305353AC
COVER
A/T
CONTROL
UNIT
16DB564A
C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
C-215
1 2
3 4 5 6
10DB084A
.
AUTOMATIC TRANSMISSION 23A-73
AUTOMATIC TRANSMISSION DIAGNOSIS
B-107 (GR)
1 2 3
AC305353AC
AC210661AB
AUTOMATIC TRANSMISSION 23A-75
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB083A
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
B-107 (GR)
1 2 3
AC305353AC
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
AUTOMATIC TRANSMISSION 23A-76
AUTOMATIC TRANSMISSION DIAGNOSIS
B-107 (GR)
1 2 3
AC305353AC
AC210662 AB
AUTOMATIC TRANSMISSION 23A-77
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB480A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB089A
AUTOMATIC TRANSMISSION 23A-78
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC
AUTOMATIC TRANSMISSION 23A-79
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC
AUTOMATIC TRANSMISSION 23A-80
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC
AUTOMATIC TRANSMISSION 23A-81
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC
AUTOMATIC TRANSMISSION 23A-82
AUTOMATIC TRANSMISSION DIAGNOSIS
BATTERY
B-107 (GR)
1 2 3
AC305353AC
AC210663AB
AUTOMATIC TRANSMISSION 23A-83
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB480A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB082A
AUTOMATIC TRANSMISSION 23A-84
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC
AUTOMATIC TRANSMISSION 23A-85
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC
16DB480A
AUTOMATIC TRANSMISSION 23A-86
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB480A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB090A
AUTOMATIC TRANSMISSION 23A-87
AUTOMATIC TRANSMISSION DIAGNOSIS
NORMAL WAVEFORM
(5) Check the output shaft speed sensor waveform.
• The output shaft speed sensor waveform should show a
(V)
pattern similar to the illustration. The maximum value
5
should be 4.8 volts or more and the minimum value 0.8
volt or less. The output waveform should not contain
electrical noise.
(6) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the waveform normal?
0
YES : Go to Step 19.
ACX02131 AD
NO : Go to Step 17.
AC305353AD
CONNECTOR: C-30
AIR
CLEANER
COVER 1 2
3 4
ENGINE
CONTROL
UNIT
10DB091A
16DB400A
. .
1 2
3 4
10DB091A
10DB091A
1 2
3 4
10DB091A
AUTOMATIC TRANSMISSION 23A-92
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2
3 4
10DB091A
BRAKE PEDAL
ACX02208AD
AUTOMATIC TRANSMISSION 23A-93
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-30
1 2
3 4
10DB091A
AUTOMATIC TRANSMISSION 23A-95
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-30
1 2
3 4
10DB091A
AUTOMATIC TRANSMISSION 23A-96
AUTOMATIC TRANSMISSION DIAGNOSIS
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AUTOMATIC TRANSMISSION 23A-97
AUTOMATIC TRANSMISSION DIAGNOSIS
23A
CAUTION
If (P0705) has been set, TCL related DTC (C1397) CONNECTORS: B-19, B-22
is also set. After (P0705) has been diagnosed, AIR
don’t forget to erase DTC (C1397). CLEANER
1 2 3 4 5 6 7
8 9 10 11
12 13 14 15 16 17
AC306223AB 16DB564A
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE C-214
1 2 3 4 5 6
CONNECTOR: D-14 4
7 8 9 10 11 12 1314
ROOF
WIRING Y
C-215
HARNESS
FLOOR
WIRING
HARNESS 1 2
2
3 4 5 6
15
D-14 10DB093A
10DB084A
CIRCUIT OPERATION connector B-22 terminal (23, 26 and 24) when the
• Battery positive voltage is applied to the transmis- selector lever is in the ("R", "N," and "D," range).
sion inhibitor switch (terminal 8) when the ignition The A/T-ECU judges that the selector lever is in
switch is turned "ON." the ("R", "N," and "D," range) when the battery
• Battery positive voltage is applied to the A/T-ECU positive voltage is applied.
connector B-22 (terminal 25) when the transmis-
sion range is in the "P" range. The A/T-ECU .
judges that the transmission range is in the "P" DTC SET CONDITIONS
range when the battery positive voltage is Check Conditions, Judgement Criteria
applied. • Transmission inhibitor switch: no signal detected.
(30 seconds)
AUTOMATIC TRANSMISSION 23A-98
AUTOMATIC TRANSMISSION DIAGNOSIS
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
<F4A5A>
Q: Does the resistance measure less than 2 ohms for each
transmission range?
YES : Go to Step 3.
NO : Replace the transmission inhibitor switch. Refer to
GROUP 23B, Transmission 23B-13.
TRANSMISSION AC305881
RANGE SWITCH AC305679AC
<F4A5A>
D
N
R
P
AC210182AC
AUTOMATIC TRANSMISSION 23A-101
AUTOMATIC TRANSMISSION DIAGNOSIS
AC306223AB
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
AUTOMATIC TRANSMISSION 23A-102
AUTOMATIC TRANSMISSION DIAGNOSIS
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
<F4A5A>
Q: Does the resistance measure less than 2 ohms for each
transmission range?
YES : Go to Step 7.
NO : Replace the transmission inhibitor switch. Refer to
GROUP 23B, Transmission 23B-13.
TRANSMISSION AC305881
RANGE SWITCH AC305679AC
<F4A5A>
D
N
R
P
AC210182AC
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-104
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB094A
AUTOMATIC TRANSMISSION 23A-105
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-106
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
<F4A5A>
Q: Is the measured resistance less than 2 ohms for each
transmission range?
YES : Go to Step 13.
NO : Replace the transmission inhibitor switch. Refer to
GROUP 23B, Transmission 23B-13.
TRANSMISSION AC305881
RANGE SWITCH AC305679AC
<F4A5A>
D
N
R
P
AC210182AC
AUTOMATIC TRANSMISSION 23A-107
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-108
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB095A
AUTOMATIC TRANSMISSION 23A-109
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-110
AUTOMATIC TRANSMISSION DIAGNOSIS
<F4A5A>
Q: Is the measured resistance less than 2 ohms for each
transmission range?
YES : Go to Step 18.
NO : Replace the transmission inhibitor switch. Refer to
GROUP 23B, Transmission 23B-13.
TRANSMISSION AC305881
RANGE SWITCH AC305679AC
<F4A5A>
D
N
R
P
AC210182AC
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-111
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB096A
AUTOMATIC TRANSMISSION 23A-112
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-113
AUTOMATIC TRANSMISSION DIAGNOSIS
<F4A5A>
Q: Is the measured resistance less than 2 ohms for each
transmission range?
YES : Go to Step 23.
NO : Replace the transmission inhibitor switch. Refer to
GROUP 23B, Transmission 23B-13.
TRANSMISSION AC305881
RANGE SWITCH AC305679AC
<F4A5A>
D
N
R
P
AC210182AC
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-114
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB097A
AUTOMATIC TRANSMISSION 23A-115
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-116
AUTOMATIC TRANSMISSION DIAGNOSIS
AC306223AB
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-117
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-118
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-119
AUTOMATIC TRANSMISSION DIAGNOSIS
.
TROUBLESHOOTING HINTS (THE MOST
CIRCUIT OPERATION LIKELY CAUSES FOR THIS CODE TO BE
Refer to P.23A-97. SET ARE:)
. • Malfunction of the transmission inhibitor switch
DTC SET CONDITIONS circuit
• Damaged harness or connector
Check Conditions, Judgement Criteria
• Malfunction of the A/T-ECU
• Transmission inhibitor switch: multiple signal. (30
seconds) Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
.
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main harness A
<F4A5A>
Q: Does the resistance measure less than 2 ohms for each
selector position?
YES : Go to Step 2.
NO : Replace the transmission inhibitor switch. Refer to
GROUP 23B, Transmission 23B-13.
TRANSMISSION AC305881
RANGE SWITCH AC305679AC
<F4A5A>
D
N
R
P
AC210182AC
AUTOMATIC TRANSMISSION 23A-121
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC210068AE
16DB564A
AUTOMATIC TRANSMISSION 23A-122
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
AUTOMATIC TRANSMISSION 23A-123
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-124
AUTOMATIC TRANSMISSION DIAGNOSIS
B-22 HARNESS
CONNECTOR:
10DB095A
AUTOMATIC TRANSMISSION 23A-125
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-126
AUTOMATIC TRANSMISSION DIAGNOSIS
B-22 HARNESS
CONNECTOR:
10DB096A
AUTOMATIC TRANSMISSION 23A-127
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-128
AUTOMATIC TRANSMISSION DIAGNOSIS
B-22 HARNESS
CONNECTOR:
10DB097A
AUTOMATIC TRANSMISSION 23A-129
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-130
AUTOMATIC TRANSMISSION DIAGNOSIS
AC306223AB
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-131
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-110
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
AUTOMATIC TRANSMISSION 23A-132
AUTOMATIC TRANSMISSION DIAGNOSIS
A-13 (GR)
1 2
1 2 3 4 5 6 7
3 4
8 9 10 11
12 13 14 15 16 17
FRONT OF
VEHICLE
CONNECTOR: B-108
CONNECTORS: B-19, B-22
B-108 (GR)
AIR
CLEANER 1 2 3 4 5 6
7 8 9 10
COVER
A/T
CONTROL
UNIT TRANSMISSION
RANGE SWITCH
AC306322AC
16DB564A
. .
solenoid. The amount of time that the circuit is OBD-II DRIVE CYCLE PATTERN
grounded is displayed on diagnostic tool Start the engine, and keep the vehicle stopped in "P"
MB991958 in percent. range for 5 seconds.
• When the solenoid is energized or de-energized,
fluid passes through the valve body and .
MB991827 00DB076A
MB991824
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-136
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210673AB
1
2
AC201141AZ
AUTOMATIC TRANSMISSION 23A-137
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-138
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-139
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210676AB
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-140
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-141
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-142
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-143
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
VALVE BODY
ASSEMBLY
B-108-5
B-108-6 B-108-4
10DB103A
AUTOMATIC TRANSMISSION 23A-144
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
MB991824
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-146
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210677AB
B-108-1
VALVE BODY
ASSEMBLY
10DB109A
AC201141BA
AUTOMATIC TRANSMISSION 23A-147
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-148
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-149
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210680 AB
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-150
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-151
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-152
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-153
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
B-108-3 B-108-1
B-108-2
VALVE BODY
ASSEMBLY
10DB106A
AUTOMATIC TRANSMISSION 23A-154
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
MB991824
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-156
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210690AB
B-108-2
VALVE BODY
ASSEMBLY
10DB108A
AC201141BB
AUTOMATIC TRANSMISSION 23A-157
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-158
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-159
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210680 AB
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-160
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-161
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-162
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-163
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
B-108-3 B-108-1
B-108-2
VALVE BODY
ASSEMBLY
10DB106A
AUTOMATIC TRANSMISSION 23A-164
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
MB991824
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-166
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210692 AB
B-108-3
VALVE BODY
ASSEMBLY
10DB107A
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-168
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-169
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210680 AB
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-170
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-171
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-172
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-173
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
B-108-3 B-108-1
B-108-2
VALVE BODY
ASSEMBLY
10DB106A
AUTOMATIC TRANSMISSION 23A-174
AUTOMATIC TRANSMISSION DIAGNOSIS
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
MB991824
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-177
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
10DB100A
B-108-6
10DB105A
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-179
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-180
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210676AB
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-181
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-182
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-183
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-184
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
VALVE BODY
ASSEMBLY
B-108-5
B-108-6 B-108-4
10DB103A
AUTOMATIC TRANSMISSION 23A-185
AUTOMATIC TRANSMISSION DIAGNOSIS
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
MB991824
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-188
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210697AB
B-108-4
10DB104A
(2) Measure the resistance between damper clutch control
B-108-4 HARNESS CONNECTOR: solenoid valve terminals 1 and 2.
TORQUE CONVERTER CLUTCH
SOLENOID VALVE SIDE Resistance value: 2.7−3.4 Ω [at 20°C (68°F)]
Q: Is the measured resistance 2.7−3.4 Ω [at 20°C (68°F)?
1
YES : Replace the harness wire between A/T control
2
solenoid valve assembly connector B-108 and the
solenoid valves.
NO : Replace the damper clutch control solenoid valve.
Refer to GROUP 23B, Valve Body 23B-62.
AC201141BD
AUTOMATIC TRANSMISSION 23A-189
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-190
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-191
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
AC210676AB
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-192
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-193
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-194
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
AUTOMATIC TRANSMISSION 23A-195
AUTOMATIC TRANSMISSION DIAGNOSIS
TRANSMISSION
RANGE SWITCH
AC306322AC
VALVE BODY
ASSEMBLY
B-108-5
B-108-6 B-108-4
10DB103A
AUTOMATIC TRANSMISSION 23A-196
AUTOMATIC TRANSMISSION DIAGNOSIS
Judgement Criteria
.
DTC SET CONDITIONS < (P0732)> • Output speed: [(input speed + 200 r/min) / 2nd
Check Conditions gear ratio] or more. (4 seconds)
• Engine speed: 450 r/min or more. • Output speed: [(input speed - 200 r/min) / 2nd
• Output speed: 500 r/min or more. gear ratio] or less. (4 seconds)
• Shift stage: 2nd gear. • If (P0732) is set consecutively four times, the
• Input speed: more than 0 r/min. transmission is locked into 3rd gear as a fail-safe
• Transmission fluid temperature sensor voltage: measure, and the "N" range light flashes once
4.5 volts or less. per second.
• Voltage of battery: 10 volts or more. .
• Transmission inhibitor switch rationality: only one OBD-II DRIVE CYCLE PATTERN <
signal. (P0732)>
• Time after shift changing finish: 2 seconds or
Start the engine, and drive at 30 km/h (19 mph) or
more.
more for 10 seconds, with 2nd gear fixed (2nd gear
in sport mode).
.
AUTOMATIC TRANSMISSION 23A-197
AUTOMATIC TRANSMISSION DIAGNOSIS
Judgement Criteria
.
DTC SET CONDITIONS < (P0734)> • Output speed: [(input speed + 200 r/min) / 4th
Check Conditions gear ratio] or more. (4 seconds)
• Engine speed: 450 r/min or more. • Output speed: [(input speed - 200 r/min) / 4th
• Output speed: 900 r/min or more. gear ratio] or less. (4 seconds)
• Shift stage: 4th gear. • If (P0734) is set consecutively four times, the
• Input speed: more than 0 r/min. transmission is locked into 3rd gear as a fail-safe
• Transmission fluid temperature sensor voltage: measure, and the "N" range light flashes once
4.5 volts or less. per second.
• Voltage of battery: 10 volts or more. .
• Transmission inhibitor switch rationality: only one OBD-II DRIVE CYCLE PATTERN <
signal. (P0734)>
• Time after shift changing finish: 2 seconds or
Start the engine, and drive at 40 km/h (25 mph) or
more.
more for 10 seconds, with 4th gear fixed (4th gear in
sport mode).
Judgement Criteria
.
DTC SET CONDITIONS < (P0735)> • Output speed: [(input speed + 200 r/min) / 4th
Check Conditions gear ratio] or more. (4 seconds)
• Engine speed: 450 r/min or more. • Output speed: [(input speed - 200 r/min) / 4th
• Output speed: 900 r/min or more. gear ratio] or less. (4 seconds)
• Shift stage: 5th gear. • If (P0735) is set consecutively four times, the
• Input speed: more than 0 r/min. transmission is locked into 3rd gear as a fail-safe
• Transmission fluid temperature sensor voltage: measure, and the "N" range light flashes once
4.5 volts or less. per second.
• Voltage of battery: 10 volts or more. .
• Transmission inhibitor switch rationality: only one OBD-II DRIVE CYCLE PATTERN <
signal. (P0735)>
• Time after shift changing finish: 2 seconds or
Start the engine, and drive at 40 km/h (25 mph) or
more.
more for 10 seconds, with 5th gear fixed (5th gear in
sport mode).
.
AUTOMATIC TRANSMISSION 23A-198
AUTOMATIC TRANSMISSION DIAGNOSIS
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
AUTOMATIC TRANSMISSION 23A-199
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB117A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-202
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
10DB117A
MB991827 00DB076A
10DB117A
AUTOMATIC TRANSMISSION 23A-207
AUTOMATIC TRANSMISSION DIAGNOSIS
A-13 (GR)
1 2
1 2 3 4 5 6 7 3 4
8 9 10 11
12 13 14 15 16 17
FRONT OF
VEHICLE
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
16DB564A
C-215
1 2
3 4 5 6
10DB084A
.
AUTOMATIC TRANSMISSION 23A-208
AUTOMATIC TRANSMISSION DIAGNOSIS
position, the A/T-ECU connector B-22 (terminal OBD-II DRIVE CYCLE PATTERN
4) receives battery voltage from the ignition Start the engine, and keep the vehicle stopped in "P"
switch. The A/T-ECU connector B-22 (terminal 4) range for 5 seconds.
applies voltage to energize the A/T control relay
(terminal 3). With the A/T control relay energized,
.
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-209
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2
3 4
FRONT OF
VEHICLE
FRONT OF
VEHICLE
1 2
3 4
FRONT OF
VEHICLE
AC306223AB
FRONT OF
VEHICLE
1 2
3 4
FRONT OF
VEHICLE
AC306223AB
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
AUTOMATIC TRANSMISSION 23A-212
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
AUTOMATIC TRANSMISSION 23A-213
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB120A
AUTOMATIC TRANSMISSION 23A-214
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
AUTOMATIC TRANSMISSION 23A-215
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
COVER
A/T
CONTROL
UNIT
16DB564A
16DB564A
AUTOMATIC TRANSMISSION 23A-216
AUTOMATIC TRANSMISSION DIAGNOSIS
FRONT OF
VEHICLE
COVER
A/T
CONTROL
UNIT
16DB564A
AUTOMATIC TRANSMISSION 23A-217
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-218
AUTOMATIC TRANSMISSION DIAGNOSIS
SYMPTOM PROCEDURES
COMMENT
If the engine does not crank when the selector lever LIKELY CAUSES FOR THIS CONDITION:)
is placed in the "P" or "N" position, the cause is prob- • Malfunction of the transmission inhibitor switch
ably a malfunction of the transmission inhibitor • Malfunction of the transmission control cable
switch system, transmission control cable assembly, assembly
engine system, torque converter or transmission oil • Malfunction of the engine system
pump. • Malfunction of the torque converter
• Malfunction of the transmission oil pump
• Check RED brake system.
.
Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-219
AUTOMATIC TRANSMISSION DIAGNOSIS
COMMENT
If the engine is idling and the selector lever is shifted LIKELY CAUSES FOR THIS CONDITION:)
from "N" to "D" range and the vehicle does not drive • Abnormal line pressure
forward then the cause is due to line pressure defect, • Malfunction of the underdrive solenoid valve
under drive clutch or valve body malfunction. • Malfunction of the underdrive clutch
• Malfunction of the oil pump
• Malfunction of the valve body
.
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
AUTOMATIC TRANSMISSION 23A-221
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
AC001859AB
AUTOMATIC TRANSMISSION 23A-222
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB117A
AC001858
AC001861
AUTOMATIC TRANSMISSION 23A-223
AUTOMATIC TRANSMISSION DIAGNOSIS
COMMENT
If the vehicle does not reverse when the selector likely causes for this condition:)
lever is shifted from "N" to "R" range while the engine • Abnormal reverse clutch pressure
is idling, the cause is probably abnormal pressure or • Abnormal low-reverse brake pressure
a malfunction of the reverse clutch, low-reverse • Malfunction of the low-reverse solenoid valve
brake, or valve body. • Malfunction of the reverse clutch
• Malfunction of the low-reverse brake
• Malfunction of the valve body
.
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-224
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB117A
AUTOMATIC TRANSMISSION 23A-225
AUTOMATIC TRANSMISSION DIAGNOSIS
AC001863 AB
AUTOMATIC TRANSMISSION 23A-226
AUTOMATIC TRANSMISSION DIAGNOSIS
COMMENT
If the vehicle does not move forward or reverse when LIKELY CAUSES FOR THIS CONDITION:)
the selector lever is shifted to any position while the • Abnormal line pressure
engine is idling, the cause is probably abnormal line • Malfunction of the powertrain
pressure, or a malfunction of the powertrain, oil • Malfunction of the oil pump
pump or valve body. • Malfunction of the valve body
• Low transmission fluid level
• Malfunction of the A/T-ECU system
.
DIAGNOSIS
10DB117A
AUTOMATIC TRANSMISSION 23A-227
AUTOMATIC TRANSMISSION DIAGNOSIS
INSPECTION PROCEDURE 5: Engine Stalls when Moving Selector Lever from "N" to "D" or "N" to "R"
COMMENT
If the engine stalls when the selector lever is shifted likely causes for this condition:)
from "N" to "D" or "R" range while the engine is idling, • Malfunction of the engine system
the cause is probably a malfunction of the engine • Malfunction of the damper clutch control solenoid
system, damper clutch control solenoid valve, valve • Malfunction of the valve body
body or torque converter (damper clutch control mal- • Malfunction of the torque converter (Malfunction
function). of the damper clutch control)
• Malfunction of the A/T-ECU system
• Check RED brake system.
.
Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
10DB122A
10DB117A
AC001857
AUTOMATIC TRANSMISSION 23A-229
AUTOMATIC TRANSMISSION DIAGNOSIS
INSPECTION PROCEDURE 6: Shift Shock when Shifting from "N" to "D" and Long Delay
COMMENT
If abnormal shock or delay of two seconds or more likely causes for this condition:)
occurs when the selector lever is shifted from "N" to • Abnormal underdrive clutch pressure
"D" range while the engine is idling, the cause is • Malfunction of the underdrive solenoid valve
probably abnormal underdrive clutch pressure or a • Malfunction of the underdrive clutch
malfunction of the underdrive clutch, valve body or • Malfunction of the valve body
TP sensor. • Malfunction of the TP sensor
• Malfunction of the A/T-ECU system
•
.
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-230
AUTOMATIC TRANSMISSION DIAGNOSIS
AC001859AB
AC001861
INSPECTION PROCEDURE 7: Shift Shock when Shifting from "N" to "R" and Long Delay
COMMENT
If abnormal shock or delay of two seconds or more likely causes for this condition:)
occurs when the selector lever is shifted from "N" to • Abnormal reverse clutch pressure
"R" range while the engine is idling, the cause is • Abnormal low-reverse brake pressure
probably abnormal reverse clutch pressure or • Malfunction of the low-reverse solenoid valve
low-reverse brake pressure, or a malfunction of the • Malfunction of the reverse clutch
reverse clutch, low-reverse brake, valve body or TP • Malfunction of the low-reverse brake
sensor. • Malfunction of the valve body
• Malfunction of the TP sensor
• Malfunction of the A/T-ECU system
.
Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-233
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB117A
AUTOMATIC TRANSMISSION 23A-235
AUTOMATIC TRANSMISSION DIAGNOSIS
INSPECTION PROCEDURE 8: Shift Shock when Shifting from "N" to "D," "N" to "R" and Long Delay
COMMENT
If abnormal shock or delay of two seconds or more LIKELY CAUSES FOR THIS CONDITION:)
occurs when the selector lever is moved from "N" to • Abnormal line pressure
"D" range or from "N" to "R" range while the engine is • Malfunction of the oil pump
idling, the cause is probably abnormal line pressure • Malfunction of the valve body
or a malfunction of the oil pump or valve body. • Malfunction of the A/T-ECU system
. Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
10DB117A
COMMENT
If shift shock when driving is due to upshifting or LIKELY CAUSES FOR THIS CONDITON:)
downshifting and the transmission speed become • Abnormal line pressure
higher than the engine speed, the cause is probably • Malfunction of each solenoid valve
abnormal line pressure or a malfunction of a solenoid • Malfunction of the oil pump
valve, oil pump, valve body or of a brake or clutch. • Malfunction of the valve body
• Malfunction of each brake or each clutch
• Malfunction of the A/T-ECU system
.
Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
AUTOMATIC TRANSMISSION 23A-237
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB117A
NEXT PAGE
PREVIOUS PAGE
AUTOMATIC TRANSMISSION 23A-239
AUTOMATIC TRANSMISSION DIAGNOSIS
23A
COMMENT
If all shift points are early or late while driving, the likely causes for this condition:)
cause is probably a malfunction of the output shaft • Malfunction of the output shaft speed sensor
speed sensor, TP sensor or a solenoid valve. • Malfunction of the TP sensor
• Malfunction of each solenoid valve
• Abnormal line pressure
.
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-240
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-241
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB117A
Damper
Reduction (RED) control clutch
solenoid solenoid
valve valve
10DB123A
COMMENT
If some of the shift points are early or late when driv- likely causes for this condition:)
ing, the cause is probably a malfunction of the valve • Malfunction of the valve body
body, or it is due to the characteristics of the • Malfunction of the A/T-ECU system
INVECS-II system but is not an abnormality. Circuit drawings
. • Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
10DB117A
AUTOMATIC TRANSMISSION 23A-244
AUTOMATIC TRANSMISSION DIAGNOSIS
CONNECTOR: B-19
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A
CIRCUIT OPERATION
A/T-ECU connector B-19 (terminal number 21) likely causes for this condition:)
receives battery positive voltage from the battery. • Malfunction of the transmission inhibitor switch
• Damaged harness, connector
.
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
COVER
A/T
CONTROL
UNIT
10DB125A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB124A
AUTOMATIC TRANSMISSION 23A-246
AUTOMATIC TRANSMISSION DIAGNOSIS
16DB564A
COVER
A/T
CONTROL
UNIT
10DB125A
AUTOMATIC TRANSMISSION 23A-247
AUTOMATIC TRANSMISSION DIAGNOSIS
COMMENT
If acceleration is poor when downshifting occurs likely causes for this condition:)
while driving, a malfunction of the engine system or a • Malfunction of the engine system
brake or clutch may exist. • Malfunction of the clutch system and brake sys-
tem
• Malfunction of the ENGINE-ECU or A/T-ECU sys-
.
tem
Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
COMMENT
If vibration occurs when driving at constant speed or likely causes for this condition:)
when accelerating in 5th gear (top range), abnormal • Abnormal damper control clutch pressure
damper control clutch pressure a malfunction of the • Malfunction of the engine system
engine system, damper control clutch solenoid, • Malfunction of the damper control clutch solenoid
torque converter or valve body may exist. • Malfunction of the torque converter
• Malfunction of the valve body
• Malfunction of the Engine or A/T system
.
Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
• Refer to component locations GROUP-70
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
AC001857
10DB117A
AUTOMATIC TRANSMISSION 23A-252
AUTOMATIC TRANSMISSION DIAGNOSIS
A-13 (GR)
ROOF
WIRING Y
HARNESS
1 2 3 4 5 6 7
FLOOR
8 9 10 11 WIRING
HARNESS
12 13 14 15 16 17 2
15
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
16DB564A
C-215
1 2
CONNECTOR: B-110
3 4 5 6
1 2 3 4 5 6
7 8 9 10
B-110 (B)
10DB084A
TRANSMISSION
RANGE SWITCH
AC210068AE
CIRCUIT OPERATION
If the select switch of the shift switch assembly is set
to the sport mode, battery positive voltage will be
applied to the A/T-ECU connector B-19 (terminal 17).
If the shift switch of the shift switch assembly is set to
"UP" or "DOWN" position, battery positive voltage
will be applied to the A/T-ECU connector B-19 (termi-
nals 8 and 9).
AUTOMATIC TRANSMISSION 23A-253
AUTOMATIC TRANSMISSION DIAGNOSIS
Circuit drawings
.
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-254
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-256
AUTOMATIC TRANSMISSION DIAGNOSIS
side.
(2) Turn the ignition switch to the "ON" position.
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
10DB126A
YES : Go to Step 8.
NO : Repair or replace the damaged components. Refer to
ROOF
WIRING
HARNESS
Y
GROUP 00E, Harness Connector Inspection
P.00E-2.
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
AUTOMATIC TRANSMISSION 23A-258
AUTOMATIC TRANSMISSION DIAGNOSIS
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
side.
(2) Turn the ignition switch to the "ON" position.
ROOF
WIRING Y
(3) Move the selector lever to the "D" position.
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
10DB127A
AUTOMATIC TRANSMISSION 23A-259
AUTOMATIC TRANSMISSION DIAGNOSIS
AC306223AB
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-260
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
10DB125A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB128A
AUTOMATIC TRANSMISSION 23A-261
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-262
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
16DB564A
AUTOMATIC TRANSMISSION 23A-263
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB129A
AUTOMATIC TRANSMISSION 23A-264
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-265
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
10DB125A
AUTOMATIC TRANSMISSION 23A-266
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
16DB564A
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
10DB130A
AUTOMATIC TRANSMISSION 23A-267
AUTOMATIC TRANSMISSION DIAGNOSIS
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
AUTOMATIC TRANSMISSION 23A-268
AUTOMATIC TRANSMISSION DIAGNOSIS
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
10DB125A
AUTOMATIC TRANSMISSION 23A-269
AUTOMATIC TRANSMISSION DIAGNOSIS
INSPECTION PROCEDURE 16: Shift Position Indicator Light System <Vehicles with Sport Mode>
. .
DIAGNOSIS
Required Special Tool:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-270
AUTOMATIC TRANSMISSION DIAGNOSIS
MB991824
MB991827 00DB076A
AUTOMATIC TRANSMISSION 23A-271
AUTOMATIC TRANSMISSION DIAGNOSIS
26-PIN 34-PIN
CONNECTOR CONNECTOR
A/T-ECU CONNECTOR A/T-ECU CONNECTOR
(B-22) (B-19)
10DB131A
CONNECTOR: B-22
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
10DB132A
CONNECTOR
(B-22)
1 Underdrive solenoid • Engine: idling Battery positive voltage
valve • Gear range: 1st gear
• Engine: idling 7−9V
• Transmission range: R
2 Overdrive solenoid • Engine: idling Battery positive voltage
valve • Gear range: 3rd gear
• Engine: idling 7−9V
• Transmission range: D (1st gear)
3 Solenoid valve power Ignition switch: LOCK (OFF) 1V or less
supply Ignition switch: ON Battery positive voltage
AUTOMATIC TRANSMISSION 23A-279
AUTOMATIC TRANSMISSION DIAGNOSIS
CONNECTOR: B-19
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR
(B-19)
1 Ground Always 1 V or less
7 Power supply Ignition switch: LOCK (OFF) 1 V or less
(Ignition) Ignition switch: ON Battery positive voltage
8 Sports mode • Ignition switch: ON Battery positive voltage
Shift switch (up) • Selector lever operation: Upshift and
hold the selector lever
• Ignition switch: ON 1 V or less
• Selector lever operation: Other than
above
9 Sports mode • Ignition switch: ON Battery positive voltage
Shift switch (down) • Selector lever operation: Downshift
and hold the selector lever
• Ignition switch: ON 1 V or less
• Selector lever operation: Other than
above
10 Ground Always 1 V or less
17 Sports select switch • Ignition switch: ON Battery positive voltage
• Transmission range: Sport mode
• Ignition switch: ON 1 V or less
• Transmission range: Other than above
18 Ground Always 1 V or less
20 Flash EPROM Data Link Connector -
battery
21 Battery Back-up Always Battery positive voltage
AUTOMATIC TRANSMISSION 23A-282
AUTOMATIC TRANSMISSION DIAGNOSIS
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
10DB133A
ENGINE-ECU
CONNECTOR (B-21)
18 Stoplight switch • Ignition switch: ON Battery positive voltage
• Brake pedal: Depressed
• Ignition switch: ON 1 V or less
• Brake pedal: Released
AUTOMATIC TRANSMISSION 23A-284
AUTOMATIC TRANSMISSION DIAGNOSIS
SPECIAL TOOL A/T- ECU CHECK HARNESS (MB992045) CONNECTOR: COMPONENT SIDE
26-PIN 34-PIN
CONNECTOR CONNECTOR
A/T-ECU CONNECTOR A/T-ECU CONNECTOR
(B-22) (B-19)
10DB131A
20
0 0
0
(ms) (ms)
(ms)
AC001872AE AC001873AD AC001875AF
AUTOMATIC TRANSMISSION 23A-286
SPECIAL TOOLS
SPECIAL TOOLS
M1231000600413
MB991825
MB991826
MB991958
AUTOMATIC TRANSMISSION 23A-287
SPECIAL TOOLS
MB992045
B991527
MB991895 −
Engine hanger
MB991895
MB991928 −
SLIDE BRACKET (HI) Engine hanger
A: MB991929
E Joint (50) ×2
B: MB991930
F A Joint (90) ×2
D
C: MB991931
B Joint (140) ×2
C D: MB991932
B991928
Foot (standard) ×4
E: MB991933
Foot (short) ×2
F: MB991934
Chain and hook
assembly
AUTOMATIC TRANSMISSION 23A-288
SPECIAL TOOLS
MB991354
B990767
ON-VEHICLE SERVICE
A/T CONTROL COMPONENT LAYOUT
M1231008600343
<3.8L ENGINE>
A B
C D E
10DB134A
10DB135A
AUTOMATIC TRANSMISSION 23A-290
ON-VEHICLE SERVICE
A BATTERY B
INPUT SHAFT
SPEED SENSOR
AC207308AI
RELAY BOX 10DB136A
C D
Overdrive Underdrive
solenoid solenoid
valve valve
Damper
Reduction (RED) control clutch
TRANSMISSION solenoid solenoid
INHIBITOR SWITCH valve valve
10DB137A
Transmission fluid Valve body
temperature asssembly
sensor 10DB138A
E F
AIR
CLEANER
STOPLIGHT SWITCH
COVER
A/T
CONTROL BRAKE PEDAL
UNIT
10DB139A AC004673AE
G H SPORTS MODE
SHIFT SWITCH
ACCELERATOR
PEDAL
SHIFT SWITCH SHIFT SWITCH
(DOWN SIDE) (UP SIDE)
10DB140A 10DB168A
AUTOMATIC TRANSMISSION 23A-291
ON-VEHICLE SERVICE
ESSENTIAL SERVICE
10DB152A
<F4A4B> 3. Remove the drain plug from the bottom of the transmission
case to drain the transmission fluid.
Approximately 1.0 litre of transmission fluid should be
removed.
4. Install the drain plug with a new gasket, and tighten it to the
specified torque.
Tightening torque: 32 ± 2 N⋅m (23 ± 2 ft-lb)
CAUTION
CENTERMEMBER AC306236AB Stop pouring if the full volume of transmission fluid can
not be added.
5. Add new transmission fluid (MITSUBISHI ATF SP III)
through the oil filter tube.
Approximately 5.5 litres of transmission fluid should
be added.
6. Repeat the procedure in Step 2. (to pump out the rest of the
contaminated transmission fluid)
7. Add new transmission fluid (MITSUBISHI ATF SP III)
through the oil filter tube.
Approximately 3.5 litres of transmission fluid should
be added.
NOTE: Check for contamination or a burnt odor. If the trans-
mission fluid is still contaminated or burnt, repeat Steps 6
and 7 before proceeding to Step 8.
AUTOMATIC TRANSMISSION 23A-293
ON-VEHICLE SERVICE
DIPSTICK
10DB151A
D
N
R
P
10DB142A
12 ± 2 N·m
107 ± 17 in-lb
10DB143A
SECTION A - A
HOLE IN END
MANUAL
CONTROL
HOLE IN LEVER
FLANGE
TRANSMISSION
RANGE SWITCH BODY
10DB144A
10DB143A
A/T
CONTROL
RELAY
RELAY BOX
AC306283AC
AUTOMATIC TRANSMISSION 23A-297
ON-VEHICLE SERVICE
4. If there is any problem with the A/T control relay, replace it.
AUTOMATIC TRANSMISSION 23A-298
ON-VEHICLE SERVICE
Second
Low-reverse
solenoid
solenoid
valve
valve
Damper
Reduction (RED) control clutch
solenoid solenoid
valve valve
10DB123A
AUTOMATIC TRANSMISSION 23A-299
ON-VEHICLE SERVICE
10DB145A
10DB143A
AUTOMATIC TRANSMISSION 23A-300
TRANSMISSION CONTROL
TRANSMISSION CONTROL
REMOVAL AND INSTALLATION
M1231006600585
WARNING
• When removing and installing the transmission control cable unit, be careful not to hit the
SRS-ECU.
12 ± 2 N·m
5
102 ± 22 in-lb
12 ± 2 N·m 2
102 ± 22 in-lb
1 12 ± 2 N·m
4 107 ± 17 in-lb
10DB164A
AC305881
MANUAL CONTROL LEVER AC305679AE
INSPECTION
M1231030000094
Check the cable assembly for function and for damage.
AUTOMATIC TRANSMISSION 23A-302
TRANSMISSION CONTROL
3
3
10DB165A
INSPECTION
M1231006900188
SPORTS MODE
SHIFT SWITCH
(UP SHIFT)
(SELECT SHIFT)
ON
ON
10DB166A
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
M1231005700459
CAUTION
*:
Indicates parts which should be temporarily tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
Pre-installation Operation Post-installation Operation
• Front Under Cover, Side Under Cover Removal • Front Exhaust Pipe Installation (Refer to GROUP 15,
• Transmission Fluid Draining (Refer to GROUP 00, Main- Exhaust Pipe and Main Muffler P.15-14.)
tenance Service − Automatic Transmission P.00-45.) • Battery and Battery Tray Installation
• Engine Cover Removal (Refer to GROUP 11C, Engine • Engine-ECU and A/T-ECU Installation (Refer to GROUP
Assembly 11A-14.) 13A 13A-675.)
• Air Cleaner Assembly Installation (Refer to GROUP 15,
• Air Cleaner Assembly Removal (Refer to GROUP 15, Air Air Cleaner P.15-4.)
Cleaner P.15-4.) • Engine Cover Installation (Refer to GROUP 11C, Engine
• Engine-ECU and A/T-ECU Removal (Refer to GROUP Assembly 11A-14.)
13A 13A-675.) • Transmission Fluid Supplying (Refer to GROUP 00, Main-
• Battery and Battery Tray Removal tenance Service − Automatic Transmission P.00-45.)
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Front Under Cover, Side Under Cover Installation
Exhaust Pipe and Main Muffler P.15-14.) • Selector Lever Operation Check (Refer to P.23A-299.)
• Speedometer Operation Check (Refer to GROUP 54A,
Combination Meter − On-vehicle Service − Speedometer
Check P.54A-92.)
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-6.)
12 ± 2 N·m
1
2
107 ± 17 in-lb 3
73 ± 10 N·m 73 ± 10 N·m
54 ± 7 ft-lb 23 54 ± 7 ft-lb
23 4 5
12 ± 2 N·m
20 102 ± 22 in-lb
6
48 ± 7 N·m
36 ± 5 ft-lb 12
65 ± 6 N·m 15 N
48 ± 4 ft-lb
22
11 10 21
30 ± 3 N·m
7N 23 ± 2 ft-lb
13 N 41 ± 4 N·m
29 ± 4 N·m 30 ± 3 ft-lb
21 ± 3 ft-lb 21
8 9
30 ± 3 N·m
226 ± 29 N·m 22 ± 2 ft-lb
167 ± 21 ft-lb
14
16 19
18 N
17 AC305969AB
REMOVAL STEPS REMOVAL STEPS (Continued)
>>E<< 1. ADJUSTING NUT 3. INHIBITOR SWITCH SENSOR
>>E<< 2. TRANSMISSION CONTROL CONNECTOR
CABLE CONNECTION 4. A/T CONTROL SOLENOID VALVE
ASSEMBLY CONNECTOR
AUTOMATIC TRANSMISSION 23A-305
TRANSMISSION ASSEMBLY
27
28 35 ± 6 N·m
30 26 ± 4 ft-lb
31 33
69 ± 10 N·m*
29 30 51 ± 7 ft-lb*
90 ± 10 N·m
67 ± 7 ft-lb
69 ± 10 N·m*
51 ± 7 ft-lb*
26
83 ± 12 N·m
61 ± 9 ft-lb
83 ± 12 N·m
61 ± 9 ft-lb
10DB155A
REMOVAL STEPS REMOVAL STEPS (Continued)
24. COVER 29. TRANSMISSION MOUNT
<<D>> 25. TORQUE CONVERTER AND BRACKET ASSEMBLY
DRIVE PLATE BOLTS >>B<< 30. TRANSMISSION MOUNT
26. CENTERMEMBER ASSEMBLY STOPPER
27. ENGINE OIL PAN AND 31. TRANSMISSION MOUNT
TRANSMISSION COUPLING BRACKET
BOLTS <<E>> • ENGINE ASSEMBLY
28. REAR ROLL STOPPER BRACKET SUPPORTING
• AIR CLEANER BRACKET • LIFTING UP OF THE VEHICLE
AUTOMATIC TRANSMISSION 23A-306
TRANSMISSION ASSEMBLY
MB990767
AC102462 AC
NUT MB991897
BOLT
BALL JOINT AC208247AC
AUTOMATIC TRANSMISSION 23A-307
TRANSMISSION ASSEMBLY
WRONG AC106821AC
MB990244
(THREE)
MB990242 MB991354
AC102550 AC
2. Remove the drive shaft from the hub by pulling the bottom of
the brake disc towards you.
DRIVE
SHAFT
AC102551AD
CAUTION
• Do not pull on the drive shaft; doing so will damage the
PTJ; be sure to use the pry bar.
• When pulling the drive shaft out from the transmission,
be careful that the spline part of the drive shaft does
not damage the oil seal.
3. Insert a pry bar between the transmission case and the drive
TRANSAXLE
shaft, and then pry and remove the drive shaft from the
transmission.
PTJ ASSEMBLY
PRY BAR
AC305799 AB
NOTE: Insert a pry bar, taking care not to damage the pro-
trusion of transmission case when removing the drive shaft
LH.
4. If the inner shaft is hard to remove from the transmission,
BRACKET ASSEMBLY strike the bracket assembly lightly with a plastic hammer
and remove the inner shaft.
AC102553 AC
CAUTION
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
MB991000
the bearing to move the vehicle, temporarily secure the
MB990998 wheel bearing by using special tools MB991000 and
MB990998.
AC210315AE
C D
AC306197AB
MB991895
(2) Set special tool MB991454 to hold the
engine/transmission assembly.
MB991454
AC306215AB
<RH> <LH> (2) Set special tool MB991928 (engine hanger) to the front
A B fender assembling bolts (A and B) and (C and D) as
shown.
C D
AC306197AB
AUTOMATIC TRANSMISSION 23A-310
TRANSMISSION ASSEMBLY
MB991454
AC306217AB
TORQUE
CONVERTER
AC209056AC
TRANSAXLE
MOUNT
AC205424 AB
10DB143A
AUTOMATIC TRANSMISSION 23A-312
TRANSMISSION FLUID COOLER, HOSE AND PIPE
3
1
AC306186AB
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1231012400245
ITEM SPECIFICATION
Transmission inhibitor switch
Transmission inhibitor switch body mounting bolt 11 ± 1 N⋅m (96 ± 8 in-lb)
Transmission control
Adjusting nut 12 ± 2 N⋅m (107 ± 17 in-lb)
Shift knob attaching screw 2.0 ± 0.3 N⋅m (18 ± 2 in-lb)
Selector lever assembly attaching bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Transmission control cable attaching bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Transmission assembly
Adjusting nut 12 ± 2 N⋅m (107 ± 17 in-lb)
Center member attaching bolt 83 ± 12 N⋅m (61 ± 9 ft-lb)
Cover attaching bolt 11 ± 0.5 N⋅m (93 ± 4 in-lb)
Drive plate bolt 49 ± 3 N⋅m (36 ± 2 ft-lb)
Drive shaft and inner shaft assembly bolt (RH) 41± 4 N⋅m (30 ± 3 ft-lb)
Drive shaft nut 226 ± 29 N⋅m (167 ± 21 ft-lb)
Engine oil pan and transmission coupling bolt 35 ± 6 N⋅m (26 ± 4 ft-lb)
Front roll stopper bracket retainer nut 69 ± 10N⋅m (51 ± 7 ft-lb)
Rear roll stopper bracket attaching bolt 90 ± 10 N⋅m (67 ± 7 ft-lb)
Rear roll stopper bracket retainer nut 69 ± 10N⋅m (51 ± 7 ft-lb)
Flange nut (lower arm ball joint connection) 110 ± 10 N⋅m
Self-locking nut (tie rod end connection) 29 ± 4 N⋅m (21 ± 3 ft-lb)
Stabilizer link to strut connecting nut 48 ± 7 N⋅m (36 ± 5 ft-lb)
Starter motor attaching bolt 30 ± 3 N⋅m (23 ± 2 ft-lb)
Starter terminal nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Transmission assembly upper part coupling bolt 73 ± 10 N⋅m (54 ± 7 ft-lb)
Transmission assembly lower part coupling bolt 88 ± 10 N⋅m (65 ± 7 ft-lb)
Transmission mount bracket attaching nut 83 ± 12 N⋅m (61 ± 9 ft-lb)
Transmission mount stopper attaching nut 83 ± 12 N⋅m (61 ± 9 ft-lb)
Transmission fluid drain plug 32 ± 2 N⋅m (23 ± 2 ft-lb)
SERVICE SPECIFICATIONS
M1231000300359
LUBRICANT
M1231000400419
GROUP 23B
AUTOMATIC
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION
M1233000100715
SECTIONAL VIEW
AK403256
AUTOMATIC TRANSMISSION OVERHAUL 23B-4
GENERAL INFORMATION
HYDRAULIC CIRCUIT
1 2 3 4 5 6 7
8 9 10 11 14 12 13
15
18
16 17
19
20
21 22 23 24 25 26
27 28 29 30 31 32
33
34 35
RND
P
36 38
39 40
37
AK502955 AB
GENERAL SPECIFICATIONS
M1233000200659
Item Specification
Transmission model F5A5A-4-C2Z
Type Electronically controlled 5-speed full-automatic
Torque converter Type 3-element with torque converter clutch
Stall torque ratio 1.71
Gear ratio 1st 3.789
2nd 2.162
3rd 1.421
4th 1.000
5th 0.686
Reverse 3.117
Final gear ratio 3.325
SERVICE SPECIFICATIONS
M1233000300504
Snap ring (For adjustment of underdrive clutch and overdrive clutch end play)
Thickness mm Identification colour Thickness mm Identification colour
1.6 Brown 2.4 Blue
1.7 None 2.5 Brown
1.8 Blue 2.6 None
1.9 Brown 2.7 Blue
2.0 None 2.8 Brown
2.1 Blue 2.9 None
2.2 Brown 3.0 Blue
2.3 None
Snap ring (For adjustment of low-reverse brake and second brake reaction plates end play)
Thickness mm Identification colour Thickness mm Identification colour
2.2 None 2.4 Brown
2.3 Blue 2.5 None
Pressure plate (For adjustment of low-reverse brake and second brake end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
Snap ring (For adjustment of reverse clutch end play)
Thickness mm Identification colour Thickness mm Identification colour
1.6 None 2.3 Blue
1.7 Blue 2.4 Brown
1.8 Brown 2.5 None
1.9 None 2.6 Blue
2.0 Blue 2.7 Brown
2.1 Brown 2.8 None
2.2 None
Snap ring (For adjustment of reverse clutch and overdrive clutch spring retainer end plays)
Thickness mm Identification colour Thickness mm Identification colour
1.48 Brown 1.58 Blue
1.53 None 1.63 Brown
Thrust race (For adjustment of underdrive sun gear end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 − 2.2 −
1.7 − 2.3 −
1.8 − 2.4 −
AUTOMATIC TRANSMISSION OVERHAUL 23B-7
ADJUSTING PLATE, SNAP RING AND SPACERS
Item Specification
Transmission Roll stopper bracket 70 ± 10 N⋅m
Control cable support bracket 23 ± 3 N⋅m
Eye bolt 24 ± 3 N⋅m
Oil cooler feed tube 11 ± 1 N⋅m
Input shaft speed sensor 11 ± 1 N⋅m
Output shaft speed sensor 11 ± 1 N⋅m
Manual control lever 22 ± 3 N⋅m
Inhibitor switch 11 ± 1 N⋅m
Sealing cap <Type with sealing cap> 5.0 ± 1.0 N⋅m
Valve body cover 11 ± 1 N⋅m
Manual control shaft detente 6.0 ± 1.0 N⋅m
Valve body mounting bolt 11 ± 1 N⋅m
Fluid temperature sensor 11 ± 1 N⋅m
Torque converter housing 48 ± 6 N⋅m
Oil pump 29 ± 2 N⋅m
Rear cover 23 ± 3 N⋅m
Transfer drive gear 34 ± 2 N⋅m
Anchor plug 98 ± 15 N⋅m
Components Direct planetary carrier lock nut 170 ± 10 N⋅m
Differential drive gear 135 ± 5 N⋅m
Solenoid valve support 6.0 ± 1.0 N⋅m
Valve body 11 ± 1 N⋅m
Plate 6.0 ± 1.0 N⋅m
SEALANTS
M1233000500412
SPECIAL TOOL(S)
M1233000600572
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1233001000766
Apply automatic
transmission fluid 11 ± 1 N·m 11 ± 1 N·m 22 ± 3 N·m
to all moving parts
before installation. 8 23 ± 3 N·m
11 ± 1 N·m 9
3 10
24 ± 3 N·m
11 ± 1 N·m 5
7
5
<Type with sealing cap>
5.0 ± 1.0 N·m 24 ± 3 N·m
11
70 ± 10 N·m 6
12
4
2
1 2
70 ± 10 N·m
AK501919AB
29
14
31 6.0 ± 1.0 N·m
30
25
26
27
28
21
11 ± 1 N·m
20 16
18
19
24 23
17
22
11 ± 1 N·m
Apply automatic
transmission fluid 15
to all moving parts
before installation.
11 ± 1 N·m 13
11 ± 1 N·m
AK403264AC
44
45
39
98 ± 15 N·m
55 59 46
58 47
48
54 11 ± 1 N·m
50
35
57 52
56 53 34
49 33
51
42 43
41 36
40
38
37
29 ± 2 N·m
Apply automatic
transmission fluid
32 to all moving parts
before installation.
48 ± 6 N·m
AK502957AB
23 ± 3 N·m
Apply automatic
transmission fluid 60
to all moving parts 62
before installation.
61
64
65
63
66
68
70 67
69
71
72
73
74
AK403289AC
87
Apply automatic 85
transmission fluid
to all moving parts 89
before installation.
98 91
96
86
94 88
95
93
90
77
97 92
34 ± 2 N·m
75
76
83
78
80
79
81
82
84
AK403290AC
AK300220
Input shaft AK301061AB
8. Remove the sealing cap and O-ring. <Type with
2. Use a dial gauge to measure the input shaft end sealing cap>
play.
3. Remove control cable support bracket.
4. Remove the oil level gauge.
5. Remove the eye bolt, gaskets and the oil cooler
feed tube.
Output shaft
speed sensor
AK301296
AK202095AB
AUTOMATIC TRANSMISSION OVERHAUL 23B-19
TRANSMISSION
CAUTION
• Make sure that the manual control lever and
the inhibitor switch are removed. See step 7.
• Do not remove the bolts (four pieces) shown
in the illustration.
13.Remove the valve body mounting bolts (twenty
seven pieces).
Manual control
shaft detent
AK403612AD
CAUTION
Do not lose the two steel balls.
14.Remove the valve body, gasket and the steel
AK403609 AD balls (two pieces).
11.Remove the manual control shaft detent.
Snap ring
Connector
AK300227AC
Fluid temperature sensor AK403610AD 15.Remove the snap ring from the connector. Push
the connector into the transmission case and
12.Disconnect the solenoid valve harness from the
remove the solenoid valve harness.
valve body by disconnecting the fluid temperature
sensor and all the connectors.
Second brake
retainer oil seal
Strainer
AK300228 AC
1 2 3 4
AK300229AD AK202103
17.Remove each accumulator piston and spring. 21.Remove the torque converter housing mounting
Number Name bolts (twenty pieces), and then remove the torque
converter housing.
1 For low-reverse brake
2 For underdrive clutch
3 For second brake
4 For overdrive clutch
O-rings
AK300232 AB
AK301866
AK300234
AUTOMATIC TRANSMISSION OVERHAUL 23B-21
TRANSMISSION
Pipe
AK300237
AK202215 AB
31.Remove thrust washer #1.
AK300238
MD998333
AK300239
AK300236AD
33.Remove thrust bearing #2.
28.Place special tool Oil pump remover (MD998333)
as shown in the drawing.
29.Turn special tool Oil pump remover (MD998333)
to remove the oil pump.
30.Remove the oil pump gasket.
AK300240
AK202112 AK202113
35.Remove the reduction brake piston cover after 39.Remove the direct planetary carrier assembly.
removing the snap ring.
36.Remove the reduction brake piston and spring
after removing the snap ring.
Anchor plug
AK202114AB
AK300241
AK202116
AK300242
AK202117
AK202118
AK AD
AK300465
43.Remove the thrust bearing #11 and thrust race
#12. 50.Remove the reverse and overdrive clutch and
thrust bearing #7.
AK300463
AK202120
AK300467
Direct clutch
accumulator piston
AK202121AB
AK300468
49.Remove the direct clutch accumulator piston and
spring after removing the O-ring. 53.Remove the planetary reverse sun gear.
AUTOMATIC TRANSMISSION OVERHAUL 23B-24
TRANSMISSION
AK300469
AK300473
54.Remove the snap ring.
58.Remove the snap ring.
AK300470
AK300474
55.Remove the second brake piston and the return
spring. 59.Remove the reaction plate and the brake disc.
AK202266 AK300475
56.Remove the pressure plate, second brake discs 60.Remove the snap ring.
(four pieces) and second brake plates (three
pieces).
AK300476
AK300479
Bolt (Four)
AK300477
AK303642 AE
AK202139
AK202140
MD998412
O-ring
AK301748AC
Identification
notches
AK300491
Transmission case
A 8. Install the wave spring onto the low-reverse brake
piston.
A AK301091AB
MB991632
5. Check the placement of the identification notches
in the one-way clutch inner race. Install the one- AK303645 AE
way clutch inner race to the transfer drive gear
bearing so that the notches fall along the A − A 9. Install the brake discs (six pieces), brake plates
line. (five pieces) and snap ring as shown in the figure.
NOTE: Do not install the pressure plate at this
time.
MD999577
MD998924 10.Install special tool Clearance dummy plate
(MB991632) on the brake disc.
11.Install the reaction plate and the used snap ring.
12.Move special tool Clearance dummy plate
(MB991632) to measure the end play of reaction
plate. Then replace the snap ring installed in step
11 to adjust the end play to standard value.
AK202194 AC
Standard value: 0 − 0.16 mm
AK303646 AD
AKX01069AE
MB991632
MD998913
1.9 0
1.8 2.0 .1
1.7 .2
1.6 .3
1.5 .4
1.4 .5
1.3 .6
1.2 .7
1.1 .8
1.0 .9
Movement
amount
AK202295AB
MB991632
AK303648 AD
CAUTION
If necessary, take the measurements in steps 9 to
18 after replacing the pressure plate, brake plate
and brake disc.
20.Remove all parts and special tools that were
installed to take the measurements in steps 9 to
18. Remove and separate the pressure plate and
snap ring chosen in steps 12, 16 and 18.
AK300498
Needle bearing
25.Install the planetary carrier assembly.
0.5 – 1.5mm
Seal ring
AK202143 AB
Identification
mark
AK202144AB
AK202139
AK300671
AK300502
32.Install second brake discs (four pieces) and
29.Install the snap ring. second brake plates (three pieces), one on top of
the other. Next, install the pressure plate that was
selected in step 17.
AK301098
AK300504
31.Install the snap ring that was selected in step 12. AK300507
#8 #7 #6 #5 #4 #3 #2 #1
AK403273 AD
AUTOMATIC TRANSMISSION OVERHAUL 23B-32
TRANSMISSION
AK301100AB
AK403613AC
AUTOMATIC TRANSMISSION OVERHAUL 23B-33
TRANSMISSION
MB990938
AK300511AD AK202120
39.Use special tool Handle (MB990938) to tap the 42.Install the O-rings (six pieces).
input shaft rear bearing in the rear cover. 43.Select a thrust race #8 whose thickness
40.Install the seal rings (four pieces) in the grooves corresponds to the measured values taken in step
of the rear cover. 40 from the table below. Install it on thrust bearing
#7.
Measurement mm Thickness mm
Underdrive clutch hub
0.3 − 0.4 1.6
0.4 − 0.5 1.7
0.5 − 0.6 1.8
0.6 − 0.7 1.9
0.7 − 0.8 2.0
0.8 − 0.9 2.1
AK300512AC 0.9 − 1.0 2.2
41.Measure the end play of the under drive sun gear 1.0 − 1.1 2.3
by the following procedures: 1.1 − 1.2 2.4
(1) Install the thinnest thrust race #8 (thickness 1.2 − 1.3 2.5
1.6 mm) on thrust bearing #7.
1.3 − 1.4 2.6
(2) Install the rear cover on the transmission case
and tighten the bolts to the specified torque of
23 ± 3 N⋅m.
(3) Turn over the transmission case so that the
installation surface of the torque converter
housing is facing up.
(4) Install the under drive clutch hub on the under
drive sun gear.
(5) Measure end play of the underdrive sun gear
and record the measurement value.
Standard value (Reference): AK202161
0.25 − 0.45 mm
(6) After taking the measurement in steps (5), 44.Apply a 2 mm diameter bead of from-in-place
take out the installed parts in steps (1) through gasket (FIGP) to the illustrated position of the rear
(4). cover.
Specified sealant: Mitsubishi genuine seal-
ant Part No. MD974421 or equivalent
AUTOMATIC TRANSMISSION OVERHAUL 23B-34
TRANSMISSION
AK202119 AK202148
45.Install the rear cover, and tighten its mounting 48.Make sure that the direct clutch can be rotated
bolts to the specified torque of 23 ± 3 N⋅m. only in the direction indicated in the illustration.
NOTE: After installation, keep the sealed area NOTE: If the clutch can be rotated in the other
away from ATF for approximately one hour. direction, remove and reinstall it correctly.
Thrust
bearing #11 Install
with this
side down.
Thrust race #12
Anchor plug
AK202115AB
AK202162AB
49.Tighten the anchor plug to the specified torque of
CAUTION 98 ± 15 N⋅m.
Install the thrust bearing with the indicated side
facing down.
46.Install the thrust race #12 and thrust bearing #11.
AK202113
AK202164
AUTOMATIC TRANSMISSION OVERHAUL 23B-35
TRANSMISSION
MB991633 (Stopper)
AK202112
AK300513
MB991633 (Socket)
54.Install the parking pawl, spacer, and spring. Then
insert the parking pawl shaft.
AK202166AB
MB991633
(Wrench)
AK202167AB
MD998412
Install with this side down
AK301246AB
AK301247AD
CAUTION
Be sure to install the thrust bearing in the correct CAUTION
direction as shown. Never use a gasket that has been tightened.
57.Check the installation direction of thrust bearing 61.Use the special tool Guide (MD998412) to install
#2, and install it on the underdrive clutch hub. a new oil pump gasket and the oil pump.
62.Tighten the oil pump mounting bolts to the
specified torque of 29 ± 2 N⋅m.
AK300238
AK300234
AK300237
64.Install the oil filter.
AUTOMATIC TRANSMISSION OVERHAUL 23B-37
TRANSMISSION
MB990938
MB990936
AK202308 AB AK301252AC
65.Use the special tools to drive the differential 69.Apply an approx. 2 mm diameter bead of from-in-
bearing outer race into the transmission case. place gasket (FIGP) to the torque converter
• Installer adapter (MB990936) housing in the area shown.
• Handle (MB990938) Specified sealant: Mitsubishi genuine seal-
ant Part No. MD974421 or equivalent
O-rings
AK301866
AK300232 AB
66.Install the differential.
70.Install the O-rings (two pieces).
67.Adjustment of differential case preload and select
the spacer. (Refer to adjustment of transmission -
spacer selection for adjustment of differential case
preload P.23B-41)
MB991445
AK202103
AK300228 AC
AK202102
78.Install the strainer and second brake retainer oil
76.Install the piston and spring of the reduction brake seal.
accumulator, then install the accumulator cover.
Snap ring
1 2 3 4 Connector
AK300227AC
AK301313AC
79.Insert a new O-ring to the groove of the solenoid
valve harness connector.
80.Insert the solenoid valve harness connector into
the hole from the inside of the transmission case
so it is oriented as shown in the illustration. Then
secure the snap ring to the connector groove.
1 2 3 4
AK300229AD
AUTOMATIC TRANSMISSION OVERHAUL 23B-39
TRANSMISSION
Manual control
shaft detent
AK403609 AD
AK403611
86.Install the manual control shaft detent and tighten
83.Install the valve body mounting bolts (twenty the bolt to the specified torque of 6.0 ± 1.0 N⋅m.
seven pieces), and tighten to the specified torque
of 11 ± 1 N⋅m.
2 1
2.4 – 2.6 mm
3 4
6 5
AK301264AE
AK501914 AK202096 AB
88.Install the valve body cover, and then tighten its 91.Install the inhibitor switch and tighten the bolt to
mounting bolts to the specified torque of 11 ± 1 the specified torque of 11 ± 1 N⋅m.
N⋅m. 92.Install the manual control lever and tighten the nut
to the specified torque of 22 ± 3 N⋅m.
Output shaft
speed sensor
B A B A
Input shaft
speed sensor
AK203140 AE
AK202095AB
89.Press Face "A" of the air breather to be on the
same plane as the Face "B" of the transmission 93.Install the input shaft speed sensor and output
case as shown in the illustration. shaft speed sensor and tighten the bolt to the
specified torque of 11 ± 1 N⋅m.
MD998412
AK301263AC AK301247AB
CAUTION CAUTION
Apply ATF to the oil pump drive hub before Never use a gasket that has been tightened.
installing the torque converter. Be careful not to 3. Use the special tool Guide (MD998412) to install a
damage the oil seal lip when installing the torque new oil pump gasket and the oil pump. Tighten the
converter. oil pump mounting bolts to the specified torque of
100.Install the torque converter, and align it with the 29 ± 2 N⋅m.
oil pump so that the shown dimension "A" meets 4. Remove the oil pump mounting bolts.
the reference value.
Reference value: Approximately 9.4 mm
MD998333
ADJUSTMENT OF TRANSMISSION
M1233030400098
Input shaft
Two beads
of solder
AK301249
Underdrive
clutch retainer AK301756AC 7. Use a micrometer to measure the thickness of the
crushed solder beads and record the measured
1. Put the solders (1.0 mm diameter, about 10 mm value.
long) in the illustrated positions of the underdrive 8. Select the thrust washer, calculated by the
clutch retainer. following formula, in the table.
2. Install the adjusting thrust washer having T = T1 + T2
minimum thickness. T: Clearance mm
T1: The crushed solder thickness mm
AUTOMATIC TRANSMISSION OVERHAUL 23B-42
TRANSMISSION
T2: The thrust washer thickness used for 4. Remove the oil pump mounting bolts.
measurement mm
Available thrust washer
MD998333
Clearance mm Thickness mm Identification
(T) mark
2.25 − 2.45 1.8 18
2.45 − 2.65 2.0 20
2.65 − 2.85 2.2 22
2.85 − 3.05 2.4 24
3.05 − 3.25 2.6 26 AK300236AC
Underdrive
clutch retainer AK301756AE Plastigage
3. Use the special tool Guide (MD998412) to install a 2.65 − 2.85 2.2 22
new oil pump gasket and the oil pump. Tighten the 2.85 − 3.05 2.4 24
oil pump mounting bolts to the specified torque of 3.05 − 3.25 2.6 26
29 ± 2 N⋅m.
3.25 − 3.45 2.8 28
AUTOMATIC TRANSMISSION OVERHAUL 23B-43
TRANSMISSION
SPACER SELECTION FOR ADJUST- 3. Install the converter housing on the transmission
MENT OF DIFFERENTIAL CASE case without applying FIPG. Tighten the mounting
bolts to the specified torque of 48 ± 6 N⋅m.
PRELOAD
4. Remove the bolts and converter housing, and
<Measurement using Solder>
take out the solder pieces.
CAUTION 5. If the solders have not crushed, use thicker the
• If the solder is not available, select the spacer solders (1.6 mm diameter, about 10 mm long) and
in accordance with Plastigage method. repeat steps 2 to 4.
• If the spacer appropriate for the standard
value cannot be selected using the solder,
select the spacer in accordance with Plasti-
gage method.
Two beads
of solder
AK301249
Plastigage
AK202226 AB
AK202103
AUTOMATIC TRANSMISSION OVERHAUL 23B-44
TRANSMISSION
AK202226 AB
Plastigage
Spacer AK402081 AB
OIL PUMP
DISASSEMBLY AND REASSEMBLY
M1233001300325
Apply automatic
transmission fluid
to all moving parts 4
before installation.
3 2
1
AK301599 AC
Disassembly steps 1. Apply a small amount of ATF to the oil seal lip.
>>B<< 1. O-ring 2. Use special tool OIl installer (MD998334) to tap
2. Seal ring the oil seal in the oil pump body.
>>A<< 3. Oil seal
4. Oil pump assembly >>B<< O-RING INSTALLATION
Install a new O-ring to the outer groove of the oil
pump, and apply ATF or petroleum jelly (Vaseline) to
REASSEMBLY SERVICE POINTS the O-ring.
>>A<< OIL SEAL INSTALLATION
MD998334
AK300522AD
AUTOMATIC TRANSMISSION OVERHAUL 23B-46
UNDERDRIVE CLUTCH AND INPUT SHAFT
13 6 9
12 13 11
14 8 12
14
15
1
3 9
11 2 8
15 5
10 7 4 10
6
3
4
5
Apply automatic
transmission fluid 7
to all moving parts
before installation.
AK301600AC
1. Place the snap ring on top of the spring retainer, 2. Install the clutch reaction plate in the direction
and then set special tool as shown in the shown.
illustration. Install it the same as the clutch plates, so that the
• Spring compressor (MD998907) areas with no teeth (marked "A") are aligned with
• Spring compressor retainer (MD998924) the retainer (marked "B").
2. Compress the return spring and install the snap
ring. >>D<< SNAP RING INSTALLATION
MB991629
AK202311 AB
Apply automatic
transmission fluid
to all moving parts 8
before installation.
6
5
4
1 2 9
12 17
3 7 15 7
5 3
19
18 20
13
10 16 19
20
11 14
13
10 18
16 11 15
1 14 12 17
8
2 6 9
AKX01127 AE
DISASSEMBLY SERVICE POINT Align the outer circumference holes ("A" and "B") of
<<A>> SNAP RING REMOVAL the reverse clutch piston and the reverse clutch
retainer to assemble them.
MD998924
MD999590 >>C<< SNAP RING INSTALLATION
MD998924
MD999590
AK300525AD
D-ring AK301765 AC
AK300526
1. Install D-rings in the grooves on the reverse clutch
retainer, piston, overdrive clutch piston and spring 3. Check that the clearance between the snap ring
retainer. Be careful not to twist or damage the D- and the return spring retainer is within the
rings. standard value. If not within the standard value,
2. Apply ATF or petroleum jelly (Vaseline) to D-rings. select a snap ring to achieve the standard value
clearance.
>>B<< REVERSE CLUTCH PISTON Standard value: 0 − 0.09 mm
INSTALLATION
B
A
AK301276AB
AUTOMATIC TRANSMISSION OVERHAUL 23B-50
REVERSE AND OVERDRIVE CLUTCH
>>D<< PRESSURE PLATE/CLUTCH PLATE/ 2. Set special tools as shown in the illustration, and
CLUTCH DISC/CLUTCH REACTION PLATE compress the clutch element.
INSTALLATION • Spring compressor (MB991629)
• Spring compressor retainer (MD998924)
Shear droop
3. Check that the clearance between the snap ring
and the clutch reaction plate is within the standard
Clutch value. If not within the standard value, select a
Clutch reaction
plates plate snap ring to achieve the standard value
clearance.
Standard value: 1.6 − 1.8 mm
Pressure
plate >>F<< CLUTCH PLATE/CLUTCH DISC/CLUTCH
Clutch discs AK303676AD
REACTION PLATE INSTALLATION
A B
A B
AK301272AB
AK301272AB
MD998924
>>G<< SNAP RING INSTALLATION 1. Install the snap ring into the groove of reverse
clutch retainer.
MB991789 2. Set special tools as shown in the illustration, and
MD998924
compress the clutch element.
• Spring compressor (MB991789)
• Spring compressor retainer (MD998924)
3. Check that the clearance between the snap ring
and the clutch reaction plate is within the standard
value. If not within the standard value, select a
snap ring to achieve the standard value
AK300528AE clearance.
Standard value: 1.5 − 1.7 mm
DIRECT CLUTCH
DISASSEMBLY AND REASSEMBLY
M1233019400071
Apply automatic 6
transmission fluid 5
to all moving parts 4
before installation.
1
2
9 13
3 12
7
3
14
11
13
14 10
11 12
8 8
1 4 6 10 7
2 5 9
AK403291 AC
MB991630 MD998924
AK202175 AC
CAUTION
Immerse the clutch disc in ATF before assem-
Snap ring bling it. If the clutch disc is new, soak it in ATF for
at least two hours.
AK202174 AB
1. Assemble the intermediate plate, cushion plate,
1. Set special tools as shown in the illustration. clutch plates, clutch discs, and clutch reaction
• Spring compressor (MB991630)
plates with their non-toothed portions (A in the
• Spring compressor retainer (MB998924)
illustration) aligned with the hole (B in the
2. Compress the return spring and remove the snap illustration) formed in a crest of the direct clutch
ring. retainer.
AK202176 AB
Apply automatic
transmission fluid
to all moving parts
before installation.
6
8
4 9
3
7 10
1
AK301602 AC
AK301280AB
AK300529AC
LOW-REVERSE BRAKE
DISASSEMBLY AND REASSEMBLY
M1233003700307
Apply automatic
transmission fluid
to all moving parts
before installation.
3
1
AK301603 AC
SECOND BRAKE
DISASSEMBLY AND REASSEMBLY
M1233021800173
Apply automatic
transmission fluid
to all moving parts
before installation.
3 2
4
AK301604 AC
Apply automatic
transmission fluid
to all moving parts
before installation.
8 10
5
4
2
9
3
1
170 ± 10 N·m
AK403295 AC
MD998917
AK202179 AB
AK202182 AB
2. Using special tool Special spanner (MD998834) to
remove the lock nut. 1. Support the transfer driven gear as shown in the
illustration.
<<B>> OUTPUT GEAR/PARKING GEAR 2. Using special tool Bearing remover (MD998917)
REMOVAL to remove the taper roller bearing.
MD998812
MD998813
MD998824
AK202180 AB
AK202184 AC
2. Using special tools to press in the taper roller >>D<< LOCK NUT INSTALLATION
bearing.
• Installer cap (MD998812)
MD998834
• Installer 100 (MD998813)
• Installer adapter (MD998824)
MD998812
MD998824 AK202186 AB
AK202185 AC
AK202187
DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
M1233003100402
Apply automatic 2
transmission fluid
to all moving parts
before installation.
4
6 8
3 5
8
135 ± 5 N·m
7 1
2 5
AK301606AE
AK301767AB
REASSEMBLY SERVICE POINTS 5. If the backlash is out of the standard value, select
>>A<< SPACER/SIDE GEAR/WASHER/PINION/ a spacer and re-measure the backlash.
PINION SHAFT INSTALLATION NOTE: Adjust until the backlash on both sides are
equal.
Differential case
Lock pin
Pinion shaft
AK300655
AK300658 AC
8 9
4 7
6 5
8 3
10 1
AK300657
AK300659 AC
4. Measure the backlash between the side gear and Apply ATF to the bolts, and tighten the bolts to the
pinion. specified torque of 135 ± 5 N⋅m in the shown
Standard value: sequence.
0.025 − 0.150 mm
AUTOMATIC TRANSMISSION OVERHAUL 23B-62
VALVE BODY
VALVE BODY
DISASSEMBLY AND REASSEMBLY
M1233005500365
20 22
21
1 6.0 ± 1.0 N·m
18
19 2
10
14 11
16
17
13 14
3
8
12 4
5
6
11 ± 1 N·m
9
11 ± 1 N·m
1 7
6.0 ± 1.0 N·m
AK501912AB
Apply automatic
transmission fluid
to all moving parts
before installation.
36
37 59
38
60 63
43 39
61
40 62
64
65 67
41 66
42 68
26 47
23 25 69
46
24 30 45
51
50 70
29 49
27 44 55
28
54
35 53
34 48
33 58
31
32 52 57 56
AK403293 AD
Apply automatic 1
transmission fluid
to all moving parts
before installation.
AK403296 AC
Apply automatic 4
transmission fluid
to all moving parts 3
before installation.
AK403292 AC
AK301290AB
>>B<< OIL SEAL INSTALLATION Use the special tool Oil seal installer (MD998800) to
install the oil seal.
MD998800
AK300549AC
AUTOMATIC TRANSMISSION OVERHAUL 23B-68
DRIVE SHAFT OIL SEAL
HOME
26-1
GROUP 26
FRONT AXLE
CONTENTS
GENERAL DESCRIPTION
M1261000100370
The front axle consists of front hubs, knuckles, wheel • Due to the use of the inner shaft and bracket
bearings and drive shafts, and has the following fea- assembly, the right and left drive shafts are
tures: approximately the same in length. This reduces
• The wheel bearing incorporates double-row noise, vibration and torque steer.L-RH>
angular contact ball bearing for reduced friction. • The dynamic damper is mounted on the LH drive-
• The front wheel hub assembly combines the hub, shaft.
wheel bearing, and oil seal in a single unit for • ABS rotor for detecting the wheel speed is
fewer parts, better durability, improved assembly press-fitted to the BJ.
precision, and better structural organization. NOTE: .
• The driveshaft incorporates BJ-PTJ type constant • TJ: Tripod Joint
velocity joints with high transmission efficiency for • PTJ: Pillow Tripod Joint
low vibration and noise. • BJ: Birfield Joint
CONSTRUCTION DIAGRAM
STRUT ASSEMBLY
KNUCKLE
PTJ (LH) <3.8L>
FRONT WHEEL
HUB ASSEMBLY DRIVE SHAFT
(LH)
DYNAMIC
BJ
DAMPER
ABS ROTOR
<L-RH>
2. Verify that the condition described by the 3. Find the malfunction by following the Symptom
customer exists. Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1261005700269
SYMPTOM PROCEDURES
DIAGNOSIS
AC102438
STEP 2. Check the drive shaft and inner shaft for bending.
Q: Is the drive shaft and inner shaft bent?
YES : Replace the part. Then go to Step 5.
NO : Go to step 3.
SPECIAL TOOLS
M1261000600405
MB991618
MB991354
MB990326
MB991248
MB991561
MB990890
FRONT AXLE 26-7
SPECIAL TOOLS
MB990925
A MB990926 39.0 (1.54)
MB990927 45.0 (1.77)
MB990928 49.5 (1.95)
MB990929 51.0 (2.00)
MB990930 54.0 (2.13)
A
INSTALLER ADAPTER MB990931 57.0 (2.24)
MB990932 61.0 (2.40)
C BRASS BAR MB990933 63.5 (2.50)
MB990934 67.5 (2.66)
B
MB990935 71.5 (2.81)
BAR (SNAP-IN TYPE) MB990936 75.5 (2.97)
MB990937 79.0 (3.11)
B MB990938 −
C MB990939 −
TOOL BOX
ACX02372 AC
FRONT AXLE 26-8
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
WHEEL BEARING END PLAY CHECK
M1261000900246
1. Remove the caliper assembly and suspend it with a wire.
2. Remove the brake disc from the front hub.
3. Attach a dial gauge as shown in the illustration, and then
measure the end play while moving the hub in the axial
direction.
Limit: 0.05 mm (0.002 inch)
4. If end 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 specified torque.
AC102438 Tightening torque: 100 ± 10 N⋅m (74 ± 7 ft-lb)
HUB BOLT
AC302114 AE
4. Install the plain washer to the new hub bolt, and install the
bolt with a nut while holding the hub with special tool
MB990767 MB990767.
PLAIN 5. Install the brake disc, caliper assembly and tighten the
WASHER caliper assembly mounting bolts to the specified torque.
Tightening torque: 100 ± 10 N⋅m (74 ± 7 ft-lb)
AC102440AC
FRONT AXLE 26-9
FRONT AXLE HUB ASSEMBLY
CAUTION
• For vehicles with ABS, 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.
• For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
Post-installation Operation
Check the dust cover for cracks or damage by pushing it with
your finger.
305 ± 25 N·m
225 ± 18 ft-lb
65 ± 6 N·m
29 ± 4 N·m
48 ± 4ft-lb
21 ± 3 ft-lb
4
12 N
14
15
13 N
9.0 ± 2.0 N·m
9 5 80 ± 17 in-lb
100 ± 10 N·m
74 ± 7 ft-lb 10 8
90 ± 10 N·m
67 ± 7 ft-lb 3
N1
6
11
7
226 ± 29 N·m 2
167 ± 21 ft-lb
AC305336 AB
MB990767
AC102462 AC
BOLTS
(M8×1.25)
AC205799AB
.
FRONT AXLE 26-11
FRONT AXLE HUB ASSEMBLY
NUT MB991897
BOLT
BALL JOINT AC208247AC
WRONG AC106821AC
MB991354
MB990242
AC201827AD
FRONT AXLE 26-12
FRONT AXLE HUB ASSEMBLY
MB990211
MB991354
AC210309AD
MB990767
AC210244AB
INSPECTION
M1261001800264
AC301927AE
FRONT AXLE 26-13
DRIVE SHAFT ASSEMBLY
AC206090AB
CAUTION
• For vehicles with ABS, 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.
• For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
N 11 <LH>
9
8N 29 ± 4 N·m
21 ± 3 ft-lb
6 4
5
41 ± 4 N·m
30 ± 3 ft-lb 3 2 1N
<RH>
10
226 ± 29 N·m
110 ± 10 N·m 167 ± 21 ft-lb
22DB014A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. SPLIT PIN <<C>> >>A<< 10. DRIVE SHAFT AND INNER
<<A>> >>B<< 2. DRIVE SHAFT NUT SHAFT ASSEMBLY RH
3. WASHER 11. CIRCLIP
4. FRONT WHEEL SPEED SENSOR Required Special Tools:
BRACKET <VEHICLES WITH • MB990767: Front Hub and Flange Yoke Holder
ABS>
• MB991897: Ball Joint Remover
5. FRONT WHEEL SPEED SENSOR
<VEHICLES WITH ABS>
• MB990242: Puller Shaft Puller
6. BRAKE HOSE BRACKET • MB990244: Puller Bar
<<B>> 7. SELF LOCKING NUT (LOWER • MB991354: Puller Body
ARM BALL JOINT CONNECTION) • MB990998: Front Hub Remover and Installer
<<B>> 8. SELF LOCKING NUT (TIE ROD • MB991000: Spacer
END CONNECTION)
<<C>> >>A<< 9. DRIVE SHAFT
FRONT AXLE 26-15
DRIVE SHAFT ASSEMBLY
MB990767
AC102462 AC
NUT MB991897
BOLT
BALL JOINT AC208247AC
WRONG AC106821AC
.
FRONT AXLE 26-16
DRIVE SHAFT ASSEMBLY
MB990244
(THREE)
MB990242 MB991354
AC102550 AC
2. Remove the drive shaft from the hub by pulling the bottom of
the brake disc towards you.
DRIVE
SHAFT
AC102551AD
CAUTION
• Do not pull on the drive shaft; doing so will damage the
PTJ; be sure to use the pry bar.
• When pulling the drive shaft out from the transaxle, be
careful that the spline part of the drive shaft does not
damage the oil seal.
3. Insert a pry bar between the transaxle case and the drive
TRANSAXLE shaft, and then pry and remove the drive shaft from the
transaxle.
NOTE: Insert a pry bar, taking care not to damage the pro-
trusion of transaxle case when removing the drive shaft LH.
PTJ ASSEMBLY
PRY BAR
AC305799 AB
FRONT AXLE 26-17
DRIVE SHAFT ASSEMBLY
AC102553 AC
CAUTION
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
MB991000
the bearing to move the vehicle, temporarily secure the
MB990998 wheel bearing by using special tools MB991000 and
MB990998.
AC210315AE
CAUTION
• For vehicles with ABS, 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.
19
12 8 21
10 22
9 20
2 N 1N
15 <RH>
14
13
BEARING DUST SEAL 4
REPAIR KIT <LH> 3
12 N
12
8
6
8N 5
6
11
10
11 9N
10 7
9
BRACKET ASSEMBLY
REPAIR KIT
15 21 GREASE
2 1 22 FOR PTJ
15 14 GREASE
20 FOR BJ
13 2 13 4 2 1
1
12 12 12
4 13
PTJ BOOT REPAIR KIT PTJ REPAIR KIT BJ BOOT REPAIR KIT
22DB016A
DISASSEMBLY STEPS DISASSEMBLY STEPS
>>G<< 1. PTJ BOOT BAND (LARGE) 11. CENTER BEARING BRACKET RH
>>G<< 2. PTJ BOOT BAND (SMALL) 12. CIRCLIP
3. PTJ CASE AND INNER SHAFT 13. SNAP RING
ASSEMBLY RH <<A>> >>B<< 14. SPIDER ASSEMBLY
<<A>> >>F<< 4. PTJ CASE <<D>> >>A<< 15. PTJ BOOT
<<B>> >>E<< 5. INNER SHAFT RH 19. BJ ASSEMBLY
6. DUST COVER RH 20. BJ BOOT BAND (SMALL)
7. BRACKET ASSEMBLY RH 21. BJ BOOT BAND (LARGE)
>>D<< 8. DUST SEAL OUTER RH 22. BJ BOOT
>>D<< 9. DUST SEAL INNER RH NOTE: .
<<C>> >>C<< 10. CENTER BEARING RH • PTJ: Pillow Tripod Joint
FRONT AXLE 26-19
DRIVE SHAFT ASSEMBLY
LUBRICATION POINTS
14 10
GREASE: REPAIR KIT GREASE GREASE: REPAIR KIT GREASE
22DB017A
FRONT AXLE 26-21
DRIVE SHAFT ASSEMBLY
MB991248
PTJ CASE
BAR
PTJ CASE
MB991248
AC205845 AB
AC205846AB
.
FRONT AXLE 26-22
DRIVE SHAFT ASSEMBLY
AC101695 AF
AC102654AC
AC101696 AC
MB990938
MB990934
DUST SEAL
OUTER
MB990890
AC101697AC
MB991172
AC101698 AC
AC205847 2. Apply repair kit grease to the inner shaft spline, then press fit
it into the PTJ case.
INNER SHAFT NOTE: When press-fitting the inner shaft into the PTJ case,
apply a thin coat of repair kit grease to the dust seal outer lip
part and the outside edge of the PTJ axial part.
PTJ CASE
AC305786 AB
.
FRONT AXLE 26-25
DRIVE SHAFT ASSEMBLY
AC102656 AC
AC102657AC
INSPECTION
M1261003800163
• Check the drive shaft for damage, bending or corrosion.
• Check the inner 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.
• Check the spider assembly for roller rotation, wear or corro-
sion.
• Check the groove inside PTJ case for wear or corrosion.
• Check the boots for deterioration, damage or cracking.
• Check the center bearing for seizure, discoloration or
roughness of rolling surface.
• Check the dust cover for damage or deterioration.
FRONT AXLE 26-26
DRIVE SHAFT ASSEMBLY
BJ BOOT REPLACEMENT
M1261005200394
AC102658
4. Align the center groove on the BJ boot small end with the
shaft groove.
AC102659
BOOT BAND
(SMALL)
PROJECTION AC102661AC
FRONT AXLE 26-27
DRIVE SHAFT ASSEMBLY
CAUTION
• Secure the drive shaft in an upright position and clamp
part of the boot band to be crimped securely in the jaws
of special tool MB991561.
• Crimp the boot band until the special tool touches the
stopper.
7. Use special tool MB991561 to crimp the boot band (small).
MB991561
AC102663 AC
11.Align the center groove on the BJ boot big end with the BJ
case groove.
AC102664 AC
BOOT BAND
(LARGE)
BOOT E
AC102665AC
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1261005400309
ITEM SPECIFICATION
Caliper assembly bolt 100 ± 10 N⋅m (74 ± 7 ft-lb)
Center bearing bracket bolt 41± 4 N⋅m (30 ± 3 ft-lb)
Drive shaft nut 226 ± 29 N⋅m (167 ± 21 ft-lb)
Dust cover bolt 9.0 ± 2.0 N⋅m (80 ± 17 in-lb)
Front strut nut 305 ± 25 N⋅m (225 ± 18 ft-lb)
Front wheel hub bolt 90 ± 10 N⋅m (67 ± 7 ft-lb)
Self-locking nut (lower arm ball joint connection) 65 ± 6 N⋅m (48 ± 4 ft-lb)
Self-locking nut (tie rod end connection) 29 ± 4 N⋅m (21 ± 3 ft-lb)
GENERAL SPECIFICATIONS
M1261000200311
ITEM SPECIFICATION
Wheel bearing Type Unit ball bearing (Double-row angular contact ball
bearing)
Drive shaft Joint type Outer Birfield joint
Inner Pillow Tripod joint
SERVICE SPECIFICATIONS
M1261000300426
LUBRICANTS
M1261000400412
GROUP 27
REAR AXLE
CONTENTS
GENERAL DESCRIPTION
M1271000100326
The rear axle has the following features: • The rear wheel hub assembly combines the hub,
• The wheel bearing incorporates a unit ball bear- wheel bearing, and oil seal in a single unit for
ing (double-row angular contact ball bearing) for fewer parts, better durability, improved assembly
reduced friction. precision, and better structural organization.
• ABS rotor for detecting the wheel speeds is
press-fitted to the rear hub.
CONSTRUCTION DIAGRAM
ABS ROTOR
REAR HUB
OIL SEAL
WHEEL BEARING
AC305169 AB
SYMPTOM PROCEDURES
M1271004400222
DIAGNOSIS
AC205869AB
SPECIAL TOOLS
M1271000600525
B990767
MB991618
ON-VEHICLE SERVICE
WHEEL BEARING END PLAY CHECK
M1271000900474
1. Remove the caliper assembly, and suspend the caliper
assembly with a wire and remove the brake disc.
2. Check the bearing's end play. Place a dial gauge against the
hub surface; then move the hub in the axial direction and
check whether or not there is end play.
Limit: 0.05 mm (0.002 inch)
3. If the play exceeds the limit, replace the rear hub assembly.
4. After having finished the inspection, install the brake disc,
caliper assembly and tighten the caliper assembly mounting
bolts to the specified torque.
AC205869AB
Tightening torque: 60 ± 5 N⋅m (45 ± 3 ft-lb)
REAR AXLE 27-5
ON-VEHICLE SERVICE
HUB BOLT
AC302114 AE
3. Install the plain washer to the new hub bolt, and install the
bolt with a nut while holding the hub with special tool
MB990767.
4. Install the brake disc, caliper assembly and tighten the
PLAIN
WASHER
caliper assembly mounting bolts to the specified torque.
Tightening torque: 60 ± 5 N⋅m (45 ± 3 ft-lb)
MB990767
AC205872 AB
REAR AXLE 27-6
REAR AXLE HUB ASSEMBLY
CAUTION
• For vehicles with ABS, be careful not to strike the pole piece at the tip of the rear wheel speed sen-
sor with tools during servicing work.
• The rear hub assembly should not be dismantled.
60 ± 5 N·m
45 ± 3 ft-lb
73 ± 7 N·m
54 ± 5 ft-lb
6 4
2 1
AC305548 AB
BOLTS
(M8 × 1.25)
AC205986AB
.
REAR AXLE 27-7
REAR AXLE HUB ASSEMBLY
AC305547AB
INSPECTION
M1271002100270
OIL SEALS
• Check the ABS rotor for chipped teeth.
ABS ROTOR
AC305554 AB
REAR AXLE 27-8
KNUCKLE
KNUCKLE
REMOVAL AND INSTALLATION
M1271003000191
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in the unladen condition.
Pre-removal Operation Post-installation Operation
• Rear Axle Hub Assembly Removal (Refer to P.27-6). • Check the ball joint dust cover for cracks or damage by
• Parking Brake Assembly Removal (Refer to GROUP 36, pushing it with your finger.
Parking Brake Lining and Drum P.36-8). • Parking Brake Assembly Installation (Refer to GROUP
36, Parking Brake Lining and Drum P.36-8).
• Rear Axle Hub Assembly Installation (Refer to P.27-6).
5N
113 ± 12 N·m*
66 ± 6 N·m 83 ± 9 ft-lb*
49 ± 4 ft-lb
2N 7
100 ± 10 N·m
74 ± 7 ft-lb
6
113 ± 12 N·m*
83 ± 9 ft-lb*
113 ± 12 N·m*
N1 83 ± 9 ft-lb*
4N
AC308327 AB
NUT MB991897
BOLT
BALL JOINT AC208247AC
2. After turning the bolt and knob to adjust the arms of special
tool MB991897 in parallel, tighten the bolt by hand and
BOLT
confirm that the arms are parallel.
PARALLEL NOTE: When adjusting the arms in parallel, turn the knob in
the direction shown in the figure.
CORRECT
3. Tighten the bolt with a wrench to disconnect the ball joint
KNOB and remove the self locking nut.
WRONG AC106821AC
INSPECTION
M1271003100143
Check the knuckle for wear or cracks.
REAR AXLE 27-10
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1271004000332
ITEM SPECIFICATION
Knuckle Lower arm assembly to knuckle nut 113 ± 12 N⋅m (83 ± 9 ft-lb)
Shock absorber assembly to knuckle 100 ± 10 N⋅m (74 ± 7 ft-lb)
bolt
Self locking nut (toe control arm 66 ± 6 N⋅m (49 ± 4 ft-lb)
connection)
Trailing arm assembly to knuckle nut 113 ± 12 N⋅m (83 ± 9 ft-lb)
Upper arm assembly to knuckle nut 113 ± 12 N⋅m (83 ± 9 ft-lb)
Rear axle hub assembly Brake caliper assembly bolt 60 ± 5 N⋅m (45 ± 3 ft-lb)
Rear hub assembly bolt 73 ± 7 N⋅m (54 ± 5 ft-lb)
SERVICE SPECIFICATIONS
M1271000300502
ITEM LIMIT
Wheel bearing end play mm (in) 0.05 (0.002)
Rear hub rotary-sliding resistance N (lb) 24 (5.4)
HOME
31-1
GROUP 31
ACX00925AB
ACX00926AB
ACX00930AB
ACX00931AB
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 33, On-vehicle
suspension Service − Front
alignment. Wheel Alignment
Check and
ACX00934
Adjustment P.33-6.
WING NUT
SPRING PLATE
WHEEL AC000041AB
MOUNTING STANDARD PASSENGER
CONE CAR WHEEL
<Confirming Proper Balance> 2. Turn the wheel again 180 degrees against the
1. After balancing the wheel, loosen the wing nut balancer's hub. If the wheel becomes
and turn the wheel 180 degrees against the out-of-balance each time it is turned against the
balancer's hub. Then re-tighten the wing nut and balancer's hub, the wheel balancer may require
check the balance again. Repeat wheel balance if calibration.
necessary.
<Wheel Balancer Calibration Checks> 3. Loosen the balancer wing nut, rotate the wheel
1. Mount an undamaged original-equipment alloy 1/4 turn (90 degrees), and retighten the nut.
rim and tyre assembly (wheel) onto your Recheck the wheel balance.
off-the-car wheel balancer. Balance the wheel. • If the imbalance is 5 g (0.18 ounce) or less, the
2. <<Zero Calibration Check>> wheel may not be centered on the balancer, or
the balancing cones, the cup, and/or wing nut are
Loosen the balancer wing nut, rotate the wheel a damaged, dirty, or inappropriate for the wheel.
half-turn (180 degrees), and retighten the nut. You may need to refer to the balancer manufac-
Recheck the balance. turer's instructions to verify the correct attach-
• If the imbalance is 5 g (0.18 ounce) or less, the ments. After making the necessary corrections,
zero calibration is OK. Rebalance the wheel, then recheck the wheel balance. If OK, then go to Step
go to Step 4 to check static balance. 4.
• If the imbalance is more than 5 g (0.18 ounce), go • If the imbalance is more than 5 g (0.18 ounce),
to Step 3. the balancer requires calibration. Contact the bal-
ancer manufacturer for calibration by their repair
representative.
WHEEL AND TYRE 31-5
WHEEL AND TYRE DIAGNOSIS
Balance wheel.
ZERO CALIBRATION
Rotate wheel 1/2 turn. CHECK
Rebalance wheel.
Rotate wheel 1/4 turn.
YES NO
DYNAMIC BALANCE
Attach a 5-g (0.18-oz) weight to the inner rim at 180
CHECK
degrees opposite the weight on the outer rim.
Is the imbalance 5 ± 2 g (0.18 ± 0.06 oz) at 170 –
190 degrees away from both 5-g (0.18-oz) weights?
YES NO
AC000040 AD
WHEEL AND TYRE 31-7
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK
M1311000900323
NOTE: For information on tyre inflation pressure, refer to the
label attached to the center pillar on the driver's side.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATION
M1311001600295
ITEM SPECIFICATION
Wheel nut 98 ± 10 N⋅m (73 ± 7 ft-lb)
GENERAL SPECIFICATIONS
M1311000200324
.
ITEM LIMIT
Tread depth of tyre mm (in) Minimum 1.6 (0.06)
Wheel runout Radial runout mm (in) 1.0 (0.04) or less
<Aluminum wheel> Lateral runout mm (in) 1.0 (0.04) or less
Wheel runout Radial runout mm (in) 1.2 (0.05) or less
<Steel wheel> Lateral runout mm (in) 1.2 (0.05) or less
WHEEL AND TYRE 31-9
SPECIFICATIONS
NOTES
HOME
32-1
GROUP 32
POWER PLANT
MOUNT
CONTENTS
GENERAL DESCRIPTION
M1321000100373
• The engine front mounting bracket is a • The liquid-filled transaxle mounting body side
dome-shaped fluid-filled mount for improved bracket improves riding comfort by its refined
responsiveness during acceleration and more insulator.
stable vehicle performance against road distur- • A roll stopper bracket in the upper area limits
bances. engine rolling. Furthermore, large diameter insu-
lator reduces idle vibration.
CONSTRUCTION DIAGRAM
TRANSAXLE MOUNTING
BODY SIDE BRACKET
ENGINE FRONT
MOUNTING
BRACKET
ENGINE REAR
ROLL STOPPER
BRACKET
ENGINE FRONT
ROLL STOPPER FRONT AXLE NO.1
BRACKET CROSSMEMBER
CENTERMEMBER
21DB021A
POWER PLANT MOUNT 32-3
SPECIAL TOOL
SPECIAL TOOL
M1321000600390
ENGINE MOUNTING
REMOVAL AND INSTALLATION
M1321001100462
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.
Pre-removal Operation
Raise the engine and transaxle assembly until its weight is
not applied to the insulator, and support it securely.
36 ± 6 N·m
5 ± 1 N·m 27 ± 4 ft-lb
108 ± 10 N·m*
3 ± 0.5 ft-lb 80 ± 9 ft-lb*
7 108 ± 10 N·m*
80 ± 9 ft-lb*
N 4
6
108 ± 10 N·m*
80 ± 9 ft-lb*
5
3
21DB014A
TRANSAXLE MOUNTING
REMOVAL AND INSTALLATION
M1321001400452
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.
Pre-removal Operation Post-installation Operation
• Engine Control Unit (ECU) , Refer to GROUP 13B, • Engine Rear Roll Stopper Bracket Installation (Refer to
Engine Control Unit (ECU) 13A-675). P.32-7).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Centremember Installation (Refer to P.32-7).
P.15-4). • Battery and Battery Tray Installation
• Battery and Battery Tray Removal • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Centremember Removal (Refer to P.32-7). P.15-4).
• Engine Rear Roll Stopper Bracket Removal (Refer to • Engine Control Unit (ECU) Installation, Refer to GROUP
P.32-7). 13B, Engine Control Unit (ECU) 13A-675).
• Raise the engine and transaxle assembly until its weight
is not applied to the insulator, and support it securely.
83 ± 12 N·m*
61 ± 9 ft-lb*
83 ± 12N·m*
1N 61 ± 5 ft-lb*
2
3
21DB022A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. SELF-LOCKING NUTS 2. TRANSAXLE MOUNTING BODY
SIDE BRACKET
>>A<< 3. TRANSAXLE MOUNTING
STOPPER
POWER PLANT MOUNT 32-6
TRANSAXLE MOUNTING
AC205424 AC
POWER PLANT MOUNT 32-7
ENGINE ROLL STOPPER AND CENTREMEMBER
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.
Pre-removal and Post-installation Operation
Side Under Cover Removal and Installation (Refer to
GROUP 51, Under Cover P.51-13).
58 ± 7 N·m*
43 ± 5 ft-lb*
90 ± 10 N·m
69 ± 10 N·m* 67 ± 7 ft -lb
N 6
69 ± 10 N·m*
5
58 ± 7 N·m*
43 ± 5 ft-lb*
N 1
2
4 3
83 ± 12 N·m
61 ± 9 ft-lb 83 ± 12 N·m
61 ± 9 ft-lb
21DB023A
FRONT ROLL STOPPER AND REAR ROLL STOPPER
CENTREMEMBER REMOVAL REMOVAL STEPS
STEPS • FRONT AXLE NO.1
1. SELF-LOCKING NUT CROSSMEMBER ASSEMBLY
2. ENGINE FRONT ROLL STOPPER (REFER TO P.32-9).
BRACKET AND 5. ENGINE REAR ROLL STOPPER
CENTREMEMBER BRACKET
>>B<< 3. ENGINE FRONT ROLL STOPPER REAR ROLL STOPPER
BRACKET BRACKET REMOVAL STEPS
4. CENTREMEMBER • FRONT NO.1 EXHAUST PIPE
(REFER TO GROUP 15,
EXHAUST PIPE AND MAIN
MUFFLER P.15-14).
1. SELF-LOCKING NUT
POWER PLANT MOUNT 32-8
ENGINE ROLL STOPPER AND CENTREMEMBER
HOLE
AC306965 AB
POWER PLANT MOUNT 32-9
CROSSMEMBER
CROSSMEMBER
REMOVAL AND INSTALLATION
M1321003200551
CAUTION
• Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions (P.52B-16), Air bag Module and Clock Spring (P.52B-237). 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 ground in the unladen condition.
Pre-removal Operation Post-installation Operation
• Power Steering Fluid Draining (Refer to GROUP 37, • Centremember Installation (Refer to P.32-7).
On-vehicle Service − Fluid Replacement P.37-18). • Front Floor Carpet Installation
• Power Steering Hoses Removal and Installation (Refer to • Accelerator Stopper Installation (Refer to GROUP 17,
GROUP 37, Power Steering Hoses P.37A-57). Accelerator Pedal P.17-9).
• Air Bag Module and Steering Wheel Assembly Removal • Trunk Lid Release Handle Cover Installation (Refer to
(Refer to GROUP 37, Steering Wheel P.37-23). GROUP 42, Trunk Lid P.42-63).
• Clock Spring Removal (Refer to GROUP 52B, Air Bag • Front Scuff Plate (LH) and Cowl Side Trim (LH) Installa-
Module and Clock Spring P.52B-237). tion (Refer to GROUP 52A, Trims P.52A-11).
• Floor Console Assembly Removal (Refer to GROUP 52A, • Floor Console Assembly Installation (Refer to GROUP
Floor Console Assembly P.52A-10). 52A, Floor Console Assembly P.52A-10).
• Front Scuff Plate (LH) and Cowl Side Trim (LH) Removal • Clock Spring Installation (Refer to GROUP 52B, Air Bag
(Refer to GROUP 52A, Trims P.52A-11). Module and Clock Spring P.52B-237).
• Trunk Lid Release Handle Cover Removal (Refer to • Steering Wheel Assembly and Air Bag Module Installation
GROUP 42, Trunk Lid P.42-63). (Refer to P.37-23).
• Accelerator Stopper Removal (Refer to GROUP 17, • Check the dust cover for cracks or damage by pushing it
Accelerator Pedal P.17-9). with your finger.
• Front Floor Carpet Removal • Power Steering Fluid Supplying (Refer to GROUP 37,
• Centremember Removal (Refer to P.32-7). On-vehicle Service − Fluid Replacement P.37-18).
• Power Steering Fluid Line Bleeding (Refer to P.37-18).
• Checking Steering Wheel Position with Wheels Straight
Ahead.
• Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service − Front Wheel Alignment Check and
Adjustment P.33-6).
POWER PLANT MOUNT 32-10
CROSSMEMBER
15 ± 3 N·m
11 ± 2 ft-lb
18 12 ± 2 N·m 11
102 ± 22 in-lb
83 ± 12 N·m*¹
2 17 58 ± 7 N·m*¹
15 ± 3 N·m
43 ± 5 ft-lb*¹
11 ± 2 ft-lb
9 10 N
7
18 ± 2 N·m 8N
69 ± 10 N·m*¹
13 ± 2 ft-lb 1 N 12
15
19 20 21 16
58 ± 7 N·m
43 ± 5 ft-lb
48 ± 7 N·m
29 ± 4 N·m 3 N
36 ± 5 ft-lb
21 ± 3 ft-lb
N4
165 ± 15 N·m
165 ± 15 N·m*²
4 122 ± 11 ft-lb*²
180 ± 20 N·m
5 N 12 133 ± 15 ft-lb
110 ± 10 N·m
180 ± 20 N·m
133 ± 15 ft-lb
14
83 ± 12 N·m 13 N
61 ± 9 ft-lb 21DB015A
21DB016A
A YOKE X
X
Y Y X
VIEW A
7.6˚ ± 3˚
X Y
AC306564 AB
.
32-12 POWER PLANT MOUNT
CROSSMEMBER
NUT MB991897
BOLT
BALL JOINT AC208247AC
WRONG AC106821AC
FRONT AXLE
CROSSMEMBER
STAY
21DB019A
POWER PLANT MOUNT 32-13
CROSSMEMBER
CROSSMEMBER
MOUNTING BOLT
21DB018A
TRANSMISSION
JACK AC306696AB
STABILIZER STABILIZER
BUSHING (LH) BRACKET (LH)
AC006141AE
.
32-14 POWER PLANT MOUNT
CROSSMEMBER
INSPECTION
M1321003300194
• Check the crossmembers for cracks or damage.
POWER PLANT MOUNT 32-15
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1321004100308
ITEM SPECIFICATION
Crossmember
Engine rear roll stopper bracket bolt 58 ± 7 N⋅m
Front axle crossmember stay bolt and nut 83 ± 12 N⋅m (61 ± 9 ft-lb)
Front axle No.1 crossmember bolt and nut 180 ± 20 N⋅m (133 ± 15 ft-lb)
Lower arm assembly bolt 165 ± 15 N⋅m (122 ± 11 ft-lb)
Lower arm assembly nut (flange nut, self-locking) M14 165 ± 15 N⋅m (122 ± 11 ft-lb)
Lower arm ball joint clamp assembly nut 110 ± 10 N⋅m
Power steering gear and linkage bolt 83 ± 12 N⋅m (61 ± 9 ft-lb)
Power steering gear bracket bolt M12 83 ± 12 N⋅m (61 ± 9 ft-lb)
Pressure hose clamp bolt and nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Pressure hose nut 15 ± 3 N⋅m (11 ± 2 ft-lb)
Return tube clamp bolt and nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Return tube nut 15 ± 3 N⋅m (11 ± 2 ft-lb)
Stabilizer bracket bolt 58 ± 7 N⋅m (43 ± 5 ft-lb)
Stabilizer link nut 48 ± 7 N⋅m (36 ± 5 ft-lb)
Steering column assembly bolt 18 ± 2 N⋅m (13 ± 2 ft-lb)
Steering gear and linkage protector bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Tie rod end nut 29 ± 4 N⋅m (21 ± 3 ft-lb)
Engine mounting
Engine mounting thru bolt M12 108 ± 10 N⋅m (80 ± 9 ft-lb)
Engine front mounting bracket bolt and nut M12 108 ± 10 N⋅m (80 ± 9 ft-lb)
Engine mounting stay bolt 36 ± 6 N⋅m (27 ± 4 ft-lb)
Engine roll stopper and centremember
Centremember bolt 83 ± 12 N⋅m (61 ± 9 ft-lb)
Engine front roll stopper thru bolt and nut 69 ± 10 N⋅m (61 ± 9 ft-lb
Engine rear roll stopper thru bolt and nut 69 ± 10 N⋅m (61 ± 9 ft-lb
Transaxle case rear roll stopper bracket bolt 90 ± 10 N⋅m (67 ± 7 ft-lb)
Transaxle mounting
Transaxle mounting body side bracket nut (nut, flange) M12 83 ± 12 N⋅m (61 ± 9 ft-lb)
Transaxle mounting body side bracket nut (nut, self-locking) M12 83 ± 12 N⋅m (61 ± 9 ft-lb)
32-16 POWER PLANT MOUNT
SPECIFICATIONS
HOME
33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
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
passenger (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 (*).
FRONT SUSPENSION 33-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1332000100270
The front suspension is a McPherson strut with coil
.
CONSTRUCTION DIAGRAM
COIL SPRING
STABILIZER LINK
STABILIZER BAR
STRUT ASSEMBLY
FRONT AXLE
CROSSMEMBER
STAY <3.8L ENGINE>
SYMPTOM CHART
M1332009400290
SYMPTOM PROCEDURES
SPECIAL TOOLS
M1332000600327
MB991004
MB990326
MB990776
FRONT SUSPENSION 33-6
ON-VEHICLE SERVICE
MB991963
MB990889 −
Rear suspension bushing
ring
MB990889
MB990890
ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1331000900701
Measure wheel alignment with alignment equipment on a level
surface. The front suspension, steering system and tyres
should be serviced to normal condition before measuring wheel
alignment.
.
TOE-IN
Standard value: 0 ± 3 mm (0 ± 0.12 inch)
1. Adjust the toe-in by undoing the clip and jam nut, and
turning the left and right tie rod turnbuckles by the same
amount (in opposite directions).
NOTE: The toe will move out as the left turnbuckle is turned
toward the front of the vehicle and the right turnbuckle is
CLIP turned toward the rear of the vehicle.
2. Install the clip and tighten the jam nut to the specified
JAM NUT
torque.
Tightening torque: 52 ± 2 N⋅m (38 ± 2 ft-lb)
AC305785 AB
3. Confirm that the toe-in is at the standard value.
4. Use a turning radius gauge to check that the steering angle
is at the standard value.
FRONT SUSPENSION 33-7
ON-VEHICLE SERVICE
STEERING ANGLE
Standard value:
ITEM VEHICLES WITH VEHICLES WITH
16-INCH 17-INCH
WHEELS WHEELS
Inner wheel 37°12' ± 2°00' 33°48' ± 2°00'
Outer wheel 30°18' 28°18'
(reference)
AC001079 AB
STRUT ASSEMBLY
REMOVAL AND INSTALLATION
M1332001100358
Post-installation Operation
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-6).
5
48 ± 7 N·m
36 ± 5 ft-lb
6
1
48 ± 7 N·m
36 ± 5 ft-lb
305 ± 25 N·m
4 225 ± 18 ft-lb
AC205769 AC
INSPECTION
M1332001200281
• Check for oil leaks from the strut assembly.
• Check the strut assembly for damage or deformation.
FRONT SUSPENSION 33-9
STRUT ASSEMBLY
1
65 ± 5 N·m
48 ± 4 ft-lb
2
8
3
4
5
9
6
10
7
AC305783 AB
MB991793
AC105115 AE
MB991795
MB991793
AC105116 AE
CAUTION
Do not use an impact wrench to tighten the strut nut, oth-
erwise the strut nut will be damaged. Vibration of the
impact wrench will cause the valve inside the strut to drop
out.
<3.8L ENGINE MODELS>
AC305844 4. Use a hexagon wrench and a pipe to secure the strut, and
then remove the strut nut (self-locking nut) using special tool
PIPE
MB991681.
HEXAGON
MB991681 WRENCH
AC305845 AB
.
FRONT SUSPENSION 33-11
STRUT ASSEMBLY
AC210097AB
FRONT SUSPENSION
STRUT AC205614 AB
ARROW ON THE
LOWER PLATE
AC210098AB
WARNING
When the strut piston rod is positioned to the hole of
strut insulator with compressing the coil spring, be
careful not that your hand is jammed by the coil
spring.
2. Compress the coil spring slowly using the following special
MB991794
tools, penetrating the strut piston rod to the hole of strut
insulator.
• MB991793: Spring Compressor
• MB991794: Upper Plate
• MB991795: Attachment A
• MB991830: Fixture
3. While the coil spring is being compressed by the special
tools, temporarily tighten the strut nut (self-locking nut).
MB991830
MB991795
MB991793
AC105116 AE
4. Ensure that the arrows on the strut bracket center and the
STRUT
strut insulator are positioned as shown.
INSULATOR
0˚ ± 2˚
STRUT
BRACKET
AC205613 AC
CAUTION
Do not use an impact wrench to tighten the strut nut, oth-
erwise the strut nut will be damaged. Vibration of the
impact wrench will cause the valve inside the strut to drop
out.
<3.8L ENGINE MODELS>
AC305844 5. For 3.8L engine models, using special tool MB991681, a
hexagon wrench and a pipe, tighten the strut nut
PIPE
(self-locking nut) to 65 ± 5 N⋅m (48 ± 4 ft-lb).
HEXAGON
MB991681 WRENCH
AC305845 AB
FRONT SUSPENSION 33-13
LOWER ARM
INSPECTION
M1332001400207
• Check the strut bearing for wear.
• Check the rubber parts for damage or deterioration.
• Check the coil spring for deformation, deterioration or dam-
age.
• Check the front suspension strut for deformation.
LOWER ARM
REMOVAL AND INSTALLATION
M1332001600364
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in an unladen condition.
Post-installation Operation
• Check the dust cover for cracks or damage by pushing it
with your finger.
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-6).
165 ± 15 N·m
AC305736
122 ± 11 ft-lb
N SPECIFIED GREASE :
MULTIPURPOSE GREASE SAE
J310, NLGI NO.2 OR EQUIVALENT
165 ± 15 N·m*
122 ± 11 ft-lb* 110 ± 10 N·m
2
12DB013A
REMOVAL STEPS Required Special Tool:
<<A>> 1. LOWER ARM AND KNUCKLE • MB991897: Ball Joint Remover
CONNECTION
2. LOWER ARM ASSEMBLY
33-14 FRONT SUSPENSION
LOWER ARM
NUT
BOLT
12DB014A
INSPECTION
M1332001700316
• Check the bushing for wear and deterioration.
• Check the lower arm assembly for bending or breakage.
• Check all bolts for condition and straightness.
.
AC305846 AB
DUST COVER
AC305847 AB
AC305736 AB
33-16 FRONT SUSPENSION
LOWER ARM
AC306250 AB
LOWER ARM
ASSEMBLY
MB990890
AC207421AB
FRONT SUSPENSION 33-17
LOWER ARM
MB990889
LOWER ARM
ASSEMBLY
MB990890
AC207422AB
33-18 FRONT SUSPENSION
STABILIZER BAR
STABILIZER BAR
REMOVAL AND INSTALLATION
M1332004000297
CAUTION
• Before removing the steering wheel and air bag module assembly, refer to GROUP 52B − Service
Precautions (P.52B-16) and Air Bag Module and Clock Spring (P.52B-237). 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 in serious driver injury.
• *: 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.
Stabilizer Bar Pre-removal Operation Stabilizer Bar Post-installation Operation
• Power Steering Fluid Draining (Refer to GROUP 37, • Check the dust covers for cracks or damage by pushing it
On-Vehicle Service − Fluid Replacement P.37-18). with your finger.
• Front Under Cover Removal. • Floor Carpet Installation
• Centermember Removal (Refer to GROUP 32, Engine • Trunk Lid Opener Cover Installation
Roll Stopper, Centermember P.32-7). • Accelerator Pedal Stopper Installation
• Lower Arm Assembly Removal (Refer to P.33-13). • Cowl Side Trim and Front Scuff Plate Removal (Refer to
• Air Bag Module Assembly, Steering Damper and Steering GROUP 52A, Trims P.52A-11).
Wheel Assembly Removal (Refer to GROUP 37, Steering • Floor Console Assembly Installation (Refer to GROUP
Wheel P.37-23). 52A, Floor Console Assembly P.52A-10).
• Floor Console Assembly Removal (Refer to GROUP 52A, • Steering Wheel Assembly, Steering Damper and Air Bag
Floor Console Assembly P.52A-10). Module Assembly Installation (Refer to GROUP 37, Steer-
• Front Scuff Plate and Cowl Side Trim Removal (Refer to ing Wheel P.37-23).
GROUP 52A, Trims P.52A-11). • Checking Steering Wheel Position with Wheels Straight
• Trunk Lid Opener Cover Removal Ahead
• Accelerator Pedal Stopper Removal • Lower Arm Assembly Installation (Refer to P.33-13).
• Floor Carpet Removal • Centremember Installation (Refer to GROUP 32, Engine
Roll Stopper, Centermember P.32-7).
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-6).
• Front Under Cover Installation.
• Power Steering Fluid Supplying (Refer to GROUP 37,
On-Vehicle Service − Fluid Replacement P.37-18).
• Power Steering Fluid Line Bleeding (Refer to GROUP 37,
On-Vehicle Service − Power Steering System Air Bleeding
P.37-18).
FRONT SUSPENSION 33-19
STABILIZER BAR
18 ± 2 N·m
13 ± 2 ft-lb 58 ± 7 N·m
43 ± 5 ft-lb
16
5 17 16
18
17 48 ± 7 N·m
36 ± 5 ft-lb
2
15 10 18 ± 2 N·m 29 ± 4 N·m
13 ± 2 ft-lb 21 ± 3 ft-lb
3
1
48 ± 7 N·m
14 7 36 ± 5 ft-lb
58 ± 7 N·m*
43 ± 5 ft-lb*
11
13
180 ± 20 N·m
133 ± 14 ft-lb 12
83 ± 12 N·m
61 ± 9 ft-lb
12DB011A
NUT MB991897
BOLT
BALL JOINT AC208247AC
WRONG AC106821AC
.
FRONT SUSPENSION 33-21
STABILIZER BAR
STEERING
CLIP COLUMN
SHAFT
21DB016A
A YOKE X
X
Y Y X
VIEW A
7.6˚ ± 3˚
X Y
AC306564 AB
FRONT AXLE
CROSSMEMBER
STAY
21DB019A
33-22 FRONT SUSPENSION
STABILIZER BAR
STABILIZER STABILIZER
BUSHING (LH) BRACKET (LH)
AC006141AE
21DB017A
INSPECTION
M1332002000291
• Check the stabilizer bushings for wear and deterioration.
• Check the stabilizer bar for deterioration or damage.
• Check all bolts for condition and straightness.
.
FRONT SUSPENSION 33-23
STABILIZER BAR
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1332008500227
ITEM SPECIFICATION
Lower arm assembly
Lower arm to crossmember connection bolt 165 ± 15 N⋅m (122 ± 11 ft-lb)
Lower arm to crossmember connection nut (self-locking 165 ± 15 N⋅m (122 ± 11 ft-lb)
nut)
Lower arm to knuckle connection nut 110 ± 10 N⋅m
Stabilizer bar
Crossmember to body connection bolt and nut 180 ± 20 N⋅m (133 ± 14 ft-lb)
Front axle crossmember stay bolt and nut 83 ± 12 N⋅m (61 ± 9 ft-lb)
Pressure hose clamp bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Rear roll stopper connection nut 69 ± 10 N⋅m
Return tube clamp bolt and nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Stabilizer bracket bolt 58 ± 7 N⋅m (43 ± 5 ft-lb)
Stabilizer link nut 48 ± 7 N⋅m (36 ± 5 ft-lb)
Steering gear and joint connecting bolt 18 ± 2 N⋅m (13 ± 2 ft-lb)
Steering gear and pressure tube flare nut 15 ± 3 N⋅m (11 ± 2 ft-lb)
Steering gear and return tube flare nut 15 ± 3 N⋅m (11 ± 2 ft-lb)
Tie rod to knuckle connection nut 29 ± 4 N⋅m (21 ± 3 ft-lb)
Strut assembly
Stabilizer link nut 48 ± 7 N⋅m (36 ± 5 ft-lb)
Strut assembly to body connection nut 48 ± 7 N⋅m (36 ± 5 ft-lb)
Strut assembly to knuckle connection nut 305 ± 25 N⋅m (225 ± 18 ft-lb)
Strut nut (self-locking nut) 65 ± 5 N⋅m (48 ± 4 ft-lb)
GENERAL SPECIFICATIONS
M1332000200233
COIL SPRING
ITEM SPECIFICATION
Wire diameter mm (in) 15.0 (0.59)
Average diameter mm (in) 170 − 180 (6.7 − 7.1)
Free length mm (in) 284
FRONT SUSPENSION 33-25
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1332000300382
LUBRICANT
M1332000400163
GROUP 34
REAR SUSPENSION
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 34-27
LOWER ARM . . . . . . . . . . . . . . . . . . . 34-10
FASTENER TIGHTENING SPECIFICATIONS 34-27
REMOVAL AND INSTALLATION . . . . . . . . 34-10
GENERAL SPECIFICATIONS . . . . . . . . . . 34-28
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 34-11
SERVICE SPECIFICATIONS . . . . . . . . . . . 34-28
TRAILING ARM . . . . . . . . . . . . . . . . . 34-12 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 34-28
REAR SUSPENSION 34-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1341000100375
A low-mount multilink suspension system is used to
.
CONSTRUCTION DIAGRAM
COIL SPRING
UPPER ARM ASSEMBLY
REAR SUSPENSION
CROSSMEMBER SHOCK
ABSORBER
STABILIZER BAR
SYMPTOM CHART
M1341013500276
SYMPTOM PROCEDURES
STEP 3. Check the stabilizer bar and/or stabilizer STEP 4. Retest the system.
bar links for deformity or damage. Q: Is the malfunction eliminated?
Q: Are the stabilizer bar and/or stabilizer bar links YES : The procedure is complete.
deformed or damaged? NO : Return to Step 1.
YES : Replace the faulty part, and then go to Step
4.
NO : Go to Step 4.
SPECIAL TOOLS
M1341000600433
MB990800
ON-VEHICLE SERVICE
REAR WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1341011000394
Measure wheel alignment with an alignment equipment on
level ground.
The rear suspension and tyres should be serviced to the nor-
mal condition prior to wheel alignment measurement.
.
CAMBER
Standard value:
− 0° 50’ ± 30’ (Left/right deviation within 30’)
NOTE: For vehicles with aluminum wheels, attach the cam-
ber/caster/kingpin gauge by using a compensator.
COMPENSATOR
AC305848 AB
TOE-IN
Standard value: 3 ± 3 mm (0.12 ± 0.12 inch)
.
AC305842 AB
REAR SUSPENSION 34-7
ON-VEHICLE SERVICE
CAUTION
When adjusting the toe, tighten the toe control arm and the
trailing arm assembly, not the lower arm assembly.
2. Carry out toe adjustment by turning the toe adjusting bolt.
NOTE: .
• LH: Clockwise viewed from the rear → Toe-in
TOE ADJUSTING • RH: Clockwise viewed from the rear → Toe-out
BOLT
• If either the camber or toe is adjusted, both should fluctu-
ate. For the relationship between the two, refer to CAM-
BER AND TOE REFERENCE TABLE (Refer to P.34-7).
LOWER ARM
ASSEMBLY
AC305842 AC
1.0
0.8
0.6
1 DIVISION OF SCALES
0.4
0.2
CAMBER 0
(DEGREE) ADJUSTING
LOWER ARM
- 0.2
ADJUSTING TOE
CONTROL ARM
- 0.4 LH: CLOCKWISE
RH: COUNTERCLOCKWISE
- 0.6 ON REAR VIEW
LH: CLOCKWISE
- 0.8 RH: COUNTERCLOCKWISE
ON REAR VIEW
- 1.0
- 15.0 - 12.0 - 9.0 - 6.0 - 3.0 0 3.0 6.0 9.0 12.0 15.0
TOE OUT ← TOE (mm) → TOE IN
AC205691AB
REAR SUSPENSION 34-8
ON-VEHICLE SERVICE
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in an unladen condition.
Post-installation Operation
• Rear Wheel Alignment Check and Adjustment (Refer to
P.34-6).
113 ± 12 N·m*
N 83 ± 9 ft-lb*
3
N
113 ± 12 N·m*
83 ± 9 ft-lb*
1
4
2
17DB051A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. UPPER ARM ASSEMBLY AND 3. UPPER ARM ASSEMBLY
KNUCKLE CONNECTION 4. UPPER ARM STOPPER
2. ABS EQUIPMENT BOLT
INSPECTION
M1341003700194
• Check the bushings for wear and deterioration.
• Check the upper arm for bending or breakage.
• Check all bolts for condition and straightness.
REAR SUSPENSION 34-10
LOWER ARM
LOWER ARM
REMOVAL AND INSTALLATION
M1341006500047
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in an unladen condition.
Post-installation Operation
• Rear Wheel Alignment Check and Adjustment (Refer to
P.34-6).
78 ± 7 N·m*
57 ± 5 ft-lb*
4
3
1
5
N
40 ± 5 N·m
30 ± 3 ft-lb 113 ± 12 N·m*
83 ± 9 ft-lb*
AC305777 AB
PLATE
LOWER ARM
ASSEMBLY AC306251 AB
INSPECTION
M1341006600055
• Check the bushings for wear and deterioration.
• Check the lower arm for bending or breakage.
• Check all bolts for condition and straightness.
34-12 REAR SUSPENSION
TRAILING ARM
TRAILING ARM
REMOVAL AND INSTALLATION
M1341002200390
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in an unladen condition.
Post-installation Operation
• Rear Wheel Alignment Check and Adjustment (Refer to
P.34-6).
A 113 ± 12 N·m* 1
83 ± 9 ft-lb*
N B
B
3 N A
2
113 ± 12 N·m*
105 ± 10 N·m 83 ± 9 ft-lb*
77 ± 7 ft-lb
17DB050A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. TRAILING ARM ASSEMBLY AND 2. TRAILING ARM ASSEMBLY
KNUCKLE CONNECTION 3. TRAILING ARM BRACKET
NOTE: Bolt A and nut B are interchangeable.
INSPECTION
M1341002300201
• Check the bushings for wear and deterioration.
• Check the trailing arm for bending or breakage.
• Check all bolts for condition and straightness.
REAR SUSPENSION 34-13
TOE CONTROL ARM
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in an unladen condition.
Post-installation Operation
• Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.
• Rear Wheel Alignment Check and Adjustment (Refer to
P.34-6).
7 ± 0.5 g
(0.247 ± 0.018 oz)
66 ± 6 N·m 4
49 ± 4 ft-lb
AC205712
MULTIPURPOSE GREASE
78 ± 7 N·m* SAE J310, NLGI No.2
78±±5 7ft-lb*
57 N·m OR EQUIVALENT
57 ± 5 ft-lb 3
N
2
2
4
AC305779 AB
NUT MB991897
BOLT
BALL JOINT AC208247AC
2. Turn the bolt and knob as necessary to make the jaws of the
special tool MB991897 parallel, tighten the bolt by hand and
BOLT
confirm that the jaws are still parallel.
PARALLEL NOTE: When adjusting the jaws in parallel, make sure the
knob is in the position shown in the figure.
CORRECT
3. Tighten the bolt with a wrench to disconnect the toe control
KNOB arm assembly and the knuckle.
WRONG AC106821AC
PLATE
CROSSMEMBER AC306251 AC
INSPECTION
M1341016800049
• Check the bushings for wear and deterioration.
• Check the toe control arm for bending or breakage.
• Check all bolts for condition and straightness.
REAR SUSPENSION 34-15
TOE CONTROL ARM
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in the unladen condition.
Pre-removal and Post-installation Operation
• Trunk Room Trim (front side) Removal and Installation
(Refer to GROUP 52A, Trims P.52A-11).
1
45 ± 5 N·m
34 ± 3 ft-lb
100 ± 10 N·m*
74 ± 7 ft-lb*
2 3
4
5
AC305780 AB
INSPECTION
M1341002600172
• Check the rubber parts for cracks and wear.
• Check the shock absorber for malfunctions, oil leakage, or
abnormal noise.
REAR SUSPENSION 34-17
SHOCK ABSORBER ASSEMBLY
23 ± 2 N·m
17 ± 1 ft-lb
1
2
10
8
3
9
11 4
6
12
7
13
AC305784 AB
MB991239
AC001070 AB
WARNING
Do not use an impact wrench to remove the coil
spring nut (self-locking nut).
• Vibration of the impact wrench will cause special
tools MB991237 and MB991239 to slip and cause
personal injury.
• Vibration of the impact wrench will cause the valve
inside the shock absorber to drop out.
<3.8L ENGINE> AC305845 For 3.8L engine models, use a hexagon wrench and a pipe
HEXAGON WRENCH to secure the piston rod, and then remove the coil spring nut
(self-locking nut) using special tool MB991681.
PIPE
MB991681
AC306398AB
REAR SUSPENSION 34-19
SHOCK ABSORBER ASSEMBLY
MB991239
AC001070 AB
LOWER BUSHING
ARROW B A
INNER PIPE
0˚ ± 2˚ AC305849 AB
0˚ ± 2˚
<RH> LOWER BUSHING
B A
ARROW INNER PIPE
COIL SPRING
LOWER END
AC305850 AB
.
34-20 REAR SUSPENSION
SHOCK ABSORBER ASSEMBLY
PIPE
MB991681
AC306398AB
AC102270 AC
REAR SUSPENSION 34-21
STABILIZER BAR
INSPECTION
M1341002800024
• Check the rubber parts for damage or deterioration.
• Check the coil spring for deformation, deterioration or dam-
age.
• Check the shock absorber for deformation.
STABILIZER BAR
REMOVAL AND INSTALLATION
M1341003000270
Post-installation Operation
• Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.
3
2 45 ± 5 N·m
34 ± 3 ft-lb
3
2
45 ± 5 N·m
34 ± 3 ft-lb
4
40 ± 5 N·m
30 ± 3 ft-lb
AC305781AB
APPROXIMATELY
20 mm (0.79 in)
AC305843 AB
INSPECTION
M1341001400313
• Check the stabilizer bushings for wear and deterioration.
• Check the stabilizer bar for deterioration or damage.
• Check all bolts for condition and straightness.
.
CAUTION
For vehicles with ABS, be careful when handling the pole piece at the tip of the wheel speed sensor
so as not to damage it by striking against other parts.
Pre-removal Operation Post-installation Operation
• Main Muffler, Center Exhaust Pipe Removal (Refer to • Rear Splash Shield Installation (Refer to GROUP 51,
GROUP 15, Exhaust pipe and Main Muffler P.15-14). Rear Bumper Assembly P.51-5).
• Rear Splash Shield Removal (Refer to GROUP 51, Rear • Main Muffler, Center Exhaust Pipe Installation (Refer to
Bumper Assembly P.51-5). GROUP 15, Exhaust pipe and Main Muffler P.15-14).
• Rear Wheel Alignment Check and Adjustment (Refer to
P.34-6).
7
8
8
6
108 ± 17 N·m
79 ± 13 ft-lb
83 ± 12 N·m
61 ± 9 ft-lb
108 ± 17 N·m 2
79 ± 13 ft-lb 5
1N
4 83 ± 12 N·m
45 ± 5 N·m 61 ± 9 ft-lb
34 ± 3 ft-lb
83 ± 12 N·m 3N
61 ± 9 ft-lb 83 ± 12 N·m
61 ± 9 ft-lb AC305782 AC
17DB049A
TRAILING ARM
ASSEMBLY
AC305742 AB
CROSSMEMBER
MOUNTING BOLT
AC306481AB
REAR SUSPENSION 34-25
REAR SUSPENSION CROSSMEMBER
CROSSMEMBER
MOUNTING BOLT
CROSSMEMBER
BRACKET AC306482AB
AC209171AB
>>B<< CROSSMEMBER
BRACKET/CROSSMEMBER NUT INSTALLATION
Ensure that the crossmember mounting bolts have been tight-
ened to specification, and then install the crossmember bracket
with the crossmember nut.
CROSSMEMBER
MOUNTING BOLT
CROSSMEMBER
BRACKET
CROSSMEMBER NUT
AC306482AC
.
34-26 REAR SUSPENSION
REAR SUSPENSION CROSSMEMBER
CROSSMEMBER
MOUNTING BOLT CROSSMEMBER
NUT
AC306481AC
INSPECTION
M1341006900089
• Check the crossmember for cracks or deformation.
• Check all bolts for condition and straightness.
REAR SUSPENSION 34-27
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1341012700330
ITEM SPECIFICATION
Lower arm assembly
Lower arm assembly to crossmember nut 78 ± 7 N⋅m (57 ± 5 ft-lb)
Lower arm assembly to knuckle nut (self-locking nut) 113 ± 12 N⋅m (83 ± 9 ft-lb)
Lower arm assembly to stabilizer bar link assembly nut 40 ± 5 N⋅m (30 ± 3 ft-lb)
Rear suspension crossmember
Crossmember bracket mounting bolt and nut (self-locking 83 ± 12 N⋅m (61 ± 9 ft-lb)
nut)
Crossmember stay (front) mounting bolt 45 ± 5 N⋅m (34 ± 3 ft-lb)
Crossmember stay (rear) mounting bolt and nut 83 ± 12 N⋅m (61 ± 9 ft-lb)
(self-locking nut)
Rear suspension crossmember to body bolt 108 ± 17 N⋅m (79 ± 13 ft-lb)
Shock absorber assembly
Shock absorber assembly to body nut 45 ± 5 N⋅m (34 ± 3 ft-lb)
Shock absorber assembly to knuckle bolt 100 ± 10 N⋅m (74 ± 7 ft-lb)
Shock absorber self-locking nut (coil spring nut) 23 ± 2 N⋅m (17 ± 1 ft-lb)
Stabilizer bar
Stabilizer bar link assembly nut 40 ± 5 N⋅m (30 ± 3 ft-lb)
Stabilizer bracket bolt 45 ± 5 N⋅m (34 ± 3 ft-lb)
Toe control arm assembly
Toe control arm assembly to crossmember nut 78 ± 7 N⋅m (57 ± 5 ft-lb)
Toe control arm assembly to knuckle nut (self-locking nut) 66 ± 6 N⋅m (49 ± 4 ft-lb)
Trailing arm assembly
Trailing arm assembly to knuckle nut (self-locking nut) 113 ± 12 N⋅m (83 ± 9 ft-lb)
Trailing arm assembly to trailing arm bracket nut 113 ± 12 N⋅m (83 ± 9 ft-lb)
(self-locking nut)
Trailing arm bracket to body bolt 105 ± 10 N⋅m (77 ± 7 ft-lb)
Upper arm assembly
Upper arm assembly to crossmember bolt and nut 113 ± 12 N⋅m (83 ± 9 ft-lb)
(self-locking nut)
Upper arm assembly to knuckle nut (self-locking nut) 113 ± 12 N⋅m (83 ± 9 ft-lb)
34-28 REAR SUSPENSION
SPECIFICATIONS
GENERAL SPECIFICATIONS
M1341000200286
COIL SPRING
ITEM 3.8L ENGINE
Wire diameter mm (in) 12.0 (0.47)
Average diameter mm (in) 86.0 − 112.0 (3.39 − 4.40)
Free length mm (in) 322.0
SERVICE SPECIFICATIONS
M1341000300421
LUBRICANT
M1341000400183
GROUP 35
SERVICE BRAKES
CONTENTS
GROUP 35A
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL DESCRIPTION
M1351000100440
The brake system has been designed to give greater
reliability and durability and to provide excellent brak-
ing performance.
FEATURES 3. Front- and rear-wheel X-type brake line layout
.
are used.
Improved braking performance 4. Ventilated discs brakes improve anti-fading per-
1. An 8+9 inch tandem brake booster provides suffi- formance.
cient braking force in sudden braking range.
.
CONSTRUCTION DIAGRAM
<VEHICLE WITH ABS>
BRAKE BOOSTER
HYDRAULIC UNIT
(INTEGRATED WITH
THE ABS-ECU)
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied
DIAGNOSIS
.
STEP 2. Check disc brake pistons for smooth STEP 3. Check brake disc(s) for runout.
operation. Refer to P.35A-19.
(1) With engine not running, depress the brake pedal Q: Is runout outside of specifications?
rapidly several times to deplete booster vacuum YES : Repair or replace the brake disc(s) as
reserves. necessary. Then go to Step 5.
(2) Test each disc brake assembly one at a time. NO : Go to Step 4.
a. Remove the lower caliper bolt, then remove
caliper from mount.
b. Have an assistant slowly depress the brake STEP 4. Check brake discs for correct thickness.
pedal. Confirm piston(s) extend slowly and Refer to P.35A-19.
smoothly with no jumpiness. Repeat for each Q: Is the thickness outside of specifications?
disc brake assembly. YES : Repair or replace the brake disc(s) as
Q: Do (does) the piston(s) move correctly? necessary. Then go to Step 5.
YES : Go to Step 3. NO : Perform the brake line bleeding. Then go to
NO : Disassemble and inspect the brake Step 5.
assembly (Front: refer to P.35A-33, Rear:
refer to P.35A-36). Then go to Step 5. STEP 5. Retest the system.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at Step 1. If a new symptom
appears, refer to the appropriate symptom
chart.
STEP 3. Check the vacuum hose and check valve STEP 7. Recheck symptom.
for damage.
Q: Is the symptom eliminated?
Refer to P.35A-15. YES : The procedure is complete.
Q: Is there a damage? NO : Start over at step 1. If a new symptom
YES : Replace the part. Then go to Step 7. surfaces, refer to the symptom chart.
NO : Go to Step 4.
BASIC BRAKE SYSTEM 35A-6
BASIC BRAKE SYSTEM DIAGNOSIS
DIAGNOSIS
AC210519 AB
AC210519AC
DIAGNOSIS
AC210519 AD
INSPECTION PROCEDURE6: Squealing, Groaning or Chattering Noise when Brakes are Applied
.
STEP 3. Adjust the brake pedal or brake booster STEP 4. Recheck symptom.
pushrod. Q: Is the symptom eliminated?
Refer to P.35A-13 or P.35A-26. YES : The procedure is complete.
Q: Are the brake pedal and the brake booster pushrod NO : Start over at step 1. If a new symptom
adjusted correctly? surfaces, refer to the symptom chart.
YES : Go to Step 4.
NO : Adjust the brake pedal or the brake booster
pushrod. Then go to Step 4.
DIAGNOSIS
.
STEP 3. Check the brake drum for wear and the shoe
spring for damage.
Q: Is there any wear or damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 4.
AC102438 AC
<REAR>
AC205869AC
INSPECTION PROCEDURE 8: Groaning, Clicking or Rattling Noise when Brakes are not Applied.
DIAGNOSIS
.
<REAR>
AC308605AB
35A-12 BASIC BRAKE SYSTEM
SPECIAL TOOLS
AC102438 AC
<REAR>
AC205869AC
SPECIAL TOOLS
M1351000600360
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
M1351000900446
AC210523 AB
(6) Screw in the stop light switch until its thread contacts the
stopper, and fix the stop light switch by turning it
approximately one quarter of a turn clockwise.
STOPPER
(7) Check that the clearance between the stop light switch
and the stopper is as shown.
CAUTION
Check that the stop light does not illuminate when the
0.5 - 1.5 mm brake pedal is not depressed.
(0.02 - 0.06 in) (8) Connect the connector at the stop light switch.
AC206322 AB
4. Return the carpet, etc. to its original position.
35A-14 BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
AC000870 AB
BASIC BRAKE SYSTEM 35A-15
ON-VEHICLE SERVICE
(2) With the engine stopped, step on the brake pedal several
WHEN ENGINE WHEN ENGINE times. Then step on the brake pedal and start the engine.
IS STOPPED IS STARTED
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective. Go to step 3.
AC000871 AB
(3) With the engine running, step on the brake pedal and
GOOD NO GOOD then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster
is in good condition, if the pedal rises, the booster is
defective.
AC000872 AB
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-15), vacuum hose for leaks, high volume engine
vacuum applied to booster. Repair or replace as necessary.
If these are OK, replace booster and repeat this test starting
at Step 1.
CAUTION
The check valve should not be removed from the vacuum
hose.
1. Remove the vacuum hose. (Refer to P.35A-26).
CAUTION
If the check valve is defective, replace it as an assembly
together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum
VALVE SPRING
pump.
A B
INTAKE VACUUM PUMP CRITERIA
BOOST- MANIFOLD CONNECTION
ER SIDE SIDE
(HOLDS)
(DOES NOT Connection at the brake A negative pressure
HOLD)
booster side (A) (vacuum) is created and
held.
Connection at the intake A negative pressure
AC000873 AB manifold side (B) (vacuum) is not created.
35A-16 BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
BLEEDING
M1351001400455
CAUTION
Use only brake fluid DOT 3 or DOT 4. Never mix the speci-
fied brake fluid with other fluid as it will influence the brak-
ing performance significantly.
.
15DB172A
4 1
15DB173A
BASIC BRAKE SYSTEM 35A-17
ON-VEHICLE SERVICE
15DB186A
<FRONT>
1. Check the brake pad thickness through the caliper body
check port.(Rear). Front pad check can be viewed from rotor
side.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
15DB192A
<REAR>
15DB179A
35A-18 BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
CAUTION
Do not wipe off the special grease that is on the lock pin.
Do not contaminate the lock pin.
<FRONT> 2. Remove the lock pin bolt . Pivot the caliper assembly
upward and secure. Hold lock pin with spanner while
loosening bolt(Rear).
AC305371AC
<REAR>
15DB196A
<REAR>
15DB195A
BASIC BRAKE SYSTEM 35A-19
ON-VEHICLE SERVICE
1 2
2
15DB197A
<REAR>
15DB196A
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 condi-
tions should be checked.
35A-20 BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
CAUTION
• After a new brake disc is installed, always grind the
brake disc with an 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.
• When the on-the-car type lathe is used, first install a
M12 flat washer on the stud bolt in the brake disc side
M12 FLAT WASHER 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 inac-
curate grinding.
• Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N⋅m (74
ft-lb). If all of the wheel nuts are not used, or the tight-
ening 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 limit, replace it with a
new one. If thickness variation exceeds the specification,
turn rotor with an on-the-car type brake lathe
M12 FLAT WASHER ("Accuturn-8750" or equivalent). If the calculated final
thickness after turning the rotor is less than the standard
value, replace the disc.
AC006226 AB
.
35A-22 BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
ACX00669AB
AC210711AB
<FRONT> (2) Remove the brake disc. Then place a dial gauge as
shown, and measure the end play while moving the hub
in the axial direction.
Limit: 0.05 mm (0.002 inch)
(3) If the end play exceeds the limit, replace the hub
assembly.
(4) If the end play does not exceed the limit, dephase the
brake disc and secure it. Then recheck the brake disc
run-out.
AC102438 AC
<REAR>
AC205869AC
BASIC BRAKE SYSTEM 35A-23
ON-VEHICLE SERVICE
CAUTION
• After a new brake disc is installed, always grind the
brake disc with an 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.
• When the on-the-car type lathe is used, first install a
M12 flat washer on the stud bolt in the brake disc side
M12 FLAT WASHER 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 inac-
curate grinding.
• Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N⋅m (74
ft-lb). If all of the wheel nuts are not used, or the tight-
ening 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
M12 FLAT WASHER equivalent).
AC006226 AB
BRAKE PEDAL
REMOVAL AND INSTALLATION
M1351003400406
Post-installation Operation
• Brake Pedal Adjustment (Refer to P.35A-13).
14 ± 2 N·m
122 ± 25 in-lb
8
4
5
2 6
7 3
11
13 ± 2 N·m
115 ± 18 in-lb 9
10
AC206452AB
INSPECTION
M1351003500221
.
NO CONTINUITY CONTINUITY
4 mm
(0.16 in)
ACX00671AB
35A-26 BASIC BRAKE SYSTEM
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
10
7
1
15
6 9
N 8 12 16
14 ± 2 N·m
122 ± 25 in-lb
2
15 ± 2 N·m
12 ± 1 ft-lb
14
2
25 ± 2 N·m
15 ± 2 N·m 13
12 ± 1 ft-lb
18 ± 2 ft-lb 11
15DB174A
VACUUM HOSE
YELLOW PAINT MARK 15DB175A
MEASURING DISTANCE A
BLOCK GAUGE
15DB185A
35A-28 BASIC BRAKE SYSTEM
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
ROD SPLINE
ANGLE-NOSE PLIERS
MB991568
AC210714 AB
MASTER CYLINDER
M1351004200375
N1
4
5
6
3 N
4 N
5 N
6
5
4
15DB194A
BRAKE FLUID: DOT 3 OR DOT 4
DISASSEMBLY STEPS DISASSEMBLY STEPS
1. BRAKE MASTER CYLINDER TO <<A>> 3. BRAKE MASTER CYLINDER UNION
FLUID RESERVOIR SEAL RETAINER
2. BRAKE MASTER CYLINDER PIN 4. PRIMARY PISTON ASSEMBLY
<VEHICLES WITH ABS> 5. SECONDARY PISTON ASSEMBLY
6. MASTER CYLINDER BODY
BASIC BRAKE SYSTEM 35A-29
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
AC000903
INSPECTION
M1351004300297
• Check the inner surface of master cylinder body for rust or
pitting.
• Check the primary and secondary pistons for rust, scoring,
wear or damage.
35A-30 BASIC BRAKE SYSTEM
DISC BRAKE ASSEMBLY
<FRONT>
100 ± 10 N·m
74 ± 7 ft-lb
30 ± 4 N·m
22 ± 3 ft-lb
1
N 2
4
3
15DB181A
<REAR> 30 ± 4 N·m
22 ± 3 ft-lb 1
2 N
60 ± 5 N·m
45 ± 3 ft-lb
4
15DB193A
SPRING SCALE
AC000906AG
<REAR>
SPRING SCALE
AC305370AB
CAUTION
Do not let any oil, grease or other contamination get onto
the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
3. Clean the piston and insert into cylinder with special tool
MB990520.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and installing the lock
pin bolt.
MB990520 5. Check the brake drag force as follows.
(1) Start the engine and hold the brake pedal down for 5
seconds. [Pedal depression force: approximately 200 N
(45 pound)]
AC002027 AB
(2) Stop the engine.
(3) Turn the brake disc forward 10 times.
35A-32 BASIC BRAKE SYSTEM
DISC BRAKE ASSEMBLY
<FRONT>
(4) Use a spring scale to measure the hub torque with pads
installed in the same direction as earlier.
(5) Calculate the drag force of the disc brake [difference
between hub torque with pads installed and hub torque
with pads removed].
Standard value:
<Front−3.8L engine> 64 N (14 pounds) or less
<Rear> 54 N (12 pounds) or less
SPRING SCALE
6. If the brake drag force exceeds the standard value,
AC000908AF
disassemble and clean the piston. Check for corrosion or
<REAR>
worn piston seal, and check the sliding condition of the lock
pin and guide pin.
SPRING SCALE
AC305369AB
INSPECTION
M1351008100046
.
12
12.5 ± 1.5 N·m
11 N 8
36.5 ± 1.5 N·m 10 N
11 10
4 GREASE
5 6
9
7N
7
CALIPER SEAL KIT
15DB187A
12 2
6 7
4 8
11
10
1
1
4
5
6 9
7 2
LUBRICATION POINTS
PISTON
SEAL
CAUTION
THE PISTON SEAL INSIDE THE
CALIPER SEAL KIT IS COATED
WITH SPECIAL GREASE DO NOT
WIPE THIS GREASE OFF.
15DB189A
25DB190A
35A-36 BASIC BRAKE SYSTEM
DISC BRAKE ASSEMBLY
12 11
4 N 11 8 4 10 8
N 10
12 7
5
6 9
36.5 ± 1.5 N·m
5 7
6 9 CALIPER KIT
N7
15DB182A
1 7
11
2 2 10
PAD SET CALIPER SEAL KIT
LUBRICATION POINTS
CAUTION
THE PISTON SEAL INSIDE THE CALIPER
SEAL KIT IS COATED WITH
SPECIAL GREASE. DO NOT WIPE
THIS GREASE OFF.
AC204331
AC204684
INSPECTION
M1351008300039
• Check the cylinder for wear, damage or rust.
• Check the piston surface for wear, damage or rust.
• Check the caliper body or sleeve for wear.
• Check the pad for damage or adhesion of grease, check the
backing metal for damage.
.
BASIC BRAKE SYSTEM 35A-39
DISC BRAKE ASSEMBLY
ACX00690
35A-40 BASIC BRAKE SYSTEM
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1351009600390
ITEM SPECIFICATION
Brake line
Brake tube flare nut 15 ± 2 N⋅m
Brake pedal
Brake booster nut 14 ± 2 N⋅m
Brake pedal bolt 13 ± 2 N⋅m
Front disc brake
Brake hose connector bolt 30 ± 4 N⋅m
Caliper bleeder 12.5 ± 1.5 N⋅m
Front brake assembly mounting bolt 100 ± 10 N⋅m
Front brake bolt (guide pin bolt) 36.5 ± 1.5 N⋅m
Master cylinder assembly and brake booster
Brake booster nut 14 ± 2 N⋅m
Brake master cylinder mounting nut 25 ± 2 N⋅m
Rear disc brake
Brake hose connector bolt 30 ± 4 N⋅m
Caliper bleeder 12.5 ± 1.5 N⋅m
Rear brake assembly mounting bolt 60 ± 5 N⋅m
Rear brake bolt (guide pin bolt) 36.5 ± 1.5 N⋅m
GENERAL SPECIFICATIONS
M1351000200362
ITEM SPECIFICATION
Master Type Tandem type
cylinder I.D. mm 25.4
Brake Type Vacuum type, tandem
booster Effective dia. of power 205 + 230
cylinder mm
Boosting ratio 6.5
Rear wheel hydraulic control method Electronic brake-force distribution (EBD)
Front brakes Type Floating caliper, Aluminium housing, 2 piston, ventilated disc
Disc effective dia × thickness 296 × 28.0
mm
Wheel cylinder I.D. mm 42.0 x 2
Pad thickness mm 10.0
Clearance adjustment Automatic
BASIC BRAKE SYSTEM 35A-41
SPECIFICATIONS
ITEM SPECIFICATION
Rear brakes Type Floating caliper, Aluminium housing, 1 piston, ventilated disc
Disc effective dia × thickness 303 × 18
mm
Wheel cylinder I.D. mm 40.5
Pad thickness mm 10.0
Clearance adjustment Automatic
SERVICE SPECIFICATIONS
M1351000300477
GROUP 35B
ANTI-LOCK
BRAKING SYSTEM
(ABS)
CONTENTS
GENERAL DESCRIPTION
M1352000100454
CONSTRUCTION DIAGRAM
35DB112A
3, 7
1 1
2 1
1 6
35DB031A
NAME OF PART NUMBER OUTLINE OF FUNCTION
Sensor Active wheel speed 1 Sends alternating voltage signals at frequencies which are
sensor independant to the rotation speeds of each wheel to the
ABS-ECU.
Stoplight switch 2 Sends a signal to the ABS-ECU to indicate whether the
brake pedal is depressed or not.
Actuator Hydraulic unit 3 Drives the solenoid valves according to signals from the
ABS-ECU in order to control the brake hydraulic pressure
for each wheel.
ABS warning light 4 Illuminates in response to signals from the ABS-ECU
when a problem develops in the ABS system.
Brake warning light 5 Illuminates in response to signals from the ABS-ECU
when a problem develops in the EBD system.
Data link connector 6 Outputs the diagnostic trouble codes and allows
communication with the diagnostic tool.
ABS-ECU 7 Controls actuators (described above) based on the signals
coming from each sensor.
Controls the self-diagnosis and fail-safe functions.
Controls the diagnostic function (diagnostic tool
compatible).
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-4
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
SYSTEM CHECK SOUND • When the brakes are applied firmly, the ABS
When the vehicle speed reaches 10 km/h after igni- operates, rapidly applying and releasing the
tion switch ON, a thudding sound can sometimes be brakes many times per second. This repeated
heard coming from the engine compartment. This is application and release of braking forces can
a normal sound during the ABS self-check. cause the suspension to make a thumping sound
and the tyres to squeak.
ABS OPERATION SOUNDS AND
SENSATIONS LONG STOPPING DISTANCES ON LOOSE
During normal operation, the ABS makes several ROAD SURFACES
sounds that may seem unusual at first: When braking on loose surfaces like snow-covered
• A whining sound is caused by the ABS hydraulic or gravel roads, the stopping distance can be longer
unit motor. for an ABS-equipped vehicle than the stopping dis-
• When pressure is applied to the brake pedal, the tance for a vehicle with a conventional brake system.
pulsation of the pedal causes a scraping sound.
SHOCK AT STARTING CHECK
Shock may be felt when the brake pedal is lightly
pressed while driving at a low speed. This is a nor-
mal characteristic because the ABS system opera-
tion check is carried out when vehicle speed is 8
km/h (5 mph) or less.
5. If you can verify the condition but there are no NOTE: Any DTCs stored in the ABS-ECU cannot
ABS DTCs, or the system cannot communicate be erased if there is a malfunction.
with the diagnostic tool, check that the basic 7. Duplicate the ABS DTC set conditions to see if the
brake system is operating properly. same ABS DTC will set again.
• If the basic brake system is not operating prop- • If the same ABS DTC sets again or the ABS DTC
erly, refer to the GROUP 35A, Basic Brake Sys- cannot be erased, perform the diagnostic proce-
tem Diagnosis P.35A-3. dures for the DTC. Refer to P.35B-9.
• If the basic brake system is operating properly, • If you cannot get the same ABS DTC to set
refer to P.35B-71. again, the malfunction is intermittent. Refer to
6. If there is an ABS DTC, record the number of the GROUP 00, How to use Troubleshooting/Inspec-
DTC, then erase the DTC from the memory using tion Service Points − How to Cope with Intermit-
the diagnostic tool. tent Malfunctions P.00-14.
DIAGNOSTIC FUNCTION
M1352011200596
MB991827 00DB076A
CAUTION
To prevent damage to diagnostic tool MB991958, always
DATA LINK turn the ignition switch to the "LOCK" (OFF) position
CONNECTOR
before connecting or disconnecting diagnostic tool
MB991958.
1. Connect diagnostic tool MB991958 to the data link
connector.
2. Turn the ignition switch to the "ON" position.
3. Select "Interactive Diagnosis" from the start-up screen.
MB991910 4. Select "System Select."
5. Choose "ABS" .
MB991824
6. Select "Data List."
7. Choose an appropriate item and select the "OK" button.
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-8
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
CAUTION
During diagnosis, a DTC code associated with
another system may be set when the ignition
switch is turned on with connector(s) discon-
nected. On completion, confirm all systems for
DTCs. If DTC code(s) are set, erase them all.
Follow the inspection chart that is appropriate for the
diagnostic trouble code.
DTC INSPECTION ITEM DIAGNOSTIC CONTENT REFERENCE PAGE
C1200 Front right wheel speed sensor Open circuit or short circuit P.35B-10
C1201 Front right wheel speed sensor Abnormal output signal P.35B-26
C1205 Front left wheel speed sensor Open circuit or short circuit P.35B-10
C1206 Front left wheel speed sensor Abnormal output signal P.35B-26
C1210 Rear right wheel speed sensor Open circuit or short circuit P.35B-10
C1211 Rear right wheel speed sensor Abnormal output signal P.35B-26
C1215 Rear left wheel speed sensor Open circuit or short circuit P.35B-10
C1216 Rear left wheel speed sensor Abnormal output signal P.35B-26
C1225 Deviation between wheel speeds P.35B-40 or refer to the
above appropriate
abnormal output sensor
signalP.35B-26
C1226 ABS front right (FR) inlet solenoid valve P.35B-41
C1231 ABS front right (FR) outlet solenoid valve P.35B-41
C1236 ABS front left (FL) inlet solenoid valve P.35B-41
C1241 ABS front left (FL) outlet solenoid valve P.35B-41
C1246 ABS rear right (RR) inlet solenoid valve P.35B-41
C1251 ABS rear right (RR) outlet solenoid valve P.35B-41
C1256 ABS rear left (RL) inlet solenoid valve P.35B-41
C1261 ABS rear left (RL) outlet solenoid valve P.35B-41
C1266 Motor pump system (seizure) P.35B-48
C1273 Motor relay (drive circuit) problem (stays off) P.35B-48
C1274 Motor relay (drive circuit) problem (stays on) P.35B-48
C1276 Valve relay malfunction P.35B-56
C1278 Valve relay problem (stays off) P.35B-56
C1279 Valve relay problem (stays on) P.35B-56
C1607 ABS-ECU malfunction P.35B-62
C1860 Power supply system Abnormal rise in voltage P.35B-63
C1861 Power supply system Abnormal drop in voltage P.35B-63
U1073 CAN-Bus off P.35B-69
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-10
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB090A
the reluctor ring fitted to the wheel hub. ABS DTC SET CONDITIONS
• Active wheel speed sensors have a constant The ABS-ECU monitors voltage fluctuation in each
incoming power supply on one wire and return a wheel speed sensor circuit. If the ECU detects a
signal on the other wire short or open circuit in the circuit, it will set a diag-
• The advantage of the active wheel speed sensor nostic trouble code.
is that there is always a signal until the wheel
has stopped. As the wheel speeds up or slows .
down, the frequency will change where the ampli- WHEEL SPEED SENSOR AIR GAP:
tude of the signal will remain constant. • Sensor air gap: (0.2mm - 0.85mm).
• A Hall switch and magnet assembly is contained .
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991222: Back-probing probe
• MB991219: Inspection test harness
.
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-13
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
11-12V FIGURE 1
OSCILLOSCOPE
Black Red
Ground
Terminals:
16, 9, 6, 8
Supply
WHEEL SPEED
Signal
SENSOR
35DB121A
FIGURE 2
Wheel speed sensor connectors:
A-04, A-01, D-30, D-31
WHEEL SPEED
SENSOR
Supply
Signal
Terminals:
5, 10, 17, 19
Ground
Black Red
ABS-ECU
(A-02)
OSCILLOSCOPE
35DB122A
V
1.50
1.00
0.50
0.00
0 20 40 60 80 100
ms
35DB120A
35DB090A
35DB090A
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-19
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB090A
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-21
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB033A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-22
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
CONNECTOR: C-25
C-25
35DB033A
Q: Are ABS-ECU connector A-02, intermediate connector
C-25 and wheel speed sensor <rear: LH> connector
D-31 damaged?
YES : Repair or replace the damaged component(s). Refer
to GROUP 00E, Harness Connector Inspection
P.00E-2. Then go to Step 16.
NO : Go to Step 13..
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-24
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991824
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-26
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
DTC C1201/C1206/C1211/1216 Wheel Speed Sensor (Abnormal Output Signal). (C1225) Deviation in
wheel speed. This code may also be set, togethor with other codes.
35DB090A
CONNECTOR: C-25
C-25
35DB033A
ABS DTC SET CONDITIONS • Malfunction of the hydraulic unit (integrated with
The ABS-ECU monitors the signals from each wheel ABS-ECU)
speed sensor while the vehicle is being driven. If any
fault below is found in these sensor signals, the ECU Past trouble
will set the relevant diagnostic trouble code. • Carry out diagnosis with particular emphasis on
• Missing sensor signal connector(s) or wiring harness in wheel speed
• Sensor signal, which will not be created under sensor circuit. For diagnosis procedures, refer to
normal operation "How to cope with past trouble" (Refer to GROUP
• Significant difference among the wheel speed 00, How to use Troubleshooting/Inspection Ser-
sensor signals vice PointsP.00-16).
NOTE: DTC C1225 may also be set with the abnor- Circuit drawings
mal wheel speed sensor codes as it too looks for a • Refer to circuit diagrams GROUP-90
variation in wheel speeds that does not meet crite- • Refer to configuration diagrams GROUP-80
ria.It is possible for DTC C1125 to be logged by itself, .
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991219: Inspection Test Harness
.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-28
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-29
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
CONNECTOR: A-02
Q: Are ABS-ECU connector A-02 and wheel speed sensor
A-02 (GR) <front: LH> connector A-04 damaged?
YES : Repair or replace the damaged component(s). Refer
to GROUP 00E, Harness Connector Inspection
P.00E-2. Then go to Step 13.
NO : Open or short circuit may be present in the front left
wheel speed sensor circuit. Repair the wiring harness
between ABS-ECU connector A-02 (terminals 5 and
16) and front left wheel speed sensor A-04 (terminals
1 and 2).Then go to Step 13.
16DB402A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-35
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-39
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-40
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
NOTE: If DTC C1225 is set, it is more likely to be set NOTE: It is possible for DTC 1225 to be logged by
togethor with other codesP.35B-26 and it too will itself, for example "during extended wheel spin". If
look for a variation in wheel speeds which do not this were the case, it would only be a history code
meet required specification. It will, in most cases be and no action is necessary.
set whenever a "plausibility" or an abnormal wheel
speed output signal is created. Refer to P.35B-26.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-41
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB090A
FUSIBLE LINK
ABS (motor supply)
No. 3 (30 A)
35DB091A
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991219: Inspection Test Harness
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-43
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-44
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
FUSIBLE LINK
ABS (solenoid valve)
(20 A) RELAY BOX
35DB093A
16DB402A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-46
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB094A
CONNECTOR: A-02
A-02 (GR)
16DB402A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-47
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
16DB402A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-48
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
35DB090A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-49
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
RELAY BOX
FUSIBLE LINK
ABS (motor supply)
No. 3 (30 A)
35DB095A
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991219: Inspection Test Harness
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-51
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-52
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
CONNECTOR: A-02
A-02 (GR)
16DB402A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-53
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
RELAY BOX
35DB097A
16DB402A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-54
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB098A
16DB402A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-55
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-56
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB090A
FUSIBLE LINK
ABS (solenoid valve)
(20 A) RELAY BOX
35DB093A
NOTE: If the ABS-8 ECU or the active wheel ABS DTC SET CONDITIONS
speed sensor are disconnected, or if the wiring is These diagnostic trouble codes will be set under the
an open/ short circuit, the ABS 8 ECU will shut cases below.
off power supply to the respective wheel speed DTC C1278 (Valve relay OFF failure)
sensor. All other wheel speed sensors will oper- • After the ABS-ECU turned on the MOSFET
ate normally. To restore the power supply, the driver, the solenoid valve is not energized (valve
ignition switch must be turned to the "OFF" posi- relay OFF failure).
tion then to the "ON" position again.
. DTC C1278 (Valve relay ON failure)
CIRCUIT OPERATION • After the ABS-ECU turned off the MOSFET
• The ABS-ECU contains the power supply circuit driver, the solenoid valve still remains energized
(terminal 3) for the solenoid valve. The solenoid (valve relay ON failure).
valve is energized by a MOSFET driver, which is .
TROUBLESHOOTING HINTS (The most • Malfunction of the hydraulic unit (integrated with
likely causes for these DTCs are to set ABS-ECU)
are:) .
Past trouble
Circuit drawings Carry out diagnosis with particular emphasis on con-
• Refer to circuit diagrams GROUP-90 nector(s) or wiring harness between the power sup-
• Refer to configuration diagrams GROUP-80 ply circuit (terminal 3) to the ABS-ECU solenoid
Currect trouble valve or ground circuit (terminal 1) . For diagnosis
• Damaged wiring harness or connector procedures, refer to "How to cope with past trouble"
(Refer to GROUP 00, How to Use Troubleshoot-
ing/Inspection Service Points P.00-16).
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991219: Inspection Test Harness
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-58
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
16DB402A
FUSIBLE LINK
ABS (solenoid valve)
(20 A) RELAY BOX
35DB093A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-60
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB094A
16DB402A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-61
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-62
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
NOTE: If the ABS-8 ECU or the active wheel TROUBLESHOOTING HINTS (The most
speed sensor are disconnected, or if the wiring is likely causes for these DTCs are to set
an open/ short circuit, the ABS 8 ECU will shut
are:)
off power supply to the respective wheel speed
• Malfunction of the hydraulic unit (integrated with
sensor. All other wheel speed sensors will oper-
ABS-ECU)
ate normally. To restore the power supply, the
ignition switch must be turned to the "OFF" posi- Circuit drawings
tion then to the "ON" position again. • Refer to circuit diagrams GROUP-90
CAUTION • Refer to configuration diagrams GROUP-80
Whenever the ECU is replaced, ensure that the
CAN bus lines are normal.
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-63
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
35DB090A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-64
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991219: Inspection Test Harness
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-65
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-66
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
16DB402A
C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
C-215
JUNCTION BLOCK 1 2
(FRONT VIEW) 3 4 5 6
35DB041A
CONNECTOR: C-308
• Ignition switch connector C-308
Q: Are the connectors and terminals in good condition?
YES : An open or short circuit may be present in the power
supply line to the ABS-ECU. Repair the wiring
harness between ABS-ECU connector A-02 terminal
18 and ignition switch connector C-308 terminal 4. Go
1 2 3
C-308 4 5 6 to Step 8.
NO : Repair or replace the damaged component(s). Refer
to GROUP 00E, Harness Connector Inspection
35DB042A P.00E-2. Then go to Step 8.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-68
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-69
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
Circuit drawings
TROUBLE JUDGMENT • Refer to circuit diagrams GROUP-90
This code is stored when the ABS-ECU has ceased • Refer to configuration diagrams GROUP-80
the CAN communication (bus off). Then, if a penalty
mode is entered after approximately five minutes, the
regular data transmission from the ABS-ECU will be
cancelled.
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-70
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-71
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
SYMPTOM CHART
M1352011400619
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Communication between Diagnostic Tool and the ABS-ECU is not
possible.
35DB090A
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-73
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-74
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB090A
CIRCUIT OPERATION
• The ABS-ECU is energized by the ignition switch likely causes for this case:)
(IG1) through multi-purpose fuse 19 and the • Damaged wiring harness or connector
ABS-ECU terminal 18. • Defective battery
• If the power supply to the ABS-ECU has failed, • Charging system failed
diagnostic tool (MUT-III Sub Assembly) will not • Malfunction of the hydraulic unit (integrated with
be able to communicate with it. ABS-ECU)
. Circuit drawings
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
.
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991219: Inspection Test Harness
.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-75
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
16DB402A
C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
C-215
JUNCTION BLOCK 1 2
(FRONT VIEW) 3 4 5 6
35DB041A
CONNECTOR: C-308
• Ignition switch connector C-308
Q: Are the connectors and terminals in good condition?
YES : An open or short circuit may be present in the power
supply line to the ABS-ECU. Repair the wiring
harness between ABS-ECU connector A-02 terminal
18 and ignition switch connector C-308 terminal 4.
1 2 3
C-308 4 5 6 Then go to Step 8.
NO : Repair or replace the damaged component(s). Refer
to GROUP 00E, Harness Connector Inspection
35DB042A P.00E-2. Then go to Step 8.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-77
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
35DB098A
16DB402A
INSPECTION PROCEDURE 3: When the Ignition Key is Turned to "ON" (Engine Stopped), the
BRAKE/ABS Warning Light does not Illuminate. INSPECTION PROCEDURE 4: The BRAKE/ABS
Warning Light Remains Illuminated after the Engine is Started.
35DB090A
DIAGNOSIS
Required Special Tools:
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-80
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-81
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
DIAGNOSIS
AC100172 AI
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-84
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
CHECK AT ABS-ECU
M1352011800769
.
.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-85
ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS
SPECIAL TOOLS
M1352000600653
DO NOT USE
MB991914
MB991825
MB991826
MB991958
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-87
SPECIAL TOOLS
ON-VEHICLE SERVICE
WHEEL SPEED SENSOR SIGNAL
MEASUREMENT
M1352001600667
Required Special Tool:
MB991222: Back probing tool
1. ABS connector (A-02) must remain connected to hydraulic
unit when checking signal measurements.
2. Remove ABS connector protection cap to access terminal
location from rear of connector for backprobing.
3. Release the parking brake and lift up the vehicle.
4. Use probe tool MB991222 to measure the output signal at
the ABS connector A-02 by back probing the terminal
positions shown in the table below.
TERMINAL NO.
Front left Front right Rear left Rear right
5 10 17 19
FIGURE 2
Wheel speed sensor connectors:
A-04, A-01, D-30, D-31
WHEEL SPEED
SENSOR
Supply
Signal
Terminals:
5, 10, 17, 19
Ground
Black Red
ABS-ECU
(A-02)
OSCILLOSCOPE
35DB122A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-89
ON-VEHICLE SERVICE
V
1.50
1.00
0.50
0.00
0 20 40 60 80 100
ms
35DB120A
NOTE: The wheel speed 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 signal waveform also under special conditions, such as
driving on a rough road.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-90
ON-VEHICLE SERVICE
MB991827 00DB076A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-91
ON-VEHICLE SERVICE
DEPRESSED
PEDAL
OPERATION SCAN TOOL ACTUATOR TEST
RELEASED (ITEM NO.01, 02, 03, 04) START
PRESSURE INCREASE
SOLENOID 2s
VALVE PRESSURE HOLD
POSITION
PRESSURE DECREASE 1s
LOCK
CHECKING
THE BRAKE
FORCE DRAG FORCE
WHEN THE 3s
PEDAL IS FREE
AC000954AB
DIAGNOSIS TABLE
MUT-III OPERATION INSPECTION JUDGMENT PROBABLE REMEDY
DISPLAY RESULT CAUSE
01 FL VALVE • Depress brake Brake force is Normal − −
02 FR VALVE pedal to lock released for
03 RL VALVE wheel. three seconds
04 RR VALVE • Using diagnostic after wheels
tool MB991958, have been
select the wheel to locked.
be checked and
Wheel does not Abnormal Clogged brake Check and clean
force the actuator
lock when brake line other than brake line
to operate.
pedal is hydraulic unit
• Turn the selected
depressed.
wheel manually to Clogged Replace
check the change hydraulic circuit hydraulic unit
of brake force. in hydraulic unit assembly
Brake force is Abnormal Incorrect Connect correctly
not released hydraulic unit
brake tube
connection
Hydraulic unit Replace
solenoid valve hydraulic unit
not functioning assembly
correctly
WARNING
If the ABS is not operating, the vehicle will be unsta-
ble during braking, Do not drive the vehicle with the
ABS-ECU connector disconnected or with the ABS
not operating.
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.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-93
HYDRAULIC UNIT
HYDRAULIC UNIT
REMOVAL AND INSTALLATION
M1352008600464
NOTE: The ABS-ECU is integrated in the hydraulic unit.
Pre-removal Operation Post-installation Operation
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Brake Fluid Filling
Tower Bar P.42-12). • Brake Line Bleeding (Refer to GROUP 35A, On-vehicle
• Brake Fluid Draining Service − Bleeding P.35A-16).
• Hydraulic Unit Check (Refer to P.35B-90).
• Strut Tower Bar Installation (Refer to GROUP 42, Strut
Tower Bar P.42-12).
3
5
15 ± 2 N·m 2
12 ± 1 ft-lb
35DB104A
Connector
A-02
LOCK LEVER
35DB105A
35DB106A
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-95
WHEEL SPEED SENSOR
Post-installation Operation
• Wheel Speed Sensor Output Signal Voltage Measure-
ment (Refer to P.35B-88).
<REAR>
<RH>
<FRONT>
1
3
2 <REAR>
<LH>
4
35DB114A
FRONT WHEEL SPEED SENSOR REAR WHEEL SPEED SENSOR
REMOVAL STEPS REMOVAL STEPS
• SPLASH SHIELD (REFER TO <<A>> 3. REAR WHEEL SPEED SENSOR
GROUP 42, FENDER P.42-10). 4. REAR WHEEL SPEED ROTOR
<<A>> 1. FRONT WHEEL SPEED SENSOR (REFER TO GROUP 27, REAR
2. FRONT WHEEL SPEED ROTOR AXLE HUB ASSEMBLY P.27-6).
(REFER TO GROUP 26, NOTE: Front wheel speed rotors are integrated with
DRIVESHAFT ASSEMBLY the BJ assembly of the drive shaft and cannot be dis-
P.26-13). assembled.
NOTE: Rear wheel speed rotors are integrated with
the rear hub assembly and cannot be disassembled.
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-96
WHEEL SPEED SENSOR
AC211046AB
INSPECTION
M1352008400459
AC000965
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-97
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATION
M1352012400377
ITEM SPECIFICATION
Brake tube flare nut 15 ± 2 N⋅m (12 ± 1 ft-lb)
GENERAL SPECIFICATIONS
M1352000200075
ITEM SPECIFICATION
ABS control method 4-sensor, 4-channel
Numbers of wheel speed Front 43
rotor teeth Rear 43
Wheel speed sensor Type Active Wheel Speed Sensor
Gap between sensor and rotor (mm) 0.2mm − 0.85mm
<Non-adjustable type>
35B-98 ANTI-LOCK BRAKING SYSTEM (ABS)
SPECIFICATIONS
HOME
36-1
GROUP 36
PARKING BRAKES
CONTENTS
GENERAL DESCRIPTION
M1361000100344
The parking brakes are a mechanical rear wheel
brake design and controlled by a lever.
CONSTRUCTION DIAGRAM
SYMPTOM PROCEDURES
ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE CHECK AND
ADJUSTMENT
M1361000900362
1. Pull the parking brake lever with a force of approximately
200 N (45 pounds) and count the number of notches.
Standard value: 5 − 7 notches
2. If the parking brake lever stroke is not within the standard
value, adjust as described below.
(1) Release the parking brake.
PARKING BRAKES 36-4
ON-VEHICLE SERVICE
<INSIDE THE FLOOR CONSOLE> (2) Remove the console inner box tray and plate (Refer to
CABLE ROD
GROUP 52A, Floor Console Assembly P.52A-10), and
then loosen the adjusting nut to move it to the cable rod
end so that the cable will be free.
ADJUSTING
NUT
AC306061AB
ADJUSTMENT
HOLE PLUG
AC209383AB
AC306064AB
CAUTION
Perform lining seating in a place with good visibility, and
pay careful attention to safety.
Perform lining seating by the following procedure when replac-
ing the parking brake shoe assemblies or the rear brake discs,
or when brake performance is insufficient.
1. Adjust the parking brake lever stroke to the standard value
(Refer to P.36-3).
PULL
2. Hook a spring scale onto the center of the parking brake
lever grip and pull it with a force of 98 − 147 N (22 − 33
pounds) in a direction perpendicular to the handle.
3. Drive the vehicle at a constant speed of 35 − 50 km/h (22 −
SPRING SCALE
31 mph) for 100 meters (328 feet).
4. Release the parking brake and let the brakes cool for five to
ten minutes.
5. Repeat the procedure in steps 2. to 4. four to five times.
APPROXIMATELY
40 mm (1.6 in) ACX00701AC
PARKING BRAKES 36-6
PARKING BRAKE LEVER
1 3
5
2
AC306274AB
SECTION A - A SECTION B - B
A
RATCHET
PAWL
B
A
RATCHET
PAWL
REMOVAL STEPS
1. ADJUSTING NUT
2. PARKING BRAKE SWITCH
CONNECTOR
3. PARKING BRAKE CABLE
CONNECTION
4. PARKING BRAKE LEVER
ASSEMBLY
5. PARKING BRAKE SWITCH
PARKING BRAKES 36-7
PARKING BRAKE CABLE
2N
AC305772AB
REMOVAL STEPS
• SHOE ASSEMBLY (REFER TO P.36-8).
• REAR PARKING BRAKE CABLE TO
BAKING PLATE CONNECTION (REFER
TO P.36-8).
• FRONT PARKING BRAKE CABLE TO
REAR PARKING BRAKE CABLE
CONNECTION (REFER TO P.36-6).
1. REAR PARKING BRAKE CABLE
2. O-RING
PARKING BRAKES 36-8
PARKING BRAKE LINING AND DRUM
Post-installation Operation
• Parking Brake Lever Stroke Check and Adjustment (Refer
to P.36-3).
• Parking Brake Lining Seating (Refer to P.36-5).
60 ± 5 N·m
45 ± 3 ft-lb 1
73 ± 7 N·m
54 ± 5 ft-lb
2
N 12
14
10
15 13
4
3
19 7
11
18 17
16
8
9 5
6
AC306238AB
13 :
13 18 6
BOLTS
(M8 × 1.25)
AC205986AB
REAR
FRONT
.
PARKING BRAKES 36-11
PARKING BRAKE LINING AND DRUM
2 (YELLOW SPRING)
AC206986 AB
REAR
1 (BLUE SPRING)
2 (YELLOW SPRING)
AC209387AB
INSPECTION
M1361002600260
ACX00708AB
ACX00709AB
36-12 PARKING BRAKES
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1361003500266
ITEM SPECIFICATION
Parking brake lining and drum
Rear brake bolt (rear brake caliper assembly mounting 60 ± 5 N⋅m (45 ± 3 ft-lb)
bolt)
Rear wheel hub assembly mounting bolt 73 ± 7 N⋅m (54 ± 5 ft-lb)
SERVICE SPECIFICATIONS
M1361000300412
LUBRICANT
M1361000400301
GROUP 37
POWER STEERING
CONTENTS
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
passenger (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 (*).
POWER STEERING 37-2
POWER STEERING OIL PUMP POWER STEERING HOSES . . . . . . . 37-45
ASSEMBLY . . . . . . . . . . . . . . . . . . . . 37-43 REMOVAL AND INSTALLATION . . . . . . . . 37-45
REMOVAL AND INSTALLATION . . . . . . . 37-43
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 37-44 SPECIFICATIONS . . . . . . . . . . . . . . . 37-49
FASTENER TIGHTENING SPECIFICATIONS 37-49
GENERAL SPECIFICATIONS . . . . . . . . . . 37-50
SERVICE SPECIFICATIONS . . . . . . . . . . . 37-51
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 37-51
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . 37-52
POWER STEERING 37-3
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1372000100360
Power steering has been adopted in all vehicles to • An oil pump responsive to engine RPM is used,
make the steering system easier to handle. to enhance steering stability at high speeds.
• A 4-spoke steering wheel is used. • The separate plastic resin oil reservoir is used to
• A steering column has a shock absorbing mecha- reduce weight and to make the fluid level check-
nism and a tilt steering mechanism. ing easier.
• A rack and pinion steering gear is used.
SYMPTOM PROCEDURES
DIAGNOSIS
DIAGNOSIS
STEP 7. Check the gear box rack piston seal for damage.
Q: Is there damage?
YES : Replace it. And then go to Step 9.
NO : Go to Step 8.
DIAGNOSIS STEP 3. Check for noise from inside the oil pump
or the steering gear.
STEP 1. Check for proper oil pump and steering Q: Is there noise?
gear installation. YES : Replace the part. And then go to Step 4.
Q: Is the oil pump and the steering gear installation NO : Go to Step 4.
correct?
YES : Go to Step 2.
STEP 4. Check for rattling noise.
NO : Repair it. And then go to Step 4.
Confirm that no noise is generated.
Q: Is there noise?
STEP 2. Check for interference of other parts with YES : Repeat from Step 1.
the steering column and the power steering NO : The procedure is complete.
hoses.
Q: Is there interference?
YES : Correct the interference. And then go to
Step 4.
NO : Go to Step 3.
POWER STEERING 37-7
POWER STEERING DIAGNOSIS
DIAGNOSIS
DIAGNOSIS
STEP 2. Check the oil pump for damage. STEP 3. Retest the system.
Q: Is there damage?
Confirm that no noise is generated.
YES : Replace the oil pump. And then go to Step Q: Is there noise?
3. YES : Repeat from Step 1.
NO : Go to Step 3. NO : The procedure is complete.
DIAGNOSIS
SPECIAL TOOLS
M1372000600387
MB990326
MB991549 MB991549-01
Power steering oil
pressure gauge
adapter (Hose
side)
MB991549
MB990662 MB990662-01
Power steering oil
pressure gauge
MB990662
POWER STEERING 37-14
ON-VEHICLE SERVICE
MB990803
MB991006
MB991561
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK
M1372001000344
1. With the engine running (hydraulic operation), set the front
wheels straight ahead.
2. Slightly move the steering wheel in both directions and
measure the play on the steering wheel circumference
before the wheels start to move.
Limit: 30 mm (1.2 inch)
3. If the play exceeds the limit, check on the steering shaft and
steering linkage connection. Correct or replace.
4. If the free play still exceeds the limit value, set the steering
wheel straight ahead with the engine stopped. Apply 5 N
(1.1 pound) towards the steering wheel circumference and
ACX01122AB
check the play.
Standard value (steering wheel play with the engine
stopped): 10 mm (0.4 inch) or less
5. If the play exceeds the standard value, remove the steering
gear (refer to P.37-30) and check the total pinion torque
(refer to P.37-38).
POWER STEERING 37-15
ON-VEHICLE SERVICE
NUT MB991897
BOLT
BALL JOINT AC208247AC
POWER STEERING 37-16
ON-VEHICLE SERVICE
BAD AC106821AB
4. Move the ball joint stud several times and install the nut on
MB990326 the stud. Using special tool MB990326, measure the ball
joint breakaway torque.
Standard value: 0.5 − 3.5 N⋅m (4.4 − 31.0 in-lb)
5. If the breakaway torque exceeds the standard value, replace
the tie rod end assembly.
6. If the breakaway torque is under the standard value, check
the ball joint for end play or ratcheting. If there is no end play
or ratcheting, the ball joint can be re-used.
ACX01129 AB
CAUTION
Always use a new ball joint nut, as it is a self-locking nut.
7. Install the tie rod end to the knuckle, then tighten a new
self-locking nut to the specified torque.
Tightening torque: 29 ± 4 N⋅m (21 ± 3 ft-lb)
ACX01130AB
FLUID REPLACEMENT
M1372002100366
1. Raise and support the front wheels.
2. Disconnect the return hose connection, and then connect a
vinyl hose to the return hose, and drain the fluid into a
container.
3. Disconnect the ignition coil connectors (refer to GROUP 16,
Ignition Coil, P.16-33 ).
RETURN
HOSE 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.
VINYL HOSE
5. Connect the return hose securely, and then secure with the
AC206743AB clip.
6. Fill the oil reservoir with GENUINE MITSUBISHI POWER
STEERING FLUID up to the lower mark of the reservoir, and
then bleed the air.
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-control valve, and this condition could reduce
the life of the power steering components.
FLUID LEVEL CHANGE:WITHIN 5 mm (0.2 in)
9. Confirm that the change in the fluid level is no more than 5
mm (0.2 inch) when the engine is stopped.
10.If the change of the fluid level is 5 mm (0.2 inch) or more,
the air has not been completely bled from the system. The
air bleeding procedure must be repeated.
8. Turn the steering wheel all the way to the left or right; then
check the retention hydraulic pressure.
Standard value:
3.8L engine: 9.3 − 9.8 MPa (1,349 − 1,421 psi)
9. If not the standard value, overhaul or replace the steering
gear. Remeasure fluid pressure.
10. Remove special tools MB991548, MB990662 and
MB991549, connect the pressure hose to the oil pump, and
then tighten the eye bolt to the specified torque.
Tightening torque: 57 ± 7 N⋅m (42 ± 5 ft-lb)
11. Bleed the system (Refer to P.37-18).
SLIDE PLATE
• If a collision occurs or severe impact is applied to the steer-
ing wheel, the collision energy absorbing mechanism (slide
RIPPING PLATE
plate, ripping plate, tilt pin) may have operated. Once the
TILT PIN mechanism has operated, it will be inoperative even if there
is no apparent damage. Determine if the steering column
shaft can be reused by the following procedure. If the colli-
sion energy absorbing mechanism has already operated,
replace the steering column assembly.
• If any excessive radial or axial free play on the steering
AC308268 AC wheel is found with the tilt lever in the lock position, always
check the steering column assembly.
WARNING
1. If the vehicle continues to be driven after the colli-
sion absorbing mechanism has operated, the
steering column shaft may be damaged while driv-
ing.
2. If there is a slack in the one-way capsule, do not
attempt to repair it. Replace the steering column
assembly.
Inspection Procedure
1. Remove the steering column covers (lower and upper).
CAUTION
Do not release the tilt lever until the steering column has
been installed to complete this inspection procedure.
2. Place the tilt lever in the locked position.
3. Loosen the two upper steering column mounting bolts by
two turns.
4. Hold the steering wheel, and then try to rock it. If there is a
radial or axial free play, replace the steering column
assembly.
POWER STEERING 37-22
ON-VEHICLE SERVICE
5. Check the tilt pin fixing detent of the lower bracket for
deformation. If there is a deformation, replace the steering
column assembly.
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 proce-
dure.
6. If no problem is found during the inspection, tighten the
steering column assembly mounting bolts to the specified
torque.
DETENT
Tightening torque: 12 ± 2 N⋅m (102 ± 22 in-lb)
TILT PIN
AC308269 AB
POWER STEERING 37-23
STEERING WHEEL
STEERING WHEEL
REMOVAL AND INSTALLATION
M1372011400224
WARNING
• Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-16) and Air Bag Module and Clock Spring (P.52B-237).
• When removing and installing the steering wheel, do not let it bump against the air bag
module.
Post-installation Operation
• Checking Steering Wheel Position with Wheels Straight
Ahead
41 ± 8 N·m
30 ± 6 ft-lb
6 N 4
2
5
2
2
AC306560 AB
AC306561AB
MB990803
AC000991AB
POWER STEERING 37-25
STEERING SHAFT
STEERING SHAFT
REMOVAL AND INSTALLATION
M1372011500135
WARNING
Before removing the air bag module and steering wheel assembly, refer to GROUP 52B, Ser-
vice Precautions and Air Bag Module and Clock Spring (P.52B-16 and P.52B-237).
Pre-removal Operation Post-installation Operation
• Air bag Module and Steering Wheel Assembly Removal • Front Floor Carpet Installation
(Refer to P.37-23). • Accelerator Pedal Stopper Installation
• Instrument Panel Lower Panel Removal (Refer to • Trunk Lid Opener Cover Installation
GROUP 52A, Instrument Panel P.52A-4). • Front Scuff Plate and Cowl Side Trim Installation (Refer to
• Floor Console Assembly Removal (Refer to GROUP 52A, GROUP 52A, Trims P.52A-11).
Floor Console Assembly P.52A-10). • Floor Console Assembly Installation (Refer to GROUP
• Front Scuff Plate and Cowl Side Trim Removal (Refer to 52A, Floor Console Assembly P.52A-10).
GROUP 52A, Trims P.52A-11). • Instrument Panel Lower Panel Installation (Refer to
• Trunk Lid Opener Cover Removal GROUP 52A, Instrument Panel P.52A-4).
• Accelerator Pedal Stopper Removal • Steering Wheel Assembly and Air bag Module Installation
• Front Floor Carpet Removal (Refer to P.37-23).
2
MOUNTING SCREW
3
5
12 ± 2 N·m
4 102 ± 22 in-lb
18 ± 2 N·m
13 ± 2 ft-lb
AC306562 AB
STEERING
CLIP COLUMN
SHAFT
21DB016A
A YOKE X
X
Y Y X
VIEW A
7.6˚ ± 3˚
X Y
AC306564 AB
POWER STEERING 37-27
STEERING SHAFT
AC306794AB
POWER STEERING 37-28
STEERING SHAFT
WARNING
Do not move the tilt lever from the lock position until the installation is completed. If you
move it accidentally, the steering column cannot be reinstalled correctly.
AC306566AB
ENGINE STARTING
SWITCH ASSEMBLY ACX01138 AE
POWER STEERING 37-29
STEERING SHAFT
ACX01139 AB
POWER STEERING 37-30
POWER STEERING GEAR BOX AND LINKAGE
WARNING
• Before removing the power steering gear assembly, refer to GROUP 52B, Service Precau-
tions and Air Bag Module and Clock Spring (P.52B-16 and P.52B-237).
• Center the front wheels. Failure to do so may damage the SRS clock spring and render the
SRS system inoperative, risking serious injury.
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal Operation Post-installation Operation
• Power Steering Fluid Draining (Refer to P.37-18). • Check the dust cover for cracks or damage by pushing it
• Front Under Cover Removal with your finger.
• Centermember Removal (Refer to GROUP 32, Engine • Stabilizer Link and Stabilizer Bar Connection (Refer to
Roll Stopper and Centermember P.32-7). GROUP 33, Stabilizer Bar P.33-18).
• Lower Arm Assembly Removal (Refer to GROUP 33, • Front Floor Carpet Installation
Lower Arm P.33-13). • Accelerator Pedal Stopper Installation
• Air Bag Module and Steering Wheel Assembly Removal • Trunk Lid Opener Cover Installation
(Refer to P.37-23). • Front Scuff Plate and Cowl Side Trim Removal (Refer to
• Floor Console Assembly Removal (Refer to GROUP 52A, GROUP 52A, Trims P.52A-11).
Floor Console Assembly P.52A-10). • Floor Console Assembly Installation (Refer to GROUP
• Front Scuff Plate and Cowl Side Trim Removal (Refer to 52A, Floor Console Assembly P.52A-10).
GROUP 52A, Trims P.52A-11). • Steering Wheel Assembly and Air Bag Module Installation
• Trunk Lid Opener Cover Removal (Refer to P.37-23).
• Accelerator Pedal Stopper Removal • Checking Steering Wheel Position with Wheels Straight
• Front Floor Carpet Removal Ahead.
• Stabilizer Link and Stabilizer Bar Disconnection (Refer to • Lower Arm Assembly Installation (Refer to GROUP 33,
GROUP 33, Stabilizer Bar P.33-18). Lower Arm P.33-13).
• Centermember Installation (Refer to GROUP 32, Engine
Roll Stopper and Centermember P.32-7).
• Front Under Cover Installation
• Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service − Front Wheel Alignment Check and
Adjustment P.33-6).
• Power Steering Fluid Supplying (Refer to P.37-18).
• Power Steering Fluid Line Bleeding (Refer to P.37-18).
POWER STEERING 37-31
POWER STEERING GEAR BOX AND LINKAGE
12 ± 2 N·m
15 ± 3 N·m
102 ± 22 in-lb
11 ± 2 ft-lb
16 7
83 ± 12 N·m 12 ± 2 N·m
2 61 ± 9 ft-lb 102 ± 22 in-lb
17 15 ± 3 N·m
58 ± 7 N·m*¹
11 ± 2 ft-lb
43 ± 5 ft-lb*¹
4 5
18 ± 2 N·m N
13 ± 2 ft-lb
N 8 83 ± 12 N·m
1 61 ± 9 ft-lb 69 ± 10 N·m
13
19 14
18
N 3
29 ± 4 N·m N
21 ± 3 ft-lb
165 ± 15 N·m
122 ± 11 ft-lb
12
N
11
180 ± 20 N·m
133 ± 14 ft-lb
83 ± 12 N·m N 10
61 ± 9 ft-lb 13DB062A
STEERING
CLIP COLUMN
SHAFT
21DB016A
A YOKE X
X
Y Y X
VIEW A
7.6˚ ± 3˚
X Y
AC306564 AB
.
POWER STEERING 37-33
POWER STEERING GEAR BOX AND LINKAGE
NUT MB991897
BOLT
BALL JOINT AC208247AC
BAD AC106821AB
FRONT AXLE
CROSSMEMBER
STAY
21DB019A
.
POWER STEERING 37-34
POWER STEERING GEAR BOX AND LINKAGE
13DB066A
TRANSMISSION
JACK AC306696AB
13DB066A
13DB071A
POWER STEERING 37-35
POWER STEERING GEAR BOX AND LINKAGE
LIP
GROOVE
13DB056A
2. Align the cover with steering gear tab, as shown.
ALIGN TAB
13DB064A
3. Use a transmission jack to lift the crossmember assembly.
AC206593
TRANSMISSION
JACK AC306696AB
4. From inside the vehicle, locate the cover to engage the clip
correctly onto vehicle body and align bolt with hole.
13DB066A
POWER STEERING 37-36
POWER STEERING GEAR BOX AND LINKAGE
13DB067A
INSPECTION
M1372011000259
.
12
12 ± 2 N·m*
107 ± 17 in-lb* 5
9 4
59 ± 10 N·m
44 ± 7 ft-lb
59 ± 10 N·m
44 ± 7 ft-lb
8
10
11
25 ± 4 N·m 2
18 ± 3 ft-lb
52 ± 2 N·m
6 1 38 ± 2 ft-lb
84 ± 14 N·m
7 62 ± 10 ft-lb
13DB058A
DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)
>>P<< 1. STEERING GEAR NUT (TIE ROD >>L<< 8. STEERING GEAR INNER NUT (JAM
END JAM NUT) NUT)
>>P<< 2. TIE ROD END ASSEMBLY <<B>> >>L<< 9. STEERING GEAR RACK SUPPORT
3. STEERING GEAR INNER CLIP COVER
>>O<< 4. STEERING GEAR BAND (BELLOWS >>K<< 10. STEERING GEAR PLUG (END
BAND) PLUG)
5. STEERING GEAR BELLOWS 11. STEERING GEAR INNER NUT
<<A>> >>N<< 6. STEERING TIE ROD 12. STEERING GEAR ASSEMBLY (less
<<A>> >>N<< 7. STEERING GEAR WASHER (TAB tie rods)
WASHER) >>M<< • TOTAL PINION TORQUE
ADJUSTMENT
TAB WASHER
AC001001AB
ACX01142AB
ACX01162 AB
.
POWER STEERING 37-40
POWER STEERING GEAR BOX AND LINKAGE
AC001009 AB
ACX01163 AB
ACX01165 AB
INSPECTION
M1372004400114
BEARING
• Check for roughness or abnormal noise during bearing
operation.
• Check the bearing for play.
OTHERS
• Check the tie rod ends for wear and boot cracking.
• Check the boots for damage, cracking or deterioration.
• Check the rack support for uneven wear or dents.
• Check the rack bushing for uneven wear or damage.
POWER STEERING 37-43
POWER STEERING OIL PUMP ASSEMBLY
42 ± 7 N·m 3
5
31 ± 5 ft-lb
1
4
57 ± 7 N·m
12 ± 2 N·m
42 ± 5 ft-lb
46 ± 8 N·m 4 102 ± 22 in-
34 ± 6 ft-lb 2
15 ± 4 N·m
7
11 ± 3 ft-lb 49 ± 9 N·m
36 ± 7 ft-lb
8 6
41 ± 8 N·m
30 ± 6 ft-lb
49 ± 9 N·m
41 ± 8 N·m
36 ± 7 ft-lb
30 ± 6 ft-lb
9
13DB069A
REMOVAL STEPS REMOVAL STEPS (Continued)
1. DRIVE BELT (REFER TO GROUP • STEERING GEAR AND LINKAGE
11C, Engine Assembly 11A-8). ) PROTECTOR (REFER TO P.37-30)
2. PRESSURE SWITCH CONNECTOR <<A>> 6. POWER STEERING OIL PUMP
3. PRESSURE HOSE ASSEMBLY
4. GASKET 7. BELT TENSIONER PULLEY
>>A<< 5. SUCTION HOSE 8. BELT TENSIONER BRACKET
• CONNECTION OF STABILIZER BAR 9. POWER STEERING OIL PUMP
AND STABILIZER LINK (REFER TO BRACKET
GROUP 33, Stabilizer Bar P.33-18)
POWER STEERING 37-44
POWER STEERING OIL PUMP ASSEMBLY
AC307223 AB
AC205022AC
INSPECTION
M1372005300206
• Check the drive belt for cracks.
• Check the pulley for uneven rotation.
POWER STEERING 37-45
POWER STEERING HOSES
12 ± 2 N·m
1 102 ± 22 in-lb 5
2
57 ± 7 N·m
42 ± 5 ft-lb
12 ± 2 N·m
3 102 ± 22 in-lb
10
9N
8
12 ± 2 N·m
102 ± 22 in-lb
7
4
15 ± 3 N·m 6 N
11 ± 2 ft-lb
11
13 12 ± 2 N·m
102 ± 22 in-lb
13DB063A
MARKING
AC307218 AB
RETURN
TUBE (R)
AC205020 AB
RETURN
TUBE
ASSEMBLY
AC307218AC
RETURN
TUBE (R)
RETURN TUBE
ASSEMBLY
AC205021AB
.
POWER STEERING 37-47
POWER STEERING HOSES
RETURN
TUBE (R)
AC205020AC
RETURN
HOSE (R)
COOLER TUBE
ASSEMBLY
AC205025AB
OIL
RESERVOIR
AC307226AB
RETURN
HOSE (M)
COOLER TUBE
ASSEMBLY
AC205025AC
.
POWER STEERING 37-48
POWER STEERING HOSES
OIL
RESERVOIR
AC307226AB
AC205022AD
POWER STEERING 37-49
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1372008400310
ITEM SPECIFICATION
Power steering gear box and linkage (removal and installation)
Crossmember mounting bolt 180 ± 20 N⋅m (133 ± 14 ft-lb)
Crossmember mounting nut 180 ± 20 N⋅m (133 ± 14 ft-lb)
Front axle crossmember stay mounting bolt and nut 83 ± 12 N⋅m (61 ± 9 ft-lb)
Lower arm and crossmember connecting nut 165 ± 15 N⋅m (122 ± 11 ft-lb)
Power steering gear bracket mounting bolt 58 ± 7 N⋅m (43 ± 5 ft-lb)
Pressure tube flare nut 15 ± 3 N⋅m (11 ± 2 ft-lb)
Pressure hose mounting bolt and nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Rear roll stopper mounting bolt 58 ± 7 N⋅m (43 ± 5 ft-lb)
Rear roll stopper to power steering gear bracket connecting bolt 58 ± 7 N⋅m (43 ± 5 ft-lb)
Rear roll stopper to rear roll stopper bracket connecting nut 69 ± 10N⋅m
Return tube flare nut 15 ± 3 N⋅m (11 ± 2 ft-lb)
Return tube mounting bolt and nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Steering column assembly and steering gear connecting bolt 18 ± 2 N⋅m (13 ± 2 ft-lb)
Steering gear and linkage mounting bolt 83 ± 12 N⋅m (61 ± 9 ft-lb)
Steering gear and linkage protector mounting bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Tie rod 89 ± 9 N⋅m (65 ± 7 ft-lb)
Tie rod end jam nut 52 ± 2 N⋅m (38 ± 2 ft-lb)
Tie rod end to knuckle self-locking nut 29 ± 4 N⋅m (21 ± 3 ft-lb)
Power steering gear box and linkage (disassembly and assembly)
P/S oil feed tube assembly flare nut 13 ± 3 N⋅m (116 ± 26 in-lb)
Steering gear inner nut (pinion and valve assembly jam nut) 25 ± 4 N⋅m (18 ± 3 ft-lb)
Steering gear inner nut (rack support cover jam nut) 59 ± 10 N⋅m (44 ± 7 ft-lb)
Steering gear nut (tie rod end jam nut) 52 ± 2 N⋅m (38 ± 2 ft-lb)
Steering gear plug (end plug) 59 ± 10 N⋅m (44 ± 7 ft-lb)
Steering gear rack support cover 12 ± 2 N⋅m (107 ± 17 in-lb)
Steering tie rod 84 ± 14 N⋅m (62 ± 10 ft-lb)
Valve housing bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Power steering hose
Cooler tube clamp bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Oil pump eye bolt 57 ± 7 N⋅m (42 ± 5 ft-lb)
Oil reservoir nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Pressure hose, pressure tube, return tube clamp bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Pressure hose clamp nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Pressure tube, return tube flare nut 15 ± 3 N⋅m (11 ± 2 ft-lb)
Return tube clamp nut 12 ± 2 N⋅m (102 ± 22 in-lb)
POWER STEERING 37-50
SPECIFICATIONS
ITEM SPECIFICATION
Power steering oil pump
Belt tensioner bracket to power steering pump bracket 41 ± 8 N⋅m (30 ± 6 ft-lb)
connecting bolt (long)
Belt tensioner bracket to power steering pump bracket 49 ± 9 N⋅m (36 ± 7 ft-lb)
connecting bolt (short)
Belt tensioner pulley mounting nut 15 ± 4 N⋅m (11 ± 3 ft-lb)
Oil pump eye bolt 57 ± 7 N⋅m (42 ± 5 ft-lb)
Power steering oil pump mounting bolt 46 ± 8 N⋅m (34 ± 6 ft-lb)
Power steering oil pump mounting nut 42 ± 7 N⋅m (31 ± 5 ft-lb)
Power steering oil pump bracket mounting bolt 41 ± 8 N⋅m (30 ± 6 ft-lb)
Pressure hose clamp nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Steering shaft
Steering column assembly and steering gear connecting bolt 18 ± 2 N⋅m (13 ± 2 ft-lb)
Steering column assembly mounting bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Steering wheel
Steering wheel dynamic damper 3.9 ± 0.9 N⋅m (35 ± 8 in-lb)
Steering wheel mounting nut 41 ± 8 N⋅m (30 ± 6 ft-lb)
Torx screw 9.0 ± 2.0 N⋅m (80 ± 17 in-lb)
GENERAL SPECIFICATIONS
M1372000200282
ITEMS SPECIFICATIONS
3.8L ENGINE
16-INCH 17-INCH
WHEELS WHEELS
Steering wheel Type 4-spoke type 4-spoke type
Outside diameter mm (in) 380 (14.9) 380 (14.9)
Maximum number of turns 2.94 2.76
Steering column Column mechanism Shock absorbing mechanism and Tilt steering mechanism
Power steering type Integral type Integral type
Oil pump Type vane pump vane pump
Basic discharge amount 9.6 (0.59) 9.6 (0.59)
cm3/rev. (cu in/rev)
Relief pressure MPa (psi) 9.8 (1,422) 9.8 (1,422)
Reservoir type Separate type (plastic)
Pressure switch Equipped Equipped
Steering gear Type Rack and pinion Rack and pinion
Stroke ratio (Rack 49.62 49.62
stroke/Steering wheel
Maximum turning radius)
Rack stroke mm (in) 145 141.5
POWER STEERING 37-51
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1372000300405
LUBRICANTS
M1372000400372
SEALANT
M1372000500379
GROUP 42
BODY
CONTENTS
HOOD
BODY DIAGNOSIS
INTRODUCTION TO HOOD DIAGNOSIS
M1421005800363
Wind noise at the hood may be caused by improper
hood adjustment.
HOOD DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1421005900337
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
hood fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1421006000371
SYMPTOM PROCEDURES
ON-VEHICLE SERVICE
AC205079 AB
AC205080 AB
BODY 42-7
HOOD
SECTION B – B
UNITS: mm (in)
HOOD DAMPER
15 ± 0.5
(0.6 ± 0.02)
AC308902 AB
BODY 42-8
HOOD
HOOD
REMOVAL AND INSTALLATION
M1421001600345
Post-installation Operation
• Adjustment of Clearance Around Hood (Refer to P.42-6).
• Alignment of Hood Latch and Striker (Refer to P.42-6).
• Hood Height Adjustment (Refer to P.42-7).
4
HOOD STUD
PIN
HOOD
GAS SPRING 5
FLAT-TAPPED
SCREWDRIVER 8
9 7
8
1
12 ± 2 N·m
10 102 ± 22 in-lb
8 12 ± 2 N·m
102 ± 22 in-lb
11 1
11
12 ± 2 N·m 1
102 ± 22 in-lb
12 ± 2 N·m
102 ± 22 in-lb
6
18DB156A
BODY 42-9
HOOD
CLIP POSITIONS
7
SECTION A – A
9
9
A
CLIP
NOTE
: CLIP POSITIONS 18DB157A
GROMET
FENDER
REMOVAL AND INSTALLATION
M1421001900313
1 5
2
3
NOTE
: CLIP POSITIONS
AC305815 AB
2
AC305819
3
FUEL FILLER LID HEIGHT AND
CLEARANCE ADJUSTMENT
1
AC305818
AC306167AB
12 ± 2 N·m
48 ± 7 N·m
102 ± 22 in-lb
36 ± 5 ft-lb
48 ± 7 N·m
36 ± 5 ft-lb
1
2
AC305562 AB
REMOVAL STEPS
1. STRUT TOWER BAR
2. STRUT TOWER BAR BRACKET
WINDOW GLASS
GENERAL
M1422000100384
The windshield and rear 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
ITEM APPLICATION QUANTITY
Wire (diameter × length) For cutting adhesive Five pieces of wire 0.6 mm × 1 m
(0.02 in × 3.3 ft)
Glass adhesive knife For cutting adhesive One
Sealant gun For adhesive application One
Wiping shop towels - As required
Sealer For prevention of water and wind As required
leaks after adhesive application
3M AAD™ Part No. 8906 or For cleaning As required
equivalent
Glass holder MB990480 For securing of window glass Two
BODY 42-13
WINDOW GLASS
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.
CLEANING
AFTER REMOVING EXCESS ADHESIVE FROM THE BODY OR
GLASS WITH A SPATULA, ETC. CLEAN OFF WITH 3M™ AAD
PART NO. 8906 OR EQUIVALENT.
AC306636 AB
BODY 42-14
WINDOW GLASS
SYMPTOM PROCEDURES
MB990480
BODY 42-15
WINDOW GLASS
WINDSHIELD
REMOVAL AND INSTALLATION
M1422001000324
4N
N 2 3N
1
2N
N5
AC305559AB
BODY 42-16
WINDOW GLASS
1 1
A
B
B
16 (0.63) PRIMER
PRIMER AC305999 16 (0.63)
AC306000
CERAMIC LINE SEAL LINE
SECTION C – C
8.5 CENTER
(0.335)
C
C AC305998 PRIMER
ADHESIVE: 3M™ AAD PART NO. 8609 SUPER FAST URETHANE AND 3M™ AAD PART NO. 8608 SUPER FAST
URETHANE PRIMER OR EQUIVALENT
CAUTION
Inserting the glass adhesive knife too deeply into wind-
shield adhesive may damage windshield.
4. Using glass adhesive knife
Keep glass adhesive knife at right angles with the
windshield edge, and put the blade at windshield edge and
surface. Then cut away adhesive along the windshield edge.
AC002060
GLASS ADHESIVE
KNIFE
AC207478 AE
MB990480
5. Use special tool MB990480 to remove the windshield.
ACX00475AB
CAUTION
• Be careful not to remove more adhesive than is neces-
sary.
• Be careful also not to damage the paint on the body
surface with the knife. If the paint is damaged, repair
the damaged area with touch-up paint.
6. Use a knife to cut away the remaining adhesive so that the
thickness is within 2 mm (0.08 inch) around the entire
circumference of the body flange.
7. Finish the flange surfaces so that they are smooth.
ACX00476 AB
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 3M™ AAD Part
number 8906 or equivalent.
9. Clean the body side in the same way.
BODY 42-18
WINDOW GLASS
CERAMIC END
LINE ALIGN THE GLASS STOPPER END
WITH THE WINDSHIELD MARK.
AC107207
40.1 ± 1
(1.579 ± 0.12)
WINDSHIELD SPACER
AC306004
WINDSHIELD SPACER
18.2 ± 1
CERAMIC LINE (0.717 ± 0.04)
13 ± 3
GLASS END LINE (5.12 ± 0.12) AC306003
A AC306002
AC306370 AB
2. Install the windshield spacer and glass stoppers to the
specified positions so that there are no adrift or warped
surfaces inside the windshield.
3. Install the windshield upper and side moldings to the
windshield.
.
BODY 42-19
WINDOW GLASS
>>B<<WINDSHIELD INSTALLATION
1. When replacing the windshield, temporarily set the
windshield against the body, and place a mating mark on the
windshield and body.
CAUTION
• The primer strengthens the adhesive, so be sure to
apply it evenly around the entire circumference. How-
ever, a too thick application will weaken the adhesive.
• Do not touch the coated surface.
• Do not apply the primer on the remaining adhesive
because of weakening the adhesive.
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.
4. Fill a sealant gun with adhesive. Then apply the adhesive
evenly around the windshield within 30 minutes after
applying the primer.
NOTE: Cut the tip of the sealant gun nozzle into a V shape
to simplify adhesive application.
10 mm 5. Align the mating marks on the windshield and the body, and
(0.4 in)
lightly press the windshield evenly so that it adheres
15 mm completely.
(0.6 in)
6. Use a spatula or similar tool to remove any excessive
ACX00480 AB
adhesive. Clean the surface with 3M™AAD Part number
8906 or equivalent. Avoid moving the vehicle until the
adhesive sets.
CAUTION
• Do not move the vehicle unless absolutely necessary.
• When testing for water leakage, do not apply strong
water pressure.
7. Wait 30 minutes or more, and then test for water leakage.
BODY 42-20
WINDOW GLASS
N 4
N3
2N
N 2
1 5N AC305560AB
B B
PRIMER
16 (0.63) 16 (0.63)
PRIMER AC306006 AC306007
SECTION C – C SEAL LINE CENTER
CERAMIC LINE 15.5 1
(0.610)
C
PRIMER
C AC306005
ADHESIVE: 3M™ AAD PART NO. 8609 SUPER FAST URETHANE AND 3M™ AAD PART NO. 8608 SUPER FAST
URETHANE PRIMER OR EQUIVALENT
REAR WINDOW GLASS SPACER, GLASS STOPPER AND REAR WINDOW GLASS MOLDING UNITS: mm (in)
INSTALLATION POSITION
GLASS END LINE
2.5 ± 2.5
(0.984 ± 0.984)
CERAMIC LINE
37 ± 3 (1.5 ± 0.12)
AC306009
REAR WINDOW
GLASS SPACER
2±1
(0.08 ± 0.04)
GLASS END
LINE
AC306011
CERAMIC END LINE
AC306514 AB
2. Install the rear window spacer and glass stopper to the
specified positions so that there are no adrift or bent
surfaces inside the rear window glass.
3. Install the rear window upper molding and side molding to
the rear window glass.
.
DOOR
GENERAL DESCRIPTION
M1423000100246
OPERATION
.
.
POWER WINDOWS
CENTRAL DOOR LOCKING SYSTEM When the power window (main or sub) switch is
The central door locking system operates the door operated, the door windows will open or close. This
lock actuator to lock or unlock the doors and the fuel system has the following operations and features:
lid door using the door lock switch built into the front • A power window lock switch on the power win-
power window (main or sub) switch or key cylinder dow main switch prevents the door window glass
built into the driver's side door outside handle. The from opening/closing with the front passenger's
system has the following operations and features: and rear power window sub switch.
• All doors and fuel lid door can be locked using the • The power window of the door window glass can
door lock switch built into the front power window be opened/closed for 30 seconds with the timer
(main or sub <LH>) switch. function after the ignition switch is turned OFF.
• Insert the key into the driver's key cylinder and (The timer expires if the front door <LH or RH> is
turn once to the unlock side to unlock the driver's opened when the timer is in operation).
door and fuel lid door. Turn the key once again to • The power window main switch contains a
the unlock side to unlock all doors and fuel lid one-touch down switch that will automatically
door. open the driver's side door window only.
• The key reminder function automatically unlocks
all doors when door lock operation is performed
and the front doors are opened while the key is
inserted into the ignition switch.
CENTRAL DOOR LOCKING SYSTEM DIAGNOSIS
M1427000700217
The central door locking system is controlled by the
simplified wiring system (SWS). Refer to GROUP
54B, SWS Diagnosis P.54B-57.
POWER WINDOW DIAGNOSIS
M1429000700224
The power window is controlled by the simplified wir-
ing system (SWS). Refer to GROUP 54B, SWS
Diagnosis P.54B-57.
DOOR DIAGNOSIS
INTRODUCTION TO GLASS AND DOOR DIAGNOSIS
M1423007300241
Glass and door faults include water leaks and
improper opening and closing. Causes for these
faults can include faults in the glass, weatherstrip,
drain hole, waterproof film or door installation.
GLASS AND DOOR DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1423006700246
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
glass and door fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
BODY 42-24
DOOR
SYMPTOM CHART
M1423007000303
SYMPTOM PROCEDURES
STEP 3. Inspect the window regulator assembly. STEP 4. Retest the system.
Q: Is the window regulator assembly in good Q: Does the door window operate correctly?
condition? YES : The procedure is complete.
YES : Go to Step 4. NO : Return to Step 1.
NO : Repair or replace the window regulator
assembly, then go to Step 4.
STEP 3. Check the door handle flexibility STEP 4. Retest the system.
(amount of movement of handle required to open Q: Does the door open easily?
door). YES : The procedure is complete.
Q: Is the door handle flexibility good? NO : Return to Step 1.
YES : Go to Step 4.
NO : Check the door outside handle and inside
handle (Refer to P.42-35 and P.42-35).
Then go to Step 4.
DIAGNOSIS
.
STEP 3. Check the clearance. STEP 4. Check the door for deformation.
Q: Are the door glass and door weatherstrip holder Q: Is the door deformed?
installed properly? YES : Replace the door. then go to Step 5.
YES : Go to Step 4. NO : Go to Step 5.
NO : Adjust the door glass and the weatherstrip
holder (Refer to P.42-32). Then go to Step
STEP 5. Retest the system.
5.
Q: Has the wind noise been improved?
YES : Return to Step 1.
NO : This diagnosis complete.
AC305691
AC205124 3. Remove the strips of tape one by one, making a road test
AC305100
after each is removed, until a wind noise source is
discovered.
AC305691
AC305100 4. When such a place is found, cover it again and repeat the
AC305691
procedure to check if there are any other noise source.
5. If no others are found, the last remaining tape is the only
source.
AC305692
BODY 42-28
DOOR
AC305100 6. Cut the remaining piece of tape into smaller pieces, attach it
AC305691
again as it was before, and then remove the pieces one by
one to narrow down the source.
AC305693
AC305693
AC305100
7. Check that wind noise occurs when the last remaining tape
is removed, and that noise does not occur when it is
re-attached.
8. When the source(s) of the wind noise is finally located,
attach butyl tape, body sealer or similar material to obstruct
this source as much as possible.
AC305694
SPECIAL TOOLS
M1423000600348
MB990900
MB990211
MB990480
MB991223AB
MB990784
BODY 42-30
DOOR
ON-VEHICLE SERVICE
AC000592 AB
WELD POINT If the door hinge mounting bolt washers are welded,
WASHER
grind off the welding according to the procedure below
beforehand.
.
1. Remove the door hinge. (Refer P.42-37.)
BOLT 2. Remove the plastic cover from bolt head. (Refer
P.42-37.)
3. Use a chisel or grinder to release the door hinge mount-
WASHER
WELD POINT ing bolt washer, which is welded to the door hinge.
DOOR HINGE AC206498 AD
4. On completion, paint the affected area with touch-up
paint to prevent corrosion.
5. Install the door hinge. (Refer P.42-37.)
3. If the door is stiff to lock and unlock:
(1) Adjustment by using the striker (vertically or toward the
inside of the vehicle)
Install an temporary bolts instead of the striker mounting
bolt, and use special tool MB990939 and a hammer to
tap the bolt in the desired direction.
MB990939
TEMPORARY STRIKER
BOLTS
AC006109 AG
BODY 42-31
DOOR
STRIKER
AC006110 AB
AC006111AB
AC306504
<REAR DOOR>
AC306505
AC307037AB
BODY 42-32
DOOR
DOOR
SASH
LOWER SASH
AC306503
AC307036 AB
5 1 2 3
4 4
1 3 5
18DB158A
BODY 42-34
DOOR
AC306509
SECTION A – A
AC205105
AC307031AB
SECTION A – A
AC205104
AC307029 AB
BODY 42-36
DOOR
AC306508
SECTION A – A
B
AC207670
AC307030 AB
INSIDE LOCK CABLE 3. If not within the standard value, adjust the inside handle lock
OUTER CABLE END knob stroke with the outer cable end connecting the inside
handle lock knob and inside lock cable.
AC306506AB
BODY 42-37
DOOR
DOOR ASSEMBLY
REMOVAL AND INSTALLATION
M1423002200294
Post-installation Operation
• Door Fit Adjustment (Refer to P.42-30).
<FRONT DOOR>
5 4
8
24 ± 3 N·m
18 ± 2 ft-lb
9 2
27 ± 5 N·m
20 ± 4 ftlb 3.9 ± 1.0 N·m <REAR DOOR>
35 ± 8 in-lb
5 4
21 ± 4 N·m 1
16 ± 2 ftlb
8
9.0 ± 2.0 N·m 24 ± 3 N·m
27 ± 5 N·m
80 ± 17 in-lb 18 ± 2 ft-lb
20 ± 4 ftlb
6 7
21 ± 4 N·m
16 ± 2 ftlb
10
11 27 ± 5 N·m
9
20 ± 4 ftlb 2
21 ± 4 N·m 3.9 ± 1.0 N·m
16 ± 2 ftlb 35 ± 8 in-lb
9, 10
27 ± 5 N·m
20 ± 4 ftlb
1
21 ± 4 N·m 10 6 7 3
16 ± 2 ftlb 9.0 ± 2.0 N·m
80 ± 17 in-lb 18DB159A
-1.5 mm
(0.06 in)
STRIKER
LATCH
AC006126AB
REAR DOOR
END LINE
A AC306180
SECTION A – A UNIT: mm (in)
0 – 1.2 (0 – 0.05)
[TARGET VALUE
1.2 (0.05)]
AC306181
AC306739 AB
INSPECTION
M1423006000333
AC210316
2
AC306163
AC306511AB
A SECTION B – B
SECTION C – C
TRIM
AC306724
CLAW
5 4
3 TRIM
NOTE
: CLAW POSITIONS CLAW
18DB160A
1
2
AC210317
AC306164
AC306512 AB
SECTION C – C
4 5 TRIM
AC306724
CLAW
3
TRIM
NOTE AC206827
AC306516 CLAW
: CLAW POSITIONS AC307260 AB
AC308968AB
.
BODY 42-43
DOOR
AC306498 AB
MB990784
AC306721 AB
INSPECTION
M1429001400293
<Front door>
BATTERY CONNECTION SLIDER POSITION
• Connect terminal No. 1 UP
and the negative battery
terminal.
• Connect terminal No. 2
1 2 and the positive battery
terminal.
<Rear door>
BATTERY CONNECTION SLIDER POSITION
• Connect terminal No. 1 UP
and the negative battery
terminal.
• Connect terminal No. 2
and the positive battery
1 2 terminal.
AC206013 AB
• Connect terminal No. 2 DOWN
and the negative battery
terminal.
• Connect terminal No. 1
and the positive battery
terminal.
BODY 42-46
DOOR
<FRONT DOOR>
8 7
3
1
2
4
18DB161A
7
AC209702 AC306499
AC306729 AB
DOOR HANDLE AND DOOR LATCH DOOR HANDLE AND DOOR LATCH
ASSEMBLY REMOVAL STEPS ASSEMBLY REMOVAL STEPS
1. DOOR INSIDE HANDLE 4. INSIDE LOCK CABLE
• WATERPROOF FILM (REFER TO 5. INSIDE HANDLE CABLE
P.42-52). 6. DOOR OUTSIDE HANDLE
>>B<< 2. LOWER SASH MOUNTING BOLT
3. DOOR LATCH ASSEMBLY
BODY 42-47
DOOR
<REAR DOOR> 6
3 5
1
2
AC306166 AB
7
AC209702 AC306499
AC306729 AB
DOOR HANDLE AND DOOR LATCH DOOR HANDLE AND DOOR LATCH
ASSEMBLY REMOVAL STEPS ASSEMBLY REMOVAL STEPS
1. DOOR INSIDE HANDLE 5. INSIDE HANDLE CABLE
• WATERPROOF FILM (REFER TO 6. DOOR OUTSIDE HANDLE
P.42-52). DOOR CHECK REMOVAL
>>B<< 2. LOWER SASH >>A<< 7. DOOR CHECK
3. DOOR LATCH ASSEMBLY Required Special Tool:
4. INSIDE LOCK CABLE • MB991223: Harness Set
BODY 42-48
DOOR
PIN
18DB162A
VIEW A
IDENTIFICATION MARK
AC204902 AB
INSPECTION
M1423004700411
1 2 3
AC210743
DOOR LOCK
<PASSENGER'S SIDE>
SWITCH SWITCH TESTER SPECIFIED
POSITION CONNECTION CONDITION
LOCK 1−3 Less than 2 ohms
OFF 1 − 3, 2 − 3 Open circuit
UNLOCK 2−3 Less than 2 ohms
1 2 3 4 5 6
7 8 9 10 11 12 13 14
18DB166A
<FRONT DOOR>
6 7
AC306365
5
A
4
SECTION A – A
7
3
FRONT
2 DOOR AC206032
NOTE AC306175
: THE CONVEX POSITION OF THE DOOR AC306732 AB
BODY 42-53
DOOR
CLIP POSITION
: SECTIONAL VIEW OF : SECTIONAL VIEW OF
6 CLIP POSITION CLIP POSITION
LH DOOR CLIPS (PINK),
RH DOOR CLIPS
(TURQUOISE)
AC306373
AC306374
AC306372
AC306725 AB
3 (0.12)
AC306376
AC306375
CLIP HOLE
AC306726 AB
ADHESIVE TAPE: DOUBLE-SIDED TAPE [ 7 mm (0.28 in) WIDTH, 85 mm (3.35 in) LENGTH AND 0.8 mm (0.031 in)
THICKNESS ]
BODY 42-55
DOOR
7
<REAR DOOR>
6
AC306366
SEALANT: 3M™ AAD PART NO. 8633
1 A
OR EQUIVALENT
5
A
SECTION A – A
7
2
3 4
REAR
DOOR AC206032
NOTE AC306176
: THE CONVEX POSITION OF THE DOOR AC306733 AB
AC306380
AC306379
AC306373
LH DOOR CLIPS (YELLOW),
6 RH DOOR CLIPS (BLUE)
AC306378 AC306730 AC
3 (0.12)
AC306381 AC306382
CLIP HOLE
AC306731AB
ADHESIVE TAPE: DOUBLE-SIDED TAPE [ 7 mm (0.28 in) WIDTH, 50 mm (1.97 in) LENGTH AND 0.8 mm (0.031 in)
THICKNESS ]
BODY 42-57
DOOR
AC306366
INNER PANEL WATER DRAIN HOLE AC306738 AB
<FRONT DOOR> 1. Stick the waterproof film to the door in sequence as shown.
3 2. Press the waterproof film toward the arrow in the illustration.
1
4
8 5
7
6 AC306357
<REAR DOOR> 3
1 2
6 7
5
AC306358
4 AC306737 AB
.
BODY 42-58
DOOR
AC306359
<REAR DOOR>
1
2 7
4 5
3
AC306360
AC306736 AB
3
2
AC306361
<REAR DOOR>
1
2 3
AC306362
AC306735 AB
.
BODY 42-59
DOOR
4 5
AC306363
<REAR DOOR>
1
2 3
5 4
AC306364
AC306734 AB
BODY 42-60
TRUNK LID
TRUNK LID
TRUNK LID DIAGNOSIS
INTRODUCTION TO TRUNK LID DIAGNOSIS
M1421005800374
Difficult locking and unlocking, uneven clearance and
height, and wind noise from the trunk lid may be
caused by improper adjustment of the trunk lid.
TRUNK LID DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1421005900348
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
trunk lid fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1421006000382
SYMPTOM PROCEDURES
ON-VEHICLE SERVICE
18DB167A
BODY 42-62
TRUNK LID
17 mm
(0.7 in)
TRUNK LID
REMOVAL AND INSTALLATION
M1421002200191
CAUTION
• Do not disassemble or throw the trunk lid gas spring into fire.
• Punch a hole in the trunk lid gas spring before disposal to release the gas inside.
• Ensure the trunk lid gas spring piston rod does not come into contact with foreign material.
Post-installation Operation
• Adjustment of Clearance Around Trunk Lid (Refer to
P.42-61).
• Trunk Lid Latch Adjustment (Refer to P.42-61).
• Trunk Lid Height Adjustment (Refer to P.42-62).
10
11
12 4
1 7
8
13 ± 2 N·m
111 ± 22 in-lb
2 3
9
9
13 ± 2 N·m 5.0 ± 1.0 N·m
111 ± 22 in-lb 44 ± 9 in-lb
9.0 ± 2.0 N·m
80 ± 17 in-lb
5
18DB170A
5
18DB171A
BODY 42-64
TRUNK LID
12
AC305830
ADHESIVE: 3M™ AAD PART NO.8531 HEAVY DRIP CHECK SEALER, 3M™ AAD PART NO.8646 AUTOMOTIVE JOINT
AND SEAM SEALER OR EQUIVALENT
AC306174 AB
TRUNK LID
GAS SPRING
FLAT-TAPPED
SCREWDRIVER
AC305996 AB
MARKING
SECTION
JOINT
SECTION
AC305825AB
INSPECTION
M1421004800144
18DB169A
BODY 42-67
KEYLESS ENTRY SYSTEM
• If none of the doors is opened or the ignition key 30 seconds (default setting) to 60, 120 or 180
is not inserted in the ignition switch within 30 sec- seconds. For further details on using the
onds after the doors are unlocked using the multi-center display (middle grade type) to adjust
transmitter, the ETACS-ECU will relock the doors the timer lock period, refer to GROUP 54B,
automatically. This is called "Timer lock function." On-vehicle Service P.54B-486.
This timer lock function prevents accidental NOTE: The timer lock period begins when the doors
unlocking of doors. The adjustment function are unlocked, and ends when the doors is relocked
allows you to change the timer lock period from automatically.
KEYLESS ENTRY SYSTEM DIAGNOSIS
BGBCJGAI
The keyless entry system is controlled by the Simpli-
fied Wiring System (SWS). Refer to GROUP 54B,
SWS Diagnosis P.54B-57.
SPECIAL TOOL
BGBBBGDH
MB991826
MB991958
BODY 42-69
KEYLESS ENTRY SYSTEM
ON-VEHICLE SERVICE
INSPECTION
M1428003800089
AC004486
CAUTION
Do not allow water or dust to enter the inside of the trans-
mitter when it is opened. Also, do not touch the precision
electronic device.
1. Insert a flat blade screwdriver (cloth covered) at the base of
Figure 1 the key transmitter case (in slot) and twist, to open the case,
as shown in figure 1, (be careful not to lose switch button
pads when opening).
2. Remove internal case and insert a flat blade screwdriver
(cloth covered) at the switch assembly (in slot) as shown in
twist to
open figure 2 and twist, to open the internal case (be careful not
Use small flat to lose battery when opening).
blade screwdriver
in slot to open Battery required for replacement: Coin type battery
18DB174A CR1620 (3V)
3. Install a battery with its (+) side face-down, at base of
Figure 2 switch, and reassemble the key transmitter.
4. Verify that the keyless entry system operates.
twist to
Use small flat
open
blade screwdriver
in slot to open
18DB173A
KEY TRANSMITTER
18DB175A
BODY 42-71
KEYLESS ENTRY SYSTEM
1. Check that the doors lock normally when the key is used.
2. Insert the ignition key.
BODY 42-74
KEYLESS ENTRY SYSTEM
CAUTION
770203CA To prevent damage to special tool MB991824 (V.C.I.),
214503CA
DATA LINK always turn the ignition switch to “LOCK” (OFF) position
CONNECTOR before connecting or disconnecting special tool MB991824
(V.C.I.).
3. Connect special tool MB991824 (V.C.I.) to the data link
connector.
MB991910
MB991824
00DB086A
SUNROOF ASSEMBLY
GENERAL DESCRIPTION
M1426000100234
A motor-driven inner slide-type glass sunroof with a
tilt-up mechanism is available in some models as a
standard or optional equipment. Even when the sun-
roof is fully closed, a sufficient amount of lighting and
a feeling of openness can still be obtained by open-
ing the sunroof sunshade.
SUNROOF DIAGNOSIS
M1426000700311
The sunroof system is controlled by the Simplified
Wiring System (SWS). Refer to GROUP 54B, SWS
Diagnosis P.54B-57.
SPECIAL TOOL
M1426000600228
D
MB991223 AD
ON-VEHICLE SERVICE
WATER TEST
M1426000900274
Check if there are any leaks in the sunroof by the following pro-
cedure.
1. Fully close the roof lid glass.
2. Adjust the water pressure so that water comes out of the
hose to a height of approximately 50 cm (19.7 inches) when
the hose is held vertically facing upwards.
3. Hold the end of the hose approximately 30 cm (11.8 inches)
HOSE APPROX
above the roof and let the water run onto the weatherstrip for
30 cm (11.8 in) 5 minutes or more.
4. Check if any water leaks can be found in the room while
watering. Even though there are any water leaks around the
roof lid glass, it can be acceptable as long as water is caught
in the drip area.
ACX00572AB
BODY 42-76
SUNROOF ASSEMBLY
AC306510
AC206306
AC307290 AB
SUNROOF CHECK
M1426004700119
Check to see that the sunroof operates by pressing the sunroof
switch. Perform troubleshooting if operations malfunction
(Refer to GROUP 54B, SWS Diagnosis P.54B-57).
SUNROOF INITIALIZATION
M1426004600123
The sunroof should be initialized when any of the following
components are replaced, the sunroof position is miss timed.
• Roof lid glass assembly
• Sunroof motor assembly
.
CAUTION
Check that the following items are normal before carrying out this operation check.
• Installation condition of the sunroof assembly
• Installation condition, deformation and contamination of the sunroof drive cable
• Installation of sunroof lid glass
• Sunroof switch and sunroof motor assembly
Check that the following items. If faulty, replace the
sunroof motor assembly.
BODY 42-78
SUNROOF ASSEMBLY
TILT-UP
AC306368
OPEN
OVERHEAD CONSOLE
AC209094
AC306500 AB
Basic operation
NO. SUNROOF REQUIREMENTS FOR THE SUNROOF TO NORMAL OPERATION
FUNCTION FUNCTION
01 OPEN 1. Ignition switch: ON The sunroof opens fully and
2. Sunroof switch: OPEN automatically and stops
several centimeters forward
of the fully open position
(position for less wind
noise).
Then, when the sunroof
switch is operated again,
the sunroof opens further to
fully open position.
02 CLOSE 1. Ignition switch: ON The sunroof closes while
2. Sunroof switch: CLOSE/TILT-DOWN the sunroof switch is
pushed to the
CLOSE/TILT-DOWN
position.
03 TILT-UP 1. Ignition switch: ON The sunroof tilts up fully and
2. Sunroof switch: TILT-UP automatically.
04 TILT-DOWN 1. Ignition switch: ON The sunroof closes while
2. Sunroof switch: CLOSE/TILT-DOWN the sunroof switch is
pushed to the
CLOSE/TILT-DOWN
position.
BODY 42-79
SUNROOF ASSEMBLY
Sunroof timer mechanism • If you open a door within that period (i.e. a door
In cases except the following, the basic operation switch is on), the sunroof timer function will be
and jam preventing mechanism will be maintained cancelled immediately.
for thirty seconds after the ignition switch is turned to • If you turn the ignition switch to the LOCK (OFF)
the LOCK (OFF) position. (Sunroof timer function) position while the timer is working, the sunroof
will continue moving until it closes fully, regard-
less of the time-out period.
BODY 42-80
SUNROOF ASSEMBLY
SUNROOF ASSEMBLY
REMOVAL AND INSTALLATION
M1426001200308
SECTION A – A
1 4.0 ± 0.5 N·m
36 ± 4 in-lb CLIP
2 AC206389
6
7
4
5
A
A
2
NOTE 5.4 N·m 3 AC307032
: CLIP POSITIONS 48 in-lb AC307985 AB
94 ± 14
(3.7 ± 0.6)
GROMMET
AC307033
<REAR>
37 ± 17
(1.5 ± 0.7)
GROMMET AC307034
AC307305 AB
BODY 42-82
SUNROOF ASSEMBLY
INSPECTION
M1421007600440
TILT-UP
OPEN
CLOSE/
TILT-DOWN
AC209094
AC307038 AB
BODY 42-83
SUNROOF ASSEMBLY
11
8 7
2.0 N·m
4 18 in-lb
6
1
5 2.0 N·m
18 in-lb
6 2
8
2.0 N·m
18 in-lb AC308120
10
1 3
2
11
2.0 N·m
18 in-lb
9
AC309052 AB
AC307035AB
LOOSE PANEL
REMOVAL AND INSTALLATION
M1421003100056
11 ± 2 N·m
98 ± 17 in-lb
1
2
22 ± 4 N·m
16 ± 2 ft-lb
22 ± 4 N·m
16 ± 2 ft-lb
6
5 3
22 ± 4 N·m
12 ± 2 N·m 16 ± 2 ft-lb
102 ± 22 in-lb
4
7
8
22 ± 4 N·m
11 ± 2 N·m 16 ± 2 ft-lb
22 ± 4 N·m
98 ± 17 in-lb 16 ± 2 ft-lb
5
6
18DB163A
REMOVAL
1. FRONT FLOOR BACKBONE BRACE
BODY 42-85
LOOSE PANEL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1421005300216
ITEM SPECIFICATION
Hood
Hood hinge bolt (body side) 12 ± 2 N⋅m (102 ± 22 in-lb)
Hood hinge bolt (hood side) 12 ± 2 N⋅m (102 ± 22 in-lb)
Hood hinge nut (body side) 12 ± 2 N⋅m (102 ± 22 in-lb)
Hood latch bolt 9.0 ± 2.0 N⋅m (80 ± 17 in-lb)
Strut tower bar
Strut tower bar nut 12 ± 2 N⋅m (102 ± 22 in-lb)
Strut tower bar bracket nut 48 ± 7 N⋅m (36 ± 5 ft-lb)
Door
Door check bolt (body side) 9.0 ± 2.0 N⋅m (80 ± 17 in-lb)
Door check bolt (door side) 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Door hinge bolt (body side) 27 ± 5 N⋅m (20 ± 4 ft-lb)
Door hinge bolt (door side) 21 ± 4 N⋅m (16 ± 2 ft-lb)
Door outside handle bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Door latch assembly screw 5.9 ± 1.0 N⋅m (52 ± 9 in-lb)
Door switch screw 3.9 ± 1.0 N⋅m (35 ± 8 in-lb)
Striker screw 24 ± 3 N⋅m (18 ± 2 ft-lb)
Trunk lid
Trunk lid hinge bolt (body side) 13 ± 2 N⋅m (111 ± 22 in-lb)
Trunk lid hinge bolt (trunk lid side) 13 ± 2 N⋅m (111 ± 22 in-lb)
Trunk lid hinge nut (trunk lid side) 13 ± 2 N⋅m (111 ± 22 in-lb)
Trunk lid latch bolt 9.0 ± 2.0 N⋅m (80 ± 17 in-lb)
Trunk lid striker bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Sunroof
Roof lid glass screw 4.0 ± 0.5 N⋅m (36 ± 4 in-lb)
Sunroof drip plate screw 2.0 N⋅m (18 in-lb)
Sunroof housing screw 2.0 N⋅m (18 in-lb)
Sunroof motor bolt 5.4 N⋅m (48 in-lb)
Loose panel
Cowl top cover outer bolt 11 ± 2 N⋅m (98 ± 17 in-lb)
Front end structure bar bolt 22 ± 4 N⋅m (16 ± 2 ft-lb)
12 ± 2 N⋅m (102 ± 22 in-lb)
11 ± 2 N⋅m (98 ± 17 in-lb)
Front floor backbone brace bolt 22 ± 4 N⋅m (16 ± 2 ft-lb)
Upper frame to front pillar brace bolt 22 ± 4 N⋅m (16 ± 2 ft-lb)
BODY 42-87
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1421000300299
<DOOR>
ITEM STANDARD VALUE
Door inside handle knob play mm Front 26.1 - 58.1 (1.028 - 2.287) [Target
(in) value 41 (1.61)]
Rear 30.3 - 58.1 (1.193 - 2.287) [Target
value 41 (1.61)]
Door inside handle lock knob stroke mm (in) 21.6 (0.850)
Door outside handle play mm (in) Front 10 ± 3.5 (0.39 ± 0.138)
Rear 11.2 ± 4 (0.441 ± 0.16)
Power window operation current A 5 ± 1 [Power supply voltage 14.5 ±
0.5V 25°C (77°F)]
<SUNROOF>
ITEM STANDARD VALUE
Roof lid glass operation current A 7 or less [at 20°C(68°F)]
<DOOR>
ITEM SPECIFIED SEALANT REMARK
Waterproof film 3 M™AAD Part No. 8633 or equivalent Ribbon sealer
ITEM SPECIFIED ADHESIVE TAPE
Front door opening outer Adhesive tape: Double-sided tape [7 mm (0.28 in) width, 85 mm (3.35
weatherstrip in) length and 0.8 mm (0.03 in) thickness]
Rear door opening outer Adhesive tape: Double-sided tape [7 mm (0.28 in) width, 50 mm (1.97
weatherstrip in) length and 0.8 mm (0.031 in) thickness]
<TRUNK LID>
ITEM SPECIFIED SEALANT REMARK
Trunk lid hinge 3 M™AAD part No. 8531 Heavy drip check sealer, Body sealer
3 M™AAD part No. 8646 Automotive joint and
seam sealer or equivalent
BODY 42-88
SPECIFICATIONS
COMPONENT IDENTIFICATIONS
M1421005400246
<DOOR CHECK>
APPLICABLE LOCATION IDENTIFICATION MARK
LH Front door P4FL
Rear door P4RL
RH Front door P4FR
Rear door P4RR
<DOOR OPENING OUTER WEATHERSTRIP>
APPLICABLE SIDE IDENTIFICATION CLIP COLOR
LH Front door Pink
Rear door Yellow
RH Front door Turquoise
Rear door Blue
HOME 51-1
GROUP 51
EXTERIOR
CONTENTS
SPLASH SHIELD
2 1
20DB121A
1
2
4
20DB124A
DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)
1. GRILLE, RADIATOR (REFER TO 3. FOG LAMP OR COVER (REFER TO
GROUP 51 P.51-6 GROUP 54A P.54A-159
2. FRONT BUMPER FACE 4. GRILLE, LOWER ASSEMBLY
SCRIVETS
20DB126A
20DB125A
EXTERIOR 51-5
REAR BUMPER ASSEMBLY
7
6
6
4N
5 N A
B
B
1
2 3
20DB122A
SECTION A – A SECTION B – B
5
3
AC306484 AB
RADIATOR GRILLE
REMOVAL AND INSTALLATION
M1511002900237
SECTION A – A SECTION B – B
FRONT BUMPER
RADIATOR GRILLE CLIP POINT
2
1
A
3
B RADIATOR GRILLE
20DB118A
REMOVAL STEPS Required Special Tools:
<<A>> 1. RADIATOR GRILLE • MB990784: Ornament Remover
2. SCRIVETS
3. FRONT THREE-DIAMOND MARK
(REFER TO P.51-25
REMOVAL SERVICE POINTS
.
20DB119A
MB990784
EXTERIOR 51-8
GARNISHES AND MOLDINGS
MOLDINGS
REMOVAL AND INSTALLATION
M1511004700165
A A
2
1
A
AC306486 AB
29 ± 1 mm
(1.14 ± 0.04 inch)
36.5 ± 1 mm
(1.44 ± 0.04 inch)
5.5 ± 0.5 mm
(0.22 ± 0.02 inch)
6.4 ± 0.5 mm
(0.25 ± 0.02 inch)
A
AC306520 AC
AC000421AB
REAR SPOILER
REMOVAL AND INSTALLATION
M1511006100147
3 1
2N
AC306525 AB
MUD GUARD
REMOVAL AND INSTALLATION
M1511011200065
B FRONT MUDGARD
AC306037 AB
SECTION A – A SECTION B – B
CLIP
GROMMET
FRONT FRONT
MUDGARD MUDGARD
SCREW AC306039 AC306040
AC306470 AB
UNDER COVER
REMOVAL AND INSTALLATION
M1511019600119
2
3
AC306125 AB
High-speed operations take place when the wiper WINDSHIELD WASHER OPERATION
speed control relay is set to "ON" and low-speed • If the windshield washer switch is turned to the
operations take place when the wiper speed control ON position with the ignition switch at "ACC" or
relay is set to "OFF". "ON" position, the windshield washer ON signal is
.
sent to the front-ECU. After 0.3 second, the wind-
WINDSHIELD INTERMITTENT WIPER shield wiper signal turns on. After the windshield
OPERATION washer switch signal turns off, the windshield
The ETACS-ECU calculates the wiper operation wiper signal turns off in three seconds.
interval according to the voltage signal sent from the • If the windshield washer switch is turned on while
column switch. Then the ETACS-ECU sends a signal the windshield wiper is at intermittent mode, and
to the front-ECU. The front-ECU determines the the windshield washer switch is turned OFF
wiper operation interval and turns on the wiper relay within 0.2 second, the wiper works only once to
signal relay. This causes the wiper auto stop relay to perform mist operation. When the windshield
turn on. Then the wiper auto stop relay will turn off washer switch is turned on for more than 0.2 sec-
after the wipers reach the park position. This causes ond, the wiper performs the same movement as
the wiper signal relay and then the wipers to turn off. normal condition from the time when 0.2 second
If the wiper signal relay remains off for the wiper has elapsed, and then returns to intermittent
operation interval, the relay turns on again, causing operation.
the wipers to operate in intermittent mode.
WINDSHIELD WIPER AND WASHER DIAGNOSIS
M1511000700389
The windshield wiper and washer are controlled by NOTE: Even when the ETACS-ECU has failed, the
the Simplified Wiring System (SWS). For trouble- windshield wiper can work at low speed as fail-safe
shooting, refer to GROUP 54B, SWS Diagnosis mode. (Normally, the windshield wiper operates
P.54B-10. when the ignition switch is at the "ACC" position. But,
if it enters the fail-safe mode, the wiper can operate
only when the ignition switch is at the "ON" position.)
EXTERIOR 51-15
WINDSHIELD WIPER AND WASHER
SPECIAL TOOLS
M1511000601170
MB991825
MB991826
MB991958
ON-VEHICLE SERVICE
MB991827 00DB076A
20DB107A
EXTERIOR 51-17
WINDSHIELD WIPER AND WASHER
WINDSHIELD WIPER
REMOVAL AND INSTALLATION
M1511007900168
1
3
A
37 ± 3 N·m
27 ± 1 ft-lb
5
8.0 ± 2 N·m
7
8
7.5 ± 1.0 N·m
66 ± 13 in-lb
20DB110A
EXTERIOR 51-18
WINDSHIELD WIPER AND WASHER
VIEW A SECTION B – B
5 5
CLIP
C
C SECTION C – C
B
WINDSHIELD
B 5
6 CLAW
SCREW
NOTE
: CLIP POSITION : CLAW POSITION
AC306703 AB
D
WIPER ARM AND PLACE WIPER BLADE ON THE
BLADE ASSEMBLY (RH) MARK OF WINDSHIELD
E D
SECTION D – D SECTION E – E
WIPER BLADE (RH)
38 ± 5 mm WIPER BLADE (LH)
(1.50 ± 0.20 inch)
38 ± 5 mm
(1.50 ± 0.20 inch)
WINDSHIELD GLASS
FENDER HOLE WINDSHIELD GLASS
COVER FRONT DECK
GARNISH
AC306640 AC306641
20DB109A
Install the wiper blade at the position specified above.
.
EXTERIOR 51-20
WINDSHIELD WIPER AND WASHER
A
WIPER BLADE
A
SECTION A – A
WIPER BLADE
BACKING
<PASSENGER'S SIDE>
BACKING
BACKING
A
WIPER BLADE
A
BACKING AC308476 AC
INSPECTION
M1511008000146
CHECK OPERATION
HIGH SPEED
LOW SPEED
20DB111A
CHECK OPERATION
(A) LOW SPEED
AC307642 AB
Windshield 23 − 31
intermittent wiper
switch
Windshield low-speed 23 − 30
wiper switch
Windshield 21 − 23
high-speed wiper
switch
UPPER
SIDE
AC307648 AB
EXTERIOR 51-23
WINDSHIELD WIPER AND WASHER
WINDSHIELD WASHER
REMOVAL AND INSTALLATION
M1511008200270
SECTION A – A
CLAW
CLAW
1
12 ± 1.0 N·m
102 ± 15 in-lb
4
5
AC306718 AB
WASHER TANK REMOVAL STEPS NOTE: For removal and installation of the wiper and
4. WINDSHIELD WASHER MOTOR washer switch, refer to GROUP 54A, Column switch
5. WASHER TANK P.54A-170.
WASHER MOTOR REMOVAL STEPS
• FRONT UNDER COVER RH (REFER
TO P.51-2).
• FRONT WASHER HOSE
CONNECTIONS
4. WINDSHIELD WASHER MOTOR
INSPECTION
M1511008300147
20DB113A
AC307642 AB
EXTERIOR 51-25
MARK
MARK
REMOVAL AND INSTALLATION
M1511011800454
20DB114A
380 MARK
20DB115A
2. Installation procedure
(1) Use 3M™ AAD Part number 8906 or equivalent to clean
the mark installation surfaces on the body.
CAUTION
When attaching the mark, the ambient temperature should
be 20 − 38°C (60 − 100°F) and the air should be completely
free of dust. If the ambient temperature is lower than 20°C
(60°F), the mark and the place on the vehicle body where
the mark is to be attached should be heated to 20 − 38°C
(60 − 100°F).
(2) Peel off the protection sheet on the back of the mark to
affix it in position.
EXTERIOR 51-27
DOOR MIRROR
DOOR MIRROR
GENERAL DESCRIPTION
M1511000100570
DOOR MIRROR
REMOVAL AND INSTALLATION
M1511006400331
SECTION B – B
B
5.0 ± 1.0 N·m
44 ± 9 inlb
B
1
2
<FRONT DOOR>
VIEW A
D D
C C
D D D
D D
D
D D A
SECTION C – C
SECTION D – D
3
TRIM
CLAW
TRIM NOTE
: CLAW POSITIONS
CLAW
20DB106A
EXTERIOR 51-29
DOOR MIRROR
MB990784
20DB116A
INSPECTION
M1511006500305
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1511015300279
ITEM SPECIFICATION
Front bumper
License plate screw 0.9 ± 0.1 N⋅m (8 ± 1 in-lb)
Windshield wiper and washer
Wiper arm and blade assembly nut 37 ± 3.0 N⋅m (27 ± 1 ft-lb)
Wiper link assembly to Body bolt 8.0 ± 2.0 N⋅m
Wiper motor to link assembly screw 7.5 ± 1.0 N⋅m (66 ± 13 in-lb)
Washer tank bolt 12 ± 1.0 N⋅m (102 ± 15 in-lb)
Door mirror
Remote controlled mirror assembly bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
SERVICE SPECIFICATIONS
M1511000300358
ADHESIVE
M1511000500448
ITEM SPECIFICATION
Door side protector molding Adhesive tape: Double-sided tape
8.0 mm (0.32 inch) width and 1.2 mm (0.05 inch)
thickness
Roof drip molding Adhesive tape: Double-sided tape
10.0 mm (0.39 inch) width and 1.52 mm (0.06 inch)
thickness
NOTES
HOME 52-1
GROUP 52
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM(SRS)
CONTENTS
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A
TSB Revision
HOME 52A-1
GROUP 52A
INTERIOR
CONTENTS
WARNING
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS
AFTER HANDLING.
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
passenger (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 (*).
INTERIOR 52A-2
FRONT SEAT ASSEMBLY* . . . . . . . 52A-21 REMOVAL AND FITMENT . . . . . . . . . . . . . 52A-49
REMOVAL AND INSTALLATION . . . . . . . . 52A-21
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 52A-23 REAR SEAT ASSEMBLY. . . . . . . . . . 52A-55
POWER SEAT CONTINUITY AND REMOVAL AND INSTALLATION . . . . . . . . 52A-55
DIAGNOSTIC CHECKS . . . . . . . . . . . . . . . 52A-23 DISASSEMBLY AND REASSEMBLY . . . . . 52A-57
OPERATION CHECK OF POWER
SEAT MOTOR . . . . . . . . . . . . . . . . . . . . . . 52A-29 FRONT SEAT BELT* . . . . . . . . . . . . . 52A-58
MEMORY SEAT CONTROLLER (MSC). . . 52A-31 REMOVAL AND INSTALLATION . . . . . . . . 52A-58
DISASSEMBLY AND ASSEMBLY RH SIDE 52A-33 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52A-59
DISASSEMBLY AND ASSEMBLY LH SIDE 52A-37
REMOVAL SERVICE POINT . . . . . . . . . . . 52A-42 REAR SEAT BELT . . . . . . . . . . . . . . . 52A-59
FRONT SEAT TRIM COVER REMOVAL AND INSTALLATION . . . . . . . . 52A-59
REMOVAL AND FITMENT . . . . . . . . . . . . . 52A-43
REAR SEAT CUSHION TRIM COVER SPECIFICATIONS . . . . . . . . . . . . . . . 52A-60
REMOVAL AND FITMENT . . . . . . . . . . . . . 52A-46
FASTENER TIGHTENING
REAR SEAT BACK TRIM COVER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 52A-60
INTERIOR 52A-3
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1521000100184
OPERATION
.
SPECIAL TOOLS
M1521000600327
MB990784
INTERIOR 52A-4
INSTRUMENT PANEL ASSEMBLY
CAUTION
• Refer to GROUP 52B, SRS Service Precautions P.52B-16 and Air bag Module and Clock Spring
P.52B-237 before removing the passenger side air bag module.
• Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel.
The following bolts and screws are used for installing the instrument panel. Bolts and screws are indicated as
marks shown in the illustration in the sections of "Removal and Installation" and "Disassembly and Assem-
bly."
d 5 × 20 BLACK
AC104448
e 6 × 16 GREEN
AC104426
f 8 × 15 -
AC307531
WASHER g 6 × 16 -
ASSEMBLY BOLT h 6 × 25 -
AC104416
i 6 × 16 -
AC104417
INTERIOR 52A-5
INSTRUMENT PANEL ASSEMBLY
12 15
c
8
c
11 16
23 17
d
22 e
16 e
e 19 18
b
e
25
b 14
i
19 i
20 a
i
17
14
i b
i b
18
b
14 4
b b
21
b
13
2
b
b
b 7
f
5 b
b
b
1
6
3 5
b
19DB004A
A
A
B
C
B C
D
D
L
L
E
G
K
K G
H H
F
J I
I F
J NOTE
(1) : CLIP POSITION
(2) : CLAW POSITION
CLIP CLIP
CLIP
SECTION E – E SECTION F – F SECTION G – G SECTION H– H
INSTRUMENT CLIP
STEERING CLIP INSTRUMENT CENTER PANEL
CLAW PANEL GARNISH
COLUMN ASSEMBLY
COVER INSTRUMENT CLIP
LOWER PANEL
SECTION I – I SECTION J – J SECTION K – K SECTION L – L
CLAW
INSTRUMENT CLIP INSTRUMENT CLAW
CENTER PANEL PANEL PARCEL
ASSEMLBY CLIP INSTRUMENT
BOX
PANEL SIDE
INSTRUMENT PANLE
COVER
SIDE COVER
19DB005A
INTERIOR 52A-8
INSTRUMENT PANEL ASSEMBLY
1 2 19DB006A
19DB007A
INTERIOR 52A-9
INSTRUMENT PANEL ASSEMBLY
4 b
b 4
5
b
1
b
b b
b
8 b
2
b
g
3 b
19DB124A
3 10
4
5 8
9
A
1 6 13
A
12 7
B
B
15
ACCESSORY
11
14
NOTE
: CLIP POSITION
SECTION A – A SECTION B – B
5 1
FLOOR
16
CONSOLE
14
1
CLIP
19DB125A
TRIMS
REMOVAL AND INSTALLATION
M1521001100455
12 10 12 13
8 18
14 18
9 44 ± 10 N·m
33 ± 7 ft-lb 14
16 15
5
16
4 18
16
6
3 17
21
25
24
7
2
1
20
23
19
22
19DB001
1. FRONT SCUFF PLATE • REAR SEATBACK ASSEMBLY
2. COWL SIDE TRIM (REFER TO P.52A-55.)
• REAR SEAT CUSHION (REFER 12. REAR PILLAR TRIM
TO P.52A-55.) 13. CHILD RESTRAINT LID
3. REAR SCUFF PLATE 14. REAR SHELF SPEAKER
• FRONT SEAT BELT LOWER GARNISH
ANCHOR BOLT 15. CHILD RESTRAINT LID
4. FRONT SEAT BELT SASH GUIDE 16. SEAT BELT GARNISH
COVER 17. REAR SHELF TRIM
5. FRONT SEAT BELT SHOLDER 18. CHILD RESTRAINT FITTING
ANCHOR BOLT 19. TRUNK ROOM FLOOR BOARD
6. CENTER PILLAR COVER 20. REAR END TRIM
7. CENTER PILLAR TRIM LOWER 21. TRUNK TRIM SIDE RH
8. FRONT DOOR OPENING TRIM 22. TRUNK TRIM, FRONT
<<A>> 9. FRONT PILLAR TRIM 23. TRUNK TRIM SIDE LH
10. REAR DOOR OPENING TRIM 24. PARCEL NET ANCHOR
11. CENTER PILLAR TRIM UPPER 25. JACK ACCESS PANEL
INTERIOR 52A-12
TRIMS
F G
E E G
B
B
H
H
E
E
D
C I
D D I
C C
A
D
C
A
NOTE
(1) : CLIP POSITION
(2) : CLAW POSITION
SECTION A – A SECTION B – B SECTION C – C
FRONT SCUFF PLATE,
REAR SCUFF PLATE
CLIP CLIP
CLAW CLIP
FRONT SCUFF PLATE, REAR PILLAR TRIM
REAR SCUFF PLATE
CLIP
CENTER PILLAR TRIM UPPER,
CENTER PILLAR TIRM LOWER
CLIP
CLAW
CLIP
19DB003A
INTERIOR 52A-13
TRIMS
A FRONT PILLAR
TRIM
A
INSTRUMENT
PANEL
ASSEMLBY AC308185 AB
INTERIOR 52A-14
DOOR TRIM
DOOR TRIM
REMOVAL AND INSTALLATION
M1521006400332
A
1
A
D 3
B
NOTE B 2
(1) : CLIP POSITION
(2) : CLAW POSITION
VIEW D VIEW C
F E
F F F
E
SECTION F – F SECTION E – E SECTION B – B SECTION A – A
CLAW
5
2 1
5
CLAW 5 CLIP
1
CLAW 7
19DB052A
REMOVAL STEPS INSTALLATION STEPS
<<A>> 1. INSIDE HANDLE COVER 7. ARMREST BRACKET
<<B>> 2. POWER WINDOW SWITCH 6. BELT LINE INNER
PANEL ASSEMBLY WEATHERSTRIP AND FRONT
3. ASSIST GRIP CAP DOOR TRIM ASSEMBLY
4. BELT LINE INNER 3. ASSIST GRIP CAP
WEATHERSTRIP 2. POWER WINDOW SWITCH
5. FRONT DOOR TRIM ASSEMBLY PANEL ASSEMBLY
7. ARMREST BRACKET 1. INSIDE HANDLE COVER
Required Special Tool:
• MB990784: Ornament Remover
INTERIOR 52A-15
DOOR TRIM
3
4
6
1 5
A
B
C
2
C
NOTE
(1) : CLIP POSITION
(2) : CLAW POSITION
VIEW A VIEW B
D
E
D
SECTION C – C SECTION D – D SECTION E – E
CLAW
1
4
CLIP 2
1
4
CLAW
CLAW
AC307435 AB
INSIDE HANDLE
COVER
AC206689 AB
POWER WINDOW
SWITCH PANEL
ASSEMBLY
19DB053A
INTERIOR 52A-17
DOOR TRIM
1
A
7
6
4
2 5
3
NOTE
: CLAW POSITION
SECTION B – B VIEW A
B
6 7
7
CLAW B
CLAW
19DB054A
DISASSEMBLY STEPS DISASSEMBLY STEPS
1. ASSIST GRIP 4. POWER WINDOW MEIN SWITCH
2. POWER WINDOW MAIN SWITCH PANEL
3. REMOTE CONTROLLED MIRROR 5. ARMREST BRACKET
SWITCH 6. ARMREST
7. FRONT DOOR TRIM
INTERIOR 52A-18
DOOR TRIM
4
3
2
NOTE 1
: CLAW POSITION
VIEW A SECTION B – B
4
4
CLAW
CLAW
AC307442 AB
HEADLINING
REMOVAL AND INSTALLATION
M1521001400360
SECTION A – A
11
CLIP
10
10
7
1
14
15
2 A 16
13
A
11
2
3 4 6
1
12
8 5
9
NOTE
: CLIP POSITION AC307811AB
FRONT PASSENGER'S
DOOR CHECK
AC307195 AB
SLIT AC000333 AB
INTERIOR 52A-21
FRONT SEAT ASSEMBLY
WARNING
• Before removing the front seat assembly, refer to GROUP 52B, Service Precautions
P.52B-16 and Air Bag Module and Clock Spring P.52B-237.
44 ± 10 N·m
33 ± 7 ft-lb
10
44 ± 10 N·m
33 ± 7 ft-lb 30 ± 5 N·m
22 ± 4 ft-lb
8
10
8
30 ± 5 N·m
22 ± 4 ft-lb
6
7 8
3
4
8 7 6
19DB002A
19DB018A
INTERIOR 52A-23
FRONT SEAT ASSEMBLY
INSPECTION
M1522005500113
LUMBAR MOTOR
CONNECTOR
RECLINER MOTOR
CONNECTOR (D-25-4)
19DB023A
CIRCUIT DIAGRAMS:
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
NOTE: Check connectors and terminals for damage or
loose connections at the seat harness and all supply
circuits connections to seat. Repair or replace wiring
harness if damaged.
INTERIOR 52A-31
FRONT SEAT ASSEMBLY
FAULT DIAGNOSIS
MEMORY SEAT CONTROLLER (MSC)
OPERATION OF DIAGNOSTICS:
The memory seat controller (MSC) stores specific fault codes
for all functions of the (MSC). The diagnostics are specifically
used to identify faults within the seat assembly, and as such will
hinder the operation of the seat.
When a fault is detected in the (MSC), the system will automat-
ically enter into diagnostic mode.
The indicator lamp (LED) will begin to flash in certain sequence
to indicate a diagnostic trouble code (DTC) as shown in the
table below. The indicator lamp (LED) will stop flashing when
the faults have been resolved.
Indicator lamp
(LED)
19DB022A
CIRCUIT DIAGRAMS:
• Refer to circuit diagrams GROUP-90
• Refer to configuration diagrams GROUP-80
NOTE: Check connectors and terminals for damage or
loose connections at the seat harness and all supply
circuits connections to seat. Repair or replace wiring
harness if damaged.
<RH SIDE>
20
21
18
5 N·m
16 17
19
22 13
26
35 N·m
12
35 N·m
24 14
23
15
7
45 N·m
1
2
10
3
6
4
28
32 N·m
27
19DB008A
INTERIOR 52A-34
FRONT SEAT ASSEMBLY
20
21
18
5 N·m
17
16
19
13
22
26
35 N·m
12
35 N·m
24 14
23
15
7
45 N·m
1
2
10
3
6
4
28
32 N·m
27
19DB009A
INTERIOR 52A-35
FRONT SEAT ASSEMBLY
20
21
18
18
5 N·m
17
16
22
35 N·m
13
12
25 26
35 N·m
14
15
8 7
45 N·m
2
1
10
5
9
28
32 N·m
27 19DB010A
INTERIOR 52A-36
FRONT SEAT ASSEMBLY
<LH SIDE>
17
18
22
15
15
5 N·m
14
19
10
35 N·m
9 13
35 N·m
11 21
12 20
1 7
45 N·m
2
3
4
24
19DB011A
INTERIOR 52A-38
FRONT SEAT ASSEMBLY
17
18 22
15
15
16
5 N·m
14
19
35 N·m
10 13
35 N·m
9
21
11
12 20
1
45 N·m
7
3
4
24
32 N·m
19DB012A
INTERIOR 52A-39
FRONT SEAT ASSEMBLY
17
18
15
22 15
16
5 N·m
14
19 35 N·m
13
10
35 N·m
9
11 21
12
20
1
45 N·m
7
2 3
5
24 32 N·m
23
19DB013A
INTERIOR 52A-40
FRONT SEAT ASSEMBLY
17
18
15
15
5 N·m
14
19
35 N·m
10
22 13
9
35 N·m
11
21
12
20
1
45 N·m
7
2 3
5
24 32 N·m
23
19DB014A
INTERIOR 52A-41
FRONT SEAT ASSEMBLY
19DB015A
ATTACHMENT
HOOK LOCATION
(LUG)
SEAT BACK
PANEL
19DB026A
INTERIOR 52A-44
FRONT SEAT TRIM COVER
FITMENT
.
1. Locate the new trim onto the pad by aligning the Velcro strip
with the grooves. Use an intersection in order to align both
directions. Whenever possible work from the centre of the
trim toward the outside.
SEAT TRIM
Intersection
BLUE VELCRO
Align trim velcro STRIP
in the pad grooves
19DB027A
SEAT TRIM
19DB028A
2. Push the Velcro strips into place along all the grooves.
19DB029A
INTERIOR 52A-45
FRONT SEAT TRIM COVER
3. Pull the cover over the outside of the pad and reattach the
retaining clips where required.
Underneath seat
Seat trim
retaining clip
19DB030A
Outer Attachments
19DB033A
1. Locate the new trim onto the pad by aligning the Velcro strip
with the grooves. Use an intersection in order toalign both
directions. Whenever possible work from the centre of the
trim toward the outside.
19DB035A
Seat Trim
Cover
Cushion Pad
19DB036A
3. Pull trim through the seat belt slots as shown and attach to
wires
Trim Cover
Cushion Pad
19DB038A
CUSHION PAD
SEAT TRIM
19DB039A
6. Work the trim into all the grooves and adjust if necessary to
remove creases as shown.
19DB040A
INTERIOR 52A-49
REAR SEAT BACK TRIM COVER
1. Remove rear seat back from the vehicle, and remove arm
rest and arm rest pivot bushes from rear seat back.
2. Release the draw string.
19DB041A
19DB043A
2. Locate the new trim onto the pad by aligning the Velcro strip
with the grooves. Use an intersection in order to align both
directions. Whenever possible work from the centre of the
trim toward the outside.
Cushion
Blue strips
in grooves Intersection
velcro
Seat
Trim
19DB044A
3. When all the grooves are aligned pull the cover over the
pad.
Seat Trim
Cover
Cushion
Pad
19DB045A
INTERIOR 52A-52
REAR SEAT BACK TRIM COVER
Holding
Point
Reattach plastic
clips over wire
19DB046A
Cushion Pad
Seat Cover
Trim
19DB047A
7. Pull inner lower arm rest trim through the hole and clip to
retainer attached to the lower part of the trim cover.
WIRE
Lower part of
trim cover
19DB049A
8. Pull the upper arm rest trim through the hole over the large
wire and clip to the small wire as shown.
Large Wire
Small Wire
Seat Cover Trim
19DB050A
9. Pull the draw string and attach to the wire attachment points
shown.
19DB041A
INTERIOR 52A-54
REAR SEAT BACK TRIM COVER
19DB040A
22 ± 4 N·m
16 ± 3 ft-lb 2
1 22 ± 4 N·m
16 ± 3 ft-lb
22 ± 4 N·m
16 ± 3 ft-lb
3
AC306948 AB
ATTACHMENT
HOOK WIRE
AC005519AG
.
INTERIOR 52A-56
REAR SEAT ASSEMBLY
AC308697 AB
2. Fit the rear seat cushion into the rear seat hook securely.
REAR SEAT
CUSHION
ASSEMBLY
REAR SEAT
HOOK AC005521AB
INTERIOR 52A-57
REAR SEAT ASSEMBLY
9
8
7 N
6
1N 5
4
AC306949AB
CAUTION
• SRS: Before removing and installing the seat belts with pre-tensioner, refer to GROUP 52B, Seat
Belt with Pre-tensioner P.52B-250.
Pre-removal and Post-installation Operation Post-installation Operation
• Turn the ignition key to the LOCK (OFF) position. Adjustment Procedures of Special Function (refer to GROUP
• Disconnect the negative battery terminal. 52B, On-Vehicle Service P.52B-250.)
4
5
44 ± 10 N·m
44 ± 10 N·m
33 ± 7 ft-lb
33 ± 7 ft-lb
2 (DRIVER'S SIDE)
3
44 ± 10 N·m
33 ± 7 ft-lb
44 ± 10 N·m 1
33 ± 7 ft-lb (PASSENGER'S SIDE)
3
6 44 ± 10 N·m
33 ± 7 ft-lb 19DB020A
INSPECTION
M1523004400116
.
19DB019A
44 ± 10 N·m
33 ± 7 ft-lb
3
44 ± 10 N·m
33 ± 7 ft-lb
44 ± 10 N·m
33 ± 7 ft-lb
1
2
44 ± 10 N·m
33 ± 7 ft-lb
AC307024 AB
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1521004100227
ITEM SPECIFICATION
FRONT SEAT
Front seatback assembly bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Front seat cushion assembly bolt 12 ± 2 N⋅m (102 ± 22 in-lb)
Front seat bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Front seat nut 30 ± 5 N⋅m (22 ± 4 ft-lb)
REAR SEAT
Seatback assembly bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
FRONT SEAT BELT
Adjustable seat belt anchor bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Inner seat belt bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Outer seat belt bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
REAR SEAT BELT
Center seat belt outer and inner seat belt bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Inner seat belt bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Seat belt shoulder anchor bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Seat belt lower anchor bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
HOME 52B-1
GROUP 52B
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
WARNING
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS
AFTER HANDLING.
WARNING
• Carefully read and observe the information in the SRS SERVICE PRECAUTIONS prior to any service.
• For information concerning diagnosis or maintenance, always observe the procedures in the SRS Diagnosis or
the SRS Maintenance sections, respectively.
• If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the
procedures in the INDIVIDUAL COMPONENT SERVICE section for the comportments involved.
• If you have any questions about the SRS, please contact Mitsubishi Motors call centre.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-2
FRONT IMPACT SENSORS . . . . . . . 52B-231 REMOVAL AND INSTALLATION . . . . . . . . 52B-247
REMOVAL AND INSTALLATION . . . . . . . . 52B-231 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B-249
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 52B-233
SEAT BELTS WITH PRE-
SRS CONTROL UNIT (SRS-ECU). . . 52B-234 TENSIONER . . . . . . . . . . . . . . . . . . . . 52B-250
REMOVAL AND INSTALLATION . . . . . . . . 52B-234 REMOVAL AND INSTALLATION . . . . . . . . 52B-250
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 52B-236 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B-253
AIR BAG MODULES AND CLOCK AIR BAG MODULE AND SEAT BELT
SPRING . . . . . . . . . . . . . . . . . . . . . . . 52B-237 PRE-TENSIONER DISPOSAL
REMOVAL AND INSTALLATION . . . . . . . . 52B-237 PROCEDURES . . . . . . . . . . . . . . . . . . 52B-254
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 52B-244
SPECIFICATIONS . . . . . . . . . . . . . . . 52B-270
SIDE IMPACT SENSOR . . . . . . . . . . 52B-247 FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 52B-270
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-3
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1524000100730
. .
WARNING The SRS consists of four air bag modules, SRS air
Improper service could result in serious bag control unit (SRS-ECU), two front impact sen-
injury of the service personnel or the pas- sors, two side impact sensors, SRS warning light,
clock spring, seat belt pre-tensioner, seat belt switch,
senger.
seat slide sensor. Air bag modules are located in the
.
center of the steering wheel and above the glove
The SRS is designed to supplement the front seat
box. Side-airbags are located inside the front seat-
belts. It reduces injury to the driver(s) and the front
back assemblies. Each air bag consists of a folded
passenger(s) by deploying air bag(s) in case of a
air bag and an inflator unit. The SRS-ECU placed on
head-on collision.
the forefront of the floor monitors the system and has
The SRS front air bags from an advanced air bag
a front air bag safing G-sensor, front air bag analog
system together with sensors at the vehicle and sen-
G-sensor and a side-airbag safing G-sensor. The
sors attached to front seats.
front impact sensor is assembled in the radiator sup-
.
port panel to monitor impact in case of front impact.
Side-airbag systems in the front seats are activated
The side impact sensors inside the center pillars
when side impacts exceed a criteria to protect the
monitor the shock incurred by the sides of the vehi-
occupants’ upper bodies.
cle. The SRS warning light on the combination meter
.
indicates the operational status of the SRS. The
The seat belts with pre-tensioner work simulta-
clock spring is installed in the steering column. The
neously with the SRS. The seat belt incorporating the
seat belt pre-tensioner is built into the driver's and
pre-tensioner automatically winds the seatbelt upon
passenger's front seat belt retractor.
front impact to reduce forward shifting of the driver’s
Only authorized service personnel should do work on
and passenger’s. The seat belt use status is used to
or around the SRS components. Those service per-
control the activation and deactivation of the pre-ten-
sonnel should read this manual carefully before start-
sioner.
ing any such work.
.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-4
GENERAL DESCRIPTION
SRS
WARNING
LAMP
35DB113A
CONSTRUCTION DIAGRAM
SRS
WARNING
LAMP
DRIVER'S AIR
BAG MODULE
PASSENGER'S (FRONT)
AIR BAG MODULE CLOCK
SPRING
SRS-ECU
SRS-ECU
SIDE-AIRBAG
MODULE
SIDE IMPACT
SENSOR
AC306795
52DB001A
NOTE: This construction diagram shows the general view of the SRS components. For details, refer to
"Schematic(P.52B-9), "Configuration Diagrams(P.52B-12), " and "Circuit Diagram(P.52B-13)".
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-6
GENERAL DESCRIPTION
WARNING/CAUTION LABELS
A number of caution labels related to the SRS are found in
the vehicle, as shown in the following illustrations. Follow
label instructions when servicing SRS. If the other labels
are dirty or damaged, replace them.
STEERING WHEEL DRIVER'S AIR BAG MODULE CLOCK SPRING PASSENGER'S AIR BAG MODULE
A D
AC306338 AC306339 AC308167
E
F
AC306334
G 24DB060A
AC306340
SIDE-AIRBAG MODULE
(DRIVER'S AND SIDE IMPACT SENSORS
FRONT PASSENGER'S SEAT) (RH AND LH)
K CENTER
PILLAR
J J
M
AC306337 AC306336
L
24DB056A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-7
GENERAL DESCRIPTION
LABEL CONTENTS
A WARNING: SRS
• BEFORE REPLACING STEERING WHEEL, READ SERVICE MANUAL, CENTER
FRONT WHEELS AND ALIGN SRS CLOCK SPRING NEUTRAL MARKS. FAILURE
TO DO SO MAY RENDER SRS SYSTEM INOPERATIVE, RISKING SERIOUS
DRIVER INJURY.
• THE AIR BAG MODULE CAN NOT BE REPAIRED. DO NOT DISASSEMBLE OR
TAMPER. DO NOT PERFORM DIAGNOSIS. DO NOT TOUCH WITH ELECTRICAL
TEST EQUIPMENT OR PROBES. REFER TO SERVICE MANUAL FOR FURTHER
INSTRUCTIONS, AND FOR SPECIAL HANDLING, STORAGE AND DISPOSAL
PROCEDURES. TAMPERING OR MISHANDLING CAN RESULT IN INJURY.
B DANGER: FLAMMABLE MATERIAL
TO PREVENT PERSONAL INJURY, DO NOT DISMANTLE, INCINERATE, OR BRING
INTO CONTACT WITH ELECTRICITY STORE BELOW 200°F(93°C). READ SERVICE
MANUAL FOR DETAIL.
C CAUTION: SRS CLOCKSPRING
THIS IS NOT A REPAIRABLE PART. IF DEFECTIVE REPLACE ENTIRE UNIT
ACCORDING TO THE SERVICE MANUAL INSTRUCTIONS. TO RE-CENTER: ROTATE
CLOCKWISE UNTIL TIGHT. THEN ROTATE IN OPPOSITE DIRECTION ROUGHLY 3
3/4 TURNS AND ALIGN ARROWS.
D, J WARNING FLAMMABLE/EXPLOSIVE
SRS AIR BAG MODULE
TO AVOID SERIOUS INJURY:
• DO NOT REPAIR, DISASSEMBLE OR TAMPER.
• AVOID CONTACT WITH FLAME OR ELECTRICITY.
• DO NOT DIAGNOSIS/USE NO TEST EQPT OR PROBES.
• STORE BELOW (93°C).
• BEFORE DOING ANY WORK INVOLVING MODULE, READ SERVICE MANUAL
FOR IMPORTANT FURTHER DATA.
E, K CAUTION:
DO NOT DISASSEMBLE OR DROP. IF DEFECTIVE REFER TO SERVICE MANUAL.
F WARNING
EVEN WITH ADVANCED AIR BAGS
• Children can be killed or seriously injured by the air bag
• The back seat is the safest place for children
• Never put a rear-facing child seat in the front
AC306673 • Always use seat belts and child restraints
• See owner’s manual for more information about air bags
G WARNING
• Extreme Hazard! Do not use a rearward facing child restraint on a seat protected by an
airbag in front of it!
• A REARWARD FACING CHILD RESTRAINT must NOT be used in the front
passenger seat as it places the infant too close to the passenger airbag. The force of
24DB061A an inflating airbag could kill or cause serious injuries to the child. A rearward facing
child restraint must only be used in the rear seat.
• A FORWARD FACING CHILD RESTRAINT should only be used in a rear seat with a
top tether strap anchor point.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-8
GENERAL DESCRIPTION
LABEL CONTENTS
L DANGER: SEAT BELT PRETENSIONER
CAUTION: THIS ASSEMBLY CONTAINS AN EXPLOSIVE INITIATOR
FLAMMABLE MATERIAL
TO PREVENT PERSONAL INJURY
• DO NOT IMPACT, DISMANTLE OR INSTALL IT INTO ANOTHER VEHICLE.
• SERVICE OR DISPOSE OF IT AS DIRECTED IN THE REPAIR MANUAL.
M CAUTION:
DO NOT DISASSEMBLE OR DROP.
N WARNING
THIS VEHICLE HAS AN AIR BAG SYSTEM.
REFER TO SERVICE MANUAL BEFORE SERVICING OR DISASSEMBLING
UNDERHOOD COMPONENTS.
READ THE "SRS" SECTION OF MANUAL FOR IMPORTANT INSTRUCTIONS.
IMPROPER SERVICE PROCEDURES CAN RESULT IN THE AIR BAG FIRING OR
BECOMING INOPERATIVE, POSSIBLY LEADING TO INJURY.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-9
GENERAL DESCRIPTION
SCHEMATIC
SIDE
CONNCTOR LOCK CLOCK CONNCTOR LOCK IMPACT
SWITCH* SPRING SWITCH* SENSOR
OFF OFF (RH)
OFF
ON
ON ON
OFF OFF
OFF
DRIVER'S ON ON
AIR BAG ON
OFF OFF
MODULE OFF
ON ON
ON
OFF OFF
OFF
ON ON ON DATA LINK CONNECTOR
OFF OFF
(FOR SCAN TOOL)
ON
CONNECTOR ON
OFF LOCK SWITCH*
OFF
CAN BUS
PASSENGER'S ON ON LINE
(FRONT) AIR BAG OFF OFF
MODULE ON CONNECTOR ON SRS-ECU COMBINATION METER
OFF LOCK SWITCH*
OFF
ON
ON
OFF OFF OFF
SEAT BELT ON CONNECTOR ON
PRE-TENSIONER OFF LOCK SWITCH* ON
(LH) OFF
ON ON
OFF OFF
SEAT BELT ON
PRE-TENSIONER CONNECTOR ON OFF
OFF LOCK SWITCH* OFF
(RH)
ON ON
ON
OFF
OFF
SIDE-AIRBAG ON ON
CONNECTOR
MODULE (LH) OFF LOCK SWITCH* OFF OFF
ON ON
OFF OFF ON
SIDE-AIRBAG ON ON CONNECTOR
CONNECTOR
MODULE (RH) OFF LOCK SWITCH* OFF LOCK SWITCH*
ON ON
FRONT FRONT
IMPACT IMPACT
SENSOR SENSOR
(LH) (RH)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-10
GENERAL DESCRIPTION
SIDE-AIRBAG MODULE
(LH)
PASSENGER'S (FRONT)
AIR BAG MODULE
CLOCK
SRS-ECU SPRING
DRIVER'S AIR BAG MODULE
SIDE-AIRBAG MODULE
(RH)
AC401872 AB
.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-11
GENERAL DESCRIPTION
ON
ON
SQUIB SQUIB
SRS-ECU SRS-ECU
OFF OFF
ON ON
<CONNECTOR SHORTING MECHANISM (E.G. SRS-ECU CONNECTOR)>
ECU-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR
A B
TERMINAL
TERMINAL (FEMALE)
(MALE)
CONNECTOR CONNECTED
PARTITION
PANEL A B TERMINAL
SHORT SPRING
(FEMALE)
SECTION A - A SECTION B - B TERMINAL
(MALE)
TERMINAL TERMINAL
(MALE) (FEMALE)
PARTITION PANEL
AC006197 AG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-12
GENERAL DESCRIPTION
CONFIGURATION DIAGRAMS
INSTRUMENT PANEL
WIRING HARNESS
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
5 D-32 D-24
2
Y
FLOOR WIRING
HARNESS
15
STEERING COLUMN
ENGINE ROOM
A-23
A-27 AC304363
AC304353 C-307
C-305
D-20
D-21
D-24
D-35
D-33
AC304366 D-32
52DB002A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-13
GENERAL DESCRIPTION
A-23 (Y) FRONT IMPACT SENSOR (LH) C-307 (Y) CLOCK SPRING
A-27 (Y) FRONT IMPACT SENSOR (RH) D-20 SIDE IMPACT SENSOR (LH)
C-101 COMBINATION METER (FOR SRS D-21 (B) SEAT BELT PRE-TENSIONER
WARNING LIGHT) (LH)
C-110 (Y) AIR BAG MODULE (FRONT D-24 (R) SIDE-AIRBAG MODULE (SQUIB)
PASSENGER’S SIDE) (LH)
D-26 (Y) SRS-ECU D-32 (R) SIDE-AIRBAG MODULE (SQUIB)
C-121 (Y) SRS-ECU (RH)
D-27 (Y) SRS-ECU D-33 (B) SEAT BELT PRE-TENSIONER
C-125 (B) DATA LINK CONNECTOR (RH)
C-305 (Y) AIR BAG MODULE (SQUIB) D-35 SIDE IMPACT SENSOR (RH)
(DRIVER’S SIDE)
CIRCUIT DIAGRAM
• Refer to circuit diagrams GROUP-90 • Refer to configuration diagrams GROUP-80
WARNING
• Do not repair, splice, or modify the SRS wiring (except for specific repairs to the instru-
ment panel wiring harness and the floor wiring harness shown on P.52B-16): replace the
wiring if necessary, after reading and following all precautions and procedures in this
manual.
• Do not use an analog ohmmeter to check the SRS wiring or components; use only the
special tools (refer to P.52B-223) and a digital multi-meter (refer to P.52B-224).
CAUTION
Improper services cause the system to be inoperative. Do not disassemble or tamper with the SRS
components to prevent the serious injury.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-14
GENERAL DESCRIPTION
COMPONENT LOCATION
AC305250
AC306289
AC305035
52DB003A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-15
GENERAL DESCRIPTION
SRS-ECU
52DB003A
NOTE: The illustration above shows the front impact sensor (RH) and the side impact sensor (RH). The posi-
tion of the front impact sensor (LH) and the side impact sensor (LH) is symmetrical to this.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-16
SERVICE PRECAUTIONS
SERVICE PRECAUTIONS
M1524000300499
DANGER
• In order to avoid injury to yourself or others from
accidental deployment of the air bag during servic-
ing, read and carefully follow all the precautions
and procedures described in this manual.
• After disconnecting the battery cable, wait 60 sec-
INSULATING TAPE onds or more before proceeding with the following
BATTERY work. The SRS system is designed to retain
enough voltage to deploy the air bag for a short
time even after the battery has been disconnected,
so serious injury may result from unintended air
bag deployment if work is done on the SRS system
immediately after the battery cables are discon-
BATTERY CABLE (–) nected.
ACX00583 AC
WARNING
• Battery posts, terminals and related accessories
contain lead and lead compounds. WASH HANDS
AFTER HANDLING.
• Do not use any electrical test equipment on or near
the SRS components, except those specified on
P.52B-224.
• Never Attempt to Repair the Following Compo-
nents: SRS-ECU, Clock Spring, Air Bag Module,
Front impact sensor, Side Impact Sensor, Seat Belt
with Pre-tensioner, Front seat assenbly. If any of
these components are diagnosed as faulty, they
should only be replaced, in accordance with the
INDIVIDUAL COMPONENT SERVICE procedures in
this manual, starting on P.52B-230.
• Do not attempt to repair the wiring harness con-
nectors of the SRS. If any of the connectors are
diagnosed as faulty, replace the wiring harness. If
SRS-ECU CONNECTOR the wires are diagnosed as faulty, replace the wir-
51 52 B A 53 54 21 2223 B A 24 25 26 1 2 B A 3 4 ing harness according to the following table.
55 56 57 5859 60 61 62 27 28 29 30 31 32 33 34 35 36 37 5 6 7 8 9 10 11 12
63 64 65 66 67 68 69 70 38 39 40 41 42 43 44 45 46 47 48 13 14 15 16 17 18 19 20 WARNING
AC3001278AB [SRS is a safety related item, therefore there shall be no
attempt to repair any component or wiring harness related
to SRS]
.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-17
SERVICE PRECAUTIONS
WARNING
• Inspection of the SRS-ECU connector harness
SRS-HARNESS CONNECTOR
should be carried out by the following procedure.
Insert the testprobe tool into connector from har-
ness side (rear side), and connect the tester to
testprobe tool. If any tool other than testprobe tool
is used, it may cause damage to the harness and
other components. Furthermore, measurement
should not be carried out by touching the
testprobe tool directly against the terminals from
the front of the connector. The terminals are plated
AC300928
to increase their conductivity, so if they are
touched directly by the testprobe tool, the plating
SRS-ECU HARNESS CONNECTOR may break, which will decrease reliability.
(REAR SIDE)
• The SRS components and seat belt with pre-ten-
sioner should not be subjected to heat, so remove
the SRS-ECU, driver’s and front passenger’s air
bag modules, clock spring, side-airbag modules,
AC301599
and seat belt pre-tensioner before drying or baking
the vehicle after painting.
24DB067A • SRS-ECU, air bag module, clock spring: 93° C
(200° F) or more
• Seat belt with pre-tensioner 90°C (194° F) or
more
• After servicing the SRS system, check the warning
light operation to make sure that the system func-
tions properly. (Refer to P.52B-3).
• Make certain that the ignition switch is in the
"LOCK"(OFF) position when the diagnostic tool is
connected or disconnected.
TROUBLESHOOTING STRATEGY
M1524003100654
Use these steps to plan your diagnostic strategy. If 5. If there is a SRS DTC, record the code number,
you follow them carefully, you will be sure that you then erase the code from vehicle memory using
have exhausted all of the possible ways to find a diagnostic tool (MUT-III Sub Assembly)
SRS fault. MB991958.
1. Gather information about the problem from the 6. Recreate the SRS DTC set conditions to see if the
customer. same SRS DTC will be set again.
2. Verify that the condition described by the • If the same SRS DTC is set again, follow the
customer exists. Inspection Chart for the DTC and find the fault.
3. Check the vehicle for any SRS diagnostic trouble • If you cannot get the same SRS DTC to be set
codes (SRS DTC). again, the malfunction is intermittent. Refer to
4. If you cannot verify the condition but there are no GROUP 00, How to Use Troubleshooting/Inspec-
SRS DTCs, the malfunction is intermittent. Refer tion Service Points − How to Cope with Intermit-
to GROUP 00, How to Use tent Malfunctions .
Troubleshooting/Inspection Service Points − How • Refer to circuit diagrams GROUP-90
to Cope with Intermittent Malfunctions . • Refer to configuration diagrams GROUP-80
DIAGNOSTIC FUNCTION
M1524013800074
MB991827 00DB076A
CAUTION
During diagnosis, a DTC code associated with
another system may be set when the ignition
switch is turned on with connector(s) discon-
nected. After completing the repair, confirm all
systems for DTC code(s). If DTC code(s) are set,
erase them all.
Inspect according to the inspection chart that is
appropriate for the DTC.
DIAGNOSTIC INSPECTION ITEM REFERENCE PAGE
TROUBLE CODE
NO.
B1400*3 Driver's air bag short-circuited P.52B-24
B1401*3 Driver's air bag open-circuited P.52B-32
B1402*3 Driver's air bag drive circuit (ground side) short-circuited P.52B-37
B1403*3 Driver's air bag drive circuit (power supply side) P.52B-43
short-circuited
B1404*3 Driver's air bag activating circuit short-circuited P.52B-173
B1405*5 Driver's air bag activating circuit open-circuited P.52B-173
B1406*5 G-sensor of front impact sensor (RH) failure P.52B-49
B1407*3 Front impact sensor (RH) voltage error P.52B-51
B1408*3 Front impact sensor (RH) communication error P.52B-55
B1409*3 Front impact sensor (RH) communication impossible P.52B-55
B1410*3 Passenger's (front) air bag short-circuited P.52B-59
B1411*3 Passenger's (front) air bag open-circuited P.52B-67
B1412*3 Passenger's (front) air bag drive circuit (ground side) P.52B-72
short-circuited
B1413*3 Passenger's (front) air bag drive circuit (power supply side) P.52B-77
short-circuited
B1414*5 Passenger's (front) air bag activating circuit short-circuited P.52B-173
B1415*5 Passenger's (front) air bag activating circuit open-circuited P.52B-173
B1416*5 G-sensor of front impact sensor (LH) failure P.52B-49
B1417*3 Front impact sensor (LH) voltage error P.52B-82
B1418*3 Front impact sensor (LH) communication error P.52B-86
B1419*3 Front impact sensor (LH) communication impossible P.52B-86
B1420*3 Side-airbag squib (RH) short-circuited P.52B-90
B1421*3 Side-airbag squib (RH) open-circuited P.52B-97
B1422*3 Side-airbag squib (RH) drive circuit (ground side) shorted P.52B-102
B1423*3 Side-airbag squib (RH) drive circuit (power supply side) P.52B-107
shorted
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-22
SRS AIR BAG DIAGNOSIS
DTC B1400: Driver’s Air Bag Module (1st Squib) System Fault 1 (Short Circuit between Terminals of
the Squib Circuit)
CIRCUIT OPERATION
• Refer to configuration diagrams GROUP-80
• The SRS-ECU judges how severe a collision is • Improper engaged connector or defective short
by detecting signals from the front impact sensors spring*
and the front air bag analog G-sensor. If the • Short circuit in the clock spring
impact is over a predetermined level, the • Short circuit between the driver's air bag module
SRS-ECU sends an ignition signal. At this time, if (squib) circuit terminals
the front air bag safing G-sensor is on, the SRS • Damaged connector(s)
air bag will inflate. • Malfunction of the SRS-ECU
• The ignition signal is input to the air bag module
via the clock spring to inflate the air bag. .
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resistor
• MB991866: Resistor harness
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-26
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-27
SRS AIR BAG DIAGNOSIS
C-307 (Y)
C-307 HARNESS
SIDE CONNECTOR
C-305 (Y) 14 13 12 11
52DB007A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-28
SRS AIR BAG DIAGNOSIS
AC306561AC
MB991865 MB991866 (RESISTOR (3) Connect special tool MB991865 to special tool MB991866.
(DUMMY RESISTOR : 3Ω) HARNESS)
CAUTION
Do not insert a test probe into the terminal from its front
side directly as the connector contact pressure may be
weakened.
(4) Insert special tool MB991866 into clock spring side of
driver’s air bag module connector C-305 (terminal No.1 and
C-305 AIR BAG 2 ) by testprobe.
MODULE
CONNECTOR
(5) Connect the negative battery terminal.
(REAR VIEW) AC306758 AB (6) Erase the diagnostic trouble code memory, and check the
diagnostic trouble code.
Q: Is DTC B1400 set?
YES : Go to Step 7.
NO : Replace the driver's air bag module (Refer to
P.52B-237). Then go to Step 10.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-29
SRS AIR BAG DIAGNOSIS
14 13 12 11
52DB008A
MB991865 MB991866 (RESISTOR (3) Connect special tool MB991865 to special tool MB991866.
(DUMMY RESISTOR : 3Ω) HARNESS)
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
weakened.
(4) Insert special tool MB991866 into clock spring harness side
connector C-307 (terminal No.13 and 14 ) by testprobe.
(5) Connect the negative battery terminal.
1112 1314 C-307 CLOCK SPRING (6) Erase the diagnostic trouble code memory, and check the
(REAR VIEW) CONNECTOR AC306767 AB diagnostic trouble code.
Q: Is DTC B1400 set?
YES : Go to Step 8.
NO : Replace the clock spring (Refer to P.52B-237). Then
go to Step 10.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-30
SRS AIR BAG DIAGNOSIS
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
DANGER
CONNECTOR: C-307
To prevent the air bag from deploying unintentionally,
disconnect clock spring connector C-307 to short the
CLOCK
SPRING squib circuit.
(2) Disconnect clock spring connector C-307.
14 13 12 11
52DB008A
CAUTION
<1ST SQUIB> C-121 HARNESS SIDE Insert an insulator such as a cable tie to a depth of 4mm
CONNECTOR (0.16 inch) or more, otherwise the short spring will not be
(FRONT VIEW) released.
(3) Insert a cable tie [3 mm (0.12 inch) wide, 0.5 mm (0.02 inch)
SECTION TERMINAL
A-A thick] between terminals 28, 27 and the short spring to
CABLE TIE release the short spring.
A
CAUTION
A Do not insert a test probe into the terminal from its front
side directly as the connector contact pressure may be
4 mm OR MORE SHORT SPRING AC308144AB
weakened.
(4) Check for continuity between C-121 harness side connector
<2ND SQUIB> C-121 HARNESS SIDE terminals 28 and 27 .
CONNECTOR It should be open circuit.
(FRONT VIEW)
Q: Does continuity exist?
SECTION TERMINAL
A-A YES : Erase the diagnostic trouble code memory, and check
CABLE TIE the diagnostic trouble code. If DTC B1400 set,
A replace the SRS-ECU (Refer to P.52B-234). Then go
A to Step 10.
NO : Go to Step 9.
4 mm OR MORE SHORT SPRING AC308141AB
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-31
SRS AIR BAG DIAGNOSIS
CONNECTOR: C-307
CLOCK
SPRING
14 13 12 11
52DB008A
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-32
SRS AIR BAG DIAGNOSIS
DTC B1401: Driver's Air Bag Module (1st Squib) System Fault 2 (Open in the Squib Circuit)
and the front air bag analog G-sensor. If the TROUBLESHOOTING HINTS
impact is over a predetermined level, the • Refer to circuit diagrams GROUP-90
SRS-ECU sends an ignition signal. At this time, if • Refer to configuration diagrams GROUP-80
the front air bag safing G-sensor is on, the SRS • Open circuit in the clock spring
air bag will inflate. • Open circuit due to improper neutral position of
• The ignition signal is input to the air bag module the clock spring
via the clock spring to inflate the air bag. • Open circuit in the driver's air bag module (squib)
. circuit
DTC SET CONDITIONS • Disengaged driver's air bag module (squib) con-
• This DTC is set if there is abnormal resistance nector
between the input terminals of the driver's side air • Improper connector contact
bag module (squib). The most likely causes for • Malfunction of the SRS-ECU
this code to be set are the followings:
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
Communication System)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-33
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-34
SRS AIR BAG DIAGNOSIS
AC306561AC
MB991865 MB991866 (RESISTOR (3) Connect special tool MB991865 to special tool MB991866.
(DUMMY RESISTOR : 3Ω) HARNESS)
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
weakened.
(4) Insert special tool MB991866 into clock spring side of
driver’s air bag module connector C-305 (terminal No.1 and
C-305 AIR BAG 2 ) by testprobe.
MODULE
CONNECTOR
(5) Connect the negative battery terminal.
(REAR VIEW) AC306758 AB (6) Erase the diagnostic trouble code memory, and check the
diagnostic trouble code.
Q: Is DTC B1401 set?
YES : Go to Step 4.
NO : Replace the driver's air bag module (Refer to
P.52B-237). Then go to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-35
SRS AIR BAG DIAGNOSIS
14 13 12 11
52DB008A
MB991865 MB991866 (RESISTOR (3) Connect special tool MB991865 to special tool MB991866.
(DUMMY RESISTOR : 3Ω) HARNESS)
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
weakened.
(4) Insert special tool MB991866 into harness side of clock
spring connector C-307 (terminal No.14 and 13 ) by
testprobe.
1112 1314 C-307 CLOCK SPRING (5) Connect the negative battery terminal.
(REAR VIEW) CONNECTOR AC306767 AB (6) Erase the diagnostic trouble code memory, and check the
diagnostic trouble code.
Q: Is DTC B1401 set?
YES : Go to Step 5.
NO : Replace the clock spring (Refer to P.52B-237). Then
go to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-36
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-37
SRS AIR BAG DIAGNOSIS
DTC B1402: Driver's Air Bag Module (1st Squib) System Fault for Power Supply Circuit
(Short-Circuited to Power Supply)
and the front air bag analog G-sensor. If the TROUBLESHOOTING HINTS
impact is over a predetermined level, the
• Refer to circuit diagrams GROUP-90
SRS-ECU sends an ignition signal. At this time, if
• Refer to configuration diagrams GROUP-80
the front air bag safing G-sensor is on, the SRS
• Malfunction of the clock spring
air bag will inflate.
• Damaged harness wires and connectors
• The ignition signal is input to the air bag module
• Short to the power supply in the driver's air bag
via the clock spring to inflate the air bag.
module (squib) harness
.
• Malfunction of the SRS-ECU
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
Communication System)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-38
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-39
SRS AIR BAG DIAGNOSIS
AC306561AC
MB991865 MB991866 (RESISTOR (3) Connect special tool MB991865 to special tool MB991866.
(DUMMY RESISTOR : 3Ω) HARNESS)
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
weakened.
(4) Insert special tool MB991866 into clock spring side air bag
module connector C-305 (terminal No.1 and 2 ) by
C-305 AIR BAG testprobe.
MODULE
CONNECTOR
(5) Connect the negative battery terminal.
(REAR VIEW) AC306758 AB (6) Erase the diagnostic trouble code memory, and check the
diagnostic trouble code.
Q: Is DTC B1402 set?
YES : Go to Step 4.
NO : Replace the driver’s air bag module (Refer to
P.52B-237). Then go to Step 7.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-40
SRS AIR BAG DIAGNOSIS
14 13 12 11
52DB008A
MB991865 MB991866 (RESISTOR (3) Connect special tool MB991865 to special tool MB991866.
(DUMMY RESISTOR : 3Ω) HARNESS)
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
weakened.
(4) Insert special tool MB991866 into clock spring harness side
connector C-307 (terminal No.13 and 14 ) by testprobe.
(5) Connect the negative battery terminal.
1112 1314 C-307 CLOCK SPRING (6) Erase the diagnostic trouble code memory, and check the
(REAR VIEW) CONNECTOR AC306767 AB diagnostic trouble code.
Q: Is DTC B1402 set?
YES : Go to Step 5.
NO : Replace the clock spring (Refer to P.52B-237). Then
go to Step 7.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-41
SRS AIR BAG DIAGNOSIS
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
DANGER
CONNECTOR: C-307
To prevent the air bag from deploying unintentionally,
disconnect the clock spring connector C-307 to short
CLOCK
SPRING the squib circuit.
(2) Disconnect the clock spring connector C-307.
(3) Turn the ignition switch to the "ON" position.
C-307 (Y) C-307 HARNESS CAUTION
SIDE CONNECTOR Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
14 13 12 11
weakened.
52DB008A (4) Measure the voltage between C-121 harness side
connector terminals 28 and 27 and body ground.
Voltage should measure 0 volt.
Q: Is the measured voltage within the specified range?
YES : Erase the diagnostic trouble code memory, and check
the diagnostic trouble code. If DTC B1402 sets,
replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 7.
NO : Go to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-42
SRS AIR BAG DIAGNOSIS
CONNECTOR: C-307
CLOCK
SPRING
14 13 12 11
52DB008A
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-43
SRS AIR BAG DIAGNOSIS
DTC 1403: Driver’s Air Bag Module (1st Squib) System Fault for Ground Circuit (Short-Circuited to
Ground)
and the front air bag analog G-sensor. If the TROUBLESHOOTING HINTS
impact is over a predetermined level, the
• Refer to circuit diagrams GROUP-90
SRS-ECU sends an ignition signal. At this time, if
• Refer to configuration diagrams GROUP-80
the front air bag safing G-sensor is on, the SRS
• Malfunction of the clock spring
air bag will inflate.
• Damaged harness wires and connectors
• The ignition signal is sent to the air bag module
• Short to the ground in the driver's air bag module
via the clock spring to inflate the air bag.
(squib) harness
.
• Malfunction of the SRS-ECU
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
Communication System)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-44
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-45
SRS AIR BAG DIAGNOSIS
AC306561AC
MB991865 MB991866 (RESISTOR (3) Connect special tool MB991865 to special tool MB991866.
(DUMMY RESISTOR : 3Ω) HARNESS)
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
weakened.
(4) Insert special tool MB991866 into clock spring side air bag
module connector C-305 (terminal No.1 and 2 ) by
C-305 AIR BAG testprobe.
MODULE
CONNECTOR
(5) Connect the negative battery terminal.
(REAR VIEW) AC306758 AB (6) Erase the diagnostic trouble code memory, and check the
diagnostic trouble code.
Q: Is DTC B1403 set?
YES : Go to Step 4.
NO : Replace the driver's air bag module (Refer to
P.52B-237). Then go to Step 7.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-46
SRS AIR BAG DIAGNOSIS
14 13 12 11
52DB008A
MB991865 MB991866 (RESISTOR (3) Connect special tool MB991865 to special tool MB991866.
(DUMMY RESISTOR : 3Ω) HARNESS)
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
weakened.
(4) Insert special tool MB991866 into clock spring harness side
connector C-307 (terminal No.13 and 14 ) by testprobe.
(5) Connect the negative battery terminal.
1112 1314 C-307 CLOCK SPRING (6) Erase the diagnostic trouble code memory, and check the
(REAR VIEW) CONNECTOR AC306767 AB diagnostic trouble code.
Q: Is DTC B1403 set?
YES : Go to Step 5.
NO : Replace the clock spring (Refer to P.52B-237). Then
go to Step 7.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-47
SRS AIR BAG DIAGNOSIS
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
DANGER
CONNECTOR: C-307
To prevent the air bag from deploying unintentionally,
disconnect the clock spring connector C-307 to short
CLOCK
SPRING the squib circuit.
(2) Disconnect the clock spring connector C-307.
CAUTION
C-307 (Y) C-307 HARNESS Do not insert a test probe into the terminal from its front
SIDE CONNECTOR side directly, as the connector contact pressure may be
weakened.
14 13 12 11
(3) Check for continuity between C-121 harness side connector
52DB008A terminals 28 and 27 and body ground.
It should be open circuit.
Q: Does continuity exist?
YES : Erase the diagnostic trouble code memory, and check
the diagnostic trouble code. If DTC B1403 sets,
replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 6.
NO : Go to Step 7.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-48
SRS AIR BAG DIAGNOSIS
CONNECTOR: C-307
CLOCK
SPRING
14 13 12 11
52DB008A
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-49
SRS AIR BAG DIAGNOSIS
DTC B1406: Front Impact Sensor (RH) System for Fault 1 DTC B1416: Front Impact Sensor (LH)
System for Fault 1
DIAGNOSIS
Required Special Tool:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-50
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
DTC B1407: Front Impact Sensor (RH) Power Supply Circuit System
C-121 (Y)
C-121
INSTRUMENT
A-27 (Y) HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
AC305206BC 38 39 40 41 42 43 44 45 46 47 48 24DB062A
CONNECTOR: C-29
52DB013A
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991223 (MB991222): Harness set (Probe)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-52
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-53
SRS AIR BAG DIAGNOSIS
A-27 (Y)
HARNESS SIDE
AC305206BA
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
A-27 HARNESS SIDE weakened.
CONNECTOR
(5) Measure the voltage between A-27 harness side connector
(REAR VIEW)
terminal 2 and ground.
Voltage should measure 9 volts or more
Q: Is the measured voltage within the specified range?
YES : Replace the front impact sensor (RH) (Refer to
P.52B-231). Then go to Step 5.
AC308161AB
NO : Go to Step 4.
A-27 (Y)
HARNESS SIDE
AC305206BA
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-54
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-55
SRS AIR BAG DIAGNOSIS
DTC B1408: Front Impact Sensor (RH) (Squib) for Power Supply Circuit
DTC B1409: Front Impact Sensor (RH) (Squib) for Communication System
A-27 (Y)
AC305206BC 52DB013A
CONNECTOR: C-121
SRS-ECU
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
.
and CPU, etc. The CPU monitors the analog G sen- TROUBLESHOOTING HINTS
sor output signal. If the CPU judges that the front air • Damaged wiring harnesses or connectors
bags should be deployed, it sends a fire signal to the • Malfunction of the front impact sensor (RH)
SRS-ECU to deploy the front air bags. In addition, • Malfunction of the SRS-ECU
the CPU diagnoses the internal components of the • Refer to circuit diagrams GROUP-90
front impact sensor. If a malfunction occurs, it • Refer to configuration diagrams GROUP-80
requests the SRS-ECU to set a diagnostic trouble
code.
.
DIAGNOSIS
Required Special Tool:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-56
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-57
SRS AIR BAG DIAGNOSIS
MB991910
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-58
SRS AIR BAG DIAGNOSIS
A-27 (Y)
HARNESS SIDE
AC305206BA
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-59
SRS AIR BAG DIAGNOSIS
DTC B1410: Passenger’s (Front) Air Bag Module (1st Squib) System Fault 1 (Short Circuit between
Terminals of the Squib Circuit)
C-121 (Y)
C-121
INSTRUMENT
C-110 (Y) HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
FRONT DECK 27 28 29 30 31 32 33 34 35 36 37
CIRCUIT OPERATION
module (squib) circuit terminals
• The SRS-ECU judges how severe a collision is
• Damaged connector(s)
by detecting signals from the front impact sensors
• Malfunction of the SRS-ECU
and the front air bag analog G-sensor. If the
• Refer to circuit diagrams GROUP-90
impact is over a predetermined level, the
• Refer to configuration diagrams GROUP-80
SRS-ECU sends an ignition signal. At this time, if
the front air bag safing G-sensor is on, the SRS .
air bag will inflate. NOTE: *: The squib circuit connectors integrate a
• The ignition signal is input to the air bag module "short" spring (which prevents the air bag from
via the clock spring to inflate the air bag. deploying unintentionally due to static electricity by
shorting the positive wire to the ground wire in the
squib circuit when the connectors are disconnected)
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
Communication System)
• MB991865: Dummy resister
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-60
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-61
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
C-110 (Y)
FRONT DECK
52DB018A CROSSMEMBER
CONNECTOR: C-121
SRS-ECU
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
(3) Slide the outer housing of the clock spring side of driver’s
air bag module connector C-110 in the arrow direction
OUTER HOUSING OF THE PASSENGER'S shown, and disconnect the connector.
AIR BAG MODULE CONNECTOR C-110
(4) Connect the negative battery terminal.
(5) Erase the diagnostic trouble code memory, and check the
diagnostic trouble code.
Q: Is DTC B1410 set?
YES : Go to Step 6.
NO : The procedure is complete. It is assumed that DTC
B1410 set as connector C-121 or C-110 was
AC306561AD engaged improperly.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-63
SRS AIR BAG DIAGNOSIS
C-110 (Y)
FRONT DECK
52DB018A CROSSMEMBER
AC306561AD
MB991865 (DUMMY (4) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω)
CAUTION
C-110 HARNESS Do not insert a test probe into the terminal from its front
CONNECTOR
side directly as the connector contact pressure may be
weakened.
MB991866 (5) Insert special tool MB991866 into the harness side
(RESISTOR HARNESS)
connector C-110 (terminal No.1 and 2 ) by testprobe.
C-110 (6) Connect the negative battery terminal.
PASSENGER'S
AIR BAG MODULE (7) Erase the diagnostic trouble code memory, and check the
CONNECTOR AC306760AB diagnostic trouble code.
Q: Is DTC B1410 ?
YES : Go to Step 7.
NO : Replace the passenger's air bag module (Refer to
P.52B-237). Then go to Step 9.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-64
SRS AIR BAG DIAGNOSIS
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
DANGER
CONNECTOR: C-110 To prevent the air bag from deploying unintentionally,
disconnect the passenger’s air bag module connec-
HARNESS SIDE
CONNECTOR
tor C-110 to short the squib circuit.
(REAR VIEW) (2) Disconnect the passenger's air bag module connector
C-110.
C-110 (Y)
FRONT DECK
52DB018A CROSSMEMBER
(3) Slide the outer housing of the clock spring side of driver’s
OUTER HOUSING OF THE PASSENGER'S air bag module connector C-110 in the arrow direction
AIR BAG MODULE CONNECTOR C-110
shown, and disconnect the connector.
AC306561AD
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-65
SRS AIR BAG DIAGNOSIS
CAUTION
<1ST SQUIB> Insert an insulator such as a cable tie to a depth of 4mm
C-121 HARNESS SIDE (0.16 inch) or more, otherwise the short spring will not be
CONNECTOR released.
(FRONT VIEW)
(4) Insert a cable tie [3 mm (0.12 inch) wide, 0.5 mm (0.02 inch)
SECTION TERMINAL
A-A thick] between terminals 37 and 36 , and the short spring to
CABLE TIE release the short spring.
A
CAUTION
A Do not insert a test probe into the terminal from its front
side directly as the connector contact pressure may be
SHORT SPRING
4 mm OR MORE AC308142AB
weakened.
(5) Check for continuity between C-121 harness side connector
<2ND SQUIB> terminals 37 and 36 .
C-121 HARNESS SIDE
CONNECTOR
It should be open circuit.
(FRONT VIEW) Q: Does continuity exist?
SECTION TERMINAL
A-A
YES : Go to Step 8.
CABLE TIE NO : Erase the diagnostic trouble code memory, and check
A the diagnostic trouble code. If DTC B1410 set,
A replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 9.
SHORT SPRING
4 mm OR MORE AC308143AB
CONNECTOR: C-121
SRS-ECU
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-66
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-67
SRS AIR BAG DIAGNOSIS
DTC B1411: Passenger’s (Front) Air Bag Module (1st Squib) System Fault 2 (Open in the Squib
Circuit)
C-121 (Y)
C-121
INSTRUMENT
C-110 (Y) HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
FRONT DECK 27 28 29 30 31 32 33 34 35 36 37
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
Communication System)
• MB991865: Dummy resister
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-68
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-69
SRS AIR BAG DIAGNOSIS
C-110 (Y)
FRONT DECK
52DB018A CROSSMEMBER
AC306561AD
MB991865 (DUMMY (4) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω)
CAUTION
C-110 HARNESS Do not insert a test probe into the terminal from its front
CONNECTOR
side directly, as the connector contact pressure may be
weakened.
MB991866 (5) Insert special tool MB991866 into the harness side
(RESISTOR HARNESS)
connector C-110 (terminal No.1 and 2 ) by testprobe.
C-110 (6) Connect the negative battery terminal.
PASSENGER'S
AIR BAG MODULE (7) Erase the diagnostic trouble code memory, and check the
CONNECTOR AC306760AB diagnostic trouble code.
Q: Is DTC B1411 set?
YES : Go to Step 4.
NO : Replace the passenger's air bag module (Refer to
P.52B-237). Then go to Step 5.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-70
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
CONNECTOR
(REAR VIEW)
C-110 (Y)
FRONT DECK
52DB018A CROSSMEMBER
CONNECTOR: C-121
(2) Disconnect SRS-ECU connector C-121 and passenger's air
bag module connector C-110.
SRS-ECU
CAUTION
C-121 (Y) Do not insert a test probe into the terminal from its front
C-121 side directly as the connector contact pressure may be
INSTRUMENT
HARNESS
weakened.
CONNECTOR (3) Check for continuity between the following terminals. It
(REAR VIEW) should be less than 2 ohms.
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37 • SRS-ECU connector C-121 (terminal No.37) and the
38 39 40 41 42 43 44 45 46 47 48 24DB062A passenger’s air bag module connector C-110 (terminal
No.1)
• SRS-ECU connector C-121 (terminal No.36) and the
passenger’s air bag module connector C-110 (terminal
No.2)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-71
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-72
SRS AIR BAG DIAGNOSIS
DTC B1412: Passenger’s (Front) Air Bag Module (1st Squib) System Fault for Power Supply Circuit
(Short-Circuited to Power Supply)
C-121 (Y)
C-121
INSTRUMENT
C-110 (Y) HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
FRONT DECK 27 28 29 30 31 32 33 34 35 36 37
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
Communication System)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-73
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-74
SRS AIR BAG DIAGNOSIS
C-110 (Y)
FRONT DECK
52DB018A CROSSMEMBER
AC306561AD
MB991865 (DUMMY (4) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω)
CAUTION
C-110 HARNESS Do not insert a test probe into the terminal from its front
CONNECTOR
side directly, as the connector contact pressure may be
weakened.
MB991866 (5) Insert special tool MB991866 into the harness side
(RESISTOR HARNESS)
connector C-110 (terminal No.1 and 2) by testprobe.
C-110 (6) Connect the negative battery terminal.
PASSENGER'S
AIR BAG MODULE (7) Erase the diagnostic trouble code memory, and check the
CONNECTOR AC306760AB diagnostic trouble code.
Q: Is DTC B1412 set?
YES : Go to Step 4.
NO : Replace the passenger's air bag module (Refer to
P.52B-237). Then go to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-75
SRS AIR BAG DIAGNOSIS
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
DANGER
CONNECTOR: C-110 To prevent the air bag from deploying unintentionally,
disconnect the passenger’s air bag module connec-
HARNESS SIDE
CONNECTOR
tor C-110 to short the squib circuit.
(REAR VIEW) (2) Disconnect the passenger's air bag module connector
C-110.
C-110 (Y)
FRONT DECK
52DB018A CROSSMEMBER
CONNECTOR: C-121
SRS-ECU
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-77
SRS AIR BAG DIAGNOSIS
DTC B1413: Passenger’s (Front) Air Bag Module (1st Squib) System Fault for Ground Circuit
(Short-Circuited to Ground)
C-121 (Y)
C-121
INSTRUMENT
C-110 (Y) HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
FRONT DECK 27 28 29 30 31 32 33 34 35 36 37
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
Communication System)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-78
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-79
SRS AIR BAG DIAGNOSIS
C-110 (Y)
FRONT DECK
52DB018A CROSSMEMBER
AC306561AD
MB991865 (DUMMY (4) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω)
CAUTION
C-110 HARNESS Do not insert a test probe into the terminal from its front
CONNECTOR
side directly, as the connector contact pressure may be
weakened.
MB991866 (5) Insert special tool MB991866 into the harness side
(RESISTOR HARNESS)
connector C-110 (terminal No.1 and 2) by testprobe.
C-110 (6) Connect the negative battery terminal.
PASSENGER'S
AIR BAG MODULE (7) Erase the diagnostic trouble code memory, and check the
CONNECTOR AC306760AB diagnostic trouble code.
Q: Is DTC B1413 set?
YES : Go to Step 4.
NO : Replace the passenger's air bag module (Refer to
P.52B-237). Then go to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-80
SRS AIR BAG DIAGNOSIS
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
DANGER
CONNECTOR: C-110 To prevent the air bag from deploying unintentionally,
disconnect the passenger’s air bag module connec-
HARNESS SIDE
CONNECTOR
tor C-110 to short the squib circuit.
(REAR VIEW) (2) Unclip passenger’s air bag module connector C-110.
(3) Disconnect the passenger's air bag module connector
C-110 (Y) C-110.
CAUTION
Do not insert a test probe into the terminal from its front
FRONT DECK side directly, as the connector contact pressure may be
52DB018A CROSSMEMBER weakened.
(4) Check for continuity between C-121 harness side connector
terminals 37 and 36, and body ground.
It should be open circuit.
Q: Does continuity exist?
YES : Go to Step 5.
NO : Erase the diagnostic trouble code memory, and check
the diagnostic trouble code. If DTC B1413 sets,
replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-81
SRS AIR BAG DIAGNOSIS
CONNECTOR: C-121
SRS-ECU
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-82
SRS AIR BAG DIAGNOSIS
DTC B1417: Front Impact Sensor (LH) Power Supply Circuit System
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
A-23 (Y) (REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
AC305210 AW 38 39 40 41 42 43 44 45 46 47 48 24DB062A
CONNECTOR: C-11
52DB010A
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991223 (MB991222): Harness set (Probe)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-83
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-84
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
A-23 (Y)
AC305210 AT
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
A-23 HARNESS SIDE weakened.
CONNECTOR
(5) Measure the voltage between A-23 harness side connector
(REAR VIEW)
terminal 2 and ground.
Voltage should measure 9 volts or more
Q: Is the measured voltage within the specified range?
YES : Replace the front impact sensor (LH) (Refer to
P.52B-231). Then go to Step 5.
AC308161AC
NO : Go to Step 4.
HARNESS SIDE
A-23 (Y)
AC305210 AT
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-85
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-86
SRS AIR BAG DIAGNOSIS
DTC B1418: Front Impact Sensor (LH) (Squib) for Power Supply Circuit
DTC B1419: Front Impact Sensor (LH) (Squib) for Communication System
A-23 (Y)
AC305210 AW
52DB010A
CONNECTOR: C-121
SRS-ECU
C-121 (Y)
C-121
INSTRUMENT
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A
.
and CPU, etc. The CPU monitors the analog G sen- TROUBLESHOOTING HINTS
sor output signal. If the CPU judges that the front air • Damaged wiring harnesses or connectors
bags should be deployed, it sends a fire signal to the • Malfunction of the front impact sensor (LH)
SRS-ECU to deploy the front air bags. In addition, • Malfunction of the SRS-ECU
the CPU diagnoses the internal components of the • Refer to circuit diagrams GROUP-90
front impact sensor. If a malfunction occurs, it • Refer to configuration diagrams GROUP-80
requests the SRS-ECU to set a diagnostic trouble
code.
.
DIAGNOSIS
Required Special Tool:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991223 (MB991222): Harness set (Probe)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-87
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-88
SRS AIR BAG DIAGNOSIS
MB991910
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-89
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
A-23 (Y)
AC305210 AT
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-90
SRS AIR BAG DIAGNOSIS
DTC B1420: Side-Airbag Module (RH) (Squib) System Fault 1 (Short Circuit between Terminals of the
Squib Circuit)
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62 D-32 (R)
63 64 65 66 67 68 69 70 24DB063A AC307779 AC
CIRCUIT OPERATION
(squib) circuit terminals
• The SRS-ECU judges how severe a collision is
• Damaged connector(s)
by detecting signals from the left and right side
• Malfunction of the SRS-ECU
impact sensors. If the impact is over a predeter-
• Refer to circuit diagrams GROUP-90
mined level, the SRS-ECU sends an ignition sig-
• Refer to configuration diagrams GROUP-80
nal. At this time, if the side-airbag safing
G-sensor is on, the SRS side-airbag will inflate. NOTE: *: The squib circuit connectors integrate a
• The ignition signal is input to the side-airbag "short" spring (which prevents the air bag from
module to inflate the side-airbag. deploying unintentionally due to static electricity by
shorting the positive wire to the ground wire in the
squib circuit when the connectors are disconnected)
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resister
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-91
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-92
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-94
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
MB991865 (DUMMY (3) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω) CAUTION
Do not insert a test probe into the terminal from its front
D-32 HARNESS SIDE side directly, as the connector contact pressure may be
CONNECTOR
weakened.
MB991866 (4) Insert special tool MB991866 into the D-32 harness side
(RESISTOR HARNESS) connector by testprobe.
(5) Connect the negative battery terminal.
D-32 SIDE-AIRBAG (6) Erase the diagnostic trouble code memory, and check the
MODULE (RH) CONNECTOR AC006042BO diagnostic trouble code.
Q: Is DTC B1420 set?
YES : Go to Step 7.
NO : Replace the seatback frame of the front seat (RH)
(Refer to GROUP 52A, Front Seat P.52A-33). Then
go to Step 9.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-95
SRS AIR BAG DIAGNOSIS
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62
63 64 65 66 67 68 69 70 24DB063A
DANGER
CONNECTOR : D-32 To prevent the air bag from deploying unintentionally,
disconnect the side-airbag module (RH) connector
HARNESS SIDE
D-32 to short the squib circuit.
CONNECTOR (2) Disconnect side-airbag module connector D-32.
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
CAUTION
Insert an insulator such as a cable tie to a depth of 4mm
(0.16 inch) or more, otherwise the short spring will not be
D-26 HARNESS SIDE
CONNECTOR (FRONT VIEW) released.
SECT-
ION
(3) Insert a cable tie [3 mm (0.12 inch) wide, 0.5 mm (0.02 inch)
CABLE TERMINAL
A-A thick] between terminals 57, 58 and the short spring to
TIE
release the short spring.
A (4) Measure at the wiring harness side.
A
SHORT SPRING
4 mm (0.16 inch) OR MORE 24DB069A
CAUTION
Do not insert a test probe into the terminal from its front
D-26 HARNESS SIDE side directly, as the connector contact pressure may be
CONNECTOR
(REAR VIEW)
weakened.
(5) Check for continuity between D-26 harness side connector
51 52 B A 53 54 terminals 57 and 58.
55 56 57 5859 60 61 62
It should be open circuit.
63 64 65 66 67 68 69 70
Q: Does continuity exist?
YES : Go to Step 8.
NO : Erase the diagnostic trouble code memory, and check
24DB070A the diagnostic trouble code. If DTC B1420 sets,
replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 7.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-96
SRS AIR BAG DIAGNOSIS
CONNECTOR : D-32
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-97
SRS AIR BAG DIAGNOSIS
DTC B1421: Side-Airbag Module (RH) (Squib) System Fault 2 (Open in the Squib Circuit)
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62 D-32 (R)
63 64 65 66 67 68 69 70 24DB063A AC307779 AC
by detecting signals from the left and right side TROUBLESHOOTING HINTS
impact sensors. If the impact is over a predeter- • Open circuit in the side-airbag module (RH)
mined level, the SRS-ECU sends an ignition sig- (squib) circuit
nal. At this time, if the side-airbag safing • Improper connector contact
G-sensor is on, the SRS side-airbag will inflate. • Malfunction of the SRS-ECU
• The ignition signal is input to the side-airbag • Refer to circuit diagrams GROUP-90
module to inflate the side-airbag. • Refer to configuration diagrams GROUP-80
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-98
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-99
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
MB991865 (DUMMY (3) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω) CAUTION
Do not insert a test probe into the terminal from its front
D-32 HARNESS SIDE side directly, as the connector contact pressure may be
CONNECTOR
weakened.
MB991866 (4) Insert special tool MB991866 into the D-32 harness side
(RESISTOR HARNESS) connector by testprobe.
(5) Connect the negative battery terminal.
D-32 SIDE-AIRBAG (6) Erase the diagnostic trouble code memory, and check the
MODULE (RH) CONNECTOR AC006042BO diagnostic trouble code.
Q: Is DTC B1421 set?
YES : Go to Step 4.
NO : Replace the seatback frame of the front seat (RH)
(Refer to GROUP 52A, Front Seat P.52A-33). Then
go to Step 5.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-100
SRS AIR BAG DIAGNOSIS
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62
63 64 65 66 67 68 69 70 24DB063A
CONNECTOR : D-32
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
CAUTION
D-32 Do not insert a test probe into the terminal from its front
D-26 FLOOR HARNESS SIDE side directly, as the connector contact pressure may be
HARNESS SIDE CONNECTOR
CONNECTOR (REAR VIEW) weakened.
(REAR VIEW) (2) Check for continuity between the following terminals. It
1 2 should be less than 2 ohms.
51 52 B A 53 54
55 56 57 5859 60 61 62 • SRS-ECU connector D-26 (terminal No.57) and the
63 64 65 66 67 68 69 70 side-airbag module (RH) connector D-32 (terminal No.2)
• SRS-ECU connector D-26 (terminal No.58) and the
side-airbag module (RH) connector D-32 (terminal No.1)
24DB071A Q: Does continuity exist?
YES : Erase the diagnostic trouble code memory, and check
the diagnostic trouble code. If DTC B1421 sets,
replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 5.
NO : Replace the harness wires between SRS-ECU
connector D-26 and side-airbag module (RH)
connector D-32. Then go to Step 5.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-101
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-102
SRS AIR BAG DIAGNOSIS
DTC B1422: Side-Airbag Module (RH) (Squib) System Fault Power Supply Circuit (Short-Circuited to
Power Supply)
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62 D-32 (R)
63 64 65 66 67 68 69 70 24DB063A AC307779 AC
by detecting signals from the left and right side TROUBLESHOOTING HINTS
impact sensors. If the impact is over a predeter- • Damaged wiring harnesses or connectors
mined level, the SRS-ECU sends an ignition sig- • Short to the power supply in the side-airbag mod-
nal. At this time, if the side-airbag safing ule (RH) (squib) harness
G-sensor is on, the SRS side-airbag will inflate. • Malfunction of the SRS-ECU
• The ignition signal is input to the side-airbag • Refer to circuit diagrams GROUP-90
module to inflate the side-airbag. • Refer to configuration diagrams GROUP-80
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-103
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-104
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
MB991865 (DUMMY (3) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω) CAUTION
Do not insert a test probe into the terminal from its front
D-32 HARNESS SIDE side directly, as the connector contact pressure may be
CONNECTOR
weakened.
MB991866 (4) Insert special tool MB991866 into the D-32 harness side
(RESISTOR HARNESS) connector by testprobe.
(5) Connect the negative battery terminal.
D-32 SIDE-AIRBAG (6) Erase the diagnostic trouble code memory, and check the
MODULE (RH) CONNECTOR AC006042BO diagnostic trouble code.
Q: Is DTC B1422 set?
YES : Go to Step 4.
NO : Replace the seatback frame of the front seat (RH)
(Refer to GROUP 52A, Front Seat P.52A-33). Then
go to Step 5.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-105
SRS AIR BAG DIAGNOSIS
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62
63 64 65 66 67 68 69 70 24DB063A
DANGER
CONNECTOR : D-32 To prevent the air bag from deploying unintentionally,
disconnect the side-airbag module (RH) connector
HARNESS SIDE
D-32 to short the squib circuit.
CONNECTOR (2) Disconnect side-airbag module (RH) connector D-32.
(REAR VIEW) (3) Turn the ignition switch to the "ON" position.
1 2
D-32 (R)
AC307779 AD
CAUTION
Do not insert a test probe into the terminal from its front
D-26 FLOOR HARNESS side directly, as the connector contact pressure may be
SIDE CONNECTOR weakened.
(REAR VIEW) (4) Measure the voltage between D-26 harness side connector
51 52 B A 53 54 terminals 57 and 58 and body ground.
55 56 57 5859 60 61 62 Voltage should measure 0 volt.
63 64 65 66 67 68 69 70
Q: Is the measured voltage within the specified range?
YES : Erase the diagnostic trouble code memory, and check
the diagnostic trouble code. If DTC B1422 sets,
24DB072A replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 6.
NO : Go to Step 5.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-106
SRS AIR BAG DIAGNOSIS
CONNECTOR : D-32
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-107
SRS AIR BAG DIAGNOSIS
DTC B1423: Side-Airbag Module (RH) (Squib) System Fault Ground Circuit (Short-Circuited to
Ground)
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62 D-32 (R)
63 64 65 66 67 68 69 70 24DB063A AC307779 AC
by detecting signals from the left and right side TROUBLESHOOTING HINTS
impact sensors. If the impact is over a predeter- • Damaged wiring harnesses or connectors
mined level, the SRS-ECU sends an ignition sig- • Short to ground in the side-airbag module (RH)
nal. At this time, if the side-airbag safing (squib) harness
G-sensor is on, the SRS side-airbag will inflate. • Malfunction of the SRS-ECU
• The ignition signal is input to the side-airbag • Refer to circuit diagrams GROUP-90
module to inflate the side-airbag. • Refer to configuration diagrams GROUP-80
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-108
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-109
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
MB991865 (DUMMY (3) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω) CAUTION
Do not insert a test probe into the terminal from its front
D-32 HARNESS SIDE side directly, as the connector contact pressure may be
CONNECTOR
weakened.
MB991866 (4) Insert special tool MB991866 into the D-32 harness side
(RESISTOR HARNESS) connector by testprobe.
(5) Connect the negative battery terminal.
D-32 SIDE-AIRBAG (6) Erase the diagnostic trouble code memory, and check the
MODULE (RH) CONNECTOR AC006042BO diagnostic trouble code.
Q: Is DTC B1423 set?
YES : Go to Step 4.
NO : Replace the seatback frame of the front seat (RH)
(Refer to GROUP 52A, Front Seat P.52A-33). Then
go to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-110
SRS AIR BAG DIAGNOSIS
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62
63 64 65 66 67 68 69 70 24DB063A
DANGER
CONNECTOR : D-32 To prevent the air bag from deploying unintentionally,
disconnect the side-airbag module (RH) connector
HARNESS SIDE
D-32 to short the squib circuit.
CONNECTOR (2) Disconnect side-airbag module (RH) connector D-32.
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
51 52 B A 53 54
55 56 57 5859 60 61 62 weakened.
63 64 65 66 67 68 69 70
(3) Check for continuity between D-26 harness side connector
terminals 57, 58 and body ground.
It should be open circuit.
Q: Does continuity exist?
D-26 FLOOR HARNESS
SIDE CONNECTOR YES : Go to Step 5.
(REAR VIEW) NO : Erase the diagnostic trouble code memory, and check
24DB073A the diagnostic trouble code. If DTC B1423 sets,
replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-111
SRS AIR BAG DIAGNOSIS
CONNECTOR : D-32
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-112
SRS AIR BAG DIAGNOSIS
DIAGNOSIS
Required Special Tool:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-113
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
DTC B1427: Side Impact Sensor (RH) Power Supply Circuit System
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62
63 64 65 66 67 68 69 70 24DB063A AC308163AB
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991223 (MB991222): Harness set (Probe)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-115
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-116
SRS AIR BAG DIAGNOSIS
AC308163AC
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
D-35 HARNESS SIDE weakened.
CONNECTOR (5) Measure the voltage between D-35 harness side connector
(REAR VIEW)
terminal 2 and ground.
1 2 Voltage should measure 9 volts or more
Q: Is the measured voltage within the specified range?
YES : Replace the side impact sensor (RH) (Refer to
P.52B-247). Then go to Step 5.
AC201627AQ
NO : Go to Step 4.
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC308163AC
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-117
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-118
SRS AIR BAG DIAGNOSIS
DTC B1428: Side-Impact sensor (RH) (Squib) for Power Supply Circuit
DTC B1429: Side-Impact sensor (RH) (Squib) for Communication System
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW)
51 52 B A 53 54
55 56 57 5859 60 61 62
63 64 65 66 67 68 69 70 24DB063A AC308163AB
and CPU, etc. The CPU monitors the analog G sen- TROUBLESHOOTING HINTS
sor output signal. If the CPU judges that the side-air- • Damaged wiring harnesses or connectors
bags should be deployed, it sends a fire signal to the • Malfunction of the side impact sensor (RH)
SRS-ECU to deploy the side-airbags. In addition, the • Malfunction of the SRS-ECU
CPU diagnoses the internal components of the side • Refer to circuit diagrams GROUP-90
impact sensor. If a malfunction occurs, it requests the • Refer to configuration diagrams GROUP-80
SRS-ECU to set a diagnostic trouble code.
.
DIAGNOSIS
Required Special Tool:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-119
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-120
SRS AIR BAG DIAGNOSIS
MB991910
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-121
SRS AIR BAG DIAGNOSIS
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC308163AC
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-122
SRS AIR BAG DIAGNOSIS
DTC B1430: Side-Airbag Module (LH) (Squib) System Fault 1 (Short Circuit between Terminals of the
Squib Circuit)
D-27 (Y)
D-27 Floor
harness
connector D-24 (R)
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A AC307778 AB
CIRCUIT OPERATION
(LH) (squib) circuit terminals
• The SRS-ECU judges how severe a collision is
• Damaged connector(s)
by detecting signals from the left and right side
• Malfunction of the SRS-ECU
impact sensors. If the impact is over a predeter-
• Refer to circuit diagrams GROUP-90
mined level, the SRS-ECU sends an ignition sig-
• Refer to configuration diagrams GROUP-80
nal. At this time, if the side-airbag safing
G-sensor is on, the SRS side-airbag will inflate. NOTE: *: The squib circuit connectors integrate a
• The ignition signal is input to the side-airbag "short" spring (which prevents the air bag from
module to inflate the side-airbag. deploying unintentionally due to static electricity by
shorting the positive wire to the ground wire in the
squib circuit when the connectors are disconnected)
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-123
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-124
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-126
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991865 (DUMMY
(3) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω) CAUTION
Do not insert a test probe into the terminal from its front
D-24 HARNESS SIDE
CONNECTOR
side directly, as the connector contact pressure may be
weakened.
MB991866 (4) Insert special tool MB991866 into the D-24 harness side
(RESISTOR HARNESS) connector by testprobe.
(5) Connect the negative battery terminal.
D-24 SIDE-AIRBAG (6) Erase diagnostic trouble code memory, and check the
MODULE (LH) CONNECTOR AC006042 BP diagnostic trouble code.
Q: Is DTC B1430 set?
YES : Go to Step 7.
NO : Replace the seatback frame of the front seat (LH)
(Refer to GROUP 52A, Front Seat P.52A-33). Then
go to Step 9.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-127
SRS AIR BAG DIAGNOSIS
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
CAUTION
Insert an insulator such as a cable tie to a depth of 4mm
D-27 FLOOR HARNESS SIDE (0.16 inch) or more, otherwise the short spring will not be
CONNECTOR (FRONT VIEW) released.
SEC- TERMINAL (3) Insert a cable tie [3 mm (0.12 inch) wide, 0.5 mm (0.02 inch)
TION CABLE TIE
thick] between terminals 9, 10 and the short spring to
A-A
A release the short spring.
SHORT SPRING
4 mm (0.16 inch) OR MORE 24DB074A
CAUTION
Do not insert a test probe into the terminal from its front
D-27 FLOOR HARNESS side directly, as the connector contact pressure may be
SIDE CONNECTOR weakened.
(REAR VIEW)
(4) Check for continuity between D-27 harness side connector
1 2 B A 3 4 terminals 9 and 10.
5 6 7 8 9 10 11 12
It should be open circuit.
13 14 15 16 17 18 19 20
Q: Is the circuit normal?
YES : Erase the diagnostic trouble code memory, and check
the diagnostic trouble code. If DTC B1430 sets,
24DB075A replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 9.
NO : Go to Step 8.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-128
SRS AIR BAG DIAGNOSIS
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-129
SRS AIR BAG DIAGNOSIS
DTC B1431: Side-Airbag Module (LH) (Squib) System Fault 2 (Open in the Squib Circuit)
D-27 (Y)
D-27 Floor
harness
connector D-24 (R)
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A AC307778 AB
by detecting signals from the left and right side TROUBLESHOOTING HINTS
impact sensors. If the impact is over a predeter- • Open circuit in the side-airbag module (squib)
mined level, the SRS-ECU sends an ignition sig- (LH) circuit
nal. At this time, if the side-airbag safing • Improper connector contact
G-sensor is on, the SRS side-airbag will inflate. • Malfunction of the SRS-ECU
• The ignition signal is input to the side-airbag • Refer to circuit diagrams GROUP-90
module to inflate the side-airbag. • Refer to configuration diagrams GROUP-80
.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-130
SRS AIR BAG DIAGNOSIS
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resistor
• MB991866: Resistor harness
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-131
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991865 (DUMMY
(3) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω) CAUTION
Do not insert a test probe into the terminal from its front
D-24 HARNESS SIDE
CONNECTOR
side directly, as the connector contact pressure may be
weakened.
MB991866 (4) Insert special tool MB991866 into the D-24 harness side
(RESISTOR HARNESS) connector by testprobe.
(5) Connect the negative battery terminal.
D-24 SIDE-AIRBAG (6) Erase diagnostic trouble code memory, and then check the
MODULE (LH) CONNECTOR AC006042 BP diagnostic trouble code.
Q: Is DTC B1431 set?
YES : Go to Step 4.
NO : Replace the seatback frame of the front seat (LH)
(Refer to GROUP 52A, Front Seat P.52A-33). Then
go to Step 5.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-132
SRS AIR BAG DIAGNOSIS
D-27 (Y)
D-27 Floor
harness
connector
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
CAUTION
D-24 Do not insert a test probe into the terminal from its front
D-27 FLOOR HARNESS SIDE
CONNECTOR
side directly, as the connector contact pressure may be
HARNESS SIDE
CONNECTOR (REAR VIEW) weakened.
(REAR VIEW) (3) Check for continuity between the following terminals. It
1 2 should be less than 2 ohms.
1 2 B A 3 4
5 6 7 8 9 10 11 12 • SRS-ECU connector D-27 (terminal No.9) and the
13 14 15 16 17 18 19 20 side-airbag module (LH) connector D-24 (terminal No.1)
• SRS-ECU connector D-27 (terminal No.10) and the
side-airbag module (LH) connector D-24 (terminal No.2)
24DB076A Q: Does continuity exist?
YES : Erase the diagnostic trouble code memory, and check
the diagnostic trouble code. If DTC B1431 sets,
replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 5.
NO : Replace the harness wires between SRS-ECU
connector D-27 and side-airbag module (LH)
connector D-24. Then go to Step 5.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-133
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-134
SRS AIR BAG DIAGNOSIS
DTC B1432: Side-Airbag Module (LH) (Squib) System Fault Power Supply Circuit (Short-Circuited to
Power Supply)
D-27 (Y)
D-27 Floor
harness
connector D-24 (R)
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A AC307778 AB
by detecting signals from the left and right side TROUBLESHOOTING HINTS
impact sensors. If the impact is over a predeter- • Damaged wiring harnesses or connectors
mined level, the SRS-ECU sends an ignition sig- • Short to the power supply in the side-airbag mod-
nal. At this time, if the side-airbag safing ule (LH) (squib) harness
G-sensor is on, the SRS side-airbag will inflate. • Malfunction of the SRS-ECU
• The ignition signal is input to the side-airbag • Refer to circuit diagrams GROUP-90
module to inflate the side-airbag. • Refer to configuration diagrams GROUP-80
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-135
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-136
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991865 (DUMMY
(3) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω) CAUTION
Do not insert a test probe into the terminal from its front
D-24 HARNESS SIDE
CONNECTOR
side directly, as the connector contact pressure may be
weakened.
MB991866 (4) Insert special tool MB991866 into the D-24 harness side
(RESISTOR HARNESS) connector by testprobe.
(5) Connect the negative battery terminal.
D-24 SIDE-AIRBAG (6) Erase the diagnostic trouble code memory, and check the
MODULE (LH) CONNECTOR AC006042 BP diagnostic trouble code.
Q: Is DTC B1432 set?
YES : Go to Step 4.
NO : Replace the seatback frame of the front seat (LH)
(Refer to GROUP 52A, Front Seat P.52A-33). Then
go to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-137
SRS AIR BAG DIAGNOSIS
D-27 (Y)
D-27 Floor
harness
connector
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A
DANGER
To prevent the air bag from deploying unintentionally,
CONNECTOR : D-24
disconnect the side-airbag module (LH) connector
D-24 to short the squib circuit.
HARNESS SIDE
CONNECTOR (2) Disconnect left hand side-airbag module (LH) connector
(REAR VIEW) D-24.
(3) Turn the ignition switch to the "ON" position.
D-24 (R)
1 2
AC307778 AC
CAUTION
Do not insert a test probe into the terminal from its front
D-27 FLOOR HARNESS side directly, as the connector contact pressure may be
SIDE CONNECTOR weakened.
(REAR VIEW) (4) Measure the voltage between D-27 harness side connector
1 2 B A 3 4 terminals 9, 10 and body ground.
5 6 7 8 9 10 11 12 Voltage should measure 0 volt.
13 14 15 16 17 18 19 20
Q: Is the measured voltage within the specified range?
YES : Erase the diagnostic trouble code memory, and check
the diagnostic trouble code. If DTC B1432 sets,
24DB077A replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 6.
NO : Go to Step 5.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-138
SRS AIR BAG DIAGNOSIS
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-139
SRS AIR BAG DIAGNOSIS
DTC B1433: Side-Airbag Module (LH) (Squib) System Fault Ground Circuit (Short-Circuited to
Ground)
D-27 (Y)
D-27 Floor
harness
connector D-24 (R)
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A AC307778 AB
by detecting signals from the left and right side TROUBLESHOOTING HINTS
impact sensors. If the impact is over a predeter- • Damaged wiring harnesses or connectors
mined level, the SRS-ECU sends an ignition sig- • Short to ground in the left hand side-airbag mod-
nal. At this time, if the side-airbag safing ule (squib) harness
G-sensor is on, the SRS side-airbag will inflate. • Malfunction of the SRS-ECU
• The ignition signal is input to the side-airbag • Refer to circuit diagrams GROUP-90
module to inflate the side-airbag. • Refer to configuration diagrams GROUP-80
.
DIAGNOSIS
Required Special Tools:
• MB991958 : diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
• MB991865: Dummy resistor
• MB991866: Resistor harness
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-140
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-141
SRS AIR BAG DIAGNOSIS
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991865 (DUMMY
(3) Connect special tool MB991865 to special tool MB991866.
RESISTOR: 3 Ω) CAUTION
Do not insert a test probe into the terminal from its front
D-24 HARNESS SIDE
CONNECTOR
side directly, as the connector contact pressure may be
weakened.
MB991866 (4) Insert special tool MB991866 into the D-24 harness side
(RESISTOR HARNESS) connector by testprobe.
(5) Connect the negative battery terminal.
D-24 SIDE-AIRBAG (6) Erase the diagnostic trouble code memory, and check the
MODULE (LH) CONNECTOR AC006042 BP diagnostic trouble code.
Q: Is DTC B1433 set?
YES : Go to Step 4.
NO : Replace the seatback frame of the front seat (LH)
(Refer to GROUP 52A, Front Seat P.52A-33). Then
go to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-142
SRS AIR BAG DIAGNOSIS
D-27 (Y)
D-27 Floor
harness
connector
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
1 2 B A 3 4
5 6 7 8 9 10 11 12
weakened.
13 14 15 16 17 18 19 20
(3) Check for continuity between D-27 harness side connector
terminals 9, 10 and body ground.
It should be open circuit.
Q: Does continuity exist?
D-27 FLOOR HARNESS
SIDE CONNECTOR YES : Go to Step 5.
(REAR VIEW) NO : Erase the diagnostic trouble code from memory, and
24DB078A check the diagnostic trouble code. If DTC B1433 sets,
replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 6.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-143
SRS AIR BAG DIAGNOSIS
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-144
SRS AIR BAG DIAGNOSIS
DTC B1437: Side Impact Sensor (LH) Power Supply Circuit System
D-27 (Y)
D-27 Floor
harness
connector
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A AC305250 AI
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-146
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
AC305250 AJ
CAUTION
Do not insert a test probe into the terminal from its front
side directly, as the connector contact pressure may be
D-20 HARNESS SIDE weakened.
CONNECTOR (5) Measure the voltage between the D-20 harness side
(REAR VIEW)
connector terminal 2 and body ground.
1 2 Voltage should measure 9 volts or more.
Q: Is the measured voltage within the specified range?
YES : Replace the side impact sensor (LH) (Refer to
P.52B-247). Then go to Step 5.
AC201627 AU
NO : Go to Step 4.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-147
SRS AIR BAG DIAGNOSIS
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC305250 AJ
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-148
SRS AIR BAG DIAGNOSIS
DTC B1438: Side Impact Sensor (LH) (Squib) for Power Supply Circuit
DTC B1439: Side Impact Sensor (LH) (Squib) for Communication System
D-27 (Y)
D-27 Floor
harness
connector
(rear view)
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A AC305250 AI
and CPU, etc. The CPU monitors the analog G sen- TROUBLESHOOTING HINTS
sor output signal. If the CPU judges that the side-air- • Damaged wiring harnesses or connectors
bags should be deployed, it sends a fire signal to the • Malfunction of the side impact sensor (LH)
SRS-ECU to deploy the side-airbags. In addition, the • Malfunction of the SRS-ECU
CPU diagnoses the internal components of the side • Refer to circuit diagrams GROUP-90
impact sensor. If a malfunction occurs, it requests the • Refer to configuration diagrams GROUP-80
SRS-ECU to set a diagnostic trouble code.
.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-149
SRS AIR BAG DIAGNOSIS
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-150
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
MB991910
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-151
SRS AIR BAG DIAGNOSIS
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC305250 AJ
MB991824
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-152
SRS AIR BAG DIAGNOSIS
DTC B1460: Seat Belt Pre-Tensioner (RH) (Squib) System Fault 1 (Short Circuit between Terminals of
the Squib Circuit)
G-sensor is on, the pre-tensioner will deploy. NOTE: *: The squib circuit connectors integrate a
. "short" spring (which prevents the seat belt pre-ten-
DTC SET CONDITIONS sioner from deploying unintentionally due to static
This DTC is set if there is abnormal resistance electricity by shorting the positive wire to the ground
between the input terminals of the driver’s seat belt wire in the squib circuit when the connectors are dis-
pre-tensioner (squib). connected) (Refer to P.52B-3). Therefore, if connec-
.
tor D-26 or D-33 is damaged or improperly engaged,
the short spring may not be released when the con-
nector is connected.
.
DIAGNOSIS
Required Special Tools:
• MB991958: diagnostic tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991827: MUT-III USB Cable
• MB991910: MUT-III Main Harness A
• MB991865: Dummy resistor
• MB991884: Resistor harness (For Pre-tensioner)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-153
SRS AIR BAG DIAGNOSIS
MB991824
MB991827 00DB076A
MB991827 00DB076A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B-154
SRS AIR BAG DIAGNOSIS
MB991827 00DB076A
AC307915 AC