345 Mitsubishi 380 Workshop Service Manual 2005 2008 (Chassis DB)

MITSUBISHI GROUP INDEX
General . . . . . . . . . . . . . . . . . . . . . . . 00
380
Engine . . . . . . . . . . . . . . . . . . . . . . . . 11
WORKSHOP MANUAL
Engine Lubrication . . . . . . . . . . . . . . 12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Cooling . . . . . . . . . . . . . . . . . 14
Intake and Exhaust . . . . . . . . . . . . . . 15
Engine Electrical. . . . . . . . . . . . . . . . 16
Engine and Emission Control . . . . . 17
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
Interior and SRS . . . . . . . . . . . . . . . . 52
Chassis Electrical . . . . . . . . . . . . . . . 54
Heater, A/C and Ventilation . . . . . . . 55

Mitsubishi Motors Australia Limited reserves the right to make changes in
design or to make additions to or improvements in its products without
Component Locations . . . . . . . . . . . 70
imosing any obligations upon itself to install them on its products previously
manufactured.
Configuration Diagrams. . . . . . . . . . 80
 Mitsubishi Motors Australia Ltd. September 2005
Circuit Diagrams . . . . . . . . . . . . . . . . 90
HOME
00-1
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

NOTES
HOME
00E-1
GROUP 00E
GENERAL
<ELECTRICAL>
CONTENTS
HARNESS CONNECTOR INSPECTION INSTRUMENTS . . . . . . . . . . 00E-5

INSPECTION . . . . . . . . . . . . . . . . . . . 00E-2 CHECKING FUSES. . . . . . . . . . . . . . . . . . . 00E-6
CHECKING SWITCHES . . . . . . . . . . . . . . . 00E-7
HOW TO DIAGNOSE. . . . . . . . . . . . . 00E-2 CHECKING RELAYS . . . . . . . . . . . . . . . . . 00E-8
HOW TO DIAGNOSE . . . . . . . . . . . . . . . . . 00E-2 CABLES AND WIRES CHECK . . . . . . . . . . 00E-9
TROUBLESHOOTING STEPS . . . . . . . . . . 00E-3 BATTERY HANDLING . . . . . . . . . . . . . . . . 00E-9
INFORMATION FOR DIAGNOSIS . . . . . . . 00E-3 GENERAL ELECTRICAL SYSTEM CHECK 00E-9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 00E-4
GENERAL <ELECTRICAL> 00E-2
HARNESS CONNECTOR INSPECTION
HARNESS CONNECTOR INSPECTION

M1001003900201
CONNECTOR CONTINUITY AND VOLTAGE TEST

Required Special Tools:
• MB991219: Test Harness Set
• MD998459: Test Harness
Follow the steps below to avoid causing poor connector contact
and/or reduced waterproof performance of connectors when
checking continuity and/or voltage at waterproof connectors.
CAUTION
MD998459
Never backtest probe a waterproof connector. Backprob-
ing a connector may cause the terminals to corrode, dete-
riorating circuit performance.
1. If the circuit to be checked is a closed state, use a special
tool like MD998459.
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.
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.
Observe the symptom carefully. Check if there are also

1 Observation of Problem Symptoms other problems.
In determining the probable causes, it is necessary to

study the wiring diagram to understand the circuit as a
2 Determination of Probable Causes system. Knowledge of switches, relays and other parts is
necessary for accurate analysis. The causes of similar
problems in the past must be taken into account.
Troubleshooting is carried out by making step-by-step

Checking of Parts Associated with checks until the cause is found.
3 Probable Causes and Determination
of Faulty Parts
After the problems are corrected, be sure to check that the

system operates correctly.
4 Confirmation
00DB087A
INFORMATION FOR DIAGNOSIS

M1001004500132
This manual contains the harness diagrams as well as the individual circuit drawings, operational explana-
tions, and troubleshooting hints for each component. The information is presented in the following manner:
1. Connector diagrams show the connector 4. Troubleshooting hints include numerous
positions, etc., on the actual vehicle as well as the examples of problems which might occur, traced
harness path. backward in a common-sense manner to the
2. Circuit diagrams show the configuration of the origin of the trouble. Problems whose origins may
circuit with all switches in their normal positions. not be found in this manner are pursued through
3. Operational explanations include circuit drawings the various system circuits.
of current flow when the switch is operated and
how the component reacts.
NOTE: Components of MPI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer
to a relevant group which includes details of these components.
HOW TO DIAGNOSE
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
3. Checking with instruments

Use an appropriate instrument in an adequate range and
POINTER
read the indication correctly.
SELECTOR KNOB ACX00938AB

HOW TO DIAGNOSE
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
2. Self-powered test light

A self-powered test light consists of a bulb, battery and lead
wires connected in series. It is used to check continuity or
grounding.
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
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
CAUTIONS IN EVENT OF BLOWN FUSE

When a fuse is blown, there are two probable causes. One is
that it is blown due to flow of current exceeding its rating. The
other is that it is blown due to repeated on/off current flowing
through it. Which of the two causes is responsible can be easily
determined by visual check as described below.
1. Fuse blown due to current exceeding rating
STATE OF FUSE BLOWN DUE TO The illustration shows the state of a fuse blown due to this
OVERCURRENT cause. In this case, do not replace the fuse with a new one
hastily since a current heavy enough to blow the fuse has
flowed through it. First, check the circuit for shorts and check
for abnormal electric parts. After correcting shorts or
replacing parts, use only a fuse of the same capacity as a
replacement. Never use a fuse of larger capacity than the
original fuse. If a larger capacity fuse is used, electric parts
ACX00952 AB or wiring could be damaged, or could start a fire.
2. Fuse blown due to repeated turning current on and off
STATE OF FUSE BLOWN DUE TO The illustration shows the state of a fuse blown due to
THERMAL FATIGUE
repeated current on/off. Normally, this type of problem
occurs after a fairly long period of use and is less frequent
than above. In this case, simply replace with a new fuse of
the same capacity.
ACX00953 AB
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.
CURRENT DOES CURRENT FLOWS

NOT FLOW
NORMALLY CLOSED (NC) TYPE

OFF ON
CURRENT CURRENT DOES

FLOWS NOT FLOW
ACX00944AC
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
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.
HOW TO DIAGNOSE
CABLES AND WIRES CHECK

M1001005100041
1. Check connections for looseness, rust, and stains.
2. Check terminals and wires for corrosion.
3. Check terminals and wires for open circuit or impending
open circuit.
4. Check wire insulation and coating for damage, cracks, and
wear.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
ACX00954 AB
6. Check grounding parts to verify that there is complete
continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that harnesses are secured to prevent contact with
sharp edges and corners or hot parts (exhaust manifold,
pipe, etc.).
9. Check that harnesses are secured firmly to provide enough
clearance from the fan pulley, fan belt, and other rotating or
moving parts.
10.Check that the harnesses between fixed parts (such as the
ACX00955AB
vehicle body) and vibrating parts (such as the engine) are
long enough to allow for vibration and movement.
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
GENERAL ELECTRICAL SYSTEM CHECK

M1001005300045
A circuit consists of the power supply, switch, relay, load,
ground, etc. There are various methods to check a circuit
including an overall check, voltage check, short-circuit check,
and continuity check. Each of the methods briefly described
below applies only to circuits similar to the illustration.
HOW TO DIAGNOSE
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
HOW TO DIAGNOSE
STEP 2. Turn the switch ON and disconnect the

illumination light connector.
Q: Does the test light illuminate?
YES : Short-circuit exists between the switch and the
POWER SUPPLY connector. Diagnose the harness between the switch
and the connector.
FUSE BLOCK NO : Short-circuit exists between the connector and the
(REMOVE
THE FUSE) illumination light. Diagnose the harness between the
connector and the illumination light.
TEST
LIGHT
SWITCH
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
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
HOW TO USE THIS MANUAL. . . . . . 00-3 OPTION CODES . . . . . . . . . . . . . . . . . . . . . 00-21

EXPORT CODES . . . . . . . . . . . . . . . . . . . . 00-21
TROUBLESHOOTING GUIDELINES 00-6 TYRE AND LOADING PLACARD . . . . . . . . 00-21
ENGINE MODEL STAMPING . . . . . . . . . . . 00-22
HOW TO USE TROUBLESHOOTING /
INSPECTION SERVICE POINTS. . . . 00-7 PRECAUTIONS BEFORE SERVICE . 00-22
TROUBLESHOOTING CONTENTS . . . . . . 00-7 SUPPLEMENTAL RESTRAINT
HOW TO USE THE INSPECTION SYSTEM (SRS . . . . . . . . . . . . . . . . . . . . . . 00-22
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 00-9 HOW TO PERFORM VEHICLE
CONNECTOR MEASUREMENT SERVICE IDENTIFICATION NUMBER (VIN) WRITING 00-23
POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11 SERVICING ELECTRICAL SYSTEM . . . . . 00-24
CONNECTOR INSPECTION SERVICE VEHICLE WASHING . . . . . . . . . . . . . . . . . . 00-24
POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 APPLICATION OF ANTI-CORROSION
HOW TO COPE WITH INTERMITTENT AGENTS AND UNDERCOATS . . . . . . . . . . 00-25
MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 00-14 DIAGNOSTIC TOOL (MUT-III) . . . . . . . . . . 00-25
INSPECTION SERVICE POINTS
FOR A BLOWN FUSE . . . . . . . . . . . . . . . . 00-16 TOWING AND HOISTING. . . . . . . . . . 00-26
HOW TO TREAT CURRENT TROUBLE . . 00-16
HOW TO TREAT PAST TROUBLE . . . . . . 00-16 GENERAL DATA AND
SPECIFICATIONS . . . . . . . . . . . . . . . 00-31
AFFILIATED DTC REFERENCE
TABLE. . . . . . . . . . . . . . . . . . . . . . . . 00-17 TIGHTENING TORQUE . . . . . . . . . . . 00-32
VEHICLE IDENTIFICATION . . . . . . . 00-18 LUBRICATION AND MAINTENANCE 00-34

VEHICLE IDENTIFICATION NUMBER . . . 00-18
VEHICLE INFORMATION NUMBER LIST 00-19 RECOMMENDED LUBRICANTS AND
VEHICLE COMPLIANCE PLATE . . . . . . . . 00-19 LUBRICANT CAPACITIES TABLE . . 00-35
VEHICLE DATA PLATE . . . . . . . . . . . . . . . 00-20
AUSTRALIAN DESIGN RULES . . . . . . . . . 00-20 Continued on next page
GENERAL 00-2
MAINTENANCE SERVICE . . . . . . . . 00-37 11. ENGINE OIL FILTER (REPLACE) . . . . 00-44
1. FUEL SYSTEM (TANK, PIPE LINE AND 12. TRANSMISSION FLUID . . . . . . . . . . . . 00-45
CONNECTION, AND FUEL TANK FILLER 13. ENGINE COOLANT (CHANGE) . . . . . . 00-47
TUBE CAP) (CHECK FOR LEAKS) . . . . . . 00-37 14. COOLANT HOSES (RADIATOR HOSE,
2. FUEL HOSES (CHECK CONDITION) . . 00-37 HEATER HOSE) (INSPECT). . . . . . . . . . . . 00-49
3. AIR CLEANER FILTER (REPLACE). . . . 00-37 15. DISC BRAKE PADS, ROTORS
4. EVAPORATIVE EMISSION SYSTEM (INSPECT FOR WEAR) . . . . . . . . . . . . . . . 00-49
(EXCEPT EVAPORATIVE EMISSION 16. BRAKE HOSES (CHECK FOR
CANISTER) (CHECK FOR CLOGGING) . . 00-37 DETERIORATION OR LEAKS) . . . . . . . . . . 00-49
5. SPARK PLUGS (REPLACE). . . . . . . . . . 00-38 17. BALL JOINT AND STEERING LINKAGE
7. TIMING BELT (REPLACE) . . . . . . . . . . . 00-38 SEALS (INSPECT FOR GREASE LEAKS
AND DAMAGE) . . . . . . . . . . . . . . . . . . . . . . 00-50
8. DRIVE BELTS (FOR ALTERNATOR, POWER
STEERING PUMP AND AIR CONDITIONING) 18. DRIVE SHAFT BOOTS (INSPECT FOR
(CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-39 GREASE LEAKS AND DAMAGE). . . . . . . . 00-50
9. EXHAUST SYSTEM (CONNECTIONS 19. SUSPENSION SYSTEM (INSPECT FOR
PORTION OF MUFFLER, MUFFLER PIPES LOOSENESS AND DAMAGE) . . . . . . . . . . 00-51
AND CONVERTER HEAT SHIELDS) (CHECK 20. SRS AIR BAG (INSPECT FOR SRS
AND SERVICE AS REQUIRED). . . . . . . . . 00-44 SYSTEM). . . . . . . . . . . . . . . . . . . . . . . . . . . 00-51
10. ENGINE OIL (CHANGE). . . . . . . . . . . . 00-44 21. TYRES (ROTATE). . . . . . . . . . . . . . . . . 00-58
GENERAL 00-3
HOW TO USE THIS MANUAL

M1001000100897
MAINTENANCE, REPAIR AND DANGER, WARNING, AND CAUTION

SERVICING EXPLANATIONS DANGER, WARNING, and CAUTION call special
This manual provides explanations, etc. concerning attention to a necessary action or to an action that
procedures for the inspection, maintenance, repair must be avoided. The differences among DANGER,
and servicing of the subject model. Unless otherwise WARNING, and CAUTION are as follows:
specified, each service procedure covers all models. • If a DANGER is not followed, the result is severe
Procedures covering specific models are identified bodily harm or even death.
by the model codes, or similar designation (engine • If a WARNING is not followed, the result could be
type, transaxle type, etc). A description of these des- bodily injury.
ignations is covered in this manual under "VEHICLE • If a CAUTION is not followed, the result could be
IDENTIFICATION." damage to the vehicle, vehicle components or
. service equipment.
ON-VEHICLE SERVICE
The "ON-VEHICLE SERVICE" section has proce- TIGHTENING TORQUE INDICATION
dures for performing inspections and adjustments of The tightening torque indicates a median and its tol-
particularly important components. These proce- erance by a unit of N⋅m (in-lb.) or N⋅m (ft.-lb.). For
dures are done with regard to maintenance and ser- fasteners with no assigned torque value, refer to
vicing, but other inspections (looseness, play, P.00-32.
cracking, damage, etc.) must also be performed.
. SPECIAL TOOL NOTE
SERVICE PROCEDURES Only MMC special tool part numbers are called out in
The service steps are arranged in numerical order. the repair sections of this manual. Please refer to the
Attention to be paid in performing vehicle service are special tool cross-reference chart located at the
described in detail in SERVICE POINTS. beginning of each group, for the special tool number
that is available in your market.
DEFINITION OF TERMS
.
ABBREVIATIONS
STANDARD VALUE The following abbreviations are used in this manual
Indicates the value used as the standard for judging for classification of model types:
whether or not a part or adjustment is correct. A/T:Automatic transaxle, or models equipped with
. automatic transaxle.
LIMIT MPI: Multipoint fuel injection, or engines equipped
Shows the maximum or minimum value for judging with multiport fuel injection.
whether or not a part or adjustment is acceptable. A/C: Air conditioning.
.
3.8L engine: 3.8 litre <6G75> engine, or a model
REFERENCE VALUE equipped with such an engine.
Indicates the adjustment value prior to starting the ABS: Anti-lock Braking System
work (presented in order to facilitate assembly and TCL: Traction Control System
adjustment procedures, and so they can be com- ECU: Electronic Control Unit
pleted in a shorter time). V.C.I.: Vehicle Communication Interface
SWS: Simplified Wiring System
.
CAN: Controller Area Network

M/T: Manual Transmission
SRS: Supplemental Restraint System
GENERAL 00-4
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.
Indicates the page number.
Indicates procedures to be performed be-

fore the work in that section is started, and
procedures to be performed after the work
in that section is finished.
Mark N denotes non-reusable part.
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.
Repair kit or parts sets are shown.

(Only very frequently used parts are shown.)
Maintenance and servicing procedures

The numbers provided within the diagram indicate the Installation steps :
sequence for maintenance and servicing procedures. Specified in case installation is impossible in
Removal steps : reverse order of removal steps. Omitted if
The part designation number corresponds to installation is possible in reverse order of
the number in the illustration to indicate removal removal steps.
steps. Assembly steps :
Disassembly steps : Specified in case installation is impossible in
The part designation number corresponds to reverse order of removal steps. Omitted if
the number in the illustration to indicate disassembly is possible in reverse order of
assembly steps. disassembly steps.
AC400266 AB
GENERAL 00-5
Classifications of major maintenance / service points

When there are major points relative to maintenance and servicing procedures (such as essential maintenance
and service points, maintenance and service standard values, information regarding the use of special tools, etc.).
These are arranged together as major maintenance and service points and explained in detail.
<<A>> : Indicates that there are essential points for removal or disassembly.
>>A<< : Indicates that there are essential points for installation or assembly.
Operating procedures,
cautions, etc. on removal,
installation, disassembly and
assembly are described
The title of the page

(following the page on which
the diagram of component
parts is presented) indicating
the locations of lubrication and
sealing procedures.
Indicates (by symbols) where

lubrication is necessary.
Symbols for lubrication, sealants and adhesives

Grease
Symbols are used to show the locations for lubrication
(Multi-purpose grease unless there is a
and for application of sealants and adhesives.
brand or type specified)
These symbols are included in the diagram of
component parts or on the page following the Sealant or adhesive
component parts page. The symbols do not always Brake fluid or automatic transmission fluid
have accompanying text to support that symbol. Engine oil, gear oil or air conditioning
compressor oil
Adhesive tape or butyl rubber tape
AC400267AB
GENERAL 00-6
TROUBLESHOOTING GUIDELINES
TROUBLESHOOTING GUIDELINES
M1001008800340
VERIFY THE COMPLAINT FIND THE PROBLEM

• Make sure the customer's complaint and the ser- After the symptoms have been confirmed, and prob-
vice writer's work order description are under- able causes have been identified, the next step is to
stood before starting work. make step-by-step checks of the suspected system
• Make sure you understand the correct operation components, junctions, and links in logical order.
of the system. Read the service manual descrip- Use the diagnostic procedures in the service manual
tion to verify normal system operation. whenever possible. Follow these procedures care-
• Operate the system to see the symptoms. Look fully to avoid missing an important step in the diagno-
for other symptoms that were not reported by the sis sequence. It might be the skipped step that leads
customer, or on the work order, that may be to the solution of the problem.
related to the problem. If the service manual doesn't have step-by-step pro-
cedures to help diagnose the problem, make a series
DETERMINE POSSIBLE CAUSES of checks based on the ranked list of probable
Compare the confirmed symptoms to the diagnostic causes. Troubleshooting checks should be made in
symptom indexes to find the right diagnosis proce- the order that the list of causes was ranked:
dure. • general to specific
If the confirmed symptoms cannot be found on any • most-likely to least-likely
symptom index, determine other possible causes. • easy-to-check to hard-to-check
• Analyze the system diagrams and list all possible
causes for the problem symptoms. REPAIR THE PROBLEM
• Rank all these possible causes in order of proba- When the step-by-step troubleshooting checks find a
bility, based on how much of the system they fault, perform the proper repairs. Make sure to fix the
cover, how likely they are to be the cause, and root cause of the problem, not just the symptom. Just
how easy they will be to check. Be sure to take fixing the symptom, without fixing the root cause, will
experience into account. Consider the causes of cause the symptom to eventually return.
similar problems seen in the past. The list of
causes should be ranked in order from general to VERIFY THE REPAIR
specific, from most-likely to least-likely, and from After repairs are made, recheck the operation of the
easy-to-check to hard-to-check. system to confirm that the problem is eliminated. Be
sure to check the system thoroughly. Sometimes
new problems are revealed after repairs have been
made.
GENERAL 00-7
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS
TROUBLESHOOTING CONTENTS
M1001013300062
CAUTION 4. DIAGNOSTIC TROUBLE CODE CHART

• During diagnosis, a DTC code associated with If the MUT-III displays a diagnostic trouble code, find
other system may be set when the ignition the applicable inspection procedure according to this
switch is turned on with connector(s) discon- chart.
nected. On completion, confirm all systems
for DTC code(s). If DTC code(s) are set, erase 5. SYMPTOM CHART
them all. If there are symptoms, even though the MUT-III
• When the DIAGNOSTIC TOOL (MUT-III) shows that no DTCs are set, inspection procedures
detects a diagnostic trouble code, its display for each symptom will be found by using this chart.
informs users whether a mechanical problem
currently exists (“current trouble”) or whether 6. DIAGNOSTIC TROUBLE CODE
it existed before but normal operation has PROCEDURES
been restored (“past trouble”). However, if an Indicates the inspection procedures corresponding to
MPI, TPMS or SRS airbag-related DTC is set, each diagnostic trouble code. (Refer to P.00-9).
“Active DTC/Stored DTC” is not displayed. In
this case, follow the diagnosis procedure for 7. SYMPTOM PROCEDURES
current trouble.
Indicates the inspection procedures corresponding to
• If a trouble, detected in a CAN communica- each symptom listed in the Symptom Chart (Refer to
tion-capable system, can be reproduced,
P.00-9).
diagnose the CAN bus lines (Refer to GROUP
54C, Can Bus Line Diagnostics Chart
8. SERVICE DATA REFERENCE TABLE
P.54C-15 or P.54C-15).
Inspection items and normal judgment values have
Troubleshooting of electronic control systems for
been provided in this chart as reference information.
which the MUT -III can be used follows the basic out-
line described below. Even in systems for which the
MUT-III cannot be used, part of these systems still
9. CHECK AT ECU TERMINALS
follow this outline. Terminal numbers for the ECU connectors, inspec-
tion items, and standard values have been provided
1. STANDARD FLOW OF DIAGNOSTIC in this chart as reference information.
.
TROUBLESHOOTING TERMINAL VOLTAGE CHECKS

Troubleshooting strategy is shown in each group. 1. Use correct tool to check each pin location on the
ENGINE-ECU Check harnes MB992044 and
2. SYSTEM OPERATION AND SYMPTOM measure with voltmeter.
VERIFICATION TESTS CAUTION
If verification of the symptom(s) is difficult, proce- Short-circuiting the positive (+) test probe
dures for checking operation and verifying symptoms between a connector terminal and ground could
are shown. damage the vehicle wiring, the sensor, the ECU,
or all three. Use care to prevent this!
3. DIAGNOSTIC FUNCTION 2. Insert the correct terminal tool into each of the
The following trouble code diagnoses are shown. ENGINE-ECU check harness connector
• How to read diagnostic trouble codes terminals, and measure the voltage while referring
• How to erase diagnostic trouble codes to the check chart.
• Input inspection service points NOTE: Measure voltage with the ECU connectors
connected.
You may find it convenient to pull out the ECU to
make it easier to connect the ENGINE-ECU check
harness.
GENERAL 00-8
Checks don't have to be carried out in the order CAUTION

given in the chart. If resistance and continuity checks are per-
3. If voltage readings differ from normal condition formed on the wrong terminals, damage to the
values, check related sensors, actuators, and vehicle wiring, sensors, ECU, and/or ohmmeter
wiring. Replace or repair as needed. may occur. Use care to prevent this!
4. After repair or replacement, recheck with the 3. Measure the resistance and check for continuity
voltmeter to confirm that the repair has corrected between the terminals of the ENGIN-ECU check
the problem. harness MB992044 connector while referring to
.
the check chart.
TERMINAL RESISTANCE AND NOTE: Checks don't have to be carried out in the
CONTINUITY CHECKS order given in the chart.
1. Turn the ignition switch to the “LOCK” (OFF) 4. If the ohmmeter shows any deviation from the
position. Normal Condition value, check the corresponding
sensor, actuator and related electrical wiring, then
2. Disconnect the ECU connector.
repair or replace.
5. After repair or replacement, recheck with the
ohmmeter to confirm that the repair has corrected
the problem.
10. INSPECTION PROCEDURES USING

AN OSCILLOSCOPE
When there are inspection procedures using an
oscilloscope, these are listed.
GENERAL 00-9
HOW TO USE THE INSPECTION PROCEDURES

M1001013500066
The causes of many of the problems occurring in electric circuitry are generally the connectors, components,
the ECU, and the harnesses between connectors, in that order. These inspection procedures follow this
order. They first try to discover a problem with a connector or a defective component.
DTC P0202: Injector Circuit Malfunction - Cylinder 2.
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
(3) Shows the location of the connector(s) from

the circuit(s) above.
MFI RELAY
FRONT OF VEHICLE
2 1 2 1 2 1 2 1
4 3 4 3 4 3 4 3
B-17X (4) Explains about the operation principle of the

component or its relevant parts in that circuit.
AK303014 AB
CIRCUIT OPERATION TROUBLESHOOTING HINTS (The most

• Refer to DTC P0300 - Random/Multiple Misfire- likely causes for this code to be set are:) (1) Relevant circuit(s) and
• No. 2 cylinder injector failed.
location(s) of the
P.13B-481 and Misfire Cylinder 2- P.13B-487. component are described
• The injector power is supplied from the MFI relay • Open or shorted to ground No.2 cylinder injector
circuit. in these reference links.
(terminal No. 4).
• The ECU controls the injector by turning the • Shorted to battery, No.2 cylinder injector circuit.
power transistor in the ECU "ON" and "OFF". • Harness or connector damage.
• Refer to component locations GROUP-70
• Refer to configuration diagrams GROUP-80
• Refer to circuit diagrams GROUP-90
00DB075A
GENERAL 00-10
(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.
Diagnostic Tool (MUT-III)

(9)
(9)Identifies
Identifiesthe
thespecial
specialtool(s)
tool(s)
necessary
necessaryforfordiagnosing
diagnosingthatthatDTC.
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
CURRENT TROUBLE HARNESS INSPECTION

Indicates that the trouble is currently present. Carry Check for an open or short circuit in the harness
out troubleshooting as described in the applicable between the terminals which were faulty according to
inspection procedure. the connector measurements. Carry out this inspec-
tion while referring to GROUP 00E, Harness Con-
PAST TROUBLE nector Inspection P.00E-2. Here, “Check harness
Indicates that the trouble is historic, but normal oper- between power supply and terminal xx” also includes
ation has been restored. Observe the applicable checking for blown fuse. For inspection service
inspection procedure with particular emphasis on points when there is a blown fuse, refer to "Inspec-
connector(s) and wiring harness. tion Service Points for a Blown Fuse P.00-16."
GENERAL 00-11
MEASURES TO TAKE AFTER

REPLACING THE ECU
If the trouble symptoms have not disappeared even
after replacing the ECU, repeat the inspection proce-
dure from the beginning.
CONNECTOR MEASUREMENT SERVICE POINTS

M1001013600063
Turn the ignition switch to the "LOCK" (OFF) position when
connecting and disconnecting the connectors. Turn the ignition
switch to "ON" when measuring, unless there are instructions
to the contrary.
IF INSPECTING WITH THE CONNECTOR

CONNECTED <WATERPROOF CONNECTORS>
Be sure to use special tool. Never insert a test probe from the
SPECIAL TOOL
harness side, as this will reduce the waterproof performance
and result in corrosion.
ACX00863AE

CONNECTED <ORDINARY (NON-WATERPROOF)
CONNECTORS>
Check by inserting the multi-meter test probe from the harness
side. Note that if the connector (control unit, etc.) is too small to
permit insertion of the test probe, it should not be forced; use
the test probe tool for this purpose.
CONNECTOR
AC001606AB
GENERAL 00-12

DISCONNECTED <WHEN INSPECTING A
FEMALE PIN>
Required Special Tool:
• MB991219: Inspection Harness (Included in MB991223,
Harness Set)
• The special tool MB991219 for connector pin contact pres-
sure should be used. The test probe should never be forc-
ibly inserted, as it may cause a defective contact.
MB991219
ACX00865 AB
• From back side of the connector (SRS-ECU harness side

SRS-ECU HARNESS
CONNECTOR
connector)
• Since the SRS-ECU harness connector is plated to improve
conductivity, observe the warning below when checking this
connector.
WARNING
Insert the test probe tool into the connector from the
harness side, and connect the tester to the test probe
tool. If any tool other than the test probe tool is used,
AC001607AB
it may cause damage to the harness and other com-
ponents. Furthermore, measurement should not be
carried out by touching the test probe tool directly
against the terminals from the front of the connector.
The terminals are plated to increase their conductiv-
ity, so that if they are touched directly by the test
probe tool, the plating may break, which will decrease
reliability.

DISCONNECTED <WHEN INSPECTING A MALE
PIN>
CAUTION
At this time, be careful not to short the connector pins with
the test probes. Doing so may damage the circuits inside
the ECU.
Touch the pin directly with the test probe.
ACX00867 AB
GENERAL 00-13
CONNECTOR INSPECTION SERVICE POINTS

M1001013700060
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
STRETCHED OR BROKEN WIRES
HARNESS WIRE BREAKAGE

AT TERMINAL SECTION
LOW CONTACT
PRESSURE
GOOD
BAD
ACX00868AC
CONNECTOR PIN INSPECTION

If the connector pin stopper is damaged, the terminal connec-
tions (male and female pins) will not be perfect even when the
connector body is connected, because the pins may pull out of
the back side of the connector. Therefore, gently pull the wires
one by one to make sure that no pins pull out of the connector.
ACX00869AB
.
GENERAL 00-14
CONNECTOR ENGAGEMENT INSPECTION

• MB991219: Inspection Harness (contained in MB991223
Test Harness)
Use special tool MB991219 to inspect the engagement of the
male pins and female pins. [Pin drawing force: 1 N (0.2 pound)
or more]
MB991219
ACX00870 AB
HOW TO COPE WITH INTERMITTENT

MALFUNCTIONS
M1001013900064
Most intermittent malfunctions occur under certain conditions. If
those conditions can be identified, the cause will be easier to
find.
.
TO COPE WITH INTERMITTENT MALFUNCTION;

1. ASK THE CUSTOMER ABOUT THE
MALFUNCTION
Ask what it feels like, what it sounds like, etc. Then ask about
driving conditions, weather, frequency of occurrence, and so
on.
.
2. DETERMINE THE CONDITIONS FROM THE

CUSTOMER'S RESPONSES
Typically, almost all intermittent malfunctions occur from condi-
tions like vibration, temperature and/or moisture change, poor
connections. From the customer's responses, it should be rea-
soned which condition is most likely.
.
3. USE SIMULATION TEST

Use the simulation tests below to attempt to duplicate the cus-
tomer's complaint. Determine the most likely circuit(s) and per-
form the simulation tests on the connectors and parts of that
circuit(s). Be sure to use the inspection procedures provided for
diagnostic trouble codes and trouble symptoms.
For temperature and/or moisture condition related intermittent
malfunctions, try to change the conditions of the suspected cir-
cuit components, then use the simulation tests below.
.
GENERAL 00-15
4. VERIFY THE INTERMITTENT MALFUNCTION IS

ELIMINATED
Repair the malfunctioning part and try to duplicate the condi-
tion(s) again to verify the intermittent malfunction has been
eliminated.
.
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
INSPECTION SERVICE POINTS FOR A BLOWN

FUSE
M1001013800067
Remove the blown fuse and measure the resistance between
the load side of the blown fuse and the ground. Close the
switches of all circuits which are connected to this fuse. If the
resistance is almost 0 Ω at this time, there is a short some-
where between these switches and the load. If the resistance is
BATTERY not 0 Ω, there is no short at the present time, but a momentary
short has probably caused the fuse to blow.
The main causes of a short circuit are the following.
• Harness being clamped by the vehicle body
• Damage to the outer casing of the harness due to wear or
FUSE heat
• Water getting into the connector or circuitry
SHORT-
CIRCUIT • Human error (mistakenly shorting a circuit, etc).
LOAD OCCURRENCE
SWITCH SECTION
LOAD
ACX00872 AB
HOW TO TREAT CURRENT TROUBLE

M1001014000020
1. Make a note of the diagnostic trouble code, and erase it.
2. Check the trouble symptom again.
3. Check for diagnostic trouble codes again.
4. If a diagnostic trouble code is set, follow the applicable
Diagnostic Trouble Code Chart.
5. If no diagnostic trouble code is set, refer to "How to Cope
with Intermittent Malfunction P.00-14."
HOW TO TREAT PAST TROUBLE

M1001014100050
1. Establish from the customer whether a fuse or connector

has been replaced or disconnected.
2. If yes, erase the diagnostic trouble code, and then check
that no diagnostic code is reset. If no diagnostic trouble
code is reset, the diagnosis is complete.
3. If no, follow the applicable Diagnostic Trouble Code Chart.
Then check the wiring harness and connector, and refer to
"How to Cope with Intermittent Malfunction P.00-14."
GENERAL 00-17
AFFILIATED DTC REFERENCE TABLE
AFFILIATED DTC REFERENCE TABLE

M1001013000027
For vehicles with CAN, when DTC which influences
the transmission data is set to the ECU which sends
the data, DTC also could be set to the ECU which
receives and controls the transmission data. The
table below shows the relativity of DTC between
ECUs.
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 NUMBER
M1001000401028
NUMBER (VIN)
00DB078A
The vehicle identification number (VIN) is stamped on the

bulkhead in the engine compartment and also on the compli-
ance plate itself. It provides information for vehicle identification
purposes and should be quoted when ordering parts or in any
correspondence related to the vehicle
NO. ITEM CONTENT
6 M M D B 4 X 41 5 T 000001 1 Geographic Area 6: Australia

2 Country within M: Australia
Geographic area
1 2 3 4 5 6 7 8 9 10 11 3 Manufacturer M: Mitsubishi Motors
4 Car line D: 380
00DB091A
5 Series B: Series
6 Engine/ 1: 3.8 litre MPI <unleaded fuel>
Transmission (5-speed manual)
combinations
4: 3.8 litre MPI <unleaded fuel>
(5-speed A/T)
7 Price class D: 380
V: 380VRX
X: 380GT
H: 380LS, 380LX(full option pack)
8 Body Type 41: Sedan
9 Year 5: 2005
10 Assembly Plant T: Tonsley Park
11 Body number 000001 to 999999
GENERAL 00-19
VEHICLE INFORMATION NUMBER LIST
DL1ASNLERJ DL1ASYLERJ DL1ASNHERJ DL1ASYHERJ DL1ASYXERJ DL1ASYDERJ

380 5M/T 380 5A/T 380VRX 5M/T 380VRX 5A/T 380GT 5A/T 380LS** 5A/T
SEDAN SEDAN SEDAN SEDAN SEDAN SEDAN
DB1D41 DB4D41 DB1V41 DB4V41 DB4X41 DB4H41
NOTE: ** = Becomes 380LX as a full option pack.
VEHICLE COMPLIANCE PLATE

The Compliance Plate is attached to the bulkhead All vehicles are manufactured to confirm to specific
(adjacent to the Data Plate) in the engine compart- safety, environmental or consumer protective
ment and must never be removed from the vehicle requirements as defined by the Australian Design
Rules (ADR).
VEHICLE COMPLIANCE
PLATE
00DB092A
GENERAL 00-20
VEHICLE DATA PLATE

M1001005400707
VEHICLE DATA
PLATE
00DB090A
The vehicle data plate is attached on the bulk-

head, between the vehicle identification number (VIN) and the
compliance plate at the top outer panel in the engine compart-
ment.
The plate shows vehicle option codes, trim codes and a daily
body sequential build number.
AUSTRALIAN DESIGN RULES
Australian Design Rules require the manufacturer of components and/ or a complete vehicle to conform to
specific safety, environmental or consumer protective requirements as defined by that particular rule. There is
legislation that requires, amongst other things that no modifications be made to a vehicle that would cause
that vehicle not to comply with the Design Rules of that vehicle (parts replacement using approved Mitsubishi
Motors Australia Limited components is permissible). Before interchanging or adding optional equipment or
using non-Genuine Parts, it is recommended that advice be sought from an Authorised Mitsubishi Motors
Australia Limited Dealer or from a Mitsubishi Motors Australia Limited Regional Office, because it is possible
to inadvertently cause a vehicle not to comply with a Design Rule.
GENERAL 00-21
OPTION CODES (380 Series)

OPTION CODE: ITEM
G39 Sunroof
C73 Leather (380 VRX)
J40 Traction Control
W51 16" Alloy Wheels
W54 17" Alloy Wheels + Sports Suspension + Strut Tower Bar
R06 Satellite Navigation Accommodation Package
J07 LX MARK (Only in combination with G39, C78, K40, W54) on
380-LS model
G39, C73 Sunroof + Leather
J40, W51 Traction Control + 16" Alloy Wheels
C78, K40 Leather (380 LS) + Power Seats
G05, J06 ECM + Vanity Mirror Lamp
J40, W51, G39 Traction Control + 16 " Alloy Wheels + Sunroof
G39, C78, K40 Sunroof + Leather (380 LS) + Power Seats
G39, C78, K40, W54 Sunroof + Leather (380 LS) + Power Seats + 17" Alloy Wheels +
Sports Suspension + Strut Tower Bar
G39, C78, K40, W54, Sunroof + Leather (380 LS) + Power Seats + 17" Alloy Wheels +
J07 Sports Suspension + Strut Tower Bar + LX Badging
EXPORT CODES
OPTION ITEM
CODE
X71 Fiji
X62 New Zealand
A18 Export Preparation (wax and brake bags)
X30 Brunei
TYRE AND LOADING INFORMATION PLACARD

The tyre and loading information placard is located on the
inside sill of the driver’s door.
00DB095A
GENERAL 00-22
PRECAUTIONS BEFORE SERVICE
ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.
<3.8L ENGINE> The engine model number is as shown as follow.
ENGINE MODEL ENGINE DISPLACEMENT
6G75 3828cc
The engine serial number is stamped near the engine model

number.
00DB080A

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
M1001011600056
1. Items to review when servicing SRS: (5) Store components removed from the SRS in a
(1) Be sure to read GROUP 52B, Supplemental clean and dry place. The air bag module
Restraint System (SRS). For safe operation, should be stored on a flat surface and placed
please follow the directions and heed all so that the pad surface is facing upward.
warnings. (6) Never attempt to disassemble or repair the
(2) Wait at least 60 seconds after disconnecting SRS components (SRS-ECU, air bag module
the battery cable before doing any further and clock spring). If there is a defect, replace
work. The SRS system is designed to retain the defective part.
enough voltage to deploy the air bag even (7) Whenever you finish servicing the SRS, check
after the battery has been disconnected. the SRS warning light operation to make sure
Serious injury may result from unintended air that the system functions properly.
bag deployment if work is done on the SRS (8) Be sure to deploy the air bag before disposing
system immediately after the battery cable is of the air bag module or disposing of a vehicle
disconnected. equipped with an air bag (Refer to GROUP
(3) Warning labels must be heeded when 52B, Air Bag Module Disposal Procedures
servicing or handling SRS components. P.52B-254).
Warning labels can be found in the following 2. Observe the following when carrying out
locations. operations on places where SRS components are
• Front impact sensor installed, including operations not directly related
• Hood to the SRS air bag.
• Sun visor (1) When removing or installing parts, do not allow
• Instrument panel (passenger’s side) any impact or shock to occur to the SRS
• SRS-ECU components.
• Steering wheel (2) If heat damage may occur during paint work,
• Clock spring remove the SRS-ECU, the air bag module,
• Air bag module (Driver's or front clock spring, the front impact sensor, the side
passenger's) impact sensor, and the seat belt pre-tensioner.
• Side-airbag module (Driver's side or front a. SRS-ECU, air bag module, clock spring,
passenger's side) front impact sensor, the side impact sensor:
93°C (200°F) or more
• Side impact sensor
b. Seat belt pre-tensioner: 90°C (194°F) or
• Seat belt pre-tensioner
more
(4) Always use the designated special tools and
test equipment.
GENERAL 00-23
HOW TO PERFORM VEHICLE IDENTIFICATION

NUMBER (VIN) WRITING
M1001011400063
The Vehicle Identification Number (VIN) is stored in the ECU by
the vehicle manufacture. If the VIN to be stored in the ECU is
eliminated fraudulently, the Malfunction Indicator Lamp (Check
Engine Lamp) illuminates and Diagnostic Trouble Code (DTC)
No.P0630 (VIN malfunction) is shown. When the ECU is
replaced, and entry of the VIN necessary due to DTC No.
P0630 (VIN malfunction). Enter the VIN in accordance with the
procedure as follows:
.
WRITING PROCEDURE
• 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
SERVICING ELECTRICAL SYSTEM

M1001011900057
WARNING
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
APPLICATION OF ANTI-CORROSION AGENTS

AND UNDERCOATS
M1001011000043
Do not to apply oil or grease to the heated oxygen sensor. If
applied, the sensor may malfunction. Protect the heated oxy-
gen sensor with a cover before applying anti-corrosion agent,
etc.
DIAGNOSTIC TOOL (MUT-III)

M1001012200062
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.
VEHICLE COMMUNICATION MUT-III USB CABLE MUT-III MAIN HARNESS A

INTERFACE (V.C.I.)
MB991824 MB991827 MB991910
MUT-III MAIN HARNESS B MUT-III MAIN HARNESS C MUT-III MEASUREMENT ADAPTER
DO NOT USE DO NOT USE
MB991911 MB991914 MB991825
MUT-III TRIGGER HARNESS
MB991826 AC2010881AD
GENERAL 00-26
TOWING AND HOISTING
TOWING AND HOISTING

M1001000800380
TOWING THE VEHICLE BY A TOW TRUCK

.
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
TOWING WITH FRONT WHEELS OFF THE

GROUND (TYPE C)
The vehicle may be towed on its rear wheels for extended dis-
tances provided the parking brake is released and gearshift
lever is in the "Neutral" position (M/T) or the selector lever is in
the "N" (NEUTRAL) position (A/T). It is recommended that vehi-
cles be towed using the front pickup whenever possible.
CAUTION
[For vehicles equipped with the traction control system
(TCL)]
• If the vehicle is towed with the ignition key in the "ON"
position and only the front wheels or only the rear
wheels raised of the ground, a malfunction may occur
in the device
.
GENERAL 00-27
TOWING AND HOISTING
TOWING WITH REAR WHEELS OFF THE

GROUND (TYPE B)
Place the gearshift lever in the "Neutral" position (M/T) or the
selector lever in the "N" (NEUTRAL) position (A/T). Turn the
ignition key to the "ACC" position and secure the steering
wheel in a straight-ahead position with a rope or tie-down strap.
Never place the ignition key in the "LOCK" position when tow-
ing.
CAUTION
• Never tow an A/T vehicle with the rear wheels up (and
the front wheels on the ground) when the automatic
transmission fluid level is low. this may cause serious
and expensive damage to the transmission.
• Do not use the steering column lock to secure the front
wheels for towing.
• Make sure the transaxle is in Neutral if vehicle will have
drive wheels on the ground.
• If these requirements cannot be met, the front wheels
must be placed on a tow dolly.
00DB093A
TOWING WHEN KEYS ARE NOT AVAILABLE

When a locked vehicle must be towed and keys are not avail-
able, the vehicle may be lifted and towed from the front, pro-
vided the parking brake is released. If not released, the rear
wheels should be placed on a tow dolly.
.
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
3. Refrain from going under a vehicle when it is lifted by the

towing equipment, unless the vehicle is adequately sup-
ported by safety stands.
4. Never allow passengers to ride in a towed vehicle.
5. State and local rules and regulations must be followed when
towing a vehicle.
LIFTING, JACKING SUPPORT LOCATION

.
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
CENTER MEMBER REAR SUSPENSION CROSSMEMBER
RIGID RACK RIGID RACK AC307266AB
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 DATA AND SPECIFICATIONS

M1001000900473
.
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
ITEM 380, 380LS, 380LX 380VRX, 380GT

Engine Model No. 6G75
Total displacement 3,828cc
Automatic Model No. F5A5A-4-C2Z
Transaxle
Type 5-speed automatic
Manual Model No. F 5M51
Trans.
Type 5-speed manual
Fuel Fuel supply system Electronic controlled multipoint fuel injection (MPI)
system
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
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
M18 1.5 150 ± 20 N⋅m (111 ± 14 290 ± 40 N⋅m (214 ± 29 335 ± 45 N⋅m (247 ± 33
GENERAL 00-33
TIGHTENING TORQUE

DIAMETER (mm) (mm)
M20 1.5 210 ± 30 N⋅m (155 ± 22 400 ± 60 N⋅m (295 ± 44 465 ± 65 N⋅m (343 ± 48
M22 1.5 290 ± 40 N⋅m (214 ± 29 540 ± 80 N⋅m (398 ± 59 630 ± 90 N⋅m (465 ± 66
M24 1.5 375 ± 55 N⋅m (277 ± 40 705 ± 105 N⋅m (520 ± 820 ± 120 N⋅m (605 ±
ft-lb) 77 ft-lb) 88 ft-lb)
FLANGE BOLT AND NUT TIGHTENING TORQUE
DIAMETER (mm) (mm)
M6 1.0 5.0 ± 1.0 N⋅m (44 ± 9 10 ± 2 N⋅m (89 ± 17 12 ± 2 N⋅m (107 ± 17
M8 1.25 13 ± 2 N⋅m (111 ± 22 24 ± 4 N⋅m (18 ± 3 ft-lb) 28 ± 5 N⋅m (20 ± 4 ft-lb)
in-lb)
M12 1.25 47 ± 9 N⋅m (35 ± 6 ft-lb) 93 ± 12 N⋅m (68 ± 9 105 ± 15 N⋅m (78 ± 11
ft-lb) ft-lb)
M12 1.75 43 ± 8 N⋅m (32 ± 6 ft-lb) 83 ± 12 N⋅m (61 ± 9 98 ± 12 N⋅m (72 ± 9
ft-lb) ft-lb)
GENERAL 00-34
LUBRICATION AND MAINTENANCE
LUBRICATION AND MAINTENANCE

M1001001200336
Maintenance and lubrication service recommenda- Either of the following engine oils should be used:
tions have been compiled to provide maximum pro- 1. Engine oil conforming to the ACEA classification:
tection for the vehicle owner's investment against all "For service A1, A2 or A3.
reasonable types of driving conditions. Since these 2. Engine oil conforming to the API classification:
conditions vary with the individual vehicle owner's "For service SG" or higher.
driving habits, the area in which the vehicle is oper-
ated and the type of driving to which the vehicle is FUEL USAGE STATEMENT
subjected, it is necessary to prescribe lubrication and
maintenance service on a time frequency as well as CAUTION
mileage interval basis. Using leaded petrol in this car will damage the
Oils, lubricants and greases are classified and catalytic converters and heated oxygen sensors,
graded according to standards recommended by the and affect the warranty coverage validity.
Society of Automotive Engineers (SAE) and the Aus- This vehicle must use unleaded petrol only.
tralian Petroleum Institute (API). This vehicle has a fuel filler tube which is especially
designed to accept only the smaller-diameter
MAINTENANCE SCHEDULES
unleaded petrol dispensing nozzle.
For Information on service maintenance refer to the The 3.8L model is designed to operate on unleaded
"Service handbook". petrol having an octane rating (DIN 51607) of 90
RON or higher.
ENGINE OIL .
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.
MATERIALS ADDED TO FUEL

Indiscriminate use of fuel system cleaning agents
should be avoided. Many materials intended for gum
and varnish removal may contain highly active sol-
vents or similar ingredients that can be harmful to
gasket and diaphragm materials used in fuel system
component parts.
GENERAL 00-35
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
RECOMMENDED LUBRICANTS AND LUBRICANT

CAPACITIES TABLE
M1001001300504
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
LUBRICANT CAPACITY TABLE

<3.8L ENGINE>
DESCRIPTION SPECIFICATION
Engine oil (Litres) Oil pan (excluding oil filter) 4.0
Oil filter 0.3
Engine coolant (Litres) 8.7
Automatic Transmission fluid (Litres) 8.4
Manual Transmission fluid (Litres) 2.8
Power steering fluid (Litres) 1.2
Fuel tank (Litres) 67.0
Washer fluid (Litres) 5.0
Refrigerant (air conditioning) (grams) 435g - 475g
GENERAL 00-36
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
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.
ENGINE COOLANT TEMPERATURE FREEZING SAFE OPERATING COOLANT

°C (°F) AND SPECIFIC GRAVITY TEMPERATURE TEMPERATURE CONCENTRATION
(SPECIFIC
VOLUME)
10 20 30 40 50 °C (°F) °C (°F) %
1.054 1.050 1.046 1.042 1.036 −16 (3.2) −11 (12.2) 30
1.063 1.058 1.054 1.049 1.044 −20 (−4) −15 (5) 35
1.071 1.067 1.062 1.057 1.052 −25 (−13) −20 (−4) 40
1.079 1.074 1.069 1.064 1.058 −30 (−22) −25 (−13) 45
1.087 1.082 1.076 1.070 1.064 −36 (−32.8) −31 (−23.8) 50
1.095 1.090 1.084 1.077 1.070 −42 (−44) −37 (−35) 55
1.103 1.098 1.092 1.084 1.076 −50 (−58) −45 (−49) 60
Example
The safe operating temperature is −15°C (5° F) when the specific gravity is 1.058 at the coolant temperature
of 20°C (68°F)
GENERAL 00-37
MAINTENANCE SERVICE
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.
2. FUEL HOSES (CHECK CONDITION)

M1001001700308
1. Inspect the surface of fuel hoses for heat and mechanical
damage. Hard and brittle rubber, cracking, tears, cuts,
abrasions and excessive swelling indicate deterioration of
the rubber.
2. If the fabric casing of the rubber hose is exposed by cracks
and abrasions in the fuel system, the hose should be
replaced.
3. AIR CLEANER FILTER (REPLACE)

M1001001800338
The air cleaner element will become dirty during use, reducing
its effectiveness. Replace it with a new one.
REPLACEMENT OF AIR CLEANER ELEMENT
1. Unclamp the air cleaner housing cover.
2. Remove the air cleaner element and install a new one.
3. When clamping the air cleaner housing cover in place, be
sure that the cover is completely closed.
AC305838AB
4. EVAPORATIVE EMISSION CANISTER (CHECK

FOR CLOGGING)
M1001001900324
If the fuel-vapor cannister is clogged or damaged, excess fuel
vapor will escape into the atmosphere causing a strong fuel
vapour smell t emitt from engine compartmrnt. emission. Dis-
connect the line at both ends, and blow it clean with com-
pressed air. Remove the fuel tank filler tube cap from the filler
tube and check to see if there is evidence that the seal makes
improper contact to the filler tube.
GENERAL 00-38
MAINTENANCE SERVICE
5. SPARK PLUGS (REPLACE)

M1001002000346
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
2. The new plugs should be checked for the proper gap.

Spark plug gap: 1.0 − 1.1 mm
3. Install the spark plugs and tighten to 25 ± 5 N⋅m (18 ± 4
ft-lb).
6. TIMING BELT (REPLACE)

M1001002300273
Replace the belt with a new one according to the vehicle main-
tenance schedule to assure proper engine performance.
<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
7. DRIVE BELTS (FOR ALTERNATOR, POWER

STEERING PUMP AND AIR CONDITIONING)
(CHECK)
M1001008700031
ALTERNATOR DRIVE BELT TENSION CHECK

<3.8L ENGINE>
.
WHEN USING DIAGNOSTIC TOOL (MUT-III)

• MB991668: Belt Tension Meter Set
• MB991824: Vehicle Communication Interface (V.C.I.)
CAUTION
To prevent damage to DIAGNOSTIC TOOL (MUT-III), always
turn the ignition switch to the "LOCK" (OFF) position
770203CA 1. Connect Belt Tension Meter Set (MB991668) to V.C.I
214503CA
DATA LINK
(MB991824).
CONNECTOR 2. Connect MUT-III Main Harness A (BLUE) (MB991910) to
V.C.I (MB991824).
3. Connect MUT-III Main Harness A (BLUE) (MB991910) to the
data link connector.
4. Turn the ignition switch to the "ON" position and select "Belt
Tension" from the menu V.C.I (MB991824) screen.
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
WHEN USING THE TENSION GAUGE

Use a belt tension gauge to check that the belt tension is within
the standard value.
ALTERNATOR
PULLEY Standard value: 490 − 686 N (110 − 154 lb)
TENSIONER
PULLEY
CRANK
SHAFT AIR
PULLEY CONDITIONING
COMPRESSOR
PULLEY
TENSION
GAUGE
00DB082A
BELT DEFLECTION CHECK

Apply approximately 98 N (22 lb) of force to the middle of the
drive belt between the pulleys (at the place indicated by the
ALTERNATOR arrow) and check that the amount of deflection in within the
PULLEY
standard value.
Standard value: 8.4 − 10.7 mm (0.33 − 0.42 in)
TENSIONER
PULLEY
APPROXIMATELY AIR
98 N (22 lb) CONDITIONING
COMPRESSOR
CRANK PULLEY
SHAFT
PULLEY
00DB083A
GENERAL 00-42
MAINTENANCE SERVICE
ALTERNATOR DRIVE BELT TENSION

ADJUSTMENT
.
1. Loosen the tensioner pulley fixing nut.

2. With the tensioner pulley fixing nut temporarily tightened to
TENSIONER 15 ± 5 N⋅m (11 ± 4 ft-lb), set the belt tension or defection
PULLEY
amount to the standard value using the adjusting bolt.
Standard value:
ITEMS DURING DURING

FIXING ADJUSTMENT REPLACEMENT
NUT
Vibration 150 − 163 180− 202
ADJUSTING BOLT AK303695AB frequency Hz
Tension N (lb) 539 − 637 785 − 981
(121 − 143) (176 − 221)
Deflection 8.9 − 10.1 6.2 − 7.5
(Reference value) (0.35 − 0.40) (0.24 − 0.30)
mm (in)
3. Tighten the tension pulley fixing nut.

Tightening torque: 49 ± 10 N⋅m (36 ± 7 ft-lb)
POWER STEERING DRIVE BELT TENSION

CHECK
.
WHEN USING DIAGNOSTIC TOOL (MUT-III)

• MB991668: Belt Tension Meter Set
POWER STEERING Gently tap the middle of the belt between the pulleys (the loca-
OIL PUMP PULLEY tion indicated by the arrow) with your finger as shown in the
TAP LIGHTLY illustration, and check that the vibration frequency of the belt is
WITH A FINGER within the standard value.
10 - 20 mm
NOTE: Refer to P.00-39 for details on the method of measuring
(0.4 - 0.8 in) the vibration frequency using the scan tool.
Standard value:
MB991668
15˚ (MICROPHONE) ITEM WHEN DURING DURING
15˚ AC210247AB CHECKED ADJUSTME REPLACEM
NT ENT
Vibration 124 − 160 134 − 151 160 − 189
frequency Hz
.
GENERAL 00-43
MAINTENANCE SERVICE
WHEN USING A TENSION GAUGE

TENSION Use a belt tension gauge to check that the belt tension is within
CRANKSHAFT
PULLEY the standard value.
PULLEY
Standard value:
ITEM WHEN DURING DURING
CHECKED ADJUSTMENT REPLACEMENT
POWER Tension N 294 − 490 343 − 441 490 − 686

STEERING (lb) (66 − 110) (77 − 99) (110 − 154)
OIL PUMP TENSION
PULLEY GAUGE AC210249AB
BELT DEFLECTION CHECK

TENSION Apply approximately 98 N (22 lb) of force to the middle of the
CRANKSHAFT
PULLEY drive belt between the pulleys (at the place indicated by the
PULLEY
arrow) and check that the amount of deflection is within the
standard value.
Standard value:
ITEM WHEN DURING DURING
APPROXIMATELY CHECKED ADJUSTMENT REPLACEMENT
98 N (22 lb)
Deflection 12.3 − 16.2 13.2 − 15.1 9.6 − 12.3
AC210250AB
(Reference (0.48 − 0.64) (0.52 − 0.59) (0.38 − 0.48)
value) mm
(in)
if the tension or deflection is outside the standard value, adjust

by the following procedure.
1. Loosen the tensioner pulley lock nut.
LOCK NUT 2. Adjust the belt tension to the standard value by turning the
adjusting bolt. The tension will increase when turning the
adjusting bolt clockwise, and decrease when turning
counterclockwise.
3. Tighten the lock nut to the specified torque.
ADJUSTING
BOLT 4. Tighten the adjusting bolt.
AC210301AB Tightening torque: 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
CAUTION
Check after turning the crankshaft one or more rotations
clockwise.
5. Check the belt deflection amount and tension, and readjust
if necessary.
GENERAL 00-44
MAINTENANCE SERVICE
8. EXHAUST SYSTEM (CONNECTIONS PORTION

OF MUFFLER, MUFFLER PIPES AND
CONVERTER HEAT SHIELDS) (CHECK AND
SERVICE AS REQUIRED)
M1001005800299
1. Check for holes and exhaust gas leaks due to damage,
corrosion, etc.
2. Check the joints and connections for looseness and exhaust
gas leaks.
3. Check the rubber hangers and brackets for damage.
9. ENGINE OIL (CHANGE)

M1001002600360
Use the specified oil. (Refer to P.00-35.)
WARNING
Use care as oil could be hot.
1. After warming up the engine, remove the oil filler cap.
2. Remove the drain plug to allow the engine oil to drain.
3. Install a new drain plug gasket so that it faces in the
<3.8L ENGINE>
direction shown in the illustration, and then tighten the drain
plug to the specified torque.
OIL PAN SIDE
4. Pour new engine oil in through the oil filler hole.
Specified Engine Oil:
39 ± 5 N·m Total quantity:
DRAIN PLUG 29 ± 3 ft-lb <3.8L Engine> 4.6 Litres
GASKET 5. Install the engine oil filler cap.
AC305937AB
6. Start the engine and run it at idle for a few minutes.
7. Pull out the oil dipstick slowly and check that the oil level is
within the marks on the oil dipstick.
8. Check that the oil is not excessively dirty, that there is no
GOOD coolant or petrol mixed in, and that it has sufficient viscosity.
MAXIMUM MINIMUM
AC205268 AB
10. ENGINE OIL FILTER (REPLACE)

M1001002700345
The quality of replacement filters varies considerably. Only high
quality filters should be used to assure most efficient service.
Genuine oil filters require that the filter is capable of withstand-
ing a pressure of 1,800 kPa (261 psi) are high quality filters.
.
GENERAL 00-45
MAINTENANCE SERVICE
Engine Oil Filter Selection

This vehicle is equipped with a full-flow, throw-away oil filter.
The same type of filter is recommended as a replacement filter
for this vehicle. It is possible, particularly in cold weather, that
this vehicle may develop high oil pressure for a short duration.
Make sure that any replacement filter used on this vehicle is a
high-quality filter. The filter must withstand a pressure of 1,800
kPa (261 psi) [manufacturer's specifications] to avoid filter and
ultimately engine damage. The Genuine Mitsubishi high-quality
filter and is strongly recommended for use on this vehicle.
Any replacement oil filter should be installed in accordance with
the oil filter manufacturer's installation instructions.
.
Oil Filter Replacement

WARNING
1. Drain the engine oil by removing the oil drain plug.
2. Use an oil filter wrench to remove the engine oil filter.
3. Clean the filter bracket side mounting surface and ensure
MB991610 OR the old O-ring has been removed.
GENERAL
SERVICE
TOOL
AC000093 AG
4. Apply a small amount of engine oil to the O-ring of the new

oil filter.
5. Where the oil filter O-ring touches the oil pan flange, tighten
the oil filter to the specified torque using the
commercially-available tool.
Tightening torque:
: Approximately 3/4 turn [14 ± 2 N⋅m]
O-RING 6. Add new engine oil through the oil filler.
ACX00396 AB
11. TRANSMISSION FLUID

M1001002900338
TRANSMISSION FLUID CHECK

1. Drive the vehicle until the transmission fluid temperature
rises to the normal operating temperature [70 − 80°C (158 −
176°F)].
NOTE: The transmission fluid temperature is measured with
Diagnostic Tool (MUT-III).
00-46 GENERAL
MAINTENANCE SERVICE
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
6. Securely insert the dipstick.

NOTE: The transmission fluid should always be replaced
under the following conditions:
.
• When troubleshooting the transaxle.
• When overhauling the transaxle.
• When the transmission fluid is noticeably dirty or burnt
(driving under severe conditions).
TRANSMISSION FLUID CHANGE

Refer to GROUP 23A, Automatic Transmission - On-vehicle
Service P.23A-296.
12. ENGINE COOLANT (CHANGE)

M1001003100357
Check the cooling system parts such as the radiator, heater
and oil cooler hoses, thermostat and their connections for leak-
age and damage.
.
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
4. Drain the water in the water jacket by unplugging the drain

<3.8L ENGINE: RIGHT BANK>
plug of the cylinder block.
5. Remove the radiator condenser tank assembly and drain the
coolant.
6. Drain the coolant then clean the path of the coolant by
injecting water into the radiator from the radiator cap area.
CYLINDER BLOCK
DRAIN PLUG
AC306132AB
<3.8L ENGINE: LEFT BANK>
CYLINDER BLOCK
DRAIN PLUG
AC306131AB
7. Apply the designated sealant to the screw area of the

cylinder block drain plug, and then tighten to the standard
CYLINDER BLOCK
DRAIN PLUG torque.
Specified sealant: Loctite 577 or equivalent
Tightening torque:
<3.8L Engine> 39 ± 5 N⋅m
8. Securely tighten the radiator drain plug.
9. Assemble the radiator condenser tank assembly.
CAUTION
AC200625AD
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.
10.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:
<3.8L Engine> 8.7 Litres
AC306129 AB NOTE: For how to use special tool MB991871, refer to its
manufacturer’s instructions.
11.Reinstall the radiator cap.
12.Start the engine and let it warm up until the thermostat
opens.
13.After repeatedly revving the engine up to 3,000 r/min
several times, stop the engine.
GENERAL 00-49
MAINTENANCE SERVICE
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.
13. COOLANT HOSES (RADIATOR HOSE,

HEATER HOSE) (INSPECT)
M1001009700034
Inspect the surface of radiator hoses and heater hoses for heat
and mechanical damage. Hard and brittle rubber, cracking,
tears, cuts, abrasions and excessive swelling indicate deterio-
ration of the rubber.
14. DISC BRAKE PADS, ROTORS (INSPECT FOR

WEAR)
M1001003200291
Check for fluid contamination and wear. Replace the complete
set of pads if any one pad is defective.
Thickness of lining
Minimum limit: 2.0 mm
CAUTION
The pads for the right and left wheels should be replaced
at the same time. Never split or intermix brake pad sets. All
four pads must be replaced as a complete set.
ACX00898AB
15. BRAKE HOSES (CHECK FOR

DETERIORATION OR LEAKS)
M1001003400314
Inspection of brake hoses should be included in all brake ser-
vice operations.
The hoses should be checked for:
BRAKE HOSES
1. Incorrect length, severe surface cracking, stretching,
scuffing or worn spots (If the fabric casing of the hoses is
exposed by cracks or abrasion in the rubber hose cover, the
hoses should be replaced. Eventual deterioration of the
hose and possible bursting failure may occur).
2. Incorrect installation, twisting or interference with wheel, tyre
or chassis.
AC306483AB
00-50 GENERAL
MAINTENANCE SERVICE
16. BALL JOINT AND STEERING LINKAGE

SEALS (INSPECT FOR GREASE LEAKS AND
DAMAGE)
M1001003500322
1. These components, which are permanently lubricated at the
factory, do not require periodic lubrication. Damaged seals
and boots should be replaced to prevent leakage or grease
BOOT
contamination.
2. Inspect the dust cover and boots for proper sealing, leakage
DUST and damage, and replace them if defective.
COVER
AC100948 AB
17. DRIVE SHAFT BOOTS (INSPECT FOR

GREASE LEAKS AND DAMAGE)
M1001003600318
1. These components, which are permanently lubricated at the
BOOTS factory, do not require periodic lubrication. Damaged seals
and boots should be replaced to prevent leakage or grease
contamination.
2. Inspect the dust cover and boots for proper sealing, leakage
and damage. Replace them if defective.
AC000109 AB
GENERAL 00-51
MAINTENANCE SERVICE
18. SUSPENSION SYSTEM (INSPECT FOR

LOOSENESS AND DAMAGE)
M1001009600048
Visually inspect the front/rear suspension components for dete-
rioration and damage. Re-tighten the front/rear suspension
components retaining bolts to specified torque.
19. SRS AIR BAG (INSPECT FOR SRS SYSTEM)

M1001003700326
The entire SRS including air bag and pre-tensioner seat belt
must be inspected by an authorized MITSUBISHI MOTORS
dealer 10 years.
SRS WARNING LIGHT CHECK
Turn the ignition key to the "ON" position. Does the

"SRS" warning light illuminate for several seconds, and then go
out? If yes, the SRS system is functioning properly. If no, refer
to GROUP 52B, Diagnosis P.52B-215.
SRS COMPONENT VISUAL CHECK

DANGER
Wait at least 60 seconds after disconnecting the bat-
TAPE tery cable before doing any further work. The SRS
BATTERY
system is designed to retain enough voltage to
deploy the air bag for a short time even after the bat-
tery has been disconnected. Serious injury may result
from unintended air bag deployment if work is done
on the SRS system immediately after the battery
cable is disconnected.
BATTERY CABLE
ACX00902 AB
WARNING
HANDLING.
1. Turn the ignition switch to the "LOCK" (OFF) position,
disconnect the negative battery cable and tape the terminal.
2. Remove the floor console assembly (Refer to GROUP 52A,
Floor Console P.52A-10).
3. Disconnect a connector from the SRS-ECU.
00-52 GENERAL
MAINTENANCE SERVICE
FRONT IMPACT SENSORS

1. Check that the arrows on the sensors face toward the front
of the vehicle.
FRONT IMPACT HEADLIGHT (RH)
WARNING
SENSOR
• The SRS may not activate if a front impact sensor
is not installed properly, which could result in seri-
ous injury or death to the vehicle's driver and pas-
senger.
• If a dent, crack, deformation or rust is detected,
RADIATOR SUPPORT replace with a new sensor.
PANEL AC306331AB
2. Check the front side member and front impact sensor for
deformation or rust.
3. Check the front impact sensor wiring harness for binding;
Check the connector for damage; and check the terminals
for deformation.
Replace the sensor and/or wiring harness if they fail the
visual check (Refer to GROUP 52B, SRS Service
Precautions P.52B-16 and GROUP 52B, Front Impact
Sensor P.52B-231).
SIDE IMPACT SENSORS

WARNING
• If the side impact sensor is not installed securely
and correctly, the side-air bag may not operate
normally.
replace with a new sensor.
1. Check the side impact sensor and bracket for dents, cracks
or deformation. The side impact sensors are located inside
FRONT SEAT BELT the center pillars (LH/RH).
RETRACTOR
2. Check the connector for damage, and terminal for
deformation.
SIDE 3. Check that there is no bending or corrosion in the center
IMPACT pillars (LH/RH).
SENSOR
Replace the side impact sensor if it fails the visual check
(Refer to GROUP 52B, Side Impact Sensor P.52B-247).
AC206185 AC
NOTE: The illustration shows the left side impact sensor (RH).
The position of the other side impact sensor (LH) is symmetri-
cal to this.
GENERAL 00-53
MAINTENANCE SERVICE
SRS AIR BAG CONTROL UNIT (SRS-ECU)

WARNING
The SRS may not activate if the SRS-ECU is not
CENTER
REINFORCEMENT installed properly, which could result in serious injury
or death to the vehicle's driver and front passenger.
SRS-ECU
1. Check the SRS-ECU case for dents, cracks, deformation or
rust.
2. Check the connector for damage, and check the terminals
for deformation or rust.
D-26 (Y),
Replace the SRS-ECU if it fails the visual checks above
C-121 (Y),
D-27 (Y) (Refer to GROUP 52B, SRS Air Bag Control Unit
P.52B-234).
SRS-ECU
24DB066A
AIR BAG MODULE, STEERING WHEEL AND

CLOCK SPRING
WARNING
• The removed air bag module should be stored in a
clean, dry place with the pad cover face up.
• Replace any visually inspected part if it fails the
following inspection.
1. Remove the air bag module, steering wheel and clock
spring.
(Refer to GROUP 52B, Air Bag Module and Clock Spring
P.52B-237).
2. Check the pad cover for dents, cracks or deformation.
00-54 GENERAL
MAINTENANCE SERVICE
<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
6. Check the clock spring connectors and protective tube for

damage, and terminals for deformities.
CASE 7. Visually check the case for damage.
WARNING
If the clock spring's mating mark is not properly
aligned, the steering wheel may not completely rotate
during turn, or the flat cable within the clock spring
may be severed, obstructing normal operation of the
PROTECTIVE TUBE SRS and possibly lead to serious injury to the vehi-
AC306766AB
cle's driver and front passenger.
8. Align the mating marks of the clock spring first. After turning
the front wheels to the straight-ahead position, install the
clock spring to the column.
Mating Marks Alignment;
After turning the clock spring fully clockwise, turn it
approximately 3 3/4 turns counterclockwise until the mating
marks are aligned.
MATING MARK
AC307538AB
9. Install the steering column covers, steering wheel and air

bag module (Refer to GROUP 52B, Air Bag Module and
Clock Spring P.52B-237).
10.Check the steering wheel for noise, binding or difficult
operation.
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).
FRONT SEATBACK ASSEMBLY WITH

SIDE-AIRBAG MODULE
WARNING
• If any improper part is found during the following
inspection, replace the front seatback assembly
with a new one.
• Dispose of the old one according to the specified
procedure (Refer to GROUP 52B, Air Bag Module
Disposal Procedures P.52B-254).
• Never attempt to measure the circuit resistance of
the air bag module (squib) even if you are using
the specified tester. If the circuit resistance is mea-
sured with a tester, accidental air bag deployment
will result in serious personal injury.
1. Check the air bag module deployment section for dents or
deformation.
AIR BAG MODULE 2. Check the connector for damage; Check the terminals for
DEPLOYMENT
deformation; and check the harness for binding.
SECTION
Replace the front seat if it fails the visual checks above
(Refer to GROUP 52A, Front Seat P.52A-33).
AC206854 AB
SEAT BELT WITH PRE-TENSIONER

WARNING
• If the seat belt pre-tensioner is not installed
securely and correctly, the seat belt pre-tensioner
may not operate normally.
replace with a new seat belt pre-tensioner.
1. Check the seat belt pre-tensioner for dents or deformation.
2. Check that the seat belt pre-tensioner is installed correctly to
the vehicle body.
Replace the seat belt pre-tensioner if it fails the visual
checks above (Refer to GROUP 52B, Seat Belt
Pre-tensioner P.52B-250).
00-56 GENERAL
MAINTENANCE SERVICE
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
AIR BAG MODULE DASH PANEL

CONNECTOR COMBINATION METER
<FRONT PASSENGER'S SIDE> CONNECTOR
DATE LINK
CONNECTOR
SRS-ECU
CONNECTOR
ENGINE ROOM STEERING COLUMN
FRONT IMPACT SENSOR FRONT IMPACT SENSOR AIR BAG MODULE CLOCK SPRING
CONNECTOR (RH) CONNECTOR (LH) CONNECTOR CONNECTOR
<DRIVER'S SIDE>
SIDE IMPACT SENSOR

CONNECTOR (RH)
FLOOR AND ROOF
SEAT BELT PRETENSIONER

CONNECTOR (RH)
SIDE AIR BAG MODULE

CONNECTOR (RH)
SIDE IMPACT SENSOR

CONNECTOR (LH)
SIDE AIR BAG MODULE SEAT BELT PRETENSIONER

CONNECTOR (LH) CONNECTOR (LH)
00DB074A
00-58 GENERAL
MAINTENANCE SERVICE
20. TYRES (ROTATE)

M1001008900303
Rotate tyres regularly to equalize tyre wear and help extend
tyre life. Recommended tyre rotation is every 12,000 km under
normal driving conditions and every 9,600 km in severe driving
conditions.
Timing for the rotation may vary according to vehicle condition,
road surface conditions, and individual driver's habits.
When rotating tyres, check for uneven wear, damage, and
wheel alignment. Abnormal wear is usually caused by incorrect
tyre pressure, improper wheel alignment, out-of balance
AC000120
wheels, or severe braking.
The first rotation is the most important, to achieve more uniform
wear for all tyres on the vehicle.
HOME
11-1
GROUP 11
ENGINE
CONTENTS
ENGINE MECHANICAL <3.8L ENGINE>. . . . . . . . . . . . . . . . . . 11A
ENGINE OVERHAUL <3.8L ENGINE>. . . . . . . . . . . . . . . . . . . . 11B

NOTES
HOME
11A-1
GROUP 11A
ENGINE
MECHANICAL
<3.8L ENGINE>
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 11A-2 OIL PAN AND OIL SCREEN . . . . . . . 11A-34

REMOVAL AND INSTALLATION . . . . . . . . 11A-34
ENGINE DIAGNOSIS. . . . . . . . . . . . . 11A-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-37
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-4 CRANKSHAFT OIL SEAL . . . . . . . . . 11A-38

REMOVAL AND INSTALLATION
ON-VEHICLE SERVICE. . . . . . . . . . . 11A-8 <FRONT OIL SEAL> . . . . . . . . . . . . . . . . . . 11A-38
DRIVE BELT TENSION CHECK AND REMOVAL AND INSTALLATION
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-8 <REAR OIL SEAL> . . . . . . . . . . . . . . . . . . . 11A-40
IGNITION TIMING CHECK . . . . . . . . . . . . . 11A-8
CURB IDLE SPEED CHECK . . . . . . . . . . . 11A-8 CYLINDER HEAD GASKET . . . . . . . . 11A-42
COMPRESSION PRESSURE CHECK. . . . 11A-10 REMOVAL AND INSTALLATION . . . . . . . . 11A-42
MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-11
LASH ADJUSTER CHECK . . . . . . . . . . . . . 11A-11 TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-46
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-14 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-51
SPECIFICATIONS . . . . . . . . . . . . . . . 11A-52
CAMSHAFT OIL SEAL . . . . . . . . . . . 11A-22 FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 11A-52
SERVICE SPECIFICATIONS . . . . . . . . . . . 11A-54
CAMSHAFT AND VALVE STEM SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 11A-54
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 11A-25
ENGINE MECHANICAL <3.8L ENGINE> 11A-2
GENERAL DESCRIPTION
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
TSB Revision
ENGINE DIAGNOSIS
ENGINE DIAGNOSIS
M1111000700273
SYMPTOMS PROBABLE CAUSE REMEDY

Compression is too Blown cylinder head gasket Replace the gasket.
low Worn or damaged piston rings Replace the rings.
Worn piston or cylinder Repair or replace the piston and/or the
cylinder block.
Worn or damaged valve seat Repair or replace the valve and/or the
seat ring
Drop in engine oil Engine oil level is too low Check the engine oil level.
pressure Malfunction of engine oil pressure switch Replace the engine oil pressure switch.
Clogged oil filter Install a new filter.
Worn oil pump gears or cover Replace the gears and/or the cover.
Thin or diluted engine oil Change the engine oil to the correct
viscosity.
Stuck (opened) oil relief valve Repair the relief valve.
Excessive bearing clearance Replace the bearings.
Engine oil pressure Stuck (closed) oil relief valve Repair the relief valve.
too high
Noisy valves Malfunction of lash adjuster (including Check the lash adjuster.
entry of air into high pressure chamber)
Thin or diluted engine oil (low engine oil Change the engine oil.
pressure)
Worn or damaged valve stem or valve Replace the valve and/or the guide.
guide
Connecting rod Insufficient oil supply Check the engine oil level.
noise/main bearing Thin or diluted engine oil Change the engine oil.
noise
Excessive bearing clearance Replace the bearings.
TSB Revision
SPECIAL TOOLS
SPECIAL TOOLS
M1111000600986
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991824-KIT • Drive belt tension check
A
Diagnostic Tool (MUT-III) NOTE: G: • Ignition timing check
A: MB991824 MB991826 • Curb idle speed check
Vehicle MUT-III Trigger • Idle mixture check
communication Harness is not • Erasing the diagnostic trouble
MB991824
interface (V.C.I.) necessary when code
B
B: MB991827 pushing V.C.I. CAUTION
MUT-III USB cable ENTER key. For vehicles with CAN
C: MB991910 communication, use MUT-III main
MUT-III main harness harness A to send simulated
MB991827
C
A (Vehicles with CAN vehicle speed. If you connect
communication MUT-III main harness B instead,
system) the CAN communication does
D: MB991911 not function correctly.
MUT-III main harness
MB991910
D
B (Vehicles without
CAN communication
system)
DO NOT USE
E: MB991914
MB991911
C (for Daimler
E Chrysler models only)
F: MB991825
DO NOT USE MUT-III measurement
adapter
MB991914 G: MB991826
F MUT-III trigger
harness
MB991825
MB991826
MB991958
MB991668 Tool not available Drive belt tension check [used

Belt tension meter set together with Diagnostic Tool
(MUT-III) ]
B991668
MB991800 MB991800-01 Holding the crankshaft pulley

Pulley holder
MB991800
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SPECIAL TOOLS

NAME
MB991802 MB991802-01 Holding the crankshaft pulley
Pin B
MB991802
MB990767 MB990767-01 Holding the camshaft sprocket

End yoke holder
B990767
MD998715 MIT308239 Holding the camshaft sprocket

Crankshaft pulley holder
pin
MD998443 MD998443-01 Holding the auto-lash adjuster

Auto-lash adjuster holder
D998443
MD998713 MD998713-01 Press-in of the camshaft oil seal

Camshaft oil seal
installer
D998713
MB991559 MB991559-01 Press-fitting the camshaft oil seal

Camshaft oil seal adapter (left bank side)
installer
B991559
MD998051 MD998051-01 or Cylinder head bolt removal and

Cylinder head bolt General service installation
wrench tool
MD998717 MD998717-01 Press-in of the crankshaft front oil

Crankshaft front oil seal seal
installer
MD998781 General service Securing the drive plate

Flywheel stopper tool
D998781
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SPECIAL TOOLS

NAME
MD998718 MD998718-01 Press-fitting the crankshaft rear oil
Crankshaft rear oil seal seal
installer
MD998767 MD998752-01 Timing belt tension adjustment

Tension pulley socket
wrench
D998767
MD998769 General service Rotating the crankshaft when

Crankshaft pulley spacer tool installing the timing belt
MD998772 General service Compressing valve spring

Valve spring compressor tool
AC204024
MD991999 MD998774-01 Valve stem seal installer

Valve stem seal installer
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SPECIAL TOOLS

NAME
MB991454 MZ203827-01 When the engine hanger is used:
Engine hanger balancer Supporting the engine assembly
during removal and installation of
the transaxle assembly
B991454
NOTE: Special tool MB991454 is a
MB991895 Tool not available part of engine hanger attachment
Engine hanger set MB991453.
MB991895
MB991928 Tool not available

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
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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.
IGNITION TIMING CHECK

M1111001701075

: Diagnostic Tool (MUT-III)
CAUTION
To prevent damage to Diagnostic Tool (MUT-III) always turn
DATA LINK the ignition switch to the "LOCK" (OFF) position before
CONNECTOR
connecting or disconnecting.
1. Connect Diagnostic Tool (MUT-III) to the data link connector.
2. Start the engine and run it at idle.
3. Check that the idle speed is approximately 680 to 750 r/min.
4. Select Diagnostic Tool (MUT-III) Data List for MPI and then
scroll to Item No.16 Advance Ignition.
MB991910
5. Check that Advance Ignition timing is alternating within a
suitable range. ie (Warm Engine, Idling + 1° to 5°).
MB991824 The timing is controlled by the ENGINE-ECU and can not be
changed.
6. If the Advance Ignition timing is not alternating within a
suitable range, check the following items:
• Diagnostic output
• Timing belt cover and crankshaft position sensor installation
conditions
• Crankshaft sensing blade condition
MB991827 00DB076A
CURB IDLE SPEED CHECK

M1111003501044

1. Before inspection, set the vehicle in the following condition:
• Engine coolant temperature: 80 − 95°C (176 − 203°F)
• Transmission: P range.
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ON-VEHICLE SERVICE
CAUTION
To prevent damage to Diagnostic Tool (MUT-III) , always
CONNECTOR
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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ON-VEHICLE SERVICE
COMPRESSION PRESSURE CHECK

M1111002601112

1. Before inspection, check that the engine oil, starter and
battery are normal. Also, set the vehicle in the following
condition:
• Transmission: P range
2. Remove all of the ignition coils and spark plugs.
3. Disconnect the crankshaft position sensor connector.
NOTE: Doing this will prevent the engine control unit from
carrying out ignition and fuel injection.
WARNING
Keep your distance from the spark plug hole when
cranking. Oil, fuel, etc., may spray out from the spark
plug hole and may cause serious injury.
CRANKSHAFT 4. Cover the spark plug hole with a shop towel etc., during
POSITION SENSOR
CONNECTOR AK303010 AB
cranking. After the engine has been cranked, check for
foreign material adhering to the shop towel.
5. Set compression gauge to one of the spark plug holes.
COMPRESSION
GAUGE 6. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 200 r/min): 1,550
kPa (225 psi)
Minimum limit (at engine speed of 200 r/min): 1,110
kPa (161 psi)
7. Measure the compression pressure for all the cylinders, and
check that the pressure differences of the cylinders are
AKX00436AB
below the limit.
Limit: 98 kPa (14 psi)
8. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount of
engine oil through the spark plug hole, and repeat the
operations in steps 6 to 8.
(1) If the compression increases after oil is added, the cause
of the malfunction is a worn or damaged piston ring
and/or cylinder inner surface.
(2) If the compression does not rise after oil is added, the
cause is a burnt or defective valve seat, or pressure is
leaking from the gasket.
9. Connect the crankshaft position sensor connector.
10.Install the spark plugs and ignition coils.
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ON-VEHICLE SERVICE
11.Use the Diagnostic Tool (MUT-III) to erase the diagnostic

DATA LINK trouble codes.
CONNECTOR
NOTE: This will erase the diagnostic trouble code resulting
from the crankshaft position sensor connector being discon-
nected.
MB991910
MB991824
MB991827 00DB076A
MANIFOLD VACUUM CHECK

M1111002700848
1. Start the engine and allow it to warm up until the
temperature of the engine coolant reaches 80 − 95°C (176 −
203°F).
2. Connect an engine tachometer.
3. Disconnect the ventilation hose from the positive crankcase
ventilation (PCV) valve, and connect a vacuum gauge to the
VACUUM ventilation hose.
GAUGE
4. Plug the PCV valve.
5. Start the engine and check that idle speed is within
specification. Then check the vacuum gauge reading.
VENTILATION HOSE
Idle speed: 680 ± 100 r/min
PLUG
Minimum limit: 60 kPa (18 in Hg)
POSITIVE CRANKCASE
VENTILATION VALVE AK301335AB
LASH ADJUSTER CHECK

M1111002900400
If an abnormal noise (chattering noise) suspected to be caused
by malfunction of the lash adjuster is produced immediately
after starting the engine and does not disappear, perform the
following check.
NOTE: An abnormal noise due to malfunction of the lash
adjuster is produced immediately after starting the engine and
changes with the engine speed, irrespective of the engine load.
If, the abnormal noise is not produced immediately after start-
ing the engine or does not change with the engine speed, or it
changes with the engine load, the lash adjuster is not the cause
for the abnormal noise.
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ON-VEHICLE SERVICE
NOTE: When the lash adjuster is malfunctioning, the abnormal

noise is rarely eliminated by continuing the warming-up of the
engine at idle speed.
However, the abnormal noise may disappear only when seizure
is caused by oil sludge in the engine whose oil is not main-
tained properly.
2. Check if the abnormal noise produced immediately after
starting the engine, changes with the change in the engine
speed.
If the abnormal noise is not produced immediately after
starting the engine or it does not change with the engine
speed, the lash adjuster is not the cause for the noise.
Therefore, investigate other causes. The abnormal noise is
probably caused by some other parts than the engine proper
if it does not change with the engine speed. (In this case, the
lash adjuster is in good condition.)
3. With the engine idling, change the engine load (shift from N
to D range, for example) to make sure that there is no
change in the level of abnormal noise.
If there is a change in the level of abnormal noise, suspect a
tapping noise due to worn crankshaft bearing or connecting
rod bearing (In this case, the lash adjuster is in good
condition.).
4. After completion of warm-up, run the engine at idle to check
for abnormal noise.
If the noise is reduced or disappears, clean the lash adjuster
(Refer to GROUP 11B, Engine Overhaul − Rocker Arms
and Camshaft − Inspection P.11B-23). As it is suspected
that the noise is due to seizure of the lash adjuster. If there is
no change in the level of the abnormal noise, proceed to
step 5.
5. Run the engine to bleed the lash adjuster system (Refer to
P.11A-11.).
6. If the abnormal noise does not disappear after air bleeding
operation, clean the lash adjuster (Refer to GROUP 11B,
Engine Overhaul − Rocker Arms and Camshaft − Inspection
P.11B-23).
.
Bleeding lash adjuster system

NOTE: Parking the vehicle on a grade for a long time may
decrease oil in the lash adjuster, causing air to enter the high
pressure chamber when starting the engine.
NOTE: After parking for many hours, oil may run out from the
oil passage and take time before oil is supplied to the lash
adjuster, causing air to enter the high pressure chamber.
NOTE: In the above cases, abnormal noise can be eliminated
by bleeding the lash adjuster system.
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ON-VEHICLE SERVICE
1. Check engine oil and add or change oil if required.

NOTE: If the engine oil level is low, air is sucked from the oil
screen, causing air to enter the oil passage.
NOTE: If the engine oil level is higher than specification, oil
GOOD
may be stirred by the crankshaft, causing oil to be mixed
with a large quantity of air.
MAXIMUM
NOTE: If oil is deteriorated, air is not easily separated from
oil, increasing the quantity of air contained in oil.
MINIMUM
AKX00328AB
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 ASSEMBLY
ENGINE ASSEMBLY
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 ASSEMBLY
3.0 ± 0.5 N·m

27 ± 4 in-lb
9.0 ± 2.0 N·m

80 ± 17 in-lb
(ENGINE OIL) 2
6 9.0 ± 2.0 N·m

80 ± 17 in-lb 01DB040AB
REMOVAL STEPS REMOVAL STEPS (Continued)

1. ENGINE COVER • DRIVE SHAFT (REFER TO
2. CONTROL WIRING HARNESS GROUP 26, DRIVE SHAFT
CONNECTION ASSEMBLY P.26-13.)
4. PURGE HOSE CONNECTION <> • EXHAUST MANIFOLD (RH)
<<A>> >>C<< 5. FUEL HIGH-PRESSURE HOSE (REFER TO GROUP 15,
CONNECTION EXHAUST MANIFOLD P.15-10.)
6. HEATER HOSE CONNECTION
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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
9.0 ± 2.0 N·m

80 ± 17 in-lb 36 ± 6 N·m
27 ± 4 ft-lb
14
15
9
108 ± 10 N·m*
80 ± 9 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

• MB991454: Engine Hanger Balancer • MB991928: Engine Hanger
• MB991895: Engine Hanger
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ENGINE ASSEMBLY
REMOVAL SERVICE POINTS

.
<<A>> FUEL HIGH-PRESSURE HOSE REMOVAL

1. Remove the fuel high-pressure hose stopper.
STOPPER
AC304581AB
2. Remove the fuel high-pressure hose in the direction shown

in the figure while the retainer is pulled up.
NOTE: If the retainer is released, install it after removing the
fuel high-pressure hose.
RETAINER
AC304582AB
<> EXHAUST MANIFOLD (RH) REMOVAL

Remove the center exhaust pipe, and pull out the exhaust man-
ifold (RH) between the crossmember and cylinder block.
.
<<C>> A/C COMPRESSOR ASSEMBLY REMOVAL

Remove the compressor from the compressor bracket with the
hose still attached.
NOTE: Place the removed A/C compressor where it will not be
a hindrance when removing and installing the engine assembly,
and secure it with a cord or wire.
.
<<D>> POWER STEERING OIL PUMP REMOVAL

Remove the power steering oil pump from the engine with the
hose attached.
NOTE: Place the removed power steering oil pump in a place
where it will not be a hindrance when removing and installing
the engine assembly, and secure it with a cord or wire.
.
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ENGINE ASSEMBLY
<<E>> RADIATOR REMOVAL

1. Assemble the front end structure bar removed temporarily
FRONT END and hang the condenser assembly with a cord.
STRUCTURE BAR
AC306135AB
<<F>> TRANSAXLE ASSEMBLY REMOVAL

Remove the transaxle assembly. (Refer to GROUP 23A, Tran-
saxle assembly <F4A5A>P.23A-304 ).
.
<<G>> ENGINE FRONT MOUNTING BRACKET

REMOVAL
1. Support the engine with a garage jack.
MB991895
2. <Engine hanger MB991895 is used>
Remove special tool MB991895.
MB991454
AC306215AB
MB991928 3. <Engine hanger MB991928 is used>

Remove special tool MB991928.
MB991454
AC306217AB
4. Hold the engine assembly with a chain block, etc.

MB991454 5. Place a garage jack against the engine oil pan with a piece
of wood in between so that the weight of the engine and
transaxle assembly is no longer being applied to the engine
mount.
6. Loosen the engine mount mounting nuts and bolts, and
remove the engine mount.
AC306687AB
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ENGINE ASSEMBLY
<<H>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring harness con-
nectors and so on are disconnected from the engine, lift the
chain block slowly to remove the engine assembly upward from
the engine compartment.
INSTALLATION SERVICE POINTS

.
>>A<< ENGINE ASSEMBLY INSTALLATION

Install the engine assembly, being careful not to pinch the
MB991454 cables, hoses or wiring harness connectors.
AC306687AB
>>B<< ENGINE FRONT MOUNTING BRACKET

INSTALLATION
1. Place a garage jack against the engine oil pan with a piece
of wood in between, and install the engine mount while
adjusting the position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
<RH> <LH> 4. <Engine hanger MB991895 is used>
A B (1) Set special tool MB991895 to the front fender assembling
bolts (A and B) and (C and D) as shown.
C D
AC306197AB
MB991895
(2) Set special tool MB991454 to hold the engine assembly.
MB991454
AC306215AB
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ENGINE ASSEMBLY
5. <Engine hanger MB991928 is used>

SLIDE BRACKET (HI)
(1) Assemble special tool MB991928. (Set following parts to
the base hanger.)
FOOT • SLIDE BRACKET (HI)
(STANDARD) • FOOT (STANDARD) (MB991932)
(MB991932) • JOINT (50) (MB991929)
JOINT (50) • JOINT (140) (MB991931)
(MB991929)
FOOT
JOINT (140) (STANDARD)
(MB991931) (MB991932)
AC306216AB
<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 ASSEMBLY
>>C<< FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
FUEL After connecting the fuel high-pressure hose, slightly pull
HIGH-PRESSURE 3 mm it to ensure that it is installed securely. Also confirm that
HOSE (0.12 in) there is a play approximately 3 mm (0.12 inch). Then install
the stopper securely.
Apply a small amount of engine oil to the fuel line pipe and then
install the fuel high-pressure hose.
FUEL LINE PIPE

(ENGINE OIL APPLIED)
AC301864AB
STOPPER
AC304583AB
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CAMSHAFT OIL SEAL
CAMSHAFT OIL SEAL

M1112002200170
Pre-removal and Post-installation Operation

Timing Belt Removal and Installation (Refer to P.11A-46.)
4N
3
88 ± 10 N·m
65 ± 7 ft-lb
1 2N
AC205540AB

<<A>> >>B<< 1. LEFT BANK CAMSHAFT <<A>> >>B<< 3. RIGHT BANK CAMSHAFT
SPROCKET SPROCKET
<> >>A<< 2. CAMSHAFT OIL SEAL <> >>A<< 4. CAMSHAFT OIL SEAL

• MB990767: End Yoke Holder • MD998713: Camshaft Oil Seal Installer
• MB991559: Camshaft Oil Seal Adapter Installer • MD998715: Crankshaft Pulley Holder Pin

.
<<A>> CAMSHAFT SPROCKET REMOVAL

Use special tools MD998715 and MB990767 to remove the
camshaft sprocket.
MB990767
MD998715
ACX00301AB
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CAMSHAFT OIL SEAL
<> CAMSHAFT OIL SEAL REMOVAL

1. Make a notch in the oil seal lip section with a knife, etc.
CAUTION
Be careful not to damage the camshaft and the cylinder
head.
2. Cover the end of a flat-tipped screwdriver with a shop towel
OIL SEAL
and insert into the notched section of the oil seal, and pry
LIP out the oil seal to remove it.
SECTION
FLAT-TIPPED
CAMSHAFT SCREWDRIVER
ACX00373AB

.
>>A<< CAMSHAFT OIL SEAL INSTALLATION

1. Apply engine oil to the camshaft oil seal lip.
2. Use special tools MD998713 and MB991559 to press-fit the
<LEFT BANK>
camshaft oil seal.
MD998713 MB991559
ACX00371AB
<RIGHT BANK>
MD998713
ACX00372 AB
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CAMSHAFT OIL SEAL
>>B<< CAMSHAFT SPROCKET INSTALLATION

1. Use special tools MD998715 and MB990767 in the same
way as during removal to install the camshaft sprocket.
MB990767
2. Tighten the camshaft sprocket mounting bolt to the specified
torque.
MD998715
ACX00301AB
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CAMSHAFT AND VALVE STEM SEAL

M1112006600299
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
<LEFT BANK>
3 10 ± 2 N·m
89 ± 17 in-lb
16 3.5 ± 0.5 N·m

6 31 ± 4 in-lb
CAM SECTION AND 4 11 ± 1 N·m
JOURNAL SECTION 98 ± 8 in-lb
5
ENGINE OIL
1 12 11
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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CAMSHAFT REMOVAL STEPS VALVE STEM SEAL REMOVAL

13. CAMSHAFT POSITION SENSOR STEPS (Continued)
SUPPORT 6. ROCKER COVER
14. CAMSHAFT POSITION SENSING 7. ROCKER COVER GASKET
CYLINDER 8. SPARK PLUG GUIDE OIL SEAL
<> >>F<< 15. CAMSHAFT SPROCKET <<A>> >>D<< 9. ROCKER ARM, SHAFT AND
16. CAMSHAFT LASH ADJUSTER ASSEMBLY
<<C>> >>E<< 17. CAMSHAFT OIL SEAL (INTAKE SIDE)
VALVE STEM SEAL REMOVAL <<A>> >>D<< 10. ROCKER ARM, SHAFT AND
STEPS LASH ADJUSTER ASSEMBLY
• ENGINE COVER (REFER TO (EXHAUST SIDE)
P.11A-14.) • SPARK PLUG (REFER TO
1. PCV HOSE CONNECTION GROUP 16, IGNITION COIL
2. PCV VALVE P.16-33.)
3. IGNITION COIL CONNECTOR <<D>> >>C<< 18. VALVE SPRING RETAINER LOCK
4. IGNITION COIL 19. VALVE SPRING RETAINER
5. ENGINE CONTROL WIRING >>B<< 20. VALVE SPRING
HARNESS CLAMP >>A<< 21. VALVE STEM SEAL
22. VALVE SPRING SEAT
• MB990767: End Yoke Holder • MD998715: Crankshaft Pulley Holder Pin
• MD998443: Auto-lash Adjuster Holder • MD998772: Valve Spring Compressor
• MB991559: Camshaft Oil Seal Adapter Installer • MD991999: Valve Stem Seal Installer
• MD998713: Camshaft Oil Seal Installer
TSB Revision
<RIGHT BANK>
4
10 ± 2 N·m
11
89 ± 17 in-lb
2
13 12
CAM SECTION AND
1 3 JOURNAL SECTION CYLINDER HEAD
3.5 ± 0.5 N·m ENGINE OIL

31 ± 4 in-lb
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
CAMSHAFT REMOVAL STEPS CAMSHAFT REMOVAL STEPS

• INTAKE MANIFOLD PLENUM <<A>> >>D<< 8. ROCKER ARM, SHAFT AND
(REFER TO GROUP 15, INTAKE LASH ADJUSTER ASSEMBLY
MANIFOLD PLENUM P.15-5.) (INTAKE SIDE)
• TIMING BELT (REFER TO <<A>> >>D<< 9. ROCKER ARM, SHAFT AND
P.11A-46.) LASH ADJUSTER ASSEMBLY
• BATTERY AND BATTERY TRAY (EXHAUST SIDE)
<> >>F<< 10. CAMSHAFT SPROCKET
• HEATER HOSE AND WATER
HOSE (REFER TO GROUP 14, 11. THRUST CASE
WATER HOSE AND WATER PIPE 12. O-RING
13. CAMSHAFT
P.14-40.)
<<C>> >>E<< 14. CAMSHAFT OIL SEAL
1. BREATHER HOSE CONNECTION
2. BLOW-BY HOSE CONNECTION
3. IGNITION COIL CONNECTOR
4. IGNITION COIL
5. ROCKER COVER
6. ROCKER COVER GASKET
7. SPARK PLUG GUIDE OIL SEAL
TSB Revision
VALVE STEM SEAL REMOVAL VALVE STEM SEAL REMOVAL

STEPS STEPS (Continued)
• INTAKE MANIFOLD PLENUM <<A>> >>D<< 8. ROCKER ARM, SHAFT AND
(REFER TO GROUP 15, INTAKE LASH ADJUSTER ASSEMBLY
MANIFOLD PLENUM P.15-5.) (INTAKE SIDE)
• TIMING BELT FRONT UPPER <<A>> >>D<< 9. ROCKER ARM, SHAFT AND
COVER, RIGHT (REFER TO LASH ADJUSTER ASSEMBLY
P.11A-46.) (EXHAUST SIDE)
1. BREATHER HOSE CONNECTION • SPARK PLUG (REFER TO
2. BLOW-BY HOSE CONNECTION GROUP 16, IGNITION COIL
3. IGNITION COIL CONNECTOR P.16-33.)
4. IGNITION COIL <<D>> >>C<< 15. VALVE SPRING RETAINER LOCK
5. ROCKER COVER 16. VALVE SPRING RETAINER
6. ROCKER COVER GASKET >>B<< 17. VALVE SPRING
7. SPARK PLUG GUIDE OIL SEAL >>A<< 18. VALVE STEM SEAL

• MB990767: End Yoke Holder • MD998715: Crankshaft Pulley Holder Pin
• MD998443: Auto-lash Adjuster Holder • MD998772: Valve Spring Compressor
• MB991559: Camshaft Oil Seal Adapter Installer • MD991999: Valve Stem Seal Installer
• MD998713: Camshaft Oil Seal Installer

.
<<A>> ROCKER ARM AND SHAFT ASSEMBLY

REMOVAL
1. Install special tool MD998443 as shown in the illustration so
that the lash adjusters will not fall out.
MD998443
CAUTION
Never disassemble the rocker arm and shaft assembly.
2. Loosen the rocker arm and shaft assembly mounting bolt,
and then remove the rocker arm and shaft assembly with the
bolt still attached.
AC205280AB
<> CAMSHAFT SPROCKET REMOVAL

camshaft sprocket.
MB990767
MD998715
ACX00301AB
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<<C>> CAMSHAFT OIL SEAL REMOVAL

1. Make a notch in the oil seal lip section with a knife, etc.
CAUTION
Be careful not to damage the camshaft and the cylinder
head.
2. Cover the end of a flat-tipped screwdriver with a shop towel
OIL SEAL
and insert into the notched section of the oil seal, and pry
LIP out the oil seal to remove it.
SECTION
FLAT-TIPPED
CAMSHAFT SCREWDRIVER
ACX00373AB
<<D>> VALVE SPRING RETAINER LOCK

REMOVAL
CAUTION
When removing valve spring retainer locks, leave the pis-
ton of each cylinder in the TDC (Top Dead Center) position.
The valve may fall into the cylinder if the piston is not
properly in the TDC position.
<LEFT BANK> Use special tool MD998772 to compress the valve spring, and
remove the valve spring retainer locks.
MD998772
AC205277AB
<RIGHT BANK>
MD998772
AC205278AB
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INSTALLATION POSITION
EXHAUST SIDE
RIGHTBANK
FRONT INTAKE SIDE
LEFTBANK EXHAUST SIDE AC204067AC
NOTE: Installation position of valve spring compressor special

tool (MD998772) is different between exhaust side and intake
side.
.
>>A<< VALVE STEM SEAL INSTALLATION

1. Apply a small amount of engine oil to the valve stem seal.
CAUTION
• Valve stem seals cannot be reused.
• Special tool MD991999 must be used to install the valve
stem seal. Improper installation could result in oil leak-
ing past the valve guide.
2. Use special tool MD991999 to fill a new valve stem seal in
MD991999 the valve guide using the valve stem area as a guide.
VALVE
VALVE
STEM
SEAL
VALVE
GUIDE
01DB052A
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>>B<< VALVE SPRING INSTALLATION

Install the valve spring with its identification color painted end
ROCKER ARM SIDE
facing the locker arm.
IDENTIFICATION
COLOR
AC107415AB
>>C<< VALVE SPRING RETAINER LOCK

INSTALLATION
<LEFT BANK> Use special tool MD998772 to compress the valve spring in the
same manner as removal.
MD998772
AC205277AB
<RIGHT BANK>
MD998772
AC205278AB
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>>D<< ROCKER ARM AND SHAFT ASSEMBLY

INSTALLATION
1. Install the rocker arm, shaft and lash adjuster assembly.
2. Tighten the mounting bolts to the specified torque.
MD998443
3. Remove special tool MD998443.
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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>>E<< CAMSHAFT OIL SEAL INSTALLATION

1. Apply engine oil to the camshaft oil seal lip.
2. Use special tools MD998713 and MB991559 to press-fit the
<LEFT BANK>
camshaft oil seal.
MD998713 MB991559
ACX00371AB
<RIGHT BANK>
MD998713
ACX00372 AB
>>F<< CAMSHAFT SPROCKET INSTALLATION

MB990767
torque.
MD998715
ACX00301AB
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OIL PAN AND OIL SCREEN

M1112002500193

• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-13.)
• Engine Oil Draining and Refilling (Refer to GROUP 12,
On-vehicle Service P.12-3.)
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
8.5 ± 3.5 N·m

76 ± 31 in-lb 3
39 ± 5 N·m 8
29 ± 3 ft-lb 9 4
1
N 2 35 ± 5 N·m 30 ± 3 N·m
11 ± 0.5 N·m 26 ± 4 ft-lb 23 ± 2 ft-lb
7 93 ± 4 in-lb
49 ± 3 N·m
11 ± 1 N·m
97 ± 9 in-lb 36 ± 2 ft-lb AC308673 AB

1. ENGINE OIL PAN DRAIN PLUG • FRONT NO.1 EXHAUST PIPE
2. ENGINE OIL PAN DRAIN PLUG (REFER TO GROUP 15,
GASKET EXHAUST PIPE AND MAIN
3. STARTER CONNECTOR MUFFLER P.15-14)
4. STARTER ASSEMBLY 8. COVER
5. ENGINE OIL DIPSTICK <> 9. TORQUE CONVERTER
ASSEMBLY CONNECTING BOLT
6. O-RING <<C>> >>A<< 10. ENGINE UPPER OIL PAN
<<A>> >>B<< 7. ENGINE LOWER OIL PAN 11. OIL SCREEN
12. GASKET
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REMOVAL SERVICE POINT

.
<<A>> ENGINE LOWER OIL PAN REMOVAL

1. Remove the engine lower oil pan mounting bolts.
CAUTION
Do not use oil pan remover special tool (MD998727). The
engine upper oil pan is made of aluminum and this tool will
damage it.
2. Apply a piece of wood to the lower oil pan and strike it with a
hammer to remove the engine lower oil pan.
LOWER OIL PAN

AC206414AB
<> TORQUE CONVERTER CONNECTING

BOLT REMOVAL
Remove the one torque converter connecting bolt as shown.
49 ± 3 N·m
36 ± 2 ft-lb
AC206538 AB
<<C>> ENGINE UPPER OIL PAN REMOVAL

1. Remove the engine upper oil pan mounting bolts.
CAUTION
Do not use oil pan remover special tool (MD998727). The
engine upper oil pan is made of aluminum and this tool will
damage it.
2. Screw in the bolt (M10) into bolt hole A in the location
shown. Then lift the upper oil pan and remove it.
AC206525 AB
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.
>>A<< ENGINE UPPER OIL PAN INSTALLATION

1. Remove sealant from the oil pan and cylinder block mating
surfaces.
2. Degrease the sealant-coated surface and the engine mating
surface.
3. Apply a bead of the sealant to the cylinder block mating
surface of the engine oil pan as shown.
Specified sealant: 3M™ AAD Part No.8672, 8704, 3M™
AAD Part No.8679/8678 or equivalent
NOTE: The sealant should be applied in a continuous bead
Ø 4.0 mm approximately 4.0 mm (0.16 inch) in diameter.
(0.16 in) 4. Assemble the oil pan to the cylinder block within 15 minutes
GROOVE BOLT HOLE after applying the sealant.
PORTION PORTION CAUTION
AC308675 AB
The bolt holes for bolts 13 and 14 in the illustration are cut
away on the transaxle side. Be careful not to insert these
bolts at an angle.
5. Tighten the bolts in order of the numbers shown in the
12 8 4 1 5 9 illustration.
17 13
16 14
11 7 3 2 6 10 15
CYLINDER BLOCK REAR OIL SEAL CASE
OIL PAN TRANSAXLE

SIDE
13, 14 AC206507 AB
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>>B<< ENGINE LOWER OIL PAN INSTALLATION

1. Remove sealant from the engine lower oil pan and engine
upper oil pan.
2. Apply a bead of the sealant to the mating surface of the
engine lower oil pan as shown.
Specified sealant: 3M™ AAD Part No.8672, 8704, 3M™
AAD Part No.8679/8678 or equivalent
NOTE: Install the engine lower oil pan within 15 minutes
after applying sealant.
Ø 4.0 mm 3. Assemble the engine lower oil pan to the engine upper oil
(0.16 in) pan.
GROOVE BOLT HOLE
PORTION PORTION AC205271AB CAUTION
Then wait at least one hour. Never start the engine or let
engine oil or coolant touch the sealant surface during that
time.
4. Tighten the bolts in order of the numbers shown in the
2 illustration.
6 4
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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CRANKSHAFT OIL SEAL
CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION <FRONT OIL SEAL>
M1112003400478

Timing Belt Removal and Installation (Refer to P.11A-46.)
ENGINE OIL
1 5
8.5 ± 0.5 N·m
76 ± 4 in-lb
2
6N
4
3
AC205520 AB

1. CRANKSHAFT POSITION >>B<< 4. CRANKSHAFT SPACER
SENSOR 5. KEY
>>B<< 2. CRANKSHAFT SPROCKET >>A<< 6. CRANKSHAFT FRONT OIL SEAL
>>B<< 3. CRANKSHAFT SENSING BLADE

MD998717: Crankshaft Front Oil Seal Installer
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CRANKSHAFT OIL SEAL

.
>>A<< CRANKSHAFT FRONT OIL SEAL INSTAL-

LATION
1. Apply a small amount of engine oil to the oil seal lip and then
insert.
2. Using special tool MD998717, tap the oil seal into the front
CRANKSHAFT
case.
MD998717
MD998717
OIL SEAL ACX00363AB
>>B<< CRANKSHAFT SPACER / CRANKSHAFT

SENSING BLADE / CRANKSHAFT SPROCKET
INSTALLATION
CRANKSHAFT To prevent the crankshaft pulley mounting bolt from loosening,
SENSING BLADE CRANKSHAFT
SPACER degrease or clean the crankshaft, the crankshaft spacer, the
crankshaft sensing blade and the crankshaft at the shown posi-
tions.
CLEANING
CRANKSHAFT
SPROCKET CRANKSHAFT
SHADED PART : DEGREASE ACX01536AB
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CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION <REAR OIL SEAL>

M1112003700446

Transaxle Assembly Removal and Installation (Refer to
GROUP 23A, Transaxle <F4A4B>P.23A-304 ,
<F4A5A>P.23A-304 .)
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

<<A>> >>B<< 1. DRIVE PLATE BOLTS 5. FLYWHEEL ASSEMBLY
2. FLYWHEEL BOLTS 6. ADAPTOR PLATE (M/T)
3. ADAPTOR PLATE >>A<< 7. CRANKSHAFT REAR OIL SEAL
4. DRIVE PLATE

• MD998718: Crankshaft Rear Oil Seal Installer • MD998781: Flywheel Stopper
TSB Revision
CRANKSHAFT OIL SEAL

.
<<A>> DRIVE PLATE BOLTS REMOVAL

Use special tool MD998781 to secure the drive plate and
remove the drive plate bolts.
MD998781
AC306686AB

.
>>A<< CRANKSHAFT REAR OIL SEAL INSTAL-

LATION
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Use special tool MD998718 to tap in the oil seal as shown in
the illustration.
MD998718
ACX00356AB
>>B<< DRIVE PLATE BOLTS INSTALLATION

Use special tool MD998781 in the same way as during removal
to install the drive plate bolts.
MD998781
AC306686AB
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CYLINDER HEAD GASKET

M1112004000804

• Intake Manifold Removal and Installation (Refer to
GROUP 15, Intake Manifold P.15-7.)
• Exhaust Manifold Removal and Installation (Refer to
GROUP 15, Exhaust Manifold P.15-10.)
• Timing Belt Removal and Installation (Refer to P.11A-46.)
• Thermostat Housing Removal and Installation (Refer to
GROUP 14, Water Hose and Water Pipe P.14-40.)
• Generator Removal and Installation (Refer to GROUP 16,
Generator Assembly P.16-14.)
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

1. BLOW-BY HOSE CONNECTION 5. IGNITION COIL
2. PCV HOSE CONNECTION 6. ENGINE CONTROL WIRING
3. PCV VALVE HARNESS CLAMP
4. IGNITION COIL CONNECTOR 7. ROCKER COVER
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REMOVAL STEPS (Continued) REMOVAL STEPS (Continued)

9. CAMSHAFT POSITION SENSOR • POWER STEERING OIL PUMP
CONNECTOR ASSEMBLY (REFER TO GROUP
10. GROUNDING 37, POWER STEERING OIL
• ENGINE OIL DIPSTICK PUMP ASSEMBLY P.37-43.)
ASSEMBLY 15. POWER STEERING OIL PUMP
<<A>> >>C<< 11. CAMSHAFT SPROCKET BRACKET BOLT
12. TIMING BELT REAR CENTER 16. IGNITION COIL CONNECTOR
COVER 17. IGNITION COIL
<> >>B<< 13. LEFT BANK CYLINDER HEAD 18. BREATHER HOSE CONNECTION
ASSEMBLY 19. BLOW-BY HOSE CONNECTION
14. CYLINDER HEAD GASKET 20. ROCKER COVER
<> >>B<< 22. RIGHT BANK CYLINDER HEAD
ASSEMBLY
>>A<< 23. CYLINDER HEAD GASKET
• MD998051: Cylinder Head Bolt Wrench
• MB990767: End Yoke Holder
• MD998715: Crankshaft Pulley Holder Pin

.
<<A>> CAMSHAFT SPROCKET REMOVAL

camshaft sprocket.
MB990767
MD998715
ACX00301AB
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<> CYLINDER HEAD ASSEMBLY REMOVAL

Use special tool MD998051 to loosen each bolt two or three
steps in the order shown in the illustration.
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

.
>>A<< CYLINDER HEAD GASKET INSTALLATION

1. Degrease the cylinder head and cylinder block gasket
mounting surfaces.
2. Make sure that the gasket has the proper identification mark
IDENTIFICATION MARK for the engine.
3. Lay the cylinder head gasket on the cylinder block with the
identification mark at the front top.
ACX00349AB
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>>B<< CYLINDER HEAD ASSEMBLY

INSTALLATION
CAUTION
Be careful that no foreign material gets into the cylinder,
coolant passages or oil passages. Engine damage may
result.
1. Use a scraper to clean the gasket surface of the cylinder
head assembly.
CAUTION
Install the head bolt washers with the beveled side facing
upwards as shown in the illustration and sequence below.
2. Using special tool MD998051 and a torque wrench, tighten
CYLINDER
HEAD BOLT
the bolts to the specified torque in the order shown in the
WASHER illustration.
Tightening torque: 108 ± 5 N⋅m (80 ± 3 ft-lb) → 0 N⋅m (0
in-lb) → 108 ± 5 N⋅m (80 ± 3 ft-lb)
3. Loosen all bolts in the order shown in the illustration.
Loosen: 0 N⋅m (0 in-lb)
MD998051 4. Re-tighten all bolts in the order shown in the illustration.
Tightening torque: 108 ± 5 N⋅m (80 ± 3 ft-lb)⋅
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
>>C<< CAMSHAFT SPROCKET INSTALLATION

MB990767
torque.
MD998715
ACX00301AB
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11A-46 ENGINE MECHANICAL <3.8L ENGINE>
TIMING BELT
TIMING BELT
M1112004300775

• Engine Cover Removal and Installation (Refer to
P.11A-14.)
51, Under Cover P.51-13.)
• Side Under Cover Removal and Installation (Refer to
GROUP 51, Under Cover P.51-13.)
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

1. GENERATOR DRIVE BELT 8. ENGINE MOUNT STAY
2. POWER STEERING OIL PUMP 9. TIMING BELT FRONT UPPER
DRIVE BELT COVER, RIGHT
<<A>> >>C<< 3. CRANKSHAFT PULLEY 10. TIMING BELT FRONT UPPER
4. CONTROL WIRING HARNESS COVER, LEFT
AND INJECTOR WIRING 11. TENSIONER PULLEY
HARNESS COMBINATION 12. TENSIONER BRACKET
CONNECTOR 13. CRANKSHAFT POSITION
5. KNOCK SENSOR CONNECTOR SENSOR HARNESS CLAMP
6. CRANKSHAFT POSITION 14. TIMING BELT LOWER COVER
SENSOR CONNECTOR
7. CONNECTOR BRACKET
TSB Revision
TIMING BELT
REMOVAL STEPS (Continued)

• ENGINE FRONT MOUNTING
BRACKET (REFER TO GROUP
32, ENGINE MOUNTING P.32-4.)
15. ENGINE SUPPORT BRACKET
<> >>B<< 16. TIMING BELT
>>A<< 17. AUTO-TENSIONER
18. TENSIONER PULLEY
19. TENSIONER ARM
20. SHAFT
• MB991800: Pulley Holder • MD998767: Tension Pulley Socket Wrench
• MB991802: Pin B • MD998769: Crankshaft Pulley Spacer

.
<<A>> CRANKSHAFT PULLEY REMOVAL

CAUTION
Use only the specified special tools, or a damaged pulley
damper could result.
Use special tools MB991800 and MB991802 to remove the
MB991800 crankshaft pulley from the crankshaft.
MB991802
ACX01675AB
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TIMING BELT
<> TIMING BELT REMOVAL

CAUTION
Never turn the crankshaft counterclockwise.
CAMSHAFT CAMSHAFT
SPROCKET SPROCKET 1. Turn the crankshaft clockwise to align each timing mark and
(RIGHT BANK) (LEFT BANK) to set the number 1 cylinder to compression top dead center.
TIMING MARK
2. If the timing belt is to be reused, chalk an arrow on the flat
side of the belt, indicating the clockwise direction.
3. Loosen the center bolt of the tensioner pulley, then remove
the timing belt.
CENTER
BOLT
TENSION
PULLEY
TIMING MARK
AC206490AB

.
>>A<< AUTO-TENSIONER INSTALLATION

1. If the auto-tensioner rod remains fully extended, set
according to the following procedure.
CAUTION
Place the auto-tensioner perpendicular to the jaws of the
DOLLY BLOCKS vice.
(1) Place two dolly blocks in a vice as shown in the
illustration, and then place the auto-tensioner in the vice.
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
TIMING BELT
CAUTION
Do not remove the setting pin from the auto-tensioner.
(4) Install the auto-tensioner to the engine.
.
>>B<< TIMING BELT INSTALLATION

1. Align the timing marks on the camshaft sprockets with those
CAMSHAFT CAMSHAFT
SPROCKET SPROCKET on the rocker cover and the timing mark on the crankshaft
(RIGHT BANK) (LEFT BANK) sprocket with that on the engine block as shown in the
TIMING MARK illustration.
CAUTION
The camshaft sprocket (right bank) can turn easily due to
the spring force applied, so be careful not to get your fin-
gers caught.
2. Install the timing belt by the following procedure so that
there is no deflection in the timing belt between each
sprocket and pulley.
CENTER
BOLT (1) Crankshaft sprocket
(2) Idler pulley
(3) Camshaft sprocket (Left bank)
(4) Water pump pulley
(5) Camshaft sprocket (Right bank)
TENSION (6) Tensioner pulley
PULLEY 3. Turn the camshaft sprocket (Right bank) counterclockwise
TIMING MARK until the tension side of the timing belt is firmly stretched.
AC206490AC Check all the timing marks again.
4. Use special tool MD998767 to push the tensioner pulley into
the timing belt, then temporarily tighten the center bolt.
MD998767
AC205274AB
5. Use special tool MD998769 to turn the crankshaft 1/4 turn

TIMING MARK counterclockwise, then turn it again clockwise until the
timing marks are aligned.
MD998769
AC205275AB
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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
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
9. Wait for at least five minutes, then check that the

A auto-tensioner pushrod extends within the standard value
range.
Standard value (A): 4.8 − 6.0 mm (0.19 − 0.24 inch)
10.If not, repeat the operation in steps 1 to 8 above.
11.Check again that the timing marks of the sprockets are
aligned.
AC206419AB
>>C<< CRANKSHAFT PULLEY INSTALLATION

Use special tools MB991800 and MB991802 to install the
MB991800 crankshaft pulley.
MB991802
ACX01675AB
TSB Revision
TIMING BELT
INSPECTION
M1112004400437
AUTO-TENSIONER ADJUSTER CHECK

1. Check for oil leak from seal, and replace it if leak is detected.
SPRING PUSHROD 2. Check for wear or damage at the top of the rod. Replace it, if
required.
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
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
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)
Cylinder head gasket

Cylinder head bolt <Cold engine> 108 ± 5 N⋅m (80 ± 3 ft-lb) → 0
N⋅m (0 in-lb) → 108 ± 5 N⋅m (80
± 3 ft-lb)
Grounding connecting bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Power steering oil pump bracket connecting bolt 41 ± 8 N⋅m (30 ± 6 ft-lb)
Timing belt rear center cover bolt 14 ± 1 N⋅m (120 ± 13 in-lb)
Engine assembly
Engine cover bolt 3.0 ± 0.5 N⋅m (27 ± 4 in-lb)
Engine front mounting insulator 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 front mounting stay bolt 36 ± 6 N⋅m (27 ± 4 ft-lb)
Grounding bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Grounding cable bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Power steering oil pump bolt 46 ± 8 N⋅m (34 ± 6 ft-lb)
Power steering oil pump nut 42 ± 7 N⋅m (31 ± 5 ft-lb)
TSB Revision
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
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1111000300747
ITEM STANDARD VALUE LIMIT

Drive belt tension Vibration frequency Hz 87 − 119 −
(Reference)
Tension N (Reference) 226 − 422 −
Basic ignition timing at idle ECU controlled −
CO contents % 0.5 or less −
HC contents ppm 100 or less −
Curb idle speed r/min 680 ± 100 −
Compression pressure (200 r/min) kPa (psi) 1,550 (225) Minimum 1,110
(161)
Compression pressure difference of all cylinder kPa (psi) − 98 (14)
Intake manifold vacuum at curb idle kPa (in Hg) − Minimum 60 (18)
Auto-tensioner pushrod movement mm (in) Within 1.0 (0.04) −
Timing belt tension torque N⋅m (in-lb) 4.4 (39) −
Auto tensioner rod protrusion amount mm (in) 4.8 − 6.0 (0.19 − 0.24) −
SEALANTS
M1111000500365
ITEM SPECIFIED SEALANT

Engine oil pan 3M™ AAD Part No.8672, 8704, 3M™ AAD Part No.8679/8678 or
equivalent
TSB Revision
HOME
11B-1
GROUP 11B
ENGINE OVERHAUL
<3.8L ENGINE>
CONTENTS
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-2 ROCKER ARMS AND CAMSHAFT . . 11B-23

REMOVAL AND INSTALLATION . . . . . . . . 11B-23
ALTERNATOR AND DRIVE BELT . . 11B-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-26
CYLINDER HEAD AND VALVES. . . . 11B-29
INTAKE MANIFOLD PLENUM AND REMOVAL AND INSTALLATION . . . . . . . . 11B-29
THROTTLE BODY ASSEMBLY . . . . 11B-6 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-34
OIL PAN AND OIL PUMP. . . . . . . . . . 11B-37
IGNITION SYSTEM . . . . . . . . . . . . . . 11B-8 REMOVAL AND INSTALLATION . . . . . . . . 11B-37
REMOVAL AND INSTALLATION . . . . . . . . 11B-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-43
TIMING BELT. . . . . . . . . . . . . . . . . . . 11B-10 PISTON AND CONNECTING ROD . . 11B-44

REMOVAL AND INSTALLATION . . . . . . . . 11B-10 REMOVAL AND INSTALLATION . . . . . . . . 11B-44
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11B-15 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-51
INTAKE MANIFOLD AND FUEL CRANKSHAFT AND CYLINDER

PARTS . . . . . . . . . . . . . . . . . . . . . . . . 11B-17 BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11B-53
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-57
WATER PUMP & WATER HOSE . . . 11B-19
REMOVAL AND INSTALLATION . . . . . . . . 11B-19 SPECIFICATIONS . . . . . . . . . . . . . . . 11B-59
FASTENER TIGHTENING
EXHAUST MANIFOLD. . . . . . . . . . . . 11B-21 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 11B-59
REMOVAL AND INSTALLATION . . . . . . . . 11B-21 GENERAL SPECIFICATIONS . . . . . . . . . . 11B-62
SERVICE SPECIFICATIONS . . . . . . . . . . . 11B-63
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 11B-65
ENGINE OVERHAUL <3.8L ENGINE> 11B-2
SPECIAL TOOLS
SPECIAL TOOLS
M1113000600603

NAME
MD998781 General service tool Loosening and tightening
Flywheel stopper crankshaft bolts
D998781
MB990767 MB990767-01 Holding camshaft sprocket when

End yoke holder loosening or torquing bolt.
B990767
MD998715 MIT308239
Pin
MD998769 General service tool Rotation of crankshaft when

Crankshaft spacer installing piston and timing belt
MD998767 MD998752-01 Adjustment of timing belt tension

Tensioner wrench
D998767
MD998443 MD998443-01 Supporting of the lash adjuster to

Lash adjuster holder prevent it from falling when rocker
(8) shaft assembly is removed or
installed
D998443
MD998713 MD998713-01 Installation of camshaft oil seal

Camshaft oil seal
installer
D998713
MB991559 MB991559-01 Installation of camshaft oil seal

Camshaft oil seal (left bank)
installer adaptor (use with MD998713)
B991559
MD998442 General service tool Air bleeding of auto lash adjuster

Air bleed wire
SPECIAL TOOLS

NAME
MD998051 General service tool Loosening and tightening cylinder
Cylinder head bolt head bolts
wrench
MD998735 MD998735-01 Compression of valve spring

Valve spring
compressor
MD998772 MLR-MD998772 or Compression of valve spring

Valve spring General service tool
compressor
MB991999 General service tool Installation of valve stem seal

Valve stem seal
installer
MD998717 MD998717-01 Installation of crankshaft front oil

Crankshaft front oil seal
seal installer
MD998054 General service tool or Removal and installation of engine

Oil pressure switch MD998054-01 oil pressure switch
wrench
MD998718 MD998718-01 Installation of crankshaft rear oil

Crankshaft rear oil seal seal
installer
ALTERNATOR AND DRIVE BELT

M1113001300230
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

1. IDLER PULLEY <<A>> >>A<< 8. CRANKSHAFT BOLT
2. ADJUSTING BOLT 9. CRANKSHAFT PULLEY WASHER
3. ADJUSTING STUD 10. DAMPER PULLEY
4. TENSIONER BRACKET 11. ALTERNATOR
5. POWER STEERING PUMP 12. ALTERNATOR BRACKET
BRACKET 13. OIL DIPSTICK
6. POWER STEERING PUMP 14. O-RING
BRACKET STAY 15. OIL DIPSTICK GUIDE
7. DRIVE BELT TENSIONER 16. O-RING

• MD998781: Flywheel Stopper

.
<<A>> CRANKSHAFT BOLT LOOSENING

1. Using special tool MD998781, hold the drive plate.
2. Remove the crankshaft bolt.
MD998781
AKX01329 AB
INSTALLATION SERVICE POINT

.
>>A<< CRANKSHAFT BOLT TIGHTENING

MD998781
AKX01329 AB
2. Clean the bolt hole in crankshaft bolt, damper pulley seating

DAMPER PULLEY
surface and the washer.
CRANKSHAFT CRANKSHAFT
BOLT 3. Degrease the cleaned seating surface of the damper pulley.
WASHER CLEAN 4. Install the damper pulley.
5. Apply a minimum amount engine oil to the thread and lower
flange of the crankshaft bolt.
6. Install the washer to the crankshaft bolt with its inside
chamfered side toward the bolt head.
INSIDE CHAMFER DEGREASE
AK204086 AB
7. Tighten the crankshaft bolt to the specified torque.
INTAKE MANIFOLD PLENUM AND THROTTLE BODY ASSEMBLY
INTAKE MANIFOLD PLENUM AND THROTTLE BODY

ASSEMBLY
M1113003300173
5.0 ± 1.0 N·m

44 ± 9 in-lb
9.0 ± 1.0 N·m
8 80 ± 9 in-lb
7 6
18 ± 2 N·m
13 ± 1 ft-lb
4 1
9
28 ± 4 N·m
21 ± 3 ft-lb
3
18 ± 2 N·m
13 ± 1 ft-lb
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

1. PURGE HOSE 6 THROTTLE BODY
>>C<< 2. PURGE VALVE ASSY >>B<< 7 THROTTLE BODY GASKET
6. INTAKE MANIFOLD PLENUM STAY, >>A<< 8 BOOST SENSOR
FRONT 9 INTAKE MANIFOLD PLENUM
4. INTAKE MANIFOLD PLENUM STAY, 10 INTAKE MANIFOLD PLENUM VALVE
REAR GASKET
5 THROTTLE BODY STAY
INTAKE MANIFOLD PLENUM AND THROTTLE BODY ASSEMBLY

.
>>A<< BOOST SENSOR INSTALLATION

CAUTION
• Do not strike or drop to the sensor.
• Never use a sensor that has been dropped.
.
>>B<< THROTTLE BODY GASKET

INSTALLATION
Install the throttle body gasket so that the tab is positioned as
shown in the illustration.
PROJECTION
03DB188A
>>C<< PURGE VALVE INSTALLATION

Install the purge valve and secure with bolt in correct orienta-
tion. Align white mark on purge hose facing upward.
WHITE MARK
CHAMBER
SOLENOID VALVE
01DB051A
IGNITION SYSTEM
IGNITION SYSTEM
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

1. IGNITION COIL >>B<< 5. CAMSHAFT POSITION SENSOR
2. SPARK PLUGS SUPPORT
3. CAMSHAFT POSITION SENSOR <<A>> >>A<< 6. CAMSHAFT POSITION SENSING
4. O-RING CYLINDER

• MD998781: Flywheel Stopper
IGNITION SYSTEM

.
<<A>> CAMSHAFT POSITION SENSING

CYLINDER REMOVAL
2. Loosen the camshaft position sensing cylinder bolt.
MD998781
AKX01329 AB

.
>>A<< CAMSHAFT POSITION SENSING

CYLINDER INSTALLATION
2. Tighten the camshaft position sensing cylinder bolt to the
specified torque.
MD998781
AKX01329 AB
>>B<< CAMSHAFT POSITION SENSOR SUPPORT

INSTALLATION
Apply a 3 mm (0.12 inch) diameter bead of sealant Mitsubishi
Genuine Part number MD970389 or equivalent to the camshaft
position sensor support.
AK000008
TIMING BELT
TIMING BELT
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

1. TIMING BELT FRONT UPPER 10. SHAFT
COVER, RIGHT 11. IDLER PULLEY
2. TIMING BELT FRONT UPPER 12. TENSIONER BRACKET
COVER, LEFT 13. ADJUSTING BOLT
3. TIMING BELT FRONT LOWER 14. ADJUSTING STUD
COVER >>B<< 15. CRANKSHAFT SPROCKET
>>E<< 4. ENGINE SUPPORT BRACKET, >>B<< 16. CRANKSHAFT SPACER
RIGHT >>B<< 17. CRANKSHAFT SENSING BLADE
5. CRANKSHAFT POSITION SENSOR 18. KEY
<<A>> >>D<< 6. TIMING BELT <> >>A<< 19. CAMSHAFT SPROCKET
>>C<< 7. AUTO-TENSIONER 20. BRACKET
8. TENSIONER PULLEY 21. TIMING BELT REAR COVER
9. TENSIONER ARM
TIMING BELT

• MB990767: End Yoke Holder • MD998767: Tensioner Pulley Wrench
• MD998715: Pins • MD998769: Crankshaft Spacer

.
<<A>> TIMING BELT REMOVAL

CAUTION
Water or oil on the belt shortens its life drastically, so the
removed timing belt, sprocket, and tensioner must be kept
free from oil and water. These parts should not be washed
or immersed in solvent. Replace parts if contaminated. If
there is oil or water on any part, check the front case oil
seal, camshaft oil seal, and water pump for leaks.
1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner pulley bolt, and then remove the timing
belt.
AK302434
<> CAMSHAFT SPROCKET REMOVAL

1. While holding the camshaft sprocket with special tools
MD998715 MB990767 and MD998715, loosen the camshaft sprocket
bolt.
2. Remove the camshaft sprocket.
MB990767
AK302435AB

.
>>A<< CAMSHAFT SPROCKET INSTALLATION

1. Fit the camshaft sprocket to the front end of the camshaft.
2. While holding the camshaft sprocket with special tools
MB990767 and MD998715, tighten the camshaft sprocket
MD998715
bolt.
MB990767
AK302436AB
.
TIMING BELT
>>B<< CRANKSHAFT SENSING

BLADE/CRANKSHAFT SPACER/CRANKSHAFT
SPROCKET INSTALLATION
1. Clean the hole in the crankshaft sprocket.
CRANKSHAFT SENSING BLADE
CRANKSHAFT
2. Clean and degrease the mating surfaces of the crankshaft
CRANKSHAFT
SPROCKET SPACER sprocket, sensing blade, and spacer.
CRANKSHAFT
NOTE: Degreasing is necessary to prevent decrease in fric-
tion on the mating surfaces.
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
>>C<< AUTO-TENSIONER INSTALLATION

B
If the auto-tensioner rod is fully extended, reset it as follows:
A
1. Clamp the auto-tensioner in the vise with soft jaws.
2. Push in the rod little by little with the vise until set hole A in
the rod is aligned with hole B in the cylinder.
3. Insert a wire [1.4 mm (0.055 inch) in diameter] into the set
holes. This auto-tensioner setting wire will be used during
timing belt alignment.
4. Unclamp the auto-tensioner from the vise.
AK204321AB
>>D<< TIMING BELT INSTALLATION

CAUTION
Do not turn the camshaft when the piston in No.1 cylinder
TIMING MARK is at top dead center on the compression stroke. Doing so
can cause the lifted valve to hit against the piston, damag-
ing parts.
1. Install special tool MD998769 and the crankshaft pulley
washer, and then tighten the crankshaft bolt.
2. Align the timing mark on the crankshaft sprocket with the
CRANKSHAFT timing mark on the oil pump case, and then rotate the
SPROCKET sprocket three teeth counterclockwise.
MD998769 AKX00632AB
TIMING BELT
3. Align the timing mark on the left bank camshaft sprocket

RIGHT TIMING MARKS LEFT
BANK BANK with the timing mark on the rocker cover.
4. Align the timing mark on the right bank camshaft sprocket
with the timing mark on the rocker cover.
CAMSHAFT SPROCKET
AKX00640AB
5. Align the timing mark on the crankshaft sprocket with the

TIMING MARK
timing mark on the oil pump case.
6. Install the timing belt on each sprocket and pulley in the
following sequence. Do not leave the belt slack between
each sprocket and pulley.
(1) Crankshaft sprocket
(2) Idler pulley
CRANKSHAFT
SPROCKET (3) Left bank camshaft sprocket
MD998769 (4) Water pump pulley
AKX00681AB
(5) Right bank camshaft sprocket
(6) Tensioner pulley
7. Install special tool MD998767 to the tensioner pulley. While
MD998767 pushing the pulley lightly against the belt using the special
tool, tighten the flange bolt.
AKX00654AB
TIMING BELT
RIGHT BANK LEFT BANK

TIMING MARK
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
10.Loosen the flange bolt securing the tensioner pulley, and

then mount special tool MD998767 and a torque wrench on
the tensioner pulley.
MD998767 11.Torque it to 4.4 N⋅m (39 in-lb) with the torque wrench.
12.While holding the tensioner pulley in position, tighten the
flange bolt to the specified torque.
13.Rotate the crankshaft two turns clockwise and leave it alone
AKX00655AB for approximately five minutes.
TIMING BELT
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.
.
>>E<< ENGINE SUPPORT BRACKET, RIGHT

INSTALLATION
The mounting bolts of the right engine support bracket must be
tightened in the order shown in the illustration.
Bolt length
85 mm (33.5 inch) − Bolt 3
1 95 mm (37.4 inch) − Bolt 2, 4
4 100 mm (39.4 inch) − Bolt 1
2
3
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
2. Cracks on rubber back.

CRACKS 3. Cracks or peeling of canvas.
4. Cracks on tooth bottom.
PEELING
5. Cracks on belt.
CRACKS
CRACKS
AKX00713AB
TIMING BELT
6. Abnormal wear of belt sides. Normal wear is indicated if the

sides are sharp as if cut by a knife. Abnormal wear is
ROUNDED EDGE indicated if the sides are ragged.
ABNORMAL WEAR
(RAGGED)
AKX00750AB
7. Abnormal wear on teeth.

Initial stage:
RUBBER EXPOSED Canvas worn (fluffy canvas fibers, rubbery texture
gone, white discoloration, canvas texture indistinct)
TOOTH MISSING AND Final stage:
CANVAS FIBER EXPOSED
Canvas worn, exposing rubber (tooth width reduced)
8. Missing tooth.
AKX00751AC
TENSIONER PULLEY AND IDLER PULLEY

Turn the pulley. If it does not rotate smoothly, or develops noise
or excessive play, replace the pulley.
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
INTAKE MANIFOLD AND FUEL PARTS
4. Press the rod with a force of 98 to 196 N (22 to 44 pounds)

98 TO 196 N
(22 TO 44 lb) and measure the movement of the rod.
MOVEMENT If the measured value is out of the standard value, replace
the auto-tensioner.
Standard value: 1.0 mm (0.03 inch) or less
AK204324 AB

M1113004300206
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

1. INJECTOR HARNESS 6. O-RING
2. INJECTOR AND FUEL RAIL 7. FUEL RAIL
3. INSULATOR 8. CONED DISC SPRING
4. INSULATOR >>A<< 9. INTAKE MANIFOLD
>>B<< 5. INJECTOR 10. INTAKE MANIFOLD GASKET

.
>>A<< INTAKE MANIFOLD INSTALLATION

1. Tighten the nuts "R" to 6.4 ± 1.5 N⋅m (57 ± 13 in-lb).
TIMING NUT "R"
BELT SIDE 2. Tighten the nuts "L" to the specified torque.
Tightening torque: 20 − 23 N⋅m (15 − 17 ft-lb)
3. Tighten the nuts "R" to the specified torque.
4. Tighten the nuts "L" to the specified torque.
NUT "L" 5. Tighten the nuts "R" to the specified torque.
AKX00680AB
.
>>B<< INJECTOR INSTALLATION

CAUTION
Use care not to let engine oil enter the fuel rail.
1. Apply clean engine oil to the O-ring.
2. Insert the injector into the fuel rail.
3. Make sure the injector rotates smoothly. If not, remove the
injector to check the O-ring for damage, and replace the
O-ring if necessary. Then reinsert the injector and check that
it rotates smoothly.
FUEL RAIL
INJECTOR AK302905AB
4. Confirm the protrusion of injector is at center. If not, rotate

FUEL RAIL
the injector for protrusion to be center.
INJECTOR
AK302906AB
WATER PUMP & WATER HOSE

M1113017900286
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)

1. WATER HOSE >>B<< 7. THERMOSTAT HOUSING GASKET
2. WATER HOSE >>A<< 8. O-RING
>>D<< 3. ENGINE COOLANT TEMPERATURE >>A<< 9. WATER INLET PIPE
SENSOR >>A<< 10. O-RING
4. WATER INLET FITTING 11. WATER PUMP
>>C<< 5. THERMOSTAT 12. WATER PUMP GASKET
6. THERMOSTAT HOUSING

.
>>A<< O-RING AND WATER INLET PIPE INSTAL-

LATION
CAUTION
Keep the O-ring free of oil or grease.
O-RING 1. Attach a new O-ring to each end of the water inlet pipe.
2. Wet the O-ring with water.
3. Insert the front end of the pipe into the water pump.
WATER INLET
PIPE AKX00711AB
>>B<< THERMOSTAT HOUSING GASKET

INSTALLATION
Install the thermostat housing gasket so that the tab is posi-
tioned as shown in the illustration.
TAB
AK302907AB
>>C<< THERMOSTAT INSTALLATION

1. Check that the rubber ring is free from damage and seated
JIGGLE VALVE correctly in the thermostat flange.
2. Install the thermostat as shown in the illustration. The jiggle
valve must be at the top position.
AKX00670AB
.
EXHAUST MANIFOLD
>>D<< SEALANT APPLICATION TO ENGINE

COOLANT TEMPERATURE SENSOR
Apply 3M™ AAD Part number 8731 or equivalent to the engine
coolant temperature sensor.
AKX00686
EXHAUST MANIFOLD
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
EXHAUST MANIFOLD

1. RIGHT BANK HEATED OXYGEN 10. LEFT BANK HEATED OXYGEN
SENSOR (FRONT) SENSOR (REAR)
2. RIGHT BANK HEATED OXYGEN 11. CONNECTOR BRACKET
SENSOR (REAR) 12. HEAT PROTECTOR, LEFT
3. HEAT PROTECTOR, RIGHT >>A<< 13. EXHAUST MANIFOLD STAY, LEFT
>>B<< 4. EXHAUST MANIFOLD STAY, RIGHT "B"
"B" 14. EXHAUST MANIFOLD STAY, LEFT
5. EXHAUST MANIFOLD STAY, RIGHT "A"
"A" 15. EXHAUST MANIFOLD, LEFT
7. EXHAUST MANIFOLD, RIGHT 16. EXHAUST MANIFOLD GASKET
8. EXHAUST MANIFOLD GASKET 17. ENGINE HANGER
9. LEFT BANK HEATED OXYGEN
SENSOR (FRONT)

.
>>A<< EXHAUST MANIFOLD STAY, LEFT "B"

INSTALLATION
1. Tighten temporarily the left "B" of exhaust manifold stay
EXHAUST MANIFOLD together with the exhaust manifold and the left "A" of
STAY LEFT "B" exhaust manifold stay.
2. Tighten the bolt on the exhaust manifold side to the
specified torque.
TIGHTENING TORQUE: 44 ± 8 N⋅m (33 ± 5 ft-lb)
3. Tighten the bolt on the left "A" side of exhaust manifold stay
to the specified torque.
01DB046A
EXHAUST MANIFOLD
STAY LEFT "B"
01DB047A
.
ROCKER ARMS AND CAMSHAFT
>>B<< EXHAUST MANIFOLD STAY, RIGHT "B"

INSTALLATION
1. Tighten temporarily the right "B" of exhaust manifold stay
together with the exhaust manifold and the right "A" of
EXHAUST MANIFOLD
exhaust manifold stay.
STAY RIGHT "B" 2. Tighten the bolt on the exhaust manifold side to the
specified torque.
3. Tighten the bolt on the right "A" side of exhaust manifold
stay to the specified torque.
AK302908

M1113005400585
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

1. BREATHER HOSE <<A>> >>C<< 13. ROCKER ARMS AND SHAFT
2. BLOW-BY HOSE <<A>> >>C<< 14. ROCKER ARMS AND SHAFT
3. POSITIVE CRANKCASE 15. ROCKER ARM A
VENTILATION HOSE 16. ROCKER ARM B
4. POSITIVE CRANKCASE 17. ROCKER ARM SHAFT
VENTILATION VALVE >>B<< 18. LASH ADJUSTER
5. OIL FILLER CAP 19. ROCKER ARM C
6. ROCKER COVER, LEFT 20. ROCKER ARM SHAFT
7. ROCKER COVER GASKET >>B<< 21. LASH ADJUSTER
8. ROCKER COVER, RIGHT 22. THRUST CASE
9. ROCKER COVER GASKET 23. O-RING
10. OIL SEAL >>A<< 24. CAMSHAFT, RIGHT
>>D<< 11. CAMSHAFT OIL SEAL >>A<< 25. CAMSHAFT, LEFT
12. ROCKER SHAFT CAP

• MB991559: Camshaft Oil Seal Installer Adapter • MD998443: Lash Adjuster Holder
• MD998442: Air Bleed Wire • MD998713: Camshaft Oil Seal Installer
.
<<A>> ROCKER ARMS AND SHAFT REMOVAL

CAUTION
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to lash adjuster inspection P.11B-26.)
MD998443 Set special tool MD998443 to prevent the lash adjuster from
coming free and falling to the floor.
AKX00613AB

.
>>A<< CAMSHAFT INSTALLATION

CAUTION
Use care to prevent confusion of the right and left bank
TIMING BELT SIDE
camshafts.
CAMSHAFT, RIGHT 1. Apply engine oil to the camshaft journals and cams and then
install the camshafts.
NOTE: The camshaft with a longer overall length is for the
left bank.
CAMSHAFT, LEFT
AK204034AB
2. Check to see that the dowel pin of the camshaft is located at

RIGHT BANK LEFT BANK
the position shown.
APPROXI- APPROXI-
MATELY MATELY
60˚ 71˚
AK204035AB
>>B<< LASH ADJUSTER INSTALLATION

CAUTION
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to lash adjuster inspection P.11B-26.)
Fit the lash adjuster onto the rocker arm without allowing diesel
fuel to spill out. Fit special tool MD998443 to prevent the lash
adjuster coming from free and falling to the floor.
MD998443
LASH
ADJUSTER
AKX00715AB
>>C<< ROCKER ARMS AND SHAFT

INSTALLATION
1. Position the end with the larger chamfer at the right on the
TIMING BELT SIDE front bank, and at the left on the rear bank.
NOTE: The side with the four bolt holes is on the intake side.
2. Position the side with the oil holes on the lower side
CHAMFERED (cylinder head side).
OIL HOLE
AK202325 AC
.
>>D<< CAMSHAFT OIL SEAL INSTALLATION

Use special tools MD998713 and MB991559 to install the cam-
<RIGHT BANK SIDE>
shaft oil seal.
MD998713
AKX00615AB
<LEFT BANK SIDE>
MD998713
MB991559
AKX00639AB
INSPECTION
M1113005500463
.
ROCKER ARM SHAFT

Check the rocker arm mounting areas of the rocker arm shafts
for wear or damage. Replace as necessary.
.
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.
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.
4. Remove the lash adjuster from the container. Then, push

down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
MD998442
DIESEL FUEL AK202681AD

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.
5. Place the lash adjuster in container B. Then, gently push
down the internal steel ball using a wire [0.5 mm (0.020
inch) in diameter] or special tool MD998442 and move the
plunger through five to ten strokes until it slides smoothly.
DIESEL FUEL This operation will clean the lash adjuster's pressure
MD998442 chamber.
AK202680 AE
6. Remove the lash adjuster from the container. Then, push

down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
MD998442
DIESEL FUEL AK202681AD

CAUTION
Do not use container C for cleaning. If cleaning is per-
formed in container C, foreign matter could enter the pres-
sure chamber when the chamber is filled with diesel fuel.
7. Place the lash adjuster in container C. Then, gently push
down the internal steel ball using a wire [0.5 mm (0.020
inch) in diameter] or special tool 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.
MD998442 DIESEL FUEL
AK202683 AD
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.

M1113006900527
APPLY ENGINE OIL 1

TO ALL MOVING 5 108 ± 5 N·m
PARTS BEFORE 6 2 80 ± 4 ft-lb
→
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

<<A>> >>D<< 1. CYLINDER HEAD BOLT <> >>C<< 5. RETAINER LOCK
2. WASHER 6. VALVE SPRING RETAINER
3. CYLINDER HEAD ASSEMBLY >>B<< 7. VALVE SPRING
4. CYLINDER HEAD GASKET 8. INLET VALVE

<> >>C<< 9. RETAINER LOCK
10. VALVE SPRING RETAINER
>>B<< 11. VALVE SPRING
12. EXHAUST VALVE
>>A<< 13. VALVE STEM SEAL
>>A<< 15. VALVE STEM SEAL
17. INLET VALVE GUIDE
18. SNAP RING
19. EXHAUST VALVE GUIDE
20. INLET VALVE SEAT
21. EXHAUST VALVE SEAT
22. CYLINDER HEAD
• MB991999: Valve Stem Seal Installer • MD998735: Valve Spring Compressor
• MD998051: Cylinder Head Bolt Wrench • MD998772: Valve Spring Compressor

.
<<A>> CYLINDER HEAD BOLT REMOVAL

Use special tool MD998051 to loosen the cylinder head bolt.
MD998051
AK302682AB
.
<> RETAINER LOCK REMOVAL

1. Using special tool MD998735 or MD998772, compress the
MD998735 spring.
2. Remove the retainer locks.
NOTE: Tag removed valves, springs and other components,
noting their cylinder numbers and locations to facilitate reas-
sembly. Store these components safely.
AK100166AB
MD998772
AKX00617AB

.
>>A<< VALVE STEM SEAL INSTALLATION

1. Install the valve spring seat.
CAUTION
• Valve stem seals for intake valves and for exhaust
RUBBER COLOR: RUBBER COLOR: valves are different. Be sure to install the correct ones.
GRAY GRAY GREEN
• Valve stem seal identification color
Intake: GRAY
Exhaust: GRAY GREEN
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
>>B<< VALVE SPRING INSTALLATION

Install the valve spring end with its identification color toward
SPRING the spring retainer.
IDENTIFI- RETAINER
CATION
COLOR
STEM SEAL
SPRING SEAT
AKX00718 AB
.
>>C<< RETAINER LOCK INSTALLATION

Using special tool MD998735 or MD998772, compress the
MD998735 valve spring and insert the retainer lock into position.
NOTE: The valve spring, if excessively compressed, causes
the bottom end of retainer to damage the stem seal.
AK100166AB
MD998772
AKX00617AB
>>D<< CYLINDER HEAD BOLT INSTALLATION

CAUTION
Attach the head bolt washer in the direction shown in the
figure.
1. Tighten the bolts in the illustrated sequence two or three
steps.
2. Back off the bolts once and tighten them again to the
MD998051
specified torque in step1.
HEAD
BOLT
WASHER
FRONT
RIGHT
BANK
LEFT
BANK
AKX01452AB
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)
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:
AKX00624
.
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
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
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:
AKX00695AB
.
VALVE SEAT RECONDITIONING PROCEDURE

CAUTION
0.9 – 1.3 mm
Before correcting the valve seat, check the clearance
0.9 – 1.3 mm
(0.04 – 0.05 in) (0.04 – 0.05 in) between the valve guide and valve and, if necessary,
replace the valve guide.
65˚ 65˚
1. Using the special tool or a seat grinder, correct to obtain the
specified seat width and angle.
2. After correcting the valve seat, lap the valve and valve seat
15˚ 25˚ using lapping compound. Then, check the valve stem
projection.
43.5˚ – 44˚
AK101830AB
.
VALVE SEAT REPLACEMENT PROCEDURE

CAUTION
0.5 – 1 mm (0.020 – 0.039 in)
Before replacing the valve seat, check the valve guide and,
if necessary, replace the valve guide.
1. Cut the valve seat from the inside to thin the wall thickness.
Then, remove the valve seat.
CUT
AWAY
0.5 – 1 mm
(0.020 – 0.039 in)
AKX00610AB
2. Rebore the valve seat hole in the cylinder head to a selected

oversize valve seat diameter.
Seat ring hole diameter:
Intake valve
HEIGHT OF 0.3 oversize 37.80 − 37.83 mm (1.4882 − 1.4894
SEAT RING
inches)
0.6 oversize 38.10 − 38.13 mm (1.5000 − 1.5012
inches)
OVERSIZE DIAMETER
Exhaust valve
AKX00611AB 0.3 oversize 34.80 − 34.83 mm (1.3701 − 1.3713
inches)
0.6 oversize 35.10 − 35.13 mm (1.3819 − 1.3831
inches)
3. Before fitting the valve seat, either heat the cylinder head up
to approximately 250°C (482°F) or cool the valve seat in
liquid nitrogen, to prevent the cylinder head bore from
galling.
4. Using a valve seat cutter, correct the valve seat to the
specified width and angle. Using a valve seat cutter, correct
the valve seat to the specified width and angle. See "VALVE
SEAT RECONDITIONING PROCEDURE" on the previous
page.
.
VALVE GUIDE REPLACEMENT PROCEDURE

1. Remove the snap ring from the exhaust valve guide.
REMOVAL INSTALLATION
PRESS PRESS 2. Using a press, remove the valve guide toward the cylinder
head gasket surface.
PUSH ROD CAUTION
Do not install a valve guide of the same size again.
VALVE VALVE 3. Re-bore the valve guide hole of the cylinder head so that it
GUIDE GUIDE
fits the press-fitted oversize valve guide.
Valve guide hole diameter:
AKX00712AB 0.05 oversize 11.05 − 11.07 mm (0.4350 − 0.4358 inch)
0.25 oversize 11.25 − 11.27 mm (0.4429 − 0.4437 inch)
0.50 oversize 11.50 − 11.52 mm (0.4528 − 0.4535 inch)
4. Install the new snap ring into the groove of exhaust valve
guide.
OIL PAN AND OIL PUMP
5. Press-fit the valve guide until it protrudes 14 mm (0.55 inch)

from the cylinder head top surface as shown in the
illustration.
NOTE: When press-fitting the valve guide, work from the cylin-
der head top surface.
NOTE: After installing the valve guides, insert new valves in
14 mm
(0.55 in) them to check for sliding condition.
AKX00727AB

M1113008100420
APPLY ENGINE OIL

TO ALL MOVING
PARTS BEFORE
INSTALLATION.
18
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

1. DRAIN PLUG 13. OIL FILTER BRACKET GASKET
>>H<< 2. DRAIN PLUG GASKET 14. RELIEF PLUG
<<A>> >>G<< 3. OIL PAN, LOWER 15. RELIEF SPRING
4. COVER 16. RELIEF PLUNGER
<> >>F<< 5. OIL PAN, UPPER >>C<< 17. CRANKSHAFT FRONT OIL SEAL
6. OIL SCREEN >>B<< 18. OIL PUMP CASE ASSEMBLY
7. OIL SCREEN GASKET 19. O-RING
8. BAFFLE PLATE 20. OIL PUMP COVER
>>E<< 9. ENGINE OIL PRESSURE SWITCH <<C>> >>A<< 21 OIL PUMP OUTER ROTOR
10. OIL FILTER COVER <<C>> >>A<< 22. OIL PUMP INNER ROTOR
>>D<< 11. OIL FILTER 23. OIL PUMP CASE
12. OIL FILTER BRACKET
Required Special Tool

• MD998054: Oil Pressure Switch Socket Wrench • MD998717: Crankshaft Front Oil Seal Installer

.
<<A>> OIL PAN, LOWER REMOVAL

1. Remove the lower oil pan mounting bolts.
CAUTION
Do not use a scraper or special tool to remove the oil pan.
2. Remove the lower oil pan by tapping on its side with a
plastic hammer (mallet) through a wooden plank held
against it.
.
<> OIL PAN, UPPER REMOVAL

1. Remove the long bolts "A" shown in the illustration first.
2. Remove all other bolts.
CAUTION
Do not use a scraper or special tool to remove the oil pan.
"A" 3. Remove the oil pan.
AK304454AB
4. Screw M10 bolts into the two bolt holes in the oil pan to
break the joint and remove the oil pan.
AKX00658
.
<<C>> OUTER ROTOR/INNER ROTOR REMOVAL

Make alignment dots on the outer and inner rotors for ease of
ALIGNMENT DOTS reassembly.
AKX00742AB

.
>>A<< INNER ROTOR/OUTER ROTOR INSTALLA-

TION
Apply engine oil to the rotors. Then install the rotors, ensuring
ALIGNMENT DOTS that the alignment dots made at disassembly are properly
aligned.
AKX00742AB
>>B<< OIL PUMP CASE ASSEMBLY

INSTALLATION
1. Clean the gasket mating surfaces of oil pump case and
BOLT HOLE cylinder block.
2. Apply a 3 mm (0.1 inch) diameter bead of sealant
GROOVE
(Mitsubishi Genuine Parts number MD970389 or equivalent)
to the oil pump case.
Apply sealant as indicated by the broken line in the
illustration; the grooves must be traced and the bolt holes
must be surrounded with a bead of sealant.
3. Install the oil pump case assembly to the front of the cylinder
block.
NOTE: Be sure to install the oil pump case quickly while the
sealant is wet (within 15 minutes).
4. Tighten the oil pump case mounting bolts to the specified
torque.
Tightening torque: 14 ± 1 N⋅m (122 ± 9 in-lb)
NOTE: After installation, keep the sealed area away from oil
and coolant for approximately one hour.
AKX00674AB
.
>>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION
1. Install the guide of special tool MD998717 to the front end of
MD998717 (GUIDE) the crankshaft.
2. Apply engine oil to the lip area of a new oil seal and push it
in until it contacts the oil pump case.
OIL SEAL
AKX00659 AB
3. Using special tool MD998717, press-fit the oil seal into the
oil pump case.
MD998717
AKX00660AB
>>D<< OIL FILTER INSTALLATION

1. Clean the installation surface of the filter bracket.
BRACKET
SIDE 2. Apply engine oil to the O-ring of the oil filter.
3. Install the oil filter to the bracket and tighten it to the
specified torque.
4. If no torque wrench can be used for tightening, use the
following procedure.
(1) Screw in the oil filter until its O-ring contacts the oil filter
AKX00692AB bracket.
(2) Tighten the oil filter 1 turn.
.
>>E<< ENGINE OIL PRESSURE SWITCH

INSTALLATION
CAUTION
Be careful not to block the oil passage with sealant.
1. Apply 3M™ AAD Part number 8672 or equivalent to the
thread of engine oil pressure switch.
AKX00688
2. Tighten the engine oil pressure switch together with the oil
MD998054 filter bracket to the specified torque, using special tool
MD998054.
AK204037AB
>>F<< OIL PAN, UPPER INSTALLATION

1. Clean both gasket surfaces of the upper oil pan and cylinder
BOLT HOLE block.
GROOVE
2. Apply a 4 mm (0.2 inch) diameter bead of sealant
(Mitsubishi Genuine Parts number MD970389 or equivalent)
to the upper oil pan.
Apply sealant as indicated by the broken line in the
CAUTION
When installing the upper oil pan, be sure not to expel the
sealant from the oil pan flange at portion A in the illustra-
tion.
3. Install the oil pan to the bottom of the cylinder block.
NOTE: Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
A
AK304451AB
4. Tighten the upper oil pan bolts in the sequence shown.

12 8 4 1 5 9 Tightening torque: 9.0 ± 3.0 N⋅m (80 ± 26 in-lb)
17 NOTE: After installation, keep the sealed area away from
13
the oil and coolant for approximately one hour.
16 14
11 7 3 2 6 10 15
AK304450AB
.
>>G<< OIL PAN, LOWER INSTALLATION

1. Clean both gasket surfaces of the upper and lower oil pans.
BOLT HOLE 2. Apply a 4 mm (0.2 inch) diameter bead of sealant
GROOVE (Mitsubishi Genuine Parts number MD970389 or equivalent)
to the lower oil pan.
Apply sealant as indicted by the broken line in the
3. Install the lower oil pan to the upper oil pan.
NOTE: Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
AK302911AB
4. Tighten the lower oil pan bolts in the sequence shown.

2
6 4 Tightening torque: 11 ± 1 N⋅m (95 ± 9 in-lb)
NOTE: After installation, keep the sealed area away from oil
for approximately one hour.
8 7
3
5
1 AK204036AB
.
>>H<< DRAIN PLUG GASKET INSTALLATION

CAUTION
If the gasket is installed in the wrong direction, oil leaks
will occur.
Install the drain plug gasket in the direction shown.
DRAIN PLUG
GASKET OIL PAN
OIL PAN
SIDE
AKX00726AB
INSPECTION
M1113008200171
.
OIL PUMP
1. Check the tip clearance.
AKX00743
2. Check the side clearance.

AKX00744
PISTON AND CONNECTING ROD
3. Check the body clearance.

AKX00745

M1113008400636
APPLY ENGINE OIL

TO ALL MOVING
PARTS BEFORE 7 6
INSTALLATION.
12
8
11
10
9
13 4
14
3
2
27 ± 2 N·m + 90˚ TO 94˚

1 20 ± 1 ft-lb
AK201085 AC

>>G<< 1. CONNECTING ROD CAP NUT >>E<< 4. PISTON AND CONNECTING ROD
<<A>> >>F<< 2. CONNECTING ROD CAP ASSEMBLY
>>D<< 3. CONNECTING ROD BEARING, >>D<< 5. CONNECTING ROD BEARING,
LOWER UPPER

>>C<< 6. PISTON RING NO.1
>>C<< 7. PISTON RING NO.2
>>B<< 8. OIL RING
9. SNAP RING
<> >>A<< 10. PISTON PIN
11. SNAP RING
12. PISTON
13. CONNECTING ROD
14. BOLT

.
<<A>> CONNECTING ROD CAP REMOVAL

1. Mark the cylinder number on the side of the connecting rod
big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings in
CYLINDER order according to the cylinder number.
NUMBER
AKX00734AB
<> PISTON PIN REMOVAL

1. Remove the snap rings.
CAUTION
The clearance between the piston and the piston pin is a
tight fit at room temperature. Therefore, be sure to heat the
piston before pulling out the piston pin. Use care since the
piston is hot after heating.
2. Heat the piston approximately 70°C (158°F) and pull out the
piston pin.
70˚C
(158˚F)
AKX01397AB
11B-46 ENGINE OVERHAUL <3.8L ENGINE>

.
>>A<< PISTON PIN INSTALLATION

TIMING BELT SIDE 1. When replacing the piston, note the cylinder bore size mark
on the cylinder block as illustrated, and select a piston
LEFT BANK according to the following table.
No.2
RIGHT BANK
No.4 CYLINDER BORE SIZE PISTON SIZE MARK
CHECK DIGIT No.6 MARK
No.5 I A
CRANKSHAFT No.3
BORE SIZE No.1 II None
MARK
III C
AK200850AD
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
6. Check that the piston moves smoothly.
AKX00716
>>B<<OIL RING INSTALLATION

1. Fit the oil ring spacer into the piston ring groove.
NOTE: The side rails and spacer may be installed in either
SIDE RAIL
direction.
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.
.
>>C<< PISTON RING NO.2/PISTON RING NO.1

INSTALLATION
1. To prevent wrong installation, check the identification mark
IDENTIFICATION MARK of each piston ring. The identification mark is stamped near
IDENTIFICATION the ring gap.
MARK SIZE MARK
Identification mark
Number 1 ring: 1T
NO.1 Number 2 ring: 2T
NO.2 NOTE: Size marks on piston rings are as follows.
SIZE SIZE MARK
AKX00689AB Standard None
0.25 mm (0.010 in) oversize 25
diameter
0.50 mm (0.020 in) oversize 50
diameter
2. Using a piston ring expander, fit the number 2 piston ring

into the number 2 groove of piston.
NOTE: Install the piston rings with their identification mark
AKX00633
facing up, to the piston crown side.
3. Install the number 1 piston ring in the same manner as step
2.
.
>>D<< CONNECTING ROD BEARING

INSTALLATION
LOCATION OF IDENTIFICATION COLOR
1. Measure the crankshaft pin diameter and confirm its
NO.2 classification from the following table. In the case of a
NO.4
NO.1 crankshaft supplied as a service part, identification
colors/marks of its pins are painted/stamped at the positions
NO.3
NO.6
NO.5
AKX00634AB
CRANKSHAFT PIN OUTSIDE DIAMETER CONNECTING ROD BEARING

IDENTIFICATION COLOR SIZE mm (in) IDENTIFICATION IDENTIFICATION
MARK COLOR
Yellow 54.994 − 55.000 0 Pink
(2.1651 − 2.1654) 1 Red
2 Green
None 54.988 − 54.994 0 Red
(2.1649 − 2.1651) 1 Green
2 Black
White 54.982 − 54.988 0 Green
(2.1646 − 2.1649) 1 Black
2 Brown
2. From the above table, select a bearing whose size is
appropriate for the crankshaft pin outside the diameter.
For example, if the crankshaft pin outside diameter
Identification color is "yellow" and the connecting rod
Identification mark is "2," select a bearing whose
Identification color is "green."
If there is no identification color paint on the crankshaft,
measure the pin outside diameter and select bearing
IDENTIFICATION MARK appropriate for the measured value.
AK000449AB 3. Install the selected bearing in the big end and in the cap of
the connecting rod.
IDENTIFICATION
COLOR
AKX00635AB
>>E<< PISTON AND CONNECTING ROD

INSTALLATION
1. Liberally coat the circumference of the piston, piston ring,
UPPER NO.1 and oil ring with engine oil.
SIDE RAIL
2. Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the illustration.
PISTON PIN 3. Rotate the crankshaft so that the crank pin is on the center
TIMING
BELT SIDE of the cylinder bore.
LOWER
NO.2 RING GAP SIDE RAIL
AND SPACER GAP
AKX00620AB
4. Insert the piston and connecting rod assembly into the

cylinder with the front mark on the piston crown pointing to
the timing belt side.
FRONT MARK
AK201081AB
5. Using a suitable piston ring compressor tool, install the

piston and connecting rod assembly into the cylinder block.
AKX00721
>>F<< CONNECTING ROD CAP INSTALLATION

1. Verifying the mark made during disassembly, install the
bearing cap to the connecting rod. If the connecting rod is
new with no index mark, make sure that the bearing locking
notches are on the same side as shown.
CYLINDER NO.
NOTCHES
AKX00735AB
2. Make sure that the connecting rod big end side clearance
meets the specification.
AK201530
.
>>G<< CONNECTING ROD CAP NUT

INSTALLATION
1. The connecting rod bolts should be examined before reuse.
If the bolt threads are damaged, the bolt should be replaced.
Hand-thread the nut to the full length of the bolt threads. If
the nut does not run down smoothly, the bolt should be
replaced.
2. Before installation of each nut, apply engine oil to the
threaded portion and bearing surface of the nut.
3. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to a torque of 27 ± 2 N⋅m
(20 ± 1 ft-lb) to install the cap properly.
PAINT 5. Make a paint mark on the head of each nut.
90˚ TO 94˚ MARKS
PAINT
CAUTION
MARKS • If the nut is turned less than 90 degrees, proper fasten-
ing performance may not be achieved. Be careful to
tighten the nut exactly 90 degrees.
• If the nut is overtightened (exceeding 94 degrees),
loosen the nut completely and then retighten it by
BOLT
NUT repeating the tightening procedure from step 3.
6. Make a paint mark on the bolt end at a position 90 to 94
AKX01401AB degrees from the paint mark made on the nut in the direction
of tightening the nut.
7. Turn the nut another 90 to 94 degrees and make sure that
the paint marks on the nut and bolt are aligned.
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.
.
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)
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)
.
CRANKSHAFT PIN OIL CLEARANCE

<PLASTIC GAUGING MATERIAL METHOD>
The crankshaft oil clearance can be measured easily by using
plastic gauging material, as follows:
SCALE
1. Remove oil from the crankshaft pin and the bearing inner
surface.
2. Cut plastic gauging material to the same length as the width
of the bearing and place it on the pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten the nuts
4. Carefully remove the connecting rod cap.
AKX00731AB
5. Measure the width of the smashed plastic gauging material
at its widest section by using a scale printed on the plastic
gauging material bag.
CRANKSHAFT AND CYLINDER BLOCK

M1113008700637
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
APPLY ENGINE OIL

TO ALL MOVING
8 PARTS BEFORE
INSTALLATION.
9 74 ± 4 N·m
54 ± 3 ft-lb
7
01DB050A

1. ADAPTER PLATE >>C<< 9. CRANKSHAFT BEARING, LOWER
2. DRIVE PLATE 10. CRANKSHAFT
3. REAR PLATE >>D<< 11. THRUST BEARING
>>G<< 4. OIL SEAL CASE ASSEMBLY >>C<< 12. CRANKSHAFT BEARING, UPPER
>>F<< 5. CRANKSHAFT REAR OIL SEAL 13. KNOCK SENSOR
6. OIL SEAL CASE >>B<< 14. KNOCK SENSOR BRACKET
>>E<< 7. BEARING CAP BOLT 16. CYLINDER BLOCK
>>E<< 8. BEARING CAP

• MD998718: Crankshaft Rear Oil Seal Installer

.
>>B<< KNOCK SENSOR BRACKET

INSTALLATION
Check that the bracket is in proper contact with the cylinder
TIMING BELT SIDE block boss and tighten to the specified torque in the order
shown.
4 Tightening torque: 28 ± 2 N⋅m (21 ± 1 ft-lb)
2
1
3
AKX00649AB
>>C<< CRANKSHAFT BEARING INSTALLATION

LOCATION OF IDENTIFCATION COLOR 1. Measure the crankshaft journal diameter and confirm its
No.4 JOURNAL classification from the following table. In the case of a
No.2 JOURNAL
No.3 JOURNAL crankshaft supplied as a service part, identification
colors/marks of its journals are painted/stamped at the
positions shown in the illustration.
No.1 JOURNAL AKX01391AB
2. The cylinder block bearing bore diameter identification

CYLINDER INSIDE marks are stamped at the position shown in the illustration
DIAMETER SIZE MARK from left to right, beginning at No.1.
No.2 No.4
BEARING BORE
DIAMETER
No.1 No.3 IDENTIFICATION
MARK
TIMING BELT SIDE

AKX00648AB
CRANKSHAFT JOURNAL OUTSIDE CYLINDER BLOCK CRANKSHAFT CRANKSHAFT

DIAMETER BEARING BORE BEARING No.1, 4 BEARING No.2, 3
IDENTIFICATION SIZE mm (in) IDENTIFICATION IDENTIFICATION IDENTIFICATION
COLOR MARK COLOR COLOR
Yellow 63.994 − 64.000 I Pink Blue
(2.5194 − 2.5197)
II Red Pink
III Green Red
None 63.988 − 63.994 I Red Pink
(2.5192 − 2.5194)
II Green Red
III Black Green
CRANKSHAFT JOURNAL OUTSIDE CYLINDER BLOCK CRANKSHAFT CRANKSHAFT

DIAMETER BEARING BORE BEARING No.1, 4 BEARING No.2, 3
IDENTIFICATION SIZE mm (in) IDENTIFICATION IDENTIFICATION IDENTIFICATION
COLOR MARK COLOR COLOR
White 63.982 − 63.988 I Green Red
(2.5190 − 2.5192)
II Black Green
III Brown Black
3. From the above table, select a bearing whose size is

appropriate for the crankshaft journal outside diameter. If the
crankshaft journal outside diameter ID color is "yellow" and
the cylinder block bearing bore ID mark is "III," for example,
select a bearing whose ID color is "green" <No.1, 4> or "red"
<No.2, 3>.
If there is no ID color paint on the crankshaft, measure the
journal outside diameter and select a bearing appropriate for
the measured valve.
IDENTIFICATION COLOR
AK203987AB
4. Install bearings with the groove toward the cylinder block.

GROOVE 5. Install the bearings having no groove to the bearing cap.
FOR UPPER
FOR LOWER
AKX00623AB
>>D<< CRANKSHAFT THRUST BEARING

INSTALLATION
1. Install the thrust bearing in the No.3 bearing bore in the
cylinder block and in the bearing cap. For easier installation,
apply engine oil to the bearings; this will help hold them in
position.
2. The thrust bearings must be installed with their groove
toward the crankshaft web.
GROOVE
THRUST
BEARING
AKX01393AB
.
>>E<< BEARING CAP/BEARING BOLT

INSTALLATION
BEARING CAP
BEARING CAP BOLT

FRONT MARK NUMBERS ARE
TIGHTENING SEQUENCE
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.
3. Check that the crankshaft rotates smoothly.
4. Check the end play. If it exceeds the limit value, replace the
thrust bearing.
AK201528
.
>>F<< CRANKSHAFT REAR OIL SEAL

INSTALLATION
Using special tool MD998718, press-fit a new crankshaft rear
oil seal into the oil seal case.
MD998718
OIL SEAL
CASE
AKX00693AB
>>G<< OIL SEAL CASE INSTALLATION

1. Apply the sealant Mitsubishi Genuine Part number
MD970389 or equivalent to the oil seal case.
2. Apply a small amount of engine oil to the entire
circumference of the oil seal lip section, and place the oil
seal case on the cylinder block.
NOTE: Install the oil seal case within 15 minutes after apply-
ing liquid gasket.Then wait at least one hour. Do not start the
engine or let engine oil or coolant touch the sealant during
that time.
AK201083
INSPECTION
M1113008800322
.
CRANKSHAFT JOURNAL OIL CLEARANCE

<PLASTIC GAUGING MATERIAL METHOD>
1. Remove oil from the crankshaft journal and crankshaft
bearing inner surface.
2. Install the crankshaft.
3. Cut plastic gauging material to the same length as the width
PLASTIC of the bearing and place it on the journal in parallel with its
GAUGING axis.
MATERIAL
AK101043AB
4. Install the crankshaft bearing cap carefully and tighten the

bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the smashed plastic gauging material
at its widest section by using a scale printed on the plastic
gauging material bag.
Standard value:
AK201526
0.02 − 0.03 mm (0.0008 − 0.0012 inch) <No.1, 4>
0.03 − 0.04 mm (0.0012 − 0.0016 inch) <No.2, 3>
.
CRANKSHAFT REAR OIL SEAL

1. Check the oil seal lip for wear and damage.
2. Check the rubber for deterioration or hardening.
3. Check the oil seal case for cracks and damage.
.
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.
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
.
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
THRUST 0.25 mm (0.010 in) Oversize 0.25

DIRECTION diameter
PISTON OUTSIDE
DIAMETER 0.50 mm (0.020 in) Oversize 0.50
diameter
AKX00740AB
NOTE: Size mark is stamped on the piston top.

2. Measure the outside diameter of the piston to be used.
Measure it in the thrust direction as shown.
3. Based on the measured piston Outside Diameter (OD),
calculate the boring finish dimension.
Boring finish dimension = Piston OD + (clearance
between piston OD and cylinder) − 0.02 mm (0.0008
inch) (honing margin)
CAUTION
To prevent distortion that may result from temperature rise
during honing, bore cylinders in the order of number 2,
number 4, number 6, number 1, number 3 and number 5.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance
between piston OD and cylinder).
Standard value:
Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:
0.02 − 0.04 mm (0.0008 − 0.0015 inch)
NOTE: When boring cylinders, finish all six cylinders to the
same oversize. Do not bore only one cylinder to an oversize.
SPECIFICATIONS
M1113023400688
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)
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)
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
Spark plugs 25 ± 5 N⋅m (18 ± 4 ft-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)
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)
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)
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)
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
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)
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
SPECIFICATIONS
M1113000300516
ITEMS STANDARD VALUE LIMIT

Timing belt
Auto tensioner rod length mm (in) 4.8 − 6.0 (0.19 − 0.21) −
Auto tensioner rod production length mm (in) 12 (0.5) −
Auto tensioner rod pushed-in amount 1.0 (0.03) or less −
[when pushed with a force of 98 to 196 N (22
to 44 lb)] mm (in)
Rocker arms and camshaft
Camshaft cam height Intake 37.70 Minimum 36.80
mm (in) Exhaust 38.36 Minimum 37.86
Camshaft journal outside diameter mm (in) 45 (1.8) −
Cylinder head and valves
Cylinder head flatness of gasket surface mm Less than 0.03 (0.001) 0.2 (0.007)
(in)
Cylinder head grinding limit of gasket surface − 0.2 (0.007)
mm (in) Total resurfacing depth of cylinder
head and cylinder block
Cylinder head overall height mm (in) 120 (4.7) −
Valve thickness of valve Intake 1.0 (0.04) Minimum 0.5 (0.02)
head (margin) mm (in) Exhaust 1.2 (0.05) Minimum 0.7 (0.03)
Valve overall height mm Intake 110.30 (4.343) Minimum 109.80 (4.323)
(in) Exhaust 112.11 (4.414) Minimum 111.61 (4.394)
Valve stem outside Intake 6.0 (0.24) −
diameter mm (in) Exhaust 6.0 (0.24) −
Valve thickness to valve Intake 0.02 − 0.05 (0.0008 − 0.0019) 0.10 (0.003)
guide clearance mm (in) Exhaust 0.04 − 0.06 (0.0016 − 0.0023) 0.15 (0.005)
Valve face angle mm (in) 43.5° − 44° −
Valve spring free length mm (in) 50.6 49.6
Valve spring load/installed height N (lb) /mm 267/44.2 (60.0/1.74) −
(in)
Valve spring out-of-squareness 2° or less 4°
Valve seat valve contact width mm (in) 0.9 − 1.3 (0.04 − 0.05) −
Valve guide inside diameter mm (in) 6.0 (0.24) −
Valve guide projection from cylinder head 14 (0.6) −
upper surface mm (in)
Valve stem projection Intake 48.30 (1.902) 48.80 (1.921)
mm (in) Exhaust 51.71 (2.036) 52.21 (2.056)
SPECIFICATIONS

Oversize rework 0.05 oversize 11.05 − 11.07 (0.4351 − 0.4358) −
dimensions of valve diameter
guide hole mm (in) 0.25 oversize 11.25 − 11.27 (0.4429 − 0.4437) −
diameter
0.50 oversize 11.50 − 11.52 (0.4528 − 0.4535) −
diameter
Intake oversize rework 0.3 oversize 37.80 − 37.83 (1.4881 − 1.4894) −
seat hole mm (in) 0.6 oversize 38.10 − 38.13 (1.5000 − 1.5012) −
diameter
Exhaust oversize rework 0.3 oversize 34.80 − 34.83 (1.3701 − 1.3713) −
seat hole mm (in) 0.6 oversize 35.10 − 35.13 (1.3819 − 1.3831) −
diameter
Oil pan and oil pump
Oil pump tip clearance mm (in) 0.06 − 0.18 (0.003 − 0.007) −
Oil pump side clearance mm (in) 0.04 − 0.10 (0.002 − 0.003) −
Oil pump body clearance mm (in) 0.10 − 0.18 (0.004 − 0.007) 0.35 (0.013)
Oil pressure at curb idle speed kPa (psi) 80 (11.6) or more −
[oil temperature is 75 to 90°C (167 to 194°F)]
Piston and connecting rod
Piston outside diameter mm (in) 95.0 (3.74) −
Piston ring to ring No.1 0.03 − 0.07 (0.0012 − 0.0027) 0.1 (0.003)
groove clearance mm No.2 0.02 − 0.06 (0.0008 − 0.0023) 0.1 (0.003)
(in)
Piston ring end gap mm No.1 0.25− 0.45 (0.010 − 0.017) 0.8 (0.03)
(in) No.2 0.35 − 0.50 (0.014 − 0.019) 0.8 (0.03)
Oil ring side rail 0.10 − 0.35 (0.003 − 0.014) 1.0 (0.03)
Piston pin outside diameter mm (in) 22.0 (0.87) −
Crankshaft pin oil clearance mm (in) 0.02 − 0.05 (0.0008 − 0.0019) 0.1 (0.003)
Connecting rod big end side clearance mm 0.10 − 0.25 (0.003 − 0.009) −
(in)
SPECIFICATIONS

Crankshaft and drive plate
Crankshaft end play mm (in) 0.05 − 0.25 (0.002 − 0.009) 0.3 (0.01)
Crankshaft journal outside diameter mm (in) 64 (2.520) −
Crankshaft pin outside diameter mm (in) 55 (2.165) −
Crankshaft journal oil No.1, 4 0.02 − 0.03 (0.0008 − 0.0012) 0.1(0.003)
clearance mm (in) No.2, 3 0.03 − 0.04 (0.0012 − 0.0016) 0.1(0.003)
Piston to cylinder clearance mm (in) 0.02 − 0.04 (0.0008 − 0.0016) −
Cylinder block flatness of gasket surface 0.05 (0.02) 0.1 (0.003)
mm (in)
Cylinder block grinding limit of gasket surface − 0.2 (0.008)
mm (in) total resurfacing depth of both
cylinder head and cylinder block
Cylinder block overall height mm (in) 227.9 − 228.1 (8.972 − 8.980) −
[upper plane of cylinder block from crankshaft
center]
Cylinder bore inside diameter mm (in) 95.0 (3.74) −
Cylindricity mm (in) 0.01 (0.0003) −
SEALANTS
M1113000500350
ITEMS SPECIFIED SEALANT QUANTITY

Camshaft position sensor support MITSUBISHI genuine part No. MD970389 or As required
equivalent
Engine coolant temperature sensor 3M™ AAD Part No. 8731 or equivalent As required
Engine oil pressure switch 3M™ AAD Part No. 8672 or equivalent As required
Oil pump case MITSUBISHI genuine part No. MD970389 or As required
equivalent
Oil pan MITSUBISHI genuine part No. MD970389 or As required
equivalent
Oil seal case MITSUBISHI genuine part No. MD970389 or As required
equivalent
NOTES
HOME
12-1
GROUP 12
ENGINE
LUBRICATION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 12-2 ENGINE OIL FILTER REPLACEMENT. . . . 12-4

ENGINE OIL PRESSURE CHECK . . . . . . . 12-6
SPECIAL TOOLS. . . . . . . . . . . . . . . . 12-3
SPECIFICATIONS . . . . . . . . . . . . . . . 12-7
ON-VEHICLE SERVICE. . . . . . . . . . . 12-3 FASTENER TIGHTENING SPECIFICATIONS 12-7
ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-3 SERVICE SPECIFICATIONS . . . . . . . . . . . 12-7
ENGINE OIL REPLACEMENT . . . . . . . . . . 12-3 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 12-7
ENGINE LUBRICATION 12-2
GENERAL DESCRIPTION
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-
.
Recommended Precautions tion should be worn i.e. chemical goggles or face

The most effective precaution is to adapt working shields. In addition, an eye wash facility should
practices which prevent, as far as practical, the risk be provided.
of skin contact with mineral oils i.e. use enclosed • Obtain first aid treatment immediately for open
systems for handling used engine oil and degrease cuts and wounds.
components, where practical, before handling them. • Wash regularly with soap and water to ensure all
. oil is removed (skin cleansers and nail brushes
Other precautions: will help). After cleaning, apply lotion, etc., con-
• Avoid prolonged and repeated contact with oil, taining lanolin to replace natural skin oils is
particularly used engine oil. advised.
• Wear protective clothing, including impervious • Do not use gasoline, kerosene, diesel fuel, gas
gloves where practical. oil, thinners or solvents for cleaning skin.
• Avoid contaminating clothes with oil. • Apply barrier creams before each work period.
• Do not put oily rags in pockets. • If skin disorders develop, obtain medical advice
• Do not wear heavily soiled clothing and immediately.
oil-soaked foot-wear. Overalls must be cleaned
regularly and kept separate from personal cloth-
ing.
SPECIAL TOOLS
SPECIAL TOOLS
M1121000600404
NAME
MB991610 General service tool Removal and installation
Oil filter wrench of engine oil filter (when
using oil filter MD356000)
MB991610
MD998054 General service tool or Removal and installation

Engine oil pressure MD998054-01 of engine oil pressure
switch wrench switch
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
ENGINE OIL REPLACEMENT

M1121001000706
temperature of the coolant reaches 80 − 90°C (176 −
194°F).
WARNING
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
ON-VEHICLE SERVICE
<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.
Use engine oil conforming to the following classifica-

tion:
ACEA classification - "for service A1,A2 or A3"

API classification - "for service SG or higher"
Total quantity:(includes oil filter)

<3.8L Engine> 4.3 litres
6. Install the engine oil filler cap.

7. Check oil level.
ENGINE OIL FILTER REPLACEMENT

M1121001100424
temperature of the coolant reaches 80 − 90°C (176 −
194°F).
WARNING
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
4. Use an oil filter wrench to remove the engine oil filter.
5. Clean the filter bracket side mounting surface and ensure
MB991610 OR the old O-ring has been removed.
GENERAL
SERVICE
TOOL
AC000093 AG
ON-VEHICLE SERVICE
6. Apply a small amount of engine oil to the O-ring of the new

oil filter.
O-RING
ACX00396 AB
7. Screw on the oil filter by hand until it touches the surface of

the flange and then tighten it with an oil filter wrench.
NUMBER ENGINE SPECIAL TOOL TIGHTENING TORQUE
MD352627, 3.8L General service tool Approximately one turn [14 ± 2 N⋅m (124 ± 18 in-lb)]
MD321589
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.
ON-VEHICLE SERVICE
ENGINE OIL PRESSURE CHECK

M1121002300614
MD998054: Engine Oil Pressure Switch Wrench
1. Check engine oil quantity.
CAUTION
Since sealant is applied to the thread of the engine oil
pressure switch, take care not to damage the engine oil
pressure switch when removing it.
2. Use special tool MD998054 to remove the engine oil
pressure switch.
NOTE: Remove the terminal of oil pressure switch where
special tool MD998054 is not fitted.
3. Install the engine oil pressure gauge.
NOTE: Use a 1/8 pipe thread adapter.
4. Run the engine to warm it.
<3.8L ENGINE> 5. After the engine has been warmed up, check that engine oil
OIL FILTER
pressure is within the standard value.
Standard value:
At idle: 29 kPa (4.2 psi) or more
At 3,500 r/min: 294 − 686 kPa (43 − 100 psi)
6. Remove the engine oil pressure gauge.
ENGINE OIL
PRESSURE
SWITCH
AK203685AC
MD998054
AKX00294 AB
7. Apply the specified sealant 3M™ AAD Part number 8672 or

equivalent to the threads of the engine oil pressure switch.
AKX00295 AB
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
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)
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
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
SPECIFICATIONS
HOME
13-1
GROUP 13
FUEL
CONTENTS
MULTIPORT FUEL INJECTION (MFI) . . . . . . . . . . . . . . . . . . . . 13A
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B
TRACTION CONTROL SYSTEM (TCL) . . . . . . . . . . . . . . . . . . . 13C

NOTES
HOME
13A-1
GROUP 13A
MULTIPOINT FUEL
INJECTION (MPI)
CONTENTS
GENERAL DESCRIPTION 13A-2 MULTIPOINT FUEL INJECTION (MPI) RELAY

CONTINUITY CHECK . . . . . . . . . . . . . . . . . 13A-666
MULTIPOINT FUEL INJECTION (MPI) FUEL PUMP RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-666
DIAGNOSIS 13A-5
INTAKE AIR TEMPERATURE SENSOR
TROUBLESHOOTING STRATEGY . . . . . . 13A-5 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-667
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 13A-5 ENGINE COOLANT TEMPERATURE
DIAGNOSTIC TROUBLE CODE CHART . . 13A-17 SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A-667
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 13A-21 HEATED OXYGEN SENSOR CHECK . . . . 13A-668
DIAGNOSTIC TROUBLE CODE INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A-670
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 13A-24 THROTTLE ACTUATOR CONTROL
SYMPTOM PROCEDURES . . . . . . . . . . . . 13A-539 MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . 13A-671
DATA LIST REFERENCE TABLE . . . . . . . 13A-637 EVAPORATIVE EMISSION PURGE SOLENOID
ACTUATOR TEST REFERENCE TABLE. . 13A-644 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-671
CHECK AT THE ENGINE ECU
. . . . . . . . . . . . . . . . . . . 13A-645 INJECTOR 13A-672
INSPECTION PROCEDURE USING AN REMOVAL AND INSTALLATION . . . . . . . . 13A-672
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13A-652
THROTTLE BODY ASSEMBLY 13A-674
SPECIAL TOOLS 13A-658 REMOVAL AND INSTALLATION . . . . . . . . 13A-674
ON-VEHICLE SERVICE 13A-660 ENGINE-ECU

COMPONENT LOCATION . . . . . . . . . . . . . 13A-660 13A-675
THROTTLE BODY (THROTTLE VALVE REMOVAL AND INSTALLATION . . . . . . . . 13A-675
AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A-660
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A-661
SPECIFICATIONS 13A-676
FUEL PUMP CONNECTOR DISCONNECTION
FASTENER TIGHTENING
(HOW TO REDUCE PRESSURIZED
FUEL LINES) . . . . . . . . . . . . . . . . . . . . . . . 13A-663
GENERAL SPECIFICATIONS . . . . . . . . . . 13A-676
FUEL PUMP OPERATION CHECK . . . . . . 13A-664
SEALANT AND ADHESIVE . . . . . . . . . . . . 13A-677
MULTIPOINT FUEL INJECTION (MPI) 13A-2
GENERAL DESCRIPTION
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 conditions to avoid fluctuations in the engine speed.
trolled so that the optimum air/fuel mixture is sup- .
plied to the engine to correspond to the IGNITION TIMING CONTROL

continually-changing engine operation conditions. The ignition power transistor located in the ignition
A single injector is mounted at the intake port of each primary circuit turns ON and OFF to control the pri-
cylinder. Fuel is sent under pressure from the fuel mary current flow to the ignition coil. This controls the
tank to the fuel injectors by the fuel pump, with the ignition timing to provide the optimum ignition timing
pressure being regulated by the fuel pressure regula- with respect to the engine operating conditions. The
tor. The regulated fuel is distributed to each of the ignition timing is determined by the ENGINE-ECU
injectors. from engine speed, intake air volume, intake air tem-
Fuel injection is normally carried out once for each perature and engine coolant temperature.
cylinder for every two rotations of the crankshaft.
The firing order is 1-2-3-4-5-6. Each cylinder has a .
dedicated fuel injector. This is called multiport. DIAGNOSTIC TEST MODE

The ENGINE-ECU provides a richer air/fuel mixture • When a fault is detected in one of the sensors or
by carrying out "open-loop" control when the engine actuators related to emission control or major
is cold or operating under high load conditions in engine control system, the (Check Engine Warn-
order to maintain engine performance.In addition, ing Lamp) illuminates to warn the driver.
when the engine is under normal operating tempera- • When a fault is detected in one of the sensors or
ture after warming-up, the ENGINE-ECU controls the actuators, a diagnostic trouble code correspond-
air/fuel mixture by using the heated oxygen sensor ing to the fault is stored in the ENGINE-ECU.
signal to carry out "closed-loop" control. The • The RAM data inside the ENGINE-ECU that is
closed-loop control achieves the theoretical air/fuel related to the sensors and actuators can be read
mixture ratio where the catalytic converter can with the diagnostic tool. In addition, the actuators
obtains the maximum cleaning performance. can be controlled by diagnostic tool (MUT-III sub
assembly) under certain circumstances.
.
THROTTLE VALVE OPENING CONTROL .
This system electrically controls the opening of the

throttle valve. The ENGINE-ECU detects the amount
of travel of the accelerator pedal via the accelerator
pedal position sensor, and controls the actuation of
the throttle actuator control motor, which is mounted
on the throttle body, in order to attain the target throt-
tle valve opening that has been predetermined in
accordance with driving conditions.
GENERAL DESCRIPTION
OTHER CONTROL FUNCTIONS Fan Control (PWM)

• The radiator fan and condenser fan speeds are
Fuel Pump Control controlled by the Fan Controller unit (PWM) in
• Turns the fuel pump relay ON so that current is response to the engine coolant temperature and
supplied to the fuel pump while the engine is vehicle speed via the engine ECU.
cranking or running.
Evaporative Emission Purge Control
A/C Compressor Clutch Relay Control • (Refer to GROUP 17, Emission Control System −
• Turns the compressor clutch of the A/C ON and Evaporative Emission System − General Descrip-
OFF. tion P.17-81.)
GENERAL DESCRIPTION
MULTIPOINT FUEL INJECTION (MPI) SYSTEM DIAGRAM

ENSE DECIDE ACT
1 MASS AIRFLOW SENSOR ENGINE-ECU 1 THROTTLE ACTUATOR
2 INTAKE AIR TEMPERATURE SENSOR CONTROL MOTOR
3 THROTTLE POSITION SENSOR (MAIN/SUB) 2 INJECTOR
4 MANIFOLD ABSOLUTE PRESSURE SENSOR 3 EVAPORATIVE EMISSION
5 ENGINE COOLANT TEMPERATURE SENSOR PURGE SOLENOID
6 CAMSHAFT POSITION SENSOR
7 CRANKSHAFT POSITION SENSOR
8 RIGHT BANK HEATED OXYGEN SENSOR (FRONT)
9 RIGHT BANK HEATED OXYGEN SENSOR (REAR)
10 LEFT BANK HEATED OXYGEN SENSOR (FRONT)
11 LEFT BANK HEATED OXYGEN SENSOR (REAR) IGNITION COIL, IGNITION
12 FUEL LEVEL SENSOR POWER TRANSISTER
MULTIPOINT FUEL
INJECTION (MPI) RELAY
FUEL PUMP RELAY
ACCELERATOR PEDAL POSITION SENSOR THROTTLE ACTUATOR
(MAIN/SUB) CONTROL MOTOR RELAY
KNOCK SENSOR ALTERNATOR G TERMINAL
POWER STEERING PRESSURE SWITCH HEATED OXYGEN SENSOR
OUTPUT SHAFT SPEED SENSOR HEATER
TRANSMISSION RANGE SWITCH FAN CONTROL MODULE
IGNITION SWITCH-IG (RADIATOR, A/C CONDENSER)
IGNITION SWITCH-ST A/C COMPRESSOR CLUTCH
POWER SUPPLY RELAY
DIAGNOSTIC OUTPUT
3 THROTTLE POSITION SENSOR

(MAIN/SUB)
MANIFOLD INTAKE AIR TEMPERATURE
ABSOLUTE THROTTLE SENSOR
PRESSURE ACTUATOR
SENSOR CONTROL MASS AIRFLOW
ENGINE MOTOR SENSOR
COOLANT
TEMPERATURE
SENSOR AIR
INLET
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)
CRANKSHAFT POSITION FUEL TANK

SENSOR FUEL PUMP
RIGHT BANK HEATED

OXYGEN SENSOR (REAR)
NOTE: For the vacuum routing, refer to GROUP 17, Emission Control System − Vacuum Hoses − Vacuum
Hose Routing P.17-77.
MULTIPOINT FUEL INJECTION (MPI) DIAGNOSIS

TROUBLESHOOTING STRATEGY
M1131150001204
Use these steps to plan your diagnostic strategy. If 7. Reconfirm the malfunction symptom and carry out
you follow them carefully, you will be sure to have a test drive with the appropriate drive cycle
exhausted most of the possible ways to find an MPI pattern.
fault. 8. If DTC is set again, carry out an inspection with
1. Gather as much information as possible about the appropriate diagnostic trouble code procedures.
complaint from the customer. Refer to Diagnostic Trouble Code Chart P.13A-17
2. Verify that the condition described by the 9. If DTC is not set again, the malfunction is
customer exists. intermittent. For information on how to cope with
3. Check the vehicle for any MPI Diagnostic Trouble intermittent malfunctions, refer to GROUP 00,
Code (DTC). How to Use Troubleshooting/Inspection Service
4. If you cannot verify the condition and there are no Points − How to Cope with Intermittent
DTCs, the malfunction is intermittent. For Malfunctions P.00-14.
information on how to cope with intermittent 10.After repairs are completed, conduct a road test
malfunctions, refer to GROUP 00, How to Use duplicating the complaint set conditions to confirm
Troubleshooting/Inspection Service Points − How the malfunction has been corrected.
to Cope with Intermittent Malfunctions P.00-14. NOTE: If the ENGINE-ECU is replaced, Immobilizer
5. If you can verify the condition but there are no Encrypted Code Registration should be carried out,
DTCs, or the system cannot communicate with Refer to GROUP 54A, Ignition Switch − On-vehicle
the diagnostic tool, refer to the trouble symptom Service − Immobilizer Encrypted Code Registration
classification table. P.54A-37.
6. If there is a DTC, record the number of the code,
then erase the code from the memory using the
diagnostic tool.
DIAGNOSTIC FUNCTION
M1131155500881
.
CHECK ENGINE WARNING LAMP

Among the on-board diagnostic items, Check Engine Warning
MALFUNCTION INDICATOR
LAMP (SERVICE ENGINE SOON Lamp illuminates to notify the driver of an emission control or
or Check Engine Lamp) major engine operating systemmalfunction.
However, when an irregular signal returns to normal and the
Engine-ECU judges that it has returned to normal, the Check
Engine Warning Lamp is switched off.
Immediately after the ignition switch is turned on, the Check
Engine Warning Lamp) is lit for 20 seconds to indicate that the
Check Engine Warning Lamp) operates normally.
03DB216A
HOW TO CONNECT THE DIAGNOSTIC TOOL

(MUT-III)
• : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I
• MB991827: USB Cable
• MB991910: Main Harness A
CAUTION
To prevent damage to diagnostic tool , always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting diagnostic tool .
1. Ensure that the ignition switch is at the "LOCK" (OFF)
DATA LINK position.
CONNECTOR
2. Start up the personal computer.
3. Connect special tool MB991827 to special tool MB991824
and the personal computer.
4. Connect special tool MB991910 to special tool MB991824.
5. Connect special tool MB991910 to the data link connector.
6. Turn the power switch of special tool MB991824 to the "ON"
MB991910
position.
MB991824
NOTE: When the special tool MB991824 is energised, spe-
cial tool MB991824 indicator lamp will be illuminated in a
green color.
7. Start the MUT-III system on the personal computer.
8. Select "System select."
9. Ensure Model & Class details are correctly entered. Refer to
MUTT III Operaters Manual if in doubt.
NOTE: Disconnecting the diagnostic tool is the reverse of
MB991827 00DB076A the connecting sequence, making sure that the ignition
switch is at the "LOCK" (OFF) position.
HOW TO READ AND ERASE DIAGNOSTIC

TROUBLE CODES.
• MB991824: V.C.I.
CAUTION
NOTE: If the battery voltage is low, diagnostic trouble codes will
not be set. Check the battery if diagnostic tool does not dis-
play.
1. Connect diagnostic tool to the data link connector.

DATA LINK
CONNECTOR 2. Turn the ignition switch to the "ON" position.
5. Choose "MPI" from the System List.
6. Select "Self Diagnosis" tab.
MB991910
7. If a DTC is set, it is shown.
8. Choose "Erase DTCs" to erase the DTC.
MB991824
MB991827 00DB076A
HOW TO READ DATA LIST

• MB991824: V.C.I.
CAUTION
DATA LINK
5. Select "Data List."
6. Choose an appropriate item and select the "OK" button(tick).
MB991910
MB991824
MB991827 00DB076A
HOW TO PERFORM ACTUATOR TEST

• MB991824: V.C.I.
CAUTION
DATA LINK
5. Select "Actuator Test."
6. Choose an appropriate item and select the "OK" button(tick).
MB991910
MB991824
MB991827 00DB076A
HOW TO DIAGNOSE THE CAN BUS LINES

• MB991824: V.C.I.
CAUTION
DATA LINK ignition switch to the "LOCK" (OFF) position before con-
CONNECTOR
3. Select "CAN bus diagnosis" from the start-up screen.
MB991910
NOTE: If details are not correct for vehicle ensure "erase"
button is used to delete incorrect details prior to entering the
MB991824 correct details.
5. Enter correct vehicle details.
6. Select the "OK" button.
7. When the optional equipment screen is displayed, choose
the one which the vehicle is fitted with, and then select the
"OK" button.
8. "CAN Bus Diagnosis" screen is diplayed. Press the check
MB991827 00DB076A button to commence diagnosis. the configuration screen will
be displayed, showing any errors in "RED".
PROVISIONAL DTCs [MUT-III EOBD Test Mode -

Results (Mode 7)]
The diagnostic tool (MUT-III sub assembly) will display the
Provisional DTCs reported by ENGINE-ECU if the
ENGINE-ECU detects some malfunction for "Misfire", "Fuel
System" and "Comprehensive" monitoring during a SINGLE
Driving Cycle. The intended use of this data is to assist the
technician after a vehicle repair, and after clearing diagnostic
information, by reporting test result after a SINGLE Driving
Cycle. Note that the test results reported by this mode do not
necessarily indicate a faulty component/system. If test results
indicate a failure after ADDITIONAL (consecutive) driving, then
the Check Engine Warning Lamp) will be illuminated and a
DTC will set.
DIAGNOSTIC BY DIAGNOSTIC TEST MODE II

(INCREASED SENSITIVITY - Where Applicable)
• MB991824: V.C.I.
CAUTION
CONNECTOR
NOTE: When mode II is selected with , the Check Engine
Warning Lamp will light when the Engine-ECU first detects the
trouble (Note that this is only for emission-related trouble). At
the same time, the relevant diagnostic trouble codes will be
registered. In respect to the comprehensive component electri-
MB991910 cal faults (opens/shorts), the time for the diagnostic trouble
code to be registered after the fault occurrence is four seconds
MB991824 → one second. Therefore, the confirmation of the trouble symp-
tom and the confirmation after completing repairs can be
reduced. To return to the normal mode I after mode II has been
selected once, the ignition switch must be turned "OFF" once
or mode I must be reselected with . The diagnostic trouble
code, system readiness test status and freeze frame data, etc.,
will be erased when mode I is returned to, so record these
before returning to mode I.
MB991827 00DB076A
3. Change the diagnostic test mode of the Engine-ECU to
DIAGNOSTIC TEST MODE II (INCREASED SENSITIVITY).
4. Road test the vehicle.
5. Read the diagnostic trouble code and repair the
malfunctioning part.
6. Turn the ignition switch to the "LOCK" (OFF) position.
7. Disconnect diagnostic tool from the data link connector.
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.
EOBD- DRIVE CYCLE

All kinds of diagnostic trouble codes (DTCs) can be monitored by carrying out a short drive according to the
following three drive cycle patterns. In other words, doing such a drive regenerates any kind of trouble which
involves illuminating the Check Engine Warning Lamp and verifies the repair procedure has eliminated the
trouble [the Check Engine Warning Lamp is no longer illuminated].
CAUTION
Two technicians should always be in the vehicle when carrying out a test.
NOTE: Check that the diagnosis trouble code (DTC) is not output before driving the EOBD- drive cycle. Erase
the DTC if it has been output.
DRIVE CYCLE PATTERN LIST
PROCEDURE MONITOR ITEM DIAGNOSTIC TROUBLE
CODE (DTC)
1 Catalytic converter monitor P0421, P0431
2 Heated oxygen sensor monitor P0133, P0139, P0153,
P0159
3 Other monitor 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 P0130, P0131, P0132,
circuit P0135, P0136, P0137,
P0138, P0140, P0150,
P0151, P0152, P0155,
P0156, P0157, P0158,
P0160, P0161, P0201,
P0202, P0203, P0204,
P0205, P0206, P0443
.
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
1.5 MINUTES OR MORE

97 (3) 56 - 64 km/h
64 (5) (5) (5) (5)

PREPARATION
VEHICLE (2) PERIOD (4)
SPEED (6) (6) (6)
km/h 32 1 ST 2 ND 6 TH (7)
MON- MON- MON-
ITOR ITOR ITOR
(1)
0
ENGINE IGNITION
START SWITCH:
100 "LOCK"
(OFF)
CALCULATED
LOAD (%)
50
FULL FULL FULL

DECEL- DECEL- DECEL-
ERATION ERATION ERATION
03DB261A
Inspection • Atmospheric temperature: −10°C (14°F) or more

conditions • A/C switch: OFF
• Condition of A/T: Selector lever D range
CATALYTIC CONVERTER MONITOR

Test 1. Engine: start
procedure 2. Accelerate until the vehicle speed is 72 km/h.
3. Travel for 5 minutes or more while keeping the vehicle speed at 72 − 97 km/h.
4. Decelerate until the vehicle speed is within 56 − 64 km/h.
5. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at
56 − 64 km/h and travel for 1.5 minutes or more. (During monitor)
6. Fully close the throttle and decelerate, and keep the deceleration state for 10 seconds.
Then, quickly accelerate until the vehicle speed reaches 56 − 64 km/h. Then, repeat steps
5 and 6, and complete six monitor sessions.
7. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.
8. Confirm that the diagnostic trouble code (DTC) is not output.
9. If DTC P0421 is output, refer to DTC P0421 − Warm - Up Catalyst Efficiency Below
Threshold (Bank 1) .
If DTC P0431 is output, refer to DTC P0431 − Warm - Up Catalyst Efficiency Below
Threshold (Bank 2) .
.
PROCEDURE 2
HEATED OXYGEN SENSOR MONITOR
DTC P0133, P0139, P0153, P0159.
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
Inspection • Engine coolant temperature: 80°C or more

conditions • Atmospheric temperature: −10°C or more
procedure 2. Accelerate until the vehicle speed is 56 − 64 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at
56 − 64 km/h and travel for 2 minutes or more.
4. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.
6. If a DTC is displayed, refer to Diagnostic Trouble Code Chart P.13A-17.
.
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.
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
ENGINE START IGNITION

SWITCH:"LOCK"
(OFF)
100
CALCULATED
LOAD (%) 50
03DB263A
Inspection • Engine coolant temperature: 80°C

conditions • Atmospheric temperature: -10°C or more
procedure 2. Accelerate until the vehicle speed is 56 - 64 km/h and travel for 5 minutes or more.
3. Return the vehicle to shop.
4. After stopping the vehicle, continue idling for 5 minutes, then turn the ignition switch to
"LOCK" (OFF) position.
6. If a DTC is displayed, refer to Diagnostic Trouble Code Chart P.13A-17.
SYSTEM READINESS TEST STATUS • Catalyst: P0421, P0431

.
• Heated oxygen sensor: P0130, P0131, P0132,

PURPOSE P0133, P0134, P0136, P0137, P0138, P0139,
The ENGINE-ECU monitors the following main diag- P0150, P0151, P0152, P0153, P0154, P0156,
nosis items, judges if these items are in good condi- P0157, P0158, P0159
tion or not, and then stores its history. The history • Heated oxygen sensor heater: P0031, P0032,
can be read out by using MUT III. (if the ECU has P0037, P0038, P0051, P0052, P0057, P0058.
judged an item before, the MUT III displays "Com-
NOTE: After a repair is made for a DTC, the techni-
plete").
cian should drive the EOBD Drive Cycle checking
In addition, if diagnosis codes are erased or the bat-
that the diagnostic tool (MUT-III Sub Assembly) dis-
tery cable is disconnected, this history will also be
plays all the Readiness Codes as "Complete".
erased (the memory will be reset)
DIAGNOSTIC TROUBLE CODE CHART

M1131151001490
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
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

PAGE
P0160 Heated oxygen sensor circuit no activity detected ( bank 2 sensor 2) P.13A-257
P0171 System too lean (bank 1) P.13A-264
P0172 System too rich (bank 1) P.13A-266
P0174 System too lean (bank 2) P.13A-268
P0175 System too rich (bank 2) P.13A-270
P0201 Injector circuit-cylinder 1 P.13A-272
P0219 Engine overspeed condition P.13A-317
P0222* Throttle position sensor (sub) circuit low input P.13A-318
P0223* Throttle position sensor (sub) circuit high input P.13A-324
P0300 Random/multiple cylinder misfire detected P.13A-330
P0301 Cylinder 1 misfire detected P.13A-334
P0325 Knock sensor circuit P.13A-346
P0335* Crankshaft position sensor circuit P.13A-354
P0340 Camshaft position sensor circuit P.13A-372
P0421 Warm up catalyst efficiency below threshold (bank 1) P.13A-383

PAGE
P0431 Warm up catalyst efficiency below threshold (bank 2) P.13A-385
P0441 Evaporative emission control system incorrect purge flow P.13A-387
P0443 Evaporative emission control system purge control valve circuit P.13A-389
P0461 Fuel level sensor (main) circuit range/performance P.13A-397
P0500* Vehicle speed signal P.13A-399
P0506 Idle control system RPM lower than expected P.13A-419
P0507 Idle control system RPM higher than expected P.13A-421
P0513 Immobilizer malfunction P.13A-423
P0562 Battery voltage too low P.13A-424
P0563 Battery voltage too high P.13A-425
P0603* EEPROM malfunction P.13A-426
P0606* Powertrain control module main processor malfunction P.13A-427
P0630 VIN malfunction P.13A-428
P0638* Throttle actuator control motor circuit range/ performance problem P.13A-430
P0830 Clutch switch - (Refer to Group 17-Auto Cruise Control) P.17-15
P1564 Auto cruise switch - (Refer to Group 17-Auto Cruise Control) P.17-19
P1571 Stop lamp switch - (Refer to Group 17-Auto Cruise Control) P.17-34
P1603 Battery backup line malfunction P.13A-437
P2096 Post catalyst system too lean 1 P.13A-443
P2097 Post catalyst system too lean 2 P.13A-446
P2098 Post catalyst system too rich 1 P.13A-449
P2099 Post catalyst system too rich 2 P.13A-452
P2100* Throttle actuator control motor circuit (open) P.13A-455
P2101* Throttle actuator control motor magneto malfunction P.13A-461
P2102* ETV motor circuit (shorted low) P.13A-466
P2103* ETV motor circuit (shorted high) P.13A-471
P2122* Accelerator pedal position sensor (main) circuit low input P.13A-476
P2123* Accelerator pedal position sensor (main) circuit high input P.13A-485
P2127* Accelerator pedal position sensor (sub) circuit low input P.13A-493
P2128* Accelerator pedal position sensor (sub) circuit high input P.13A-502
P2135* Throttle position sensor (main and sub) range/performance problem P.13A-510
P2138* Accelerator pedal position sensor (main and sub) range/performance P.13A-515
problem
U1100 Engine CAN time−out/ not equipped - (Refer to Group 54A) P.54A-51
U1102 ABS−ECU time−out - (Refer to Group 54A) P.54A-55
U1120 Engine CAN message - (Refer to Group 54A) P.54A-64
U1121 T/M CAN message P.13A-537
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.
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.
TROUBLE SYMPTOMS INSPECTION REFERENCE

PROCEDURE PAGE
Communication Communication with all systems is not possible 1 P.13A-539
with diagnostic Communication with ENGINE-ECU only is not 2 P.13A-541
tool is possible
impossible
Check Engine The Check Engine Lamp) does not illuminate right 3 P.13A-543
Warning Lamp) after the ignition switch is turned to the "ON" position
and related The Check Engine Warning Lamp) remains illuminated 4 P.13A-544
parts and never goes out
Starting Cranks, won't start 5 P.13A-546
Starts up and dies 6 P.13A-553
Hard starting 7 P.13A-560
Idling stability Unstable idle (rough idle, hunting) 8 P.13A-566
(improper Idle speed is high (improper idle speed) 9 P.13A-571
idling)
Idle speed is low (improper idle speed) 10 P.13A-573
Idling stability When the engine is cold, it stalls at idle (die out) 11 P.13A-574
(engine stalls) When the engine is hot, it stalls at idle (die out) 12 P.13A-577
The engine stalls when accelerating (pass out) 13 P.13A-581
The engine stalls when decelerating 14 P.13A-583
Driving Hesitation, sag or stumble 15 P.13A-585
Acceleration shock 16 P.13A-588
Deceleration shock 17 P.13A-589
Poor acceleration 18 P.13A-590
Surge 19 P.13A-594
Knocking 20 P.13A-598
Dieseling (Run-on) 21 P.13A-599
Too high CO and HC concentration when idling 22 P.13A-600
IM240 test Purge flow test of the evaporative emission canister 23 P.13A-602
failure failure
Power supply system and ignition switch-IG system 24 P.13A-604
TROUBLE SYMPTOMS INSPECTION REFERENCE

PROCEDURE PAGE
Fuel pump system 25 P.13A-613
Ignition switch-ST system and transmission range switch system 26 P.13A-624
Ignition circuit system 27 P.13A-628
A/C system 28 P.13A-634
.
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)

ITEMS SYMPTOM
At starting Won't start The starter cranks the engine, but there is no combustion within the
cylinders, and the engine won't start.
Starts up and The engine starts, but then engine soon stalls.
dies
Hard starting Engine starts after cranking a while.
Idling stability Hunting Engine speed doesn't remain constant; changes at idle.
Rough idle Usually, a judgement can be based upon the movement of the
tachometer pointer, and the vibration transmitted to the steering wheel,
shift lever, body, etc.
Incorrect idle The engine doesn't idle at the correct speed.
speed
Engine stall (die The engine stalls when the foot is taken from the accelerator pedal,
out) regardless of whether the vehicle is moving or not.
Engine stall The engine stalls when the accelerator pedal is depressed.
(pass out)
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
Poor Poor acceleration is inability to obtain an acceleration corresponding to

acceleration the degree of throttle opening, even though acceleration is smooth.
Also the inability to reach maximum speed.
Stumble Engine speed increase is delayed
VEHICLE
when the accelerator pedal is SPEED
initially depressed for acceleration.
INITIAL
ACCEL- NORMAL
ERATOR
PEDAL
DEP-
RESSION
IDLING STUMBLE
TIME AKX01362
Shock The feeling of a comparatively large impact or vibration when the

engine is accelerated or decelerated.
Surge This is slight acceleration and deceleration feel usually felt during
steady, light throttle cruise. Most notable under light loads.
Knocking A sharp sound during driving, which sounds like a hammer striking the
cylinder walls. It makes poor driveability.
At stopped Run on The condition in which the engine continues to run after the ignition
("Dieseling") switch is turned to the "LOCK" (OFF) position. Also called "dieseling".
DIAGNOSTIC TROUBLE CODE PROCEDURES
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
CONNECTOR: B-09 RIGHT BANK

B-17X HEATED OXYGEN
SENSOR (FRONT)
AK303014 AB
THROTTLE BODY
B-09 (B)
AK303047 AB
. .
CIRCUIT OPERATION TECHNICAL DESCRIPTION

• Power is supplied from the MPI relay (terminal • The ENGINE-ECU checks whether the heater
No. 4) to the right bank heated oxygen sensor current is within a specified range when the
(front) heater. heater is energized.
• The ENGINE-ECU (terminal No. 47) controls • The ENGINE-ECU checks whether the heater
continuity to the right bank heated oxygen sensor current is within a specified range when the
(front) heater by turning the power transistor in heater is not energized.
the ENGINE-ECU "ON" and "OFF". .
DTC SET CONDITIONS

Check Conditions EOBD DRIVE CYCLE PATTERN
• Battery voltage is between 10.7 - 16.1 volts. Refer to Diagnostic Function − EOBD Drive Cycle −
• Engine starting sequence is completed.
P.13A-11.
• Engine speed is above 20 r/min.
• Oxygen sensor heater is active. .
TROUBLESHOOTING HINTS (The most

Judgment Criteria
• The heater voltage is less than 2.4 V during the
likely causes for this code to be set are: )
calibrated time interval. • Open or shorted right bank heated oxygen sen-
or sor (front) heater circuit, harness damage, or
• The heater voltage is not within 2.4 - 3.6 Volts connector damage.
during the calibrated time interval. • Open circuit in right bank heated oxygen sensor
• MIL is activated after 2 Driving Cycles. (front) heater.
• No limp home mode. • Refer to component locations GROUP-70
.

DIAGNOSIS
• Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB992044: ENGINE-ECU Check Harness
STEP 1. Check harness connector B-09 at the right bank

heated oxygen sensor (front) for damage.
CONNECTOR: B-09 RIGHT BANK Q: Is the harness connector in good condition?
HEATED OXYGEN YES : Go to Step 2.
SENSOR (FRONT)
NO : Repair or replace it. Refer to GROUP 00E, Harness
Connector Inspection P.00E-2. Then go to Step 11.
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE AK303048 AB
STEP 2. Check the right bank heated oxygen sensor

(front).
CONNECTOR: B-09 RIGHT BANK (1) Disconnect right bank heated oxygen sensor (front)
HEATED OXYGEN connector B-09.
SENSOR (FRONT) (2) Measure the resistance between heated oxygen sensor
connector terminal No. 3 and terminal No. 4.
Standard value: 9.0 − 11.0 ohms [at 20°C (68°F)]
Q: Is the measured resistance between 9.0 and 11.0 ohms
[at 20°C (68°F)]?
YES : Go to Step 3.
NO : Replace the right bank heated oxygen sensor (front).
Then go to Step 11.
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
STEP 3. Measure the power supply voltage at right bank

heated oxygen sensor (front) harness side connector B-09.
(1) Disconnect the connector B-09 and measure at the harness
CONNECTOR: B-09 RIGHT BANK side.
HEATED OXYGEN
SENSOR (FRONT) (2) Turn the ignition switch to the "ON" position.
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
(3) Measure the voltage between terminal No. 3 and ground.

• Voltage should be battery positive voltage.
B-09 HARNESS
CONNECTOR: (4) Turn the ignition switch to the "LOCK" (OFF) position.
COMPONENT SIDE Q: Is battery positive voltage (approximately 12 volts)
present?
2 1
YES : Go to Step 5.
4 3
NO : Go to Step 4.
03DB200A
STEP 4. Check harness connector B-17X at the MPI relay

for damage.
CONNECTOR: B-17X Q: Is the harness connector in good condition?
YES : Repair harness wire between MPI relay connector
B-17X (terminal No. 4) and right bank heated oxygen
sensor (front) connector B-09 (terminal No. 3)
because of open circuit or short circuit to ground.
Then go to Step 11.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
STEP 5. Measure the power supply voltage at ENGINE-ECU

connector B-20 by using ENGINE-ECU check harness
special tool MB992044.
(1) Disconnect the all ENGINE-ECU connectors and connect
ENGINE-ECU check harness special tool MB992044
between the separated connectors.
AIR (2) Turn the ignition switch to the "ON" position.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

B-20 HARNESS • Voltage should be battery positive voltage.
CONNECTOR (4) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is battery positive voltage (approximately 12 volts)
present?
YES : Go to Step 8.
NO : Go to Step 6.
03DB201A
STEP 6. Check harness connector B-20 at ENGINE-ECU for

damage.
Q: Is the harness connector in good condition?
YES : Go to Step 7.
AIR Connector Inspection P.00E-2. Then go to Step 11.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 7. Check for open circuit or short circuit to ground

between right bank heated oxygen sensor (front)
connector B-09 (terminal No. 4) and ENGINE-ECU
connector B-20 (terminal No. 47).
CONNECTOR: B-09 RIGHT BANK Q: Is the harness wire in good condition?
HEATED OXYGEN YES : Then go to Step 8.
SENSOR (FRONT)
NO : Repair it. Then go to Step 11.
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
YES : Go to Step 9.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 9. Check for harness damage between MPI relay

connector B-17X (terminal No. 4) and right bank heated
oxygen sensor (front) connector B-09 (terminal No. 3).
CONNECTOR: B-17X Q: Is the harness wire in good condition?
YES : Go to Step 10.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

HEATED OXYGEN
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
STEP 10. Check for harness damage between right bank

heated oxygen sensor (front) connector B-09 (terminal No.
4) and ENGINE-ECU connector B-20 (terminal No. 47).
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 11. Test the EOBD drive cycle.

(1) Carry out a test drive with the drive cycle pattern. Refer to
Diagnostic Function − EOBD Drive Cycle − P.13A-11.
(2) Check the diagnostic trouble code (DTC).
Q: Is DTC P0031 set?
YES : Retry the troubleshooting.
NO : The inspection is complete.
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

B-17X HEATED OXYGEN
SENSOR (FRONT)
AK303014 AB
THROTTLE BODY
B-09 (B)
AK303047 AB
. .

• The ENGINE-ECU (terminal No. 47) controls .
continuity to the right bank heated oxygen sensor

(front) heater by turning the power transistor in
the ENGINE-ECU "ON" and "OFF".
DTC SET CONDITIONS

Check Conditions • Oxygen sensor heater is active.
• Battery voltage is within 10.7 to 16.1 volts.
Judgment Criteria
• Heater voltage is above 3.6 Volts during the cali-
brated time interval.
• MIL is activated after 2 Driving Cycles. TROUBLESHOOTING HINTS (The most

• No limp home mode. likely causes for this code to be set are: )
.
• Right bank heated oxygen sensor (front) failed.
EOBD DRIVE CYCLE PATTERN • Short circuit to 12 Volt.
Refer to Diagnostic Function − EOBD Drive Cycle − • Connector damaged.
P.13A-11. • Refer to component locations GROUP-70
.
DIAGNOSIS
• MB991824: V.C.I.

SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
STEP 2. Check the right bank heated oxygen sensor

(front).
CONNECTOR: B-09 RIGHT BANK (1) Disconnect right bank heated oxygen sensor (front)
HEATED OXYGEN connector B-09.
SENSOR (FRONT) (2) Measure the resistance between heated oxygen sensor
[at 20°C (68°F)]?
YES : Go to Step 3.
Then go to Step 4.
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
STEP 3. Check the trouble symptoms.

YES : Then go to Step 4.
NO : 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.

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
. .

(rear) heater. heater is energized.
continuity to the right bank heated oxygen sensor current is within a specified range when the
(rear) heater by turning the power transistor in the heater is not energized.
ENGINE-ECU "ON" and "OFF". .
DTC SET CONDITIONS

• Battery voltage is between 9.04 - 16.1 volts.
Judgment Criteria
• IC internal test (open circuit, short earth)

.
calibrated time interval.

or likely causes for this code to be set are: )
• The heater voltage is not within 2.4 - 3.6 Volts • Open or shorted right bank heated oxygen sen-
during the calibrated time interval. sor (rear) heater circuit, harness damage, or con-
• MIL is activated after 2 Driving Cycles. nector damage.
• No limp home mode. • Right bank heated oxygen sensor (rear) heater
failed.
.
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
• MB991824: V.C.I.

heated oxygen sensor (rear) for damage.
CONNECTOR: B-08 Q: Is the harness connector in good condition?
YES : Go to Step 2.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
COMPONENT SIDE AK303064AB
STEP 2. Check the right bank heated oxygen sensor (rear).

CONNECTOR: B-08 (1) Disconnect right bank heated oxygen sensor (rear)
connector B-08.
(2) Measure the resistance between heated oxygen sensor
[at 20°C (68°F)]?
RIGHT BANK
SENSOR (REAR) NO : Replace the right bank heated oxygen sensor (rear).
Then go to Step 11.
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
STEP 3. Measure the power supply voltage at right bank

heated oxygen sensor (rear) harness side connector B-08.
CONNECTOR: B-08
side.
(2) Turn the ignition switch to the "ON" position.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:

B-08 HARNESS
COMPONENT SIDE
present?
2 1
YES : Go to Step 5.
4 3
NO : Go to Step 4.
03DB205A

for damage.
B-17X (terminal No. 4) and right bank heated oxygen
sensor (rear) connector B-08 (terminal No. 4)
Then go to Step 12.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

present?
YES : Go to Step 8.
NO : Go to Step 6.
03DB206A

damage.
YES : Go to Step 7.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

between right bank heated oxygen sensor (rear) connector
B-08 (terminal No. 3) and ENGINE-ECU connector B-20
(terminal No. 32).
CONNECTOR: B-08 Q: Is the harness wire in good condition?
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
YES : Go to Step 9.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

connector B-17X (terminal No. 4) and right bank heated
oxygen sensor (rear) connector B-08 (terminal No. 4).
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:
STEP 10. Check for harness damage between right bank

heated oxygen sensor (reart) connector B-08 (terminal No.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

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
. .

continuity to the right bank heated oxygen sensor

(rear) heater by turning the power transistor in the
ENGINE-ECU "ON" and "OFF".
DTC SET CONDITIONS

Check Conditions Judgment Criteria
• Battery voltage is within 9.04 to 16.01 volts. • IC internal test (short circuit to battery).
• Engine speed is above 801 r/min. • MIL is activated after 2 Driving Cycles.
• No limp home mode.
• Short circuit to 12 Volts.

.
EOBD DRIVE CYCLE PATTERN • Connector damaged.

Refer to Diagnostic Function − EOBD Drive Cycle − • Refer to component locations GROUP-70
P.13A-11. • Refer to configuration diagrams GROUP-80
.
• Right bank heated oxygen sensor (rear) failed.
DIAGNOSIS
• MB991824: V.C.I.

SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
STEP 2. Check the right bank heated oxygen sensor (rear).

CONNECTOR: B-08 (1) Disconnect right bank heated oxygen sensor (rear)
connector B-08.
[at 20°C (68°F)]?
RIGHT BANK
SENSOR (REAR) NO : Replace the right bank heated oxygen sensor (front).
Then go to Step 4.
THROTTLE BODY
B-08 (GR)
AK303063AB


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
. .

No. 4) to the left bank heated oxygen sensor current is within a specified range when the
continuity to the left bank heated oxygen sensor current is within a specified range when the
(front) heater by turning the power transistor in heater is not energized.
the ENGINE-ECU "ON" and "OFF". .
DTC SET CONDITIONS

Check Conditions • Engine strting sequence is complete.
• Battery voltage is within 10.7 to 16.1 volts. • Oxygen sensor heater is active.
Judgment Criteria
.

calibrated time interval. likely causes for this code to be set are: )
or • Open or shorted left bank heated oxygen sensor
• The heater voltage is not within 2.4 - 3.6 Volts (front) heater circuit, harness damage, or connec-
during the calibrated time interval. tor damage.
• MIL is activated after 2 Driving Cycles. • Left bank heated oxygen sensor (front) heater.
• No limp home mode. • Refer to component locations GROUP-70
.
EOBD DRIVE CYCLE PATTERN

Refer to Diagnostic Function − EOBD Drive Cycle −
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check harness connector B-25 at the left bank

YES : Go to Step 2.
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
STEP 2. Check the left bank heated oxygen sensor (front).

CONNECTOR: B-25 (1) Disconnect left bank heated oxygen sensor (front)
connector B-25.
LEFT BANK Q: Is the measured resistance between 9.0 and 11.0 ohms
HEATED OXYGEN [at 20°C (68°F)]?
SENSOR (FRONT)
YES : Go to Step 3.
NO : Replace the left bank heated oxygen sensor (front).
Then go to Step 11.
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB
STEP 3. Measure the power supply voltage at left bank

heated oxygen sensor (front) harness side connector B-25.
CONNECTOR: B-25 (1) Disconnect the connector B-25 and measure at the harness
side.
LEFT BANK
HEATED OXYGEN
SENSOR (FRONT)
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB

B-25 HARNESS
present?
2 1
YES : Go to Step 5.
4 3
NO : Go to Step 4.
03DB210A

for damage.
B-17X (terminal No. 4) and left bank heated oxygen
sensor (front) connector B-25 (terminal No. 3)
Then go to Step 11.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

present?
YES : Go to Step 8.
NO : Go to Step 6.
03DB211A

damage.
YES : Go to Step 7.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

between left bank heated oxygen sensor (front) connector
(terminal No. 48).
CONNECTOR: B-25
Q: Is the harness wire in good condition?
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

damage.
YES : Go to Step 9.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

connector B-17X (terminal No. 4) and left bank heated
oxygen sensor (front) connector B-25 (terminal No. 3).
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
STEP 10. Check for harness damage between left bank

heated oxygen sensor (front) connector B-25 (terminal No.
CONNECTOR: B-25
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

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
. .

continuity to the left bank heated oxygen sensor

(front) heater by turning the power transistor in
the ENGINE-ECU "ON" and "OFF".
DTC SET CONDITIONS

• Battery voltage is within 10.7 to 16.1 volts.
Judgment Criteria
• Heater voltage is above 3.6 Volts during the cali-
brated time interval.
• MIL is activated after 2 Driving Cycles. TROUBLESHOOTING HINTS (The most

• No limp home mode. likely causes for this code to be set are: )
.
• Left bank heated oxygen sensor (front) heater
EOBD DRIVE CYCLE PATTERN failed.
Refer to Diagnostic Function − EOBD Drive Cycle − • Short circuit to 12 Volt.
P.13A-11. • Connector damaged.
.

DIAGNOSIS
• MB991824: V.C.I.

SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
STEP 2. Check the left bank heated oxygen sensor (front).

CONNECTOR: B-25 (1) Disconnect left bank heated oxygen sensor (front)
connector B-25.
SENSOR (FRONT)
YES : Go to Step 3.
Then go to Step 4.
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB


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:
. .

continuity to the left bank heated oxygen sensor current is within a specified range when the
(rear) heater by turning the power transistor in the heater is not energized.
ENGINE-ECU "ON" and "OFF". .
DTC SET CONDITIONS

• Battery voltage is within 9.04 to 16.01 volts. • IC internal test (open circuit, short to earth).

.
calibrated time interval.

• The heater voltage is not within 2.4 - 3.6 Volts • Open or shorted left bank heated oxygen sensor
during the calibrated time interval. (rear) heater circuit, harness damage, or connec-
• MIL is activated after 2 Driving Cycles. tor damage.
• No limp home mode. • Left bank heated oxygen sensor (rear) heater
failed.
.

P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

YES : Go to Step 2.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
STEP 2. Check the left bank heated oxygen sensor (rear).

CONNECTOR: B-24 (1) Disconnect left bank heated oxygen sensor (rear) connector
B-24.
LEFT BANK [at 20°C (68°F)]?
HEATED OXYGEN
SENSOR (REAR) YES : Go to Step 3.
NO : Replace the left bank heated oxygen sensor (rear).
Then go to Step 11.
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
STEP 3. Measure the power supply voltage at left bank

heated oxygen sensor (rear) harness side connector B-24.
side.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:

B-25 HARNESS
present?
2 1
YES : Go to Step 5.
4 3
NO : Go to Step 4.
03DB229A

for damage.
B-17X (terminal No. 4) and left bank heated oxygen
sensor (rear) connector B-24 (terminal No. 4)
Then go to Step 11.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

present?
YES : Go to Step 8.
NO : Go to Step 6.
03DB215A

damage.
YES : Go to Step 7.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

between left bank heated oxygen sensor (rear) connector
(terminal No. 33).
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
13A-70 MULTIPOINT FUEL INJECTION (MPI)

damage.
YES : Go to Step 9.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

connector B-17X (terminal No. 4) and left bank heated
oxygen sensor (rear) connector B-24 (terminal No. 4).
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:
STEP 10. Check for harness damage between left bank

heated oxygen sensor (rear) connector B-24 (terminal No.
CONNECTOR: B-24
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

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:
. .

continuity to the left bank heated oxygen sensor

(rear) heater by turning the power transistor in the
ENGINE-ECU "ON" and "OFF".
DTC SET CONDITIONS

• Battery voltage is within 9.04 to 16.01 volts. • IC internal test (short circuit to battery)
• Engine speed is above 801 r/min. • MIL is activated after 2 Driving Cycles.
• Left bank heated oxygen sensor (rear) heater

.
EOBD DRIVE CYCLE PATTERN failed.

Refer to Diagnostic Function − EOBD Drive Cycle − • Short circuit to 12 Volts.
P.13A-11. • Connector damaged.
.
TROUBLESHOOTING HINTS (The most • Refer to configuration diagrams GROUP-80
likely causes for this code to be set are: ) • Refer to circuit diagrams GROUP-90
• Open or shorted left bank heated oxygen sensor
(rear) heater circuit, harness damage, or connec-
tor damage.
DIAGNOSIS
• MB991824: V.C.I.

SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
STEP 2. Check the left bank heated oxygen sensor (rear).

CONNECTOR: B-25 (1) Disconnect left bank heated oxygen sensor (rear) connector
B-24.
SENSOR (FRONT)
YES : Go to Step 3.
Then go to Step 4.
B-25 (B)
2 1
4 3
HARNESS
CONNECTOR:
COMPONENT SIDE
AK303071 AB


DTC P0074 Ambient Air Temperature Intermittant.
CONNECTOR: B-10 CONNECTOR: B-17X

MASS
AIRFLOW
SENSOR
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.
.
DTC SET CONDITIONS

• Ambient air temperature is a modelled signal Refer to Diagnostic Function − EOBD Drive Cycle −
from the intake air temperature.
P.13A-11.
Judgement Criteria .
• Signal out of calibrated threshold range. TROUBLESHOOTING HINTS (The most

• No MIL. likely causes for this code to be set are:)
.
• Ambient air temperature was outside threshold
values of -38.3°C to 135°C
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool , check data list item 5:

Intake Air temperature Sensor.
CAUTION
CONNECTOR
(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 5,
Intake Air temperature Sensor.
(4) The intake air temperature sensor reading should be similar
outside ambient air temperature.
MB991910
(5) 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.
NO : Go to Step 2.
MB991827 00DB076A

DTC P0101: Mass Airflow Circuit Range/Performance Problem.
CAUTION
CONNECTOR: B-17X
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
.
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.
.
DTC SET CONDITIONS <Range/Performance problem - low input>

Check Conditions Judgement Criteria
• Battery voltage is above 8.01 volts. • Air flow sensor output is below lower threshold
• Crankshaft revolution is above 150 r/min. (0-283.0 kg/h) for 4 seconds.
• MIL is activated immediately.
.
DTC SET CONDITIONS <Range/Performance problem - high input>

• Battery voltage is above 8.01 volts. Refer to Diagnostic Function − EOBD Drive Cycle −
• Crankshaft revolution is above 150 r/min.
P.13A-11.
Judgement Criteria .
• 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.
• Mass airflow sensor circuit harness damage, or
.
connector damage.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool , check data list item AA:

Mass Airflow Sensor.
CAUTION
CONNECTOR
(3) Set diagnostic tool to the data reading mode for item AA,
(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.
Q: Is the sensor operating properly?
MB991827 00DB076A Cope with Intermittent Malfunctions P.00-14.
NO : Replace the mass airflow sensor.Then go to Step 2.

DTC P0102: Mass Airflow Circuit Low Input.
CAUTION CONNECTOR: B-10

If DTC P0102 has been set, TCL related DTC MASS
U1120 is also set. After P0102 has been diag- AIRFLOW
SENSOR
nosed, don't forget to erase DTC U1120.
CONNECTOR: B-17X
B-10 (GR)
MFI RELAY
03DB217A
AIR
CLEANER
MFI RELAY COVER

FRONT OF VEHICLE ENGINE
CONTROL
2 1 2 1 2 1 2 1 UNIT
4 3 4 3 4 3 4 3
B-17X
AK303014 AB
16DB400A
• Crankshaft revolution is above 150 r/min.

.
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). .
. EOBD DRIVE CYCLE PATTERN

TECHNICAL DESCRIPTION Refer to Diagnostic Function − EOBD Drive Cycle −
• While the engine is running, the mass airflow P.13A-11.
sensor outputs voltage which corresponds to the
mass airflow rate.
.

• The ENGINE-ECU checks whether the voltage
output by the mass airflow sensor while the likely causes for this code to be set are:)
engine is running is within a specified speed and • Mass airflow sensor failed.
load range. • Open or shorted mass airflow sensor circuit, or
connector damage.
.
DTC SET CONDITIONS

Check Conditions • Refer to circuit diagrams GROUP-90
• Battery voltage is above 8.01 volts.
DIAGNOSIS
• MB991824: V.C.I.
• MB992044: ECU Check Harness

CAUTION
CONNECTOR
to 95°C (176°F to 203°F).
MB991910
mately 4.7 g/sec.
MB991824
MB991827 00DB076A
NO : Go to Step 2.
STEP 2. Check harness connector B-10 at mass airflow

sensor for damage.
CONNECTOR: B-10
YES : Go to Step 3.
HARNESS Connector Inspection P.00E-2. Then go to Step 11.
CONNECTOR:
COMPONENT SIDE
B-10 (GR)
03DB218A
STEP 3. Measure the power supply voltage at mass airflow

sensor harness side connector B-10.
CONNECTOR: B-10
side.
HARNESS (3) Measure the voltage between terminal No. 2 and ground.
CONNECTOR:
COMPONENT SIDE • Voltage should be battery positive voltage.
B-10 (GR)
present?
YES : Go to Step 5.
03DB218A NO : Go to Step 4.
B-10 HARNESS
CONNECTOR:
COMPONENT SIDE
03DB220A
STEP 4. Check harness connector B-17X at MPI relay for

damage.
B-17X (terminal No. 4) and mass airflow sensor
connector B-10 (terminal No. 2) because of open
circuit or short circuit to ground. Then go to Step 11.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

damage.
YES : Go to Step 6.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 6. Measure the sensor output voltage at

ENGINE-ECU connector B-20 by using ECU check
harness special tool MB992044.
ECU check harness special tool MB992044 between the
separated connectors.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

B-20 HARNESS • When the engine is revved, voltage should be increase
CONNECTOR
in response to revving.
Q: Is the measured voltage normal?
YES : Go to Step 9.
NO : Go to Step 7.
03DB225A

between mass airflow sensor connector B-10 (terminal No.
CONNECTOR: B-10
YES : Replace the mass airflow sensor. Then go to Step 8.
HARNESS
CONNECTOR:
COMPONENT SIDE
B-10 (GR)
03DB218A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 8. Replace the mass airflow sensor.

CONNECTOR: B-10 (1) Replace the mass airflow sensor.
HARNESS
CONNECTOR: (3) Check the diagnostic trouble code (DTC).
COMPONENT SIDE
B-10 (GR) YES : Then go to Step 11.
03DB218A

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CAUTION
CONNECTOR
to 95°C (176°F to 203°F).
MB991910
mately 4.7 g/sec.
MB991824
MB991827 00DB076A
NO : Then go to Step 11.

DTC P0103: Mass Airflow Circuit High Input.
CAUTION
CONNECTOR: B-10
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
MFI RELAY COVER

FRONT OF VEHICLE
ENGINE
CONTROL
2 1 2 1 2 1 2 1
UNIT
4 3 4 3 4 3 4 3
B-17X
AK303014 AB
16DB400A
Crankshaft revolution is above 150 r/min.

.
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). .
. EOBD DRIVE CYCLE PATTERN

TECHNICAL DESCRIPTION Refer to Diagnostic Function − EOBD Drive Cycle −
• While the engine is running, the mass airflow P.13A-11.
sensor outputs voltage which corresponds to the
mass airflow rate.
.

• The ENGINE-ECU checks whether the voltage
output by the mass airflow sensor while the likely causes for this code to be set are:)
engine is running is within a specified speed and • Mass airflow sensor failed.
load range. • Shorted mass airflow sensor, circuit, or connector
damage.
.
DTC SET CONDITIONS

• Battery voltage is above 8.01 volts.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
to 95°C (176°F to 203°F).
MB991910
mately 4.7 g/sec.
MB991824 increase according to the increase in engine speed.
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check harness connector B-10 at mass airflow

sensor for damage.
YES : Go to Step 3.
HARNESS NO : Repair or replace it. Refer to GROUP 00E, Harness
CONNECTOR: Connector Inspection P.00E-2. Then go to Step 7.
COMPONENT SIDE
B-10 (GR)
03DB218A
STEP 3. Check the continuity at mass airflow sensor

harness side connector B-10.
side.
(2) Check for the continuity between terminal No. 3 and
HARNESS
CONNECTOR: ground.
COMPONENT SIDE • Should be less than 2 ohms.
Q: Does continuity exist?
B-10 (GR)
YES : Go to Step 6.
NO : Go to Step 4.
03DB218A
B-10 HARNESS
CONNECTOR:
COMPONENT SIDE
03DB219A

damage.
YES : Go to Step 5.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 5. Check for short circuit between mass airflow

sensor connector B-10 (terminal No. 3) and ENGINE-ECU
YES : Go to Step 6.
HARNESS
CONNECTOR:
COMPONENT SIDE
B-10 (GR)
03DB218A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
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
MB991827
00DB076A
NO : Replace the Mass Airflow Sensor. Then go to Step 7.

DTC P0106: Manifold Absolute Pressure Circuit Range/Performance Problem.
CONNECTOR: B-02
MANIFOLD
ABSOLUTE
PRESSURE AIR
INTAKE SENSOR CLEANER
MANIFOLD
B-02 (B) COVER

ENGINE
CONTROL
UNIT
03DB222A
16DB400A
. .

• A 5-volt voltage is supplied to the manifold abso- • The manifold absolute pressure sensor outputs a
lute pressure sensor power terminal (terminal No. voltage which corresponds to the intake manifold
3) from the ENGINE-ECU (terminal No. 25). The pressure.
ground terminal (terminal No. 2) is grounded with • The ENGINE-ECU checks whether this voltage is
ENGINE-ECU (terminal No. 12). within a specified range.
• A voltage that is proportional to the intake mani- .
fold pressure is sent to the ENGINE-ECU (termi-

nal No. 41) from the manifold absolute pressure
sensor output terminal (terminal No. 1).
DTC SET CONDITIONS <Range/Performance problem>

• None Refer to Diagnostic Function − EOBD Drive Cycle −
Judgement Criteria P.13A-11.
• MAP sensor output is above upper threshold .
(223 - 1300 hPa) for 2 seconds. TROUBLESHOOTING HINTS (The most

MAP sensor output is below lower threshold (0 -
• Manifold absolute pressure sensor failed.
395 kg/h) for 2 seconds.
• Harness damage.
• MIL is activated after 2 Drive cycles.
• Connector damage.
• No limp home mode (backed-up by AFS).
.
DIAGNOSIS
• MB991824: V.C.I.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(3) Measure the voltage between terminal No. 41 of

B-20 HARNESS ENGINE-ECU check harness and ground.
CONNECTOR
• When altitude is 0 m, voltage should be 4.01 to 4.15
volts.
volts.
• When altitude is 1,200 m, voltage should be 3.45 to 3.62
volts.
03DB224A
volts.
Q: Is the measured voltage correct?
NO : Go to Step 2.
STEP 2. Measure the sensor supply voltage at

CONNECTOR: B-02 (1) Disconnect the all ENGINE-ECU connectors and connect
MANIFOLD ECU check harness special tool MB992044 between the
ABSOLUTE separated connectors.
PRESSURE
INTAKE SENSOR (2) Turn the ignition switch to the "ON" position.
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
(3) Measure the sensor supply voltage between terminal No.

B-20 HARNESS 25 and ground.
CONNECTOR • Voltage should be between 4.9 and 5.1 volts.
Q: Is the measured voltage between 4.9 and 5.1 volts?
YES : Go to Step 3.
03DB225A
STEP 3. Check harness connector B-02 at the manifold

absolute pressure sensor and harness connector B-20 at
ENGINE-ECU for damage.
MANIFOLD YES : Go to step 4.
ABSOLUTE NO : Repair or replace it. Refer to GROUP 00E, Harness
PRESSURE
INTAKE SENSOR Connector Inspection P.00E-2. Then go to Step 10.
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for harness damage between manifold

absolute pressure sensor connector B-02 (terminal No. 3)
and ENGINE-ECU connector B-20 (terminal No. 25).
MANIFOLD YES : Go to Step 5.
ABSOLUTE NO : Repair it. Then go to Step 10.
PRESSURE
INTAKE SENSOR
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 5. Measure the ground voltage at ENGINE-ECU

connector B-20 by using ECU check harness special tool
MB992044.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

B-20 HARNESS • Voltage should be 0.5 volt or less.
Q: Is the measured voltage 0.5 volt or less?
YES : Go to Step 8.
NO : Go to Step 6.
03DB242A

PRESSURE
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 7. Check for harness damage between manifold

absolute pressure sensor connector B-02 (terminal No. 2)
and ENGINE-ECU connector B-20 (terminal No. 12).
PRESSURE
INTAKE SENSOR
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 8. Check harness connector B-02 at manifold

absolute pressure sensor for damage.
CONNECTOR: B-02
MANIFOLD YES : Replace the manifold absolute pressure sensor. Then
ABSOLUTE go to Step 10.
PRESSURE
INTAKE SENSOR NO : Repair or replace it. Refer to GROUP 00E, Harness
MANIFOLD Connector Inspection P.00E-2. Then go to Step 10.
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
volts.
volts.
volts.
03DB224A
volts.
NO : Repair harness wire between manifold absolute
pressure sensor connector B-02 (terminal No. 1) and
ENGINE-ECU connector B-20 (terminal No. 41)
because of harness damage. Then go to Step 10.

DTC P0107: Manifold Absolute Pressure Circuit Low Input.
CONNECTOR: B-02
MANIFOLD
ABSOLUTE
PRESSURE AIR
MANIFOLD
B-02 (B) COVER

ENGINE
CONTROL
UNIT
03DB222A
16DB400A
. .

3) from the ENGINE-ECU (terminal No. 25). The pressure.

DTC SET CONDITIONS

Check Conditions
.
• None
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
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
volts.
volts.
volts.
03DB224A
volts.
NO : Go to Step 2.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(3) Measure the sensor supply voltage between terminal No.

B-20 HARNESS 25 and ground.
CONNECTOR • Voltage should be between 4.9 and 5.1 volts.
YES : Go to Step 8.
NO : Go to Step 3.
03DB225A

damage.
YES : Go to Step 4.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for short circuit to ground between

manifold absolute pressure sensor connector B-02
(terminal No. 3) and ENGINE-ECU connector B-20 (terminal
No. 25).
CONNECTOR: B-02
PRESSURE
INTAKE SENSOR
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

absolute pressure sensor for damage.
Q: Is the connector in good condition?
CONNECTOR: B-02
MANIFOLD YES : Repair harness wire between manifold absolute
ABSOLUTE pressure sensor connector B-02 (terminal No. 3) and
PRESSURE
INTAKE SENSOR ENGINE-ECU connector B-20 (terminal No. 25)
MANIFOLD because of open circuit. Then go to Step 12.
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A

absolute pressure sensor and connector B-20 at
CONNECTOR: B-02
PRESSURE Connector Inspection P.00E-2. Then go to Step 12.
INTAKE SENSOR
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
volts.
volts.
volts.
03DB224A
volts.
NO : Go to Step 10.
STEP 10. Check for open or short circuit to ground

between manifold absolute pressure sensor connector
(terminal No. 41).
CONNECTOR: B-02
PRESSURE NO : Repair it. Then go to Step 12.
INTAKE SENSOR
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
volts.
volts.
volts.
03DB224A
volts.
NO : Replace the sensor. Then go to Step 12.

DTC P0108: Manifold Absolute Pressure Circuit High Input.
CONNECTOR: B-02
MANIFOLD
ABSOLUTE
PRESSURE AIR
MANIFOLD
B-02 (B) COVER

HARNESS ENGINE
CONNECTOR: CONTROL
COMPONENT SIDE UNIT
3 2 1 03DB223A
16DB400A
. .

3) from ENGINE-ECU (terminal No. 25). The pressure.

DTC SET CONDITIONS

Check Conditions
.
• None
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
• MB991824: V.C.I.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(3) Measure and record the voltage between terminal No. 41 of

CONNECTOR
volts.
volts.
volts.
03DB224A
volts.
NO : Go to Step 2.
STEP 2. Measure the ground voltage at manifold absolute

pressure sensor connector B-02 by backprobing.
CONNECTOR: B-02 (1) Do not disconnect the connector B-02.
MANIFOLD (2) Turn the ignition switch to the "ON" position.
ABSOLUTE
PRESSURE
INTAKE SENSOR
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
(3) Measure the voltage between terminal No. 2 and ground by

backprobing.
• Voltage should be 0.5 volt or less.
B-02 HARNESS
HARNESS SIDE Q: Is the measured voltage 0.5 volt or less?
YES : Go to Step 6.
1 2 3
NO : Go to Step 3.
AK303030 AB

PRESSURE
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for open circuit between manifold absolute

pressure sensor connector B-02 (terminal No. 2) and
ENGINE-ECU connector B-20 (terminal No. 12).
CONNECTOR: B-02
PRESSURE
INTAKE SENSOR
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 5. Refer to data checked in Step 1.

(1) Use the data recorded during Step 1 of diagnosis flow.
DATA LINK
CONNECTOR Q: Is the sensor operating properly?
NO : Replace the ENGINE-ECU. Then go to Step 7.
MB991910
MB991824
MB991827 00DB076A

PRESSURE
INTAKE SENSOR NO : Repair or replace it. Refer to GROUP 00E, Harness
MANIFOLD
B-02 (B)
HARNESS
CONNECTOR:
COMPONENT SIDE
3 2 1 03DB223A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

DTC P0112: Intake Air Temperature Circuit Low Input.
CAUTION CONNECTORS: B-21, B-22

nosed, don't forget to erase DTC U1120. PCM
CONNECTOR: B-10
MASS AIR CLEANER
AIRFLOW
SENSOR
B-10 (GR)
B-21 (B)
B-22 (B)
03DB217A
AK303013 AB
• The intake air temperature sensor output voltage

.
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 .
the resistor in the ENGINE-ECU. The ground ter- TECHNICAL DESCRIPTION

minal (terminal No. 3) is grounded with • The intake air temperature sensor is contained
ENGINE-ECU (terminal No. 26). within the Mass Airflow Sensor assembly and
• The intake air temperature sensor is a negative converts the intake air temperature to a voltage.
temperature coefficient type of resistor. When the • The ENGINE-ECU checks whether this voltage is
intake air temperature rises, the resistance within a specified range.
decreases. .
DTC SET CONDITIONS

Check Conditions
.
• None
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
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

Intake Air Temperature Sensor.
CAUTION
CONNECTOR
• The actual intake air temperature and temperature
shown with the diagnostic tool should approximately
MB991910
match.
MB991824
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check harness connector B-10 at the intake air

temperature sensor for damage.
YES : Go to Step 3.
COMPONENT SIDE
B-10 (GR)
03DB218A
STEP 3. Check the intake air temperature sensor.

CONNECTOR: B-10 (1) Disconnect the intake air temperature sensor connector
B-10.
HARNESS
CONNECTOR:
COMPONENT SIDE
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
STEP 4. Check for short circuit to ground between intake

air temperature sensor connector B-10 (terminal No. 1) and
YES : Go to Step 5.
HARNESS
CONNECTOR:
COMPONENT SIDE
B-10 (GR)
03DB218A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

DTC P0113: Intake Air Temperature Circuit High Input.

CONNECTOR: B-10
MASS AIR CLEANER
AIRFLOW
SENSOR
B-10 (GR)
B-21 (B)
B-22 (B)
03DB217A
AK303013 AB
• The intake air temperature sensor output voltage

.
CIRCUIT OPERATION
increases when the resistance increases and
• Approximately 5 volts are applied to the intake air decreases when the resistance decreases.

minal (terminal No. 3) is grounded with • The intake air temperature sensor is contained
ENGINE-ECU (terminal No. 26). within the Mass Airflow Sensor assembly and
• The intake air temperature sensor is a negative converts the intake air temperature to a voltage.
temperature coefficient type of resistor. When the • The ENGINE-ECU checks whether this voltage is
intake air temperature rises, the resistance within a specified range.
decreases. .
DTC SET CONDITIONS

Check Conditions
.
• None.
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.
.
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
• The actual intake air temperature and temperature
MB991910
match.
MB991824
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check harness connector B-10 at the intake air

temperature sensor for damage.
YES : Go to Step 3.
COMPONENT SIDE
B-10 (GR)
03DB218A
STEP 3. Check the intake air temperature sensor.

CONNECTOR: B-10 (1) Disconnect the intake air temperature sensor connector
B-10.
HARNESS
CONNECTOR:
COMPONENT SIDE
B-10 (GR)
03DB218A
(2) Measure the resistance between intake air temperature

sensor side connector terminal No. 1 and No. 3.
SENSOR CONNECTOR • There should be continuity. (300Ω − 16 kΩ)
Q: Is the measured resistance between 300Ω and 16 kΩ?
YES : Go to Step 4.
NO : Replace the Mass Airflow Sensor assembly. Then go
to Step 11.
03DB158A
STEP 4. Measure the sensor supply voltage at intake air

temperature sensor harness side connector B-10.
side.
HARNESS
CONNECTOR:
COMPONENT SIDE
B-10 (GR)
03DB218A

B-10 HARNESS • Voltage should be between 4.5 and 4.9 volts.
COMPONENT SIDE
YES : Go to Step 8.
NO : Go to Step 5.
03DB226A

AIR (2) Disconnect the intake air temperature sensor connector
CLEANER
B-10.
COVER
ENGINE
CONTROL • Voltage should be between 4.5 and 4.9 volts.
UNIT (5) Turn the ignition switch to the "LOCK" (OFF) position.
YES : Go to Step 6.
NO : Go to Step 7.
16DB400A
B-20 HARNESS
CONNECTOR
03DB227A

damage.
YES : Repair harness wire between intake air temperature
sensor connector B-10 (terminal No. 1) and
AIR ENGINE-ECU connector B-20 (terminal No. 58)
CLEANER because of open circuit. Then go to Step 11.
COVER Connector Inspection P.00E-2. Then go to Step 11.
ENGINE
CONTROL
UNIT
16DB400A

damage.
AIR Troubleshooting/Inspection Service Points − How to
CLEANER Cope with Intermittent Malfunctions P.00-14.
ENGINE
CONTROL
UNIT
16DB400A
STEP 8. Check the continuity at intake air temperature

side.
HARNESS
CONNECTOR:
COMPONENT SIDE
B-10 (GR)
03DB218A

B-10 HARNESS ground.
CONNECTOR: • Should be less than 2 ohms.
COMPONENT SIDE
NO : Go to Step 9.
03DB219A

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 10. Check for open circuit between intake air

temperature sensor connector B-10 (terminal No. 3) and
CONNECTOR: B-10
HARNESS
CONNECTOR:
COMPONENT SIDE
B-10 (GR)
03DB218A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

DTC P0116: Engine Coolant Temperature Circuit Range/Performance Problem.

CONNECTOR: B-104
AIR CLEANER
B-104 (B)
THROTTLE
ENGINE BODY B-21 (B)
COOLANT B-22 (B)
TEMPERATURE
SENSOR
AK303036AB
AK303013 AB
• The engine coolant temperature sensor output

.
CIRCUIT OPERATION voltage increases when the resistor increases

• 5-volt voltage is applied to the engine coolant and decreases when the resistance decreases.

minal (terminal No. 2) is grounded with • The engine coolant temperature sensor converts
ENGINE-ECU (terminal No. 12). the engine coolant temperature to a voltage and
• The engine coolant temperature sensor is a neg- outputs it.
ative temperature coefficient type of resistor. It • The ENGINE-ECU checks whether this voltage is
has the characteristic that when the engine cool- within a specified range.
ant temperature rises the resistance decreases. .
DTC SET CONDITIONS

Check Conditions
.
• Air mass flow.

Judgement Criteria • Engine coolant temperature sensor failed.
• Difference between real engine temperature and • Harness damage or connector damage.
model temperature. • Refer to component locations GROUP-70
• MIL is activated after 2 Drive cycles. • Refer to configuration diagrams GROUP-80
• No limp home mode. • Refer to circuit diagrams GROUP-90
.

Refer to Diagnostic Function−EOBD Drive Cycle−
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

Engine Coolant Temperature Sensor.
CAUTION
CONNECTOR
• The actual engine coolant temperature and the temper-
ature shown with the diagnostic tool should approxi-
MB991910
mately match.
MB991824
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check the engine coolant temperature sensor(On

Car).
(1) Ensure engine coolant temperature is between 20° C and
CONNECTOR: B-104
below 100° C.
(2) Disconnect the engine coolant temperature sensor
B-104 (B) connector B-104.
(3) Check the resistance between terminal No. 1 & No. 2 of the
sensor.
THROTTLE Q: Is the measured resistance between 186Ω and 2.4 kΩ?
2 1 BODY
YES : Go to Step 3.
HARNESS
CONNECTOR: NO : Replace the sensor and go to Step 10.
STEP 3. Check the engine coolant temperature sensor(Off

Car).
CONNECTOR: B-104
connector B-104.
(2) Remove the engine coolant temperature sensor.
B-104 (B)
WARNING
Ensure cooling system pressure is released at radia-
tor cap slowly, prior to removing sensor to avoid get-
THROTTLE
2 1 BODY ting burned by hot coolant.
HARNESS
CONNECTOR:
(3) With the temperature sensing portion of engine coolant

temperature sensor immersed in hot water, measure
resistance.Refer to Service Specifications 13A-677
AKX01622
(4) Apply 3M™ AAD part number 8731 or equivalent on the

screw section of the engine coolant temperature sensor.
(5) Install the engine coolant temperature sensor, and tighten
Tightening torque: 21 ± 3 N⋅m
Q: Is the measured resistance normal?
YES : Go to Step 4.
NO : Go to Step 6.
AKX01623 AB
STEP 4. Check harness connector B-104 at the engine

coolant temperature sensor for damage.
CONNECTOR: B-104
YES : Go to Step 5.
B-104 (B) Connector Inspection P.00E-2. Then go to Step 11.
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
STEP 5. Check for continuity at engine coolant

CONNECTOR: B-104
(1) Disconnect the connector B-104 and measure at the
harness side.
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:

CONNECTOR:
2 1 Q: Does continuity exist?
YES : Go to Step 8.
NO : Go to Step 6.
AK000235 AQ

damage.
YES : Go to Step 7.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 7. Check for harness damage between engine

coolant temperature sensor connector B-104 (terminal No.
CONNECTOR: B-104
YES : Go to Step 8.
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
YES : Go to Step 9.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 9. Check for harness damage between engine

CONNECTOR: B-104
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
• The engine coolant temperature and temperature
MB991910
match.
MB991824
YES : The inspection is complete.
MB991827 00DB076A

DTC P0117: Engine Coolant Temperature Circuit Low Input.
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.
CONNECTOR: B-104 COVER

ENGINE
CONTROL
UNIT
B-104 (B)
THROTTLE
ENGINE BODY
COOLANT
TEMPERATURE
SENSOR
AK303036AB 16DB400A

.
CIRCUIT OPERATION voltage increases when the resistance increases


DTC SET CONDITIONS

Check Conditions
.
• Mass air flow.

• Engine coolant temperature is below -39 • Shorted engine coolant temperature sensor cir-
degreeC for 0.5 second. cuit, or connector damage.
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
mately match.
MB991824
NO : Go to Step 2.
MB991827 00DB076A

CONNECTOR: B-104 YES : Go to Step 3.
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
STEP 3. Check for short circuit to ground between engine

CONNECTOR: B-104
YES : Go to Step 4.
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
YES : Go to Step 5.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

Car).
CONNECTOR: B-104
below 100° C.
sensor.
2 1 BODY
YES : Go to Step 6.
HARNESS

Car).
CONNECTOR: B-104
connector B-104.
B-104 (B)
WARNING
Ensure cooling system pressure is released at radia-
tor cap slowly, prior to removing sensor to avoid get-
THROTTLE
2 1 BODY ting burned by hot coolant.
HARNESS
CONNECTOR:

AKX01622

Q: Is the measured resistance at the standard value?
NO : Replace the engine coolant sensor. Then go to Step
AKX01623 AB 7.

DTC P0118: Engine Coolant Temperature Circuit High Input.
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.
CONNECTOR: B-104 COVER

ENGINE
CONTROL
UNIT
B-104 (B)
THROTTLE
ENGINE BODY
COOLANT
TEMPERATURE
SENSOR
AK303036AB 16DB400A

.
CIRCUIT OPERATION voltage increases when the resistance increases


DTC SET CONDITIONS

Check Conditions
.
• Mass air flow.

• Engine coolant temperature is above 138.8 • Open engine coolant temperature sensor circuit,
degreeC for 0.5 second. or connector damage.
.
• Short to 12 volt.
EOBD DRIVE CYCLE PATTERN • Refer to component locations GROUP-70
Refer to Diagnostic Function−EOBD Drive Cycle− • Refer to configuration diagrams GROUP-80
P.13A-11. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
mately match.
MB991824
NO : Go to Step 2.
MB991827 00DB076A

CONNECTOR: B-104
YES : Go to Step 3.
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
STEP 3. Measure the sensor supply voltage at engine

coolant temperature sensor harness side connector B-104.
CONNECTOR: B-104
harness side.
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:

B-104 HARNESS
CONNECTOR: • Voltage should be between 4.5 and 4.9 volts.
COMPONENT SIDE (4) Turn the ignition switch to the "LOCK" (OFF) position.
2 1 Q: Is the measured voltage between 4.5 and 4.9 volts?
YES : Go to Step 7.
NO : Go to Step 4.
AK303039 AB

AIR (2) Disconnect the engine coolant temperature sensor
CLEANER connector B-104.
COVER
ENGINE
CONTROL
UNIT
16DB400A

• Voltage should be between 4.5 and 4.9 volts.
B-20 HARNESS
YES : Go to Step 5.
NO : Go to Step 6.
03DB228A

damage.
YES : Repair harness wire between engine coolant
temperature sensor connector B-104 (termial No. 1)
AIR and ENGINE-ECU connector B-20 (termial No. 56)
CLEANER because of open circuit. Then go to Step 13.
ENGINE
CONTROL
UNIT
16DB400A

damage.
YES : Go to Step 7.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 7. Check the continuity at engine coolant

CONNECTOR: B-104
harness side.
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:

B-104 HARNESS
CONNECTOR: ground.
NO : Go to Step 8.
AK303040 AB

damage.
YES : Go to Step 9.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 9. Check for open circuit between engine coolant

sensor connector B-104 (terminal No. 2) and ENGINE-ECU
CONNECTOR: B-104
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

Car).
CONNECTOR: B-104
below 100° C.
sensor.
2 1 BODY
HARNESS

Car).
CONNECTOR: B-104
connector B-104.
B-104 (B)
THROTTLE
2 1 BODY
HARNESS
CONNECTOR:

AKX01622

Q: Is the measured resistance at the standard value?
NO : Replace the engine coolant sensor. Then go to Step
AKX01623 AB 13.

CAUTION
CONNECTOR
• The engine coolant temperature and temperature
MB991910
match.
MB991824
YES : The inspection is complete.
MB991827 00DB076A

NEXT PAGE
PREVIOUS PAGE MULTIPORT FUEL INJECTION (MPI)
MULTIPORT FUEL INJECTION (MPI) DIAGNOSIS
13A-148
13A
DTC P0122: Throttle Position Sensor (Main) Circuit Low Input.
CAUTION
AIR
CONNECTOR: B-06
COVER
ENGINE
CONTROL
UNIT
B-06 (B)
03DB180A
16DB400A
. .

• 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 connector B-20 ing angle.
(terminal No. 10). • The ENGINE-ECU checks whether the voltage is
The ground terminal (terminal No. 2) is grounded within a specified range.
with ENGINE-ECU connector B-20 (terminal No. .
27).
DTC SET CONDITIONS

Check Condition
.
• Ignition switch is "ON" position.

Judgement Criteria • Throttle position sensor failed.
• Throttle position sensor (main) output voltage is • Open or shorted throttle position sensor (main)
low. circuit, harness damage, or connector damage.
• MIL activated immediately • Refer to component locations GROUP-70
• Engine speed limited to 1500rpm. • Refer to configuration diagrams GROUP-80
None.
MULTIPORT FUEL INJECTION (MPI) 13A-149
DIAGNOSIS
• MB991824: V.C.I.
• 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.

Throttle Position Sensor (main).
CAUTION
DATA LINK ignition switch to the "LOCK"(OFF) position before con-
CONNECTOR necting or disconnecting diagnostic tool .
(4) Apply the accelerator pedal as required to check the
following:
MB991910 • Output voltage should be between 1035 and 1250 mV
when the throttle valve is fully close.
MB991824 • Output voltage should be approximately 4000 and 4824
mV when the throttle valve is fully open.
(5) Turn the ignition switch to the "LOCK"(OFF) position.
MB991827 00DB076A NO : Go to Step 2.
STEP 2. Check harness connector B-06 at throttle position

sensor for damage.
CONNECTOR: B-06
YES : Go to Step 3.
B-06 (B)
03DB180A
STEP 3. Measure the sensor supply voltage at throttle

position sensor harness side connector B-06.
CONNECTOR: B-06 side.
B-06 (B)
03DB180A
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.
YES : Go to Step 6.
NO : Go to Step 4.
03DB195A

damage.
YES : Go to Step 5.
AIR
CLEANER Connector Inspection P.00E-2. Then go to Step 9.
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 5. Check for open circuit and short circuit to ground

between throttle position sensor connector B-06 (terminal
No. 3) and ENGINE-ECU connector B-20 (terminal No. 10).
CONNECTOR: B-06
YES : Go to Step 6.
NO : Repair or replace it. Then go to Step 9.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 6. Check for harness damage between throttle

position sensor connector B-06 (terminal No. 3) and
CONNECTOR: B-06
YES : Go to Step 7.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 7. Check for open circuit, short circuit to ground and

harness damage between throttle position sensor
CONNECTOR: B-06
YES : Go to Step 8.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 8. Replace the throttle body assembly.

(1) Replace the throttle body assembly.
CONNECTOR: B-06
(3) After the DTC has been deleted, read the DTC again.
B-06 (B)
03DB180A
STEP 9. Using diagnostic tool, read the diagnostic trouble

code (DTC).
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 .
MB991910
MB991824
MB991827 00DB076A
DTC P0123: Throttle Position Sensor (main) Circuit High Input.
CAUTION
AIR
CONNECTOR: B-06
COVER
ENGINE
CONTROL
UNIT
B-06 (B)
03DB180A
16DB400A
.
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.
.
DTC SET CONDITIONS

Check Conditions
.

• Throttle position sensor (main) output voltage is • Refer to configuration diagrams GROUP-80
above range. • Refer to circuit diagrams GROUP-90
• MIL activated immediately • Throttle position sensor failed.
• Engine speed limited to 1500rpm. • Open throttle position sensor (main) circuit, or
.
harness damage or connector damage.
EOBD DRIVE CYCLE PATTERN • Short circuit to 5 volt.
None.
DIAGNOSIS
• MB991824: V.C.I.
WARNING

CAUTION
CONNECTOR
following:
MB991910
• Output voltage should be between 1035 and 1250 mV
MB991824
when the throttle valve is fully open.
MB991827 00DB076A
NO : Go to Step 2.

sensor for damage.
CONNECTOR: B-06
YES : Go to Step 3.
B-06 (B)
03DB180A
STEP 3. Check the continuity at throttle position sensor

CONNECTOR: B-06
side.
B-06 (B)
03DB180A
(2) Measure the continuity between terminal No. 2 and ground

THROTTLE ACTUATOR • Should be less than 2 ohms.
CONTROL MOTOR
CONNECTOR Q: Does continuity exist?
YES : Go to Step 6.
NO : Go to Step 4.
03DB197A

damage.
YES : Go to Step 5.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 5. Check for open circuit and harness damage

No. 2) and ENGINE-ECU connector B-20 (terminal No. 27).
CONNECTOR: B-06
YES : Go to Step 6.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: B-06
NO : The procedure is complete.
B-06 (B)
03DB180A

code (DTC).
CAUTION
DATA LINK tion switch to the "LOCK"(OFF) position before connect-
CONNECTOR
ing or disconnecting diagnostic tool .
MB991910 YES : Retry the troubleshooting.
MB991824
MB991827 00DB076A
DTC P0130: Heated Oxygen Sensor Circuit (bank 1, sensor 1).

HEATED OXYGEN
SENSOR (FRONT)
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
THROTTLE BODY
B-09 (B) 16DB400A
AK303047 AB
DTC SET CONDITIONS

.
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
sensor (front) is grounded with ENGINE-ECU
• No limp home.
(terminal No. 44).
.

.
• 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.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool, check data list item AC:

Heated Oxygen Sensor Bank 1, Sensor 1 (right front).
CAUTION
DATA LINK tion switch to the "LOCK" (OFF) position before connect-
CONNECTOR
(3) Ensure engine is at running temperature (80° C or higher).
(4) Set diagnostic tool to the data reading mode for item AC,
• Warm engine. When the engine is revved up and down,
MB991910
the output voltage should cycle between 0.1 to 1.0 volt.
• Warm engine. When the engine is idling, the output volt-
MB991824
age should alternate between 0.1 to 0.6 -1.0 volt.
NOTE: If data list readings are consistantly low or appear
slow to cycle( should cycle every 0.5-1.0 sec.) during check
the sensor is likely to be malfuctioning. Ensure wiring and
connector checks are performed prior to replacing sensor.
MB991827 00DB076A YES : It can be assumed that this malfunction is intermittent.
NO : Go to Step 2.

ENGINE-ECU connector B-20 by using ENGINE-ECU
check harness special tool MB992044.
(1) Disconnect the ENGINE-ECU connectors and connect
AIR (2) Start the engine and run at idle.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

B-20 HARNESS • Warm engine. When the engine is 2,500 r/min, the out-
CONNECTOR
put voltage should cycle between 0.1 to 0.8-1.0 volt
alternately.
Q: Is the measured voltage cycling within the specified
range?
YES : Go to Step 6.
NO : Go to Step 3.
03DB199A
STEP 3. Check harness connector B-09 at right bank

heated oxygen sensor (front) and harness connector B-20
at ENGINE-ECU for damage or loose terminals.
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for short to heater circuit ground harness

wire between right bank heated oxygen sensor (front)
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
MB991824
age should alternate between 0.1 to 0.6 - 1.0 volt.
NOTE: If data list readings are low or appear slow to cycle
during check the sensor is likely to be malfuctioning. Ensure
wiring and connector checks are performed prior to replac-
ing sensor.
NO : Replace the faulty oxygen sensor. Then go to Step 6.

DTC P0131: Heated Oxygen Sensor Circuit Low Voltage (bank 1, sensor 1).

HEATED OXYGEN
SENSOR (FRONT)
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
THROTTLE BODY
16DB400A
B-09 (B)
AK303047 AB
DTC SET CONDITIONS

.
CIRCUIT OPERATION
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 .
sensor signal response becomes poor. TROUBLESHOOTING HINTS (The most

• The ENGINE-ECU forcibly varies the air/fuel mix- likely causes for this code to be set are:)
ture to make it leaner and richer, and checks the
• Right bank heated oxygen sensor (front) failed.
response speed of the right bank heated oxygen
• Short circuit to ground in right bank heated oxy-
sensor (front). In addition, the ENGINE-ECU also
gen sensor (front) output line.
• Wiring harness or connector damage.
heated oxygen sensor (front) output line.
.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
MB991910 the output voltage should cycle between 0.1 to 1.0 volt.
MB991824 age should alternate between 0.1 to 0.6 -1.0 volt.
MB991827 00DB076A
NO : Go to Step 2.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
alternately.
range?
YES : Go to Step 6.
03DB199A

heated oxygen sensor (front) and connector B-20 at
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for short circuit to ground in the harness

between right bank heated oxygen sensor (front)
HEATED OXYGEN YES : Then go to Step 5.
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
MB991824
ing sensor.

NO : The inspetion is complete.
DTC P0132: Heated Oxygen Sensor Circuit High Voltage (bank 1, sensor 1).

HEATED OXYGEN
SENSOR (FRONT)
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
THROTTLE BODY
16DB400A
B-09 (B)
AK303047 AB
DTC SET CONDITIONS

.
CIRCUIT OPERATION
oxygen sensor (front). Judgment Criteria
• Terminal No. 2 of the right bank heated oxygen • Internal Resistance of the Nernst - cell is equal or
elled exhasused gas temperature.
.
• Idling.
• The right bank heated oxygen sensor (front) • No limp home.
.
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 .
sensor signal response becomes poor. TROUBLESHOOTING HINTS (The most

• The ENGINE-ECU forcibly varies the air/fuel mix- likely causes for this code to be set are: )
• Short circuit to battery voltage in right bank
.
DIAGNOSIS

CAUTION
CONNECTOR
(5) Warm up the engine, hold at 2,500 r/min.
MB991910
• Output voltage alternates between 0.1 volt and 0.6 − 1.0
volt 10 times or more within 10 seconds.
MB991824
the sensor is likely to be malfuctioning.
MB991827 00DB076A Troubleshooting/Inspection Service Points − How to

heated oxygen sensor (front) and harness connector B-20
at ENGINE-ECU for damage.
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 3. Check for short circuit to power supply between

right bank heated oxygen sensor (front) connector B-09
No. 45).
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
MB991824

DTC P0133: Heated Oxygen Sensor Circuit Slow Response (bank 1, sensor 1).

HEATED OXYGEN
SENSOR (FRONT)
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
THROTTLE BODY
B-09 (B) 16DB400A
AK303047 AB
. .
CIRCUIT OPERATION DTC SET CONDITIONS

• 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. 45) from the output
terminal (terminal No. 1) of the right bank heated Judgment Criteria
oxygen sensor (front). • MIL is activated after 2 Drive cycles.
• Terminal No. 2 of the right bank heated oxygen • No limp home.
sensor (front) is grounded with ENGINE-ECU .
(terminal No. 44). EOBD DRIVE CYCLE PATTERN

.
TECHNICAL DESCRIPTION P.13A-11.
• The right bank heated oxygen sensor (front)
.

and inputs the resulting signals to the likely causes for this code to be set are: )
ENGINE-ECU. • Right bank heated oxygen sensor (front) deterio-
• When the right bank heated oxygen sensor rated.
(front) begins to deteriorate, the heated oxygen • Refer to component locations GROUP-70
sensor signal response becomes poor. • Refer to configuration diagrams GROUP-80
• The ENGINE-ECU forcibly varies the air/fuel mix- • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.


CAUTION
CONNECTOR
MB991910
MB991824

DTC P0134: Heated Oxygen Sensor Circuit No Activity Detected (bank 1, sensor 1).
.
CAUTION DTC SET CONDITIONS

U1120 is also set. After P0134 has been diag- Check Conditions
nosed, don't forget to erase DTC U1120. • Battery voltage < 11.02 volts
. • Engine coolant temperature is higher than 80°C.
CIRCUIT OPERATION
Judgment Criteria
• No limp home.
terminal (terminal No. 1) of the right bank heated .
oxygen sensor (front). EOBD DRIVE CYCLE PATTERN

• Terminal No. 2 of the right bank heated oxygen Refer to Diagnostic Function − EOBD Drive Cycle −
sensor (front) is grounded with ENGINE-ECU P.13A-11.
(terminal No. 44).
.
. TROUBLESHOOTING HINTS (The most

TECHNICAL DESCRIPTION likely causes for this code to be set are: )
• The right bank heated oxygen sensor (front) • Right bank heated oxygen sensor failed.
detects the concentration of oxygen in the • Open circuit in right bank heated oxygen sensor
exhaust gas; it converts those data to voltage, (front) output line.
and inputs the resulting signals to the • Open circuit in right bank heated oxygen sensor
ENGINE-ECU. (front) sensor ground.
• When the right bank heated oxygen sensor • Wiring harness or connector damage.
(front) begins to deteriorate, the heated oxygen • Refer to component locations GROUP-70
heated oxygen sensor (front) output and ground
lines.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
• Warming up the engine. When the engine is revved, the
MB991910
output voltage should alternate between 0 and 0.6 to 1.0
volts.
MB991824
MB991827 00DB076A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

B-20 HARNESS • Warm engine. When the engine is revved, the output
CONNECTOR
voltage should alternate between 0 and 0.6-1.0 volts.
range?
YES : Go to Step 6.
03DB199A

heated oxygen sensor (front) and connector B-20 at
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for open circuit between right bank heated

oxygen sensor (front) connector B-09 (terminal No. 1) and
SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

SENSOR (FRONT)
THROTTLE BODY
2 1 B-09 (B)
4 3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 6. Using diagnostic tool, check data list item AD:

Heated Oxygen Sensor Bank 1, Sensor 2 (right rear).
CAUTION
CONNECTOR
(4) Set diagnostic tool to the data reading mode for item AD,
MB991910
volts.
MB991824
MB991827 00DB076A
Then go to Step 7.

CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB
• Engine coolant temperature is higher than 80°C.

.
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 .

• The output signal of the right bank heated oxygen
sensor (front) is compensated by the output sig-
nal of the right bank heated oxygen sensor (rear). • Right bank heated oxygen sensor (rear) failed.
• The ENGINE-ECU checks for an open circuit in • Short circuit in right bank heated oxygen sensor
the right bank heated oxygen sensor (rear) output (rear) output line to heater circuit ground.
line. • Wiring harness or connector damage.
.

DTC SET CONDITIONS • Refer to circuit diagrams GROUP-90
Check Conditions
• Battery voltage < 11.02 volts
DIAGNOSIS
• : Diagnostic tool (MUT-III Sub Assembly)
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
volts.
MB991824
NO : Go to Step 2.
MB991827 00DB076A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

B-20 HARNESS • Warming up the engine. When the engine is 2,500 r/min,
CONNECTOR
the output voltage should repeat 0 volt and 0.6 to 1.0
volt alternately.
Q: Is the measured voltage within the specified range?
YES : Go to Step 6.
NO : Go to Step 3.
03DB203A

heated oxygen sensor (rear) and harness connector B-20
YES : Go to Step 4.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

wire between right bank heated oxygen sensor (rear)
YES : Go to Step 5.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB

.
CIRCUIT OPERATION • Engine start achieved.

tration in the exhaust gas is sent to the Judgement Criteria
ENGINE-ECU (terminal No. 60) from the output • Signal check.
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- EOBD DRIVE CYCLE PATTERN
minal No. 59).
.
P.13A-11.
.

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) failed.
the right bank heated oxygen sensor (rear) output • Short circuit to ground in right bank heated oxy-
line. gen sensor (rear) output line.
.
DTC SET CONDITIONS

• Battery voltage is between 10.7 and 16.1volts.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
(4) Set diagnostic tool to the data reading mode for itemAD,
MB991910
volts.
MB991824
MB991827 00DB076A Refer to GROUP 00, How to Use
NO : Go to Step 2.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
alternately.
range?
YES : Go to Step 3.
03DB199A Then go to Step 6.

YES : Go to Step 4.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for short circuit to ground between right

bank heated oxygen sensor (rear) connector B-08
No. 60).
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
volts.
MB991824

CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB

.

tration in the exhaust gas is sent to the Judgment Criteria
minal No. 59).
.
P.13A-11.
.

• The ENGINE-ECU checks for an open circuit in • Short circuit to battery voltage in right bank
the right bank heated oxygen sensor (rear) output heated oxygen sensor (rear) output line.
.
DTC SET CONDITIONS

Check Conditions
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

YES : Go to Step 3.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

right bank heated oxygen sensor (rear) connector B-08
No. 60).
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

CONNECTOR: B-08
AIR
CLEANER
COVER
ENGINE
RIGHT BANK CONTROL
HEATED OXYGEN UNIT
SENSOR (REAR)
THROTTLE BODY
16DB400A
B-08 (GR)
AK303063AB
DTC SET CONDITIONS

.
CIRCUIT OPERATION
tration in the exhaust gas is sent to the • Engine speed between 1320 and 3200rpm.
Judgment Criteria
terminal (terminal No.1) of the right bank heated
oxygen sensor (rear).
• No limp home.
• Terminal No. 2 of the right bank heated oxygen
sensor (rear) is grounded with ENGINE-ECU (ter- .
minal No. 59). EOBD DRIVE CYCLE PATTERN

.
• The output signal of the right bank heated oxygen .
sensor (front) is compensated by the output sig- TROUBLESHOOTING HINTS (The most
• 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
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

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

.

minal No. 59).
• The ENGINE-ECU applies an offset voltage of
0.5 volt to terminal No. 2 of the right bank heated P.13A-11.
.
• 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.
.
DTC SET CONDITIONS

DIAGNOSIS
• MB991824: V.C.I.


CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
range?
YES : Go to Step 6.
03DB203A

heated oxygen sensor (rear) and connector B-20 at
YES : Go to Step 4.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

oxygen sensor (rear) connector B-08 (terminal No. 1) and
YES : Go to Step 5.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

YES : Go to Step 6.
RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
THROTTLE BODY
2 1
4 3 B-08 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
volts.
MB991824
NO : Replace the right bank heated oxygen sensor (rear).
MB991827 00DB076A
Then go to Step 7.

CONNECTOR: B-25
AIR
CLEANER
LEFT BANK COVER

HEATED OXYGEN ENGINE
SENSOR (FRONT) CONTROL
UNIT
B-25 (B) 16DB400A
AK303070 AB
. .

Check Conditions
terminal (terminal No. 1) of the left bank heated
• Terminal No. 2 of the left bank heated oxygen • Idling.
sensor (front) is grounded with or ENGINE-ECU • MIL is activated after 2 Drive cycles.
(terminal No. 14). • No limp home.
.
.
TECHNICAL DESCRIPTION EOBD DRIVE CYCLE PATTERN

• The left 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 that data to voltage, and
sends it to the ENGINE-ECU.
.

• When the left bank heated oxygen sensor (front)
begins to deteriorate, the heated oxygen sensor likely causes for this code to be set are: )
signal response deteriorates also. • Left bank heated oxygen sensor (front) failed.
• The ENGINE-ECU forcibly varies the air/fuel mix- • Short circuit in left bank heated oxygen sensor
ture to make it leaner and richer, and checks the (front) output line to heater circuit ground line.
response speed of the left bank heated oxygen • Wiring harness or connector damage.
sensor (front). In addition, the ENGINE-ECU also • Refer to component locations GROUP-70
checks for an open circuit in the left bank heated • Refer to configuration diagrams GROUP-80
oxygen sensor (front) output line. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.

STEP 1. Using diagnostic tool, check data list item AE:

Heated Oxygen Sensor Bank 2, Sensor 1 (left front).
CAUTION
CONNECTOR
(4) Set diagnostic tool to the data reading mode for item AE,
MB991910
MB991824
NO : Go to Step 2.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
alternately.
range?
YES : Go to Step 6.
NO : Go to Step 3.
03DB208A
STEP 3. Check harness connector B-25 at left bank heated

oxygen sensor (front) and harness connector B-20 at
ENGINE-ECU for damage or loose terminals.
YES : Go to Step 4.
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

wire between right bank heated oxygen sensor (front)
YES : Go to Step 5.
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

CAUTION
CONNECTOR
MB991910
MB991824
ing sensor.

CONNECTOR: B-25
AIR
CLEANER
LEFT BANK COVER

UNIT
B-25 (B) 16DB400A
AK303070 AB
DTC SET CONDITIONS

.
CIRCUIT OPERATION
oxygen sensor (front). Judgement Criteria
• Terminal No. 2 of the left bank heated oxygen • Internal Resistance of the Nernst - cell is equal or
elled exhasused gas temperature
.
• Idling.
• The left bank heated oxygen sensor (front) • No limp home.
.
and input the resulting signal to the EOBD DRIVE CYCLE PATTERN
• When the left bank heated oxygen sensor (front) P.13A-11.
begins to deteriorate, the heated oxygen sensor .
signal response becomes poor. TROUBLESHOOTING HINTS (The most

• The ENGINE-ECU forcibly varies the air/fuel mix- likely causes for this code to be set are:)
• Left bank heated oxygen sensor (front) failed.
response speed of the left bank heated oxygen
• Short circuit to ground in left bank heated oxygen
sensor (front) output line.
checks for an open circuit in the left bank heated
oxygen sensor (front) output line.
.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
MB991824
NO : Go to Step 2.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
alternately.
range?
YES : Go to Step 6.
03DB208A

oxygen sensor (front) and connector B-20 at ENGINE-ECU
for damage.
YES : Go to Step 4.
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
STEP 4. Check for short circuit to ground in the harness

between left bank heated oxygen sensor (front) connector
(terminal No. 15).
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

CAUTION
CONNECTOR
MB991910
MB991824
ing sensor.

NO : The inspetion is complete.
CONNECTOR: B-25
AIR
CLEANER
LEFT BANK COVER

UNIT
B-25 (B) 16DB400A
AK303070 AB
DTC SET CONDITIONS

.
CIRCUIT OPERATION
• Terminal No. 2 of the left bank heated oxygen • Internal Resistance of the Nernst - cell is equal or
elled exhasused gas temperature.
.
• Idling.
• The left bank heated oxygen sensor (front) • No limp home.
.
and input the resulting signals to the EOBD DRIVE CYCLE PATTERN
• When the left bank heated oxygen sensor (front) P.13A-11.
begins to deteriorate, the heated oxygen sensor .
signal response becomes poor. TROUBLESHOOTING HINTS (The most

• The ENGINE-ECU forcibly varies the air/fuel mix- likely causes for this code to be set are: )
• Short circuit to battery voltage in left bank heated
.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
MB991824
ing sensor.

oxygen sensor (front) and harness connector B-20 at
YES : Go to Step 3.
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

left bank heated oxygen sensor (front) connector B-25
No. 15).
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

CAUTION
CONNECTOR
MB991910
MB991824
ing sensor.

CONNECTOR: B-25
AIR
CLEANER
LEFT BANK COVER

UNIT
B-25 (B) 16DB400A
AK303070 AB
. .

Check Conditions
• Engine speed between 1320 and 3200rpm.
terminal (terminal No. 1) of the left bank heated Judgment Criteria
oxygen sensor (front). • MIL is activated after 2 Drive cycles.
• Terminal No. 2 of the left bank heated oxygen • No limp home.
sensor (front) is grounded with ENGINE-ECU .
(terminal No. 14). EOBD DRIVE CYCLE PATTERN

.
• The left bank heated oxygen sensor (front)
.

and inputs the resulting signals to the likely causes for this code to be set are: )
ENGINE-ECU. • Left bank heated oxygen sensor (front) deterio-
• When the left bank heated oxygen sensor (front) rated.
begins to deteriorate, the left bank heated oxygen • Refer to component locations GROUP-70
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
MB991824

DTC P0154: Heated Oxygen Sensor Circuit No Activity Detected (bank 2, sensor 1)
.

U1120 is also set. After P0134 has been diag- Check Conditions
nosed, don't forget to erase DTC U1120. • Battery voltage < 11.02 volts
. • Engine coolant temperature is higher than 80°C.
CIRCUIT OPERATION
Judgment Criteria
• No limp home.
terminal (terminal No. 1) of the left bank heated .
oxygen sensor (front). EOBD DRIVE CYCLE PATTERN

• Terminal No. 2 of the left bank heated oxygen Refer to Diagnostic Function − EOBD Drive Cycle −
sensor (front) is grounded with ENGINE-ECU P.13A-11.
(terminal No. 14).
.

• The left bank heated oxygen sensor (front) • Left bank heated oxygen sensor failed.
detects the concentration of oxygen in the • Open circuit in left bank heated oxygen sensor
exhaust gas; it converts those data to voltage, (front) output line.
and inputs the resulting signals to the • Open circuit in left bank heated oxygen sensor
ENGINE-ECU. (front) sensor ground.
• When the left bank heated oxygen sensor (front) • Wiring harness or connector damage.
begins to deteriorate, the heated oxygen sensor • Refer to component locations GROUP-70
signal response becomes poor. • Refer to configuration diagrams GROUP-80
oxygen sensor (front) output and ground lines.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
range?
YES : Go to Step 6.
03DB208A

oxygen sensor (front) and connector B-20 at ENGINE-ECU
for damage.
YES : Go to Step 4.
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
STEP 4. Check for open circuit between left bank heated

YES : Go to Step 5.
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

YES : Go to Step 6.
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

CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

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.
• 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 .

• The output signal of the left bank heated oxygen
sensor (front) is compensated by the output sig- likely causes for this code to be set are: )
nal of the left bank heated oxygen sensor (rear). • Left bank heated oxygen sensor (rear) failed.
• The ENGINE-ECU checks for an open circuit in • Short circuit in left bank heated oxygen sensor
the left bank heated oxygen sensor (rear) output (rear) output line to heater circuit ground.
.

Check Conditions
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool, check data list item AF: Left
Bank Heated Oxygen Sensor Bank 2, Sensor 2 (left rear).
CAUTION
CONNECTOR
(3) Set diagnostic tool to the data reading mode for item AF,
Heated Oxygen Sensor Bank 2, Sensor 2 (left rear).
MB991910
volts.
MB991824
NO : Go to Step 2.
MB991827 00DB076A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
range?
YES : Go to Step 6.
03DB213A

oxygen sensor (rear) and harness connector B-20 at
YES : Go to Step 4.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

wire between left bank heated oxygen sensor (rear)
YES : Go to Step 5.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 5. Using diagnostic tool, check data list item AF:

CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB

.

tration in the exhaust gas is sent to the Judgement Criteria
terminal (terminal No. 1) of the left bank heated • MIL is activated after 2 Drive cycles.
• Terminal No. 2 of the left bank heated oxygen .
minal No. 29).
.
P.13A-11.
.

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) failed.
the left bank heated oxygen sensor (rear) output • Short circuit to ground in left bank heated oxygen
line. sensor (rear) output line.
.
DTC SET CONDITIONS

DIAGNOSIS
• MB991824: V.C.I.

Heated Oxygen Sensor Bank 2, Sensor 2 (rear).
CAUTION
CONNECTOR
(4) Set diagnostic tool to the data reading mode for itemAF,
MB991910
volts.
MB991824
NO : Go to Step 2.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
alternately.
range?
YES : Go to Step 3.
03DB213A Then go to Step 6.

YES : Go to Step 4.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for short circuit to ground between left

bank heated oxygen sensor (rear) connector B-24
No. 30).
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
volts.
MB991824

CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB

.

minal No. 29).
.
Procedure 6 − Other Monitor P.13A-11.
.

nal of the left bank heated oxygen sensor (rear).
• The ENGINE-ECU checks for an open circuit in • Short circuit t battery voltage in left bank heated
the left bank heated oxygen sensor (rear) output oxygen sensor (rear) output line.
.

Check Conditions
DIAGNOSIS
• MB991824: V.C.I.

Heated Oxygen Sensor Bank 2, Sensor 2 (rear).
CAUTION
CONNECTOR
MB991910
volts.
MB991824
NO : Go to Step 2.

YES : Go to Step 2.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

left bank heated oxygen sensor (rear) connector B-24
No. 30).
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
volts.
MB991824

CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB
DTC SET CONDITIONS

.
CIRCUIT OPERATION
tration in the exhaust gas is sent to the • Engine speed between 1320 and 3200rpm.
Judgment Criteria
oxygen sensor (rear).
• No limp home.
• Terminal No. 2 of the left bank heated oxygen
sensor (rear) is grounded with ENGINE-ECU (ter- .
minal No. 29) . EOBD DRIVE CYCLE PATTERN

.
• The output signal of the heated left bank oxygen .
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
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
(4) Warm up the engine.
MB991910
volts.
MB991824
NO : Replace the heated oxygen sensor (rear). Then go to
MB991827 00DB076A
Step 2.

Diagnostic Function − EOBD Drive Cycle −P.13A-11.
DTC P0160: Heated Oxygen Sensor Circuit No Activity (bank 2, sensor 2).
CONNECTOR: B-24
AIR
CLEANER
COVER
LEFT BANK ENGINE
SENSOR (REAR) UNIT
16DB400A
B-24 (GR)
AK303079 AB

.
CIRCUIT OPERATION
• Engine start achieved.
minal No. 29) .
• 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). .
.
• 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.
.
DTC SET CONDITIONS

DIAGNOSIS
• MB991824: V.C.I.


CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
range?
YES : Go to Step 6.
03DB213A

oxygen sensor (rear) and connector B-20 at ENGINE-ECU
for damage.
YES : Go to Step 4.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

YES : Go to Step 5.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

YES : Go to Step 6.
LEFT BANK
HEATED OXYGEN
SENSOR (REAR)
2 1
4 3 B-24 (GR)
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CAUTION
CONNECTOR
MB991910
volts.
MB991824
MB991827 00DB076A
Then go to Step 7.

NEXT PAGE
PREVIOUS PAGE MULTIPORT FUEL INJECTION (MFI)
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
13A-264
13A
DTC P0171: System too Lean (bank 1)
• No limp home.
.
CIRCUIT OPERATION
• Multiplicative or Additive adaption performed by .
ENGINE-ECU. EOBD DRIVE CYCLE PATTERN

.

• If a malfunction occurs in the fuel system, the fuel .
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.
.
DTC SET CONDITIONS

• Use of incorrect or contaminated fuel.
Check Conditions • Refer to component locations GROUP-70
• Bank 1 too lean • Refer to configuration diagrams GROUP-80
Judgment Criteria • Refer to circuit diagrams GROUP-90
• MIL on after 2 drive cycles.
DIAGNOSIS
• Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
STEP 1. Check for intake system vacuum leak.

Q: Are there any abnormalities?
YES : Repair it. Then go to Step 4.
NO : Go to Step 2.
MULTIPORT FUEL INJECTION (MFI) 13A-265
STEP 2. Using diagnostic tool , check actuator test items

01, 03, 05: Injector.
CAUTION
CONNECTOR
(1) Connect diagnostic tool to the data link connector. Refer to
Actuator Test Table P.13A-644
(3) Set diagnostic tool to the Actuator Test mode for MPI -
Items 01, 03, 05: Injector.
MB991910
to 95°C.
(5) Perform Actuator test on each injector.
MB991824
(6) Conduct a Power Balance test on each cylinder. Refer to
On-Vehicle Service - Injector Check P.13A-670.
Q: Is each injector operating properly?
YES : YES: Go to Step 3.
NO : Refer to On-Vehicle Service - Injector Check
P.13A-670. If injector is malfuctioning replace and go
to Step 3.
MB991827 00DB076A
STEP 3. Check the fuel pressure.

Refer to On-vehicle Service − Fuel Pressure Test P.13A-661.
Q: Is the fuel pressure normal?
YES : Go to Step 4.

DTC P0172: System too Rich (bank 1)
Judgment Criteria
.
CIRCUIT OPERATION • MIL on after 2 drive cycles.

• Multiplicative or Additive adaption performed by • No limp home.
ENGINE-ECU.
.

• If a malfunction occurs in the fuel system, the fuel
P.13A-11.
trim value becomes too small.
• The ECU checks whether the fuel trim value is .
within a specified range. TROUBLESHOOTING HINTS (The most likely

causes for this code to be set are:)
• Injector (Number 1, 3, 5) malfunctioning.
.
DTC SET CONDITIONS

• Bank 1 too rich. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

01, 03, 05: Injector.
CAUTION
CONNECTOR
MB991910
to 95°C.
MB991824
to Step 3.
MB991827 00DB076A

YES : Go to Step 3.

DTC P0174: System too Lean (bank 2)
• No limp home.
.
CIRCUIT OPERATION
• Multiplicative or Additive adaption performed by .
ENGINE-ECU. EOBD DRIVE CYCLE PATTERN

.

• If a malfunction occurs in the fuel system, the fuel .
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.
• Air drawn in from gaps in gasket, seals, etc.
.
DTC SET CONDITIONS

• Use of incorrect or contaminated fuel.
• Bank 2 too lean • Refer to configuration diagrams GROUP-80
Judgment Criteria • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check for intake system vacuum leak.

NO : Go to Step 2.

02, 04, 06: Injector.
CAUTION
CONNECTOR
MB991910
to 95°C.
MB991824
to Step 3.
MB991827 00DB076A

YES : Go to Step 4.

DTC P0175: System too Rich (bank 2)
Judgment Criteria
.
CIRCUIT OPERATION • MIL on after 2 drive cycles.

• Multiplicative or Additive adaption performed by • No limp home.
ENGINE-ECU.
.

• If a malfunction occurs in the fuel system, the fuel
P.13A-11.
trim value becomes too small.
• The ECU checks whether the fuel trim value is .
within a specified range. TROUBLESHOOTING HINTS (The most likely

causes for this code to be set are:)
• Injector (Number 2, 4, 6) malfunctioning.
.
DTC SET CONDITIONS

• Bank 2 too rich. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

02, 04, 06: Injector.
CAUTION
CONNECTOR
MB991910
to 95°C.
MB991824
to Step 3.
MB991827 00DB076A

YES : Go to Step 3.

CONNECTOR: B-01 CONNECTOR: B-32
B-01 (GR)
B-32 (B)
AK303097AB
AK303096AB
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
.
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".
.
DTC SET CONDITIONS

Check Conditions • Misfire present.
• Battery voltage is between 9.04 and 16.01vols.
.

Judgment Criteria Refer to Diagnostic Function − EOBD Drive Cycle
• IC internal test (open circuit, short to earth, short P.13A-11
to battery).
.
TROUBLESHOOTING HINTS (The most • Shorted to battery, No.1cylinder injector circuit.

likely causes for this code to be set are:) • Harness or connector damage.
• Open or shorted to ground No.1cylinder injector
circuit.
DIAGNOSIS
• MB991824: V.C.I.
• MB992044: Power Plant ECU Check Harness
STEP 1. Using diagnostic tool , check actuator test item

01: No. 1 Injector.
CAUTION
CONNECTOR
(3) Set diagnostic tool to the actuator testing mode for item 01,
No. 1 injector.
to 95°C (176°F to 203°F).
MB991910
• The idle should become slightly rougher.
MB991824
Q: Does the idle vary or engine run "rough"?
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check harness connector B- 32 at intermediate

connector for damage.
YES : Go to Step 3.
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
STEP 3. Check the No.1 cylinder injector resistance at

intermediate connector B-32.
CONNECTOR: B-32 (1) Disconnect the intermediate connector B-32.
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
(2) Measure the resistance between terminal No. 5 and No. 9.

B-32 • Resistance should be between 10.5 and 13.5 ohms.
INTERMEDIATE
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.
AK303098 AB
STEP 4. Check the harness connector B-01 at No. 1

cylinder injector for damage.
CONNECTOR: B-01 Remove the intake manifold.
B-01 (GR) YES : Go to Step 5.
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303099AB
STEP 5. Check the No. 1 cylinder injector B-01.

CONNECTOR: B-01 (1) Disconnect the No. 1 cylinder injector connector B-01.
B-01 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303099AB
(2) Measure the resistance between injector side connector

INJECTOR SIDE terminal No. 1 and No. 2.
CONNECTOR Standard value: 10.5 − 13.5 ohms [at 20°C (68°F)]
1 2
[at 20°C (68°F)]?
YES : Repair harness wire between intermediate connector
B-32 (terminal No. 9) and injector connector B-01
(terminal No. 1) and harness wire between No.1
cylinder injector connector B-01 (terminal No. 2)
AK000559 AB
and intermediate connector B-32 (terminal No. 5)
because of open circuit or short circuit to ground
or harness damage.
Then go to Step 12.
NO : Replace the No.1 cylinder injector. Then go to Step
12.
STEP 6. Measure the power supply voltage at intermediate

connector B-32.
CONNECTOR: B-32 (1) Disconnect the connector B-32 and measure at the female
connector side.
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:

B-32 HARNESS
CONNECTOR:
COMPONENT (4) Turn the ignition switch to the "LOCK" (OFF) position.
SIDE
5 4 3 2 1 present?
10 9 8 7 6
YES : Go to Step 8.
NO : Go to Step 7.
AK203172 AB
STEP 7. Check harness connector B-17X at MFI relay for

damage.
YES : Repair harness wire between MFI relay connector
B-17X (terminal No. 4) and intermediate connector
B-32 (terminal No. 9) because of open circuit or short
circuit to ground. Then go to Step 12.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
STEP 8. Check for harness damage between MFI relay

connector B-17X (terminal No. 4) and intermediate
YES : Go to Step 9.
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:
STEP 9. Check harness connector B-20 at ECU for

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 10. Check for open circuit and short circuit to

ground and harness damage between intermediate
connector B-32 (terminal No. 5) and ECU connector B-20
(terminal No. 03).
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 11. Using the oscilloscope, check the No. 1 cylinder

injector.
CONNECTOR: B-32 (1) Disconnect the intermediate connector B-32 and connect
the test harness MB991658 between the separated
connectors.
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
OSCILLOSCOPE (2) Connect the oscilloscope probe to injector intermediate

B-32 INTERMEDIATE
CONNECTOR connector terminal to No.5.
NOTE: When measuring with the ECU side connector, dis-
1 2 3 4 5 connect the all ECU connectors and connect check harness
6 7 8 9 10 special tool (MB992044) between the separated connec-
MB991658 tors. Then connect an oscilloscope probe to the check har-
ness connector terminal No.03.
AK203300 AB
NORMAL WAVEFORM
(4) Measure the waveform.
• The waveform should show a normal pattern similar to
the illustration.
A:INJECTOR DRIVE TIME
Q: Is the waveform normal?
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
.
CIRCUIT OPERATION
(terminal No. 4).
.
DTC SET CONDITIONS <Circuit continuity − open circuit and shorted low>
.

Judgment Criteria Refer to Diagnostic Function − EOBD Drive Cycle
• IC internal test (open circuit, short to earth, short P.13A-11.
to battery).
.
TROUBLESHOOTING HINTS (The most • Shorted to battery, No.2 cylinder injector circuit.
• Open or shorted to ground No.2 cylinder injector
circuit.
DIAGNOSIS
• MB991824: V.C.I.

02: No. 2 injector.
CAUTION
No. 2 injector.
to 95°C (176°F to 203°F).
MB991910 • The idle should become slightly rougher.
MB991824 Q: Does the idle vary or engine run "rough"?
NO : Go to Step 2.
MB991827 00DB076A

YES : Go to Step 3.
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
STEP 3. Check the No. 2 cylinder injector.

B-30 (GR)
M
2 1
HARNESS CONNECTOR:

1 2
[at 20°C (68°F)]?
YES : Go to Step 4.
NO : Replace the No. 2 cylinder injector. Then go to Step
10.
AK000559 AB
STEP 4. Measure the power supply voltage at No.2 cylinder

injector connector B-30.
CONNECTOR: B-30 (1) Disconnect connector B-30 and measure at the harness
side.
B-30 (GR)
M
2 1
HARNESS CONNECTOR:

COMPONENT SIDE
2 1 present?
YES : Go to Step 6.
NO : Go to Step 5.
AK303104 AB

damage.
B-17X (terminal No. 4) and No.2 cylinder injector
circuit or short circuit to ground.
Then go to Step 10.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

connector B-17X (terminal No.4) and No. 2 cylinder injector
connector B-30.
YES : Go to Step 7.
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:

damage.
YES : Go to Step 8.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

and harness damage between No.2 cylinder injector
(terminal No. 04).
YES : Go to Step 9.
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 9. Using the oscilloscope, check the No.2 cylinder

injector.
CONNECTOR: B-30 (1) Disconnect the No. 2 cylinder injector connector B-30 and
connect the test harness special tool (MB991658) between
the separated connectors. (All terminals should be
connected)
B-30 (GR)
M
2 1
HARNESS CONNECTOR:
OSCILLOSCOPE (2) Connect the oscilloscope probe to the injector side

INJECTOR
CONNECTOR connector terminal No. 2.
1 2 MB991658 connect the all ECU connectors and connect check harness
special tool (MB992044) between the separated connec-
tors. Then connect an oscilloscope probe to the check har-
ness connector terminal No. 04.
AK302166 AB
NORMAL WAVEFORM
the illustration.
A Cope with Intermittent Malfunctions P.00-14.
AKX01557 AB

CONNECTOR: B-03 CONNECTOR: B-32
B-32 (B)
B-03 (GR)
AK303097AB
AK303106AB
CONNECTOR: B-17X
AIR
CLEANER
MFI RELAY COVER

ENGINE
CONTROL
UNIT
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
.
CIRCUIT OPERATION
(terminal No. 4).
.
.

Judgment Criteria Refer to Diagnostic Function − EOBD Drive Cycle −
to battery).
.
circuit.
DIAGNOSIS
• MB991824: V.C.I.

03: No. 3 injector.
CAUTION
CONNECTOR
No. 3 injector.
to 95°C (176°F to 203°F).
MB991910
MB991824
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check harness connector B-32 at intermediate

YES : Go to Step 3.
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
STEP 3. Check the No. 3 cylinder injector resistance at

B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
B-32
INTERMEDIATE
• Resistance should be between 10.5 and 13.5 ohms.
ohms?
1 2 3 4 5
6 7 8 9 10 YES : Go to Step 6.
NO : Go to Step 4.
AK303107 AB
STEP 4. Check the connector B-03 at No. 3 cylinder

injector for damage.
YES : Go to Step 5.
M
B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303108AB

M B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303108AB

1 2
[at 20°C (68°F)]?
(terminal No. 1) and harness wire between No.3
AK000559 AB
or harness damage.
Then go to Step 12.
NO : Replace the No.3 cylinder injector. Then go to Step
12.

connector B-32.
connector side.
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:

B-32 HARNESS
CONNECTOR:
SIDE
5 4 3 2 1 present?
10 9 8 7 6
YES : Go to Step 8.
NO : Go to Step 7.
AK203172 AB

damage.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

YES : Go to Step 9.
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:

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

(terminal No. 34).
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

injector.
connectors.
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:

B-32 INTERMEDIATE
AK203300 AB
NORMAL WAVEFORM
the illustration.
Refer to 00E, How to Use Troubleshooting/Inspection
A Malfunctions P.00-14.
AKX01557 AB

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
.
CIRCUIT OPERATION
(terminal No. 4).
.
.

to battery).
.
• No.4 cylinder injector failed.
circuit.
DIAGNOSIS
• MB991824: V.C.I.

04: No. 4 injector.
CAUTION
CONNECTOR
No. 4 injector.
to 95°C (176°F to 203°F).
MB991910
MB991824
NO : Go to Step 2.
MB991827 00DB076A

YES : Go to Step 3.
B-27 (GR)
M
2 1
HARNESS CONNECTOR:

CONNECTOR: B-27 (1) Disconnect the No.4 cylinder injector connector B-27.
B-27 (GR)
M
2 1
HARNESS CONNECTOR:

1 2
[at 20°C (68°F)]?
YES : Go to Step 4.
10.
AK000559 AB
STEP 4. Measure the power supply voltage at No. 4

cylinder injector connector B-27.
side.
B-27 (GR)
M
2 1
HARNESS CONNECTOR:

COMPONENT SIDE
2 1 present?
YES : Go to Step 6.
NO : Go to Step 5.
AK303111 AB

damage.
B-17X (terminal No. 4) and No. 4 cylinder injector
circuit or short circuit to ground.
Then go to Step 10.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

connector B-17X (terminal No. 4) and No. 4 cylinder
injector connector B-27 (terminal No. 1).
YES : Go to Step 7.
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:

damage.
YES : Go to Step 8.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

and harness damage between No. 4 cylinder injector
(terminal No. 35).
YES : Go to Step 9.
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

injector.
CONNECTOR: B-27 (1) Disconnect the No. 4 cylinder injector B-27 and connect the
test harness special tool (MB991658) between the
separated connectors. (All terminals should be connected)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:

INJECTOR
AK302166 AB
NORMAL WAVEFORM
the illustration.
AKX01557 AB

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
.
CIRCUIT OPERATION
(terminal No. 4).
.
.

to battery).
.
circuit.
DIAGNOSIS
• MB991824: V.C.I.

05: No. 5 injector.
CAUTION
CONNECTOR
(3) Set diagnostic tool to the actuator testing mode for item 05
No. 5 cylinder injectors.
to 95°C (176°F to 203°F).
MB991910
MB991824
NO : Go to Step 2.
MB991827 00DB076A

YES : Go to Step 3.
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
STEP 3. Check the No. 5 cylinder injector resistance at

B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:

B-32 • Resistance should be between 10.5 and 13.5 ohms.
INTERMEDIATE
ohms?
1 2 3 4 5
6 7 8 9 10 YES : Go to Step 6.
NO : Go to Step 4.
AK303113 AB

B-04 (GR) Q: Is the harness connector in good condition?
YES : Go to Step 5.
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303114AB
STEP 5. Check the No.5 cylinder injector.

B-04 (GR)
M
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303114AB

1 2
[at 20°C (68°F)]?
(terminal No. 1) and harness wire between No. 5
AK000559 AB
or harness damage.
Then go to Step 12.
12.

connector B-32.
connector side.
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:

B-32 HARNESS
CONNECTOR:
SIDE
5 4 3 2 1 present?
10 9 8 7 6
YES : Go to Step 8.
NO : Go to Step 7.
AK203172 AB

damage.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

YES : Go to Step 9.
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:

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

(terminal No. 16).
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

injector.
connectors.
B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:

B-32 INTERMEDIATE
AK203300 AB
NORMAL WAVEFORM
the illustration.
AKX01557 AB

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
.
CIRCUIT OPERATION
(terminal No. 4).
.
.

to battery).
.
circuit.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool , check actuator test item 02,

04, 06: No. 6 injector.
CAUTION
CONNECTOR
No. 6 Injector.
to 95°C (176°F to 203°F).
MB991910
MB991824
NO : Go to Step 2.
MB991827 00DB076A

YES : Go to Step 3.
B-26 (GR) Connector Inspection P.00E-2. Then go to Step 10.
M
2 1
HARNESS CONNECTOR:

CONNECTOR: B-26 (1) Disconnect the No.6 cylinder injector connector B-26.
B-26 (GR)
M
2 1
HARNESS CONNECTOR:

1 2
[at 20°C (68°F)]?
YES : Go to Step 4.
10.
AK000559 AB
STEP 4. Measure the power supply voltage at No. 6

cylinder injector connector B-26.
side.
B-26 (GR)
M
2 1
HARNESS CONNECTOR:

COMPONENT SIDE
2 1 present?
YES : Go to Step 6.
NO : Go to Step 5.
AK303117 AB

damage.
B-17X (terminal No. 4) and injector connector
B-26 (terminal No. 1) because of open circuit or
short circuit to ground.
Then go to Step 10.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

connector B-17X and No. 6 cylinder injector connector
B-26 (terminal No. 1).
YES : Go to Step 7.
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:

damage.
YES : Go to Step 8.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

and harness damage between No. 6 cylinder injector
(terminal No. 17).
YES : Go to Step 9.
B-26 (GR)
M
2 1
HARNESS CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

injector.
CONNECTOR: B-26 (1) Disconnect the No. 6 cylinder injector connector B-26 and
connect the test harness special tool (MB991658) between
the separated connectors. (All terminals should be
B-26 (GR) connected)
M
2 1
HARNESS CONNECTOR:

INJECTOR
AK302166 AB
NORMAL WAVEFORM
the illustration.
AKX01557 AB

DTC P0219: Engine Overspeed Condition

. .

• The actual engine speed has exceeded the Refer to Diagnostic Function − EOBD Drive Cycle −
pre-set threshold value. P.13A-11.
.
.
Check Conditions TROUBLESHOOTING HINTS (The most

• None. likely causes for this code to be set are: )
Judgment Criteria • Refer to component locations GROUP-70
• Engine speed is greater than 6,600 r/min. • Refer to configuration diagrams GROUP-80
• No MIL. • Refer to circuit diagrams GROUP-90
• No Limp home. • Excessive engine speed.
DIAGNOSIS
Required Special Tools
• MB991824: V.C.I.
STEP 1. Using diagnostic tool , read the diagnostic trouble

code (DTC).
CAUTION
CONNECTOR
Q: Is a diagnostic trouble code other than P0219 set?
MB991910 YES : Refer to Diagnostic Trouble Code Chart P.13A-17.
NO : Go to Step 2.
MB991824
MB991827 00DB076A

(1) Carry out a test drive with the drive cycle pattern. Refer to −
P.13A-11.
DTC P0222: Throttle Position Sensor (Sub) Circuit Low Input.
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
16DB400A
. .

• A 5-volt power supply is applied on the throttle • The throttle position sensor (sub) outputs voltage
position sensor (sub) power terminal (terminal which corresponds to the throttle valve opening
No. 3) from the ECU (terminal No. 10). angle.
The throttle position sensor (sub) outputs a volt- • The ECU checks whether the voltage is within a
age from (terminal No. 5) to the specified range.
ENGINE-ECU(terminal No. 57) .
The ground terminal (terminal No. 2) is grounded

with ECU (terminal No. 27).
DTC SET CONDITIONS

Check Conditions
.

• TPS is normal. likely causes for this code to be set are:)
• Throttle position sensor failed.
Judgement Criteria • Open or short circuit to ground in throttle position
• MIL is actvated immediately. sensor (sub) circuit. .
• Vehicle in Limp home - Engine speed limited to • Harness or connector damage.
1500rpm. • Refer to component locations GROUP-70
None.
DIAGNOSIS
• MB991824: V.C.I.
WARNING

Throttle Position Sensor (sub).
CAUTION
CONNECTOR
following:
MB991910
MB991824
• Output voltage should be approximately 4000 and 4824
MB991827 00DB076A
NO : Go to Step 2.

sensor for damage.
CONNECTOR: B-06
YES : Go to Step 3.
B-06 (B)
03DB180A
STEP 3. Measure the sensor supply voltage at throttle

CONNECTOR: B-06
side.
(3) Measure the voltage between terminal No. 3 and ground
YES : Go to Step 6.
B-06 (B)
NO : Go to Step 4.
03DB180A

damage.
YES : Go to Step 5.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A

No. 3) and ECU connector B-20 (terminal No. 10).
CONNECTOR: B-06
YES : Go to Step 6.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

harness damage between throttle position sensor
(terminal No. 42).
CONNECTOR: B-06
YES : Go to Step 7.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: B-06
B-06 (B)
03DB180A

code (DTC).
CAUTION
CONNECTOR
MB991824
MB991827 00DB076A
DTC P0223: Throttle Position Sensor (Sub) Circuit High Input.
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
16DB400A
. .

• A 5-volt power supply is applied on the throttle • The throttle position sensor (sub) outputs voltage
position sensor (sub) power terminal (terminal which corresponds to the throttle valve opening
No. 3) from the ENGINE-ECU(terminal No. 10). angle.
The throttle position sensor (sub) outputs a volt- • The ECU checks whether the voltage is within a
age from (terminal No. 5) to the specified range.
ENGINE-ECU(terminal No. 57). .
The ground terminal (terminal No. 2) is grounded

with ECU (terminal No. 27).
DTC SET CONDITIONS

Check Conditions
.

• TPS is normal. likely causes for this code to be set are:)
• Throttle position sensor failed.
Judgement Criteria • Short circuit to 5 Volts in throttle position sensor
• MIL is actvated immediately. (sub) circuit.
• Vehicle in Limp home - Engine speed limited to • Harness or connector damage
1500rpm. • Refer to component locations GROUP-70
None.
DIAGNOSIS
• MB991824: V.C.I.
WARNING

CAUTION
CONNECTOR
following:
MB991910
MB991824
• Output voltage should be approximately 4000 and 4824
MB991827 00DB076A
NO : Go to Step 2.

sensor for damage.
CONNECTOR: B-06
YES : Go to Step 3.
B-06 (B)
03DB180A
STEP 3. Check the continuity at throttle position sensor

CONNECTOR: B-06
side.
B-06 (B)
03DB180A
(2) Measure the continuity between terminal No. 2 and ground

THROTTLE ACTUATOR • Should be less than 2 ohms.
CONTROL MOTOR
CONNECTOR Q: Does continuity exist?
YES : Go to Step 6.
NO : Go to Step 4.
03DB195A

damage.
YES : Go to Step 5.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 5. Check for short circuit to 5-Volts and harness

damage between throttle position sensor connector B-06
(terminal No. 2) and ECU connector B-20 (terminal No. 27).
CONNECTOR: B-06
YES : Go to Step 6.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage between throttle position sensor connector B-06
CONNECTOR: B-06
YES : Go to Step 7.
NO : Repair or repalce it. Then go to Step 8.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: B-06
B-06 (B)
03DB180A

code (DTC).
CAUTION
CONNECTOR
MB991824
MB991827 00DB076A
DTC P0300: Random/Multiple Cylinder Misfire Detected
• The ECU checks for such changes in engine

.
TECHNICAL DESCRIPTION speed.

• If a misfire occurs while the engine is running, the
engine speed changes for an instant. .
DTC SET CONDITIONS

Check Conditions
.
• 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 .
r/min is exceeded) is above 6. TROUBLESHOOTING HINTS (The most

• Torque intervention by traction control is not likely causes for this code to be set are:)
active.
• Ignition system related part(s) failed.
• Safety fuel cut off is not active.
• Poor crankshaft position sensor.
• A/C compressor switching is not active. <M/T>
• Incorrect air/fuel ratio.
• Clutch pedal is not pressed. <M/T>.
• Low compression pressure.
Judgement Criteria (change in the angular accel- • Timing belt mialignment.
eration of the crankshaft is used for misfire • Leaking vacuum hose connection
detection). • ECU failed.
• MIL activated after 2 drive cycles. • Refer to component locations GROUP-70
• No Limp home. • Refer to configuration diagrams GROUP-80
• If MIL "blinks" in 1 Hz frequency, then there has • Refer to circuit diagrams GROUP-90
been possible catalyst damage caused by the
misfire.
DIAGNOSIS
• MB991824: V.C.I.

Crank Angle Sensor.
CAUTION
CONNECTOR
Crankshaft Angle Sensor.
(4) Check the waveform of the crankshaft position sensor while
keeping the engine speed constant.
MB991910
• The pulse width should be constant.
YES : Go to Step 2.
NO : Refer to, DTC P0335 − Crankshaft Position Sensor
Circuit Malfunction. P.13A-354
MB991827 00DB076A
STEP 2. Using diagnostic tool , check data list item 28

<bank 1> and 29 <bank2>: Short-Term Fuel Trim.
DATA LINK (2) Set diagnostic tool to the data reading mode for item
CONNECTOR
28<bank 1> and 29 <bank2>, Short-Term Fuel Trim.
• The fuel trim should be between −7.0 and +7.0 percent
when the load is 2,500 r/min (during closed loop) after
the engine is warmed.
Q: Is the specification normal?
YES : Go to Step 3.
MB991910 NO : Refer to:
DTC P0171 − System too Lean (bank 1) P.13A-264,
MB991824 DTC P0172 − System too Rich (bank 1) P.13A-266,
DTC P0174 − System too Lean (bank 2) P.13A-268,
DTC P0175 − System too Rich (bank 2) P.13A-270.
MB991827 00DB076A
STEP 3. Check each ignition coil spark.

(1) Remove the intake manifold.
(2) Remove the ignition coil.
(3) Remove the spark plug and connect to the ignition coil.
(4) Ground the spark plug side electrode securely.
• When the engine is cranked, the spark plug should
spark.
CAUTION
If prolonged engine cranking is required disconnect Fuel
Pump to prevent excessive unburnt fuel damaging the
SPARK PLUG exhaust catalysts.
Q: Did it spark?
AKX00432 AB
YES : Go to Step 5.
NO : Go to Step 4.
STEP 4. Check the spark plugs.

CAUTION
Do not attempt to adjust the gap of the iridium plug. Clean-
ing of the iridium plug may result in damage to the iridium
and platinum 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.
IRIDIUM
TIP (1) Check the plug gap and replace if the limit is exceeded.
Standard value: 1.0 − 1.1 mm
PLATINUM Q: Is the plug gap at the standard value?
TIP AKX01327AB
YES : Refer to, INSPECTION PROCEDURE 27 − Ignition
Circuit System P.13A-628.
NO : Replace the faulty spark plug. Then go to Step 7.
STEP 5. Check the following items.

(1) Check the following items, and repair or replace the
defective component.
a. Check timing belt alignment.
b. Check compression.
YES : Repair or replace it. Then go to Step 7.
NO : Go to Step 7.

Diagnostic Function − EOBD Drive Cycle−P.13A-11.
YES : Replace the ECU. Then go to Step 7.

DTC P0301: Cylinder 1 Misfire Detected
• The ECU checks for such changes in engine

.
TECHNICAL DESCRIPTION speed.

• If a misfire occurs while the engine is running, the
engine speed changes for an instant. .
DTC SET CONDITIONS

Check Conditions • If MIL "blinks" in 1 Hz frequency, then there has
• Engine speed is beween idle and 6200 r/min. been possible catalyst damage caused by the
• Engine torque is above 0. misfire.
• Engine speed during start is above 530 r/min.
• Ignition counter (starts when engine speed 530
.

r/min is exceeded) is above 6.
• Torque intervention by traction control is not
active. P.13A-11.
• Safety fuel cut off is not active. .
• 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
STEP 1. Check the No.1 cylinder ignition coil spark.

(2) Remove the No.1 cylinder ignition coil.
(3) Remove the spark plug and connect to the No.1 cylinder
ignition coil.
(4) Ground the spark plug side electrode securely.
spark.
CAUTION
If prolonged engine cranking is required disconnect Fuel
SPARK PLUG Pump to prevent excessive unburnt fuel damaging the
exhaust catalysts.
AKX00432 AB
Q: Did it spark?
YES : Go to Step 3.
NO : Go to Step 2.
STEP 2. Check the No.1 cylinder spark plug.

CAUTION
brush.
IRIDIUM
TIP (1) Inspect the spark plug.
(2) Check the plug gap and replace if the limit is exceeded.
PLATINUM Standard value: 1.0 − 1.1 mm
TIP AKX01327AB Q: Is the plug gap at the standard value?
YES : Refer to, INSPECTION PROCEDURE 27 − Ignition
NO : Replace the No.1 cylinder spark plug. Then go to Step
4.
STEP 3. Check the compression.

Refer to GROUP 11C, On-Vehicle Service − Compression
Pressure Check P.11A-10.
NO : Go to Step 4.

Judgement Criteria (change in the angular accel-

.
TECHNICAL DESCRIPTION eration of the crankshaft is used for misfire

• If a misfire occurs while the engine is running, the detection).
engine speed changes for an instant. • MIL activated after 2 drive cycles.
• The ECU checks for such changes in engine • No Limp home.
speed. • If MIL "blinks" in 1 Hz frequency, then there has
. been possible catalyst damage caused by the
DTC SET CONDITIONS misfire.
Check Conditions .
• Engine torque is above 0. Refer to Diagnostic Function − EOBD Drive Cycle −
.

active. likely causes for this code to be set are:)
• Safety fuel cut off is not active. • Ignition system related part(s) failed.
• A/C compressor switching is not active. <M/T> • Low compression pressure.
• Clutch pedal is not pressed. <M/T>. • Refer to component locations GROUP-70
DIAGNOSIS

(2) Remove the No.2 cylinder spark plug and connect to the
ignition coil.
(3) Ground the No.2 cylinder spark plug side electrode
securely.
spark.
Q: Did it spark?
SPARK PLUG YES : Go to Step 3.
NO : Go to Step 2.
AKX00432 AB
STEP 2. Check the No.2 cylinder spark plugs.

CAUTION
brush.
IRIDIUM Check the plug gap and replace if the limit is exceeded.
TIP
TIP AKX01327AB YES : Refer to, INSPECTION PROCEDURE 27 − Ignition
4.

Refer to GROUP 11B, On-Vehicle Service − Compression
NO : Go to Step 4.


.

Check Conditions .
.

DIAGNOSIS

ignition coil.
securely.
spark.
Q: Did it spark?
YES : Go to Step 3.
SPARK PLUG
NO : Go to Step 2.
AKX00432 AB

CAUTION
brush.
TIP
4.

NO : Go to Step 4.


.

Check Conditions .
.

DIAGNOSIS

ignition coil.
securely.
spark.
Q: Did it spark?
YES : Go to Step 3.
SPARK PLUG
NO : Go to Step 2.
AKX00432 AB

CAUTION
brush.
TIP
4.

NO : Go to Step 4.


.

Check Conditions .
.

DIAGNOSIS

ignition coil.
securely.
spark.
Q: Did it spark?
YES : Go to Step 3.
SPARK PLUG
NO : Go to Step 2.
AKX00432 AB

CAUTION
brush.
TIP
4.

NO : Go to Step 4.


.

Check Conditions .
.

DIAGNOSIS

ignition coil.
securely.
spark.
Q: Did it spark?
YES : Go to Step 3.
SPARK PLUG
NO : Go to Step 2.
AKX00432 AB

CAUTION
brush.
TIP
4.

NO : Go to Step 4.

DTC P0325: Knock Sensor Circuit Malfunction.
CONNECTOR: B-120
AIR
CLEANER
COVER
KNOCK SENSOR
ENGINE
CONTROL
UNIT
B-120 (GR)
16DB400A
AK303118 AB
Judgment Criteria
.
CIRCUIT OPERATION • No MIL or Limp home for Knock Control Zero

• The knock sensor sends a signal voltage to the Test.
ENGINE-ECU (terminal No. 28) and is grounded • Engine speed limitation for sensor failure.
to the ENGINE-ECU(terminal 13).
.

• The knock sensor converts the vibration of the
cylinder block into a voltage and outputs it. If • Knock sensor failed.
there is a malfunction of the knock sensor, the • Open or shorted knock sensor circuit.
voltage output will not change. • Harness or connector damage.
• The ECU checks whether the voltage output • ECU failed.
changes. • Refer to component locations GROUP-70
.

DTC SET CONDITIONS
Check Conditions
• ECU internal testing of IC chip for Knock Con-
trol(ECU internal failure)
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check harness connector B-120 at the knock

sensor for damage.
CONNECTOR: B-120
YES : Go to Step 2.
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
STEP 2. Check the continuity at knock sensor harness

side connector B-120.
CONNECTOR: B-120
harness side.
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:

CONNECTOR: • Should be less than 2 ohms.
COMPONENT SIDE
2 1 YES : Go to Step 3.
NO : Repair an open circuit or harness damage between
knock sensor connector B-120 (terminal No. 2) and
ground. Then go to Step 8.
AK303121 AB

damage.
YES : Go to Step 4.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A

between knock sensor connector B-120 (terminal No. 2)
and ECU connector B-20 (terminal No. 13).
CONNECTOR: B-120
YES : Go to Step 5.
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
YES : Go to Step 6.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

harness damage between knock sensor connector B-120
CONNECTOR: B-120
YES : Go to Step 7.
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 7. Check the knock sensor.

CONNECTOR: B-120
(1) Disconnect the knock sensor connector B-120.
KNOCK SENSOR
B-120 (GR)
2 1
HARNESS
CONNECTOR:
(3) Measure the voltage between knock sensor side connector

terminal No. 1 (output) and No. 2 (ground).
KNOCK SENSOR (4) Gradually increase the engine speed.
CONNECTOR • The voltage increases with the increase in the engine
speed.
1 2
YES : Replace the ECU. Then go to Step 8.
NO : Replace the knock sensor. Then go to Step 8.
AK303857 AB

code (DTC).
CAUTION
DATA LINK (2) Turn the ignition switch to the "ON" position.
CONNECTOR (3) Erase the DTC.
(4) Test drive under the following conditions:
• Engine speed: 3000 − 5000r/min
• Engine load: 40% or more
• Drive a minimum of 3 seconds after the above condi-
tions have been met.
(5) After completing the test drive, check for DTC.Turn the
MB991910 ignition switch to the "LOCK" (OFF) position.
MB991824
MB991827 00DB076A
DTC P0335: Crankshaft Position Sensor Circuit.
CONNECTOR: B-119
CRANKSHAFT AIR
POSITION CLEANER
SENSOR
COVER
ENGINE
CRANKSHAFT CONTROL
SPROCKET UNIT
B-119 (B)
16DB400A
AK303122 AB
. .

• The crankshaft position sensor power is supplied • The crankshaft position sensor detects the crank
from the ECU(terminal No. 25). angle (position) of each cylinder, and converts
• Terminal No. 1 of the crankshaft position sensor that data to pulse signals, then which are input to
is grounded with ECU (terminal No. 8). the ECU.
• A 5-volt voltage is applied on the crankshaft posi- • When the engine is running, the crankshaft posi-
tion sensor output terminal (terminal No. 2) from tion sensor outputs a pulse signal.
the ECU (terminal No. 23). The crankshaft posi- • The ECU checks whether pulse signal is input
tion sensor generates a pulse signal when the while the engine is cranking.
output terminal is opened and grounded. .
DTC SET CONDITIONS <Range/Performance problem - Alignment>

Check Conditions, Judgment Criteria • Crank angle signal frequently missing.
• '+/- 1 tooth correction several times continuous or .
loosing reference gap during engine running for

0.5 second.
DTC SET CONDITIONS <Range/Performance problem - Circuit continuity>

• Engine is being cranked. Refer to Diagnostic Function − EOBD Drive Cycle −
Judgment Criteria P.13A-11.
• no reference gap detection during engine start for .
0.5 second. TROUBLESHOOTING HINTS (The most

• Crank angle signal missing.
.
• Crankshaft position sensor failed.

• 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
DIAGNOSIS
• MB991824: V.C.I.
• MD998478: Test Harness (3pin, triangle)

Crankshaft Position Sensor.
CAUTION
• The tachometer and engine speed indicated on the
diagnostic tool should match.
MB991910 (4) Turn the ignition switch to the "LOCK" (OFF) position.
MB991824
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Using the oscilloscope, check the crankshaft

position sensor.
CONNECTOR: B-119 (1) Disconnect the crankshaft position sensor connector B-119,
and connect the test harness special tool (MD998478)
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
OSCILLOSCOPE (2) Connect the oscilloscope probe to crankshaft position

CRANKSHAFT POSITION sensor connector terminal No. 2 (black clip of special tool).
SENSOR CONNECTOR
1 2 connect the all ECU connectors and connect check harness
3 special tool (MB992044) between the separated connec-
MD998478
tors. then connector the oscilloscope probe to the check
harness connector terminal No. 23.
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.
YES : Go to Step 3.
NO : Go to Step 5.
AK302211AB
STEP 3. Check harness connector B-119 at the crankshaft

position sensor for damage.
YES : Go to Step 4.
CRANKSHAFT
POSITION Connector Inspection P.00E-2. Then go to Step 18.
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:

CAUTION
CONNECTOR
• The tachometer and engine speed indicated on the
diagnostic tool should match.
MB991910
MB991827 00DB076A
STEP 5. Check harness connector B-119 at the crankshaft

CONNECTOR: B-119
YES : Go to Step 6.
CRANKSHAFT
POSITION Connector Inspection P.00E-2. Then go to Step 18.
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
STEP 6. Measure the sensor supply voltage at crankshaft

CONNECTOR: B-119 (1) Disconnect the connector B-119 and measure at the
harness side.
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:

B-119 HERNESS • Voltage should be between 4.9 and 5.1 volts.
CONNECTOR:
2 1 Q: Is the measured voltage between 4.9 and 5.1 volts?
3 YES : Go to Step 11.
NO : Go to Step 7.
AK303125 AB
STEP 7. Measure the sensor supply voltage at ECU

connector B-20 by using power plant ECU check harness
(1) Disconnect the all ECU connectors and connect power
plant ECU check harness special tool MB992044 between
the separated connectors.
AIR (2) Disconnect the crankshaft position sensor connector B-119.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

YES : Go to Step 8.
NO : Go to Step 9.
03DB196A

damage.
YES : Repair harness wire between crankshaft position
sensor connector B-119 (terminal No. 2) and ECU
AIR connector B-20 (terminal No. 23) because of open
CLEANER circuit. Then go to Step 18.
ENGINE
CONTROL
UNIT
16DB400A

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

crankshaft position sensor connector B-119 (terminal No.
2) and ECU connector B-20 (terminal No. 23).
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 11. Measure the power supply voltage at crankshaft

harness side.
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:

B-119 HARNESS
CONNECTOR:
• Voltage should be 4.9 - 5.1 volts.
2 1 Q: Is the measured voltage between 4.9 and 5.1volts?
NO : Go to Step 12.
AK303127AB

damage.
YES : Repair harness wire between ECU connector B-20
(terminal No. 25) and crankshaft position sensor
AIR connector B-119 (terminal No. 3) because of open
CLEANER circuit or short circuit to ground. Then go to Step 18.
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-119
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
STEP 13. Check for continuity at crankshaft position

harness side.
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:

CONNECTOR:
NO : Go to Step 14.
AK303128 AB

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

between crankshaft position sensor connector B-119
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 17. Check for harness damage between crankshaft

position sensor connector B-119 (terminal No. 2) and ECU
CRANKSHAFT
POSITION
SENSOR
CRANKSHAFT
SPROCKET
B-119 (B)
2 1
3
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

NEXT PAGE
13A-372
13A
DTC P0340: Camshaft Position Sensor Circuit.
CONNECTOR: B-106
CAMSHAFT POSITION
SENSOR AIR
CLEANER
COVER
B-106 (B) ENGINE
CONTROL
UNIT
AK303129AB
16DB400A
. .

• The camshaft position sensor power is supplied • The camshaft position sensor functions to detect
from the ECU (terminal No. 25). the top dead center position of the number 1 cyl-
• Terminal No. 3 of the camshaft position sensor is inder and to convert that data to pulse signals
grounded with ECU (terminal No. 8). that are input to the ECU.
• A 5-volt supply is applied to the camshaft position • When the engine is running, the camshaft posi-
sensor output terminal (terminal No. 2) from the tion sensor outputs a pulse signal.
ECU (terminal No. 38). The camshaft position • The ECU checks whether pulse signal is input
sensor generates a pulse signal when the output while the engine is cranking.
terminal is opened and grounded. .
DTC SET CONDITIONS <Range/Performance problem - Alignment>

Check Conditions • MIL activated immediately.
• Engine speed is higher than 50 r/min. • Engine stalls.
Judgment Criteria .
• Normal signal pattern has not been input for cyl-

inder identification from the crankshaft position
sensor signal and camshaft position sensor sig-
nal for 2 seconds.
DTC SET CONDITIONS <Range/Performance problem - Circuit continuity>

• Engine speed is higher than 50 r/min. Refer to Diagnostic Function − EOBD Drive Cycle −
Judgment Criteria P.13A-11.
• Camshaft position sensor output voltage has not .
changed (no pulse signal is input) for 2 seconds. TROUBLESHOOTING HINTS (The most
• MIL activated immediately.
• Engine stalls.
• Camshaft position sensor failed.
.
• Open or shorted camshaft position sensor circuit.

• Harness or connector damage.
• Refer to configuration diagrams GROUP-80 • Refer to circuit diagrams GROUP-90

DIAGNOSIS
• MB991824: V.C.I.
• MB992044: Engine ECU Check Harness
STEP 1. Using the oscilloscope, check the camshaft

position sensor.
(1) Disconnect the all ECU connectors and connect engine
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(2) Connect the oscilloscope probe to the ECU check harness

out put connector B-20 (terminal No. 38).
B-20 HARNESS
CONNECTOR OSCILLOSCOPE
03DB232A
(4) Check the waveform.

CAMSHAFT
POSITION • The waveform should show a pattern similar to the illus-
SENSOR OUTPUT tration.
WAVE PATTERN
NORMAL WAVEFORM Q: Is the waveform normal?
5V YES : Go to Step 2..
NO : Go to Step 4.
0
(TIME)
03DB260A
STEP 2. Check harness connector B-106 at camshaft

CONNECTOR: B-106
YES : Go to Step 3.
CAMSHAFT POSITION NO : Repair or replace it. Refer to GROUP 00E, Harness
SENSOR Connector Inspection P.00E-2. Then go to Step 20.
B-106 (B)
3 2 1
HARNESS
CONNECTOR:

STEP 4. Check harness connector B-106 at camshaft

CONNECTOR: B-106
YES : Go to Step 5.
CAMSHAFT POSITION NO : Repair or replace it. Refer to GROUP 00E, Harness
SENSOR Connector Inspection P.00E-2. Then go to Step 20.
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
STEP 5. Measure the sensor supply voltage at camshaft

position sensor connector B-106.
harness side.
CAMSHAFT POSITION (2) Turn the ignition switch to the "ON" position.
SENSOR
B-106 (B)
3 2 1
HARNESS
CONNECTOR:

CONNECTOR:
3 2 1 YES : Go to Step 10.
NO : Go to Step 6.
AKX01421AF
STEP 6. Measure the sensor supply voltage at ECU

connector B-20 by using engine ECU check harness
AIR (2) Disconnect the camshaft position sensor connector B-106.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

YES : Go to Step 7.
NO : Go to Step 8.
03DB191A

damage.
YES : Repair harness wire between camshaft position
sensor connector B-106 (terminal No. 2) and ECU
AIR
CLEANER connector B-22 (terminal No. 38) because of open
circuit. Then go to Step 20.
COVER
ENGINE Connector Inspection P.00E-2. Then go to Step 20.
CONTROL
UNIT
16DB400A

damage.
YES : Go to Step 9.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A

camshaft position sensor connector B-106 (terminal No. 2)
CAMSHAFT POSITION NO : Repair it. Then go to Step 20.
SENSOR
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 10. Measure the power supply voltage at camshaft

position sensor connector B-106.
harness side.
CAMSHAFT POSITION (2) Turn the ignition switch to the "ON" position.
SENSOR
B-106 (B)
3 2 1
HARNESS
CONNECTOR:

B-106 HARNESS • Voltage should be approximately 4.9 - 5.1 volts.
CONNECTOR:
Q: Is the voltage approximately between 4.9 - 5.1volts?
NO : Go to Step 11.
AK303134 AB
STEP 11. Check ECU harness connector B-20 for damage.

YES : Repair harness wire between ECU connector B-20
(terminal No. 25) and camshaft position sensor
AIR
CLEANER connector B-106 (terminal No. 01) because of open
circuit or short circuit to ground. Then go to Step 20.
COVER
ENGINE Connector Inspection P.00E-2. Then go to Step 20.
CONTROL
UNIT
16DB400A
STEP 12. Check the continuity at camshaft position sensor

connector B-106.
harness side.
CAMSHAFT POSITION
SENSOR
B-106 (B)
3 2 1
HARNESS
CONNECTOR:

B-106 HARNESS
ground.
CONNECTOR:
NO : Go to Step 13.
03DB192A

damage.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A

between camshaft position sensor connector B-106
SENSOR
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 15. Check ECU harness connector B-20 for damage.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 17. Check for harness damage between connector

B-20 (terminal No. 25) and camshaft position sensor
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-106
CAMSHAFT POSITION
SENSOR
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
STEP 18. Check for harness damage between camshaft

position sensor connector B-106 (terminal No. 2) and ECU
SENSOR
B-106 (B)
3 2 1
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 19. Check the camshaft position sensing cylinder.

Q: Is the camshaft position sensing cylinder in good
condition?
YES : Replace the camshaft position sensor. Then go to
Step 20.

Diagnostic Function − EOBD Drive Cycle− P.13A-11.
DTC P0421: Warm Up Catalyst Efficiency Below Threshold (bank 1)
• The ECU compares the output of the front and

.
TECHNICAL DESCRIPTION rear heated oxygen sensor signals.

• The signal from the rear heated oxygen sensor
differs from the front heated oxygen sensor. That .
is because the catalytic converter purifies

exhaust gas. When the catalytic converter has
deteriorated, the signal from the front heated oxy-
gen sensor becomes similar to the rear heated
oxygen sensor.
DTC SET CONDITIONS

• Lambda control upstream catalyst is active. • calculated aeging value (based on the sensor
• Downstream oxygen sensor ready for operation. signal ratio) exceeds 0.55.
• Lambda controller does not reach MIN/MAX limit. • MIL activated after 2 drive cycles.
• P-part of lambda control downstream is active. • No Limp home.
• Neutralization of catalyst oxygen stroge is not .
active. EOBD DRIVE CYCLE PATTERN

• No misfire.
• Transient control is not active.
• Active charcoal is not highly charged. P.13A-11.
• No rapid load changes. .
• Catalyst load within range. TROUBLESHOOTING HINTS (The most

• Load is between 14 and 30% <M/T> or 16 and likely causes for this code to be set are: )
38% <A/T>. • Right bank side catalytic converter deteriorated.
• Engine speed is between 1080 and 2480 r/min • Exhaust leak.
<M/T> or 1120 and 2480 r/min <A/T>. • Refer to component locations GROUP-70
• Catalyst temperature is between 580 and 780 • Refer to configuration diagrams GROUP-80
degreeC <M/T> or 535 and 730 degreeC <A/T>. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check for exhaust leak.

NO : Go to Step 2.

CAUTION
output voltage should repeat 0 volt and 0.6 to 1.0 volt
MB991910 alternately.
YES : Go to Step 3.
NO : Refer to DTC P0136 − Heated Oxygen Sensor Circuit
(Bank 1, Sensor 2) P.13A-186, DTC P0137 − Heated
Oxygen Sensor Circuit Low Voltage (Bank 1, Sensor
2) P.13A-192, DTC P0138 − Heated Oxygen Sensor
Circuit High Voltage (Bank 1, Sensor 2) P.13A-198,
DTC P0139 − Heated Oxygen Sensor Circuit Slow
MB991827 00DB076A Response (Bank 1, Sensor 2) P.13A-203.

(2) Read the diagnostic trouble code.
YES : Replace the right bank side catalytic converter.
DTC P0431: Warm Up Catalyst Efficiency Below Threshold (bank 2)

.


exhaust gas. When the catalytic converter has
deteriorated, the signal from the front heated oxy-
gen sensor becomes similar to the rear heated
oxygen sensor.
DTC SET CONDITIONS

• Lambda control upstream catalyst is active. • calculated aeging value (based on the sensor
• Downstream oxygen sensor ready for operation. signal ratio) exceeds 0.55.
• Lambda controller does not reache MIN/MAX • MIL activated after 2 drive cycles.
limit. • No Limp home.
• P-part of lambda control downstream is active.
• Neutralization of catalyst oxygen stroge is not
.

active.
• No misfire.
• Transient control is not active. P.13A-11.
• Active charcoal is not highly charged. .
• No rapid load changes. TROUBLESHOOTING HINTS (The most

• Catalyst load within range. likely causes for this code to be set are: )
• Load is between 14 and 30% <M/T> or 16 and • Left bank side catalytic converter deteriorated.
38% <A/T>. • Exhaust leak.
• Engine speed is between 1080 and 2480 r/min • Refer to component locations GROUP-70
<M/T> or 1120 and 2480 r/min <A/T>. • Refer to configuration diagrams GROUP-80
• Catalyst temperature is between 580 and 780 • Refer to circuit diagrams GROUP-90
degreeC <M/T> or 535 and 730 degreeC <A/T>.
DIAGNOSIS
• MB991824: V.C.I.

NO : Go to Step 2.

CAUTION
YES : Go to Step 3.
NO : Refer to DTC P0156 − Heated Oxygen Sensor Circuit
(Bank 2, Sensor 2) P.13A-238, DTC P0157 − Heated
Oxygen Sensor Circuit Low Voltage (Bank 2, Sensor
2) P.13A-244, DTC P0158 − Heated Oxygen Sensor
Circuit High Voltage (Bank 2, Sensor 2) P.13A-250,
DTC P0159 − Heated Oxygen Sensor Circuit Slow
MB991827 00DB076A Response (Bank 2, Sensor 2) P.13A-255.

YES : Replace the left bank side catalytic converter.
DTC P0441: Evaporative Emission Control System Incorrect Purge Flow.
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
. .

• The evaporative emission purge solenoid power • To judge if the purge valve is stuck open.
is supplied from the MPI relay (terminal No. 4).
• The ECU controls ground evaporative emission
.
purge solenoid by turning the power transistor in

the ECU "ON" and "OFF".
DTC SET CONDITIONS

Check Conditions
.

Engine speed is above 801r/min. likely causes for this code to be set are: )
• Purge solenoid valve stuck open.
Judgment Criteria • Refer to component locations GROUP-70
• Purge valve operation • Refer to configuration diagrams GROUP-80
• No MIL. • Refer to circuit diagrams GROUP-90
.

P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool, check actuator test item 10:

Evaporative Emission Purge Solenoid.
CAUTION
CONNECTOR
(3) Set diagnostic tool to the actuator test mode for item 10,
Evaporative emission purge solenoid.
• An operation sound should be heard and vibration
should be felt when the evaporative emission purge
MB991910
solenoid is operated.
MB991824
Q: Is the solenoid operating properly?
NO : Go to Step 2.
MB991827 00DB076A
STEP 2 Check the Purge solenoid valve operation. Refer to

Group 17 , Evaporative Emission Purge Solenoid Valve
Check P.17-82
Q:Is the Purge Solenoid Valve operating correctly?
2 1 Troubleshooting/Inspection Service Points − How to
HARNESS
CONNECTOR: NO : Repair or replace it. Then go to Step 3.
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
STEP3. Test the EOBD drive cycle.

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
. .

• The evaporative emission purge solenoid power • To judge if there is open circuit in the evaporative
is supplied from the MPI relay (terminal No. 4). emission purge solenoid drive circuit, the ECU
• The ECU controls ground evaporative emission performs an internal test.
purge solenoid by turning the power transistor in .
the ECU "ON" and "OFF".
DTC SET CONDITIONS

Check Conditions
.

Engine speed is above 801r/min. likely causes for this code to be set are: )
• Evaporative emission purge solenoid failed.
Judgment Criteria • Open or shorted evaporative emission purge
• IC internal test (open circuit, short to earth, short solenoid circuit.
to battery). • Harness or connector damage.
• No MIL. • Refer to component locations GROUP-70
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.
• MB992044: Engine ECU Check Harness

Evaporative Emission Purge Solenoid.
CAUTION
CONNECTOR
Evaporative emission purge solenoid.
• An operation sound should be heard and vibration
should be felt when the evaporative emission purge
MB991910
solenoid is operated.
MB991824
Q: Is the solenoid operating properly?
NO : Go to Step 2.
MB991827 00DB076A
STEP 2 Check harness connector F-08 at the evaporative

emission purge solenoid for damage.
Q:Is the harness connector in good condition?
YES : Go to Step 3.
2 1 Connector Inspection P.00E-2. Then go to Step 12.
HARNESS
CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
STEP 3 Check the evaporative emission purge solenoid.

(1)Disconnect the evaporative emission purge solenoid
connector F-08.
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
STEP 4. Measure the power supply voltage at evaporative

emission purge solenoid harness side connector F-08.
(1)Disconnect the connector F-08 and measure at the harness
side.
(2)Turn the ignition switch to the "ON" position.
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
(3)Measure the voltage between terminal No. 2 and ground.

B-05 HARNESS (4) Turn the ignition switch to the "LOCK" (OFF) position.
CONNECTOR:
2 1 present?
YES : Go to Step 6.
NO : Go to Step 5.
AK303144 AB

damage.
CONNECTOR: B-17X
B-17X (terminal No. 4) and evaporative emission
purge solenoid connector F-08 (terminal No. 2)
Then go to Step 12.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
STEP 6. Measure the power supply voltage at ECU

connector B-20 by using engine ECU check harness
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
present?
YES : Go to Step 9.
NO : Go to Step 7.
03DB194A

damage.
YES : Go to Step 8.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

between evaporative emission purge solenoid connector
F-08 (terminal No. 1) and ECU connector B-20 (terminal No.
21).
Q:Is the harness wire in good condition?
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

connector B-17X (terminal No. 4) and evaporative emission
purge solenoid connector F-08 (terminal No. 2).
CONNECTOR: B-17X Q:Is the harness wire in good condition?
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
STEP 11. Check for harness damage between evaporative

emission purge solenoid connector F-08 (terminal No. 1)
2 1
HARNESS
CONNECTOR:
COMPONENT SIDE
EVAPORATIVE
EMISSION PURGE
SOLENOID
F-08
03DB193A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

DTC P0461: Fuel Level Sensor (main) Circuit Range/Performance
.
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.
.
DTC SET CONDITIONS

Check Conditions, Judgement Criteria
.
• Fuel level in tank is too low.

• Fuel level too low in tank.
.

None .
NEXT PAGE
MULTIPORT FUEL INJECTION (MPI) DIAG
13A-399
13A
P0500: Vehicle Speed Sensor System
NOTE: If vehicle is equipped with an automatic

transmission, the code P0720 will also be set in MANUAL
the A/T-ECU therefore refer to Output Shaft TRANSMISSION
Speed Sensor troubleshooting procedure
P.23A-72 and also CAN-BUS diagnosis section
P.54C-13
NOTE: If vehicle is equipped with a manual
transmission, proceed with the following test
procedures.
CONNECTOR: A-13
A-13 (GR)
1 2 3 4 5 6 7
8 9 10 11
22DB018A
SPEED SENSOR
12 13 14 15 16 17
CONNECTORS: C-214, 215
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
CONNECTOR: B-17X
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
. .
CIRCUIT OPERATION DRIVE CYCLE PATTERN

• The vehicle speed sensor (manual) generates a Start and drive vehicle at 50km/h for 3mins. Stop
0 ⇔ 5 volt pulse signal when the driven (pinion) vehicle, turn engine "OFF". Restart engine and drive
gear rotates. The pulse signal frequency vehicle again at 50km/h for 3 mins. and confirm if
increases with a rise in driven gear speed. speedometer is working and the status of the engine
• The vehicle speed sensor (manual) is connected warning lamp.
to the ENGINE-ECU connector B-21 (terminals .
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
DTC SET CONDITIONS • Refer to configuration diagrams GROUP-80
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
• MB991958: Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
• MB991910: MUT-III Main Harness A
• MB992044: Engine-ECU Check Harness
STEP 1. Using diagnostic tool MB991958, check MPI data

list item 4: Vehicle Speed Sensor System.
CAUTION
To prevent damage to diagnostic tool MB991958, always
CONNECTOR before connecting or disconnecting diagnostic tool
MB991958.
(1) Connect diagnostic tool MB991958 to the data link
connector.
(2) Start the engine.
(3) Set diagnostic tool MB991958 to the data reading mode.
• Item 4: Vehicle Speed Sensor.
MB991910 • When driving at a constant speed of 50km/h, the dis-
play should be "1,900 − 2,100 r/min".
Q: Is the sensor within the specified range?
Cope with Intermittent Malfunction P.00-14.
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Measure the power supply voltage at the vehicle

speed sensor connector B-121.
(1) Disconnect connector B-121 and measure at the harness
CONNECTOR: B-121 side.
VEHICLE
SPEED SENSOR
B-121
03DB234A
(3) Measure the voltage between terminal 1 and ground.

• The voltage should measure battery positive voltage.
B-121 HARNESS
CONNECTOR: Q: Is the measured voltage battery positive voltage?
YES : Go to Step 5.
NO : Go to Step 3.
03DB233A

for damage.
YES : Go to Step 4.
NO : Repair or replace the damaged components. Refer to
GROUP 00E, Harness Connector Inspection
P.00E-2.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB

connector B-17X (terminal No. 4) and vehicle speed sensor
YES : Go to Step 5.
NO : Repair harness wire between MPI relay connector
B-17X (terminal No. 4) and vehicle speed sensor
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
STEP 5. Check intermediate connector A-13 and MPI relay

connector B-17X for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
CONNECTOR: A-13 Q: Are the connectors and terminals in good condition?
YES : Go to Step 6.
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
10DB083A
STEP 6. Check the harness for open circuit or short circuit

to ground between the MPI relay connector B-17X terminal
1 and the intermediate connector A-13 terminal 5.
YES : Go to Step 7.
NO : Repair or replace the harness wire.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
STEP 7. Measure the ENGINE-ECU to speed sensor, output

voltage at the vehicle speed sensor connector B-121.
(1) Disconnect connector B-121 from the speed sensor and
CONNECTOR: B-121 measure voltage at the harness side.
VEHICLE
SPEED SENSOR
B-121
03DB234A

• The voltage should measure between 4.5 and 4.9 volts.
B-121 HARNESS
CONNECTOR Q: Is the measured voltage between 4.5 and 4.9 volts?
YES : Go to Step 9.
NO : Go to Step 8.
03DB235A
STEP 8. Check intermediate connector A-13 for loose,

corroded or damaged terminals, or terminals pushed back
in the connector.
Q: Is the connector and terminals in good condition?
CONNECTOR: A-13
YES : Go to Step 9.
A-13 (GR)
P.00E-2.
1 2 3 4 5 6 7
8 9 10 11
12 13 14 15 16 17
10DB083A
STEP 9. Measure the ENGINE-ECU output voltage to the

speed sensor at the ENGINE-ECU connector B-21 by using
(1) Disconnect all the connectors from the ENGINE-ECU.
(2) Connect special tool MB992044 (check harness) between
the ENGINE-ECU and the control-side harness connectors.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(4) Measure the voltage between connector B-21 (terminal 85)

and ground.
MB992044 CHECK HARNESS
CONNECTOR: B-21
NO : Go to Step 12.
03DB236A
STEP 10. Check ENGINE-ECU connector B-21 and vehicle

speed sensor connector B-121 for loose, corroded or
damaged terminals, or terminals pushed back in the
connector.
Q: Are the connectors in good condition?
AIR GROUP 00E, Harness Connector Inspection
CLEANER
P.00E-2.
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
STEP 11. Check the harness for open circuit or damage

between ENGINE-ECU connector B-21 terminal 85 and
vehicle speed sensor connector B-121 terminal 3.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A

connector.
Q: Are the connectors and terminals in good condition?
NO : Repair or replace the damages components. Refer to
CLEANER P.00E-2.
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A

in the connector.
CONNECTOR: A-13 Q: Is the connector and terminals in good condition?
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
10DB083A
STEP 14. Check the harness for short circuit to ground

AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
STEP 15. Measure the ground circuit for resistance at the

vehicle speed sensor connector B-121.
(1) Disconnect connector B-121 from the speed sensor and
CONNECTOR: B-121 measure at the harness side.
VEHICLE
SPEED SENSOR
B-121
03DB234A
(2) Measure the resistance between terminal 2 and ground.

• The resistance should measure less than 2 ohms.
B-121 HARNESS Q: Is the measured resistance less than 2 ohms?
CONNECTOR: YES : Go to Step 17.
NO : Go to Step 16.
03DB237A

in the connector.
CONNECTOR: A-13 Q: Is the connector and terminals in good condition?
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
10DB083A
STEP 17. Measure the resistance at the ENGINE-ECU

connector B-21 by using check harness special tool
MB992044.
the ENGINE-ECU and the body and control-side harness
AIR connector.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

MB992044 CHECK HARNESS
CONNECTOR: B-21
Q: Is the measured resistance less than 2 ohms?
NO : Repair or replace wiring harness.
03DB238A

connector.
CLEANER P.00E-2.
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A

AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: B-121
VEHICLE
SPEED SENSOR
B-121
03DB234A
STEP 20. Check ENGINE-ECU connector B-21 for loose,

in the connector.
Q: Are the connector and terminals in good condition?
CLEANER
P.00E-2.
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 21. Using the oscilloscope, check the vehicle speed

sensor waveform at ENGINE-ECU connector B-21 by using
the ENGINE-ECU and the body and control-side harness
AIR connector.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(3) Connect an oscilloscope probe to ENGINE-ECU connector

B-21 CONNECTOR: B-21 terminal 85 and 82.
(4) Start the engine and drive the vehicle at constant speed of
50 km/h.
PROBE
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.
0
ACX02131 AD
NO : Go to Step 22.
STEP 22. Replace the vehicle speed sensor.

(1) Replace the vehicle speed sensor. Refer to GROUP 22B,
MANUAL Manual transmission overhaul P.22B-30.
TRANSMISSION (2) Test drive the vehicle.
(3) Check for Engine MPI diagnostic trouble code.
YES : The procedure is complete.
NO : Repeat the troubleshooting procedure again. Go back
to Step 1.
22DB018A
SPEED SENSOR
DTC P0506: Idle Control Sytem RPM Lower Than Expected
Judgment Criteria
.
TECHNICAL DESCRIPTION • Idle correction deviation is below -200r/min for 19

• The amount of air taken in during idling is regu- seconds.
lated by the opening and closing of the throttle • MIL activated after 2 drive cycles.
valve. • No Limp home.
• The ENGINE-ECU checks the difference
between the actual engine speed and the target .
engine speed. EOBD DRIVE CYCLE PATTERN

.
P.13A-11.
Check Conditions
• Vehicle speed is 0 km/h. .
• Intake air temperature is above -9.8°C. TROUBLESHOOTING HINTS (The most

• Engine speed is idle. likely causes for this code to be set are:)
• Engine coolant temperature is above 60°C. • Throttle valve area is dirty.
• Altitude is lower than 3000 meters. • Throttle body assembly failed.
DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
CONNECTOR ing or disconnecting diagnostic tool.
MB991910
YES : Refer to Diagnostic Trouble Code Chart P.13A-17.
NO : Go to Step 2.
MB991824
MB991827 00DB076A
STEP 2. Check the throttle body. (throttle valve area)

Q: Is the throttle valve area dirty?
YES : Perform cleaning. Refer to Throttle body (throttle
valve area) cleaning P.13A-660. Then go to Step 4.
NO : Go to Step 3.

(3) After the DTC has been deleted, read the DTC again

DTC P0507: Idle Control Sytem RPM Higher Than Expected
Judgment Criteria
.
TECHNICAL DESCRIPTION • Idle correction deviation is above 100r/min for 19

• The amount of air taken in during idling is regu- seconds.
lated by the opening and closing of the throttle • MIL activated after 2 drive cycles.
valve. • No Limp home.
• The ENGINE-ECU checks the difference
between the actual engine speed and the target .
engine speed. EOBD DRIVE CYCLE PATTERN

.
P.13A-11.
Check Conditions
• Vehicle speed is 0 km/h. .
• Intake air temperature is above -9.8?. TROUBLESHOOTING HINTS (The most

• Engine speed is idle. likely causes for this code to be set are: )
• Engine coolant temperature is above 60?. • Intake system vacuum leak.
• Altitude is lower than 3000 meters. • Throttle body assy failed.
DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
NO : Go to Step 2.
MB991824
MB991827 00DB076A
STEP 2. Check the intake system vacuum leak.

NO : Go to Step 3.


(1) Carry out a test drive with the drive cycle pattern. Refer to −
P.13A-11.
DTC P0513: Immobilizer Malfunction
• No MIL
.
TECHNICAL DESCRIPTION • Engine will not start.

• ENGINE-ECU monitors the communication con-
dition with the ETACS-ECU. When an abnormal- .
ity in communication is found, ENGINE-ECU TROUBLESHOOTING HINTS (The most likely

prevents engine start. causes for this code to be set are: )
• Incorrect VIN in ENGINE-ECU.
.
• ENGINE-ECU programmed VIN does not match

DTC SET CONDITIONS ETACS VIN.
• Ignition switch: ON • Refer to configuration diagrams GROUP-80
Judgment Criteria
• When the communication error between
ENGINE-ECU and the ETACS-ECU continues for
2 seconds or more.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool , read the immobilizer

diagnostic trouble code (DTC).
CAUTION
(3) Read the immobilizer-DTC.
Q: Is the immobilizer-DTC- P0513 or P0630 set?
MB991910
YES : Refer to GROUP 54A, Ignition Switch and
Immobilizer System − Diagnostic Trouble Code Chart
MB991824
P.54A-13.
NO : Inspection is complete.
MB991827 00DB076A
DTC P0562: Battery Voltage too Low

. .
TECHNICAL DESCRIPTION TROUBLESHOOTING HINTS (The most likely

• ENGINE-ECU monitors the supply voltage. causes for this code to be set are: )
• Malfunction of Alternator.
• Battery failed.
.
DTC SET CONDITIONS

• Battery terminals dirty.
• Vehicle speed is 5 km/h. • Refer to configuration diagrams GROUP-80
• Time after start is 3 minutes. • Refer to circuit diagrams GROUP-90
Judgment Criteria
• Supply voltage is below 9.99 volts.
DIAGNOSIS
• MB991824: V.C.I.

Power supply voltage.
CAUTION
CONNECTOR
• Check that it is between 9.99 and 17.05 volts.
MB991910
Q: Is the measured voltage within specification?
MB991824 YES : Go to Step 2.
NO : Refer to GROUP 16 , Engine Electrical - Charging
System P.16-3. Then go to Step 2.
MB991827 00DB076A

code (DTC)
DTC P0563: Battery Voltage too High
Judgment Criteria
.
TECHNICAL DESCRIPTION • Supply voltage is above 17.05 volts.

• ENGINE-ECU monitors the supply voltage.
.
TROUBLESHOOTING HINTS (The most likely

DTC SET CONDITIONS causes for this code to be set are: )
Check Conditions • Malfunction of Alternator.
• Vehicle speed is 5 km/h. • Refer to component locations GROUP-70
• Time after start is 3 minutes. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991910
Q: Is the measured voltage within specification?
MB991824
YES : Go to Step 2.
NO : Refer to GROUP 16 , Engine Electrical - Charging
System P.16-3. Then go to Step 2.
MB991827 00DB076A

code (DTC)
DTC P0603: EEPROM Malfunction
CAUTION • EPPROM defect - No MIL.

The MIL may or may not illuminate when DTC • Incorrect ECU fitted - MIL activated immediately
P0603 is detected. Refer below: and engine only idling.
.
.

• ENGINE-ECU performs a check on the match None.
between hardware and software for different
transmission configurations (M/T, A/T). .

.
Check Conditions
• Ignition switch is in "ON" position. • EPPROM defect in ENGINE-ECU.
• Incorrect ENGINE-ECU fitted.
• Mismatch between software variant and trans- • Refer to configuration diagrams GROUP-80
misssion. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.

code (DTC)
CAUTION
CONNECTOR
MB991910 YES : Replace the ENGINE-ECU.
MB991824 Refer to GROUP 00, How to Use
MB991827 00DB076A
DTC P0606: Powertrain Control Module Main Processor Malfunction
. .
• Throttle actuator control module processor
checks the ENGINE-ECU for abnormal condi-
tions.
DTC SET CONDITIONS

• Ignition "ON". • MIL activated imediately.
• Fuel cut and engine speed limited.

.

None.
• ENGINE-ECU failed.
.

DIAGNOSIS
• MB991824: V.C.I.

code (DTC)
CAUTION
MB991910
YES : Replace the ENGINE-ECU.
MB991824
MB991827 00DB076A
DTC P0630: Vehicle Identification Number (VIN) Malfunction
. .
• The Vehicle Identification Number (VIN) is stored
in the ENGINE-ECU by the vehicle manufacturer.
DTC SET CONDITIONS

Check Conditions
.
• Ignition switch is in "ON" position.

• EPPROM is normal. likely causes for this code to be set are:)
• Incorrect VIN in ENGINE-ECU.
Judgement Criteria • ENGINE-ECU programmed VIN does not match
• VIN (current) has not been written. ETACS VIN.
• No MIL • Refer to component locations GROUP-70
• Engine will not start. • Refer to configuration diagrams GROUP-80
.
None.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool , check VIN Information.

CAUTION
(2) Set diagnostic tool to the coding mode for VIN Information.
Q: Has VIN (current) been written?
YES : Go to Step 2.
NO : Write VIN. Then go to Step 2.
MB991910
MB991824
MB991827 00DB076A

code (DTC)
DATA LINK (2) Check the diagnostic trouble code (DTC).
CONNECTOR
YES : Replace the ENGINE-ECU.
MB991910
MB991824
MB991827 00DB076A
DTC P0638: Throttle Actuator Control Motor Circuit Range/Performance Problem
CIRCUIT OPERATION
.
THROTTLE ACTUATOR CONTROL

• Refer to DTC P2101 − Throttle Actuator Control
MOTOR CIRCUIT Motor Circuit P.13A-461.
RANGE/PERFORMANCE PROBLEM
.
CIRCUIT TECHNICAL DESCRIPTION

• Refer to DTC P2101 − Throttle Actuator Control • ENGINE-ECU checks the electronic controlled
Motor Circuit P.13A-461. throttle system for abnormal conditions.
.
DTC SET CONDITIONS <Throttle Body: Error at spring check>

• Vehicle speed is 0 km/h. • Throttle angle is 12% more than adapted limp
• Engine speed is below 300 r/min. home for 0.14s.
• Engine coolant temperature is above 5.3 or
degreeC. • Throttle angle is 3% lower than adapted limp
• Intake air temperature is above 5.3 degreeC. home for 0.56s.
• Battery voltage is above 6.5 volts. .
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.
.
DTC SET CONDITIONS <Throttle Body: Error at UMA-Learning>

Check Conditions • Gas pedal angle is below 14.9%.
• Vehicle speed is 0 km/h.
Judgement Criteria
• Engine speed is below 300 r/min.
• Voltage sensor 1 at lower throttle stop is above
0.89111377 volt.
105 degreeC.
• Stationary portion is below 0.212402 volt.
• or
degreeC.
• Battery voltage is above 10 volts.
4.841309 volts.
• Time with ignition on (engine off) is more than
Stationary portion is below 4.11621123 volts.
1310.7 seconds.
.
DTC SET CONDITIONS <Throttle Body: Adaption caused by Ambient Conditions>

Check Conditions • Battery voltage is below 10 volts.
• Vehicle speed is above 0km/h. • Throttle valve currentless.
Judgement Criteria
• Engine coolant temperature is below 5.3 degreeC
• None.
or above 105 degreeC.
• Intake air temperature is below 5.3 degreeC or .
above 143,3 degreeC.
DTC SET CONDITIONS <Throttle Body: Error at UMA-Relearning>

Check Conditions • Gas pedal angle is below 14.9%.
• Vehicle speed is 0 km/h.
Judgement Criteria
• Engine speed is below 300 r/min.
0.89111377 volt.
105 degreeC.
• Stationary portion is below 0.212402 volt.
• or
degreeC.
• Battery voltage is above 10V.
4.841309 volts.
• Time with ignition on (engine off) is more than
Stationary portion is below 4.11621123 volts.
1310.7 seconds.
.
DTC SET CONDITIONS <Throttle Body: Error at Amplifier Adjustment>

Check Conditions • Time with ignition on (engine off) is more than
• Vehicle speed is 0 km/h. 1310.7 seconds.
• Engine speed is below 300 r/min. • Gas pedal angle is below 14.9%.
Judgement Criteria
105 degreeC.
• Amplifier value is above 4.324219 volts or below
3.996064 volts.
degreeC.
• Offset limit for amplifier value is above 0.054932
• Battery voltage is above 10 volts.
volt or below -0.054932 volt.
.

None.
• Harness damage in throttle actuator control
.
TROUBLESHOOTING HINTS (The most motor circuit, or connector damage.

likely causes for this code to be set are:) • Refer to component locations GROUP-70
• Throttle valve return spring failed. • Refer to configuration diagrams GROUP-80
• Throttle valve operation failed. • Refer to circuit diagrams GROUP-90
• Throttle actuator control motor failed.
DIAGNOSIS
• MB991824: V.C.I.

Target ETV Value.
CAUTION
CONNECTOR
Target ETV Value.
MB991910
MB991824
YES : Go to Step 2..
NO : Replace the throttle body assembly. Then go to Step
8.
MB991827 00DB076A
WARNING
STEP 2. Check the throttle actuator control motor.

(1) Disconnect the connector B-06.
CONNECTOR: B-06
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.
8.
03DB181A
STEP 3. Check harness connector B-06 at throttle actuator

control motor for damage.
CONNECTOR: B-06
YES : Go to Step 4.
Connector Inspection P.00E-2. Then go to Step 8..
B-06 (B)
03DB180A

damage.
YES : Go to Step 5.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

actuator control motor connector B-06 (terminal No. 4) and
CONNECTOR: B-06
YES : Go to Step 6.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

actuator control motor connector B-06 (terminal No. 1) and
CONNECTOR: B-06
YES : Go to Step 7.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

code (DTC).
CAUTION
MB991910 YES : Then go to Step 8.
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR (3) After the DTC has been deleted, read the DTC again.
MB991910
MB991824
MB991827 00DB076A
DTC P1603: Battery Backup Line Malfunction
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
NOTE: When the system detects an open circuit in

.
TECHNICAL DESCRIPTION the battery backup line, it makes 1 failure judgment

• The ENGINE-ECU checks the open circuit of bat- of other diagnostic trouble codes (DTCs).
tery backup line.
.
DTC SET CONDITIONS

Check Conditions TROUBLESHOOTING HINTS (The most
• None likely causes for this code to be set are: )
• RAM area check failed • Refer to configuration diagrams GROUP-80
•
.
EOBD DRIVE CYCLE PATTERN Open or shorted battery backup line, harness
damage or connector damage.
None.
.
DIAGNOSIS
• MB991824: V.C.I.
• MB992044: Power Plant ENGINE-ECU Check Harness

code (DTC).
CAUTION
(3) Erase the DTC.
(4) Start the engine and run it at idle.
(5) Read the DTC.
MB991910
MB991824
YES : Go to Step 2.
MB991827 00DB076A
STEP 2. Measure the backup power supply voltage at

ENGINE-ECU connector B-21 by using power plant
ENGINE-ECU check harness special tool MB992044.
power plant ENGINE-ECU check harness special tool
MB992044 between the separated connectors.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(2) Measure the voltage between terminal No.16 and ground.

POWER PLANT ECU • Voltage should be battery positive voltage.
CHECK HARNESS
CONNECTOR Q: Is battery positive voltage (approximately 12 volts)
present?
YES : Go to Step 5.
NO : Go to Step 3.
03DB182A

ENGINE-ECU harness side connector B-21.
(1) Disconnect the ENGINE-ECU connector B-21 and measure
at the harness side.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

B-21HARNESS
CONNECTOR • Voltage should be battery positive voltage.
present?
YES : Go to Step 5.
03DB183A
STEP 4. Check No. 9 fuse, 20 A in Relay box.

Q: Is the Fuse servicable and in good condition?
YES : Repair harness wire between battery and
because of harness damage. Then go to Step 6.
NO : Replace the fuse. Then go to Step 7.

damage.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage.
YES : Replace the ENGINE-ECU. Then go to Step 7.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

code (DTC).
CAUTION
(3) Read the DTC.
MB991910
MB991824
MB991827 00DB076A
DTC P2096: Post Catalyst System too Lean (bank 1)

.


exhaust gas. When the catalytic converter or oxy-
gen sensor has deteriorated, the signal from the
front heated oxygen sensor becomes similar to
the rear heated oxygen sensor.
DTC SET CONDITIONS

Check Conditions
.
• None
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.
.
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

NO : Go to Step 2.

CAUTION
MB991824
YES : Go to Step 3.
NO : Replace right bank, rear oxygen sensor. Then go to
Step 4.
NOTE: When replacing a deteriorated oxygen sensor the vehi-
cle mileage is most likely high and as a result the emission con-
trol system will be deteriorated considerably. Therefore it is
MB991827 recommended to replace both front and rear oxygen sensors
00DB076A
as a set. Also check that the Catalytic convertor is functioning
correctly.

DATA LINK (2) Set diagnostic tool to the data reading mode for item AC,
CONNECTOR Heated Oxygen Sensor Bank 1, Sensor 1 (right front).
output voltage should be 0.6 to 1.0 volt.
YES : Go to Step 4.
MB991910
NO : Replace the right bank, front oxygen sensor. Then go
to Step 4.
MB991824 NOTE: When replacing a deteriorated oxygen sensor the vehi-
recommended to replace both front and rear oxygen sensors
correctly.
MB991827 00DB076A

Diagnostic Function − EOBD Drive Cycle −P.13A-11
DTC P2097: Post Catalyst System too Lean (bank 2)

.


DTC SET CONDITIONS

Check Conditions
.
• None.
Judgment Criteria • Left bank heated oxygen sensor deterio-
• MIL activated after 2 drive cycles. • Left bank side catalytic converter deteriorated.
.
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

NO : Go to Step 2.

CAUTION
MB991824
YES : Go to Step 3.
NO : Replace the left bank, rear oxygen sensor. Then go to
Step 4.
00DB076A
correctly.

DATA LINK (2) Set diagnostic tool to the data reading mode for item AE,
CONNECTOR Heated Oxygen Sensor Bank 2, Sensor 1 (left front).
YES : Go to Step 4.
MB991910
NO : Replace the left bank, front oxygen sensor. Then go
to Step 4.
correctly.
MB991827 00DB076A

DTC P2098: Post Catalyst System too Rich (bank 1)

.


DTC SET CONDITIONS

Check Conditions
.
• None.
Judgment Criteria • Right bank heated oxygen sensor deterio-
• MIL activated after 2 drive cycles. • Right bank side catalytic converter deteriorated.
.
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

NO : Go to Step 2.

CAUTION
MB991824
YES : Go to Step 3.
NO : Replace the right bank, rear oxygen sensor. Then go
to Step 4.
00DB076A
correctly.

DATA LINK (2) Set diagnostic tool to the data reading mode for item AC,
CONNECTOR Heated Oxygen Sensor Bank 1, Sensor 1 (right front).
YES : Go to Step 4.
MB991910
NO : Replace the right bank, front oxygen sensor. Then go
to Step 4.
correctly.
MB991827 00DB076A

DTC P2099: Post Catalyst System too Rich (bank 2)

.


DTC SET CONDITIONS

Check Conditions
.
• None.
Judgment Criteria • Left bank heated oxygen sensor deterio-
• MIL activated after 2 drive cycles. • Left bank side catalytic converter deteriorated.
.
P.13A-11.
DIAGNOSIS
• MB991824: V.C.I.

NO : Go to Step 2.

CAUTION
MB991824
YES : Go to Step 3.
NO : Replace the left bank, rear oxygen sensor. Then go to
Step 4.
00DB076A
correctly.

DATA LINK (2) Set diagnostic tool to the data reading mode for item AE,
CONNECTOR Heated Oxygen Sensor Bank 2, Sensor 1 (left front).
YES : Go to Step 4.
MB991910
NO : Replace the left bank, front oxygen sensor. Then go
to Step 4.
correctly.
MB991827 00DB076A

DTC P2100: Throttle Actuator Control Motor Circuit (Open)
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
CONNECTOR: A-14
A-14 (GR)
16DB400A
AK303190 AB
• Throttle power stage voltage is below 5 volts.

.
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.
.
.

• ENGINE-ECU varies the direction and the None.
amperage of the current that is applied to the
throttle actuator control motor in order to control .
the opening of the throttle valve. TROUBLESHOOTING HINTS (The most

.
DTC SET CONDITIONS

• Open throttle actuator control motor circuit, har-
Check Condition ness damage, or connector damage.
• None. • Refer to component locations GROUP-70
Judgement Criteria • Refer to configuration diagrams GROUP-80
• Throttle power stage current is above 8 amps. • Refer to circuit diagrams GROUP-90
or
DIAGNOSIS
• MB991824: V.C.I.

CONNECTOR: B-06
YES : Go to Step 2.
B-06 (B)
03DB180A

CONNECTOR: B-06
B-06 (B)
03DB180A

THROTTLE ACTUATOR
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.
8.
03DB181A

damage
YES : Go to Step 4.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check the continuity at ENGINE-ECU harness side

connector B-21.
side.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(2) Measure the continuity between terminals No. 4 and ground

B-21 HARNESS ,No. 6 and ground.
CONNECTOR • Should be less than 2 ohms.
YES : Go to Step 5.
NO : Repair harness wire between ENGINE-ECU
connector B-21 (terminals No. 04, No. 06) and ground
because of open circuit or harness damage. Then go
to Step 8.
03DB163A

between throttle actuator control motor connector B-06
No. 50).
CONNECTOR: B-06
YES : Go to Step 6.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

between throttle actuator control motor connector B-06
No. 49).
CONNECTOR: B-06
YES : Go to Step 7.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

code (DTC).
CAUTION
CONNECTOR
MB991827 00DB076A

code (DTC).
MB991910
MB991824
MB991827 00DB076A
DTC P2101: Throttle Actuator Control Motor Magneto Malfunction.
CONNECTOR: B-06
AIR
CLEANER
COVER
ENGINE
CONTROL
B-06 (B) UNIT
03DB180A
16DB400A
• Throttle valve position does not match with ECU

.
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). .

.
TECHNICAL DESCRIPTION None.

• ENGINE-ECU check whether the throttle actuator .
control motor magneto has failed. TROUBLESHOOTING HINTS (The most

.
DTC SET CONDITIONS • Throttle actuator control motor failed.
• Shorted throttle actuator control motor circuit,
Check Condition harness damage or connector damage.
• Battery positive voltage is higher than 8.3 volts. • Refer to component locations GROUP-70
• The coil current of the throttle actuator control • Refer to circuit diagrams GROUP-90
motor is 8 ampere or more for 0.3 second.
DIAGNOSIS
• MB991824: V.C.I.

CONNECTOR: B-06
YES : Go to Step 2.
B-06 (B)
03DB180A

CONNECTOR: B-06
B-06 (B)
03DB180A
THROTTLE ACTUATOR
CONTROL MOTOR Standard value: 1.5 ± 0.3 ohms [at 20°C (68°F)]
CONNECTOR
YES : Go to Step 3.
7.
03DB181A

damage
YES : Go to Step 4.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 4. Check for short circuit to ground and harness

damage between throttle actuator control motor connector
(terminal No. 50).
CONNECTOR: B-06
YES : Go to Step 5.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

(terminal No. 49).
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

code (DTC).
CAUTION
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR
MB991910
MB991824
MB991827 00DB076A
DTC P2102: Throttle Actuator Control Motor Circuit (Shorted Low).
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).
.

None.
• ENGINE-ECU varies the direction and the
amperage of the current that is applied to the .
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:)
.
DTC SET CONDITIONS • Shorted throttle actuator control motor circuit,
Check Condition • Refer to component locations GROUP-70
• Battery positive voltage is higher than 6.5 volts. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

CONNECTOR: B-06
YES : Go to Step 2.
B-06 (B)
03DB180A

CONNECTOR: B-06
B-06 (B)
03DB180A
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)]
YES : Go to Step 3.
7.
03DB181A

damage
YES : Go to Step 4.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A

(terminal No. 50).
CONNECTOR: B-06
YES : Go to Step 5.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

(terminal No. 49).
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

code (DTC).
CAUTION
MB991910
MB991824
MB991827 00DB076A

code (DTC).
MB991910
MB991824
MB991827 00DB076A
DTC P2103: Throttle Actuator Control Motor Circuit (Shorted High).
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).
.

None.
• ENGINE-ECU varies the direction and the
amperage of the current that is applied to the .
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:)
.
DTC SET CONDITIONS • Shorted throttle actuator control motor circuit,
Check Condition • Refer to component locations GROUP-70
• Battery positive voltage is higher than 6.5 volts. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

CONNECTOR: B-06
YES : Go to Step 2.
B-06 (B)
03DB180A

CONNECTOR: B-06
B-06 (B)
03DB180A
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)]
YES : Go to Step 3.
7.
03DB181A

damage
YES : Go to Step 4.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A

(terminal No. 50).
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

(terminal No. 49).
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

code (DTC).
CAUTION
MB991910
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR
MB991910
MB991824
MB991827 00DB076A
DTC P2122: Accelerator Pedal Position Sensor (main) Circuit Low Input.
CONNECTOR: C-24
C-24 (B) AIR

ACCELERATOR
CLEANER
PEDAL POSITION
SENSOR
ACCELERATOR COVER
PERAL ENGINE
CONTROL
UNIT
AK303201 AB
16DB400A
. .

• A 5-volt power supply is applied on the accelera- • The accelerator pedal position sensor (main) out-
tor pedal position sensor (main) power terminal puts voltage which corresponds to the accelera-
(terminal No.5) from the ENGINE-ECU (terminal tor pedal depression.
No. 75). • The ENGINE-ECU checks whether the voltage is
with ENGINE-ECU (terminal No. 13). .
DTC SET CONDITIONS

Check Conditions
.

• Battery voltage is above 6.5 volt. likely causes for this code to be set are:)
• Accelerator pedal position sensor failed.
Judgement Criteria • Open or shorted accelerator pedal position sen-
• Accelerator pedal position sensor (main) output sor (main) circuit, harness damage or connector
voltage is below 0.859 volt for 0.2 second. damage.
• MIL activated immediately. • Refer to component locations GROUP-70
• Engine speed limited to 1200rpm and power • Refer to configuration diagrams GROUP-80
restricted. • Refer to circuit diagrams GROUP-90
.

None.
DIAGNOSIS
• MB991824: V.C.I.

Accelerator Pedal Position Sensor (main).
CAUTION
ignition switch to the "LOCK"(OFF) position before con-
CONNECTOR (3) Set diagnostic tool to the data reading mode for item 11,
• Output voltage is between 435 and 1035 mV when foot
is released from accelerator pedal.
• Output voltage is between 4000 - 4824 mV when accel-
erator pedal is fully depressed.
MB991910
MB991824
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check harness connector C-24 at accelerator

pedal position sensor for damage.
CONNECTOR: C-24
YES : Go to Step 3.
C-24 (B)
ACCELERATOR Connector Inspection P.00E-2. Then go to Step 10.
PEDAL POSITION
SENSOR
ACCELERATOR
PERAL
6 5 4 3 2 1
HARNESS
CONNECTOR:
STEP 3. Measure the sensor supply voltage at accelerator

pedal position sensor harness side connector C-24.
(1) Disconnect the connector C-24 and measure at the harness
CONNECTOR: C-24
HARNESS
side.
CONNECTOR:
COMPONENT SIDE
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
C-24 HARNESS
CONNECTOR: (4) Turn the ignition switch to the "LOCK"(OFF) position.
COMPONENT SIDE
6 5 4 3 2 1 YES : Go to Step 7.
NO : Go to Step 4.
03DB251A

damage.
YES : Go to Step 5.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

between accelerator pedal position sensor connector C-24
No. 75).
CONNECTOR: C-24
HARNESS YES : Go to Step 6.
CONNECTOR:
COMPONENT SIDE NO : Repair it. Then go to Step 10.
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 6. Check for harness damage between accelerator

pedal position sensor connector C-24 (terminal No. 5) and
CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

No. 59).
CONNECTOR: C-24
CONNECTOR:
COMPONENT SIDE NO : Repair or replace it. Then go to Step 10.
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24
CONNECTOR:
COMPONENT SIDE NO : Repairor replace it. Then go to Step 10.
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 9. Replace the accelerator pedal assembly.

CONNECTOR: C-24
(1) Replace the accelerator pedal assembly.
HARNESS (2) Turn the ignition switch to the "ON" position.
CONNECTOR:
COMPONENT SIDE (3) After the DTC has been deleted, read the DTC again.
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
STEP 10. Using diagnostic tool , read the diagnostic

trouble code (DTC).
CAUTION
CONNECTOR
MB991824
MB991827 00DB076A
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
. .

• A 5-volt power supply is applied on the accelera- • The accelerator pedal position sensor (main) out-
tor pedal position sensor (main) power terminal puts voltage which corresponds to the accelera-
(terminal No. 5) from the ENGINE-ECU (terminal tor pedal depression.
DTC SET CONDITIONS

Check Conditions
.

Judgement Criteria • Open accelerator pedal position sensor (main)
• Accelerator pedal position sensor (main) output circuit, harness damage or connector damage.
voltage is above 0.43 volts for 0.2 second. • Short circuit to 5 volt.
.

None.
DIAGNOSIS
• MB991824: V.C.I.


CAUTION
CONNECTOR
MB991910
MB991824 YES : It can be assumed that this malfunction is intermittent.
NO : Go to Step 2.
MB991827 00DB076A

CONNECTOR: C-24 Q: Is the harness connector in good condition?
HARNESS
CONNECTOR:
YES : Go to Step 3.
C-24 (B)
COMPONENT SIDE NO : Repair or replace it. Refer to GROUP 00E, Harness
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
STEP 3. Check the continuity at accelerator pedal position

sensor harness side connector C-24.
CONNECTOR: C-24 (1) Disconnect the connector C-24 and measure at the harness
HARNESS side.
CONNECTOR:
COMPONENT SIDE
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
(2) Measure the continuity between terminal No. 4 and ground.

• Should be less than 2 ohms.
C-24 HARNESS
CONNECTOR: Q: Does continuity exist?
COMPONENT SIDE
YES : Go to Step 6.
6 5 4 3 2 1 NO : Go to Step 4.
03DB252A

damage.
YES : Go to Step 5.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

No. 13).
CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage between throttle position sensor connector C-24
CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 7. Replace the accelerator pedal position sensor.

CONNECTOR: C-24
(1) Replace the accelerator pedal position sensor.
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

CAUTION
CONNECTOR (3) Set diagnostic tool to the data reading mode for item 11,
MB991910
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR
MB991910
MB991824
MB991827 00DB076A
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
. .

• A 5-volt power supply is applied on the accelera- • The accelerator pedal position sensor (sub) out-
tor pedal position sensor (sub) power terminal puts voltage which corresponds to the accelera-
DTC SET CONDITIONS

Check Conditions
.

Judgement Criteria • Open or shorted accelerator pedal position sen-
• Accelerator pedal position sensor (sub) output sor (sub) circuit.
voltage is below 0.43 volts for 0.2 second. • Harness or connector damage.
.

None.
DIAGNOSIS
• MB991824: V.C.I.

Accelerator Pedal Position Sensor (sub).
CAUTION
CONNECTOR
MB991910
MB991824
NO : Go to Step 2.
MB991827 00DB076A

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
STEP 3. Measure the sensor supply voltage at accelerator

pedal position sensor harness side connector C-24.
HARNESS side.
CONNECTOR:
COMPONENT SIDE (2) Turn the ignition switch to the "ON" position.
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

C-24 HARNESS
CONNECTOR: (4) Turn the ignition switch to the "LOCK"(OFF) position.
COMPONENT SIDE
6 5 4 3 2 1 YES : Go to Step 7.
NO : Go to Step 4.
03DB253A

damage.
YES : Go to Step 5.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

No.76).
CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

No.81).
CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24 (1) Replace the accelerator pedal position sensor.
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

trouble code (DTC).
CAUTION
MB991910
MB991824
MB991827 00DB076A
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
. .

• A 5-volt power supply is applied on the accelera- • The accelerator pedal position sensor (sub) out-
tor pedal position sensor (sub) power terminal puts voltage which corresponds to the accelera-
DTC SET CONDITIONS

Check Conditions
.

Judgement Criteria • Open accelerator pedal position sensor (sub) cir-
• Accelerator pedal position sensor (sub) output cuit.
voltage is above 4.824 volts for 0.2 second. • Short circuit to 5 volt.
• MIL activated immediately. • Harness or connector damage.
• Engine speed limited to 1200rpm and power • Refer to component locations GROUP-70
restricted. • Refer to configuration diagrams GROUP-80
.
None.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
MB991910 • Output voltage is between 4000 - 4824 mV when accel-
MB991824 (4) Turn the ignition switch to the "LOCK"(OFF) position.
NO : Go to Step 2.
MB991827 00DB076A

CONNECTOR: C-24 Q: Is the harness connector in good condition?
HARNESS
CONNECTOR:
YES : Go to Step 3.
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

HARNESS side.
CONNECTOR:
COMPONENT SIDE
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

C-24 HARNESS
COMPONENT SIDE
YES : Go to Step 6.
6 5 4 3 2 1 NO : Go to Step 4.
AK303204 AB

damage.
YES : Go to Step 5.
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

No. 35).
CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

damage between throttle position sensor connector C-24
CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24 (1) Replace the accelerator pedal position sensor.
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

CAUTION
CONNECTOR
MB991910
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR
MB991910
MB991824
MB991827 00DB076A
DTC P2135: Throttle Position Sensor (Main and Sub) Range/Performance Problem
Check Conditions
.
THROTTLE POSITION SENSOR (MAIN • Ignition switch is "ON" position.

AND SUB) RANGE/PERFORMANCE • Battery voltage is above 6.5 volt.
PROBLEM CIRCUIT Judgement Criteria
• Refer to DTC P0122 − Throttle Position Sensor • Throttle angle variances are outside specifica-
(Main) Circuit P.13A-148. tions.
• Refer to DTC P0222 − Throttle Position Sensor • MIL activated immediately.
(Sub) Circuit P.13A-318. • Engine speed limited to 1200rpm and power
. restricted.
CIRCUIT OPERATION
• Refer to DTC P0122 − Throttle Position Sensor
.

(Main) Circuit P.13A-148.
None.
• Refer to DTC P0222 − Throttle Position Sensor
(Sub) Circuit P.13A-318. .

.
TECHNICAL DESCRIPTION likely causes for this code to be set are:)

• ENGINE-ECU checks the throttle position sensor • Throttle position sensor failed.
output signal characteristics for abnormal condi- • Shorted throttle position sensor circuit or connec-
tions. tor damage.
.
DIAGNOSIS
• MB991824: V.C.I.

sensor and harness connector B-20 at ENGINE-ECU for
damage.
CONNECTOR: B-06
YES : Go to Step 2.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 2. Check for short circuit to ground between throttle

CONNECTOR: B-06
YES : Go to Step 3.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 3. Check for short circuit to ground between throttle

CONNECTOR: B-06
YES : Go to Step 4.
B-06 (B)
03DB180A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: B-06 (2) Turn the ignition switch to the "ON" position.
B-06 (B)
03DB180A

code (DTC).
CAUTION
CONNECTOR
MB991824
MB991827 00DB076A
DTC P2138: Accelerator Pedal Position Sensor (main and sub) Circuit Range/Performance Problem
CAUTION • Battery voltage is above 6.5 volt.

If DTC P2138 has been set, DTC U1120 is also set. Judgement Criteria
After P2138 has been diagnosed, don't forget to • Difference in voltage between APS(main) and
erase DTC U1120. APS(sub) is above 0.215 volt for 0.24 sec.
or
.
ACCELERATOR PEDAL POSITION • Difference in voltage between APS(main) and

SENSOR (MAIN AND SUB) APS(sub) is above 0.273 volt for 0.24 sec.
RANGE/PERFORMANCE CIRCUIT or
• Refer to DTC P2122 − Accelerator Pedal Position • Difference in voltage between APS(main) and
Sensor (Main) Circuit P.13A-476. APS(sub) is above 1.133 volt for 0.24 sec.
• Refer to DTC P2127 − Accelerator Pedal Position
Sensor (Sub) Circuit P.13A-493. • MIL activated immediately.
• Engine speed limited to 1200rpm and power
.
CIRCUIT OPERATION restricted.

• Refer to DTC P2122 − Accelerator Pedal Position .
Sensor (Main) Circuit P.13A-476. EOBD DRIVE CYCLE PATTERN

• Refer to DTC P2127 − Accelerator Pedal Position None.
Sensor (Sub) Circuit P.13A-493. .

TECHNICAL DESCRIPTION likely causes for this code to be set are:)
• ENGINE-ECU checks the accelerator pedal posi- • Accelerator pedal position sensor failed.
tion sensor output signal characteristics for • Harness damage in accelerator pedal position
abnormal conditions. sensor circuit or connector damage.
.
Check Condition • Refer to configuration diagrams GROUP-80
• Ignition switch is "ON" position. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

HARNESS side.
CONNECTOR:
COMPONENT SIDE
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

C-24 HARNESS
COMPONENT SIDE
YES : Go to Step 5.
6 5 4 3 2 1 NO : Go to Step 3.
03DB252A

damage.
Q: Q: Is the harness connector in good condition?
YES : Go to Step 4.
AIR
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

HARNESS side.
CONNECTOR:
COMPONENT SIDE
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

C-24 HARNESS
COMPONENT SIDE
YES : Go to Step 7.
6 5 4 3 2 1 NO : Go to Step 6.
AK303204 AB

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: C-24 (1) Replace the assertory pedal position sensor.
CONNECTOR:
C-24 (B)
ACCELERATOR
PEDAL POSITION
SENSOR
ACCELERATOR
PEDAL
16DB562A

trouble code (DTC).
CAUTION
CONNECTOR
MB991824
MB991827 00DB076A
DTC U1100: ENGINE CAN TIME-OUT/Not equipped
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.
.
DTC SET CONDITIONS

Check Conditions NOTE: If a malfunction occurred in the past, a failure
• Battery positive voltage is 10 volts or higher. cannot be discovered through the MUT − III CAN bus
diagnosis even if there might be a problem with the
Judgement Criteria
CAN bus. In this case, refer to GROUP 00, How to
• Unable to receive combination meter signals
Use Troubleshooting/Inspection Service Points −
through the CAN bus line.
How to Cope with Intermittent Malfunctions P.00-14.
• No MIL.
Furthermore, it is possible to narrow down the areas
.
of the possible failures from the DTCs that are output
COMMENT by the ECUs, which are communicating on the CAN
Current Trouble bus (Refer to GROUP 54C, CAN bus line Diagnos-
• Some of the possible causes are a harness or tics Flow P.54C-6).
connector damage between the ENGINE-ECU .
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.
.

Past Trouble likely causes for this code to be set are:)
• Proceed to troubleshoot based on a harness or • CAN line harness damage or connector damage.
connector damage on the CAN bus line between • Combination meter failed.
the ENGINE-ECU and combination meter, and a
failure in the combination meter power supply
system. Refer to "How to cope with past trouble"
(Refer to GROUP 00, How to Use Troubleshoot-
ing/Inspection Service Points − How to Cope with
Intermittent Malfunctions P.00-14).
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool , diagnose CAN bus line.

CAUTION
CONNECTOR
(3) Diagnose CAN bus line.
Q: Is the CAN bus line normal?
NO : Repair the CAN bus line. Refer to GROUP 54C, Can
MB991824
Bus Diagnostics Table P.54C-15. Then go to Step 6.
MB991827 00DB076A

code (DTC).
CONNECTOR (3) Read the combination meter-DTC.
Q: Is the combination meter-DTC set?
YES : Refer to GROUP 54A, Chassis Electrical-Diagnostic
Trouble Code Chart P.54A-13.
NO : Go to Step 3.
MB991910
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR (3) Read the combination ETACS-DTC.
Q: Is DTC 013 set?
YES : Go to Step 4.
NO : Go to Step 5.
MB991910
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR (3) After the MPI-DTC has been deleted, read the MPI-DTC
again.
Q: Is DTC U1100 set?
YES : Replace the combination meter. Then go to Step 5.
NO : It can be assumed that this malfunction is intermittent
MB991910 of CAN bus line between ENGINE-ECU and
combination meter. Refer to GROUP 00, How to Use
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR
(3) After the MPI-DTC has been deleted, read the MPI-DTC
again.
MB991910
MB991824
MB991827 00DB076A
DTC U1102: ABS-ECU TIME-OUT
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).
.
COMMENT NOTE: If a malfunction occurred in the past, a failure

cannot be discovered through the CAN bus diagno-
Current Trouble sis even if there might be a problem with the CAN
• Some of the possible causes are a harness or bus. In this case, refer to GROUP 00, How to Use
connector damage between the ENGINE-ECU Troubleshooting/Inspection Service Points − How to
and the ABS-ECU on the CAN bus line, a failure Cope with Intermittent Malfunctions P.00-14. Fur-
in the ABS-ECU power supply system, a failure in thermore, it is possible to narrow down the areas of
the ABS-ECU, or a failure in the ENGINE-ECU. the possible failures from the DTCs that are output
Past Trouble by the ECUs, which are communicating on the CAN
• Proceed to troubleshoot based on a harness or bus (Refer to GROUP 54C, CAN bus line Diagnos-
connector damage on the CAN bus line between tics Flow P.54C-6).
the ENGINE-ECU and ABS-ECU, and a failure in .
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
Points − How to Cope with Intermittent Malfunc-
tions P.00-14).
• CAN line harness damage or connector damage.
• ABS-ECU failed.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991824 Bus Diagnostics Table P.54C-15. Then go to Step 6.
MB991827 00DB076A

code (DTC).
CONNECTOR
(3) Read the ABS-DTC.
Q: Is the ABS-DTC set?
YES : Refer to GROUP 35B, Anti-Lock Braking
System-Diagnostic Trouble Code Chart P.35B-9.
NO : Go to Step 3.
MB991910
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR
(3) Read the combination meter-DTC.
YES : Go to Step 4.
NO : Go to Step 5.
MB991910
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR
again.
YES : Replace the ABS-ECU. Then go to Step 6.
ABS-ECU. Refer to GROUP 00, How to Use
MB991824 Troubleshooting/Inspection Service Points − How to
MB991827 00DB076A

code (DTC).
CONNECTOR
again.
ABS-ECU. Refer to GROUP 00, How to Use
MB991824 Troubleshooting/Inspection Service Points − How to
MB991827 00DB076A

code (DTC).
CONNECTOR
again.
MB991910
MB991824
MB991827 00DB076A
DTC U1120: Engine CAN Message
CAUTION Judgement Criteria

• Before replacing the ENGINE-ECU, make sure • No MIL.
that the communication circuit is operating .
normally. TROUBLESHOOTING HINTS (The most

.
DTC SET CONDITIONS likely causes for this code to be set are:)
Check Conditions • ECU.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991824 Bus Diagnostics Table P.54C-15. Then go to Step 2.
MB991827 00DB076A

code (DTC).
CONNECTOR
again.
MB991910
MB991824
MB991827 00DB076A
DTC U1121: T/M CAN Message
CAUTION • Limp home - locked in 3rd gear and engine speed

• Before replacing the ENGINE-ECU, make sure limted.
that the communication circuit is operating .
normally. TROUBLESHOOTING HINTS (The most

.
DTC SET CONDITIONS likely causes for this code to be set are:)
Check Conditions • TCU or transmission
• MIL activated after 2 drive cycles. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
MB991910
YES : Go to Step 2.
Bus Diagnostics Table P.54C-15. Then go to Step 6.
MB991824
MB991827 00DB076A

code (DTC).
CONNECTOR
again.
MB991910
MB991824
MB991827 00DB076A
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Communication with Diagnostic Tool Is Not Possible. (Comunication

with All Systems Is Not Possible.)
CONNECTOR: C-125 CONNECTOR: C-211
JUNCTION
BLOCK C-211
DATA LINK
CONNECTOR
03DB187A 03DB172A
JUNCTION
BLOCK
C-29
C-216
03DB189A 03DB171A
. .

• A battery positive voltage is applied on the data likely causes for this case:)
link connector power terminal (terminal No. 16). • Malfunction of the data link connector.
The ground terminals (terminal No. 4, No. 5) are • Damaged harness wire.
grounded to the vehicle body. • Refer to component locations GROUP-70
.
COMMENT • Refer to circuit diagrams GROUP-90
• The cause is probably a defect in power supply
system (including ground) for the on-board diag-
nostic test mode line.
DIAGNOSIS
STEP 1. Measure the power supply voltage at data link

connector C-125.
CONNECTOR: C-125 (1) Measure voltage between terminal No. 16 and ground.
DATA LINK present?
CONNECTOR YES : Go to step 2.
NO : Check harness connectors C-211, C-216 and C-29 at
intermediate connector for damage, and repair or
replace as required. Refer to GROUP 00E, Harness
Connector Inspection P.00E-2. If intermediate
03DB187A connector C-211, C-216 and C-29 are in good
condition, repair an open circuit between fusible link
C-125 HARNESS
CONNECTOR:
(1) and data link connector C-125 (terminal No. 16).
COMPONENT SIDE Then confirm that the malfunction symptom is
1 2 3 4 5 6 7 8 eliminated.
9 10 111213141516
AK303229 AB
STEP 2. Check the continuity at data link connector C-125.

CONNECTOR: C-125 (1) Check for the continuity between terminal No. 4, No. 5 and
ground.
DATA LINK Q: Does continuity exist?
CONNECTOR YES : Replace the diagnostic tool. Then confirm that the
malfunction symptom is eliminated.
NO : Repair an open circuit or harness damage between
data link connector C-125 (terminal No. 4, No. 5) and
ground. Then confirm that the malfunction symptom is
03DB187A eliminated.
1 2 3 4 5 6 7 8
9 10 111213141516
D-125 HARNESS
CONNECTOR:
COMPONENT SIDE
AK303230 AB
INSPECTION PROCEDURE 2: Diagnostic Tool Communication with ENGINE-ECU Is Not Possible.
C-29
DATA LINK
CONNECTOR
03DB187A 03DB171A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
. .

• A diagnostic output is made from the likely causes for this case:)
ENGINE-ECU (terminal No. 44) to the diagnostic • Malfunction of ENGINE-ECU power supply cir-
output terminal (terminal No. 7) of the data link cuit.
connector. • Malfunction of the ENGINE-ECU.
.
• Open circuit between ENGINE-ECU and data link
COMMENT connector.
• No power supply to ENGINE-ECU. • Refer to component locations GROUP-70
• Defective ground circuit of ENGINE-ECU. • Refer to configuration diagrams GROUP-80
• Defective ENGINE-ECU. • Refer to circuit diagrams GROUP-90
• Improper communication line between
ENGINE-ECU and diagnostic tool.
DIAGNOSIS

damage.
YES : Go to Step 2.
AIR Connector Inspection P.00E-2. Then confirm that the
CLEANER malfunction symptom is eliminated.
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP2. Check for open circuit, short circuit to ground and

harness damage between data link connector C-125
No. 44).
CONNECTOR: C-125
DATA LINK
CONNECTOR
03DB187A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
NOTE: Check harness after checking intermediate connector

C-29. If intermediate connector C-29 is damaged, repair or
replace them. Refer to GROUP 00E, Harness Connector
Inspection P.00E-2. Then check that the malfunction is elimi-
nated.
YES : Refer to INSPECTION PROCEDURE 24 − Power
Supply System and Ignition Switch-IG System
P.13A-604.
NO : Repair it. Then confirm that the malfunction symptom
is eliminated.
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.
.

DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
AIR (1) Connect diagnostic tool to the data link connector.
CLEANER (2) Turn the ignition switch to the "ON" position.
(3) Read the DTC.
COVER (4) Turn the ignition switch to the "LOCK" (OFF) position.
ENGINE
CONTROL Q: Is DTC set?
UNIT
YES : Refer to Diagnostic Trouble Code Chart.
NO : Go to step 2.
16DB400A

• The malfunction indicator lamp (Check Engine Lamp)
should illuminate immediately after the ignition switch is
turned to the "ON" position.
Q: Does the malfunction indicator lamp (Check Engine
Lamp) illuminate?
NO : Replace the combination meter.
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
.
DIAGNOSIS
• MB991824: V.C.I.


code (DTC).
CAUTION
CONNECTOR
(3) Read the DTC.
Q: Is DTC set?
NO : Go to Step. 2.
MB991824
MB991827 00DB076A

• The malfunction indicator lamp (Check Engine Lamp)
should go out when 30 seconds have passed after the
ignition switch was turned to the "ON" position.
Q: Does the malfunction indicator lamp (Check Engine
Lamp) go out?
INSPECTION PROCEDURE 5: Cranks, Won't Start

. .
Cranks, Won't Start Circuit TROUBLESHOOTING HINTS (The most

• Refer to Ignition circuit P.13A-628. likely causes for this case:)
.
• Malfunction of the ignition system.
CIRCUIT OPERATION • Malfunction of the fuel pump system.
• Refer to Ignition circuit P.13A-628. • Malfunction of the injector system.
• Malfunction of the ENGINE-ECU.
• Contaminated fuel.
.
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
• MB991824: V.C.I.
STEP 1. Measure the battery positive voltage.

(1) Measure the battery positive voltage during cranking.
• The voltage should be 8 volts or more.
Q: Is the measured voltage 8 volts or more?
YES : Go to Step 2.
NO : Check the battery. Refer to GROUP 54A, Battery −
Battery Check P.54A-5. Then confirm that the
STEP 2. Check the timing belt for breaks.

Q: Is the timing belt good condition?
YES : Go to Step 3.
NO : Replace timing belt. Then confirm that the malfunction
symptom is eliminated.

code (DTC).
CAUTION
CONNECTOR
(3) Read the DTC.
Q: Is DTC set?
NO : Go to Step 4.
MB991824
MB991827 00DB076A
STEP 4. Using diagnostic tool , check data list.

CAUTION
CONNECTOR
(3) Check the following items in the data List. Refer to Data List
Reference Table P.13A-637.
a. Item 1: Power Supply Voltage.
MB991910 b. Item 2: Crankshaft Position Sensor.
c. Item 6: Engine Coolant Temperature Sensor.
Q: Are they operating properly?
YES : Go to Step 5.
NO : Repair or replace it. Then confirm that the malfunction
MB991827 00DB076A
STEP 5. Check for Fuel Pump operation.

(1) Refer to Fuel Pump Operation Check P.13A-664.
Q: Is the actuator operating properly?
YES : Go to Step 6.
STEP 6. Check the ignition system.

CONNECTOR: B-101, B-102, B-103, B-114, (1) Refer to INSPECTION PROCEDURE 27 − Ignition Circuit
B-117, B-118 B-102 (GR) System P.13A-628.
B-101 (GR) Q: Is the ignition system operating correctly?
YES : Go to Step 7.
B-103 (GR)
NO : Repair or replace required components. Then confirm
B-118 (GR)
that the malfunction symptom is eliminated.
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB

CAUTION
CONNECTOR
(1) Check Data list item No. 16 while cranking engine.
Approximate value: - 3° to BTDC ± 3°
Q: Is the advance ignition timing normal?
YES : Go to Step 8.
NO : Check that the crankshaft position sensor and timing
MB991910 belt cover are in the correct position. Then confirm
MB991824
MB991827 00DB076A
STEP 8. Check the left bank injector.

CONNECTOR: B-26, B-27, B-30 (1) Disconnect the left bank injector connector B-27, B-26,
B-30.
B-26 (GR)
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
(2) Measure the resistance between each injector side

INJECTOR SIDE connector terminal No. 1 and No. 2.
1 2
[at 20°C (68°F)]?
YES : Go to Step 9.
NO : Replace the faulty injector. Then confirm that the
AK000559 AB
STEP 9. Check the right bank injector resistance at

B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
(2) Measure the resistance between each male connector side

B-32 terminal.
INTERMEDIATE
CONNECTOR a. Measure the resistance between terminal No. 5 and No.
9 at No. 1 cylinder injector.
1 2 3 4 5
b. Measure the resistance between terminal No. 10 and
6 7 8 9 10
No. 9 at No. 3 cylinder injector.
c. Measure the resistance between terminal No. 4 and No.
• Resistance should be between 10.5 and 13.5 ohms [at
AK303098 AB 20°C (68°F)].
[at 20°C (68°F)]?
NO : Go to Step 10.
STEP 10. Check the right bank injector.

CONNECTOR: B-01, B-03, B-04 (1) Remove the intake manifold.
B-04 (GR) (2) Disconnect the right bank injector connector, which
deviates from the standard value at Step 8.
B-01 (GR)
M B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303055AB

CONNECTOR Standard value: 10.5 − 13.5 ohms [at 20 °C (68°F)]
1 2
[at 20°C (68°F)]?
NO : Replace the injector. Then confirm that the
AK000559 AB
STEP 11. Check harness connector B-03 or B-04 or B-01 at

right bank injector for damage.
CONNECTOR: B-01, B-03, B-04 (1) Check the injector connector, which deviates from the
B-04 (GR) standard value at Step 9.
YES : Repair harness wire between injector intermediate
M
connector and right bank injector connector because
B-03 (GR)
2 1 of harness damage. Then confirm that the
HARNESS CONNECTOR:
Connector Inspection P.00E-2. Then confirm that the
AK303055AB

B-32 (B) Connector Inspection P.00E-2. Then confirm that the
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
STEP 13. Check harness connector B-27, B-26, B-30 at left

bank injector for damage.
CONNECTOR: B-26, B-27, B-30 Q: Is the harness connector in good condition?
B-26 (GR) Connector Inspection P.00E-2. Then confirm that the
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
STEP 14. Check harness connector B-20 at ENGINE-ECU

for damage.
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 15. Check for harness damage between injector

connector and ENGINE-ECU connector.
CONNECTOR: B-01, B-03, B-04, B-26,B-27, a. Check the harness wire between injector connector B-01
B-30 (terminal No. 2) and ENGINE-ECU connector B-20 (termi-
B-03 (GR) nal No. 03) at No. 1 cylinder injector.
B-04 (GR)
b. Check the harness wire between injector connector B-30
B-01 (GR)
(terminal No. 2) and ENGINE-ECU connector B-20 (termi-
B-30 (GR) nal No. 04) at No. 2 cylinder injector.
B-27 (GR)
c. Check the harness wire between injector connector B-03
B-26 (GR) (terminal No. 2) and ENGINE-ECU connector B-20 (termi-
M nal No. 34) at No. 3 cylinder injector.
2 1
HARNESS CONNECTOR: d. Check the harness wire between injector connector B-27
COMPONENT SIDE AK303235 AB (terminal No. 2) and ENGINE-ECU connector B-20 (termi-
nal No. 35) at No. 4 cylinder injector.
e. Check the harness wire between injector connector B-04
AIR
CLEANER f. Check the harness wire between injector connector B-26
COVER
ENGINE Q: Is the harness wire in good condition?
CONTROL
UNIT YES : Check the following items, and repair or replace the
defective items.
a. Check the ignition coil and spark plugs.
b. Check if the injectors are clogged.
c. Check if fuel is contaminated.
d. Check compression.
Then confirm that the malfunction symptom is
16DB400A
eliminated.
is eliminated.
STEP 16. Check injector is insulated from earth.

(1) Measure the resistance between each injector housing and
earth.
Q: Is there no continuity?
INJECTOR
HOUSING YES : ok.
NO : Repair or replace injector. Then confirm that the
03DB230A
INSPECTION PROCEDURE 6: Starts Up and Dies.
• Malfunction of the injector system.

.
COMMENT • Contaminated fuel.

• In such cases as the above, the cause is usually • Poor compression.
improper air/fuel mixture. It is possible, though • Dirtiness around throttle valve.
less likely, that the spark plugs are generating • Malfunction of the ENGINE-ECU.
sparks but the sparks are weak. • Refer to component locations GROUP-70
TROUBLESHOOTING HINTS (The most • Refer to circuit diagrams GROUP-90
likely causes for this case:)
DIAGNOSIS
• MB991824: V.C.I.

• The voltage should be 8 volts or more.
Q: Does the voltage remain greater than 8 volts while the
engine is cranked?
YES : Go to Step 2.
NO : Refer to GROUP 54A, Battery − Battery Check
P.54A-5.

code (DTC).
CAUTION
CONNECTOR
(3) Read the DTC.
Q: Is the DTC set?
NO : Go to Step 3.
MB991824
MB991827 00DB076A

YES : Go to Step 4.

DATA LINK (2) Check the following items in the data list. Refer to Data List
CONNECTOR
a. Item 06: Engine Coolant Temperature Sensor.
YES : Go to Step 5.
MB991910 symptom is eliminated.
MB991824
MB991827 00DB076A
STEP 5. Inspection of throttle body (throttle valve area) for

dirtiness.
YES : Refer to On-vehicle Service − Throttle Body (Throttle
Valve Area) Cleaning. P.13A-660.
NO : Go to Step 6.
STEP 6. Check the advance ignition timing.

(1) Check the iadvance gnition timing at cranking.
Standard value: 5° BTDC ± 3°
Q: Is the ignition timing normal?
YES : Go to Step 7.
belt cover are in the correct position. Then confirm

B-30.
B-26 (GR)
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:

1 2
[at 20°C (68°F)]?
YES : Go to Step 8.
AK000559 AB

B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:

B-32 terminal.
INTERMEDIATE
1 2 3 4 5
b. Measure the resistance between terminal No. 9 and No.
6 7 8 9 10
AK203093 AB 20°C (68°F)].
[at 20°C (68°F)]?
NO : Go to Step 9.

B-01 (GR)
M B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303055AB

1 2
[at 20°C (68°F)]?
AK000559 AB

CONNECTOR: B-01, B-03, B-04 (1) Check the injector connector, which deviates from the
B-04 (GR) standard value at Step 9.
M
B-03 (GR)
HARNESS CONNECTOR:
AK303055AB

5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
STEP 12. Check harness connector B-27, B-26, B-30 at left

bank injector for damage.
B-26 (GR) Connector Inspection P.00E-2.Then confirm that the
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
STEP 13. Check harness connector B-20 at ENGINE-ECU

for damage.
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: B-01, B-03, B-04, B-26,B-27, a. Check the harness wire between injector connector
B-30 B-01 (terminal No. 2) and ENGINE-ECU connector B-20
B-03 (GR) (terminal No. 03) at No. 1 cylinder injector.
B-04 (GR)
b. Check the harness wire between injector connector
B-01 (GR)
B-27 (GR)
c. Check the harness wire between injector connector
B-26 (GR) B-03 (terminal No. 2) and ENGINE-ECU connector B-20
M (terminal No. 34) at No. 3 cylinder injector.
2 1
HARNESS CONNECTOR: d. Check the harness wire between injector connector
COMPONENT SIDE AK303235 AB B-27 (terminal No. 2) and ENGINE-ECU connector B-20
(terminal No. 35) at No. 4 cylinder injector.
e. Check the harness wire between injector connector
AIR
CLEANER f. Check the harness wire between injector connector
COVER
CONTROL
defective items.
c. Check compression pressure.
d. Check fuel lines for clogging.
e. Check if the foreign materials (water,
16DB400A
kerosene, etc.) got into fuel.
eliminated.
is eliminated.

earth.
INJECTOR
HOUSING YES : ok.
03DB230A
INSPECTION PROCEDURE 7: Hard Starting
• Malfunction of the injector system.

.
COMMENT • Poor fuel quality. (Contamination)

• In cases such as the above, the cause is usually • Poor compression.
either weak spark, improper air-fuel mixture or • Dirtiness around throttle valve.
low compression. • Refer to component locations GROUP-70
DIAGNOSIS
• MB991824: V.C.I.

• The voltage is 8 volts or more.
Q: Does the voltage remain greater than 8 volts while the
engine is cranked?
YES : Go to Step 2.
NO : Refer to GROUP 54A, Battery − Battery check
P.54A-5.

code (DTC).
CAUTION
CONNECTOR
(3) Read the DTC.
(4) Turn the ignition switch the "LOCK" (OFF) position.
Q: Is the DTC set?
NO : Go to Step 3.
MB991824
MB991827 00DB076A

YES : Go to Step 4.

(1) Turn the ignition switch the "ON" position.
CONNECTOR Reference Table P.13A-637.
(3) Turn the ignition switch the "LOCK" (OFF) position.
YES : Go to Step 5.
NO : Repair or Replace. Then confirm that the malfunction
MB991824
MB991827 00DB076A

dirtiness.
YES : Refer to On-vehicle service − Clean the throttle valve
area P.13A-660.
NO : Go to Step 6.

(1) Check the advance ignition timing at cranking.
Standard value: 5° BTDC ± 3°
Q: Is the ignition timing normal?
YES : Go to Step 7.

B-30.
B-26 (GR)
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:

1 2
[at 20°C (68°F)]?
YES : Go to Step 8.
AK000559 AB

B-32 (B)
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:

B-32 terminal.
INTERMEDIATE
1 2 3 4 5
b. Measure the resistance between terminal No. 9 and No.
6 7 8 9 10
AK203093 AB 20°C (68°F)].
[at 20°C (68°F)]?
NO : Go to Step 9.

B-01 (GR)
M B-03 (GR)
2 1
HARNESS CONNECTOR:
COMPONENT SIDE
AK303055AB

1 2
[at 20°C (68°F)]?
AK000559 AB

CONNECTOR: B-01, B-03, B-04 (1) Check the injector connector, which deviated from the
B-04 (GR) standard value listed in Step 8.
M
B-03 (GR)
HARNESS CONNECTOR:
AK303055AB
STEP 11. Check harness connector B-32 at the

intermediate connector for damage.
5 4 3 2 1
10 9 8 7 6
HARNESS CONNECTOR:
STEP 12. Check harness connector B-27, B-26, B-30 at the

left bank injector for damage.
B-26 (GR) Connector Inspection P.00E-2. Then confirm that the
B-30 (GR)
B-27 (GR)
M
2 1
HARNESS CONNECTOR:
STEP 13. Check the harness connector B-20 at the

COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR: B-01, B-03, B-04, B-26,B-27, a. Check the harness wire between injector connector
B-30 B-01 (terminal No. 2) and ENGINE-ECU connector B-20
B-04 (GR)
b. Check the harness wire between injector connector
B-01 (GR)
B-27 (GR)
c. Check the harness wire between injector connector
B-26 (GR) B-03 (terminal No. 2) and ENGINE-ECU connector B-20
M (terminal No. 34) at No. 3 cylinder injector.
2 1
HARNESS CONNECTOR: d. Check the harness wire between injector connector
COMPONENT SIDE AK303235 AB B-27 (terminal No. 2) and ENGINE-ECU connector B-20
e. Check the harness wire between injector connector
AIR
CLEANER f. Check the harness wire between injector connector
COVER
CONTROL
defective items.
c. Check the compression pressure.
d. Check if the foreign materials (water,
16DB400A
eliminated.
is eliminated.

earth.
INJECTOR
HOUSING YES : ok.
03DB230A
INSPECTION PROCEDURE 8: Unstable Idle (Rough Idle, Hunting).
• Malfunction of air/fuel ratio control system.

.
COMMENT • Malfunction of the electronic control throttle valve

• In cases such as the above, the cause is proba- system.
bly the air/fuel mixture or electronic control throt- • Malfunction of the evaporative emission purge
tle valve system. Other systems affecting idle solenoid system.
quality include the ignition system and compres- • Poor compression pressure.
sion. • Vacuum leak.
. • Refer to component locations GROUP-70
TROUBLESHOOTING HINTS (The most • Refer to configuration diagrams GROUP-80
likely causes for this case:) • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check if the battery terminal is disconnected

Q: Has the battery terminal been disconnected lately?
YES : Start the engine and let it run at idle for approximate
10 minutes after engine warm up. Then, if a
malfunction occurs, go to Step 2.
NO : Go to Step 2.

code (DTC).
CAUTION
DATA LINK ignition switch is to the "LOCK" (OFF) position before con-
CONNECTOR
(3) Read the DTC.
Q: Is the DTC set?
NO : Go to Step 3.
MB991824
MB991827 00DB076A
STEP 3. Check the engine idling state.

Q: Is it noticeably hunting?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Carry out the following cleaning.
a. Refer to On-vehicle Service − Clean the throttle valve
area P.13A-660.
(2) After cleaning, confirm that the malfunction symptom is
eliminated.
Q: Is the malfunction symptom resolved?
YES : The check is completed.
NO : Check the following items, and repair or replace the
defective items.
a. Broken intake manifold gasket.
b. Broken air intake hose.
c. Broken vacuum hose.
d. Positive crankcase ventilation valve does not
operate.
eliminated.

01, 02, 03, 04, 05, 06: Injector.
CAUTION
CONNECTOR
(3) Check following items in the actuator test. Refer to Actuator
Test Reference Table P.13A-644.
a. Item 01, 02, 03, 04, 05, 06: Injector.
MB991910
NO : Refer to DTC P0201P.13A-272, P0202P.13A-280,
P0203P.13A-287, DTC P0204P.13A-295,
P0205P.13A-302, P0206P.13A-310 − Injector Circuit .
MB991827 00DB076A

CONNECTOR
a. Item 5: Intake Air Temperature Sensor.
b. Item 6: Engine Coolant Temperature Sensor.
c. Item AD: Right Bank Heated Oxygen Sensor (rear).
d. Item AC: Right Bank Heated Oxygen Sensor (front).
e. Item AF: Left Bank Heated Oxygen Sensor (rear).
MB991910 f. Item AE: Left Bank Heated Oxygen Sensor (front).
g. Item 83: Power Steering Pressure Switch.
YES : Go to Step 7.
MB991827 00DB076A
STEP 7. Using diagnostic tool, check actuator test.

DATA LINK (2) Check the following items in the actuator test. Refer to
CONNECTOR
Actuator Test Reference Table P.13A-644.
a. Item 10: Evaporative Emission Purge Solenoid.
YES : Go to Step 8.
MB991824
MB991827 00DB076A

YES : a. Check the following items, and repair or replace
the defective items.
• Vacuum leak.
• Broken intake manifold gasket.
• Broken air intake hose.
• Broken vacuum hose.
• Positive crankcase ventilation valve does not
operate.
b. Injector clogged.
eliminated.
STEP 9. Check Data list item No. 16, advance ignition

timing.
Ignition timing is controlled by the ENGINE-ECUand will vary
depending on engine requirement.
YES : Check the following items, and repair or replace the
defective items.
b. Check the purge control system.
d. Check if the foreign materials (water,
eliminated.
NEXT PAGE
PREVIOUS PAGE MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE>
13A-571
13A
INSPECTION PROCEDURE 9: Idle speed is high (improper idle speed).

.
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.
.

DIAGNOSIS
• MB991958: Diagnostic Tool(MUT-III Sub Assembly)
• MB991824: V.C.I.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is DTC set?
MB991910
NO : Go to Step 2.
MB991824
MB991827 00DB076A
MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE> 13A-572
STEP 2. Using diagnostic tool, check data list.

CAUTION
(3) Check the following item in the data list. Refer to Data List
MB991910
MB991824
YES : Go to Step 3.
MB991827 00DB076A

DATA LINK (2) Check the following item in the actuator test. Refer to
CONNECTOR
Actuator Test Reference Table P.13A-644.
Valve Area) Cleaning. P.13A-660.
MB991910 NO : Repair or replace it. Then confirm that the malfunction
MB991824
MB991827 00DB076A
INSPECTION PROCEDURE 10: Idle Speed Is Low (Improper Idle Speed).

.
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.
.

DIAGNOSIS
• MB991958: Diagnostic Tool(MUT-III Sub Assembly)
• MB991824: V.C.I.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 2.
MB991824
MB991827 00DB076A

CAUTION
(3) Check the following item in the data list. Refer to Data List
MB991910
YES : Refer to On-vehicle Service − Clean the throttle valve
MB991824
area P.13A-660.
MB991827 00DB076A
INSPECTION PROCEDURE 11: When the engine is cold, it stalls at idle (die out).

.
COMMENT • Malfunction of the injector system.

• In such cases as the above, the air/fuel mixture • Malfunction of the ignition system.
may be inappropriate when the engine is cold. • Refer to component locations GROUP-70
• Malfunction of the electronic control throttle valve
system.
DIAGNOSIS
• Diagnostic tool(MUT-III Sub Assembly)
• MB991824: V.C.I.
STEP 1. Check if the battery terminal is disconnected.

malfunction occurs, go to Step 2.
NO : Go to Step 2.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 3.
MB991824
MB991827 00DB076A
STEP 3. Checking by operating the accelerator pedal.

Q: Does the engine stall right after the accelerator pedal is
released?
YES : Refer to GROUP13B, On-vehicle Service − Throttle
Body (Throttle Valve Area) Cleaning. P.13A-660.
NO : Go to Step 4.
STEP 4. Check the engine idling.

Q: Is the idling good enough after warm up?
YES : Go to Step 5.
NO : Refer to INSPECTION PROCEDURE 8 − Unstable
Idle (Rough Idle, Hunting) P.13A-566.
STEP 5. Using diagnostic tool, check actuator test items

01, 02, 03, 04, 05, 06: Injector.
CAUTION
a. Item 01, 02, 03, 04, 05, 06: Injector.
MB991910
MB991824
YES : Go to Step 6.
P0203P.13A-287, DTC P0204P.13A-295,
P0205P.13A-302, P0206P.13A-310 − Injector Circuit.
MB991827 00DB076A

YES : Go to Step 7.
MB991824
MB991827 00DB076A

YES : Go to Step 8.

Ignition timing is controlled by the ENGIN-ECUand will vary
depending on engine requirement..
defective items.
b. Check compression pressure.
c. Check the engine oil viscosity.
eliminated.
INSPECTION PROCEDURE 12: When the Engine Is Hot, It Stalls at Idle (Die Out).

.

• In cases such as the above, the ignition system, system.
air/fuel mixture, electronic control throttle valve • Vacuum leak.
system or compression pressure may be faulty. In • Improper connector contact.
addition, if the engine suddenly stalls, the cause • Refer to component locations GROUP-70
may also be a connector damage. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

malfunction occurs, go to step 2.
NO : Go to Step 2.

code (DTC).
CAUTION
DATA LINK
tion switch to the "LOCK" (OFF) position before connect-
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 3.
MB991824
MB991827 00DB076A

01, 02, 03, 04, 05, 06: Injector.
CAUTION
DATA LINK
tion switch to the "LOCK" (OFF) position before connect-
a. Item 01, 02, 03, 04, 05, 06: Injector.
MB991910
YES : Go to Step 4.
MB991824
P0203P.13A-287, DTC P0204P.13A-295,
MB991827 00DB076A
STEP 4. Checking by depressing and releasing the

accelerator pedal.
Q: Does the engine stall right after the accelerator pedal is
released?
Valve Area) Cleaning P.13A-660.
NO : Go to Step 5.
STEP 5. Engine stall reproduction test.

Q: Is it easy to reproduce the engine stall?
YES : Go to Step 6.
NO : Check if the following signals change suddenly by
wiggling the circuit harness and connectors.
a. Crankshaft position sensor signal.
b. Mass airflow sensor signal.
c. Injector drive signal.
d. Primary and secondary ignition signal.
e. Fuel pump drive signal.
f. ECU power supply voltage.
Repair or replace it. Then confirm that the malfunction

CAUTION
(3) Check the following items in the data list. Refer to Data List
MB991910 c. Item AD: Right Bank Heated Oxygen Sensor (rear).
MB991824
f. Item AE: Left Bank Heated Oxygen Sensor (front).
g. Item 83: Power Steering Pressure Switch.
h. Item 13: Throttle position sensor (main).
YES : Go to Step 7.
MB991827 00DB076A NO : Repair or replace it. Then confirm that the malfunction

DATA LINK (2) Check the following items of the data list. Refer to Data List
a. Item AC: Right Bank Heated Oxygen Sensor (front).
b. Item AE: Left Bank Heated Oxygen Sensor (front).
• Fluctuates between 0 − 0.4 volt and 0.6 − 1.0 volt while
idling after the engine has been warmed.
YES : Go to Step 9.
MB991824 NO : Go to Step 8.
MB991827 00DB076A

defective items.
a. Vacuum leak.
• Positive crankcase ventilation valve does
not operate.
eliminated.

defective items.
c. Check the engine oil viscosity.
eliminated.
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.
.

DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 2.
MB991824
MB991827 00DB076A

DATA LINK (2) Check the following item in the actuator test. Refer to
CONNECTOR Actuator Test Reference Table P.13A-644.
defective items.
MB991910 a. Check the ignition coil, spark plugs.
b. Check for vacuum leaks.
MB991824 • Broken intake manifold gasket.
• Broken or disconnected vacuum hose.
• Improper operation of the PCV valve.
eliminated.
MB991827 00DB076A
INSPECTION PROCEDURE 14: The engine stalls when decelerating.

.
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.
.

DIAGNOSIS
• MB991824: V.C.I.

10 minutes after engine warm up. Then if a
malfunction occurs, go to step 2.
NO : Go to Step 2.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 3.
MB991824
MB991827 00DB076A

a. Item 13: Throttle Position Sensor (main).
b. Item 15: Throttle Position Sensor (sub).
c. Item 11: Accelerator Pedal Position Sensor (main).
d. Item 12: Accelerator Pedal Position Sensor (sub).
MB991910 Q: Are they operating properly?
YES : Go to Step 4.
MB991824 NO : Repair or replace it. Then confirm that the malfunction
MB991827 00DB076A

dirtiness.
YES : Refer to On-vehicle Service − Clean the throttle valve
area P.13A-660.
NO : Check the following items, and repair, replace or
clean the defective sections.
eliminated.
INSPECTION PROCEDURE 15: Hesitation, sag or stumble.

.
COMMENT • Malfunction of the fuel supply system.

• In cases such as the above, the ignition system, • Poor compression pressure.
air/fuel mixture compression pressure may be • Refer to component locations GROUP-70
defective. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
CONNECTOR
ing or disconnecting diagnostic tool.
(3) Read the DTC.
Q: Is the DTC set?
NO : Go to Step 2.
MB991824
MB991827 00DB076A

01, 02, 03, 04, 05, 06: Injector.
DATA LINK Test Reference Table P.13A-644.
CONNECTOR
a. Item 01, 02, 03, 04, 05, 06: Injector.
Q: Are thy operating properly?
YES : Go to Step 3.
P0203P.13A-287, DTC P0204P.13A-295,
MB991910 P0205P.13A-302, P0206P.13A-310 − Injector Circuit.
MB991824
MB991827 00DB076A

YES : Got to Step 4.
STEP 4. Using diagnostic tool, check data list and actuator

test.
CAUTION
CONNECTOR
MB991910 b. Item 06: Engine Coolant Temperature Sensor.
MB991824 d. Item AC: Right Bank Heated Oxygen Sensor (front).
YES : Go to Step 5.
MB991827 00DB076A

DATA LINK (2) Check the following items of data list. Refer to Data List
• Voltage should fluctuate between 0 − 0.4 volt and 0.6 −
1.0 volt while idling after the engine has warmed-up.
YES : Go to Step 7.
MB991827 00DB076A

defective items.
a. Vacuum leak.
not operate.
eliminated.

defective items.
c. Check the fuel filter or fuel line for clogging.
eliminated.
INSPECTION PROCEDURE 16: Acceleration shock.

.
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.
.

DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
CONNECTOR
(3) Read the DTC.
Q: Is The DTC set?
NO : Check the following items, and repair or replace the
MB991824 defective items.
b. Check for occurrence of ignition leak.
eliminated.
MB991827 00DB076A
INSPECTION PROCEDURE 17: Deceleration Shock

.
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.
.

DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
CONNECTOR
(3) Read the DTC.
Q: Is the DTC set?
MB991910 NO : Refer to On-vehicle Service − Throttle Body (Throttle
MB991824
Valve Area) CleaningP.13A-660
MB991827 AC305412AB
INSPECTION PROCEDURE 18: Poor acceleration.

.

• Defective ignition system, abnormal air/fuel ratio, system.
the electronic control throttle valve system, poor • Malfunction of the fuel supply system.
compression pressure, etc. are suspected. • Poor compression pressure.
. • Clogged exhaust system.
TROUBLESHOOTING HINTS (The most • Refer to component locations GROUP-70
likely causes for this case:) • Refer to configuration diagrams GROUP-80
• Malfunction of the ignition system. • Refer to circuit diagrams GROUP-90
DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 2.
MB991824
MB991827 00DB076A

01, 02, 03, 04, 05, 06: Injector.
DATA LINK (2) Check following items in the actuator test. Refer to Actuator
CONNECTOR Test Table P.13A-644.
a. Item 01, 02, 03, 04, 05, 06: Injector.
YES : Go to Step 3.
MB991910
P0203P.13A-287, DTC P0204P.13A-295,
MB991824
MB991827 00DB076A

YES : Go to Step 4.

CAUTION
MB991910 c. Item AD: Right Bank Heated Oxygen Sensor (rear).
MB991824
YES : Go to Step 5.
MB991827 00DB076A

1.0 volt while idling after the engine has been warmed.
YES : Go to Step 7.
MB991827 00DB076A

defective items.
a. Vacuum leak.
not operate.
eliminated.

defective items.
c. Check the fuel filter or fuel line for clogging.
d. Broken air intake hose.
e. Clogged air cleaner.
f. Clogged exhaust system.
eliminated.
INSPECTION PROCEDURE 19: Surge.

.

• Defective ignition system, abnormal air/fuel ratio, system.
the electronic control throttle valve system failed, • Refer to component locations GROUP-70
etc. are suspected. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 2.
MB991824
MB991827 00DB076A

01, 02, 03, 04, 05, 06: Injector.
DATA LINK (2) Check following items in the actuator test. Refer to Actuator
CONNECTOR Test Reference Table P.13A-644.
a. Item 01, 02, 03, 04, 05, 06: Injector.
YES : Go to Step 3.
P0203P.13A-287, DTC P0204P.13A-295,
MB991910
MB991824
MB991827 00DB076A

YES : Go to Step 4.

CAUTION
CONNECTOR
MB991910 b. Item 06: Engine Coolant Temperature Sensor.
YES : Go to Step 5.
MB991827 00DB076A

CONNECTOR
YES : Go to Step 7.
MB991827 00DB076A

defective items.
a. Vacuum leak.
not operate.
eliminated.

defective items.
eliminated.
INSPECTION PROCEDURE 20: Knocking

.
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.
.

DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using the diagnostic tool, read the diagnostic

trouble code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 2.
MB991824
MB991827 00DB076A
STEP 2. Check Data list, Item No. 16 advance ignition

timing.
(1) The advance ignition timing should retard more when knock
CONNECTOR: B-120
sensor connector B-120 is disconnected than when it is
connected.
Q: When the knock sensor connector B-120 was
disconnected, was the advance ignition timing delayed?
KNOCK SENSOR defective items.
a. Check the spark plugs.
b. Fuel quality, octane level.
c. Check if the foreign materials (water,
eliminated.
B-120 (GR)
NO : Refer to DTC P0325 − Knock Sensor Circuit
P.13A-346.
2 1
HARNESS
CONNECTOR:
INSPECTION PROCEDURE 21: Dieseling (Run-on).

. .
COMMENT TROUBLESHOOTING HINTS (The most

• Fuel leakage from injectors is suspected, or car- likely causes for this case:)
bon build up. • Fuel leakage from injectors.
DIAGNOSIS
Replace the leaking injector. Then confirm that the malfunction
INSPECTION PROCEDURE 22: Too high CO and HC concentration when idling
• Deteriorated catalyst.
.
COMMENT • Refer to component locations GROUP-70

• Abnormal air/fuel ratio is suspected. • Refer to configuration diagrams GROUP-80
DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Go to Step 2.
MB991824
MB991827 00DB076A

YES : Go to Step 3.

CAUTION
CONNECTOR
MB991910
b. Item 6: Intake Air Temperature Sensor.
YES : Go to Step 4.
MB991827 00DB076A

DATA LINK (2) Check the following items of the data list. Refer to Data List
CONNECTOR
YES : Replace the heated oxygen sensor (front). Then
MB991824 confirm that the malfunction symptom is eliminated. If
not resolved, go to step 6.
NO : Go to Step 5.
MB991827 00DB076A

YES : Go to Step 6.

(1) Check the following items, and repair or replace the
defective items.
a. Check the injectors for fuel leakage.
b. Check the ignition coil and spark plugs.
d. Check the positive crank case ventilation system.
e. Check the evaporative emission system.
(2) Then check the malfunction symptom.
Q: Is the malfunction symptom eliminated?
YES : The check is completed.
NO : Replace the catalytic converter. Then confirm that the
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.
.

• Purge line or purge port is clogged.
DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
(3) Read the DTC.
Q: Is the DTC set?
MB991910
NO : Refer to GROUP 17, Emission Control System −
Purge Control System Check (Purge Flow Check)
MB991824
P.17-82.
MB991827 00DB076A
INSPECTION PROCEDURE 24: Power supply system and ignition switch - IG system.
• The ECU (terminals No. 25, No. 29) is grounded

.
CIRCUIT OPERATION to the vehicle body.

• Battery positive voltage is applied to the MPI
relay (terminals No. 1, No. 2). .
• 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

damage.
CONNECTOR: B-17X Q: Is the connector in good condition?
YES : Go to Step 2.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
STEP 2. Check the MPI relay.

CAUTION
CONNECTOR: B-17X Because it is not possible to distinguish the top and the
bottom of the MPI relay, inspect it with the triangle mark
printed on the relay facing upward.
(1) Remove the MPI relay.
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
STEP 3. Measure the power supply voltage at MPI relay

harness side connector B-17X.
CAUTION
Because it is difficult to distinguish the top and bottom of
the MPI relay connector at the wiring harness, inspect it by
using triangle mark on the junction block as reference.
CONNECTOR: B-17X (1) Disconnect the connector B-17X and measure at the
harness side.
RELAY BOX
FRONT OF VEHICLE
2 1
4 3
HARNESS B-17X
CONNECTOR:
COMPONENT SIDE
AK303017 AB
(2) Measure the voltage between terminals No. 1, No. 2 and

ground.
B-17X HARNESS
CONNECTOR: • Voltage should be battery positive voltage.
COMPONENT SIDE
2 1 present?
NO : Check harness connector A-13 at intermediate
connector for damage, and repair or replace as
required. Refer to, GROUP 00E, Harness Connector
AK303247 AB Inspection P.00E-2. If intermediate connector is in
good condition, repair harness wire between relay
box (9) and MPI relay connector B-17X (terminals No.
1, No. 2) because of open circuit. Then confirm that
the malfunction symptom is eliminated.
STEP 4. Check harness connector B-20 and B-21 at ECU

for damage.
YES : Go to Step 5.
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 5. Measure the ignition switch-IG signal voltage at

ECU harness side connector B-21.
side.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
present?
YES : Go to Step 6.
NO : Check harness connector C-214 and C-215 at
replace as required. Refer to, GROUP 00E, Harness
03DB161A Connector Inspection P.00E-2. If intermediate
connectors are in good condition, repair harness wire
between ignition switch connector C-308 (terminal
No. 2) and ECU connector B-21 (terminal No. 70)
because of open circuit. Then confirm that the
STEP 6. Measure the backup power supply voltage at ECU

side.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
present?
YES : Go to Step 7.
NO : Repair harness wire between relay box (9) and ECU
connector B-21 (terminal No. 16) because of short
circuit. Then confirm that the malfunction symptom is
eliminated.
03DB162A
STEP 7. Check for continuity at ECU harness side

connector B-21.
side.
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.
YES : Go to Step 8.
NO : Check harness connector A-14 at grounding
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
eliminated.
STEP 8. Measure the power supply voltage at ECU harness

side.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
present?
YES : Go to Step 9.
B-17X (terminal No. 3) and ECU connector B-20
(terminal No. 24) because of open circuit. Then
confirm that the malfunction symptom is eliminated.
03DB164A
STEP 9. Measure the power supply voltage at ECU harness

side.
(2) Using a jumper wire, connect terminal No. 24 to ground.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(3) Measure the voltage between terminals (No. 05) and

CONNECTOR
present?
YES : Replace the ECU. Then confirm that the malfunction
B-17X (terminal No. 4) and ECU connector B-20
03DB165A (terminal No. 05) because of open circuit. Then
INSPECTION PROCEDURE 25: Fuel pump system.
CONNECTOR: C-208, C-210

JUNCTION
BLOCK C-208
C-210 AIR
CLEANER
COVER
ENGINE
CONTROL
HARNESS 2 1 UNIT
CONNECTOR 4 3
03DB166A
CONNECTOR: C-29
C-29
16DB400A
JUNCTION CONNECTOR: C-215

BLOCK
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
CONNECTOR: C-214 C-308

JUNCTION
BLOCK
03DB170A
CONNECTOR: C-211
JUNCTION
BLOCK C-211
C-214 03DB174A
03DB172A
.
CIRCUIT OPERATION switch-IG.

• Battery positive voltage is applied to the fuel Ground is provided through terminal No. 2 to
pump relay 1 (terminal No. 3) from the ignition chassis ground.
• When the ignition switch is turned to the "ON"

.
position, the battery positive voltage is applied to

the fuel pump relay 2 (terminal No. 1) from the likely causes for this code to be set are:)
fuel pump relay 1 (terminal No. 1). • Malfunction of the fuel pump relay.
• Battery positive voltage is applied to the fuel • Malfunction of the fuel pump.
pump relay 2 (terminal No. 3) from the ignition • Improper connector contact, open or short-circu-
switch-IG. lated harness wire.
• During cranking and while the engine is running, • Malfunction of the ECU.
the ECU turns the power transistor in the ECU • Refer to component locations GROUP-70
ON to ground the fuel pump relay 2 coil. With this, • Refer to configuration diagrams GROUP-80
the fuel pump relay turns ON, and the battery • Refer to circuit diagrams GROUP-90
positive voltage is supplied to the fuel pump from
the fuel pump relay 2 (terminal No. 4).
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check fuel pump operation.

(1) Turn the ignition switch to "ON". Listen for fuel pump
running for approximately 2 seconds. Pump will
automatically stop after this time.
NOTE: As the fuel pump is an in-tank type, the fuel pump
sound is hard to hear. Remove the fuel tank filler tube cap
and check from the tank inlet.
Q: Is the fuel pump operating properly?
YES : 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.
STEP 2. Check harness connector C-210 at fuel pump relay

1 and harness connector C-208 at fuel pump relay 2 for
damage.
CONNECTOR: C-208, C-210 Q: Is the harness connector in good condition?
JUNCTION YES : Go to Step 3.
BLOCK C-208 NO : Repair or replace it. Refer to GROUP 00E, Harness
C-210 Connector Inspection P.00E-2. Then confirm that the
HARNESS 2 1
CONNECTOR 4 3
03DB166A
STEP 3. Check the fuel pump relay 1 and 2.

CAUTION
CONNECTOR: C-208, C-210 Because it is not possible to distinguish the top and the
bottom of the fuel pump relay, inspect it with the triangle
JUNCTION
BLOCK C-208
mark printed on the relay facing upward.
C-210
(1) Remove the fuel pump relay 1 and 2.
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
STEP 4. Measure the power supply voltage at fuel pump

relay 1 harness side connector C-210.
CAUTION
CONNECTOR: C-208, C-210 Because it is difficult to distinguish the top and bottom of
the fuel pump relay connector at the wiring harness,
JUNCTION
BLOCK C-208
inspect it by using the triangle mark on the junction block
C-210
as a reference.
(1) Disconnect the connector C-210 and measure at the
harness side.
HARNESS 2 1
CONNECTOR 4 3
03DB166A

C-210 HARNESS • Voltage should measure battery positive voltage.
CONNECTOR:
1 3 present?
NO : Check harness connector C-214 at intermediate
JUNCTION connector for damage, and repair or replace as
BLOCK
TRIANGLE required. Refer to, GROUP 00E, Harness Connector
MARK Inspection P.00E-2. If intermediate connector is in
AK203269 AB good condition, repair harness wire between relay
box and fuel pump relay 1 connector C-210 (terminal
No. 4) because of open circuit. Then confirm that the

CAUTION
JUNCTION
BLOCK C-208
C-210
as a reference.
harness side.
HARNESS 2 1
CONNECTOR 4 3
03DB166A

C-210 HARNESS (4) Turn the ignition switch to the "LOCK" (OFF) position.
CONNECTOR:
1 3 present?
JUNCTION
BLOCK connector for damage, and repair or replace as
MARK AK203270 AB Inspection P.00E-2. If intermediate connector is in
good condition, repair harness wire between ignition
switch connector C-308 (terminal No. 2) and fuel
pump relay 1 connector C-210 (terminal No. 3)
STEP 6. Check for continuity at fuel pump relay 1 harness

side connector C-210.
CAUTION
JUNCTION
BLOCK C-208
C-210
as a reference.
harness side.
HARNESS 2 1
CONNECTOR 4 3
03DB166A

C-210 HARNESS ground.
CONNECTOR:
JUNCTION
BLOCK NO : Check connector C-211 at intermediate connector for
TRIANGLE damage, and repair or replace as required. Refer to
MARK
P.00E-2. If intermediate connector is in good
AK203271 AB
condition, repair harness wire between fuel pump
relay 1 connector C-210 (terminal No. 2) and ground

CAUTION
CONNECTOR: C-208 Because it is difficult to distinguish the top and bottom of
JUNCTION BLOCK
as a reference.
3 4
1 2
harness side.
1 2
C-208
3 4
HARNESS CONNECTOR:
COMPONENT SIDE
03DB167A

JUNCTION
BLOCK Q: Is battery positive voltage (approximately 12 volts)
TRIANGLE
MARK present?
4 3 NO : Repair harness wire between fuel pump relay 1
C-208 HARNESS connector C-210 (terminal No. 1) and fuel pump relay
CONNECTOR: 2 connector C-208 (terminal No. 1) because of open
COMPONENT SIDE
AK203273 AB eliminated.

CAUTION
CONNECTOR: C-208 Because it is difficult to distinguish the top and bottom of
JUNCTION BLOCK
as a reference.
3 4
1 2
harness side.
1 2
C-208
3 4
HARNESS CONNECTOR:
COMPONENT SIDE
03DB167A

C-208 HARNESS
CONNECTOR: Q: Is battery positive voltage (approximately 12 volts)
COMPONENT SIDE
present?
1 3
YES : Go to Step 9.
2 4
JUNCTION
BLOCK connector for damage, and repair or replace as
MARK AK203274 AB Inspection P.00E-2. If intermediate connector is in
switch connector C-308 (terminal No. 2) and fuel
pump relay 2 connector C-208 (terminal No. 3)
STEP 9. Check connector D-18 at fuel pump for damage.

CONNECTOR: D-18 Q: Is the connector in good condition?
FUEL PUMP MODULE YES : Go to Step 10.
(INCORPORATING FUEL NO : Repair or replace it. Refer to GROUP 00E, Harness
3 2 1 malfunction symptom is eliminated.
5 4
HARNESS
CONNECTOR:
COMPONENT SIDE
SERVICE
HOLE
03DB168A
STEP 10. Check the fuel pump operation.

CONNECTOR: D-18 (1) Disconnect fuel pump connector D-18.
FUEL PUMP MODULE
(INCORPORATING FUEL
3 2 1
5 4
HARNESS
CONNECTOR:
COMPONENT SIDE
SERVICE
HOLE
03DB168A
(2) Use jumper wires to connect fuel pump connector terminal

FUEL PUMP SIDE
CONNECTOR No. 5 to the positive battery terminal and terminal No. 4 to
the negative battery terminal.
1 2 3 • An operating sound of the fuel pump should be heard.
4 5
Q: Is the fuel pump operating properly?
NO : Replace the fuel pump. Then confirm that the
AKX01439 AB
STEP 11. Check for continuity at fuel pump harness side

connector D-18.
CONNECTOR: D-18 (1) Disconnect the connector D-18 and measure at the harness
FUEL PUMP MODULE
side.
(INCORPORATING FUEL
3 2 1
5 4
HARNESS
CONNECTOR:
COMPONENT SIDE
SERVICE
HOLE
03DB168A

D-18 HARNESS CONNECTOR:
COMPONENT SIDE ground.
3 2 1
NO : Repair harness wire between fuel pump connector
D-18 (terminal No. 4) and ground because of open
circuit. or harness damage. Then confirm that the
AK303266 AB

ground and harness damage between fuel pump relay 2
connector C-208 (terminal No. 4) and fuel pump connector
D-18 (terminal No. 5).
CONNECTOR: C-208
C-208 NOTE: Check harness after checking intermediate connector
JUNCTION BLOCK
C-204. If intermediate connector is damaged, repair or replace
JUNCTION BLOCK
it. After to GROUP 00E, Harness Connector Inspection
P.00E-2. Then check that the malfunction is eliminated.
3 4
4 3
2 1
1 2
4 3
2 1
1 2
3 4
C-208 C-208
HARNESS CONNECTOR:
HARNESS CONNECTOR: is eliminated.
COMPONENT SIDECOMPONENT SIDE
03DB167A AK203272 AB
CONNECTOR: D-18
FUEL PUMP MODULE
(INCORPORATING FUEL
3 2 1
5 4
HARNESS
CONNECTOR:
COMPONENT SIDE
SERVICE
HOLE
03DB168A
STEP 13. Check connector B-21 at ECU for damage.

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 14. Measure the power supply voltage at ECU

connector B-21.
side.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
present?
NO : Check harness connectors C-29 and C-211 at
03DB169A replace as required. Refer to, GROUP 00E, Harness
Connector Inspection P.00E-2. If intermediate
connectors are in good condition, repair harness wire
between fuel pump relay 2 connector C-208 (terminal
No. 2) and ECU connector B-21 (terminal No. 92)
INSPECTION PROCEDURE 26: Ignition Switch-ST System and Transmission Inhibitor Switch System
CONNECTOR: B-110 CONNECTOR: A-13
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
If the selector lever is moved to "P" or "N" range

.
COMMENT with the ignition switch turned on (except

• If the selector lever is moved to "P" or "N" range "START" position), continuity will exist between
and the ignition switch is turned to "START" posi- the ECU and ground through the transmission
tion, battery positive voltage is supplied to ECU inhibitor switch and starter motor. The terminal
(terminal No. 9) through the ignition switch and voltage of the ECU will become low. If the selec-
transmission inhibitor switch. Because of this, the tor lever is moved to the other ranges, continuity
ECU detects that the engine is cranking. will be lost between the ECU and ground. The
• The transmission inhibitor switch detects the terminal voltage of the ECU will become high.
transmission inhibitor (P, N or other ranges) and
converts it to a voltage signal (high or low). Then .
the transmission inhibitor switch sends that signal

to the ECU.
TROUBLESHOOTING HINTS (The most • Improper connector contact, open circuit or

likely caused for this code to be set are:) short-circuit in the harness wire.
• Malfunction of the ECU.
• Malfunction of the ignition switch.
• Malfunction of the transmission inhibitor switch.
DIAGNOSIS
STEP 1. Check connector B-110 at transmission inhibitor

switch for damage.
CONNECTOR: B-110 Q: Is the connector in good condition?
YES : Go to Step 2.
B-110 (B) NO : Repair or replace it. Refer to GROUP 00E, Harness
6 5 4 3 2 1
10 9 8 7
TRANSMISSION
RANGE SWITCH
HARNESS
CONNECTOR:
STEP 2. Check the transmission inhibitor switch.

Refer to GROUP 23A, On-vehicle Service − Essential Service −
Transmission Inhibitor Switch Continuity Check P.23A-294.
YES : Repair or replace it. Then confirm that the malfunction
NO : Go to Step 3.
STEP 3. Measure the power supply voltage at transmission

inhibitor switch connector B-110.
harness side.
B-110 (B) (2) Turn the ignition switch to the "START" position.
6 5 4 3 2 1
10 9 8 7
TRANSMISSION
RANGE SWITCH
HARNESS
CONNECTOR:

B-110 HARNESS
COMPONENT SIDE
present?
6 5 4 3 2 1
YES : Go to Step 4.
10 9 8 7
NO : Check connector A-13 and C-29 at intermediate
required. Refer to GROUP 00E, Harness Connector
AK303270 AB Inspection P.00E-2. If intermediate connector are in
switch connector C-308 (terminal No. 5) and
transmission inhibitor switch connector B-110
(terminal No. 10) because of open circuit. Then

YES : Go to Step 5.
COVER
ENGINE
CONTROL
UNIT
16DB400A

and harness damage between transmission inhibitor
switch connector B-110 (terminal No. 9) and ECU
B-110 (B) symptom is eliminated.
is eliminated.
6 5 4 3 2 1
10 9 8 7
TRANSMISSION
RANGE SWITCH
HARNESS
CONNECTOR:
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
INSPECTION PROCEDURE 27: Ignition Circuit System.
CONNECTOR: B-101, B-102, B-103, B-114, CONNECTOR: C-215

B-117, B-118 JUNCTION
B-102 (GR) BLOCK
B-101 (GR)
B-103 (GR)
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
CONNECTOR: B-111
B-111 (B)
AK303272AB
. .

• The ignition coil is energized by battery positive likely causes for this case:)
voltage from the ignition switch. • Malfunction of the ignition coil.
• When the ECU turns off its internal power transis- • Malfunction of the ignition power transistor.
tor, battery positive voltage is applied to the igni- • Improper connector contact, open circuit or
tion power transistor (terminal No. 3) inside the short-circuit harness wire.
ignition coil, causing the ignition power transistor • Malfunction of the ECU.
to be turned on. • Refer to component locations GROUP-70
• If the ignition power transistor is turned on, the • Refer to configuration diagrams GROUP-80
primary circuit of the ignition coil is energized by • Refer to circuit diagrams GROUP-90
grounding the ignition coil through terminal No. 2,
causing the primary current to flow to the ignition
coil.
DIAGNOSIS
STEP 1. Check the ignition coil.

(2) Refer to GROUP 16, Ignition System − On-vehicle service −
Ignition Coil Check P.16-31.
YES : Replace the ignition coil. Then confirm that the
NO : Go to Step 2.
STEP 2. Check harness connectors B-114, B-117, B-118,

B-102, B-103, B-101 at ignition coil for damage.
CONNECTOR: B-101, B-102, B-103, B-114, Q: Is the harness connector in good condition?
B-117, B-118 B-102 (GR) YES : Go to Step 3.
B-101 (GR)
B-103 (GR) malfunction symptom is eliminated.
B-118 (GR)
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB
STEP 3. Measure the power supply voltage at ignition coil

connectors B-114, B-117, B-118, B-102, B-103, B-101.
CONNECTOR: B-101, B-102, B-103, B-114, (1) Disconnect the connector B-114, B-117, B-118, B-102,
B-117, B-118 B-102 (GR) B-103, B-101 and measure at the harness side.
B-101 (GR)
B-103 (GR)
B-118 (GR)
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB

B-101, B-102, B-103, B-114, (4) Turn the ignition switch to the "LOCK" (OFF) position.
B-117, B-118 HARNESS
CONNECTOR: Q: Is battery positive voltage (approximately 12 volts)
COMPONENT SIDE
present?
NO : Go to Step 4.
AK303273 AB
STEP 4. Check for open circuit between ignition switch

connector C-308 (terminal No. 2) and ignition coil
connectors B-114, B-117, B-118, B-102, B-103, B-101
(terminal No. 1).
CONNECTOR: C-308 NOTE: Check harness after checking intermediate connectors
A-13, B-32, C-29, C-211, C-215 and C-308. If intermediate con-
nectors are damaged, repair or replace them. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Then confirm that
3 2 1
the malfunction symptom is eliminated.
C-308 6 5 4 Q: Is the harness wire in good condition?
HARNESS YES : Repair harness wire between ignition switch
CONNECTOR: connector C-308 (terminal No. 2) and capacitor
COMPONENT SIDE
connector B-111 (terminal No. 1) because of short
03DB175A circuit to ground. Then confirm that the malfunction
is eliminated.
STEP 5. Check the circuit at ignition coil harness side

connectors B-114, B-117, B-118, B-102, B-103, B-101.
CONNECTOR: B-101, B-102, B-103, B-114, (1) Disconnect the connectors B-114, B-117, B-118, B-102,
B-117, B-118 B-102 (GR) B-103, B-101 and measure at the harness side.
(2) Crank the engine.
B-101 (GR)
B-103 (GR)
B-118 (GR)
B-117 (GR)
3 2 1
B-114 (GR)
HARNESS CONNECTOR:
COMPONENT SIDE
AK303233 AB

NOTE: The average voltage through an analog voltmeter is
B-101, B-102, B-103, B-114,
B-117, B-118 HARNESS described in this service manual (because the average volt-
CONNECTOR: age is too stable to be shown on a digital voltmeter).
COMPONENT SIDE
• Voltage should be 0.3 and 3.0 volts.
3 2 1
YES : Go to Step 8.
NO : Go to Step 6.
AK303275 AB

YES : Go to Step 7.
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 7. Check for open circuit, short circuit to ground or

harness damage between ignition coil connector and ECU
connector.
CONNECTOR: B-101, B-102, B-103, B-114,
B-117, B-118 B-102 (GR)
B-101 (GR)
B-103 (GR)
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
NOTE: Check harness after checking intermediate connector

B-32. If intermediate connector is damaged, repair or replace it.
Refer to GROUP 00E, Harness Connector Inspection. Then
a. Check the harness wire between ignition coil connector
B-101 (terminal No. 3) and ECU connector B-20 (terminal
No. 07) at ignition coil 1.
b. Check the harness wire between ignition coil connector
c. Check the harness wire between ignition coil connector
d. Check the harness wire between ignition coil connector
e. Check the harness wire between ignition coil connector
f. Check the harness wire between ignition coil connector
is eliminated.
INSPECTION PROCEDURE 28: A/C system.
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
.
DIAGNOSIS

A/C Relay.
CAUTION
CONNECTOR
A/C Relay.
• An operation sound of the relay should be heard.
MB991910
Q: Is the A/C Relay operating properly?
MB991824 YES : Replace the ECU. Then confirm that the malfunction
sympton is eliminated.
NO : Go to Step 2.
MB991827 00DB076A

damage.
YES : Go to Step 3.
COVER
ENGINE
CONTROL
UNIT
16DB400A
STEP 3. Check the circuit at ECU connector B-20.

(1) Disconnect the connectors B-20 and measure at the
harness side.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR
Q: Is there battery voltage at terminal No. 06?
sympton is eliminated.
NO : Refer to GROUP 55, Diagnosis − Introduction To
Heater, Air Conditioning And Ventilation Diagnosis
P.55-5. Then confirm that the malfunction symptom is
03DB176A
eliminated.
DATA LIST REFERENCE TABLE

M1131152001578
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.
1 Power supply Ignition switch: "ON" Battery positive Procedure P.13A-604

voltage voltage No. 24
2 Crank angle • Engine: cranking Engine speeds Code No. P.13A-354
sensor • Tachometer: connected displayed on the P0335
diagnostic tool and
tachometer are
identical.
Engine: idling Engine coolant 1,300 − 1,500 r/min
temperature is
−20°C (−40°F)
Engine coolant 1,300 − 1,500 r/min
temperature is
0°C (32°F)
temperature is
20°C (68°F)
temperature is
40°C (104°F)
Engine coolant 680 − 750 r/min
temperature is
80°C (176°F)
3 Target idle speed Engine idling 710 r/pm Code No. P.13A-419
Coolant temp <60°C P0506 P.13A-421
P0507
4 Vehicle speed Actual vehicle speed matches km/h Code No. P.13A-399
diplayed. P0500

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
temperature is
40°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

NO. PROCEDURE PAGE
NO.
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,
pedal P2128
Depress the Increases in
stroke
accelerator
pedal fully
13 TPS (main) Ignition switch: Release the 1035 to 1250 mV Code No. P.13A-148,
pedal P0123 P.13A-510
Depress the Increases in P2135
stroke
accelerator
pedal fully
15 TPS (sub) Ignition switch: Release the 1035 to 1250 mV Code No. P.13A-318
pedal P0223 P.13A-510
Depress the Increases in P2135
stroke
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

NO. PROCEDURE PAGE
NO.
17 Injectors*2 • Engine Engine is idling 1 - 2 ms P0201, P.13A-272

coolant P0202, P.13A-280
temperature 2,500 r/min 1 - 3 ms P0203, P.13A-287
: 80 − 95°C P0204, P.13A-295
(176 − When engine 1 - 4 ms P0205, P.13A-302
203°F) is suddenly P0206 P.13A-310
• All revved
accessories
: "OFF"
• Transaxle:
"P" range
23 A/C pressure • Engine: running 1275 − 1863 kPa Procedure P.13A-634

sensor • A/C switch: "ON" No. 28
26 Long-term fuel N/A

trim bank 1
27 Long-term fuel N/A
trim bank 2
28 Short-term fuel Engine: warming up, 2,500 -7.0 to 7.0% Code No. P.13A-264,
trim bank 1 r/min without any load (during P0171, P.13A-266
closed loop) P0172
29 Short-term fuel Engine: warming up, 2,500 -7.0 to 7.0 % Code No. P.13A-268,
trim bank 2 r/min without any load (during P0174, P.13A-270
closed loop) P0175
32 Knock retard Quick throttle "blips" idle to 0 - 4.2 Code No. P.13A-346
3,000 rpm P0325
47 Fan duty Ignition switch: "ON" or with 0 to 100% - -
engine running
49 Purge control Ignition switch: "ON" 0 to 100% Code No. P.13A-389
solenoid VAL. P0443
duty
58 Throttle actuator Ignition switch: Release the 2 to 4 % Code No. P.13A-455
pedal P2101, P.13A-466
Depress the 100 % P2102,
P.13A-471
accelerator P2103
pedal fully
59 Target ETV value Ignition switch: "ON" 1.1 V Procedure P.13A-573
No. 10
72 Absolute engine • Engine Engine is idling 17.3 % Code No. P.13A-92
load value coolant 2,500 r/min 14.9 % P0106, P.13A-101
temperature P0107, P.13A-109
: 80 − 95°C Revving Volumetric P0108
• Transaxle:"P" engine efficiency increases
range according to
amount of revving.

NO. PROCEDURE PAGE
NO.
73 Calculated load Engine: Engine is idling 22.7 % − −

value warming up 2,500 r/min 18.8 %
74 Brake lamp > 8V + OFF Code No. P.17-35
switch Pedal applied ON P1571
76 A/C switch 1 A/C switch: A/C switch OFF Procedure P.13A-634
"ON" "OFF" No. 28
A/C switch ON
"ON"
79 Cranking signal Ignition switch: Engine: OFF Procedure P.13A-624
"ON" stopped No. 26
Engine: ON
cranking
83 Power steering Engine: idling Steering wheel OFF - -
pressure switch stationary
Steering wheel ON
turning
84 Idle position Engine: idling Signal ON Code No. P.13A-419
signal Engine: not Signal OFF P0506, P.13A-421
idling P0507
85 Ignition switch Ignition switch: IGN switch OFF Procedure P.13A-624

"OFF" No. 26
IGN switch ON
"ON"
87 Neutral switch Ignition A/T selector in OFF Procedure P.13A-628
switch:"ON" "P,R,D" No. 27
A/T selector in ON
"N"
89 Normally closed > 8V + OFF Code No. P.17-35
brake switch Pedal applied ON P1571
93 A/C compressor • Engine: warming up, idling OFF Procedure P.13A-634
clutch relay • A/C switch: "OFF" No. 28
• Engine: A/C OFF
warming up, compressor
idling clutch is not
• A/C switch: operating
"ON" A/C ON
compressor
clutch is
operating
95 Engine control Battery 8V + OFF - -
relay Engine ON
cranking/start

NO. PROCEDURE PAGE
NO.
97 Fuel pump relay Ignition Fuel pump ON Procedure P.13A-613

switch:"ON operates for 2 No. 25
seconds &
then stops
Pump stops OFF
after 2 seconds
AA Airflow sensor • Engine Engine is idling 3 to 5 g/sec Code No. P.13A-78
coolant 2,500 rpm 13 to16 g/sec P0101, P.13A-81
temperatur P0102, P.13A-87
e: 80 − Revving Increases in P0103
95°C engine proportion to
• Transaxle:"P amount of revving.
" range
AB TPS (main) Ignition Release the 0% Code No. P.13A-148
switch:"ON" accelerator P0122, P.13A-155
pedal P0123
Depress the 100 %
accelerator
pedal fully
AC Oxygen sensor, Engine: When the 200 mV or less Code No. P.13A-160,
bank 1, sensor 1 Warming up engine is P0130, P.13A-166,
(front) (Air/fuel running at P0131, P.13A-172,
mixture is 4,000 r/min, P0132, P.13A-177,
made leaner decelerate P0133, P.13A-179
when suddenly. P0134
decelerating,
and is made
richer when
revving.)
Engine: When engine 600 − 1,000 mV
Warm is suddenly
revved.
Engine: Engine is idling Voltage alternates
Warming up 2500 r/min quckly 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.)
AD Oxygen sensor Engine: Revving Alternates slowly Code No. P.13A-186,
bank 1, sensor 2 warming up between 0 and 600 P0136, P.13A-192,
(rear) − 1,000mV . P0137, P.13A-198,
P0138, P.13A-203
P0139

NO. PROCEDURE PAGE
NO.
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
ACTUATOR TEST REFERENCE TABLE

M1131152500570
MUT-III ITEM INSPECTION DRIVE INSPECTION REQUIREMENT NORMAL INSPECTION REFERENCE

DIAGNOS NO. ITEM CONTENTS CONDITION PROCEDURE PAGE
TIC TOOL NO.
DISPLAY
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
No.4 injector P0204
No.5 injector P0205
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
CHECK AT THE ELECTRONIC CONTROL UNIT (ECU)

1. Disconnect the ECU connectors B-20 and B-21 2. Measure the voltage between each check
and connect check harness special tool harness connector terminal and check harness
MB992044 between the ECU connectors. connector ground terminal (No. 25 or No. 29).
TERMINAL VOLTAGE CHECK CHART
Check Harness Special Tool MB992044 Connector Terminal Arrangement
03DB159A
(CONNECTOR INSPECTION INSPECTION CONDITION (ENGINE NORMAL

HOUSING NO.) ITEM CONDITION) CONDITION
TERMINAL NO.
(B-21) - 71 Fan control Ignition switch: "ON" 5 V fan off
Carry out the actuator test to revolve the fan at 1 V or less
high speed.
(B-21) - 92 Fuel pump relay Ignition switch: "ON" B+
Engine: idling 1 V or less
(B-20) - 25 Sensor supplied Ignition switch: "ON" 4.9 − 5.1 V
(B-21) - 76 voltage
(B-21) - 59 Accelerator pedal Ignition switch: Release the accelerator 0.996 V
position sensor "ON" pedal
(main) Depress the accelerator 4.043 V
pedal fully
(B-21) - 81 Accelerator pedal Ignition switch: Release the accelerator 0.996 V
position sensor "ON" pedal
(sub) Depress the accelerator 4.043 V
pedal fully
(B-21) - 75 Power supply Ignition switch: "ON" 4.9 − 5.1 V
voltage applied to
accelerator pedal
position sensor
(B-21) - 21 Brake lamp switch Depress the brake pedal B+
Release the brake pedal 1 V or less
(B-21) - 16 Backup power Ignition switch: "LOCK" (OFF) B+
supply
(B-21) - 70 Ignition switch-IG Ignition switch: "ON" B+
(B-20) - 05 Power supply Ignition switch: "ON" B+
(B-20) - 24 MPI relay (power Ignition switch: "LOCK" (OFF) B+
supply) Ignition switch: "ON" 1 V or less

TERMINAL NO.
(B-20) - 53 Power steering Engine: warming When steering wheel is not B+
pressure switch up, idling turned
When steering wheel is 1V or less
turned
(B-20) - 06 A/C compressor • Engine: idling B+→ 1 V or less
clutch relay • A/C switch: OFF→ ON (A/C compressor is as A/C clutch
operating) cycles
(B-20) - 09 Ignition switch-ST Engine: cranking 8 V or more
(B-20) - 15 Left bank heated Engine: warming up, 2,500 r/min (check using a 0 ⇔ 0.8 V
oxygen sensor digital voltmeter) (changes
(front) repeatedly)
(B-20) - 45 Right bank heated Engine: warming up, 2,500 r/min (check using a 0 ⇔ 0.8 V
oxygen sensor digital voltmeter) (changes
(front) repeatedly)
(B-20) - 56 Engine coolant Ignition switch: When engine coolant 3.9 − 4.5 V
temperature "ON" temperature is −20°C (−4°F)
sensor When engine coolant 3.2 − 3.8 V
temperature is 0°C (32°F)
When engine coolant 2.3 − 2.9 V
(B-20) - 10 Power supply Ignition switch: "ON" 4.9 − 5.1 V
voltage applied to
throttle position
sensor
(B-20) - 30 Left bank heated • Engine: warming up 0 and 0.6 − 1.0 V
oxygen sensor • Revving alternates
(rear)
(B-20) - 60 Right bank heated • Engine: warming up 0 and 0.6 − 1.0 V
oxygen sensor • Revving alternates
(rear)

TERMINAL NO.
(B-20) - 57 Throttle position • Remove the Fully depress and release 1172 − 4043 mV
sensor (sub) 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.
(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.
(B-20) - 41 Manifold absolute Ignition switch: AT altitude of 0 m (0 ft.) 3.8 − 4.2 V

pressure sensor "ON" AT altitude of 600 m (1,969 3.5 − 3.9 V
ft.)
AT altitude of 1,200 m (3,937 3.3 − 3.7 V
ft.)
AT altitude of 1,800 m (5,906 3.0 − 3.4 V
ft.)
Engine: warming up, idling 0.6 − 1.4 V
When engine is suddenly revved Voltage Varies
(B-20) - 23 Crankshaft Engine: cranking 0.4 - 4.0 V
position sensor Engine: idling 2.0 - 3.0 V

TERMINAL NO.
(B-20) - 38 Camshaft position Engine: cranking 0.4 - 4.0 V
sensor Engine: idling 2.9 - 3.9 V
(B-20) - 58 Intake air Ignition switch: When Intake air temperature 3.8 − 4.4 V
temperature "ON" is −20°C (−4°F)
sensor When Intake air temperature 3.2 − 3.8 V
is 0°C (32°F)
When Intake air temperature 2.3 − 2.9 V
is 20°C (68°F)
is 40°C (104°F)
is 60°C (140°F)
is 80°C (176°F)
(B-20) - 26 Mass airflow Engine: revving Voltage increase
sensor in response to
revving
(B-20) - 48 Left bank heated Engine: warming up, idling (15 seconds after 0 − 11 V at slow
oxygen sensor starting engine) pulse rate
heater (front) Engine: revving 0 − 11 V at slow
pulse rate
(B-20) - 47 Right bank heated Engine: warming up, idling (15 seconds after 0 − 11 V at slow
oxygen sensor starting engine) pulse rate
heater (front) Engine: revving 0 − 11 V at slow
pulse rate
(B-20) - 33 Left bank heated Engine: warming up, idling 0 − 11 V at slow
oxygen sensor pulse rate
heater (rear) Engine: revving 0 − 11 V at slow
pulse rate
(B-20) - 32 Right bank heated Engine: warming up, idling 0 − 11 V at slow
oxygen sensor pulse rate
heater (rear) Engine: revving 0 − 11 V at slow
pulse rate
(B-20) - 49 Throttle actuator • Ignition switch: "ON" Decreases
control motor (−) • Accelerator pedal: fully closed → fully opened slightly AC
voltage.
(B-20) - 50 Throttle actuator • Ignition switch: "ON" Decreases
control motor (+) • Accelerator pedal: fully opened → fully closed slightly AC
voltage.
(B-20) - 21 Evaporative Ignition switch: "ON" B+
emission purge Engine: warm up, 3,000 r/min (within 3 minutes B+ to 0.1V
solenoid after the engine starting sequence is completed) pulses

TERMINAL NO.
(B-20) - 07 Ignition coil − No. 1 Engine: 3,000 r/min 0.3 − 3.0 V using
(ignition power oscilloscope
transistor)
(B-20) - 22 Ignition coil − No. 2
(ignition power
transistor)
(ignition power
transistor)
(ignition power
transistor)
(ignition power
transistor)
(ignition power
transistor)
(B-20) - 03 No. 1 injector • Engine: warming up, idling From 9 − 13 V
(B-20) - 04 No. 2 injector • Suddenly depress the accelerator pedal using
oscilloscope
(B-20) - 34 No. 3 injector
TERMINAL RESISTANCE AND CONTINUITY CHECK

ECU Harness Connector Terminal Arrangement
03DB160A
(CONNECTOR INSPECTION ITEM NORMAL CONDITION (INSPECTION

HOUSING NO.) CONDITION)
TERMINAL NO.
(B-21) - 04 to ECU ground Continuity (2 Ω or less)
Body ground
(B-21) - 04 to ECU ground
Body ground
(B-20) - 12−56 Engine coolant temperature sensor 14.10 − 15.46 kΩ [when engine coolant
temperature is −20°C (−4°F)]
5.47 − 5.90 kΩ [when engine coolant
temperature is 0°C (32°F)]
(B-20) - 11−58 Intake air temperature sensor 12.660 − 15.120 kΩ [when intake air
temperature is −20°C (−4°F)]
5.119 − 5.892 kΩ [when intake air temperature
is 0°C (32°F)]
is 20°C (68°F)]
is 40°C (104°F)]
is 60°C (140°F)]
is 80°C (176°F)]
(B-20) - 05−48 Left bank heated oxygen sensor heater 9.0 − 11.0 Ω [at 20°C (68°F)]
(front)
(B-20) - 05−47 Right bank heated oxygen sensor heater 9.0 − 11.0 Ω [at 20°C (68°F)]
(front)
(B-20) - 05−33 Left bank heated oxygen sensor heater 9.0 − 11.0 Ω [at 20°C (68°F)]
(rear)
(CONNECTOR INSPECTION ITEM NORMAL CONDITION (INSPECTION

HOUSING NO.) CONDITION)
TERMINAL NO.
(B-20) - 05−32 Right bank heated oxygen sensor heater 9.0 − 11.0 Ω [at 20°C (68°F)]
(rear)
(B-20) - 49−50 Throttle actuator control motor 1.5 ± 0.3 Ω [at 20°C (68°F)]
(B-20) - 05−21 Evaporative emission purge solenoid 16 Ω [at 20°C (68°F)]
(B-20) - 05−03 No. 1 injector 10.5 − 13.5 Ω [at 20°C (68°F)]
(B-20) - 05−04 No. 2 injector
(B-20) - 05−34 No. 3 injector
(B-20) - 05−35 No. 4 injector
(B-20) - 05−16 No. 5 injector
(B-20) - 05−17 No. 6 injector
INSPECTION PROCEDURE USING AN

OSCILLOSCOPE
M1131154501085
CAMSHAFT POSITION SENSOR AND

CRANKSHAFT POSITION SENSOR
.
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
3. Connect the oscilloscope to check harness terminal No. 23.

(Check the crankshaft position sensor signal wave pattern.)
OSCILLOSCOPE B-20 HARNESS
CONNECTOR Standard Wave Pattern
Observation condition
Function Special pattern
Pattern height Low
Pattern selector Display
03DB244A Engine r/min Idle speed
Standard wave pattern

(VOLT)
2 ENGINE REVOLUTIONS (1 CAMSHAFT REVOLUTION)
No. 1TDC No. 3TDC No. 4TDC No. 2TDC

5
CRANKSHAFT
POSITION
SENSOR OUTPUT
WAVE PATTERN
0
5
CAMSHAFT
POSITION
SENSOR OUTPUT
WAVE PATTERN
(TIME)
0
03DB259A
Wave Pattern Observation Points

1. Check that cycle time becomes shorter when the engine
speed increased.
.
Examples of Abnormal Wave Patterns

Example 1
Cause of problem
• Sensor interface malfunction.
Wave pattern characteristics
• Rectangular wave pattern is output even when the
engine is not started.
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
INJECTOR
.
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
<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-
nectors.
AK302166 AB
OSCILLOSCOPE 3. Connect the oscilloscope probe to each check harness con-

POWER PLANT ECU
CHECK HARNESS nector terminal to analyze each cylinder:
CONNECTOR • Terminal No. 153 for the number 1 cylinder.
• Terminal No. 146 for the number 2 cylinder.
Standard Wave Pattern
03DB145A
Observation conditions
Pattern height Variable
Variable knob Adjust while viewing the
wave pattern
Engine r/min Idle speed
(V)
50 POINT A
INJECTION COIL INDUCED

VOLTAGE (APPROXIMATELY 50-60 V)
POINT B:
INJECTOR DRIVE
TIME
POWER VOLTAGE
0 DRIVE SIGNAL:"ON" DRIVE SIGNAL:"OFF"
AKX01604 AB

Point A: Height of injector coil induced voltage.
CONTRAST WITH PROBABLE CAUSE
STANDARD WAVE
PATTERN
Injector coil induced voltage is Short in the injector solenoid
low or doesn't appear at all
Point B: Injector drive time

1. The injector drive time should be synchronized with the
diagnostic tool display.
2. When the engine is suddenly revved, the drive time will be
greatly extended at first, but the drive time will soon return
to original length.
WHEN IDLING
WHEN RACING AKX01605 AB
IGNITION COIL AND IGNITION POWER

TRANSISTOR
.
Measurement Method
1. Disconnect the all ECU connectors, and connect check har-
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.
Standard Wave Pattern
03DB246A Observation condition
Pattern height Low
Engine r/min Idle speed

(VOLT)
2 ENGINE REVOLUTIONS (1 CAMSHAFT REVOLUTION)
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

Point: The power transistor control signal (ignition timing) is
advanced when the engine speed is increased.
CONDITION OF WAVE PROBABLE CAUSE
PATTERN BUILD-UP
SECTION AND MAXIMUM
VOLTAGE
Voltage value is too low Open-circuit in ignition primary
circuit
.
Examples of Abnormal Wave Patterns

Example 1 (Wave pattern during engine cranking)
NORMAL WAVE • Cause of problem
PATTERN Open-circuit in ignition primary circuit
• Wave pattern characteristics
Voltage value is too low.
AK203246 AC
SPECIAL TOOLS
SPECIAL TOOLS
M1131000601293

NAME
MB991824-KIT • Reading diagnostic
A
A: MB991824 NOTE: G: MB991826 trouble code
B: MB991827 MUT-III Trigger Harness • MFl system inspection
C: MB991910 is not necessary when • Measurement of fuel
D: MB991911 pushing V.C.I. ENTER pressure
MB991824
E: MB991914 key. CAUTION
B F: MB991825 For vehicles with CAN
G: MB991826 communication, use
MUT-III sub assembly MUT-III main harness A
A: Vehicle to send simulated
Communication Interface vehicle speed. If you
MB991827
(V.C.I.) connect MUT-III main
C
B: MUT-III USB Cable harness B instead, the
C: MUT-III Main Harness CAN communication
A (Vehicles with CAN does not function
communication system) correctly.
MB991910 D: MUT-III Main Harness
D B (Vehicles without CAN
communication system)
DO NOT USE E: MUT-III Main Harness
C (for Daimler Chrysler
models only)
MB991911
F: MUT-III Measurement
E Adapter
G: MUT-III Trigger
DO NOT USE Harness
MB991914
MB991825
MB991826
MB991958
MB992044 MD998478-01 • lnspection using an

ECU check harness oscilloscope
• lnspection of the
electronic control unit
(ECU) terminal voltage
check
SPECIAL TOOLS

NAME
MD998478 MD998478-01 • Inspection using an
Test harness (3 pin, oscilloscope
triangle)
MB991637 Tool not available • Measurement of fuel

Fuel pressure gauge set pressure
MB991637
TBA Measurement of fuel

Adaptor hose pressure
03DB257A
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
COMPONENT LOCATION
• Refer to component locations GROUP70
THROTTLE BODY (THROTTLE VALVE AREA)

CLEANING M1131001000503
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.
ON-VEHICLE SERVICE
FUEL PRESSURE TEST

M1131001900584

• MB991824: V.C.I.
• MB991637: Fuel Pressure Gauge Set
• TBA: Adaptor Hose
1. Release residual pressure from the fuel line to prevent fuel
spray. (Refer to P.13A-663.)
WARNING
To prevent a fire, cover the hose connection with
shop towels to prevent splashing of fuel that could be
caused by some residual pressure in the fuel pipe
line.
2. Disconnect the fuel high-pressure hose at the fuel rail side.
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
<When using the fuel pressure gauge>

FUEL PRESSURE
1. Use a suitable 1/4" BSP adaptor between fuel hose and
GAUGE Gauge. Attach the gauge and fitting to the adaptor hose.
O-RING OR GASKET 2. Install the assembled fuel pressure measurement tools to
1/4” BSP ADAPTOR the vehicle between the fuel rail and fuel pipe. For correct
hose fittment Refer to Fuel Hose Installation P.13A-673
FUEL
RAIL FUEL
HIGH-PRESSURE
ADAPTOR HOSE
03DB255A
ON-VEHICLE SERVICE
<When using special tool MB991637 (fuel pressure gauge

set)>
1. Use a suitable 1/4" BSP adaptor between fuel hose and
MB991637 special tool MB991637. Attach the special tool and fitting to
the adaptor hose.
O-RING OR GASKET
2. Install the assembled fuel pressure measurement tools to
1/4” BSP ADAPTOR the vehicle between the fuel rail and fuel pipe. For correct
FUEL hose fittment Refer to Fuel Hose Installation P.13A-673
RAIL FUEL
HIGH-PRESSURE
ADAPTOR HOSE
03DB256A
4. Turn the Ignition to "ON" listen for fuel pump actuation (

Approx. 2 seconds). Check that there is no fuel leaking from
any section when the fuel pump is operating.
5. Start the engine and run at idle.
6. Measure fuel pressure while the engine is running at idle.
Standard value: Approximately 324 kPa (95.7 in.Hg) at
curb idle
7. Check to see that fuel pressure at idle does not drop even
after the engine has been revved several times.
8. If any of fuel pressure measured in steps 8 to 9 is out of
specification, troubleshoot and repair according to the table
below.
SYMPTOM PROBABLE CAUSE REMEDY

• Fuel pressure too low Clogged fuel filter Replace fuel filter
• Fuel pressure drops after racing
Fuel leaking to return side due to Replace fuel pump
poor fuel regulator valve seating or
settled spring
Low fuel pump delivery pressure Replace fuel pump
Fuel pressure too high Binding valve in fuel pressure Replace fuel pump
regulator
9. Stop the engine and observe fuel pressure gauge reading. It

is normal if the reading does not drop within two minutes. If it
does, observe the rate of drop and troubleshoot and repair
according to the table below. Start, then stop the engine.
(1) Squeeze the fuel supply line closed to confirm leak-down
occurs from defective fuel pump check valve.
(2) If pressure continues to drop with both fuel lines
squeezed closed, injector(s) are leaking.
ON-VEHICLE SERVICE

Fuel pressure drops gradually Leaky injector Replace injector
after engine is stopped
Leaky fuel regulator valve seat Replace fuel pressure regulator
Fuel pressure drops sharply Check valve in fuel pump is held Replace fuel pump
immediately after engine is open
stopped
10.Release residual pressure from the fuel pipe line. (Refer to

P.13A-663.)
WARNING
Cover the hose connection with shop towels to pre-
vent splash of fuel that could be caused by some
residual pressure in the fuel pipe line.
11.Remove the fuel pressure gauge, and special tools from the
fuel rail.
12.Insert fuel hose quick connector onto fuel rail pipe, taking
care not to damage or dislodge O-ring. Push connector onto
pipe firmly and depress clip to attach. Check that connector
does not dislodge when pulled firmly.
13.Check for fuel leaks.
(1) Turnthe ignition to "ON" to operate the fuel pump.
(2) Check the fuel line for leaks and repair as needed.
FUEL PUMP CONNECTOR DISCONNECTION

(HOW TO REDUCE PRESSURIZED FUEL LINES)
M1131000900622
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
ON-VEHICLE SERVICE
3. Disconnect the fuel pump module connector.

FUEL PUMP MODULE 4. After starting the engine and letting it run until it stops
CONNECTOR naturally, turn the ignition switch to the "LOCK" (OFF)
position.
5. Connect the fuel pump module connector.
AC306490 AB
6. Install the hole cover (LHS).

HOLE COVER Tightening torque: 1.5 ± 0.5 N⋅m (14 ± 4 in-lb)
7. Install the rear seat cushion assembly (Refer to GROUP
52A, Rear Seat Assembly P.52A-55).
03DB150A
FUEL PUMP OPERATION CHECK

M1131002000692
1. If the fuel pump will not operate, check by using the
following procedure. If normal, check the fuel pump drive
circuit.
(1) Turn the ignition switch to "ON". Listen for fuel pump
running for approximately 2 seconds. Pump will
automatically stop after this time.
(2) Remove the rear seat cushion assembly (Refer to
GROUP 52A, Rear Seat P.52A-55).
(3) Remove the hole cover (LHS).
HOLE COVER
03DB150A
ON-VEHICLE SERVICE
(4) Disconnect the fuel pump module connector.

FUEL PUMP MODULE
CONNECTOR
AC306490 AB
(5) Attach 12 Volt supply to fuel pump, terminal no. 4 to earth

and terminal no.5 to power. Check if the sound of the fuel
pump operation can be heard. If no operating sound is
1 2 3 heard, replace the fuel pump module (Refer to GROUP
4 5
13B, On-vehicle Service − Fuel Pump Module
Replacement P.13B-6).
AC305681 (6) Check for fuel pressure by pinching the fuel hose with
fingertips.
(7) Connect the fuel pump module connector.
(8) Install the hole cover (LHS).
(9) Install the rear seat cushion assembly (Refer to GROUP
52A, Rear Seat Assembly P.52A-55).
03DB150A
ON-VEHICLE SERVICE
MULTIPORT FUEL INJECTION (MPI) RELAY

CONTINUITY CHECK
M1131050000345
Inspect the MPI relay relay for continuity in accordance with the
chart shown below.
BATTERY TERMINAL NO. TERMINAL NO.
VOLTAGE TO BE TO BE
1 2 CONNECTED TO CONDUCTED
3 4 BATTERY
MPI RELAY Not supplied − 2−3

SIDE CONNECTOR
Supplied 2−3 1−4
MPI RELAY
SIDE CONNECTOR
1 2
3 4
03DB258A
FUEL PUMP RELAY CONTINUITY CHECK

M1131033000342
Inspect the fuel pump relay for continuity in accordance with
FUEL PUMP RELAY the chart shown below.
SIDE CONNECTOR
BATTERY TERMINAL NO. TERMINAL NO.
VOLTAGE TO BE TO BE
CONNECTED TO CONDUCTED
1 2 BATTERY
3 4
Not supplied − 2−3
Supplied 2−3 1−4
FUEL PUMP RELAY
SIDE CONNECTOR
1 2
3 4
AK302122 AB
ON-VEHICLE SERVICE
INTAKE AIR TEMPERATURE SENSOR CHECK

M1131002800557
1. Disconnect the mass airflow sensor connector.(Refer to
GROUP 15, Air Cleaner, Removal and Installation P.15-4)
SENSOR CONNECTOR 2. Measure resistance between terminals 1 and 3.
Standard value:
12.66 − 15.12 kΩ [at -20°C (-4°F)]
5.119 − 5.892 kΩ [at 0°C (32°F)]
2.290 − 2.551 kΩ [at 20°C (68°F)]
1.096 − 1.258 kΩ [at 40°C (104°F)]
0.565 − 0.654 kΩ [at 60°C (140°F)]
03DB158A 0.312 − 0.370 kΩ [at 80°C (176°F)]
3. If not within specifications, replace the mass airflow sensor.
4. Measure resistance while heating the sensor using a hair
dryer.
Normal condition:
TEMPERATURE RESISTANCE (kΩ)
Higher Smaller
5. If resistance does not decrease as heat increases, replace

the mass airflow sensor.
MASS AIRFLOW
SENSOR 03DB177A CAUTION
Do not remove Air Temperature Sensor unit from the
housing. If sensor is faulty replace complete Air Flow Sen-
sor assembly.
ENGINE COOLANT TEMPERATURE SENSOR

CHECK
M1131003100528
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)]
ON-VEHICLE SERVICE
3. If resistance deviates from the standard value greatly,

replace the sensor.
4. Apply 3M™ AAD part number 8731 or equivalent to threaded
portion.
5. Install the engine coolant temperature sensor and tighten it
Tightening torque: 18 to 25 N⋅m
AKX01623 AB
HEATED OXYGEN SENSOR CHECK

M1131005000691
• MB991824: V.C.I.
.

CAUTION
DATA LINK To prevent damage to diagnostic tool, always turn the igni-
CONNECTOR tion switch to the "LOCK" (OFF) position before connect-
2. Start the engine and run at idle.
3. Set the diagnostic tool to display the Data List for MPI.
Check the following items in the data list. Refer to Data List
MB991910 (1) Item AC: Right Bank Heated Oxygen Sensor (front).
(2) Item AD: Right Bank Heated Oxygen Sensor (rear).
MB991824 (3) Item AE: Left Bank Heated Oxygen Sensor (front).
(4) Item AF: Left Bank Heated Oxygen Sensor (rear).
MB991827 00DB076A
ON-VEHICLE SERVICE
4. Using diagnostic tool, observe HO2S reading. If values are

DATA LINK
CONNECTOR unsatisfactory, check for malfunctioning sensor or damaged
connector/wiring.
(1) Warm up the engine until engine coolant is 80°C (176°F)
or higher.
5. While repeatedly revving the engine, check each heated
oxygen sensor output voltage.
Standard value:
MB991910
ENGINE HEATED OXYGEN REMARKS
MB991824 SENSOR OUTPUT
VOLTAGE
When revving 0.6 − 1.0 V If you make the
engine air/fuel ratio rich by
revving the engine
repeatedly, a
normal heated
oxygen sensor will
MB991827 00DB076A output a voltage of
0.6 − 1.0 V.
6. If the output voltage for a sensor is not within the standard

SENSOR
HARNESS value:
CONNECTOR: (1) Turn "OFF" engine.
COMPONENT SIDE
(2) Disconnect the heated oxygen sensor connector and
2 1 measure the resistance between terminal No. 3 and No.
4 3 4 on heated oxygen sensor side.
(3) Make sure that there is a resisitance of: .
9.0 - 11.0 ohms at 20°C (68°F)⋅
(4) If the sensor voltage is unsatisfactory or the resistance of
03DB231A
heater is outside value, replace the heated oxygen
sensor.
NOTE: For removal and installation of the heated oxygen sen-
sor, refer to GROUP 15, Exhaust Pipe and Main Muffler
P.15-14.
ON-VEHICLE SERVICE
INJECTOR CHECK
M1131005200521
.
<Right bank side (number 1, 3, 5 cylinders)>

1. Disconnect the intermediate connector B-32.
2. Measure the resistance between the injector intermediate
B-32 connector terminals.
INTERMEDIATE
CONNECTOR Standard value:
1 2 3 4 5 INJECTOR NO. MEASUREMENT RESISTANCE
6 7 8 9 10 TERMINAL
NO.1 5−9 10.5 − 13.5 Ω [20°C
(68°F)]
NO.3 10 − 9
AK203093 AB NO.5 4−9
3. Connect the injector intermediate connector.

.
<Left bank side (number 2, 4, 6 cylinders)>

1. Disconnect the injector connector.
2. Measure the resistance between injector side connector
terminals 1 and 2.
3. Connect the injector connector.
AK000126
ON-VEHICLE SERVICE
THROTTLE ACTUATOR CONTROL MOTOR

CHECK
M1131051000070
.
<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
ment at any time. Do not under any circumstances activate the throttle plate by hand.
.
<Checking the Terminal Resistance>

1. Disconnect the throttle position sensor connector.
THROTTLE ACTUATOR
CONTROL MOTOR 2. Measure the resistance between terminal No. 1 and No. 4.
CONNECTOR
Standard value: 1.5Ω ± 0.3Ω
3. If resistance is outside the standard value, replace the
throttle body assembly.
03DB157A
EVAPORATIVE EMISSION PURGE SOLENOID

CHECK
M1131005600240
Refer to GROUP 17, Emission Control System − Evaporative
Emission System − Evaporative Emission Purge Solenoid
Check P.17-83.
INJECTOR
INJECTOR
M1131007100768

• Fuel Discharge Prevention (Refer to P.13A-663). • Intake Manifold Plenum Installation (Refer to GROUP 15,
• Intake Manifold Plenum Removal (Refer to GROUP 15, Intake Manifold Plenum P.15-5).
Intake Manifold Plenum P.15-5). • Fuel Leakage Inspection.
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
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
INJECTOR

.
<<A>> FUEL RAIL AND INJECTOR ASSEMBLY

REMOVAL
CAUTION
Do not drop the fuel injector.
Remove the fuel rail with the fuel injectors attached to it.

.
>>A<< O-RING/FUEL INJECTORS/FUEL

HIGH-PRESSURE HOSE CONNECTION (FUEL
RAIL SIDE) INSTALLATION
CAUTION
• Do not kink the fuel high-pressure hose as it is made of
plastics.
• Do not let the engine oil get into the fuel rail.
1. Apply a drop of new engine oil to the O-ring.
2. Turn the fuel injector to the right and left to install to the fuel
rail. Repeat for fuel damper and fuel high-pressure hose. Be
careful not to damage the O-ring. After installing, check that
they turn smoothly.
3. If some of them dose not turn smoothly, the O-ring may be
trapped, remove it, re-install it into the fuel rail and check
again.
4. Connect fuel hose to rail.
.
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.
MAIN PIPE NOZZLE OR

FUEL MAIN PIPE
AC209221AB
THROTTLE BODY ASSEMBLY
THROTTLE BODY ASSEMBLY

M1131007700652
WARNING
• 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

1. THROTTLE POSITION SENSOR 2. THROTTLE BODY
CONNECTOR >>A<< 3. THROTTLE BODY GASKET
ENGINE CONTROL UNIT (ECU)

.
>>A<<THROTTLE BODY GASKET INSTALLATION

CAUTION
Poor idling etc. may result if the throttle body gasket is
installed incorrectly.
Install the gasket as its protrusion is in the direction shown.
PROJECTION
03DB188A
ENGINE CONTROL UNIT (ECU)

M1131033400243
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

1. COVER 3. ECU MOUNTING BRACKET
2. ENGINE-ECU CONNECTOR 4. A/T ECU - A/T VEHICLE ONLY
SPECIFICATIONS
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
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
SPECIFICATIONS
M1131000300705
ITEMS STANDARD VALUE

Fuel pressure kPa (in.Hg) Approximately 324 (95.7) at curb
idle
Intake air temperature sensor resistance kΩ −20°C (−4°F) 12.66 − 15.12
0°C (32°F) 5.119 − 5.892
20°C (68°F) 2.290 − 2.5510
40°C (104°F) 1.096 − 1.238
60°C (140°F) 0.565 − 0.654
80°C (176°F) 0.312 − 0.370
Engine coolant temperature sensor −20°C (−4°F) 14.1 − 16.83
resistance kΩ 0°C (32°F) 5.47 − 6.33
20°C (68°F) 2.35 − 2.65
40°C (104°F) 1.12 − 1.23
60°C (140°F) 0.573 − 0.618
80°C (176°F) 0.313 − 0.332
Heated oxygen sensor output voltage V 0.6 − 1.0
Heated oxygen sensor heater resistance Ω <Front> 9.0 - 11.0 [at 20°C (68°F)]
<Rear> 9.0 - 11.0 [at 20°C (68°F)]
Heated oxygen sensor - Heater current A <2.1A
Injector coil resistance Ω 10.5 − 13.5 [at 20°C (68°F)]
Throttle actuator control motor coil resistance Ω 1.5 ± 0.3 [at 20°C (68°F)]
SEALANT AND ADHESIVE

M1131000500442

Engine coolant temperature sensor threaded portion 3M™ AAD part number 8731or equivalent
13A-678 MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE>
SPECIFICATIONS
NOTES
13A-680 MULTIPORT FUEL INJECTION (MPI) <3.8L ENGINE>
SPECIFICATIONS
HOME
13B-1
GROUP 13B
FUEL SUPPLY
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 13B-2 FUEL LEVEL SENSOR (SUB) REMOVAL . 13B-12

FUEL PUMP OPERATION CHECK . . . . . . 13B-6
FUEL SUPPLY DIAGNOSIS . . . . . . . 13B-2 FUEL PUMP MODULE REPLACEMENT . . 13B-6
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 13B-2
TROUBLESHOOTING STRATEGY . . . . . . 13B-2 FUEL TANK . . . . . . . . . . . . . . . . . . . . 13B-8
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 13B-2 REMOVAL AND INSTALLATION . . . . . . . . 13B-8
SYMPTOM PROCEDURES . . . . . . . . . . . . 13B-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 13B-14
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13B-5 SPECIFICATIONS . . . . . . . . . . . . . . . 13B-15

FASTENER TIGHTENING
ON-VEHICLE SERVICE. . . . . . . . . . . 13B-6 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 13B-15
FUEL LEVEL SENSOR CHECK . . . . . . . . . 13B-6 SERVICE SPECIFICATION . . . . . . . . . . . . 13B-15
FUEL SUPPLY 13B-2
GENERAL DESCRIPTION
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 LEVEL SENSOR (SUB)

CANISTER ASSY FUEL TANK
FUEL RAIL
FUEL PUMP MODULE

FUEL INJECTOR FUEL PIPE
03DB142A
FUEL SUPPLY DIAGNOSIS

INTRODUCTION
M1135004000388
The fuel system is used to supply an appropriate fuel Engine malfunctions caused by insufficient fuel sup-
mixture to the engine. The system consists of the ply and evaporative emission system operation mal-
fuel tank, fuel filter, fuel pump and fuel pipes. An functions can be caused by faults in the vapor line,
evaporative emission system is provided to prevent fuel pipe, hose, or fuel tank pressure control valve,
evaporated fuel from escaping into the atmosphere. etc.
M1135004100277
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 to find customer exists.
most of the fuel supply faults. 3. Find the malfunction by following the Symptom
1. Gather information from the customer. Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1135004200382
SYMPTOM INSPECTION PROCEDURE REFERENCE PAGE

Engine Malfunctions Due to Insufficient Fuel Supply 1 P.13B-3
FUEL SUPPLY 13B-3
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1 : Engine Malfunctions Due to Insufficient Fuel Supply
TROUBLESHOOTING HINTS (The most likely

causes for this case: )
• Injector failed.
• Open or shorted injector circuit, or loose connector.
• Bent, twisted or clogged fuel pipe or hose.
• Malfunction of the fuel pump module.
DIAGNOSIS
• MB991824: V.C.I.

code (DTC).
CAUTION
CONNECTOR
(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
(4) Connect special tool MB991910 to special tool MB991824.
MB991910
(5) Connect special tool MB991910 to the data link connector.
(6) Turn the power switch of special tool MB991824 to the "ON"
MB991824
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.
(9) Select "Interactive Diagnosis" from the start-up screen.
MB991827
(10)Select "System select."
00DB076A
(11)Choose "MFI" from the "POWER TRAIN" tab.
(12)Select "MITSUBISHI."
(13)Select "Diagnostic Trouble Code."
(14)If a DTC is set, it is shown.
Q: Is the DTC set?
YES : Refer to Diagnostic Trouble Code Chart. P.13A-17 .
NO : Turn the ignition switch to the "LOCK" (OFF) position,
and then remove diagnostic tool in the reverse order
of installation. Go to Step 2.
FUEL SUPPLY 13B-4

Release residual pressure from the fuel line to prevent fuel
spray. Refer to Fuel Pressure Test. P.13A-661 .
Q: Is the fuel pressure in good condition?
YES : Go to Step 5.
NO : Repair or replace. Then go to Step 3.
STEP 3. Check for bending, twisting or clogging of the fuel

pipe or hose.
Q: Are the fuel pipe and hose in good condition?
YES : Go to Step 4.
NO : Repair or replace. Then go to Step 6.
FUEL
HOSE
FUEL PIPE
AC307454AB
STEP 4. Check the fuel pump module operation.

Refer to Fuel Pump Operation Check.P.13A-664 .
Q: Is the fuel pump module operation in good condition?
NO : Replace (Refer to P.13B-8). Then go to Step 6.
STEP 5. Check the inside of the fuel tank for contamination

and rust.
(1) Drain fuel.
(2) Remove the fuel tank (Refer to P.13B-8).
Q: Is the fuel tank in good condition?
YES : Go to Step 6.
NO : Replace the fuel filter, and clean the fuel tank and fuel
line. Then go to Step 6.
STEP 6. Retest the system.

Q: Is the engine malfunction eliminated?
NO : Return to Step 1.
FUEL SUPPLY 13B-5
SPECIAL TOOLS
SPECIAL TOOLS
M1135000600300

NAME
MB991824-KIT Checking diagnostic trouble
A
A: MB991824 NOTE: G: codes
B: MB991827 MB991826 MUT-III CAUTION
C: MB991910 Trigger Harness is For vehicles with CAN
D: MB991911 not necessary communication, use MUT-III
MB991824
E: MB991914 when pushing main harness A to send
B F: MB991825 V.C.I. ENTER key. simulated vehicle speed. If
G: MB991826 you connect MUT-III main
MUT-III sub assembly harness B instead, the CAN
A: Vehicle communication does not
communication function correctly.
MB991827
interface (V.C.I.)
C
B: MUT-III USB cable
C: MUT-III main harness
A (Vehicles with CAN
communication
MB991910 system)
D D: MUT-III main harness
B (Vehicles without
DO NOT USE CAN communication
system)
E: MUT-III main harness
MB991911
E models only)
F: MUT-III measurement
DO NOT USE adapter
G: MUT-III trigger
MB991914 harness
F
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.
FUEL PUMP OPERATION CHECK

M1135001000152
: Refer to GROUP 13B - On-vehicle Service, Fuel Pump Oper-
ation Check P.13A-664.
FUEL PUMP MODULE REPLACEMENT

M1135004900314
1. Remove the rear seat cushion assembly. (Refer to GROUP
52A, Rear Seat Assembly P.52A-55.)
2. Remove the hole cover (LH).
HOLE COVER
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
5. Connect the suction hose to the fuel pump module, and

install the fuel pump module to the fuel tank whilst ensuring
FUEL PUMP that the suction hose is not kinked.
MODULE 6. Install the plate to the fuel tank.
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
8. Install the hole cover (LH).

9. Install the rear seat cushion assembly. (Refer to GROUP
03DB150A
FUEL SUPPLY 13B-8
FUEL TANK
FUEL TANK
M1135001900508
Pre-removal Operation Pre-installation Operation

• Draining Fuel • Center Exhaust Pipe Installation (Refer to GROUP 15
• Fuel Pump Connector Disconnection (How to Reduce P.15-14).
Fuel Pressure) (Refer to GROUP 13A - On-vehicle Ser- • Refilling Fuel
vice P.13A-663). • Checking for Fuel Leaks
• Center Exhaust Pipe Removal (Refer to GROUP 15
P.15-14).
1 7
3
9 10
11 12 5
6
26 ± 5 N·m
19 ± 4 ft-lb
4
11
4 03DB147A
FUEL TANK REMOVAL STEPS FUEL TANK REMOVAL STEPS

<<A>> 1. FUEL PUMP MODULE 7. FUEL TANK VAPOR HOSE
CONNECTOR CONNECTION CONNECTION
<> 3. FUEL LEVEL SENSOR (SUB) 9. FUEL FILLER HOSE
CONNECTOR CONNECTION CONNECTION
4. PARKING BRAKE CABLE CLAMP 10. FUEL LEVELING HOSE
CONNECTION CONNECTION
5. PARKING BRAKE CABLE CLAMP <<D>> >>D<< 11. FUEL TANK ASSEMBLY
CONNECTION <<D>> >>D<< 12. FUEL TANK BAND
<<C>> >>C<< 6. FUEL HIGH-PRESSURE HOSE
CONNECTION
FUEL SUPPLY 13B-9
FUEL TANK
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
FUEL TANK FILLER TUBE FUEL TANK FILLER TUBE

34. FUEL CAP 38. FUEL TANK FILLER TUBE
35. VAPOR HOSE CONNECTION 39. FUEL TANK FILLER TUBE
36. FUEL FILLER HOSE AND FUEL PACKING
TANK LEVELING HOSE
CONNECTION
37. FUEL TANK FILLER TUBE
PROTECTOR

.
<<A>> FUEL PUMP MODULE CONNECTOR CON-

NECTION REMOVAL
1. Remove the rear seat cushion assembly. (Refer to GROUP
2. Remove the hole cover (LH).
HOLE COVER
03DB150A
FUEL SUPPLY 13B-11
FUEL TANK
FUEL PUMP MODULE 3. Disconnect the fuel pump module connector.

CONNECTOR
FUEL HIGH-
PRESSURE HOSE
AC306090 AB
<> FUEL LEVEL SENSOR (SUB) CONNECTOR

CONNECTION REMOVAL
1. Remove the grommet and disconnect the fuel level sensor
FUEL LEVEL (sub) connector.
SENSOR (SUB)
GROMMET
03DB149A
<<C>> FUEL HIGH-PRESSURE HOSE

CONNECTION REMOVAL
CAUTION
As there will be some pressure remaining in the fuel pipe
line, cover it with a shop towel to prevent fuel from spray-
ing out.
.
<<D>> FUEL TANK ASSEMBLY/FUEL TANK BAND

REMOVAL
1. Support the fuel tank with a transaxle jack.
2. Remove the fuel tank band and fuel tank assembly as
follows.
(1) Remove the front securing nut of the fuel tank band.
(2) Tilt the fuel tank assembly forward and lower it gradually
to remove it.
(3) Remove the fuel tank band.
.
FUEL SUPPLY 13B-12
FUEL TANK
<<E>> FUEL PUMP MODULE REMOVAL

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
FLOAT
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
<<F>> FUEL LEVEL SENSOR (SUB) REMOVAL

CAUTION
When withdrawing the fuel level sensor (sub) from the fuel
tank, be careful not to damage the sensor unit and the
float.
1.Remove the fuel level sensor (sub) mounting bolts and
remove the fuel tank gauge unit from the tank hole.
FUEL LEVEL FLOAT
SENSOR (SUB)
AC307206AB
FUEL SUPPLY 13B-13
FUEL TANK

.
>>A<< FUEL LEVEL SENSOR (SUB) INSTALLA-

TION
CAUTION
When inserting the fuel level sensor (sub) into the fuel
tank, be careful not to damage the sensor unit and the
float.
1. Install the fuel level sensor to the fuel tank hole.
FUEL LEVEL FLOAT

SENSOR (SUB)
AC307206AB
>>B<< FUEL PUMP MODULE INSTALLATION

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
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
.
FUEL SUPPLY 13B-14
FUEL TANK
>>C<< FUEL HIGH-PRESSURE HOSE/FUEL

HIGH-PRESSURE HOSE CONNECTION
INSTALLATION
CAUTION
Connect the fuel high-pressure hose, and then pull it gen-
CONNECTOR tly in the direction of removal to check that the hose is
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.
MAIN PIPE NOZZLE OR

FUEL MAIN PIPE
AC209221AB
>>D<< FUEL TANK BAND/FUEL TANK ASSEMBLY

INSTALLATION
1. Raise the fuel tank assembly carefully with a transaxle jack.
2. Ensure that the fuel tank assembly does not interfere with
surrounding parts. Then install the fuel tank band and
tighten the mounting nuts to the specified torque.
3. Again, ensure that the fuel tank assembly does not interfere
with surrounding components. If the fuel tank assembly
interferes surrounding components, remove the fuel tank
assembly and the tank band and reinstall them.
INSPECTION
M1135002000241
.
FUEL SHUT-OFF VALVE CHECK

FLAPPER Check that the flapper of the fuel shut-off valve opens and
closes as shown in the illustration.
OPEN
80°
CLOSED
AC005004A
03DB148A
FUEL SUPPLY 13B-15
SPECIFICATIONS
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
ITEM STANDARD VALUE

NOTES
HOME
13C-1
GROUP 13C
TRACTION
CONTROL SYSTEM
(TCL)
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 13C-2 RESISTANCE AND CONTINUITY

BETWEEN ABS-ECU AND WHEEL SPEED
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-39
TRACTION CONTROL SYSTEM (TCL)
VOLTAGE AND SIGNAL CHECK AT
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 13C-3
ABS-ECU USING AN OSCILLOSCOPE . . . 13C-41
INTRODUCTION TO TRACTION CONTROL
SYSTEM (TCL) DIAGNOSIS . . . . . . . . . . . 13C-3
SPECIAL TOOLS . . . . . . . . . . . . . . . . 13C-45
TROUBLESHOOTING STRATEGY . . . . . . 13C-3
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 13C-3
ON-VEHICLE SERVICE . . . . . . . . . . . 13C-47
DIAGNOSTIC TROUBLE CODE CHART . . 13C-8
TCL INDICATOR LIGHT CHECK . . . . . . . . 13C-47
DIAGNOSTIC TROUBLE CODE
TCL OPERATION CHECK . . . . . . . . . . . . . 13C-47
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 13C-10
TCL SWITCH CHECK . . . . . . . . . . . . . . . . . 13C-48
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 13C-23
WHEEL SPEED SENSOR CHECK . . . . . . . 13C-48
SYMPTOM PROCEDURES . . . . . . . . . . . . 13C-23
DATA LIST REFERENCE TABLE . . . . . . . 13C-36
TCL SWITCH . . . . . . . . . . . . . . . . . . . 13C-49
ACTUATOR TEST REFERENCE TABLE. . 13C-37
REMOVAL AND INSTALLATION . . . . . . . . 13C-49
CHECK AT ABS/TCL-ECU RESISTANCE
AND TERMINAL VOLTAGE . . . . . . . . . . . . 13C-38
WHEEL SPEED SENSOR . . . . . . . . . 13C-49
ABS/TCL-ECU . . . . . . . . . . . . . . . . . . 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
and retard ignition to one or more cylinders depend-
WHEEL SPEED SENSOR
HYDRAULIC UNIT
ASSEMBLY
(BUILT-IN ABS/TCL-ECU)
ENGINE
ECU
WHEEL SPEED SENSOR
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) DIAGNOSIS

INTRODUCTION TO TRACTION CONTROL SYSTEM (TCL) DIAGNOSIS
M1136004600026
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
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

(MUT-III)
CAUTION
MB991958.
position.
MB991910 and the personal computer.
MB991824 5. Connect special tool MB991910 to the data link connector.
position.
color.
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.

TROUBLE CODES
• MB991824: V.C.I.
CAUTION
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
MB991824 3. Select "Interactive Diagnosis" from the start-up screen.
4. Select "System Select".
5. Choose "TCL" .
6. Select "Diagnostic Trouble Code".
8. Choose "DTC erase" to erase the DTC.
MB991827 00DB076A 10.Disconnect diagnostic tool MB991958.

• MB991824: V.C.I.
CAUTION
MB991958.
connector.
3. Select "Interactive Diagnosis" from the start-up screen.
MB991910 4. Select "System Select."
5. Choose "TCL" .
MB991824 6. Select "Data List."
7. Choose an appropriate item.
9. Disconnect diagnostic tool MB991958.
MB991827 00DB076A

• MB991824: V.C.I.
CAUTION
MB991958.
connector.
5. Choose "TCL" .
MB991824 6. Choose "Actuator Test" from "TCL" screen.
MB991827 00DB076A
HOW TO DIAGNOSE THE CAN BUS LINE

• MB991824: V.C.I.
CAUTION
MB991958.
connector.
3. Select the "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
MB991824 diagnosed.
• 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.
MB991827 00DB076A • If not, go to step 5.
8. Press the "OK" button.
"OK" button.
10.Turn the ignition switch to the "LOCK" (OFF) position.
11.Disconnect diagnostic tool MB991958.

M1136003300022
CAUTION Follow the inspection chart that is appropriate for the

During diagnosis, a DTC associated with other diagnostic trouble code.
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.
NOTE: If the ABS-8 ECU or the active wheel
speed sensor are disconnected, or if the wiring is
an open/ short circuit, the ABS 8 ECU will shut
off power supply to the respective wheel speed
sensor. All other wheel speed sensors will oper-
ate normally. To restore the power supply, the
ignition switch must be turned to the "OFF" posi-
tion then to the "ON" position again.
DTC INSPECTION ITEM DIAGNOSTIC CONTENT REFERENCE PAGE
C1200 Front right wheel speed sensor Open circuit or short circuit GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1200 P.35B-10
C1201 Front right wheel speed sensor Abnormal output signal GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1201 P.35B-26
C1205 Front left wheel speed sensor Open circuit or short circuit GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1205 P.35B-10
C1206 Front left wheel speed sensor Abnormal output signal GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1206 P.35B-26
C1210 Rear right wheel speed sensor Open circuit or short circuit GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1210 P.35B-10
C1211 Rear right wheel speed sensor Abnormal output signal GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1211 P.35B-26
C1215 Rear left wheel speed sensor Open circuit or short circuit GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1215 P.35B-10

C1216 Rear left wheel speed sensor Abnormal output signal GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1216 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 solenoid inlet valve -
C1231* ABS front right solenoid outlet valve -
C1236* ABS front left solenoid valve inlet valve -
C1241* ABS front left solenoid valve outlet valve -
C1246* ABS rear right solenoid valve inlet valve -
C1251* ABS rear right solenoid valve outlet valve -
C1256* ABS rear left solenoid valve inlet valve -
C1261* ABS rear left solenoid valve outlet valve -
C1266* ABS hydraulic unit motor stuck -
C1273* ABS hydraulic unit motor drive circuit stuck off -
C1274* ABS hydraulic unit motor drive circuit stuck on -
C1276* ABS valve relay malfunction -
C1278* ABS solenoid valve power circuit stuck off -
C1279* ABS solenoid valve power circuit stuck on -
C1607 ABS/TCL-ECU failure GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1607 P.35B-62
C1640 Variant code value not valid. (TCL only) Incorrect code
programmed into
ABS-ECU. Replace
ABS-ECU modulator.
C1860 ABS/TCL-ECU power supply Abnormal rise in voltage GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1860 P.35B-63
C1861 ABS/TCL-ECU power supply Abnormal drop in voltage GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
C1861 P.35B-63

U1073 CAN communications system bus off GROUP 35B, ABS
Diagnosis −
Diagnostic Trouble
Code Procedures
U1073 P.35B-68
U1100 CAN communications system time out error engine related data P.13C-10
U1101 CAN communications system time out error A/T related data P.13C-14
U1400 Dynamic range error APS1 P.13C-22
U1415 CAN invalid signal Gear Position GROUP 23A
Diagnostic Trouble
Code Chart P.23A-34
NOTE: Since the TCL is controlled with the same ABS/TCL-ECU used to control the ABS, the codes (with a
*) used only for the ABS also appear.
The inspection contents for the codes (with a *) used only for the ABS do not described in this group.
U1100 CAN Communications System Time Out Error Engine Related Data
CAUTION DTC SET CONDITION

• If DTC U1100 is set in the ABS/TCL-ECU, The ABS/TCL-ECU receives engine system-related
always diagnose the CAN main bus line. If signals from the ENGINE-ECU via CAN bus lines.
there is any fault in the CAN bus lines, an
incorrect DTC may be set. .
TROUBLESHOOTING HINTS (THE MOST

• Whenever the ABS/TCL-ECU is replaced,
ensure that the communication circuit is nor- LIKELY CAUSES FOR THESE DTCS ARE
mal. TO SET ARE:)
NOTE: If the ABS-8 ECU or the active wheel • Damaged harness or connector.
speed sensor are disconnected, or if the wiring is • Malfunction of the ENGINE-ECU.
an open/ short circuit, the ABS 8 ECU will shut • Malfunction of the ABS/TCL-ECU.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool MB991958, diagnose the

CAN bus line.
CAUTION
MB991958.
connector. (Refer to P.13C-3).
(3) Diagnose the CAN bus line. (Refer to P.13C-3).
MB991910 (5) Disconnect diagnostic tool MB991958.
Q: Is the CAN bus line found to be normal?
MB991824
YES : Go to Step 2.
NO : Repair the CAN bus line. (Refer to GROUP 54C,
Diagnosis − Can Bus Diagnostic Chart P.54C-15).
Then go to Step 6.
MB991827 00DB076A
STEP 2. Using diagnostic tool MB991958, read the

diagnostic trouble code.
CAUTION
MB991958.
(3) Check for MPI system diagnostic trouble code. (Refer to
GROUP 13A, MPI Diagnosis − Diagnostic Function − How
MB991910 to Read and Erase Diagnostic Trouble Code P.13A-6).
Q: Is any DTC set?
YES : Repair the MPI control system. (Refer to GROUP
13A, MPI Diagnosis − Diagnostic Trouble Code Chart
P.13A-17). Then go to Step 6.
NO : Go to Step 3.
MB991827 00DB076A

CAUTION
MB991958.
(3) Check if a DTC, which relates to CAN
communication-linked systems below, is set.
MB991910 ETACS-ECU
• DTC (U1100): ENGINE-ECU time-out (related to
MB991824 engine). (Refer to GROUP 54B, SWS Diagnosis −
General Description − Diagnostic Function − How to
Read and Erase Diagnostic Trouble Code
P.54B-10).
Combination meter
engine). (Refer to GROUP 54A, Combination Meter
Assembly Diagnosis − Diagnosis Function − How to
MB991827 00DB076A Read and Erase Diagnostic Trouble Code
P.54A-46).
Multi-center display
engine). (Refer to GROUP 54A, Multi-center Display
− Diagnosis Function − How to Read and Erase
Diagnostic Trouble Code P.54A-251).
A/C-ECU
engine). (Refer to GROUP 55, Auto A/C Diagnosis −
Diagnostic Function − How to Read and Erase Diag-
nostic Trouble Code P.55-6) <Vehicle with auto
A/C>.
(5) Disconnect diagnostic tool MB991958.
Q: Is DTC (U1100) set?
YES : Go to Step 4.
NO : Go to Step 5.

CAUTION
MB991958.
(3) Use diagnostic tool MB991958 to read the TCL diagnostic
trouble codes. (Refer to P.13C-3).
MB991824
YES : Replace the Engine-ECU. [Refer to GROUP 13A,
Engine-ECU P.13A-675]. Then go to Step 6.
(Refer to GROUP 00, How to Use
Cope with Intermittent Malfunction P.00-14).
MB991827 00DB076A

CAUTION
MB991958.
MB991824
YES : Replace the hydraulic unit (integrated with
ABS/TCL-ECU). (Refer to GROUP 35B − Hydraulic
Unit P.35B-93). Then go to Step 6.
MB991827 00DB076A

CAUTION
MB991958.
MB991824
YES : Return to Step 1.
MB991827 00DB076A
U1101 CAN Communications System Time Out Error A/T Related Data

• If DTC U1101 is set in the ABS/TCL-ECU, The ABS/TCL-ECU receives A/T system-related sig-
always diagnose the CAN main bus line. If nals from the A/T-ECU via CAN bus lines.
there is any fault in the CAN bus lines, an
incorrect DTC may be set. .

ensure that the communication circuit is nor- LIKELY CAUSES FOR THESE DTCS ARE
mal. TO SET ARE:)
NOTE: If the ABS-8 ECU or the active wheel • Damaged harness or connector.
speed sensor are disconnected, or if the wiring is • Malfunction of the A/T-ECU.
an open/ short circuit, the ABS 8 ECU will shut • Malfunction of the ABS/TCL-ECU.
DIAGNOSIS
• MB991824: V.C.I.

CAN bus line.
CAUTION
MB991958.
MB991824
YES : Go to Step 2.
NO : Repair the CAN bus lines. (Refer to GROUP 54C,
Then go to Step 6.
MB991827 00DB076A

CAUTION
MB991958.
(3) Check for A/T system diagnostic trouble code. (Refer to
GROUP 23A, A/T Diagnosis − Diagnostic Function − How
Q: Is any DTC set?
YES : Repair the automatic transaxle control system. (Refer
to GROUP 23A, A/T Diagnosis − Diagnostic Trouble
Code Chart P.23A-34). Then go to Step 6.
NO : Go to Step 3.
MB991827 00DB076A

CAUTION
MB991958.
MB991910 ETACS-ECU
• DTC (U1101): A/T-ECU time-out (related to A/T).
MB991824 (Refer to GROUP 54B, SWS Diagnosis − General
Description − Diagnostic Function − How to Read
and Erase Diagnostic Trouble Code P.54B-10).
Combination meter
(Refer to GROUP 54A, Combination Meter Assem-
bly Diagnosis − Diagnosis Function − How to Read
and Erase Diagnostic Trouble Code P.54A-46).
MB991827 00DB076A Multi-center display
(Refer to GROUP 54A, Multi-center Display − Diag-
nosis Function − How to Read and Erase Diagnostic
Trouble Code P.54A-251).
YES : Go to Step 4.
NO : Go to Step 5.

CAUTION
MB991958.
MB991824
MB991827 00DB076A

CAUTION
MB991958.
MB991824
MB991827 00DB076A

CAUTION
MB991958.
MB991824
MB991827 00DB076A
U1120 CAN Communications System TCL Uncontrollable by Engine Malfunction

• If DTC U1120 is set in the ABS/TCL-ECU, The ABS/TCL-ECU receives engine system-related
always diagnose the CAN main bus line. If signals from the Engine-ECU via CAN bus lines. If a
there is any fault in the CAN bus lines, an fail-safe related data is contained in the signal from
incorrect DTC may be set. the Engine-ECU, DTC U1120 will be stored.
ensure that the communication circuit is nor-
.

mal.
• The engine control system-related DTC may LIKELY CAUSES FOR THESE DTCS ARE
be set when DTC U1120 is set. (For details TO SET ARE:)
refer to GROUP 00, Intersystem Affiliated DTC • Damaged harness or connector.
Reference Table P.00-17). Diagnose the • Malfunction of the Engine-ECU.
engine control system first when the engine • Malfunction of the ABS/TCL-ECU.
control system-related DTC is set.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
MB991958.
Q: Is any DTC set?
YES : Repair the MPI control system. (Refer to GROUP
13A, MPI Diagnosis − Diagnostic Trouble Code Chart
NO : Go to Step 2.
MB991827 00DB076A

CAN bus line.
CAUTION
MB991958.
MB991824
YES : Go to Step 3.
Then go to Step 6.
MB991827 00DB076A

CAUTION
MB991958.
MB991910 A/C-ECU
• DTC U1120: Failure Information on Engine-ECU
MB991824 (related to engine). (Refer to GROUP 55, Auto A/C
Diagnosis − Diagnostic Function − How to Read and
Erase Diagnostic Trouble Code P.55-6).
YES : Go to Step 4.
NO : Go to Step 5.
MB991827 00DB076A

CAUTION
MB991958.
MB991824
MB991827 00DB076A

CAUTION
MB991958.
MB991824
MB991827 00DB076A

CAUTION
MB991958.
MB991824
MB991827 00DB076A
U1400 Dynamic range error APS1

.
DTC SET CONDITION

This code is set when the MPI system sets either of LIKELY CAUSES FOR THESE DTCS ARE
DTCs P2138, P2122 or P2123. TO SET ARE:)
.
• Malfunction of the MPI system
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).
SYMPTOM CHART
M1136003400029
SYMPTOM INSPECTION REFERENCE

PROCEDURE NO. PAGE
Communication with Communication with all systems is - Group 13A, MPI
diagnostic tool is not impossible Diagnosis −
possible Symptom
Procedures −
Inspection
Procedure 1
P.13A-539.
Communication with the ABS/TCL-ECU - Group 35B, ABS
only is impossible Diagnosis −
Symptom
Procedures −
Inspection
Procedure 1
P.35B-72.
When the ignition switch is turned to the "ON" position (engine 1 P.13C-23
stopped), the "TCL OFF" indicator light dose not illuminate.
When the ignition switch is turned to the "ON" position (engine 2
stopped), the TCL work indicator light does not illuminate.
The "TCL OFF" indicator light remains illuminated after the engine 3
is started.
The TCL work indicator light remains illuminated after the engine 4
is started.
When the TCL switch is push on, TCL does not be cancelled. 5 P.13C-28
TCL dose not operate. 6 P.13C-34
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.
CONNECTOR: A-02 CONNECTORS: C-02, C-29, C-101

A-02 (GR)
C-101
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
CONNECTORS: C-211, C-215
C-211 HARNESS CONNECTOR:

COMPONENT SIDE
C-215 HARNESS CONNECTOR:

COMPONENT SIDE
17DB047A
• ABS/TCL-ECU send the illumination signal of

.
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.
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
.
COMMENT TROUBLESHOOTING HINTS

This may be caused by faults in the CAN bus line, • Malfunction of the combination meter.
the combination meter or the ABS/TCL-ECU. • Damaged harness or connector.
.
• Malfunction of the ABS/TCL-ECU.
DIAGNOSIS
• MB991824: V.C.I.

CAN bus line.
CAUTION
MB991958.
Q: Is the check result satisfactory?
MB991824
YES : Go to Step 2
Then go to Step 4.
MB991827 00DB076A

CAUTION
MB991958.
MB991824
Q: Is any DTC set?
YES : Refer to P.13C-8, Diagnostic Trouble Code Chart.
Then go to Step 4.
NO : Go to Step 3.
MB991827 00DB076A

CAUTION
MB991958.
connector. (Refer to P.17-11).
(3) Check for Combination meter system diagnostic trouble
code. (Refer to GROUP 54A, Combination Meter Assembly
MB991910 Diagnosis − Diagnosis Function − How to Read and Erase
Diagnostic Trouble Code P.54A-46).
NO : Replace the combination meter assembly. (Refer to
GROUP 54A − Combination Meter Assembly
MB991827 00DB076A
STEP 4. Retest the system

Q: Turn the ignition switch to the "ON" position. Do the
"TCL OFF" indicator light and the TCL work indicator
light illuminate for three seconds, and then go out after
the engine starts?
NO : . Return to Step 1.
INSPECTION PROCEDURE 5: When the TCL Switch is Pushed On, TCL does not Cancel.
CONNECTOR: A-02 CONNECTORS: C-29, C-131

A-02 (GR)
C-29
C-131(GR)
C-29 MALE SIDE

CONNECTOR
C-131 HARNESS
CONNECTOR:
COMPONENT SIDE
16DB402A 35DB115A

.

COMMENT
an open/ short circuit, the ABS 8 ECU will shut The cause is probably an open-circuit in the TCL
off power supply to the respective wheel speed switch circuit.
sensor. All other wheel speed sensors will oper- .
ate normally. To restore the power supply, the TROUBLESHOOTING HINTS

ignition switch must be turned to the "OFF" posi- • Malfunction of the TCL switch.
tion then to the "ON" position again. • Damaged harness or connector.
.

CIRCUIT OPERATION
ABS/TCL-ECU terminal 21 is grounded every time
the TCL switch is pressed. ABS/TCL-ECU monitors
this operation state and turns the TCL ON or OFF.
DIAGNOSIS
• MB991223: Harness Set
• MB991219: Inspection Test Harness
STEP 1. Measure the resistance at ABS/TCL-ECU

connector A-02.
(1) Disconnect the ABS/TCL-ECU connector A-02.
CONNECTOR: A-02
A-02 (GR)
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.
35DB119A
• 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.
(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.
STEP 2. Check the TCL switch.

(1) Remove the TCL switch. (Refer to P.13C-49).
(2) Connect an ohmmeter to the TCL switch between terminals
1 and 2.
C-131 TCL SWITCH (3) Check for continuity between terminals 1 and 2 when the
CONNECTOR
TCL switch is operated.
• There is no continuity between terminals 1 and 2 when
the TCL switch is not pressed.
• There is continuity between terminals 1 and 2 when the
TCL switch is pressed.
Q: Is there no continuity between terminals 1 and 2 when
AC307176AB the TCL switch is not pressed, and is there continuity
when the TCL switch is pressed?
YES : Install the TCL switch. (Refer to P.13C-49). Then go
to Step 3.
NO : Replace the TCL switch. (Refer to P.13C-49). Then
go to Step 7.
STEP 3. Check ABS/TCL-ECU connector A-02,

intermediate connector C-29 and TCL switch connectors
C-131 for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
CONNECTOR: A-02
Q: Are there connectors and terminals in good condition?
A-02 (GR) YES : Go to Step 4.
NO : Repair or replace the faulty connector. (Refer to
P.00E-2). Then go to Step 7.
16DB402A
C-29
C-131(GR)
C-29 MALE SIDE

CONNECTOR
C-131 HARNESS
CONNECTOR:
COMPONENT SIDE
35DB115A
STEP 4. Check the harness wire between ABS/TCL-ECU

connector A-02 terminal 21 and TCL switch connector
C-131 terminal 1 for damage.
CONNECTOR: A-02
Q: Are there harness wires in good condition?
A-02 (GR) YES : Go to Step 5.
NO : Repair the damaged harness wire. Then go to Step 7.
16DB402A
CONNECTOR: C-131
C-131(GR)
C-131 HARNESS
CONNECTOR:
COMPONENT SIDE
35DB116A
STEP 5. Check the harness wire between TCL switch

connector C-131 terminal 2 and ground for damage.
CONNECTOR: C-131 Q: Is the harness wire in good condition?
YES : Go to Step 6.
C-131(GR)
C-131 HARNESS
CONNECTOR:
COMPONENT SIDE
35DB116A
COMBINATION METER
CONNECTOR
GROUND
TERMINAL
35DB117A

Q: Does TCL system cancel, when the TCL switch is
pushed on?
NO : Replace the hydraulic unit (integrated with

Q: Does TCL system cancel, when the TCL switch is
pushed on?
INSPECTION PROCEDURE 6: TCL does not Operate.
NOTE: If the ABS-8 ECU or the active wheel COMMENT

speed sensor are disconnected, or if the wiring is The fail-safe function is probably cancelling TCL. In
an open/ short circuit, the ABS 8 ECU will shut this case, diagnostic tool MB991958 can be used to
off power supply to the respective wheel speed retest each system by checking the diagnostic trou-
sensor. All other wheel speed sensors will oper- ble codes.
.

. LIKELY CAUSES FOR THIS CASE:)
• Malfunction of the CAN bus line.
• Malfunction of the MPI system.
• Malfunction of the A/T system.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
MB991958.
MB991824
Q: Is any DTC set?
YES : Repair the TCL. (Refer to P.13C-8, Diagnostic
Trouble Code Chart). Then go to Step 4.
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Using diagnostic tool MB991958, check TCL

actuator test item09: Engine TCL Drive.
CAUTION
MB991958.
CAUTION
The engine speed increases after the actuator test
MB991910
because the actuator test continues for only three sec-
onds. Therefore, release the accelerator pedal immedi-
MB991824
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 prevents the engine speed from rising for
MB991827 00DB076A three seconds.
Q: Are the check results for actuator test item 09
satisfactory?
YES : Go to Step 3.

Q: Does the TCL work normally?

Q: Does the TCL work normally?

M1136003500071
NOTE: If the ABS-8 ECU or the active wheel The following items can be read by the diagnostic
speed sensor are disconnected, or if the wiring is tool from the ABS/TCL-ECU input data. (Refer to
an open/ short circuit, the ABS 8 ECU will shut P.13C-3).
MUT-III ITEM CHECK ITEM CHECKING REQUIREMENTS NORMAL
DIAGNOSTI NO. VALUE
C TOOL
DISPLAY
FL wheel 01 Front left wheel speed sensor Drive the vehicle Vehicle speeds
speed sensor displayed on the
FR wheel 02 Front right wheel speed sensor speedometer
speed sensor and diagnostic
tool are identical.
RL wheel 03 Rear left wheel speed sensor
speed sensor
RR wheel 04 Rear right left wheel speed
speed sensor sensor
Power supply 05 ABS/TCL-ECU power supply Ignition switch power supply Battery positive
voltage voltage voltage voltage
Stoplamp 06 Stoplamp switch Depress the brake pedal. ON
switch Release the brake pedal. OFF
(input)*
Stoplamp 13 Stoplamp switch Depress the brake pedal. ON
switch* Release the brake pedal. OFF
Pump motor 21 Pump motor When the ABS outputs the ON
operation permission signal
during driving
When the ABS outputs the OFF
during driving
Valve relay 30 Valve relay When the ABS outputs the ON
during driving
during driving
TCL mode 35 TCL operation When the TCL outputs the ON
during driving
When the TCL outputs the OFF
operation inhibition signal
during driving
NOTE: Since the TCL is controlled with the same ABS/TCL-ECU used to control the ABS, the stoplight switch
check item (No.6) used only for the ABS also appear.

M1136003600067
NOTE: If the ABS-8 ECU or the active wheel The diagnostic tool activates the following actuators
speed sensor are disconnected, or if the wiring is for testing. (Refer to P.13C-3).
MUT-III ITEM NO. CHECK ITEM PARTS TO BE ACTIVATED
DIAGNOSTIC TOOL
DISPLAY
FL wheel ABS Drive* 01 Solenoid valve for front left wheel Solenoid valves and pump
FR wheel ABS Drive* 02 Solenoid valve for front right wheel motors in the hydraulic unit
(simple inspection mode)
RL wheel ABS Drive* 03 Solenoid valve for rear left wheel
RR wheel ABS 04 Solenoid valve for rear right wheel
Drive*
Engine TCL Drive 09 TCL operation check Outputs the engine torque
control signal (engine torque =
0) to PCM for three seconds.
NOTE: Since the TCL is controlled with the same ABS/TCL-ECU used to control the ABS, the FL, FR, RL or
RR Wheel ABS Drive testing items (No.01 to 04) used only for the ABS also appear.
CHECK AT ABS/TCL-ECU CONNECTOR: A-02

RESISTANCE AND TERMINAL VOLTAGE
M1136003800072
RESISTANCE AND TERMINAL VOLTAGE CHECK

CHART
.

MB991219: Inspection Test Harness
MB991223: Harness Set
CONNECTOR: A-02
1. Disconnect the ABS/TCL-ECU connector A-02.
A-02 (GR) 2. Measure the resistance and terminal voltage at the
ABS/TCL-ECU wiring harness-side connector A-02 using
the Inspection test harness MB991219 (by inserting probe)
between terminals shown in the table below 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.
3. The terminal layouts are shown in the illustrations below.
16DB402A
CONNECTOR SIGNAL CHECKING REQUIREMENT NORMAL

TERMINAL NO CONDITION
21 TCL switch Ignition When the TCL switch is not More than 2 ohms
switch: "ON" pressed. (open circuit)
When the TCL switch is Less than 2 ohms
pressed.
18 ABS/TCL-ECU power Ignition switch: "ON" Battery positive
supply voltage
Ignition switch: "START" 1 V or less
RESISTANCE AND CONTINUITY BETWEEN

ABS-ECU AND WHEEL SPEED SENSOR
HARNESS-SIDE CONNECTOR TERMINALS
.

MB991223: Harness Set
Wheel speed ABS-ECU

sensor connectors: CONNECTOR
A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
WHEEL SPEED 5, 10, 17, 19
SENSOR
35DB123A
1. Disconnect the ABS/TCL-ECU connector A-02 and the

related wheel speed sensor connector, then turn the ignition
switch to the "LOCK" (OFF) position.
2. Measure the resistance and continuity between the
ABS/TCL-ECU wiring harness-side connector A-02 and the
Wheel Speed Sensor connectors using the Inspection test
harness MB991219 (by inserting probe) and an ohmmeter
between terminals shown in the table below.
defective contact.
3. The terminal layout is shown in the table below.
SIGNAL TERMINAL NO. NORMAL CONDITION

ABS (A-02) SENSOR
FR wheel speed sensor 9 2 Less than 2 ohms
(A-01)
10 1 Less than 2 ohms
RR wheel speed sensor 8 1 Less than 2 ohms
(D-30)
FL wheel speed sensor 16 2 Less than 2 ohms
(A-04)
RL wheel speed sensor 6 1 Less than 2 ohms
(D-31)
VOLTAGE AND SIGNAL CHECK AT ABS-ECU

(A-02) USING OSCILLOSCOPE
NOTE: If the ABS-8 ECU or the active wheel speed
.
sensor are disconnected, or if the wiring is an open/

WHEEL SPEED SENSOR AIR GAP:
short circuit, the ABS 8 ECU will shut off power sup- • Sensor air gap: (0.2mm - 0.85mm).
ply to the respective wheel speed sensor. All other
wheel speed 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.
.
Measure supply voltage for wheel speed sensor using an

oscilloscope.
(1) ABS-ECU must remain connected.
(2) Wheel speed sensors must emain connected
(3) Remove ABS connector protection cap to access terminal
location from the rear of connector for back-probing.
(4) Using probe (MB991222) , backprobe the wheel speed
sensor voltage supply circuit terminals (16, 9, 6 and 8) at
the ABS-ECU connector (A-02) individually.
(5) Connect oscilloscope (as per figure 1) shows, to the
appropriate terminal positions and check supply voltage
individually with scope.
11-12V FIGURE 1
OSCILLOSCOPE
Black Red
Ground
Terminals:
16, 9, 6, 8
Supply
Signal
WHEEL SPEED
SENSOR
Wheel speed sensor connectors: ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
35DB121A
• Connect oscilloscope to FL sensor signal terminal (16)

at ABS-ECU (A-02)
• Connect oscilloscope to FR sensor signal terminal (9) at
ABS-ECU (A-02)
• Connect oscilloscope to RL sensor signal terminal (6) at
ABS-ECU (A-02)
• Connect oscilloscope to RR sensor signal terminal (8) at
ABS-ECU (A-02)
(7) The recommended Supply Voltage at terminals 16, 9, 6,

and 8 are:
• Set value: 10.0Volts - 14.5Volts
Q: Is the supply voltage within the set value?
YES : Check wheel speed sensor signal at ABS-ECU using
an oscillopscope
NO : • Refer to Power supply systemP.35B-63
• Refer to Motor supply systemP.35B-48
• Refer to Valve relay systemP.35B-56
Measure wheel speed sensor signals using an

oscilloscope.
NOTE: To check connections of the wheel speed sensors,
remove the rear seat to access the rear wheel speed sen-
sor connectors, and remove inner front guard (splash
shield) to access the front wheel speed sensors.
(1) Wheel speed sensor must remain connected to measure
active sensor.
(4) Using probe (MB991222), backprobe the wheel speed
sensor signal circuit terminals (5, 10, 17, 19), and check
individually at the ABS-ECU connector A-02
(5) The wheel to be tested must be free to turn by hand or be
driven by brake dynamometer
appropriate terminal positions and check sensor operation
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
• Connect oscilloscope to FL sensor signal terminal (5) at

ABS-ECU (A-02)
• Connect oscilloscope to FR sensor signal terminal (10)
at ABS-ECU (A-02)
• Connect oscilloscope to RL sensor signal terminal (17)
at ABS-ECU (A-02)
• Connect oscilloscope to RR sensor signal terminal (19)
at ABS-ECU (A-02)
(7) Recommended Oscilloscope setting:
• Y-axis: 2Volts
• X-axis: 100ms
(9) Turn wheel by hand at approximately 1 revolution per
second (r/sec) or drive on brake dynamometer at 5km/h.
The measurement reading of the active wheel speed sen-
sors on the oscilloscope should correspond to figure 3
below.
Test Procedure: Universal Oscilloscope FIGURE 3

U-CH1
V
1.50
1.00
0.50
0.00
0 20 40 60 80 100
ms
35DB120A
NOTE: If the oscilloscope signal shape is correct and wheel

sensor air gap is within specification, but the voltage values are
either higher or lower as shown in the table below, the wheel
speed sensor must be changed.
SPECIAL TOOLS
SPECIAL TOOLS
M1136000600024
TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION

MB991958 MB991824-KIT Checking diagnostic
A
A: MB991824 NOTE: G: MB991826 trouble codes
B: MB991827 MUT-III trigger CAUTION
C: MB991910 harness is not For vehicles with CAN
D: MB991911 necessary when communication, use
MB991824
E: MB991914 pushing V.C.I. ENTER MUT-III main harness A
B F: MB991825 key. to send simulated
G: MB991826 vehicle speed. If you
MUT-III sub assembly connect MUT-III main
A: Vehicle communication harness B instead, the
interface (V.C.I.) CAN communication
MB991827
B: MUT-III USB cable does not function
C
C: MUT-III main harness A correctly.
(Vehicles with CAN
D: MUT-III main harness B
MB991910 (Vehicles without CAN
D communication system)
E: MUT-III main harness C
DO NOT USE (for Daimler Chrysler
models only)
MB991911
adapter
E G: MUT-III trigger harness
DO NOT USE
MB991914
MB991825
MB991826
MB991958
SPECIAL TOOLS

MB991223 General service tools Checking the continuity
A
A: MB991219 and measuring the
B: MB991220 voltage at the harness
C: MB991221 connector
D: MB991222
B Harness set
A: Inspection harness
B: LED harness
C: LED harness adapter
C
D: Probe
D
MB991223 AD
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).
TCL OPERATION CHECK

M1136001100055

• MB991824: V.C.I.
ON-VEHICLE SERVICE
CAUTION
MB991958.
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.
6. If defective, repair it. (Refer to P.13C-34, TCL diagnosis −
Symptom Procedures − Inspection Procedure 6).
TCL SWITCH CHECK

M1136001700024
1. Remove the TCL switch. (Refer to P.13C-49).
2. Measure the resistance between terminal 1 and terminal 2
when the TCL switch is pressed or released. If the values
measured at the time correspond to those in the table below,
the resistance values are correct.
POSITION CONNECTION CONDITION
Pressed 1-2 Less than 2
ohms
AC307194AB
Released 1-2 Open circuit
WHEEL SPEED SENSOR CHECK

M1136001300026
Refer to GROUP 35B, On-vehicle Service P.35B-88.
TCL SWITCH
TCL SWITCH
M1136001600027
1
2
3
03DB141A

• HOOD LOCK RELEASE HANDLE • INSTRUMENT PANEL GARNISH
(REFER TO GROUP 42, HOOD P.42-8.) (REFER TO GROUP 52A,
• INSTRUMENT LOWER PANEL (REFER INSTRUMENT PANEL ASSEMBLY
TO GROUP 52A, INSTRUMENT PANEL P.52A-4.)
ASSEMBLY P.52A-4.) 1. SWITCH BEZEL ASSEMBLY
2. SWITCH PANEL ASSEMBLY
3. TCL SWITCH
WHEEL SPEED SENSOR

M1136002500023
Refer to GROUP 35B, Wheel Speed Sensor P.35B-95.
ABS/TCL-ECU
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. . . . . . . . . 14-2 RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-32

REMOVAL AND INSTALLATION . . . . . . . . 14-32
SPECIAL TOOL . . . . . . . . . . . . . . . . . 14-2
THERMOSTAT . . . . . . . . . . . . . . . . . . 14-35
ENGINE COOLING DIAGNOSIS . . . . 14-2 REMOVAL AND INSTALLATION . . . . . . . . 14-35
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 14-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-38
TROUBLESHOOTING STRATEGY . . . . . . 14-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 14-3 WATER PUMP . . . . . . . . . . . . . . . . . . 14-39
SYMPTOM PROCEDURES . . . . . . . . . . . . 14-3 REMOVAL AND INSTALLATION . . . . . . . . 14-39
ON-VEHICLE SERVICE. . . . . . . . . . . 14-26 WATER HOSE AND WATER PIPE . . 14-40

ENGINE COOLANT LEAK CHECK . . . . . . 14-26 REMOVAL AND INSTALLATION . . . . . . . . 14-40
RADIATOR CAP PRESSURE CHECK. . . . 14-27 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-41
ENGINE COOLANT REPLACEMENT . . . . 14-27
ENGINE COOLANT CONCENTRATION TEST 14-29 SPECIFICATIONS . . . . . . . . . . . . . . . 14-42
FAN CONTROLLER CHECK . . . . . . . . . . . 14-29 FASTENER TIGHTENING
FAN CONTROL RELAY CONTINUITY CHECK 14-31 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 14-42
SERVICE SPECIFICATION . . . . . . . . . . . . 14-43
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 14-43
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 14-43
ENGINE COOLING 14-2
GENERAL DESCRIPTION
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

NAME
MB991871 General service tool Coolant refilling
LLC changer
MB991871
ENGINE COOLING DIAGNOSIS

INTRODUCTION
M1141005300347
The system cools the engine so that it does not over-
heat and maintains the engine at an optimum tem-
perature. The system components are the radiator,
water pump, thermostat, condenser and fan assem-
blies. Possible faults include low coolant, contamina-
tion, belt loosening and component damage.
M1141005200340
you follow them carefully, you will be sure to find customer exists.
most of the engine cooling faults. 3. Find and repair the malfunction by following the
1. Gather information from the customer. SYMPTOM CHART.
4. Verify that the malfunction is eliminated.
ENGINE COOLING 14-3
SYMPTOM CHART
M1141005600393

PROCEDURE PAGE
Coolant leak 1 14-3
Engine overheating 2 14-4
Radiator fan and condenser fan do not operate 3 14-4
Radiator fan and condenser fan do not change speed or stop 4 14-20
Radiator fan does not operate 5 14-25
Condenser fan does not operate 6 14-25
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Coolant Leak
DIAGNOSIS
STEP 1. Check for coolant leaks.

WARNING
When pressure testing the cooling system, slowly
release cooling system pressure to avoid being
burned by hot coolant.
CAUTION
• Be sure to completely clean away any moisture from
the places checked.
• When the tester is removed, be careful not to spill any
coolant.
• When installing and removing the tester and when test-
ing, be careful not to deform the filler neck of the radia-
tor.
Check that the coolant level is up to the filler neck. Install a radi-
CAP ADAPTER
ator tester and apply 160 kPa (23 psi) pressure, and then check
for leakage from the radiator hose or connections.
Q: Is leakage present from the radiator hose or
ADAPTER connections?
YES : Repair or replace the appropriate part, then go to
Step 2.
NO : There is no action to be taken.
ACX01844 AB

Q: Is there still coolant leakage?
ENGINE COOLING 14-4
INSPECTION PROCEDURE 2: Engine Overheating
DIAGNOSIS
STEP 1. Remove the radiator cap and check for coolant

contamination.
Q: Is the coolant contaminated with rust and oil?
YES : Replace it. Refer to P.14-27.
NO : There is no action to be taken. Go to Step 2.
STEP 2. Check the radiator cap valve opening pressure.

NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
(1) Use a cap adapter to attach the cap to the tester.
(2) Increase the pressure until the gauge indicator stops
moving.
CAP ADAPTER
Minimum limit: 83 kPa (12 psi)
Standard value: 93 − 123 kPa (14 − 18 psi)
Q: Does the reading remain at or above the minimum limit?
YES : Go to Step 3.
NO : Replace the radiator cap. Then go to Step 5.
ACX01845 AB
STEP 3. Check thermostat operation.

Refer to 38.
Q: Does the thermostat operate correctly?
YES : Go to Step 4.
NO : Replace the thermostat, then go to Step 5.
STEP 4. Check the drive belt for slippage or damage.

(Check Condition). <3.8L Engine>39 .
Q: Is the drive belt loose or damaged?
YES : Adjust or replace the drive belt, then go to Step 5.

Check the engine coolant temperature.
Q: Is the engine coolant temperature abnormally high?
ENGINE COOLING 14-5
INSPECTION PROCEDURE 3: Radiator Fan and Condenser Fan do not Operate
• The cause could also be a malfunction of input

.
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-
.
TECHNICAL DESCRIPTION ler

• The cause could be a malfunction of the fan con- • Malfunction of engine-ECU.
troller power supply or earth circuit. • Damaged wiring harness or connector
• If the communication line wiring harness between • Refer to component locations GROUP-1
the fan controller and the engine-ECU is • Refer to configuration diagrams GROUP-1
short-circuited to earth, the radiator fan motor • Refer to circuit diagrams GROUP-1
and the condenser fan motor will not rotate.
ENGINE COOLING 14-6
DIAGNOSIS
STEP 1. Measure the power supply voltage at fan

controller connector A-24.
Connector: A-24
A-24
3 2 1
04DB008A
(1) Disconnect fan controller connector A-24 and measure

wiring harness side connector.
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.
(5) Connect fan controller connector A-24.
Q: Is the measured voltage system voltage?
NO : Go to Step 2.
STEP 2. Check the fan controller connector A-24.

Connector: A-24
A-24
3 2 1
04DB008A

YES : Go to Step 3.
NO : Repair or replace the connector. Then go to Step 24.
ENGINE COOLING 14-7
STEP 3. Check the fusible link No.2.
Relay box
Fusible link
No.2
Fan control
relay
04DB010A
Q: Is the fusible link No.2 in good condition?

YES : Go to Step 4.
NO : Replace the fusible link No.2. Then go to Step 24.
STEP 4. Measure the power supply voltage at fan control

relay connector A-10X.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
(1) Disconnect fan control relay connector A-10X (remove the

fan control relay) and measure relay box side connector.
A-10X Connector
(Relay box side)
04DB013A
(3) Measure the voltage between fan control relay connector

A-10X terminal 4 and body earth.
(5) Connect fan control relay connector A-10X (install the fan
control relay).
YES : Go to Step 7.
NO : Go to Step 5.
ENGINE COOLING 14-8
STEP 5. Check the fan control relay connector A-10X.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A

YES : Go to Step 6.
NO : Repair the connector or replace the relay box. Then
go to Step 24.
STEP 6. Check the harness wire between fusible link No.2

and fan control relay connector A-10X terminal 4.
Relay box
Fusible link
No.2
Fan control
relay
04DB010A
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A

YES : An intermittent malfunction is suspected (Refer to
GROUP 00 - How to use troubleshooting 00-7).
NO : Repair the damaged harness wire. Then go to Step
24.
STEP 7. Check the fan control relay.

Refer to 14-31.
Q: Is the fan control relay in good condition?
YES : Go to Step 8.
NO : Replace the fan control relay. Then go to Step 24.
ENGINE COOLING 14-9
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A

YES : Go to Step 9.
go to Step 24.
STEP 9. Check the harness wire between fan control relay

connector A-10X terminal 2 and fan controller connector
A-24 terminal 3.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Connector: A-24
A-24
3 2 1
04DB008A

24.
ENGINE COOLING 14-10
STEP 10. Measure the terminal voltage at fan control relay

connector A-10X.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A

A-10X Connector
(Relay box side)
04DB014A
(3) Measure the voltage between fan control relay connector

control relay).
NO : Go to Step 11.
STEP 11. Check the ECU connector B-21, intermediate

connector A-13 and fan control relay connector A-10X.
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
Q: Are there connectors in good condition?

STEP 12. Check the harness wire between intermediate

connector A-13 terminal 2 and fan control relay connector
A-10X terminal 3.
CONNECTOR: A-13
A-13(GR)
AK303148 AB
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Q: Are these harness wires in good condition?

00-7).
24.
STEP 13. Check the continuity between fan control relay

connector A-10X and body earth.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A

A-10X Connector
(Relay box side)
04DB015A
(2) Measure the resistance between fan control relay connector

• Continuity exists.
control relay).
Q: Does the continuity exists?
00-7).
NO : Go to Step 14.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A

go to Step 24.
STEP 15. Check the earth connector A-14.
RELAY BOX
A-14
04DB019A

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

24.
STEP 17. Check the continuity between fan controller

connector A-24 and body earth.
Connector: A-24
A-24
3 2 1
04DB008A
(1) Disconnect fan controller connector A-24 and measure

wiring harness side connector.
A-24 Connector
(Wiring harness side)
04DB016A
(2) Measure the resistance between fan controller connector

A-24 terminal 1 and body earth.
• Continuity exists.
(3) Connect fan controller connector A-24.
Q: Dose the continuity exists?
NO : Go to Step 18.
STEP 18. Check the fan controller connector A-24.

Connector: A-24
A-24
3 2 1
04DB008A

STEP 19. Check the harness wire between fan controller

connector A-24 terminal 1 and body earth.
Connector: A-24
A-24
3 2 1
04DB008A

24.
STEP 20. Check the fan controller connector A-24,

intermediate connector A-13 and engine-ECU connector
B-21.
Connector: A-24
A-24
3 2 1
04DB008A
CONNECTOR: A-13
A-13(GR)
AK303148 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
Q: Are these connectors in good condition?


connector A-24 terminal 2 and engine-ECU connector B-21
terminal 71.
Connector: A-24
A-24
3 2 1
04DB008A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

24.
STEP 22. Check the fan controller.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(1) Disconnect fan controller connector A-24.

Connector: A-24
A-24
3 2 1
04DB008A
(2) Back out connector terminal pin 2 from connector housing.

(3) Reconnect the connector with connector terminal pin 2 still
removed.
(5) Check for the cooling fan operation.
• The cooling fan rotates. (with connector terminal pin 2
disconnected)
• Using a suitable probe connect the fan controller termi-
nal 2 at controller side to earth.The cooling fan stops.
(When pin 2 of fan controller is connected to earth)
(7) Turn the ignition switch to the "OFF" position.
(8) Disconnect fan controller connector A-24, and re-locate
connector terminal pin 2 into connector housing.
(9) Reconnect the connector with connector terminal pin 2
installed correctly.
Q: Does the cooling fan rotate? And when the fan
controller pin 2 is connected to the body earth, does
the cooling fan stop?
NO : Replace the fan motor and fan controller (Refer to
14-25). Then go to Step 24.
STEP 23. MUT-III self-diag code

Check if an MPI system self-diag code is set. (Refer to GROUP
13A - Trouble shooting 13A-5).
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer to GROUP
13A - Trouble shooting 13A-17)
NO : Replace the engine-ECU (Refer to GROUP 13A,
Engine-ECU 13A-675 ). Then go to Step 24.
STEP 24. Check the symptoms.

Q: Does the radiator fan motor and the condenser fan
motor operate correctly?
YES : This symptom is complete.
INSPECTION PROCEDURE 4: Radiator Fan and Condenser Fan do not Change Speed or Stop
• The cause could also be a malfunction of input

.
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. .
• If the communication line wiring harness between TROUBLESHOOTING HINTS

the fan controller and the engine-ECU is • Malfunction of fusible link No.2
short-circuited to earth, the radiator fan motor • Malfunction of fan control relay
and the condenser fan motor will not rotate. • Malfunction of cooling fan motor
• Malfunction of fan controller
• Malfunction of engine-ECU
• Damaged wiring harness or connector
DIAGNOSIS
STEP 1. Check the fan control relay.

Refer to 14-31.
Q: Is the fan control relay in good condition?
YES : Go to Step 2.
NO : Replace the fan control relay. Then go to Step 8.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A

YES : Go to Step 3.
go to Step 8.

connector A-10X terminal 2 and fan controller connector
A-24 terminal 3.
Relay box
Fusible link
No.2
Fan control
A-10X relay
4
04DB012A
Connector: A-24
A-24
3 2 1
04DB008A

YES : Go to Step 4.
STEP 4. Check the fan controller connector A-24,

intermediate connector A-13 and engine-ECU connector
B-21.
Connector: A-24
A-24
3 2 1
04DB008A
CONNECTOR: A-13
A-13(GR)
AK303148 AB
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
Q: Are these connectors in good condition?

YES : Go to Step 5.

connector A-24 terminal 2 and engine-ECU connector
B-21 terminal 71.
Connector: A-24
A-24
3 2 1
04DB008A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

YES : Go to Step 6.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
(1) Disconnect fan controller connector A-24.

Connector: A-24
A-24
3 2 1
04DB008A
(2) Back out connector terminal pin 2 from connector housing.

(3) Reconnect the connector with connector terminal pin 2 still
removed.
• The cooling fan rotates. (with connector terminal pin 2
disconnected)
• Using a suitable probe connect the fan controller termi-
nal 2 at controller side to earth.The cooling fan stops.
(When pin 2 of fan controller is connected to earth)
(7) Turn the ignition switch to the "OFF" position.
(8) Disconnect fan controller connector A-24, and re-locate
connector terminal pin 2 into connector housing.
(9) Reconnect the connector with connector terminal pin 2
installed correctly.
Q: Does the cooling fan rotate? And when the fan
controller pin 2 is connected to the body earth, does
the cooling fan stop?
YES : Go to Step 7.
STEP 7. MUT-III self-diag code

Check if an MPI system self-diag code is set. (Refer to GROUP
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer to GROUP
NO : Replace the engine-ECU (Refer to GROUP 13A,
Engine-ECU 13A-675 ) Then go to Step 8 .

Q: Does the radiator fan motor and the condenser fan
motor operate correctly?
INSPECTION PROCEDURE 5: Radiator Fan does not Operate

. .
Radiator Fan and Condenser Fan Drive TROUBLESHOOTING HINTS

Circuit • Malfunction of radiator fan motor
.
TECHNICAL DESCRIPTION • Refer to circuit diagrams GROUP-1

The cause could be a malfunction of the radiator fan
motor or an open circuit between the fan controller
and the radiator fan motor.
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.
INSPECTION PROCEDURE 6: Condenser Fan does not Operate

. .
Radiator Fan and Condenser Fan Drive TROUBLESHOOTING HINTS

Circuit • Malfunction of condenser fan motor
.
TECHNICAL DESCRIPTION • Refer to circuit diagrams GROUP-1

The cause could be a malfunction of the condenser
fan motor or fan controller.
ON-VEHICLE SERVICE
DIAGNOSIS
STEP 1. Check the condenser fan motor.

Condenser fan motor check. (Refer to GROUP 55, Condenser
and Condenser Fan Motor.
Q: Is the condenser fan motor in good condition?
YES : Go to Step 2.
NO : Replace the condenser fan motor, then go to Step 3.

Refer to 29.
Q: Is the fan controller in good condition?
YES : Go to Step 3.

Q: Do the condenser fan operate?
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
ON-VEHICLE SERVICE
RADIATOR CAP PRESSURE CHECK

M1141001300419
NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops
CAP ADAPTER moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93 − 123 kPa (14 − 18 psi)
3. Replace the radiator cap if the reading does not remain at or
above the limit.
ACX01845 AB
ENGINE COOLANT REPLACEMENT

M1141001200478
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.
ON-VEHICLE SERVICE
2. Drain the water in the water jacket by unplugging the drain

<3.8L ENGINE: RIGHT BANK>
plug of the cylinder block.
3. Remove the radiator condenser tank assembly and drain the
coolant.
4. Drain the coolant then clean the path of the coolant by
injecting water into the radiator from the radiator cap area.
CYLINDER BLOCK
DRAIN PLUG
AC306132AB
CYLINDER BLOCK
DRAIN PLUG
AC306131AB

CYLINDER BLOCK
DRAIN PLUG
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.
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.
ENGINE COOLANT CONCENTRATION TEST

M1141001100396
Refer to GROUP 00, RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIES TABLE 35.
FAN CONTROLLER CHECK

M1141007400113
Fan controller
3 2 1
04DB017A
1. Remove the fan controller connector.

2. Turn the ignition switch to the "ON" position, and measure
the voltage between the harness-side connector terminals.
Standard value: System voltage
ON-VEHICLE SERVICE
Fan controller
1 2
04DB018A
3. Connect the fan controller connector, and disconnect the

condenser fan motor connector.
4. Ensure that the A/C switch is off, and start the engine and
run it at idle.
5. Measure the voltage between the fan controller-side
connector terminals.
Standard value: 1V or less
WARNING
Stay clear of the fan when the fan starts running.
6. Turn the A/C switch to the "ON" position.
7. Measure the voltage between the fan controller-side
connector terminals while the fan is running. The voltage
should repeat the values below.
Standard value:
8.2 ± 2.6 V
System voltage ± 2.6 V
8. If the voltage does not repeatedly change as indicated,
replace the cooling fan motor and fan controller.
ON-VEHICLE SERVICE
FAN CONTROL RELAY CONTINUITY CHECK

M1141006200310
BATTERY TERMINAL NO. TO CONTINUITY TEST

FAN CONTROL RELAY
VOLTAGE BE CONNECTED RESULTS
TO TESTER
Not applied 4−2 Open circuit
Connect 4−2 Less than 2 ohms
terminal No.3
and battery (−)
terminal.
AC305017 Connect
terminal No.1
and battery (+)
terminal.
2 4
2
1 3
4 1 3
AC307445AB
RADIATOR
RADIATOR
M1141001500521

• Engine Coolant Draining (Refer to 27). • Air Cleaner Installation (Refer to GROUP 15 4).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner 4). • Engine Coolant Refilling and Level Check (Refer to 27).
• A/T Fluid Refilling and Level Check (Refer to GROUP 00,
Maintenance Service 45).
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
RADIATOR REMOVAL STEPS RADIATOR REMOVAL STEPS

1. RADIATOR CONDENSER TANK 12. RADIATOR CONDENSER TANK
HOSE ASSEMBLY
<<A>> >>A<< 2. RADIATOR UPPER HOSE <> 13. A/T OIL COOLER HOSE
<<A>> >>A<< 3. RADIATOR LOWER HOSE 14. CONDENSER FAN SHROUD
<> 4. A/T OIL COOLER HOSE ASSEMBLY
CONNECTION 15. COOLING FAN SHROUD
5. CONDENSER FAN MOTOR ASSEMBLY
CONNECTOR 16. RADIATOR
6. FAN CONTROLLER CONNECTOR FAN MOTOR REMOVAL STEPS
• HOOD LATCH (REFER TO 1. RADIATOR CONDENSER TANK
GROUP 42, HOOD 8). HOSE
7. FRONT END STRUCTURE BAR 5. CONDENSER FAN MOTOR
8. UPPER INSULATOR CONNECTOR
9. CONDENSER BOLTS <<A>> >>A<< 3. RADIATOR UPPER HOSE
10. RADIATOR ASSEMBLY 6. FAN MOTOR CONNECTOR
11. LOWER INSULATOR 12. RADIATOR CONDENSER TANK
ASSEMBLY
RADIATOR
FAN MOTOR REMOVAL STEPS RADIATOR CONDENSER TANK

14. CONDENSER FAN SHROUD REMOVAL STEPS
ASSEMBLY • UNDER COVER (LH)
15. COOLING FAN SHROUD • AIR INTAKE DUCT (REFER TO
ASSEMBLY GROUP 15, AIR CLEANER 4).
17. CONDENSER FAN 1. RADIATOR CONDENSER TANK
18. HEAT PROTECTOR HOSE
19. CONDENSER FAN MOTOR 5. CONDENSER FAN MOTOR
20. COOLING FAN CONNECTOR
21. COOLING FAN MOTOR& FAN 6. FAN MOTOR CONNECTOR
CONTROLLER 12. RADIATOR CONDENSER TANK
ASSEMBLY
RADIATOR

.
<<A>> RADIATOR UPPER HOSE/RADIATOR

LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.
MATING MARKS
AC200641AB
<> A/T OIL COOLER HOSE REMOVAL

After removing the hose from the radiator, plug the hose and
the radiator nipple to prevent dust or foreign particles from get-
ting in.

.
>>A<< RADIATOR LOWER HOSE/RADIATOR

UPPER HOSE CONNECTION
1. Insert each hose as far as the projection of the water inlet
fitting.
PROJECTION
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
WATER OUTLET MATING

FITTING MARKS
AC200642 AB
THERMOSTAT
THERMOSTAT
M1141002400475

• Engine Coolant Draining and Refilling (Refer to 27).
• Engine Cover Removal and Installation (Refer to GROUP
11C, Engine Assembly 11A-14).
• Engine Control Unit (ECU) Removal and Installation
(Refer to GROUP 00, General 00-7).
• Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner 4).
• Strut Tower Bar Removal and Installation (Refer to
GROUP 42, Strut Tower Bar 12).
• Battery and Battery Tray Removal and Installation
5.0 ± 1.0 N·m 5.0 ± 1.0 N·m

44 ± 9 in-lb 44 ± 9 in-lb
6
19
5
7 15
4 9.0 ± 2.0 N·m
3 80 ± 17 in-lb
9
1
13
14 18
16
13
10 20 17
11 2 22 ± 4 N·m
16 ± 3 ft-lb
04DB006A

1. LEFT BANK HEATED OXYGEN 7. MANIFOLD ABSOLUTE
SENSOR (REAR) CONNECTOR PRESSURE SENSOR
2. LEFT BANK HEATED OXYGEN CONNECTOR
SENSOR (FRONT) CONNECTOR 8. POWER STEERING PRESSURE
3. RIGHT BANK HEATED OXYGEN SWITCH CONNECTOR
SENSOR (REAR) CONNECTOR 9. CONTROL WIRING HARNESS
4. RIGHT BANK HEATED OXYGEN AND WIRING HARNESS
SENSOR (FRONT) CONNECTOR COMBINATION CONNECTOR
5. THROTTLE BODY ASSEMBLY 10. KNOCK SENSOR CONNECTOR
CONNECTOR 11. CRANKSHAFT POSITION
6. EVAPORATIVE EMISSION SENSOR CONNECTOR
PURGE SOLENOID CONNECTOR 13. INJECTOR CONNECTOR
THERMOSTAT

14. ENGINE COOLANT
TEMPERATURE SENSOR
CONNECTOR
15. CAPACITOR CONNECTOR
16. CAMSHAFT POSITION SENSOR
CONNECTOR
17. INHIBITOR SWITCH SENSOR
CONNECTOR
18. A/T CONTROL SOLENOID VALVE
ASSEMBLY CONNECTOR
19. OUTPUT SHAFT SPEED
SENSOR CONNECTOR
20. INPUT SHAFT SPEED SENSOR
CONNECTOR
23
22
19 ± 1 N·m
14 ± 1 ft-lb
21
AC306959AB

<<A>> >>B<< 21. RADIATOR LOWER HOSE 22. WATER INLET FITTING
CONNECTION >>A<< 23. THERMOSTAT
THERMOSTAT

.
<<A>> RADIATOR LOWER HOSE DISCONNEC-

TION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.
MATING MARKS
AC200641AB

.
>>A<< THERMOSTAT INSTALLATION

CAUTION
Make absolutely sure that no oil adheres to the rubber ring
of the thermostat. Also do not fold or scratch the rubber
ring during installation.
Install the thermostat so that the jiggle valve is facing straight
up. Be careful not to fold or scratch the rubber ring.
JIGGLE VALVE
RUBBER RING
AC000279 AB
>>B<< RADIATOR LOWER HOSE CONNECTION

1. Insert each hose as far as the projection of the water inlet
PROJECTION fitting.
WATER INLET MATING

FITTING MARKS
AC200642 AE
THERMOSTAT
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
2. Check that the amount of valve lift is at the standard value

when the water is at the full-opening temperature.
NOTE: Measure the valve height when the thermostat is
fully closed, and use this measurement to compare the
valve height when the thermostat is fully open.
Standard value:
Full-opening temperature:
VALVE LIFT
100°C (212°F)
Amount of valve lift:
ACX00401AB
9.0 mm (0.35 inch) or more
WATER PUMP
WATER PUMP
M1141002700498

• Engine Coolant Draining and Refilling (Refer to 27).
• Timing Belt Removal and Installation (Refer to GROUP
11C, Timing Belt 11A-46).
• Crankshaft Position Sensor Removal and Installation
(Refer to GROUP 16, Crankshaft Position Sensor 35).
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)
42 ± 8 N·m THREAD DIAMETER × LENGTH mm(in)

31 ± 6 ft-lb 2
24 ± 3 N·m
18 ± 2 ft-lb
AC205662 AB

1. WATER PUMP BRACKET 3. WATER PUMP GASKET
2. WATER PUMP >>A<< 4. O-RING

.
>>A<< O-RING INSTALLATION

CAUTION
Do not let the O-ring get contaminated with grease or
engine oil.
Fit the O-ring into the groove of the water pipe ends, and apply
water or coolant to the circumference of the O-ring and the pipe
bores to insert the pipe assembly.
O-RING
WATER PIPE
AC200644 AB
WATER HOSE AND WATER PIPE

M1141003300493

Thermostat Removal and Installation (Refer to 35).
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

<<A>> >>C<< 1. RADIATOR UPPER HOSE >>B<< 7. ENGINE COOLANT
CONNECTION TEMPERATURE SENSOR
2. HEATER HOSE CONNECTION 8. WATER PUMP INLET PIPE
5. THERMOSTAT HOUSING >>A<< 9. O-RING
6. GASKET

.
<<A>> RADIATOR UPPER HOSE DISCONNEC-

TION
After making mating marks on the radiator hose and hose
clamp, disconnect the radiator hose.
MATING MARKS
AC200641AB

.
>>A<< O-RING INSTALLATION

CAUTION
Do not allow engine oil or other grease to adhere to the
O-ring
Insert the O-ring to the water pipe, and coat the outer portion of
the O-ring with water or engine coolant.
O-RING
WATER PIPE
AC200644 AB
>>B<< ENGINE COOLANT TEMPERATURE

SENSOR INSTALLATION
Apply the specified sealant to the thread of the engine coolant
temperature sensor, and then tighten it to the specified torque.
Specified Sealant: 3M™ AAD Part No. 8731 or equiva-
lent
AC208408AB
>>C<< RADIATOR UPPER HOSE CONNECTION

1. Insert each hose as far as the projection of the water outlet
fitting.
PROJECTION
WATER OUTLET MATING

FITTING MARKS
AC200642 AB
INSPECTION
M1141003400337
.
Water Pipe and Hose Check

Check the water pipe and hose for cracks, damage and clogs.
Replace them if necessary.
SPECIFICATIONS
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)
SPECIFICATIONS
M1141000300449

Fan Controller V A/C OFF 1 or less -
A/C ON Repeat -
8.2 ± 2.6
System voltage ± 2.6
High-pressure valve opening pressure of radiator cap kPa (psi) 93 − 123 (14 − 18) Minimum 83 (12)
Thermostat Valve opening temperature 3.8L Engine 88 ± 1.5 (190 ± 3)
of thermostat °C (°F) -
Full-opening temperature 3.8L Engine 100 (212)
of thermostat °C (°F) -
Valve lift mm (in) 3.8L Engine 9.0 (0.35) or more
-
CAPACITIES
M1141005100138
ITEM QUANTITY dm3 (qt)

Long life antifreeze coolant or an equivalent 3.8L Engine 8.7 (9.2)
SEALANTS
M1141000500368

Cylinder block drain plug 3M™ AAD Part No.8731 or equivalent
Engine coolant temperature sensor
SPECIFICATIONS
HOME
15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 15-2 INTAKE MANIFOLD . . . . . . . . . . . . . . 15-7

INTAKE AND EXHAUST DIAGNOSIS 15-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-9
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 15-2
TROUBLESHOOTING STRATEGY . . . . . . 15-2 EXHAUST MANIFOLD . . . . . . . . . . . . 15-10
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 15-2 REMOVAL AND INSTALLATION . . . . . . . . 15-10
SYMPTOM PROCEDURES . . . . . . . . . . . . 15-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-13
SPECIAL TOOLS. . . . . . . . . . . . . . . . 15-3 EXHAUST PIPE AND MAIN MUFFLER 15-14

AIR CLEANER . . . . . . . . . . . . . . . . . . 15-4
REMOVAL AND INSTALLATION . . . . . . . . 15-4 SPECIFICATIONS . . . . . . . . . . . . . . . 15-16
FASTENER TIGHTENING SPECIFICATIONS 15-16
INTAKE MANIFOLD PLENUM . . . . . 15-5 SERVICE SPECIFICATION . . . . . . . . . . . . 15-18
REMOVAL AND INSTALLATION . . . . . . . 15-5 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
INTAKE AND EXHAUST 15-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1151000100446
The exhaust pipe is divided into four parts.
INTAKE AND EXHAUST DIAGNOSIS

INTRODUCTION
M1151006900321
Intake leaks usually create driveability issues that
are not obviously related to the intake system.
Exhaust leaks or abnormal noise is caused by
cracks, gaskets and fittings, or by exhaust pipe or
muffler damage due to impacts during travel. The
exhaust leaks from these sections and causes the
exhaust noise to increase. There may be cases
when the system contacts the body and vibration
noise is generated.
M1151007000321
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find an 3. Find the malfunction by following the Symptom
intake or exhaust system fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1151007100328

Exhaust Leakage 1 P.15-2
Abnormal Noise 2 P.15-3
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Exhaust Leakage
DIAGNOSIS STEP 2. Check the gasket for cracks, damage.

Q: Is the gasket damaged?
STEP 1. Start the engine. Have an assistant stay YES : Replace the gasket, then go Step 1.
in the driver’s seat. Raise the vehicle on a hoist. NO : Go to Step 3.
Have the assistant rev the engine while
searching for exhaust leaks.
STEP 3. Check for loose coupling sections.
Q: Is the exhaust leaking?
Q: Are there any loose each sections?
YES : Go to Step 2.
YES : Tighten, then go to Step 1.
SPECIAL TOOLS
INSPECTION PROCEDURE 2: Abnormal Noise
DIAGNOSIS STEP 4. Check for interference of the pipes and

muffler with the body.
STEP 1. Start the engine. Have an assistant stay Q: Are the pipes and muffler interfering with the
in the drivers seat. Raise the vehicle on a hoist. body?
Have the assistant rev the engine while YES : Repair, then go to Step 1.
searching for exhaust leaks. NO : Go to Step 5.
Q: Is any abnormal noise generated?
YES : Go to Step 2. STEP 5. Check the heat protectors.
Q: Are any heat protectors loose or damaged?
YES : Tighten or replace, then go to Step 1.
STEP 2. Check for missing parts in the muffler. NO : Go to Step 6.
Tap the muffler lightly to check for loose baffles,
etc. STEP 6. Check the pipes and muffler for damage.
Q: Are there any missing parts in the muffler?
Q: Are the pipes and muffler damaged?
YES : Replace, then go to Step 1.
NO : Go to Step 3.
STEP 3. Check the hanger for cracks.

Q: Is the hanger cracked?
NO : Go to Step 4.
SPECIAL TOOLS
M1151000600429

NAME
MD998412 MD998412 Installation of intake
Guide manifold plenum
MB991953 - Removal and installation

Oxygen sensor wrench of heated oxygen sensor
B991953
MD998770 MD998770-01 or General Removal and installation

Oxygen sensor wrench service tool of heated oxygen sensor
AIR CLEANER
AIR CLEANER
M1151002100516
6
7
4.0 ± 0.9 N·m

35 ± 8 in-lb
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
8.8 ± 1.0 N·m

78 ± 9 in-lb
8.8 ± 1.0 N·m
78 ± 9 in-lb 05DB026A

1. AIR DUCT 7. AIR INTAKE HOSE
2. AIRFLOW SENSOR CONNECTOR • ENGINE CONTROL UNIT (ECU) ).
3. AIRFLOW SENSOR 8. AIR CLEANER BODY
4. AIR CLEANER COVER 9. AIR CLEANER BRACKET
5. AIR CLEANER ELEMENT • UNDER COVER (LH)
6. BREATHER HOSE CONNECTION 10. AIRFLOW SENSOR NUT
INTAKE MANIFOLD PLENUM

M1151002700198

• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Throttle Body Installation (Refer to GROUP 13B, Throttle
Service P.14-27). Body 13A-674).
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Air Cleaner Cover and Air Intake Hose Installation (Refer
Tower Bar P.42-12). to P.15-4).
• Air Cleaner Cover and Air Intake Hose Removal (Refer to • Strut Tower Bar Installation (Refer to GROUP 42, Strut
P.15-4). Tower Bar P.42-12).
• Throttle Body Removal (Refer to GROUP 13B, Throttle • Engine Coolant Supplying (Refer to GROUP 14, On-vehi-
Body 13A-674). cle Service P.14-27).
.
9
CHAMBER
2
20 01DB051A
9.0 ± 1.0 N·m

5.0 ± 1.0 N·m 6 80 ± 9 in-lb
44 ± 9 in-lb
11 ± 1 N·m 24
98 ± 8 in-lb
N 25 1 18 ± 2 N·m
13 ± 2 ft-lb
4
3 23
11 ± 1 N·m
5 12 ± 2 N·m 98 ± 8 in-lb
102 ± 22 in-lb 11 ± 1 N·m
12 ± 2 N·m 18 ± 2 N·m 23 98 ± 8 in-lb
102 ± 22 in-lb 10 13 ± 2 ft-lb
8
23
36 ± 6 N·m
27 ± 4 ft-lb
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

1. MANIFOLD ABSOLUTE • STEERING GEAR AND LINKAGE
PRESSURE SENSOR PROTECTOR (REFER TO 37,
CONNECTOR STEERING GEAR BOX AND
2. CONTROL WIRING HARNESS LINKAGE P.37-30)
AND INJECTOR WIRING • POWER STEERING OIL PUMP
HARNESS COMBINATION (REFER TO 37, POWER
CONNECTOR STEERING OIL PUMP ASSEMBLY
3. CRANKSHAFT POSITION P.37-43)
SENSOR CONNECTOR 15. POWER STEERING OIL PUMP
4. KNOCK SENSOR CONNECTOR BRACKET CONNECTING BOLT
5. POWER STEERING PRESSURE 16. INTAKE MANIFOLD PLENUM
SWITCH CONNECTOR STAY, FRONT
6. EVAPORATIVE EMISSION >>A<< 17. INTAKE MANIFOLD PLENUM
PURGE SOLENOID CONNECTOR 18. INTAKE MANIFOLD PLENUM
8. VACUUM HOSE CONNECTION GASKET
9. PURGE HOSE 19. VACUUM PIPE
10. POWER STEERING PRESSURE 20. EVAPORATIVE EMISSION
HOSE CLAMP PURGE SOLENOID ASSEMBLY
11. POWER STEERING PRESSURE 23. HARNESS BRACKET
HOSE CLAMP BRACKET 24. MANIFOLD ABSOLUTE
12. INTAKE MANIFOLD PLENUM PRESSURE SENSOR
STAY, REAR 25. O-RING

• MD998412: Guide

.
>>A<< INTAKE MANIFOLD PLENUM INSTALLA-

TION
Use special tool MD998412 to install the intake manifold ple-
INTAKE MANIFOLD
PLENUM GASKET num.
MD998412
AC306688 AB
INTAKE MANIFOLD
INTAKE MANIFOLD
M1151003000802

• Fuel Discharge Prevention [Refer to GROUP 13B, • Intake Manifold Plenum Installation (Refer to P.15-5.)
On-vehicle Service − Fuel Pump Relay Disconnection • Fuel Leakage Inspection
(How to Reduce Pressurized Fuel Lines) 13A-663.]
• Intake Manifold Plenum Removal (Refer to P.15-5.)
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
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 MANIFOLD

.
<<A>> FUEL RAIL AND INJECTOR REMOVAL

CAUTION
Care must be taken when removing the fuel rail not to drop
the injector.
Remove the fuel rail with the injectors attached to it.

.
>>A<< INTAKE MANIFOLD GASKET INSTALLA-

TION
Install the gasket with the protrusions in the position illustrated.
PROTRUSION FRONT OF VEHICLE
PROTRUSION
ACX02434 AC
>>B<< INTAKE MANIFOLD INSTALLATION

1. Coat the intake manifold mounting studs with engine oil.
2. Tighten the intake manifold mounting nuts by the following
RIGHT BANK
procedure.
LEFT BANK
ORDER MOUNTING NUTS TIGHTENING TORQUE
1st Right-bank nuts 6.5 ± 1.5 N⋅m (58 ± 13 in-lb)
2nd Left-bank nuts 22 ± 1 N⋅m (16 ± 1 ft-lb)
3rd Right-bank nuts 22 ± 1 N⋅m (16 ± 1 ft-lb)
4th Left-bank nuts 22 ± 1 N⋅m (16 ± 1 ft-lb)
AC001433 AB
5th Right-bank nuts 22 ± 1 N⋅m (16 ± 1 ft-lb)
.
INTAKE MANIFOLD
>>C<< FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
• Be careful not to allow any engine oil to enter the fuel
rail.
• Be careful not to bend the fuel high-pressure hose as it
is made of plastics.
1. When connecting the fuel high-pressure hose to the fuel rail,
CONNECTOR apply a small amount of new engine oil to the O-ring and
then insert the fuel high-pressure hose, being careful not to
damage the O-ring.
2. While turning the fuel high-pressure hose to the left and
right, install it to the fuel rail.
3. Check that the injector turns smoothly. If it does not turn
smoothly, the O-ring may be trapped. Remove the fuel
MAIN PIPE NOZZLE OR high-pressure hose and then re-insert it into the fuel rail and
FUEL MAIN PIPE
AC209221AB check again.
INSPECTION
M1151003100672
Check the following points; replace the part if a problem is
found.
.
Intake Manifold Check

1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port.
3. Using a straight edge and feeler gauge, check for distortion
of the cylinder head installation surface.
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1151003301055
<LEFT BANK>
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
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<< 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
EXHAUST MANIFOLD
<RIGHT BANK>
• Air Cleaner Cover and Air Intake Duct Removal and
Installation (Refer to P.15-4).
• Battery Removal and Installation
• 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

1. CENTER UNDER FLOOR HEAT 5. RIGHT BANK HEATED OXYGEN
PROTECTOR SENSOR (REAR) CONNECTOR
• STEERING GEAR AND LINKAGE <<A>> >>A<< 6. RIGHT BANK HEATED OXYGEN
PROTECTOR (REFER TO GROUP 37, SENSOR (FRONT)
POWERSTEERING GEAR BOX AND <<A>> >>A<< 7. RIGHT BANK HEATED OXYGEN
LINKAGE P.37-30) SENSOR (REAR)
2. FRONT UNDER FLOOR HEAT 10. UPPER HEAT PROTECTOR
PROTECTOR 11. EXHAUST MANIFOLD STAY, RIGHT B
3. EXHAUST MANIFOLD STAY, RIGHT A 12. EXHAUST MANIFOLD
4. RIGHT BANK HEATED OXYGEN 13. EXHAUST MANIFOLD GASKET
SENSOR (FRONT) CONNECTOR

• MB991953: Oxygen Sensor Wrench • MD998770: Oxygen Sensor Wrench
EXHAUST MANIFOLD

.
<<A>> LEFT BANK HEATED OXYGEN SENSOR

(FRONT)/RIGHT BANK HEATED OXYGEN SEN-
SOR (FRONT)/RIGHT BANK HEATED OXYGEN
SENSOR (REAR) REMOVAL
Use special tool MD998770 to remove the heated oxygen sen-
sor.
MD998770
ACX02426 AB
<> LEFT BANK HEATED OXYGEN SENSOR

(REAR) REMOVAL
Use special tool MB991953 to remove the heated oxygen sen-
HEATED OXYGEN sor.
SENSOR
MB991953
AC301966AC

.
>>A<< RIGHT BANK HEATED OXYGEN SENSOR

(REAR)/RIGHT BANK HEATED OXYGEN SENSOR
(FRONT)/LEFT BANK HEATED OXYGEN SENSOR
(FRONT) INSTALLATION
Use special tool MD998770 to install the heated oxygen sen-
sor.
MD998770
ACX02426 AB
.
EXHAUST MANIFOLD
>>B<< LEFT BANK HEATED OXYGEN SENSOR

(REAR) INSTALLATION
Use special tool MB991953 to install the heated oxygen sensor.
HEATED OXYGEN
SENSOR
MB991953
AC301966AC
INSPECTION
M1151003400587
Check the following points; replace the part if a problem is
found.
.
Exhaust Manifold Check

1. Check for damage or cracking of any part.
2. Using a straight edge and a feeler gauge, check for
distortion of the cylinder head installation surface.
EXHAUST PIPE AND MAIN MUFFLER

M1151008700334
<3.8L ENGINE> 19 12 ± 2 N·m

12 ± 2 N·m 107 ± 17 in-lb
17 107 ± 17 in-lb 3
18 3
12 ± 2 N·m
107 ± 17 in-lb 1
49 ± 4 N·m
14 37 ± 3 ft-lb
N 12 N7 15
2N
8
49 ± 9 N·m
N 11 37 ± 6 ft-lb 6 4
13 N
5 45 ± 5 N·m
10 22 ± 4 N·m 34 ± 3 ft-lb
49 ± 9 N·m 49 ± 4 N·m 16 ± 3 ft-lb
37 ± 6 ft-lb 37 ± 3 ft-lb AC306969 AB
MAIN MUFFLER REMOVAL STEPS FRONT EXHAUST PIPE REMOVAL

1. MAIN MUFFLER STEPS
10. FRONT NO.1 EXHAUST PIPE
2. SEAL RING
11. GASKET
3. HANGER
12. GASKET
CENTER EXHAUST PIPE
13. SEAL RING
REMOVAL STEPS
14. FRONT NO.2 EXHAUST PIPE
4. CROSSMEMBER STAY
7. GASKET
5. FRONT FLOOR BACKBONE BRACE
15. HANGER
6. CENTER EXHAUST PIPE
17. CENTER UNDER FLOOR HEAT
2. SEAL RING
PROTECTOR
7. GASKET
18. FRONT UNDER FLOOR HEAT
8. HANGER
PROTECTOR
19. REAR UNDER FLOOR HEAT
PROTECTOR
• MB991953: Oxygen Sensor Wrench

.
<<A>> HEATED OXYGEN SENSOR REMOVAL

Use special tool MB991953 to remove the heated oxygen sen-
HEATED OXYGEN sor.
SENSOR
MB991953
AC301966AC

.
>>A<< HEATED OXYGEN SENSOR INSTALLA-

TION
Use special tool MB991953 to install the heated oxygen sensor.
HEATED OXYGEN
SENSOR
MB991953
AC301966AC
SPECIFICATIONS
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>
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)
Exhaust manifold <Right bank>
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)
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)
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)
SPECIFICATIONS
ITEM SPECIFICATION
Water pump bracket bolt 24 ± 3 N⋅m (18 ± 2 ft-lb)
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)
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)
M1151000300462

Manifold distortion of the installation surface mm (in) 0.15 (0.006) or less 0.20 (0.008)
SEALANTS
M1151000500187

Thermostat case assembly 3M™ AAD Part No.8672, 3M™ AAD Part No.8679/8678 or
equivalent
Thermostat case assembly bolt 3M™ AAD Part No. 8730, 8731 or equivalent
HOME
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . . 16-2 GENERAL DESCRIPTION . . . . . . . 16-30
GENERAL DESCRIPTION . . . . . . 16-2 SPECIAL TOOLS . . . . . . . . . . . . . . 16-30
CHARGING SYSTEM DIAGNOSIS 16-3 ON-VEHICLE SERVICE . . . . . . . . . 16-31

KNOCK CONTROL SYSTEM CHECK. . 16-31
IGNITION COIL CHECK. . . . . . . . . . . . . 16-31
SPECIAL TOOL . . . . . . . . . . . . . . . 16-6 SPARK PLUG TEST . . . . . . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING 16-32
ON-VEHICLE SERVICE. . . . . . . . . 16-7 CAMSHAFT POSITION SENSOR CHECK 16-32
ALTERNATOR OUTPUT WIRE VOLTAGE CRANKSHAFT POSITION SENSOR
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-7 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32
OUTPUT CURRENT TEST . . . . . . . . . . 16-8
REGULATED VOLTAGE TEST. . . . . . . 16-10 IGNITION COIL. . . . . . . . . . . . . . . . 16-33
WAVE PATTERN CHECK USING AN REMOVAL AND INSTALLATION . . . . . 16-33
OSCILLOSCOPE. . . . . . . . . . . . . . . . . . 16-11
CAMSHAFT POSITION SENSOR . 16-34

ALTERNATOR ASSEMBLY . . . . . 16-14 REMOVAL AND INSTALLATION . . . . . 16-34
REMOVAL AND INSTALLATION . . . . . 16-14
DISASSEMBLY AND ASSEMBLY. . . . . 16-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17
CRANKSHAFT POSITION SENSOR 16-35
STARTING SYSTEM . . . . . . . . . 16-20 KNOCK SENSOR . . . . . . . . . . . . . . 16-36

GENERAL DESCRIPTION . . . . . . 16-20
STARTING SYSTEM DIAGNOSIS . . . . 16-21
SPECIFICATIONS . . . . . . . . . . 16-38
STARTER MOTOR ASSEMBLY . . 16-23
FASTENER TIGHTENING
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-24 SPECIFICATIONS . . . . . . . . . . . . . 16-38
DISASSEMBLY AND ASSEMBLY. . . . . 16-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-28 GENERAL SPECIFICATIONS . . . . 16-38
IGNITION SYSTEM . . . . . . . . . . . . . . 16-30 SERVICE SPECIFICATIONS . . . . . 16-39

16-2
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
CHARGING SYSTEM DIAGNOSIS

M1161000700427
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.
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 −
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 −
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.
CHARGING SYSTEM
STEP 9.
Q: Is the regulated voltage normal? (Refer to Charging
System − On-vehicle Service − Regulated Voltage Test
P.16-10.)
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.
CHARGING SYSTEM
SPECIAL TOOL
M1161000600486

NAME
MB991824-KIT Checking of engine
A
Diagnostic tool (MUT-III) NOTE: G: MB991826 speed
A: MB991824 MUT-III Trigger Harness CAUTION
Vehicle is not necessary when For vehicles with CAN
communication pushing V.C.I. ENTER communication, use
MB991824 interface (V.C.I.) key. MUT-III main harness A
B B: MB991827 to send simulated
MUT-III USB cable vehicle speed. If you
C: MB991910 connect MUT-III main
MUT-III main harness harness B instead, the
A (Vehicles with CAN CAN communication
MB991827
C
communication does not function
system) correctly.
D: MB991911
B (Vehicles without
MB991910 CAN communication
D system)
E: MB991914
DO NOT USE MUT-III main harness
MB991911
models only)
F: MB991825
E MUT-III measurement
adapter
DO NOT USE G: MB991826
MUT-III trigger
MB991914 harness
F
MB991825
MB991826
MB991958
MB998467 MIT530 Checking of alternator

Alternator harness Micrd 530 charging ("S" terminal voltage)
connector system tester.
CHARGING SYSTEM
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.
4. Connect a clamp-type DC test ammeter with 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.
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.
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
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.
CHARGING SYSTEM
REGULATED VOLTAGE TEST

M1161001100666
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.
4. Use the special tool (Alternator harness
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.
• 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.
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
WAVE PATTERN CHECK USING AN

OSCILLOSCOPE
M1161001200180
.
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
CHARGING SYSTEM
(V)
0.4
0.2
VOLTAGE AT
GENERATOR 0
"B" TERMINAL
–0.2
–0.4
TIME
AKX00189 AB
NOTE: The voltage waveform of the alternator "B" terminal can

undulate as shown at left. This waveform is produced when the
regulator operates according to fluctuations in the alternator
load (current), and is normal for the alternator.
If the ripple height is abnormally high (approximately 2 V or
more during idling), the wires between the alternator "B" termi-
nal and the battery have broken due to fuse blowing, etc. The
alternator is usually operating properly.
.
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
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
CHARGING SYSTEM
ALTERNATOR ASSEMBLY
M1161001400601

• Side Under Cover Removal and Installation (Refer to
GROUP 51, Under Cover P.51-13).
2
12 ± 2 N·m
102 ± 22 in-lb
5
49 ± 9 N·m
36 ± 7 ft-lb
3
1
4
06DB030A
1. ALTERNATOR DRIVE BELT 3. A/C COMPRESSOR ASSEMBLY
2. ALTERNATOR CONNECTOR CONNECTOR
<<A>> 4. A/C COMPRESSOR ASSEMBLY
<> 5. ALTERNATOR ASSEMBLY

.
<<A>> A/C COMPRESSOR ASSEMBLY REMOVAL

Remove the compressor from the compressor bracket with the
hose still attached.
CHARGING SYSTEM
NOTE: Place the removed A/C compressor where it will not be

a hindrance when removing and installing the alternator, and
secure it with a cord or wire.
.
<> ALTERNATOR ASSEMBLY REMOVAL

Move the A/C compressor assembly to one side, and then
remove the alternator assembly from under the vehicle.
DISASSEMBLY AND ASSEMBLY

M1161001600188
1 4
4.4 ± 1.0 N·m
39 ± 9 in-lb 3
5
7 6
3.7 ± 0.7 N·m

33 ± 6 in-lb
118 ± 19 N·m
87 ± 14 ft-lb
12
10
9
14
8
13
11
3.7 ± 0.7 N·m

33 ± 6 in-lb
06DB031A
DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)

<<A>> 1. FRONT BRACKET ASSEMBLY <<C>> 8. STATOR
<> 2. ALTERNATOR PULLEY 9. PLATE
>>B<< 3. ROTOR ASSEMBLY >>A<< 10. REGULATOR ASSEMBLY
4. REAR BEARING 11. BRUSH
5. BEARING RETAINER 12. SLINGER
6. FRONT BEARING 13. RECTIFIER
7. FRONT BRACKET 14. REAR BRACKET
CHARGING SYSTEM
DISASSEMBLY SERVICE POINTS

.
<<A>> FRONT BRACKET ASSEMBLY REMOVAL

CAUTION
Do not insert a screwdriver too deep. The stator coil will be
damaged.
Insert a flat-tipped screwdriver between the front bracket
assembly and the stator core, and pry it downward to separate
the stator and front bracket assembly.
AKX00355
<> ALTERNATOR PULLEY REMOVAL

CAUTION
Make sure not to damage the rotor.
Set the pulley upward, clamp the rotor in a vise, and remove
the pulley.
AKX00356
<<C>> STATOR REMOVAL

CAUTION
SOLDERED
• Check that the heat from the soldering iron is not trans-
RECTIFIER mitted to the diode for a long time.
• Use care that no undue force is exerted to leads of
diodes.
1. Use a soldering iron (180 to 250 W) to unsolder the stator.
This work should complete within approximately four
seconds to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly,
SOLDERED
unsolder the points soldered on the rectifier.
AKX00357AB
CHARGING SYSTEM
ASSEMBLY SERVICE POINTS

.
>>A<< REGULATOR ASSEMBLY INSTALLATION

After installing the regulator assembly, insert a wire through the
hole provided on the rear bracket while pressing down on the
brush, and secure the brush.
NOTE: By inserting a wire, the brush will be secured in place,
and the installation of the rotor will be easier.
WIRE
REAR BRACKET
BRUSH
WIRE
AKX00358 AB
>>B<< ROTOR ASSEMBLY INSTALLATION

After installing the rotor, remove the wire used to secure the
brush.
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
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
CHARGING SYSTEM
2. Check the continuity between the negative rectifier and the

stator coil lead connection terminal with a tester. If there is
continuity between the terminals, the diode is grounded, so
replace the rectifier.
AKX00365
3. Check the continuity of the three diodes by connecting an

ohmmeter to both ends of each diode. If there is continuity
between the directions, or if there is no continuity, the diode
is damaged, so replace the rectifier.
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
2. The brush can be removed by unsoldering the brush lead

SOLDERED wire.
3. When installing a new brush, push the brush in to the brush
holder, and solder the lead wire.
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.
STARTING SYSTEM
STARTING SYSTEM DIAGNOSIS

M1162000700293
The starter motor does not operate at all.
WARNING
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
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.
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.
STARTING SYSTEM
STARTER MOTOR ASSEMBLY

M1162001000651

Under Cover Removal and Installation (Refer to GROUP 51,
Under Cover P.51-13).
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

1. STARTER CONNECTOR AND 2. STARTER COVER
TERMINAL <<A>> 3. STARTER ASSEMBLY
STARTING SYSTEM

.
<<A>> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from under the vehicle.
INSPECTION
M1162001100197
.
PINION GAP ADJUSTMENT

<3.8L ENGINE>
1. Disconnect the field coil wire from the M-terminal of the
SWITCH magnetic switch.
2. Connect a 12-volt battery between the S-terminal and
B M-terminal.
S M CAUTION
This test must be performed quickly (in less than 10 sec-
BATTERY
onds) to prevent the coil from burning.
STARTER WIRE
MOTOR 3. Set the switch to "ON", and the pinion will move out.
AKX01239 AE
4. Check the pinion-to-stopper clearance (pinion gap) with a

feeler gauge.
STOPPER
PINION
PINION GAP AKX00198 AB
5. If the pinion gap is out of specification, adjust by adding or

removing gasket(s) between the magnetic switch and front
bracket.
AKX00199
MAGNETIC SWITCH PULL-IN TEST

<3.8L ENGINE>
magnetic switch.
CAUTION
B
S M
2. Connect a 12-volt battery between the S-terminal and
BATTERY
M-terminal.
STARTER WIRE 3. If the pinion moves out, the pull-in coil is good. If it doesn't,
MOTOR
replace the magnetic switch.
AKX01243 AE
STARTING SYSTEM
.
MAGNETIC SWITCH HOLD-IN TEST

<3.8L ENGINE>
magnetic switch.
CAUTION
B
S M
2. Connect a 12-volt battery between the S-terminal and body.
BATTERY
3. Manually pull out the pinion as far as the pinion stopper
STARTER
MOTOR position.
WIRE
4. If the pinion remains out, everything is operating properly. If
AKX01245 AE the pinion moves in, the hold-in circuit is open. Replace the
magnetic switch.
.
FREE RUNNING TEST

<3.8L ENGINE> 1. Place the starter motor in a vise equipped with soft jaws and
CARBON-PILE connect a fully-charged 12-volt battery to the starter motor
RHEOSTAT
B as follows:
AMMETER 2. Connect a test ammeter (100-ampere scale) and carbon pile
S A
M rheostat in series between the positive battery terminal and
starter motor terminal.
BATTERY
STARTER V 3. Connect a voltmeter (15-volt scale) across the starter motor.
MOTOR VOLTMETER
4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the negative battery terminal
AKX01247 AE to the starter motor body.
6. Adjust the rheostat until the battery positive voltage shown
on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly and
freely.
Current: maximum 95 Amps
.
MAGNETIC SWITCH RETURN TEST

<3.8L ENGINE> 1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
CAUTION
B
S onds) to prevent the coil from burning.
M
2. Connect a 12-volt battery between the M-terminal and body.
BATTERY
STARTER WARNING
MOTOR Be careful not to get your fingers caught when pulling
WIRE
out the pinion.
AKX01249 AE
3. Pull the pinion out and release. If the pinion quickly returns
to its original position, everything is operating properly. If it
doesn't, replace the magnetic switch.
STARTING SYSTEM

M1162001200150
11
12
14
13
1
19
10
18
17
15 16
20
4
3
5
7
6
9
AK204336AB
DISASSEMBLY STEPS DISASSEMBLY STEPS

1. SCREW 11. PACKING B
2. MAGNETIC SWITCH 12. PLATE
3. SCREW 13. PLANETARY GEAR
4. SCREW 14. LEVER
5. REAR BRACKET <<A>> >>A<< 15. SNAP RING
6. BRUSH <<A>> >>A<< 16. STOP RING
7. REAR BEARING 17. OVERRUNNING CLUTCH
8. ARMATURE 18. INTERNAL GEAR
9. YOKE ASSEMBLY 19. PLANETARY GEAR HOLDER
10. PACKING A 20. FRONT BRACKET
STARTING SYSTEM

.
<<A>> SNAP RING AND STOP RING REMOVAL

1. Press a long socket wrench of appropriate size to the stop
SOCKET ring. Then tap the socket wrench to remove the stop ring to
the pinion gear side.
STOP RING
PINION GEAR
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
STARTER MOTOR PART CLEANING

1. Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe these parts with a shop towel only.
2. Do not immerse the drive unit in cleaning solvent.
Overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with
cleaning solvent and wiped dry with a shop towel.
ASSEMBLY SERVICE POINT
.
>>A<< STOP RING AND SNAP RING INSTALLA-

TION
Using a suitable pulling tool, pull the overrunning clutch stop
ring over the snap ring.
STOP
RING
OVERRUNNING
STOP RING CLUTCH
SNAP RING
AKX00372 AB
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.
AKX00373
2. Check the outer diameter of the commutator.

Standard value: 29.4 mm (1.16 inches)
Minimum limit: 28.8 mm (1.13 inches)
AKX00374
UNDERCUT 3. Check the depth of the undercut between segments.

SEGMENT
Minimum limit: 0.2 mm (0.008 inch)
MICA
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
.
STARTING SYSTEM
OVERRUNNING CLUTCH CHECK

1. While holding the clutch housing, rotate the pinion. The drive
pinion should rotate smoothly in one direction, but should
not rotate in the opposite direction. If the clutch does not
function properly, replace the overrunning clutch assembly.
FREE 2. Inspect the pinion for wear or burrs. If the pinion is worn or
burred, replace the overrunning clutch assembly. If the
pinion is damaged, also inspect the ring gear for wear or
LOCK
burrs.
AKX00378 AB
FRONT AND REAR BRACKET BUSHING CHECK

Inspect the bushing for wear or burrs. If the bushing is worn or
burred, replace the front bracket assembly or rear bracket
assembly.
.
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
4. Check the insulation between the armature coil cores and

the commutator segments. They are normal if there is no
continuity.
AKX00380
5. Check for continuity between the segments. The condition is

normal if there is continuity.
AKX00381
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

NAME
MD998773 MD998773-01 Knock sensor removal
Knock sensor wrench and installation
IGNITION SYSTEM
ON-VEHICLE SERVICE
KNOCK CONTROL SYSTEM CHECK

M1163001800081
Check the knock sensor circuit if diagnostic trouble code, No.
P0325 is shown.
Refer to GROUP 13B, Multiport Fuel Injection (MPI) − Multiport

Fuel Injection (MPI) Diagnosis − Diagnostic Trouble Code Pro-
cedures − DTC P0325 : Knock Sensor Circuit 13A-346.
IGNITION COIL CHECK

M1163001200380
Check by the following procedure, and replace the coil if there
is a malfunction.
.
PRIMARY COIL AND IGNITION POWER

TRANSISTOR CONTINUITY CHECK
NOTE: No test can be performed on the Primary side of coil.
.
SECONDARY COIL CHECK

NOTE: It is impossible to check the secondary coil through the
continuity check as a diode is integrated in the secondary coil
circuit of this ignition coil. Accordingly, check the secondary coil
in the following procedure.
1. Disconnect the ignition coil connector.
2. Remove the ignition coil and install a new spark plug to the
ignition coil.
3. Connect the ignition coil connector.
4. Disable vehicle fuel pump by removing fuel pump relay or
disconnecting fuel pump connector D-18 (under rear seat).
5. Ground the side electrode of the spark plug and crank the
engine.
6. Check that spark is produced between the electrodes of the
spark plug.
7. If no spark is produced, replace the ignition coil with a new
one and recheck.
8. If spark is produced with the new ignition coil, replace the
old one as it is faulty. If no spark is produced again, the
ignition circuit is suspected as faulty. Check the ignition
circuit.
IGNITION SYSTEM
SPARK PLUG TEST

M1163001500143
1. Remove the spark plug and connect to the ignition coil.
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.
DEFECTIVE INSULATION GOOD
AKX00277 AB
SPARK PLUG CHECK AND CLEANING

M1163004300397
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
AKX00383 AK
CAMSHAFT POSITION SENSOR CHECK

M1163004400208

cedures − DTC P0340 : Camshaft Position Sensor Circuit
13A-372.
CRANKSHAFT POSITION SENSOR CHECK

M1163004500261

cedures − DTC P0335 : Crankshaft Position Sensor Circuit
13A-354.
IGNITION SYSTEM
IGNITION COIL
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

• ENGINE COVER (REFER TO • INTAKE MANIFOLD PLENUM
GROUP 11C, ENGINE ASSEMBLY (REFER TO GROUP 15, INTAKE
11A-14). MANIFOLD PLENUM P.15-5).
1. IGNITION COIL CONNECTORS 4. IGNITION COIL CONNECTORS
(LH) (RH)
2. IGNITION COILS (LH) 5. IGNITION COILS (RH)
3. SPARK PLUGS (LH) 6. SPARK PLUGS (RH)
IGNITION SYSTEM
CAMSHAFT POSITION SENSOR

M1163003400476
1 11 ± 1 N·m
98 ± 8 in-lb
3N
06DB032A

1. CAMSHAFT POSITION SENSOR 2. CAMSHAFT POSITION SENSOR
CONNECTOR 3. O-RING
IGNITION SYSTEM

M1163003500473

Timing Belt Lower Cover Removal and Installation (Refer to
GROUP 11C, Timing Belt 11A-46).
9.0 ± 1.0 N·m

80 ± 9 in-lb

AC306927AB
IGNITION SYSTEM
KNOCK SENSOR
M1163002800589

Intake Manifold Removal and Installation (Refer to GROUP
15, Intake Manifold P.15-7).
23 ± 2 N·m
17 ± 1 ft-lb
AC307548 AB
REMOVAL
<<A>> >>A<< 1. KNOCK SENSOR
MD998773: Knock Sensor Wrench

.
<<A>> KNOCK SENSOR REMOVAL

Use special tool MD998773 to remove the knock sensor.
MD998773
ACX02082AB
IGNITION SYSTEM

.
>>A<< KNOCK SENSOR INSTALLATION

Use special tool MD998773 to install the knock sensor.
MD998773
ACX02082AB
SPECIFICATIONS
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
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)
M1161000200411
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
SPECIFICATIONS
M1161000300322

Alternator
Regulated voltage −20°C (−4°F) 14.2 − 15.4 −
(Ambient temperature at voltage 13.9 − 14.9
20°C (68°F) −
regulator)
60°C (140°F) 13.4 − 14.5 −
80°C (176°F) 13.1 − 14.5 −
Alternator output wire voltage drop (at 30 A) V − Maximum 0.3
Nominal Output current 110A 70 % of normal output
current
Field coil resistance Ω Approximately 2 − 5 −
Brush protrusion length mm (in) − Minimum 2 (0.08)
Starter motor
Free running characteristics Terminal voltage 11 −
V
Current A 95 −
Speed r/min 2,500 or more −
Pinion gap mm (in) 0.5 − 2.0 (0.02 − 0.07) −
Commutator run-out mm (in) 0.05 (0.002) Minimum 0.1 (0.004)
Commutator diameter mm (in) 29.4 (1.16) Minimum 28.8 (1.13)
Undercut depth mm (in) 0.5 (0.02) Minimum 0.2 (0.008)
Ignition parts
Spark plug gap mm 1.0 1.1
SPECIFICATIONS
HOME
17-1
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL . . . . . . . . . . 17-3 AUTO-CRUISE CONTROL SYSTEM

DIAGNOSIS . . . . . . . . . . . . . . . . . . 17-10
INTRODUCTION TO AUTO-CRUISE
CONTROL SYSTEM DIAGNOSIS . . . . . 17-10
DIAGNOSTIC TROUBLESHOOTING
ENGINE CONTROL SYSTEM STRATEGY . . . . . . . . . . . . . . . . . . . . . . 17-11
DIAGNOSIS . . . . . . . . . . . . . . . . . . 17-3 DIAGNOSTIC FUNCTION . . . . . . . . . . . 17-11
INTRODUCTION . . . . . . . . . . . . . . . . . . 17-3 DIAGNOSTIC TROUBLE CODE CHART 17-14
TROUBLESHOOTING STRATEGY . . . 17-3 DIAGNOSTIC TROUBLE CODE
SYMPTOM CHART . . . . . . . . . . . . . . . . 17-4 PROCEDURES . . . . . . . . . . . . . . . . . . . 17-15
SYMPTOM PROCEDURES . . . . . . . . . 17-4 SYMPTOM CHART . . . . . . . . . . . . . . . . 17-53
SYMPTOM PROCEDURES . . . . . . . . . . 17-54
DATA LIST REFERENCE TABLE . . . . . 17-65
SPECIAL TOOL . . . . . . . . . . . . . . . 17-8
ENGINE ECU TERMINAL VOLTAGE
REFERENCE CHART FOR AUTO-CRUISE
ACCELERATOR PEDAL. . . . . . . . 17-9 CONTROL SYSTEM OPERATION . . . . 17-67
SPECIAL TOOLS . . . . . . . . . . . . . . 17-69
AUTO-CRUISE CONTROL . . . . 17-10
ON-VEHICLE SERVICE . . . . . . . . . 17-71
GENERAL DESCRIPTION . . . . . . 17-10 AUTO-CRUISE CONTROL SWITCH
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-71
AUTO-CRUISE CONTROL SYSTEM
COMPONENT CHECK. . . . . . . . . . . . . . 17-73
AUTO-CRUISE CONTROL. . . . . . . 17-75

REMOVAL AND INSTALLATION. . . . . . 17-75
Continued on next page

ENGINE AND EMISSION CONTROL 17-2
EMISSION CONTROL . . . . . . . . 17-76 SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-81
GENERAL DESCRIPTION (EVAPORATIVE
EMISSION SYSTEM) . . . . . . . . . . . . . . . 17-81
GENERAL DESCRIPTION . . . . . . 17-76 COMPONENT LOCATION. . . . . . . . . . . 17-82
PURGE CONTROL SYSTEM CHECK
DIAGNOSIS . . . . . . . . . . . . . . . . . . 17-76 (PURGE FLOW CHECK) . . . . . . . . . . . . 17-82
EVAPORATIVE EMISSION PURGE
SOLENOID CHECK . . . . . . . . . . . . . . . . 17-83
SPECIAL TOOLS. . . . . . . . . . . . . . 17-76
MASS AIRFLOW SENSOR CHECK . . . 17-84
ENGINE COOLANT TEMPERATURE
VACUUM HOSES . . . . . . . . . . . . . 17-77 SENSOR CHECK. . . . . . . . . . . . . . . . . . 17-84
VACUUM HOSE ROUTING. . . . . . . . . . 17-77 INTAKE AIR TEMPERATURE SENSOR
VACUUM CIRCUIT DIAGRAM . . . . . . . 17-78 CHECK . . . . . . . . . . . . . . . . . . . . . .17-84
VACUUM HOSE INSTALLATION . . . . . 17-78
VACUUM HOSE CHECK. . . . . . . . . . . . 17-79
EVAPORATIVE EMISSION CANISTER
............................ 17-81
POSITIVE CRANKCASE VENTILATION REMOVAL AND INSTALLATION. . . . . . 17-81
SYSTEM. . . . . . . . . . . . . . . . . . . . . 17-79 INSPECTION . . . . . . . . . . . . . . . . . . . . . 17-81
GENERAL DESCRIPTION (POSITIVE
CRANKCASE VENTILATION SYSTEM) 17-79
CATALYTIC CONVERTER . . . . . . 17-84
COMPONENT LOCATION . . . . . . . . . . 17-80
GENERAL DESCRIPTION (CATALYTIC
POSITIVE CRANKCASE VENTILATION
CONVERTER) . . . . . . . . . . . . . . . . . . . . 17-84
SYSTEM CHECK. . . . . . . . . . . . . . . . . . 17-80
POSITIVE CRANKCASE VENTILATION
VALVE CHECK . . . . . . . . . . . . . . . . . . . 17-80 SPECIFICATIONS . . . . . . . . . . 17-85
FASTENER TIGHTENING
EVAPORATIVE EMISSION CONTROL SPECIFICATIONS . . . . . . . . . . . . . . . . . 17-85
ENGINE CONTROL
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
ENGINE CONTROL SYSTEM DIAGNOSIS

INTRODUCTION
M1171002000254
If there is a malfunction in the engine control system,
the accelerator pedal or throttle body may be faulty.
M1171002100284
Use these steps to plan your diagnostic strategy. 2. Verify that the condition described by the
If you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find an 3. Find the malfunction by following the Symptom
engine control system fault. Chart.
1. Gather information from the customer. 4. Verify that the malfunction is eliminated.
ENGINE CONTROL
SYMPTOM CHART
M1171002200292

Throttle Valve Will Not Fully Open or Close 1 P.17-4
Accelerator Pedal Operation Not Smooth (Over 2 P.17-6
Acceleration)
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Throttle Valve Will Not Fully Open or Close

.
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.
.
• Malfunction of the Engine ECU.

Circuit drawings
ENGINE CONTROL
DIAGNOSIS
STEP 1. Using Diagnostic Tool MB991958, read the

CAUTION
To prevent damage to Diagnostic Tool MB991958, always
CONNECTOR
before connecting or disconnecting Diagnostic Tool
MB991958.
position.
MB991910
MB991824
position.
tool MB991824 indicator lamp will be illuminated in a green
color.
MB991827
00DB076A
to Read and Erase Diagnostic Trouble Code P.13A-6) .
(10)Turn the ignition switch to the "LOCK" (OFF) position, and
then remove Diagnostic Tool MB991958 in the reverse
order of installation.
Q: Is any DTC set?
YES : Repair MPI system.(Refer to GROUP 13A, MPI
Diagnosis − Diagnostic Trouble Code Chart 13A-17) .
Then go to Step 2.
NO : Go to Step 2.

Q: Does the throttle valve fully open and close?
ENGINE CONTROL
INSPECTION PROCEDURE 2: Accelerator Pedal Operation Not Smooth (Over Acceleration)

.
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
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check if the accelerator pedal is installed

correctly.
Q: Is the accelerator pedal installed correctly?
YES : Go to Step 2.
NO : Replace and reinstall the accelerator pedal. (Refer to
P.17-9). Go to Step 3.
ENGINE CONTROL

CAUTION
before connecting or disconnecting Diagnostic Tool
MB991958.
position.
position.
tool MB991824 indicator lamp will be illuminated in a green
color.
(9) Check for MPI system diagnostic trouble code.(Refer to
to Read and Erase Diagnostic Trouble Code 13A-6) .
(10)Turn the ignition switch to the "LOCK" (OFF) position, and
then remove Diagnostic Tool MB991958 in the reverse
order of installation.
Q: Is any DTC set?
YES : Repair MPI system.(Refer to GROUP 13A, MPI
Diagnosis − Diagnostic Trouble Code Chart 13A-17) .
Then go to Step 3.
NO : Go to Step 3.

Q: Does the accelerator pedal work normally?
ENGINE CONTROL
SPECIAL TOOL
M1171000600045

NAME
MB991958 MB991824-KIT Checking diagnostic trouble
A
A: MB991824 NOTE: G: codes
B: MB991827 MB991826 MUT-III CAUTION
C: MB991910 trigger harness is For vehicles with CAN
D: MB991911 not necessary communication, use MUT-III
MB991824
E: MB991914 when pushing main harness A to send
B F: MB991825 V.C.I. ENTER key. simulated vehicle speed. If
G: MB991826 you connect MUT-III main
MUT-III sub assembly harness B instead, the CAN
A: Vehicle communication does not
communication function correctly.
MB991827
interface (V.C.I.)
C
communication
MB991910 system)
B (Vehicles without
system)
MB991911
E models only)
DO NOT USE adapter
G: MUT-III trigger
MB991914 harness
F
MB991825
MB991826
MB991958
ENGINE CONTROL
ACCELERATOR PEDAL
M1171003000116
2
1
13 ± 2 N·m
111 ± 22 in-lb

1. ACCELERATOR PEDAL POSITION 2. ACCELERATOR PEDAL ASSEMBLY
(APP) SENSOR CONNECTOR 3. ACCELERATOR STOPPER
AUTO-CRUISE CONTROL
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.
"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
ACCELERATOR PEDAL DATA LINK

(BUILT-IN ACCELERATOR TRANSMISSION CONNECTOR
PEDAL POSITION SENSOR) RANGE SWITCH AC305701
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 AC30570
17DB039A
AUTO-CRUISE CONTROL SYSTEM DIAGNOSIS

INTRODUCTION TO AUTO-CRUISE CONTROL SYSTEM DIAGNOSIS
M1172003300251
The auto-cruise control system allows driving without Auto-cruise control system diagnostic
stepping on the accelerator pedal by setting a ran- trouble codes
dom speed between 40 km/h (25 mph) and 200 km/h
The auto-cruise control system consists of the
(124 mph). Problems in this system can be investi-
Engine ECU, control switches and sensors. The con-
gated by the following methods.
trol switches and sensors monitor the state of the
vehicle. The Engine ECU controls the throttle valve
opening angle in the throttle body in accordance with
the input signals from the switches and sensors. If
the Engine ECU detects a problem on any of those
AUTO-CRUISE CONTROL
components, the Engine ECU estimates where the

problem may be occurring, and will set a diagnostic
trouble code. Diagnostic trouble codes cover the
auto-cruise control switch, stoplamp switch and
Engine ECU.
DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1172002000484
Use these steps to plan your diagnostic strategy. If 5. If you can verify the condition but there are no
you follow them carefully, you will check most of the auto-cruise control system DTCs, or the system
possible causes of an auto-cruise control system cannot communicate with Diagnostic Tool
problem. MB991958 (MUT-III sub assembly), and find the
1. Gather information from the customer. fault. (Refer to P.17-53, Symptom Chart).
2. Verify that the condition described by the 6. If there is an auto-cruise control system DTC,
customer exists. record the number of the code, then erase the
3. Check the vehicle for any auto-cruise control code from Engine ECU memory using the
system DTC. (Refer to P.17-11, Diagnostic Diagnostic Tool MB991958 (MUT-III sub
Function − How to Read and Erase Diagnostic assembly). (Refer to P.17-11, Diagnostic Function
Trouble Codes). − How to Read and Erase Diagnostic Trouble
4. If you can verify the condition but no auto-cruise Codes).
control system DTCs are set, the malfunction may 7. Re-create the auto-cruise control system DTC set
be intermittent. (Refer to GROUP 00, How to Use conditions to see if the same Auto-cruise Control
Troubleshooting/Inspection Service Points − How System DTC will set again. (Refer to P.17-11,
to Cope with Intermittent Malfunctions P.00-14). Diagnostic Function − How to Read and Erase
Diagnostic Trouble Codes).
• If the same Auto-cruise Control System DTC sets
again, perform the diagnostic procedures for the
set code. (Refer to P.17-14, Diagnostic Trouble
Code Chart).
DIAGNOSTIC FUNCTION
M1172004900171
HOW TO CONNECT THE DIAGNOSTIC TOOL.

AUTO-CRUISE CONTROL
CAUTION
CONNECTOR before connecting or disconnecting Diagnostic Tool
MB991958.
position.
position.
tool MB991824 indicator lamp will be illuminated in green
color.
MB991827 NOTE: Disconnecting Diagnostic Tool MB991958 is the
00DB076A
reverse of the connecting sequence, making sure that the

TROUBLE CODES
• MB991824: V.C.I.
CAUTION
MB991958.
will not be set. Check the battery if Diagnostic Tool
1. Connect Diagnostic Tool MB991958 to the data link
connector.
MB991910
MB991824 3. Depress the "CRUISE" (MAIN) switch to illuminate the
"CRUISE" indicator lamp in the combination meter.
4. Select the "Interactive Diagnosis" from the start-up screen.
5. Select the "System Select."
6. Choose the "Auto-cruise Control System" .
7. Select the "Diagnostic Trouble Code."
MB991827 00DB076A
9. Choose the "DTC erase" to erase the DTC.
AUTO-CRUISE CONTROL
11.Disconnect Diagnostic Tool MB991958.

• MB991824: V.C.I.
CAUTION
MB991958.
connector.
3. Select the "Interactive Diagnosis" from the start-up screen.
MB991910 4. Select the "System Select."
5. Choose the "Auto-cruise Control System" .
MB991824 6. Select the "Data List."
9. Disconnect Diagnostic Tool MB991958.
MB991827 00DB076A

• MB991824: V.C.I.
AUTO-CRUISE CONTROL
CAUTION
MB991958.
connector.
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.
that it matches the vehicle which is diagnosed CAN bus line.
MB991827 00DB076A 8. Press the "OK" button.
"OK" button.
11.Disconnect Diagnostic Tool MB991958.
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
AUTO-CRUISE CONTROL
DTC P0830: Clutch Switch (5M/T Only)
Judgement Criteria
.
CIRCUIT OPERATION • Gear shift is above 5 times.

• A 5 Volt power supply is applied to the clutch • Clutch control is below 2 times.
switch output terminal (terminal No. 1) from the • No MIL.
ENGINE-ECU(terminal No. B-21 pin 41) when • No Limp home.
the clutch pedal is applied the power supply is
switched to earth. .

.
• 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.
.
Check Conditions
• Vehicle speed is above 50 km/h.
DIAGNOSIS
• MB991824: V.C.I.
AUTO-CRUISE CONTROL

Clutch Switch.
CAUTION
CONNECTOR
Clutch Switch.
• When the clutch pedal is depressed the display on diag-
nostic tool should read "ON".
MB991910 • When the clutch pedal is released the display on diag-
nostic tool should read "OFF".
MB991824 (4) Turn the ignition switch to the "LOCK"(OFF) position.
Q: Is the switch operating properly?
Cope with Intermittent Malfunctions 00-14.
MB991827 00DB076A
STEP 2. Check the clutch pedal adjustment and switch

operation.
Refer to GROUP 21A, Clutch - On-vehicle Service - Clutch
Pedal Check and Adjustment P.21A-2
Q: Is the pedal and switch adjustment correct?
YES : Go to Step 3.
NO : Adjust the pedal or replace the switch if damaged or
not operating correctly. Then go to Step 6.
AUTO-CRUISE CONTROL
STEP 3. Measure the clutch switch power supply voltage

by backprobing the clutch switch connector C-07 (terminal
1).
C-07 HARNESS • Voltage should be battery positive voltage.
CONNECTOR
present?
YES : Go to Step 5.
03DB247A
CONNECTOR: C-30
C-07
C-07 HARNESS
CONNECTOR
COMPONENT SIDE
17DB052A
STEP 4. Check harness connector C-07 at Clutch switch

for damage, loose or corroded terminals .
Connector Inspection 00E-2. Then go to Step 6.
AUTO-CRUISE CONTROL

CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

present?
YES : Repair or replace the open or damaged wiring circuit
between ENGINE-ECU connector B-21 and Clutch
switch connector C-07. Then go to Step 8.
NO : Check the connector B-21 for damage and ensure
03DB248A check harness connection t ENGINE-ECU is correct.
If connection is correct and no power supply is
present at terminal 41 of ENGIN-ECU then replace it.
Then go to Step 7.
STEP 5. Measure the clutch switch power supply voltage

by backprobing the clutch switch connector C-07 (terminal
2).
(1) Measure the voltage between terminal No. 2 and ground by
C-07 HARNESS
CONNECTOR backprobing. while depressing the clutch pedal.
• When pedal is not depressed an (open circuit) , voltage
should be battery positive voltage.
• When pedal is depressed an (closed circuit) , voltage
should be less than 1.0 volt.
Q: Is there battery voltage at terminal No. 2 when pedal is
depressed?
YES : Go to Step 6.
03DB249A
NO : Replace the Clutch switch. Refer to GROUP 21A,
Clutch - On-vehicle Service - Clutch Pedal Check and
Adjustment P.21A-2. Then go to Step 7.
AUTO-CRUISE CONTROL
STEP 6. Measure the resistance between Clutch switch

connector C-07 (terminal No. 2) and earth.
(1) Measure the resitence between terminal No. 2 and ground.
C-07 HARNESS
CONNECTOR • The resistance should measure less than 2 ohms.
YES : Go to Step 7.
NO : Repair harness wire or connection between Clutch
switch connector C-07 (terminal No. 2) and earth
because of open circuit. Then go to Step 7.
03DB250A
CONNECTOR: C-30
C-07
C-07 HARNESS
CONNECTOR
COMPONENT SIDE
17DB052A
STEP 7. Test the OBD-II drive cycle.

Diagnostic Function − OBD-II Drive Cycle − P.13A-13.
AUTO-CRUISE CONTROL
DTC1564 : Auto-cruise Control Switch System
CONNECTOR: C-29
AIR
CLEANER C-29
COVER
ENGINE
CONTROL
UNIT
C-29 MALE SIDE CONNECTOR
16DB400A
17DB041A
CONNECTORS: C-302, C-303, C-306
CLOCK
SPRING
C-302 (Y)
C-303 (GR)
C-306
C-302 HARNESS C-303 HARNESS

CONNECTOR: CONNECTOR:
COMPONENT SIDE COMPONENT SIDE
C-306 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB040A
.
AUTO-CRUISE CONTROL
CIRCUIT OPERATION Judgement Criteria

This circuit judges the signals of each switch • If the auto-cruise control switch is operated, this
("COAST/SET", "ACC/RES" and "CANCEL") of the DTC will be set when the Engine ECU terminal
auto-cruise control switch. The Engine ECU detects voltage is different from the standard value.
the state of the auto-cruise control switch by sensing .
the voltages shown below. TROUBLESHOOTING HINTS (THE MOST

• When all switches are OFF: 4.7 − 5.0 volts LIKELY CAUSES FOR THIS CASE:)
• When the "CRUISE" (MAIN) switch is "ON": 0 − • Malfunction of the auto-cruise control switch.
0.3 volt • Malfunction of the clock spring.
• When the "COAST/SET" switch is ON: 2.0 − 2.8 • Damaged harness or connector.
volts • Malfunction of the Engine ECU.
• When the "ACC/RES" switch is ON: 3.3 − 4.1
volts Circuit drawings
• When the "CANCEL" switch is ON: 0.8 − 1.5 volts • Refer to circuit diagrams GROUP-90
.
DTC SET CONDITIONS

Check Condition
• The "CRUISE" indicator lamp illuminates.
DIAGNOSIS
• MB991824: V.C.I.
AUTO-CRUISE CONTROL
STEP 1. Using Diagnostic Tool MB991958, check data list

item 86: Main Switch, list item 92: Set Switch, item 91:
Resume Switch and list item 75: Cancel Switch.
CAUTION
MB991958.
(1) Connect Diagnostic Tool MB991958 to the data link
(3) Set Diagnostic Tool MB991958 to data reading mode for
auto-cruise control system. (Refer to P.17-11).
MB991910 • Item 86: Main Switch.
• When "CRUISE" (MAIN) switch is at the "ON" posi-
MB991824 tion, the display on Diagnostic Tool MB991958
should be "ON".
• When ""CRUISE" (MAIN) switch is at the "OFF"
position, the display on Diagnostic Tool MB991958
should be "OFF".
• Item 92: Set Switch.
• When "COAST/SET" switch is at the "ON" position,
the display on Diagnostic Tool MB991958 should be
MB991827 00DB076A "ON".
• When "COAST/SET" switch is at the "OFF" position,
"OFF".
• Item 91: Resume Switch.
• When "ACC/RES" switch is at the "ON" position, the
display on Diagnostic Tool MB991958 should be
"ON".
• When "ACC/RES" switch is at the "OFF" position,
"OFF".
• Item 75: Cancel Switch.
• When "CANCEL" switch is at the "ON" position, the
"ON".
• When "ACC/RES" switch is at the "OFF" position,
"OFF".
(5) Disconnect Diagnostic Tool MB991958.
NO : Go to Step 2.
AUTO-CRUISE CONTROL
STEP 2. Measure the power supply voltage at auto-cruise

control switch connector C-302 by backprobing.
(1) Remove the air bag module (driver’s side). (Refer to
GROUP 52B, Air Bag Modules and Clock Spring
P.52B-237).
(2) Connect the negative (−) battery cable.
CONNECTOR: C-302 (3) Do not disconnect auto-cruise control switch connector
C-302.
CLOCK (4) Turn the ignition switch to the "ON" position.
SPRING
(5) The "CRUISE" (MAIN) switch to the "OFF" position.
C-302 (Y)
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.
1 2 3
YES : Go to Step 9.
NO : Go to Step 3.
AC205053 AC
STEP 3. Measure the power supply voltage at Engine ECU

connector B-21.
(1) Disconnect all the connectors from the Engine ECU.
(2) Connect special tool MB992044 between the Engine ECU
and the body-side harness connector.
CLEANER (4) The "CRUISE" (MAIN) switch to the "OFF" position.
(5) Measure the power supply voltage between special tool
COVER 94-pin connector terminal 14 (Engine ECU connector B-21
ENGINE terminal 14) and ground.
CONTROL
(7) Disconnect special tool MB992044 between the Engine
ECU and the body-side harness connector.
(8) Reconnect all the connectors to the Engine ECU.
YES : Go to Step 6.
NO : Go to Step 4.
16DB400A
AUTO-CRUISE CONTROL
STEP 4. Check Engine ECU connector B-21 for loose,

in the connector.
YES : Go to Step 5.
NO : Repair the faulty connector if possible or as
AIR recommended, replace complete wiring harness.
CLEANER (Refer to GROUP 00E, Harness Connector Inspection
P.00E-2). Install the air bag module (driver’s side).
COVER (Refer to GROUP 52B, Air Bag Modules and Clock
ENGINE
CONTROL Spring P.52B-237). Then go to Step 18.
UNIT
10DB133A

between the Engine ECU connector B-21 terminal 14 and
the auto-cruise control switch connector C-302 terminal 2.
(1) Disconnect Engine ECU connector B-21 and measure at
the harness connector side.
AIR (3) Measure the continuity between Engine ECU connector
CLEANER B-21 terminal 14 and ground.
(4) Reconnect Engine ECU connector B-21.
COVER Q: Is the measured continuity open circuit?
ENGINE
CONTROL YES : Install the air bag module (driver’s side). (Refer to
UNIT
P.52B-237). Then go to Step 17.
NO : Go to Step 6.
10DB133A
AUTO-CRUISE CONTROL
STEP 6. Check intermediate connector C-29, auto-cruise

control switch connector C-302 and clock spring
connectors C-303 and C-306 for loose, corroded or
connector.
CONNECTOR: C-29 Q: Are the connectors and terminals in good condition?
YES : Go to Step 7.
NO : Repair the faulty connector if possible or as
recommended, replace complete wiring harness.
C-29 (Refer to GROUP 00E, Harness Connector Inspection
P.00E-2). Install the air bag module (driver’s side).
(Refer to GROUP 52B, Air Bag Modules and Clock
Spring P.52B-237). Then go to Step 18.
17DB041A
CLOCK
SPRING
C-302 (Y)
C-303 (GR)
C-306

C-306 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB040A
AUTO-CRUISE CONTROL
STEP 7. Check the harness wire between Engine ECU

connector B-21 terminal 14 and auto-cruise control switch
connector C-302 terminal 2 for damage.
Q: Are the harness wires in good condition?
YES : Go to Step 8.
NO : Repair the damaged harness wire if possible or as
AIR recommended replace complete wiring harness and
CLEANER install the air bag module (driver’s side). (Refer to
COVER P.52B-237). Then go to Step 18.
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-302
CLOCK
SPRING
C-302 (Y)
C-302 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB042A
STEP 8. Check the clock spring.

Refer to GROUP 52B, Air Bag Modules and Clock Spring
P.52B-244.
Q: Is the clock spring in good condition?
Cope with Intermittent Malfunction P.00-14). Install
the air bag module (driver’s side). (Refer to GROUP
52B, Air Bag Modules and Clock Spring P.52B-237).
Then go to Step 18.
NO : Replace the clock spring and install the air bag
module (driver’s side). (Refer to GROUP 52B, Air Bag
Modules and Clock Spring P.52B-237). Then go to
Step 18.
AUTO-CRUISE CONTROL
STEP 9. Measure the ground voltage at auto-cruise control

switch connector C-302 by backprobing.
CONNECTOR: C-302 (1) Do not disconnect auto-cruise control switch connector
C-302.
CLOCK (2) Turn the ignition switch to the "ON" position.
SPRING
(3) Turn the "CRUISE" (MAIN) switch to the "ON" position.
C-302 (Y)
C-302 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB042A
(4) Measure the ground voltage between auto-cruise control

C-302 HARNESS switch connector C-302 terminal 3 and ground by
CONNECTOR:
HARNESS SIDE backprobing.
(5) Turn the "CRUISE" (MAIN) switch to the "OFF" position.
1 2 3 (6) Turn the ignition switch to the "LOCK" (OFF) position.
NO : Go to Step 10.
AC209264 AB
STEP 10. Measure the ground voltage at Engine ECU

connector B-21.
CLEANER (4) Turn the "CRUISE" (MAIN) switch to the "ON" position.
(5) Measure the ground voltage between special tool 94-pin
COVER connector terminal 15 (Engine ECU connector B-21
ENGINE terminal 15) and ground.
CONTROL
UNIT (6) Turn the "CRUISE" (MAIN) switch to the "OFF" position.
16DB400A NO : Go to Step 11.
AUTO-CRUISE CONTROL
STEP 11. Check Engine ECU connector B-21 for loose,

in the connector.
YES : Install the air bag module (driver’s side). (Refer to
AIR P.52B-237). Then go to Step 17.
CLEANER
NO : Repair the faulty connector if possible, or as
recommended, replace complete wiring harness.
COVER (Refer to GROUP 00E, Harness Connector Inspection
ENGINE
CONTROL P.00E-2). Install the air bag module (driver’s side).
UNIT (Refer to GROUP 52B, Air Bag Modules and Clock
10DB133A
AUTO-CRUISE CONTROL
STEP 12. Check Engine ECU connector B-21, intermediate

connector C-29, auto-cruise control switch connector
C-302 and clock spring connectors C-303 and C-306 for
loose, corroded or damaged terminals, or terminals
pushed back in the connector.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-29
C-29
17DB041A
AUTO-CRUISE CONTROL

NO : Repair the faulty connector if possible, or as
CLOCK recommended, replace complete wiring harness.
SPRING
(Refer to GROUP 00E, Harness Connector Inspection
C-302 (Y) P.00E-2). Install the air bag module (driver’s side).
C-303 (GR)
C-306

C-306 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB040A

connector B-21 terminal 15 and auto-cruise control switch
NO : Repair the damaged harness wire if possible, or
AIR replace complete wiring harness and install the air
CLEANER bag module (driver’s side). (Refer to GROUP 52B, Air
Bag Modules and Clock Spring P.52B-237). Then go
COVER to Step 18.
ENGINE
CONTROL
UNIT
10DB133A
CONNECTOR: C-302
CLOCK
SPRING
C-302 (Y)
C-302 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB042A
AUTO-CRUISE CONTROL
STEP 14. Check the clock spring.

Refer to GROUP 52B, Air Bag Modules and Clock Spring
P.52B-244.
Q: Is the clock spring in good condition?
Cope with Intermittent Malfunction P.00-14). Install
the air bag module (driver’s side). (Refer to GROUP
52B, Air Bag Modules and Clock Spring P.52B-237).
Then go to Step 18.
NO : Replace the clock spring and install the air bag
module (driver’s side). (Refer to GROUP 52B, Air Bag
Modules and Clock Spring P.52B-237). Then go to
Step 18.
STEP 15. Check auto-cruise control switch connector

CONNECTOR: C-302 Q: Are the connector and terminals in good condition?
CLOCK
SPRING NO : Repair the faulty connector if possible, or as
recommended, replace complete wiring harness or
C-302 (Y)
module. (Refer to GROUP 00E, Harness Connector
Inspection P.00E-2). Install the air bag module
C-302 HARNESS (driver’s side). (Refer to GROUP 52B, Air Bag
CONNECTOR:
COMPONENT SIDE Modules and Clock Spring P.52B-237). Then go to
Step 18.
17DB042A
AUTO-CRUISE CONTROL
STEP 16. Check the auto-cruise control switch.

(1) Remove auto-cruise control switch. (Refer to P.17-75).
(2) Measure the resistance between terminal 2 and terminal 3
when each of the "CRUISE" (MAIN), "COAST/SET",
"ACC/RES" and "CANCEL" switch is pressed.
1 2 3 SWITCH POSITION SPECIFIED CONDITION
"CRUISE" (MAIN) switch Open circuit
"OFF"
2 "CRUISE" (MAIN) switch Less than 2 ohms
"ON"
"CANCEL" switch ON Approximately 100 Ω
"ACC/RES" switch ON Approximately 887 Ω
"COAST/SET" switch ON Approximately 300 Ω
MAIN RES SET CAN
OFF
Q: Is the resistance within specifications?
OFF OFF OFF
YES : Install the air bag module (driver’s side). (Refer to
ON ON ON ON
3
NO : Replace the auto-cruise control switch. (Refer to
AC203822AB P.17-75). Install the air bag module (driver’s side).

CAUTION
MB991958.
(3) Set Diagnostic Tool MB991958 to read the diagnostic
trouble codes. (Refer to P.17-11).
MB991824
Q: Is DTC 1564 set?
YES : Replace the Engine ECU.[Refer to GROUP 13A,
Engine ECU 13A-675] . Then go to Step 18.
MB991827 00DB076A
AUTO-CRUISE CONTROL

CAUTION
MB991958.
MB991824
Q: Is DTC 1564 set?
MB991827 00DB076A
AUTO-CRUISE CONTROL
DTC 1575: Cancel Latch Signal System

.
DTC SET CONDITIONS

The Engine ECU communicates cancellation reten- LIKELY CAUSES FOR THIS CODE TO BE
tion information between the two microprocessors. SET ARE:)
This DTC is set when cancellation retention informa- Malfunction of the Engine ECU.
tion contains inconsistency.
Circuit drawings
.
DIAGNOSIS
Replace the Engine ECU.[Refer to GROUP 13A, Engine ECU
13A-675] . Then check that diagnostic trouble code P1575 is
not set.
AUTO-CRUISE CONTROL
DTC 1571: Stoplamp Switch System
CONNECTOR: C-30
AIR
CLEANER
COVER
ENGINE
CONTROL C-30
UNIT
C-30 HARNESS
16DB400A
CONNECTOR:
COMPONENT SIDE
17DB043A
• Open circuit in the brake switch circuit between

.
CIRCUIT OPERATION ENGINE-ECU(terminal 18) and ground.

• Battery positive voltage is supplied to the
stoplamp switch (terminal 2). .
• 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.
.
DTC SET CONDITIONS

Check Condition Circuit drawings
• The "CRUISE" indicator lamp illuminates. • Refer to circuit diagrams GROUP-90
• Short in stop lamp switch circuit.
AUTO-CRUISE CONTROL
DIAGNOSIS
• MB991958: Diagnostic ToolDiagnostic Tool (MUT-III Sub
Assembly)
• MB991824: V.C.I.

item 74: Stoplamp Switch.
CAUTION
MB991958.
MB991910 • Item 74, Stoplamp Switch.
• When the brake pedal is depressed, the display on
MB991824 Diagnostic Tool MB991958 should be "ON".
• When the brake pedal is released, the display on
Diagnostic Tool MB991958 should be "OFF".
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check the stoplamp operation.

Check the stoplamp operation.
• When the brake pedal is depressed, the stoplamp will
illuminate.
• When the brake pedal is released, the stoplamp does
not illuminate.
Q: Does the stoplamp illuminate (when the brake pedal is
depressed) and the stoplamp does not illuminate (when
the brake pedal is released)?
YES : Go to Step 3.
NO : Go to Step 6.
AUTO-CRUISE CONTROL
STEP 3. Measure the terminal voltage at Engine ECU

connector B-21.
CLEANER
COVER
ENGINE
CONTROL
UNIT
10DB133A
(4) Measure the terminal voltage between special tool 94-pin

connector terminal 18 (Engine ECU connector B-21
terminal 18) and ground.
AIR • When the brake pedal is depressed, the voltage should
CLEANER measure battery positive voltage (approximately 12
volts).
COVER • When the brake pedal is released, the voltage should
ENGINE measure 1 volt or less.
CONTROL
Q: Is the measured voltage battery positive voltage
(approximately 12 volts) when the brake pedal is
depressed and 1 volt or less when the brake pedal is
16DB400A released?
NO : Go to Step 4.
AUTO-CRUISE CONTROL
STEP 4. Check Engine ECU connector B-21 and stoplamp

switch connector C-30 for loose, corroded or damaged
YES : Go to Step 5.
NO : Repair or replace the damaged components. (Refer to
AIR
CLEANER GROUP 00E, Harness Connector Inspection
COVER
ENGINE
CONTROL
UNIT
10DB133A
CONNECTOR: C-30
C-30 C-30 HARNESS

CONNECTOR:
COMPONENT SIDE
17DB045A
AUTO-CRUISE CONTROL

connector B-21 terminal 18 and stoplamp switch
NO : Repair the damaged harness wire if possible, or as
AIR
CLEANER recommended, replace complete wiring harness.
Then go to Step 22.
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-30
C-30 C-30 HARNESS

CONNECTOR:
COMPONENT SIDE
17DB045A
AUTO-CRUISE CONTROL
STEP 6. Measure the power supply voltage at stoplamp

switch connector C-30 by backprobing.
CONNECTOR: C-30 (1) Disconnect stoplamp switch connector C-30.
C-30 C-30 HARNESS

CONNECTOR:
COMPONENT SIDE
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.
(approximately 12 volts)?
NO : Go to Step 7.
AC305712AB
STEP 7. Check stoplamp switch connector C-30 for loose,

in the connector.
YES : Go to Step 8.
C-30 C-30 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB045A
AUTO-CRUISE CONTROL
STEP 8. Check the harness wire between stoplamp switch

connector C-30 terminal 2 and fuse number 11 at the relay
box at engine compartment for damage.
YES : Go to Step 9.
22.
C-30 C-30 HARNESS

CONNECTOR:
COMPONENT SIDE
17DB045A
BATTERY
FUSE NUMBER 11
(HOUSING COLOR:
BLUE)
RELAY BOX
AC305713AB
STEP 9. Check the fuse number 11 at the relay box at

engine compartment.
Q: Is the fuse in good condition?
BATTERY
FUSE NUMBER 11
(HOUSING COLOR: NO : Check the stoplamp system harness and replace the
BLUE) fuse. Then go to Step 22.
RELAY BOX
AC305713AB
AUTO-CRUISE CONTROL
STEP 10. Check the stoplamp switch.

(1) Remove the stoplamp switch. (Refer to GROUP 35A, Brake
Pedal P.35A-24).
(2) Connect an ohmmeter to the stoplamp switch between
terminals 1 and 2.
(3) Check for continuity between the terminals when the
plunger of the stoplamp switch is pushed in and when it is
released.
(4) The stoplamp switch is operating properly if the circuit is
open between terminals 1 and 2 when the plunger is
released, and if the resistance value is less than 2 ohms
C-30 STOPLIGHT SWITCH between terminals 1 and 2 when it is pushed in.
CONNECTOR ACX02256 AL Q: Is the stoplamp switch operating properly?
YES : Install the stoplamp switch. (Refer to GROUP 35A,
Brake Pedal P.35A-24). Then go to Step 11.
NO
CONTINUITY CONTINUITY NO : Replace the stoplamp switch. (Refer to GROUP 35A,
4.0 mm (0.16 in)

AC205057 AB
STEP 11. Check stoplamp switch connector C-30 and joint

connector (1) C-01 for loose, corroded or damaged
CONNECTOR: C-30
C-30
C-30 HARNESS
CONNECTOR:
COMPONENT SIDE
17DB043A
AUTO-CRUISE CONTROL
STEP 12. Check the harness wire between stoplamp

switch connector C-30 terminal 1 and Engine-ECU
connector B-21 terminal 18 for damage.
22.
C-30 C-30 HARNESS

CONNECTOR:
COMPONENT SIDE
17DB045A
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
10DB133A
AUTO-CRUISE CONTROL

CAUTION
MB991958.
NO : Replace the Engine ECU. [Refer to GROUP 13A,
MB991827 00DB076A

item 89: Normally closed Brake Switch.
CAUTION
MB991958.
MB991910 • Item 89, Normally closed Brake Switch.
NO : Go to Step 15.
MB991827 00DB076A
AUTO-CRUISE CONTROL
STEP 15. Measure the terminal voltage at Engine ECU

connector B-21.
CLEANER (4) Measure the terminal voltage between special tool 94-pin
connector terminal 21 (Engine ECU connector B-21
COVER terminal 21) and ground.
ENGINE • When the brake pedal is depressed, the voltage should
CONTROL
UNIT measure battery positive voltage (approximately 12
volts).
• When the brake pedal is released, the voltage should
measure 1 volt or less.
16DB400A
(approximately 12 volts) when the brake pedal is
depressed and 1 volt or less when the brake pedal is
released?
NO : Go to Step 16.

(1) Remove the stoplamp switch. (Refer to GROUP 35A, Brake
Pedal P.35A-24).
(2) Connect an ohmmeter to the stoplamp switch between
C-30 STOPLIGHT SWITCH
terminals 3 and 4.
CONNECTOR
(3) Check for continuity between the terminals when the
1 2 plunger of the stoplamp switch is pushed in and when it is
3 4 released.
(4) The stoplamp switch is operating properly if the circuit is
open between terminals 3 and 4 when the plunger is
pushed in, and if resistance value is less than 2 ohms
between terminals 3 and 4 when the plunger is released.
ACX01917AJ Q: Is the stoplamp switch operating properly?
YES : Install the stoplamp switch. (Refer to GROUP 35A,
NO Brake Pedal P.35A-24). Then go to Step 17.
CONTINUITY CONTINUITY NO : Replace the stoplamp switch. (Refer to GROUP 35A,
4.5 mm (0.18 in)

AC205057AC
AUTO-CRUISE CONTROL
STEP 17. Check Engine ECU connector B-21 and stoplamp

switch connector C-30 for loose, corroded or damaged
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-30
C-30 C-30 HARNESS

CONNECTOR:
COMPONENT SIDE
17DB045A
AUTO-CRUISE CONTROL

connector B-21 terminal 21 and stoplamp switch
AIR recommended, replace complete harness. Then go to
CLEANER
Step 22.
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-30
C-30 C-30 HARNESS

CONNECTOR:
COMPONENT SIDE
17DB045A
STEP 19. Check the harness wire between stoplamp

switch connector C-30 terminal 4 and ground for damage.
GROUND
TERMINAL recommended, replace complete harness. Then go to
Step 22.
ENGINE
ECU
RELAY BOX
16DB401A
AUTO-CRUISE CONTROL

item 89: Normally closed Brake Switch.
CAUTION
MB991958.
MB991910 • Item 89, Normally closed Brake Switch.
MB991827 00DB076A

diagnostic trouble codes.
CAUTION
MB991958.
MB991824
Q: Is DTC 1571 set?
MB991827 00DB076A
AUTO-CRUISE CONTROL

diagnostic trouble codes.
CAUTION
MB991958.
MB991824
Q: Is DTC 1571 set?
MB991827 00DB076A
AUTO-CRUISE CONTROL
DTC 1574: Engine ECU and Its Related Components

.
DTC SET CONDITIONS

This DTC is set when there is a failure in the Engine LIKELY CAUSES FOR THIS CODE TO BE
ECU and its related components. SET ARE:)
• Malfunction of the MPI system.
• Malfunction of the A/T system.
.

Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using Diagnostic Tool MB991958, read the MPI

system diagnostic trouble code.
CAUTION
MB991958.
MB991910 to Read and Erase Diagnostic Trouble Code 13A-6) .
MB991824 (5) Disconnect Diagnostic Tool MB991958.
Q: Is any DTC set?
YES : Diagnose the MPI system. (Refer to GROUP 13A,
MPI Diagnosis − Diagnostic Trouble Code Chart
13A-17) . Then go to Step 4.
NO : Go to Step 2.
MB991827 00DB076A
AUTO-CRUISE CONTROL
STEP 2. Using Diagnostic Tool MB991958, read the A/T

system diagnostic trouble code.
CAUTION
MB991958.
Q: Is any DTC set?
YES : Diagnose the A/T system. (Refer to GROUP 23A, A/T
Diagnosis − Diagnostic Trouble Code Chart
NO : Go to Step 3.
MB991827 00DB076A

auto-cruise control system diagnostic trouble code.
CAUTION
MB991958.
(3) Use Diagnostic Tool MB991958 to read the auto-cruise
control system diagnostic trouble codes. (Refer to P.17-11).
MB991824
Q: Is DTC 1574 set?
MB991827 00DB076A
AUTO-CRUISE CONTROL

auto-cruise control system diagnostic trouble code.
CAUTION
MB991958.
(3) Use Diagnostic Tool MB991958 to read the auto-cruise
control system diagnostic trouble codes. (Refer to P.17-11).
MB991824
Q: Is DTC 1574 set?
MB991827 00DB076A
AUTO-CRUISE CONTROL
SYMPTOM CHART
M1172002300366

PROCEDURE NO. PAGE
Communication with Communication with all systems is - Group 13A, MPI
Diagnostic Tool is impossible Diagnosis −
not possible Symptom
Procedures −
Inspection
Procedure 1
13A-539 .
Communication with the Engine ECU only - Group 13A, MPI
is impossible Diagnosis −
Symptom
Procedures −
Inspection
Procedure 2
13A-541 .
Auto-cruise control When brake pedal is depressed 1 P.17-54
system is not When selector lever is moved to "N" range 2 P.17-54
cancelled.
When "CANCEL" switch is turned ON 3 P.17-55
When clutch pedal is depressed 4 P.17-55
Auto-cruise control system cannot be set. 5 P.17-56
Hunting (repeated acceleration and deceleration) occurs at the 6 P.17-60
set vehicle speed.
When "CRUISE" (MAIN) switch is turned "ON", "CRUISE" 7 P.17-62
indicator lamp inside combination meter does not illuminate.
(However, auto-cruise control system is normal).
NOTE: If engine speed reaches and exceeds 6000
r/min the Auto Cruise Control System will be can-
celled automatically.
AUTO-CRUISE CONTROL
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.
.

Circuit drawings
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.
•
.
Damaged harness or connector.

• Malfunction of A/T ECU.
Circuit drawings
DIAGNOSIS
Refer to GROUP 23A, A/T Diagnosis − Diagnostic Trouble
Code Procedures − DTC 0705: Transmission Inhibitor Switch
System (Open/short Circuit) P.23A-97.
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
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.
.

Circuit drawings
DIAGNOSIS
Refer to P.17-15, Diagnostic Trouble Code Procedures − DTC
0830: Clutch Switch System.
AUTO-CRUISE CONTROL
INSPECTION PROCEDURE 5: Auto-cruise Control System cannot be Set.

.
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
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
MB991958.
(3) Check for auto-cruise control system diagnostic trouble
code. (Refer to P.17-11).
MB991824
Q: Is DTC set?
YES : Diagnose the auto-cruise control system. (Refer to
P.17-14, Diagnostic Trouble Code Chart). Then go to
Step 6.
NO : Go to Step 2.
MB991827 00DB076A
AUTO-CRUISE CONTROL

item 75: Cancel Switch.
CAUTION
MB991958.
(3) Set Diagnostic ToolDiagnostic Tool MB991958 to data
reading mode for auto-cruise control system. (Refer to
MB991910 P.17-11).
• Item 75, Cancel Switch.
MB991824 • When "CANCEL" switch is at the ON position, the
"ON".
• When "CANCEL" switch is at the OFF position, the
"OFF".
MB991827 00DB076A Q: Is the switch operating properly?
YES : Go to Step 3.
NO : Refer to P.17-55, Symptom Procedures − Inspection
Procedure 3. Then go to Step 6.
AUTO-CRUISE CONTROL
STEP 3. Using Diagnostic ToolDiagnostic Tool MB991958,

check data list item 74: Stoplamp Switch and data list item
89: Brake switch.
CAUTION
MB991958.
• When brake pedal is depressed, the display on
• When brake pedal is released, the display on
• Item 89, Brake Switch.
• When brake pedal is depressed, the display on
Diagnostic Tool MB991958 should be "ON".
• When brake pedal is released, the display on
MB991827 00DB076A (4) Turn the ignition switch to the "LOCK" (OFF) position.
YES : Go to Step 4.
AUTO-CRUISE CONTROL
STEP 4. Using Diagnostic Tool MB991958, check A/T data

list item 34: Transmission Inhibitor Switch.
CAUTION
MB991958.
Auto Transmission system. (Refer to P.17-11).
MB991910 • Item 34, Transmission Inhibitor Switch.
• When selector lever is at the "P" or "N" position, the
MB991824 display on Diagnostic Tool MB991958 should be
"ON".
• When selector lever is at the "R" or "D" position, the
"OFF".
MB991827 00DB076A
YES : Go to Step 5.

Q: Can auto-cruise control be set?
NO : Replace the Engine ECU.[Refer to GROUP 13A,

Q: Can auto-cruise control be set?
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 Engine ECU.

• Malfunction of the A/T ECU.
Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
MB991958.
Q: Is any DTC set?
YES : Diagnose the A/T system. (Refer to GROUP 23A, A/T
Diagnosis − Diagnostic Trouble Code Chart
NO : Go to Step 2.
MB991827 00DB076A
AUTO-CRUISE CONTROL

CAUTION
MB991958.
(3) Check for MPI system diagnostic trouble code(Refer to
MB991910 to Read and Erase Diagnostic Trouble Code 13A-6).
Q: Is any DTC set?
YES : Diagnose the MPI system. (Refer to GROUP 13A,
MPI Diagnosis − Diagnostic Trouble Code Chart
13A-17). Then go to Step 4.
NO : Go to Step 3.
MB991827 00DB076A

Q: Does hunting occur?
YES : Replace the Engine ECU[Refer to GROUP 13A,
Engine ECU 13A-675]. Then go to Step 4.

Q: Does hunting occur?
AUTO-CRUISE CONTROL
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
CONNECTORS: C-02, C-29, C-101 CONNECTORS: C-211, C-215
C-101
C-29
C-02
C-02 HARNESS
CONNECTOR: C-211 HARNESS CONNECTOR:
C-101 HARNESS
C-29 MALE SIDE CONNECTOR:
CONNECTOR COMPONENT SIDE C-215 HARNESS CONNECTOR:
COMPONENT SIDE
17DB046A 17DB047A
.
AUTO-CRUISE CONTROL
CIRCUIT OPERATION
.
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.
.
COMMENT Circuit drawings

Connector(s), wiring harness in the CAN bus line
between the Engine ECU and the combination
meter, power supply to the Engine ECU, the combi-
nation meter, the Engine ECU may be defective.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using Diagnostic Tool MB991958, diagnose the

CAN bus line.
CAUTION
MB991958.
(3) Diagnose the CAN bus line. (Refer to P.17-11).
MB991824
YES : Go to Step 2
Then go to Step 4.
MB991827 00DB076A
AUTO-CRUISE CONTROL
STEP 2. Using Diagnostic Tool MB991958, read the MPI

CAUTION
MB991958.
(3) Check for MPI system diagnostic trouble code(Refer to
MB991910 to Read and Erase Diagnostic Trouble Code 13A-6).
YES : . Then go to Step 4.
NO : Go to Step 3.
MB991827 00DB076A

Q: Does the "CRUISE" indicator lamp illuminate when the
"CRUISE" (MAIN) switch is turned "ON"?
Engine ECU 13A-675]. Then go to Step 4.

Q: Does the "CRUISE" indicator lamp illuminate when the
"CRUISE" (MAIN) switch is turned "ON"?
AUTO-CRUISE CONTROL
DATA LIST REFERENCE TABLE - Auto Cruise Control

M1172002400471
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).
MUT-III ITEM INSPECTION ITEM INSPECTION REQUIREMENT NORMAL

Diagnostic NO. CONDITION
Tool
DISPLAY
APS 11 Accelerator pedal Ignition Accelerator pedal: Released 435 − 1,035 mV
SNS(MAIN) position sensor (main) switch: Accelerator pedal: Gradually Increases in
"ON" depressed response to the
pedal depression
stroke
Accelerator pedal: Fully 4,000 mV or more
depressed
BRAKE SW 89 Stoplamp switch Brake pedal: Depressed ON
Brake pedal: Released OFF
CANCEL 57 Cancel code Ignition switch: "ON" The cancel code,
CODE which set when the
auto-cruise control
system was
cancelled at the
last time, is set
again.
CANCEL 75 Auto-cruise CANCEL "CANCEL" switch: ON ON
SWITCH control "CANCEL" switch: OFF OFF
switch
CLUTCH SW 78 Transmission inhibitor Transmission inhibitor switch: "P" or ON
switch "N"
Transmission inhibitor switch: Other OFF
than above
CRUISE 81 Auto-cruise control Auto-cruise control system: active ON
system operation Auto-cruise control system: Inactive OFF
MAIN SW 86 Auto-cruise CRUISE "CRUISE" (MAIN) switch: "ON" ON
control (MAIN) "CRUISE" (MAIN) switch: "OFF" OFF
switch
RESUME 91 Auto-cruise ACC/RES "ACC/RES" switch: ON ON
SWITCH control "ACC/RES" switch: OFF OFF
switch
SET SWITCH 92 Auto-cruise COAST/S "COAST/SET" switch: ON ON
control ET "COAST/SET" switch: OFF OFF
switch
STOPLIGHT 74 Stoplamp switch Brake pedal: Depressed ON
SW Brake pedal: Released OFF
AUTO-CRUISE CONTROL
MUT-III ITEM INSPECTION ITEM INSPECTION REQUIREMENT NORMAL

Diagnostic NO. CONDITION
Tool
DISPLAY
TP 13 Throttle position sensor (1) Accelerator pedal: (1) Throttle 1035 − 1250 mV
SNSR(MAIN) (main)* Released valve fully
(2) Accelerator pedal: closed
Depressed (2) Throttle 4,000 mV or more
valve fully
open
A/C switch: "OFF" to "ON" Voltage rises
Selector lever: "N" to "D" Voltage rises
VSS 04 Vehicle speed signal Road test the vehicle The speedometer
and Diagnostic
Tool MB991958
display the same
value.
WARNING
AUTO-CRUISE CONTROL
ENGINE ECU TERMINAL VOLTAGE REFERENCE CHART FOR AUTO-CRUISE

CONTROL SYSTEM OPERATION
M1172004800055
1. Disconnect the Engine ECU connectors B-20, 2. Measure the voltages between the check
B-21, and connect special tool MB992044 connector terminals of special tool MB992044 and
(ENGINE ECU check harness) in between. ground connector B-21 terminals 4 or 6.
SPECIAL TOOL- ENGINE ECU CHECK HARNESS (MB992044) CONNECTOR:
94-PIN 60-PIN
CONNECTOR CONNECTOR
(ENGINE ECU CONNECTOR (ENGINE ECU CONNECTOR
B-21) B-20)
16DB403A
TERMINAL CHECK ITEM CHECK CONDITION NORMAL

NO. CONDITION
18 (B-21) Stoplamp switch Ignition Depress the brake pedal. Battery positive
switch: voltage
"ON" Release the brake pedal. 1V or less
14 (B-21) Auto-cruise control Ignition All switches: OFF 4.7 − 5.0 V
switch power supply switch: "CRUISE" (MAIN) switch: "ON" 0 − 0.3 V
"ON"
"COAST/SET" switch: ON 2.0 − 2.8 V
"ACC/RES" switch: ON 3.3 − 4.1 V
"CANCEL" switch: ON 0.8 − 1.5 V
76 (B-21) Accelerator pedal Ignition switch: "ON" 4.9 − 5.1 V
position sensor (sub)
power supply
59 (B-21) Accelerator pedal Ignition Release the accelerator pedal 0.435 − 1.035 V
position sensor switch: Depress the accelerator pedal. 4.0 V or more
(main) "ON"
81 (B-21) Accelerator pedal Ignition Release the accelerator pedal 0.435 − 1.035 V
position sensor (sub) switch: Depress the accelerator pedal. 4.0 V or more
"ON"
75 (B-21) Accelerator pedal Ignition switch: "ON" 4.9 − 5.1 V
position sensor
(main) power supply
21 (B-21) Brake switch Ignition Depress the brake pedal. 1V or less
switch: Release the brake pedal. 1V or less
"ON"
9 (B-20) Transmission inhibitor Ignition Transmission inhibitor switch: "P" or Battery positive
switch: "P" and "N" switch: "N" Crank switch signal voltage
Crank switch signal "ON" Transmission inhibitor switch: Other 1V or less
than above
AUTO-CRUISE CONTROL
TERMINAL CHECK ITEM CHECK CONDITION NORMAL

NO. CONDITION
10 (B-20) Throttle position Ignition switch: "ON" 4.9 − 5.1 V
sensor power supply
57 (B-20) Throttle position (1) Accelerator pedal: (1) Throttle 1035 − 1250 mV
sensor (sub) Released valve fully
Depressed (2) Throttle 4000 mV or more
valve fully open
42 (B-20) Throttle position (1) Accelerator pedal: (1) Throttle 1035 − 1250 mV
sensor (main) Released valve fully
Depressed (2) Throttle 4000 mV or more
valve fully open
49 (B-20) Throttle actuator • Ignition switch: "ON" Decreases slightly
control motor (−) • Accelerator pedal: fully closed to fully (approx. 2 V) from
opened battery voltage.
50 (B-20) Throttle actuator • Ignition switch: "ON" Decreases slightly
control motor (+) • Accelerator pedal: fully opened to fully (approx. 2 V) from
closed battery voltage.
WARNING
AUTO-CRUISE CONTROL
SPECIAL TOOLS
M1172000600509

NAME
MB991958 MB991824-KIT Checking diagnostic
A
B: MB991827 MUT-III trigger harness is CAUTION
C: MB991910 not necessary when For vehicles with CAN
D: MB991911 pushing V.C.I. ENTER communication, use
MB991824
E: MB991914 key. MUT-III main harness A
B F: MB991825 to send simulated
MUT-III sub assembly connect MUT-III main
A: Vehicle harness B or C instead,
communication the CAN
MB991827
interface (V.C.I.) communication does
C
B: MUT-III USB cable not function correctly.
communication
MB991910 system)
B (Vehicles without
system)
MB991911
E models only)
DO NOT USE adapter
G: MUT-III trigger
MB991914 harness
F
MB991825
MB991826
MB991958
AUTO-CRUISE CONTROL

NAME
MB991223 General service tools Checking the continuity
A
A: MB991219 and measuring the
B: MB991220 voltage at the harness
C: MB991221 connector
D: MB991222
B Harness set
A: Inspection harness
B: LED harness
C: LED harness adapter
C
D: Probe
D
MB991223 AD
MB992044 − Measuring the terminal

Engine ECU check voltage at the Engine
harness ECU
MB992045 − Measuring the terminal
Auto Trans. ECU check voltage at the Auto Trans.
harness ECU
AUTO-CRUISE CONTROL
ON-VEHICLE SERVICE
AUTO-CRUISE CONTROL SWITCH CHECK

M1172001200054
AUTO-CRUISE CONTROL MAIN SWITCH CHECK

2. Check that the "CRUISE" indicator lamp within the
combination meter illuminates when the "CRUISE" (MAIN)
switch is switched "ON".
"CRUISE"
(MAIN)
SWITCH:
"ON"
AUTO-CRUISE
CONTROL SWITCH
AC305702
"CRUISE" INDICATOR
LIGHT
AC206195
16DB404A
AUTO-CRUISE CONTROL SETTING

1. Switch "ON" the "CRUISE" (MAIN) switch.
2. Drive at the desired speed, above approximately 40 km/h.
3. Push the auto-cruise control switch in the direction of the
arrow.
4. Check to be sure that when the switch is released the speed
is the desired constant speed.
NOTE: If the vehicle speed decreases to approximately 15
km/h below the set speed because of climbing a hill for
example, it is normal for the auto-cruise control to be can-
celled.
ACX01172 AD
AUTO-CRUISE CONTROL
SPEED-INCREASE SETTING
1. Set to the desired speed.
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.
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
RETURN TO THE SET SPEED BEFORE

CANCELLATION AND AUTO-CRUISE CONTROL
CANCELLATION
1. Set the auto-cruise speed control.
2. When any of the following operations are performed while at
constant speed during auto-cruise control, check if normal
driving is resumed and deceleration occurs.
(1) The auto-cruise control switch is pulled in the direction of
the arrow.
(2) The brake pedal is depressed.
(3) The selector lever is moved to the "N" range.
3. At a vehicle speed of 40 km/h or higher, check if when the
"ACC/RES" switch is switched ON, the vehicle speed
returns to the speed before auto-cruise control driving was
cancelled, and constant speed driving occurs.
ACX01172 AG
4. When the "CRUISE" (MAIN) switch is turned to the "OFF"
while driving at constant speed, check if normal driving is
resumed and deceleration occurs.
AUTO-CRUISE CONTROL
AUTO-CRUISE CONTROL SYSTEM COMPONENT

CHECK M1172001700316
AUTO-CRUISE CONTROL SWITCH CHECK
1. Remove the auto-cruise control switch. (Refer to P.17-75).
2. Measure the resistance between terminal 2 and terminal 3
when each of the "COAST/SET", "ACC/RES", "CANCEL"
and "CRUISE" (MAIN) switches is pressed. If measure
1 2 3 values measured at the time correspond to those in the table
below, the resistance values are correct.
SWITCH POSITION SPECIFIED CONDITION
2 "CRUISE" (MAIN) switch Open circuit
"OFF"
"CRUISE" (MAIN) switch "ON" Less than 2 ohms
"CANCEL" switch ON Approximately 100 Ω
"ACC/RES" switch ON Approximately 887 Ω
"COAST/SET" switch ON Approximately 300 Ω
MAIN RES SET CAN
OFF OFF OFF OFF
ON ON ON ON
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)
AUTO-CRUISE CONTROL
THROTTLE POSITION SENSOR

Refer to GROUP 13A, On-vehicle Service − Throttle Actuator
Control Motor Check 13A-671 (3.8L engine).
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.
TRANSMISSION INHIBITOR SWITCH ("N"

POSITION)
Refer to GROUP 23A, On-vehicle Service − Essential Service
P.23A-294.
AUTO-CRUISE CONTROL
AUTO-CRUISE CONTROL
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
9.0 ± 2.0 N·m

5 80 ± 17 in-lb
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)
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

Engine will not start or hard Vacuum hose disconnected or damaged Repair or replace
to start Malfunction of the evaporative emission Repair or replace
purge solenoid
Rough idle or engine stalls
Vacuum hose disconnected or damaged. Repair or replace
Malfunction of the positive crankcase Replace
ventilation valve
Malfunction of the purge control system Check the system; If there is a
problem, check its component
parts.
Excessive oil consumption Positive crankcase ventilation line Check positive crankcase
clogged ventilation system
SPECIAL TOOLS
M1173000600193

NAME
MB995061 MLR6890A Inspection of purge
Purge flow indicator Part of MIT280220 control system
MD998770 MD998770-01 or General Removal/installation of

Oxygen sensor wrench service tool heated oxygen sensor
EMISSION CONTROL
VACUUM HOSES
VACUUM HOSE ROUTING
M1173000900398
EVAPORATIVE EMISSION
VENTILATION SOLENOID
CHAMBER
INTAKE MANIFOLD
PLENUM
TO EVAPORATIVE EMISSION
CANISTER
THROTTLE
BODY
FRONT
AK301810
EMISSION CONTROL
VACUUM CIRCUIT DIAGRAM

M1173007100252
INTAKE MANIFOLD THROTTLE BODY
TO
COMBUSTION FROM
CHAMBER AIRCLEANER
PURGESOLENOID
(ON: OPEN)
CHAMBER
B
FUEL
TANK
CANISTER
B: BLACK
07DB110A
VACUUM HOSE INSTALLATION

M1173007200129
1. When connecting the vacuum hoses, they should be
securely inserted onto the nipples.
2. Connect the hoses correctly, using the VACUUM HOSE
ROUTING diagram as a guide.
EMISSION CONTROL
VACUUM HOSE CHECK

M1173007300171
1. Using the VACUUM HOSE ROUTING diagram as a guide,
check that the vacuum hoses are correctly connected.
2. Check the connection of the vacuum hoses, (removed,
loose, etc.) and confirm that there are no sharp bends or
damage.
POSITIVE CRANKCASE VENTILATION SYSTEM

GENERAL DESCRIPTION (POSITIVE CRANKCASE VENTILATION SYSTEM)
M1173005000293
The positive crankcase ventilation (PCV) system pre- The PCV valve is designed to lift the plunger accord-
vents the escape of blow-by gases from inside the ing to the intake manifold vacuum so as to regulate
crankcase into the atmosphere. the flow of blow-by gas properly.
Fresh air is sent from the air cleaner into the crank- In other words, the blow-by gas flow is regulated dur-
case through the breather hose to be mixed with the ing low load engine operation to maintain engine sta-
blow-by gas inside the crankcase. bility, while the flow is increased during high load
The blow-by gas inside the crankcase is drawn into operation to improve the ventilation performance.
the intake manifold through the PCV valve.
SYSTEM DIAGRAM
VENTILATION HOSE
BREATHER HOSE
POSITIVE CRANKCASE
VENTILATION VALVE
07DB111A
EMISSION CONTROL
COMPONENT LOCATION
M1173007400189
POSITIVE CRANKCASE VENTILATION SYSTEM

CHECK
M1173001100232
1. Remove the positive crankcase ventilation (PCV) valve from
the rocker cover.
2. With the engine idling, put your finger on the open end of the
PCV valve, and check for negative pressure (vacuum).
NOTE: At this time, the plunger in the PCV valve should
move back and forth as the open end is covered and uncov-
ered.
3. If negative pressure is not felt, clean or replace the PCV
PCV VALVE
valve. Inspect the vacuum supply hose and vacuum supply
hose port for restriction or plugged condition.
07TE008A
POSITIVE CRANKCASE
VENTILATION VALVE
POSITIVE CRANKCASE VENTILATION VALVE

CHECK
M1173001200228
1. Hold the positive crankcase ventilation (PCV) valve with the
POSITIVE
CRANKCASE vacuum side down. Insert a thin rod, and using lamp
VENTILATION pressure, depress the end of the PCV valve spring by 5 − 10
VALVE mm. Release pressure on the rod to see if the PCV valve
spring will lift the rod to its original position.
2. If the rod returns quickly to its original position, the PCV
valve is OK. If the stick does not return quickly, clean or
replace the PCV valve.
6EM0400
EMISSION CONTROL
EVAPORATIVE EMISSION CONTROL SYSTEM

GENERAL DESCRIPTION (EVAPORATIVE EMISSION SYSTEM)
M1173005100706
The evaporative emission (EVAP) system prevents When the engine coolant temperature is low or when
fuel vapors generated in the fuel tank from escaping the intake air quantity is small (when the engine is at
into the atmosphere. idle, for example), the Engine-ECU brings the EVAP
Fuel vapors from the fuel tank flow through the vapor purge solenoid into the OFF state to shut off the fuel
pipe/hose to be stored temporarily in the EVAP can- vapor flow to the intake manifold plenum. This
ister. ensures driveability when the engine is cold or run-
When the vehicle is in operation, fuel vapors stored ning under low load and also stabilizes the emission
in the EVAP canister flow through the EVAP purge level.
solenoid, purge port and intake manifold plenum to
the combustion chamber.
SYSTEM DIAGRAM
EVAPORATIVE
EMISSION
PURGE
SOLENOID FUEL
ON: OPEN TANK

SENSOR
ENGINE COOLANT MFI
TEMPERATURE SENSOR RELAY EVAPORATIVE EMISSION
CANISTER
MASS AIRFLOW SENSOR
ENGINE
ECU
07DB112A
EMISSION CONTROL
COMPONENT LOCATION
M1173007500205
WHITE MARK
CHAMBER
SOLENOID VALVE
01DB051A
PURGE CONTROL SYSTEM CHECK (PURGE FLOW CHECK)

M1173001400620
INTAKE MANIFOLD THROTTLE BODY
TO
COMBUSTION FROM
CHAMBER AIRCLEANER
OFF
PURGESOLENOID
(ON: OPENED)
ON
CHAMBER
PURGE
PURGE HOSE FLOW
INDICATOR
(MB995061)
CANISTER
07DB115A
EMISSION CONTROL

MB995061: Purge Flow Indicator
1. Disconnect the purge hose from the evaporative emission
(EVAP) purge solenoid, and connect special tool MB995061
between the EVAP purge solenoid and the purge hose.
2. Before inspection, set the vehicle in the following conditions:
• Lights, electric cooling fan and accessories: OFF
• Transaxle: P range
3. Run the engine at idle for more than four minutes.
4. Check the purge flow volume when engine is revved
suddenly several times.
Standard value: Momentarily 20 cm3/s (2.5 SCFH) or
more.
5. If the purge flow volume is less than the standard value,
check it again with the vacuum hose disconnected from the
EVAP canister. If the purge flow volume is less than the
standard value, check the vacuum port and the vacuum
hose for clogging. Also check the EVAP purge solenoid. If
the purge flow volume is at the standard value, replace the
EVAP canister.
EVAPORATIVE EMISSION PURGE SOLENOID

CHECK
M1173001700289
1. Disconnect the vacuum hose (black, black with red paint
mark) from the evaporative emission (EVAP) purge
solenoid.
NOTE: When disconnecting the vacuum hose, always place
an identification mark so that it can be reconnected at its
original position.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the EVAP
purge solenoid (refer to the illustration at left).
4. As described in the chart below, check airtightness by
applying a vacuum with voltage applied directly from the
battery to the EVAP purge solenoid valve and without
applying voltage.
BATTERY POSITIVE NORMAL CONDITION
VOLTAGE
Applied Vacuum leaks
AK200339
Not applied Vacuum maintained
EMISSION CONTROL
5. Measure the resistance between the terminals of the EVAP

purge solenoid.
Standard value: 16 Ω [at 20°C )]
6. Replace the solenoid if resistance is out of specification.
07DB114A
MASS AIRFLOW SENSOR CHECK

M1173050400053
To inspect these parts, refer to GROUP 13A, Multipoint Fuel

Injection (MPI) − Multipoint Fuel Injection (MPI) Diagnosis −
Diagnostic Trouble Code Chart 13A-17.
ENGINE COOLANT TEMPERATURE SENSOR

CHECK
M1173008100523
To inspect the sensor, refer to GROUP 13A, Multipoint Fuel

INTAKE AIR TEMPERATURE SENSOR CHECK

M1173008200263
To inspect the sensor, refer to GROUP 13A, Multipoint Fuel

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).
SPECIFICATIONS
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)
M1173000300545
ITEMS STANDARD VALUE

Engine control system
Curb idle speed r/min 3.8L Engine 680 ± 100
Emission control system
Purge flow cm3/s (SCFH) [at 80 − 95°C (176 − 205°F) with sudden revving] 20 (2.5)
Evaporative emission purge solenoid coil resistance [at 20°C)] Ω 16 Ω
17-86 ENGINE AND EMISSION CONTROL
SPECIFICATIONS
HOME
21-1
GROUP 21
CLUTCH
CONTENTS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A
CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B

NOTES
HOME
21A-1
GROUP 21A
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . . 21A-2 CLUTCH PEDAL. . . . . . . . . . . . . . . . . 21A-4

SERVICE SPECIFICATIONS. . . . . . . 21A-2
CLUTCH CONTROL . . . . . . . . . . . . . . 21A-5
LUBRICANTS . . . . . . . . . . . . . . . . . . 21A-2 REMOVAL AND INSTALLATION . . . . . . . . 21A-5
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-6
ON-VEHICLE SERVICE. . . . . . . . . . . 21A-2 DISASSEMBLY AND REASSEMBLY . . . . . 21A-7
CLUTCH PEDAL CHECK AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-8
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21A-2
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-3
CLUTCH 21A-2
GENERAL INFORMATION
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.
M1211000300227
Item Standard value

Clutch pedal height (mm) 183 − 186
Clutch pedal clevis pin play (mm) 1−3
Clutch pedal free play clearance (mm) 0.5 − 1.5
Distance between the clutch pedal and the clutch pedal 35 or more
stopper when the clutch pedal is released (mm)
LUBRICANTS
M1211000400183
Item Specified lubricant Quantity

Clutch fluid Brake Fluid DOT 3 or DOT 4 As required
Pushrod assembly Rubber grease As required
Boot Rubber grease As required
Release cylinder push rod MITSUBISHI genuine grease Part As required
No.0101011
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
Clutch pedal height
B
A
AC100355 AB
AC312890AB 3. Measure the clutch pedal clevis pin play.

Standard value (B): 1 − 3 mm
CLUTCH 21A-3
ON-VEHICLE SERVICE
CAUTION 6. After completing the adjustments, confirm that the

Do not push in the master cylinder pushrod at clutch pedal free play clearance (measured
this time, otherwise the clutch will not operate between pedal switch and bracket) and the
properly. distance between the clutch pedal (the face of the
4. If the clutch pedal height and clutch pedal clevis pedal pad) and the clutch pedal stopper when the
pin play are not within the standard value, loosen clutch is disengaged are within the standard value
the setting nut to adjust the clutch pedal height ranges.
and clevis pin play to the standard value. Standard value (C): 0.5 − 1.5 mm
Standard value (D): 35 mm or more
Setting nut 7. If the clutch pedal free play and the distance
between the clutch pedal and the clutch pedal
stopper or toeboard when the clutch is
disengaged do not agree with the standard
values, it is probably the result of either air in the
hydraulic system or a faulty master cylinder,
Clutch pedal release cylinder or clutch. Bleed the air, or
12 ± 2 N·m disassemble and inspect the master cylinder,
AC100356 AD
release cylinder or clutch.
5. Check the clutch pedal switch clearance is within CLUTCH BLEEDING

specification when pedal height is adjusted M1211001400205
correctly and is positioned at rest. If adjustment is CAUTION

required, loosen nut and rotate switch to achieve Use the specified brake fluid. Do not mix brake
correct clearance. fluids.
Switch clearance value (C): 0.5 − 1.5 mm Specified fluid: Brake fluid DOT 3 or DOT 4
Nut tightening torque : 10 - 15 Nm
Clutch Pedal Switch
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
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
Removal steps Removal steps (Continued)

• Instrument panel under cover 5. Clutch pedal assembly mounting
(Refer to GROUP 52A, Instrument bolt
panel 52A-4). 6. Pedal pad
1. Stopper 7. Pedal stopper
2. Snap pin 8. Clutch pedal assembly
3. Clevis pin 8. Clutch pedal switch
4. Clutch master cylinder mounting
nut
CLUTCH 21A-5
CLUTCH CONTROL
CLUTCH CONTROL
M1211001900255

Clutch Fluid Draining • Clutch Fluid Supplying
• Clutch Line Bleeding (Refer to P.21A-3).
• Clutch Pedal Adjustment (Refer to P.21A-2).
Release fork 15 ± 2 N·m
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
INSTALLATION SERVICE POINT >>A<< CLUTCH HOSE/CLUTCH PIPE

<<A>> CLUTCH HOSE INSTALLATION INSTALLATION
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
DISASSEMBLY AND REASSEMBLY

M1211002100230
CLUTCH MASTER CYLINDER
CAUTION
Do not disassemble the piston assembly.
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 . . . . . . 21B-2 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 21B-3

CLUTCH REMOVAL AND INSTALLATION 21B-3
SERVICE SPECIFICATIONS. . . . . . . 21B-2 CLUTCH INSPECTION . . . . . . . . . . . . . . . . 21B-5
TORQUE SPECIFICATIONS . . . . . . . 21B-2 CLUTCH RELEASE CYLINDER . . . . 21B-7

CLUTCH RELEASE CYLINDER DISASSEMBLY AND
LUBRICANTS . . . . . . . . . . . . . . . . . . 21B-2 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21B-7
CLUTCH RELEASE CYLINDER INSPECTION
. . . . . . . . . . . . . . . . . . . 21B-8
CLUTCH OVERHAUL 21B-2
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
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
Item Specified lubricant

Release fork and release cylinder pushrod contact surface Mitsubishi Part No. 0101011 or
Release fork and release bearing contact surface equivalent
Release fork bushing inner surface
Clutch disc splines
Piston and piston cup Brake Fluid DOT 3 or DOT 4
Release cylinder inner surface
CLUTCH
CLUTCH
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
Removal steps Removal steps ( つづき )

1. Insulator >>D<< 12. Clutch disc
2. Clutch fluid line bracket >>C<< 13. Sealing cap
3. Washer 14. Release fork shaft
4. Clutch tube 15. Support spring (L)
5. Union bolt 16. Packing
6. Union >>B<< 17. Release fork
7. Gasket >>A<< 18. Bushing
>>E<< 8. Valve plate 19. Clutch release bearing
>>E<< 9. Valve plate spring 20. Packing
10. Clutch release cylinder 21. Support spring (R)
>>D<< 11. Clutch cover 22. Release fork boot

.
CLUTCH
>>A<< OUTER RACE INSTALLATION

Press in the bushing into the release fork to the position shown
in the illustration.
Bushing AKX00755AD
>>B<< RELEASE FORK INSTALLATION

Apply grease to the illustrated positions of the release fork.
Specified grease:
Mitsubishi Part No. 0101011 or equivalent
Apply
grease
Apply
grease
Apply
grease
AKX00757 AF
>>C<< SEALING CAP INSTALLATION

Press in the sealing cap to the position shown in the illustration.
Be sure that it is not installed in a slanted position.
2 mm
AKX00756AD
.
CLUTCH
>>D<< CLUTCH DISC/CLUTCH COVER INSTALLATION

1. Apply Mitsubishi grease to the clutch disc splines and rub it
in the splines with a brush.
Specified grease:
Flywheel Mitsubishi Part No. 0101011 or equivalent
2. Use the clutch disc guide to position the clutch disc on the
Clutch disc
flywheel.
3. Install the clutch cover onto the flywheel.
Clutch disc
guide
Clutch cover
AK204214 AB
>>E<< VALVE PLATE SPRING/VALVE PLATE

INSTALLATION
Valve plate spring Set the spring’s large diameter side to the valve plate side, and
install the valve plate spring and valve plate.
Release cylinde
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
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.
.
CLUTCH RELEASE BEARING

CAUTION
Release bearing is packed with grease. Do not wash it in a
cleaning solvent.
1. Check for seizure, damage, noise or improper rotation.
2. Check for wear on the surface which contacts the diaphragm
spring.
3. Check for wear on the surface which contacts the release
fork. If abnormally worn, replace.
.
RELEASE FORK
If the surface which contacts the bearing is abnormally worn,
replace.
.
RELEASE FORK SHAFT

Check the release fork shaft for bend and wear, and replace if
necessary.
CLUTCH RELEASE CYLINDER

M1212001500302
8
11 ± 1 N·m
9
1
6
5 4
AK502008AB
Disassembly steps Disassembly steps ( つづき )

1. Push rod 6. Conical spring
2. Boot 7. Cap
<<A>> >>A<< 3. Piston assembly 8. Air bleeder
4. Piston cup 9. Release cylinder
5. Piston
DISASSEMBLY SERVICE POINT

.
<<A>> PISTON ASSEMBLY REMOVAL

1. Cover with a shop towel to prevent the piston from popping
out.
CAUTION
Apply compressed air slowly to prevent brake fluid from
splashing.
2. Apply the compressed air into the tube mounting hole to
remove the piston assembly.
AK305228AB
REASSEMBLY SERVICE POINT

.
>>A<< PISTON ASSEMBLY INSTALLATION

1. Apply brake fluid to the piston cup and inner surface of the
release cylinder.
Specified brake fluid:
Brake fluid DOT3 or DOT4
2. Insert the piston assembly into the release cylinder.
Piston Piston cup

AK201613AD
AK201613
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
MANUAL TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A
MANUAL TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . . . . 22B

NOTES
HOME
22A-1
GROUP 22A
MANUAL
TRANSMISSION
CONTENTS
GENERAL INFORMATION . . . . . . . . 22A-2 TRANSMISSION CONTROL . . . . . . . 22A-4

LUBRICANTS . . . . . . . . . . . . . . . . . . 22A-2 SHIFT AND SELECT CABLE ASSEMBLY . 22A-5
SHIFT KNOB ASSEMBLY. . . . . . . . . . . . . . 22A-5
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22A-2
TRANSMISSION ASSEMBLY . . . . . . 22A-7
ON-VEHICLE SERVICE. . . . . . . . . . . 22A-3 REMOVAL AND INSTALLATION . . . . . . . . 22A-7
TRANSMISSION OIL LEVEL CHECK . . . . 22A-3 TRANSMISSION MOUNT STOPPER . . . . . 22A-11
TRANSMISSION OIL REPLACEMENT . . . 22A-3
MANUAL TRANSMISSION 22A-2
GENERAL INFORMATION
GENERAL INFORMATION
M1222000100379
MANUAL TRANSMISSION MODELS

Transmission model Combined engine Vehicle model
F5M51-1-S5P 6G75-S4-MPI DL1ASN
LUBRICANTS
M1222000400358
Item Specified lubricant Quantity (litres)

Transmission oil Genuine Mitsubishi MTF 2.8
SPECIAL TOOLS
M1222000600396

NAME
MB991897 MB991113-01 Knuckle and tie rod end ball
Ball joint remover MB990635-01 or joint disconnection
General service tool
AC106827
MB991895 - When the engine hanger is

Engine hanger used: Supporting the engine
assembly during removal and
installation of the transaxle
MB991895
assembly
MB991460 - Preventing foreign substances

Plug from entering transmission
case
09DB017
SPECIAL TOOLS
ON-VEHICLE SERVICE
.
TRANSMISSION OIL LEVEL CHECK

1. Remove the oil filler plug.
2. The oil level should be at the lower portion of the filler plug
hole.
Filler plug hole 3. Check that the transmission oil is not noticably dirty and that
Transmission oil
it has suitable viscosity.
4. Tighten the filler plug to specified torque.
09DB018A
1. Remove the transmission drain plug.

2. Drain oil.
3. Replace and tighten drain plug after draining oil.
Filler plug Specified torque:
32 Nm
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
TRANSMISSION CONTROL
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
TRANSMISSION CONTROL >>A<< 8. Shift cable connection

CABLE ASSEMBLY REMOVAL (Transmission side)
STEPS >>A<< 9. Shift cable and select cable
>>B<< 1. Shift knob assembly
>>B<< 2. Sleeve SHIFT LEVER ASSEMBLY
Front floor console (Refer Group REMOVAL STEPS
52A.) >>B<< 1. Shift knob
3. Select cable connection (shift lever >>B<< 2. Sleeve
side) Front floor console (Refer Group
4. Clip 52A.)
>>C<< 5. Shift cable connection (Shift lever 3. Select cable connection (shift lever
side) side)
6. R-clip 4. Clip
>>A<< 7. Select cable connection >>C<< 5. Shift cable connection (Shift lever
(Transmission side) side)
10. Shift lever assembly

.
>>A<< SHIFT CABLE AND SELECT CABLE ASSEMBLY/

SHIFT CABLE CONNECTION/SELECT CABLE CONNEC-
TION
1. Ensure the shift cable and select lever assembly is mounted
in the vehicle with the "UP" symbol and arrow on the
mounting plate pointing upward as shown in the illustration.
09DB021A
2. Set the transmission side shift lever and the passenger

compartment side shift lever to neutral position.
Shift lever
Neutral position
09DB022A
3. Fit "U"clip to transmission shift cable bracket securely (feel

CABLE click). Then fit cable assembly into bracket securely (feel
click).
“U” CLIP
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
.
>>B<< SLEEVE SHIFT KNOB

1. Instal the sleeve onto tip of lever assembly.
M/T KNOB
2. Fit M/T Knob onto lever assembly.
SLEEVE
3. Screw M/T Knob onto lever , initially 7 turns and then add 4
2 turns with knob aligned in correct direction for shift pattern.
3
1
09DB031A
.
>>C<< SELECT CABLE FITMENT

1. Select cable is a "snap" fit onto lever pin.
SELECT LEVER 1 2. Align cable eye with lever pin and push on firmly, ensuring
2
cable is secured and lever pin marking is visible.
Mark on pin
SELECT CABLE
09DB032A
TRANSMISSION ASSEMBLY
• 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
REMOVAL STEPS REMOVAL STEPS

1. Shift cable and select cable <<C>> Disengage clutch release bearing
connection (Refer On-Vehicle 6. Transmission assembly upper part
Service) coupling bolts
2. Reverse lamp switch connector <<D>> 7. Transmission mount bracket
3. Vehicle speed sensor connector >>A<< 8. Transmission mount stopperPoppet
<<A>> 4. Starter motor spring
<> 5. Clutch release cylinder <<E>> Supporting engine assembly
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
REMOVAL STEPS (cont.) REMOVAL STEPS (cont.)

9. Stabiliser bar connection 16. Centre member assembly
10. Wheel speed sensor cable 17. Rear roll stopper bracket
connection 18. Rear transmission mount
11. Brake hose clamp 19. Cover
<<F>> 12. Tie rod end connection 20. Transmission assembly lower
<<F>> 13. Lower arm ball joint nut attaching bolts
<<G>> 14. Drive shaft(LH) 21. Transmission assembly
<<G>> 15. Drive shaft(RH)

.
<<A>> STARTER MOTOR

1. Remove the starter motor form transmission with the
harness still connected and secure it in position on top of
exhaust manifold.
.
<> CLUTCH RELEASE CYLINDER

1. Remove the clutch release cylinder without disconnecting
18 ± 3.0 N·m the fluid line and secure to vehicle chassis.
18 ± 3.0 N·m
09DB030A
<<C>> RELEASE BEARING

1. Remove the access hole covers from th top and bottom of
the clutch housing.
2. Push the clutch cylinder end of the release fork so that the
release bearing pushes against the diaphram spring.
09DB025A
3. Insert a flat blade screwdriver in both top and bottom access

hole in the clutch housing, between the release bearing and
the diaphram spring. Simultaneously turn both srewdrivers
through 90 to diengage the release bearing.
09DB026A
DIAPHRAGM SPRING
Place
screwdriver
here
RELEASE
BEARING
RING
09DB027A
.
22A-10 MANUAL TRANSMISSION
<<D>> TRANSMISSION MOUNT BRACKET

1. Jack up the transmission assembly gently with garage jack
CHASSIS BRACKET and then remove the transmission mount bracket through
bolt. Mount assembly remains attached to transmission until
removed from vehicle.
MOUNT
09DB035A
<<E>> ENGINE ASSEMBLY SUPPORTING

1. Set up the special tool to the vehicle to support the engine
MB991895
assembly.
MB991527
MB991454
AC306198 AB
<<F>> TIE ROD END/LOWER ARM BALL JOINT REMOVAL

1. Set up the special tool to the vehicle to support the engine
CORD assembly.
NUT MB991897
BOLT
BALL JOINT AC208247AC
<<G>> DRIVE SHAFT REMOVAL

1. Insert a pry bar between the transmission case and the drive
TRANSAXLE shaft to remove the shaft from trnsmission housing.
PTJ ASSEMBLY
PRY BAR AC100141AL

2. To prevent foreign material from entering the transmission

MB991460 case, insert a suitable plug into the drive shaft openings.
3. Suspend the RH drive shaft with wire so that there are no
sharp bends in any of the joints.
09DB028A

.
>>A<< TRANSMISSION MOUNT STOPPER INSTALLATION

1. Install the transmission mount stopper so that the arrow
ENGINE SIDE TRANSAXLE points upward as shown in illustration. Ensure stoppers are
MOUNTING installed onto mount correctly prior to fitment and do not
STOPPER
dislodge during transmission installation.
09DB029A
22A-12 MANUAL TRANSMISSION
HOME
22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . . 22B-2 REVERSE IDLER GEAR . . . . . . . . . . 22B-29

REVERSE IDLER GEAR DISASSEMBLY AND
GENERAL SPECIFICATIONS . . . . . . 22B-3 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-29
SERVICE SPECIFICATIONS. . . . . . . 22B-3 VEHICLE SPEED SENSOR . . . . . . . . 22B-30

VEHICLE SPEED SENSOR DISASSEMBLY AND
SNAP RING, SPACER AND THRUST REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-30
PLATE FOR ADJUSTMENT . . . . . . . 22B-3
SELECT LEVER . . . . . . . . . . . . . . . . . 22B-31
TORQUE SPECIFICATION . . . . . . . . 22B-5 SELECT LEVER DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . 22B-31
SEALANTS . . . . . . . . . . . . . . . . . . . . 22B-6
CONTROL HOUSING . . . . . . . . . . . . . 22B-32
LUBRICANTS . . . . . . . . . . . . . . . . . . 22B-6 CONTROL HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-32
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22B-7

CLUTCH HOUSING . . . . . . . . . . . . . . 22B-35
CLUTCH HOUSING DISASSEMBLY AND
INPUT SHAFT . . . . . . . . . . . . . . . . . . 22B-10 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-35
INPUT SHAFT DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . 22B-10
TRANSMISSION CASE . . . . . . . . . . . 22B-38
INPUT SHAFT INSPECTION . . . . . . . . . . . 22B-16
TRANSMISSION CASE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-38
OUTPUT SHAFT . . . . . . . . . . . . . . . . 22B-18
OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY DIFFERENTIAL. . . . . . . . . . . . . . . . . . 22B-41
. . . . . . . . . . . . . . . . . . . 22B-18
DIFFERENTIAL DISASSEMBLY AND REASSEMBLY
OUTPUT SHAFT INSPECTION . . . . . . . . . 22B-26 . . . . . . . . . . . . . . . . . . . 22B-41
MANUAL TRANSMISSION OVERHAUL 22B-2
GENERAL INFORMATION
GENERAL INFORMATION
M1222000100379
MANUAL TRANSMISSION MODELS

F5M51-1-S5P 6G75-S4-MPI DL1ASN
SECTIONAL VIEW
AK502566
M1222000200495
TRANSMISSION MODEL TABLE

Transmission Speedometer Final gear Vehicle model Engine model
model gear ratio ratio
F5M51-1-S5P 28/36 4.111 DL1ASN 6G75-S4-MPI
GEAR RATIO TABLE
Item F5M51
1st 3.333
2nd 2.105
3rd 1.407
4th 1.031
5th 0.804
Reverse 3.416
M1222000300362
Item Standard value Minimum limit

Input shaft end play mm 0.05 − 0.17 −
Input shaft front bearing end play mm 0 − 0.12 −
Input shaft rear bearing end play mm 0 − 0.12 −
Input shaft 5th speed gear end play mm 0 − 0.09 −
Output shaft preload mm 0.13 − 0.18 −
Output shaft rear bearing end play mm 0 − 0.09 −
Output shaft 3rd speed gear end play mm 0 − 0.09 −
Backlash between differential gear and pinion mm 0.025 − 0.150 −
Differential case preload mm 0.05 − 0.11 −
Synchronizer ring back surface to gear clearance mm − 0.5
SNAP RING, SPACER AND THRUST PLATE FOR

ADJUSTMENT
M1222012000409
SPACER (FOR ADJUSTMENT OF INPUT SHAFT END PLAY)

Thickness mm Identification symbol Thickness mm Identification symbol
0.98 98 1.43 43
1.07 07 1.52 52
1.16 16 1.61 61
1.25 25 1.70 70
1.34 34 1.79 79
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
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)
1.44 None 1.58 Brown
1.51 Blue
THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY)
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)
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)
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)
2.81 None 2.97 Green
2.85 Blue 3.01 Black
2.89 Brown 3.05 White
2.93 Yellow 3.09 Orange
SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD)

0.74 74 1.04 04
0.77 77 1.07 07
0.80 80 1.10 J
0.83 83 1.13 D
0.86 86 1.16 K
0.89 89 1.19 L
0.92 92 1.22 G
0.95 95 1.25 M
0.98 98 1.28 N
1.01 01 1.31 E
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION)
0.6 − 0.9 −
0.7 − 1.0 −
0.8 − 1.1 −
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
SEALANTS
SEALANTS
M1222000500366
Item Specified sealant

Clutch housing-transmission case mating surface Mitsubishi Genuine sealant part No. MD997740 or
Control housing-transmission case mating equivalent
surface
Under cover-transmission case mating surface
Air breather 3M SUPER WEATHERSTRIP No. 8001 or equivalent
Differential drive gear bolt 3M STUD Locking No. 4170 or equivalent
. .
FORM-IN-PLACE GASKET (FIPG) Surface Preparation

This transmission has several areas where the form- Thoroughly remove all substances deposited on the
in-place gasket (FIPG) is used for sealing. To ensure FIPG application surface, using a gasket scraper.
that the FIPG fully serves its purpose, it is necessary Make sure that the FIPG application surfaces is flat
to observe some precautions when applying it. Bead and smooth. Also make sure that the surface is free
size, continuity and location are of paramount impor- from oils, greases and foreign substances. Do not fail
tance. to remove old FIPG that may remain in the fastener
Too thin a bead could cause leaks. Too thick a bead, fitting holes.
on the other hand, could be squeezed out of location, .
causing blocking or narrowing of fluid passages. To FIPG Application

prevent leaks or blocking of passages, therefore, it is Applied FIPG bead should be of the specified size
absolutely necessary to apply the FIPG evenly with- and free of any break. FIPG can be wiped away
out a break, while observing the correct bead size. unless it has completely hardened. Install the mating
FIPG hardens as it reacts with the moisture in the parts in position while the FIPG is still wet (in less
atmospheric air, and it is usually used for sealing than 10 minutes after application). Do not allow FIPG
metallic flange areas. to spread beyond the sealing areas during installa-
.
tion. Avoid operating the transmission or letting oils
Disassembly or water come in contact with the sealed area before
Parts sealed with a FIPG can be easily removed a time sufficient for FIPG to harden (approximately
without need for the use of a special method. In one hour) has passed.
some cases, however, the FIPG in joints may have to FIPG application method may vary from location to
be broken by tapping parts with a mallet or similar location. Follow the instruction for each particular
tool. case described later in this manual.
LUBRICANTS
M1222000400358

Control shaft oil seal lip gear oil GENUINE MITSUBISHI MTF
Drive shaft oil seal lip gear oil
Each O-ring
Select lever shoe Mitsubishi part No. 0101011 or equivalent
Input shaft oil seal lip gear oil
SPECIAL TOOLS
SPECIAL TOOLS
M1222000600396
Tool Number Name Use

MB990935 Installer adapter • Installation of output shaft
taper roller bearing outer
race
• Installation of differential rear
race
MB990938 Handle Use with Installer adapter
MD998801 Bearing remover Installation and removal of

gears, bearings and sleeves
MD998812 Installer cap Use with Installer and Installer

adapter
MD998813 Installer-100 Use with Installer cap and

Installer adapter
MD998818 Installer adapter (38) Installation of input shaft front

bearing
MD998825 Installer adapter (52) Installation of 1st speed gear

sleeve, 3rd-4th speed
synchronizer hub, 4th speed
gear sleeve, 5th speed gear
and thrust plate stopper
MD998819 Installer adapter (40) • Installation of input shaft rear

bearing
• Installation of output shaft
taper roller bearing
SPECIAL TOOLS

MD998917 Bearing remover Installation and removal of
gears, bearing and sleeves
MD998814 Installer-200 Use with Installer cap and

Installer adapter
MD998824 Installer adapter (50) • Installation of 1st speed gear

sleeve
• Installation of 1st-2nd speed
synchronizer hub
• Installation of 2nd speed
gear sleeve
• Installation of 3rd speed gear
MD998364 Camshaft oil seal Installation of gear, bearing and
installer sleeve
MD998821 Installer adapter (44) • Installation of 4th speed gear

• Installation of 5th speed gear
sleeve
• Installation of 5th-reverse
speed synchronizer hub
MD998820 Installer adapter (42) Installation of reverse gear

bearing sleeve
MD999566 Claw Removal of taper roller bearing

outer race
MB991445 Bushing remover and Installation of differential front

installer base taper roller bearing outer race
SPECIAL TOOLS

MB990928 Installer adapter Installation of input shaft oil seal
MD998800 Oil seal installer • Installation of differential oil

seal
• Installation of transfer oil
seal
MB990930 Installer adapter Removal of differential front

MB990937 Installer adapter • Installation of differential

front taper roller bearing
• Installation of transfer oil
seal
MD998823 Installer adapter (48) Installation of differential rear

MD999506 Crankshaft installer Installation of transfer oil seal
MB990933 Installer adapter Installation of transfer oil seal

22B-10 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT
INPUT SHAFT
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

>>L<< 1. Snap ring >>E<< 12. 3rd-4th speed synchronizer hub
<<A>> >>K<< 2. Ball bearing 13. Outer synchronizer ring
<> >>J<< 3. Thrust plate stopper >>D<< 14. Synchronizer spring
>>I<< 4. Thrust plate 15. Synchronizer cone
<<C>> >>H<< 5. 5th speed gear 16. Inner synchronizer ring
6. 4th speed gear 17. 3rd speed gear
7. Needle roller bearing 18. Needle roller bearing
<<D>> >>G<< 8. 4th speed gear sleeve >>C<< 19. Snap ring
9. Synchronizer ring <<E>> >>B<< 20. Ball bearing
>>D<< 10. Synchronizer spring >>A<< 21. Oil seal
>>F<< 11. Synchronizer sleeve 22. Input shaft
INPUT SHAFT

.
<<A>> BALL BEARING REMOVAL

1. Using special tool Bearing remover (MD998801), support
MD998801
the ball bearing, and then set them on the press.
2. Push down on the input shaft with the press and extract the
ball bearing.
AK201631AD
<> THRUST PLATE STOPPER REMOVAL

Using a screwdriver, pry up the position shown in the illustration
and remove the thrust plate stopper.
AK201632
<<C>>5TH SPEED GEAR REMOVAL

MD998801
the 5th speed gear, and then set them on the press.
2. Push down on the input shaft with the press and take off the
5th speed gear.
AK201633AE
<<D>>4TH SPEED GEAR SLEEVE REMOVAL

MD998801 the 3rd speed gear, and then set them on the press.
2. Push down on the input shaft with the press and remove the
4th speed gear sleeve.
AK201634AD
.
INPUT SHAFT
<<E>> BALL BEARING REMOVAL

the ball bearing, and then set them on the press.
MD998801
2. Push down on the input shaft with the press and extract the
ball bearing.
AK201635AD
REASSEMBLY SERVICE POINTS

.
>>A<< OIL SEAL INSTALLATION

Install the oil seal into the illustrated position of the input shaft.
Oil seal 3.5 mm
AK204243 AC
>>B<< BALL BEARING INSTALLATION

MD998812
the 2nd speed gear portion of the input shaft, and then set
MD998813 them on the press.
MD998801
2. Using special tools, press install the bearing with the press.
MD998818
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998818)
AK201636 AD
>>C<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the snap
ring groove of input shaft.
2. Make sure that the front bearing end play meets the
standard value.
Standard value: 0 − 0.12 mm
Snap ring
AK201637AD
.
INPUT SHAFT
>>D<< SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring to the illustrated position of the
synchronizer ring and outer synchronizer ring.
Synchronizer spring
AK201638AD
Synchronizer
spring
AKX00951AE
>>E<< 3RD-4TH SPEED SYNCHRONIZER HUB

INSTALLATION
them on the press.
2. Make sure that the inner synchronizer ring has been
perfectly matched to the 3rd speed gear cone.
3. Check the installation direction of the 3rd-4th speed
Installation
direction synchronizer hub, and put it on the input shaft.
4. Using special tools, press install the 3rd-4th speed
Groove synchronizer hub with the press.
AK302753AB
MD998812 • Installer adapter (MD998825)
MD998801
5. Make sure that the outer synchronizer ring can rotate freely.
MD998813
MD998825
AK201639 AD
.
INPUT SHAFT
>>F<< SYNCHRONIZER SLEEVE INSTALLATION

Identification
1. Check the installation direction of the synchronizer sleeve,
groove and install it onto the 3rd-4th speed synchronizer hub.
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
>>G<< 4TH SPEED GEAR SLEEVE INSTALLATION

MD998812
MD998801 MD998813 them on the press.
MD998825 2. Using special tools, press install the 4th speed gear sleeve
with the press.
AK201640 AD
>>H<< 5TH SPEED GEAR INSTALLATION

MD998812 the 2nd speed gear portion of the input shaft, and then set
MD998813
them on the press.
MD998801
2. Using special tools, press install the 5th speed gear in the
MD998825
input shaft.
AK201641 AD
.
INPUT SHAFT
>>I<< THRUST PLATE INSTALLATION

Surface 1. Install the thickest thrust plates that can be fitted in the
stamped wit groove of input shaft. Install the thrust plate so the surface
identificat
mark stamped with the identification mark is facing up.
2. Make sure that the 5th speed gear end play meets the
standard value.
Thrust
plate AK201642AD
>>J<< THRUST PLATE STOPPER INSTALLATION

Install the thrust plate stopper by pressing special tools by
MD998812 hand. Make sure that it is not tilted.
MD998825
AK201643 AD
>>K<< BALL BEARING INSTALLATION

MD998812 the 2nd speed gear portion of the input shaft, and then set
them on the press.
MD998801 MD998819 2. Using special tools, press install the ball bearing in the input
shaft.
AK201644 AD
>>L<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the groove
of input shaft.
2. Make sure that the rear bearing end play meets the standard
value.
Snap ring
AK201645AD
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
NEEDLE ROLLER BEARING

1. Combine the needle roller bearing with the input shaft or
bearing sleeve and gear, and check that it rotates smoothly
without noise or play.
2. Check the needle roller bearing cage for deformation.
.
SYNCHRONIZER RING
1. Check the clutch gear teeth for damage and broken.
2. Check internal surface for damage, wear and broken
threads.
AK204298AB
3. Force the synchronizer ring toward the clutch gear and

A
Gear
check clearance "A". If "A" is less than the limit, replace the
Synchronize
ring synchronizer ring.
AK204307 AB
.
INPUT SHAFT
SYNCHRONIZER SLEEVE AND HUB

1. Combine the synchronizer sleeve and hub, and check that
Sleeve
they slide smoothly.
2. Check that the sleeve is free from damage at its inside
splines ends.
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
OUTPUT SHAFT
OUTPUT SHAFT
M1222002200220
Apply gear oil

to all moving 24 23
parts before 25
installation.
27 26
29 28
32 30
33 31 21 20
22
35 4
34 1
37
15 2
38 14
17 4
16
18 6 5
7
19
9 8
36 10
11
12
13
15
AK203133AD

>>Q<< 1. Snap ring >>I<< 18. Snap ring
<<A>> >>P<< 2. Taper roller bearing <<D>> >>H<< 19. 3rd speed gear
<> >>O<< 3. Reverse gear bearing sleeve 20. 2nd speed gear
4. Needle roller bearing 21. Needle roller bearing
5. Reverse gear <<E>> >>G<< 22. 2nd speed gear sleeve
6. Inner synchronizer ring 23. Inner synchronizer ring
7. Synchronizer cone 24. Synchronizer cone
8. Outer synchronizer ring 25. Outer synchronizer ring
>>L<< 9. Synchronizer spring >>D<< 26. Synchronizer spring
>>N<< 10. Synchronizer sleeve >>F<< 27. Synchronizer sleeve
<<C>> >>M<< 11. 5th speed-reverse synchronizer >>E<< 28. 1st-2nd speed synchronizer hub
hub 29. Outer synchronizer ring
12. Synchronizer ring >>D<< 30. Synchronizer spring
>>L<< 13. Synchronizer spring 31. Inner synchronizer ring
14. 5th speed gear 32. Synchronizer cone
15. Needle roller bearing 33. 1st speed gear
>>K<< 16. 5th speed gear sleeve 34. Needle roller bearing
>>J<< 17. 4th speed gear <<F>> >>C<< 35. 1st speed gear sleeve
<<G>> >>B<< 36. Taper roller bearing
OUTPUT SHAFT
Disassembly steps ( つづき )

>>A<< 37. Oil seal
38. Output shaft

.
<<A>> TAPER ROLLER BEARING REMOVAL

MD998801 Taper roller
bearing the taper roller bearing, and then set them on the press.
2. Push down on the output shaft with the press, and take out
the taper roller bearing.
AK201646 AD
<> REVERSE GEAR BEARING SLEEVE REMOVAL

Reverse gear
MD998801 bearing the reverse gear, and then set them on the press.
sleeve
2. Push down on the output shaft with the press and remove
the reverse gear bearing sleeve.
AK201647 AD
<<C>> 5TH SPEED-REVERSE SYNCHRONIZER HUB

REMOVAL
Synchronizer
MD998801 hub the 4th speed gear, and then set them on the press.
the 5th speed-reverse synchronizer hub.
AK201648 AD
.
OUTPUT SHAFT
<<D>> 3RD SPEED GEAR REMOVAL

the 2nd speed gear, and then set them on the press.
3rd
MD998917 speed gear 2. Push down on the output shaft with the press and remove
the 3rd speed gear.
AK201649 AD
<<E>> 2ND SPEED GEAR SLEEVE REMOVAL

the 1st speed gear, and then set them on the press.
MD998917 2nd speed 2. Push down on the output shaft with the press and remove
gear sleeve
the 2nd speed gear sleeve.
AK201650 AD
<<F>> 1ST SPEED GEAR SLEEVE REMOVAL

the 1st speed gear sleeve, and then set them on the press.
MD998801 1st speed 2. Push down on the output shaft with the press and remove
gear sleeve
the 1st speed gear sleeve.
AK201651AD
<<G>> TAPER ROLLER BEARING REMOVAL

MD998801 Taper roller the taper roller bearing, and then set them on the press.
bearing
the taper roller bearing.
AK201652 AD
OUTPUT SHAFT

.

Make sure that the oil seal is pressed into the position shown in
the illustration.
Oil seal 3.5 mm
AK204243 AC
>>B<< TAPER ROLLER BEARING INSTALLATION

1. Using Bearing remover (MD998801), support the output
MD998812 shaft gear, and then set them on the press.
MD998801 2. Using special tools, press install the taper roller bearing with
MD998819
Taper
the press.
roller • Installer cap (MD998812)
bearing • Installer adapter (MD998819)
AK201653 AD
>>C<<1ST SPEED GEAR SLEEVE INSTALLATION

1. Set the output shaft on the press support stand.
2. Using special tools, press install the 1st speed gear sleeve
MD998812 with the press.
MD998814
1st speed • Installer adapter (MD998824)
gear sleeve • Camshaft oil seal installer (MD998364)
MD998824
MD998364
AK201654 AD
>>D<< SYNCHRONIZER SPRING INSTALLATION

outer synchronizer ring.
Synchronizer spring
AK201638AD
.
OUTPUT SHAFT
>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB

INSTALLATION
2. Check that the 1st-2nd speed synchronizer hub is in the
correct installation direction, and put it on the output shaft.
Installation
direction
Groove
AK302754AB
3. Using special tools, press install the 1st-2nd speed

MD998812 synchronizer hub with the press.
MD998814
1st-2nd speed • Camshaft oil seal installer (MD998364)
synchronizer
hub MD998824 4. Make sure that the outer synchronizer ring on the 1st speed
gear side can rotate freely.
MD998364
AK201655 AD
>>F<< SYNCHRONIZER SLEEVE INSTALLATION

1. Check that the synchronizer sleeve is in the correct direction
Groove
for installation, and install it on the 1st-2nd speed
synchronizer hub.
Installation
direction
AK302755AB
Teeth with
Deep grooves
>>G<< 2ND SPEED GEAR SLEEVE INSTALLATION

OUTPUT SHAFT
2. Using special tools, press install the 2nd speed sleeve onto
MD998812 the output shaft.
MD998814 • Installer-200 (MD998814)
2nd speed • Installer adapter (MD998824)
gear sleeve
• Camshaft oil seal installer (MD998364)
MD998824
MD998364
AK201656 AD
>>H<< 3RD SPEED GEAR INSTALLATION

1. Check that the 2nd speed gear and the outer synchronizer
ring have been properly installed. Also, make sure the claws
on the synchronizer cone (four places) are correctly fitted
into the holes in the 2nd speed gear (four places).
2. Using special tools, press install the 3rd speed gear onto the
MD998812
output shaft.
MD998814 • Installer-200 (MD998814)
3rd speed • Installer adapter (MD998824)
gear MD998824 • Camshaft oil seal installer (MD998364)
3. Make sure that the 2nd speed gear and the outer
synchronizer ring can rotate freely.
MD998364
AK201657 AD
>>I<< SNAP RING INSTALLATION

of output shaft.
2. Make sure that the 3rd speed gear end play meets the
Snap ring standard value.
AK201658AD
>>J<< 4TH SPEED GEAR INSTALLATION

OUTPUT SHAFT
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)
MD998364
AK201659 AD
>>K<< 5TH SPEED GEAR SLEEVE INSTALLATION

Using special tools, press install the 5th speed gear sleeve
MD998812
onto the output shaft.
5th speed
MD998813 • Installer cap (MD998812)
gear sleeve MD998821 • Installer-100 (MD998813)
MD998364
AK201660 AD
>>L<< SYNCHRONIZER SPRING INSTALLATION

synchronizer ring.
Synchronizer spring AK305144AB
>>M<< 5TH SPEED-REVERSE SYNCHRONIZER HUB

INSTALLATION
2. Make sure that the synchronizer ring is fitted correctly on the
cone of the 5th speed gear.
3. Check that the 5th speed-reverse synchronizer hub is
oriented correctly for installation, and fit it on the output
shaft.
Installation
direction
Groove
AK302758AB
OUTPUT SHAFT
4. Using special tools, press install the 5th speed-reverse

MD998812 synchronizer hub with the press.
Synchronizer MD998813
hub • Installer-100 (MD998813)
MD998821
5. Make sure that the synchronizer ring on the 5th speed gear
side can rotate freely.
MD998364
AK201661 AD
>>N<< SYNCHRONIZER SLEEVE INSTALLATION

Identification
1. Check that the synchronizer sleeve is in the correct direction
groove for installation, and install it on the 5th speed-reverse
synchronizer hub.
Installation
direction
(5th speed side)
AK400081AB
Teeth with
Deep grooves
>>O<< REVERSE GEAR BEARING SLEEVE INSTALLATION

1. Make sure the synchronizer ring, reverse gear and needle
MD998812 roller bearing have been correctly installed.
MD998820 2. Using special tools, press fit the reverse gear sleeve. Make
Reverse sure that the reverse gear and the synchronizer ring can
Reverse gear sleeve
gear rotate freely during the pressing process.
AK201662AD
.
OUTPUT SHAFT
>>P<< TAPER ROLLER BEARING INSTALLATION

Using special tools, press install the taper roller bearing.
MD998812
Taper roller
MD998819
bearing • Installer adapter (MD998819)
MD998364
AK201663 AD
>>Q<< SNAP RING INSTALLATION

Standard value of output shaft.
Snap ring
2. Make sure that the rear bearing end play meets the standard
Taper roller value.
bearing Standard value: 0 − 0.09 mm
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
NEEDLE ROLLER BEARING

1. Combine the needle roller bearing with the bearing sleeve
and gear, and check that it rotates smoothly without noise or
play.
2. Check the needle roller bearing cage for deformation.
.
OUTPUT SHAFT
SYNCHRONIZER RING <FOR 5TH SPEED>

1. Check if the clutch gear teeth are damaged.
2. Check internal surface for damage, wear and broken
threads.
AK204298AB
3. Force the synchronizer ring toward the clutch gear and

A
Gear
check clearance "A." If "A" is less than the limit, replace the
Synchronize
ring synchronizer ring.
AK204307 AB
OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER

CAUTION
RING/SYNCHRONIZER CONE <FOR REVERSE>
When replacing, replace the outer ring, inner ring and cone
as a set.
1. Check that the clutch gear tooth surfaces and cone surfaces
are not damaged or broken.
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.
Outer ring
Cone
Inner ring
AK204259 AB
.
OUTPUT SHAFT
OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER

RING/SYNCHRONIZER CONE <FOR 1ST SPEED AND 2ND
SPEED>
CAUTION
When replacing, replace the outer ring, inner ring and cone
as a set.
1. Check that the clutch gear tooth surfaces and cone surfaces
are not damaged or broken.
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
Cone
Inner ring
AK203130AD
SYNCHRONIZER SLEEVE AND HUB

1. Combine the synchronizer sleeve and hub, and check that
they slide smoothly.
Sleeve
2. Check that the sleeve is free from damage at its inside
splines ends.
Hub
AK201697AD
SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or broken.
AKX00943
.
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
REVERSE IDLER GEAR

M1222012500277
Apply gear oil to all

moving parts before
installation.
1
5
4
3
AK305225 AB

1. Snap ring 4. Needle roller bearing
2. Thrust washer 5. Reverse idler gear shaft
3. Reverse idler gear
VEHICLE SPEED SENSOR
VEHICLE SPEED SENSOR

M1222007000038

moving parts before
installation.
AK204397AB

1. E-clip 3. O-ring
2. Speed sensor gear 4. Speed sensor
SELECT LEVER
SELECT LEVER
M1222012800193
7
1
8
2 11 ± 1 N·m
9 3
10
AK502136AB

1. Dust cover 6. Select lever shoe
2. Nut 7. Select lever
3. Spring washer >>A<< 8. Select lever bushing
4. Washer >>A<< 9. Dust cover
>>A<< 5. Select lever bushing 10. Select lever shaft
CONTROL HOUSING
REASSEMBLY SERVICE POINT

.
>>A<< DUST COVER AND SELECT LEVER BUSHING

INSTALLATION
Make sure the dust cover and select lever bushing installation
Select lever
bushing direction is correct, and distinguished parts are correctly
assembled. Refer to the figure at left.
Dust cover
AK204311 AB
CONTROL HOUSING
M1222013100302
9 6
7 3
12
11 5
13
4
8
14
10
2
1
21.7 ± 0.3 N·m

AK502052AB
CONTROL HOUSING

1. Spring washer 8. Neutral return spring
2. Stopper bracket 9. Control shaft
<<A>> >>E<< 3 Lock pin >>C<< 10. Air breather
4. Interlock plate 11. Control shaft boot
5. Control finger >>B<< 12. Oil seal
>>D<< 6. Spring pin >>A<< 13. Needle bearing
7. Stopper body 14. Control housing

.
<<A>> LOCK PIN REMOVAL

Drive out the lock pin from the direction shown.
Lock pin
Control fing
AK204273 AB

.
>>A<< NEEDLE BEARING INSTALLATION

Press fit the needle bearing into the control housing side as
Control housing shown.
Needle bearing Make sure that the side with the model number stamped on it
faces the end of the control housing as shown.
Model number
stamped side
0 – 0.5 mm
AK204176AC
>>B<< OIL SEAL INSTALLATION

Apply transmission oil to the oil seal lip area.
Transmission oil:
Genuine Mitsubishi MTF
AK204303AB
.
CONTROL HOUSING
>>C<< AIR BREATHER INSTALLATION

1. Apply sealant to the inserting portion of air breather.
Specified sealant:
3M SUPER WEATHERSTRIP No.8001 or equivalent
AK204274AB
2. Install the air breather so that the emboss mark is in the

direction shown in the figure.
Emboss
mark
AK204220 AB
>>D<< SPRING PIN INSTALLATION

Drive in the spring pin so that the slit is in the direction shown in
Control shaft the figure.
Stopper body
Installation direc
Slit
Spring pin
AK204177AB
>>E<< LOCK PIN INSTALLATION

Drive the lock pin in from the direction shown in the figure.
AK204273 AC
CLUTCH HOUSING
CLUTCH HOUSING
M1222003700369
5*
9.8 ± 2.0 N·m 1

AK502134 AB

1. Clutch release bearing retainer >>A<< 7. Cover-B
>>E<< 2. Oil seal 8. Clutch housing
<<A>> >>D<< 3. Outer race NOTE: *Refer to the bushing installation procedures only
<> >>C<< 4. Outer race when replacing the clutch housing.
>>B<< 5. Bushing*
>>A<< 6. Cover-A
CLUTCH HOUSING

.
<<A>> OUTER RACE REMOVAL

Using special tool Claw (MD999566), remove the outer race
MD999566 from the clutch housing.
Outer race
AK201665AD
<> OUTER RACE REMOVAL

Using special tool Claw (MD999566), remove the outer race
from the clutch housing.
MD999566
AK201666 AD

.
>>A<< COVER-B/COVER-A INSTALLATION

Install the covers directed as shown in the illustration.
Cover-B
Cover-A
AK201667 AD
>>B<< BUSHING INSTALLATION

1. Press fit the bushing so the seam is away from the air vent.
Air vent
Seam of
bushing
AK201668 AD
CLUTCH HOUSING
2. Be sure the bushing is fully seated as shown. It must be 1

mm below the housing surface.
1 mm
AK204291 AC
>>C<< OUTER RACE INSTALLATION

Using special tools, press fit the outer race into the clutch hous-
MB990938 ing.
• Handle (MB990938)
MB990935
• Installer adapter (MB990935)
AK201669 AD
>>D<< OUTER RACE INSTALLATION

1. Check the installation direction of the outer race.
2. Using special tools, press fit the outer race into the clutch
MB990938 housing.
MB991445 • Handle (MB990938)
• Bushing remover and installer base (MB991445)
AK201670AD
>>E<< OIL SEAL INSTALLATION

1. Pack grease in the oil seal lip area.
Specified grease:
Mitsubishi Part No. 0101011 or equivalent
AK204284AC
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
M1222013400303
2*
5*
4
6
3 AK203131AD

>>D<< 1. Oil seal >>B<< 4. Oil guide
>>C<< 2. Needle bearing* >>A<< 5. Bushing*
>>B<< 3 Oil guide 6. Transmission
TRANSMISSION CASE
NOTE: *Refer to the needle bearing and bushing installa-

tion procedures only when replacing the transmission
case.

.
>>A<< BUSHING INSTALLATION

1. Press fit the bushing so the seam is away from the air vent.
Air vent Seam of

bushing
AK201672AD
2. Be sure the bushing is fully seated as shown. It must be 3

mm below the housing surface.
3 mm
AK204304 AC
>>B<< OIL GUIDE INSTALLATION

Evenly press the oil guide so it is fully seated and not at an
angle.
Oil guide
AK500016 AB
>>C<< NEEDLE BEARING INSTALLATION

1. Check the installation direction of the needle bearing.
2. Press fit the needle bearing until it is flush with the case.
Model number
stamped side
AK204287 AB
.
TRANSMISSION CASE
>>D<< OIL SEAL INSTALLATION

1. Apply transmission oil to the oil seal lip area.
Transmission oil:
Genuine Mitsubishi MTF
1.5 mm
AK204286 AD
2. Using special tool Differential oil seal installer (MD998800),

press fit the oil seal into the transmission case.
MD998800
AK201673 AD
DIFFERENTIAL
DIFFERENTIAL
M1222002500254

moving parts before
installation.
6 8
5
4
8 133 ± 4 N·m
7 1
3
5
9
2
AK502153AB

>>D<< 1. Differential drive gear >>A<< 6. Washer
<<A>> >>C<< 2. Taper roller bearing >>A<< 7. Side gear
>>B<< 3. Lock pin >>A<< 8. Spacer
>>A<< 4. Pinion shaft 9. Differential case
>>A<< 5. Pinion
DIFFERENTIAL

.
<<A>> TAPER ROLLER BEARING REMOVAL

MD998801 the taper roller bearing, and then set them on the press.
2. Push down on the differential case with the press and
remove the bearing.
AK305171AB

.
>>A<< SPACER/SIDE GEAR/WASHER/PINION/PINION

SHAFT INSTALLATION
1. After a spacer has been mounted on the back surface of the
side gear, install the side gear in the differential case.
NOTE: When a new side gear is to be installed, mount a
medium thickness spacer.
2. Set the washer on the back of each pinion, and put both
pinions simultaneously in mesh with the side gears. While
rotating them, install them in position.
AK305230
3. Insert the pinion shaft.
AK305231
4. Measure the backlash between the side gear and pinion.

5. If the backlash is out of specification, select a spacer that
should get the back lash with in the standard value and re-
measure the backlash.
NOTE: Repeat until the backlash on both sides are equal.
AK305229
.
DIFFERENTIAL
>>B<< LOCK PIN INSTALLATION

Install the lock pin so that it will be oriented in the direction
Differential case
shown.
Lock pin
Pinion shaft
AK204290 AB
>>C<< TAPER ROLLER BEARING INSTALLATION

Using special tools, install the taper roller bearing with the
MD998812 press.
MD998823
AK305199AB
>>D<< DIFFERENTIAL DRIVE GEAR INSTALLATION

1. Apply sealant to the entire threaded portion of the bolt.
Specified sealant: 3M STUD Locking No.4170 or equiv-
alent
AK500017AB
2. Tighten to the specified torque of 133 ± 4 N⋅m in the

1 10 illustrated sequence.
3
8
5 6
7 4
9 2
AK103662AC
DIFFERENTIAL
HOME
23-1
GROUP 23
AUTOMATIC
TRANSAXLE
CONTENTS
AUTOMATIC TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A
AUTOMATIC TRANSAXLE OVERHAUL . . . . . . . . . . . . . . . . . . 23B

NOTES
HOME
23A-1
GROUP 23A
AUTOMATIC
TRANSMISSION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 23A-3 LINE PRESSURE ADJUSTMENT. . . . . . . . 23A-33

DIAGNOSTIC TROUBLE CODE CHART . . 23A-34
AUTOMATIC TRANSMISSION SYMPTOM CHART . . . . . . . . . . . . . . . . . . . 23A-35
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 23A-12 DIAGNOSTIC TROUBLE CODE
DIAGNOSTIC TROUBLESHOOTING FLOW 23A-12 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 23A-36
INTRODUCTION TO A/T DIAGNOSIS . . . . 23A-12 SYMPTOM PROCEDURES . . . . . . . . . . . . 23A-218
A/T DIAGNOSTIC TROUBLESHOOTING DATA LIST REFERENCE TABLE . . . . . . . . 23A-271
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . . 23A-13 ACTUATOR TEST REFERENCE TABLE . . 23A-276
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 23A-13 A/T-ECU TERMINAL VOLTAGE REFERENCE
HOW TO INITIALIZE A/T LEARNING CHART FOR TRANSMISSION OPERATION 23A-278
VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-17 A/T-ECU TERMINAL RESISTANCE AND
FAIL-SAFE/BACKUP FUNCTION. . . . . . . . 23A-18 CONTINUITY INSPECTION CHART . . . . . 23A-284
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . 23A-19 INSPECTION PROCEDURE USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 23A-285
TORQUE CONVERTER STALL TEST . . . . 23A-25
HYDRAULIC PRESSURE TESTS . . . . . . . 23A-26
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . 23A-32
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
• Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
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
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
A/T CONTROL RELAY CHECK . . . . . . . . . 23A-296
SOLENOID VALVE CHECK . . . . . . . . . . . . 23A-298
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 23A-314
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
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.
.
TRANSMISSION CONFIGURATION DRAWING

REV OWC
2ND LR
OD UD
DIR
OWC RED
10DB146A
.
COMPONENTS AND FUNCTIONS

COMPONENT FUNCTION
Underdrive clutch UD connects the input shaft to the underdrive sun gear.
Reverse clutch REV connects the input shaft to the reverse sun gear.
Overdrive clutch OD connects the input shaft to the overdrive planetary carrier.
Direct clutch DIR connects the direct sun gear and direct planetary carrier.
Low-reverse brake LR holds the low-reverse annulus gear and the overdrive planetary
carrier.
Second brake 2ND holds the reverse sun gear.
Reduction brake RED locks the direct sun gear.
One-way clutch(DIR) OWC-D restricts the rotation direction of the direct sun gear.
One-way clutch(LR) OWC-LR restricts the rotation direction of the low-reverse annulus gear.
GENERAL DESCRIPTION
FUNCTION ELEMENT TABLE

OPERATING START PARKING UNDER REVERSE OVER- DIRECT LOW- SECOND REDUCTI-
ELEMENT MECHANI DRIVE CLUTCH DRIVE CLUTCH REVERSE BRAKE ON
SM CLUTCH (REV) CLUTCH (DIR) BRAKE (2ND) BRAKE
TRANSMISSION (UD) (OD) (LR) (RB)
RANGE
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].
GENERAL DESCRIPTION
SECTIONAL VIEW <F5A5A>
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
1. OVERDRIVE CLUTCH 13. TORQUE CONVERTER CLUTCH

2. REVERSE CLUTCH 14. TORQUE CONVERTER
3. OVERDRIVE PLANETARY CARRIER 15. INPUT SHAFT
4. OUTPUT PLANETARY CARRIER 16. DIFFERENTIAL
5. SECOND BRAKE 17. REAR COVER
6. LOW-REVERSE BRAKE 18. OUTPUT SHAFT
7. ONE-WAY CLUTCH 19. DIRECT CLUTCH
8. TRANSFER DRIVE GEAR 20. REDUCTION BRAKE BAND
9. TRANSMISSION CASE 21. DIRECT PLANETARY CARRIER
10. UNDERDRIVE CLUTCH 22. TRANSFER DRIVEN GEAR
11. OIL PUMP 23. OUTPUT GEAR
12. TORQUE CONVERTER HOUSING 24. DIFFERENTIAL DRIVE GEAR
GENERAL DESCRIPTION
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
DRIVER'S HABITS AND

PREFERENCE
AC000841AB
INVECS-II Sports Mode Automatic Transmission

A further development of the INVECS-II automatic transmis-
sion, incorporating a sports mode that enables quasi-manual
gear shifts. When the gear shift lever is pushed sideways fronm
the "D" position to the sports mode position, the driver can use
it to make gear selections manually. The sports mode has the
following features.
• In contrast to the automatic "D" range, the sports mode
does not perform automatic upshifts. Thus, the engine can
be driven fully into its red zone.
• For more rapid gear shifting, it is possible to shift directly
from 4th gear to 2nd gear, therby skipping a gear.
• When the vehicle decelerates and stops, the system auto-
maticaly shifts down to 1st gear for conveinience when the
vehicle starts moving again. Further, 2nd gear can be
selected with the vehicle stationary, so standing starts can
be made in 2nd gear on slippery surfaces.
10DB155A
.
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
NEURAL NETWORK 2. We introduce the latest control technologies with an innova-

tive new algorithm called the "neural network" that works to
DATA imitate the decision-making processes of the human brain.
ACCELERATOR PROCESSED The neural network links a wide variety of input data regard-
POSITION
ing road and operating conditions, and instantly makes
INTERRE- OPTIMUM
VEHICLE SPEED LATED GEAR accurate shift control decisions.
SELECTION
FOOT BRAKE DECI-

SION
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.
ADAPTIVE SHIFT CONTROL DURING ACCELERATION
DRIVER WHO PREFERS

RELAXING RIDE 4TH 5TH
DRIVER WHO PREFERS

SPORTIER RIDE 4TH 5TH
50 100
VEHICLE SPEED [km/h]

10DB078A
.
GENERAL DESCRIPTION
SYSTEM CONSTRUCTION DIAGRAM
SENSE DECIDE ACT
Ignition switch Automatic Transmission - A/T control relay

Electronic Control Unit
(A/T-ECU)
Input shaft speed sensor Torque converter clutch solenoid valve
Output shaft speed sensor Low-reverse solenoid valve
Transmission fluid temperature

A/T fluid temperature sensor sensor Second solenoid valve
Transmission range switch

Park/Neutral position switch Underdrive solenoid valve
Select switch
<Vehicles with sport mode> Overdrive solenoid valve
Shift switch (up, down) Reduction solenoid valve

<Vehicles with sport mode>
Fail-safe operation
Fail-safe operation
(''N''range
("N" rangelight
lightflashing)
flashing)
<Vehicles with sport mode>
Serial communication
Diagnostic tool (MUT-III)

Scan tool (MUT-II) 10DB080A
GENERAL DESCRIPTION
SHIFT PATTERN CONTROL

.
UPSHIFT PATTERN <F5A5A>
THROTTLE
OPENING (%) THICK LINE: STANDARD SHIFT PATTERN
OUTPUT SHAFT SPEED r/min

10DB157A
DOWNSHIFT PATTERN <F5A5A>
THROTTLE
OPENING (%) THICK LINE: STANDARD SHIFT PATTERN

10DB158A
NOTE: INVECS does not function on downshift.

GENERAL DESCRIPTION
TORQUE CONVERTER CLUTCH CONTROL

.
5TH GEAR RANGE <F5A5A>
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
0 (0) 50 (31) 100 (62) 150 (93) 200 (124)

VEHICLE SPEED km/h (mph)
10DB159A
.
4TH GEAR RANGE <F5A5A>

THROTTLE
OPENING THROTTLE
VOLTAGE (V) OPENING (%)
4.5 100
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
0 50 100 150 200

VEHICLE SPEED km/h
10DB160A
AUTOMATIC TRANSMISSION DIAGNOSIS

DIAGNOSTIC TROUBLESHOOTING FLOW
M1231013500353
Gather information from customer.
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.
Perform the repair.

Abnormality exists (no diagnostic
trouble code)
Road test
Abnormality exists No abnormality
(diagnostic trouble
code present) Recheck diagnostic trouble codes
which were read before road test.
Diagnostic trouble code No diagnostic trouble code
displayed. displayed.
To DIAGNOSTIC TROUBLE CODE To SYMPTOM CHART

CHART
Search for cause.

Found Not found
Repair INTERMITTENT MALFUNCTIONS

(Refer to GROUP 00, How to Use NG
Troubleshooting/Inspection
Service Points.)
OK
NG OK
Confirmation test (road test) Completed
AC210189 AB
INTRODUCTION TO A/T DIAGNOSIS

M1231012300226
The automatic transmission can exhibit any of the The following items are suspected as causes for the
following symptoms: noise or vibration is generated, INVECS-II troubles: malfunction of the A/T-ECU, the
Transmission fluid leaks, the vehicle does not move sensors, the switches, the harness or connectors.
forward or backward. The causes of these symptoms
could come from: Incorrect mounting, the Transmis-
sion fluid may be low, or a component of the
transmission may be faulty.
A/T DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1231007600339
Use these steps to plan your diagnostic strategy. If 6. If there is a DTC, record the number of the code,
you follow them carefully, you will find most A/T mal- then erase the code from memory using
functions. diagnostic tool.
1. Gather as much information as possible about the 7. Reconfirm the symptom with a Road Test.
complaint from the customer. 8. If a DTC is set again, go to the Inspection Chart
2. Verify that the condition described by the for Diagnostic Trouble Codes.
customer exists. 9. If a DTC is not set again, the malfunction is
3. Check the vehicle for any A/T Diagnostic Trouble intermittent. For information on how to cope with
Codes (DTCs). intermittent malfunctions, refer to GROUP 00,
4. If you can not verify the condition and there are no How to Use Troubleshooting/Inspection Service
DTCs, the malfunction is intermittent. For Points − How to Cope with Intermittent
information on how to cope with intermittent Malfunction P.00-14.
malfunctions, refer to GROUP 00, How to Use 10.After repairs are completed, conduct a Road Test
Troubleshooting/Inspection Service Points − How duplicating the complaint conditions to confirm the
to Cope with Intermittent Malfunction P.00-14. malfunction has been eliminated.
5. If you can verify the condition but there are no
DTCs, or the system can not communicate with
diagnostic tool, refer to the Symptom Chart
P.23A-35.
DIAGNOSTIC FUNCTION
M1231022500135
CHECK "N" RANGE LIGHT

The "N" range light flashes once per second if there is an
abnormality in any of the items in the table below which are
related to the A/T system. Check for diagnostic trouble codes if
the "N" range light is flashing once per second.
NOTE: The "N" indicator lamp warning function does not
operate with the selector lever in the "P" (PARK), "R"
(REVERSE) or "N" (NEUTRAL) position.
"N" range light flashing items
• Input shaft speed sensor
NEUTRAL “N” INDICATOR LAMP 10DB076A • Output shaft speed sensor
• Each solenoid valve
• Gear incorrect ratio
• A/T control relay system
CAUTION
If the "N" range light is flashing rapidly (twice per second),
the transmission fluid temperature is too high. (It flashes
when the fluid is approximately 125°C or more and goes
off when the fluid is approximately 115°C or less)
ON-BOARD DIAGNOSTICS diagnostic tool. Diagnostic trouble codes are kept in

The automatic transmission -electronic control unit memory by direct battery feed. The codes are
(A/T-ECU) monitors its input/output signals (some retained in memory even if the ignition switch is in
signals all the time and others under specified condi- the "LOCK" (OFF) position. DTCs are not erased
tions). When an irregular signal is initially monitored, even after the battery terminals and the A/T-ECU
the A/T-ECU decides that a malfunction has connector are disconnected. In addition, the diagnos-
occurred and records the occurrence as a diagnostic tic trouble code can also be erased by diagnostic
trouble code. The diagnostic results can be read with tool.
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.

(MUT-III)
CAUTION
DATA LINK
MB991958.
position.
MB991910
position.
color.
NOTE: Disconnecting diagnostic tool MB991958 is the reverse
MB991827 00DB076A of the connecting sequence, making sure that the ignition

TROUBLE CODES
• MB991824: V.C.I.
CAUTION
DATA LINK
MB991958.
will not be set. Check the battery if diagnostic tool
connector.
MB991910
MB991824
5. Choose "ELC-A/T" from the "POWER TRAIN" tab.
6. Select "MITSUBISHI."
7. Select "Diagnostic Trouble Code."
MB991827 00DB076A

• MB991958 : Diagnostic Tool (MUT-III Sub Assembly)
• MB991824: V.C.I.
CAUTION
DATA LINK
MB991958.
connector.
MB991910
MB991824 6. Select "MITSUBISHI."
8. Choose an appropriate item and select the "OK" button.
MB991827 00DB076A

• MB991824: V.C.I.
CAUTION
DATA LINK
MB991958.
connector.
MB991910
MB991824 6. Select "MITSUBISHI."
7. Select "Actuator Test."
MB991827 00DB076A
HOW TO DIAGNOSE THE CAN BUS LINES

• MB991824: V.C.I.
CAUTION
DATA LINK
MB991958.
connector.
MB991910
4. When the vehicle information is displayed, confirm that it
diagnosed.
MB991824
that it matches the vehicle whose CAN bus lines will be
diagnosed.
MB991827 00DB076A • If they match, go to step 8.
8. Select the "OK" button.
"OK" button.
HOW TO INITIALIZE A/T LEARNING VALUE
M1231022600121
AIM INITIALIZATION PROCEDURE

The use of EEPROM has enabled the A/T learned 1. Shift the selector lever to the P range and turn the
value to be retained even after the battery terminals ignition switch to the LOCK (OFF) position. Then,
are disconnected. However, the learned value should connect the MUT-III to the diagnosis connector.
be initialized if the A/T assembly, the engine assem- 2. Initialize the learned value on the initialization
bly, the valve body assembly or the solenoid valves screen.
are replaced. The initialization procedure is as
3. After this initialization, make the system learn the
below:
idling in accordance with "Learning procedure for
idling in MPI engine" (Refer to GROUP 00 −
Precautions before Service 00-22).
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.
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).

TEST/OPERATION PAGE
Shift shock
when shifting
from N to D and
long delay
(P.23A-229).
Shift shock
when shifting
from N to R and
long delay
(P.23A-232).
Shift shock
when shifting
from N to D, N
to R and long
delay
(P.23A-235).
Does not Does not move
move forward
(P.23A-220).
Does not move
in reverse
(P.23A-223).
Does not move
(forward or in
reverse)
(P.23A-226).
6 Transmission Gear range and Data list No.11 Shift -
range: N (on a vehicle speed (Each (2) 1st, (3) 2nd, (4) position
flat and straight condition should be 3rd, (5) 4th, (6) 5th
road) maintained for 10
seconds or more).
(1) Idling in 1st gear
(Vehicle stopped)
(2) Driving at
constant speed of 10
km/h in 1st gear
(3) Driving at
km/h in 2nd gear
(4) Driving at
km/h in 3rd gear
(5) Driving at
km/h in 4th gear
(6) Driving at
km/h in 5th gear

TEST/OPERATION PAGE
Data list No.12 Low-revers Low-reverse
(2) 100%, (3) 100%, e solenoid solenoid valve
(4) 100%, (6) 100% valve duty system
% (P.23A-133).
Data list No.13 Underdrive Underdrive
(2) 0%, (3) 0%, (4) solenoid solenoid valve
0%, (6) 100% valve duty system
% (P.23A-144).
Data list No.14 Second Second
(2)100%, (3) 0%, (4) solenoid solenoid valve
% (P.23A-154).
Data list No.15 Overdrive Overdrive
(2) 100%, (3) 100%, solenoid solenoid valve
(4) 0%, (6) 0% valve duty system
% (P.23A-164).
Data list No.16 Reduction Reduction
(2) 0%, (3) 0%, (4) solenoid solenoid valve
% (P.23A-174).
Data list No.9 Vehicle vehicle speed
(1) 0km/h speed sensor system
(4) 50km/h sensor
Data list No.5 Input shaft Input shaft
(4) 1,600 − 1,900 speed speed sensor
r/min sensor system
(P.23A-55).
Data list No.6 Output Output shaft
(4) 1,600 − 1,900 shaft speed speed sensor
r/min sensor system
(P.23A-72).
Data list No.17 Damper Damper control
(3) 0% control clutch solenoid
(5) 70 − 90% clutch system
solenoid (P.23A-185,
valve duty P.23A-201,
% P.23A-204).
Data list No.10 Damper

(3) 100-300 rpm clutch
(5) 0-10 rpm slippage

TEST/OPERATION PAGE
7 Transmission Transmission range Data list No.17 Damper Damper control
range: 3 (on a and vehicle speed (2) 70 − 99.6% control clutch solenoid
flat and straight (1) Driving at speed (3) 70 − 99.6% to 0% clutch system
road) of 60 km/h in 3rd solenoid (P.23A-185,
gear valve duty P.23A-201,
(2) Driving at % P.23A-204).
km/h
(3) Release
accelerator pedal
(Speed under 50
km/h
Data list No.10 Damper
(2) 100 to 300 r/min control
(3) The value clutch
changes from (2) amount of
slippage
8 Use the (1)Accelerate to 5th Data list No.11, 6 Malfunction Shift shock and
diagnostic tool gear at a throttle The shifting points when slipping
MB991958 position sensor correspond with the shifting (P.23A-236).
(MUT-III sub output of 1.5 V diagnostic tool
assembly) to (accelerator opening display and the TP
stop the angle of 25%) sensor voltage
INVECS-II (2)Slowly decelerate (opening angle) and
function to a stop output shaft speed,
Transmission (3)Accelerate to 5th which are shown in
range: D (on a gear at a throttle the standard shift
flat and straight position sensor pattern
road) output of 2.5 V
(accelerator opening
angle of 50%)
Does not Early or late
shift shifting in all
according gears
to (P.23A-239).
instructions
Early or late
shifting in some
gears
(P.23A-242).

TEST/OPERATION PAGE
Does not No diagnostic
shift trouble code
(P.23A-244).
Input shaft
speed sensor
system
(P.23A-55).
Output shaft
speed sensor
system
(P.23A-72).
8 Use the (1) Accelerate from Data list No.11 Does not Low-reverse
diagnostic tool 1st gear to 5th gear. (1) 1st → 2nd → 3rd shift from 1 solenoid valve
MB991958 (2) While driving at → 4th → 5th to 2 or 2 to system
(MUT-III sub 60 km/h in 5th gear, (2) 5th → 4th 1 (P.23A-133).
assembly) to downshift to 4th gear (3) 4th → 3rd
stop the (3) While driving at (4) 3rd → 2nd
INVECS-II 40 km/h in 4th gear, (5) 2nd → 1st
function downshift to 3rd gear
Transmission (4) While driving at
range: D (on a 30 km/h in 3rd gear,
flat and straight downshift to 2nd gear
road) (5) While driving at
20 km/h in 2nd gear,
downshift to 1st gear
Second
solenoid valve
system
(P.23A-154).
1st gear
incorrect ratio
(P.23A-196).
2nd gear
incorrect ratio
(P.23A-196).
Does not Second
shift from 2 solenoid valve
to 3 or 3 to system
2 (P.23A-154).
Overdrive
solenoid valve
system
(P.23A-164).
2nd gear
incorrect ratio
(P.23A-196).

TEST/OPERATION PAGE
3rd gear
incorrect ratio
(P.23A-196).
Does not Low-reverse
to 4 or 4 to system
3 (P.23A-133).
Reduction
solenoid valve
system
(P.23A-154).
3rd gear
incorrect ratio
(P.23A-196).
4th gear
incorrect ratio
(P.23A-196).
Does not Underdrive
to 5 or 5 to system(
4 23A-200).
Second
solenoid valve
system
(P.23A-154).
4th gear
incorrect ratio
(P.23A-196).
5th gear
incorrect ratio
(P.23A-196).

TEST/OPERATION PAGE
9 Transmission Monitor data list The ratio between Does not Input shaft
range: N (on a No.22 and No.23 data list No.22 and shift speed sensor
flat and straight with the diagnostic No.23 should be the system
road) tool MB991958 same as the gear (P.23A-55).
(MUT-III sub ratio when reversing.
assembly)
(1) Move selector
lever to R range,
drive at constant
speed of 10 km/h
Output shaft
speed sensor
system
(P.23A-72).
Reverse gear
incorrect ratio
(P.23A-196).
TORQUE CONVERTER STALL TEST

M1231005400362
This test measures the maximum engine speed when the
Low- Under- Reverse
Reverse selector lever is in the "D" or "R" position and the torque con-
reverse drive clutch
clutch verter stalls. This tests the operation of the torque converter,
brake clutch
starter motor and one-way clutch operation, as well as the hold-
ing performance of the clutches and brakes in the transmission.
WARNING
Do not let anyone stand in front of or behind the vehi-
cle while this test is performed.
1. Check the transmission fluid level and temperature. Check
the engine coolant temperature.
• Transmission fluid level: At the "HOT" mark on the dipstick
• Transmission fluid temperature: 70 − 80°C
• Engine coolant temperature: 80 − 100°C
NOTE: Measures transmission fluid temperature with
diagnostic tool MB991958 (MUT-III sub assembly).
Second 2. Check both rear wheels.
brake
3. Pull the parking brake lever on, with the brake pedal fully
depressed.
10DB148A
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
TORQUE CONVERTER STALL TEST JUDGMENT

RESULTS
1. Stall speed is too high in both "D" and "R" range
• Malfunction of the torque converter (Slippage on the splines
of the torque converter and the input shaft)
• Low line pressure
• Low-reverse brake slippage and malfunction of the one-way
clutch
2. Stall speed is too high in "D" range only
• Underdrive clutch slippage
3. Stall speed is too high in "R" range only
• Reverse clutch slippage
4. Stall speed is too low in both "D" and "R" ranges
• Malfunction of the torque converter (Slippage of the
one-way clutch)
• Insufficient engine output
HYDRAULIC PRESSURE TESTS

M1231005500392
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.
<UNDER SIDE VIEW>

3. Connect the special tools (3.0 MPa (427 psi) oil pressure
MD998330
gauge [MD998330] and adapters [MD998332, MD998900])
to each pressure discharge port.
MD998332 NOTE: .
• 2ND: Second brake pressure port
• UD: Underdrive clutch pressure port
• LR: Low-reverse brake pressure port
VALVE BODY COVER • DR: Torque converter release pressure port
• DA: Torque converter apply pressure port
AC006150AB
• RV: Reverse clutch pressure port
• OD: Overdrive clutch pressure port
MD998330
• DIR: Direct clutch pressure port
• RED: Reduction clutch pressure port
VALVE BODY COVER 4. Restart the engine.
5. Check that there are no leaks around the special tool port
adapters.
6. Measure the hydraulic pressure at each port under the
MD998332 conditions given in the standard hydraulic pressure table,
and check that the measured values are within the standard
AC006149AB
value ranges.
7. If the pressure is not within the standard value, stop the
MD998330 engine and refer to the hydraulic pressure test diagnosis
table.
8. Remove the O-ring from the port plug and replace it.
9. Remove the special tool, and install the plugs to the
hydraulic pressure ports.
MD998900 10.Start the engine and check that there are no leaks around
the plugs.
VALVE BODY
COVER AC006151AB
MD998330
TOPSIDE
DIR MD998900
PORT 10DB153A
RED PORT
TOPSIDE
MD998900
10DB154A
STANDARD HYDRAULIC PRESSURE TABLE

<F5A5A>
MEASUREMENT STANDARD HYDRAULIC PRESSURE kPa
CONDITIONS
SELECT- SHIFT ENGINE UNDERDRIVE REVERSE OVERDRIVE DIRECT LOW- SECOND TORQUE
OR RANGE SPEED CLUTCH CLUTCH CLUTCH CLUTCH REVERSE BRAKE CONVERTER
LEVER POSITIO (r/min) PRESSURE PRESSURE PRESSURE PRESSURE BRAKE PRESSURE PRESSURE
POS’N N [UD] [RV] [OD] [DIR] PRESSURE [2ND] [DR]
[LR]
P − 2,500 − − − − 260 − 360 − 260 − 360

R Rev. 2,500 − 1270−1770 − − 1270−1770 − 500 − 730
N − 2,500 − − − − 260 − 360 − 220 − 360
Sport 1st 2,500 980 −1050 − − − 980 − 1050 − 500 − 730
mode
2nd 2,500 980 −1050 − − − − 980 − 1050 500 − 730
3rd 2,500 780 − 900 − 780 − 900 − − − 450 − 720
4th 2,500 780 − 900 − 780 − 900 780 − 880 − − 450 − 720
5th 2,500 − − 780 − 900 780 − 880 − 780 − 880 450 − 720
NOTE: When the torque converter pressure is measured, the engine speed should be 1,500 r/min or less.
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

SYMPTOM PROBABLE CAUSE
All hydraulic pressures are high. Malfunction of the regulator valve
All hydraulic pressures are low. Malfunction of the oil pump
Clogged internal oil filter
Clogged oil cooler
Malfunction of the regulator valve
Malfunction of the relief valve
Incorrect valve body installation
Improperly installed solenoid valves
Damaged solenoid valve O-rings
Hydraulic pressure is abnormal Malfunction of the regulator valve
in reverse gear only. Clogged orifice
Hydraulic pressure is abnormal Malfunction of the overdrive solenoid valve
in 3rd or 4th gear only. Malfunction of the overdrive pressure control valve
Malfunction of the regulator valve
Malfunction of the switch valve
Clogged orifice

Only underdrive clutch hydraulic Malfunction of the oil seal K
pressure is abnormal. Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of the check ball
Clogged orifice
Malfunction of the accumulator for underdrive clutch
Only reverse clutch hydraulic Malfunction of the oil seal A
pressure is abnormal. Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Only overdrive clutch hydraulic Malfunction of the oil seal D
pressure is abnormal. Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Clogged orifice
Malfunction of the accumulator for overdrive clutch
Only direct clutch hydraulic Malfunction of the oil seal R, S or T
pressure is abnormal. Malfunction of the low-reverse solenoid valve(also used for direct clutch)
Malfunction of the low-reverse pressure control valve
Malfunction of the fail safe valve C
Clogged orifice
Only low-reverse brake Malfunction of the oil seal I
hydraulic pressure is abnormal. Malfunction of the oil seal J
Malfunction of the low-reverse solenoid valve
Malfunction of the low-reverse pressure control valve
Malfunction of the fail safe valve A
Malfunction of all the check balls
Clogged orifice
Malfunction of the accumulator for low-reverse brake

Only second brake hydraulic Malfunction of the oil seal G
pressure is abnormal. Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Malfunction of the accumulator for second brake
Only reduction brake hydraulic Malfunction of the oil seal U or V
pressure is abnormal. Malfunction of the reduction solenoid valve
Malfunction of the reduction pressure control valve
Clogged orifice
Only torque converter pressure Clogged oil cooler
is abnormal. Malfunction of the oil seal N
Malfunction of the torque converter clutch solenoid
Malfunction of the torque converter pressure control valve
Clogged orifice
Pressure applied to element Incorrect transmission control cable adjustment
which should not receive Malfunction of the manual valve
pressure.
OIL SEAL LAYOUT
M N
K L
E F G H I J
D
C
B
A
P Q R
O
S
T
10DB149A
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
1. REVERSE CLUTCH 19. RED PRESSURE CONTROL VALVE

2. LOW-REVERSE BRAKE 20. TORQUE CONVERTER CLUTCH SOLENOID
3. SECOND BRAKE VALVE
4. UNDERDRIVE CLUTCH 21. LOW-REVERSE SOLENOID VALVE
5. OVERDRIVE CLUTCH 22. SECOND SOLENOID VALVE
6. RED CLUTCH 23. UNDERDRIVE SOLENOID VALVE
7. DIR CLUTCH 24. OVERDRIVE SOLENOID VALVE
8. TORQUE CONVERTER CLUTCH 25. RED SOLENOID VALVE
9. FAIL SAFE VALVE A 26. TORQUE CONVERTER PRESSURE
10. FAIL SAFE VALVE B CONTROL VALVE
11. FAIL SAFE VALVE C 27. REGULATOR VALVE
12. SWITCH VALVE 28. MANUAL VALVE
13. TRANSMISSION FLUID COOLER 29. OIL STRAINER
14. TORQUE CONVERTER CLUTCH CONTROL 30. OIL FILTER
VALVE 31. OIL PUMP
15. LOW-REVERSE PRESSURE CONTROL VALVE 32. OIL FILTER
16. SECOND PRESSURE CONTROL VALVE 33. RELIEF VALVE
17. UNDERDRIVE PRESSURE CONTROL VALVE 34. OIL PAN
18. OVERDRIVE PRESSURE CONTROL VALVE
LINE PRESSURE ADJUSTMENT

M1231001700361
1. Drain the transmission fluid.
NOTE: The hydraulic pressure test must be performed
before attempting any adjustments.
2. Remove the valve body cover.
ADJUSTING
3. Turn the adjusting screw shown in the illustration to adjust
SCREW the line pressure to the standard value in "D" range 1st or
2nd gear. The pressure increases when the screw is turned
counterclockwise approximately 35 kPa for each turn.
AC006153AB
NOTE: When adjusting the line pressure, adjust to the mid-
dle of the standard value range.
Standard value: 980 − 1050 kPa
4. Install the valve body cover. Pour in the standard volume of
automatic transmission fluid.
5. Repeat the hydraulic pressure test. (Refer to P.23A-26).
Readjust the line pressure if necessary.

M1231007900330
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.
SYMPTOM CHART
M1231008000277
CAUTION
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.
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
"N" to "R" and long delay
"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
(P0713): Transmission Fluid Temperature Sensor System (Open Circuit)
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
DTC SET CONDITIONS

.
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 .
temperature sensor resistance is low. OBD-II DRIVE CYCLE PATTERN

.
Start the engine, drive at 60 km/h or more for 15 min-
utes in total.
.

SET ARE:)
• Malfunction of the transmission fluid temperature Circuit drawings
sensor circuit • Refer to circuit diagrams GROUP-90
• Damaged harness or connector • Refer to configuration diagrams GROUP-80
• Malfunction of the A/T-ECU • Refer to component locations GROUP-70
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool MB991958, check data list

item 7: Transmission Fluid Temperature Sensor.
CAUTION
DATA LINK
MB991958.
connector.
• Item 7: Transmission Fluid Temperature Sensor.
MB991910 • When the engine is cool: Diagnostic tool display is
almost equal to the ambient temperature (atmo-
MB991824 spheric temperature)
NOTE: Set diagnostic tool MB991958 to the Engine
MPI data list reading mode for item number 5, Intake
Air Temperature (IAT) Sensor and note the tempera-
ture measurement. When the engine is cool, the
temperature should be almost equal to the ambient
temperature (atmospheric temperature), and the IAT
sensor measurement should be approximately the
MB991827 00DB076A same as the Transmission Fluid Temperature Sen-
sor.
• When the engine is warm, at approximately running
temperature: 70 − 80°C.
NO : Go to Step 2.
STEP 2. Measure the sensor output voltage at the A/T

control solenoid valve assembly connector B-108 by
backprobing.
CONNECTOR: B-108 (1) Do not disconnect connector B-108.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
(3) Measure the voltage between terminal 1 and ground by

backprobing.
• When transmission fluid temperature is 20°C, voltage
should measure between 3.8 and 4.0 volts.
1 2 3 4 5 6
7 8 9 10 should measure between 3.2 and 3.4 volts.
B-108 HARNESS
CONNECTOR: should measure between 1.7 and 1.9 volts.
HARNESS SIDE (4) Turn the ignition switch to the "LOCK" (OFF) position.
AC200996 AG Q: Is the measured voltage within the specified range?
YES : Go to Step 6.
NO : Go to Step 3.
STEP 3. Measure the ground voltage at the A/T control

solenoid valve assembly connector B-108 by backprobing.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

backprobing.
• The voltage should measure 0.5 volt or less.
1 2 3 4 5 6 Q: Is the measured voltage 0.5 volt or less?
7 8 9 10
YES : Go to Step 4.
B-108 HARNESS NO : Go to Step 7.
CONNECTOR:
HARNESS SIDE
AC201005AG
STEP 4. Check the sensor output voltage at A/T control

solenoid valve assembly connector B-108.
side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

6 5 4 3 2 1
10 9 8 7
YES : Go to Step 5.
CONNECTOR:
COMPONENT SIDE
AC201006AE
STEP 5. Check the transmission fluid temperature sensor

at A/T control solenoid valve assembly connector B-108.
CONNECTOR: B-108 (1) Disconnect connector B-108 and measure at the sensor
side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
(2) Measure the resistance between terminal 1 and 2.

• When transmission fluid temperature is 0°C (32°F),
resistance should be between 16.7 and 20.5 kΩ.
1 2 3 4 5 6
7 8 9 10 • When transmission fluid temperature is 40°C (104°F),
B-108 HARNESS • When transmission fluid temperature is 60°C (140°F),
CONNECTOR:
TRANSMISSION FLUID resistance should be between 1.9 and 2.2 kΩ.
TEMPERATURE SENSOR SIDE
AC209994AB • When transmission fluid temperature is 80°C (176°F),
YES : Go to Step 6.
NO : Replace the transmission fluid temperature sensor.
Refer to GROUP 23B, Transmission P.23B-13.

CAUTION
MB991958.
connector.
sor.
NO : Replace the A/T-ECU.
STEP 7. Check A/T control solenoid valve assembly

connector B-108 for loose, corroded or damaged
CONNECTOR: B-108 Q: Are the connector and terminals in good condition?
B-108 (GR)
YES : Go to Step 8.
1 2 3 4 5 6 GROUP 00E, Harness Connector Inspection
7 8 9 10
P.00E-2.
TRANSMISSION
RANGE SWITCH
AC306322AC
STEP 8. Measure the resistance of the ground circuit at A/T

control solenoid valve assembly connector B-108.
side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

Q: Is the resistance less than 2 ohms?
YES : Go to Step 5.
6 5 4 3 2 1 NO : Go to Step 12.
10 9 8 7
B-108 HARNESS
CONNECTOR:
COMPONENT SIDE
AC209995AB
STEP 9. Measure the sensor output voltage at A/T-ECU

MB992045 .
(1) Disconnect all the connectors from the A/T-ECU.
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

A/T-ECU CHECK HARNESS the A/T-ECU and the body-side harness connector.
MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

and ground.
B-22 CONNECTOR: • When transmission fluid temperature is 20°C (68°F),
voltage should measure between 3.8 and 4.0 volts.
10DB081A Q: Is the measured voltage within the specified range?
YES : Go to Step 6.
NO : Go to Step 10.
STEP 10. Check A/T-ECU connector B-22 for loose,

in the connector.
CONNECTORS: B-19, B-22 YES : Go to Step 11.
AIR NO : Repair or replace the damaged components. Refer to
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
STEP 11. Check the harness for open circuit or short

circuit to ground between A/T-ECU connector B-22
terminal 6 and A/T control solenoid valve connector B-108
terminal 1.
AIR NO : Repair or replace the harness wire.
CLEANER
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
STEP 12. Measure the ground voltage at A/T-ECU

MB992045.
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

A/T-ECU CHECK HARNESS
MB992045 the A/T-ECU and the body-side harness connector.
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

• Voltage should measure 0.5 volt or less.
B-22 CONNECTOR: (5) Turn the ignition switch to the "LOCK" (OFF) position.
NO : Go to Step 14.
10DB082A

between A/T-ECU connector B-22 terminal 12 and A/T
control solenoid valve connector B-108 terminal 2.
CLEANER
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

in the connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
(P0712): Transmission Fluid Temperature Sensor System (Short Circuit)
OBD-II DRIVE CYCLE PATTERN

.
TRANSMISSION FLUID TEMPERATURE

Start the engine, keep the vehicle stopped in "P"
SENSOR SYSTEM CIRCUIT range for 5 seconds.
Refer to P.23A-36.
.

CIRCUIT OPERATION
Refer to P.23A-36.
SET ARE:)
• Malfunction of the transmission fluid temperature
.
DTC SET CONDITIONS

sensor circuit
Check Conditions, Judgement Criteria • Damaged harness or connector
• Transmission fluid temperature sensor voltage: • Malfunction of the A/T-ECU
0.2 volt or less. (1 second) Circuit drawings
.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
MB991958.
connector.
sor.
NO : Go to Step 2.
STEP 2. Measure the sensor output voltage at the A/T

control solenoid valve assembly connector B-108 by
backprobing.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

backprobing.
1 2 3 4 5 6
7 8 9 10 voltage should measure between 3.2 and 3.4 volts.
B-108 HARNESS
CONNECTOR: voltage should measure between 1.7 and 1.9 volts.
HARNESS SIDE (4) Turn the ignition switch to the "LOCK" (OFF) position.
AC200996 AG Q: Is the measured voltage within the specified range?
YES : Go to Step 6.
NO : Go to Step 3.
STEP 3. Check A/T control solenoid valve assembly

connector B-108 for loose, corroded or damaged
B-108 (GR)
YES : Go to Step 4.
1 2 3 4 5 6 GROUP 00E, Harness Connector Inspection
7 8 9 10
P.00E-2.
TRANSMISSION
RANGE SWITCH
AC306322AC
STEP 4. Check the sensor output voltage at A/T control

side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

6 5 4 3 2 1
10 9 8 7
YES : Go to Step 5.
CONNECTOR:
COMPONENT SIDE
AC201006AE
STEP 5. Check the transmission fluid temperature sensor

CONNECTOR: B-108 (1) Disconnect connector B-108 and measure at the sensor
side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
(2) Measure the resistance between terminal 1 and 2.

1 2 3 4 5 6
7 8 9 10
B-108 HARNESS
CONNECTOR:
TRANSMISSION FLUID • When transmission fluid temperature is 60°C (140°F),
TEMPERATURE resistance should be between 1.9 and 2.2 kΩ.
SENSOR SIDE
AC210626AB
YES : Go to Step 6.
NO : Replace the transmission fluid temperature sensor.
Refer to GROUP 23B, Transmission P.23B-13.

CAUTION
MB991958.
connector.
sor.
STEP 7. Measure the sensor output voltage at A/T-ECU

MB992045.
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

B-22 CONNECTOR: voltage should measure between 3.8 and 4.0 volts.
10DB081A
YES : Go to Step 6.
NO : Go to Step 8.

in the connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
STEP 9. Check the harness for a short circuit to ground

between A/T-ECU connector B-22 terminal 6 and A/T
control solenoid valve connector B-108 terminal 1.
CLEANER
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
(P0715): Input Shaft Speed Sensor System
CONNECTOR: A-13 CONNECTOR: B-109
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

AIR
CLEANER
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
.
CIRCUIT OPERATION Judgement Criteria

• The input shaft speed sensor generates 0 ⇔ 5 • Input shaft speed sensor signal: no signal
volts pulse signal when the input shaft rotates. change. (4 seconds)
The pulse signal frequency increases with a rise • If (P0715) is set consecutively four times, the
in input shaft speed. transmission is locked into 3rd gear or 2nd gear
• The input shaft speed sensor is connected to the as a fail-safe measure, and the "N" range light
A/T-ECU connector B-22 (terminals 5 and 12) via flashes once per second.
the input shaft speed sensor connector (terminals .
1 and 2). OBD-II DRIVE CYCLE PATTERN

• The A/T-ECU detects the input shaft speed by the Start the engine, shift to 3rd gear or higher, and drive
signal input to terminal 5. at 40 km/h or more for 10 seconds.
• The input shaft speed sensor generates the pulse
.
signal as the teeth of the underdrive clutch

retainer pass the magnetic tip of the sensor.
SET ARE:)
.
DTC SET CONDITIONS

• Malfunction of the input shaft speed sensor
Check Conditions • Malfunction of the underdrive clutch retainer
• A/T range switch position: D, 5, 4, 3, 2, 1 • Damaged harness or connector
• Output speed: 1,000 r/min or more. • Malfunction of the A/T-ECU
4.5 volts or less. Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool MB991958, check A/T data

list item 5: Input Shaft Speed Sensor.
CAUTION
MB991958.
connector.
(3) Set diagnostic tool MB991958 to data reading mode.
• Item 5: Input Shaft Speed Sensor.
MB991910 • When driving at constant speed of 50 km/h, the dis-
play should be "2,000 r/min" (Gear range: 3rd gear).
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Measure the power supply voltage at the input

shaft speed sensor connector B-109.
side.
B-109 (GR) (2) Turn the ignition switch to the "ON" position.
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

B-109 HARNESS • The voltage should measure battery positive voltage.
COMPONENT SIDE
Q: Is the measured voltage battery positive voltage?
YES : Go to Step 5.
3 2 1
NO : Go to Step 3.
AC210629AC
STEP 3. Check intermediate connector A-13 and junction

block connector C-214 for loose, corroded or damaged
YES : Go to Step 4.
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
10DB083A
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A

to ground between the input shaft speed sensor connector
B-109 terminal 3 and the junction block connector C-214
terminal 12.
YES : Go to Step 5.
B-109 (GR) NO : Repair or replace the harness wire.
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
STEP 5. Measure the A/T-ECU to speed sensor output

voltage at the input shaft speed sensor connector B-109.
CONNECTOR: B-109 (1) Disconnect connector B-109 from the speed sensor and
measure voltage at the harness side.
B-109 (GR) (2) Turn the ignition switch to the "ON" position.
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

B-109 HARNESS • The voltage should measure between 4.5 and 4.9 volts.
COMPONENT SIDE
3 2 1
NO : Go to Step 6.
AC210631AC
STEP 6. Measure the A/T-ECU output voltage to the speed

sensor at the A/T-ECU connector B-22 by using check
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
(4) Measure the voltage between A/T-ECU connector B-22

(terminal 5) and ground.
B-22 CONNECTOR: • The voltage should measure between 4.5 and 4.9 volts.
YES : Go to Step 7.
NO : Go to Step 9.
10DB086A
STEP 7. Check A/T-ECU connector B-22 and input shaft

connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

between A/T-ECU connector B-22 terminal 5 and input
shaft speed sensor connector B-109 terminal 2.
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

connector.
AIR NO : Repair or replace the damages components. Refer to
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

input shaft speed sensor connector B-109.
measure at the harness side.
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

B-109 HARNESS • The resistance should measure less than 2 ohms.
CONNECTOR:
COMPONENT SIDE
NO : Go to Step 12.
3 2 1
AC210632 AD
STEP 12. Measure the resistance at the A/T-ECU connector

B-22 by using check harness special tool.
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

NO : Go to Step 15.
10DB086A

connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: B-109
B-109 (GR)
1 2 3
TRANSMISSION
RANGE SWITCH
AC305354AC

in the connector.
CONNECTORS: B-19, B-22 YES : Replace the A/T-ECU.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
STEP 16. Using the oscilloscope, check the input shaft

speed sensor waveform at A/T-ECU connectors B-22 by
using check harness special tool MB992045.
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
(3) Connect an oscilloscope probe to A/T-ECU connector B-22

B-22 CONNECTOR:
terminal 5 and to 12.
PROBE 50 km/h (Gear range: 3rd gear).
OSCILLO-
SCOPE
10DB088A
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
electrical noise.
0
ACX02131 AD
NO : Go to Step 17.
STEP 17. Replace the input shaft speed sensor.

(1) Replace the input shaft speed sensor. Refer to GROUP
23B, Transmission P.23B-13.
INPUT SHAFT (2) Test drive the vehicle.
SPEED SENSOR
(3) Check for A/T diagnostic trouble code.
Q: Is A/T (P0715) set?
TRANSMISSION YES : Go to Step 18.
RANGE SWITCH NO : The procedure is complete.
AC305354AD
STEP 18. Replace the underdrive clutch retainer.

(1) Replace the underdrive clutch retainer. Refer to GROUP
23B, Underdrive Clutch and Input Shaft P.23B-46.
(2) Test drive the vehicle.
YES : An A/T DTC may have set due to external radio
frequency interference (RFI) possibility caused by
cellular phone activity, or aftermarket components
installed on the vehicle.
AC001836AB

item 5: Input Shaft Speed Sensor.
CAUTION
MB991958.
connector.
• Item 5: Input Shaft Speed Sensor.
play should be "2,000 r/min" (Gear range: 3rd gear).
MB991827 00DB076A
(P0720): Output Shaft Speed Sensor System
CONNECTOR: A-13 CONNECTOR: B-107
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

AIR
CLEANER
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
.
CIRCUIT OPERATION • Transmission fluid temperature sensor voltage:

• The output shaft speed sensor generates a 0 ⇔ 5 4.5 volts or less.
volt pulse signal when the output shaft rotates. • Rapid output speed change: -31.9 r/min / 0.016
The pulse signal frequency increases with a rise second or less.
output shaft speed. Judgement Criteria
• The output shaft speed sensor is connected to • Output speed: [(input speed - 200 r/min) / gear
the A/T-ECU connector B-22 (terminals 11 and ratio] or less. (4 seconds)
12) via the output shaft speed sensor connector • If (P0720) is set consecutively four times, the
(terminals 1 and 2). transmission is locked into 3rd gear as a fail-safe
• The A/T-ECU detects the output shaft speed by measure, and the "N" range light flashes once
the signal input to terminal 11. per second.
• The output shaft speed sensor generates the
pulse signal as the teeth of the transfer drive gear
.
pass the magnetic tip of the sensor.

Start the engine, and drive for 5 seconds, with 1st
.
gear fixed (1st gear in sport mode), at 20 km/h or

DTC SET CONDITIONS more with 50% or more of throttle valve opening.
Check Conditions Then stop the vehicle, and drive again for 5 seconds,
• A/T range switch position: D, 5, 4, 3, 2, 1. with 1st gear fixed (1st gear in sport mode), at 20
• Input speed: 1,000 r/min or more. km/h or more with 50% or more of throttle valve
• Engine speed: 1,000 r/min or more. opening.
• Transmission fluid temperature sensor voltage: .
4.5 volts or less. TROUBLESHOOTING HINTS (THE MOST

• Calculated slip (engine speed - input speed): 100 LIKELY CAUSES FOR THIS CODE TO BE
r/min or more.
SET ARE:)
Judgement Criteria • Malfunction of the output shaft speed sensor
• Output speed: no signal change. (4 seconds) • Malfunction of the transfer drive gear or driven
• If (P0720) is set consecutively four times, the gear
transmission is locked into 3rd gear as a fail-safe • Damaged harness or connector
measure, and the "N" range light flashes once • Malfunction of the A/T-ECU
per second.
Circuit drawings
• A/T range switch position: D, 5, 4, 3, 2, 1. • Refer to configuration diagrams GROUP-80
• Input speed: 500 r/min or more. • Refer to component locations GROUP-70
DIAGNOSIS
• MB991824: V.C.I.
• MB992045: A/T-ECU Check Harness

item 6: Output Shaft Speed Sensor.
CAUTION
MB991958.
connector.
• Item 6: Output Shaft Speed Sensor.
MB991910 • When driving at a constant speed of 50km/h, the dis-
play should be "1,900 − 2,100 r/min" (Gear range:
MB991824 3rd gear).
Q: Is the sensor within the specified range?
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Measure the power supply voltage at the output

shaft speed sensor connector B-107.
side.
BATTERY
B-107 (GR)
1 2 3
AC305353AC

B-107 HARNESS (4) Turn the ignition switch to the "LOCK" (OFF) position.
CONNECTOR:
COMPONENT SIDE Q: Is the measured voltage battery positive voltage?
YES : Go to Step 5.
3 2 1 NO : Go to Step 3.
AC210661AB

YES : Go to Step 4.
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
10DB083A
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A

to ground between the output shaft speed sensor
connector B-107 terminal 3 and the junction block
connector C-214 terminal 12.
YES : Go to Step 5.
BATTERY
B-107 (GR)
1 2 3
AC305353AC
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
STEP 5. Measure the A/T-ECU to speed sensor output

voltage at the output shaft speed sensor connector B-107.
measure voltage at the harness side.
BATTERY
B-107 (GR)
1 2 3
AC305353AC

B-107 HARNESS
CONNECTOR:
COMPONENT SIDE Q: Is the measured voltage between 4.5 and 4.9 volts?
3 2 1 NO : Go to Step 6.
AC210662 AB
STEP 6. Measure the A/T-ECU output voltage to the speed

sensor at the A/T-ECU connector B-22 by using check
ENGINE
CONTROL
AIR UNIT
CLEANER
COVER
A/T
CONTROL
UNIT
16DB480A

MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

and ground.
B-22 CONNECTOR: • The voltage should measure between 4.5 and 4.9 volts.
YES : Go to Step 7.
NO : Go to Step 9.
10DB089A
STEP 7. Check A/T-ECU connector B-22 and output shaft

connector.
ENGINE YES : Go to Step 8.
CONTROL
AIR UNIT NO : Repair or replace the damaged components. Refer to
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC

between A/T-ECU connector B-22 terminal 11 and output
ENGINE
CONTROL NO : Repair or replace the harness wire.
AIR UNIT
CLEANER
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC

connector.
ENGINE
CONTROL NO : Repair or replace the damages components. Refer to
AIR UNIT
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC

CONTROL
AIR UNIT NO : Repair or replace the harness wire.
CLEANER
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC

output shaft speed sensor connector B-107.
measure at the harness side.
BATTERY
B-107 (GR)
1 2 3
AC305353AC

B-107 HARNESS
CONNECTOR: Q: Is the measured resistance less than 2 ohms?
COMPONENT SIDE YES : Go to Step 16.
NO : Go to Step 12.
3 2 1
AC210663AB
STEP 12. Measure the resistance at the A/T-ECU connector

B-22 by using check harness special tool MB992045.
ENGINE
CONTROL
AIR UNIT
CLEANER
COVER
A/T
CONTROL
UNIT
16DB480A

MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

NO : Go to Step 15.
10DB082A

connector.
CONTROL
AIR UNIT NO : Repair or replace the damaged components. Refer to
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC

CONTROL
AIR UNIT NO : Repair or replace the harness wire.
CLEANER
COVER
A/T
CONTROL
UNIT
16DB480A
CONNECTOR: B-107
BATTERY
B-107 (GR)
1 2 3
AC305353AC

in the connector.
ENGINE YES : Replace the A/T-ECU.
CONTROL NO : Repair or replace the damaged components. Refer to
AIR UNIT
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB480A
STEP 16. Using the oscilloscope, check the output shaft

speed sensor waveform at A/T-ECU connectors B-22 by
using check harness special tool MB992045.
ENGINE
CONTROL
AIR UNIT
CLEANER
COVER
A/T
CONTROL
UNIT
16DB480A

MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
(3) Connect an oscilloscope probe to A/T-ECU connector B-22

B-22 CONNECTOR: terminal 11 and 12.
50 km/h (Gear range: 3rd gear).
PROBE
OSCILLO-
SCOPE
10DB090A
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
electrical noise.
0
ACX02131 AD
NO : Go to Step 17.
STEP 17. Replace the output shaft speed sensor.

(1) Replace the output shaft speed sensor. Refer to GROUP
BATTERY (2) Test drive the vehicle.
OUTPUT SHAFT
SPEEDB SENSOR
AC305353AD
STEP 18. Replace the transfer drive gear or driven gear.

(1) Replace the transfer drive gear or driven gear. Refer to
GROUP 23B, Transmission P.23B-13, Direct Planetary
Carrier P.23B-57.
TRANSFER
DRIVE GEAR Q: Is A/T (P0720) set?
TRANSFER
frequency interference (RFI) possibility caused by
DRIVEN GEAR
AC002221AC installed on the vehicle.

item 6: Output Shaft Speed Sensor.
CAUTION
MB991958.
connector.
play should be "1,900 − 2,100 r/min" (Gear range:
MB991824 3rd gear).
MB991827 00DB076A
Data List Item 19: Stoplamp Switch System
CONNECTOR: C-30
AIR
CLEANER
COVER 1 2
3 4
ENGINE
CONTROL
UNIT
10DB091A
16DB400A
. .
CIRCUIT OPERATION TROUBLESHOOTING HINTS (THE MOST

• Battery positive voltage is supplied to the LIKELY CAUSES FOR THIS CODE TO BE
stoplamp switch (terminal 2). SET ARE:)
• When the brake pedal is depressed, battery posi-
• Malfunction of the stoplamp switch
tive voltage is applied to the ENGINE-ECU con-
• Malfunction of stoplamp switch plunger
nector B-21 (terminal 18).
• Damaged harness or connector
.
DTC SET CONDITIONS Circuit drawings

If the stoplamp switch is on for five minutes or more
while driving above 50 km/h, or all of the stop light
bulbs are blown, it is judged there is a short circuit or
open circuit in the stoplamp switch. This causes Item
19 to be set.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check the brake pedal height.

Refer to GROUP 35A, On-vehicle Service − Brake Pedal
Check and Adjustment P.35A-13.
Q: Is the height adjusted properly?
YES : Go to Step 2.
NO : Adjust the brake pedal to the proper height.
STEP 2. Check the stoplamp switch plunger.

Refer to GROUP 54A, Rear combination light P.54A-161.
Q: Is the stoplamp switch plunger in good condition?
YES : Go to Step 3.
NO : Replace the stoplamp switch. Refer to GROUP 35A,
Brake Pedal P.35A-24.

CAUTION
MB991958.
connector.
• Item 19: Stoplamp Switch.
MB991910 • When the brake pedal is depressed, the display on
diagnostic tool MB991958 should be "ON."
MB991824 • When the brake pedal is not depressed, the display
on diagnostic tool MB991958 should be "OFF."
YES : It can be assumed that this malfunction may be
intermittent. Refer to GROUP 00, How to Use
MB991827 00DB076A NO : Go to Step 4.
STEP 4. Measure the stoplamp switch power supply

voltage at connector C-30 by backprobing.
CONNECTOR: C-30 (1) Remove the stoplamp switch from the mounting bracket.
(2) Do not disconnect connector C-30.
1 2
3 4
10DB091A

backprobing.
3 4 NO : Go to step 5.
C-30 HARNESS
CONNECTOR:
HARNESS SIDE
AC201487AG
STEP 5. Check stoplamp switch connector C-30 for loose,

in the connector.
YES : Go to Step 6.
P.00E-2.
1 2
3 4
10DB091A
STEP 6. Check the harness for damage between stoplamp

switch connector C-30 terminal 2 and the power supply
fuse.
CONNECTOR: C-30
YES : Go to Step 7.
1 2
3 4
10DB091A
STEP 7. Measure the stoplamp switch output voltage to the

ENGINE-ECU at connector C-30 by backprobing.
CONNECTOR: C-30 (1) Remove the stoplamp switch from the mounting bracket.
(2) Do not disconnect connector C-30.
1 2
3 4
10DB091A

backprobing.
• When the switch button is out (closed circuit), voltage
should equal battery positive voltage.
1 2
• When the switch button is depressed (open circuit), volt-
3 4 age should measure less than 1.0 volt.
Q: Is the measured voltage battery positive voltage with
C-30 HARNESS
CONNECTOR: the switch button released (closed circuit), and less
HARNESS SIDE than 1.0 volt with the switch button depressed (open
AC201041AH circuit)?
YES : Go to Step 9.
NO : Go to Step 8.

Refer to GROUP 35A, On-vehicle Service − Stoplamp Switch
Check P.35A-25.
Q: Does the stoplamp switch pass the checks?
STOPLIGHT
YES : Go to Step 9.
SWITCH NO : Replace the stoplamp switch. Refer to GROUP 35A,
Brake Pedal P.35A-24.
BRAKE PEDAL
ACX02208AD
STEP 9. Measure the stoplamp switch output voltage at the

ENGINE-ECU connector B-21 by using check harness
(1) Install the stoplamp switch into the mounting bracket if it
was removed.
the ENGINE-ECU and the body-side harness connector.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A

CONNECTOR:
COMPONENT SIDE
• When the brake pedal is depressed, voltage should
measure battery positive voltage.
• When the brake pedal is not depressed, voltage should
measure less than 1.0 volt.
Q: Is the measured voltage battery positive voltage with
the brake pedal depressed (closed circuit), and less
than 1.0 volt with the brake pedal released (open
10DB092A
circuit)?
NO : Go to Step 10.
STEP10. Check ENGINE-ECU connector B-21 and

stoplamp switch connector C-30 for loose, corroded or
connector.
CLEANER P.00E-2.
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-30
1 2
3 4
10DB091A
STEP 11. Check the harness for damage between

ENGINE-ECU connector B-21 terminal 18 and stoplamp
switch connector C-30 terminal 1.
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
16DB400A
CONNECTOR: C-30
1 2
3 4
10DB091A

CAUTION
MB991958.
connector.
• Item 19: Stoplamp Switch.
MB991910 • When the brake pedal is depressed, the display on
diagnostic tool MB991958 should be "ON."
MB991824 • When the brake pedal is not depressed, the display
on diagnostic tool MB991958 should be "OFF."
YES : It can be assumed that this malfunction may be
MB991827 00DB076A NO : Repeat Troubleshooting procedure. Go to Step 1.
NEXT PAGE
PREVIOUS PAGE
23A
(P0705): Transmission Inhibitor Switch System (Open Circuit)
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
CONNECTOR: A-13 COVER

A/T
CONTROL
A-13 (GR) UNIT
1 2 3 4 5 6 7
8 9 10 11
12 13 14 15 16 17
AC306223AB 16DB564A
CONNECTOR: B-110 CONNECTORS: C-214, 215
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
• Battery positive voltage is applied to the A/T-ECU

.
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)

.

Start the engine, keep the vehicle stopped in "P," "R," LIKELY CAUSES FOR THIS CODE TO BE
"N," and "D" ranges respectively for more than one SET ARE:)
minute, and turn "LOCK" (OFF) the ignition switch. • Malfunction of the transmission inhibitor switch
Then restart the engine, and stop the vehicle in "P," • Malfunction of the ignition switch
"R," "N," and "D" ranges respectively for more than • Damaged harness or connector
one minute. • Malfunction of the A/T-ECU
.
Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

item 34: Transmission Inhibitor Switch.
CAUTION
MB991958.
connector.
(2) Turn the ignition switch to "ON" position.
• Item 34: Transmission Inhibitor Switch.
MB991910 • Move the selector lever to "P," "R," "N," "D" and sport
mode positions and confirm that the selected trans-
MB991824 mission range match the positions shown on
diagnostic tool MB991958. (Sport mode is indicated
as "D" on the diagnostic tool).
Q: Does the diagnostic tool indication correspond to the
actual transmission range?
NO (no correct transmission range is displayed) : Go to
Step 2.
NO (Only "P" position is not displayed correctly) : Go
to Step 6.
NO (Only "R" position is not displayed correctly) : Go
to Step 12.
NO (Only "N" position is not displayed correctly) : Go
to Step 17.
NO (Only "D" position is not displayed correctly) : Go
to Step 22.
NO [Only sport mode position is not displayed correctly
("D" is not displayed.)] : Go to Step 29.

<F4A4B> Measure the resistance between the terminals for each trans-
mission range as indicated in the table below.
TRANSMISSION TERMINAL CONNECTION OF SPECIFIED CONDITION
RANGE TESTER
P 3 − 8, 9 − 10 Less than 2 ohms.

R 7−8
N 4 − 8, 9 − 10
TRANSMISSION D 1−8
RANGE SWITCH AC305532
<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
STEP 3. Check intermediate connector A-13, transmission

inhibitor switch connector B-110 and junction block
connector C-214 for loose, corroded or damaged
YES : Go to Step 4.
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
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
STEP 4. Check harness for open or short circuit to ground

between transmission inhibitor switch connector B-110
terminal 8 and junction block connector C-214 terminal 12.
YES : Go to Step 5.
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

item 34:Transmission Inhibitor Switch.
CAUTION
MB991958.
connector.
MB991910 • Move the selector lever to "P," "R," "N," "D," and
sport mode positions and confirm that the selected
MB991824 transmission range match the positions shown on
diagnostic tool MB991958. (Sport mode is indicated
as "D" on the diagnostic tool).
YES : It can be assumed that this malfunction is
MB991827 00DB076A Cope with Intermittent Malfunction P.00-14.

RANGE TESTER
P 3 − 8, 9 − 10 Less than 2 ohms.

R 7−8
N 4 − 8, 9 − 10
<F4A5A>
transmission range?
YES : Go to Step 7.
<F4A5A>
D
N
R
P
AC210182AC
STEP 7. Check transmission inhibitor switch connector

B-110 for loose, corroded or damaged terminals, or
YES : Go to Step 8.
1 2 3 4 5 6
7 8 9 10
B-110 (B) P.00E-2.
TRANSMISSION
RANGE SWITCH
AC210068AE
STEP 8. Measure the transmission inhibitor switch output

voltage at A/T-ECU connector B-22 by using check
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

(4) Move the selector lever to the "P" position.
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A
(5) Measure the voltage between connector B-22 terminal 25

CONNECTOR: • The voltage should measure battery positive voltage.
NO : Go to Step 9.
10DB094A

in the connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
STEP 10. Check harness for open circuit or short circuit to

ground between A/T-ECU connector B-22 terminal 25 and
transmission inhibitor switch connector B-110 terminal 3.
CLEANER
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

in the connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A

RANGE TESTER
P 3 − 8, 9 − 10 Less than 2 ohms.

R 7−8
N 4 − 8, 9 − 10
<F4A5A>
Q: Is the measured resistance less than 2 ohms for each
transmission range?
<F4A5A>
D
N
R
P
AC210182AC

1 2 3 4 5 6
7 8 9 10
B-110 (B) P.00E-2.
TRANSMISSION
RANGE SWITCH
AC210068AE

AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

MB992045
(4) Move the selector lever to the "R" position.
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

CONNECTOR: • The voltage should measure below battery positive volt-
age.
NO : Go to Step 15.
10DB095A

in the connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A

CLEANER
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

RANGE TESTER
P 3 − 8, 9 − 10 Less than 2 ohms.

R 7−8
N 4 − 8, 9 − 10
<F4A5A>
transmission range?
<F4A5A>
D
N
R
P
AC210182AC

1 2 3 4 5 6
7 8 9 10
B-110 (B) P.00E-2.
TRANSMISSION
RANGE SWITCH
AC210068AE

AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

MB992045
(4) Move the selector lever to the "N" position.
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

NO : Go to Step 20.
10DB096A

in the connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A

CLEANER
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

RANGE TESTER
P 3 − 8, 9 − 10 Less than 2 ohms.

R 7−8
N 4 − 8, 9 − 10
<F4A5A>
transmission range?
<F4A5A>
D
N
R
P
AC210182AC

1 2 3 4 5 6
7 8 9 10
B-110 (B) P.00E-2.
TRANSMISSION
RANGE SWITCH
AC210068AE

AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

MB992045
(4) Move the selector lever to the "D" position.
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

and ground.
B-22 HARNESS • The voltage should equal battery voltage
CONNECTOR:
(approximately12 volts).
Q: Does the voltage measure battery positive voltage?
NO : Go to Step 25.
10DB097A

in the connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A

CONNECTORS: B-19, B-22 YES <Vehicles without sport mode> : Go to Step 5.
AIR YES <Vehicles with sport mode> : Go to Step 27.
CLEANER NO : Repair or replace the harness wire.
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
STEP 27. Check intermediate connector A-13 and shift

switch assembly connector D-14 for loose, corroded or
connector.
CONNECTOR: A-13 Q: Are the connector and terminals in good condition?
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
AC306223AB
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
STEP 28. Check harness for short circuit to ground

between transmission inhibitor switch connector B-110
terminal 1 and shift switch assembly connector D-14
terminal 1.
YES : Go to Step 5.
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
STEP 29. Check A/T-ECU connector B-19 and shift switch

assembly connector D-14 for loose, corroded or damaged
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
STEP 30 . Check harness for short circuit to ground

between A/T-ECU connector B-19 terminal 17 and shift
switch assembly connector D-14 terminal 6.
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A
(P0705): Transmission Inhibitor Switch System (Short Circuit)
CAUTION OBD-II DRIVE CYCLE PATTERN

If (P0705) has been set, TCL related DTC (C1397) Start the engine, keep the vehicle stopped in "P," "R,"
is also set. After (P0705) has been diagnosed, "N," and "D" ranges respectively for more than one
don’t forget to erase DTC (C1397). minute, and turn "LOCK" (OFF) the ignition switch.
.
Then restart the engine, and stop the vehicle in "P,"
TRANSMISSION INHIBITOR SWITCH "R," "N," and "D" ranges respectively for more than
SYSTEM CIRCUIT one minute.
Refer to P.23A-97. .
.
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
Check Conditions, Judgement Criteria
• Malfunction of the A/T-ECU
• Transmission inhibitor switch: multiple signal. (30
seconds) Circuit drawings
.

DIAGNOSIS
• MB991824: V.C.I.
• MB991910: MUT-III Main harness A

RANGE TESTER
P 3 − 8, 9 − 10 Less than 2 ohms.

R 7−8
N 4 − 8, 9 − 10
<F4A5A>
selector position?
YES : Go to Step 2.
<F4A5A>
D
N
R
P
AC210182AC

YES : Go to Step 3.
1 2 3 4 5 6
7 8 9 10
B-110 (B) P.00E-2.
TRANSMISSION
RANGE SWITCH
AC210068AE

in the connector.
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A

harness special tool MB992045. ("P" position)
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

MB992045
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

B-22 HARNESS • When transmission range is "P," voltage should equal
CONNECTOR: battery positive voltage.
• When transmission range is "R," voltage should mea-
sure 0.5 volt or less.
• When transmission range is "N," voltage should mea-
• When transmission range is "D," voltage should mea-
10DB094A • When transmission range is sport mode, voltage should
measure 0.5 volt or less.
YES : Go to Step 6.
NO : Turn the ignition switch to the "LOCK" (OFF) position.
Go to Step 5.
STEP 5. Check harness for damage between A/T-ECU

connector B-22 terminal 25 and transmission inhibitor
switch connector B-110 terminal 3.
CLEANER
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

harness special tool MB992045. ("R" position)
Measure the voltage between terminal 23 and ground.
• When transmission range is "P," voltage should measure
AIR 0.5 volt or less.
CLEANER
• When transmission range is "R," voltage should equal bat-
tery positive voltage.
COVER • When transmission range is "N," voltage should measure
A/T 0.5 volt or less.
CONTROL
UNIT
• When transmission range is "D," voltage should measure
0.5 volt or less.
• When transmission range is sport mode, voltage should
YES : Go to Step 8.
16DB564A Go to Step 7.
B-22 HARNESS
CONNECTOR:
10DB095A
STEP 7. Check the harness for damage between A/T-ECU

CLEANER
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

harness special tool MB992045. ("N" position)
CLEANER
• When transmission range is "R," voltage should measure
0.5 volt or less.
COVER • When transmission range is "N," voltage should equal bat-
A/T tery positive voltage.
CONTROL
UNIT
• When transmission range is "D," voltage should measure
0.5 volt or less.
B-22 HARNESS
CONNECTOR:
10DB096A

CLEANER
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

harness special tool MB992045. ("D" position)
CLEANER
• When transmission range is "R," voltage should measure
0.5 volt or less.
COVER • When transmission range is "N," voltage should measure
A/T 0.5 volt or less.
CONTROL
UNIT
• When transmission range is "D," voltage should equal bat-
tery positive voltage.
equal battery positive voltage.
B-22 HARNESS
CONNECTOR:
10DB097A

CLEANER
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
STEP 12. Check intermediate connector A-13, A/T-ECU

connector B-19 and shift switch assembly connector D-14
for loose, corroded or damaged terminals, or terminals
pushed back in the connector.
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
AC306223AB

AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

CLEANER
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

item 34: Transmission Inhibitor Switch.
CAUTION
MB991958.
connector.
MB991910 • Move the selector lever to "P," "R," "N," "D" and sport
mode positions and confirm that the selected trans-
MB991824 mission ranges match the positions. (Sport mode is
indicated as "D" on the diagnostic tool MB991958).
MB991827 00DB076A NO : Replace the A/T-ECU.
(P0753): Low-Reverse Solenoid Valve System
CONNECTOR: A-13 CONNECTOR: B-16X
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
AC306223AB RELAY BOX 10DB098A
CONNECTOR: B-108
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
. .

• The A/T control relay supplies battery positive
Check Conditions
voltage to the solenoid valve assembly (terminals
• Solenoid status: either solid ON or OFF.
9 and 10).
• Shift status: in-gear.
• The solenoid valve closes when energized (on),
• Voltage of battery: 10 volts or more.
and opens when not energized (off). The
A/T-ECU energizes the solenoid valve based on Judgement Criteria
input data from sensors such as the Throttle • Solenoid voltage: 3 volts or less. (0.3 second)
Position Sensor, Transmission Inhibitor Switch, • If (P0753) is set consecutively four times, the
Stoplight Switch, Input Shaft Speed Sensor, Out- transmission is locked into 3rd gear as a fail-safe
put Shaft Speed Sensor, and Transmission Fluid measure, and the "N" range light flashes once
Temperature Sensor. per second.
• The A/T-ECU provides the ground to energize the .
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 .
transmission passages to apply and release com-

ponents.
TROUBLESHOOTING HINTS (THE MOST Circuit drawings

LIKELY CAUSES FOR THIS CODE TO BE • Refer to circuit diagrams GROUP-90
SET ARE:) • Refer to component locations GROUP-70
• Malfunction of the low-reverse solenoid valve
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool MB991958, check actuator

test item 01: Low-Reverse Solenoid Valve.
CAUTION
MB991958.
connector.
(3) Set diagnostic tool MB991958 to the actuator test mode.
• Item 01: Low-Reverse Solenoid Valve.
MB991910 • An audible clicking or buzzing should be heard when
the low-reverse solenoid valve is energized.
Q: Is the solenoid valve operating properly?
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Using diagnostic tool MB991958, read the A/T

DATA LINK connector.
CONNECTOR (2) Turn the ignition switch to the "ON" position.
Q: Is (P1751) set? (P1751 may be set along with multiple
DTCs).
YES : Refer to P.23A-207 P1751: A/T Control Relay
System.
MB991910
NO : Go to Step 3.
MB991824
MB991827 00DB076A

Q: Is (P0743) set?
YES : Go to Step 8.
NO : Go to Step 4.
MB991910
MB991824
MB991827 00DB076A
STEP 4. Measure the low-reverse solenoid valve resistance

CONNECTOR: B-108 (1) Disconnect connector B-108 and measure at the solenoid
valve side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
(2) Measure the resistance between solenoid valve assembly

B-108 HARNESS CONNECTOR: connector B-108 terminals 6 and 10.
A/T CONTROL SOLENOID
Resistance value: 2.7−3.4 Ω [at 20°C]
VALVE ASSEMBLY SIDE
Q: Is the measured resistance 2.7−3.4 Ω [at 20°C]?
YES : Go to Step 6.
1 2 3 4 5 6 NO : Go to Step 5.
7 8 9 10
AC210673AB
STEP 5. Measure the solenoid valve resistance at the

low-reverse solenoid valve assembly inside the
transmission.
(1) Disconnect connector B-108-5 and measure at the solenoid
valve side.
CONNECTORS: B-108-5 (2) Measure the resistance between low-reverse solenoid
valve terminals 1 and 2.
VALVE BODY Resistance value: 2.7−3.4 Ω [at 20°C (68°F)]
ASSEMBLY
Q: Is the measured resistance 2.7−3.4 Ω [at 20°C (68°F)?
YES : Replace the harness wire between A/T control
B-108-5
solenoid valve assembly connector B-108 and the
solenoid valves.
NO : Replace the low-reverse solenoid valve. Refer to
GROUP 23B, Valve Body 23B-62.
10DB110A
B-108-5 HARNESS CONNECTOR:

LOW-REVERSE
SOLENOID VALVE SIDE
1
2
AC201141AZ
STEP 6. Check A/T-ECU connector B-22 and A/T control

solenoid valve assembly connector B-108 for loose,
in the connector.
YES : Go to Step 7.
CLEANER
P.00E-2.
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
STEP 7. Check the harness for an open or short circuit to

A/T control solenoid valve assembly connector B-108
terminal 6.
YES : Replace the A/T-ECU.
CLEANER
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
STEP 8. Measure the supply voltage at A/T control

CONNECTOR: B-108 (1) Disconnect solenoid valve assembly harness connector
B-108.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
(3) Measure the voltage between harness connector B-108

B-108 HARNESS
terminal 10 and ground.
CONNECTOR: • The voltage should equal battery positive voltage.
6 5 4 3 2 1
10 9 8 7
NO : Go to Step 9.
AC210676AB
STEP 9. Check A/T control relay connector B-16X in the

engine component relay box and A/T control solenoid
valve assembly connector B-108 for loose, corroded or
connector.
CONNECTOR: B-16X Q: Are the connectors and terminals in good condition?
1 2
3 4 P.00E-2.
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
STEP 10. Check the harness for an open circuit or short

circuit to ground between A/T control relay connector
B-16X terminal 4 in the engine component relay box and
terminal 10.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

in the connector.
CLEANER
P.00E-2.
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

ground between A/T-ECU connector B-22 (terminals 8, 21
and 15) and A/T control solenoid valve assembly
connector B-108 (terminals 7, 6 and 8).
CLEANER
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

ground between A/T control solenoid valve assembly
connector B-108 (terminals 6, 7, 8 and 10) and solenoid
valve connectors B-108-4, B-108-5 and B-108-6.
B-108 (GR)
NO : Replace the harness wire.
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
CONNECTORS: B-108-4, B-108-5, B-108-6
VALVE BODY
ASSEMBLY
B-108-5
B-108-6 B-108-4
10DB103A
(P0758): Underdrive Solenoid Valve System

. .
SOLENOID VALVE SYSTEM CIRCUIT OBD-II DRIVE CYCLE PATTERN

Refer to P.23A-133. Start the engine, and keep the vehicle stopped in "P"
.
range for 5 seconds.
CIRCUIT OPERATION .
Refer to P.23A-133. TROUBLESHOOTING HINTS (THE MOST

.
DTC SET CONDITIONS SET ARE:)
• Malfunction of the underdrive solenoid valve
Check Conditions • Damaged harness or connector
• Solenoid status: either solid ON or OFF. • Malfunction of the A/T-ECU
• Shift status: in-gear.
• Voltage of battery: 10 volts or more. Circuit drawings
• Solenoid voltage: 3 volts or less. (0.3 second) • Refer to component locations GROUP-70
• If (P0758) is set consecutively four times, the
transmission is locked into 3rd gear as a fail-safe
measure, and the "N" range light flashes once
per second.
DIAGNOSIS
• MB991824: V.C.I.

test item 02: Underdrive Solenoid Valve.
CAUTION
MB991958.
connector.
• Item 02: Underdrive Solenoid Valve.
the underdrive solenoid valve is energized.
NO : Go to Step 2.
MB991827 00DB076A

CONNECTOR
DTCs).
YES : Refer to P.23A-207 (P1751): A/T Control Relay
MB991910 System.
NO : Go to Step 3.
MB991824
MB991827 00DB076A

CONNECTOR
Q: Are (P0763) and (P0768) set? (Multiple DTCs may be
set).
YES : Go to Step 8.
MB991824
MB991827 00DB076A
STEP 4. Measure the underdrive solenoid valve resistance

valve side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

B-108 HARNESS CONNECTOR:
A/T CONTROL SOLENOID VALVE
connector B-108 terminals 3 and 9.
ASSEMBLY 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)]?
YES : Go to Step 6.
1 2 3 4 5 6
7 8 9 10
NO : Go to Step 5.
AC210677AB

underdrive solenoid valve assembly inside the
transmission.
CONNECTORS: B-108-1 (1) Disconnect connector B-108-1 and measure at the solenoid
valve side.
B-108-1
VALVE BODY
ASSEMBLY
10DB109A
(2) Measure the resistance between Underdrive solenoid valve

terminals 1 and 2.
UNDERDRIVE
Resistance value: 2.7−3.4 Ω [at 20°C (68°F)]
SOLENOID VALVE SIDE 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 Underdrive solenoid valve. Refer to
AC201141BA

in the connector.
YES : Go to Step 7.
CLEANER
P.00E-2.
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

terminal 3.
CLEANER
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

B-108.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

B-108 HARNESS terminal 9 and ground.
6 5 4 3 2 1
10 9 8 7 YES : Go to Step 11.
NO : Go to Step 9.
AC210680 AB

connector.
1 2
3 4 P.00E-2.
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

terminal 9.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX AC306354AB
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

in the connector.
CLEANER
P.00E-2.
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

and 2) and A/T control solenoid valve assembly connector
B-108 (terminals 3, 4 and 5).
CLEANER
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

connector B-108 (terminals 3, 4, 5, and 9) and solenoid
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
CONNECTORS: B-108-1, B-108-2, B-108-3
B-108-3 B-108-1
B-108-2
VALVE BODY
ASSEMBLY
10DB106A
(P0763): Second Solenoid Valve System

. .

.
CIRCUIT OPERATION .

.
Check Conditions • Malfunction of the second solenoid valve
• Solenoid status: either solid ON or OFF. • Damaged harness or connector
• Shift status: in-gear. • Malfunction of the A/T-ECU
Judgement Criteria • Refer to circuit diagrams GROUP-90
• Solenoid voltage: 3 volts or less. (0.3 second) • Refer to configuration diagrams GROUP-80
• If (P0763) is set consecutively four times, the • Refer to component locations GROUP-70
per second.
DIAGNOSIS
• MB991824: V.C.I.

test item 03: Second Solenoid Valve.
CAUTION
MB991958.
connector.
• Item 03: Second Solenoid Valve.
the second solenoid valve is energized.
NO : Go to Step 2.
MB991827 00DB076A

DTCs).
MB991910 System.
NO : Go to Step 3.
MB991824
MB991827 00DB076A

set).
YES : Go to Step 8.
MB991824
MB991827 00DB076A
STEP 4. Measure the Second solenoid valve resistance at

A/T control solenoid valve assembly connector B-108.
valve side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

YES : Go to Step 6.
1 2 3 4 5 6 NO : Go to Step 5.
7 8 9 10
AC210690AB

second solenoid valve assembly inside the transmission.
valve side.
B-108-2
VALVE BODY
ASSEMBLY
10DB108A
(2) Measure the resistance between Second solenoid valve

terminals 1 and 2.
Resistance value: 2.7−3.4 Ω [at 20°C (68°F)]
SECOND
SOLENOID VALVE SIDE Q: Is the measured resistance 2.7−3.4 Ω [at 20°C (68°F)?
2 solenoid valve assembly connector B-108 and the
solenoid valves.
NO : Replace the Second solenoid valve. Refer to GROUP
23B, Valve Body 23B-62.
AC201141BB

in the connector.
YES : Go to Step 7.
CLEANER
P.00E-2.
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

terminal 4.
CLEANER
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

B-108.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

6 5 4 3 2 1
10 9 8 7 YES : Go to Step 11.
NO : Go to Step 9.
AC210680 AB

connector.
1 2
3 4 P.00E-2.
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

terminal 9.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

in the connector.
CLEANER
P.00E-2.
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

CLEANER
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

B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
CONNECTORS: B-108-1, B-108-2, B-108-3
B-108-3 B-108-1
B-108-2
VALVE BODY
ASSEMBLY
10DB106A
(P0768): Overdrive Solenoid Valve System

. .

.
CIRCUIT OPERATION .

.
Check Conditions • Malfunction of the overdrive solenoid valve
• Shift status: in-gear. • Malfunction of the A/T-ECU
Judgement Criteria • Refer to circuit diagrams GROUP-90
• Solenoid voltage: 3 volts or less. (0.3 second) • Refer to configuration diagrams GROUP-80
• If (P0768) is set consecutively four times, the • Refer to component locations GROUP-70
per second.
DIAGNOSIS
• MB991824: V.C.I.

test item 04: Overdrive Solenoid Valve.
CAUTION
MB991958.
connector.
• Item 04: Overdrive Solenoid Valve.
the overdrive solenoid valve is energized.
NO : Go to Step 2.
MB991827 00DB076A

DTCs).
MB991910 System.
NO : Go to Step 3.
MB991824
MB991827 00DB076A

set).
YES : Go to Step 8.
MB991824
MB991827 00DB076A
STEP 4. Measure the Overdrive solenoid valve resistance

valve side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

YES : Go to Step 6.
1 2 3 4 5 6
7 8 9 10
NO : Go to Step 5.
AC210692 AB

overdrive solenoid valve assembly inside the
transmission.
valve side.
B-108-3
VALVE BODY
ASSEMBLY
10DB107A
(2) Measure the resistance between Overdrive solenoid valve

B-180-3 HARNESS CONNECTOR: terminals 1 and 2.
OVERDRIVE Resistance value: 2.7−3.4 Ω [at 20°C (68°F)]
SOLENOID VALVE SIDE
1
2
solenoid valves.
NO : Replace the Overdrive solenoid valve. Refer to
AC201141BC

in the connector.
YES : Go to Step 7.
CLEANER
P.00E-2.
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

terminal 5.
CLEANER
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

B-108.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

6 5 4 3 2 1
10 9 8 7 YES : Go to Step 11.
NO : Go to Step 9.
AC210680 AB

connector.
1 2
3 4 P.00E-2.
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

terminal 9.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

in the connector.
CLEANER
P.00E-2.
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

CLEANER
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

B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
CONNECTORS: B-108-1, B-108-2, B-108-3
B-108-3 B-108-1
B-108-2
VALVE BODY
ASSEMBLY
10DB106A
(P0773): Reduction Solenoid Valve System

. .

.
CIRCUIT OPERATION .

.
Check Conditions • Malfunction of the reduction solenoid valve
• Voltage of battery: 10 volts or more. • Malfunction of the A/T-ECU
Judgement Criteria Circuit drawings

• Solenoid voltage: 3 volts or less. (0.3 second) • Refer to circuit diagrams GROUP-90
• If (P0773) is set consecutively four times, the • Refer to configuration diagrams GROUP-80
transmission is locked into 3rd gear as a fail-safe • Refer to component locations GROUP-70
per second.
DIAGNOSIS
• MB991824: V.C.I.

test item 05: Reduction Solenoid Valve.
CAUTION
MB991958.
connector.
• Item 05: Reduction Solenoid Valve.
the reduction solenoid valve is energized.
NO : Go to Step 2.
MB991827 00DB076A

DTCs).
MB991910 System.
NO : Go to Step 3.
MB991824
MB991827 00DB076A

set).
YES : Go to Step 8.
MB991824
MB991827 00DB076A
STEP 4. Measure the reduction solenoid valve resistance

valve side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

A/T CONTROL SOLENOID Resistance value: 2.7−3.4 Ω [at 20°C (68°F)]
VALVE ASSEMBLY SIDE
YES : Go to Step 6.
1 2 3 4 5 6
7 8 9 10
NO : Go to Step 5.
10DB100A

reduction solenoid valve assembly inside the
transmission.
CONNECTOR: B-108-6 (1) Disconnect connector B-108-6 and measure at the solenoid
valve side.
VALVE BODY
ASSEMBLY
B-108-6
10DB105A
(2) Measure the resistance between reduction solenoid valve

B-108-6 HARNESS CONNECTOR: terminals 1 and 2.
REDUCTION SOLENOID
VALVE SIDE Resistance value: 2.7−3.4 Ω [at 20°C (68°F)]
2
solenoid valves.
NO : Replace the reduction solenoid valve. Refer to
10DB101A

in the connector.
YES : Go to Step 7.
CLEANER
P.00E-2.
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

terminal 8.
CLEANER
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

B-108.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

B-108 HARNESS
6 5 4 3 2 1
10 9 8 7
NO : Go to Step 9.
AC210676AB

connector.
1 2
3 4 P.00E-2.
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

terminal 10.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

in the connector.
CLEANER
P.00E-2.
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

CLEANER
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

B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
CONNECTORS: B-108-4, B-108-5, B-108-6
VALVE BODY
ASSEMBLY
B-108-5
B-108-6 B-108-4
10DB103A
(P0743): Damper Clutch Control Solenoid Valve System

. .

.
CIRCUIT OPERATION .

.
Check Conditions • Malfunction of the damper clutch control solenoid
• Solenoid status: either solid ON or OFF. valve
• Voltage of battery: 10 volts or more. • Damaged harness or connector
Judgement Criteria
• Solenoid voltage: 3 volts or less. (0.3 second) Circuit drawings
• If (P0743) is set consecutively four times, the • Refer to circuit diagrams GROUP-90
transmission is locked into 3rd gear as a fail-safe • Refer to configuration diagrams GROUP-80
measure, and the "N" range light flashes once • Refer to component locations GROUP-70
per second.
DIAGNOSIS
• MB991824: V.C.I.

test item 06: Damper Clutch Control Solenoid Valve.
CAUTION
MB991958.
connector.
• Item 06: Damper Clutch Control Solenoid Valve.
the damper clutch control solenoid valve is ener-
MB991824 gized.
NO : Go to Step 2.
MB991827 00DB076A

DTCs).
MB991910 System.
NO : Go to Step 3.
MB991824
MB991827 00DB076A

set).
YES : Go to Step 8.
MB991824
MB991827 00DB076A
STEP 4. Measure the damper clutch control solenoid valve

resistance at A/T control solenoid valve assembly
connector B-108.
valve side.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

A/T CONTROL SOLENOID
VALVE ASSEMBLY SIDE Resistance value: 2.7−3.4 Ω [at 20°C (68°F)]
1 2 3 4 5 6 YES : Go to Step 6.
7 8 9 10
NO : Go to Step 5.
AC210697AB

damper clutch control solenoid valve assembly inside the
transmission.
CONNECTOR: B-108-4 (1) Disconnect connector B-108-4 and measure at the solenoid
valve side.
VALVE BODY
ASSEMBLY
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)]
1
2
solenoid valves.
NO : Replace the damper clutch control solenoid valve.
Refer to GROUP 23B, Valve Body 23B-62.
AC201141BD

in the connector.
YES : Go to Step 7.
CLEANER
P.00E-2.
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

terminal 7.
CLEANER
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

B-108.
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

B-108 HARNESS
6 5 4 3 2 1
10 9 8 7
NO : Go to Step 9.
AC210676AB

connector.
1 2
3 4 P.00E-2.
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

terminal 10.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: B-108
B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC

in the connector.
CLEANER
P.00E-2.
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

CLEANER
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

B-108 (GR)
1 2 3 4 5 6
7 8 9 10
TRANSMISSION
RANGE SWITCH
AC306322AC
CONNECTORS: B-108-4, B-108-5, B-108-6
VALVE BODY
ASSEMBLY
B-108-5
B-108-6 B-108-4
10DB103A
(P0731): 1st Gear Incorrect Ratio

(P0732): 2nd Gear Incorrect Ratio
(P0733): 3rd Gear Incorrect Ratio
(P0734): 4th Gear Incorrect Ratio
(P0735): 5th Gear Incorrect Ratio
(P0736): Reverse Gear Incorrect Ratio

.
CIRCUIT OPERATION 4.5 volts or less.

• The input shaft speed sensor generates a pulsed • Voltage of battery: 10 volts or more.
signal of 0 ⇔ 5 volts. The pulsed signal fre- • Transmission inhibitor switch rationality: only one
quency increases with an increase in the input signal.
shaft speed. • Time after shift changing finish: 2 seconds or
• The A/T-ECU continuously monitors the input more.
shaft speed signal.
• The output shaft speed sensor generates a Judgement Criteria
pulsed signal of 0 ⇔ 5 volts. The pulsed signal • Output speed: [(input speed - 200 r/min) / 1st
frequency increases with an increase in the out- gear ratio] or less. (4 seconds)
put shaft speed. • If (P0731) is set consecutively four times, the
• The A/T-ECU continuously monitors the output transmission is locked into 3rd gear as a fail-safe
shaft speed signal. measure, and the "N" range light flashes once
per second.
.
DTC SET CONDITIONS < (P0731)> .
OBD-II DRIVE CYCLE PATTERN <

Check Conditions
(P0731)>
• Engine speed: 450 r/min or more.
• Output speed: 350 r/min or more. Start the engine, and drive at 20 km/h (12 mph) or
• Shift stage: 1st gear. more for 10 seconds, with 1st gear fixed (1st gear in
• Input speed: more than 0 r/min. sport mode).
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).
.
DTC SET CONDITIONS < (P0733)> Judgement Criteria

• Output speed: [(input speed + 200 r/min) / 3rd
• Engine speed: 450 r/min or more. • Output speed: [(input speed - 200 r/min) / 3rd
• Shift stage: 3rd gear. • If (P0733) is set consecutively four times, the
• Transmission inhibitor switch rationality: only one .
signal. OBD-II DRIVE CYCLE PATTERN <

• Time after shift changing finish: 2 seconds or (P0733)>
more. Start the engine, and drive at 40 km/h (25 mph) or
more for 10 seconds, with 3rd gear fixed (3rd gear in
sport mode).
Judgement Criteria
.
DTC SET CONDITIONS < (P0734)> • Output speed: [(input speed + 200 r/min) / 4th
• Engine speed: 450 r/min or more. • Output speed: [(input speed - 200 r/min) / 4th
• Shift stage: 4th gear. • If (P0734) is set consecutively four times, the
signal. (P0734)>
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
• Engine speed: 450 r/min or more. • Output speed: [(input speed - 200 r/min) / 4th
• Shift stage: 5th gear. • If (P0735) is set consecutively four times, the
signal. (P0735)>
more.
more for 10 seconds, with 5th gear fixed (5th gear in
sport mode).
.
DTC SET CONDITIONS < (P0736)> Judgement Criteria

• Output speed: [(input speed + 200 r/min) /
Check Conditions reverse gear ratio] or more. (1 second)
• Engine speed: 450 r/min or more. • Output speed: [(input speed - 200 r/min) / reverse
• Output speed: 100 r/min or more. gear ratio] or less. (1 second)
• Shift stage: reverse gear. • If (P0736) is set consecutively four times, the
• Transmission inhibitor switch rationality: only one .
signal. OBD-II DRIVE CYCLE PATTERN <

• Time after shift changing finish: 0.5 second or (P0736)>
more. Start the engine, and drive in "R" range at 15 km/h (9
mph) or more for 10 seconds.
• Malfunction of the underdrive clutch system (, , or
.

)
LIKELY CAUSES FOR THIS CODE TO BE • Malfunction of the second brake system ( or )
SET ARE:) • Malfunction of the overdrive clutch system ( or )
• Malfunction of the input shaft speed sensor • Malfunction of the reduction clutch system ( or )
• Malfunction of the output shaft speed sensor • Malfunction of the reverse clutch system ()
• Malfunction of the A/T-ECU • Electrical noise generated
• Malfunction of the underdrive clutch retainer Circuit drawings
• Malfunction of the transfer drive gear or driven • Refer to circuit diagrams GROUP-90
gear • Refer to configuration diagrams GROUP-80
• Malfunction of the low-reverse brake system ( or ) • Refer to component locations GROUP-70
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
before connecting or disconnecting diagnostic tool
MB991958.
connector.
MB991910
Q: Is DTC set?
MB991824 YES <P0715 set> : Refer to P.23A-55, P0715: Input Shaft
Speed Sensor System.
YES <P0720 set> : Refer to P.23A-72, P0720: Output Shaft
YES <P0753 set> : Refer to P.23A-133, P0753:
Low-Reverse Solenoid Valve System.
YES <P0758 set> : Refer to P.23A-144, P0758: Underdrive
Solenoid Valve System.
MB991827 00DB076A
YES <P0763 set> : Refer to P.23A-154, P0763: Second
YES <P0768 set> : Refer to P.23A-164, P0768: Overdrive
YES <P0773 set> : Refer to P.23A-164, P0773: Reduction
NO : Go to Step 2.
STEP 2. Check the hydraulic pressure.

Each hydraulic pressure of the elements below, which DTCs
indicate, should be within the standard value. P.23A-26.
• DTC P0731: Underdrive clutch and low-reverse brake.
• DTC P0732: Underdrive clutch and second brake
• DTC P0733: Underdrive clutch and overdrive clutch
• DTC P0734: Overdrive clutch and second brake
• DTC P0735: Direct clutch and reduction brake
• DTC P0736: Reverse clutch and low-reverse brake
Q: Does the hydraulic pressures meet the standard value
range?
YES : Go to Step 5.
NO <out of the range in one place> : Go to Step 4.
NO <out of the range in all places> : Go to Step 3.
STEP 3. Adjust the line pressure.

Adjust the line pressure. Refer to P.23A-33, Line Pressure
Adjustment. Then check the symptom.
Q: Is the symptom eliminated?
NO : Go to Step 4.
STEP 4. Disassemble and clean the valve body.

Check the O-ring installation bolts for looseness and the valve
body for damage. Repair or replace the faulty parts. Refer to
VALVE BODY GROUP 23B, Valve Body 23B-62.
ASSEMBLY Replace the valve body assembly if the damages are thought
to be irreparable. Then check the symptom.
NO : Go to Step 6.
10DB117A
STEP 5. Replace the A/T-ECU.

(1) Replace the A/T-ECU.
Q: Were any A/T DTCs set?
YES : Go to Step 6.
STEP 6. Overhaul the A/T.

(1) Replace the following parts.
• If P0731, P0732 or P0733 are set individually or in a
group, replace the underdrive clutch. Refer to GROUP
23B, Underdrive Clutch and Input Shaft 23B-46.
• If P0733 or P0734 are set individually or in a group,
replace the overdrive clutch. Refer to GROUP 23B,
Reverse and Overdrive Clutch 23B-48.
• If P0736 is set, replace the reverse clutch. Refer to
GROUP 23B, Reverse and Overdrive Clutch 23B-48.
replace the low-reverse brake. Refer to GROUP 23B,
Transmission 23B-55.
replace the second brake. Refer to GROUP 23B,
• If P0731 is set, replace the one-way clutch. Refer to
GROUP 23B, Planetary Gear 23B-53.
• If P0735 is set, check second brake, check overdrive
clutch and DIR clutch.
Q: Are any A/T DTCs set again?
frequency interference (RFI) possibly caused by
installed on the vehicle.
(P0741): Damper Clutch Control System

. .
DTC SET CONDITIONS TROUBLESHOOTING HINTS (The most

Check Conditions likely causes for this code to be set are:)
• Solenoid status: plunging into connecting condi- • Malfunction of the damper clutch control solenoid
tion. valve
• Transmission inhibitor switch position: D. • Malfunction of the input shaft speed sensor
• Malfunction of the valve body
Judgement Criteria • Damaged harness or connector
• Time during 100% duty: 4 seconds or more. • Malfunction of the A/T-ECU
. • Malfunction of the torque converter
OBD-II DRIVE CYCLE PATTERN Circuit drawings
Start the engine, and drive at 100 km/h (62 mph) for • Refer to circuit diagrams GROUP-90
10 seconds. Then stop the vehicle, and turn OFF the • Refer to configuration diagrams GROUP-80
ignition switch. After that, restart the engine, and • Refer to component locations GROUP-70
drive again at 100 km/h (62 mph) for 10 seconds.
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
Q: Is (P0715) or (P0743) set?
MB991824 YES <P0715 set> : Refer to P.23A-55, P0715: Input Shaft
YES <P0743 set> : Refer to P.23A-185, P0743: Damper
Clutch Control Solenoid Valve System.
NO : Go to Step 2.
MB991827 00DB076A

item 17: Damper Clutch Control Solenoid Valve Duty%.
CAUTION
CONNECTOR
MB991958.
connector.
(2) Start the engine. (Warming up engine)
• Item 17: Damper Clutch Control Solenoid Valve Duty%.
MB991910
• When driving at constant speed of 50 km/h, the dis-
play should be "70 − 90%" (Gear range: 3rd gear).
MB991824
• When the accelerator pedal is released [at less than
50 km/h], the display should be "70 − 90% → 0%"
(decreases gradually as the vehicle speed
decreases) (Gear range: 3rd gear).
YES : Go to Step 3.
MB991827 00DB076A
NO : Go to Step 5.

item 10: Damper Clutch Control Amount of Slippage.
CAUTION
CONNECTOR
MB991958.
connector.
• Item 10: Damper Clutch Control Amount of Slippage.
MB991910
• Driving at a constant speed of 50 km/h, the display
should be "100 to 300 r/min."
MB991824
should be "0 to 10 r/min."
• If the accelerator pedal is released, the display on
the diagnostic tool changes (50 km/h and less).
Q: Is the clutch operating properly?
YES : Go to Step 4.
MB991827 00DB076A
NO : Go to Step 5.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
Q: Is Item 10 set?
MB991824 YES : Replace the A/T-ECU.
MB991827 00DB076A
STEP 5. Check the hydraulic pressure (for torque

converter).
Measure the hydraulic pressure for torque converter. Check if
the hydraulic pressure is within the standard value. Refer to
P.23A-26, Hydraulic Pressure Test.
Q: Is the hydraulic pressure within the standard value?
YES : Go to Step 7.
NO : Go to Step 6.
STEP 6. Adjust line pressure.

Adjust line pressure. Refer to P.23A-33, Line Pressure Adjust-
ment. Then check the symptom.
NO : Go to Step 8.

NO : Go to Step 8.
STEP 8. Replace the valve body.

(1) Replace the valve body. Refer to GROUP 23B,
VALVE BODY (2) Test drive the vehicle.
ASSEMBLY (3) Check for A/T diagnostic trouble code.
Q: Is A/T Item 10 set?
YES : Replace the torque converter. Refer to GROUP 23B,
10DB117A
(P0742): Damper Clutch Control is Stuck On

.
DTC SET CONDITIONS

Start the engine, and drive at 30 km/h for 30 sec-
Check Conditions onds. Then stop the vehicle, and turn "LOCK" (OFF)
• Throttle position sensor voltage: 1.5 volts or the ignition switch. After that, restart the engine, and
more. drive again at 30 km/h (19 mph) for 30 seconds.
• Output speed: 1,000 r/min or more.
• Solenoid status: OFF.
.

• Transmission inhibitor switch position: D, 3, 2 or
L. LIKELY CAUSES FOR THIS CODE TO BE
• Time after lock up clutch release: 5 seconds or SET ARE:)
more. • Malfunction of the damper clutch control solenoid
valve
Judgement Criteria
• Calculated slip (engine speed - input speed): 5
r/min or more. (5 seconds)
• Calculated slip (engine speed - input speed): -5
r/min or less. (5 seconds) Circuit drawings
.

DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
Q: Is (P0743) set?
MB991824 YES : Refer to P.23A-185, (P0743): Damper Clutch Control
NO : Go to Step 2.
MB991827 00DB076A

list item 10: Amount of Damper Clutch Control Slippage.
CAUTION
CONNECTOR
MB991958.
connector.
• Item 10: Damper Clutch Control Amount of Slippage.
MB991910
should be "−10 to 10 r/min."
MB991824
• If the accelerator pedal is released, the display on
the diagnostic tool changes (50 km/h and less).
Q: Is the damper clutch control slippage within the
specified range?
MB991827 00DB076A
NO : Go to Step 3.

(1) Replace the A/T-ECU.
Q: Is (P0742) set?
YES : Go to Step 4.
STEP 4. Replace the valve body.

(1) Replace the valve body. Refer to GROUP 23B,
VALVE BODY (2) Test drive the vehicle.
ASSEMBLY (3) Check for A/T diagnostic trouble code.
Q: Is (P0742) set?
YES : Replace the Torque Converter. Refer to GROUP 23B,
10DB117A
(P1751): A/T Control Relay System
CONNECTOR: A-13 CONNECTOR: B-16X
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
AC306223AB RELAY BOX 10DB098A
CONNECTORS: B-19, B-22 CONNECTORS: C-214, 215
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
.
CIRCUIT OPERATION • If (P1751) is set consecutively four times, the

• A/T control relay (terminal 1) receives the battery transmission is locked into 3rd gear as a fail-safe
positive voltage through a dedicated 20 amp measure, and the "N" range light flashes once
fuse. per second.
• When the ignition switch is turned to the "ON" .
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,
.

system voltage is applied to the A/T-ECU connec-
tor B-22 (terminals 9 and 3). LIKELY CAUSES FOR THIS CODE TO BE
SET ARE:)
• Malfunction of the A/T control relay
.
DTC SET CONDITIONS

Check Conditions • Malfunction of the A/T-ECU
• Time after A/T-ECU turns on A/T control relay: Circuit drawings
0.5 second or more. • Refer to circuit diagrams GROUP-90
• A/T control relay output voltage: 7 volts or less.
(0.1 second)
DIAGNOSIS
• MB991824: V.C.I.

item 8: A/T Control Relay Output Voltage.
CAUTION
CONNECTOR
MB991958.
connector.
• Item 8: A/T Control Relay Output Voltage.
MB991910
• The voltage should equal battery positive voltage.
MB991824
Q: Is the measured voltage equal battery positive voltage?
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check the A/T control relay.

CONNECTOR: B-16X (1) Remove the A/T control relay from the engine component
relay box connector B-16X.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A
(2) Using jumper wires, connect terminal 2 to the positive

B-16X HARNESS CONNECTOR:
A/T CONTROL RELAY SIDE battery terminal, and terminal 3 to the negative battery
terminal.
FRONT OF VEHICLE
(3) Measure the resistance between terminals 1 and 4 of the
1 2 A/T control relay.
3 4 • The resistance should be measured less than 2 ohms.
• Disconnect the jumper wires. The resistance between
terminals 1 and 4 should measure over limits (open cir-
cuit).
AC210725AD Q: Is the measured resistance less than 2 ohms when the
relay is energized, and open circuit when the relay is
de-energized?
YES : Go to Step 3.
NO : Replace the A/T control relay.
STEP 3. Check A/T control relay socket B-16X in the

engine compartment relay box for loose, corroded or
socket.
CONNECTOR: B-16X Q: Is the relay connector in good condition?
YES : Go to Step 4.
1 2
3 4 P.00E-2.
FRONT OF
VEHICLE
RELAY BOX 10DB098A

STEP 4. Measure the supply voltage at A/T control relay

connector B-16X in the engine component relay box.
CONNECTOR: B-16X (1) Disconnect the A/T control relay.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A

B-16X HARNESS • The measured voltage should equal battery positive
CONNECTOR: voltage.
RELAY BOX SIDE
Q: Is the measured voltage equal to battery positive
voltage?
2 1
YES : Go to Step 7.
4 3
NO : Go to Step 5.
FRONT OF
VEHICLE
AC210728AC

in the connector.
YES : Go to Step 6.
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
AC306223AB

to ground between A/T control relay connector B-16X
terminal 1 in the engine component relay box and battery.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A

STEP 7. Measure the supply voltage at A/T control relay

connector B-16X in the engine component relay box.
CONNECTOR: B-16X (1) Disconnect the A/T control relay.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A

B-16X HARNESS • The measured voltage should equal battery positive
CONNECTOR: voltage.
RELAY BOX SIDE
voltage?
2 1
4 3
NO : Go to Step 8.
FRONT OF
VEHICLE AC210734AC

CONNECTOR: A-13 Q: Are the connectors in good condition?
YES : Go to Step 9.
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
AC306223AB
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A

to ground between A/T control relay connector B-16X
terminal 2 in the engine component relay box and junction
block connector C-214 terminal 12.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A
CONNECTOR: C-214
1 2 3 4 5 6
7 8 9 10 11 12 1314
10DB085A
STEP 10. Measure the A/T control relay output voltage at

A/T-ECU connector B-22 by using check harness special
tool MB992045.
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

CONNECTOR: • The measured voltage should equal battery positive
voltage.
10DB120A

CONNECTOR: • The measured voltage should equal battery positive
voltage.
voltage between terminal 3 and ground, and between
terminal 9 and ground?
10DB121A
NO : Go to Step 11.

in the connector.
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A

ground between A/T control relay connector B-16X
(terminal 4) in the engine component relay box and
A/T-ECU connector B-22 (terminals 3 and 9).
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A

AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

in the connector.
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A

ground between A/T control relay connector B-16X
terminal 3 in the engine component relay box and A/T-ECU
connector B-22 terminal 4.
1 2
3 4
FRONT OF
VEHICLE
RELAY BOX 10DB098A

AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

list item 8: A/T control relay output Voltage.
CAUTION
CONNECTOR
MB991958.
connector.
• Item 8: A/T Control Relay Output Voltage.
MB991910
• The voltage should equal battery positive voltage.
MB991824
Q: Is the measured voltage equal battery positive voltage?
YES : It can be that this malfunction is intermittent. Refer to
GROUP 00, How to Use Troubleshooting/Inspection
Malfunction P.00-14.
MB991827 00DB076A
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Engine does not Crank

.
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
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
Q: Is A/T DTC "(P0705)" set?
MB991824 YES <(P0705) set> : Refer to P.23A-97: Transmission
Inhibitor Switch System (Open Circuit) or refer to
P.23A-119: Transmission Inhibitor Switch System
(Short Circuit).
NO : Go to Step 2.
MB991827 00DB076A
STEP 2. Check the transmission control cable assembly.

<F5A5A> Move the selector lever to each position. The manual control
lever position of the transmission inhibitor switch should match
the transmission range.
Q: Is the manual control lever position correct?
YES : Go to Step 3.
NO : Repair the transmission control cable. Refer to
D
N
P.23A-299, Transmission Inhibitor Switch and Control
R Cable Adjustment. Retest the system to verify the
P repair.
10DB163A
STEP 3. Check the engine system.

Refer to GROUP 13A, Diagnosis − Trouble Symptom Chart −
Starting 13A-21.
Q: Is the inspection result good?
YES : Go to Step 4.
NO : Repair or replace the appropriate engine
components.
STEP 4. Check the torque converter.

(1) Remove the starter.
(2) Turn the torque converter and check for a binding or
sticking condition. Check the ring gear for damaged or
missing teeth.
NOTE: Since the torque converter drives the oil pump, turn-
ing the torque converter also check for a binding oil pump. If
either of these components are damaged the transmission
will need to be removed for inspection.
Q: Does the torque converter turn freely without any
missing or damaged teeth?
AC001857
YES : Go to Step 5.
NO : Replace the torque converter. Refer to GROUP 23B,
Transmission P.23B-13.
STEP 5. Repair or replace the starter.

NO : Go to Step 6.
STEP 6. Check the oil pump.

(1) Remove the transmission assembly.
(2) Check the oil pump (incorrect installation, damage and etc.)
and replace the oil pump assembly if necessary (The oil
pump cannot be disassembled).Refer to GROUP 23B,
Transmission P.23B-13. Confirm that the malfunction
NO : Start over at Step 1.
AC001858
INSPECTION PROCEDURE 2: Does not Move Forward

.
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 A/T-ECU system

Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
• An audible clicking or buzzing should be heard when
MB991824
YES : Go to Step 2.
NO : Repair or replace the underdrive solenoid valve.
Refer to GROUP 23B, Valve Body P.23B-62. Then
confirm that the symptom is eliminated.
MB991827 00DB076A

Shift the selector lever to the sport mode then measure the
hydraulic pressure of each element in 1st speed to check and
see if each respective hydraulic pressure is within the range of
standard pressure. Refer to P.23A-26, Hydraulic Pressure Test.
YES : Go to Step 3.
NO : Go to Step 4.
STEP 3. Check the underdrive clutch system.

(1) Remove the valve body cover and valve body. Refer to
P.23A-304, Transmission Assembly and GROUP 23B,
Transmission P.23B-13.
(2) Blow 108 kPa (15psi) compressed air into the underdrive
clutch oil orifice of the transmission case, and check if the
underdrive clutch piston moves and air pressure is
maintained in that condition.
UNDERDRIVE Q: Is the air pressure maintained?
CLUTCH OIL
ORIFICE YES : Go to Step 4.
NO : Go to Step 6.
AC001859AB

Check the O-ring installation bolts for looseness and valve
VALVE BODY GROUP 23B, Valve Body P.23B-62.
NO : Go to Step 5.
10DB117A

pump cannot be disassembled). Refer to GROUP 23B,
Transmission P.23B-13. Then check the symptom.
AC001858
STEP 6. Check the underdrive clutch.

(2) Check the facing for seizure and the piston seal ring for
damage and interference with the retainer. Repair or
replace the faulty parts. Refer to GROUP 23B, Underdrive
Clutch and Input Shaft P.23B-46. Then check the symptom.
AC001861
INSPECTION PROCEDURE 3: Does not Reverse

.
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
.

Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991824
YES : Go to Step 2.
NO : Repair or replace the low-reverse solenoid valve.
MB991827 00DB076A
STEP 2. Check the hydraulic pressure (for reverse clutch).

Measure the hydraulic pressure for the reverse clutch when the
selector lever is at the "R" range, and check if the hydraulic
pressure is within the standard value. Refer to P.23A-26,
Hydraulic Pressure Test.
YES : Go to Step 3.
NO : Go to Step 5.
STEP 3. Check the hydraulic pressure (for low-reverse

brake).
Measure the hydraulic pressure for the low-reverse brake when
the selector lever is at the "R" range, and check if the hydraulic
Hydraulic Pressure Test.
YES : Go to Step 4.
NO : Go to Step 5.
STEP 4. Check the reverse clutch system and low-reverse

brake system.
P.23A-304 <F5A5A>, Transmission Assembly and GROUP
(2) Blow 108 kPa (15psi) compressed air into the reverse
clutch oil orifice of the transmission case. Then check if the
reverse clutch piston moves and air pressures are
maintained in that condition. Repeat for the low-reverse
brake.
Q: Are the reverse clutch, low-reverse brake or both air
pressures maintained?
YES : Go to Step 5.
NO : Go to Step 6.

10DB117A
STEP 6. Check the reverse clutch, low-reverse brake or

both. Remove the transmission.
Check the facing for seizure and the piston seal ring for dam-
age and interference with the retainer. Repair or replace the
faulty parts. Refer to GROUP 23B, Transmission P.23B-13,
LOW-REVERSE BRAKE
Reverse and Overdrive Clutch P.23B-48. Then check the
symptom.
REVERSE CLUTCH
AC001863 AB
INSPECTION PROCEDURE 4: Does not Move (Forward or Reverse)

.
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
.

Circuit drawings
DIAGNOSIS

Measure the hydraulic pressure of each element when the
transmission is in 1st, 2nd or reverse. Check if each hydraulic
Hydraulic Pressure Test. If some elements pressures are within
the standard value and some are not, recheck the symptom.
Q: Are all pressures within the standard value?
YES : Check transmission fluid level and condition. If not
OK, repair or replace as necessary, then retest the
system. If OK, go to Step 3.
NO : Go to Step 2.

to be irreparable. Then retest the symptom.
NO : Go to Step 4.
10DB117A
STEP 3. Check the transmission powertrain components.

Disassemble the transmission and check the planetary gear
and output shaft, etc. Repair or replace the damaged parts.
Refer to GROUP 23B, Transmission P.23B-13, Planetary Car-
rier Assembly P.23B-53, Direct Planetary Carrier P.23B-57, Dif-
ferential P.23B-60. Then check the symptom.

(1) Remove the transmission.
pump cannot be disassembed).Refer to GROUP 23B,
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)
.
Circuit drawings
DIAGNOSIS

Refer to GROUP 13A <3.8L Engine>, Diagnosis − Trouble
Symptom Chart − When the engine is hot, it stalls at idle
13A-21.
YES : Go to Step 2.
NO : Repair or replace the engine components.
STEP 2. Replace the damper clutch control solenoid valve.

Replace the damper clutch control solenoid valve. Refer to
GROUP 23B, Valve Body P.23B-62. Then check the symptom.
VALVE BODY Q: Is the symptom eliminated?
ASSEMBLY YES : The procedure is complete.
NO : Go to Step 3.
DCC
Solenoid
Valve
10DB122A

Q: Is the repair possible and the symptom eliminated?
NO : Go to Step 4.
10DB117A
STEP 4. Replace the torque converter assembly.

(2) Replace the torque converter assembly. Refer to GROUP
23B, Transmission P.23B-13. Then check the symptom.
AC001857
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
•
.
Check RED brake system

Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991824
YES : Go to Step 2.
NO : Repair or replace the underdrive solenoid valve.
MB991827 00DB076A
STEP 2. Check when shift shock occurs.

Q: When does the shift shock occur?
When engaging from "N" to "D" : Go to Step 3.
When the vehicle starts moving : Go to Step 6.
STEP 3. Check the hydraulic pressure (for underdrive

clutch).
Measure the hydraulic pressure for underdrive clutch when the
selector lever is shifted from "N" to "D" range. Check if the
hydraulic pressure is within the standard value. Refer to
YES : Go to Step 4.
NO : Go to Step 8.
STEP 4. Check the underdrive clutch system.

(2) Blow 108 kPa (15 psi) compressed air into the underdrive
underdrive clutch piston moves and air pressure is
maintained in that condition.
UNDERDRIVE Q: Is the air pressure maintained?
CLUTCH OIL
ORIFICE YES : Go to Step 8.
NO : Go to Step 5.
AC001859AB
STEP 5. Check the underdrive clutch.

replace the faulty parts. Refer to GROUP 23B P.23B-46,
Underdrive Clutch and Input Shaft. Then check the
symptom.
AC001861
STEP 6. Check shift shock.

Q: Does shift shock occur?
YES : Go to Step 7.
NO : Go to Step 8.

list item 13: TP Sensor (main).
CAUTION
CONNECTOR
MB991958.
connector.
• Item 13: TP Sensor (main).
MB991910
• With the throttle valve in idle position, voltage should
measure between 1100 and 1200 mV.
MB991824
• With the throttle valve in full-open position, voltage
should measure 4,000 mV or more.
Q: Is the measured voltage between 1100 and 1200 mV at
idle, and 4,000 mV or more at the full-open position?
YES : Go to Step 8.
NO : Check the TP sensor. Refer to GROUP13A
MB991827 00DB076A
,Diagnostic Trouble Code Procedures 13A-17, DTCs
P0122, P0123: TP Sensor System. Then check the
symptom.

NO : Replace the valve body assembly. Then check the
symptom. Start over at Step 1.
10DB117A
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
.
Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991824
YES : Go to Step 2.
NO : Repair or replace the low-reverse solenoid valve.
MB991827 00DB076A

When engaging from "N" to "R" : Go to Step 3.
STEP 3. Check the hydraulic pressure (for reverse clutch).

Measure the hydraulic pressure for reverse clutch when the
selector lever is at the "R" range. Check if the hydraulic pres-
sure is within the standard value. Refer to P.23A-26, Hydraulic
Pressure Test.
YES : Go to Step 4.
NO : Go to Step 9.
STEP 4. Check the hydraulic pressure (for low-reverse

brake).
Measure the hydraulic pressure for low-reverse brake when the
selector lever is at the "R" range. Check if the hydraulic pres-
sure is within the standard value. Refer to P.23A-26, Hydraulic
Pressure Test.
YES : Go to Step 5.
NO : Go to Step 9.
STEP 5. Check the reverse clutch system and low-reverse

brake system.
(2) Blow 108 kPa (15 psi) compressed air into the reverse
reverse clutch piston moves and air pressures are
maintained in that condition. Repeat for the low-reverse
brake.
Q: Are both air pressures maintained?
YES : Go to Step 6.
NO : Go to Step 9.
STEP 6. Check the reverse clutch and low-reverse brake.

replace the faulty parts. Refer to GROUP 23B,
Transmission P.23B-13, Reverse and Overdrive Clutch
P.23B-48. Then Retest the system.
STEP 7. Check shift shock.

Q: Does shift shock occur sometimes?
YES : Go to Step 8.
NO : Go to Step 9.

list item 13: TP Sensor (main).
CAUTION
CONNECTOR
MB991958.
connector.
• Item 13: TP Sensor (main).
MB991910
MB991824
Q: Is the measured voltage between 1100 and 1200 mV at
YES : Go to Step 9.
NO : Check the TP sensor. Refer to GROUP13A <3.8L
MB991827 00DB076A
Engine>, Diagnostic Trouble Code Procedures
13A-17, DTCs P0122, P0123: TP Sensor System.
Then check the symptom.

10DB117A
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
DIAGNOSIS

(1) Measure the hydraulic pressure of each element when the
transmission is in 1st, 2nd or reverse. Check if each
hydraulic pressure is within the standard value. Refer to
(2) If some elements pressures are within the standard value
and some are not, recheck the symptom.
Q: Are all hydraulic pressures within the standard value?
YES : Go to Step 3.
NO : Go to Step 2.
STEP 2. Adjust line pressure.

Adjust line pressure. Refer to P.23A-33, Line Pressure Adjust-
ment. Then check the symptom.
NO : Go to Step 3.

When engaging from "N" to "D" and "N" to "R" : Go to
Step 4.


Check the installation bolts for looseness and the O-ring,
valves and valve body for damage. Repair or replace the faulty
VALVE BODY parts. Refer to GROUP 23B, Valve Body P.23B-62.
10DB117A
INSPECTION PROCEDURE 9: Shift Shock and Slipping

.
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
.
Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

test.
CAUTION
CONNECTOR
MB991958.
connector.
(3) Set diagnostic tool MB991958 to the actuator test mode for
following items.
MB991910
a. Item 01: Low-reverse solenoid valve
MB991824
b. Item 02: Underdrive solenoid valve
c. Item 03: Second solenoid valve
d. Item 04: Overdrive solenoid valve
e. Item 05: Reduction solenoid valve
the solenoid valves are energized.
Q: Are the solenoid valves operating properly?
MB991827 00DB076A YES : Go to Step 2.
NO : Repair or replace the solenoid valves. Refer to
GROUP 23B, Valve Body P.23B-62. Then confirm
that the symptom is eliminated.

(1) Measure the hydraulic pressure of each element. Check if
each hydraulic pressure is within the standard value. Refer
to P.23A-26, Hydraulic Pressure Test.
(2) If some elements pressure are within the standard value
and some are not, recheck the symptom.
Q: Are all hydraulic pressures within the standard value?
YES : Go to Step 6.
NO : Go to Step 3.

NO : Go to Step 4.

NO : Go to Step 5.
10DB117A

AC001865
STEP 6. Check each brake and clutch.

(2) Check the facing for seizure and piston seal ring for
damage and interference with retainer. Repair or replace
the faulty parts. Refer to GROUP 23B, Transmission
P.23B-13, Underdrive Clutch and Input Shaft P.23B-46,
Reverse and Overdrive Clutch P.23B-48. Then Retest the
system.
NEXT PAGE
PREVIOUS PAGE
23A
INSPECTION PROCEDURE 10: Early or Late Shifting in All Gears

.
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
.

Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

list item 6: Output Shaft Speed Sensor.
CAUTION
MB991958.
connector.
MB991910 • When driving at constant speed of 50km/h, the dis-
play should be "1,100 - 1,400 r/min" (Gear range:
MB991824 3rd gear).
YES : Go to Step 2.
NO : Refer to P.23A-72, DTC (P0720): Output shaft speed
sensor system.
MB991827 00DB076A

list item 13: TP Sensor.
CONNECTOR
• Item 13: TP Sensor (MAIN).
MB991910
MB991824 Q: Is the measured voltage between 1100 and 1200 mV at
YES : Go to Step 3.
NO : Check the TP sensor. Refer to GROUP13B <3.8L
Engine>, Diagnostic Trouble Code Procedures
13A-17, DTCs P0122, P0123: TP Sensor System.
Then check the symptom.
MB991827 00DB076A
STEP 3. Using diagnostic tool MB991958, check data list.

CONNECTOR
(3) Set diagnostic tool MB991958 to the data reading mode for
following items.
a. Item 12: Low-Reverse Solenoid Valve Duty (%)
b. Item 13: Underdrive Solenoid Valve Duty (%)
c. Item 14: Second Solenoid Valve Duty (%)
MB991910 d. Item 15: Overdrive Solenoid Valve Duty (%)
e. Item 16: Reduction Solenoid Valve Duty (%)
MB991824 • Check that the values shown below are displayed
when each data list item is entered.
MB991827 00DB076A
DATA LIST ITEM

DRIVING CONDITION
12 13 14 15 16
Driving at constant speed of 10 km/h in 1st gear 100% 0% 100% 100% 0%
Driving at constant speed of 30 km/h in 2nd gear 100% 0% 0% 100% 0%
Driving at constant speed of 50 km/h in 3rd gear 100% 0% 100% 0% 0%
Driving at constant speed of 50 km/h in 4th gear 0% 0% 100% 0% 100%
Driving at constant speed of 50 km/h in 5th gear 0% 100% 0% 0% 100%
Q: Are the solenoid valves operating properly?
YES : Go to Step 4.
NO : Go to Step 6.

NO : Go to Step 5.

NO : Go to Step 7.
10DB117A
STEP 6. Replace each solenoid valve.

Replace the faulty solenoid valve with a new one.
Overdrive Underdrive Q: Is the symptom eliminated?
solenoid solenoid
valve valve YES : The procedure is complete.
NO : Go to Step 7.
Second
Low-reverse
solenoid
solenoid
valve
valve
Damper
Reduction (RED) control clutch
solenoid solenoid
valve valve
10DB123A

INSPECTION PROCEDURE 11: Early or Late Shifting in Some Gears

.
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
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Using diagnostic tool MB991958, check A/T

Special Function test item 33: INVECS-II Control Stop.
CAUTION
CONNECTOR
MB991958.
connector.
(3) Set diagnostic tool MB991958 to the A/T special function
test mode.
MB991910
• Item 33: INVECS-II Control Stop.
• Drive the vehicle and confirm the gear shifting corre-
MB991824
spond to the standard shift line of the shift pattern
diagram. Refer to P.23A-3.
Q: Does the gear shifting correspond to the standard shift
line of the shift pattern diagram?
YES : The symptom is due to characteristics of the
INVECS-II system, but is not abnormal.
MB991827 00DB076A
NO : Go to Step 2.
STEP 2. Check the shift points.

Q: Are the shift points early or late only when transmission
fluid is 35°C or less (early), or 125°C or more (late)?
YES : The symptom is due to characteristics of the
INVECS-II system, but is not abnormal.
NO : Go to Step 3.

10DB117A
INSPECTION PROCEDURE 12: No Diagnostic Trouble Codes (Does not Shift)
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
.

COMMENT
If shifting does not occur while driving and no diag- Circuit drawings
nostic trouble codes are output, a malfunction of the • Refer to circuit diagrams GROUP-90
transmission inhibitor switch, or A/T-ECU may exist. • Refer to configuration diagrams GROUP-80
.
DIAGNOSIS
• MB991824: V.C.I.
STEP 1. Check the vehicle acceleration.

Q: Does the vehicle accelerate poorly (transmission stays
in 3rd gear) when starting from a stop with the selector
lever in "D" range?
YES : Go to Step 2.
NO : Go to Step 5.

A/T-ECU connector B-19 by using check harness special
tool MB992045.
CONNECTOR: B-19
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A

A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

CONNECTOR:
YES : Go to Step 5.
NO : Go to Step 3.
10DB124A

in the connector.
YES : Go to Step 4.
CLEANER
P.00E-2. Then retest the system.
COVER
A/T
CONTROL
UNIT
16DB564A
STEP 4. Check the harness for open circuit between

A/T-ECU connector B-19 terminal 21 and battery.
CONNECTOR: B-19
YES : Go to Step 5.
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A

item 34: Inhibitor Switch.
CAUTION
MB991958.
CONNECTOR
• Item 34: Inhibitor Switch.
• Item 27: Sports mode select switch
• Item 28: Sports mode upshift switch
• Item 29: Sports mode downshift switch
• Move the selector lever positions and confirm that
MB991910
the selected transmission range match the positions
shown on diagnostic tool MB991958.
MB991824
YES : Check for the symptom. If the symptom is not
eliminated, replace the A/T-ECU.
NO : Refer to P.23A-97, P.23A-119, (P0705): Transmission
Inhibitor Switch system, and refer to inspection
procedure 15 (Sports mode switch system)
MB991827 00DB076A
INSPECTION PROCEDURE 13: Poor Acceleration

.
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
DIAGNOSIS

Refer to GROUP 13A, Diagnosis − Symptom Chart − Poor
acceleration 13A-21.
YES : Go to Step 2.
NO : Repair or replace the engine component(s).
STEP 2. Check each brake and clutch.

Perform the torque converter stall test. Refer to P.23A-25,
Torque Converter Stall Test. Then retest the system.
NO : Go to Step 3.
STEP 3. Perform the hydraulic pressure test.

Perform the hydraulic pressure test. Refer to P.23A-26,
Hydraulic Pressure Test. Then retest the system.
NO : Go to Step 4.
STEP 4. Check each brake system and each clutch system.

GROUP 23B, Transmission P.23B-13.
(2) Blow 108 kPa (15 psi) compressed air into the each brake
oil orifice and clutch oil orifice of the transmission case, and
check if each brake and each clutch piston move and air
pressure is maintained.
Q: Is the air pressure maintained?
NO : Go to Step 5.
STEP 5. Check each brake system and clutch system.

(2) Check the facings for seizure and piston seal ring for
damage and interference with retainer. Repair or replace
the faulty parts. Refer to GROUP 23B, Transmission
P.23B-13, Underdrive Clutch and Input Shaft P.23B-46,
Reverse and Overdrive Clutch P.23B-48. Then retest the
system.
INSPECTION PROCEDURE 14: Vibration

.
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 Engine or A/T system
.
Circuit drawings
DIAGNOSIS
• MB991824: V.C.I.

test item 6: Damper Control Clutch Solenoid Valve.
CAUTION
CONNECTOR
MB991958.
connector.
• Item 06: Damper Control Clutch Solenoid Valve.
MB991910
the damper control clutch solenoid valve is ener-
MB991824
gized.
YES : Go to Step 2.
NO : Repair or replace the damper control clutch solenoid
valve. Refer to GROUP 23B, Valve Body P.23B-62.
Then confirm that the symptom is eliminated.
MB991827 00DB076A
STEP 2. Check the vibration.

Q: Does the vibration occur when the transmission fluid
temperature sensor connector has been disconnected?
YES : Check the engine system. Refer to GROUP 13A ,
Diagnosis − Symptom Chart − Driving 13A-21. If the
inspection result is not good, diagnose, repair, and/or
replace the engine component(s).
NO : Go to Step 3.
STEP 3. Check the torque converter hydraulic pressure.

Measure the torque converter hydraulic pressure. Then check if
the torque converter hydraulic pressure is within the standard
value. Refer to P.23A-26, Hydraulic Pressure Test.
Q: Is the torque converter hydraulic pressure within the
standard value?
YES : Go to Step 4.
NO : Go to Step 5.
STEP 4. Replace the torque converter assembly.

(2) Replace the torque converter assembly. Refer to GROUP
23B, Transmission P.23B-13. Then check the symptom.
AC001857

10DB117A
INSPECTION PROCEDURE 15: Sports Mode Switch System
CONNECTOR: A-13 CONNECTOR: D-14 4
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
AC306223AB D-14 10DB093A
CONNECTORS: B-19, B-22 CONNECTORS: C-214, 215
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).
Circuit drawings
.
COMMENT • Refer to circuit diagrams GROUP-90

When sport mode shift does not operate the cause is • Refer to configuration diagrams GROUP-80
probably a malfunction of the transmission inhibitor • Refer to component locations GROUP-70
switch circuit, shift switch assembly circuit or a defec-
tive A/T-ECU.
.

LIKELY CAUSES FOR THIS CASE:)
• Malfunction of the transmission inhibitor switch
• Malfunction of the shift switch assembly select
switch
• Malfunction of the shift switch assembly shift
switch (Up)
• Malfunction of the shift switch assembly shift
switch (Down)
DIAGNOSIS
• MB991824: V.C.I.

CAUTION
CONNECTOR
MB991958.
connector.
MB991910
Q: Is (P0705) set?
MB991824 YES <(P0705)> : Refer to P.23A-97: Transmission Inhibitor
Switch System (Open Circuit) or refer to P.23A-119:
Transmission Inhibitor Switch System (Short Circuit).
NO : Go to Step 2.
MB991827 00DB076A

item 27: Select Switch, item 28: Shift Switch (Up), item 29:
Shift Switch (Down).
CONNECTOR
following items.
a. Item 27: Select Switch
b. Item 28: Shift Switch (Up)
c. Item 29: Shift Switch (Down)
MB991910 SELECTOR LEVER DATA LIST ITEM
OPERATION
MB991824 27 28 29
D range OFF OFF OFF
Sport mode ON OFF OFF
Upshift and hold the selector ON ON OFF
lever
Downshift and hold the ON OFF ON
selector lever
MB991827 00DB076A
NOTE: The switches above are displayed, depending on

the selector lever condition as shown in the table.
NO <If completely NG> : Go to Step 3.
NO <If item 28 and item 29 both are NG> : Go to Step 5.
NO <If only item 27 is NG> : Go to Step 9.

CONNECTOR: B-19
YES : Go to Step 4.
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

item 27: Select Switch, item 28: Shift Switch (Up), item 29:
Shift Switch (Down).
CAUTION
CONNECTOR
MB991958.
connector.
following items.
MB991910
a. Item 27: Select Switch
MB991824
b. Item 28: Shift Switch (Up)
c. Item 29: Shift Switch (Down)
SELECTOR LEVER DATA LIST ITEM
OPERATION
27 28 29
D range OFF OFF OFF
Sport mode ON OFF OFF
MB991827 00DB076A Upshift and hold the selector ON ON OFF
lever
Downshift and hold the ON OFF ON
selector lever
NOTE: The switches above are displayed, depending on

the selector lever condition as shown in the table.
STEP 5. Check the shift switch assembly.

Refer to P.23A-303, Transmission Control.
YES : Go to Step 6.
NO : Replace the shift switch assembly. Refer to
P.23A-302, Transmission Control.
STEP 6. Measure the power supply voltage at shift switch

assembly connector D-14.
(1) Disconnect connector D-14 and measure at the harness
CONNECTOR: D-14 4
side.
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

(D-14) FLOOR HARNESS
YES : Go to Step 4.
NO : Go to Step 7.
10DB126A
STEP 7. Check junction block connector C-214 and shift

connector.
CONNECTOR: D-14 4
YES : Go to Step 8.
ROOF
WIRING
HARNESS
Y
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

to ground between junction block connector C-214
terminal 2.
CONNECTOR: C-214
YES : Go to Step 4.
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
STEP 9. Measure the power supply voltage at shift switch

assembly connector D-14.
(1) Disconnect connector D-14 and measure at the harness
CONNECTOR: D-14 4
side.
ROOF
WIRING Y
(3) Move the selector lever to the "D" position.
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

(D-14) FLOOR HARNESS
NO : Go to Step 10.
10DB127A
STEP 10. Check intermediate connector A-13 and shift

connector.
A-13 (GR)
1 2 3 4 5 6 7 P.00E-2.
8 9 10 11
12 13 14 15 16 17
AC306223AB
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

ground between transmission inhibitor switch connector
B-110 terminal 1 and shift switch assembly connector D-14
terminal 1.
YES : Go to Step 4.
1 2 3 4 5 6
7 8 9 10
B-110 (B)
TRANSMISSION
RANGE SWITCH
AC210068AE
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

STEP 13. Measure the switch output voltage at A/T-ECU

MB992045.
CONNECTOR: B-19
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A

(4) Move the selector lever to the sport mode.
A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

CONNECTOR:
NO : Go to Step 14.
10DB128A

CONNECTOR: B-19
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

terminal 6.
CONNECTOR: B-19
YES : Go to Step 4.
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

in the connector.
YES : Go to Step 4.
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
16DB564A


MB992045.
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

CONNECTOR:
• The voltage should measure battery positive voltage
when the selector lever is upshift and hold.
NO : Go to Step 19.
10DB129A

CONNECTOR: B-19
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

terminal 7.
CONNECTOR: B-19
YES : Go to Step 4.
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

in the connector.
CONNECTOR: B-19
YES : Go to Step 4.
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
10DB125A


MB992045.
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
16DB564A

A/T-ECU
A/T-ECU CHECK
HARNESS
CONNECTORS
10DB161A

B-19 HARNESS • The voltage should measure battery positive voltage
CONNECTOR:
when the selector lever is downshift and hold.
NO : Go to Step 24.
10DB130A

CONNECTOR: B-19
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

terminal 3.
CONNECTOR: B-19
YES : Go to Step 4.
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A
CONNECTOR: D-14 4
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
15
D-14 10DB093A

in the connector.
CONNECTOR: B-19
YES : Go to Step 4.
CLEANER
P.00E-2.
COVER
A/T
CONTROL
UNIT
10DB125A
INSPECTION PROCEDURE 16: Shift Position Indicator Light System <Vehicles with Sport Mode>
. .

• The A/T-ECU detects the transmission range ("P," likely causes for this condition:)
"R," "N," "D," sport mode "5", "4," "3," "2," or "1"), • Malfunction of the combination meter
and display it on the combination meter. • Damaged harness, connector
.
COMMENT Circuit drawings
Connector(s), wiring harness in the CAN bus line • Refer to circuit diagrams GROUP-90
between the A/T-ECU and the combination meter, • Refer to configuration diagrams GROUP-80
power supply to the A/T-ECU, the combination • Refer to component locations GROUP-70
meter, the A/T-ECU may be defective.
DIAGNOSIS
• MB991824: V.C.I.

CAN bus line.
CAUTION
CONNECTOR
MB991958.
Use diagnostic tool MB991958 to diagnose the CAN bus lines.
connector.
(3) Diagnose the CAN bus line.
MB991910
MB991824 Q: Is the check result properly?
YES : Go to Step 2.
NO : Repair the CAN bus lines (Refer to GROUP 54C,
Diagnosis-CAN Bus Diagnostic Chart P.54C-15).
MB991827 00DB076A
STEP 2. Using diagnostic tool MB991958, read the MPI

CONNECTOR
(3) Check for MPI diagnostic trouble code.
YES : Retry the troubleshooting procedures.
MB991910
MB991824
MB991827 00DB076A

M1231008100337
MUT-III ITEM INSPECTION ITEM INSPECTION NORMAL

DIAGNOSTI NO. REQUIREMENT CONDITION
C TOOL
DISPLAY
2ND SOL 14 Second solenoid Transmission range: Driving at constant 100%
DUTY valve duty % Sport mode speed of 10 km/h (6.2
<Vehicles with sport mph) in 1st gear
mode>
Transmission range: Driving at constant 0%
Sport mode speed of 30 km/h (19
<Vehicles with sport mph) in 2nd gear
mode>
<Vehicles with sport mph) in 3rd gear
mode>
<Vehicles with sport mph) in 4th gear
mode>
mode>
A/T CONT 8 A/T control relay Ignition switch: ON Battery voltage
RLY output voltage (V)
ENGINE 1 ENGINE SPEED Accelerator pedal: 600 − 900
SPEED (r/min) Release r/min
Accelerator pedal: Gradually rises
Depressed from the above
value
A/C 21 A/C Compressor • Engine: Idling A/C switch: ON (while ON
Compressor Relay • Transmission the A/C compressor is
Relay range: P, N in operation)
A/C switch: OFF OFF
ISS SENSOR 5 Input shaft speed Gear range: 4th gear Driving at constant 1,100 − 1,400
sensor (r/min) speed of 50 km/h (31 r/min
mph)

C TOOL
DISPLAY
L/R SOL 12 Low-reverse Transmission range: Driving at constant 100%
DUTY solenoid valve duty Sport mode speed of 10 km/h (6.2
% <Vehicles with sport mph) in 1st gear
mode>
mode>
mode>
mode>
mode>
O/D SOL 15 Overdrive solenoid Transmission range: Driving at constant 100%
mode>
mode>
mode>
mode>
mode>
OSS 6 Output shaft speed Gear range: 3rd gear Driving at constant 1,100 − 1,400
SENSOR sensor (r/min) speed of 50 km/h (31 r/min
mph)

C TOOL
DISPLAY
SELECT SW 27 Select switch Ignition switch: ON Transmission range: D OFF
<Vehicles with sport Selector lever ON
mode> operation: Select sport
mode
Selector lever ON
operation: Upshift and
hold the selector lever
Selector lever ON
operation: Downshift
and hold the selector
lever
SHIFT POS 11 Shift position Transmission range: Driving at constant 1st
Sport mode speed of 10 km/h in
<Vehicles with sport 1st gear
mode>
Transmission range: Driving at constant 2nd
<Vehicles with sport 2nd gear
mode>
Transmission range: Driving at constant 3rd
<Vehicles with sport 3rd gear
mode>
Transmission range: Driving at constant 4th
<Vehicles with sport 4th gear
mode>
Transmission range: Driving at constant 5th
<Vehicles with sport 5th gear
mode>
Transmission range: Driving at constant REV
R speed of 5 km/h in
reverse gear
Transmission range: P, N NP

C TOOL
DISPLAY
SHIFT SW 29 Shift switch (Down) Ignition switch: ON Transmission range: D OFF
DOWN <Vehicles with sport Selector lever OFF
mode
Selector lever OFF
Selector lever ON
lever
SHIFT SW 28 Shift switch (Up) Ignition switch: ON Transmission range: D OFF
UP <Vehicles with sport Selector lever OFF
mode
Selector lever ON
Selector lever OFF
lever
STOPLIGHT 19 Stoplight switch Ignition switch: ON Brake pedal: ON
SW Engine: stopped Depressed
Brake pedal: Released OFF
DCC 10 Damper clutch • Warmed up Driving at constant Approx. 100 to
SLIPPAGE amount of slippage • Transmission speed of 50 km/h in 300 r/min
range: Sport 3rd gear
mode <Vehicles Driving at constant Approx. 0 to
with sport mode> speed of 70 km/h in 10 r/min
4th gear
Release accelerator The value
pedal (at less than 50 should
km/h) fluctuate when
the accelerator
is released.
DCC SOL 17 Damper control • Warmed up Driving at constant Approx. 70 −
DUTY clutch solenoid valve • Transmission speed of 50 km/h in 90%
duty % range: 3rd gear
Sport mode Accelerate to 50 km/h 70 − 90% →
<Vehicles with in 3 position, then 0% Decreases
sport mode> release accelerator gradually as
pedal the vehicle
speed
decreases

C TOOL
DISPLAY
TFT 7 Transmission fluid Warmed up Drive for 15 minutes or Gradually rises
SENSOR temperature sensor more so that the to 70 − 90°C
transmission fluid
temperature becomes
70 − 90°C
AP SENSOR 2 AP sensor (mV) • Ignition switch: Accelerator pedal: 900 − 1100 mV
ON Release
• Engine: Stopped Accelerator pedal: Gradually rises
• Transmission Depressed from the above
range: P value
Accelerator pedal: 4,000 mV or
Fully depressed more
INHIBITOR 34 Transmission Ignition switch: ON Transmission range: P P
SWITCH inhibitor switch Transmission range: R R
Transmission range: N N
Transmission range: D D
U/D SOL 13 Underdrive solenoid Transmission range: Driving at constant 0%
mode>
mode>
mode>
mode>
mode>

C TOOL
DISPLAY
RED SOL 16 Reduction solenoid Transmission range: Driving at constant 0%
mode>
mode>
mode>
mode>
mode>

M1231008200408
MUT-III ITEM INSPECTION TEST CONTENT INSPECTION NORMAL

DIAGNOSTI NO. ITEM REQUIREMENT CONDITION
C TOOL
DISPLAY
1st SIFT LMP 07 Shift position Illuminate each indicator • Ignition Shift indicator light
indicator light (1st) light for three seconds to switch: ON illuminates.
the signal from the • Transmission
diagnostic tool range: P
MB991958 (MUT-III sub • Engine:
assembly). stopped
• Throttle
opening
voltage: Less
than one volt
2nd SIFT 08 Shift position
LMP indicator light (2
nd)
2ND SOL 03 Second solenoid Drive the solenoid valve The solenoid
valve specified by the should click when
diagnostic tool activated
MB991958 (MUT-III sub
assembly) at 50% duty
for five seconds. No
other solenoid valve
should be energized.
MUT-III ITEM INSPECTION TEST CONTENT INSPECTION NORMAL

DIAGNOSTI NO. ITEM REQUIREMENT CONDITION
C TOOL
DISPLAY
3rd SIFT LMP 09 Shift position illuminate each indicator Shift indicator light
indicator light (3rd) light for three seconds to illuminates.
the signal from the
diagnostic tool
assembly).
4th SIFT LMP 10 Shift position
indicator light (4th)
5th SIFT LMP 11 Shift position
indicator light (5th)
A/T RELAY 12 A/T control relay Actuator test in scope Data list No.54
mode, data list No.54. • During test: 0 V
Control relay is OFF for • Normal: Battery
three seconds. positive voltage
[12 V]
L/R SOL 01 Low-reverse Drive the solenoid valve The solenoid
solenoid valve specified by the should click when
diagnostic tool activated
assembly) at 50% duty
for five seconds. No
other solenoid valve
should be energized.
O/D SOL 04 Overdrive
solenoid valve
RED SOL 05 Reduction
solenoid valve
DCC SOL 06 Damper control
clutch solenoid
valve
U/D SOL 02 Underdrive
solenoid valve
A/T-ECU TERMINAL VOLTAGE REFERENCE CHART FOR TRANSMISSION

OPERATION
M1231008400305
1. Disconnect the A/T-ECU connectors, and connect 2. Measure the voltages between each check
special tool MB992045 in between. connector terminals of special tool MB992045 and
connector B-19 ground terminals 1 or 10.
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
CONNECTOR: B-22
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
10DB132A
TERMINAL INSPECTION ITEM INSPECTION REQUIREMENT NORMAL CONDITION

NO.
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
• Transmission range: D (1st gear)
3 Solenoid valve power Ignition switch: LOCK (OFF) 1V or less
supply Ignition switch: ON Battery positive voltage

NO.
4 A/T control relay Always 1 V or less

5 Input shaft speed • Measure between (B-22) terminal 5 Refer to P.23A-285,
sensor and (B-19) terminal 1 with an Inspection Procedure
oscilloscope. Using an Oscilloscope.
• Gear range: 3rd gear
6 Transmission fluid • Ignition switch: ON 3.8 − 4.0 V
temperature sensor • Transmission fluid temperature: 25°C
• Ignition switch: ON 2.3 − 2.5 V
• Transmission fluid temperature: 80°C
7 Signal ground Always 1 V or less
8 Damper control clutch • Engine: idling Battery positive voltage
solenoid valve • Gear range: 1st gear
• Gear range: 3rd gear (60km/h)
9 Solenoid valve power Ignition switch: LOCK (OFF) 1 V or less
supply Ignition switch: ON Battery positive voltage
11 Output shaft speed • Measure between (B-22) terminal 11 Refer to P.23A-285,
sensor and (B-19) terminal 1 with an Inspection Procedure
oscilloscope. Using an Oscilloscope.
12 Sensor ground Always 1 V or less
13 Power supply Ignition switch: LOCK (OFF) 1 V or less
Ignition switch: ON Battery positive voltage
14 Second solenoid valve • Engine: idling Battery positive voltage
• Gear range: 2nd gear
• Transmission range: D (1st gear)
15 Reduction solenoid • Engine: idling Battery positive voltage
valve • Gear range: 1st gear
• Transmission range: D (5th gear)
Ignition switch: ON Battery positive voltage
21 Low-reverse solenoid • Engine: idling Battery positive voltage
valve • Transmission range: D (1st gear)
• Gear range: 2nd gear
23 Transmission inhibitor • Ignition switch: ON Battery positive voltage
switch: R • Transmission range: R
• Ignition switch: ON 1 V or less
• Transmission range: Other than above

NO.

switch: D • Transmission range: D
switch: P • Transmission range: P
switch: N • Transmission range: N
CONNECTOR: B-19
AIR
CLEANER
COVER
A/T
CONTROL
UNIT
10DB125A

NO.
CONNECTOR
(B-19)
1 Ground Always 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
• 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
• Selector lever operation: Other than
above
17 Sports select switch • Ignition switch: ON Battery positive voltage
• Transmission range: Sport mode
20 Flash EPROM Data Link Connector -
battery
21 Battery Back-up Always Battery positive voltage

NO.
24 Vehicle speed signal • Measure between connector (B-19) Refer to P.23A-285,

terminal 24 and 1 with an oscilloscope. Inspection Procedure
• Engine: 2,000 r/min Using an Oscilloscope.
29 K-Line Data Link Connector -
30 P- Signal [vehicles - -
with power memory
seat- (driver side)]
31 N- Signal [vehicles - -
with power memory
seat- (driver side)]
AIR
CLEANER
COVER
ENGINE
CONTROL
UNIT
10DB133A

NO.
ENGINE-ECU
CONNECTOR (B-21)
18 Stoplight switch • Ignition switch: ON Battery positive voltage
• Brake pedal: Depressed
• Brake pedal: Released
A/T-ECU TERMINAL RESISTANCE AND CONTINUITY INSPECTION CHART

M1231013400204
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
NOTE: The A/T-ECU connectors should be discon-

nected for this inspection.
TERMINAL NO. INSPECTION ITEM NORMAL CONDITION (CHECK CONDITION)
(B-22) 12 − 6 Transmission fluid temperature 16.7 − 20.5 kΩ [at 0°C]
sensor
7.3 − 8.9 kΩ [at 20°C]
3.4 − 4.2 kΩ [at 40°C]
1.9 − 2.2 kΩ [at 60°C]
1.0 − 1.2 kΩ [at 80°C]
0.57 − 0.69 kΩ [at 100°C]
INSPECTION PROCEDURE USING AN OSCILLOSCOPE

M1231008500313
(B-22) INSPECTION ITEM INSPECTION REQUIREMENT NORMAL

TERMINAL CONDITION
NO. (WAVEFORM
SAMPLE)
5 Input shaft speed Gear range: 3rd gear Driving at constant Waveform B
sensor speed of 50 km/h in 3rd
11 Output shaft speed gear ( 1,900 − 2,100
sensor r/min)
21 Low-reverse solenoid • Ignition switch: ON Force drive each Waveform C
valve • Transmission range: P solenoid valve (Actuator
1 Underdrive solenoid • Engine: Stopped test)
valve • Throttle (Accelerator)
opening voltage: 1 V or
14 Second solenoid valve less
2 Overdrive solenoid
valve
15 Reduction (RED)
solenoid valve
8 Damper clutch control
(DCC) solenoid
Waveform sample
WAVEFORM B WAVEFORM C
WAVEFORM A (V) (V)
(V) 60
5
5
40
20
0 0
0
(ms) (ms)
(ms)
AC001872AE AC001873AD AC001875AF
SPECIAL TOOLS
SPECIAL TOOLS
M1231000600413

NAME
MD998330 (Includes MD998330-01 Measurement of hydraulic pressure
MD998331)
Oil pressure gauge (3.0
MPa, 427 psi)
AC103525
MD998332 MD998332-01 Connection for oil pressure gauge

Adapter
MB991958 MB991824-KIT Checking diagnostic trouble codes

A
A: MB991824 NOTE: G: CAUTION
B: MB991827 MB991826 For vehicles with CAN
C: MB991910 MUT-III trigger communication, use MUT-III main
D: MB991911 harness is not harness A to send simulated
MB991824 E: MB991914 necessary when vehicle speed. If you connect
B F: MB991825 pushing V.C.I. MUT-III main harness B instead,
G: MB991826 ENTER key. the CAN communication does
MUT-III sub assembly not function correctly.
A: Vehicle
MB991827 communication
C
interface (V.C.I.)
D
system)
D: MUT-III main harness
DO NOT USE B (Vehicles without
CAN communication
MB991911 system)
E E: MUT-III main harness
C (for Daimler
DO NOT USE Chrysler models only)
MB991914 adapter
F
G: MUT-III trigger
harness
MB991825
MB991826
MB991958
SPECIAL TOOLS

NAME
MB992045 MD998478-01 Measurement of A/T-ECU terminal
A/T-ECU Test Check voltage
Harness
MB992045
MD998900 MIT220433 Connection for oil pressure gauge

Adapter
MB995062 MLR-6906B or Flushing cooler and tube

Flushing tool Equivalent
MB991454 MZ203827-01 When the engine hanger is used:

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

NAME
MB991897 MB991113-01, Knuckle and tie rod end ball joint
Ball joint remover MB990635-01 or breakaway torque check
general service NOTE: Steering linkage
tool puller(MB990635 or MB991113)is
AC106827 also used to disconnect knuckle
and tie rod end ball joint.
A MB990241 MB990241-01 or Removal of the drive shaft
Axle shaft puller General service
B
A: MB990242 tool
Puller shaft
MB990241AB B: MB990244
Puller bar
MB991354 General service
Puller body tool
MB991354
MB990767 MB990767-01 Fixing of the hub

End yoke holder
B990767
A A: MB991017 MB990998-01 • Removal of the hub

B: MB990998 • Provisional holding of the wheel
C: MB991000 bearing
B A, B: Front hub remover • Measurement of hub starting
C
AC100320 AB and installer torque
C: Spacer • Measurement of wheel bearing
end play
NOTE: MB991000, which
belongs to MB990998, should be
used as a spacer.
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
A/T CONTROL COMPONENT LAYOUT
M1231008600343
NAME SYMBOL NAME SYMBOL

A/T control relay B A/T-ECU E
A/T control solenoid valves D Stoplight switch F
Data link connector G Sports mode shift switch H
Input shaft speed sensor A Transmission fluid temperature sensor D
Output shaft speed sensor A Transmission inhibitor switch C
<3.8L ENGINE>
A B
C D E
10DB134A
10DB135A
ON-VEHICLE SERVICE
A BATTERY B
OUTPUT SHAFT A/T

SPEED SENSOR CONTROL
RELAY
INPUT SHAFT
SPEED SENSOR
AC207308AI
RELAY BOX 10DB136A
C D
Overdrive Underdrive
solenoid solenoid
valve valve
B-110 (B) Low-reverse

Second
solenoid
solenoid
valve
valve
Damper
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
ON-VEHICLE SERVICE
ESSENTIAL SERVICE
TRANSMISSION FLUID CHECK

M1231021400050
1. Drive the vehicle until the transmission fluid temperature
176°F)].
0 (0)
– 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
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.
Transmission overhaul and cooler line flushing may be nec-
essary.
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 transmission will churn
the fluid and air into a foamy liquid. Both conditions (level
AC106828AB
too 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 transmission vent
where it may be mistaken for a leak.
6. Securely insert the dipstick.
NOTE: The transmission fluid should always be replaced
under the following conditions:
.
• When troubleshooting the transmission.
• When overhauling the transmission.
• When the transmission fluid is noticeably dirty or burnt
(driving under severe conditions).
ON-VEHICLE SERVICE
TRANSMISSION FLUID CHANGE

M1231021500057
If you have a transmission fluid changer, use this changer to
replace the transmission fluid. If you do not have an transmis-
sion fluid changer, replace the transmission fluid by the follow-
ing procedure.
1. Disconnect the hose shown in the illustration which
connects the transmission and the oil cooler (inside the
INLET FROM
COOLER
radiator). Place a container under the hose to collect the
discharge.
CAUTION
The engine should be stopped within one minute after it is
started. If all the transmission fluid has drained out before
then, the engine should be stopped at that point.
DIPSTICK 2. Start the engine and let the transmission fluid drain out.
10DB151A (Running conditions: "N" range with engine idling)
TO Approximately 4.5 litres of transmission fluid should
COOLER
FROM be removed.
COOLER
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.
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.
ON-VEHICLE SERVICE
8. Reconnect the hose which was disconnected in step 1

above, and firmly replace the dipstick.
INLET FROM
COOLER 9. Start the engine and run it at idle for one to two minutes.
10.Move the selector lever through all positions, and then move
it to the "N" position.
DIPSTICK
10DB151A
11.Check that the transmission fluid level is at the "COLD"

mark on the dipstick. If the level is less than this, add
transmission fluid.
12.Drive the vehicle until the transmission fluid temperature
176°F)], and then check the transmission fluid level again.
The transmission fluid level must be at the "HOT" mark.
AC106828AB
NOTE: The "COLD" level is for reference only; the "HOT"
level should be regarded as the standard level.
0 (0)
– 10 (– 0.4) 13.When the transmission fluid is less than the specified level,
– 20 (– 0.8)
add transmission fluid.
When the transmission fluid is greater than the specified
DIPSTICK
– 30 (– 1.2)
40 60 80
level, drain the excess fluid through the drain plug to adjust
(104) (140) (176) the transmission fluid to the specified level.
14.Firmly insert the dipstick into the oil filler tube.
ON-VEHICLE SERVICE
OIL COOLER FLOW CHECK

M1231013100214
After the new or repaired transmission has been installed, fill to
the proper level with MITSUBISHI ATF SP III. The flow should
be checked using the following procedure:
CAUTION
With the fluid set at the proper level, transmission fluid
collection should not exceed one litre or internal damage
to the transmission may occur.
TO
1. Disconnect the OUTLET line (from cooler) at the
COOLER
FROM transmission and place a collecting container under the
COOLER disconnected line.
2. Run the engine at curb idle speed with the shift selector in
neutral.
3. If transmission fluid flow is intermittent or it takes more than
20 seconds to collect one litre of transmission fluid, replace
the cooler.
4. If flow is within acceptable limits, reconnect the cooler line.
10DB152A Then fill the transmission to the proper level, using
MITSUBISHI ATF SP III.
TRANSMISSION INHIBITOR SWITCH CHECK

M1231021600106

RANGE TESTER
P 3 − 8, 9 − 10 Less than 2 ohms.

B-110 (B) R 7−8
N 4 − 8, 9 − 10
D 1−8
TRANSMISSION
INHIBITOR SWITCH
10DB167A NOTE: For vehicles with sport mode, four positions (P, R, N, D)
are used.
D
N
R
P
10DB142A
TRANSMISSION INHIBITOR SWITCH AND

CONTROL CABLE ADJUSTMENT
M1231021700051
1. Set the selector lever to the "N" position.
ON-VEHICLE SERVICE
2. Loosen the control cable to the manual control lever

MANUAL coupling nut to free the cable and lever.
CONTROL ADJUSTING NUT
3. Set the manual control lever to the neutral position.
LEVER
12 ± 2 N·m
107 ± 17 in-lb
10DB143A
4. Loosen the transmission inhibitor switch body mounting

11 ± 1 N·m
96 ± 8 in-lb
bolts and turn the park/neutral position switch body so the
hole in the end of the manual control lever and the hole
MANUAL
(section A − A in the figure on the left) in the flange of the
CONTROL transmission inhibitor switch body flange are aligned.
LEVER 5. Tighten the transmission inhibitor switch body mounting
bolts to the specified torque. Be careful at this time that the
switch body does not move.
MOUNTING BOLTS Tightening torque: 11 ± 1 N⋅m (96 ± 8 in-lb)
SECTION A - A
HOLE IN END
MANUAL
CONTROL
HOLE IN LEVER
FLANGE
TRANSMISSION
RANGE SWITCH BODY
10DB144A
6. Gently push the transmission control cable in the direction of

MANUAL the arrow, until the cable is taut. Tighten the adjusting nut.
LEVER
7. Check that the selector lever is in the "N" position.
8. Check that each position of the manual control lever
12 ± 2 N·m matches each position of the selector lever using diagnostic
107 ± 17 in-lb
tool MB991958 (MUT-III sub assembly).
10DB143A
AUTOMATIC TRANSMISSION CONTROL

COMPONENT CHECK
CRANKSHAFT POSITION SENSOR CHECK

M1231009000355
Refer to GROUP 13A <3.8L Engine>, Diagnosis − Inspection
Procedure Using an Oscilloscope 13A-652.
ON-VEHICLE SERVICE
TRANSMISSION FLUID TEMPERATURE SENSOR

CHECK
M1231021800133
1. Remove the transmission fluid temperature sensor.
2. Measure the resistance between terminals 1 and 2 of the
transmission fluid temperature sensor connector.
Standard value:
1 2 3 4 5 6
7 8 9 10 TRANSMISSION FLUID RESISTANCE
TEMPERATURE
0°C (32°F) 16.7 − 20.5 kΩ
20°C (68°F) 7.3 − 8.9 kΩ
TRANSMISSION FLUID
AC210186AC 40°C (104°F) 3.4 − 4.2 kΩ
60°C (140°F) 1.9 − 2.2 kΩ
80°C (176°F) 1.0 − 1.2 kΩ
100°C (212°F) 0.57 − 0.69 kΩ
3. If the transmission fluid temperature sensor resistance is

outside the specified range and the "N" range indicator light
is flashing, replace the transmission fluid temperature
sensor.
NOTE: The "N" range indicator light on the combination
meter flashes when the temperature reaches approximately
125°C (257°F) or greater, and then stops flashing when the
temperature drops below approximately 115°C (238°F).
TRANSMISSION INHIBITOR SWITCH CHECK

M1231021600117
Refer to P.23A-294.
STOPLIGHT SWITCH CHECK

M1231009100192
Refer to GROUP 35A, Brake Pedal − Brake Pedal Inspection
P.35A-25.
A/T CONTROL RELAY CHECK

M1231009300248
1. Remove the A/T control relay.
BATTERY
A/T
CONTROL
RELAY
RELAY BOX
AC306283AC
ON-VEHICLE SERVICE
2. Use jumper wires to connect A/T control relay terminal 3 to

the negative battery terminal and terminal 2 to the positive
FRONT OF VEHICLE battery terminal.
3. Check for continuity between A/T control relay terminals 1
1 2
and 4 when the jumper wires are connected to and
3 4 disconnected from the battery.
JUMPER WIRE CONTINUITY BETWEEN TERMINALS
NO.1 AND NO.4
AC100115AJ Connected Continuity
Disconnected No continuity
4. If there is any problem with the A/T control relay, replace it.
ON-VEHICLE SERVICE
SOLENOID VALVE CHECK

M1231009400267
1. Use diagnostic tool MB991958 (MUT-III sub assembly) to
measure the transmission fluid temperature. The desired
transmission fluid temperature setting for performing the
solenoid valve check is 20°C (68°F).
2. Remove the A/T control solenoid valve assembly connector.
1 2 3 4 5 6
7 8 9 10 3. Measure the resistance between the solenoid valve
terminals.
4. The measured resistance of the solenoid valve when the
transmission fluid temperature is 20°C (68°F) should match
the specified resistance on the chart below.
A/T CONTROL Specified resistance:
SOLENOID VALVE
ASSEMBLY
TERMINAL NAME RESISTANCE
NO.
AC306288AB
7 - 10 Damper control clutch 2.7 − 3.4 Ω [at
(DCC) solenoid valve 20°C (68°F)]
6 - 10 Low-reverse solenoid
valve
8 - 10 Reduction (RED)
solenoid valve
4-9 Second solenoid valve
3-9 Underdrive solenoid
valve
5-9 Overdrive solenoid valve
5. If the solenoid valve resistance is within the specified range,

check the power supply and the ground circuits.
6. If the solenoid valve resistance is not within the specified
range, drain the transmission fluid and remove the valve
body cover.
7. Disconnect the connector of any solenoid valves that are not
Overdrive Underdrive
within the specified range.
solenoid solenoid
valve valve
Second
Low-reverse
solenoid
solenoid
valve
valve
Damper
solenoid solenoid
valve valve
10DB123A
ON-VEHICLE SERVICE
8. Measure the resistance between terminals 1 and 2 of any

solenoid valve that was not within the specified range.
Specified resistance: 2.7 − 3.4 Ω [at 20°C (68°F)]
1 9. If the resistance is not within the specified range, replace the
2 solenoid valve.
10.If the resistance is within the specified range, check the
wiring harness between the affected A/T control solenoid
valve assembly and the solenoid valve. If a problem is not
found in the above steps, check the solenoid valve O-rings
AC100378 AB
and replace them if necessary.
SELECTOR LEVER OPERATION CHECK

M1231001300426
1. Apply the parking brake, and check that the selector lever
moves smoothly and accurately to each position.
2. Check that the engine starts when the selector lever is at the
"N" or "P" position, and that it does not start when the
selector lever is in any other position.
3. Start the engine, release the parking brake, and check that
the vehicle moves forward when the selector lever is moved
from "N" position to "D" position or to 1st or 2nd gear in
Sports mode, and that the vehicle reverses when the
selector lever is moved to "R" position.
4. Stop the engine.
5. Turn the ignition switch to the "ON" position, and check that
the backup lamp illuminates when the selector lever is
shifted from "P" position to "R" position.
THE SELECTOR LEVER MOVES WITHOUT

PUSHING THE BUTTON.
THE SELECTOR LEVER MOVES WHEN THE

BUTTON IS PUSHED.
10DB145A
TRANSMISSION CONTROL CABLE

ADJUSTMENT
M1231028000064
1. Move the selector lever to the "N" position.
2. Loosen the upper control lever adjusting nut.
MANUAL 3. Gently push the transmission control cable in the direction of
the arrow, and then tighten the adjusting nut.
LEVER
4. Check that the transmission shifts to the correct range
12 ± 2 N·m corresponding to the position of the selector lever, and that it
107 ± 17 in-lb
functions correctly in that range.
10DB143A
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
TRANSMISSION CONTROL CABLE TRANSMISSION CONTROL CABLE

ASSEMBLY REMOVAL STEPS ASSEMBLY REMOVAL STEPS
• AIR DUCT AND AIR CLEANER 4. TRANSMISSION CONTROL CABLE
ASSEMBLY (REFER TO GROUP 15 ASSEMBLY CONNECTION
P.15-4.) (SELECTOR LEVER ASSEMBLY
SIDE)
• BATTERY AND BATTERY TRAY
5. TRANSMISSION CONTROL CABLE
• ENGINE-ECU AND A/T-ECU
ASSEMBLY
(REFER TO GROUP 13A 13A-675.)
SELECTOR LEVER ASSEMBLY
• HEATER UNIT AND DECK
ASSEMBLY REMOVAL STEPS
CROSSMEMBER ASSEMBLY
(REFER TO GROUP 55, HEATER • FLOOR CONSOLE (REFER TO
UNIT, HEATER CORE, BLOWER GROUP 52A, FLOOR CONSOL
ASSEMBLY AND EVAPORATOR ASSEMBLY 52A-10)
UNIT 55-151.) 4. TRANSMISSION CONTROL CABLE
>>B<< 1. ADJUSTING NUT ASSEMBLY CONNECTION
(SELECTOR LEVER ASSEMBLY
>>B<< 2. TRANSMISSION CONTROL CABLE SIDE)
ASSEMBLY CONNECTION
(TRANSMISSION SIDE)
6. A/T SELECTOR LEVER POSITION
ILLUMINATION LIGHT HARNESS
CONNECTOR AND
SHIFT SWITCH ASSEMBLY
HARNESS CONNECTOR
8. SELECTOR LEVER ASSEMBLY

.
>>B<< TRANSMISSION CONTROL CABLE

ASSEMBLY (TRANSMISSION SIDE)/ADJUSTING
NUT INSTALLATION
1. Place the selector lever and manual control lever in the "N"
position.
<F4A4B>
2. Place the cable stud into the manual control lever slot and
ADJUSTING NUT install the nut loosely. Gently push the transmission control
12 ± 2 N·m cable into the manual control lever slot until the cable is taut.
107 ± 17 in-lb Tighten the nut to the specified torque.
MANUAL CONTROL LEVER AC305532
<F4A5A> ADJUSTING NUT

12 ± 2 N·m
107 ± 17 in-lb
AC305881
MANUAL CONTROL LEVER AC305679AE
INSPECTION
M1231030000094
Check the cable assembly for function and for damage.

M1231006800363
2.0 ± 0.3 N·m

18 ± 2 in-lb
3
3
10DB165A

1. SHIFT KNOB 3. LED ILLUMINATION BULBS
2. INDICATOR PANEL 4. SHIFT LEVER ASSEMBLY
INSPECTION
M1231006900188
SPORTS MODE
SHIFT SWITCH
(UP SHIFT)
(SELECT SHIFT)
ON
ON
(DOWN SHIFT) (SELECT SHIFT)

ON OFF
SHIFT SWITCH SHIFT SWITCH

(DOWN SIDE) (UP SIDE)
SHIFT SWITCH AND

10DB169A
ILLUMINATION CONNECTOR
10DB166A
SHIFT SWITCH ASSEMBLY CONTINUITY CHECK

SWITCH POSITION TERMINAL NO.
Select switch (select shift) ON 6−1
OFF −
Shift switch (up shift) ON 2−7
OFF −
Shift switch (down shift) ON 2−3
OFF −
illumination (tail lamp ON (12V) 5
relay supply)
OFF (0V)
illumination (rheostat/ < than 2 4

dimmer switch) ohms
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
>>E<< 1. ADJUSTING NUT 3. INHIBITOR SWITCH SENSOR
>>E<< 2. TRANSMISSION CONTROL CONNECTOR
CABLE CONNECTION 4. A/T CONTROL SOLENOID VALVE
ASSEMBLY CONNECTOR

5. INPUT SHAFT SPEED SENSOR <> 14. TIE ROD END CONNECTION
CONNECTOR 15. SELF-LOCKING NUT
6. OUTPUT SHAFT SPEED (CONNECTION FOR LOWER
SENSOR CONNECTOR ARM BALL JOINT)
7. SPLIT PIN <> 16. LOWER ARM BALL JOINT
<<A>> >>D<< 8. DRIVE SHAFT NUT CONNECTION
9. WHEEL SPEED SENSOR <<C>> >>C<< 17. DRIVE SHAFT <LH>
10. WHEEL SPEED SENSOR 18. CIRCLIP
BRACKET <<C>> >>C<< 19. DRIVE SHAFT AND INNER
11. BRAKE HOSE CLAMP SHAFT ASSEMBLY <RH>
12. STABILIZER LINK CONNECTION 20. TRANSMISSION FLUID COOLER
<STRUT SIDE> HOSE
13. SELF-LOCKING NUT 21. STARTER MOTOR ATTACHING
(CONNECTION FOR TIE ROD BOLTS
END) 22. STARTER MOTOR
23. TRANSMISSION ASSEMBLY
UPPER PART COUPLING BOLTS
88 ± 10 N·m
65 ± 7 ft-lb
25
32 49 ± 3 N·m
83 ± 12 N·m*
61 ± 9 ft-lb* 36 ± 2 ft-lb
83 ± 12 N·m* 24
61 ± 9 ft-lb*
11 ± 0.5 N·m
93 ± 4 in-lb
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
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

• SUPPORT THE TRANSMISSION
WITH A TRANSMISSION JACK
32. TRANSMISSION ASSEMBLY
LOWER PART COUPLING BOLTS
>>A<< 33. TRANSMISSION ASSEMBLY
• MB990767: End Yoke Holder • MB991454: Engine Hanger Balancer
• MB991897: Ball Joint Remover • MB991895: Engine Hanger
• MB990242: Puller Shaft Puller • MB991928: Engine Hanger
• MB990244: Puller Bar • MB991932: Foot (standard)
• MB991354: Puller Body • MB991929: Joint (50)
• MB990998: Front Hub Remover and Installer • MB991931: Joint (140)
• MB991000: Spacer • MB991934: Chain and Hook Assembly
.
<<A>> DRIVE SHAFT NUT REMOVAL

CAUTION
Do not apply pressure to the wheel bearing by the vehicle
weight to avoid possible damage when the drive shaft nut
is loosened.
Use special tool MB990767 to fix the hub and remove the drive
shaft nut.
MB990767
AC102462 AC
<> TIE ROD END CONNECTION/LOWER ARM

BALL JOINT CONNECTION REMOVAL
CAUTION
• Do not remove the nut from ball joint. Loosen it and use
the special tool to avoid possible damage to ball joint
threads.
• Hang the special tool with cord to prevent it from fall-
ing.
1. Replace the self locking nut with a regular nut, because the
CORD
original one is a little bit large to install the special tool.
Install special tool MB991897 as shown in the figure.
NUT MB991897
BOLT
2. Turn the bolt and knob as necessary to make the jaws of

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 tie rod end
KNOB and remove the self locking nut.
WRONG AC106821AC
<<C>> DRIVE SHAFT <LH>/DRIVE SHAFT AND

INNER SHAFT ASSEMBLY <RH> REMOVAL
1. Use special tools MB990242, MB990244, MB991354 and
MB990767 to push out the drive shaft or the drive shaft and
inner shaft assembly from the hub.
MB990767
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 AC100141AL

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
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
<<D>> TORQUE CONVERTER AND DRIVE PLATE

COUPLING BOLTS REMOVAL
1. Remove the drive plate coupling bolts while turning the
crank shaft.
2. Pry the torque converter towards the transmission side.
Remove the torque converter with the transmission.
.
<<E>> ENGINE ASSEMBLY SUPPORTING

<RH> <LH> 1. <Engine hanger (special tool MB991895) is used>
A B (1) Set special tool MB991895 (engine hanger) to the front
fender assembling bolts (A and B) and (C and D) as
shown.
C D
AC306197AB
MB991895
(2) Set special tool MB991454 to hold the
engine/transmission assembly.
MB991454
AC306215AB
2. <Engine hanger (special tool MB991928) is used>

SLIDE BRACKET (HI)
(1) Assemble the engine hanger (special tool MB991928).
Attach following parts to the base hanger.)
FOOT • SLIDE BRACKET (HI)
(STANDARD) • FOOT (STANDARD) (MB991932)
(MB991932) • JOINT (50) (MB991929)
JOINT (50) • JOINT (140) (MB991931)
(MB991929)
FOOT
JOINT (140) (STANDARD)
(MB991931) (MB991932)
AC306216AB
<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
MB991928 (3) Position special tool MB991454 to hold the

engine/transmission assembly.
NOTE: Adjust the engine hanger balance by sliding the
slide bracket (HI).
MB991454
AC306217AB

.
>>A<< TRANSMISSION ASSEMBLY INSTALLA-

TION
Engage the torque converter into the transmission side
securely, and then assemble the transmission assembly on the
engine.
APPROXIMATELY
9.4 mm (0.37 in)
TORQUE
CONVERTER
AC209056AC
>>B<< TRANSMISSION MOUNT STOPPER

INSTALLATION
Install the transmission mount stopper so that the arrow points
ENGINE SIDE TRANSAXLE upward as shown in illustration. Ensure stoppers are installed
MOUNT
STOPPER
onto mount correctly prior to fitment and do not dislodge during
transmission installation.
TRANSAXLE
MOUNT
AC205424 AB
>>C<< DRIVE SHAFT AND INNER SHAFT

ASSEMBLY <RH>/DRIVE SHAFT <LH>
INSTALLATION
CAUTION
When installing the drive shaft or the drive shaft and inner
shaft assembly, be careful that the spline part of the drive
shaft or the drive shaft and inner shaft assembly do not
damage the oil seal.
.
>>D<< DRIVE SHAFT NUT INSTALLATION

1. Be sure to install the drive shaft washer in the specified
WASHER
direction.
CAUTION
Before securely tightening the drive shaft nuts, make sure
there is no load on the wheel bearings. Otherwise the
wheel bearing will be damaged.
2. Using special tool MB990767, tighten the drive shaft nut to
the specified torque.
MB990767 Tightening torque: 226 ± 29 N⋅m (167 ± 21 ft-lb)
AC210244AB
>>E<< TRANSMISSION CONTROL

CABLE/ADJUSTING NUT INSTALLATION
1. Place the selector lever and manual control lever in the “N”
position.
2. Place the cable stud into the manual control lever slot and
MANUAL install the nut loosely. Gently push the transmission control
CONTROL ADJUSTING NUT cable into the manual control lever slot until the cable is taut.
LEVER Tighten the nut to the specified torque.
12 ± 2 N·m
107 ± 17 in-lb
10DB143A
TRANSMISSION FLUID COOLER, HOSE AND PIPE
TRANSMISSION FLUID COOLER, HOSE AND PIPE

M1231021900033

• Transmission Fluid Draining and Supplying (Refer to
GROUP 00, Maintenance Service − Automatic Transmis-
sion Fluid P.00-45.)
• Front Under Cover <LH> Removal and Installation
3
1
AC306186AB
TRANSMISSION FLUID COOLER TRANSMISSION FLUID COOLER

LINE ASSEMBLY REMOVAL LINE ASSEMBLY REMOVAL
<<A>> 1. HOSE ASSEMBLY CONNECTION <<A>> 2. HOSE ASSEMBLY CONNECTION
<RADIATOR SIDE> <TRANSMISSION SIDE>
• AIR CLEANER ASSEMBLY 3. HOSE ASSEMBLY
(REFER TO GROUP 15 P.15-4).

.
<<A>> HOSE ASSEMBLY <RADIATOR

SIDE>/HOSE ASSEMBLY <TRANSMISSION SIDE>
REMOVAL
Drain the transmission fluid, which still remained in the hose
assembly and the transmission fluid cooler.
SPECIFICATIONS
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)
M1231000300359
ITEM STANDARD VALUE

Transmission fluid temperature sensor kΩ at 0°C (32°F) 16.7 − 20.5
at 20°C (68°F) 7.3 − 8.9
at 40°C (104°F) 3.4 − 4.2
at 60°C (140°F) 1.9 − 2.2
at 80°C (176°F) 1.0 − 1.2
at 100°C (212°F) 0.57 − 0.69
SPECIFICATIONS
ITEM STANDARD VALUE

Line pressure kPa 980 − 1050
Resistance of damper control clutch solenoid valve coil [at 20°C (68°F)] Ω 2.7 − 3.4
Resistance of low-reverse solenoid valve coil [at 20°C (68°F)] Ω 2.7 − 3.4
Resistance of overdrive solenoid valve coil [at 20°C (68°F)] Ω 2.7 − 3.4
Resistance of second solenoid valve coil [at 20°C (68°F)] Ω 2.7 − 3.4
Resistance of underdrive solenoid valve coil [at 20°C (68°F)] Ω 2.7 − 3.4
Resistance of reduction (RED) solenoid valve coil [at 20°C (68°F)] Ω 2.7 − 3.4
Stall speed r/min 2,100 − 2,600 r/min
LUBRICANT
M1231000400419
ITEM SPECIFIED LUBRICANT QUANTITY

Transmission fluid (litres) F5A5A MITSUBISHI ELC4 SP III 8.4
HOME
23B-1
GROUP 23B
AUTOMATIC
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . . 23B-3 . . . . . . . . . . . . . . . . 23B-48

REVERSE AND OVERDRIVE CLUTCH
GENERAL SPECIFICATIONS . . . . . . 23B-5 DISASSEMBLY AND REASSEMBLY . . . . . 23B-48
SERVICE SPECIFICATIONS. . . . . . . 23B-5 DIRECT CLUTCH . . . . . . . . . . . . . . . . 23B-51

DIRECT CLUTCH DISASSEMBLY AND
SNAP RING, SPACER, THRUST WASHER, REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-51
THRUST RACE AND PRESSURE PLATE FOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . 23B-5 PLANETARY CARRIER ASSEMBLY 23B-53
PLANETARY CARRIER ASSEMBLY DISASSEMBLY
TORQUE SPECIFICATIONS . . . . . . . 23B-8 AND REASSEMBLY . . . . . . . . . . . . . . . . . . 23B-53
SEALANTS . . . . . . . . . . . . . . . . . . . . 23B-8 LOW-REVERSE BRAKE . . . . . . . . . . 23B-55

LOW-REVERSE BRAKE DISASSEMBLY AND
SPECIAL TOOLS. . . . . . . . . . . . . . . . 23B-9 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-55
TRANSMISSION . . . . . . . . . . . . . . . . 23B-13 SECOND BRAKE . . . . . . . . . . . . . . . . 23B-56

SECOND BRAKE DISASSEMBLY AND
TRANSMISSION DISASSEMBLY AND REASSEMBLY
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-56
. . . . . . . . . . . . . . . . . . . 23B-13
ADJUSTMENT OF TRANSMISSION . . . . . 23B-41
DIRECT PLANETARY CARRIER. . . . 23B-57
OIL PUMP . . . . . . . . . . . . . . . . . . . . . 23B-45 DIRECT PLANETARY CARRIER DISASSEMBLY AND
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 23B-57
OIL PUMP DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . 23B-45
DIFFERENTIAL. . . . . . . . . . . . . . . . . . 23B-60
UNDERDRIVE CLUTCH AND INPUT SHAFT DIFFERENTIAL DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . 23B-60
. . . . . . . . . . . . . . . . . 23B-46
UNDERDRIVE CLUTCH AND INPUT SHAFT VALVE BODY . . . . . . . . . . . . . . . . . . . 23B-62
DISASSEMBLY AND REASSEMBLY. . . . . 23B-46
VALVE BODY DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . 23B-62
23B-2
REDUCTION BRAKE PISTON . . . . . 23B-65 DRIVE SHAFT OIL SEAL . . . . . . . . . . 23B-66

REDUCTION BRAKE PISTON DISASSEMBLY AND DRIVE SHAFT OIL SEAL DISASSEMBLY AND
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 23B-65 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-66
AUTOMATIC TRANSMISSION OVERHAUL 23B-3
GENERAL INFORMATION
GENERAL INFORMATION
M1233000100715

F5A5A-4-C2Z 6G75-S4-MPI DL1A
SECTIONAL VIEW
AK403256
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
1. Reverse clutch 21. Cooler

2. Low -reverse brake 22. Low-reverse pressure control valve
3. Second brake 23. Second pressure control valve
4. Underdrive clutch 24. Under drive pressure control valve
5. Overdrive clutch 25. Overdrive pressure control valve
6. Reduction clutch 26. Reduction pressure control valve
7. Direct clutch 27. Dumper clutch control solenoid valve
8. Low -reverse accumulator 28. Low-pressure solenoid valve
9. Second accumulation 29. Second solenoid valve
10. Underdrive accumulator 30. Under drive solenoid valve
11. Overdrive accumulator 31. Overdrive solenoid valve
12. Reduction accumulation 32. Reduction solenoid valve
13. Direct clutch 33. Torque converter pressure control valve
14. Check ball 34. Regulator valve
15. Dumper clutch 35. manual valve
16. Fail-safe valve A 36. Oil filter
17. Fail-safe valve B 37. Oil pan
18. Fail-safe valve C 38. Oil pump
19. Dumper clutch control valve 39. Relief valve
20. Switching valve 40. Oil strainer
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
M1233000300504
Item Standard value

Brake reaction plate end play mm 0 − 0.16
Second brake end play mm 1.09 − 1.55
Low-reverse brake end play mm 1.65 − 2.11
Underdrive sun gear end play mm 0.25 − 0.45
Input shaft end play mm 0.70 − 1.45
Differential case preload mm 0.045 − 0.105
Underdrive clutch end play mm 1.60 − 1.80
Reverse and overdrive clutch return spring retainer end play mm 0 − 0.09
Reverse clutch end play mm 1.6 − 1.8
Overdrive clutch end play mm 1.5 − 1.7
Direct clutch end play 0.6 − 0.8
Backlash between differential side gear and pinion mm 0.025 − 0.150
ADJUSTING PLATE, SNAP RING AND SPACERS

M1233023000526
Thrust washer (For adjustment of input shaft end play)

1.8 18 2.4 24
2.0 20 2.6 26
2.2 22 2.8 28
Snap ring (For adjustment of underdrive clutch and overdrive clutch end play)
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)
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)
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)
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)
1.48 Brown 1.58 Blue
1.53 None 1.63 Brown
Thrust race (For adjustment of underdrive sun gear end play)
1.6 − 2.2 −
1.7 − 2.3 −
1.8 − 2.4 −

1.9 − 2.5 −
2.0 − 2.6 −
2.1 −
Spacer (For adjustment of direct clutch end play)
1.9 Brown 2.5 Brown
2.0 None 2.6 None
2.1 Blue 2.7 Blue
2.2 Brown 2.8 Brown
2.3 None 2.9 None
2.4 Blue 3.0 Blue
Spacer (For adjustment of differential case preload)
0.65 65 1.01 01
0.68 68 1.04 04
0.71 71 1.07 07
0.74 74 1.10 10
0.77 77 1.13 13
0.80 80 1.16 16
0.83 83 1.19 19
0.86 86 1.22 22
0.89 89 1.25 25
0.92 92 1.28 28
0.95 95 1.31 31
0.98 98 1.34 34
Spacer (For adjustment of backlash between differential side gear and pinion)
Thickness mm Identification Thickness mm Identification
symbol symbol
0.56 − 0.64 − 0.86 − 0.94 −
0.66 − 0.74 − 0.96 − 1.04 −
0.76 − 0.84 − 0.97 − 1.15 −

M1233023100697
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

Rear cover MITSUBISHI genuine sealant Part No. MD974421 or equivalent
Torque converter housing MITSUBISHI genuine sealant Part No. MD974421 or equivalent
Valve body cover MITSUBISHI genuine sealant Part No. MD974421 or equivalent
FORM-IN-PLACE GASKET (FIPG) Too thin a bead could cause leaks. Too thick a bead,
This transmission has several areas where the form- on the other hand, could be squeezed out of location,
in-place gasket (FIPG) is used for sealing. To ensure causing blocking or narrowing of fluid passages. To
that the FIPG fully serves its purpose, it is necessary prevent leaks or blocking of passages, therefore, it is
to observe some precautions when applying it. Bead absolutely necessary to apply the FIPG evenly with-
size, continuity and location are of paramount impor- out a break, while observing the correct bead size.
tance. FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.
SPECIAL TOOL(S)
Disassembly FIPG Application

Parts sealed with a FIPG can be easily removed Applied FIPG bead should be of the specified size
without need for the use of a special method. In and free of any break. FIPG can be wiped away
some cases, however, the FIPG in joints may have to unless it has completely hardened. Install the mating
be broken by tapping parts with a mallet or similar parts in position while the FIPG is still wet (in less
tool. than 10 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during installa-
Surface Preparation tion. Avoid operating the transmission or letting oils
Thoroughly remove all substances deposited on the or water come in contact with the sealed area before
FIPG application surface, using a gasket scraper. a time sufficient for FIPG to harden (approximately
Make sure that the FIPG application surface is flat one hour) has passed.
and smooth. Also make sure that the surface is free FIPG application method may vary from location to
from oils, greases and foreign substances. Do not fail location. Follow the instruction for each particular
to remove old FIPG that may remain in the fastener case described later in this manual.
fitting holes.
SPECIAL TOOL(S)
M1233000600572

MD998333 Oil pump remover Removal of oil pump
MD999577 Spring compressor Removal and installation

of one-way clutch inner
race snap ring
MD998924 Spring compressor Use with spring

retainer compressor
MB991633 Reduction brake set Adjustment of reduction

brake piston
MD998412 Guide Installation of transfer

drive gear and oil pump
SPECIAL TOOL(S)

MB991445 Bushing remover and Installation of differential
installer base taper roller bearing outer
race
MB991632 Clearance dummy Measurement of reaction

plate plate low-reverse brake
and second brake end
play
MD998913 Dial gauge extension Measurement of low-

reverse brake end play
MB990938 Handle • Installation of input

shaft rear bearing
• Use with installer
adapter
MB990936 Installer adapter Installation of differential

race
MD998334 Oil seal installer Installation of oil pump oil

seal

of underdrive clutch snap
ring
MB991630 Spring compressor Measurement of

underdrive clutch and
overdrive clutch end play
SPECIAL TOOL(S)

MB991629 Spring compressor Measurement of
underdrive clutch and
overdrive clutch end play

of overdrive clutch snap
ring
MD998824 Installer adapter (50) Installation of direct clutch

snap ring and transfer
driven gear
MB991789 Spring compressor Measurement of reverse

clutch end play
MD998917 Bearing remover Removal of transfer driven

gear, output gear and
parking gear
MD998801 Bearing remover Removal of each bearing
MD998812 Installer cap Use with installer and

installer adapter
MD998813 Installer 100 Use with installer cap and

installer adapter
SPECIAL TOOL(S)

MD998820 Installer adapter (42) Installation of differential
MD998800 Oil seal installer Installation of drive shaft

oil seal
MD998834 Special spanner Removal and installation

of direct planetary carrier
lock nut
TRANSMISSION
TRANSMISSION
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
1. Torque converter 7. Input shaft speed sensor

2. Roll stopper bracket 8. Output shaft speed sensor
3. Control cable support bracket 9. Manual control lever
4. Oil level gauge 10. Inhibitor switch
5. Eye bolt 11. Sealing cap <Type with sealing cap>
6. Oil cooler feed tube 12. Air breather
TRANSMISSION
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
13. Valve body cover 23. Accumulator spring

14. Manual control shaft detent 24. Accumulator spring
15. Valve body 25. Snap ring
16. Steel ball 26. Accumulator cover
17. Gasket 27. Accumulator spring
18. Snap ring 28. Accumulator piston
19. Solenoid valve harness 29. Manual control lever shaft roller
20. Strainer 30. Manual control lever shaft
21. Solenoid brake retainer oil seal 31. Parking pawl rod
22. Accumulator piston
TRANSMISSION
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
48 ± 6 N·m
AK502957AB
32. Torque converter housing 46. Snap ring

33. Spacer 47. Reduction brake piston
34. Outer race 48. Reduction brake spring
35. Differential 49. Parking pawl shaft
36. Oil filter 50. Parking pawl spring
37. Oil pump 51. Parking roller support shaft
38. Gasket 52. Parking pawl
39. Pipe 53. Parking roller support
40. Thrust washer # 1 54. Direct planetary carrier assembly
41. Underdrive clutch and input shaft 55. Anchor plug
42. Thrust bearing #2 56. Direct clutch
43. Underdrive clutch hub 57. Reduction brake band
44. Snap ring 58. Thrust bearing #11
45. Reduction brake piston cover 59. Thrust race #12
TRANSMISSION
23 ± 3 N·m
Apply automatic
to all moving parts 62
61
64
65
63
66
68
70 67
69
71
72
73
74
AK403289AC
60. Rear cover 68. Thrust bearing #6

61. Thrust race #8 69. Overdrive clutch hub
62. Seal ring 70. Thrust bearing #5
63. Input shaft rear bearing 71. Planetary reverse sun gear
64. Accumulator piston 72. Snap ring
65. Accumulator spring 73. Second brake piston
66. Thrust bearing #7 74. Return spring
67. Reverse and overdrive clutch
TRANSMISSION
87
Apply automatic 85
transmission fluid
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
75. Pressure plate 87. One-way clutch inner race

76. Second brake disc 88. O-ring
77. Second brake plate 89. Spring retainer
78. Planetary carrier assembly 90. Return spring
79. Snap ring 91. Low-reverse brake piston
80. Reaction plate 92. Transfer drive gear
81. Snap ring 93. Snap ring
82. Low-reverse brake disc 94. One-way clutch
83. Low-reverse brake plate 95. Seal ring
84. Pressure plate 96. Needle bearing
85. Wave spring 97. Outer race
86. Snap ring 98. Transmission case
TRANSMISSION
DISASSEMBLY 6. Remove the input shaft speed sensor and output

shaft speed sensor.
CAUTION
• The automatic transmission includes many
high-precision parts. Handle these parts Manual control lever
extremely carefully not to scratch or damage Inhibitor switch
them during disassembly and reassembly.
• Work bench should be covered with a rubber
mat and keep it clean at all times.
• Do not wear any cloth gloves and do not use
any rags during disassembly. Use only nylon
cloth or paper towels if necessary.
• All removed parts must be washed clean.
AK202096 AB
Metal parts may be washed in an ordinary sol-
vent, but they should be dried completely CAUTION
using compressed air. The manual control lever tightening nut must be
• Clutch discs, plastic thrust plates and rubber removed before removing the valve body. If the
parts should be washed in automatic trans- valve body is removed before the nut, the inhibi-
mission fluid (ATF) and keep them free of dirt tor switch will be damaged.
after washing. 7. Loosen the manual control lever tightening nut,
• If the transmission has been found damaged and then remove the manual control lever and the
and repaired, also disassemble and clean the inhibitor switch.
ATF cooler system.
1. Remove the torque converter.
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
Input shaft 9. Remove the air breather by inserting a

speed sensor screwdriver into the air breather and prying it up.
AK202095AB
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).
AK501914 Steel ball
10.Remove the valve body cover.
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
AK403611AB 16.Remove the strainer and the second brake

retainer oil seal.
TRANSMISSION
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
22.Remove the O-rings (two pieces).

23.Remove the differential bearing outer race and
spacer from the converter housing.
AK202102
18.Remove the reduction brake accumulator cover

after removing the snap ring, then remove the
spring and piston.
Parking pawl rod

Manual control
lever shaft roller
AK301866
24.Remove the differential.

Manual control
lever shaft
AK300230 AC
19.Remove the manual control lever shaft roller.

20.Remove the manual control lever shaft and the
parking pawl rod.
AK300234
TRANSMISSION
25.Remove the oil filter.
Pipe
AK300237
AK202215 AB
31.Remove thrust washer #1.
26.Remove the pipe clamp bolts (two places).
AK300238
32.Holding the input shaft, remove the underdrive

AK300235
clutch and input shaft.
27.Remove the oil pump mounting bolts (six pieces).
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
34.Remove the underdrive clutch hub.

TRANSMISSION
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
40.Remove the anchor plug and O-ring.
AK300241
37.Remove the parking pawl shaft, and then remove

the spacer and spring.
AK202116
41.Remove the direct clutch.
AK300242
38.Remove the parking roller support shafts (two

pieces), and then remove the parking pawl and
parking roller support.
AK202117
42.Remove the reduction brake band.

TRANSMISSION
Thrust bearing #11

Thrust race #12
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
44.Remove the rear cover. AK300466

45.Remove the thrust race #8.
51.Remove overdrive clutch hub and thrust bearing
46.Remove the seal rings (four pieces).
#6.
47.Remove the input shaft rear bearing.
AK202120
AK300467
48.Remove the O-rings (six pieces). 52.Remove thrust bearing #5.
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.
TRANSMISSION
57.Remove the planetary carrier assembly.
AK300469
AK300473
54.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
AK300472 61.Remove the brake plates (five pieces), brake

discs (six pieces) and pressure plate.
TRANSMISSION
NOTE: *Includes the brake discs removed in step

57.
AK300479
Bolt (Four)
AK300477
62.Remove the wave spring.

Bolt
(Four)
MD999577
MD998924
AK303642 AE
64.Remove the transfer drive gear bearing mounting

bolts (four pieces).
Then, turn the gear 1/8 turn and remove the
remaining bolts (four pieces).
AK202194 AC
63.Remove the one-way clutch inner race and low-

reverse brake piston as follows:
(1) Using special tools to compress the one-way
clutch inner race.
• Spring compressor (MD999577)
• Spring compressor retainer (MD998924)
(2) Remove the snap ring.
(3) Remove the special tools.
(4) Remove the one-way clutch inner race, O-ring,
AK300480
spring retainer, return spring and low-reverse
brake piston. 65.Remove the transfer drive gear.
AK202139

TRANSMISSION
1. Install special tool Guide (MD998412) in the

installation screw hole of the transfer drive gear
bearing located in the transmission case. Using
this as a guide, install the transfer drive gear
bearing and gear in the transmission case.
AK202140
67.Remove the one-way clutch.

68.Remove the seal rings (two pieces).
69.Remove the needle bearing.
70.Remove the differential bearing outer race from
the transmission case. AK300489
2. Tighten the mounting bolts (eight pieces) of the

REASSEMBLY transfer drive gear bearing to the specified torque
CAUTION of 34 ± 2 N⋅m.
• Never reuse any gasket, O-ring, and oil seal.
Always replace them with new ones.
• Never use any product other than blue petro- Low-reverse brake piston
latum jelly or white Vaseline to lubricate or Return spring
hold parts during assembly.
Spring retainer
• Apply ATF to friction elements, rotating parts,
and sliding parts before installation.Soak new
clutch discs or brake discs in ATF for at least
two hours before installing them.
• Never apply sealant or adhesive to gaskets.
• When a bushing requires replacement, AK301620AC
replace the assembly of which the bushing

3. Install the low-reverse brake piston, return spring,
forms a part.
and spring retainer into the transmission case.
• Never use any cloth gloves or any rags during
reassembly. Use only nylon cloth or paper
towels if necessary.
• Change also the ATF in the cooler circuit. One-way clutch inner race
MD998412
O-ring
AK301748AC
4. Fit a new O-ring into the groove of one-way clutch

AK301090AE inner race.
TRANSMISSION
Identification
notches
AK300491
Transmission case
A 8. Install the wave spring onto the low-reverse brake
piston.
Reaction plate Snap ring
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
6. Put the snap ring on the inner race.

Second brake piston
7. Set special tools as shown, and then compress
the one-way clutch inner race and install the snap MB991632 Snap ring
ring.
• Spring compressor (MD999577)
Return spring
AK303646 AD
13.Install the brake discs (four pieces) and brake

plates (three pieces) as shown in the figure.
TRANSMISSION
NOTE: Do not install the pressure plate at this

time.
14.Place special tool Clearance dummy plate MD998913
(MB991632) on top of the brake disc in place of
the pressure plate.
15.Install the return spring, second brake piston and MB991632
snap ring.
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
18.Turn the transmission over so that the installation

surface of the torque converter housing is facing
up.
Movement Install special tool Dial gauge extension
amount
(MD998913) in a dial gauge, and then move
special tool Clearance dummy plate (MB991632)
AK303647AD
and measure its movement.
Standard value of end play (Reference):
16.Move special tool Clearance dummy plate 1.65 − 2.11 mm
(MB991632) and measure its movement.
19.Select a pressure plate whose thickness
Standard value of end play (Reference): corresponds to the measured amount of
1.09 − 1.55 mm movement from the table below.
17.Select a pressure plate whose thickness Available pressure plates
corresponds to the measured amount of
Amount of Thickness mm Identificati
movement from the following table.
movement mm on symbol
Available pressure plates 1.0 − 1.2 1.6 F
Amount of Thickness mm Identification
movement mm symbol 1.2 − 1.4 1.8 E
1.1 − 1.3 1.8 E 1.4 − 1.6 2.0 D
1.3 − 1.5 2.0 D 1.6 − 1.8 2.2 C
1.5 − 1.7 2.2 C 1.8 − 2.0 2.4 B

2.0 − 2.2 2.6 A
1.7 − 1.9 2.4 B
1.9 − 2.1 2.6 A 2.2 − 2.4 2.8 0
2.1 − 2.3 2.8 0 2.4 − 2.6 3.0 1

TRANSMISSION
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
21.Install the needle bearing as shown in the

illustration.
22.Install the two seal rings.
AK300499
26.Install the planetary reverse sun gear.
Identification
mark
AK202144AB
23.Install the snap ring into the groove of

transmission case output shaft bore. AK300500
27.Install the wave spring on the low-reverse brake

piston.
AK202139
24.Install the snap ring.

AK301754
28.Install the pressure plate that was selected in step

19. Next, install brake discs (six pieces) and brake
plates (five pieces), one on top of the other.
TRANSMISSION
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
30.Install the reaction plate. AK300506
33.Install the return spring and second brake piston.
AK300504
31.Install the snap ring that was selected in step 12. AK300507
34.Install the snap ring.

TRANSMISSION
IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS
#8 #7 #6 #5 #4 #3 #2 #1
#12 #11 #10 #9
AK403273 AD
TRANSMISSION
Symbol O.D. mm I.D. mm Thickness Symbol O.D. mm I.D. mm Thickness

mm mm
#1 59 47 1.8 #8 48.9 37 1.8
59 47 2.0 48.9 37 1.9
59 47 2.2 48.9 37 2.0
59 47 2.4 48.9 37 2.1
59 47 2.6 48.9 37 2.2
59 47 2.8 48.9 37 2.3
#2 49 34 3.6 48.9 37 2.4
#3 57 38.5 4.1 48.9 37 2.5
#4 55.4 38.5 3.3 48.9 37 2.6
#5 57 38.5 4.1 #9 80 60 2.5
#6 57 38.5 4.1 # 10 80 60 2.5
#7 59 37 2.8 # 11 55.4 38.5 3.3
#8 48.9 37 1.6 # 12 54.6 43 3.0
48.9 37 1.7
CAUTION
Use care to install the thrust bearing in the
proper direction.
36.Attach thrust bearing #6 to the inside of the
Install with
this side down overdrive clutch hub using petroleum jelly
(Vaseline). Then install the assembly in the
reverse and overdrive clutch.
AK301100AB
CAUTION Install with

this side down
Be sure to install the thrust bearing in the correct
direction as shown.
35.Check the installation direction of the thrust
bearing #5, and install it on the hub of the
planetary reverse sun gear. AK301224AB
37.Install the reverse and overdrive clutch.

CAUTION
Be sure to install the thrust bearing in the correct
Thrust bearing #6 direction as shown.
38.Check the installation direction of thrust bearing
#7, and install it on the reverse clutch retainer.
AK403613AC
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
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
50.Install the direct planetary carrier assembly.

AK202163
47.Finger-tighten the anchor plug and a new O-ring,

then install the reduction brake band and direct
clutch simultaneously.
AK202164
TRANSMISSION
51.Install the reduction brake spring and piston in

position in the transmission case, then install the
snap ring.
MB991633 (Stopper)
AK202112
53.Install the reduction brake piston cover and snap

ring.
AK202165AB
52.Adjust the reduction brake piston using the

following procedure:
(1) Remove the nut from the reduction brake
piston.
(2) Install the stopper of the special tool
Reduction brake set (MB991633) to hold the
reduction brake piston against rotation.
AK300513
MB991633 (Socket)
54.Install the parking pawl, spacer, and spring. Then
insert the parking pawl shaft.
AK202166AB
(3) Using a torque wrench fitted with the socket of

the special tool Reduction brake set
(MB991633), tighten the adjusting rod to 10
N⋅m, then loosen it. Repeat this operation
twice. Tighten the adjusting rod to 5 N⋅m, then AK300514
turn it back 5-1/2 to 5-3/4 turns.
55.Install the parking roller support, and then insert
the parking roller support shafts (two pieces).
MB991633
(Socket)
MB991633
(Wrench)
AK202167AB
(4) Install the nut on the adjusting rod and tighten

the nut to 19 ± 3 N⋅m using the wrench of the
AK300240
special tool.
56.Install the underdrive clutch hub to the underdrive
sun gear.
TRANSMISSION
60.Install thrust washer #1 that was selected in step

59 on the underdrive clutch retainer.
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
58.Hold the input shaft, and install the underdrive AK300517

clutch.
63.Measure the end play of the input shaft. Make
sure that the end play of the input shaft is within
59.Adjustment of input shaft end play and select the
the standard value range with the thrust washer
thrust washer #1. (Refer to adjustment of
#1 in place.
transmission - thrust washer selection for
adjustment of input shaft end play P.23B-41) Standard value: 0.70 − 1.45 mm
AK300234
AK300237
64.Install the oil filter.
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
71.Install the converter housing and tighten the

mounting bolts to the specified torque of 48 ± 6
N⋅m.
AK202226 AC 72.Insert the O-rings (two pieces) into the grooves of
the manual control lever shaft.
68.Use special tools Bushing remover and installer
base (MB991445) to press the differential bearing 73.Install the manual control lever shaft and parking
outer race into the torque converter housing. pawl rod.
TRANSMISSION
77.Identify the accumulator spring and insert it and

the accumulator piston into each hole of the
Hole "A"
transmission case.
NOTE: Accumulator springs are identified as
No. Name Identification
"BLUEING"
1 For low-reverse None
AK300520 AC
brake
2 For underdrive Half
74.Align hole "A" with the groove in the manual clutch
control lever shaft. Insert the manual control lever
shaft roller into hole "A." 3 For second brake Whole surface
75.Insert the new seal rings in the grooves of the 4 For overdrive None
accumulator pistons. clutch
NOTE: The piston and seal ring are common
parts.
Second brake
retainer oil seal
Strainer
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
TRANSMISSION
No. Solenoid Cable Connector

Steel ball
valve colour housing colour
1 Underdrive White, red, Black
solenoid valve red
2 Overdrive Orange, Black
solenoid valve red
3 Low-reverse Brown, Milky white
solenoid valve yellow
AK403612AD 4 Second Blue, red, Milky white
solenoid valve red
81.Install the steel balls into each of the two holes in
the top face of the valve body (outside valve 5 Damper Blue, Black
body). clutch control yellow,
82.Install the valve body and gasket to the solenoid valve yellow
transmission case. 6 Reduction Green, Black
Make sure that the manual valve's pin is in the solenoid valve yellow,
groove in the detent plate of the manual control yellow
lever.
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
AK403610 AE 87.Apply an approx. 2 mm diameter bead of from-in-

place gasket (FIGP) to the valve body cover in the
84.Attach the solenoid valve harness to the valve area shown.
body by connecting all the connectors.
Specified sealant: Mitsubishi genuine seal-
85.Install the fluid temperature sensor to the ant Part No. MD974421 or equivalent
TRANSMISSION
Manual control lever

Inhibitor switch
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
94.Apply ATF on the both sides of the new gasket

and threads of the eyebolts, and then tighten to
the specified torque of 24 ± 3 N⋅m.
95.Tighten the oil cooler feed pipe clamp bolt to the
96.Install the oil dipstick.
97.Install the control cable support brackets to the
AK300220
90.Install the sealing cap and tighten the bolt to the 98.Install the harness bracket to the specified torque
specified torque of 5.0 ± 1.0 N⋅m. <Type with of 11 ± 1 N⋅m.
sealing cap> 99.Install the roll stopper brackets to the specified
torque of 70 ± 10 N⋅m.
TRANSMISSION
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
THRUST WASHER SELECTION FOR

ADJUSTMENT OF INPUT SHAFT END
PLAY
<Measurement using Solder>
CAUTION AK300236AC
• If the solder is not available, select the thrust

5. Using special tools Oil pump remover
washer in accordance with Plastigage
(MD998333) remove the oil pump and then take
method.
out the crushed solders.
• If the thrust washer appropriate for the stand-
ard value cannot be selected using the solder, 6. If the solders have not crushed, use thicker thrust
select the thrust washer in accordance with washer and repeat steps 3 to 5.
Plastigage method.
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
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
3.25 − 3.45 2.8 28

5. Using special tools Oil pump remover
(MD998333) to remove the oil pump and then
<Measurement using Plastigage> take out the crushed plastigages.
Input shaft 6. If the plastigages have not crushed, use thicker
Two beads
adjusting thrust washer and repeat steps 3 to 5.
of plastigage
Underdrive
clutch retainer AK301756AE Plastigage
1. Put the plastigage (about 10 mm long) in the Thrust washer AK402081AG

illustrated positions of the underdrive clutch
retainer. 7. Measure the width of the crushed plastigage at its
2. Install the adjusting thrust washer having the widest part using a scale printed on the plastigage
minimum thickness. package.
8. Select the thrust washer, calculated by the
MD998412 following formula, in the table.
T = T3 + T2
T: Clearance mm
T3: The crushed plastigage thickness mm
T2: The thrust washer thickness used for
measurement mm
Available thrust washer
Clearance mm Thickness mm Identification
AK301247AB
(T) mark
2.25 − 2.45 1.8 18
CAUTION
Never use a gasket that has been tightened. 2.45 − 2.65 2.0 20
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
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
6. Measure the thickness of the crushed solder with

a micrometer, and then select a spacer that will
provide the standard value.
AK301758AD
Spacer thickness: (T1 − 0.045 mm) to (T1 −
1. Put the solders (1.0 mm diameter, about 10 mm 0.105 mm)
long) in the illustrated positions of the converter T1: The crushed solder thickness mm
housing.
MB991445
<Measurement using Plastigage>
Plastigage
AK202226 AB
2. Use the special tools Bush remover and installer

(MB991445) to press the differential bearing outer AK400083AC
race into the torque converter housing.
1. Put the plastigage (about 10 mm long) in the
illustrated positions of the converter housing.
2. Install the adjusting spacer having the minimum
thickness.
AK202103
TRANSMISSION
4. Install the converter housing on the transmission

MB991445 case without applying FIPG. Tighten the mounting
bolts to the specified torque of 48 ± 6 N⋅m.
5. Remove the bolts and converter housing, and
take out the crushed plastigage.
6. If the plastigages have not crushed, replace the
spacer with a thicker one and repeat steps 3 to 5.
AK202226 AB
3. Use the special tools Bush remover and installer

(MB991445) to press the differential bearing outer
race into the torque converter housing.
Plastigage
Spacer AK402081 AB
7. Measure the width of the crushed plastigage at its

widest part using a scale printed on the plastigage
package, and then select a spacer that will
provide the standard value.
Spacer thickness: (T3 − 0.045 mm) to (T3 −
AK202103
0.105 mm)
T3: The crushed plastigage thickness mm

OIL PUMP
OIL PUMP
M1233001300325
Apply automatic
transmission fluid
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.
MD998334
AK300522AD
UNDERDRIVE CLUTCH AND INPUT SHAFT

M1233020900199
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
to all moving parts
AK301600AC
Disassembly steps DISASSEMBLY SERVICE POINT

1. Snap ring <<A>> SNAP RING REMOVAL
2. Input shaft
3. Seal ring
MD998924
>>D<< 4. Snap ring
>>C<< 5. Clutch reaction plate
>>C<< 6. Clutch disc MD998907
>>C<< 7. Clutch plate
<<A>> >>B<< 8. Snap ring
9. Spring retainer
>>A<< 10. D-ring
11. Return spring
12. Underdrive clutch piston
AK300523AC
>>A<< 13. D-ring
>>A<< 14. D-ring 1. Use the special tools to install the snap ring.
15. Underdrive clutch retainer • Spring compressor (MD998907)
2. Compress the return spring and remove the snap
ring.
REASSEMBLY SERVICE POINTS CAUTION

>>A<< D-RING INSTALLATION Immerse the clutch disc in ATF before assem-
1. Install a D-ring in the groove in the underdrive bling it. If the clutch disc is new, soak it in ATF for
clutch retainer and piston, and in the groove in the at least two hours.
outside of the spring retainer. Be careful not to 1. Assemble the four clutch plates and four clutch
twist or damage the D-rings. discs one on top of the other inside the underdrive
2. Apply ATF or petroleum jelly (Vaseline) to the D- clutch retainer. All four clutch plates should be
rings. assembled so that the places with no teeth
(marked "A") are aligned with the holes in the
>>B<< SNAP RING INSTALLATION retainer (marked "B").
Clutch plates
MD998924 Rounded edge
Clutch
reaction
MD998907 plate
Piston
side
Clutch discs AK301764 AC

AK300523AC
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
>>C<< CLUTCH PLATE/CLUTCH DISC/CLUTCH MD998924

REACTION PLATE INSTALLATION
A B
MB991629
AK202311 AB
1. Install the snap ring into the groove of clutch

retainer.
AK301272AB
2. Set special tools as shown in the illustration, and
then compress the clutch element.
• Spring compressor (MB991629)
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
clearance.

M1233021200256
Number of clutch discs and plates
Pressure plate Clutch disc Clutch plate Clutch reaction
plate
Over drive clutch 1 4 3 1
Reverse clutch − 2 2 1
Apply automatic
transmission fluid
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

>>G<< 1. Snap ring 11. Spring retainer
>>F<< 2. Clutch reaction plate >>A<< 12. D-ring
>>F<< 3. Clutch disc 13. Return spring
>>F<< 4. Clutch plate 14. Overdrive clutch piston
>>E<< 5. Snap ring >>A<< 15. D-ring
>>D<< 6. Clutch reaction plate >>B<< 16. Reverse clutch piston
>>D<< 7. Clutch disc >>A<< 17. D-ring
>>D<< 8. Clutch plate >>A<< 18. D-ring
>>D<< 9. Pressure plate >>A<< 19. D-ring
<<A>> >>C<< 10. Snap ring 20. Reverse clutch retainer
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
1. Set special tools as shown in the illustration.

• Spring compressor (MD999590) AK300525AD
2. Compress the return spring and remove the snap 1. Set special tools as shown in the illustration.
ring. • Spring compressor (MD999590)
REASSEMBLY SERVICE POINTS 2. Tighten the nut on the special tool to press down
>>A<< D-RING INSTALLATION on the spring retainer and reverse clutch retainer,
and then install the snap ring.
Reverse clutch retainer
Reverse clutch piston
Overdrive clutch piston
Spring retainer
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
>>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)
Shear droop
Clutch value. If not within the standard value, select a
Clutch reaction
plates plate snap ring to achieve the standard value
clearance.
Pressure
plate >>F<< CLUTCH PLATE/CLUTCH DISC/CLUTCH
Clutch discs AK303676AD
REACTION PLATE INSTALLATION
A B
A B
AK301272AB
AK301272AB
1. Install the pressure plate in the direction shown

CAUTION
CAUTION Immerse the clutch disc in ATF before assem-
Immerse the clutch disc in ATF before assembling it. If the clutch disc is new, soak it in ATF for
bling it. If the clutch disc is new, soak it in ATF for at least two hours.
more than two hours. 1. Assemble two clutch discs and two clutch plates,
2. Assemble the clutch discs and clutch plates, one one on top of the other, inside the reverse clutch
on top of the other, inside the reverse clutch retainer. Assemble both clutch plates so that the
piston. Assemble both clutch plates so that the places with no teeth (marked "A") are aligned with
places with no teeth (marked "A") are aligned with the holes in the retainer (marked "B").
the holes in the retainer (marked "B").
3. Install the clutch reaction plate in the direction Clutch plates
Shear droop
shown.
>>E<< SNAP RING INSTALLATION
MD998924
Clutch reaction plate

Clutch discs
AK301320 AB
2. Install the clutch reaction plate in the direction

MB991629 shown. Install it the same as the clutch plate, so
that the places with no teeth (marked "A") are
AK202313 AB
aligned with the holes in the retainer (marked "B").
1. Install the snap ring into the groove in the reverse

clutch piston.
DIRECT CLUTCH
>>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.
value. If not within the standard value, select a
snap ring to achieve the standard value
AK300528AE clearance.
DIRECT CLUTCH
M1233019400071
Apply automatic 6
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

>>D<< 1. Snap ring >>C<< 3. Clutch disc
>>C<< 2. Clutch reaction plate >>C<< 4. Clutch plate
DIRECT CLUTCH
Disassembly steps ( つづき ) • Spring compressor (MB991630)

>>C<< 5. Cushion plate • Spring compressor retainer (MB998924)
>>C<< 6. Intermmediate plate 2. Using special tool to press down on the spring
<<A>> >>B<< 7. Snap ring
retainer, and then install the snap ring.
8. Spring retainer
>>A<< 9. D-ring
10. Return spring >>C<< INTERMEDIATE PLATE/CUSHION PLATE/
11. Underdrive clutch piston CLUTCH PLATE/CLUTCH DISC/CLUTCH
>>A<< 12. D-ring REACTION PLATE INSTALLATION
>>A<< 13. D-ring
B
14. Direct clutch retainer
A
<<A>> SNAP RING REMOVAL
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
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.
REASSEMBLY SERVICE POINTS Clutch Shear

plate drop
Stepped Clutch
>>A<< D-RING INSTALLATION reaction
side
Apply ATF, blue petrolatum jelly or white Vaseline to plate
the D-rings and handle them carefully not to damage
them during installation.
>>B<< SNAP RING INSTALLATION
MD998924 Clutch disc AK403614 AC

MB991630
2. Orient the clutch reaction plate and intermediate
plate as shown in the illustration when it is
installed.
>>D<< SNAP RING INSTALLATION

Snap ring 1. Install the snap ring.
AK202174 AB 2. Press down the clutch reaction plate with a force
of 49 N on its entire circumference.
1. Set special tools as shown in the illustration.
PLANETARY CARRIER ASSEMBLY
3. Check the clearance between the snap ring and

Snap ring clutch reaction plate. If the clearance is not within
the standard value range, make adjustment by
selecting a snap ring of an appropriate thickness.
Standard value:
0.6 − 0.8 mm
AK202176 AB

M1233002500258
Apply automatic
transmission fluid
to all moving parts
6
8
4 9
3
7 10
1
AK301602 AC

1. Stopper plate >>A<< 5. Thrust bearing #3
>>B<< 2. One-way clutch 6. Underdrive sun gear
3. Snap ring >>A<< 7. Thrust bearing #4
4. Output planetary carrier 8. Snap ring
Disassembly steps ( つづき ) CAUTION

9. Overdrive planetary carrier Use care to install the thrust bearings in the cor-
10. Overdrive annulus gear
rect direction.
Check the installation direction of thrust bearings #3
and 4, and install them as shown.
>>A<< THRUST BEARING #3 AND THRUST
BEARING #4 INSTALLATION >>B<< ONE-WAY CLUTCH INSTALLATION
Thrust bearing #4
One-way clutch
Thrust bearing #3
AK301280AB
AK300529AC
Insert the one-way clutch into the overdrive annulus

gear so that the arrow points towards the output
planetary carrier.
LOW-REVERSE BRAKE
LOW-REVERSE BRAKE
M1233003700307
Apply automatic
transmission fluid
to all moving parts
3
1
AK301603 AC
Disassembly steps REASSEMBLY SERVICE POINT

>>A<< 1. D-ring >>A<< D-RING INSTALLATION
>>A<< 2. D-ring Apply ATF or petroleum jelly (Vaseline) to the D-ring,
3. Low -reverse brake piston
and install carefully.
SECOND BRAKE
SECOND BRAKE
M1233021800173
Apply automatic
transmission fluid
to all moving parts
3 2
4
AK301604 AC
Disassembly steps REASSEMBLY SERVICE POINT

1. Second brake retainer >>A<< D-RING INSTALLATION
>>A<< 2. D-ring Apply ATF or petroleum jelly (Vaseline) to the D-ring,
3. Second brake piston
and install carefully.
>>A<< 4. D-ring
DIRECT PLANETARY CARRIER

M1233026300087
Apply automatic
transmission fluid
to all moving parts
8 10
5
4
2
9
3
1
170 ± 10 N·m
AK403295 AC
Disassembly steps DISASSEMBLY SERVICE POINTS

<<A>> >>D<< 1. Lock nut <<A>> LOCK NUT REMOVAL
2. Roller bearing
3. Thrust bearing #9
4. Thrust bearing #10
<> >>C<< 5. Output gear
<> >>C<< 6. Parking gear
<<C>> >>B<< 7. Taper roller bearing
8. Transfer driven gear and direct
annulus gear
<<D>> >>A<< 9. Taper roller bearing
10. Direct planetary carrier
AK202178
1. Un stake staking of the lock nut.

<<D>> TAPER ROLLER BEARING REMOVAL

MD998834
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.
<> OUTPUT GEAR/PARKING GEAR 2. Using special tool Bearing remover (MD998917)
REMOVAL to remove the taper roller bearing.

MD998917 >>A<< TAPER ROLLER BEARING INSTALLATION
MD998812
MD998813
MD998824
AK202180 AB
Using special tool Bearing remover (MD998917) to

remove the output gear and parking gear.
AK202183 AB
<<C>> TAPER ROLLER BEARING REMOVAL
1. Set the transfer driven gear as shown in the
illustration.
2. Using special tools to press in the taper roller
bearing.
• Installer 100 (MD998813)
>>B<< TAPER ROLLER BEARING INSTALLATION

AK202181
MD998812
1. Support the transfer driven gear as shown in the MD998813
illustration.
2. Push the shaft of the direct planetary carrier to MD998824
remove the taper roller bearing and gear.
AK202184 AC
1. Set the transfer driven gear as shown in the

illustration.
2. Using special tools to press in the taper roller >>D<< LOCK NUT INSTALLATION
bearing.
MD998834
• Installer 100 (MD998813)
>>C<< OUTPUT GEAR/PARKING GEAR

INSTALLATION
MD998812
MD998824 AK202186 AB
1. Apply ATF on a new locknut, and use special tool

Special spanner (MD998834) to tighten the
specified torque. Then turn back on turn, and
tighten to the specified torque of 170 ± 10 N⋅m.
AK202185 AC
1. Using special tools to press in the parking gear.

AK202187
2. Use a punch to stake the lock nut at two places.

DIFFERENTIAL
DIFFERENTIAL
M1233003100402
Apply automatic 2
transmission fluid
to all moving parts
4
6 8
3 5
8
135 ± 5 N·m
7 1
2 5
AK301606AE
Disassembly steps DISASSEMBLY SERVICE POINT

>>D<< 1. Differential drive gear <<A>> TAPER ROLLER BEARING REMOVAL
<<A>> >>C<< 2. Taper bearing
>>B<< 3. Lock pin MD998801
>>A<< 4. Pinion shaft
>>A<< 5. Pinion
>>A<< 6. Washer
>>A<< 7. Side gear
>>A<< 8. Spacer
9. Differential case
AK301767AB
1. Support the taper roller bearing with special tool

Bearing remover (MD998801) and then set them
on the press.
2. Push down on the differential case with the press
to remove the bearing.
DIFFERENTIAL
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.
>>B<<LOCK PIN INSTALLATION
Differential case
Lock pin
Pinion shaft
AK300655
1. Mount a spacer on the back surface of the side

gear, and then install the side gear in the
AK301284AB
differential case.
NOTE: When a new side gear is to be installed, Install the lock pin so that it will be oriented in the
use a medium thickness spacer (0.93 to 1.00 direction shown.
mm).
2. Set the washer on the back of each pinion, and >>C<< TAPER ROLLER BEARING INSTALLATION
put both pinions simultaneously in mesh with the
side gears. While rotating them, install them into MD998812
position. MD998820
AK300658 AC
Using special tools to press in the taper roller bear-

ing.
AK300656 • Installer adapter (MD998820)
3. Insert the pinion shaft.
>>D<< DIFFERENTIAL DRIVE GEAR
INSTALLATION
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
VALVE BODY
VALVE BODY
M1233005500365
6.0 ± 1.0 N·m Apply automatic

transmission fluid
to all moving parts
15 before installation.
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

1. Solenoid valve support >>B<< 12. Steel ball (orifice check ball)
<<A>> >>C<< 2. Underdrive solenoid valve >>B<< 13. Spring
<<A>> >>C<< 3. Second solenoid valve 14. Knock bushing
<<A>> >>C<< 4. Damper clutch control solenoid 15. Plate (separating inside)
valve >>A<< 16. Damping valve
<<A>> >>C<< 5. Overdrive solenoid valve >>A<< 17. Damping valve spring
<<A>> >>C<< 6. Low-reverse solenoid valve >>A<< 18. Steel ball (line relief)
<<A>> >>C<< 7. Reduction solenoid valve >>A<< 19. Spring
8. Manual valve >>A<< 20. Steel ball (orifice check ball)
9. Cover >>A<< 21. Spring
10. Plate (separating outside) 22. Inside valve body assembly
11. Outside valve body assembly
VALVE BODY
Apply automatic
transmission fluid
to all moving parts
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

23. Roller 45. Overdrive pressure control valve
24. Damper clutch control valve sleeve sleeve
25. Damper clutch control valve 46. Overdrive pressure control valve
26. Damper clutch control valve spring 47. Overdrive pressure control valve
27. Plate spring
28. Screw 48. Roller
29. Regulator valve spring 49. Low-reverse pressure control valve
30. Regulator valve sleeve
31. Plate 50. Low-reverse pressure control valve
32. Fail-safe valve A sleeve 51. Low-reverse pressure control valve
33. Fail-safe valve A2 spring
34. Fail-safe valve A spring 52. Roller
35. Fail-safe valve A1 53. Reduction pressure control valve
36. Plate sleeve
37. Plug 54. Reduction pressure control valve
38. Torque converter valve 55. Reduction pressure control valve
39. Torque converter valve spring spring
40. Plate 56. Plate
41. Fail-safe valve B sleeve 57. Plug
42. Fail-safe valve B 58. Switch valve
43. Inside valve body 59. Roller
44. Roller
VALVE BODY
Disassembly steps ( つづき ) >>B<< SPRING AND STEEL BALL

60. Underdrive pressure control valve INSTALLATION
sleeve
61. Underdrive pressure control valve Steel balls
and springs
62. Underdrive pressure control valve
spring
63. Roller
64. Second pressure control valve Steel ball
sleeve
65. Second pressure control valve
66. Second pressure control valve
spring
67. Plate AK202214AB
68. fail-save valve C sleeve
69. fail-save valve C Install the steel balls (three pieces) and springs (two
70. fail-save valve body pieces) to the inside valve body as shown.
DISASSEMBLY SERVICE POINT >>C<< SOLENOID VALVES INSTALLATION

<<A>> SOLENOID VALVES REMOVAL
4
Mark the solenoid valves with white paint to make
assembly easier. 5 1
REASSEMBLY SERVICE POINTS 6 2
>>A<< SPRING, STEEL BALL, DAMPING VALVE

AND DAMPING VALVE SPRING INSTALLATION 3
Steel ball Damping valve

and spring and spring AK202190 AB
1. Apply ATF or petroleum jelly (Vaseline) to the O-

ring and install carefully.
Steel ball 2. Install the solenoid valves by referring to the
and spring marks applied during disassembly.
NO. Name
1 Underdrive solenoid valve
AK202088AB 2 Second solenoid valve
1. Install the steel balls (two pieces) and springs (two 3 Damper clutch control solenoid valve
pieces) to the inside valve body as shown.
4 Overdrive solenoid valve
2. Install the damping valve and spring to the inside
5 Low-reverse solenoid valve
valve body as shown.
6 Reduction solenoid valve
REDUCTION BRAKE PISTON
REDUCTION BRAKE PISTON

M1233026600066
Apply automatic 1
transmission fluid
to all moving parts
AK403296 AC

1. Nut 3. Reduction brake piston
2. Adjusting rod 4. Seal ring
DRIVE SHAFT OIL SEAL

M1233004300283
Apply automatic 4
transmission fluid
AK403292 AC
Disassembly steps REASSEMBLY SERVICE POINTS

>>A<< 1. Oil seal >>A<< OIL SEAL INSTALLATION
2. Converter housing
>>B<< 3. Oil seal
4. Transmission case
MD998800
AK301290AB
Use the special tool to Oil seal installer (MD998800)

install the oil seal.
>>B<< OIL SEAL INSTALLATION Use the special tool Oil seal installer (MD998800) to
install the oil seal.
MD998800
AK300549AC
HOME
26-1
GROUP 26
FRONT AXLE
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 26-2 FRONT AXLE HUB ASSEMBLY . . . . 26-9

FRONT AXLE DIAGNOSIS . . . . . . . . 26-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-12
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 26-3 DRIVE SHAFT ASSEMBLY . . . . . . . . 26-13
SYMPTOM PROCEDURES . . . . . . . . . . . . 26-3 REMOVAL AND INSTALLATION . . . . . . . . 26-13
DISASSEMBLY AND ASSEMBLY . . . . . . . 26-18
SPECIAL TOOLS. . . . . . . . . . . . . . . . 26-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-25
BJ BOOT REPLACEMENT . . . . . . . . . . . . . 26-26
ON-VEHICLE SERVICE. . . . . . . . . . . 26-8
WHEEL BEARING END PLAY CHECK . . . 26-8 SPECIFICATIONS . . . . . . . . . . . . . . . 26-29
HUB BOLT REPLACEMENT . . . . . . . . . . . 26-8 FASTENER TIGHTENING SPECIFICATIONS 26-29
GENERAL SPECIFICATIONS . . . . . . . . . . 26-29
SERVICE SPECIFICATIONS . . . . . . . . . . . 26-29
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 26-30
FRONT AXLE 26-2
GENERAL DESCRIPTION
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
STRUT ASSEMBLY
KNUCKLE
PTJ (LH) <3.8L>
FRONT WHEEL
HUB ASSEMBLY DRIVE SHAFT
(LH)
DYNAMIC
BJ
DAMPER
ABS ROTOR
<L-RH>
OIL BRACKET PTJ (RH)

SEAL ASSEMBLY
DRIVE SHAFT (RH)

HUB WHEEL
BEARING INNER SHAFT
22DB013A
FRONT AXLE DIAGNOSIS

M1261005600240
Use these steps to plan your diagnostic strategy. If front axle fault.
you follow them carefully, you will be sure that you 1. Gather information from the customer.
have exhausted most of the possible ways to find a
FRONT AXLE 26-3
FRONT AXLE DIAGNOSIS
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 INSPECTION REFERENCE PAGE

PROCEDURE
Drive shaft Noise during wheel rotation 1 P.26-3
Noise due to excessive play of wheel in turning 2 P.26-4
direction
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Noise during Wheel Rotation
DIAGNOSIS
STEP 1. Check the wheel bearing end play.

(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.
Q: Is the wheel bearing end play within the limit?
YES : Go to step 2.
NO : Replace the part, then go to Step 5.
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.
STEP 3. Check the center bearing for wear.

Q: Is the center bearing worn?
YES : Replace the bearing. Then go to Step 5.
NO : Go to step 4.
STEP4. Check the drive shaft assembly for wear or

damage.
Q: Is the drive shaft assembly worn or damaged?
YES : Replace the drive shaft assembly. Then go to Step 5.
FRONT AXLE 26-4
SPECIAL TOOLS

Q: Is the abnormal noise eliminated?
NO : Repeat from Step 1.
INSPECTION PROCEDURE 2: Noise Due to Excessive Play of Wheel in Turning Direction
DIAGNOSIS STEP 2. Retest the system.

Q: Is the abnormal noise eliminated?
STEP 1. Check for play in the inner shaft and side YES : The procedure is complete.
gear serration, the drive shaft and side gear NO : Repeat from Step 1.
serration, or the drive shaft and front hub
serration.
Q: Is the play found?
SPECIAL TOOLS
M1261000600405
TOOL TOOL NUMBER SUPERSESSION APPLICATION

AND NAME
MB990767 MB990767-01 Fixing of the hub
Front hub and
flange yoke
holder
B990767
MB991618 General service Removal of the hub bolt

Hub bolt remover tool
MB991618

Ball joint MB990635-01 or disconnection
remover General service NOTE: Steering linkage puller
tool (MB990635 or MB991113)is also used
to disconnect knuckle and tie rod end
AC106827
ball joint.
FRONT AXLE 26-5
SPECIAL TOOLS

AND NAME
A MB990241 Axle MB990241-01 or Removal of the drive shaft
shaft puller General service
B A: MB990242 tool
Puller shaft
B: MB990244
MB990241AB
Puller bar
Puller body tool
MB991354
B MB990590 Rear − Removal of the front wheel hub

axle shaft oil seal
remover
A: MB990212
Adapter
A MB990590
B: MB990211
Slide hammer
A A: MB991017 MB990998-01 • Removal of the hub
B: MB990998 • Provisional holding of the wheel
C: MB991000 bearing
B A, B: Front hub • Measurement of hub starting torque
C remover and • Measurement of wheel bearing end
AC100320 AB
installer play
C: Spacer NOTE: MB991000, which belongs to
MB990998, should be used as a
spacer.
MB990685 General service Measurement of hub starting torque
Torque wrench tool

Preload socket tool
MB990326
MB990810 General service • Removal of the center bearing

Side bearing tool bracket
puller • Removal of the wheel bearing inner
race (outside)
MB990810
FRONT AXLE 26-6
SPECIAL TOOLS

AND NAME
MB991172 − Press-fitting of the inner shaft
Inner shaft
installer base
MB991248 MD998348-01 or Removal of the inner shaft

Inner shaft General service
remover tool
MB991248
MB991561 MB991561 BJ boot (resin boot) band installation

Boot band
crimping tool
MB991561
MB990925 MB990925-01 or • Removal and installation of the

Bearing and oil General service center bearing
seal installer set tool • Press-fitting of the dust seal outer,
inner
MB990925
MB990890 MB990890-01 Press-fitting of the dust seal outer, inner

Rear suspension
bushing base
MB990890
FRONT AXLE 26-7
SPECIAL TOOLS
TOOL TYPE TOOL NUMBER O D mm (in)
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.
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 REPLACEMENT

M1261001000310

• MB990767: Front Hub and Flange Yoke Holder
• MB991618: Hub Bolt Remover
1. Remove the caliper assembly and suspend it with wire so
that it does not fall.
2. Remove the brake disc.
3. Use special tool MB991618 to remove the hub bolts.
MB991618
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.
AC102440AC
FRONT AXLE 26-9
FRONT AXLE HUB ASSEMBLY

M1261001700386
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.
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

1. SPLIT PIN 9. DRIVE SHAFT
<<A>> >>A<< 2. DRIVE SHAFT NUT <<E>> 10. FRONT WHEEL HUB ASSEMBLY
>>A<< 3. WASHER 11. DUST COVER
4. FRONT WHEEL SPEED SENSOR <<D>> 12. SELF LOCKING NUT (CONNECTION
BRACKET <VEHICLES WITH ABS> FOR LOWER ARM BALL JOINT)
5. FRONT WHEEL SPEED SENSOR <<D>> 13. SELF LOCKING NUT (CONNECTION
<VEHICLES WITH ABS> FOR TIE ROD END)
6. BRAKE HOSE BRACKET 14. FRONT STRUT TO KNUCKLE
MOUNTING BOLT AND NUT
<> 7. CALIPER ASSEMBLY
15. KNUCKLE
<<C>> 8. BRAKE DISC
Required Special Tools: • MB991354: Puller Body

• MB990767: Front Hub and Flange Yoke Holder • MB990211: Slide Hammer
• MB990242: Puller Shaft • MB991897:Ball Joint Remover
• MB990244: Puller Bar
FRONT AXLE 26-10

.

CAUTION
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage when drive shaft nut is
loosened.
shaft nut.
MB990767
AC102462 AC
<> CALIPER ASSEMBLY REMOVAL

Secure the removed caliper assembly with wire, etc.
.
<<C>> BRAKE DISC REMOVAL

If the brake disc is seized, install a M8 x 1.25 bolts as shown,
and remove the disc by tightening the bolts evenly and gradu-
ally.
BOLTS
(M8×1.25)
AC205799AB
.
FRONT AXLE 26-11
<<D>> SELF LOCKING NUT (CONNECTION FOR

LOWER ARM BALL JOINT AND TIE ROD END)
REMOVAL
CAUTION
threads.
ing.
1. Replace the self locking nut for lower arm ball joint with a
CORD
regular nut, because the original one is a little bit large to
install the special tool. Install special tool MB991897 as
shown in the figure.
NUT MB991897
BOLT

special tool parallel, tighten the bolt by hand and confirm
BOLT
that the jaws are still parallel.
CORRECT 3. Tighten the bolt with a wrench to disconnect the lower arm
KNOB ball joint, tie rod end and remove the self locking nut.
WRONG AC106821AC
<<E>> FRONT WHEEL HUB ASSEMBLY

REMOVAL
MB990244
(THREE) MB990767 to push out the drive shaft from the hub and
knuckle.
MB990767 2. If the front wheel hub is seized, remove the knuckle together
with front wheel hub and fix them with a vise.
3. Hang the drive shaft on the vehicle body with a rope.
MB991354
MB990242
AC201827AD
FRONT AXLE 26-12
4. Use special tools MB990244, MB991354 and MB990211 to

pull out the front wheel hub from the knuckle.
MB990244
MB990211
MB991354
AC210309AD

.
>>A<<WASHER/ DRIVE SHAFT NUT INSTALLA-

TION
CAUTION
wheel bearings will be damaged.
WASHER
direction.
MB990767
AC210244AB
INSPECTION
M1261001800264
WHEEL BEARING ROTATION STARTING

TORQUE AND AXIAL PLAY CHECK
• MB990998: Front Hub Remover and Installer
• MB991000: Spacer
• MB990326: Preload Socket
• MB990685: Torque Wrench
1. Install special tools MB991000, MB990998 and tighten them
MB990998
2. Hold front wheel hub assembly in a vice, using wooden
blocks.
3. Rotate the hub in order to seat the bearing.
MB991000
AC301927AE
FRONT AXLE 26-13
DRIVE SHAFT ASSEMBLY
4. Measure the wheel bearing rotation starting torque by using

MB990326 WOODEN
the special tools MB990326 and MB990685.
BLOCK
Limit: 1.4 N⋅m (12 in-lb)
5. If the rotation starting torque is not within the limit when the
WOODEN nut is tightened to 226 ± 29 N⋅m (167 ± 21 ft-lb), replace the
BLOCK
front wheel bearing assembly. If there is any signs of binding
MB990685
or tight spots when the wheel bearing turns, replace it.
AC206090AB
6. Measure to determine whether the wheel bearing axial play

WOODEN
is within the specified limit or not.
BLOCK
7. If the play exceeds the limit when the nut is tightened to 226
± 29 N⋅m (167 ± 21 ft-lb), replace the front wheel hub
assembly.
MB990998
WOODEN
BLOCK
AC206091AF

M1261003500429
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.
Pre-installation Operation Post-installation Operation

• Front Under Cover, Side Under Cover Removal • Front Exhaust Pipe Installation <3.8L-RH side>
• Transmission Fluid Draining (Refer to GROUP (Refer to GROUP 15, Exhaust Pipe and Muffler
23A, On-vehicle Service − Transmission Fluid P.15-14).
Change P.23A-292). • Check the ball joint dust cover for cracks or
• Front Exhaust Pipe Removal <3.8L-RH side> damage by pushing it with your finger.
(Refer to GROUP 15, Exhaust Pipe and Muffler • Transmission Fluid Filling (Refer to GROUP
P.15-14). 23A, On-vehicle Service − Transmission Fluid
Change P.23A-292).
• Front Under Cover, Side Under Cover
Installation
FRONT AXLE 26-14
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
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
<> 7. SELF LOCKING NUT (LOWER • MB991354: Puller Body
ARM BALL JOINT CONNECTION) • MB990998: Front Hub Remover and Installer
<> 8. SELF LOCKING NUT (TIE ROD • MB991000: Spacer
END CONNECTION)
<<C>> >>A<< 9. DRIVE SHAFT
FRONT AXLE 26-15

.

CAUTION
weight to avoid possible damage when the drive shaft nut
is loosened.
shaft nut.
MB990767
AC102462 AC
<SELF LOCKING NUT ( LOWER ARM BALL

JOINT/TIE ROD END CONNECTION) REMOVAL
CAUTION
threads.
ing.
1. Replace the self locking nut with a regular nut, because the
CORD
original one is a little bit large to install the special tool.
Install special tool MB991897 as shown in the figure.
NUT MB991897
BOLT

BOLT
CORRECT 3. Tighten the bolt with a wrench to disconnect the tie rod end
WRONG AC106821AC
.
FRONT AXLE 26-16
<<C>>RH DRIVE SHAFT/DRIVE SHAFT AND

INNER SHAFT ASSEMBLY REMOVAL
MB990767 to push out the drive shaft or the drive shaft and
inner shaft assembly from the hub.
MB990767
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
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 22DB015A
PRY BAR
AC305799 AB
FRONT AXLE 26-17
4. If the inner shaft is hard to remove from the transaxle, strike

BRACKET ASSEMBLY the bracket assembly lightly with a plastic hammer and
remove the inner shaft.
AC102553 AC
CAUTION
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

.
>>A<< DRIVE SHAFT AND INNER SHAFT ASSEM-

BLY RH DRIVE SHAFT INSTALLATION
CAUTION
When installing the drive shaft or the drive shaft and inner
shaft assembly, be careful that the spline part of the drive
shaft or the drive shaft and inner shaft assembly do not
.
>>B<< DRIVE SHAFT NUT INSTALLATION

WASHER
direction.
CAUTION
wheel bearing will be damaged.
MB990767 Tightening torque: 226 ± 29 N⋅m (167 ± 21 ft-lb)
AC210244AB
FRONT AXLE 26-18

M1261003700490
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
>>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
<> >>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
• BJ: Birfield Joint • MB990930: Installer Adapter

• For BJ boot removal and installation, refer to • MB990932: Installer Adapter
P.26-26. • MB990934: Installer Adapter
• MB990938: Bar (snap-in type)
• MB990890: Rear Suspension Bushing Base
• MB991248: Inner Shaft Remover
• MB991172: Inner Shaft Installer Base
• MB990810: Side Bearing Puller
FRONT AXLE 26-20
LUBRICATION POINTS
GREASE: REPAIR KIT GREASE GREASE: REPAIR KIT GREASE

AMOUNT USED: 165 ± 10 g AMOUNT USED: 220 ± 10 g
GREASE: REPAIR KIT GREASE

AMOUNT USED:
CAUTION DUST SEAL INNER: 14 - 20 g
THE DRIVE SHAFT JOINT USES CAUTION
SPECIAL GREASE. DO NOT MIX OLD THE DRIVE SHAFT JOINT USES DUST SEAL OUTER: 8 - 12 g
AND NEW OR DIFFERENT TYPES OF SPECIAL GREASE. DO NOT MIX OLD
GREASE. AND NEW OR DIFFERENT TYPES OF
GREASE.
14 10
22DB017A
FRONT AXLE 26-21

.
PTJ CASE/SPIDER ASSEMBLY REMOVAL

CAUTION
Do not disassemble the spider assembly.
1. Wipe off grease from the spider assembly and the inside of
the PTJ case.
2. Clean the spider assembly if water or foreign material is
observed.
.
<>INNER SHAFT RH REMOVAL

BAR 1. Use special tool MB991248 to remove the inner shaft
assembly from the PTJ case.
MB991248
PTJ CASE
BAR
PTJ CASE
MB991248
AC205845 AB
2. Use special tool MB990810 to remove the center bearing

bracket from the inner shaft.
MB990810
AC205846AB
.
FRONT AXLE 26-22
<<C>>CENTER BEARING RH REMOVAL

Use special tools MB990938 and MB990930 to remove the
MB990938 center bearing from the center bearing bracket.
MB990930
CENTER BEARING BRACKET

AC102652 AC
PTJ BOOT REMOVAL

1. Wipe off grease from the shaft spline.
2. When reusing the PTJ boot, wrap plastic tape around the
shaft spline to avoid damaging the boot.

.
DYNAMIC DAMPER LH /DAMPER BAND /PTJ

BOOT INSTALLATION
CAUTION
There should be no grease adhered to the rubber part of
the dynamic damper.
1. Install the dynamic damper in the position (L) shown in the
illustration.
L L: 260.5 ± 3 mm LH>
2. Secure the damper bands.
3. Wrap plastic tape around the shaft spline, and then install
the PTJ boot band (small) and PTJ boot.
AC101695 AF
>>B<< SPIDER ASSEMBLY INSTALLATION

CAUTION
• The drive shaft joint use special grease. Do not mix old
and new or different types of grease.
• If the spider assembly has been cleaned, take special
care to apply the specified grease.
1. Apply the specified grease furnished in the repair kit to the
spider assembly between the spider axle and the roller.
Specified grease: Repair kit grease
FRONT AXLE 26-23
2. Install the spider assembly to the shaft from the direction of

the spline chamfered side.
CHAMFERED
SIDE
AC102654AC
>>C<<CENTER BEARING <3.8L-RH>

INSTALLATION
Use special tools MB990938 and MB990932 to press-fit the
MB990938 center bearing into the center bearing bracket.
MB990932
CENTER BEARING BRACKET

AC102655 AC
>>D<<DUST SEAL INNER <3.8L-RH> /DUST SEAL

OUTER <3.8L-RH> INSTALLATION
CAUTION
When applying grease, make sure that it does not adhere
to anything outside the lip.
1. Apply the specified grease to the rear surface of all dust
seals.
Amount used (Dust seal inner): 14 − 20 g (0.5 − 0.7
ounce)
Amount used (Dust seal outer): 8 − 12 g (0.3 − 0.4
ounce)
FRONT AXLE 26-24
2. Use special tools MB990890, MB990938, and MB990934 to

press the dust seals into the center bearing bracket until
MB990890
they are flush with each other.
3. Apply repair kit grease to the lip of each dust seal.
DUST
SEAL
INNER
AC101696 AC
MB990938
MB990934
DUST SEAL
OUTER
MB990890
AC101697AC
>>E<<INNER SHAFT <3.8L-RH> INSTALLATION

1. Use special tool MB991172 to hold the center bearing inner
race, and then press-in the inner shaft.
INNER SHAFT
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
>>F<< PTJ CASE <3.8L> INSTALLATION

CAUTION
The drive shaft joint use special grease. Do not mix old
After applying the specified grease to the PTJ case, insert the
drive shaft and apply grease again.
Amount to use <3.8L>: 220 ± 10 g (7.8 ± 0.3 ounces)
NOTE: The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
AC102656 AC
>>G<< PTJ BOOT BAND (SMALL) <3.8L>/PTJ

BOOT BAND (LARGE) <3.8L> INSTALLATION
Set the PTJ boot bands at the specified distance in order to
adjust the amount of air inside the PTJ boot, and then tighten
the PTJ boot band (small), PTJ boot band (large) securely.
Standard value (A): 85 ± 3 mm (3.35 ± 0.12 inches)
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
BJ BOOT REPLACEMENT
M1261005200394

MB991561:Boot Band Crimping Tool
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the BJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble
the boot band and BJ boot.
AC102658
4. Align the center groove on the BJ boot small end with the
shaft groove.
AC102659
5. Turn the adjusting bolt on special tool MB991561 so that the

MB991561
size of the opening (W) is at the standard value.
STOPPER Standard value (W): 2.9 mm (0.11 inch)
<If it is larger than 2.9 mm (0.11 inch)> Tighten the
adjusting bolt.
W
<If it is smaller than 2.9 mm (0.11 inch)> Loosen the
adjusting bolt.
NOTE: The value of W will change by approximately 0.7 mm
ADJUSTING BOLT (0.03 inch) for each turn of the adjusting bolt.
AC102660 AC
NOTE: The adjusting bolt should not be turned more than
once.
BOOT 6. Position the BJ boot band (small) so that there is even
clearance at either end (A and B).
A
BOOT BAND
(SMALL)
PROJECTION AC102661AC
FRONT AXLE 26-27
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
8. Check that the crimping amount (C) of the boot band is at

the standard value.
Standard value (D): 2.4 − 2.8 mm (0.09 − 0.11 inch)
C
<If the crimping amount is larger than 2.8 mm (0.11
inch)>
Readjust the value of (W) in step 5 according to the
following formula, and then repeat the operation in
step 7.
W = 5.5 mm (0.22 inch) − D
AC102662 AD Example: If D = 2.9 mm (0.11 inch), then W = 2.6 mm
(0.10 inch).
<If the crimping amount is smaller than 2.4 mm (0.09
inch)>
Remove the EBJ boot band, readjust the value of
(W) in step 5 according to the following formula,
and then repeat the operations in steps 6 and 7
using a new EBJ boot band.
W = 5.5 mm (0.22 inch) − D
Example: If D = 2.3 mm (0.09 inch), then W = 3.2
mm (0.13 inch).
9. Check that the boot band is not sticking out past the place
where it has been installed. If the boot band is sticking out,
remove it and then repeat steps 6 to 8, using a new boot
band.
CAUTION
The drive shaft joint uses special grease. Do not mix old
10.Fill the inside of the boot with the specified amount of the
specified grease.
Amount to use <3.8L>: 165 ± 10 g (5.8 ± 0.3 ounces)
FRONT AXLE 26-28
11.Align the center groove on the BJ boot big end with the BJ
case groove.
AC102664 AC
12.Follow the same procedure as in step 5 to adjust the size of

the opening (W) on special tool so that it is at the standard
value.
Standard value (W): 2.9 mm (0.11 inch)
13.Position the BJ boot band (large) so that there is even
PROJECTION
clearance at either end (D and E).
BOOT BAND
(LARGE)
BOOT E
AC102665AC
14.Use special tool to crimp the BJ boot band (large) in the

same way as in step 7.
15.Check that the crimping amount (F) of the boot band is at
the standard value.
Standard value (F): 2.4 − 2.8 mm (0.09 − 0.11 inch)
<If the crimping amount is larger than 2.8 mm (0.11
inch)>
Readjust the value of (W) in step 12 according to
the following formula, and then repeat the opera-
tion in step 14.
W = 5.8 mm (0.23 inch) − F
F
AC102666 AD Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm
(0.11 inch).
<If the crimping amount is smaller than 2.4 mm (0.09
inch)>
Remove the EBJ boot band, readjust the value of
(W) in step 12 according to the following formula,
and then repeat the operations in steps 13 and 14
using a new EBJ boot band.
W = 5.8 mm (0.23 inch) − F
Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm
(0.14 inch).
16.Check that the boot band is not sticking out past the place
where it has been installed. If the boot band is sticking out,
remove it and then repeat steps 13 to 15, using a new boot
band.
FRONT AXLE 26-29
SPECIFICATIONS
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)
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
M1261000300426

Wheel bearing end play mm (in) − 0.05 (0.002)
Wheel bearing rotation starting torque N⋅m (in-lb) − 1.4 (12)
Setting of PTJ boot length mm 3.8L 85 ± 3 (3.35 ± 0.12) −
(in)
Opening dimension of the When the BJ boot band 2.9 (0.11) −
special tool (MB991561) mm (small) is crimped
(in) When the BJ boot band 2.9 (0.11) −
(large) is crimped
Crimped width of the BJ boot band mm (in) 2.4 − 2.8 (0.09 − 0.11) −
FRONT AXLE 26-30
SPECIFICATIONS
LUBRICANTS
M1261000400412

PTJ boot grease Repair kit grease 220 ± 10 g (7.8 ± 0.3 oz)
BJ boot grease Repair kit grease 165 ± 10 g (5.8 ± 0.3 oz)
Dust seal inner grease Repair kit grease 14 − 20 g (0.5 − 0.7 oz)
Dust seal outer grease Repair kit grease 8 − 12 g (0.3 − 0.4 oz)
HOME
27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 27-2 HUB BOLT REPLACEMENT. . . . . . . . . . . . 27-5
REAR AXLE DIAGNOSIS . . . . . . . . . 27-2 REAR AXLE HUB ASSEMBLY . . . . . 27-6

INTRODUCTION TO REAR AXLE DIAGNOSIS 27-2 REMOVAL AND INSTALLATION . . . . . . . . 27-6
REAR AXLE DIAGNOSTIC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27-7
SYMPTOM PROCEDURES . . . . . . . . . . . . 27-3 KNUCKLE . . . . . . . . . . . . . . . . . . . . . . 27-8
SPECIAL TOOLS. . . . . . . . . . . . . . . . 27-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27-9
ON-VEHICLE SERVICE. . . . . . . . . . . 27-4 SPECIFICATIONS . . . . . . . . . . . . . . . 27-10

WHEEL BEARING END PLAY CHECK . . . 27-4 FASTENER TIGHTENING SPECIFICATIONS 27-10
REAR HUB ROTARY-SLIDING RESISTANCE SERVICE SPECIFICATIONS . . . . . . . . . . . 27-10
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-5
REAR AXLE 27-2
GENERAL DESCRIPTION
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.
ABS ROTOR
REAR HUB
OIL SEAL
WHEEL BEARING
AC305169 AB
REAR AXLE DIAGNOSIS

INTRODUCTION TO REAR AXLE DIAGNOSIS
M1271004100254
Noise from the rear axle may be caused by defects in
the components.
REAR AXLE DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1271004200273
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
rear axle fault. Procedures.
REAR AXLE 27-3
REAR AXLE DIAGNOSIS
SYMPTOM PROCEDURES
M1271004400222
INSPECTION PROCEDURE 1: Abnormal Noise
DIAGNOSIS
STEP 1. Check the rear hub assembly installation bolts for

looseness.
Q: Are the rear hub assembly installation bolts loosened?
YES : Tighten the rear hub assembly installation bolts to the
specified torque 73 ± 7 N⋅m (54 ± 5 ft-lb). Then go to
Step 4.
NO : Go to Step 2.
STEP 2. Check the wheel bearing end play.

(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.
Q: Is the wheel bearing end play within the limit?
YES : Go to Step 3.
NO : Replace the rear hub assembly, then go to Step 4.
AC205869AB
STEP 3. Check the rear hub rotary-sliding resistance.

(1) Remove the caliper assembly, and suspend the caliper
(2) Turn the hub a few times to seat the bearing.
(3) Wind a rope around the hub bolt and turn the hub by pulling
at a 90° angle with a spring balance. Measure to determine
whether or not the rotary-sliding resistance of the rear hub
is within the limit value.
Limit: 24 N (5.4 lbs)
Q: Is the rear hub rotary-sliding resistance within the limit?
YES : Go to Step 4.
NO : Replace the rear hub assembly, then go to Step 4 .
AC205870
STEP 4. Retest the systems.

Q: Are abnormal noises generated?
REAR AXLE 27-4
SPECIAL TOOLS
SPECIAL TOOLS
M1271000600525

NAME
MB990767 MB990767-01 Hub fixing
Front hub and flange
yoke Holder
B990767
MB991618 General service tool Hub bolt removal

Hub bolt remover
MB991618
MB991897 MB991113-1, Ball joint disconnection

Ball joint remover MB990635-01 or general NOTE: Steering linkage
service tool puller(MB990635 or
MB991113)is also used
to disconnect knuckle
AC106827
and toe control arm ball
joint.
ON-VEHICLE SERVICE
WHEEL BEARING END PLAY CHECK
M1271000900474
1. Remove the caliper assembly, and suspend the caliper
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.
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
AC205869AB
REAR AXLE 27-5
ON-VEHICLE SERVICE
REAR HUB ROTARY-SLIDING RESISTANCE

CHECK
M1271001100266
2. Turn the hub a few times to seat the bearing.
3. Wind a rope around the hub bolt and turn the hub by pulling
at a 90 degree angle with a spring balance. Measure to
determine whether or not the rotary-sliding resistance of the
rear hub is within the limit value.
Limit: 24 N (5.4 pounds)
4. If the rotary−sliding resistance exceeds the limit value,
replace the rear hub assembly.
5. After having finished the inspection, install the brake disc,
caliper assembly and tighten the caliper assembly mounting
AC205870
HUB BOLT REPLACEMENT

M1271001000270

• MB990767: Front Hub and Flange Yoke Holder
• MB991618: Hub Bolt Remover
2. Use special tool MB991618 to remove the hub bolts.
MB991618
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.
MB990767
AC205872 AB
REAR AXLE 27-6
REAR AXLE HUB ASSEMBLY

M1271002000411
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

1. REAR WHEEL SPEED SENSOR <> 4. BRAKE DISC
<VEHICLES WITH ABS> 5. PLUG
2. BRAKE HOSE CLAMP BOLT <<C>> 6. REAR HUB ASSEMBLY
<<A>> 3. CALIPER ASSEMBLY

.
<<A>> CALIPER ASSEMBLY REMOVAL

Secure the removed caliper assembly with wire, etc.
.
<> BRAKE DISC REMOVAL

If the brake disc is seized, install M8 × 1.25 bolts as shown, and
remove the disc by tightening the bolts evenly and gradually.
BOLTS
(M8 × 1.25)
AC205986AB
.
REAR AXLE 27-7
<<C>> REAR HUB ASSEMBLY REMOVAL

Insert a flat-tipped screwdriver into the mounting holes of
knuckle hub to prevent the rear brake shoe and backing plate
from falling down after the rear hub assembly has been
SCREW- removed from the knuckle.
DRIVERS
AC305547AB
INSPECTION
M1271002100270
OIL SEALS
• Check the ABS rotor for chipped teeth.
ABS ROTOR
AC305554 AB
REAR AXLE 27-8
KNUCKLE
KNUCKLE
M1271003000191
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in the unladen condition.
• 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

1. SELF LOCKING NUT (TRAILING 5. SELF LOCKING NUT (UPPER
ARM CONNECTION) ARM CONNECTION)
<<A>> 2. SELF LOCKING NUT (TOE 6. KNUCKLE
CONTROL ARM CONNECTION) 7. UPPER ARM STOPPER
3. SHOCK ABSORBER Required Special Tool:
CONNECTION MB991897: Ball Joint Remover
4. SELF LOCKING NUT (LOWER
ARM CONNECTION)
REAR AXLE 27-9
KNUCKLE

.
<<A>> SELF LOCKING NUT ( TOE CONTROL

ARM CONNECTION) REMOVAL
CAUTION
• Do not remove the nut from the ball joint. Loosen it and
use the special tool to avoid possible damage to ball
joint threads.
• Hang the special tool with a cord to prevent from fall-
ing.
1. Install special tool MB991897 as shown in the figure.
CORD
NUT MB991897
BOLT
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
WRONG AC106821AC
INSPECTION
M1271003100143
Check the knuckle for wear or cracks.
REAR AXLE 27-10
SPECIFICATIONS
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)
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
WHEEL AND TYRE

CONTENTS
WHEEL AND TYRE DIAGNOSIS . . . 31-2 WHEEL AND TYRE . . . . . . . . . . . . . . 31-7

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 31-2 INSTALLATION SERVICE POINT . . . . . . . 31-7
WHEEL BALANCE ACCURACY . . . . . . . . 31-3
SPECIFICATIONS . . . . . . . . . . . . . . . 31-8
ON-VEHICLE SERVICE. . . . . . . . . . . 31-7 FASTENER TIGHTENING SPECIFICATION 31-8
TYRE INFLATION PRESSURE CHECK . . 31-7 GENERAL SPECIFICATIONS . . . . . . . . . . 31-8
TYRE WEAR CHECK . . . . . . . . . . . . . . . . . 31-7 SERVICE SPECIFICATIONS . . . . . . . . . . . 31-8
WHEEL RUNOUT CHECK . . . . . . . . . . . . . 31-7
WHEEL AND TYRE 31-2
WHEEL AND TYRE DIAGNOSIS

DIAGNOSIS
M1311000700404
SYMPTOM PROBABLE CAUSE REMEDY REFERENCE

PAGE
Rapid wear Under-inflation Adjust the tyre For tyre inflation
at shoulders or lack of pressure. pressure, refer to
rotation the label on the
driver's side center
pillar.
ACX00923AB
ACX00924 AB
Rapid wear Over-inflation

at center or lack of
rotation
ACX00925AB
ACX00926AB
Cracked Under-inflation Adjust the tyre For tyre inflation

treads pressure. pressure, refer to
the label on the
driver's side center
pillar.
ACX00927AB
WHEEL AND TYRE 31-3
SYMPTOM PROBABLE CAUSE REMEDY REFERENCE

PAGE
Wear on one Excessive Check the camber. Refer to GROUP
side camber 33, On-vehicle
Service − Front
Wheel Alignment
Check and
ACX00928 AB
Adjustment P.33-6.
ACX00929 AB
Feathered Incorrect toe-in Adjust the toe-in.

edge
ACX00930AB
ACX00931AB
Bald spots Unbalanced Balance the wheels. −

wheel
ACX00932AB
ACX00933 AB
Scalloped Lack of rotation of tyres or worn Rotate the tyres, and Refer to GROUP
wear or out-of-alignment suspension check the front 33, On-vehicle
suspension Service − Front
alignment. Wheel Alignment
Check and
ACX00934
Adjustment P.33-6.
WHEEL BALANCE ACCURACY

M1311001700258
PURPOSE 2. Off-the-car wheel balancers must be calibrated

This section contains tips and procedures for achiev- periodically to ensure good balancing results. An
ing accurate wheel balance. Steering wheel vibration inaccurately calibrated balancer could cause
and/or body shake can result if any of these proce- unnecessary replacement of tyres, shocks,
dures are not carefully observed. suspension components, or steering components.
1. Wheels and tyres must be properly mounted on a Check your balancer's calibration approximately
balancer in order to achieve correct balance. every 100 balances. Your wheel balancer's instruc-
Centering the wheel on the shaft of the balancer is tion manual should include calibration procedures. If
essential for proper mounting. the calibration procedures specifically for your bal-
ancer are missing, use the generic steps in this sec-
tion for zero calibration, static balance, and dynamic
balance checks. The wheel balancer calibration
checks are also described in the flowchart. (Refer to
P.31-6.)
WHEEL AND TYRE 31-4
PROCEDURE <Balancing Tips> 3. Install a wheel mounting cone. The appropriate

1. Confirm that the balancer's cone and the wheel size cone for this vehicle is 67.0 mm (2.64
mounting cone are undamaged and free of dirt inches).
and rust. 4. Before balancing the wheel, remove any wheel
2. On this vehicle, the wheel's center hole on the weights from both sides. Also check both sides for
hub side has a chamfered edge. Use a any damage.
back-mounting cone on your wheel balancer to 5. When installing wheel weights, hammer them at a
center the wheel on the balancer shaft. straight (not diagonal) angle.
HUB/SHAFT CLAMPING CUP

ASSEMBLY
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
4. <<Static Balance Check>> 5. <<Dynamic Balance Check>>

Attach a 5-g (0.18-ounce) weight to the outer rim. Attach a 5-g (0.18-ounce) weight to the inner rim
Recheck the balancer. The balancer should at 180 degrees opposite the 5-g (0.18-ounce)
detect 5 ± 2 g (0.18 ± 0.06 ounce) of imbalance weight that was added in Step 4. Recheck the
170 to 190 degrees away from the 5-g balance. The balancer should detect 5 ± 2 g (0.18
(0.18-ounce) weight. ± 0.06 ounce) of imbalance 170 to 190 degrees
• If the imbalance is within specification, the static away from both the inner and outer 5-g
balance calibration is correct. Go to Step 5 to (0.18-ounce) weights.
check the dynamic balance. • If the imbalance is within specification, the
• If the imbalance is out of specification, the bal- dynamic balance calibration is correct. The bal-
ancer requires calibration. Contact the balancer ancer calibration checks are complete.
manufacturer for calibration by their repair repre- • If the imbalance is out of specification, the bal-
sentative. ancer requires calibration. Contact the balancer
manufacturer for calibration by their repair repre-
sentative.
WHEEL AND TYRE 31-6
WHEEL BALANCER CALIBRATION CHECKING FLOW CHART
Balance wheel.
ZERO CALIBRATION
Rotate wheel 1/2 turn. CHECK
Imbalance = 5 g (0.18 oz) or less Imbalance = more than 5 g (0.18 oz)
Rebalance wheel.
Rotate wheel 1/4 turn.
Imbalance = 5 g (0.18 oz) or less Imbalance = more than 5 g (0.18 oz)
Verify wheel is properly centered.

Verify cones, cup, and wing nut are clean,
undamaged, and appropriate for wheel.
Make necessary corrections, then recheck
wheel balance.
Attach a 5-g (0.18-oz) weight to the outer rim. STATIC BALANCE

Is the imbalance 5 ± 2 g (0.18 ± 0.06 oz) at 170 – CHECK
190 degrees away from the 5-g (0.18-oz) weight?
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
Balancer does not require Balancer requires calibration.

calibration. Contact balancer manufacturer.
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.
TYRE WEAR CHECK

M1311001000345
Measure the tread depth of the tyres.
If the remaining tread depth is less than the minimum limit,
replace the tyre.
NOTE: When the tread depth of the tyres is reduced to 1.6 mm
(0.06 inch) or less, wear indicators will appear.
WHEEL RUNOUT CHECK

M1311001100364
Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with a
dial indicator.
RADIAL
Limit:
ITEM STEEL WHEEL ALUMINUM

WHEEL
Radial runout 1.2 mm (0.05 inch) 1.0 mm (0.04 inch)
LATERAL or less or less
ACX00651AB
Lateral 1.2 mm (0.05 inch) 1.0 mm (0.04 inch)
runout or less or less
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE

M1311001300302
Tighten the wheel nuts to the specified torque.
WHEEL AND TYRE 31-8
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATION
M1311001600295
ITEM SPECIFICATION
Wheel nut 98 ± 10 N⋅m (73 ± 7 ft-lb)
M1311000200324
.
ITEM 380 380LS 380VRX 380GT
Wheel Type Steel Alloy Alloy Alloy

Size 16 × 6 1/2JJ 16 × 6 1/2JJ 17 × 7JJ
17 × 7JJ*
Amount of wheel 46 (1.8)
offset mm (in)
Pitch circle 114.3 (4.50)
diameter (PCD)
mm (in)
Tyre Size P215/60 R16 94H P215/55 R17 93V
Spare Type Steel type
wheel Size 16 × 6 1/2JJ
Amount of wheel 40 (1.5)
offset mm (in)
Pitch circle 114.3 (4.50)
diameter (PCD)
mm (in)
Spare tyre Size P215/60 R16 94H
NOTE: .
• The * mark indicates OEM optional item.
• PCD (Pitch Circle Diameter) indicates the pitch circle diameter of the wheel installation holes.
M1311000300406
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. . . . . . . . . 32-2 ENGINE ROLL STOPPER AND

CENTREMEMBER . . . . . . . . . . . . . . . 32-7
SPECIAL TOOL . . . . . . . . . . . . . . . . . 32-3 REMOVAL AND INSTALLATION . . . . . . . . 32-7
ENGINE MOUNTING . . . . . . . . . . . . . 32-4 CROSSMEMBER . . . . . . . . . . . . . . . . 32-9

REMOVAL AND INSTALLATION . . . . . . . . 32-4 REMOVAL AND INSTALLATION . . . . . . . . 32-9
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 32-14
TRANSAXLE MOUNTING . . . . . . . . . 32-5
REMOVAL AND INSTALLATION . . . . . . . . 32-5 SPECIFICATIONS . . . . . . . . . . . . . . . 32-15
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 32-15
POWER PLANT MOUNT 32-2
GENERAL DESCRIPTION
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.
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
SPECIAL TOOL
SPECIAL TOOL
M1321000600390

AND NAME
Ball joint remover MB990635-01 or disconnection
General service tool NOTE: Steering linkage puller
(MB990635 or MB991113)is also
used to disconnect the knuckle
AC106827
and tie rod end ball joint.
ENGINE MOUNTING
ENGINE MOUNTING
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

2. ENGINE MOUNTING STAY 5. ENGINE MOUNT BRACKET
3. MOUNTING BOLT 6. ENGINE MOUNT STOPPER
4. SELF LOCKING NUTS 7. DYNAMIC DAMPER
TRANSAXLE MOUNTING
TRANSAXLE MOUNTING
M1321001400452
CAUTION
• 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
1. SELF-LOCKING NUTS 2. TRANSAXLE MOUNTING BODY
SIDE BRACKET
>>A<< 3. TRANSAXLE MOUNTING
STOPPER
TRANSAXLE MOUNTING

.
>>A<< TRANSAXLE MOUNTING STOPPER

INSTALLATION
Install the transaxle mounting stopper so that its arrow points
ENGINE SIDE TRANSAXLE
MOUNTING upward.
STOPPER
AC205424 AC
ENGINE ROLL STOPPER AND CENTREMEMBER

M1321002300306
CAUTION
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
REAR ROLL STOPPER

BRACKET REMOVAL STEPS
2. ENGINE FRONT ROLL STOPPER
BRACKET AND
CENTREMEMBER
6. SELF-LOCKING NUT
7. TRANSAXLE CASE REAR ROLL
STOPPER BRACKET

.
>>B<< ENGINE FRONT ROLL STOPPER

BRACKET INSTALLATION
AC205425 Install the engine front roll stopper bracket so that its hole
FRONT OF VEHICLE
points towards the front side of the vehicle.
HOLE
AC306965 AB
CROSSMEMBER
CROSSMEMBER
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
• *2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in the unladen condition.
• 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).
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

1. STEERING SHAFT PAD <<D>> 13. SELF LOCKING NUTS
<<A>> 2. STEERING COLUMN ASSEMBLY <<C>> >>D<< 14. FRONT AXLE CROSSMEMBER
AND STEERING GEAR STAY
CONNECTION <<E>> >>C<< 15. ENGINE REAR ROLL STOPPER
<> 3. SELF LOCKING NUTS BRACKET, POWER STEERING
(CONNECTION FOR TIE ROD GEAR AND LINKAGE,
END) STABILIZER BAR AND FRONT
<> 4. SELF LOCKING NUTS AXLE NO.1 CROSSMEMBER
(CONNECTION FOR LOWER ASSEMBLY
ARM BALL JOINT) 16. ENGINE REAR ROLL STOPPER
5. LOWER ARM ASSEMBLY BRACKET
6. STABILIZER LINK CONNECTION 17. HEAT PROTECTOR "A"
7. RETURN TUBE CONNECTION 18. HEAT PROTECTOR "B"
8. O-RING 19. POWER STEERING GEAR AND
9. PRESSURE HOSE CONNECTION LINKAGE
10. O-RING >>A<< 20. STABILIZER BAR
11. PRESSURE HOSE CLAMP 21. FRONT AXLE NO.1
12. SELF LOCKING NUTS CROSSMEMBER
CROSSMEMBER


.
<<A>> STEERING COLUMN ASSEMBLY AND

STEERING GEAR DISCONNECTION
Pinch the steering column shaft clip with pliers, and pull up the
shaft in the direction shown to disengage the steering column
assembly.
NOTE:
STEERING
CLIP COLUMN
SHAFT
21DB016A
If the steering column shaft is removed accidentally,

X
remove the steering column assembly and be sure to insert the
steering column shaft into the steering column as shown in the
Y figure.
YOKE Y
A YOKE X
X
Y Y X
VIEW A
7.6˚ ± 3˚
X Y
AC306564 AB
.
32-12 POWER PLANT MOUNT
CROSSMEMBER
<> SELF LOCKING NUTS (CONNECTION FOR

TIE ROD END AND LOWER ARM BALL JOINT)
REMOVAL
CAUTION
special tool MB991897 to avoid possible damage to ball
joint threads.
• Hang special tool MB991897 with a cord to prevent it
from falling.
1. Replace the self locking nut for lower arm ball joint with a
CORD
regular nut, because the original one is a little bit large to
install special tool MB991897. Install special tool MB991897
as shown in the figure.
NUT MB991897
BOLT

special tool parallel, tighten the bolt by hand and confirm
BOLT
that the jaws are still parallel.
CORRECT 3. Tighten the bolt with a wrench to disconnect the lower arm
KNOB ball joint, tie rod end and remove the self locking nut.
WRONG AC106821AC
<<C>> FRONT AXLE CROSSMEMBER STAY

REMOVAL
Remove the self locking nut and two bolts attaching the stay.
The crossmember mounting bolt will need to be checked for
torque loss after removing the stay nut, when only replacing the
crossmember stopper.
CAUTION
Always fit new self locking nuts after removal.
.
FRONT AXLE
CROSSMEMBER
STAY
21DB019A
CROSSMEMBER
<<D>> FRONT AXLE CROSSMEMBER

MOUNTING BOLT REMOVAL
Remove the crossmember mounting bolt.
CROSSMEMBER
MOUNTING BOLT
21DB018A
<<E>> ENGINE REAR ROLL STOPPER BRACKET,

POWER STEERING GEAR AND LINKAGE,
STABILIZER BAR AND FRONT AXLE NO.1
CROSSMEMBER ASSEMBLY REMOVAL
AC206593 Support the front axle number 1 crossmember with a transmis-
sion jack, and then remove the crossmember mounting nuts
and bolts.
TRANSMISSION
JACK AC306696AB

.
>>A<< STABILIZER BAR INSTALLATION

OUTSIDE OF APPROXIMATELY Align the stabilizer bar identification mark with the right end of
VEHICLE 20 mm ( 0.79 in ) the bushing (LH).
IDENTIFICATION
MARK
STABILIZER STABILIZER
BUSHING (LH) BRACKET (LH)
AC006141AE
.
CROSSMEMBER
>>D<< FRONT AXLE CROSSMEMBER BOLT/

STAY/SELF-LOCKING NUTS INSTALLATION
1. Ensure that the crossmember mounting bolts have been
tightened to specification. .
2. Install the front crossmember stay/stopper and tighten self
CROSSMEMBER locking nuts and bolts to specification.
MOUNTING BOLT
CAUTION
FRONT AXLE
CROSSMEMBER Always fit new self locking nuts after removal.
STAY
SELF-LOCKING NUT 21DB020A
INSPECTION
M1321003300194
• Check the crossmembers for cracks or damage.
SPECIFICATIONS
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)
SPECIFICATIONS
HOME
33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 33-2 DISASSEMBLY AND ASSEMBLY . . . . . . . 33-9

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-13
FRONT SUSPENSION DIAGNOSIS . 33-2
INTRODUCTION TO FRONT SUSPENSION LOWER ARM . . . . . . . . . . . . . . . . . . . 33-13
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 33-2 REMOVAL AND INSTALLATION . . . . . . . . 33-13
FRONT SUSPENSION DIAGNOSIS INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-14
TROUBLESHOOTING STRATEGY . . . . . . 33-2 LOWER ARM BALL JOINT DUST COVER
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 33-3 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-15
SYMPTOM PROCEDURES . . . . . . . . . . . . 33-3 LOWER ARM BUSHING (REAR)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-16
SPECIAL TOOLS. . . . . . . . . . . . . . . . 33-5
STABILIZER BAR* . . . . . . . . . . . . . . . 33-18
ON-VEHICLE SERVICE. . . . . . . . . . . 33-6 REMOVAL AND INSTALLATION . . . . . . . . 33-18
FRONT WHEEL ALIGNMENT CHECK AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-22
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 33-6
LOWER ARM BALL JOINT END PLAY CHECK 33-7 SPECIFICATIONS . . . . . . . . . . . . . . . 33-24
BALL JOINT DUST COVER CHECK . . . . . 33-7 FASTENER TIGHTENING SPECIFICATIONS 33-24
STRUT ASSEMBLY. . . . . . . . . . . . . . 33-8 SERVICE SPECIFICATIONS . . . . . . . . . . . 33-25
REMOVAL AND INSTALLATION . . . . . . . . 33-8 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 33-25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 33-8
WARNING
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
.
spring. The shock absorber is gas-filled hydraulic

double-tube type.
COIL SPRING
STABILIZER LINK
STABILIZER BAR
STRUT ASSEMBLY
FRONT AXLE
CROSSMEMBER
STAY <3.8L ENGINE>
FRONT AXLE No.1

CROSSMEMBER
CENTER MEMBER
LOWER ARM ASSEMBLY
AC305733 AB
FRONT SUSPENSION DIAGNOSIS

INTRODUCTION TO FRONT SUSPENSION DIAGNOSIS
M1332009000269
If the front suspension is faulty, the vehicle will not
run straightforward or noise will occur. Incorrect
wheel alignment, malfunction of strut assembly, sta-
bilizer bar, coil spring, or worn or out-of-balance tyres
can cause these problems.
FRONT SUSPENSION DIAGNOSIS TROUBLESHOOTING STRATEGY
M1332009100255
you follow them thoroughly, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find and repair the malfunction by following the
front suspension fault. Symptom Chart and Symptom Procedures.
SYMPTOM CHART
M1332009400290

PROCEDURE
Steering wheel is heavy, vibrates or pulls to one side 1 P.33-3
Excessive body rolling 2 P.33-3
Poor ride 3 P.33-4
Unequal ride height 4 P.33-4
Noise 5 P.33-4
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Steering Wheel is Heavy, Vibrates or Pulls to One Side
DIAGNOSIS STEP 3. Check the lower arm ball joint.

Q: Is the ball joint in good condition?
STEP 1. Check the tyres. YES : Go to Step 4.
Check for the tyre pressure, the tyre pressure bal- NO : Replace the lower arm assembly, and then
ance between left and right tyres, and the tyre condi- go to Step 5.
tion. Refer to GROUP 31, Diagnosis P.31-2.
Q: Are the tyres in normal condition? STEP 4. Check the coil spring.
YES : Go to Step 2.
NO : If out of pressure, adjust the tyre pressure. If Q: Is the coil spring in good condition?
out of balance, balance the tyres as YES : Go to Step 5.
necessary. If excessively worn, replace the NO : Replace it, and then go to Step 5.
tyres as necessary and then go to Step 5.
STEP 2. Check the wheel alignment. Q: Is the malfunction eliminated?
Refer to P.33-6. YES : The procedure is complete.
Q: Is the wheel alignment correct?
YES : Go to Step 3.
NO : Adjust it, and then go to Step 5.
INSPECTION PROCEDURE 2: Excessive Body Rolling
DIAGNOSIS STEP 2. Check the strut assembly for damage.

Q: Is the strut assembly in good condition?
STEP 1. Check for broken or deteriorated YES : Go to Step 3.
stabilizer bar. NO : Replace it, and then go to Step 3.
Q: Is the stabilizer bar in good condition?
YES : Go to Step 2. STEP 3. Retest the system.
NO : Replace it, and then go to Step 3.
Q: Is the malfunction eliminated?
INSPECTION PROCEDURE 3: Poor Ride
DIAGNOSIS STEP 3. Check for strut assembly damage.

Q: Is the strut assembly damaged?
STEP 1. Check for improper tyre inflation YES : Replace it, and then go to Step 4.
pressure. NO : Go to Step 4.
Refer to GROUP 31, On-vehicle Service − Tyre Infla-
tion Pressure Check P.31-7.
Q: Is the tyre inflation correct?
YES : Go to Step 2. Q: Is the malfunction eliminated?
NO : Adjust it, and then go to Step 4. YES : The procedure is complete.
STEP 2. Check for broken or deteriorated coil

spring(s).
Q: Are the coil spring(s) broken or deteriorated?
YES : Replace the coil spring(s), and then go to
Step 4.
NO : Go to Step 3.
INSPECTION PROCEDURE 4: Unequal Ride Height

STEP 1. Check for broken or deteriorated coil YES : The procedure is complete.
spring(s). NO : Return to Step 1.
Q: Is the coil spring(s) broken or deteriorated?
YES : Replace it, and then go to Step 2.
NO : Go to Step 2.
INSPECTION PROCEDURE 5: Noise
DIAGNOSIS STEP 3. Check for broken coil springs.

Q: Is the coil spring broken?
STEP 1. Check for lack of lubrication. YES : Replace it, and then go to Step 5.
Q: Is lubrication inadequate? NO : Go to Step 4.
YES : Lubricate it, and then go to Step 5.
NO : Go to Step 2.
STEP 4. Check for strut assembly damage.
Q: Is the strut assembly damaged?
STEP 2. Check the tightened parts for looseness YES : Replace it, and then go to Step 5.
and check the bushings for wear. NO : Go to Step 5.
Q: Are the tightened parts and bushings in good
condition? STEP 5. Retest the system.
YES : Go to Step 3.
NO : Tighten or replace as necessary, then go to Q: Is the malfunction eliminated?
Step 5. YES : The procedure is complete.
SPECIAL TOOLS
SPECIAL TOOLS
M1332000600327

NAME
MB991004 MB991004-01 or General Wheel alignment
Wheel alignment gauge service tool measurement
attachment
MB991004
C MB991832 General service tool Front coil spring

B Spring compressor set compression
A E • A: MB991793 NOTE: The coil spring can
D Spring compressor not be compressed by
F MB991832
• B: MB991795 following conventional
Attachment A special tools.
• C: MB991794 .
Upper plate • MB991237
• D: MB991829 Spring compressor
Arm bracket body
• E: MB991831 • MB991238
Spacer Arm set
• F: MB991830
Fixture
A MB991680 − Strut assembly
B Wrench set disassembly and
• A: MB991681 assembly
Wrench
MB991680
• B: MB991682
Socket
MB991897 MB991113-01, Ball joint disconnection
Ball joint remover MB990635-01 or General NOTE: Steering linkage
service tool puller (MB990635 or
MB991113) is also
AC106827 available to disconnect
knuckle and ball joint.
MB990326 General service tool Ball joint breakaway
Preload socket torque check
MB990326
MB990776 MB990776-01 Lower arm ball joint dust

Front axle base cover installation
MB990776
ON-VEHICLE SERVICE

NAME
MB991963 − Lower arm bushing
Suspension bushing arbor removal and press-fitting
MB991963
MB990889 −
Rear suspension bushing
ring
MB990889
MB990890 MB990890-01 or general

Rear suspension bushing service tool
base
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.
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.
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)
CAMBER, CASTER AND KINGPIN INCLINATION

• MB991004: Wheel Alignment Gauge Attachment
Standard value:
Camber: 0° 00' ± 30' (Left/right deviation within 30')
Caster: 3° 00' ± 30' (Left/right deviation within 30')
Kingpin inclination: 12° 54' ± 1° 30'
NOTE: Caster are preset at the factory and cannot be adjusted.
CAUTION
Never subject the wheel bearings to the vehicle load when
the drive shaft nuts are loosened.
NOTE: Attach the camber/caster/kingpin gauge to the drive-
MB991004 shaft by using special tool MB991004. Tighten special tool
MB991004 to the same torque 226 ± 29 N⋅m (167 ± 21 ft-lb) as
the drive shaft nut.
AC001079 AB
LOWER ARM BALL JOINT END PLAY CHECK

M1332011300085
1. Raise the vehicle.
2. Move the lower arm up and down with your hands to check
for excessive play in the axial direction of the ball joint. If
there is excessive play, replace the lower arm assembly.
BALL JOINT DUST COVER CHECK

M1332008600354
1. Press the dust cover with your finger to check that there are
no cracks or damage in the dust cover.
2. If the dust cover is cracked or damaged, replace the lower
arm assembly or the stabilizer link.
NOTE: If the dust cover is cracked or damaged, it is possible
that there may also be damage to the ball joint.
STRUT ASSEMBLY
STRUT ASSEMBLY
M1332001100358
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

1. STABILIZER LINK 5. STRUT NUT
2. BRAKE HOSE BRACKET • STRUT TOWER BAR BRACKET
3. FRONT WHEEL SPEED SENSOR <VRX & GT> (REFER TO GROUP
CLAMP 42, STRUT TOWER BAR P.42-12).
4. STRUT BOLT 6. STRUT ASSEMBLY
INSPECTION
M1332001200281
• Check for oil leaks from the strut assembly.
• Check the strut assembly for damage or deformation.
STRUT ASSEMBLY

M1332001300352
1
65 ± 5 N·m
48 ± 4 ft-lb
2
8
3
4
5
9
6
10
7
AC305783 AB
DISASSEMBLY STEPS Required Special Tools:

<<A>> >>C<< 1. STRUT NUT (SELF-LOCKING NUT) • MB991680: Wrench Set
>>B<< 2. STRUT INSULATOR • MB991681: Wrench
3. STRUT BEARING • MB991682: Socket
4. SPRING UPPER SEAT • MB991832: Spring Compressor Set
5. SPRING UPPER PAD • MB991793: Spring Compressor
6. STRUT COVER • MB991794: Upper Plate
7. STRUT DAMPER • MB991795: Attachment A
8. COIL SPRING
• MB991829: Arm Bracket
>>A<< 9. SPRING LOWER PAD
<> 10. FRONT SUSPENSION STRUT
• MB991830: Fixture
• MB991831: Spacer
STRUT ASSEMBLY

.
<<A>> STRUT NUT (SELF-LOCKING NUT)

REMOVAL
1. Install special tool MB991795 to special tool MB991793 as
MB991795
MB991793
AC105115 AE
2. Set the strut assembly to the following special tools.

MB991794
• MB991793: Spring Compressor
• MB991794: Upper Plate
• MB991795: Attachment A
NOTE: Set the strut assembly by using the bolt and nut that
are removed from the vehicle. When installing the bolt and
nut, lightly tighten them by hand.
3. Compress the coil spring approximately 5 mm (0.20 inch)
MB991830 using the spring compressor.
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
.
STRUT ASSEMBLY
<> FRONT SUSPENSION STRUT DISPOSAL

WARNING
Wear goggles when drilling to protect your eyes from
flying metal debris.
The gas must be discharged from the strut before discarding it.
Place the strut horizontally with its piston rod extended. Then
drill a hole of approximately 3 mm (0.1 inch) in diameter at the
location shown in the illustration and discharge the gas.
AC210097AB

.
>>A<< SPRING LOWER PAD INSTALLATION

Engage the three lugs of the spring lower pad into the holes on
SPRING LOWER
the front suspension strut as shown.
PAD
FRONT SUSPENSION
STRUT AC205614 AB
>>B<< STRUT INSULATOR INSTALLATION

If the upper plate and lower plate of the strut insulator have
ARROW ON THE been disassembled, assemble them as shown.
UPPER PLATE
ARROW ON THE
LOWER PLATE
AC210098AB
>>C<< STRUT NUT (SELF-LOCKING NUT)

INSTALLATION
1. Ensure that the bearing is seated correctly.
33-12 FRONT SUSPENSION
STRUT ASSEMBLY
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
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
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
M1332001600364
CAUTION
the ground in an unladen condition.
• Check the dust cover for cracks or damage by pushing it
with your finger.
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
LOWER ARM

.
<<A>> LOWER ARM AND KNUCKLE DISCON-

NECTION
CAUTION
joint threads.
from falling.
1. Loosen nut and remove bolt. If bolt is difficult to remove use
a soft drift to loosen from knuckle.
2. Use a large flat blade to spring clamp apart if required and
remove ball joint from knuckle.
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.
.
LOWER ARM BALL JOINT BREAKAWAY TORQUE

CHECK
1. Move the ball joint stud several times and install the lower
arm nut on the stud. Using special tool MB990326, measure
MB990326 the ball joint breakaway torque.
Standard value: 3.5 − 6.9 N⋅m (31 − 61 in-lb)
2. If the measured value is not within the standard value, or if
the ball joint is difficult to turn or does not turn smoothly,
replace the lower arm assembly.
AC305846 AB
LOWER ARM BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing it
with your finger.
2. If the dust cover is cracked or damaged, replace the lower
arm assembly.
NOTE: Cracks or damage to the dust cover may cause
damage to the ball joint. When it is damaged during service
work, replace the dust cover.
LOWER ARM
LOWER ARM BALL JOINT DUST COVER

REPLACEMENT
M1332008200282

• MB990776: Front Axle Base
If the dust cover is damaged accidentally during service work,
replace the dust cover as follows:
1. Remove the dust cover.
2. Apply the multipurpose grease SAE J310, NLGI No.2 or
equivalent to the lip and the inside of a new dust cover.
Grease amount for the inside the dust cover (refer-
ence): 13 ± 0.5 g (0.45 ± 0.02 oz)
3. Using special tool MB990776, drive in the dust cover until it
MB990776 is fully seated.
DUST COVER
AC305847 AB
AC205611 4. Position the dust cover as shown in the illustration. Make

sure that there is no abnormal bulge or pressure applied to
the dust cover.
DUST COVER
32.3 mm
with your finger.
1.27 in
AC305736 AB
LOWER ARM
LOWER ARM BUSHING (REAR) REPLACEMENT

M1332008100371

• MB991963: Suspension Bushing Arbor
• MB990889: Rear Suspension Bushing Ring
• MB990890: Rear Suspension Bushing Base
Replace the lower arm bushing as follows:
LOWER ARM BUSHING
AC306250 AB
1. Use special tools MB991963 and MB990890 to drive out the

lower arm bushing.
LOWER ARM
BUSHING
MB991963
LOWER ARM
ASSEMBLY
MB990890
AC207421AB
LOWER ARM
2. Position the lower arm bushing so that its projections are

LOWER ARM ASSEMBLY
positioned as shown, and then use special tools MB991963,
MB990889 and MB990890 to press in the lower arm
bushing.
30˚± 3˚ CAUTION
When pressing in the lower arm bushing, take care not to
PROJECTIONS deform the lower arm.
3. Press the lower arm bushing until its outer tube is flush with
the lower arm assembly surface while checking that the
AC207423AB press-in pressure is at the standard value. If the press-in
pressure is lower than the standard value, replace the lower
arm assembly.
Standard value: 10 kN (2,248 pounds) or more
LOWER ARM
BUSHING
MB991963 OUTER TUBE
MB990889
LOWER ARM
ASSEMBLY
MB990890
AC207422AB
STABILIZER BAR
STABILIZER BAR
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
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).
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).
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
STABILIZER LINK REMOVAL STABILIZER BAR REMOVAL

1. STABILIZER NUT <> 6. STEERING GEAR AND
2. STABILIZER NUT STEERING COLUMN
3. STABILIZER LINK ASSEMBLY CONNECTION
STABILIZER BUSHING 7. STEERING GEAR AND
REMOVAL STEPS RETURN TUBE
1. STABILIZER NUT CONNECTION
15. STEERING GEAR AND HEAT 8. RETURN TUBE CLAMP NUT
PROTECTORS (REFER TO AND BOLT
GROUP 32, CROSSMEMBER 9. PRESSURE HOSE CLAMP
P.32-9). BOLT
>>A<< 16. STABILIZER BRACKET 10. STEERING GEAR AND
>>A<< 17. STABILIZER BUSHING PRESSURE TUBE
STABILIZER BAR REMOVAL CONNECTION
STEPS 11. REAR ROLL STOPPER
1. STABILIZER NUT CONNECTION BOLT
<<A>> 4. TIE ROD END AND >>C<< 12. SELF-LOCKING NUT
KNUCKLE CONNECTION <<C>> >>C<< 13. FRONT AXLE
5. STEERING SHAFT PAD CROSSMEMBER STAY
STABILIZER BAR
STABILIZER BAR REMOVAL STABILIZER BAR REMOVAL

STEPS (Continued) STEPS (Continued)
>>B<< 14. FRONT AXLE NO.1 >>A<< 17. STABILIZER BUSHING
CROSSMEMBER, REAR >>A<< 18. STABILIZER BAR
ROLL STOPPER AND
STEERING GEAR
ASSEMBLY
15. STEERING GEAR AND
LINKAGE PROTECTOR
(REFER TO GROUP 32,
CROSSMEMBER P.32-9).
>>A<< 16. STABILIZER BRACKET

.
<<A>> TIE ROD END DISCONNECTION

CAUTION
• Do not remove the nut from tie rod end ball joint.
Loosen it and use special tool MB991897 to avoid pos-
sible damage to tie rod end ball joint threads.
from falling.
CORD
NUT MB991897
BOLT

BOLT
CORRECT
3. Tighten the bolt with a wrench to disconnect the tie rod end.
KNOB
WRONG AC106821AC
.
STABILIZER BAR
<> STEERING GEAR AND STEERING

COLUMN ASSEMBLY DISCONNECTION
1. Remove the steering gear and steering column assembly
connecting bolt.
2. Pinch the steering column shaft clip with pliers, and pull up
the shaft in the direction shown to disengage the steering
column assembly.
STEERING
CLIP COLUMN
SHAFT
21DB016A
NOTE: If the steering column shaft is removed accidentally,

X
Y figure.
YOKE Y
A YOKE X
X
Y Y X
VIEW A
7.6˚ ± 3˚
X Y
AC306564 AB

REMOVAL
The crossmember mounting bolts need not be unscrewed
when the front axle crossmember stay is replaced. However,
the bolts may be loosened while the front axle crossmember
stay is removed. It is recommended that you retighten the bolts
to specification.
FRONT AXLE
CROSSMEMBER
STAY
21DB019A
STABILIZER BAR

.
>>A<< STABILIZER BAR/STABILIZER BUSH-

ING/STABILIZER BRACKET INSTALLATION
OUTSIDE OF APPROXIMATELY
Align the stabilizer bar identification mark with the right end of
VEHICLE 20 mm ( 0.79 in ) the bushing (LH).
IDENTIFICATION
MARK
STABILIZER STABILIZER
BUSHING (LH) BRACKET (LH)
AC006141AE
>>B<< FRONT AXLE NO.1 CROSSMEMBER,

REAR ROLL STOPPER AND STEERING GEAR
ASSEMBLY INSTALLATION
Align the steering column dash panel cover notch (arrow A)
STEERING GEAR with the steering gear lug (arrow B), and install the front axle
number 1 crossmember, the rear roll stopper and steering gear
assembly.
A
STEERING COLUMN B
DASH PANEL COVER
21DB017A
>>C<< FRONT AXLE CROSSMEMBER

STAY/SELF-LOCKING NUT INSTALLATION
Ensure that the crossmember mounting bolts have been tight-
ened to specification, and then install the front crossmember
stay with the self-locking nut.
CROSSMEMBER
MOUNTING BOLT
FRONT AXLE
CROSSMEMBER
STAY
INSPECTION
M1332002000291
• Check the stabilizer bushings for wear and deterioration.
• Check the stabilizer bar for deterioration or damage.
.
STABILIZER BAR
STABILIZER LINK BALL JOINT BREAKAWAY

TORQUE CHECK
1. After shaking the ball joint stud several times, install the nut
MB990326 to the stud and use special tool MB990326 to measure the
breakaway torque of the ball joint.
2. When the measured value exceeds the standard value,
replace the stabilizer link.
3. When the measured value is lower than the standard value,
check that the ball joint turns smoothly without excessive
play. If so, it is possible to re-use that ball joint.
AC001129 AB
.
STABILIZER LINK BALL JOINT DUST COVER

CHECK
with your finger.
2. If the dust cover is cracked or damaged, replace the
stabilizer link.
NOTE: Cracks or damage of the dust cover may cause
damage to the ball joint.
SPECIFICATIONS
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)
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
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)
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
SPECIFICATIONS
M1332000300382
ITEM STANDARD VALUE

Toe-in mm (in) 0 ± 3 (0 ± 0.12)
Steering angle Inner wheel 37°12' ± 2°00' <vehicles with 16-inch wheels>
33°48' ± 2°00' <vehicles with 17-inch wheels>
Outer wheel (reference) 30°18' <vehicles with 16-inch wheels>
28°18' <vehicles with 17-inch wheels>
Camber 0°00' ± 30' (Left/right deviation within 30')
Caster 3°00' ± 30' (Left/right deviation within 30')
Kingpin inclination 12°54' ± 1°30'
Lower arm ball joint breakaway torque N⋅m (in-lb) 3.5 − 6.9 (31 − 61)
Lower arm bushing press-in pressure kN (lb) 10 (2,248) or more
Stabilizer link ball joint breakaway torque N⋅m (in-lb) 3.4 − 9.0 (30 − 80)
LUBRICANT
M1332000400163

Lower arm Lip portion of dust cover Multipurpose grease SAE J310, As required
ball joint Inside of dust cover NLGI No.2 or equivalent 13 ± 0.5 g (0.45 ± 0.02 oz)
SPECIFICATIONS
NOTES
SPECIFICATIONS
HOME
34-1
GROUP 34
REAR SUSPENSION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 34-2 REMOVAL AND INSTALLATION . . . . . . . . 34-12

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-12
REAR SUSPENSION DIAGNOSIS . . 34-2
INTRODUCTION TO REAR SUSPENSION TOE CONTROL ARM . . . . . . . . . . . . . 34-13
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 34-2 REMOVAL AND INSTALLATION . . . . . . . . 34-13
REAR SUSPENSION DIAGNOSTIC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-14
TROUBLESHOOTING STRATEGY . . . . . . 34-2 TOE CONTROL ARM BALL JOINT DUST
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 34-3 COVER REPLACEMENT . . . . . . . . . . . . . . 34-15
SYMPTOM PROCEDURES . . . . . . . . . . . . 34-3
SHOCK ABSORBER ASSEMBLY . . . 34-16
SPECIAL TOOLS. . . . . . . . . . . . . . . . 34-5 REMOVAL AND INSTALLATION . . . . . . . . 34-16
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-16
ON-VEHICLE SERVICE. . . . . . . . . . . 34-6 DISASSEMBLY AND ASSEMBLY . . . . . . . 34-17
REAR WHEEL ALIGNMENT CHECK AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-21
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 34-6
LOWER ARM PILLOW BALL BUSHING END STABILIZER BAR. . . . . . . . . . . . . . . . 34-21
PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . 34-8
TOE CONTROL ARM BALL JOINT END PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-22
BALL JOINT DUST COVER INSPECTION 34-8

REAR SUSPENSION
CROSSMEMBER . . . . . . . . . . . . . . . . 34-23
UPPER ARM ASSEMBLY . . . . . . . . . 34-9
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 34-9
SPECIFICATIONS . . . . . . . . . . . . . . . 34-27
LOWER ARM . . . . . . . . . . . . . . . . . . . 34-10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 34-11
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
.
reduce road noise, making the vehicle quieter by all

suspension arms except a trailing arm connected to
the crossmembers with an elastic structure.
COIL SPRING
UPPER ARM ASSEMBLY
REAR SUSPENSION
CROSSMEMBER SHOCK
ABSORBER
STABILIZER BAR
TRAILING ARM TOE CONTROL ARM

ASSEMBLY ASSEMBLY
LOWER ARM ASSEMBLY

AC305738AB
REAR SUSPENSION DIAGNOSIS

INTRODUCTION TO REAR SUSPENSION DIAGNOSIS
M1341013100245
If the rear suspension is faulty, the vehicle will not run
straightforward or noise will occur. Incorrect wheel
alignment, malfunction of shock absorber, stabilizer
bar, coil spring, control arms or worn or out-of-bal-
ance will cause these problems.
REAR SUSPENSION DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1341013200242
rear suspension fault. Chart.
SYMPTOM CHART
M1341013500276

Squeaks or other abnormal noise 1 P.34-3
Poor ride 2 P.34-3
Body tilting 3 P.34-4
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Squeaks or other Abnormal Noise
DIAGNOSIS STEP 3. Check the upper arms and/or lower arms

and/or toe control arms for deformity or damage.
STEP 1. Check for loose rear suspension Q: Are the upper arms and/or lower arms and/or toe
installation bolts and nuts. control arms in good condition?
Q: Are the rear suspension installation bolts and nuts YES : Go to Step 4.
loose? NO : Replace the faulty part, and then go to Step
YES : Retighten them, and then go to Step 5. 5.
NO : Go to Step 2.
STEP 4. Check the trailing arms for deformity or
STEP 2. Check the condition of the shock damage.
absorbers (worn bushings). Q: Are the trailing arms in good condition?
Q: Are the shock absorbers (bushings) in good YES : Go to Step 5.
condition? NO : Replace the faulty part, and then go to Step
YES : Go to Step 3. 5.
NO : Replace the faulty part, and then go to Step
5.
INSPECTION PROCEDURE 2: Poor Ride
DIAGNOSIS STEP 2. Check the condition of the shock

absorbers (weak or broken springs).
STEP 1. Check for excessive tyre inflation Q: Are the shock absorbers in good condition?
pressure. YES : Go to Step 3.
Refer to GROUP 31, On-vehicle Service − Tyre Infla- NO : Replace the faulty part, and then go to Step
tion Pressure Check P.31-7. 4.
Q: Is the tyre inflation pressure correct?
YES : Go to Step 2.
NO : Adjust the pressure, and then go to Step 4.
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.
INSPECTION PROCEDURE 3: Body Tilting
DIAGNOSIS STEP 3. Check the upper arms and/or lower arms

and/or toe control arms for deformity or damage.
STEP 1. Check for weak or deteriorated Q: Are the upper arms and/or lower arms and/or toe
bushings. control arms deformed or damaged?
Q: Are the bushings in good condition? YES : Replace the faulty part, and then go to Step
YES : Go to Step 2. 5.
NO : Replace the faulty part, and then go to Step NO : Go to Step 4.
5.
STEP 4. Check the trailing arms for deformity or
STEP 2. Check for weak or broken coil springs. damage.
Q: Are the coil springs in good condition? Q: Are the trailing arms deformed or damaged?
YES : Go to Step 3. YES : Replace the faulty part, and then go to Step
NO : Replace the faulty part, and then go to Step 5.
5. NO : Go to Step 5.

SPECIAL TOOLS
SPECIAL TOOLS
M1341000600433

NAME
MB991897 MB991113-01, Knuckle and toe control
Ball joint remover MB990635-01 or General arm ball joint
service tool disconnection
NOTE: Steering linkage
AC106827
puller (MB990635 or
MB991113) is also
available to disconnect
knuckle and tie rod end
ball joint.
MB990326 General service tool • Toe control arm ball
Preload socket joint turning torque
check
• Stabilizer bar link ball
joint breakaway
MB990326
torque check
MB990800 MB990800-01or General Toe control arm ball joint
Ball joint dust cover service tool dust cover installation
installer
MB990800
• A: MB991237 MIT221369 or general Coil spring removal and

Spring compressor service tool installation
body NOTE: Spring
A
• B: MB991239 compressor set
Arm set (MB991832) is also
B MB991237
available to compress
coil spring (refer to
GROUP 33, Special
Tools P.33-5).
A MB991680 − Shock absorber
B Wrench set disassembly and
• A: MB991681 assembly
Wrench
MB991680
• B: MB991682
Socket
ON-VEHICLE SERVICE
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)
.
If camber and/or toe-in is not within the standard value, adjust

by the following procedures.
CAUTION
• When adjusting the camber, tighten the lower arm
assembly and the trailing arm assembly, not the toe
control arm.
• After adjusting the camber, be sure to adjust the toe.
1. Carry out camber adjustment by turning the camber
CAMBER adjusting bolt.
ADJUSTING
BOLT NOTE: .
TOE CONTROL ARM
• LH: Clockwise viewed from the rear → (−) camber
• RH: Clockwise viewed from the rear → (+) camber
• 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).
AC305842 AB
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
CAMBER AND TOE REFERENCE TABLE
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
ON-VEHICLE SERVICE
LOWER ARM PILLOW BALL BUSHING END PLAY

CHECK
M1341016900143
2. Remove the stabilizer bar link assembly from the lower arm
assembly.
3. Move the lower arm up and down with your hands to check
for excessive play in the axial direction of the pillow ball
bushing. If there is excessive play, replace the knuckle
assembly. (Refer to GROUP 27, Knuckle P.27-8).
4. After inspection, install the stabilizer bar link assembly to the
lower arm assembly, and tighten the mounting nuts to 40 ± 5
N⋅m (30 ± 3 ft-lb).
TOE CONTROL ARM BALL JOINT END PLAY

CHECK
M1341015800080
2. Move the toe control arm up and down with your hands to
check for excessive play in the axial direction of the ball
joint. If there is excessive play, replace the toe control arm
assembly.
BALL JOINT DUST COVER INSPECTION

M1341012800296
Check the ball joint dust cover of the toe control arm assembly
and the stabilizer bar link assembly as follows.
1. Check dust cover for cracks or damage by pushing it with
your finger.
2. If a dust cover is cracked or damaged, replace the toe
control arm assembly or the stabilizer bar link assembly.
NOTE: Cracks or damage to the dust cover may cause
UPPER ARM ASSEMBLY
UPPER ARM ASSEMBLY

M1341003600216
CAUTION
• 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
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.
LOWER ARM
LOWER ARM
M1341006500047
CAUTION
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

• SHOCK ABSORBER ASSEMBLY 2. LOWER ARM ASSEMBLY AND
AND KNUCKLE CONNECTION KNUCKLE CONNECTION
(REFER TO P.34-16). <<A>> 3. LOWER ARM BOLT
1. LOWER ARM ASSEMBLY AND 4. LOWER ARM PLATE
STABILIZER BAR LINK ASSEMBLY 5. LOWER ARM ASSEMBLY
CONNECTION
LOWER ARM

.
<<A>> LOWER ARM BOLT REMOVAL

Place mating marks on the crossmember and the plate before
removing the lower arm bolt.
CROSSMEMBER MATING MARKS
PLATE
LOWER ARM
ASSEMBLY AC306251 AB
INSPECTION
M1341006600055
• Check the lower arm for bending or breakage.
34-12 REAR SUSPENSION
TRAILING ARM
TRAILING ARM
M1341002200390
CAUTION
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
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 trailing arm for bending or breakage.
TOE CONTROL ARM
TOE CONTROL ARM

M1341016600045
CAUTION
• Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.
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

• TRAILING ARM ASSEMBLY AND 3. ASSIST LINK PLATE
KNUCKLE CONNECTION (REFER 4. TOE CONTROL ARM ASSEMBLY
TO P.34-12). Required Special Tool:
<<A>> 1. TOE CONTROL ARM ASSEMBLY • MB991897: Ball Joint Remover
AND KNUCKLE CONNECTION
<> 2. ASSIST LINK BOLT
TOE CONTROL ARM

.
<<A>> TOE CONTROL ARM ASSEMBLY AND

KNUCKLE DISCONNECTION
CAUTION
joint threads.
from falling.
CORD
NUT MB991897
BOLT
2. Turn the bolt and knob as necessary to make the jaws of the
BOLT
CORRECT
3. Tighten the bolt with a wrench to disconnect the toe control
KNOB arm assembly and the knuckle.
WRONG AC106821AC
<> ASSIST LINK BOLT REMOVAL

TOE CONTROL Place mating marks on the crossmember and the plate before
ARM ASSEMBLY removing the assist link bolt.
MATING MARKS
PLATE
CROSSMEMBER AC306251 AC
INSPECTION
M1341016800049
• Check the toe control arm for bending or breakage.
TOE CONTROL ARM
TOE CONTROL ARM BALL JOINT TURNING

TORQUE CHECK
1. After shaking the ball joint stud several times, in order to
MB990326 make the ball joint turn smoothly, install the nut to the stud
and use special tool MB990326 to measure the turning
torque of the ball joint.
Standard value: 1.0 − 2.6 N⋅m (8.9 − 23 in-lb)
2. If the measured value exceeds the standard value, replace
the toe control arm assembly.
3. If the measured value is lower than the standard value,
AC101919AB check that the ball joint turns smoothly without excessive
TOE CONTROL ARM BALL JOINT DUST COVER

CHECK
1. Check the toe control arm ball joint dust cover for cracks or
damage by pushing it with your finger.
BALL JOINT 2. If the dust cover is cracked or damaged, replace the toe
DUST COVER control arm assembly.
damage to the ball joint. When it is damaged during service
work, replace the dust cover.
TOE CONTROL ARM
ASSEMBLY
AC209167AB
TOE CONTROL ARM BALL JOINT DUST COVER

REPLACEMENT
M1341010900264

• MB990800: Ball Joint Remover and Installer
Only when the dust cover is damaged accidentally during ser-
vice work, replace the dust cover as follows:
MB990800 1. Remove the dust cover.
2. Fill the new dust cover with multipurpose grease and
lubricate the lip [Amount of grease in the dust cover:
approximately 7g (0.247 ounce)].
3. Using special tool MB990800, punch the dust cover until it
contacts the snap ring.
4. Press the dust cover with your finger to check that there are
AC212031AB
no cracks or damage in the dust cover.
SHOCK ABSORBER ASSEMBLY

M1341002500283
CAUTION
the ground in the unladen condition.
• 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

1. COIL SPRING NUT 5. SHOCK ABSORBER ASSEMBLY
2. COIL SPRING BOLT AND KNUCKLE CONNECTION
3. COIL SPRING WASHER 6. SHOCK ABSORBER ASSEMBLY
4. COIL SPRING WASHER
INSPECTION
M1341002600172
• Check the rubber parts for cracks and wear.
• Check the shock absorber for malfunctions, oil leakage, or
abnormal noise.

M1341005300266
23 ± 2 N·m
17 ± 1 ft-lb
1
2
10
8
3
9
11 4
6
12
7
13
AC305784 AB

<<A>> >>C<< 1. COIL SPRING NUT (SELF-LOCKING 11. SHOCK ABSORBER COVER
NUT) 12. SHOCK ABSORBER DAMPER
2. COIL SPRING WASHER 13. SHOCK ABSORBER
3. COIL SPRING BUSHING Required Special Tools:
4. SHOCK ABSORBER GASKET • MB991237: Spring Compressor Body
>>B<< 5. SHOCK ABSORBER INSULATOR
• MB991239: Arm Set
6. SPRING UPPER PAD
7. COIL SPRING BUSHING
• MB991680: Wrench Set
8. COIL SPRING COLLAR • MB991681: Wrench
>>A<< 9. COIL SPRING • MB991682: Socket
10. SHOCK ABSORBER CUP

.
<<A>> COIL SPRING NUT (SELF-LOCKING NUT)

REMOVAL
CAUTION
• To hold the coil spring securely, install special tools
MB991237 and MB991239 evenly, and so that the space
between both arms of the special tool will be maximum
within the installation range.
• Do not use an impact wrench to tighten the bolt of spe-
cial tool MB991237. The usage of impact wrench will
break the special tool.
1. Use special tools MB991237 and MB991239 to compress
the coil spring.
MB991237
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

.
>>A<< COIL SPRING INSTALLATION

CAUTION
Do not use an impact wrench to tighten the bolt of special
tool MB991237. It will break the special tool.
1. Use special tools MB991237 and MB991239 to compress
the coil spring, and install it to the spring seat of the shock
MB991237 absorber.
2. Align the end of the coil spring with the stepped section of
the spring seat of the shock absorber.
MB991239
AC001070 AB
>>B<< SHOCK ABSORBER INSULATOR

INSTALLATION
Install the shock absorber insulator as follows.
1. Position the coil spring lower end as shown.
<LH>
2. Position a center line (A) of the shock absorber lower
bushing inner pipe as shown from the arrow (B) on the
shock absorber insulator.
COIL SPRING
LOWER END
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
.
>>C<< COIL SPRING NUT (SELF-LOCKING NUT)

INSTALLATION
1. Temporarily tighten the coil spring nut (self-locking nut).
CAUTION
Do not use an impact wrench to tighten the bolt of special
tool MB991237. It will break the special tool. Vibration of
the impact wrench will cause the valve inside the shock
absorber to drop out.
2. Remove special tools MB991237 and MB991239.
<3.8L ENGINE> AC305845 For 3.8L engine models, using special tool MB991681, a
HEXAGON WRENCH hexagon wrench and a pipe, tighten the coil spring nut
(self-locking nut) to 23 ± 2 N⋅m (17 ± 1 ft-lb).
PIPE
MB991681
AC306398AB
SHOCK ABSORBER DISPOSAL

WARNING
Wear goggles when drilling to protect your eyes from
flying metal debris.
The gas must be discharged from the shock absorber before
discarding it. Place the shock absorber horizontally with its pis-
ton rod extended. Then drill a hole of approximately 3 mm (0.1
inch) in diameter at the location shown in the illustration and
discharge the gas.
AC102270 AC
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
M1341003000270
• 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

1. STABILIZER BAR LINK >>A<< 3. STABILIZER BUSHING
ASSEMBLY >>A<< 4. STABILIZER BAR
>>A<< 2. STABILIZER BAR BRACKET
STABILIZER BAR

.
>>A<< STABILIZER BAR/STABILIZER BUSH-

ING/STABILIZER BAR BRACKET INSTALLATION
1. Position the stabilizer bar identification paint to the left side.
OUTSIDE OF
2. Adjust the identification paint position as shown in the figure,
VEHICLE IDENTIFICATION PAINT and tighten the stabilizer bolt.
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.
.
STABILIZER BAR LINK BALL JOINT

BREAKAWAY TORQUE CHECK
1. After shaking the ball joint stud several times, install the nut
MB990326 to the stud and use special tool MB990326 to measure the
breakaway torque of the ball joint.
2. When the measured value exceeds the standard value,
replace the stabilizer bar link assembly.
3. When the measured value is lower than the standard value,
check that the ball joint turns smoothly without excessive
AC001129 AB
.
STABILIZER BAR LINK BALL JOINT DUST

COVER CHECK
with your finger.
2. If the dust cover is cracked or damaged, replace the
stabilizer bar link assembly.
REAR SUSPENSION CROSSMEMBER

M1341006800297
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.
• 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).
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

<<A>> • REAR WHEEL SPEED SENSOR >>C<< 1. CROSSMEMBER NUT
<VEHICLES WITH ABS> <<C>> >>C<< 2. CROSSMEMBER STAY
• STABILIZER BAR LINK >>B<< 3. CROSSMEMBER NUT
ASSEMBLY (REFER TO P.34-21). <<D>> >>B<< 4. CROSSMEMBER BRACKET
• LOWER ARM ASSEMBLY (REFER >>A<< 5. CROSSMEMBER STAY
TO P.34-10). 6. CROSSMEMBER PLATE
<> • TOE CONTROL ARM ASSEMBLY 7. REAR SUSPENSION
(REFER TO P.34-13). CROSSMEMBER
• UPPER ARM ASSEMBLY (REFER 8. CROSSMEMBER UPPER
TO P.34-9). STOPPER
• STABILIZER BAR (REFER TO
P.34-21).

.
<<A>> REAR WHEEL SPEED SENSOR REMOVAL

<VEHICLES WITH ABS>
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.
The rear wheel speed sensor can be damaged during service
work. Unclamp the rear wheel speed sensor cable as shown,
and use a cord to tie it out of the way.
17DB049A
<> TOE CONTROL ARM ASSEMBLY

REMOVAL
Disconnect the toe control arm only from its rear suspension
TOE CONTROL
crossmember side, and use a cord to tie it to the trailing arm
ARM ASSEMBLY assembly as shown.
TRAILING ARM
ASSEMBLY
AC305742 AB
<<C>> CROSSMEMBER STAY REMOVAL

when the crossmember stay is replaced. However, the bolts
CROSSMEMBER
may be loosened while the crossmember stay is removed. It is
STAY recommended that you should retighten the bolts to specifica-
tion.
.
CROSSMEMBER
MOUNTING BOLT
AC306481AB
<<D>> CROSSMEMBER BRACKET REMOVAL

when the crossmember bracket is replaced. However, the bolts
may be loosened while the crossmember bracket is removed. It
is recommended that you retighten the bolts to specification.
CROSSMEMBER
MOUNTING BOLT
CROSSMEMBER
BRACKET AC306482AB

.
>>A<< CROSSMEMBER STAY INSTALLATION

Install the crossmember stay with its arrow facing the front of
FRONT OF VEHICLE
vehicle.
CROSSMEMBER
STAY
AC209171AB
>>B<< CROSSMEMBER
BRACKET/CROSSMEMBER NUT INSTALLATION
ened to specification, and then install the crossmember bracket
with the crossmember nut.
CROSSMEMBER
MOUNTING BOLT
CROSSMEMBER
BRACKET
CROSSMEMBER NUT
AC306482AC
.
>>C<< CROSSMEMBER STAY/CROSSMEMBER

NUT INSTALLATION
ened to specification, and then install the crossmember stay
with the crossmember nut.
CROSSMEMBER
STAY
CROSSMEMBER
MOUNTING BOLT CROSSMEMBER
NUT
AC306481AC
INSPECTION
M1341006900089
• Check the crossmember for cracks or deformation.
SPECIFICATIONS
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)
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)
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
M1341000300421
ITEM STANDARD VALUE

Camber −0°50' ± 30' (Difference between
right and left within 30')
Toe-in mm (in) 3 ± 3 (0.12 ± 0.12)
Toe control arm ball joint turning torque N⋅m (in-lb) 1.0 − 2.6 (8.9 − 23)
Stabilizer bar link ball joint breakaway torque N⋅m (in-lb) 3.4 − 9.0 (30 − 80)
LUBRICANT
M1341000400183

Toe control arm ball joint (lip and Multipurpose grease SAE J310, NLGI 7 ± 0.5 g (0.247 ± 0.018 oz)
inside of dust cover) No.2 or equivalent
HOME
35-1
GROUP 35
SERVICE BRAKES
CONTENTS
BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A
ANTI-LOCK BRAKING SYSTEM (ABS). . . . . . . . . . . . . . . . . . . 35B

NOTES
HOME
35A-1
GROUP 35A
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 35A-2 BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A-24

BASIC BRAKE SYSTEM DIAGNOSIS 35A-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-25
INTRODUCTION TO BASIC BRAKE
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . 35A-3 MASTER CYLINDER ASSEMBLY
BASIC BRAKE SYSTEM DIAGNOSTIC AND BRAKE BOOSTER . . . . . . . . . . 35A-26
TROUBLESHOOTING STRATEGY . . . . . . 35A-3
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 35A-3
MASTER CYLINDER . . . . . . . . . . . . . . . . . 35A-28
SYMPTOM PROCEDURES . . . . . . . . . . . . 35A-3
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-29
SPECIAL TOOLS. . . . . . . . . . . . . . . . 35A-12 DISC BRAKE ASSEMBLY . . . . . . . . . 35A-30

ON-VEHICLE SERVICE. . . . . . . . . . . 35A-13
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-32
BRAKE PEDAL CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 35A-13
<FRONT> . . . . . . . . . . . . . . . . . . . . . . . . . . 35A-33
BRAKE BOOSTER OPERATING TEST . . . 35A-14
DISASSEMBLY AND ASSEMBLY <REAR> 35A-36
CHECK VALVE OPERATION CHECK . . . . 35A-15
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-38
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 35A-16
BRAKE FLUID LEVEL SENSOR CHECK. . 35A-17 SPECIFICATIONS . . . . . . . . . . . . . . . 35A-40
DISC BRAKE PAD CHECK AND
FASTENER TIGHTENING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 35A-17
DISC BRAKE ROTOR CHECK. . . . . . . . . . 35A-19
GENERAL SPECIFICATIONS . . . . . . . . . . 35A-40
MASTER CYLINDER FUNCTION CHECK. 35A-23
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 35A-41
BASIC BRAKE SYSTEM 35A-2
GENERAL DESCRIPTION
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.
.
2. 296mm front ventilated disc brakes provide sta- Improved serviceability

ble braking force and improved braking feel.
1. A diagnosis function for the ABS system makes
3. 303mm rear ventillated disc brakes are used.
inspection easier.
.
2. An outer disc separated hub and rotor make
Improved stability removal and installation easier.
1. A 4-wheel anti-lock braking system (4ABS) pre- 3. The master cylinder reservoir is utilised for both
vents slipping caused by the vehicle wheels lock- brake and clutch fluid on manual transmission
ing up, in order to maintain a stable vehicle vehicles.
posture and steering performance. 4. The master cylinder filter is coloured black for
2. An electronic brake-force distribution (EBD) improved viewing.
makes it possible to maintain the maximum 5. The ABS-ECU and hydraulic unit are integrated
amount of braking force even when the vehicle's to make them more compact and light weight.
load is unevenly distributed.
<VEHICLE WITH ABS>
BRAKE BOOSTER
HYDRAULIC UNIT
(INTEGRATED WITH
THE ABS-ECU)
REAR DISC BRAKE

MASTER CYLINDER
FRONT DISC BRAKE
BASIC BRAKE SYSTEM DIAGNOSIS

INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS
M1351009700319
Hydraulic brakes are composed of the brake pedal,
master cylinder, brake booster and disc brakes. Mal-
functions such as insufficient braking power or the
generation of noise may occur due to wear, damage
or incorrect adjustment of these components.
BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1351009800316
have exhausted most of the possible ways to find a 3. Find the malfunction by following the symptom
basic brake system fault. chart.
SYMPTOM CHART
M1351009900324

PROCEDURE PAGE
Vehicle pulls to one side when brakes are applied 1 P.35A-3
Insufficient braking power 2 P.35A-4
Increased pedal stroke (Reduced pedal-to-floor board clearance) 3 P.35A-5
Brake drag 4 P.35A-6
Scraping or grinding noise when brake are applied 5 P.35A-7
Squealing, groaning or chattering noise when brake are applied 6 P.35A-8
Squealing noise when brakes are not applied 7 P.35A-9
Groaning, clicking or rattling noise when brakes are not applied 8 P.35A-11
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied
DIAGNOSIS
.
STEP 1. Check for oil, water, etc., on the pad

contact surface of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES : Replace the part and determine the
source/cause of foreign material. Then go to
Step 5.
NO : Go to Step 2.
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.
NO : Start over at Step 1. If a new symptom
appears, refer to the appropriate symptom
chart.
INSPECTION PROCEDURE 2: Insufficient Braking Power

.
DIAGNOSIS STEP 2. Check for spongy (not firm) brakes.

(1) With engine not running, depress the brake pedal
rapidly several times to deplete the booster
STEP 1. Check that the specified brake fluid is vacuum reserve.
used, its level is correct, and no contamination is (2) With the brake pedal fully released, depress the
found. brake pedal slowly until it stops.
Q: Is there a fault? (3) With a measuring device (ruler, etc.) next to the
YES : Refill or replace with the specified brake brake pedal, depress the pedal firmly and
fluid DOT 3 or DOT 4. Bleed the brakes if measure the distance the pedal traveled.
necessary (Refer to P.35A-16). Then go to
Q: Is the distance greater than 20 mm (0.8 inch)?
Step 7. YES : Bleed the brakes to remove air in the fluid
NO : Go to Step 2.
(Refer to P.35A-16). Then go to Step 7.
NO : Go to Step 3.
STEP 3. Check the brake booster function.

Refer to P.35A-14.
Q: Is there a fault?
YES : Replace the brake booster. Then go to Step
7.
NO : Go to Step 4.
STEP 4. Check for pinched or restricted brake STEP 7. Recheck symptom.

tube or hose. Q: Is the symptom eliminated?
Q: Is there a pinched or restricted brake tube or hose? YES : The procedure is complete.
YES : Replace that complete section of brake tube NO : Start over at step 1. If a new symptom
or brake hose. Then go to Step 7. surfaces, refer to the appropriate symptom
NO : Go to Step 5. chart.
STEP 5. Check for oil, water, etc., on the pad

contact surfaces of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES : Replace the part and determine the
source/cause of foreign material. Recheck
symptom. Then go to Step 7.
NO : The procedure is complete. If condition
persists for vehicles without ABS, go to Step
6.
INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)

.
DIAGNOSIS STEP 4. Check the master cylinder function.

Refer to P.35A-23.
STEP 1. Check for spongy (not firm) brakes. Q: Is there a fault?
(1) With engine not running, depress the brake pedal YES : Repair it. Then go to Step 7.
rapidly several times to deplete booster vacuum NO : Go to Step 5.
reserve.
(2) With the brake pedal fully released, depress the STEP 5. Check for brake fluid leaks.
brake pedal slowly until it stops.
Q: Is there a leak?
(3) With a measuring device (ruler, etc.) next to the YES : Check the connection for looseness,
brake pedal, depress the pedal firmly and corrosion, etc. Clean and repair as
measure the distance the pedal traveled. necessary. If leaking in any tube or hose
Q: Is the distance greater than 20 mm (0.8 inch)? section, replace the complete tube or hose.
YES : Bleed the brakes to remove air in the fluid Then go to Step 7 .
(Refer to P.35A-16). Then go to Step 7. NO : Go to Step 6.
NO : Go to Step 2.
STEP 6. Check for excessive clearance between
STEP 2. Check the pad for wear. the push rod and primary piston.
Refer to P.35A-17. Refer to P.35A-26.
Q: Is the pad thickness outside of specifications? Q: Is the clearance outside of specifications?
YES : Replace the part. Then go to Step 7. YES : Adjust the clearance. Then go to Step 7.
NO : Go to Step 3. NO : Go to Step 7.
STEP 3. Check the vacuum hose and check valve STEP 7. Recheck symptom.
for damage.
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.
INSPECTION PROCEDURE 4: Brake Drag

.
DIAGNOSIS
STEP 1. Check the parking brake operating lever return.

Q: Is the operation faulty?
PARKING BRAKE
OPERATING LEVER
NO : Go to Step 2.
AC210519 AB
STEP 2. Check the brake shoe springs for breakage.

Q: Are the brake shoe springs broken?
SHOE
YES : Replace the spring. Then go to Step 9.
SPRINGS NO : Go to Step 3.
AC210519AC
STEP 3. Check the amount of grease at each sliding

section.
Refer to GROUP 36, Parking Brake Lining and Drum P.36-8.
Q: Is the grease amount low?
YES : Apply grease. Then go to Step 9.
NO : Go to Step 4.
STEP 4. Check the parking brake pull amount.

Refer to GROUP 36, On-vehicle Service − Parking Brake lever
Stroke Check and Adjustment P.36-3.
YES : Adjust it. Then go to Step 9.
NO : Go to Step 5.
STEP 5. Check for insufficient clearance between the push

rod and primary piston.
Refer to P.35A-26.
YES : Adjust the clearance. Then go to Step 9.
NO : Go to Step 6.
STEP 6. Check the master cylinder piston return spring for

damage and return port for clogging.
Refer to P.35A-28.
Q: Is there damage?
NO : Go to Step 7.
STEP 7. Check port for clogging.

Q: Is the port clogged?
NO : Go to Step 8.
STEP 8. Check disc brake pistons for sticking.

Depress the brake pedal, then release. Confirm each wheel
spins freely.
Q: Does any wheel stick?
YES : Inspect that brake assembly. Then go to Step 9.
NO : Go to Step 9.
STEP 9. Recheck symptom.

NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied

.
DIAGNOSIS
STEP 1. Check the front brakes, then rear brakes, for

metal-to-metal condition.
Q: Is any metal-to-metal contact evident?
YES : Repair or replace the components. Then go to Step 6.
NO : Go to Step 2.
STEP 2. Check for interference between the caliper and

wheel.
Q: Is there any interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 3.
STEP 3. Check for interference between the dust cover and

brake disc.
<FRONT> <REAR> Q: Is there any interference?
DUST COVER YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 4.
BRAKE DISC 15DB177A
STEP 4. Check the brake drums or discs for cracks.

Q: Are there cracks?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 5.
STEP 5. Check for bent backing plate(s).

<REAR> Q: Is (Are) the backing plate(s) bent?
BACKING PLATE YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 6.
AC210519 AD

INSPECTION PROCEDURE6: Squealing, Groaning or Chattering Noise when Brakes are Applied
.
DIAGNOSIS STEP 2. Check the calipers for rust.

Q: Is there any rust?
STEP 1. Check the brake disc and pads for wear YES : Remove the rust. Then go to Step 4.
or cutting. NO : Go to Step 3.
Q: Is there wear or cutting?

YES : Repair or replace the part. Then go to Step
4.
NO : Go to Step 2.
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.
INSPECTION PROCEDURE 7: Squealing Noise when Brakes are not Applied
DIAGNOSIS
.
STEP 1. Check whether the backing plate is bent or loose

and interfering with the drum.
NO : Go to Step 2.
STEP 2. Check whether the drum is damaged due to

interference with the backing plate or shoe.
Q: Is there any damage?
NO : Go to Step 3.
STEP 3. Check the brake drum for wear and the shoe
spring for damage.
Q: Is there any wear or damage?
NO : Go to Step 4.
STEP 4. Check the brake discs for rust.

Q: Are the brake discs rusted?
YES : Remove the rust by using sand paper. If still rusted,
turn the rotors with an on-the-car brake lathe. Then go
to Step 10.
NO : Go to Step 5.
STEP 5. Check the brake pads for correct installation.

Q: Are the pads installed incorrectly?
YES : Repair the pads. Then go to Step 10.
NO : Go to Step 6.
STEP 6. Check the calipers for correct installation.

Q: Are the calipers installed incorrectly?
YES : Repair the calipers. Then go to Step 10.
NO : Go to Step 7.
STEP 7. Check the wheel bearings for end play.

(1) Remove the brake discs.
<FRONT> (2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 10.
NO : Go to Step 8.
AC102438 AC
<REAR>
AC205869AC
STEP 8. Check whether the brake booster or master

cylinder return is insufficient.
Q: Is the brake booster or master cylinder return
insufficient?
NO : Go to Step 9.
STEP 9. Adjust the brake pedal or brake booster pushrod.

Refer to P.35A-13 or P.35A-26.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
NO : Adjust the brake pedal or the brake booster pushrod.
Then go to Step 10.

INSPECTION PROCEDURE 8: Groaning, Clicking or Rattling Noise when Brakes are not Applied.
DIAGNOSIS
.
STEP 1. Check whether foreign material has entered the

wheel covers.
Q: Is there any foreign material?
YES : Remove it. Then go to Step 5.
NO : Go to Step 2.
STEP 2. Check for looseness of the wheel nuts.

Q: Are the wheel nuts loose?
YES : Tighten to 98 ± 10 N⋅m (73 ± 7 ft-lb). Then go to Step
5.
NO : Go to Step 3.
STEP 3. Check for looseness of the caliper installation

bolt.
<FRONT>
Q: Is the caliper installation bolt loose?
YES : Tighten to 100 ± 10 N⋅m (74 ± 7 ft-lb) for the front
caliper. Tighten to 60 ± 5 N⋅m (45 ± 3 ft-lb) for the rear
caliper. Then go to Step 5.
NO : Go to Step 4.
<REAR>
AC308605AB
35A-12 BASIC BRAKE SYSTEM
SPECIAL TOOLS
STEP 4. Check the wheel bearings for end play.

(1) Remove the brake discs.
<FRONT> (2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 5.
NO : Go to Step 5.
AC102438 AC
<REAR>
AC205869AC

SPECIAL TOOLS
M1351000600360

NAME
MB991568 General service Adjustment of the brake booster
Push rod adjusting socket tool push rod protrusion amount
MB990964 MB990620-01 or Pushing-in of the disc brake

A Brake tool set general service piston
B
A: MB990520 tool
Disc brake piston expander
MB990964
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
M1351000900446
BRAKE PEDAL HEIGHT

1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value: 168..5 − 171.5 mm− A/T
Standard value: 169.4 − 172.4 mm - M/T
[From the surface of dash panel to the face of pedal
pad]
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stoplight switch connector.
(2) Remove the brake booster (Refer to P.35A-26).
AC210522
NOTE: With the master cylinder and brake pipe con-
nected, remove the brake booster only.
(3) Adjust the brake pedal height by turning the clevis.
NOTE: When the clevis is turned 180 degrees, the pedal
height is changed by approximately 2.2 mm (0.09 in).
(4) Install the brake booster (Refer to P.35A-26).
(5) Measure the brake pedal height, and ensure that the
CLEVIS
measured value is within the specified value. If it is out of
the specified value, repeat Step (3) - (6).
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.
ON-VEHICLE SERVICE
BRAKE PEDAL FREE PLAY

1. Turn the ignition switch to the "LOCK" (OFF) position, and
depress the brake pedal two or three times. After eliminating
the vacuum in the brake booster, press the pedal down by
hand, and confirm that the amount of movement before
resistance is met (free play) is within the standard value
range.
Standard value: 3 − 8 mm (0.12 − 0.31 inch)
2. If the brake pedal play is not within the standard value,
check the following, and adjust or replace if necessary:
AC206445 AB
• Excessive play between the brake pedal and the clevis pin,
or between the clevis pin and the brake booster operating
rod
• Brake pedal height
• Installation position of the stop light switch, etc.
CLEARANCE BETWEEN BRAKE PEDAL AND

DASH PANEL
1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 500 N (112 pounds) of force, and measure
the clearance between the brake pedal and the dash panel.
Standard value: 110 mm (4.33 inches) or more [From
the surface of dash panel to the face of pedal pad]
3. If the clearance is outside the standard value, check for air
trapped in the brake line and check the thickness of the disc
brake pad. Andjust and replace defective parts as required.
4. Return the carpet etc. to its original position.
AC206446AB
BRAKE BOOSTER OPERATING TEST

M1351001000372
1. For simple checking of the brake booster operation, carry
out the following tests:
(1) Run the engine for one or two minutes, and then stop it. If
GOOD NO GOOD
the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective. Go to step 2.
AC000870 AB
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.
CHECK VALVE OPERATION CHECK

M1351009000376
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.
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.
.
MASTER CYLINDER BLEEDING

The master cylinder used has no check valve, so if bleeding is
carried out by the following procedure, bleeding of air from the
brake pipeline will become easier. (When brake fluid is not con-
tained in the master cylinder).
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a
finger.
4. With the outlet still closed, release the brake pedal.
OUTLET
5. Repeat steps 2 − 4 three or four times to fill the inside of the
master cylinder with brake fluid.
15DB172A
BRAKE LINE BLEEDING

Start the engine and bleed the air in the sequence shown in the
VEHICLES WITH ABS figure.
2 3
4 1
15DB173A
ON-VEHICLE SERVICE
BRAKE FLUID LEVEL SENSOR CHECK

M1351009100403
The brake fluid level sensor is in good condition if there is no
continuity when the float surface is above "MIN" and if there is
continuity when the float surface is below "MIN".
15DB186A
DISC BRAKE PAD CHECK AND REPLACEMENT

M1351002300398
NOTE: Uneven wearor tapering of brake pad may be caused
WHEN NEW WHEN WORN
by either caliper piston not operating correctly .
PAD CAUTION
• Whenever a pad must be replaced, replace both LH and
RH wheel pads as a set to prevent the vehicle from pull-
ing to one side when braking.
• If there is a significant difference in the thicknesses of
BRAKE
DISC the pads on the left and right sides, check the sliding
condition of the piston and slide pins.
15DB191A
<FRONT>
1. Check the brake pad thickness through the caliper body
check port.(Rear). Front pad check can be viewed from rotor
side.
15DB192A
<REAR>
15DB179A
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
ON-VEHICLE SERVICE
3. Remove the following parts from the caliper support.

<FRONT>
(1) Pad assembly
(2) Clip
4. In order to measure the brake drag force after pad
1 installation, measure the rotary-sliding resistance of the hub
with the pads removed (Refer to P.35A-30).
5. Install the pads and caliper assembly, and then check the
brake drag force (Refer to P.35A-30).
<REAR> 6. Tighten lock pin bolt. Ensure lock pin is held with spanner
while tightening lock pin bolt(Rear) to specified torque.
1 2
2
15DB197A
<REAR>
15DB196A
DISC BRAKE ROTOR CHECK

M1351002900334
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.
ON-VEHICLE SERVICE
INSPECTION ITEM REMARK

Scratches, rust, saturated lining materials and wear • If the vehicle is not driven for a long period of
time, sections of the discs that are not in contact
with the pads will become rusty, causing noise
and shuddering.
• If grooves and scratches resulting from excessive
disc wear are not removed prior to installing a new
pad assembly, there will be inadequate contact
between the disc and the lining (pad) until the
pads conform to the disc.
Run-out Excessive run-out of the discs will increase the pedal
depression resistance due to piston kick-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause
pedal pulsation, shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing
will cause warping or distortion.
.
BRAKE DISC THICKNESS CHECK

1. Using a micrometer, measure disc thickness at eight
positions, approximately 45 degrees apart and 10 mm (0.4
inch) in from the outer edge of the disc.
FRONT BRAKE DISC
Standard value: 26.0 mm (1.02 inches)
REAR BRAKE DISC
ACX00668AB
NOTE: Thickness variation (at least 8 positions) should not
be more than 0.015 mm (0.0006 inch).
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
.
ON-VEHICLE SERVICE
BRAKE DISC RUN-OUT CHECK AND

CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disc with the hub nut.
3. Place a dial gauge approximately 5 mm (0.2 inch) from the
outer circumference of the brake disc, and measure the
run-out of the disc.
Limit:
<Front brake disc>: 0.10 mm (0.0039 inch)
<Rear brake disc>: 0.04 mm (0.0016 inch)
ACX00669AB
4. If the brake disc run-out exceeds the limit, correct it as

follows:
(1) Chalk phase marks on the wheel stud and the brake disc
CHALK MARKS
as shown.
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.
(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
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
MASTER CYLINDER FUNCTION CHECK

M1351010200266
1. Remove the reservoir cap.
2. While watching the open reservoir from a distance of 50 cm
(20 inches), have an assistant depress the brake pedal. If
there was a stream of brake fluid rising from the reservoir,
proceed to Step 3. If there was no stream of brake fluid
rising from the reservoir, repair or replace the master
cylinder.
3. While watching the open reservoir from a distance of 50 cm
(20 inches), have the assistant release the brake pedal. If
there was a small amount of air bubbles rising through the
brake fluid, master cylinder function is normal. If there were
no bubbles rising through the brake fluid, repair or replace
the master cylinder.
BRAKE PEDAL
BRAKE PEDAL
M1351003400406
• 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

1. BRAKE BOOSTER PIN • WIRING HARNESSES CLAMPED
2. BRAKE BOOSTER PIN ASSEMBLY ON BRAKE PEDAL ASSEMBLY
3. SHIFT LOCK CABLE CONNECTION 7. BRAKE PEDAL BOLT
4. STOPLIGHT SWITCH CONNECTOR 8. BRAKE BOOSTER NUT
5. STOPLIGHT SWITCH 9. BRAKE PEDAL ASSEMBLY
6. BRAKE PEDAL CLIP 10. BRAKE PEDAL PAD
11. BRAKE PEDAL STOPPER
BRAKE PEDAL
INSPECTION
M1351003500221
.
STOPLIGHT SWITCH CHECK

1. Connect an ohmmeter between the stoplight switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
TESTER PLUNGER SPECIFIED
CONNECTION CONDITION
1−2 IN Open circuit
OUT Less than 2Ω
NO CONTINUITY CONTINUITY
4 mm
(0.16 in)
ACX00671AB
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

M1351003700407

• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Brake Fluid Supplying and Air Bleeding (Refer to
Tower Bar P.42-12). P.35A-16).
• Battery Removal • Brake Pedal Adjustment (Refer to P.35A-13).
• Brake Fluid Draining • Battery Installation
• Strut Tower Bar Installation (Refer to GROUP 42, Strut
Tower Bar P.42-12).
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
BRAKE MASTER CYLINDER BRAKE BOOSTER ASSEMBLY

ASSEMBLY REMOVAL STEPS REMOVAL STEPS
1. BRAKE FLUID LEVEL INDICATOR 1. BRAKE FLUID LEVEL INDICATOR
SWITCH CONNECTOR SWITCH CONNECTOR
2. BRAKE TUBE CONNECTION 2. BRAKE TUBE CONNECTION
5. BRAKE MASTER CYLINDER 5. BRAKE MASTER CYLINDER
ASSEMBLY ASSEMBLY
6. SPRING PIN >>B<< • PUSH ROD PROTRUSION
7. BRAKE FLUID RESERVOIR AMOUNT CHECK AND
ASSEMBLY ADJUSTMENT
8. MASTER CYLINDER FLUID >>A<< 11. BRAKE BOOSTER VACUUM
RESERVOIR SEAL HOSE
9. BRAKE FLUID LEVEL INDICATOR 12. BRAKE BOOSTER PIN
SWITCH 13. BRAKE BOOSTER PIN
10. BRAKE FLUID RESERVOIR CAP ASSEMBLY
BRAKE BOOSTER VACUUM 14. BRAKE BOOSTER NUT
HOSE REMOVAL STEP 15. BRAKE BOOSTER ASSEMBLY
>>A<< 11. BRAKE BOOSTER VACUUM 16. BRAKE BOOSTER BODY SEAL
HOSE Required Special Tool:
• MB991568: Push Rod Adjusting Socket

.
>>A<< BRAKE BOOSTER VACUUM HOSE

CONNECTION
Insert vacuum hose with its paint mark facing upward.
WHITE PAINT MARK
VACUUM HOSE
YELLOW PAINT MARK 15DB175A
>>B<< PUSH ROD PROTRUSION AMOUNT

CHECK AND ADJUSTMENT
1. Use the vacuum pump to measure dimension "A" applying a
negative pressure of 66.7 kPa (19.7 inHg) to the brake
booster.
Standard value (A): 5.0 mm ± 0.1
A
MEASURING DISTANCE A
BLOCK GAUGE
15DB185A
2. If the protrusion amount is not within the standard value

range, adjust the push rod length by turning the push rod.
Use special tool MB991568 to turn the push rod while
holding the rod spline with angle-nose pliers.
ROD SPLINE
ANGLE-NOSE PLIERS
MB991568
AC210714 AB
MASTER CYLINDER
M1351004200375
N1
4
5
2 MASTER CYLINDER KIT
6
3 N
4 N
5 N
6
5
4
15DB194A
BRAKE FLUID: DOT 3 OR DOT 4
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

.
<<A>> BRAKE MASTER CYLINDER UNION

RETAINER DISASSEMBLY
Remove the brake master cylinder union retainer while
depressing the piston.
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.
DISC BRAKE ASSEMBLY
DISC BRAKE ASSEMBLY

M1351008000050

• Brake Fluid Draining • Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-16).
<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
REMOVAL STEPS INSTALLATION STEPS (Continued)

• BRAKE FLUID DRAINING 1. BRAKE HOSE CONNECTION
1. BRAKE HOSE CONNECTION • BRAKE FLUID SUPPLYING AND AIR
2. GASKET BLEEDING (Refer to P.35A-16.)
3. BRAKE CALIPER ASSEMBLY >>A<< • BRAKE DRAG FORCE CHECK
4. BRAKE DISC Required Special Tool:
INSTALLATION STEPS • MB990520: Disc Brake Piston Expander
• BRAKE FLUID DRAINING
4. BRAKE DISC
3. BRAKE CALIPER ASSEMBLY
2. GASKET
DISC BRAKE ASSEMBLY

.
>>A<< BRAKE DRAG FORCE CHECK

<FRONT>
1. In order to measure the brake drag force, measure the hub
torque with the pads removed by the following procedure.
Use a spring scale to measure the hub torque in the forward
direction. Record hub torque with pads removed.
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.
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
.
BRAKE DISC CHECK

• Disc wear (Refer to P.35A-19).
• Disc run-out (Refer to P.35A-19).
DISC BRAKE ASSEMBLY
DISASSEMBLY AND ASSEMBLY <FRONT>

M1351008200065
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
CALIPER KIT PAD SET

1. PAD & SHIM ASSEMBLY 7. BOOT
2. CLIP 8. CALIPER SUPPORT
3. N/A <<A>> 9. CALIPER PISTON
4. GUIDE PIN BOLT <<A>> 10. PISTON BOOT
5. CALIPER BODY <> 11. PISTON SEAL
6. GUIDE PIN
DISC BRAKE ASSEMBLY
LUBRICATION POINTS
PISTON
SEAL
CAUTION
THE PISTON SEAL INSIDE THE
CALIPER SEAL KIT IS COATED
WITH SPECIAL GREASE DO NOT
WIPE THIS GREASE OFF.
BRAKE FLUID: DOT3 OR DOT4 15DB188A

CAUTION
When disassembling the front disc brakes, disassemble
both sides (left and right wheels) as a set.
.
DISC BRAKE ASSEMBLY
<<A>> CALIPER PISTON/PISTON BOOT

REMOVAL
CAUTION
Blow air little by little to remove the pistons. The pistons
will pop out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown.
Blow compressed air through the brake hose connection hole
to remove the piston boots and pistons.
15DB189A
<> PISTON SEAL REMOVAL

CAUTION
Do not use a flat-tipped screwdriver or similar tool to
remove the piston seal. These may damage the inner side
of the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean the piston surface and inner cylinder with alcohol or
brake fluid DOT 3 or DOT 4.
25DB190A
DISC BRAKE ASSEMBLY
DISASSEMBLY AND ASSEMBLY <REAR>

M1351008200076
12.5 ± 1.5 N·m
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

1. PAD & SHIM ASSEMBLY 7. PIN BOOT
2. CLIP 8. CALIPER SUPPORT
3. N/A <<A>> 9. PISTON
>>A<< 4. REAR BRAKE BOLT <<A>> 10. PISTON BOOT
5. CALIPER BODY <> 11. PISTON SEAL
6. GUIDE PIN 12. BLEEDER
DISC BRAKE ASSEMBLY
LUBRICATION POINTS

PISTON
SEAL
CAUTION
THE PISTON SEAL INSIDE THE CALIPER
SEAL KIT IS COATED WITH
SPECIAL GREASE. DO NOT WIPE
THIS GREASE OFF.
BRAKE FLUID: DOT3 OR DOT4
GREASE: REPAIR KIT GREASE 15DB183A

CAUTION
When disassembling the disc brakes, disassemble both
sides (left and right) as a set.
.
DISC BRAKE ASSEMBLY
<<A>> PISTON BOOT/CALIPER PISTON

REMOVAL
CAUTION
Blow air little by little to remove the piston. The piston will
pop out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown.
Blow compressed air through the brake hose connection hole
to remove the piston boot and piston.
AC204331
<> PISTON SEAL REMOVAL

CAUTION
Do not use a flat-tipped screwdriver or similar tool to
remove piston seal. These may damage the inner side of
the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean piston surface and inner cylinder with alcohol or brake
fluid DOT 3 or DOT 4.
AC204684

.
>>A<< REAR BRAKE PIN INSTALLATION

Attach a guide pin (with "g" on the bolt head) at the bleeder nip-
ple side of the caliper body and a lock pin (with "l" on the bolt
head) at the opposite side.
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.
.
DISC BRAKE ASSEMBLY
PAD WEAR CHECK

WARNING
• Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Fail-
ure to do so will result in uneven braking, which
may cause unreliable brake operation.
• If there is significant difference in the thickness of
the pads on the left and right sides, check the slid-
ing condition of the piston and slide pins.
1. Measure thickness at the thinnest and most worn area of the
pad.
Standard value: 10 mm (0.39 inch)
2. Replace the pad assembly if pad thickness is less than the
limit value.
ACX00690
SPECIFICATIONS
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
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
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
M1351000300477

Brake pedal height mm A/T 168.5 − 171.5 −
M/T 169.4 − 172.4
Brake pedal free play mm 3−8 −
Brake pedal to floor board clearance mm 110 or more −
Disc brake pad thickness mm 10.0 Minimum 2.0
Disc brake disc thickness Front 28.0 Minimum 26.4
mm Rear 18.0 Minimum 16.4
Disc brake disc run-out Front − 0.1
mm Rear − 0.04
Disc brake drag force N Front 64 or less −
Rear 54 or less −
Hub end play mm − 0.05
Brake booster push rod protruding length mm. 5.0 ± 0.1 −
[When applying negative pressure of 66.7 kPa to the
brake booster]
LUBRICANTS
M1351000400429
ITEM SPECIFIED LUBRICANT

Brake fluid DOT3 or DOT4
Piston boot, piston seal Repair kit grease
Front brake pin, rear brake pin (guide pin)
NOTES
HOME
35B-1
GROUP 35B
ANTI-LOCK
BRAKING SYSTEM
(ABS)
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 35B-2 ON-VEHICLE SERVICE . . . . . . . . . . . 35B-88

WHEEL SPEED SENSOR OUTPUT
ANTI-LOCK BRAKING SYSTEM (ABS) SIGNAL VOLTAGE MEASUREMENT . . . . 35B-88
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 35B-4 HYDRAULIC UNIT CHECK . . . . . . . . . . . . . 35B-90
INTRODUCTION TO ANTI-LOCK BRAKING IN THE EVENT OF A DISCHARGED
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . 35B-4 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-92
ABS DIAGNOSTIC TROUBLESHOOTING
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . . 35B-4 HYDRAULIC UNIT . . . . . . . . . . . . . . . 35B-93
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 35B-5 REMOVAL AND INSTALLATION . . . . . . . . 35B-93
DIAGNOSTIC TROUBLE CODE CHART . . 35B-9
DIAGNOSTIC TROUBLE CODE WHEEL SPEED SENSOR . . . . . . . . . 35B-95
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 35B-10 REMOVAL AND INSTALLATION . . . . . . . . 35B-95
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 35B-71 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35B-96
SYMPTOM PROCEDURES . . . . . . . . . . . . 35B-72
DATA LIST REFERENCE TABLE . . . . . . . 35B-82 SPECIFICATIONS . . . . . . . . . . . . . . . 35B-97
ACTUATOR TEST REFERENCE TABLE. . 35B-83 FASTENER TIGHTENING
CHECK AT ABS-ECU . . . . . . . . . . . . . . . . . 35B-84 SPECIFICATION . . . . . . . . . . . . . . . . . . . . . 35B-97
GENERAL SPECIFICATIONS . . . . . . . . . . 35B-97
SPECIAL TOOLS. . . . . . . . . . . . . . . . 35B-86
ANTI-LOCK BRAKING SYSTEM (ABS) 35B-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1352000100454
FEATURES • As the tooth on the reluctor approaches the sen-

The ABS 8 ensures directional stability and control sor, the magnetic circuit is completed therefore
during hard braking. turning on the Hall switch. As the tooth departs
This ABS uses a 4-sensor 4-channel system that the sensor, the Hall switch will turn off.
controls all four wheels independently of each other. • The output waveform displayed on the oscillo-
• EBD (Electronic Brake-force Distribution system) scope will be a square wave, (between signal
control provides the ideal braking force for the wire and ground).
rear wheels. • To shorten the harness wires and enhance data
• Active wheel speed sensors have been installed, transmission reliability, communication with other
that produce changes of current flow through the ECU is performed over a CAN (Controller Area
wheel speed sensor circuit which is influenced by Network).
the reluctor ring fitted to the wheel hub. NOTE: For further details on CAN communica-
• Active wheel speed sensors have a constant tion, refer to GROUP 54C, CAN.
incoming power supply on one wire and return a • Fail-safe function ensures that safety is main-
signal on the other wire tained.
• The advantage of the active wheel speed sensor • Diagnostic function provides improved service-
is that there is always a signal until the wheel has ability.
stopped. As the wheel speeds up or slows down, NOTE: If the ABS-8 ECU or the active wheel
the frequency will change where the amplitude of speed sensor are disconnected, or if the wiring is
the signal will remain constant. an open/ short circuit, the ABS 8 ECU will shut
• A Hall switch and magnet assembly is contained off power supply to the respective wheel speed
within the sensor. sensor. All other wheel speed sensors will oper-
ignition switch must be cycled to the "OFF" posi-
EBD CONTROL • Because the system provides the optimum rear
In ABS, electronic control is used so the rear wheel wheel braking force regardless of vehicle load
brake hydraulic pressure during braking is regulated and the condition of the road surface, the system
by rear wheel control solenoid valves in accordance reduces the required pedal depression force, par-
with the vehicle's rate of deceleration. The front and ticularly when the vehicle is heavily loaded.
rear wheel slippage are calculated from the signals • Because the duty placed on the front brakes is
received from the various wheel sensors. EBD con- reduced, the increases in pad temperature can
trol provides a high level of control for both vehicle be controlled during front brake application to
braking force and vehicle stability. The system has improve pad wear.
the following features: • Control valves such as the proportioning valve
are not required.
GENERAL DESCRIPTION
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) 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.

INTRODUCTION TO ANTI-LOCK BRAKING SYSTEM DIAGNOSIS
M1352012500396
The anti-lock braking system (ABS) operates differ- ABS Diagnostic Trouble Code Detection
ently from conventional brake systems. These differ- Conditions
ences include sounds, sensations, and vehicle
ABS diagnostic trouble codes (ABS DTCs) are set
performance that owners and service technicians
under different conditions, depending on the mal-
who are not familiar with ABS may not be used to.
function detected. Most ABS DTCs will only be set
Some operational characteristics may seem to be
during vehicle operation. Some ABS DTCs will also
malfunctions, but they are simply signs of normal
be set during the ABS self-check immediately after
ABS operation. When diagnosing the ABS system,
the engine is started.
keep these operational characteristics in mind.
When you check if an ABS DTC will be displayed
Inform the owner of the kind of performance charac-
again after the DTC has been erased, you should
teristics to expect from an ABS-equipped vehicle.
duplicate the ABS DTC set conditions. Depending on
the detection timing and set conditions for the spe-
cific ABS DTC, you must either drive the vehicle or
turn the engine off and restart it. To set the proper
conditions for that DTC again, refer to "ABS DTC
SET CONDITIONS" for each ABS DTC that you are
trying to reset.
ABS DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1352011100771
Use these steps to plan your diagnostic strategy. If 3. Check the vehicle for any ABS DTC.
you follow them carefully, you will be sure that you 4. If you cannot verify the condition and there are no
have exhausted most of the possible ways to find an ABS DTCs, the malfunction is intermittent. Refer
ABS fault. to GROUP 00, How to use
1. Gather information about the problem from the Troubleshooting/Inspection Service Points − How
customer. to Cope with Intermittent Malfunctions P.00-14.
2. Verify that the condition described by the
customer exists.
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
ON-BOARD DIAGNOSTICS (OBD) MB991958 (MUT-III sub assembly.) The stored

If the ABS-ECU detects any problem in the CAN DTCs are not erased even after the ignition switch
communication line or the ECUs, which the has been turned to the LOCK (OFF) position, or the
ABS-ECU is communicating with, it stores a diagnos- battery has been disconnected. The DTCs can be
tic trouble code. The DTCs have 9 items. The DTCs erased by operating diagnostic tool MB991958
can be confirmed by connecting diagnostic tool (MUT-III sub assembly.)

(MUT-III)
CAUTION
CONNECTOR
MB991958.
position.
4. Connect special tool MB991910 to the special tool
MB991824 MB991824.
5. Connect special tool MB991910 to the data link connector.
6. Turn the power switch special tool MB991824 to the "ON"
position.
NOTE: When the special tool MB991824 is energized, the
special tool MB991824 indicator light will be illuminated in a
green color.
MB991827 00DB076A
NOTE: Disconnect the diagnostic tool MB991958 in the
reverse order of the connecting sequence, making sure that the

TROUBLE CODES
CAUTION
CONNECTOR
MB991958.
not be set. Check the battery if diagnostic tool MB991958 does
not display.
MB991910 connector.
4. Select "System Select."
5. Choose "ABS" .
8. Choose "DTC erase" to erase the DTC.
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
connector.
5. Choose "ABS" .
MB991824
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
connector.
5. Choose "ABS" .
MB991824
6. Choose "Actuator Test" from "ABS" screen.
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
connector.
MB991910 4. When the vehicle information is displayed, confirm that it
MB991824 diagnosed.
5. Select "view vehicle information" button.
that it matches the vehicle which is being diagnosed.
MB991827 00DB076A
7. Press the "OK" button.
8. When the options are displayed, choose the options (mark
the check) and then select "OK".

M1352011300601
CAUTION
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
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

U1100* CAN communications system time out error engine related GROUP 13D,
data Diagnostic Trouble Code
Procedures 13A-527
U1101* CAN communications system time out error A/T related data GROUP 54C,
Diagnostic Trouble Code
Procedures
U1400* CAN invalid signal Accelerator Position (Dynamic range error GROUP 13D,
APS) Diagnostic Trouble Code
Procedures 13A-515
U1415 CAN invalid signal Gear Position GROUP 23A
Diagnostic Trouble Code
Chart P.23A-34
NOTE: Since the ABS system is controlled with the same ABS/TCL-ECU used to control the TCL system, the
codes (with a *) used only for the ABS system also appear.
The inspection contents for the codes (with a *) used only for the TCL system do not described in this group.
DTC C1200/C1205/C1210/1215 Wheel Speed Sensor (Open circuit or short circuit)
35DB090A
CAUTION an open/ short circuit, the ABS 8 ECU will shut

• Wheel speed sensor wires/ wiring are not to off power supply to the respective wheel speed
be interchanged, as this could destroy the sensor. All other wheel speed sensors will oper-
sensor. ate normally. To restore the power supply, the
• Never apply external voltage (e.g. battery volt-
age) to sensors. Excessively high voltages or
current can lead to failures.
CAUTION • As the tooth on the reluctor approaches the sen-

If there is any problem in the CAN bus lines, an sor, the magnetic circuit is completed therefore
incorrect diagnostic trouble code may be set. turning on the Hall switch. As the tooth departs
Diagnose the CAN bus lines before the DTC the sensor, the Hall switch will turn off.
(Refer to GROUP 54C, Trouble code diagno- • The output waveform displayed on the oscillo-
sisP.54C-13). scope will be a square wave, (between signal
. wire and ground).
CIRCUIT OPERATION • The ABS hydraulic unit modulates the amount of
• Active wheel speed sensors have been installed, braking force individually applied to each wheel
that produce changes of current flow through the cylinder.
wheel speed sensor circuit which is influenced by .
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 .
within the sensor.

TROUBLESHOOTING HINTS (The most Past trouble

likely causes for these DTCs are to set • Carry out diagnosis with particular emphasis on
connector(s) or wiring harness in wheel speed
are:) sensor circuit. For diagnosis procedures, refer to
Current trouble "How to cope with past trouble" (Refer to GROUP
• Malfunction of the wheel speed sensor 00, How to use Troubleshooting/Inspection Ser-
• Damaged wiring harness or connector vice PointsP.00-16).
• Malfunction of the hydraulic unit (integrated with Circuit drawings
ABS-ECU) • Refer to circuit diagrams GROUP-90
.
DIAGNOSIS
• MB991222: Back-probing probe
• MB991219: Inspection test harness
.

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991824 YES : Go to Step 3
NO : Repair the CAN bus line (Refer to GROUP 54C,
Diagnosis P.54C-15). Then go to Step 2.
MB991827 00DB076A
STEP 2. Recheck for diagnostic trouble code.

CAUTION
CONNECTOR
MB991958.
(2) Erase the DTC.
(5) Check if the DTC is set.
MB991910
MB991824 Q: Is DTC C1200, C1205, C1210 or C1215 set?
YES : Go to Step 3
MB991827 00DB076A
STEP 3. Using diagnostic tool MB991958, check data list.

CAUTION
CONNECTOR
MB991958.
connector.
(3) Set diagnostic tool MB991958 to the data reading mode,
and check the data list items by driving the vehicle.
MB991910
• Item 01 (DTC C1205 is set): Front left wheel speed sen-
sor
MB991824
• Item 02 (DTC C1200 is set): Front right wheel speed
sensor
• Item 03 (DTC C1215 is set): Rear left wheel speed sen-
sor
• Item 04 (DTC C1210 is set): Rear right wheel speed
sensor
MB991827 Q: Does the speedometer indication match the diagnostic
00DB076A
tool indication?
NO : Go to Step 4.
STEP 4. Measure supply voltage for wheel speed sensor

using an oscilloscope.
(3) Using probe (MB991222) , backprobe the wheel speed
sensor voltage supply circuit terminals (16, 9, 6 and 8) at
the ABS-ECU connector (A-02) individually.
appropriate terminal positions and check supply voltage
11-12V FIGURE 1
OSCILLOSCOPE
Black Red
Ground
Terminals:
16, 9, 6, 8
Supply
WHEEL SPEED
Signal
SENSOR
Wheel speed sensor connectors: ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
35DB121A
• If Item 01 (DTC C1205 is set): Connect oscilloscope to

FL sensor signal terminal (16) at ABS-ECU (A-02)
FR sensor signal terminal (9) at ABS-ECU (A-02)
RL sensor signal terminal (6) at ABS-ECU (A-02)
RR sensor signal terminal (8) at ABS-ECU (A-02)
(6) The recommended Supply Voltage at terminals 16, 9, 6,

and 8 are:
• Set value: 10.0Volts - 14.5Volts
Q: Is the supply voltage within the set value?
YES : Go to Step 5
NO : • Refer to Power supply systemP.35B-63
• Refer to Motor supply systemP.35B-48
• Refer to Valve relay systemP.35B-56
STEP 5. Measure wheel speed sensor signals using an

oscilloscope.
NOTE: To check connections of the wheel speed sensors,
remove the rear seat to access the rear wheel speed sen-
sor connectors, and remove inner front guard (splash
shield) to access the front wheel speed sensors.
(1) Wheel speed sensor must remain connected to measure
active sensor.
(4) Using probe (MB991222), backprobe the wheel speed
sensor signal circuit terminals (5, 10, 17, 19), and check
individually at the ABS-ECU connector A-02
(5) The wheel to be tested must be free to turn by hand or be
driven by brake dynamometer
appropriate terminal positions and check sensor operation
FIGURE 2
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

FL sensor signal terminal (5) at ABS-ECU (A-02)
FR sensor signal terminal (10) at ABS-ECU (A-02)
RL sensor signal terminal (17) at ABS-ECU (A-02)
RR sensor signal terminal (19) at ABS-ECU (A-02)
(7) Recommended Oscilloscope setting:
• Y-axis: 2Volts
• X-axis: 100ms
(9) Turn wheel by hand at approximately 1 revolution per
Q: Does the oscilloscope measurement signal shape

correspond to the figure 3 below?

U-CH1
V
1.50
1.00
0.50
0.00
0 20 40 60 80 100
ms
35DB120A

NO : • FR sensor malfunction. Go to Step 6
• FL sensor malfunction. Go to Step 8
• RR sensor malfunction. Go to Step 10
• RL sensor malfunction. Go to Step 12
STEP 6. Check ABS-ECU connector A-02 and wheel speed

sensor <front: RH> connector A-01 for loose, corroded or
connector.
35DB090A
Q: Are ABS-ECU connector A-02 and wheel speed sensor

<front: RH> connector A-01 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 7.
35DB090A
STEP 7. Check the harness wires and continuity resistance

between ABS-ECU connector A-02 (terminal 9, 10) and
wheel speed sensor <front: RH> connector A-01 (terminal
2, 1). (see figure and table below)
defective contact.
Wheel speed ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
SENSOR
35DB123A

ABS (A-02) SENSOR
(A-01)
(D-30)
(A-04)
(D-31)
Q: Is the harness wire between ABS-ECU connector A-02

(terminal 9, 10) and wheel speed sensor <front: RH>
connector A-01 (terminal 2, 1) damaged?
YES : Repair the wiring harness. Then go to Step 16.
NO : Go to Step 14.

sensor <front: LH> connector A-04 for loose, corroded or
connector.
<front: LH> connector A-04 damaged?
NO : Go to Step 9.
35DB090A
STEP 9. Check the harness wires and continuity resistance

between ABS-ECU connector A-02 (terminal 5, 16) and
wheel speed sensor <front: LH> connector A-04 (terminal
1, 2). (see figure and table below).
defective contact.
Wheel speed ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
SENSOR
35DB123A

ABS (A-02) SENSOR
(A-01)
(D-30)
(A-04)
(D-31)

(terminal 5, 16) and wheel speed sensor <front: LH>
connector A-04 (terminal 1, 2) damaged?
NO : Go to Step 14.
STEP 10. Check ABS-ECU connector A-02, intermediate

connector C-25 and wheel speed sensor <rear: RH>
connector D-30 for loose, corroded or damaged terminals,
or terminals pushed back in the connector.
Q: Are ABS-ECU connector A-02, intermediate connector
CONNECTOR: C-25 C-25 and wheel speed sensor <rear: RH> connector
D-30 damaged?
NO : Go to Step 11.
C-25
35DB033A
STEP 11. Check the harness wires and continuity

resistance between ABS-ECU connector A-02 (terminal 8,
19) and wheel speed sensor <rear: RH> connector D-30
(terminal 1, 2). (see figure and table below).
defective contact.
Wheel speed ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
SENSOR
35DB123A

ABS (A-02) SENSOR
(A-01)
(D-30)
(A-04)
(D-31)

(terminal 8, 19) and wheel speed sensor <rear: RH>
connector D-30 (terminal 1, 2) damaged?
NO : Go to Step 14.

connector C-25 and wheel speed sensor <rear: LH>
CONNECTOR: C-25
C-25
35DB033A
C-25 and wheel speed sensor <rear: LH> connector
D-31 damaged?
NO : Go to Step 13..
STEP 13. Check the harness wires and continuity

resistance between ABS-ECU connector A-02 (terminal 6,
17) and wheel speed sensor <rear: LH> connector D-31
(terminal 1, 2). (see figure and table below).
defective contact.
Wheel speed ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
SENSOR
35DB123A

ABS (A-02) SENSOR
(A-01)
(D-30)
(A-04)
(D-31)
Q: Is the harness wire between ABS-ECU connector A-02 (

terminal 6, 17) and wheel speed sensor <rear: LH>
connector D-31 (terminal 1, 2) damaged?
NO : Go to Step 14.
STEP 14. Inspect the wheel speed sensor.

Check the wheel speed sensor relevant to the DTC code. For
the applicable inspection procedure, refer to P.35B-96.
• When DTC code C1200 is set: Front right wheel speed sen-
sor
• When DTC code C1205 is set: Front left wheel speed sen-
sor
• When DTC code C1210 is set: Rear right wheel speed sen-
sor
• When DTC code C1215 is set: Rear left wheel speed sen-
sor
Q: Is the wheel speed sensor damaged?
YES : Replace the wheel speed sensor. Then go to Step
16.
NO : Still replace the wheel speed sensor. Then go to Step
15

Check again if the DTC is set.
CONNECTOR
(2) Erase the DTC.
(5) Check if the DTC is reset.
Q: Is DTC C1200, C1205, C1210 or C1215 set?
MB991910 YES : Replace the hydraulic unit (integrated with
ABS-ECU). Then go to Step 16.
MB991824 NO : It can be assumed that this malfunction is intermittent.
MB991827 00DB076A

DATA LINK (2) Erase the DTC.
CONNECTOR
YES : Repeat the troubleshooting from Step 1.
MB991910 NO : The procedure is complete.
MB991824
MB991827 00DB076A
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
CAUTION • Active wheel speed sensors have a constant

If there is any problem in the CAN bus lines, an incoming power supply on one wire and return a
incorrect diagnostic trouble code may be set. signal on the other wire
Prior to this diagnosis, diagnose the CAN bus • The advantage of the active wheel speed sensor
lines. 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-
tude of the signal will remain constant.
• A Hall switch and magnet assembly is contained
within the sensor.
• As the tooth on the reluctor approaches the sen-
sor, the magnetic circuit is completed therefore
turning on the Hall switch. As the tooth departs
.
the sensor, the Hall switch will turn off.
CIRCUIT OPERATION • The output waveform displayed on the oscillo-
• Active wheel speed sensors have been installed, scope will be a square wave, (between signal
that produce changes of current flow through the wire and ground).
wheel speed sensor circuit which is influenced by • The ABS hydraulic unit modulates the amount of
the reluctor ring fitted to the wheel hub. braking force individually applied to each wheel
cylinder.

.
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, .
"during an extended wheel spin" and only be stored Past trouble

as a history code and no action is required.
For diagnosis procedures, refer to "How to cope with
.
past trouble" (Refer to GROUP 00, How to Use Trou-
TROUBLESHOOTING HINTS (The most bleshooting P.00-16).
likely causes for these DTCs are to set
are:)
Current trouble
• Malfunction of the wheel speed sensor or wheel
speed rotor
.
DIAGNOSIS
.

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991824 YES : Go to Step 3
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
(2) Erase the DTC.
MB991910
MB991824 Q: Is DTC C1201, C1206, C1211 or C1216 set?
YES : Go to Step 3
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
Use diagnostic tool MB991958 to check whether DTC codes
C1200, C1205, C1210 and C1215 have been set simulta-
neously.
connector.
MB991910
(3) Check whether DTC C1200, C1205, C1210 or C1215 have
MB991824
been set.
YES : Carry out diagnosis relevant to DTC C1200, C1205,
C1210 or C1215 (Refer to P.35B-10).
NO : Go to Step 4.
MB991827 00DB076A
STEP 4. Check the installation condition of the wheel

speed sensors.
For the wheel speed sensor, which the DTC code indicates,
check whether the sensor or its mounting bolts are loosened.
• DTC C1201 is set: Front right wheel speed sensor
• DTC C1206 is set: Front left wheel speed sensor
• DTC C1211 is set: Rear right wheel speed sensor
• DTC C1216 is set: Rear left wheel speed sensor
Q: Is the wheel speed sensor installed correctly?
YES : Go to Step 5.
NO : Reinstall the wheel speed sensor correctly. Then go
to Step 16.
STEP 5. Check the wheel speed sensor after it is removed

from the vehicle.
Check the wheel speed sensor which the DTC code indicates
(Refer to P.35B-96).
Q: Is the wheel speed sensor in good condition?
YES : Go to Step 6.
NO : Replace the wheel speed sensor (Refer to P.35B-95).
Then go to Step 16.
STEP 6. Check the wheel bearing for looseness.

NOTE: If the wheel bearing is loose, the gap between the
wheel speed sensor and rotor may become excessive. Check
the wheel bearing, which DTC code indicates, for looseness.
• DTC C1201 is set: Check the front right wheel bearing
(Refer to GROUP 26, On-vehicle service − Wheel bearing
end play check P.26-8).
• DTC C1206 is set: Check the front left wheel bearing (Refer
to GROUP 26, On-vehicle service − Wheel bearing end play
check P.26-8).
• DTC C1211 is set: Check the rear right wheel bearing
(Refer to GROUP 27, On-vehicle service − Wheel bearing
end play check P.27-4).
• DTC C1216 is set: Check the rear left wheel bearing (Refer
to GROUP 27, On-vehicle service − Wheel bearing end play
check P.27-4)
Q: Is the wheel bearing end play within the standard value?
YES : Go to Step 7.
NO (front bearing end play is not within the standard
value) : Replace the front hub assembly (Refer to GROUP
26, Front axle hub assembly P.26-9).
NO (rear bearing end play is not within the standard
value) : Replace the rear hub assembly (Refer to GROUP
27, Rear axle hub assembly P.27-4).
STEP 7. Check the wheel speed rotor.

Check the wheel speed rotor, which DTC code indicates, for
foreign material or deformation.
Q: Is the wheel speed rotor in good condition?
YES : Go to Step 8.
NO (front bearing end play is not within the standard
value) : If the wheel speed rotor is contaminated with
foreign material, clean it. If the driveshaft is
deformed, replace it (Refer to GROUP 26, Drive shaft
assembly P.26-13).
NO (rear bearing end play is not within the standard
value) : If the wheel speed rotor is contaminated with
foreign material, clean it. If the wheel speed rotor is
deformed, replace it (Refer to GROUP 27, Rear axle
hub assembly P.27-6).

sensor <front: RH> connector A-01 for loose, corroded or
connector.
Wheel speed ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
SENSOR
35DB123A

defective contact.
ABS (A-02) SENSOR
(A-01)
(D-30)
(A-04)
(D-31)

CONNECTOR: A-01 <front: RH> connector A-01 damaged?
A-01 (B) YES : Repair or replace the damaged component(s). Refer
2 1 NO : Open or short circuit may be present in the front right
A-01 HARNESS wheel speed sensor circuit. Repair the wiring harness
CONNECTOR between ABS-ECU connector A-02 (terminals 9 and
(HARNESS SIDE) 10) and front right wheel speed sensor A-01
(terminals 2 and 1).Then go to Step 13.
AC305206 AV

sensor <front: LH> connector A-04 for loose, corroded or
connector.
Wheel speed ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
SENSOR
35DB123A

defective contact.
ABS (A-02) SENSOR
(A-01)
(D-30)
(A-04)
(D-31)
CONNECTOR: A-02
A-02 (GR) <front: LH> connector A-04 damaged?
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

connector C-25 and wheel speed sensor <Rear: RH>
Wheel speed ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
SENSOR
35DB123A

defective contact.
ABS (A-02) SENSOR
(A-01)
(D-30)
(A-04)
(D-31)

CONNECTOR: C-25 C-25 and wheel speed sensor <Rear: RH> connector
D-30 damaged?
NO : Open or short circuit may be present in the rear right
C-25 wheel speed sensor circuit. Repair the wiring harness
19) and rear right wheel speed sensor D-30 (terminals
35DB033A
1 and 2).Then go to Step 13.

connector C-25 and wheel speed sensor <rear: LH>
Wheel speed ABS-ECU

A-04, A-01, D-31, D-30 (A-02)
Terminals:
16, 9, 6, 8 Supply
Signal
Terminals:
SENSOR
35DB123A

defective contact.
ABS (A-02) SENSOR
(A-01)
(D-30)
(A-04)
(D-31)

CONNECTOR: C-25 C-25 and wheel speed sensor <rear: LH> connector
D-31 damaged?
NO : Open or short circuit may be present in the rear left
C-25
wheel speed sensor circuit. Repair the wiring harness
6) and rear left wheel speed sensor D-31 (terminals 2
35DB033A
and 1).Then go to Step 13.

CONNECTOR
(2) Erase the DTC.
MB991827 00DB076A

CONNECTOR
(2) Erase the DTC.
MB991824
MB991827 00DB076A
DTC C1225: Deviation between wheel speeds.
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.
DTC C1226/C1231/C1236/C1241/C1246/C1251/C1256/C1261: ABS Solenoid Valve
35DB090A
FUSIBLE LINK RELAY BOX

ABS (solenoid valve)
(20 A)
FUSIBLE LINK
ABS (motor supply)
No. 3 (30 A)
35DB091A
CAUTION tion then to the "ON" position again.

.
If there is any problem in the CAN bus lines, an CIRCUIT OPERATION

incorrect diagnostic trouble code may be set.
• The ABS-ECU contains the power supply circuit
Prior to this diagnosis, diagnose the CAN bus
(terminal 3) for the solenoid valve. The solenoid
lines.
valve is energized by a MOSFET driver, which is
NOTE: If the ABS-8 ECU or the active wheel integrated in the ABS-ECU.
speed sensor are disconnected, or if the wiring is • A MOSFET driver, which is integrated in the
an open/ short circuit, the ABS 8 ECU will shut ABS-ECU, is always energizing the solenoid
off power supply to the respective wheel speed valve unless the initial check is in progress when
sensor. All other wheel speed sensors will oper- the ignition switch is turned on.
ate normally. To restore the power supply, the • The ABS-ECU activates the solenoid valve by
ignition switch must be turned to the "OFF" posi- turning on its driving transistor.

.
ABS DTC SET CONDITIONS

These diagnostic trouble codes will be set under the likely causes for these DTCs are to set
cases below. are:)
• The solenoid valve is not energized even after
Current trouble
the ABS-ECU has turned on the driving transistor
(Open circuit is present in the power supply cir-
• Malfunction of the hydraulic unit (integrated with
cuit to the ABS-ECU solenoid valve, or the valve
ABS-ECU)
relay has failed).
• The solenoid valve is not energized even after .
the ABS-ECU has turned on the driving transistor Past trouble

(Open circuit is present in the solenoid valve cir- • Carry out diagnosis with particular emphasis on
cuit inside the ABS-ECU, or the valve relay has connector(s) or wiring harness between the
failed). power supply circuit (terminal 3) to the ABS-ECU
• After the ABS-ECU has turned off the driving solenoid valve or ground circuit (terminal 1) . For
transistor, the solenoid valve still remains ener- diagnosis procedures, refer to "How to cope with
gized (short in the solenoid valve circuit). past trouble" (Refer to GROUP 00, How to Use
• When a solenoid valve failure is detected Troubleshooting/Inspection Service Points
.
P.00-16).
Circuit drawings
.
DIAGNOSIS

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
(1) Erase the DTC.
MB991910 Q: Is DTC C1226, C1231, C1236, C1241, C1246, C1251,
C1256 or C1261 set?
MB991827 00DB076A
STEP 3. Measure the voltage at ABS-ECU connector A-02.

(1) Disconnect the connector A-02, and use special tool
CONNECTOR: A-02 Inspection Check Harness (MB991219) to probe the wiring
HYDRAULIC UNIT harness-side connector.
(WITH BUILT-IN ABS-ECU)
TEST may cause a defective contact.
(MB991219) (3) Measure the voltage between terminal 3 and ground. It
should be approximately 12 volts (battery positive voltage).
Q: Is the voltage approximately 12 volts (battery positive
voltage)?
YES : Go to Step 5.
NO : Go to Step 4.
35DB092A
FUSIBLE LINK
(20 A) RELAY BOX
35DB093A
STEP 4. Check ABS-ECU connector A-02 for loose,

in the connector.
Q:Is ABS-ECU connector A-02 damaged?
CONNECTOR: A-02
A-02 (GR) YES : Repair or replace the damaged component(s). Refer
NO : An open or short circuit may be present in the
solenoid valve power supply circuit. Repair the wiring
harness between ABS-ECU connector A-02 terminal
3 and external (20A) fusible link.Then go to Step 8.
16DB402A
STEP 5. Measure the resistance at ABS-ECU connector

A-02.
HARNESS (2) Measure the resistance between terminal 1 and ground. It
(MB991219) should be 2 ohms or less.
Q: Is the measured resistance 2 ohms or less?
YES : Go to Step 7.
NO : Go to Step 6.
35DB094A
CONNECTOR: A-02
A-02 (GR)
16DB402A

in the connector.
CONNECTOR: A-02
Q: Is ABS-ECU connector A-02 damaged?
NO : An open circuit may be present in the ground circuit.
Repair the wiring harness between ABS-ECU
connector A-02 terminal 1 and the body ground. Then
go to Step 8.
16DB402A

CONNECTOR
(2) Erase the DTC.
Q: Is DTC C1226, C1231, C1236, C1241, C1246, C1251,
MB991910 C1256 or C1261 set?
MB991824 ABS-ECU). Then go to Step 8.
MB991827 00DB076A

CONNECTOR
(2) Erase the DTC.
Q: Is DTC C1226, C1231, C1236, C1241, C1246, C1251,
MB991910 C1256 or C1261 set?
YES : Go to Step 1.
MB991824 NO : The procedure is complete.
MB991827 00DB076A
DTC C1266/C1273/C1274: Motor system
35DB090A
RELAY BOX
FUSIBLE LINK
ABS (motor supply)
No. 3 (30 A)
35DB095A
CAUTION ABS DTC SET CONDITIONS

If there is any problem in the CAN bus lines, an These diagnostic trouble codes will be set under the
incorrect diagnostic trouble code may be set. cases below.
Prior to this diagnosis, diagnose the CAN bus DTC C1266: Motor system (seizure)
lines. • This DTC is set when the ECU determines the
NOTE: If the ABS-8 ECU or the active wheel pump motor is not running smoothly (i.e. motor
speed sensor are disconnected, or if the wiring is seizure) by the motor relay ON/OFF.
off power supply to the respective wheel speed DTC C1273: Motor relay problem (stuck off)
sensor. All other wheel speed sensors will oper- • If the ABS-ECU determines that the motor is not
ate normally. To restore the power supply, the running after the MOSFET driver is turned on, the
ignition switch must be turned to the "OFF" posi- ECU determines that the motor relay is stuck off,
tion then to the "ON" position again. and sets this DTC.
.
DTC C1274: Motor relay problem (stuck on)

CIRCUIT OPERATION • If the ABS-ECU determines that the motor is run-
• The ABS-ECU contains the power supply circuit ning after the MOSFET driver is turned off, the
(terminal 2) for the pump motor. The pump motor ECU determines that the motor relay is stuck on,
is energized by a MOSFET driver, which is inte- and sets this DTC.
grated in the ABS-ECU.
• A MOSFET driver, which is integrated in the .
ABS-ECU, is always off unless the motor sole-

noid valve check is activated when the vehicle is likely causes for these DTCs are to set
started. are:)
• The ABS-ECU activates the pump motor by turn-
ing on the ECU built-in MOSFET driver when the Current trouble
ABS is working. • Damaged wiring harness or connector
.
ABS-ECU)
.
Past trouble Circuit drawings

• Carry out diagnosis with particular emphasis on • Refer to circuit diagrams GROUP-90
connector(s) or wiring harness between the • Refer to configuration diagrams GROUP-80
power supply circuit (terminal 2) to the ABS-ECU
motor or ground circuit (terminal 4). For diagnosis
procedures, refer to "How to cope with past trou-
ble" (Refer to GROUP 00, How to Use Trouble-
shooting/Inspection Service Points P.00-16).
.
DIAGNOSIS

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
(2) Erase the DTC.
MB991910
MB991824 Q: Is DTC C1266, C1273 or C1274 set?
YES : Go to Step 3.
MB991827 00DB076A

voltage)?
YES : Go to Step 5.
NO : Go to Step 4.
35DB096A
CONNECTOR: A-02
A-02 (GR)
16DB402A
RELAY BOX
FUSIBLE LINK No.3

ABS (motor supply)
(30 A)
35DB097A

in the connector.
CONNECTOR: A-02
2 and fusible link No.3.Then go to Step 8.
16DB402A

A-02.
YES : Go to Step 7.
NO : Go to Step 6.
35DB098A

in the connector.
CONNECTOR: A-02
go to Step 8.
16DB402A

CONNECTOR
(2) Erase the DTC.
Q: Is DTC C1266, C1273 or C1274 set?
MB991827 00DB076A

CONNECTOR
(2) Erase the DTC.
Q: Is DTC C1266, C1273 or C1274 set?
MB991824
MB991827 00DB076A
DTC C1276/ C1278/ C1279 Valve Relay System
35DB090A
FUSIBLE LINK
(20 A) RELAY BOX
35DB093A
CAUTION • A MOSFET driver, which is integrated in the

If there is any problem in the CAN bus lines, an ABS-ECU, is always energizing the solenoid
incorrect diagnostic trouble code may be set. valve unless the initial check is in progress when
Prior to this diagnosis, diagnose the CAN bus the ignition switch is turned on.
lines. .
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).
. 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 .
integrated in the ABS-ECU.

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

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
(2) Erase the DTC.
MB991910
MB991824 Q: Is DTC C1278 or C1279 set?
YES : Go to Step 3.
MB991827 00DB076A

voltage)?
YES : Go to Step 5.
NO : Go to Step 4.
35DB092A

in the connector.
CONNECTOR: A-02
3 and external (20 amp) fusible link. Then go to Step
8.
16DB402A
FUSIBLE LINK
(20 A) RELAY BOX
35DB093A

A-02.
YES : Go to Step 7.
NO : Go to Step 6.
35DB094A

in the connector.
CONNECTOR: A-02
go to Step 8.
16DB402A

CONNECTOR
(2) Erase the DTC.
Q: Is DTC C1278 or C1279 set?
MB991827 00DB076A

CONNECTOR
(2) Erase the DTC.
MB991824
MB991827 00DB076A
DTC C1607: ABS-ECU malfunction
CAUTION ABS DTC SET CONDITIONS

If there is any problem in the CAN bus lines, an The ABS-ECU always monitors itself while the sys-
incorrect diagnostic trouble code may be set. tem is working. If the ECU detects any faults, it will
Prior to this diagnosis, diagnose the CAN bus set this DTC.
lines. .
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
are:)
ABS-ECU)
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

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
(2) Erase the DTC.
MB991910
MB991824 Q: Is DTC C1607 set?
ABS-ECU).
MB991827 00DB076A
DTC C1860/C1861: Power supply system (abnormal decrease or increase in voltage)
35DB090A
.
CAUTION TROUBLESHOOTING HINTS (The most

If there is any problem in the CAN bus lines, an
incorrect diagnostic trouble code may be set.
Prior to this diagnosis, diagnose the CAN bus are:)
lines. Circuit drawings
NOTE: If the ABS-8 ECU or the active wheel • Refer to circuit diagrams GROUP-90
speed sensor are disconnected, or if the wiring is • Refer to configuration diagrams GROUP-80
Currect trouble
• Excessive electrical load
• Defective battery
.
ABS-ECU)
CIRCUIT OPERATION • Charging system failed
The ABS-ECU is energized by the ignition switch .
(IG1) through multi-purpose fuse 23 and the Past trouble

ABS-ECU terminal 18. Carry out diagnosis with particular emphasis on con-
.
nector(s) or wiring harness in the power supply cir-
ABS DTC SET CONDITIONS cuit (terminal 18) to the ABS-ECU. For diagnosis
DTC C1861 will be set when the power supply volt- procedures, refer to "How to cope with past trouble"
age to the ABS-ECU has decreased to a predeter- (Refer to GROUP 00, How to Use Troubleshoot-
mined value or lower. C1860 will be set when the ing/Inspection Service Points P.00-16).
power supply voltage to the ABS-ECU has increased
to a predetermined value or higher.
.
DIAGNOSIS

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991827 00DB076A

CAUTION
CONNECTOR
MB991958.
(2) Erase the DTC.
MB991910
MB991824 Q: Is DTC C1860 or C1861 set?
YES : Go to Step 3.
MB991827 00DB076A
STEP 3. Check the battery.

Check the battery (Refer to GROUP 54A, Battery test
P.54A-6).
Q: Is the battery in good condition?
YES : Go to Step 4.
NO : Charge or replace the battery. Then go to Step 8.
STEP 4. Check the charging system.

Check the charging system (Refer to GROUP 16, Charging
system diagnosis P.16-3).
Q: Is the charging system in good condition?
YES : Go to Step 5.
NO : Repair or replace the charging system component(s).
Then go to Step 8.

(3) Measure the voltage between terminal 18 and ground. It
TEST
HARNESS
(MB991219) voltage)?
YES : Go to Step 7.
NO : Go to Step 6.
35DB101A
STEP 6. Check ABS-ECU connector A-02, junction block

connectors C-214, C-215 and ignition switch connector
CONNECTOR: A-02
• ABS-ECU connector A-02
A-02 (GR)
16DB402A

• Junction block connectors C-214 and C-215
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
YES : An open or short circuit may be present in the power
supply line to the ABS-ECU. Repair the wiring
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
35DB042A P.00E-2. Then go to Step 8.

CONNECTOR
(2) Erase the DTC.
MB991827 00DB076A

CONNECTOR
(2) Erase the DTC.
MB991824
MB991827 00DB076A
DTC U1073: CAN-Bus off
CAUTION TROUBLESHOOTING HINTS (The most

• If DTC U1073 is set in the ABS-ECU, always
diagnose the CAN main bus line. If there is
any fault in the CAN bus lines, an incorrect are:)
DTC may be set. • Damaged wiring harness or connector
• Whenever the ECU is replaced, ensure that • Malfunction of the hydraulic unit (integrated with
the communication circuit is normal. ABS-ECU)
.
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

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991827 00DB076A

CONNECTOR
(2) Erase the DTC.
MB991910 YES : Replace the ABS-ECU. Then go to Step 3.
MB991827 00DB076A

CONNECTOR
(2) Erase the DTC.
MB991824
MB991827 00DB076A
SYMPTOM CHART
M1352011400619
CAUTION NOTE: If steering movements are made when driv-

During diagnosis, a DTC code associated with ing at high speed, or when driving on road surfaces
another system may be set when the ignition with low frictional resistance, or when passing over
switch is turned on with connector(s) discon- bumps, the ABS may operate although sudden brak-
nected. On completion, confirm all systems for ing is not being applied. Because of this, when get-
DTC code(s). If DTC code(s) are set, erase them ting information from the customer, check if the
all. problem occurred while driving under such condi-
tions as these.
speed sensor are disconnected, or if the wiring is NOTE: During ABS operation, the brake pedal may
an open/ short circuit, the ABS 8 ECU will shut vibrate a little or may not be able to be pressed. Such
off power supply to the respective wheel speed conditions are due to intermittent changes in hydrau-
sensor. All other wheel speed sensors will oper- lic pressure inside the brake line to prevent the
ate normally. To restore the power supply, the wheels from locking. This is normal.
SYMPTOMS INSPECTION REFERENCE PAGE
PROCEDURE NO.
Communication between the diagnostic tool and the 1 P.35B-72
ABS-ECU is not possible.
Power supply circuit system 2 P.35B-74
When the ignition key is turned to "ON" (Engine 3 P.35B-79
stopped), the ABS warning light does not illuminate.
The ABS warning light remains illuminated after the 4 P.35B-79
engine is started.
Faulty ABS operation 5 P.35B-81
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Communication between Diagnostic Tool and the ABS-ECU is not
possible.
35DB090A

.
TECHNICAL DESCRIPTION (COMMENT)

If the diagnostic tool (MUT-III Sub Assembly) cannot likely causes for this case:)
communicate with the ABS system, the CAN bus • Damaged wiring harness or connector
lines may be defective. If the ABS system does not • Malfunction of the hydraulic unit (Integrated with
work, the ABS-ECU or its power supply circuit may ABS-ECU)
be defective. Circuit drawings
.
DIAGNOSIS

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
MB991824 YES : Check and repair the power supply circuit system
(Refer to P.35B-74).
MB991827 00DB076A
INSPECTION PROCEDURE 2: Power Supply Circuit System
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
.
DIAGNOSIS
.

(3) Measure the voltage between terminal 18 and ground. It
should measure approximately 12 volts (battery positive
TEST voltage).
HARNESS
(MB991219) Q: Is battery positive voltage (approximately 12 volts)
present?
YES : Go to Step 3.
NO : Go to Step 2.
35DB101A
STEP 2. Check ABS-ECU connector A-02, junction block

connectors C-214, C-215 and ignition switch connector
CONNECTOR: A-02
• ABS-ECU connector A-02
A-02 (GR)
16DB402A

• Junction block connectors C-214 and C-215
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
YES : An open or short circuit may be present in the power
supply line to the ABS-ECU. Repair the wiring
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
35DB042A P.00E-2. Then go to Step 8.

A-02.
HARNESS (2) Measure the resistance between terminal 1, 4 and ground.
(MB991219) It should be 2 ohms or less.
YES : Go to Step 5.
NO : Go to Step 4.
35DB098A

in the connector.
CONNECTOR: A-02
connector A-02 terminals 1, 4 and the body ground.
Then go to Step 8.
16DB402A
STEP 5. Check the battery.

Check the battery (Refer to GROUP 54A, Battery test
P.54A-6).
Q: Is the battery in good condition?
YES : Go to Step 6.
NO : Charge or replace the battery. Then go to Step 8.
STEP 6. Check the charging system.

Check the charging system (Refer to GROUP 16, Charging
system diagnosis P.16-3).
Q: Is the charging system in good condition?
YES : Go to Step 7.
NO : Repair or replace the charging system
component(s).Then go to Step 8.

Q: Can the ABS-ECU communicate with the diagnostic tool
(MUT-III Sub Assembly)?
NO : Replace the ABS-ECU. Then go to Step 8.

Q: Can the ABS-ECU communicate with the diagnostic tool
(MUT-III Sub Assembly)?
NO : Go to Step 1.
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

.

• The ABS-ECU sends the ABS warning light and likely causes for this case:)
the brake warning light signals to the combination • Damaged wiring harness or connector
meter via the CAN communication. • Combination meter defective
• This may be caused by faults in the CAN bus line, • Malfunction of the hydraulic unit (integrated with
the combination meter, or the ABS-ECU. ABS-ECU)
. Circuit drawings
.
DIAGNOSIS
.

CAN bus line.
CAUTION
CONNECTOR
MB991958.
connector.
MB991910
Repair the CAN bus lines, and then go to Step 2.
MB991827 00DB076A

combination meter diagnostic trouble code.
CAUTION
CONNECTOR
MB991958.
Use diagnostic tool MB991958 to check whether combination
meter DTC U1102 has been set.
connector.
MB991910
(3) Check whether combination meter DTC U1102 has been
set.
MB991824
Q: Is combination meter DTC U1102 set?
ABS-ECU).
MB991827 00DB076A
INSPECTION PROCEDURE 5: Faulty ABS Operation

.

The cause depends on driving and road surface con- likely causes for this case:)
ditions, so diagnosis may be difficult. However, if no • Malfunction of the hydraulic unit
diagnostic trouble code is displayed, carry out the fol- Circuit drawings
lowing inspection. • Refer to circuit diagrams GROUP-90
.
DIAGNOSIS
STEP 1. Hydraulic unit check

Refer to P.35B-90.
Q: Is the hydraulic unit normal?
YES : Go to Step 2.
NO : Connect the brake pipes correctly, repair the external
brake lines, or replace the hydraulic unit.
STEP 2. Verify that the condition described by the

customer exists.
Q: Can any faults be found with the brake operation?
YES : Check the brake system related components except
the ABS system.

M1352011500780
The following items can be read by the diagnostic
tool from the ABS-ECU input data.
MUT-III DATA CHECK ITEM CHECKING REQUIREMENTS NORMAL
DIAGNOSTI LIST VALUE
C TOOL ITEM
DISPLAY NO.
FL wheel 01 Front-left wheel speed sensor Drive the vehicle Vehicle speeds
speed sensor displayed on the
FR wheel 02 Front-right wheel speed sensor speedometer
speed sensor and diagnostic
tool are identical.
RL wheel 03 Rear-left wheel speed sensor
speed sensor
RR wheel 04 Rear-right wheel speed sensor
speed sensor
Power supply 05 ABS-ECU power supply voltage Ignition switch power supply Battery positive
voltage voltage and valve monitor voltage
voltage
Stop lamp 06 Stoplamp switch Depress the brake pedal. ON
switch (input) Release the brake pedal. OFF
Stop lamp 13 Stoplamp switch Depress the brake pedal. ON
switch Release the brake pedal. OFF
Pump motor 21 Pump motor When the ABS outputs the ON
during driving
during driving
Valve relay 30 Valve relay When the ABS outputs the ON
during driving
during driving
TCL mode 35 TCL operation When the TCL outputs the ON
during driving
When the TCL outputs the OFF
operation inhibition signal
during driving

M1352011600765
The diagnostic tool activates the following actuators NOTE: Actuator testing is only possible when the
for testing. vehicle is stationary.
NOTE: If the ABS-ECU runs down, actuator testing
cannot be carried out.
.
ACTUATOR TEST SPECIFICATIONS

ACTIVATION PATTERN
NO. ITEM PARTS TO BE
END OF ACTIVATED
START OF
FORCED FORCED
ACTION ACTION 01 FL wheel speed sensor Solenoid valves and
pump motors in the
SOLENOID A 02 FR wheel speed sensor
VALVE hydraulic unit (simple
B 1s 03 RL wheel speed sensor inspection mode)
C 2s
APPROXIMATELY APPROXIMATELY 04 RR wheel speed sensor
0.05 s 0.01 s
PUMP ON 09 Engine TCL Drive Outputs the engine
MOTOR OFF torque control signal
(engine torque = 0) to
Engine ECU for three
seconds.
NOTE
A: HYDRAULIC PRESSURE INCREASES
B: HYDRAULIC PRESSURE HOLDS
C: HYDRAULIC PRESSURE DECREASES
AC100172 AI
CHECK AT ABS-ECU
M1352011800769
.
TERMINAL VOLTAGE CHECK CHART

1. Disconnect the ABS-ECU connector A-02, and use special
tool Inspection Test Harness (MB991219) to probe the
wiring harness-side connector.
2. Measure the voltages between ground and each terminal
listed below in the table. Also measure voltages between
ground and each terminal listed below in the table.
defective contact.
3. The terminal layouts are shown in the illustrations below.
CONNECTOR SIGNAL CHECKING REQUIREMENT NORMAL
TERMINAL NO CONDITION
3 Solenoid valve power Always Battery positive
supply voltage
20 Stop light switch input Ignition Stop light switch: "ON" Battery positive
switch: "ON" voltage
Stop light switch: "OFF" Approximately 0 V
2 Motor power supply Always Battery positive
voltage
18 ABS-ECU power Ignition switch: "ON" Battery positive
supply voltage
Ignition switch: "START" Approximately 0 V
.
GROUND RESISTANCE AND CONTINUITY

BETWEEN HARNESS-SIDE CONNECTOR
TERMINALS AND BODY GROUND
1. Turn the ignition switch to the "LOCK" (OFF) position and
CONNECTOR: A-02 disconnect the ABS-ECU connectors before checking
HYDRAULIC UNIT resistance and continuity.
2. Using the Inspection Test Harness (MB991219) to probe the
wiring harness-side connector, check the resistance and
continuity between the terminals indicated in the table
TEST below.
HARNESS 3. The terminal layout is shown in the illustration.
(MB991219)
NOTE: If the ABS-8 ECU or the active wheel speed sensor are
disconnected, or if the wiring is an open/ short circuit, the ABS
8 ECU will shut off power supply to the respective wheel speed
sensor. All other wheel speed 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.
35DB098A
CONNECTOR TERMINAL NO. SIGNAL NORMAL CONDITION

1 − body ground Ground Less than 2 ohms
4 − body ground Ground Less than 2 ohms
SPECIAL TOOLS
SPECIAL TOOLS
M1352000600653

MB991958 MB991824−KIT Checking diagnostic
A
B: MB991827 MUT-III Trigger CAUTION
C: MB991910 Harness is not For vehicles with CAN
D: MB991911 necessary when communication, use
MB991824
E: MB991914 pushing V.C.I. ENTER MUT-III main harness A
B F: MB991825 key. to send simulated
MUT-III Sub Assembly connect MUT-III main
A: Vehicle Communication harness B instead, the
Interface (V.C.I.) CAN communication
MB991827
B: MUT-III USB Cable does not function
C
C: MUT-III Main Harness A correctly.
(Vehicles with CAN
D: MUT-III Main Harness B
D communication system)
E: MUT-III Main Harness C
models only)
F: MUT-III Adapter Harness
MB991911
G: MUT-III Trigger Harness
E
DO NOT USE
MB991914
MB991825
MB991826
MB991958
SPECIAL TOOLS

MB991223 General service tools (A): Resistance
A
Harness set measurement between
(A): MB991219 ABS-ECU and wheel
Inspection harness speed sensors
(B): MB991222 ABS-ECU terminal
Back probing tool voltage measurement
ABS-ECU terminal
(ground) resistance
measurement
(B): ABS-ECU wheel
speed sensor signal
voltage measurement
ABS-ECU wheel speed
sensor signal
B measurement
MB991222
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
WHEEL SPEED SENSOR SIGNAL
MEASUREMENT
M1352001600667
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
NOTE: To check wheel speed sensor connectors, remove

the rear seat to access the rear wheel speed sensor connec-
tions and remove inner guard (splash shield) to access front
wheel speed sensors, to confirm the connection of the sen-
sor harness and connector before using the oscilloscope.
5. Connect oscilloscope (as per figure 2) shows, to the
appropriate terminal positions by back probing (using probe
MB991222) and check sensor operation individually with
scope.
Turn the ignition switch to the "ON" position.
FIGURE 2
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
ON-VEHICLE SERVICE
6. Turn wheel by hand at approximately 1 revolution per

Recommended Oscilloscope setting:
• Y-axis: 2Volts
• X-axis: 100ms

U-CH1
V
1.50
1.00
0.50
0.00
0 20 40 60 80 100
ms
35DB120A

Wheel speed Standard Value
sensor High 0.9V - 1.5V
Low 0.3V - 0.8V
Probable causes of low output voltage
• Wheel speed sensor pole piece to wheel speed rotor clear-
ance too large
• Faulty wheel speed sensor
7. To observe the waveform with an oscilloscope:
• Front and Rear Wheels: Turn the wheels manually at a con-
stant speed
NOTE: The output voltage will remain same regardless of
vehicle speed.
.
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.
ON-VEHICLE SERVICE
HYDRAULIC UNIT CHECK

M1352001700512

• MB991958: MUT-III Sub Assembly
• MB991910: MUT-III Main Harness A (Vehicles with CAN
CAUTION
• The roller of the braking force tester and the tyre
should be dry during testing.
• When testing the front brakes, apply the parking brake.
When testing the rear brakes, stop the front wheels
with chocks.
1. Jack up the vehicle. Then support the vehicle with rigid
racks at the specified jack-up points or place the front or rear
wheels on the rollers of the braking force tester.
2. Release the parking brake, and feel the drag force (drag
torque) on each road wheel. When using the braking force
tester, take a reading of the brake drag force.
CAUTION
MB991958.
CONNECTOR
4. After checking that the selector lever is in "P" range, start the
engine.
6. Select "System Select."
7. Choose "ABS" .
8. Select "Actuator Test" from "ABS" screen
MB991910
9. Choose an appropriate item for hydraulic unit check.
MB991824 NOTE: The ABS system will switch to the diagnostic tool
mode and the ABS warning light will illuminate.
NOTE: When the ABS has been interrupted by the fail-safe
function, diagnostic tool MB991958 actuator testing cannot
be used.
MB991827 00DB076A
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
10.Turn the wheel by hand and check the change in braking

force when the brake pedal is depressed. When using the
braking force tester, depress the brake pedal until the
braking force is at the following values, and check that the
braking force changes to the brake drag force reading taken
in step 2 when the actuator is force-driven. The result should
be as shown in the diagram above.
Front wheel 785 − 981 N (176 − 220 lb.)
Rear wheel 588 − 784 N (132 − 176 lb.)
11.If the result of inspection is abnormal, repair according to the

Diagnosis Table below.
ON-VEHICLE SERVICE
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
12.After inspection, disconnect diagnostic tool MB991958

immediately after turning the ignition switch to the "LOCK"
(OFF) position.
IN THE EVENT OF A DISCHARGED BATTERY

M1352003500547
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.
HYDRAULIC UNIT
HYDRAULIC UNIT
M1352008600464
NOTE: The ABS-ECU is integrated in the hydraulic unit.
• 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

• BATTERY AND BATTERY TRAY >>A<< 2. BRAKE TUBE CONNECTION
• HARNESS CONNECTORS 3. ABS EQUIPMENT BOLT AND NUTS
AROUND THE ABS-ECU <> 4. BRAKE MODULATOR HYDRAULIC
• HARNESS CLAMPS AROUND THE UNIT (HYDRAULIC UNIT AND
ABS-ECU ABS-ECU)
• CONNECTOR BRACKETS AROUND 5. BRAKE HYDRAULIC UNIT
THE ABS-ECU <3.8L ENGINE> BRACKET
<<A>> 1. ABS-ECU HARNESS CONNECTOR
HYDRAULIC UNIT

.
<<A>> ABS-ECU HARNESS CONNECTOR DIS-

CONNECTION
Move the lock lever of the ABS-ECU connector as shown in the
illustration, and then disconnect the harness connector.
Connector
A-02
LOCK LEVER
35DB105A
<> BRAKE MODULATOR HYDRAULIC UNIT

(HYDRAULIC UNIT AND ABS-ECU) REMOVAL
WARNING
The hydraulic unit is heavy. Use care when removing
it.
CAUTION
• The hydraulic unit cannot be disassembled. Never
loosen its nuts or bolts.
• Do not drop or shock the hydraulic unit.
• Do not turn the hydraulic unit upside down or lay it on
its side.

.
>>A<< BRAKE TUBE CONNECTION

Connect the tubes to the hydraulic unit assembly as shown in
2 1
3 the illustration.
4 1. To the front brake (LH)
5 2. To the rear brake (RH)
3. To the rear brake (LH)
6 4. To the front brake (RH)
5. From the master cylinder (secondary)
6. From the master cylinder (primary)
35DB106A
WHEEL SPEED SENSOR
WHEEL SPEED SENSOR

M1352008300548
• 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.
WHEEL SPEED SENSOR

.
<<A>> FRONT WHEEL SPEED SENSOR/REAR

WHEEL SPEED SENSOR REMOVAL
CAUTION
Be careful when handling the projection at the tip of the
wheel speed sensor and the toothed edge of the wheel
speed rotor so as not to damage them by contacting other
parts.
AC211046AB
INSPECTION
M1352008400459
WHEEL SPEED SENSOR CHECK

1. Check whether any metallic foreign material has adhered to
the projection at the speed sensor tip. Remove any foreign
material. Also check whether the pole piece is damaged.
Replace it with a new one if it is damaged.
NOTE: The projection can become magnetized due to the
magnet inside the wheel speed sensor, and may cause for-
eign material to adhere to it. The projection may not be able
to correctly sense the wheel rotation speed if foreign matter
is on it or if it is damaged.
2. Check the wheel speed sensor cable for breakage, damage
or disconnection. Replace with a new one if a problem is
found.
NOTE: When checking for cable damage, remove the cable
clamp part from the body and then gently bend and pull the
cable near the clamp.
TOOTHED WHEEL SPEED ROTOR CHECK

Check whether the wheel speed rotor teeth are broken or
deformed. Replace the BJ assembly of the drive shaft, or the
rear hub assembly, respectively, if the teeth are damaged or
deformed.
AC000965
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATION
M1352012400377
ITEM SPECIFICATION
Brake tube flare nut 15 ± 2 N⋅m (12 ± 1 ft-lb)
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. . . . . . . . . 36-2 PARKING BRAKE LEVER . . . . . . . . . 36-6

PARKING BRAKE DIAGNOSIS . . . . 36-2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 36-2 PARKING BRAKE CABLE. . . . . . . . . 36-7
TROUBLESHOOTING STRATEGY . . . . . . 36-2 REMOVAL AND INSTALLATION . . . . . . . . 36-7
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 36-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 36-3 PARKING BRAKE LINING AND
DRUM . . . . . . . . . . . . . . . . . . . . . . . . . 36-8
ON-VEHICLE SERVICE. . . . . . . . . . . 36-3 REMOVAL AND INSTALLATION . . . . . . . . 36-8
PARKING BRAKE LEVER STROKE CHECK INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 36-11
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 36-3
PARKING BRAKE SWITCH CHECK . . . . . 36-5 SPECIFICATIONS . . . . . . . . . . . . . . . 36-12
PARKING BRAKE LINING SEATING FASTENER TIGHTENING SPECIFICATIONS 36-12
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 36-5 SERVICE SPECIFICATIONS . . . . . . . . . . . 36-12
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 36-12
PARKING BRAKES 36-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1361000100344
The parking brakes are a mechanical rear wheel
brake design and controlled by a lever.
PARKING BRAKE LEVER
FRONT PARKING BRAKE CABLE

AC206222
REAR PARKING BRAKE CABLE AC306017 AB
PARKING BRAKE DIAGNOSIS

INTRODUCTION
M1361003700282
If the parking brake is faulty, parking brake effort will
become insufficient. The cause may be a malfunc-
tion of parking brake parts or the parking brake pedal
being out of adjustment.
M1361003800290
parking brakes fault. Chart.
1. Gather Information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1361004100302

Brake drag − Refer to GROUP 35A, Basic Brake
System Diagnosis − Symptom
Chart P.35A-6.
Insufficient parking brake function 1 P.36-3
PARKING BRAKES 36-3
ON-VEHICLE SERVICE
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Insufficient Parking Brake Function
DIAGNOSIS STEP 3. Check the brake lining and brake drum

for wear.
STEP 1. Check the excessive parking brake lever Refer to P.36-11.
stroke. Q: Is the brake lining thickness or brake drum inside
Refer to P.36-3. diameter outside of specification?
Q: Is the parking brake lever stroke adjusted YES : Replace the rear brake shoe assembly or
properly? rear brake disc (Refer to P.36-8). Then go to
YES : Go to Step 2. Step 5.
NO : Adjust the parking brake lever stroke or NO : Go to Step 4.
check the parking brake cable routing. Then
go to Step 5. STEP 4. Check for oil, water, etc., on the lining
contact surfaces.
STEP 2. Check the parking brake cable for Q: Is oil, water, etc., on the lining contact surface?
sticking. YES : Replace the part and determine and repair
Q: Is the parking brake cable stuck? source/cause of foreign material. Then go to
YES : Replace the cable. Then go to Step 5. Step 5.
NO : Go to Step 3. NO : Carry out the parking brake lining seating
(Refer to P.36-5) and then go to Step 5.

NO : Recheck from Step 1.
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
(3) Remove the rear wheels, and then remove the

adjustment hole plug on the brake disc.
ADJUSTMENT
HOLE PLUG
AC209383AB
(4) Use a flat-tip screwdriver to turn the adjuster in the

direction of the arrow (the direction which expands the
ADJUSTER
shoe) so that the disc will not rotate by hand. Return the
adjuster five notches in the direction opposite to the
direction of the arrow.
(5) Install the rear wheels, and then tighten the wheel nuts to
98 ± 10 Nm (73 ± 7 ft-lb).
BRAKE DISC
CAUTION
Be careful that the parking brake lever stroke should be
AC206725 AB within the standard value. If the stroke is too short, brake
dragging can be caused.
<INSIDE THE FLOOR CONSOLE> (6) Turn the adjusting nut to adjust the parking brake lever
CABLE ROD
stroke to the standard value. After adjustment, check that
the adjust nut and the cable rod is not loose.
(7) Release the parking brake and turn the rear wheels to
check that the rear brakes are not dragging.
3. If either of the parking brake cables is replaced, adjust the
parking brake lever stroke as described previously, pull the
ADJUSTING parking brake lever 10 times with approximately 200 N (45
NUT pounds) to eliminate the initial slack of the cable. Then
AC306061AB adjust the parking brake lever stroke as described
previously again.
PARKING BRAKES 36-5
ON-VEHICLE SERVICE
PARKING BRAKE SWITCH CHECK

M1361003300411
1. Remove the floor console. (Refer to GROUP 52A, Floor
Console P.52A-10.)
2. Check for continuity between the parking brake switch
terminal and the switch mounting bolt.
When parking brake pedal is pulled 2 ohms or less
When parking brake pedal is released Open circuit
AC306064AB
PARKING BRAKE LINING SEATING PROCEDURE

M1361001100262
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
PARKING BRAKE LEVER

M1361001300363

Rear Floor Console Assembly and Rear Console Bracket • Parking Brake Lever Stroke Adjustment (Refer to P.36-3.)
Removal (Refer to GROUP 52A, Floor Console P.52A-10.) • Rear Console Bracket and Rear Floor Console Assembly
Installation (Refer to GROUP 52A, Floor Console
P.52A-10.)
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
PARKING BRAKE CABLE

M1361001900547

• 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).
• Parking Brake Lever Stroke Check and Adjustment (Refer
to P.36-3).
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

M1361002500315
• 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
BRAKE GREASE: BRAKE GREASE SAE J310, NLGI No.1

<<A>> 1. REAR BRAKE BOLT 9. REAR BRAKE SHOE SPRING
<<A>> 2. REAR BRAKE CALIPER CUP AND SHOE HOLD-DOWN
ASSEMBLY SPRING
<> 3. REAR BRAKE DISC 10. PARKING BRAKE CABLE CLIP
>>C<< 4. SHOE-TO-ANCHOR SPRING 11. REAR PARKING BRAKE CABLE
5. ADJUSTING WHEEL SPRING CONNECTION
>>B<< 6. REAR BRAKE SHOE SLACK 12. O-RING
ADJUSTER 13. REAR BRAKE SHOE ASSEMBLY
7. PARKING BRAKE OPERATING <<C>> >>A<< 14. REAR BRAKE CHAMBER
LEVER STRUT RETAINER
8. STRUT-TO- SHOE SPRING 15. REAR BRAKE WASHER
16. PARKING BRAKE OPERATING
LEVER
PARKING BRAKES 36-9

• REAR WHEEL SPEED SENSOR
<VEHICLES WITH ABS> (REFER
TO GROUP 35B, WHEEL SPEED
SENSOR P.35B-95).
17. REAR WHEEL HUB ASSEMBLY
18. BACKING PLATE
19. SHOE HOLD-DOWN PIN

.
<<A>> REAR BRAKE BOLT/REAR BRAKE CALI-

PER ASSEMBLY REMOVAL
Remove the rear brake caliper assembly and support it with
wire or something similar.
.
<> REAR BRAKE DISC REMOVAL

If the rear brake disc is seized, install M8×1.25 bolts as shown,
and remove the rear brake disc by tightening the bolts evenly
and gradually.
BOLTS
(M8 × 1.25)
AC205986AB
<<C>> REAR BRAKE CHAMBER RETAINER

REMOVAL
Use a flat-tipped screwdriver or a similar tool to open up the
PIN OF REAR BRAKE
SHOE ASSEMBLY rear brake chamber retainer joint. Then remove the rear brake
chamber retainer.
REAR BRAKE CHAMBER

RETAINER AC000924 AD
PARKING BRAKES 36-10

.
>>A<< REAR BRAKE CHAMBER RETAINER

INSTALLATION
PIN OF REAR BRAKE Use pliers or a similar tool to close the rear brake chamber
SHOE ASSEMBLY retainer end onto the pin.
REAR BRAKE CHAMBER

RETAINER AC000926 AF
>>B<< REAR BRAKE SHOE SLACK ADJUSTER

INSTALLATION
LEFT SIDE WHEEL Install the rear brake shoe slack adjuster as shown.
REAR
REAR BRAKE SHOE

SLACK ADJUSTER AC206987AB
RIGHT SIDE WHEEL
FRONT
REAR BRAKE SHOE

SLACK ADJUSTER AC206987 AC
.
PARKING BRAKES 36-11
>>C<< SHOE-TO-ANCHOR SPRING

INSTALLATION
CAUTION
LEFT SIDE WHEEL
The front and rear shoe-to-anchor springs are not inter-
REAR changeable, so the blue spring must be installed at the
front side and the yellow spring must be installed at the
rear side.
Install the shoe-to-anchor springs in the order shown in the
illustration.
1 (BLUE SPRING)
2 (YELLOW SPRING)
AC206986 AB
RIGHT SIDE WHEEL
REAR
1 (BLUE SPRING)
2 (YELLOW SPRING)
AC209387AB
INSPECTION
M1361002600260
PARKING BRAKE LINING AND BRAKE DRUM

CHECK
1. Measure the thickness of the brake lining at several places.
Minimum Limit: 1.0 mm (0.04 inch)
2. If the thickness of the brake lining is below the limit, replace
the shoe assemblies on both sides of the vehicle. Never
replace only one side.
ACX00708AB
3. Measure the inside diameter of the brake disc in two places

or more.
Standard value: 190.0 mm
Limit: 191.0 mm
4. If the inside diameter exceeds the limit, or if it is excessively
worn on one side, replace the brake disc.
ACX00709AB
36-12 PARKING BRAKES
SPECIFICATIONS
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)
M1361000300412

Parking brake lever stroke 5 − 7 notches −
[Parking brake lever pull force: Approximately 200 N
(45 pounds)]
Rear brake lining thickness mm (in) 2.8 Minimum 1.0
Brake drum inside diameter mm (in) 190.0 191.0
LUBRICANT
M1361000400301
ITEM SPECIFIED LUBRICANT

Rear brake shoe slack adjuster Brake grease SAE J310, NLGI No.1
Backing plate
Rear brake shoe assembly
NOTES
36-14 PARKING BRAKES
SPECIFICATIONS
HOME 37-1
GROUP 37
POWER STEERING
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 37-3 POWER STEERING SYSTEM AIR

BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37-18
POWER STEERING DIAGNOSIS . . . 37-3 OIL PUMP PRESSURE TEST . . . . . . . . . . 37-19
INTRODUCTION TO POWER STEERING POWER STEERING PRESSURE SWITCH
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 37-3 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-20
POWER STEERING DIAGNOSIS TIE ROD END BALL JOINT DUST COVER
TROUBLESHOOTING STRATEGY . . . . . . 37-3 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-21
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 37-3 STEERING COLUMN SHAFT ASSEMBLY
SHOCK ABSORBING MECHANISM CHECK 37-21
SYMPTOM PROCEDURES . . . . . . . . . . . . 37-4
STEERING WHEEL*. . . . . . . . . . . . . . 37-23

SPECIAL TOOLS. . . . . . . . . . . . . . . . 37-13
ON-VEHICLE SERVICE. . . . . . . . . . . 37-14

STEERING SHAFT* . . . . . . . . . . . . . . 37-25
STEERING WHEEL FREE PLAY CHECK . 37-14
STEERING ANGLE CHECK . . . . . . . . . . . . 37-15
DISASSEMBLY AND ASSEMBLY . . . . . . . 37-28
TIE ROD END BALL JOINT BREAKAWAY
TORQUE CHECK . . . . . . . . . . . . . . . . . . . . 37-15
STATIONARY STEERING EFFORT CHECK 37-16
POWER STEERING GEAR BOX AND
LINKAGE* . . . . . . . . . . . . . . . . . . . . . . 37-30
STEERING WHEEL RETURN TO CENTER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-17 REMOVAL AND INSTALLATION . . . . . . . . 37-30
DRIVE BELT TENSION CHECK. . . . . . . . . 37-17 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37-37
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37-17 DISASSEMBLY AND ASSEMBLY . . . . . . . 37-38
FLUID REPLACEMENT . . . . . . . . . . . . . . . 37-18 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37-42

WARNING
NOTE
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
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.
POWER STEERING DIAGNOSIS

INTRODUCTION TO POWER STEERING DIAGNOSIS
M1372008500209
Hydraulic power steering is used for all vehicles.
Faults in the power steering can include excessive
play of the steering wheel, difficult steering wheel
operation, noise, vibration, and oil leaks, etc. Possi-
ble causes of these faults can include defects in the
gear box, oil pump or steering linkage.
POWER STEERING DIAGNOSIS TROUBLESHOOTING STRATEGY
M1372007300202
power steering fault. Chart.
SYMPTOM CHART
M1372007600225

PROCEDURE
Excessive play of steering wheel 1 P.37-4
Difficult steering wheel operation (insufficient power assist) 2 P.37-4
Rattling noise 3 P.37-6
Shrill noise 4 P.37-7
Squealing noise 5 P.37-7
Hissing noise 6 P.37-8
Droning noise 7 P.37-8
Squeaking noise 8 P.37-9
Vibration 9 P.37-10
Oil leakage from hose connection 10 P.37-11
Oil leakage from hose assembly 11 P.37-11
Oil leakage from oil reservoir 12 P.37-11
Oil leakage from oil pump 13 P.37-12
Oil leakage from steering gear 14 P.37-12
POWER STEERING 37-4
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Excessive Play of Steering Wheel
DIAGNOSIS
STEP 1. Check for looseness at the steering shaft coupling

section and at the steering wheel linkage.
Q: Is there any looseness?
YES : Repair or replace the part. And then go to Step 3.
NO : Go to Step 2.
STEP 2. Check the steering wheel free play.

(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 free play exceeds the limit, set the steering wheel
straight ahead with the engine stopped. Apply
approximately 5 N (1.1 pound) to the steering
circumference and check the play.
Standard value (steering wheel play with engine
ACX01122AB
stopped): 10 mm (0.4 inch) or less
Q: Does the play exceed the standard value?
YES : Remove the steering gear box (refer to P.37-30) and
check the total pinion torque (refer to P.37-38). And
then go to Step 3.
NO : Go to Step 3.
STEP 3. Check the steering wheel play.

Verify that the steering wheel play is not excessive.
Q: Is the steering wheel play excessive?
YES : Repeat from Step 1.
INSPECTION PROCEDURE 2: Difficult Steering Wheel Operation (Insufficient Power Assist)
DIAGNOSIS
STEP 1. Check the drive belt for damage.

Q: Is the drive belt damaged?
YES : Replace the drive belt. And then go to Step 9.
NO : Go to Step 2.
POWER STEERING 37-5
STEP 2. Check the power steering oil pump drive belt

tension.
P.00-39.
Q: Is the power steering oil pump drive belt tension within
the standard value?
YES : Go to Step 3.
NO : Adjust the tension (refer to GROUP 00, Maintenance
Service − Drive Belts P.00-39). And then go to Step 9.
STEP 3. Check the fluid level.

(1) Park the vehicle on a flat, level surface, and then start the
engine.
(2) Turn the steering wheel several times to raise the
temperature of the fluid to approximately 50 − 60°C (122 −
140°F).
(3) With the engine running, turn the wheel all the way to the
left and right several times.
(4) Check the fluid in the oil reservoir for foaming or milkiness.
FLUID FLUCTUATION
Check the difference of the fluid level when the engine is
stopped, and while it is running.
Q: Is the check result OK?
YES : Go to Step 4.
NO : Bleed the air (refer to P.37-18). And then go to Step 9.
WHILE ENGINE WHILE ENGINE

RUNNING STOPPED ACX01131 AB
STEP 4. Check each hose for crushing or twisting.

Q: Is any hose crushed or twisted?
YES : Repair or replace the hose. And then go to Step 9.
NO : Go to Step 5.
STEP 5. Check for oil leaks.

Q: Are there oil leaks?
YES : Find the cause of the oil leakage and repair it. And
then go to Step 9.
NO : Go to Step 6.
STEP 6. Check the wheel alignment (camber and caster).

Refer to GROUP 33, On-vehicle Service − Front Wheel Align-
ment Check and Adjustment P.33-6.
Q: Is the wheel alignment incorrect?
YES : Adjust wheel alignment. And then go to Step 9.
NO : Go to Step 7.
POWER STEERING 37-6
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.
STEP 8. Check for excessive tie rod end ball joint

breakaway torque.
Refer to P.37-15.
Q: Is the breakaway torque out of specification?
YES : Replace the tie rod end. And then go to Step 9.
NO : Go to Step 9.
STEP 9. Check the steering wheel operation.

Verify that the steering wheel operation is not difficult.
Q: Is the steering wheel operation difficult?
INSPECTION PROCEDURE 3: Rattling Noise
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
INSPECTION PROCEDURE 4: Shrill Noise
DIAGNOSIS

engine.
140°F).
FLUID FLUCTUATION
YES : Go to Step 2.
NO : Bleed the air (Refer to P.37-18). And then go to Step
3.

STEP 2. Check for seizure in the oil pump.

Q: Is there seizure?
YES : Replace the part. And then go to Step 3.
NO : Go to Step 3.

Q: Is there noise?
INSPECTION PROCEDURE 5: Squealing Noise
DIAGNOSIS STEP 2. Check for seizure in the oil pump.

Q: Is there seizure?
STEP 1. Check the drive belt tension. YES : Replace the part. And then go to Step 3.
Refer to GROUP 00, Maintenance Service − Drive NO : Go to Step 3.
Belts P.00-39.
Q: Is the drive belt tension incorrect? STEP 3. Retest the system.
YES : Adjust the belt tension. (Refer to GROUP Confirm that no noise is generated.
00, Maintenance Service − Drive Belts
P.00-39). And then go to Step 3. Q: Is there noise?
NO : Go to Step 2. YES : Repeat from Step 1.
POWER STEERING 37-8
INSPECTION PROCEDURE 6: Hissing Noise
DIAGNOSIS

engine.
140°F).
FLUID FLUCTUATION
YES : Go to Step 2.
4.

STEP 2. Check each hose for crushing or twisting.

Q: Is any hose crushed or twisted?
YES : Repair or replace the hose. And then go to Step 4.
NO : Go to Step 3.
STEP 3. Check the steering gear for damage.

Q: Is there damage?
NO : Go to Step 4.

Q: Is there noise?
INSPECTION PROCEDURE 7: Droning Noise
NOTE: If a slight "beat noise" is produced by the oil DIAGNOSIS

pump when the steering wheel is turned fully and
held in that position, this is normal. STEP 1. Check the oil pump or oil pump bracket
installation.
Q: Is the oil pump or the oil pump bracket installation
correct?
YES : Go to Step 2.
NO : Repair it. And then go to Step 3.
POWER STEERING 37-9
STEP 2. Check the oil pump for damage. STEP 3. Retest the system.
Q: Is there damage?
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.
INSPECTION PROCEDURE 8: Squeaking Noise
DIAGNOSIS
STEP 1. Check for interference of the wheel and the

vehicle body.
If interfering, adjust the steering angle.
(1) Place the front wheel on a turning radius gauge and
measure the steering angle.
Standard value:
ITEM 17" WHEELS 16" WHEELS

Inner wheel 33°48' ± 2°00' 37°12' ± 2°00'
Outer wheel 28°18' 30°18'
(reference)
AC000756AB
(2) If the steering angle is not within the standard value, adjust
the toe.
(3) Adjust the toe 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.
Q: Is the steering angle normal?
JAM NUT YES : Go to Step 2.
NO : Repeat the toe adjustment. And then go to Step 3.
AC305785 AB

Q: Is there damage?
NO : Go to Step 3.

Q: Is there noise?
POWER STEERING 37-10
INSPECTION PROCEDURE 9: Vibration
NOTE: A slight vibration may be felt when the stationary steer-

ing effort is made due to the condition of the road surface. To
check whether the vibration actually exists or not, test-drive the
vehicle on a dry concrete or asphalt surface. A very slight
amount of vibration is not a malfunction.
DIAGNOSIS
STEP1. Check the tyres for out-of-balance.

YES : Go to Step 2.
NO : Balance the tyres (Refer to GROUP 31, Wheel and
Tyre Diagnosis − Wheel Balance Accuracy P.31-3).
And then go to Step 4.

engine.
140°F).
FLUID FLUCTUATION
YES : Go to Step 3.
4.


Q: Is there damage?
NO : Go to Step 4.

Confirm that there is no steering wheel vibration.
Q: Is there vibration?
INSPECTION PROCEDURE 10: Oil Leakage from Hose Connection
DIAGNOSIS STEP 2. Check the hose connection and the

clamp installation.
STEP 1. Check for loosening of the Refer to P.37-45.
pressure/return tube flare nut. Q: Are they correct?
Q: Is the flare nut loose? YES : Go to Step 3.
YES : Tighten it to 15 ± 3 N⋅m (11 ± 2 ft-lb). And NO : Correct hose connection and/or clamp
then go to Step 3. installation. And then go to Step 3.
NO : Go to Step 2.
Check that no oil is leaking.
Q: Is there oil leakage?
INSPECTION PROCEDURE 11: Oil Leakage from Hose Assembly

STEP 1. Check the hose for damage or clogging. Q: Is there oil leakage?
Q: Is the hose damaged or clogged? YES : Repeat from Step 1.
YES : Repair or replace it. And then go to Step 2. NO : The procedure is complete.
NO : Go to Step 2.
INSPECTION PROCEDURE 12: Oil Leakage from Oil Reservoir
DIAGNOSIS STEP 2. Check for overflowing.

Q: Is there oil overflowing from the reservoir?
STEP 1. Check the oil reservoir for damage. YES : Adjust fluid level. And then go to Step 3.
Q: Is there damage? NO : Go to Step 3.
YES : Repair or replace it. And then go to Step 3.
NO : Go to Step 2.
INSPECTION PROCEDURE 13: Oil Leakage from Oil Pump
DIAGNOSIS STEP 2. Check the O-ring or oil seal for damage.

Q: Is there damage?
STEP 1. Check the oil pump body for damage. YES : Replace the part. And then go to Step 3.
Q: Is there damage? NO : Go to Step 3.
NO : Go to Step 2.
INSPECTION PROCEDURE 14: Oil Leakage from Steering Gear

STEP 1. Check the steering gear housing for Q: Is there oil leakage?
damage. YES : Repeat from Step 1.
Q: Is there damage? NO : The procedure is complete.
NO : Go to Step 2.
SPECIAL TOOLS
SPECIAL TOOLS
M1372000600387

AND NAME
Ball joint remover MB990635-01 or disconnection
General service NOTE: Steering linkage puller
tool (MB990635 or MB991113) is also
available to disconnect knuckle and
AC106827
tie rod end ball joint.
MB990326 General service Tie rod end ball joint breakaway
Preload socket tool torque check
MB990326
MB991548 MB991548-01 Oil pump pressure test

Power steering oil
pressure gauge
adapter (Pump
side)
MB991548
MB991549 MB991549-01
Power steering oil
pressure gauge
adapter (Hose
side)
MB991549
MB990662 MB990662-01
Power steering oil
pressure gauge
MB990662
ON-VEHICLE SERVICE

AND NAME
MB990803 - Steering wheel removal
Steering wheel
puller
MB990803
MB991006 MB990228-01 Steering gear total pinion torque

Preload socket check
MB991006
MB991561 MB991561 Bellows band installation

Boot band crimping
tool
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).
ON-VEHICLE SERVICE
STEERING ANGLE CHECK

M1372001100396
1. Place the front wheel on a turning radius gauge and
measure the 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'
AC000756AB Outer wheel 30°18' 28°18'
(reference)
2. If the steering angle is not within the standard value, adjust

the toe as follows.
(1) Loosen the jam nut, and unclip the bellows.
(2) Adjust the toe by 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 turn-
CLIP buckle is turned toward the rear of the vehicle.
(3) Tighten the jam nut to the specified torque, and tighten
JAM NUT
the bellows by the clip.
AC305785 AB
3. Recheck the steering angle.
TIE ROD END BALL JOINT BREAKAWAY

TORQUE CHECK
M1372001500305

CAUTION
special tool MB991897 to avoid possible damage to the
ball joint threads.
from falling.
CORD
NUT MB991897
BOLT
ON-VEHICLE SERVICE

BOLT
GOOD
KNOB
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.
STATIONARY STEERING EFFORT CHECK

M1372001700354
1. With the vehicle stopped on a flat and paved surface, turn
the steering wheel to the straight ahead position.
2. Start the engine and allow to idle.
3. Attach a spring scale to the outer circumference of the
steering wheel and measure the steering force required to
turn the steering wheel from the straight ahead position to
the left and right (within a range of 1.5 turns). Also check to
be sure that there is no significant change in the required
steering effort.
Standard value:
Steering effort: 30 N (6.7 lb) or less
Fluctuation allowance: 5.9 N (1.33 lb) or less
ACX01122AB
4. If the measured value exceeds the standard value, refer to
Inspection Procedure 2 "Difficult Steering Wheel Operation
(Insufficient Power Assist)" P.37-4.
ON-VEHICLE SERVICE
STEERING WHEEL RETURN TO CENTER CHECK

M1372001800339
Conduct a road test:
1. Make both gradual and sudden turns and check the steering
wheel return.
2. At a vehicle speed of approximately 35 km/h (22 mph), turn
the steering wheel 90 degrees, hold a few seconds, then
release. If the steering wheel then returns 70 degrees or
70˚ 70˚ more, the return can be judged as satisfactory.
NOTE: There will be a momentary feeling or "heaviness"
when the wheel is turned quickly, but this is not abnormal.
(Oil pump discharge amount is especially apt to be insuffi-
cient during idling.)
ACX01130AB
DRIVE BELT TENSION CHECK

M1372001900284
P.00-39.
FLUID LEVEL CHECK

M1372002000303
1. Park the vehicle on a flat, level surface.
2. Start the engine, and then turn the steering wheel several
times to raise the temperature of the fluid to approximately
50 − 60°C (122 − 140°F).
3. With the engine running, turn the wheel all the way to the left
and right several times.
FLUID LEVEL CHANGE:WITHIN 5 mm (0.2 in)
4. Check the fluid in the oil reservoir for foaming or milkiness.
stopped, and while it is running. If the fluid contains air or
has milky appearance, or the fluid level fluctuate by 5 mm
(0.2 inch) or more, power steering system air bleeding
should be done.

RUNNING STOPPED ACX01131AC
ON-VEHICLE SERVICE
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.
POWER STEERING SYSTEM AIR BLEEDING

M1372002200352
Perform air bleeding procedure as necessary after replacing
the steering gear, oil pump or the steering fluid lines.
1. Raise and support the front wheels.
2. Disconnect the ignition coil connectors (Refer to GROUP 16,
CAUTION
Perform air bleeding only while cranking the engine. Do
not perform air bleeding while the engine is running. If you
do so, air in the fluid will be increased and air bleeding will
become more difficult. During air bleeding, refill the steer-
ing fluid so that the level never falls below the lower mark
on the dipstick.
3. Turn the steering wheel all the way to the left and right five
or six times while using the starter motor to crank the engine
intermittently several times (for 15 to 20 seconds).
4. Connect the ignition coil connectors (Refer to GROUP 16,
5. Start the engine and allow to idle.
6. Turn the steering wheel to the left and right until there are no
air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the level is
between the high and low dipstick marks.
8. Confirm that there is very little change in the fluid level when
the steering wheel is turned left and right.
ON-VEHICLE SERVICE
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.

RUNNING STOPPED ACX01131AC
OIL PUMP PRESSURE TEST

M1372002300337

• MB990662: Power Steering Oil Pressure Gauge
• MB991548: Power Steering Oil Pressure Gauge Adapter
(Pump Side)
(Hose Side)
1. Disconnect the pressure hose from the oil pump, and then
connect special tools MB991548, MB990662 and
PRESSURE SHUT-OFF VALVE
THERMO- GAUGE (FULLY CLOSED)
MB991549.
METER (MB990662) 2. Bleed air, then turn the steering wheel several times while
the vehicle is not moving so that the temperature of the fluid
rises to approximately 50 − 60°C (122 − 140°F).
RESERVOIR 3. Start the engine and idle it.
ADAPTER CAUTION
(MB991548)
The pressure gauge shut-off valve must not remain closed
for more than 10 seconds.
4. Fully close the shut-off valve of the pressure gauge and
measure the oil pump relief pressure to confirm that it is
OIL
PUMP within the standard value range. Open it again immediately
after checking the pressure.
Standard value:
ADAPTER 3.8L engine: 9.3 − 9.8 MPa (1,349 − 1,421 psi)
(MB991549)
5. If it is not within the standard value, replace the oil pump.
6. Check whether or not the hydraulic pressure is the standard
value when no-load conditions are created by fully opening
ACX01133 AB the shut-off valve of the pressure gauge.
Standard value: 0.8 − 1.0 MPa (116 − 145 psi)
7. If it is not within the standard value, the probable cause is a
malfunction of the oil line or steering gear, so check these
parts and repair as necessary.
ON-VEHICLE SERVICE
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.
11. Bleed the system (Refer to P.37-18).
POWER STEERING PRESSURE SWITCH CHECK

M1372007200346

• MB990662: Power Steering Oil Pressure Gauge
(Pump Side)
(Hose Side)
1. Disconnect the pressure hose from the oil pump, and then
connect the special tools MB991548, MB990662 and
SHUT-OFF MB991549.
ADAPTER VALVE
(MB991548) PRESSURE
2. Bleed air, and then turn the steering wheel several times
GAUGE while the vehicle is not moving so that the temperature of
THERMO- (MB990662) the fluid rises to approximately 50 − 60°C (122 − 140°F).
METER
3. The engine should be idling.
4. Disconnect the connector for the oil pressure switch, and
place an ohmmeter at the switch.
5. Gradually close the shut-off valve of the pressure gauge and
increase the hydraulic pressure, then check whether or not
the hydraulic pressure that activates the switch is the
OIL
standard value.
PUMP Standard value: 1.8 − 2.4 MPa (261 − 348 psi)
6. Gradually open the shut-off valve and reduce the hydraulic
ADAPTER
RESERVOIR pressure; then check whether or not the hydraulic pressure
(MB991549)
that deactivates the switch is the standard value.
Standard value: 0.8 − 2.4 MPa (116 − 348 psi)
ACX01134 AB
7. 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.
8. Bleed the system. (Refer to P.37-18).
ON-VEHICLE SERVICE
TIE ROD END BALL JOINT DUST COVER CHECK

M1372008600284
1. Press the dust cover with your finger to check whether the
dust cover is cracked or damaged.
2. If the dust cover is cracked or damaged, replace the tie rod
end.
NOTE: If the dust cover is cracked or damaged, the ball joint
could be damaged.
STEERING COLUMN SHAFT ASSEMBLY SHOCK

ABSORBING MECHANISM CHECK
M1372013500131
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.
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
TILT PIN
AC308269 AB
STEERING WHEEL
STEERING WHEEL
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.
• Checking Steering Wheel Position with Wheels Straight
Ahead
41 ± 8 N·m
30 ± 6 ft-lb
6 N 4
3.9 ± 0.9 N·m 3

35 ± 8 in-lb
2
5
2
2
9.0 ± 2.0 N·m

80 ± 17 in-lb
1
AC306560 AB
REMOVAL STEPS INSTALLATION STEPS

1. STEERING WHEEL LOWER 5. STEERING WHEEL REMOTE
COVER CONTROL HARNESS
<<A>> 2. CONNECTORS (FOR HORN, AIR 4. STEERING WHEEL DYNAMIC
BAG MODULE, AND STEERING DAMPER
WHEEL REMOTE CONTROL 3. AIR BAG MODULE
HARNESS) 2. CONNECTORS (FOR HORN, AIR
3. AIR BAG MODULE BAG MODULE, AND STEERING
4. STEERING WHEEL DYNAMIC WHEEL REMOTE CONTROL
DAMPER HARNESS)
5. STEERING WHEEL REMOTE 1. STEERING WHEEL LOWER
CONTROL HARNESS COVER
<> 6. STEERING WHEEL ASSEMBLY NOTE: For air bag module removal, refer to GROUP
INSTALLATION STEPS 52B, Air Bag Module and Clock Spring P.52B-237.
• CLOCK SPRING MATING MARK
ALIGNMENT (REFER TO GROUP Required Special Tool:
52B, AIR BAG MODULE AND • MB990803: Steering Wheel Puller
CLOCK SPRING P.52B-237).
6. STEERING WHEEL ASSEMBLY
STEERING WHEEL

.
<<A>> CONNECTOR (FOR AIR BAG MODULE)

REMOVAL
Slide the outer housing of the clock spring connector in the
OUTER HOUSING OF THE
arrow direction shown, and disconnect the connector.
CLOCK SPRING CONNECTOR
AC306561AB
<>STEERING WHEEL ASSEMBLY REMOVAL

Use special tool MB990803 to remove the steering wheel.
MB990803
AC000991AB
STEERING SHAFT
STEERING SHAFT
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).
• 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

1. STEERING COLUMN LOWER 3. CLOCK SPRING AND COLUMN
COVER SWITCH ASSEMBLY (REFER TO
2. STEERING COLUMN UPPER GROUP 52B, AIR BAG MODULE
COVER AND CLOCK SPRING P.52B-237).
4. STEERING SHAFT PAD
<<A>> >>A<< 5. STEERING COLUMN ASSEMBLY
STEERING SHAFT

.
<<A>> STEERING COLUMN ASSEMBLY

REMOVAL
CAUTION
The tilt lever should be held in the lock position until the
steering column assembly is installed to the vehicle. If the
steering column assembly is removed with the tilt lever
released, or the tilt lever is released after the steering col-
umn assembly was removed from the vehicle, the steering
column assembly cannot be reinstalled correctly. If the
steering column assembly is installed incorrectly, the colli-
sion energy absorbing mechanism may be damaged.
1. Ensure that the tilt lever is in the lock position, and remove
the steering column assembly mounting bolts.
column assembly.
STEERING
CLIP COLUMN
SHAFT
21DB016A

X
Y figure.
YOKE Y
A YOKE X
X
Y Y X
VIEW A
7.6˚ ± 3˚
X Y
AC306564 AB
STEERING SHAFT

.
>>A<< STEERING COLUMN ASSEMBLY INSTAL-

LATION
CAUTION
1. If reusing the steering column assembly, do not release
the tilt lever until the steering column assembly has
been installed.
2. If a new steering column assembly is being installed,
do not release the tilt lever until it has been installed.
Do not remove the tilt lever fixing band until the instal-
lation is completed.
3. When installing the steering column assembly, do not
leave it fixed temporarily at only one point and make
sure the steering column assembly is not shaken
strongly. If this happens, the collision absorbing mech-
anism at the steering column assembly mounting loca-
tion may be damaged.
Ensure that the tilt lever is in the lock position, and install the
steering column assembly. Tighten the four bolts finger-tight in
3
the order shown, and then tighten them to the specified torque
1 in the order shown.
2 TILT
LEVER Tightening torque: 12 ± 2 N⋅m (102 ± 22 in-lb)
4
AC306794AB
STEERING SHAFT

M1372011700117
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

<<A>> >>A<< 1. STEERING LOCK BOLT >>A<< 2. ENGINE STARTING SWITCH
ASSEMBLY
3. STEERING COLUMN ASSEMBLY

.
<<A>> STEERING LOCK BOLT REMOVAL

STEERING REVERSE SCREW TAP
1. Drill in the steering lock bolt a hole deep enough for the tap
LOCK BOLT to stand.
2. Remove the steering lock bolt with a left-hand tap.
CLAMP
ENGINE STARTING
SWITCH ASSEMBLY ACX01138 AE
STEERING SHAFT

.
>>A<< ENGINE STARTING SWITCH ASSEM-

BLY/STEERING LOCK BOLT INSTALLATION
CAUTION
The bolts must be replaced with new ones when the steer-
ing lock is installed.
1. When installing the engine starting switch assembly to the
steering column assembly, temporarily install the engine
starting switch assembly in alignment with the column boss.
2. After checking that the lock works properly, tighten the
steering lock bolts until the head is twisted off.
ACX01139 AB
POWER STEERING GEAR BOX AND LINKAGE

M1372010900259
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
• 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).
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

1. STEERING SHAFT PAD <<C>> >>C<< 11. FRONT AXLE CROSSMEMBER
<<A>> 2. STEERING COLUMN ASSEMBLY STAY
AND STEERING GEAR <<D>> >>B<< 12. CROSSMEMBER ASSEMBLY
CONNECTION >>B<< 13. STEERING COLUMN DASH PANEL
<> 3. SELF LOCKING NUT (TIE ROD END COVER
AND KNUCKLE CONNECTION) 14. REAR ROLL STOPPER
4. RETURN TUBE CONNECTION <<E>> 16. HEAT PROTECTOR "B"
5. PRESSURE HOSE CONNECTION <<E>> 17. HEAT PROTECTOR "A"
7. PRESSURE HOSE CLAMP <<E>> 18. HEAT PROTECTOR "C"
8. O-RING 19. POWER STEERING GEAR AND
9. REAR ROLL STOPPER LINKAGE.
CONNECTING BOLT Required Special Tool:
>>C<< 10. SELF LOCKING NUT • MB991897: Ball Joint Remover

.
<<A>> STEERING COLUMN ASSEMBLY AND

STEERING GEAR DISCONNECTION
column assembly.
STEERING
CLIP COLUMN
SHAFT
21DB016A

X
Y figure.
YOKE Y
A YOKE X
X
Y Y X
VIEW A
7.6˚ ± 3˚
X Y
AC306564 AB
.
<> TIE ROD END AND KNUCKLE

DISCONNECTION
CAUTION
joint threads.
from falling.
CORD
NUT MB991897
BOLT

BOLT
GOOD
KNOB
BAD AC106821AB

REMOVAL
when the front axle crossmember stay is replaced. However,
the bolts may be loose while the front axle crossmember stay is
removed. Retighten the bolts to 180 ± 20 N⋅m (133 ± 14 ft-lb).
FRONT AXLE
CROSSMEMBER
STAY
21DB019A
.
<<D>> CROSSMEMBER ASSEMBLY REMOVAL

1. From inside the vehicle, remove the nut and lower cover to
disengage clip from body.
13DB066A
AC206593 2. Use a transmission jack to hold the crossmember, and then

remove the crossmember mounting nuts and bolts.
1. Lower the crossmember with the rear roll stopper, the stabilizer
bar and the steering gear.
TRANSMISSION
JACK AC306696AB
<<E>> HEAT PROTECTOR REMOVAL

1. Remove M8 bolts from Heat Protectors "A, "B", "C".
HEAT PROTECTOR ‘C’
13DB066A
HEAT PROTECTOR ‘B’

HEAT PROTECTOR ‘A’
13DB071A

.
>>B<< STEERING COLUMN DASH PANEL

COVER/CROSSMEMBER ASSEMBLY
INSTALLATION
1. Install the steering column dash panel cover until the lip is
securely located in the groove of steering gear.
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
5. After installing the steering column dash panel cover, check

that the steering column dash panel cover rubber is not
disengaged from the retainer. If there is any doubt, release
NUT the cover from the body, engage the rubber again and
reinstall to the body.
6. Tighten the nut 4 - 6 Nm.
13DB067A
>>C<< FRONT AXLE CROSSMEMBER

STAY/SELF-LOCKING NUT INSTALLATION
ened to specification, and then install the front crossmember
stay with a new self-locking nut.
CROSSMEMBER
MOUNTING BOLT
FRONT AXLE
CROSSMEMBER
STAY

INSPECTION
M1372011000259
.
STEERING GEAR TOTAL PINION TORQUE

CHECK
CAUTION
• When holding the steering gear in a vice, secure its
mounting positions. If it is secured in any other place,
the gear housing may become deformed or damaged.
• Do not loosen the adjust screw more than 2 rotations.
• If the adjust screw is loosened more than 2 rotations, or
if it is removed, replace the steering gear assembly.
1. Using special tool MB991006, rotate the pinion gear at the
MB991006 rate of one rotation in approximately 4 to 6 seconds to check
the total pinion torque.
Standard value: 0.8 − 1.9 N⋅m (7.1 − 16.8 in-lb)
[Change in torque: 0.7 N⋅m (6.2 in-lb) or less]
NOTE: When measuring, remove the bellows from the rack
housing. Measure the pinion torque through the whole
stroke of the rack.
RACK SUPPORT 2. If the total pinion torque or the change in torque is outside
COVER AC306793 AB the standard value, loosen the rack support cover once and
retighten it to the specified torque 12 ± 2 N⋅m (107 ± 17
in-lb). And then loosen the rack support cover 10 degrees,
and check the pinion torque again.
If the total pinion torque cannot be adjusted to within the
standard range by adjusting the rack support cover, replace
the power steering gear.
.
TIE ROD SWING RESISTANCE CHECK

1. Give 10 hard swings to the tie rod.
2. Measure the tie rod swing resistance with a spring scale.
Standard value:
3.7 − 18.1 N (0.83 − 4.07 lb) <vehicles with 16-inch
wheels>
3.6 − 17.8 N (0.81 − 4.00 lb) <vehicles with 17-inch
wheels>
[Swing torque: 1.0 − 4.9 N⋅m (8.9 − 43.3 in-lb)]
3. If the measured value exceeds the standard value, replace
the tie rod.
AC000997
4. If the measured value is below the standard value, the tie
rod can be re-used if it swings smoothly without excessive
play.
.
TIE ROD END BALL JOINT DUST COVER CHECK

with your finger.
2. If the dust cover is cracked or damaged, replace the tie rod
end. (Refer to P.37-38).

M1372011100223
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
>>P<< 1. STEERING GEAR NUT (TIE ROD >>L<< 8. STEERING GEAR INNER NUT (JAM
END JAM NUT) NUT)
>>P<< 2. TIE ROD END ASSEMBLY <> >>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
Required Special Tools: • MB991204: Torque Wrench Socket

• MB991006: Preload Socket • MB991561: Boot Band Crimping Tool

.
<<A>> STEERING TIE ROD/STEERING GEAR

WASHER (TAB WASHER) REMOVAL
Unstake the tab washer which secures the tie rod and rack with
a chisel.
TAB WASHER
AC001001AB
<> STEERING GEAR RACK SUPPORT

COVER REMOVAL
Using special tool MB991204, remove the rack support cover
from the gear box.
MB991204
ACX01142AB

.
>>K<< STEERING GEAR PLUG (END PLUG)

INSTALLATION
1. Apply 3MTM AAD Part number 8661, 8663, 8672, 8678,
8679 or equivalent to the threaded part of the end plug.
END PLUG END PLUG
2. Secure the threaded portion of the end plug at two places by
using a punch.
ACX01162 AB
.
>>L<< STEERING GEAR RACK SUPPORT

COVER/STEERING GEAR INNER NUT (JAM NUT)
INSTALLATION
1. Position the rack at its center.
2. Apply 3MTM AAD Part number 8661, 8663, 8672, 8678,
8679 or equivalent to the threaded part of the rack support
cover.
3. Use special tool MB991204 to tighten the rack support cover
to 12 ± 2 N⋅m (107 ± 17 in-lb).
MB991204
4. Turn the rack support cover 10 degree angle
counterclockwise.
5. Use special tool MB991204 to hold the rack support cover,
and then tighten the jam nut to 59 ± 10 N⋅m (44 ± 7 ft-lb).
AC001009 AB
>>M<< TOTAL PINION TORQUE ADJUSTMENT

CAUTION
• Be sure there is no ratcheting or catching when operat-
ing the rack towards the shaft.
• Measure the total pinion torque through the whole
stroke of the rack.
1. Using special tool MB991006, rotate the pinion shaft at the
MB991006 rate of one rotation in 4 to 6 seconds to check the total
pinion torque and the change in torque.
Standard value:
Total pinion torque: 0.8 − 1.9 N⋅m (7.1 − 16.8 in-lb)
[Change in torque: 0.7 N⋅m (6.2 in-lb) or less]
CAUTION
RACK SUPPORT When adjusting, set at the highest value of the standard
COVER value range.
13DB061A
NOTE: If the total pinion toque cannot be adjusted to the
standard value within the standard range, replace the power
steering gear and linkage assembly.
2. If the total pinion torque or the change in torque is outside
the standard value, loosen the rack support cover once and
retighten it to the specified torque 12 ± 2 N⋅m (107 ± 17
in-lb). And then loosen the rack support cover 10 degrees,
and check the pinion torque again.
.
>>N<< STEERING GEAR WASHER (TAB

WASHER)/STEERING TIE ROD INSTALLATION
After installing the tie rod to the rack, fold tab washer end (two
locations) to tie rod notch.
ACX01163 AB
>>O<< STEERING GEAR BAND (BELLOWS

BAND) INSTALLATION
1. Turn the adjusting bolt of special tool MB991561 to adjust
MB991561 the opening dimension (W) to the standard value.
STOPPER NOTE: The dimension (W) is adjusted by approximately 0.7
mm (0.03 inch) per one turn.
W
NOTE: Do not turn the adjusting bolt more than one turn.
Standard value (W): 1.9 mm (0.07 inch)
<When more than 1.9 mm (0.07 inch)>: Screw in the
ADJUSTING BOLT adjusting bolt.
<When less than 1.9 mm (0.07 inch)>: Loosen the
ACX01164 AB
adjusting bolt.
CAUTION
• Hold the rack housing, and use special tool MB991561
MB991561
to crimp the bellows band securely.
• Crimp the bellows band until special tool MB991561
touches the stopper.
2. Use special tool MB991561 to crimp the bellows band.
ACX01165 AB
3. Check that crimped width (A) is within the standard value.

Standard value (A): 1.4 − 1.8 mm (0.06 − 0.07 inch)
A
<When more than 1.8 mm (0.07 inch)>: Readjust the
dimension (W) of step (1) to the value calculated by
the following equation, and repeat step (2).
W = 5.5 mm (0.22 inch) − A [Example: if (A) is 1.9 mm
(0.07 inch), (W) is 3.6 mm (0.14 inch).]
<When less than 1.4 mm (0.06 inch)>: Remove the bel-
lows band, readjust the dimension (W) of step (1) to
ACX01166 AB the value calculated by the following equation, and
use a new bellows band to repeat steps (2) to (3).
W = 5.5 mm (0.22 inch) − A [Example: if (A) is 1.3 mm
(0.05 inch), (W) is 4.2 mm (0.17 inch).]
.
>>P<< TIE ROD END ASSEMBLY/STEERING

GEAR NUT (TIE ROD END JAM NUT)
INSTALLATION
Screw in the tie rod end to achieve the right and left length as
EDGE OF BELLOWS JAM NUT illustrated. Lock with the jam nut.
ASSEMBLY GROOVE NOTE: The locking nuts must be tightened securely only after
the steering gear is installed and toe is adjusted.
207.4 mm (8.2 in) <GTVi MODELS>

203.9 mm (8.0 in) <OTHER MODELS>
13DB068A
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 OIL PUMP ASSEMBLY

M1372005200351

• Side Under Cover (RH) Removal (Refer to GROUP 51, • Power Steering Fluid Supplying and Bleeding (Refer to
Under Cover P.51-13). P.37-18).
• Strut Tower Bar (Refer to GROUP 42, Strut Tower Bar • Drive Belt Tension Adjusting (Refer to GROUP 00, Main-
P.42-12). tenance Service − Drive Belts P.00-39).
• Power Steering Fluid Draining (Refer to P.37-18). • Strut Tower Bar (Refer to GROUP 42, Strut Tower Bar
P.42-12).
• Side Under Cover (RH) Installation (Refer to GROUP 51,
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
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)

.
<<A>> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
Turn up the stabilizer disconnected from the stabilizer link fully,
STABILIZER BAR and remove the power steering oil pump assembly after turning
POWER STEERING the steering wheel fully to left.
OIL PUMP ASSEMBLY
AC307223 AB

.
>>A<< SUCTION HOSE INSTALLATION

Install the suction hose so that the marking is positioned as
SUCTION HOSE
AC205022AC
INSPECTION
M1372005300206
• Check the drive belt for cracks.
• Check the pulley for uneven rotation.
POWER STEERING HOSES

M1372005700431

• Side Under Cover (RH) Removal (Refer to GROUP 51, • Radiator Grille Installation (Refer to P.51-6).
Under Cover P.51-13). • Front Bumper Installation (Refer to P.51-2).
• Power Steering Fluid Draining (Refer to P.37-18). • Power Steering Fluid Supplying and Bleeding (Refer to
• Front Bumper Removal (Refer to P.51-2). P.37-18).
• Radiator Grille Removal (Refer to P.51-6). • Side Under Cover (RH) Installation (Refer to GROUP 51,
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

1. OIL RESERVOIR 8. EYE BOLT
>>F<< 2. SUCTION HOSE 9. GASKET
>>E<< 3. RETURN HOSE (M) >>A<< 10. PRESSURE HOSE
>>D<< 4. RETURN HOSE (R) >>A<< 11. TUBE ASSEMBLY RETURN (G)
>>C<< 5. RETURN TUBE ASSEMBLY 12. O-RING
6. O-RING 13. COOLER TUBE ASSEMBLY
>>B<< 7. RETURN TUBE (R)

.
>>A<< PRESSURE TUBE ASSEMBLY/PRESSURE

HOSE INSTALLATION
STEERING
Align the markings as shown in the illustration and tighten the
GEAR PRESSURE TUBE nut.
ASSEMBLY ASSEMBLY
MARKING
AC307218 AB
>>B<< RETURN TUBE (R) INSTALLATION

Install the return tube (R) so that the marking is positioned as
RETURN shown in the illustration.
HOSE (R)
RETURN
TUBE (R)
AC205020 AB
>>C<< RETURN TUBE ASSEMBLY

INSTALLATION
STEERING
1. Install the return tube assembly so that the marking is
GEAR MARKING positioned as shown in the illustration.
ASSEMBLY 2. Align the markings as shown in the illustration and tighten
the nut.
RETURN
TUBE
ASSEMBLY
AC307218AC
RETURN
TUBE (R)
RETURN TUBE
ASSEMBLY
AC205021AB
.
>>D<< RETURN HOSE (R) INSTALLATION

Install the return hose (R) so that the markings are positioned
RETURN as shown in the illustration.
HOSE (R)
RETURN
TUBE (R)
AC205020AC
RETURN
HOSE (R)
COOLER TUBE
ASSEMBLY
AC205025AB
>>E<< RETURN HOSE (M) INSTALLATION

RETURN
Install the return hose (M) so that the markings are positioned
SUCTION HOSE (M) as shown in the illustration.
HOSE
MARKING
OIL
RESERVOIR
AC307226AB
RETURN
HOSE (M)
COOLER TUBE
ASSEMBLY
AC205025AC
.
>>F<< SUCTION HOSE INSTALLATION

RETURN
Install the suction hose so that the marking is positioned as
SUCTION HOSE (M) shown in the illustration.
HOSE
MARKING
OIL
RESERVOIR
AC307226AB
<3.8L ENGINE> SUCTION HOSE
AC205022AD
SPECIFICATIONS
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)
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)
M1372000200282
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
SPECIFICATIONS
M1372000300405

Steering wheel With engine running − 30 (1.2)
free play mm (in) With engine stopped 10 (0.4) or less −
Steering angle Inside wheel 37°12' ± 2°00' <vehicles with 16-inch −
wheels>
33°48' ± 2°00' <vehicles with 17-inch
wheels>
Outside wheel (reference) 30°18' <vehicles with 16-inch wheels> −
28°18' <vehicles with 17-inch wheels>
Toe-in mm (in) 0 ± 3 (0 ± 0.12) −
Tie rod end ball joint breakaway torque N⋅m (in-lb) 0.5 − 3.5 (4.4 − 31.0) −
Tie rod swing resistance N (lb) [Tie rod swing torque 3.7 − 18.1 (0.83 − 40.7) <vehicles with −
N⋅m (in-lb)] 16-inch wheels>
3.6 − 17.8 (0.81 − 4.00) <vehicles with
17-inch wheels>
[1.0 − 4.9 (8.8 − 43.4)]
Stationary steering effort N (lb) [Fluctuation allowance 30 (6.7) or less −
N (lb)] [5.9 (1.33) or less]
Oil pump Oil pump relief pressure 9.3 − 9.8 (1,349 − 1,421) −
pressure MPa 0.8 − 1.0 (116 − 145)
Pressure under no-load conditions −
(psi)
Steering gear retention hydraulic 9.3 − 9.8 (1,349 − 1,421) −
pressure
Oil pressure switch operating pressure OFF → ON 1.8 − 2.4 (261 − 348) −
MPa (psi) ON → OFF 0.8 − 2.4 (116 − 348) −
Steering gear total pinion torque N⋅m (in-lb) [Change in 0.8 − 1.9 (7.1 − 16.8) −
torque N⋅m (in-lb)] [0.7 (6.2) or less]
Opening dimension of special tool MB991561 mm (in) 1.9 (0.07) −
Band crimped width mm (in) 1.4 − 1.8 (0.06 − 0.07) −
LUBRICANTS
M1372000400372
ITEM SPECIFIED LUBRICANT QUANTITY dm3 (qt)

Power steering fluid GENUINE MITSUBISHI 1.2 (1.3)
POWER STEERING FLUID
Gear box Bearing GENUINE MITSUBISHI As required
O-ring POWER STEERING FLUID
Oil seal
Special tool (MB991213)
Pinion and valve assembly
seal ring part
Bellows Silicon grease As required
Oil pump Power steering fluid GENUINE MITSUBISHI 0.8 (0.85)
POWER STEERING FLUID
SPECIFICATIONS
SEALANT
M1372000500379

Power steering gear box End plug 3M™ AAD Part No.8661, 8663, 8672,
Rack support cover 8678, 8679 or equivalent
SPECIFICATIONS
NOTES
HOME 42-1
GROUP 42
BODY
CONTENTS
HOOD. . . . . . . . . . . . . . . . . . . . . 42-4 STRUT TOWER BAR. . . . . . . . 42-12
BODY DIAGNOSIS . . . . . . . . . . . . 42-4 REMOVAL AND INSTALLATION . 42-12

INTRODUCTION TO HOOD DIAGNOSIS 42-4
HOOD DIAGNOSTIC TROUBLESHOOTING
STRATEGY . . . . . . . . . . . . . . . . . . . . . . 42-4 WINDOW GLASS. . . . . . . . . . . 42-12
SYMPTOM CHART . . . . . . . . . . . . . . . . 42-4
SYMPTOM PROCEDURES . . . . . . . . . 42-4 GENERAL. . . . . . . . . . . . . . . . . . . . 42-12
ON-VEHICLE SERVICE. . . . . . . . . 42-6 WINDOW GLASS DIAGNOSIS . . . 42-14

ADJUSTMENT OF CLEARANCE INTRODUCTION TO WINDOW GLASS
AROUND HOOD . . . . . . . . . . . . . . . . . . 42-6 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-14
ALIGNMENT OF HOOD LATCH AND WINDOW GLASS DIAGNOSTIC
STRIKER . . . . . . . . . . . . . . . . . . . . . . . . 42-6 TROUBLESHOOTING STRATEGY . . . . 42-14
ADJUSTMENT OF HOOD HEIGHT . . . 42-7 WINDOW GLASS DIAGNOSTIC TROUBLE
SYMPTOM CHART . . . . . . . . . . . . . . . . 42-14
HOOD. . . . . . . . . . . . . . . . . . . . . . . 42-8 SYMPTOM PROCEDURES . . . . . . . . . . 42-14
SPECIAL TOOL . . . . . . . . . . . . . . . 42-14
FENDER. . . . . . . . . . . . . . . . . . . 42-10
WINDSHIELD . . . . . . . . . . . . . . . . . 42-15
REMOVAL AND INSTALLATION. . . . . . 42-15
REMOVAL AND INSTALLATION . 42-10
REAR WINDOW GLASS . . . . . . . . 42-20

FUEL FILLER LID . . . . . . . . . . . 42-11 REMOVAL AND INSTALLATION. . . . . . 42-20
REMOVAL AND INSTALLATION . 42-11 Continued on next page

BODY 42-2
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 42-23 WINDOW GLASS RUNCHANNEL
AND DOOR OPENING
GENERAL DESCRIPTION . . . . . . 42-23 WEATHERSTRIP . . . . . . . . . . . . . . 42-52
CENTRAL DOOR LOCKING SYSTEM REMOVAL AND INSTALLATION. . . . . . 42-52
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-23
POWER WINDOW DIAGNOSIS . . . . . . 42-23
DOOR DIAGNOSIS . . . . . . . . . . . . . . . . 42-23
TRUNK LID. . . . . . . . . . . . . . . . 42-60
INTRODUCTION TO GLASS AND DOOR
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-23 TRUNK LID DIAGNOSIS . . . . . . . . 42-60
GLASS AND DOOR DIAGNOSTIC INTRODUCTION TO TRUNK LID
TROUBLESHOOTING STRATEGY . . . 42-23 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-60
SYMPTOM CHART . . . . . . . . . . . . . . . . 42-24 TRUNK LID DIAGNOSTIC
SYMPTOM PROCEDURES . . . . . . . . . 42-24 TROUBLESHOOTING STRATEGY . . . . 42-60
HOW TO LOCATE WIND NOISE . . . . . 42-27 SYMPTOM CHART . . . . . . . . . . . . . . . . 42-60
SYMPTOM PROCEDURES . . . . . . . . . . 42-60
SPECIAL TOOLS. . . . . . . . . . . . . . 42-28
ON-VEHICLE SERVICE . . . . . . . . . 42-61
ON-VEHICLE SERVICE. . . . . . . . . 42-30 ADJUSTMENT OF CLEARANCE
DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-30 AROUND TRUNK LID . . . . . . . . . . . . . . 42-61
DOOR WINDOW GLASS ADJUSTMENT 42-31 TRUNK LID LATCH ADJUSTMENT. . . . 42-61
GLASS SLIDING MECHANISM CHECK TRUNK LID HEIGHT ADJUSTMENT. . . 42-62
AND ADJUSTMENT . . . . . . . . . . . . . . . 42-32
POWER WINDOW TIMER FUNCTION TRUNK LID . . . . . . . . . . . . . . . . . . . 42-63
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 42-32 REMOVAL AND INSTALLATION. . . . . . 42-63
POWER WINDOW OPERATING INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-65
CURRENT CHECK . . . . . . . . . . . . . . . . 42-33
POWER WINDOW RELAY CHECK . . . 42-33
CIRCUIT BREAKER (INCORPORATED IN
KEYLESS ENTRY SYSTEM 42-67
THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-34 GENERAL DESCRIPTION . . . . . . . 42-67
POWER WINDOW CHECK . . . . . . . . . . 42-34
CENTRAL DOOR LOCKING SYSTEM KEYLESS ENTRY SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-34
DOOR OUTSIDE HANDLE PLAY CHECK 42-35
DIAGNOSIS . . . . . . . . . . . . . . . . . . 42-68
DOOR INSIDE HANDLE PLAY CHECK 42-35
SPECIAL TOOL . . . . . . . . . . . . . . . 42-68
DOOR ASSEMBLY . . . . . . . . . . . . 42-37
REMOVAL AND INSTALLATION . . . . . 42-37 ON-VEHICLE SERVICE . . . . . . . . . 42-69
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-38 TRANSMITTER BATTERY CHECK. . . . 42-69
HOW TO REPLACE THE TRANSMITTER
DOOR GLASS AND REGULATOR 42-39 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 42-70
REMOVAL AND INSTALLATION . . . . . 42-39 KEYLESS ENTRY SYSTEM INSPECTION 42-71
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-43 KEYLESS ENTRY SYSTEM TIMER LOCK
FUNCTION INSPECTION . . . . . . . . . . . 42-71
ENABLING/DISABLING THE
DOOR HANDLE AND LATCH. . . . 42-46
ANSWERBACK FUNCTION . . . . . . . . . 42-72
HOW TO REGISTER SECRET CODE . 42-73
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-49

42-3
SUNROOF ASSEMBLY. . . . . . . . . . . 42-75 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-82

DISASSEMBLY AND ASSEMBLY . . . . . 42-83
LOOSE PANEL . . . . . . . . . . . . 42-84
SUNROOF DIAGNOSIS . . . . . . . . 42-75
REMOVAL AND INSTALLATION . 42-84
SPECIAL TOOL . . . . . . . . . . . . . . . 42-75
SPECIFICATIONS . . . . . . . . . . 42-86
ON-VEHICLE SERVICE. . . . . . . . . 42-75
WATER TEST . . . . . . . . . . . . . . . . . . . . 42-75
SUNROOF TIMER FUNCTION CHECK 42-76 FASTENER TIGHTENING
SUNROOF FIT ADJUSTMENT . . . . . . . 42-76 SPECIFICATIONS . . . . . . . . . . . . . 42-86
SUNROOF CHECK . . . . . . . . . . . . . . . . 42-76
ROOF LID GLASS OPERATION SERVICE SPECIFICATIONS . . . . . 42-87
CURRENT CHECK . . . . . . . . . . . . . . . . 42-76
SUNROOF INITIALIZATION . . . . . . . . . 42-77
SUNROOF OPERATION CHECK . . . . . 42-77 SEALANT AND ADHESIVES. . . . . 42-87
SUNROOF ASSEMBLY. . . . . . . . . 42-80 COMPONENT IDENTIFICATIONS. 42-88

BODY 42-4
HOOD
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
hood fault. Chart.
SYMPTOM CHART
M1421006000371

PROCEDURE
Difficult locking and unlocking 1 P.42-4
Uneven body clearance 2 P.42-5
Uneven height 3 P.42-5
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Difficult Locking and Unlocking
DIAGNOSIS STEP 3. Check for proper lubrication of release

cable.
STEP 1. Check that the release cable is routed Q: Is the release cable properly lubricated?
correctly. YES : Go to Step 4.
Q: Is the release cable routed correctly? NO : Lubricate, then go to Step 4.
YES : Go to Step 2.
NO : Re-route the release cable. Then go to Step
4.
Q: Does the hood lock operate easily?
STEP 2. Check the engagement of the hood latch NO : Return to Step 1.
and hood striker.
Q: Are the hood latch and hood striker engaged
correctly?
YES : Go to Step 3.
NO : Adjust the hood latch (Refer to P.42-6).
Then go to Step 4.
BODY 42-5
HOOD
INSPECTION PROCEDURE 2: Uneven Body Clearance

Q: Are the clearances between body panels even?
STEP 1. Check the clearance around the hood. YES : The procedure is complete.
Q: Is the clearance around the hood even? NO : Return to Step 1.
YES : Go to Step 2.
NO : Adjust the hood (Refer to P.42-6). Then go
to Step 2 .
INSPECTION PROCEDURE 3: Uneven Height

Q: Are the hood and body height even?
STEP 1. Check the hood damper height. YES : The procedure is complete.
Q: Is the hood damper height correct? NO : Return to Step 1.
YES : Go to Step 2.
NO : Adjust the hood damper (Refer to P.42-7).
Then go to Step2.
BODY 42-6
HOOD
ON-VEHICLE SERVICE
ADJUSTMENT OF CLEARANCE AROUND HOOD

M1421007200130
Detach the front deck garnish (Refer to GROUP 51, Windshield
Wiper P.51-17). Then loosen the hood hinge mounting nuts
and bolts as shown, and adjust the hood by moving it until the
clearance around it is even.
HOOD HINGE NOTE:
AC205079 AB
If the hood hinge mounting bolt washers are welded,

BOLT grind off the welding according to the procedure below before-
hand.
WASHER .
WELD POINT 1. Remove the hood hinge (Refer P.42-8).
NUT
2. Use a chisel or grinder to release the hood hinge mounting
bolt washer, which is welded to the hood hinge.
3. On completion, paint the affected area with a suitable
HOOD HINGE touch-up brush to prevent corrosion.
AC210131AB
4. Install the hood hinge (Refer P.42-8).
ALIGNMENT OF HOOD LATCH AND STRIKER

M1421008500026
Note the routing of the hood release cable, and then loosen the
HOOD LATCH hood latch mounting bolts. Then align the latch with the striker
by moving the hood latch. After alignment, ensure that the hood
can be locked and unlocked correctly.
AC205080 AB
BODY 42-7
HOOD
ADJUSTMENT OF HOOD HEIGHT

M1421007400145
Turn the hood damper until its height is as shown. If the hood
height is still not even at the left and right sides, turn the hood
damper further until the hood height is even.
NOTE: Turning a new hood damper one full turn will
increase/decrease the hood height by approximately 3 mm (0.1
inch).
B
SECTION B – B
UNITS: mm (in)
HOOD DAMPER
15 ± 0.5
(0.6 ± 0.02)
AC308902 AB
BODY 42-8
HOOD
HOOD
M1421001600345
• 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
9.0 ± 2.0 N·m

4 80 ± 17 in-lb
6
18DB156A
BODY 42-9
HOOD
CLIP POSITIONS
7
SECTION A – A
9
9
A
CLIP
NOTE
: CLIP POSITIONS 18DB157A
REMOVAL HOOD LATCH AND HOOD LOCK

1. HOOD DAMPER RELEASE CABLE REMOVAL
HOOD LATCH AND HOOD LOCK STEPS (Continued)
RELEASE CABLE REMOVAL 5. HOOD LOCK RELEASE HANDLE
STEPS <<A>> 6. HOOD LOCK RELEASE CABLE
• RADIATOR GRILLE (REFER TO HOOD AND HOOD HINGE
GROUP 51, RADIATOR GRILLE REMOVAL STEPS
P.51-6). 7. HOOD INSULATOR
4. HOOD LATCH 8. HOOD WEATHERSTRIP
• SPLASH SHIELD (REFER TO • WINDSHIELD WASHER HOSE,
P.42-10). WINDSHIELD WASHER NOZZLE
(REFER TO GROUP 51,
• FRONT BUMPER ASSEMBLY
(REFER TO GROUP 51, FRONT WINDSHIELD WASHER P.51-23).
BUMPER P.51-2). 9. HOOD
10. GAS STRUTS
• HEADLIGHT ASSEMBLY <LH>
(REFER TO GROUP 54A, • FRONT DECK GARNISH (REFER
HEADLIGHT AND FRONT TO GROUP 51, WINDSHIELD
COMBINATION LIGHT P.54A-153). WIPER P.51-17).
11. HOOD HINGE
• FRONT END STRUCTURE BAR
(REFER TO P.42-84).

.
<<A>> HOOD LOCK RELEASE CABLE REMOVAL

Release the grommet as shown, and pull out the hood lock
release cable in the arrow direction (passenger compartment
FENDER
side).
NOTE: If you attempt to pull out the hood lock release cable in
the opposite direction, the end of the hood lock release cable
will engage the grommet and prevent cable removal.
GROMET
HOOD LOCK RELEASE CABLE

AC210333AB
BODY 42-10
FENDER
FENDER
M1421001900313

• Front Bumper Assembly Removal and Installation (Refer
to GROUP 51, Front Bumper P.51-2).
• Front Mud Guard Removal and Installation (Refer to
GROUP 51, Mud Guard P.51-12).
• Headlight Removal and Installation (Refer to GROUP
54A, Headlight and Front Combination Light P.54A-153).
1 5
2
3
NOTE
: CLIP POSITIONS
AC305815 AB

1. SPLASH SHIELD MOUNTING CLIP • DOOR MIRROR COVER (REFER TO
<DRIVER SIDE ONLY> GROUP 51, DOOR MIRROR
2. SPLASH SHIELD MOUNTING BOLT P.51-28).
<PASSENGER SIDE ONLY> • FRONT DELTA GARNISH (REFER
3. SPLASH SHIELD TO GROUP 51, GARNISHES AND
MOLDING P.51-8).
4. FENDER
BODY 42-11
FUEL FILLER LID
FUEL FILLER LID

M1421002500288
2
AC305819
3
FUEL FILLER LID HEIGHT AND
CLEARANCE ADJUSTMENT
1
AC305818
AC306167AB
REMOVAL REMOVAL (Continued)

1. FUEL FILLER CAP 2. FUEL FILLER LID
3. FUEL FILLER LID DAMPER
BODY 42-12
STRUT TOWER BAR
STRUT TOWER BAR

REMOVAL AND INSTALLATION (Where fitted)
M1421005600109
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
WINDOW GLASS INSTALLATION

CAUTION
Do not apply the primer on the adhesive
remained as the adhesion may be reduced.
WINDOW GLASS INSTALLATION

PROCEDURE
BODY SIDE WINDOW GLASS SIDE
REUSING THE GLASS REPLACE THE GLASS
CLEANING OF ADHESION SURFACE CLEANING OF ADHESION SURFACE CLEANING OF ADHESION SURFACE

CUT OFF THE RESIDUAL ADHESIVE COMPLETELY CUT OFF ALL OF THE CLEAN OFF ANY DIRT ADHERING TO
UNTIL THE THICKNESS IS LESS THAN RESIDUAL ADHESIVE. CLEAN THE THE ADHESION SURFACE WITH 3M™
2 mm (0.08 inch). CLEAN THE ADHESION ADHESIVE SURFACE WITH 3M™ AAD AAD PART NO. 8906 OR EQUIVALENT,
SURFACE WITH 3M™ AAD PART PART NO. 8906 OR EQUIVALENT, AND AND LET DRY FOR 3 MINUTES OR
NO. 8906 OR EQUIVALENT, AND LET LET DRY FOR 3 MINUTES OR MORE. MORE.
DRY FOR 3 MINUTES OR MORE.
ATTACHING OF WINDOW SPACER GLUING OF WINDOW DAM AND WINDOW SPACER

ATTACH THE WINDOW SPACER TO SET GLUE THE WINDOW DAM AND WINDOW SPACER TO THE GLASS, FOLLOWING THE
THE POSITIONS FOR THE GLASS TO BE STANDARD POSITION ALL THE WAY AROUND THE INSIDE EDGE OF THE GLASS.
INSTALLED.
APPLICATION OF PRIMER
DO NOT APPLY PRIMER ON RESIDUAL ADHESIVE AS DOING SO MAY AFFECT ADHESION. APPLY ENOUGH PRIMER ON ADHESION
SURFACE EVENLY TAKING CARE NOT TO APPLY IT ON THE RESIDUAL ADHESIVE. AFTER APPLYING PRIMER, LET IT DRY FOR
3 MINUTES OR MORE.
APPLICATION OF ADHESIVE
WITHIN 30 MINUTES AFTER APPLYING THE PRIMER, APPLY THE ADHESIVE EVENLY
ALL THE WAY AROUND THE INSIDE EDGE OF THE GLASS.
INSTALLING THE GLASS

AFTER APPLYING THE ADHESIVE, LIGHTY PRESS THE GLASS
EVENLY SO THAT IT ADHERES COMPLETELY.
CLEANING
AFTER REMOVING EXCESS ADHESIVE FROM THE BODY OR
GLASS WITH A SPATULA, ETC. CLEAN OFF WITH 3M™ AAD
PART NO. 8906 OR EQUIVALENT.
CHECKING FOR WATER LEAKS

CARRY OUT A SHOWER TEST TO CHECK THAT NO WATER
LEAKS THROUGH.
AC306636 AB
BODY 42-14
WINDOW GLASS
WINDOW GLASS DIAGNOSIS

INTRODUCTION TO WINDOW GLASS DIAGNOSIS
M1422006700254
If water emerges from the following points, there is a • Windshield
problem in the seal or body flange. • Rear window glass
WINDOW GLASS DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1422006800240
window glass fault. Chart.
WINDOW GLASS DIAGNOSTIC TROUBLE SYMPTOM CHART
M1422006900281

PROCEDURE
Water leak through windshield 1 P.42-14
Water leak through rear window glass
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Water Leak Through Windshield/Rear Window Glass
DIAGNOSIS STEP 2. Check if the body flange is deformed.

Q: Is the body flange deformed?
STEP 1. Check if the seal is faulty. YES : Replay the body flange, then go to Step 3.
Q: Is the seal faulty? NO : Go to Step 3.
YES : Repair the seal, then go to Step 3.
NO : Go to Step 2.
Q: Is any water leaking?
NO : This diagnosis complete.
SPECIAL TOOL
M1422000600301

NAME
MB990480 Glass holder General service tool Removal and installation
of window glass
MB990480
BODY 42-15
WINDOW GLASS
WINDSHIELD
M1422001000324

• Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper and Washer P.51-17).
• Roof Drip Molding Removal and Installation (Refer to
GROUP 51, Garnish and Molding P.51-8).
• Front Pillar Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-11).
• Instrument Panel Front End Garnish Removal and Instal-
lation (Refer to GROUP 52A, Instrument Panel Assembly
P.52A-4).
• Inside Rear View Mirror Removal and Installation (Refer
to GROUP 52A, Inside Rear View Mirror P.52A-20).
4N
N 2 3N
1
2N
N5
AC305559AB
BODY 42-16
WINDOW GLASS
SECTION A – A SECTION B – B UNITS: mm (in)

SEAL LINE 9 SEAL LINE 8.2 (0.323)
A CENTER (0.35) 3 CENTER 2
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
1 SEAL LINE 16 (0.63)

5
AC306001
1 AC306369 AB
ADHESIVE: 3M™ AAD PART NO. 8609 SUPER FAST URETHANE AND 3M™ AAD PART NO. 8608 SUPER FAST
URETHANE PRIMER OR EQUIVALENT

<<A>> >>B<< 1. WINDSHIELD • MB990480: Glass Holder
>>A<< 2. WINDSHIELD SIDE MOLDING
>>A<< 3. WINDSHIELD UPPER MOLDING
>>A<< 4. GLASS STOPPER
>>A<< 5. WINDSHIELD SPACER

.
<<A>> WINDSHIELD REMOVAL

1. To protect the body (paint surface), apply cloth tape to all
body areas around the installed windshield.
2. Make mating marks on the windshield and body.
3. Using piano wire.
(1) Using a sharp-point drill, make a hole in the windshield
adhesive.
(2) Pass the piano wire from the inside of the vehicle through
the hole.
CAUTION
Do not let the piano wire touch the edge of the windshield.
(3) Pull the piano wire alternately from the inside and outside
along the windshield to cut the adhesive.
AC308988
BODY 42-17
WINDOW GLASS
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

.
>>A<< WINDSHIELD SPACER/GLASS STOP-

PER/WINDSHIELD UPPER MOLDING/WIND-
SHIELD SIDE MOLDING INSTALLATION
CAUTION
Leave the degreased parts for 3 or more minutes to dry
well, before starting on the next step. Do not touch the
degreased parts.
1. Use 3M™ AAD Part number 8906 or equivalent to degrease
the inside and outside of the windshield and the body
flanges.
WINDSHIELD SPACER AND GLASS STOPPER INSTALLATION POSITION UNITS: mm (in)
GLASS END LINE
17.5 ± 0.5 (0.689 ± 0.020)
CERAMIC END
LINE ALIGN THE GLASS STOPPER END
WITH THE WINDSHIELD MARK.
AC107207
GLASS STOPPER WINDSHIELD

SECTION A – A
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
REAR WINDOW GLASS

M1422001600122

• Roof Drip Moulding Removal and Installation (Refer to
GROUP 51, Garnishes and Moulding P.51-8.)
• Rear Pillar Trim and Rear Shelf Trim Removal and Instal-
lation (Refer to GROUP 52A, Trims P.52A-11.)
N 4
N3
2N
N 2
1 5N AC305560AB
SECTION A – A SECTION B – B UNITS: mm (in)

SEAL LINE 15.5 (0.610) SEAL LINE 11.5 (0.453) 2
CENTER 3 CENTER
A
1 1
A
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
1 SEAL LINE 5 16 (0.63)

AC306008
AC306513 AB
ADHESIVE: 3M™ AAD PART NO. 8609 SUPER FAST URETHANE AND 3M™ AAD PART NO. 8608 SUPER FAST
URETHANE PRIMER OR EQUIVALENT

<<A>> >>B<< 1. REAR WINDOW GLASS • MB990480: Glass Holder
>>A<< 2. REAR WINDOW SIDE MOLDING
>>A<< 3. REAR WINDOW UPPER MOLDING
>>A<< 4. GLASS STOPPER
>>A<< 5. REAR WINDOW SPACER
BODY 42-21
WINDOW GLASS

.
<<A>> REAR WINDOW GLASS REMOVAL

Remove the rear window glass using the same procedure as
for the windshield (Refer to P.42-15).

.
>>A<< REAR WINDOW SPACER/GLASS STOP-

PER/REAR WINDOW UPPER MOLDING/REAR
WINDOW SIDE MOLDING INSTALLATION
CAUTION
Leave the degreased parts for 3 or more minutes to dry
well, before starting on the next step. Do not touch the
degreased parts.
1. Use 3M™ AAD Part number 8906 or equivalent. to degrease
the inside and outside edges of the rear window glass and
the surface of the body flange.
BODY 42-22
WINDOW GLASS
REAR WINDOW GLASS SPACER, GLASS STOPPER AND REAR WINDOW GLASS MOLDING UNITS: mm (in)
INSTALLATION POSITION
GLASS END LINE
21.5 ± 0.5 (0.846 ± 0.020)
ALIGN THE GLASS STOPPER END

WITH THE REAR WINDOW GLASS MARK.
CERAMIC END
LINE AC107207
REAR WINDOW GLASS
UPPER MOLDING GLASS END
GLASS STOPPER
LINE
2.5 ± 2.5
(0.984 ± 0.984)
CERAMIC END LINE

AC306012
REAR WINDOW GLASS
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.
.
>>B<< REAR WINDOW GLASS INSTALLATION

Install the rear window glass in the same way as for the wind-
shield installation (Refer to P.42-15).
BODY 42-23
DOOR
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
glass and door fault. Chart.
BODY 42-24
DOOR
SYMPTOM CHART
M1423007000303

PROCEDURE
Water leak through door window glass 1 P.42-24
Door window glass malfunction 2 P.42-24
Water leak through door edge 3 P.42-25
Water leak from door center 4 P.42-25
Door hard to open 5 P.42-25
Door does not open or close completely 6 P.42-26
Uneven gap between body 7 P.42-26
Wind noise around door 8 P.42-26
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Water Leak Through Door Window Glass
DIAGNOSIS STEP 3. Check the clearance at the top of the

door window glass.
STEP 1. Check the window glass runchannel. Q: Is the clearance at the top of the door window
Q: Is the window glass runchannel in good condition? glass correct?
YES : Go to Step 2. YES : Go to Step 4.
NO : Replace the runchannel, then go to Step 4. NO : Adjust the door window glass. Refer to
P.42-31. Then go to Step 4.
STEP 2. Check the door window glass
installation. STEP 4. Retest the system.
Q: Is the door window glass installed correctly? Q: Is any water leaking?
YES : Go to Step 3. YES : Return to Step 1.
NO : Reinstall the door window glass. (Refer to NO : The procedure is complete.
P.42-39). Then go to Step 4.
INSPECTION PROCEDURE 2: Door Window Glass Malfunction
DIAGNOSIS STEP 2. Check the door sash.

Q: Is the door sash in good condition?
STEP 1. Check the door window glass YES : Go to Step 3.
installation condition. NO : Repair or replace door sash, then go to Step
Q: Is the door window installed correctly? 4.
YES : Go to Step 2.
NO : Reinstall the door window glass. (Refer to
BODY 42-25
DOOR
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.
INSPECTION PROCEDURE 3: Water Leak Through Door Edge
DIAGNOSIS STEP 2. Check the door fit (alignment).

Q: Is the door fit (alignment) correct?
STEP 1. Check the weatherstrip. YES : Go to Step 3.
Q: Is the weatherstrip in good condition? NO : Adjust the door fit (Refer to P.42-30). Then
YES : Go to Step 2. go to Step 3.
NO : Replace the weatherstrip, then go to Step 3.
INSPECTION PROCEDURE 4: Water Leak from Door Center
DIAGNOSIS STEP 2. Check the weatherstrip.

Q: Is the weatherstrip in good condition?
STEP 1. Check the drain hole. YES : Go to Step 3.
Q: Is the drain hole clogged? NO : Repair or replace the weatherstrip, then go
YES : Clean the drain hole, then go to Step 3. to Step 3.
NO : Go to Step 2.
INSPECTION PROCEDURE 5: Door Hard to Open
DIAGNOSIS STEP 2. Check for lock cable damage.

Q: Is the lock rod damaged?
STEP 1. Adjust the latch and striker engagement. YES : Repair or replace the lock cable, then go to
Refer to P.42-30. Step 4.
Q: Is the latch and striker engagement adjusted? NO : Go to Step 3.
YES : Go to Step 2.
NO : Adjust the latch and striker. (Refer to
BODY 42-26
DOOR
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.
INSPECTION PROCEDURE 6: Door Does Not Open or Close Completely
DIAGNOSIS STEP 3. Check lubrication.

Q: Are the door check and door hinge sufficiently
STEP 1. Check the door hinge position. lubricated?
Q: Is the door hinge correct? YES : Go to Step 4.
YES : Go to Step 2. NO : Apply grease, then go to Step 4.
NO : Adjust the door hinge (Refer to P.42-30).
Then go to Step 4. STEP 4. Retest the system.
Q: Does the door open and close completely?
STEP 2. Check the door for damage. YES : The procedure is complete.
Q: Is the door in good condition? NO : Return to Step 1.
YES : Go to Step 3.
NO : Repair or replace the door, then go to Step
4.
INSPECTION PROCEDURE 7: Uneven Gap Between Body
DIAGNOSIS
.
Adjust the door fit (Refer to P.42-30). Then check

that the gap has been improved.
INSPECTION PROCEDURE 8: Wind Noise Around Door
DIAGNOSIS STEP 2. Check the weatherstrip for installation

condition.
STEP 1. Check the weatherstrip for holding Q: Is the weatherstrip installed properly?
condition. YES : Go to Step 3.
Q: Is the weatherstrip holding firmly? NO : Repair or replace the weatherstrip. Then go
YES : Go to Step 2. to Step 5.
NO : Adjust fit of door (Refer to P.42-32). Then
go to Step 5.
BODY 42-27
DOOR
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
5.
Q: Has the wind noise been improved?
NO : This diagnosis complete.
HOW TO LOCATE WIND NOISE

M1421004200227
AC205124 1. Attach cloth tape to every place, such as panel seams,
AC305100
projections, molding seams, glass and body seams, etc.
which might conceivably be the source of wind noise.
2. Then make a road test to check that the places not covered
by tape are not sources of wind noise.
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

NAME
MB990900 or MB990900-01 Adjustment of door fit
MB991164 Door
adjusting wrench
MB990900
MB990925 Bearing and MB990925-01 or Adjustment of door striker

oil seal installer set General service tool
A
A: MB990939 Remover
bar
MB990925AD
MB990211 Slider MB990211-01

hammer
MB990211
MB990241 Axle shaft MB990241-01 or

puller General service tool
A A: MB990243 Body
puller
MB990241AC
BODY 42-29
DOOR

NAME
MB990480 Glass holder General service tool Removal of power window
regulator assembly
MB990480
MB991223 Harness set General service tools Measurement of terminal

A A: MB991219 Test voltage
harness A: Connector pin contact
B: MB991220 LED pressure inspection
B
harness B: Power circuit inspection
C: MB991221 LED C: Power circuit inspection
harness adapter D: Commercial tester
D: MB991222 Probe connection
C
MB991223AB
MB990784 Ornament General service tool Removal of power window

remover switch panel assembly
MB990784
BODY 42-30
DOOR
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENT

M1423001100380
• MB990211: Slide Hammer
• MB990243: Body Puller
• MB990900 or MB991164: Door adjusting Wrench
• MB990939: Brass Bar
CAUTION
• Attach protection tape to the fender and door edges
where the hinge is installed.
• Do not rotate special tool MB991164 with a torque of
over 98 N⋅m (72 ft-lb).
1. Use special tool MB990900 or MB991164 to loosen the
hinge mounting bolts on the body side, and then adjust the
clearance around the door so that it is uniform on all sides.
2. If a door is not flush with its surrounding panels, loosen the
MB990900 door-side door hinge mounting bolts and adjust the door as
OR necessary.
MB991164
NOTE:
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
(2) Adjustment by using the striker (toward the outside of the

vehicle)
Use special tools MB990211 and MB990243 to pull the
MB990211
MB990243 striker toward the outside of the vehicle.
STRIKER
AC006110 AB
(3) Adjustment by using shims (forward and rearward)

SHIM Increase or decrease the number of shims so that the
striker engages with the door latch properly.
STRIKER
AC006111AB
DOOR WINDOW GLASS ADJUSTMENT

M1423001000349
Check that the door glass moves while contacting the door
glass channel when it is raised and lowered fully. If not, adjust
the door window according to the following procedures.
1. Remove the door trim assembly (Refer to GROUP 52A,
Door trim P.52A-14).
2. Remove the waterproof film (Refer to P.42-52).
<FRONT DOOR> 3. Loosen the door window glass mounting bolts.
4. Adjust the position of the door window glass so that it is
aligned with the runchannel. On completion, tighten the door
window glass mounting bolts.
AC306504
<REAR DOOR>
AC306505
AC307037AB
BODY 42-32
DOOR
GLASS SLIDING MECHANISM CHECK AND

ADJUSTMENT
M1429000900109
If the window glass automatically starts moving downwards at
the wrong time while it is being raised, carry out the following
adjustment or replacement procedures.
Door trim P.52A-14).
2. Remove the waterproof film (Refer to P.42-52).
CAUTION
Insert a cushion or similar object to prevent damage to the
glass if it should fall.
3. Remove the window regulator assembly from the door
window glass, and then raise and lower the door window
glass by hand to check the operation force.
<FRONT DOOR> 4. If the door window glass does not move up and down
RUNCHANNEL smoothly, check or repair the following points:
• Check the installation condition of the runchannel.
• Repair any twisting in the door sash.
• Check the installation condition of the lower sash.
DOOR
SASH NOTE: To align the lower sash, loosen the lower sash
mounting bolts, and move the lower sash along the oblong
LOWER mounting holes.
SASH 5. If repair or adjustment is not possible, replace the door
AC306502 assembly.
<REAR DOOR> RUNCHANNEL
DOOR
SASH
LOWER SASH
AC306503
AC307036 AB
POWER WINDOW TIMER FUNCTION CHECK

M1429004300154
After the doors are closed and the ignition switch is turned to
the "LOCK" (OFF) position, the power windows should work
within 30 seconds. The timer expires if the front door is opened
during that 30 seconds. If it does not, carry out the timer trou-
bleshooting in GROUP 54B, SWS Diagnosis P.54B-57.
BODY 42-33
DOOR
POWER WINDOW OPERATING CURRENT CHECK

M1429001100195
1. Remove the power window fuse and connect an ammeter
as shown in the illustration.
2. When the power window switch is pressed in the “UP”
position, a large amount of current flows from the time the
window starts to close until it is fully closed, Measure the
current during this time
Standard value (A): 5 ± 1A [Power supply voltage
14.5 ± 0.5V, 25°C (77°F)]
3. If the operation current is outside the standard value, refer to
AC305015AG
GROUP 54B, SWS Diagnosis P.54B-61.
POWER WINDOW RELAY CHECK

M1429001800213
BATTERY TESTER SPECIFIED

VOLTAGE CONNECTION CONDITION
Not applied 4−5 Open circuit
• Connect terminal 4−5 Less than 2 ohms
No. 3 and the
negative battery
INSTRUMENT
terminal.
PANEL • Connect terminal
No. 1 and the
POWER WINDOW RELAY
positive battery
terminal.
5 1 2 3
4 4
1 3 5
18DB158A
BODY 42-34
DOOR
CIRCUIT BREAKER (INCORPORATED IN THE

POWER WINDOW MOTOR) INSPECTION
M1429001000284
1. Pull the power window switch to the UP position to fully

close the door window glass, and keep pulling the switch for
an additional ten seconds.
2. Release the power window switch from the UP position and
immediately press it to the DOWN position. The condition of
the circuit breaker is good if the door window glass starts to
move downwards within about 60 seconds.
POWER WINDOW CHECK

M1429004400214
1. Operate the power window switch of each door to verify that
the power windows operate properly. If they don't, then
troubleshoot as described in GROUP 54B, SWS Diagnosis
P.54B-57.
2. Turn ON the power window lock switch of the power window
main switch. Then operate the passenger's door and rear
door power window sub-switches to ensure that they do not
operate. If they do, replace the power window main switch
(Refer to P.42-39).
CENTRAL DOOR LOCKING SYSTEM

INSPECTION
M1427001100144
Check the following. Troubleshoot if operations malfunction
(Refer to GROUP 54B, SWS Diagnosis P.54B-57).
• Insert the key into the driver's key cylinder and turn once to
the unlock side to unlock the driver's door and fuel lid door.
Turn the key once again to the unlock side to unlock all
doors and fuel lid door.
• All doors and fuel lid door can be locked using the door lock
switch built into the front power window (main or sub <LH>)
switch.
BODY 42-35
DOOR
DOOR OUTSIDE HANDLE PLAY CHECK

M1423001600288
1. Check that the door outside handle play is within the
standard value range.
Standard value (B):
Front door: 10 ± 3.5 mm (0.39 ± 0.138 inch)
Rear door: 11.2 ± 4 mm (0.441 ± 0.16 inch)
2. If the door outside handle play is not within the standard
A
value range, check the door outside handle or the door latch
A assembly. Replace if necessary.
AC306509
SECTION A – A
AC205105
AC307031AB
DOOR INSIDE HANDLE PLAY CHECK

M1423009400028
DOOR INSIDE HANDLE KNOB PLAY CHECK

1. Check that the door inside handle play is within the standard
value range.
A Standard value (B):
Front door: 26.1 −58.1 mm (1.028 −2.287 inches) [Tar-
A get value 41 mm (1.61inches)]
Rear door: 30.3 −58.1 mm (1.193 −2.287 inches) [Target
value 41 mm (1.61inches)]
2. If the door inside handle play is not within the standard value
range, check the door inside handle or the inside handle
AC306508 cable. Replace if necessary.
SECTION A – A
AC205104
AC307029 AB
BODY 42-36
DOOR
DOOR INSIDE HANDLE LOCK KNOB STROKE

CHECK
Door Trim P.52A-14).
2. Check that the door inside handle lock knob stroke is within
A the standard value.
Standard value (B): 21.6 mm (0.850 inch)
A
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
M1423002200294
• 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
REMOVAL DOOR ASSEMBLY REMOVAL STEPS

1. DAMPER • COWL SIDE TRIM <FRONT DOOR>
(REFER TO GROUP 52A, TRIMS
2. DOOR SWITCH P.52A-11).
>>B<< 3. REAR DOOR PROTECTOR FILM 6. HARNESS CONNECTOR
STRIKER REMOVAL STEPS
7. DOOR CHECK MOUNTING BOLT
>>A<< 4. STRIKER 8. DOOR ASSEMBLY
5. STRIKER SHIM 9. DOOR UPPER HINGE
10. DOOR LOWER HINGE
11. COVER, BOLT
BODY 42-38
DOOR

.
>>A<< STRIKER INSTALLATION

Align the center of the striker and latch within ± 1.5 mm (0.06
LATCH CENTER
STRIKER CENTER inch), and install.
+1.5 mm
(0.06 in)
-1.5 mm
(0.06 in)
STRIKER
LATCH
AC006126AB
>>B<< REAR DOOR PROTECTOR FILM

INSTALLATION
DOOR PROTECTOR FILM
Install the rear door protector film as shown.
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
DOOR SWITCH CHECK

Check continuity between the switch terminals and body
ON ground.
OFF SWITCH TESTER SPECIFIED
Released (ON) 1 − body ground Less than 2 ohms
Depressed (OFF) 1 − body ground Open circuit
1 2 3
ACX01865AB
BODY 42-39
DOOR
DOOR GLASS AND REGULATOR

M1429001300326

• Door Trim Assembly Removal (Refer to GROUP 52A • Door Window Glass Adjustment (Refer to P.42-31).
Door Trim P.52A-14). • Waterproof Film Installation (Refer to P.42-52).
• Waterproof Film Removal (Refer to P.42-52). • Door Trim Assembly Installation (Refer to GROUP 52A,
<FRONT DOOR WINDOW REGULATOR ASSEMBLY>
AC210316
2
AC306163
AC306511AB
DOOR WINDOW REGULATOR DOOR WINDOW REGULATOR

• DOOR BELTLINE MOLDING 1. DOOR WINDOW GLASS
(REFER TO P.42-52). 2. WINDOW REGULATOR ASSEMBLY
BODY 42-40
DOOR
<FRONT DOOR POWER WINDOW SWITCH> VIEW A

C C
B B
C C C
C C
C
C C
A SECTION B – B
SECTION C – C
TRIM
AC306724
CLAW
5 4
3 TRIM
NOTE
: CLAW POSITIONS CLAW
18DB160A
POWER WINDOW SWITCH Required Special Tool:

REMOVAL STEPS • MB990784: Ornament Remover
<<C>> 3. POWER WINDOW SWITCH PANEL
ASSEMBLY
4. POWER WINDOW SWITCH PANEL
5. POWER WINDOW MAIN SWITCH
(LH), POWER WINDOW SUB
SWITCH (RH)
BODY 42-41
DOOR
<REAR DOOR WINDOW REGULATOR ASSEMBLY>
1
2
AC210317
AC306164
AC306512 AB
DOOR WINDOW REGULATOR DOOR WINDOW GLASS REMOVAL

ASSEMBLY REMOVAL STEPS (Continued)
<<A>> 1. WINDOW REGULATOR ASSEMBLY • LOWER SASH (REFER TO P.42-46).
DOOR WINDOW GLASS REMOVAL <> 2. REAR DOOR STATIONARY
STEPS WINDOW GLASS ASSEMBLY
• DOOR WINDOW GLASS 3. DOOR WINDOW GLASS
RUNCHANNEL (REFER TO Required Special Tool:
P.42-52). • MB990480: Window Glass Holder
• DOOR BELTLINE MOLDING
(REFER TO P.42-52).
BODY 42-42
DOOR
<REAR DOOR POWER WINDOW SWITCH> VIEW A C

B B C
C
C
C
A C
C C
C
C C AC306723
C
SECTION B – B
SECTION C – C
4 5 TRIM
AC306724
CLAW
3
TRIM
NOTE AC206827
AC306516 CLAW
: CLAW POSITIONS AC307260 AB
POWER WINDOW SWITCH Required Special Tool:

REMOVAL STEPS • MB990784: Ornament Remover
<<C>> 4. POWER WINDOW SWITCH PANEL
ASSEMBLY
5. POWER WINDOW SWITCH PANEL
6. POWER WINDOW SUB SWITCH

.
<<A>> WINDOW REGULATOR ASSEMBLY

REMOVAL
1. Remove the door window glass installation bolts.
CAUTION
If tinting film is adhered to the door window glass, attach
special tool MB990480 to the outside of the glass to pre-
vent the film from peeling off.
2. Lift the door window glass, and attach special tool
MB990480
MB990480 to the glass as shown to prevent the glass from
falling.
3. Remove the window regulator assembly and power window
motor assembly.
AC308968AB
.
BODY 42-43
DOOR
<> REAR DOOR STATIONARY WINDOW

GLASS ASSEMBLY REMOVAL
Remove the mounting screw of the top of the rear door station-
ary window glass assembly (the screw is hidden by the mold-
SCREW
ing).
AC306498 AB
<<C>> POWER WINDOW SWITCH PANEL

ASSEMBLY REMOVAL
Insert special tool MB990784 as shown to remove the power
POWER WINDOW SWITCH
PANEL ASSEMBLY window switch panel assembly.
MB990784
AC306721 AB
INSPECTION
M1429001400293
POWER WINDOW SWITCH CONTINUITY CHECK

Remove the power window switch. (Refer to P.42-39.)
.
Power window main switch's front <RH> switch

check
Connect terminal number 13 to the battery positive (+) post,
and connect terminal number 12 to the battery negative (−)
post.
Main switch
SWITCH POSITION TESTER SPECIFIED
FRONT UP 12 − 10, 14 − 2, Less than 2 ohms
(RH)
OFF 12 − 2, 14 − 2 Less than 2 ohms
DOWN 14 − 10, 12 − 2 Less than 2 ohms
1 2 3 4 5 6 FRONT UP 7 − 10, 9 − 2* Less than 2 ohms
7 8 9 10 11 12 13 14
(LH)
AC210745 OFF 7 − 9, 7 − 2*, 14 − Less than 2 ohms
2*
DOWN 9 − 10, 7 − 2* Less than 2 ohms
BODY 42-44
DOOR

REAR (RH) UP 4 − 10, 6 − 2* Less than 2 ohms
OFF 4 − 6, 4 − 2*, 6 − 2* Less than 2 ohms
DOWN 6 − 10, 4 − 2* Less than 2 ohms
REAR (RH) UP 1 − 10, 3 − 2* Less than 2 ohms
OFF 3 − 1, 3 − 2*, 2* − 1 Less than 2 ohms
DOWN 3 − 10, 2* − 1 Less than 2 ohms
NOTE: *: Set the window lock switch to UNLOCK position.

.
Sub switch <Front>

<FRONT>
UP 4 − 5, 6 − 7 Less than 2 ohms
1 2 3
4 5 6 7 8
AC210746 AD
Sub switch <Rear>

<REAR>
UP 4 − 5, 6 − 7 Less than 2 ohms
1 2 3
4 5 6 7 8
AC210747AB
BODY 42-45
DOOR
DOOR WINDOW REGULATOR CHECK

.
1. Connect a battery directly to the motor terminals and check

that the motor runs smoothly.
2. Check that the motor runs in the opposite direction when the
battery is connected with the polarity reversed.
3. If a defect is found, replace the window regulator as an
assembly.
.
<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.
AC204901AB • Connect terminal No. 2 DOWN

terminal.
and the positive battery
terminal.
.
<Rear door>
BATTERY CONNECTION SLIDER POSITION
• Connect terminal No. 1 UP
terminal.
1 2 terminal.
AC206013 AB
• Connect terminal No. 2 DOWN
terminal.
terminal.
BODY 42-46
DOOR
DOOR HANDLE AND LATCH

M1423004600340

• Door Trim Assembly Removal (Refer to GROUP 52A • Door Inside Handle Play Check (Refer to P.42-35).
Door Trim P.52A-14). • Door Outside Handle Play Check (Refer to P.42-35).
• Door Trim Assembly Installation (Refer to GROUP 52A,
<FRONT DOOR>
8 7
5.0 ± 1.0 N·m 6

44 ± 9 in-lb 5
5.9 ± 1.0 N·m
52 ± 9 in-lb
3
1
2
4
5.0 ± 1.0 N·m 9

44 ± 9 in-lb
18DB161A
7
AC209702 AC306499
AC306729 AB
DOOR HANDLE AND DOOR LATCH DOOR HANDLE AND DOOR LATCH
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
DOOR HANDLE AND DOOR LATCH DOOR CHECK REMOVAL

ASSEMBLY REMOVAL STEPS >>A<< 9. DOOR CHECK
<<A>> 7. DOOR LOCK KEY CYLINDER
ASSEMBLY (LH)
8. DOOR OUTSIDE HANDLE
<REAR DOOR> 6
5.9 ± 1.0 N·m

52 ± 9 in-lb
5.0 ± 1.0 N·m

4 44 ± 9 in-lb
N
3 5
1
2
7 5.0 ± 1.0 N·m

44 ± 9 in-lb
AC306166 AB
7
AC209702 AC306499
AC306729 AB
DOOR HANDLE AND DOOR LATCH DOOR HANDLE AND DOOR LATCH
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

.
<<A>> DOOR LOCK KEY CYLINDER ASSEMBLY

REMOVAL
DOOR LOCK KEY 1. Create clearance between the door panel and the door
CYLINDER ASSEMBLY DOOR OUTSIDE
HANDLE outside handle to access the pin.
2. Open the pin and remove the door lock key cylinder
assembly.
PIN
18DB162A

.
>>A<< DOOR CHECK INSTALLATION

Install the door check so that the identification mark faces
upwards.
A
ITEM IDENTIFICATION
MARK
Front Door Left door P4FL
Right door P4FR
Rear Door Left door P4RL
Right door P4RR
VIEW A
IDENTIFICATION MARK
AC204902 AB
>>B<< LOWER SASH INSTALLATION

Securely insert the lower sash into the window rear sash.
BODY 42-49
DOOR
INSPECTION
M1423004700411
FRONT DOOR LATCH CHECK

FRONT DOOR The illustration shows when the door lock actuator is viewed
<LEFT SIDE> from inside the door.
LOCK UNLOCK
DOOR LOCK ACTUATOR CHECK <LEFT SIDE>
LEVER BATTERY CONNECTION LEVER
VIEW A
POSITION OPERATION
1 2 3
4 5 6
At the • Connect terminal No. 4 The lever moves
"LOCK" and the negative battery from the "LOCK"
LEVER
position terminal. position to the
• Connect terminal No. 6 "UNLOCK"
A and the positive battery position.
<RIGHT SIDE> terminal.
UNLOCK LOCK
"UNLOCK" and the negative battery from the
VIEW B position terminal. "UNLOCK"
• Connect terminal No. 4 position to the
1 2 3
4 5 6 and the positive battery "LOCK" position.
terminal.
LEVER
DOOR LOCK ACTUATOR SWITCH CHECK <LEFT SIDE>
B AC210729 AB LEVER POSITION TESTER SPECIFIED
At the "LOCK" 1−2 Open circuit
position
At the "UNLOCK" 1−2 Less than 2 ohms
position
DOOR LOCK ACTUATOR CHECK <RIGHT SIDE>

POSITION OPERATION
and the positive battery position.
terminal.
position terminal. "UNLOCK"
and the positive battery "LOCK" position.
terminal.
BODY 42-50
DOOR
DOOR LOCK ACTUATOR SWITCH CHECK <RIGHT SIDE>

LEVER POSITION TESTER SPECIFIED
At the "LOCK" 2−3 Open circuit
position
At the "UNLOCK" 2−3 Less than 2 ohms
position
REAR DOOR LOCK ACTUATOR CHECK

REAR DOOR The illustration shows when the door lock actuator is viewed
<LEFT SIDE> LOCK from outside the door.
UNLOCK DOOR LOCK ACTUATOR CHECK <LEFT SIDE>
VIEW A LEVER BATTERY CONNECTION LEVER
POSITION OPERATION
1 2 3 LEVER
4 5 6 At the • Connect terminal No. 6 The lever moves
A and the positive battery position.
UNLOCK terminal.
<RIGHT SIDE>
LOCK
VIEW B
LEVER • Connect terminal No. 6 position to the
1 2 3
4 5 6 and the positive battery "LOCK" position.
terminal.
DOOR LOCK ACTUATOR CHECK <RIGHT SIDE>

B AC210730 AB LEVER BATTERY CONNECTION LEVER
POSITION OPERATION
terminal.
terminal.
BODY 42-51
DOOR
FUEL LID D00R ACTUATOR CHECK

POSITION OPERATION
terminal.
terminal.
DOOR LOCK KEY CYLINDER SWITCH CHECK

LOCK 2−3 Less than 2 ohms
NEUTRAL (OFF) 1 − 2, 2 − 3 Open circuit
UNLOCK 1−2 Less than 2 ohms
1 2 3
AC210743
CENTRAL DOOR LOCK SWITCH CONTINUITY

CHECK
Remove the power window switch (Refer to P.42-39).
<DRIVER'S SIDE>
DOOR LOCK
SWITCH SWITCH TESTER SPECIFIED
OFF 2 − 5, 2 − 13 Open circuit
UNLOCK 2 − 13 Less than 2 ohms
1 2 3
4 5 6 7 8
18DB165A
BODY 42-52
DOOR
DOOR LOCK
<PASSENGER'S SIDE>
SWITCH SWITCH TESTER SPECIFIED
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
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP

M1423003100319
<FRONT DOOR>
6 7
AC306365
SEALANT: 3M™ AAD PART NO. 8633

1 OR EQUIVALENT
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
REMOVAL DOOR OPENING OUTER

>>D<< 1. DOOR WINDOW GLASS WEATHERSTRIP REMOVAL
RUNCHANNEL STEPS
WATERPROOF FILM AND DOOR • DOOR CHECK MOUNTING BOLT
PANEL CORE REMOVAL STEPS (BODY SIDE) (REFER TO P.42-37).
• DOOR TRIM ASSEMBLY (REFER >>B<< 6. DOOR OPENING OUTER
TO GROUP 52A, DOOR TRIM WEATHERSTRIP
P.52A-14). DOOR BELTLINE MOLDING
• DOOR INSIDE HANDLE (REFER TO REMOVAL STEPS
P.42-46). • DOOR TRIM ASSEMBLY (REFER
2. DOOR ARMREST BRACKET TO GROUP 52A, DOOR TRIM
>>A<< 3. WATERPROOF FILM P.52A-14).
4. DOOR PANEL CORE • REMOTE CONTROLLED MIRROR
DOOR OPENING INNER ASSEMBLY (REFER TO GROUP 51,
WEATHERSTRIP REMOVAL DOOR MIRROR P.51-28).
STEPS 7. DOOR BELTLINE MOLDING
• FRONT SCUFF PLATE (REFER TO
GROUP 52A, TRIMS P.52A-11).
>>C<< 5. DOOR OPENING INNER
WEATHERSTRIP (BODY SIDE)
BODY 42-54
DOOR
DOUBLE-SIDED TAPE POSITION

<FRONT DOOR> UNITS: mm (in)
DOOR OPENING OUTER

WEATHERSTRIP
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
CLIP POSITION :SECTIONAL VIEW OF :SECTIONAL VIEW OF :SECTIONAL VIEW OF

CLIP POSITION CLIP POSITION CLIP POSITION
AC306380
AC306379
AC306373
LH DOOR CLIPS (YELLOW),
6 RH DOOR CLIPS (BLUE)
AC306378 AC306730 AC
REMOVAL DOOR ARMREST BRACKET

>>D<< 1. DOOR WINDOW GLASS REMOVAL STEPS
RUNCHANNEL • DOOR TRIM ASSEMBLY (REFER
DOOR PANEL BRACKET TO GROUP 52A, DOOR TRIM
REMOVAL STEPS P.52A-14).
• DOOR TRIM ASSEMBLY (REFER 3. DOOR ARMREST BRACKET
TO GROUP 52A, DOOR TRIM
P.52A-14).
2. DOOR PANEL BRACKET
BODY 42-56
DOOR
WATERPROOF FILM REMOVAL DOOR OPENING OUTER

STEPS WEATHERSTRIP REMOVAL
• DOOR TRIM ASSEMBLY (REFER STEPS
TO GROUP 52A, DOOR TRIM • DOOR CHECK MOUNTING BOLT
P.52A-14). (BODY SIDE) (REFER TO P.42-37).
• DOOR INSIDE HANDLE (REFER TO >>B<< 6. DOOR OPENING OUTER
P.42-46). WEATHERSTRIP
>>A<< 4. WATERPROOF FILM DOOR BELTLINE MOLDING
DOOR OPENING INNER REMOVAL STEPS
WEATHERSTRIP REMOVAL • DOOR TRIM ASSEMBLY (REFER
STEPS TO GROUP 52A, DOOR TRIM
• REAR SCUFF PLATE (REFER TO P.52A-14).
GROUP 52A, TRIMS P.52A-11). 7. DOOR BELTLINE MOLDING
>>C<< 5. DOOR OPENING INNER
WEATHERSTRIP (BODY SIDE)
DOUBLE-SIDED TAPE POSITION

<REAR DOOR> UNITS: mm (in)
DOOR OPENING OUTER

WEATHERSTRIP
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

.
>>A<< WATERPROOF FILM INSTALLATION

CAUTION
<FRONT DOOR> When the waterproof film is adhered, be careful that
3M™AAD Part number 8633 or equivalent can pass under
the inner panel water drain hole.
INNER PANEL WATER DRAIN HOLE AC306365

<REAR 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
>>B<< DOOR OPENING OUTER WEATHERSTRIP

INSTALLATION
<FRONT DOOR> Install the door opening outer weatherstrip in the sequence
shown.
1 2 3
AC306359
<REAR DOOR>
1
2 7
4 5
3
AC306360
AC306736 AB
>>C<< DOOR OPENING INNER WEATHERSTRIP

INSTALLATION
<FRONT DOOR> Install the door opening inner weatherstrip in the sequence
shown.
1
3
2
AC306361
<REAR DOOR>
1
2 3
AC306362
AC306735 AB
.
BODY 42-59
DOOR
>>D<< DOOR WINDOW GLASS RUNCHANNEL

INSTALLATION
<FRONT DOOR> 3 Install the door window glass runchannel in the sequence
shown.
1
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
trunk lid fault. Chart.
SYMPTOM CHART
M1421006000382

PROCEDURE
Difficult locking and unlocking 1 P.42-60
Uneven body clearance 2 P.42-60
Uneven height 3 P.42-61
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Difficult Locking and Unlocking
DIAGNOSIS STEP 2. Check the engagement of the trunk lid

latch and trunk lid striker.
STEP 1. Check the function of trunk lid opening Q: Are the trunk lid latch and trunk lid striker engaged
switch inside glove compartment. correctly?
Q: Can the latch unlocking mechanism noise "click" YES : Then go to Step 3.
be heard when operating the switch NO : Adjust the trunk lid latch. Refer to P.42-61.
YES : Go to Step 2.
NO : Check switch circuit. Refer to P.42-65.
Then go to Step 2.
Q: Does the trunk lid lock operate easily?
INSPECTION PROCEDURE 2: Uneven Body Clearance
DIAGNOSIS adjacent body panels aligned correctly?

NO : Adjust the trunk lid panel assembly. Refer to
STEP 1. Check the clearance around the trunk
P.42-61.
lid..
Q: Are the apertures between the trunk lid and the
BODY 42-61
TRUNK LID

Q: Are the clearances between the body panels even?
INSPECTION PROCEDURE 3: Uneven Height

Q: Are the trunk lid and body height even?
STEP 1. Check the trunk lid bumper height. YES : The procedure is complete.
Q: Is the trunk lid bumper height proper? NO : Return to Step 1.
NO : Adjust the trunk lid bumper. Refer to
P.42-62.
ON-VEHICLE SERVICE
ADJUSTMENT OF CLEARANCE AROUND TRUNK

LID
M1421008100040
Loosen the trunk lid panel assembly mounting bolt and nut, and
TRUNK LID
HINGE move the trunk lid panel assembly to make the clearance
around the trunk lid even.
TRUNK LID PANEL

ASSEMBLY AC305824AB
TRUNK LID LATCH ADJUSTMENT

M1421008600012
After checking the trunk lid release cable for proper routing,
TRUNK LID LATCH loosen the trunk lid latch mounting bolts. Change the position of
the trunk lid latch relative to the trunk lid striker so that trunk lid
locking and unlocking effort is correct.
18DB167A
BODY 42-62
TRUNK LID
TRUNK LID HEIGHT ADJUSTMENT

M1421008300044
Turn each trunk lid damper to achieve the height shown in the
drawing is reached. If the trunk lid panel height on one side is
different from that on the other side (even after the trunk lid
dampers have been adjusted to the height indicated in the
drawing), turn the trunk lid damper(s) slightly to make fine
adjustments to the trunk lid panel height.
NOTE: When the damper is new, one full turn of the trunk lid
A
damper changes the height approximately 3 mm. Turn it clock-
wise to reduce height. Turn it counterclockwise to increase
A
AC305822 height.
SECTION A – A TRUNK LID PANEL
ASSEMBLY
17 mm
(0.7 in)
TRUNK LID DAMPER

AC305823
AC306177AB
BODY 42-63
TRUNK LID
TRUNK LID
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.
• 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
<FRONT VIEW > <REAR VIEW>
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
REMOVAL TRUNK LID EMERGENCY

1. TRUNK LID DAMPER RELEASE CABLE AND TRUNK LID
2. TRUNK LID STRIKER EMERGENCY RELEASE HANDLE
3. TRUNK LID INSIDE HANDLE REMOVAL STEPS (Continued)
TRUNK LID WEATHERSTRIP 7. TRUNK LID EMERGENCY
REMOVAL STEPS RELEASE HANDLE
• REAR END TRIM (REFER TO 8. TRUNK LID EMERGENCY
GROUP 52A, TRIMS P.52A-11.) RELEASE CABLE
>>A<< 4. TRUNK LID WEATHERSTRIP TRUNK LID PANEL ASSEMBLY
TRUNK LID LATCH REMOVAL REMOVAL STEPS
STEPS 1. TRUNK LID DAMPER
• REAR END TRIM (REFER TO 2. TRUNK LID STRIKER
GROUP 52A, TRIMS P.52A-11.) 3. TRUNK LID INSIDE HANDLE
5. TRUNK LID LATCH ASSEMBLY • THREE-DIAMOND MARK (REFER
TRUNK LID EMERGENCY TO GROUP 51 MARKS P.51-25.)
RELEASE CABLE AND TRUNK LID • HIGH MOUNT STOPLIGHT
EMERGENCY RELEASE HANDLE <VEHICLES WITHOUT REAR
REMOVAL STEPS SPOILER> (REFER TO GROUP
• REAR END TRIM (REFER TO 54A, HIGH-MOUNTED STOPLIGHT
GROUP 52A, TRIMS P.52A-11.) P.54A-166.)
• TRUNK TRIM ASSEMBLY (REFER • REAR SPOILER ASSEMBLY
TO GROUP 52A, TRIMS P.52A-11.) <VEHICLES WITH REAR SPOILER>
• REAR SEAT (REFER TO GROUP (REFER TO GROUP 51, REAR
52A, SEAT P.52A-55.) SPOILER P.51-11.)
• CENTER PILLAR LOWER TRIM 9. TRUNK LID PANEL ASSEMBLY
(REFER TO GROUP 52A, TRIMS MOUNTING BOLT AND NUT
P.52A-11.) 10. TRUNK LID PANEL ASSEMBLY
• COWL SIDE TRIM (REFER TO TRUNK LID HINGE REMOVAL
GROUP 52A, TRIMS P.52A-11.) STEPS
10. TRUNK LID PANEL ASSEMBLY
<<A>> 11. TRUNK LID GAS SPRING
12. TRUNK LID HINGE
BODY 42-65
TRUNK LID

.
<<A>> TRUNK LID GAS SPRING REMOVAL

TRUNK LID HINGE As shown in the figure, slide the pin upward, then remove the
PIN trunk lid gas spring in the direction of the arrow to unscrew the
trunk lid hinge.
TRUNK LID
GAS SPRING
FLAT-TAPPED
SCREWDRIVER
AC305996 AB

.
>>A<< TRUNK LID WEATHERSTRIP

INSTALLATION
Install the trunk lid weatherstrip so that the marking and the
joint are aligned with the body center line,
MARKING
SECTION
JOINT
SECTION
AC305825AB
INSPECTION
M1421004800144
TRUNK LID LATCH ASSEMBLY CHECK

.
TRUNK LID LATCH ACTUATOR CHECK

<REAR VIEW> LEVER BATTERY CONNECTION LEVER
POSITION OPERATION
1 2
At the "OFF" • Connect ground and the The lever moves
position negative battery from the "OFF"
LEVER terminal. position to the
• Connect terminal No. 1 "OPEN" position.
terminal.
OFF OPEN
18DB168A
.
BODY 42-66
TRUNK LID
TRUNK LID LATCH SWITCH CONTINUITY CHECK

<FRONT LEVER
LEVER POSITION TESTER SPECIFIED
VIEW>
ON
ON (Latch open) 2 − Ground Less than 2 ohms
OFF (Latch shut) 2 − Ground Open circuit
OFF
1 2
18DB169A
BODY 42-67
KEYLESS ENTRY SYSTEM

GENERAL DESCRIPTION
BGBJABIE
• Antenna and receiver are incorporated in the • When the transmitter unlock button is pressed
ETACS-ECU. once, the driver's door will be unlocked. If the but-
• ID code can be registered by using Diagnostic ton is pressed twice, all the doors will be
tool (MUT-III). unlocked. The adjustment function also allows
• Transmitter is a key holder type, which incorpo- you to open all the doors by pressing the unlock
rates lock button, unlock button, trunk button and button only once. For further details on using the
panic button <Vehicles with panic alarm system>. multi-center display to adjust the unlock opera-
tion, refer to GROUP 54B, On-vehicle Service
P.54B-486.
• When the transmitter is operated, the answer-
back function will work as follows:
ITEM OPERATION
DOORS LOCKED DOORS UNLOCKED
Dome light Flashes once Illuminates for 15 seconds
Turn-signal lights (RH and LH) Flashes once Flashes twice
Horn Sounds once when the lock button -
is pressed with all the doors locked
• The answerback operation can be altered as fol- NOTE: Enabling/disabling the hazard warning
lows: light flashing, the horn sounding in accordance
with the answerback function. For further details
on using the transmitter to adjust answerback,
P.42-72 see the section below. For further details
on using the multi-center display to adjust
answerback, refer to GROUP 54B, On-vehicle
Service P.54B-486.
ITEM ADJUSTMENT ITEM ADJUSTMENT DETAIL
Keyless entry system Adjustment of hazard answerback When adjusting hazard answerback after the
confirmation by turn when the transmitter is used to doors are locked with the transmitter, the
signal lights lock doors following flashing conditions can be selected.
a. Flash (default)
b. No flash
Adjustment of hazard answerback When adjusting hazard answerback after the
when the transmitter is used to doors are unlocked with the transmitter, the
unlock doors following flashing conditions can be selected.
a. Flash (default)
b. No flash
Keyless entry system Adjustment of horn answerback When adjusting horn answerback after the
confirmation by horn when the transmitter is used to doors are locked with the transmitter, the
lock doors following horn conditions can be selected.
a. Horn sounds
b. Horn sounds if doors are already locked
(default)
c. Horn does not sound
BODY 42-68
• 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

NAME
A
MB991824-KIT For registration of secret
A: MB991824 NOTE: G: MB991826 code
B: MB991827 MUT-III Trigger Harness is CAUTION
C: MB991910 not necessary when For vehicles with CAN
MB991824 D: MB991911 pushing V.C.I. ENTER key. communication, use
B
E: MB991914 MUT-III main harness A to
F: MB991825 send simulated vehicle
G: MB991826 speed. If you connect
MB991827 MUT-III Sub Assembly MUT-III main harness B
C
A: Vehicle communication instead, the CAN
interface (V.C.I.) communication does not
B: MUT-III USB cable function correctly.
MB991910 C: MUT-III main harness A
D
(Vehicles with CAN
DO NOT USE
D: MUT-III main harness B
E communication system)
E: MUT-III main harness C
MB991914
models only)
F
adapter
G: MUT-III trigger harness
MB991825
MB991826
MB991958
BODY 42-69
ON-VEHICLE SERVICE
INSPECTION
M1428003800089
KEY TRANSMITTER BATTERY CHECK
AC004486
Measure the voltage of the battery. If the voltage of the battery

is not within the standard value, replace the battery.
Standard value:2.5 − 3.2 V
BODY 42-70
HOW TO REPLACE THE TRANSMITTER

BATTERY
BGBCHGFB
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 INSPECTION

BGBHCDAE
Check the following items. If defective, refer to GROUP 54B,
SWS Diagnosis P.54B-10).
1. Operate the transmitter to check that the doors can be
locked and unlocked.
NOTE: The adjustment function allows you to change the
unlock operation setting as follows. Prior to that check, con-
firm which setting is activated.
.
a. When the unlock button is pressed once, the driver's
door will be unlocked. Then when the button is pressed
once again, all the doors will be opened (initial setting).
b. When the unlock button is pressed only once, all the
doors will be opened.
2. Press the trunk lid button of transmitter twice (press once,
and then press again within 5 seconds) and confirm that the
trunk lid opens.
3. Operate the transmitter to check that the answerback
function works in response to doors locking/unlocking.
hazard answerback setting as follows. Prior to that check,
confirm which setting is activated.
.
a. Turn-signal lights: Flash once when doors are locked,
and twice when unlocked (initial setting)
b. Turn-signal lights: Flash once when doors are locked,
but does not flash when unlocked.
c. Turn-signal lights: Do not flash when doors are locked,
but flash twice when unlocked.
d. Turn-signal lights: Do not flash when doors are locked
and unlocked.
horn answerback setting as follows. Prior to that check, con-
firm which setting is activated.
.
a. Horn: Sounds once when the lock button is pressed.
b. Horn: Sounds once when the lock button is pressed (ini-
tial setting).
c. Horn: Does not sound.
KEYLESS ENTRY SYSTEM TIMER LOCK

FUNCTION INSPECTION
BGBEBDIA
If the doors are not locked within 30 seconds after the unlock
button is pressed, refer to GROUP 54B, SWS Diagnosis
P.54B-10.
NOTE: If either of the doors is opened or the key is inserted in
the ignition switch within that 30-second period, the timer lock
function will be cancelled.
BODY 42-72
NOTE: The adjustment function allows you to change the timer

lock period from 30 seconds (initial setting) to 60, 120 or 180
seconds. Prior to this inspection, confirm which setting is acti-
vated.
ENABLING/DISABLING THE ANSWERBACK

FUNCTION
BGBDGCGD
When the doors are locked or unlocked by using the transmit-
ter, the dome light will flash/illuminate, the turn-signal lights will
flash (hazard answerback), or the horn will sound (horn
answerback) to inform the driver.
The hazard answerback and horn answerback functions can be
enabled or disabled according to the following procedure:
ENABLING/DISABLING THE HAZARD

ANSWERBACK FUNCTION
.
How to adjust hazard answerback when the trans-

mitter is used to lock doors
1. Remove the ignition key.
2. Push the ”unlock” button and then push the ”lock“ button
within 4 seconds to 10 seconds.
3. Release the ”lock” button within 10 seconds after Step 2 and
then release the “unlock” button. The ETACS-ECU tone
alarm will sound, indicating that the hazard answerback
function can be enabled or disabled when the doors are
locked.
• Enable the hazard answerback function when the
doors are locked: The ETACS-ECU tone alarm will
sound once.
• Disable the hazard answerback function when the
doors are locked: The ETACS-ECU tone alarm will
sound twice.
.
How to adjust hazard answerback when the

transmitter is used to unlock doors
alarm will sound, indicating that the hazard answerback
function can be enabled or disabled when the door are
unlocked.
• Enable the hazard answerback function when the
doors are unlocked: The ETACS-ECU tone alarm
will sound once.
• Disable the hazard answerback function when the
doors are unlocked: The ETACS-ECU tone alarm
will sound twice.
BODY 42-73
ENABLING/DISABLING THE HORN

ANSWERBACK FUNCTION
.

alarm will sound, indicating that the horn answerback
function can be enabled or disabled.
• Enable the horn answerback function*: The
ETACS-ECU tone alarm will sound once.
• Disable the horn answerback function: The
ETACS-ECU tone alarm will sound twice.
• Enable the horn answerback function**: The
ETACS-ECU tone alarm will sound three times.
NOTE: .
*: The horn will sound if "LOCK" button is pressed with the
doors locked.
**: The horn will sound if the doors are locked with the key-
less entry system.
HOW TO REGISTER SECRET CODE

BGBHCCCB
• : MUT-III Sub Assembly
• MB991910: MUT-III Main harness A
Each individual secret code is registered inside the transmitter,
and so it is necessary to resister these codes with the
EEPROM inside the receiver in the following cases.
• When the transmitter or ETACS-ECU is replaced
• If more transmitters are to be used
• If it appears that a problem is occurring because of faulty
registration of a code.
A maximum of four different codes can be stored in the
EEPROM memory (four different transmitters can be used).
When the code for the first transmitter is registered, the previ-
ously registered codes for all transmitters are cleared. There-
fore, if you are using four transmitters or are adding more
transmitters, the codes for all transmitters must be registered at
the same time.
WHEN SPECIAL TOOL MB991824 (V.C.I.) IS USED

.
1. Check that the doors lock normally when the key is used.
2. Insert the ignition key.
BODY 42-74
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
4. Press the hazard warning light switch six times within 10

V. C. I. CONNECTED seconds.
NOTE: When the hazard warning light switch has been
WITHIN 10 SECONDS
pressed six times, the ETACS-ECU locks and unlocks the
doors automatically once. The ETACS-ECU is ready to reg-
ister an encrypted code.
HAZARD 1 2 3 4 5 6 NOTE: The hazard warning light switch is a toggle switch.
WARNING ON
LIGHT 5. Press the transmitter button, and then press it two times
SWITCH OFF within 10 seconds of the first press. This will register the
ACX00571 AR
code.
6. When the encrypted code has been registered, the
ETACS-ECU locks and unlocks the doors automatically
once.
7. If you are using two or more transmitters or have added a
second transmitter, the next transmitter should be registered
within one minute after registering the code for the previous
transmitter. The registration procedure is common for all the
transmitter.
8. Registration mode will be canceled under the following
conditions:
• When the secret code for four transmitters has been regis-
tered;
• When passing one minute after finishing the registration of
all transmitters;
• When special tool MB991824 (V.C.I.) is disconnected;
• When the key is removed from the key cylinder;
9. After the registration is completed, remove the ignition key
and close all the doors, and then check that the keyless
entry system operates normally.
BODY 42-75
SUNROOF ASSEMBLY
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
TOOL TOOL NUMBER AND SUPER APPLICATION

NAME SESSION
A
MB991223 General service Measurement of terminal voltage
Harness set tools • A: Connector pin contact
• A: MB991219 pressure inspection
Test harness • B: Power circuit inspection
B • B: MB991220 • C: Power circuit inspection
LED harness • D: Commercial tester connection
• C: MB991221
C
LED harness adapter
• D: MB991222
Probe
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
SUNROOF TIMER FUNCTION CHECK

M1426004300100
Keep the door closed, turn OFF the ignition switch and check to
see if the sunroof can be operated for 30 seconds after that. If
not, perform troubleshooting (Refer to GROUP 54B, SWS
Diagnosis P.54B-57).
SUNROOF FIT ADJUSTMENT

M1426001000285
1. Fully close the roof lid glass.
2. Fully open the sunshade.
3. Loosen the roof lid glass assembly mounting screws. Align
the roof lid glass by moving it backward, forward, up or down
along the guide oblong hole so that the clearance between
the glass and the vehicle body is even.
4. Check to be sure that the roof lid glass is flush with the roof
panel at corner areas.
5. Check to be sure that the sunroof operates smoothly.
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).
ROOF LID GLASS OPERATION CURRENT CHECK

M1426003200166
1. Remove the fuse of the sunroof, then connect the circuit
tester as shown in the Figure.
2. Turn ON the sunroof switch, then measure the operating
current when the roof lid glass is halfway opened.
Standard value: 7 A or less [at 20 °C (68 °F)]
3. Check the following areas if the operating current of
exceeds the standard value:
• Sunroof installation, deformation and appearance of any
foreign substances.
18DB172A • Drive cable installation.
• Tilting of roof lid glass.
BODY 42-77
SUNROOF ASSEMBLY
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
.
1. Ensure the components are correctly assembled. Ensure all

the connectors are connected securely.
2. If the sunroof is already in learn mode, go to step 3. If the
sunroof is not in learn mode, enter learn mode by (1) or (2)
below.
(1) Disconnect the sunroof motor assembly connector while
the sunroof is operating.
(2) Stop the sunroof operation by fitting the block (board
etc.). Then press and hold the sunroof close switch for 10
seconds with the sunroof stopped.
3. Press the sunroof Close switch repeatedly until the sunroof
is tilted up fully.
4. Press and hold the sunroof Close switch for at least three
seconds.
5. Press the sunroof Close switch until the sunroof closes fully.
6. The sunroof should work normally.
AC203084 AB
NOTE: Do not stop the sunroof before it reaches the fully
closed position during operations in steps 5 above. If the sun-
roof has stopped accidentally, repeat the procedure from step
1.
SUNROOF OPERATION CHECK
M1426002600332
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
CLOSE/TILT-DOWN SUNROOF SWITCH
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
NO. SUNROOF REQUIREMENTS FOR THE SUNROOF TO NORMAL OPERATION

FUNCTION FUNCTION
05 AUTOMATIC A 1. Ignition switch: ON The sunroof stops the
OPERATION 2. Sunroof switch: OPEN or TILT-UP automatic opening
INTERRUPTION operation.
(OPEN) B 1. Ignition switch: ON The sunroof stops the
2. Sunroof switch: CLOSE/TILT DOWN (Push automatic opening
the sunroof switch to the operation.
CLOSE/TILT-DOWN position while the
sunroof is automatically opening and
release the switch within two seconds)
C 1. Ignition switch: ON The sunroof stops the
2. Sunroof switch: CLOSE/TILT DOWN (Push automatic opening
the sunroof switch to the operation, and the sunroof
CLOSE/TILT-DOWN position more than closes while the sunroof
two seconds while the sunroof is switch is pushed to the
automatically opening) CLOSE/TILT-DOWN
position.
06 AUTOMATIC 1. Ignition switch: ON The sunroof stops the
OPERATION 2. Sunroof switch: OPEN or TILT-UP, CLOSE/TILT automatic opening
INTERRUPTION DOWN operation.
(TILT-UP)
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
M1426001200308
Post-installation Operation <Roof lid glass assembly,

Sunroof assembly>
• Sunroof Water Test (Refer to P.42-75).
• Sunroof Fit Adjustment (Refer to P.42-76).
Post-installation Operation <Roof lid glass assembly,
Sunroof motor assembly>
• Sunroof Initializing Adjustment (Refer to P.42-77).
SECTION A – A
1 4.0 ± 0.5 N·m
36 ± 4 in-lb CLIP
2 AC206389
4.0 ± 0.5 N·m

36 ± 4 in-lb
6
7
4
5
A
A
2
NOTE 5.4 N·m 3 AC307032
: CLIP POSITIONS 48 in-lb AC307985 AB
REMOVAL DRAIN PIPE REMOVAL STEPS

1. ROOF LID GLASS ASSEMBLY >>A<< 3. FRONT DRAIN PIPE
2. OVERHEAD CONSOLE ASSEMBLY • REAR HEADLINING PAD (REFER
DRAIN PIPE REMOVAL STEPS TO GROUP 52A, HEADLINING
• FRONT HEADLINING PAD (REFER P.52A-19).
TO GROUP 52A, HEADLINING • TRUNK TRIM ASSEMBLY (REFER
P.52A-19). TO GROUP 52A, TRIMS P.52A-11).
• FRONT SPLASH SHIELD (REFER • REAR SPLASH SHIELD (REFER TO
TO P.42-10). GROUP 51, REAR BUMPER P.51-5).
• UPPER FRAME TO FRONT PILLAR >>A<< 4. REAR DRAIN PIPE
BRACE (FRONT DRAIN PIPE <LH>) SUNROOF MOTOR ASSEMBLY
(REFER TO P.42-84). REMOVAL STEPS
• INSTRUMENT PANEL PARCEL BOX • HEADLINING (REFER TO GROUP
(FRONT DRAIN PIPE <RH>) 52A, HEADLINING P.52A-19).
(REFER TO GROUP 52A, 5. SUNROOF MOTOR ASSEMBLY
INSTRUMENT PANEL P.52A-4).
BODY 42-81
SUNROOF ASSEMBLY
SUNROOF ASSEMBLY REMOVAL SUNROOF ASSEMBLY REMOVAL

1. ROOF LID GLASS ASSEMBLY 6. OVERHEAD CONSOLE BRACKET
• HEADLINING (REFER TO GROUP 7. SUNROOF ASSEMBLY
52A, HEADLINING P.52A-19).
• DRAIN PIPE CONNECTION
• MB991223: Harness set
5. SUNROOF MOTOR ASSEMBLY

.
>>A<< REAR DRAIN PIPE/FRONT DRAIN PIPE

INSTALLATION
<FRONT> UNITS: mm (in)
Install the grommet, and then position the drain pipe so that it
protrudes from the grommet as shown in the illustration.
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
SUNROOF SWITCH CONTINUITY CHECK

OVERHEAD CONSOLE
Open 4−5 Less than 2 ohms
Off 3 − 4, 3 − 5, 3 − 6, Open circuit
4 − 5, 4 − 6, 5 − 6
Tilt-up 3−4 Less than 2 ohms
Close/Tilt-down 4−6 Less than 2 ohms
SUNROOF SWITCH AC306720
TILT-UP
OPEN
CLOSE/
TILT-DOWN
AC209094
AC307038 AB
BODY 42-83
SUNROOF ASSEMBLY

M1426001400294
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

1. SUNROOF DRIP PLATE 6. SUNROOF GUIDE RAIL ROD
2. SUNROOF SUNSHADE STOPPER HOLDER
3. SUNROOF SUNSHADE 7. SUNROOF DRIP RAIL
<<A>> 4. SUNROOF DEFLECTOR 8. ROOF LID SLIDER
ASSEMBLY 9. SLIDING ROOF OPERATING UNIT
5. SUNROOF DEFLECTOR 10. ROOF BLIND STOPPER
11. SUNROOF HOUSING
BODY 42-84
LOOSE PANEL

.
<<A>> SUNROOF DEFLECTOR ASSEMBLY

REMOVAL
Slide the sunroof deflector assembly to the front of the vehicle
SUNROOF DEFLECTOR
ASSEMBLY by holding the arrow area shown in the illustration with a
flat-tipped screwdriver, and remove it.
AC307035AB
LOOSE PANEL
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
COWL TOP COVER OUTER FRONT BUMPER

REMOVAL STEPS REINFORCEMENT BRACKET
• FRONT DECK GARNISH (REFER REMOVAL STEPS
TO GROUP 51, WINDSHIELD • FRONT BUMPER
WIPER P.51-17.) REINFORCEMENT ASSEMBLY
2. COWL TOP COVER OUTER (REFER TO GROUP 51, FRONT
UPPER FRAME TO FRONT PILLAR BUMPER P.51-2.)
BRACE REMOVAL STEPS 5. AIR GUIDE PANEL SIDE
• SPLASH SHIELD (REFER TO 6. FRONT BUMPER
P.42-10.) REINFORCEMENT BRACKET
3. UPPER FRAME TO FRONT PILLAR FRONT END STRUCTURE BAR
BRACE REMOVAL STEPS
AIR GUIDE PANEL REMOVAL • RADIATOR GRILLE (REFER TO
STEPS GROUP 51, RADIATOR GRILLE
• FRONT BUMPER ASSEMBLY P.51-6.)
(REFER TO GROUP 51, FRONT • FRONT BUMPER MOUNTING
BUMPER P.51-2.) CLIPS UPPER (REFER TO GROUP
4. AIR GUIDE PANEL CENTER 51, FRONT BUMPER P.51-2.)
• FRONT BUMPER • HOOD DAMPER AND HOOD LATCH
REINFORCEMENT ASSEMBLY (REFER TO P.42-8.)
(REFER TO GROUP 51, FRONT 7. COOLER TUBE ASSEMBLY
BUMPER P.51-2.) MOUNTING BOLT
5. AIR GUIDE PANEL SIDE 8. FRONT END STRUCTURE BAR
BODY 42-86
SPECIFICATIONS
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
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)]
SEALANT AND ADHESIVES

M1421000500204
<WINDOW GLASS>
ITEM SPECIFIED ADHESIVE
Rear window glass 3 M™ AAD part No. 8609 super fast urethane and 3 M™ AAD part No.
Windshield 8608 super fast urethane primer or equivalent
<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
FRONT BUMPER ASSEMBLY . . . . . 51-2 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . 51-14

REMOVAL AND INSTALLATION . . . . . . . . 51-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 51-15
DISASSEMBLY AND ASSEMBLY . . . . . . . 51-3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-15
WINDSHIELD INTERMITTENT WIPER
REAR BUMPER ASSEMBLY . . . . . . 51-5 VOLUME CHECK . . . . . . . . . . . . . . . . . . . . 51-15
REMOVAL AND INSTALLATION . . . . . . . . 51-5 WINDSHIELD WASHER FLUID EJECTION
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-16
WINDSHIELD WIPER . . . . . . . . . . . . . . . . . 51-17
RADIATOR GRILLE. . . . . . . . . . . . . . 51-6
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-20
GARNISHES AND MOLDINGS . . . . . 51-7 WINDSHIELD WASHER . . . . . . . . . . . . . . . 51-23
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 51-7
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-24
MOLDINGS . . . . . . . . . . . . . . . . . . . . . . . . . 51-8
MARK . . . . . . . . . . . . . . . . . . . . . . . . . 51-25
REAR SPOILER. . . . . . . . . . . . . . . . . 51-11 REMOVAL AND INSTALLATION . . . . . . . . 51-25

DOOR MIRROR . . . . . . . . . . . . . . . . . 51-27
MUD GUARD . . . . . . . . . . . . . . . . . . . 51-12 GENERAL DESCRIPTION . . . . . . . . . . . . . 51-27
DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . 51-28
UNDER COVER . . . . . . . . . . . . . . . . . 51-13 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-29
SPECIFICATIONS . . . . . . . . . . . . . . . 51-31
WINDSHIELD WIPER AND WASHER 51-14 FASTENER TIGHTENING SPECIFICATIONS 51-31
GENERAL DESCRIPTION . . . . . . . . . . . . . 51-14 SERVICE SPECIFICATIONS . . . . . . . . . . . 51-31
WINDSHIELD WIPER AND WASHER ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-31
EXTERIOR 51-2
FRONT BUMPER ASSEMBLY

M1511001400499
SPLASH SHIELD
2 1
20DB121A

• RADIATOR GRILLE (REFER TO • FOG LAMP CONNECTOR
P.51-6). CONNECTION
1. SPLASH SHIELD MOUNTING CLIPS 5. FRONT BUMPER
2. FRONT BUMPER UNDER COVER REINFORCEMENT ASSEMBLY
3. FRONT BUMPER ASSEMBLY DISASSEMBLY STEPS
4. FRONT BUMPER CORE, LH/RH • FOG LAMP OR COVER (REFER TO
GROUP 54A P.54A-159
<<A>> >>A<< 7. LOWER GRILLE
EXTERIOR 51-3

M1511001600493
1
2
4
20DB124A
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

.
<<A>> LOWER GRILLE ASSEMBLY REMOVAL

1. Ensure that the front bumper surface around grille is clean
SCRIVETS (6 PLACES) and free of any foreign material to prevent damaging paint
surface during grille removal.
2. Remove the attaching scrivets from bumper. The 380 and
380LS models grille lower is attached by scrivets only. For
VRX and GT models use step 3 in removal process.
380/380LS TYPE GRILLE

20DB127A
EXTERIOR 51-4
SCRIVETS
VRX/GT TYPE GRILLE
20DB126A
3. For VRX and GT models, using Special Tool MB990784 or

GRILLE, LOWER similar. Insert the tool carefully into each bumper locating
FRONT BUMPER
clip point and release the grille from bumper.
4. Carefully remove the grille from bumper and avoid any paint
damage.
SPECIAL TOOL CLIP POINT
20DB125A
EXTERIOR 51-5
REAR BUMPER ASSEMBLY
REAR BUMPER ASSEMBLY

M1511001900427
7
6
6
4N
5 N A
B
B
1
2 3
20DB122A
SECTION A – A SECTION B – B
5
3
3 SIDE OUTER PANEL

REAR END OUTER
PANEL
4
AC306484 AB

• REAR COMBINATION LIGHT 2. TAPPING SCREW
(REFER TO GROUP 54A, REAR 3. REAR BUMPER ASSEMBLY
COMBINATION LIGHT P.54A-161). 4. REAR BUMPER CENTER BRACKET
• REAR END TRIM REFER TO 5. REAR BUMPER SIDE BRACKET
GROUP 52A, TRIMS P.52A-11). 6. REAR BUMPER CORES, LH/RH
1. REAR SPLASH SHIELD 7. REAR BUMPER REINFORCEMENT
EXTERIOR 51-6
RADIATOR GRILLE
RADIATOR GRILLE
M1511002900237
CLIP RADIATOR GRILLE

FRONT END
UPPER BAR
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
.
<<A>> RADIATOR GRILLE ASSEMBLY REMOVAL

Ensure that the front bumper surface around grille is clean and
free of any foreign material to prevent damaging paint surface
during grille removal.
EXTERIOR 51-7
GARNISHES AND MOLDINGS
1. Open the engine hood and remove the 6 attaching scrivets

SCRIVETS
from the top edge of grille.
20DB119A
2. Using Special Tool MB990784 or similar. Insert the tool

RADIATOR GRILLE between the top surface of the bumper and lower edge of
the grille at each clipping point and release grille lower side.
3. Carefully remove the grille from bumper and avoid any paint
damage.
SPECIAL TOOL CLIP POINT
FRONT BUMPER 20DB120A

SPECIAL TOOLS
M1511000601158

NAME
MB990784 Ornament General service tool Side protector molding
remover Roof drip molding
MB990784
EXTERIOR 51-8
MOLDINGS
M1511004700165
A A
2
1
A
AC306486 AB
REMOVAL FRONT DELTA GARNISH REMOVAL

<<A>> >>A<< 1. FRONT DOOR SIDE PROTECTOR STEPS
MOLDING 4. FRONT DELTA GARNISH
<<A>> >>A<< 2. REAR DOOR SIDE PROTECTOR Required Special Tools:
MOLDING • MB990784: Ornament Remover
ROOF DRIP MOLDING REMOVAL
STEPS
<<A>> >>A<< 3. ROOF DRIP MOLDING
EXTERIOR 51-9
ADHESIVE TAPE POSITION
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
ROOF DRIP MOLDING
FRONT DOOR SIDE PROTECTOR MOLDING
REAR DOOR SIDE PROTECTOR MOLDING
AC306520 AC
ADHESIVE TAPE: DOUBLE-SIDED TAPE

A: 10.0 mm ( 0.39 in ) WIDTH AND 1.52 mm ( 0.06 in ) THICKNESS,
B: 8.0 mm ( 0.32 in ) WIDTH AND 1.2 mm ( 0.05 in ) THICKNESS

.
<<A>> SIDE PROTECTOR MOLDING/ROOF DRIP

MOLDING REMOVAL
Gently lift and remove the side protector molding/roof drip
molding. If there is any double-sided tape remaining on the side
protector molding, remove according to the following instruc-
tions.
<Remove double-sided tape remaining on the body surface>
1. Attach protection tape all the way along the edges of the
double-sided tape which is still adhering to the body.
PROTECTION TAPE
DOUBLE-SIDED TAPE AC000420 AB

EXTERIOR 51-10
2. Scrape off the double-sided tape with a resin spatula as

DOUBLE-SIDED TAPE
much as possible.
3. Peel off the protection tape.
4. Use a shop towel moistened with 3M™ AAD Part number
8906 or equivalent to wipe the body.
AC000421AB
<Remove double-sided tape remaining on SIDE PROTECTOR

MOLDING/ROOF DRIP MOLDING and adhere double-sided
tape (when re-using SIDE PROTECTOR MOLDING/ROOF
DRIP MOLDING)>
1. Scrape off the double-sided tape on the side protector
molding with a resin spatula as much as possible.
2. Use a shop towel moistened with 3M™ AAD Part number
8906 or equivalent to wipe the side protector molding
surface.
3. Remove only a small portion of the residual adhesive.
4. Apply primer to adherence area of the side protector
molding, then adhere the double-sided tape as specified on
the side protector molding (Refer to double-sided tape
AC000422
adherence location ).

.
>>A<< SIDE PROTECTOR MOLDING/ROOF DRIP

MOLDING INSTALLATION.
1. Tear off the double-sided tape backing paper.
NOTE: If you attach the adhesive tape to the edge of the
backing paper, it will be easy to tear off.
2. Install the side protector molding/roof drip molding.
NOTE: If the double-sided tape is difficult to affix in cold tem-
perature, etc., warm the bonding surfaces of the body and
side protector molding to about 40 − 60°C (104 − 140°F)
before affixing the tape.
3. Firmly press in the side protector molding.
AC000657
EXTERIOR 51-11
REAR SPOILER
REAR SPOILER
M1511006100147
3 1
2N
AC306525 AB

• TRUNK LID BUMPER (REFER TO 2 PACKING
GROUP 42, TRUNK LID P.42-63). 3 HIGH-MOUNTED STOPLIGHT
1. REAR SPOILER ASSEMBLY (REFER TO GROUP 54A,
HIGH-MOUNTED STOPLIGHT
P.54A-166).
EXTERIOR 51-12
MUD GUARD
MUD GUARD
M1511011200065
B FRONT MUDGARD
AC306037 AB
CLIP
GROMMET
FRONT FRONT
MUDGARD MUDGARD
SCREW AC306039 AC306040
AC306470 AB

• MB990784: Ornament Remover
EXTERIOR 51-13
UNDER COVER
UNDER COVER
M1511019600119
2
3
AC306125 AB

• FRONT BUMPER UNDER COVER 2. PLUG
(REFER TO P.51-2). 3. SIDE UNDER COVER (RH)
1. SIDE UNDER COVER (LH)
EXTERIOR 51-14
WINDSHIELD WIPER AND WASHER

GENERAL DESCRIPTION
M1511000100558

.
WINDSHIELD MIST WIPER OPERATION

OPERATION • If the windshield mist wiper switch is turned to the
ON position with the ignition switch at the "ACC"
.
WINDSHIELD LOW-SPEED (AND

or "ON" position, the mist wiper high-speed oper-
HIGH-SPEED) WIPER OPERATION ation signal is sent to the front-ECU. This signal
• If the windshield low-speed wiper switch is turned turns on the wiper speed control relay, causing
to the ON position with the ignition switch at the the wipers to work at high-speed while the mist
"ACC" or "ON" position, the column switch sends switch is on.
a low-speed wiper ON and high-speed wiper OFF • While the windshield mist wiper switch remains
signals to the front-ECU. This turns the wiper sig- turned on when the intermittent mode is still work-
nal on and the wiper speed control relay off ing, the wipers work as the mist wiper. However,
(low-speed), causing the wipers to operate at the wipers return to the intermittent mode again
low-speed. when the switch is changed back to "INT" posi-
• If the windshield high-speed wiper switch is tion.
turned to the ON position, the column switch • To prevent the windshield mist wiper from operat-
sends a low-speed wiper OFF and high-speed ing when the windshield wiper switch is turned
wiper ON signals to the front-ECU. This turns OFF, the windshield mist wiper does not work for
both the wiper signal and the wiper speed control 0.5 second after the windshield intermittent wiper
relay on (high-speed), causing the wipers to switch, the windshield low-speed wiper switch
operate at high-speed. and the windshield high-speed wiper switch are
NOTE: The windshield wiper speed is adjustable turned OFF.
with the built-in wiper speed control relay. .
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
SPECIAL TOOLS
M1511000601170

NAME
Diagnostic Tool Windshield intermittent wiper check
A
A: MB991824 CAUTION
B: MB991827 For vehicles with CAN
C: MB991910 communication, use MUT-III main
D: MB991911 harness A to send simulated
MB991824 E: MB991914 vehicle speed. If you connect
B F: MB991825 MUT-III main harness B instead,
G: MB991826 the CAN communication does
MUT-III sub assembly not function correctly.
A: Vehicle
MB991827 Communication
C
Interface (V.C.I.)
B: MUT-III USB Cable
C: MUT-III Main Harness
D
system)
D: MUT-III Main Harness
DO NOT USE B (Vehicles without
CAN communication
MB991911 system)
E E: MUT-III Main Harness
C (for Chrysler models
DO NOT USE only)
F: MUT-III Adapter
MB991914 Harness
F
G: MUT-III Trigger
Harness
MB991825
MB991826
MB991958
ON-VEHICLE SERVICE
WINDSHIELD INTERMITTENT WIPER VOLUME

CHECK
M1511018900043
EXTERIOR 51-16
If the windshield intermittent wiper interval control is operated,

the wiper interval should change.
CAUTION
CONNECTOR
ing or disconnecting.
3. Operate diagnostic tool according to the procedure below to
display "Simulated Vehicle Speed Output."
(1) Select "SYSTEM SELECT."
MB991910 (2) Select "SWS."
(3) Select "Simulated Vehicle Speed Output."
MB991824
4. Holding the windshield intermittent wiper interval control,
input the simulated vehicle speed with diagnostic tool and
check that the wiper interval changes as the vehicle speed
changes.
5. If not, carry out the troubleshooting (Refer to GROUP 54B,
SWS Diagnosis P.54B-57).
MB991827 00DB076A
WINDSHIELD WASHER FLUID SPRAY CHECK

M1511018400060
The windshield washer nozzle aiming cannot be adjusted. If the
washer nozzles do not spray washer fluid within the windshield
wiper wiping area, check the nozzles as follows:
WINDSHIELD WIPER WIPING AREA 1. Check that the windshield washer nozzles are fitted on the
hood correctly, and reinstall them if necessary.
2. If the windshield washer nozzles are damaged, replace
them (Refer to P.51-23).
20DB107A
EXTERIOR 51-17
WINDSHIELD WIPER
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
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
WIPER BLADE REMOVAL STEPS WINDSHIELD WIPER MOTOR AND

>>B<< 1. WIPER BLADE ASSEMBLY LINK ASSEMBLY REMOVAL STEPS
>>B<< 2. WIPER BLADE RUBBER 6. GUTTER
>>A<< 3. WIPER ARM AND BLADE 7. WINDSHIELD WIPER MOTOR AND
ASSEMBLY LINK ASSEMBLY
WINDSHIELD WIPER MOTOR AND 8. MOTOR
LINK ASSEMBLY REMOVAL STEPS NOTE: For removal and installation of the wiper and
4. FENDER HOLE COVER washer switch, refer to GROUP 54A, Column switch
5. FRONT DECK GARNISH P.54A-170.
ASSEMBLY
EXTERIOR 51-19

.
>>A<< WIPER ARM AND BLADE ASSEMBLY

INSTALLATION
D
WIPER ARM AND PLACE WIPER BLADE ON THE
BLADE ASSEMBLY (RH) MARK OF WINDSHIELD
E D
WIPER ARM AND FENDER HOLE

FRONT DECK GARNISH BLADE ASSEMBLY (LH) COVER
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
>>B<< WIPER BLADE RUBBER/ WIPER BLADE

ASSEMBLY INSTALLATION
CAUTION
<DRIVER'S SIDE> Ensure that the backings are bent in the direction indi-
cated, and then install the backings to the wiper blade rub-
ber.
BACKING
A
WIPER BLADE
A
SECTION A – A
WIPER BLADE
BACKING
<PASSENGER'S SIDE>
BACKING
BACKING
A
WIPER BLADE
A
BACKING AC308476 AC
INSPECTION
M1511008000146
WINDSHIELD WIPER MOTOR CHECK

Inspect the windshield wiper motor by removing the harness
connector with the motor attached to the vehicle.
.
EXTERIOR 51-21
Wiper Motor at Low-Speed and High-Speed

Operation
Connect the battery to the windshield wiper motor to inspect
the operation of motor rotation in low or high speed.
CHECK OPERATION
HIGH SPEED
LOW SPEED
20DB111A
Wiper Motor at Stop Position Operation

1. Connect the battery to the windshield wiper motor as shown
in the illustration (A).
2. Run the windshield wiper motor at low speed, then
disconnect the battery in the middle of the motor turning and
check to see that the motor stops.
3. As shown in the illustration (B), connect the terminals of the
windshield wiper motor connectors.
4. Check to see that the windshield wiper motor runs at low
speed and then stops at the automatic stop position.
CHECK OPERATION
(A) LOW SPEED
(B) AUTOMATIC STOP 20DB112A

EXTERIOR 51-22
WINDSHIELD WIPER SWITCH CHECK

Check continuity between the switch terminals.
32 3130 2928 27 2625 2423 22 21
OFF 23 − 32, 23 − 31, Open circuit
UPPER SIDE
23 − 30, 23 − 21
Windshield mist wiper 23 − 32 Less than 2 ohms
switch
AC307642 AB
Windshield 23 − 31
intermittent wiper
switch
Windshield low-speed 23 − 30
wiper switch
Windshield 21 − 23
high-speed wiper
switch
WINDSHIELD INTERMITTENT WIPER INTERVAL

CHECK
Check that the resistance varies between 0 and 1 kiloohm
when the windshield intermittent interval is turned from FAST to
SLOW by after measuring resistance between connector termi-
nals 27 and 28 at the column switch.
32 3130 2928 27 2625 2423 22 21
UPPER
SIDE
AC307648 AB
EXTERIOR 51-23
WINDSHIELD WASHER
M1511008200270
SECTION A – A
CLAW
CLAW
1
12 ± 1.0 N·m
102 ± 15 in-lb
4
5
AC306718 AB
WINDSHIELD WASHER NOZZLE WASHER TANK REMOVAL STEPS

REMOVAL STEPS • FRONT UNDER COVER RH (REFER
• WINDSHIELD WASHER HOSE TO P.51-2).
CONNECTION • FRONT SPLASH SHIELD RH
1. WINDSHIELD WASHER NOZZLE MOUNTING CLIPS (REFER TO
WASHER HOSE REMOVAL STEPS GROUP 42, FENDER P.42-10).
• WINDSHIELD WASHER NOZZLE • FRONT BUMPER (REFER TO
CONNECTION P.51-2).
2. WINDSHIELD WASHER HOSE • HEAD LIGHT (REFER TO GROUP
54A, HEADLIGHT P.54A-153).
• FRONT WASHER HOSE
CONNECTIONS
3. WASHER TANK ASSEMBLY
EXTERIOR 51-24
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
WINDSHIELD WASHER MOTOR CHECK

1. Remove the washer tank assembly with the washer hose
attached. Then fill the washer tank with water.
2. Check to see that the water is vigorously sprayed when
connecting the positive battery terminal to terminal number
2 and terminal number 1 to ground.
20DB113A
WINDSHIELD WASHER SWITCH CHECK
32 3130 2928 27 2625 2423 22 21 SWITCH POSITION TESTER SPECIFIED

OFF 22 − 23 Open circuit
UPPER SIDE Windshield washer 22 − 23 Less than 2 ohms
switch ON
AC307642 AB
EXTERIOR 51-25
MARK
MARK
M1511011800454
20DB114A
1. FRONT THREE-DIAMOND MARK 2. REAR THREE-DIAMOND MARK

>>A<< 3. GRADE MARK
EXTERIOR 51-26
MARK

.
>>A<< MARK INSTALLATION

1. Installation position
Attach the correct grade mark to the position shown in the
illustration. ie (380/380LS/380VRX/380GT).
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
OPERATION DOOR MIRROR

Remote Controlled Mirror Operation
• The mirror on the door mirror moves up/down
and left/right by operating the remote controlled
door mirror switch when the ignition switch is in
the "ON" or "ACC" position.
EXTERIOR 51-28
DOOR MIRROR
DOOR MIRROR
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
REMOTE CONTROLLED MIRROR REMOTE CONTROLLED MIRROR

REMOVAL STEPS SWITCH REMOVAL STEPS
• FRONT DOOR TRIM (REFER TO <<A>> 3. POWER WINDOW SWITCH PANEL
GROUP 52A, DOOR TRIMS ASSEMBLY
P.52A-14). 4. REMOTE CONTROLLED MIRROR
1. DOOR MIRROR COVER SWITCH
2. REMOTE CONTROLLED MIRROR
ASSEMBLY
.
<<A>> POWER WINDOW SWITCH PANEL

ASSEMBLY REMOVAL
POWER WINDOW SWITCH
PANEL ASSEMBLY
window switch panel assembly.
MB990784
20DB116A
INSPECTION
M1511006500305
ELECTRIC REMOTE CONTROL MIRROR

OPERATION CHECK
Check that the mirror moves as described in the table when
each terminal is connected to the battery.
BATTERY CONNECTION DIRECTION
OPERATION
• Connect terminal 6 to the negative Up
battery terminal.
• Connect terminal 4 to the positive battery
terminal.
20DB117A • Connect terminal 6 to the positive battery Down
terminal.
• Connect terminal 4 to the negative
battery terminal.
• Connect terminal 6 to the negative Right
battery terminal.
• Connect terminal 5 to the positive battery
terminal.
• Connect terminal 6 to the positive battery Left
terminal.
• Connect terminal 5 to the negative
battery terminal.
EXTERIOR 51-30
DOOR MIRROR
DOOR MIRROR CONTROL SWITCH CONTINUITY

CHECK

OFF 9 − 2, 9 − 3, 9 − 6, Open circuit
1 2 3 4 9 − 10, 9 − 11, 1 − 2,
5 6 7 8 9 10 11 1 − 3, 1 − 6, 1 − 10,
1 − 11
Left side OFF 9 − 6, 9 − 10, 9 − 11, Open circuit
1 − 6, 1 − 10, 1 − 11
AC005970
Up 1 − 6, 9 − 11 Less than 2
ohms
Down 1 − 11, 6 − 9
Right 1 − 6, 9 − 10
Left 1 − 10, 6 − 9
Right side OFF 9 − 2, 9 − 3, 9 − 6, Open circuit
1 − 2, 1 − 3, 1 − 6
Up 1 − 6, 3 − 9 Less than 2
ohms
Down 1 − 3, 6 − 9
Right 1 − 6, 2 − 9
Left 1 − 2, 6 − 9
EXTERIOR 51-31
SPECIFICATIONS
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)
M1511000300358
ITEM STANDARD VALUE

Windshield wiper blade (RH) park position 38 ± 5 mm (1.50 ± 0.20 inches)
Windshield wiper blade (LH) park position 38 ± 5 mm (1.50 ± 0.20 inches)
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
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . 52B

52-2 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM(SRS)
TSB Revision
HOME 52A-1
GROUP 52A
INTERIOR
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 52A-3 TRIMS . . . . . . . . . . . . . . . . . . . . . . . . . 52A-11

SEAT BELT DIAGNOSIS. . . . . . . . . . 52A-3
DOOR TRIM . . . . . . . . . . . . . . . . . . . . 52A-14
SPECIAL TOOLS. . . . . . . . . . . . . . . . 52A-3 REMOVAL AND INSTALLATION . . . . . . . . 52A-14
DISASSEMBLY AND ASSEMBLY . . . . . . . 52A-17
INSTRUMENT PANEL ASSEMBLY*. 52A-4
REMOVAL AND INSTALLATION . . . . . . . . 52A-4 HEADLINING . . . . . . . . . . . . . . . . . . . 52A-19
DISASSEMBLY AND ASSEMBLY . . . . . . . 52A-9 REMOVAL AND INSTALLATION . . . . . . . . 52A-19
FLOOR CONSOLE ASSEMBLY . . . . 52A-10 INSIDE REAR VIEW MIRROR . . . . . . 52A-20

WARNING
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS
AFTER HANDLING.
WARNING
NOTE
INTERIOR 52A-2
FRONT SEAT ASSEMBLY* . . . . . . . 52A-21 REMOVAL AND FITMENT . . . . . . . . . . . . . 52A-49
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
.
Seat belt warning system

If the driver turn the ignition switch to the "ON" posi-
tion without fastening the seat belt, the seat belt
warning light illuminates.
SEAT BELT DIAGNOSIS

M1523000700182
The seat belt warning system is controlled by the
Simplified Wiring System (SWS). For troubleshoot-
ing, refer to GROUP 54B, SWS diagnosis
P.54B-101.
SPECIAL TOOLS
M1521000600327

NAME
MB990784 General service Removal of switch, trim,
Ornament remover tool etc.
MB990784
INTERIOR 52A-4
INSTRUMENT PANEL ASSEMBLY

M1521001700684
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."
NAME SYMBOL SIZE (D × L) mm COLOR SHAPE

TAPPING SCREW a 5 × 12 BLACK
b 5 × 16 -
c 5 × 20 - AC104450
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
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

1. GLOVEBOX ASSEMBLY • HOOD LOCK RELEASE HANDLE
2. INSTRUMENT PANEL PARCEL (REFER TO GROUP 42, HOOD
BOX P.42-8.)
3. GLOVEBOX LOCK 4. INSTRUMEN LOWER PANEL
5. INSTURMENT CENTER PANEL
ASSEMBLY
INTERIOR 52A-6

6. RADIO AND CD PLAYER, <<A>> • CLOCK SPRING CONNECTOR
ASSEMBLY <<A>> • COLUMN SWITHC CONNECTOR
7. RADIO, CD PLAYER AND CD • CLOCK SPRING AND COLUMN
CHANGER ASSEMBLY SWITCH ASSEMBLY (REFER TO
8. CONSOLE METER HOOD GROUP 37, STEERING SHAFT
11. MULTI-CENTER DISPLAY P.37-25.)
ASSEMBLY 21. INTERIOR TEMPERATURE
12. INSTRUMENT DIGITAL CLOCK SENSOR (GROUP 55B,
ASSEMBLY SENSORS 55-160.)
13. CENTER CONSOLE ASSEMBLY 22. INSTRUMENT PANEL FRONT
14. INSTURMENT PANEL GARNISH END GARNISH
15. COMBINATION METER 23. PHOTO SENSOR (GROUP 55B,
ASSEMBLY SENSORS 55-160.) AND
• FRONT PILLAR TRIM (REFER TO SECURITY LED.
P.52A-11.) • FLOOR CONSOLE ASSEMBLY
16. FRONT SPEAKER GARNISH (REFER TO P.52A-10.)
17. TWEETER • COWL SIDE TRIM (REFER TO
18. INSTRUMENT PANEL SIDE P.52A-11.)
COVER <<A>> • AIR BAG MODULE CONNECTOR
19. INSTRUMETN PANEL SIDE AIR (PASSENGER’S SIDE) (REFER
OUTLET TO GROUP 52B, AIR BAG
• AIR BAG MODULE ASSEMBLY MODULE AND CLOCK SPRING
(DRIVER’S SIDE) (REFER TO
P.52B-237.)
GROUP 52B, AIR BAG MODULE
25. INSTRUMENT PANEL ASSEMBLY
AND CLOCK SPRING P.52B-237.)
• STEERING WHEEL ASSEMBLY
(REFER TO GROUP 37,
STEERING WHEEL P.37-23.)
20. STEERING COLUMN COVER
INTERIOR 52A-7
CLIP AND CLAW POSITIONS
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
SECTION A – A SECTION B – B SECTION C – C SECTION D – D

CONSOLE METER INSTRUMENT PANEL INSTURMENT
HOOD FRONT END GARNISH FRONT SPEAKER PANEL SIDE
GARNISH AIR OUTLET
CLIP
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

.
<<A>> CONNECTOR DISCONNECTION

Disconnect the connectors shown in the illustration.
1. CLOCK SPRING CONNECTOR (6)
2. CLOCK SPRING CONNECTOR (4-Y)
3. COLUMN SWITCH CONNECTOR (10)
3
1 2 19DB006A
4. AIR BAG MODULE (FRONT PASSENGER’S SIDE)

CONNECTOR (4-Y)
19DB007A
INTERIOR 52A-9

M1521001900376
4 b
b 4
5
b
1
b
b b
b
8 b
2
b
g
3 b
19DB124A

1. DISTRIBUTION DUCT. REAR 3. AIR BAG MODULE ASSEMBLY
CONSOLE DUCTS REFER TO (FRONT PASSENGER’S SIDE)
GROUP 55 HEATER ,AIR (REFER TO GROUP 52B, AIR
CONDITIONING AN BAG MODULE(S) AND CLOCK
VENTILATION P.55-175 SPRING P.52B-237.)
2. BACKBONE BRACKET 4. SIDE DEFROSTER DUCT
5. DEFROSTER NOZZLE
6. COMBINATION METER BRACKET
7. GLOVEBOX STRIKER
8. INSTRUMENT PANEL
INTERIOR 52A-10
FLOOR CONSOLE ASSEMBLY
FLOOR CONSOLE ASSEMBLY

M1521002200314
3 10
4
5 8
9
A
1 6 13
A
12 7
B
B
15
ACCESSORY
11
14
NOTE
: CLIP POSITION
5 1
FLOOR
16
CONSOLE
14
1
CLIP
19DB125A

1. GEARSHIFT LEVER PANEL 8. LID LOCK LEVER
2. HEATED SEAT SWITCH 9. HINGE
<VEHICLES WITH HEATED SEAT 10. LID
SWITCH> 11. INNER BOX
3. ACCESSORY SOCKET (ACC) 12. ACCESSORY SOCKET (+B)
(REFERTO GROUP 54A, (REFERTO GROUP 54A,
ACCESSORY SOCKET ACCESSORY SOCKET
P.54A-174.) P.54A-174.)
4. ACCESSORY SOCKET COVER 13. ACCESSORY SOCKET COVER
5. FRONT BOX 14. FLOOR CONSOLE
6. PLATE 15. ACCESSORY SOCKET HARNESS
7. FLOOR CONSOLE ASSEMBLY 16. REAR BRACKET
INTERIOR 52A-11
TRIMS
TRIMS
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
CLIP AND CLAW POSITION

F
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
COWL SIDE TRIM

FRONT PILLAR TRIM CLIP
SECTION D – D SECTION E – E SECTION F – F
CLAW CLIP
FRONT SCUFF PLATE, REAR PILLAR TRIM
REAR SCUFF PLATE
CLIP
CENTER PILLAR TRIM UPPER,
CENTER PILLAR TIRM LOWER
SECTION G – G SECTION H – H SECTION I – I

REAR SHELF
REAR END TRIM
SPEAKER GARNISH REAR SHELF TRIM
CLIP
CLAW
CLIP
19DB003A
INTERIOR 52A-13
TRIMS

.
<<A>> FRONT PILLAR TRIM REMOVAL

SECTION A – A
Release the clip and remove the front pillar trim by pulling it to
the direction shown.
FRONT PILLAR
TRIM
A FRONT PILLAR
TRIM
A
INSTRUMENT
PANEL
ASSEMLBY AC308185 AB
INTERIOR 52A-14
DOOR TRIM
DOOR TRIM
M1521006400332
<FRONT DOOR TRIM>

6
4
5
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
<> 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
• MB990784: Ornament Remover
INTERIOR 52A-15
DOOR TRIM
<REAR 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

<<A>> 1. INSIDE HANDLE COVER 5. ARMREST BRACKET
<> 2. POWER WINDOW SWITCH 6. REAR DOOR PANEL BRACKET
PANEL ASSEMBLY Required Special Tool:
3. BELT LINE INNER • MB990784: Ornament Remover
WEATHERSTRIP
4. REAR DOOR TRIM ASSEMBLY
INTERIOR 52A-16
DOOR TRIM

.
<<A>> INSIDE HANDLE COVER REMOVAL

Insert special tool MB990784 as shown to remove the inside
MB990784 handle cover.
INSIDE HANDLE
COVER
AC206689 AB
<> POWER WINDOW SWITCH PANEL

ASSEMBLY REMOVAL
MB990784 window switch panel assembly.
POWER WINDOW
SWITCH PANEL
ASSEMBLY
19DB053A
INTERIOR 52A-17
DOOR TRIM

M1521006900100
<FRONT 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
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
<REAR DOOR TRIM>
4
3
2
NOTE 1
: CLAW POSITION
VIEW A SECTION B – B
4
4
CLAW
CLAW
AC307442 AB

1. POWER WINDOW SUB SWITCH 3. ARMREST
2. POWER WINDOW SUB SWITCH 4. REAR DOOR TRIM
PANEL
INTERIOR 52A-19
HEADLINING
HEADLINING
M1521001400360

• Front Seat Assembly (Refer to P.52A-21.)
• Removal and Installation of Rear Seat Cushion Assembly
and Rear Seatback Assembly (Refer to P.52A-55.)
• Removal and Installation of Front Pillar Trim, Center Pillar
Trim Upper and Rear Pillar Trim (Refer to P.52A-11.)
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

1. SUN VISOR 8. ROOF HARNESS CLAMP
2. SUN VISOR HOLDER • INSTRUMENT PANEL SIDE
3. OVERHEAD CONSOLE COVER (REFER TO P.52A-4.)
ASSEMBLY 9. ROOF HARNESS CONNECTOR
4. DOME LIGHT ASSEMBLY (REFER • FLOOR CONSOLE ASSEMBLY
TO GROUP 54A, DOME LIGHT (REFER TO P.52A-10.)
P.54A-163.) • PARKING BRAKE LEVER
5. ASSIST GRIP PLUG ASSEMBLY MOUNTING BOLT
6. ROOF INSIDE ASSIST GRIP (REFER TO GROUP 36, PARKING
<VEHICLES WITH ROOF INSIDE BRAKE LEVER P.36-6.)
ASSIST GRIP> <<A>> 10. HEADLINING ASSEMBLY
7. SUNROOF OPENING TRIM 11. OVERHEAD CONSOLE BRACKET
<VEHICLES WITH SUNROOF> 12. FRONT HEADLINING PAD
INTERIOR 52A-20
INSIDE REAR VIEW MIRROR

13. CENTER HEADLINING PAD
14. REAR HEADLINING PAD
15. ROOF INSIDE ASSIST GRIP
BRACKET <VEHICLES WITH
ROOF INSIDE ASSIST GRIP>
16. ASSIST GRIP BRACKET

.
<<A>> HEADLINING ASSEMBLY REMOVAL

Remove the front passenger's door check (body side mounting
bolt), open the front passenger's door and remove the headlin-
ing assembly. (Refer to GROUP 42, Door Assembly P.42-37.)
FRONT PASSENGER'S
DOOR CHECK
AC307195 AB
INSIDE REAR VIEW MIRROR

M1521002600248

.
INSIDE REAR VIEW MIRROR REMOVAL

Insert a narrow flat-tip screwdriver into the slit in the inside rear
view mirror bracket, keep the spring pushed in and remove the
BUTTON
inside rear view mirror in the direction of the arrow in the illus-
tration.
BRACKET NOTE: While the spring is pushed in, the connection between
the spring and the pawl of the button is released.
SPRING
SLIT AC000333 AB
INTERIOR 52A-21
FRONT SEAT ASSEMBLY
FRONT SEAT ASSEMBLY

M1522001300560
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
2. HEADREST FRONT SEAT ASSEMBLY

FRONT SEAT ASSEMBLY REMOVAL STEPS (Continued)
REMOVAL STEPS 7. SIDE-AIR BAG MODULE
3. SEAT BELT SWITCH CONNECTOR <VEHICLES WITH
CONNECTOR SIDE-AIR BAG>
4. POWER SEAT CONNECTOR RH 8. FRONT SEAT REAR ANCHOR
<VEHICLES WITH MEMORY COVER
SEAT> >>A<< 10. FRONT SEAT ASSEMBLY
6. POWER SEAT CONNECTOR
<VEHICLES WITH POWER SEAT>
INTERIOR 52A-22
FRONT SEAT ASSEMBLY

.
>>A<< FRONT SEAT ASSEMBLY INSTALLATION

CAUTION
Install the front passenger's seat assembly before install-
ing the outer seat belt.
1. Temporarily tighten the nuts in mounting locations shown in
2 the illustration with no weight on the front seat cushion and
check the operation of the seat slide.
2. Temporarily tighten the bolts in mounting locations shown in
1 the illustration with no weight on the front seat cushion.
3. Tighten the nuts and bolts in all mounting locations to the
specified torque.
19DB018A
INTERIOR 52A-23
FRONT SEAT ASSEMBLY
INSPECTION
M1522005500113
POWER SEAT CONTINUITY AND DIAGNOSIS

CHECK
SPECIAL TOOL:
CIRCUIT DIAGRAMS:
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.
NON-MEMORY SEAT DIAGNOSIS

POWER SEAT SUPPLY AND GROUND CONNECTOR (D-40)
defective contact.
SUPPLY TEST SPECIFIED CONDITION

CONNECTION
(D-40)
BATTERY 1 12V
SUPPLY
GROUND 2 Less than 2 ohms or 0V
4-WAY TRACK (NON MEMORY)

defective contact.
SWITCH POSITION TEST CONNECTION SPECIFIED CONDITION

SWITCH MOTOR
REAR LIFT MOTOR UP 1 1 Less than 2 ohms
DOWN 4 5 Less than 2 ohms
FRONT LIFT MOTOR UP 2 1 Less than 2 ohms
INTERIOR 52A-24
FRONT SEAT ASSEMBLY
6-WAY TRACK (NON MEMORY)

defective contact.

SWITCH MOTOR
TRACK/ SLIDE MOTOR FORWARD 5 2 Less than 2 ohms
BACK 8 1 Less than 2 ohms
8 and 10-WAY TRACK (NON MEMORY)

defective contact.

SWITCH MOTOR
RECLINING MOTOR FORWARD 4 1 Less than 2 ohms
INTERIOR 52A-25
FRONT SEAT ASSEMBLY
MEMORY SEAT DIAGNOSIS

POWER SEAT SUPPLY AND GROUND CONNECTOR (D-40)
SPECIAL TOOL:
CIRCUIT DIAGRAMS:
harness if damaged.

defective contact.
SUPPLY TEST SPECIFIED CONDITION

CONNECTION
(D-40)
BATTERY 1 12V
SUPPLY
GROUND 2 Less than 2 ohms or 0V
10-WAY TRACK (MEMORY)- SOURCE TO (MSC) POWER

CONNECTOR (D-38)
defective contact.
CIRCUIT TEST CONNECTION

DESCRIPTION
(MSC) SOURCE INTERMEDIATE
POWER CONNECTOR
(D-38)
GROUND 1 GROUND 15 -
"NEUTRAL" 2 A/T-ECU (B-19) 31 (B-25) pin 9
Bus LT 3 - -
IGNITION- LED ON 4 (IGN 2) J/B fuse 9 (C-28) pin 35
DOOR SW.- LED ON 5 RH Door sw. (D-34) 2 -
VEHICLE SPEED 6 A/T-ECU (B-19) 24 (C-25) pin 8
"PARK" 7 A/T-ECU (B-19) 30 (C-25) pin 10
N.C - - -
INTERIOR 52A-26
FRONT SEAT ASSEMBLY
10-WAY TRACK (MEMORY)-switch to module- 20 pin

CIRCUIT DIAGRAMS:
harness if damaged.

defective contact.

SWITCH (MSC)
MODULE
20 PIN
RECLINING MOTOR FORWARD 4 14 Less than 2 ohms
10-WAY TRACK (MEMORY) 12pin connector (A) at module

to motor circuits
defective contact.

(MSC) MOTOR
MODULE
12 PIN(A)
INTERIOR 52A-27
FRONT SEAT ASSEMBLY
10-WAY TRACK (MEMORY) lumbar switch to module

(20-pin)
CIRCUIT DIAGRAMS:
harness if damaged.

defective contact.

SWITCH (MSC)
MODULE
LUMBAR SWITCH SOFTER 2 12 (20pin) Less than 2 ohms
HARDER 4 6 (20pin) Less than 2 ohms
MEMORY 3 6 (16pin) Less than 2 ohms
10-WAY TRACK (MEMORY) lumbar and recline module

connector (12-pin) to motors
defective contact.

(MSC) MOTOR
MODULE
12 PIN
LUMBAR MOTOR SOFTER 7 1 Less than 2 ohms
HARDER 2 2 Less than 2 ohms
RECLINER MOTOR FORWARD 1 1 Less than 2 ohms
INTERIOR 52A-28
FRONT SEAT ASSEMBLY
ACTIVATION OF A MEMORY RECALL

All memory button seat position recalls will be refused while the
vehicle is in any other gear select position other than "PARK" or
"NEUTRAL". Memory recalls are also disabled if vehicle is in
"PARK" or "NEUTRAL" but the vehicle speed is greater than
15km/h (see table below).
IGNITION PARK NEUTRAL >15km/h MEMORY

RECALL
POSSIBLE
N X X N Y
N X X Y N
Y N N X N
Y Y N N Y
Y Y N Y N
Y N Y N Y
Y N Y Y N
INTERIOR 52A-29
FRONT SEAT ASSEMBLY
OPERATION CHECK OF POWER SEAT MOTOR

CIRCUIT DIAGRAMS:
harness if damaged.
MOTOR DESCRIPTION TERMINAL MEASUREMENT

TRACK/ SLIDE MOTOR BACKWARD 1 MOTOR ON= 12V
MOTOR OFF = GROUND.
FORWARD 2 MOTOR ON= 12V
MOTOR OFF = GROUND.
FRONT LIFT MOTOR UP 1- non memory MOTOR ON= 12V
5- memory
MOTOR OFF = GROUND.
DOWN 5- non memory MOTOR ON= 12V
1- memory
MOTOR OFF = GROUND.
REAR LIFT MOTOR UP 1 MOTOR ON= 12V
MOTOR OFF = GROUND.
DOWN 5 MOTOR ON= 12V
MOTOR OFF = GROUND.
RECLINER MOTOR FORWARD 1 MOTOR ON= 12V
MOTOR OFF = GROUND.
BACKWARD 5 MOTOR ON= 12V
MOTOR OFF = GROUND.
LUMBAR MOTOR SOFTER 1 MOTOR ON= 2.5V - 5V
MOTOR OFF = GROUND.
HARDER 2 MOTOR ON= 2.5V - 5V
MOTOR OFF = GROUND.
INTERIOR 52A-30
FRONT SEAT ASSEMBLY
1.If abnormality was found, check the power seat

adjuster assembly.
LUMBAR MOTOR
CONNECTOR
RECLINER MOTOR
CONNECTOR (D-25-4)
REAR LIFT MOTOR

CONNECTOR (D-25-2)
(BLACK)
FRONT LIFT MOTOR
CONNECTOR (D-25-1)
(WHITE)
TRACK/ SLIDE MOTOR

CONNECTOR (D-25-3)
19DB023A
CIRCUIT DIAGRAMS:
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
DIAGNOSTIC TROUBLE CODES (DTC’s)

The indicator lamp (LED) transmits a certain sequence flash to
distinguish faults.The DTC sequence for the most recent cur-
rent trouble is flashed twice only. If there are multiple faults
present, you can display the next current DTC by pressing the
memory button 2 before the MSC goes into the sub-active
mode. Once all DTC’s have been cycled through, the most
recent current DTC will be displayed. There will be no history of
DTC’s displayed.
INTERIOR 52A-32
FRONT SEAT ASSEMBLY
LED FLASH FAULT CONDITION POSSIBLE CAUSE

SEQUENCE DETECTED
2 then 1 No fore lift motor sensor Connection at motor sensor
or open/ short circuit in
wiring harness.
2 then 2 No aft lift motor sensor Connection at motor sensor
wiring harness.
2 then 3 No track motor sensor Connection at motor sensor
wiring harness.
2 then 4 No pedal motor sensor Connection at motor sensor
wiring harness.
2 then 5 No recliner motor sensor Connection at motor sensor
wiring harness.
2 then 6 No lumbar motor sensor Connection at motor sensor
wiring harness.
3 then 1 Button stuck MEMORY Button switch cap stuck on
side cover
3 then 2 Manual Button stuck position Button switch cap stuck on
side cover
6 then 3 Power relay welded shut Grime on contact
CIRCUIT DIAGRAMS:
harness if damaged.
ERASING DIAGNOSTIC TROUBLE CODES (DTC’s)

The Memory Seat Controller will temporarily store DTC’s when
incorrect operating conditions are detected. The DTC’s are
self-clearing as soon as each fault condition is rectified and
returns to normal operating function.
INTERIOR 52A-33
FRONT SEAT ASSEMBLY

M1522001500456
<RH SIDE>
RHS: 380 (fabric)

11
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
RHS: 380VRX (fabric and leather), 380LS (fabric)

11
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
RHS: 380LS, 380LX, 380GT (leather)

11
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
<<A>> HEADREST 13. SEAT CUSHION COVER
1. HINGE COVER 14. SEAT CUSHION PAD
2. INNER SEAT BELT 15. SEAT CUSHION FRAME
3. MANUAL RECLINER ADJUSTER 16. SEAT BACK PANEL

(VEHICLES WITH MANUAL 17. SIDE AIRBAG MODULE
RECLINER)
<> 18. HEADREST GUIDE
4. SIDE SHIELD COVER
19. MANUAL LUMBAR ADJUSTER
5. POWER RECLINER ADJUSTER HANDLE
(VEHICLES WITH POWER
RECLINER) <<C>> 20. SEAT BACK COVER
6. SEAT HEIGHT ADJUSTER 21. SEAT BACK PAD

KNOB 22. LUMBAR ASSEMBLY
7. MAIN POWER SWITCH 23. RECLINER LEVER RETURN
8. LUMBAR POWER SWITCH SPRING
(VEHICLES WITH POWER 24. RECLINER LEVER SHAFT
RECLINER)
25. SEAT BACK PATCH HARNESS
9. MEMORY BUTTON MODULE (VEHICLES FITTED WITH
(VEHICLES WITH MEMORY POWER SEAT BACK)
SEATS)
26. SEAT BACK FRAME
10. SIDE SHIELD MOUNT BRACKET
27. SEAT POWER HARNESS
11. FRONT SEAT BACK ASSEMBLY
28. SEAT SLIDE ADJUSTER
12. CUSHION ASSEMBLY
INTERIOR 52A-37
FRONT SEAT ASSEMBLY
<LH SIDE>
LHS: 380 (fabric), 380VRX (fabric and leather)
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
LHS: 380LS (fabric)

8
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
LHS: 380LS, 380LX (leather)

8
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
LHS: 380GT (leather)

8
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
<<A>> HEADREST 13. SEATBACK PANEL
1. HINGE COVER 14. SIDE AIRBAG MODULE
2. INNER SEAT BELT <> 15. HEADREST GUIDE
3. MANUAL RECLINER ADJUSTER 16 MANUAL LUMBAR ADJUSTER

HANDLE (VEHICLES WITH HANDLE
MANUAL RECLINER) <<C>> 17. SEATBACK COVER
4. SIDE SHIELD COVER 18. SEATBACK PAD
5. FORE AFT ADJUSTER KNOB 19. LUMBAR ASSEMBLY
6. MAIN POWER SWITCH 20. RECLINER LEVER RETURN
7. SIDE SHIELD MOUNT BRACKET SPRING
8. FRONT SEAT BACK ASSEMBLY 21. RECLINER LEVER SHAFT
9. CUSHION ASSEMBLY 22. SEAT BACK FRAME
10. SEAT CUSHION COVER 23. SEAT POWER HARNESS
11. SEAT CUSHION PAD 24. SEAT SLIDE ADJUSTER
12. SEAT CUSHION FRAME

INTERIOR 52A-42
FRONT SEAT ASSEMBLY

.
<<A>> HEADREST REMOVAL

1. Raise the head restraint fully.
2. Insert a probe that is suited to fit into the hole (1) in the right
hand head restraint sleeve (2) as illustrated in the figure
below.
3. Whilst the probe is inserted slightly, apply slight pressure on
the head restraint. Apply and hold pressure upwards.
4. To remove the head restraint, you must depress the sleeve
height adjuster lock (3) on the left-hand head restraint
sleeve as illustrated below.
19DB015A
<> HEADREST SLEEVE REMOVAL <<C>> SEAT BACK PANEL REMOVAL

1. To reveal upper portion of the seat back frame or AND FITMENT
active head restraint frame (1) as shown in figure 1. Move front seat to the most forward position.
below, push down on the surrounding seat cover. 2. Pull the lower edge of seat panel towards you, as
2. By using a small flat blade screwdriver, depress shown below (1).
the sleeve locking tab (2), and remove the head 3. Slide the panel downwards (2) as the top section
restaint sleeve (3) in upwards movement from the is held in by 2 locating hooks (lugs).
frame as illustrated below.
3. If required, repeat process for the remaining
FRONT
sleeve.
SEATBACK (2) Slide panel
ASSEMBLY downwards
ATTACHMENT
HOOK LOCATION
(LUG)
SEAT BACK
PANEL
CLIP (1) Pull bottom side

19DB016A
panel out
19DB017A
4. Upon fitment, be sure to firstly locate the top 2
lugs into position (2), as shown above.
5. Approximately square up panel to the seat, so by
doing this you will be able to locate the bottom 2
clips to press in the panel (1), as shown above.
INTERIOR 52A-43
FRONT SEAT TRIM COVER

REMOVAL AND FITMENT
REMOVAL
.
1. Remove seat from vehicle and cushion or seat back

assembly as required. Remove all seat plastic covers etc.
2. Unclip all the plastic retainer clips at the rear of the trim
cover. This is typical for the cushion and the back of the
seat.
CLIPS LOCATED UNDERNEATH SEAT

19DB031A
3. Peel cover away from the foam pad.

NOTE: Place a finger on the Blue Velcro strip when peeling
the cover to prevent the strip being pulled out of the foam
pad.
19DB026A
INTERIOR 52A-44
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
SEAT CUSHION PAD
19DB028A
2. Push the Velcro strips into place along all the grooves.
19DB029A
INTERIOR 52A-45
3. Pull the cover over the outside of the pad and reattach the
retaining clips where required.
Underneath seat
Seat trim
retaining clip
19DB030A
NOTE: It may be necessary to make some adjustment and

work the cover into position to remove creases. Reassemble
seat and fit to vehicle.
INTERIOR 52A-46
REAR SEAT CUSHION TRIM COVER

REMOVAL AND FITMENT
REAR SEAT CUSHION TRIM REMOVAL
.
1. Remove rear seat cushion from vehicle.

2. Release the trim cover draw string.
Draw String 19DB032A
3. Release all outer cover attachment points.
Outer Attachments
19DB033A

pad.
Blue Velcro Strip
Seat Trim Cover

19DB034A
INTERIOR 52A-47
REAR SEAT CUSHION TRIM FITMENT

.
with the grooves. Use an intersection in order toalign both
Align trim at internal

corner of pad shown here
19DB035A
2. Pull the cover around the sides of the pad.
Seat Trim
Cover
Cushion Pad
19DB036A
3. Pull trim through the seat belt slots as shown and attach to
wires
Trim Cover
Cushion Pad
Seat Belt slots 19DB037A

INTERIOR 52A-48
4. Pull draw string and attach to the centre wire as shown.
TRIM COVER AND DRAW

STRING ATTACHED TO
THESE WIRES
19DB038A
5. Reattach all outer points.
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

REMOVAL AND FITMENT
REAR SEAT BACK TRIM REMOVAL
.
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
3. Release all outer attachment points. Release all the centre

clips.
Release all clips around

arm rest hole
Release trim from

all outer attachments
19DB042A
INTERIOR 52A-50

pad.
Blue Velcro Strip
Seat Trim Cover

19DB034A
INTERIOR 52A-51
REAR SEAT BACK TRIM FITMENT

.
1. Fit the trim over the lower wire brackets.
LOWER WIRE BRACKET
19DB043A
with the grooves. Use an intersection in order to align both
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
4. Reattach the upper trim holding points including the plastic

clips.
Holding
Point
Reattach plastic
clips over wire
19DB046A
5. Attach the centre lower trim hold points.
Cushion Pad
Seat Cover
Trim
19DB047A
6. Attach the clips around the arm rest as shown.
Bring lower arm rest trim

panel through this gap
and clip to wire 19DB048A
INTERIOR 52A-53
7. Pull inner lower arm rest trim through the hole and clip to
retainer attached to the lower part of the trim cover.
Inner lower arm rest trim
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
10.Attach all the outer trim attachment points.
Outer trim attachment points

19DB051A
11.Work in all the seams, and adjust as required to remove any

creases.
19DB040A
12.Fit seat back to vehicle in reverse order of removal.

INTERIOR 52A-55
REAR SEAT ASSEMBLY
REAR SEAT ASSEMBLY

M1522001800297
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

>>B<< 1. REAR SEAT CUSHION >>A<< 2. REAR SEATBACK ASSEMBLY
ASSEMBLY 3. REAR SEAT HOOK

.
>>A<< INSTALLATION OF REAR SEATBACK

ASSEMBLY
Press the rear seatback assembly in the direction shown in the
REAR illustration and fit the attachment wire into the hook securely to
SEATBACK install the rear seatback assembly.Confirm that back is hooked
ASSEMBLY
and secured by pulling forward.
ATTACHMENT
HOOK WIRE
AC005519AG
.
INTERIOR 52A-56
REAR SEAT ASSEMBLY
>>B<< INSTALLATION OF REAR SEAT CUSHION

ASSEMBLY
1. Fit the rear seat cushion into the bracket securely.
REAR SEAT CUSHION BRACKET
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

M1522002000357
9
8
7 N
6
1N 5
4
AC306949AB

2. SEAT CUSHION COVER 6. ARMREST PAD
3. SEAT CUSHION PAD 8. SEATBACK COVER
4. ARMREST 9. SEATBACK PAD
5. BUSH
INTERIOR 52A-58
FRONT SEAT BELT
FRONT SEAT BELT

M1523001300370
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
1. EXTENDER SEAT BELT OUTER SEAT BELT REMOVAL

ASSEMBLY* STEPS (Continued)
OUTER SEAT BELT REMOVAL 4. CENTER PILLAR TRIM UPPER
STEPS (REFER TO P.52A-11.)
2. SASH GUIDE COVER 5. ADJUSTABLE SEAT BELT ANCOR
INNER SEAT BELT
• CENTER PILLAR TRIM LOWER
(REFER TO P.52A-11.) 6. SEAT BELT SWITCH
3. OUTER SEAT BELT (REFER TO CONNECTOR
GROUP 52B, SEAT BELTS WITH • SHIELD COVER (REFER TO
PRE-TENSIONER P.52B-250.) P.52A-33.)
7. INNER SEAT BELT
*
NOTE: If so equipped
INTERIOR 52A-59
REAR SEAT BELT
INSPECTION
M1523004400116
.
SEAT BELT SWITCH CONTINUITY CHECK
ITEM TESTER SPECIFIED

Fastened seat belt 1−2 Open circuit
Unfastened seat belt 1 − 2 Less than 2 ohms
19DB019A
REAR SEAT BELT

M1523001600371
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

• REAR SEAT CUSHION • REAR SHELF TRIM (REFER TO
ASSEMBLY (REFER TO P.52A-11.)
P.52A-55.) 3. OUTER SEAT BELT
1. INNER SEAT BELT 4. CENTER SEAT BELT OUTER
2. CENTER SEAT BELT INNER
INTERIOR 52A-60
SPECIFICATIONS
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
GENERAL DESCRIPTION. . . . . . . . . 52B-3 ACTUATOR TEST REFERENCE TABLE . . 52B-222
SERVICE PRECAUTIONS. . . . . . . . . 52B-16 SPECIAL TOOLS . . . . . . . . . . . . . . . . 52B-223
SRS AIR BAG DIAGNOSIS . . . . . . . . 52B-18 TEST EQUIPMENT . . . . . . . . . . . . . . . 52B-224

INTRODUCTION TO DIAGNOSIS . . . . . . . 52B-18
TROUBLESHOOTING STRATEGY . . . . . . 52B-19 SRS MAINTENANCE . . . . . . . . . . . . . 52B-224
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 52B-19
SRS WARNING LIGHT CHECK . . . . . . . . . 52B-20 POST-COLLISION DIAGNOSIS. . . . . 52B-225
DIAGNOSTIC TROUBLE CODE CHART . . 52B-21
DIAGNOSTIC TROUBLE CODE
INDIVIDUAL COMPONENT
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 52B-24 SERVICE. . . . . . . . . . . . . . . . . . . . . . . 52B-230
TROUBLE SYMPTOM CHART. . . . . . . . . . 52B-215
SYMPTOM PROCEDURES . . . . . . . . . . . . 52B-216 Continued on next page
DATA LIST REFERENCE TABLE . . . . . . . 52B-222
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
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
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.
.
GENERAL DESCRIPTION
SRS
WARNING
LAMP
35DB113A
ON-BOARD DIAGNOSTIC/SRS WARNING LIGHT

FUNCTION
The diagnosis unit monitors the SRS system and stores data
concerning any detected faults in the system. When the ignition
switch is in "ON" or "START" position, the SRS warning light
should illuminate for about seven seconds and then turn "OFF."
That indicates that the SRS system is in operational order. If
the SRS warning light does any of the following, immediate
inspection by an authorized dealer is needed:
1. The SRS warning light does not illuminate as described
above.
2. The SRS warning light stays on for more than seven
seconds.
3. The SRS warning light illuminates while driving.
If a vehicle's SRS warning light is in any of these three condi-
tions, the SRS system must be inspected, diagnosed and ser-
viced in accordance with this manual.
GENERAL DESCRIPTION
SRS
WARNING
LAMP
DRIVER'S AIR
BAG MODULE
PASSENGER'S (FRONT)
AIR BAG MODULE CLOCK
SPRING
SRS-ECU
DATA LINK CONNECTOR

SIDE-AIRBAG
(FOR SCAN TOOL)
MODULE
SIDE IMPACT
SEAT BELT WITH
SENSOR AC306796
PRE-TENSIONER
SRS-ECU
SIDE-AIRBAG
MODULE
SIDE IMPACT
SENSOR
SEAT BELT WITH

PRE-TENSIONER
FRONT IMPACT
SEAT BELT SENSOR
SWITCH
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)".
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
SRS-ECU SUN VISOR INSTUMENT PANEL
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
SEAT BELT WITH

PRE-TENSIONER
(DRIVER'S AND FRONT FRONT IMPACT SENSORS (RH AND LH) HOOD
PASSENGER'S SEATBELT) RADIATOR
M
AC306337 AC306336
L
24DB056A
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.
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.
GENERAL DESCRIPTION
SCHEMATIC
IGNITION SWITCH (IG1)

SIDE
No.22 IMPACT
No.23
7.5A 7.5A SENSOR
(LH)
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)
GENERAL DESCRIPTION
SRS AIR BAG SPECIAL CONNECTOR

To enhance the system reliability, a connector lock
switch is integrated in the SRS-ECU connector, the
air bag module connectors, the clock spring connec-
tor, the seat belt pretensioner connectors (black con-
nector "A" shown in the illustration below).
A
SEAT BELT WITH
PRE-TENSIONER
A (FRONT PASSENGER'S
SIDE)
SIDE-AIRBAG MODULE
(LH)
PASSENGER'S (FRONT)
AIR BAG MODULE
CLOCK
SRS-ECU SPRING
DRIVER'S AIR BAG MODULE
SIDE-AIRBAG MODULE
(RH)
SEAT BELT WITH

PRE-TENSIONER
(DRIVER'S SIDE)
A
AC401872 AB
.
GENERAL DESCRIPTION
SQUIB CIRCUIT CONNECTOR LOCK CAUTION

SWITCH When the connector is disconnected, there will
The switch is a mechanism that shorts the power be short circuit between the terminals. This is not
supply terminal to the ground terminal automatically a fault.
in the air bag squib circuit when the connector is dis-
connected. A "short" spring is integrated inside the
connector. This spring prevents static electricity from
flowing to the squib by shorting the power supply ter-
minal to the ground terminal (i.e. there is no potential
difference between the two terminals).
CONNECTOR CONNECTED CONNECTOR DISCONNECTED

OFF OFF
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
PARTITION SHORT SHORT SPRING

PANEL SPRING
AC006197 AG
GENERAL DESCRIPTION
CONFIGURATION DIAGRAMS
INSTRUMENT PANEL
WIRING HARNESS
DASH PANEL 4 FLOOR AND ROOF

C-110
ROOF
WIRING Y
HARNESS
FLOOR
WIRING
HARNESS
5 D-32 D-24
2
Y
FLOOR WIRING
HARNESS
15
C-121 D-26 D-27

37DB228A 37DB232A
STEERING COLUMN
ENGINE ROOM
A-23
A-27 AC304363
AC304353 C-307
C-305
FLOOR AND ROOF
D-20
D-21
D-24
D-35
D-33
AC304366 D-32
52DB002A
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.
GENERAL DESCRIPTION
COMPONENT LOCATION
SIDE IMPACT SENSOR

CENTER
PILLER
SIDE IMPACT
SENSOR
AC305250
AC306289
FRONT IMPACT SENSOR

FRONT IMPACT
SENSOR
AC305035
52DB003A
GENERAL DESCRIPTION
SRS-ECU DATA LINK CONNECTOR
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.
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]
.
SERVICE PRECAUTIONS
SRS-ECU TERMINAL DESTINATION OF HARNESS CORRECTIVE ACTION

NO.
7, 8 Floor wiring harness → Seat belt Replace the floor wiring harness.
pre-tensioner (LH)
9*, 10* Floor wiring harness → Side-airbag Replace the floor wiring harness.
module (LH)
19*, 20* Floor wiring harness → Side impact Replace the floor wiring harness.
sensor (LH)
23 Floor wiring harness → Instrument Replace each wiring harness.
panel wiring harness → Junction block
(fuse No.18)
24 Floor wiring harness → Instrument Replace each wiring harness.
panel wiring harness → Junction block
(fuse No.19)
27, 28 Floor wiring harness → Instrument Replace each wiring harness.
panel wiring harness → Clock spring →
Air bag module (Driver's side) <1st
squib side>
32 Can line (H) Correct or replace can line.
36, 37 Floor wiring harness → Instrument Replace each wiring harness. Replace
panel wiring harness → Air bag module the clock spring.
(Front passenger’s side) <1st squib
side>
panel wiring harness → Front wiring
harness → Front impact sensor (RH)
43 Can line (L) Correct or replace can line.
46 Floor wiring harness → Ground Replace the floor wiring harness.
panel wiring harness → Front impact
sensor (LH)
57*, 58* Floor wiring harness → Side-airbag Replace the floor wiring harness.
module (RH)
59, 60 Floor wiring harness → Seat belt Replace the floor wiring harness.
pre-tensioner (RH)
63*, 64* Floor wiring harness → Side impact Replace the floor wiring harness.
sensor (RH)
NOTE: *Vehicles with side-airbags
.
SRS AIR BAG DIAGNOSIS
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.

INTRODUCTION TO DIAGNOSIS
M1524005000330
The SRS system is controlled by the SRS-ECU. The • The SRS warning light does not go off within
SRS-ECU judges how severe a collision is by detect- approximately seven seconds after the ignition
ing signals from the left and right front impact sen- switch has been turned to the "ON" position.
sors and side impact sensors, front air bag analog • The SRS warning light does not illuminate when
G-sensor and front air bag safing G-sensor and the ignition switch is turned to the "ON" position.
side-airbag safing G-sensor. If the impact is over a Refer to Post-collision Diagnosis when inspecting
predetermined level, the SRS-ECU sends an ignition and servicing a vehicle that has been in a collision
signal. At this time, if the safing G-sensor is on, the (Refer to P.52B-225).
SRS air bag will inflate. The SRS warning light in the
combination meter alerts a malfunction of the SRS
system. If the following symptoms occur even when
the vehicle has not been in a collision, there may be
a malfunction in the SRS system.
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

(MUT-III)
• MB991958: diagnostic tool (MUT-III Sub Assembly)
CAUTION
MB991958.
position.
position.
NOTE: When special tool MB991824 is energised, special
color.
MB991827 NOTE: Disconnecting diagnostic tool MB991958 is the reverse
00DB076A
of the connecting sequence, making sure that the ignition

TROUBLE CODES
CAUTION
MB991958.
not be set. Check the battery if diagnostic tool MB991958 does
not display.
connector.
MB991910
5. Choose "SRS-AIR BAG".
MB991827 00DB076A
SRS WARNING LIGHT CHECK

M1524004300361
1. Check that the SRS warning light illuminates when the
ignition switch is in the "ON" position.
2. Check that it illuminates for approximately seven seconds
and then goes out.
3. If not, check for DTC.

M1524003300777
CAUTION
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

TROUBLE CODE
NO.
B1424*5 Side-airbag squib (RH) drive circuit shorted P.52B-173
B1425*5 Side-airbag squib (RH) drive circuit open P.52B-173
B1426*5 G-sensor of side impact sensor (RH) failure P.52B-112
B1427*3 Side impact sensor (RH) voltage error P.52B-114
B1428*3 Side impact sensor (RH) communication error P.52B-118
B1429*3 Side impact sensor (RH) communication impossible P.52B-118
B1430*3 Side-airbag squib (LH) short-circuited P.52B-122
B1431*3 Side-airbag squib (LH) open-circuited P.52B-129
B1432*3 Side-airbag squib (LH) drive circuit (ground side) shorted P.52B-134
B1433*3 Side-airbag squib (LH) drive circuit (power supply side) P.52B-139
shorted
B1434*5 Side-airbag squib (LH) drive circuit shorted P.52B-173
B1435*5 Side-airbag squib (LH) drive circuit open P.52B-173
B1436*5 G-sensor of side impact sensor (LH) failure P.52B-112
B1437*3 Side impact sensor (LH) voltage error P.52B-144
B1438*3 Side impact sensor (LH) communication error P.52B-148
B1439*3 Side impact sensor (LH) communication impossible P.52B-148
B1460*3 Seat belt pre-tensioner P.52B-152
(RH) squib short-circuited
(RH) squib open-circuited
(RH) squib drive circuit (ground side) short-circuited
(RH) squib drive circuit (power supply side) short-circuited
(RH) (squib ignition drive circuit) system detected short
(RH) (squib ignition drive circuit) system detected open
B1466*5 Analog G-sensor malfunction P.52B-173
B1467*5 Safing G-sensor open-circuited (for frontal collision) P.52B-173
B1468*5 Safing G-sensor short-circuited (for frontal collision) P.52B-173
B1469*5 Safing G-sensor malfunction (for side collision) P.52B-173
(LH) squib short-circuited
(LH) squib open-circuited

TROUBLE CODE
NO.
(LH) squib (ground side) short-circuited
(LH) squib (power supply side) short-circuited
(LH) (squib ignition drive circuit) system detected short
(LH) (squib ignition drive circuit) system detected open
B1476*2 Power supply voltage (IG1 (A) voltage) drops abnormally. P.52B-197
B1477*2 Power supply voltage (IG1 (B) voltage) drops abnormally. P.52B-197
B1478*5 SRS-ECU capacitor circuit voltage too high P.52B-173
B1479*5 SRS-ECU capacitor circuit voltage too low P.52B-173
B1496*5 SRS-ECU non-volatile memory (EEPROM) P.52B-173
B1497*5 SRS-ECU ASIC (for frontal activation) P.52B-173
B1498*5 SRS-ECU ROM or RAM P.52B-173
B1499*5 Collision decision P.52B-204
B1509*2 Incorrect SRS-ECU P.52B-205
B1519*3 SRS-ECU connector lock out of order P.52B-207
B1547*4*5 Cut OFF for passenger’s front air bag P.52B-210
B1552*5 Changing circuit shorted P.52B-173
B1553*5 Changing circuit open P.52B-173
B1554*5 SG BY-PASS circuit malfunction P.52B-173
B1555*5 SG BY-PASS circuit (FET) open P.52B-173
B1557*5 SRS-ECU ASIC P.52B-173
U1073*2 Bus-off P.52B-213
NOTE: *1: Electrically Erasable Programmable ROM
*2
: This DTC will remain in memory and the SRS warning light will be switched off when the system returns to
normal condition.
*3
: This DTC will remain in memory and the SRS warning light will be switched on even if the system returns
to normal condition.
*4
: This DTC will remain in memory when the front passenger's air bag is inactive condition in the event of an
impact.
*5: This DTC cannot be erased by "Erase DTCs" function.
DTC B1400: Driver’s Air Bag Module (1st Squib) System Fault 1 (Short Circuit between Terminals of
the Squib Circuit)
CONNECTOR: C-121 CONNECTORS: C-305, C-307

SRS-ECU CLOCK
SPRING
C-121 (Y)
C-121
INSTRUMENT C-307 (Y)
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26 C-305 (Y)
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 24DB062A 52DB006A
CAUTION However, if no DTC reset, the SRS warning light will

If DTC B1400 or B1480 <2nd squib> is set in the be turned off (DTC will OK).
combination meter, always diagnose the CAN .
bus lines. TROUBLESHOOTING HINTS

.
CIRCUIT OPERATION
• 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. .
NOTE: *: The squib circuit connectors integrate a

.
"short" spring (which prevents the air bag from
DTC SET CONDITIONS deploying unintentionally due to static electricity by
• This DTC is set if there is abnormal resistance shorting the positive wire to the ground wire in the
between the input terminals of the driver's side air squib circuit when the connectors are disconnected)
bag module (squib). The most likely causes for (Refer to P.52B-3). Therefore, if connector C-121, ,
this code to be set are the followings: C-307 or C-305 is damaged or improperly engaged,
• Short circuit in driver’s air bag module (squib) the short spring may not be released when the con-
or harness nector is connected.
• Short circuit in the clock spring
.
DIAGNOSIS
• MB991865: Dummy resistor
• MB991866: Resistor harness

CAN bus line.
CAUTION
MB991958.
(1) Connect diagnostic tool MB991958. Refer to "How to
connect the diagnostic tool P.52B-19."
MB991910
MB991824
YES : Go to Step 2.
Diagnosis ).
MB991827 00DB076A

CONNECTOR (2) Turn the ignition switch to "ON" position.
Q: Is the DTC set?
YES : Go to Step 3.
NO : There is an intermittent malfunction such as poor
MB991910 engaged connector(s) or open circuit (Refer to
MB991824
Malfunctions ).
MB991827 00DB076A

CAUTION
MB991958.
(3) Turn the ignition switch to the "LOOK (OFF)" position.
Q: Is DTC B1519 set?
NO : Go to Step 5.
MB991824
MB991827 00DB076A
STEP 4. Check SRS-ECU connector C-121.

Q: Is the connector correctly engaged?
CONNECTOR: C-121
YES : Go to Step 5.
SRS-ECU
NO : Engage the connector correctly. Then go to Step 10.
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
STEP 5. Check SRS-ECU connector C-121, clock spring

connector C-307 and driver’s air bag module connector
C-305. (Using diagnostic tool MB991958, read the
diagnostic trouble code.)
(1) Disconnect the negative battery terminal.
(2) Disconnect connectors C-121, C-307 and C-305, and then
CONNECTOR: C-121 reconnect them.
SRS-ECU (3) Connect the negative battery terminal.
(4) Erase the diagnostic trouble code memory, and check the
C-121 (Y) diagnostic trouble code.
C-121
INSTRUMENT Q: Is DTC B1400 set?
CONNECTOR
(REAR VIEW)
NO : The procedure is complete. It is assumed that DTC
21 2223 B A 24 25 26 B1400 set because connector C-121, C-307 or C-305
27 28 29 30 31 32 33 34 35 36 37
was engaged improperly.
38 39 40 41 42 43 44 45 46 47 48 24DB062A

CLOCK
C-305 HARNESS
SPRING
SIDE CONNECTOR
C-307 (Y)
C-307 HARNESS
SIDE CONNECTOR
C-305 (Y) 14 13 12 11
52DB007A
STEP 6. Check the driver's air bag module. (Using

diagnostic tool MB991958, read the diagnostic trouble
code.)
(2) Slide the outer housing of the clock spring side of driver’s
OUTER HOUSING OF THE DRIVER'S air bag module connector C-305 in the arrow direction
AIR BAG MODULE CONNECTOR C-305
shown, and disconnect the connector.
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
YES : Go to Step 7.
NO : Replace the driver's air bag module (Refer to
STEP 7. Check the clock spring. (Using diagnostic tool

MB991958, read the diagnostic trouble code.)
CONNECTOR: C-307
(2) Disconnect the clock spring connector C-307.
CLOCK
SPRING
C-307 (Y) C-307 HARNESS

SIDE CONNECTOR
14 13 12 11
52DB008A
CAUTION
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.
1112 1314 C-307 CLOCK SPRING (6) Erase the diagnostic trouble code memory, and check the
(REAR VIEW) CONNECTOR AC306767 AB diagnostic trouble code.
YES : Go to Step 8.
NO : Replace the clock spring (Refer to P.52B-237). Then
go to Step 10.
STEP 8. Check the driver’s air bag module circuit. Measure

the resistance at SRS-ECU connector C-121.
CONNECTOR: C-121
(1) Disconnect SRS-ECU 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
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.

SIDE CONNECTOR
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
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)
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
STEP 9. Check the harness for short circuit between

SRS-ECU connector C-121 (terminal No.28 and 27 ) and
clock spring connector C-307 (terminal No.13 and 14 ).
Q: Are harness wires between SRS-ECU connector C-121
CONNECTOR: C-121
(terminal No.28 and 27 ) and clock spring connector
SRS-ECU C-307 (terminal No.13 and 14 ) in good condition?
C-121 (Y) YES : Go to Step 10.
C-121 NO : Replace the harness wires between SRS-ECU
INSTRUMENT connector C-121 and clock spring connector C-307.
HARNESS Then go to Step 10.
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
CONNECTOR: C-307
CLOCK
SPRING

SIDE CONNECTOR
14 13 12 11
52DB008A

MB991910
MB991824
MB991827 00DB076A
DTC B1401: Driver's Air Bag Module (1st Squib) System Fault 2 (Open in the Squib Circuit)

SRS-ECU CLOCK
SPRING
C-121 (Y)
C-121
INSTRUMENT
C-307 (Y)
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
C-305 (Y)
38 39 40 41 42 43 44 45 46 47 48 24DB062A 52DB006A
CAUTION • Open circuit in the driver's air bag module

If DTC B1401 is set in the SRS-ECU, always diag- (squib) or harness
nose the CAN main bus line. • Open circuit in the clock spring
. • Malfunction of connector contact
CIRCUIT OPERATION However, if no DTC reset, the SRS warning light will
• The SRS-ECU judges how severe a collision is be switched off (DTC will be retained).
by detecting signals from the front impact sensors .
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
Communication System)

CAN bus line.
CAUTION
MB991958.
DATA LINK connect the diagnostic tool P.52B-19."
YES : Go to Step 2.
MB991910 Diagnosis ).
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
(2) Slide the outer housing of the driver’ s air bag module
OUTER HOUSING OF THE DRIVER'S connector C-305 in the arrow direction shown, and
disconnect the connector.
AC306561AC
CAUTION
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
YES : Go to Step 4.

CONNECTOR: C-307
CLOCK
SPRING

SIDE CONNECTOR
14 13 12 11
52DB008A
CAUTION
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
YES : Go to Step 5.
go to Step 6.
STEP 5. Check the harness between the SRS-ECU

connector C-121 (terminal No.28 and 27) and the clock
spring connector C-307 (terminal No.13 and 14) for open
circuit.
CONNECTOR: C-121
(1) Disconnect SRS-ECU connector C-121 and clock spring
connector C-307.
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 (2) 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
38 39 40 41 42 43 44 45 46 47 48 24DB062A
• SRS-ECU connector C-121 (terminal No.28) and the
CONNECTOR: C-307
clock spring connector C-307 (terminal No.13)
CLOCK
SPRING clock spring connector C-307 (terminal No.14)
YES : Erase the diagnostic trouble code memory, and check
C-307 (Y) C-307 HARNESS the diagnostic trouble code. If DTC B1401 set,
SIDE CONNECTOR replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 6.
14 13 12 11
NO : Replace the harness wires between SRS-ECU
52DB008A connector C-121 and clock spring connector C-307.
Then go to Step 6.

MB991910
MB991824
MB991827 00DB076A
DTC B1402: Driver's Air Bag Module (1st Squib) System Fault for Power Supply Circuit
(Short-Circuited to Power Supply)

SRS-ECU CLOCK
SPRING
C-121 (Y)
C-121
INSTRUMENT
C-307 (Y)
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
C-305 (Y)
38 39 40 41 42 43 44 45 46 47 48 24DB062A 52DB006A

If DTC B1402 is set in the SRS-ECU, always diag- This DTC is set if there is abnormal resistance
nose the CAN main bus line. between the input terminals of the driver's air bag
.
module (squib). However, if no DTC resets, the SRS
CIRCUIT OPERATION warning light will be switched off (DTC will be
• The SRS-ECU judges how severe a collision is retained).
by detecting signals from the front impact sensors
.
impact is over a predetermined level, the
SRS-ECU sends an ignition signal. At this time, if
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

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
AC306561AC
CAUTION
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
YES : Go to Step 4.
NO : Replace the driver’s air bag module (Refer to

CONNECTOR: C-307
CLOCK
SPRING

SIDE CONNECTOR
14 13 12 11
52DB008A
CAUTION
weakened.
YES : Go to Step 5.
go to Step 7.

the voltage at the SRS-ECU connector C-121.
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
DANGER
CONNECTOR: C-307
disconnect the clock spring connector C-307 to short
CLOCK
SPRING the squib circuit.
C-307 (Y) C-307 HARNESS CAUTION
SIDE CONNECTOR Do not insert a test probe into the terminal from its front
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.
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.
STEP 6. Check the harness for short circuit to power

supply between SRS-ECU connector C-121 (terminal No.28
and 27 ) and clock spring connector C-307 (terminal No.13
and 14).
CONNECTOR: C-121
Q: Are harness wires between the SRS-ECU connector
C-121 (terminal No.28 and 27 ) and clock spring
SRS-ECU
connector C-307 (terminal No.13 and 14) in good
C-121 (Y) condition?
C-121 YES : Go to Step 7.
INSTRUMENT NO : Replace the harness wires between SRS-ECU
HARNESS
CONNECTOR connector C-121 and clock spring connector C-307.
(REAR VIEW) Then go to Step 7.
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
CONNECTOR: C-307
CLOCK
SPRING

SIDE CONNECTOR
14 13 12 11
52DB008A

MB991910
MB991824
MB991827 00DB076A
DTC 1403: Driver’s Air Bag Module (1st Squib) System Fault for Ground Circuit (Short-Circuited to
Ground)

SRS-ECU CLOCK
SPRING
C-121 (Y)
C-121
INSTRUMENT
C-307 (Y)
HARNESS
CONNECTOR
(REAR VIEW)
21 2223 B A 24 25 26
27 28 29 30 31 32 33 34 35 36 37
C-305 (Y)
38 39 40 41 42 43 44 45 46 47 48 24DB062A 52DB006A

nose the CAN main bus line. between the input terminals of the driver's air bag
.
module (squib). However, if no DTC resets, the SRS
CIRCUIT OPERATION warning light will be switched off (DTC will be
.
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
.
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
AC306561AC
CAUTION
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
YES : Go to Step 4.

CONNECTOR: C-307
CLOCK
SPRING

SIDE CONNECTOR
14 13 12 11
52DB008A
CAUTION
weakened.
YES : Go to Step 5.
go to Step 7.

the resistance at the SRS-ECU connector C-121.
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
DANGER
CONNECTOR: C-307
disconnect the clock spring connector C-307 to short
CLOCK
SPRING the squib circuit.
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
52DB008A terminals 28 and 27 and body ground.
It should be open circuit.
to Step 6.
NO : Go to Step 7.

between SRS-ECU connector C-121 (terminal No.28 and 27
) and clock spring connector C-307 (terminal No.13 and
14).
CONNECTOR: C-121
Q: Are the harness wires between SRS-ECU connector
C-121 (terminal No.28 and 27 ) and clock spring
SRS-ECU
connector C-307 (terminal No.13 and 14) in good
C-121 YES : Go to Step 7.
INSTRUMENT NO : Replace the harness wires between SRS-ECU
HARNESS
CONNECTOR connector C-121 and clock spring connector C-307.
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
CONNECTOR: C-307
CLOCK
SPRING

SIDE CONNECTOR
14 13 12 11
52DB008A

MB991910
MB991824
MB991827 00DB076A
DTC B1406: Front Impact Sensor (RH) System for Fault 1 DTC B1416: Front Impact Sensor (LH)
System for Fault 1
CAUTION • Analog G-sensor output is abnormal.

If DTC B1406 or B1416 is set in the SRS-ECU, .
always diagnose the CAN main bus line. TROUBLESHOOTING HINTS

.
Malfunction of front impact sensor (RH) (for DTC

DTC SET CONDITIONS B1406) and front impact sensor (LH) (for DTC
These DTCs are set if the following conditions are B1416)
detected from the analog G-sensor inside the front • Refer to circuit diagrams GROUP-90
impact sensor output: • Refer to configuration diagrams GROUP-80
• Analog G-sensor is not operating.
• Analog G-sensor characteristics are abnormal.
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A
STEP 3. Check the front impact sensor. (Using diagnostic

tool MB991958, read the diagnostic trouble code.)
Replace front impact sensor (RH) and front impact sensor (LH)
(for DTC B1416) (Refer to P.52B-231).
Check the diagnostic trouble code.
Q: Is either DTC B1406 or B1416 set?
YES : Replace the SRS-ECU (Refer to P.52B-234).
DTC B1407: Front Impact Sensor (RH) Power Supply Circuit System
CONNECTOR: A-27 CONNECTOR: C-121

SRS-ECU
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

If DTC B1407 is set in the SRS-ECU, always diag- This DTC will set when the power supply voltage to
nose the CAN main bus line. the front impact sensor (RH) remains less than a pre-
.
CIRCUIT OPERATION determined value for five seconds. However, if the

system returns to normal condition, code number
The front impact sensor includes an analog G sensor
B1407 will be erased automatically and the SRS
and CPU, etc. The CPU monitors the analog G sen-
warning light will go out.
sor output signal. If the CPU judges that the front air
bags should be deployed, it sends a fire signal to the .
SRS-ECU to deploy the front air bags. In addition, TROUBLESHOOTING HINTS

the CPU diagnoses the internal components of the • Damaged wiring harness or connectors
front impact sensor. If a malfunction occurs, it • Malfunction of the front impact sensor (RH)
requests the SRS-ECU to set a diagnostic trouble • Malfunction of the SRS-ECU
code. • Refer to circuit diagrams GROUP-90
.
DIAGNOSIS
• MB991223 (MB991222): Harness set (Probe)

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A
STEP 3. Check the front impact sensor (RH) power supply

circuit. Measure the voltage at the front impact sensor (RH)
connector A-27.
CONNECTOR: A-27 (2) Disconnect front impact sensor (RH) connector A-27, and
measure at the wiring harness side.
A-27 (Y)
HARNESS SIDE
AC305206BA
CAUTION
A-27 HARNESS SIDE weakened.
CONNECTOR
(5) Measure the voltage between A-27 harness side connector
(REAR VIEW)
Voltage should measure 9 volts or more
YES : Replace the front impact sensor (RH) (Refer to
AC308161AB
NO : Go to Step 4.
STEP 4. Check the harness wires for open circuit or short

circuit between SRS-ECU connector C-121 (terminal No.38
and 39) and front impact sensor (RH) connector A-27
(terminal No.1 and 2).
CONNECTOR: C-121
C-121 (terminal No.38 and 39) and front impact sensor
SRS-ECU
(RH) connector A-27 (terminal No.1 and 2) in good
C-121 YES : Erase the diagnostic trouble code memory, and check
INSTRUMENT the diagnostic trouble code. If DTC B1407 sets,
HARNESS
CONNECTOR replace the SRS-ECU (Refer to P.52B-234). Then go
(REAR VIEW) to Step 5.
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 connector C-121 and front impact sensor (RH)
connector A-27. Then go to Step 5.
CONNECTOR: A-27
A-27 (Y)
HARNESS SIDE
AC305206BA

MB991910
MB991824
MB991827 00DB076A
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
.

If DTC B1408 or B1409 is set in the SRS-ECU, These DTCs are set if communication between the
always diagnose the CAN main bus line.
.
front impact sensor (RH) and the SRS-ECU is not
CIRCUIT OPERATION possible or faulty.
The front impact sensor includes an analog G sensor .
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

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A
STEP 3. Check for any diagnostic trouble code. (Using

code.)
Check the front impact sensor (RH).
(2) Replace the front impact sensor (RH) with the front impact
sensor (LH).
(4) Erase diagnostic trouble code from memory, and check the
DATA LINK diagnostic trouble code.
CONNECTOR
Q: Is DTC B1418 or B1419 set?
YES : Replace the front impact sensor (RH) with a new one
(Refer to P.52B-247). Then go to Step 5.
NO : Go to Step 4.
MB991910
MB991824
MB991827 00DB076A

and 39) and front impact sensor (RH) connector A-27
CONNECTOR: C-121
SRS-ECU
(RH) connector A-27 (terminal No.1 and 2) in good
INSTRUMENT the diagnostic trouble code. If DTC B1408 or B1409
HARNESS
CONNECTOR sets, replace the SRS-ECU (Refer to P.52B-234).
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 connector C-121 and front impact sensor (RH)
CONNECTOR: A-27
A-27 (Y)
HARNESS SIDE
AC305206BA

MB991910
MB991824
MB991827 00DB076A
DTC B1410: Passenger’s (Front) Air Bag Module (1st Squib) System Fault 1 (Short Circuit between
Terminals of the Squib Circuit)

SRS-ECU
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
52DB017A CROSSMEMBER 38 39 40 41 42 43 44 45 46 47 48 24DB062A
CAUTION TROUBLESHOOTING HINTS

If DTC B1410 is set in the SRS-ECU, always diag- • Improper engaged connector or defective short
nose the CAN main bus line. spring*
• Short circuit between the passenger's air bag
.
CIRCUIT OPERATION
module (squib) circuit terminals
• The SRS-ECU judges how severe a collision is
• Damaged connector(s)
and the front air bag analog G-sensor. If the
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)
.
DTC SET CONDITIONS

(Refer to P.52B-3). Therefore, if connector C-121, or
This DTC is set if there is abnormal resistance C-110 is damaged or improperly engaged, the short
between the input terminals of the passenger's side spring may not be released when the connector is
air bag module (squib). However, if no DTC reset, connected.
the SRS warning light will be switched off (DTC will
be retained).
.
DIAGNOSIS
• MB991865: Dummy resister

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

CAUTION
MB991958.
NO : Go to Step 5.
MB991824
MB991827 00DB076A
STEP 4. Check SRS-ECU connector C-121.

CONNECTOR: C-121
YES : Go to Step 5.
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
STEP 5. Check SRS-ECU connector C-121 and passenger’s

air bag module connector C-110. (Using diagnostic tool
CONNECTOR: C-110 (2) Disconnect connectors C-121 and C-110, and then
reconnect them.
HARNESS SIDE
CONNECTOR
(REAR VIEW)
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
air bag module connector C-110 in the arrow direction
OUTER HOUSING OF THE PASSENGER'S shown, and disconnect the connector.
(5) Erase the diagnostic trouble code memory, and check the
YES : Go to Step 6.
B1410 set as connector C-121 or C-110 was
AC306561AD engaged improperly.
STEP 6. Check the passenger's air bag module. (Using

code.)
CONNECTOR: C-110 (2) Disconnect the passenger’s air bag module connector
C-110.
HARNESS SIDE
CONNECTOR
(REAR VIEW)
C-110 (Y)
FRONT DECK
(3) Slide the outer housing of the clock spring side of

OUTER HOUSING OF THE PASSENGER'S passenger’s air bag module connector C-110 in the arrow
direction shown, and disconnect the connector.
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
weakened.
MB991866 (5) Insert special tool MB991866 into the harness side
(RESISTOR HARNESS)
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
STEP 7. Check the passenger’s air bag module circuit at

SRS-ECU connector C-121.
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
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
OUTER HOUSING OF THE PASSENGER'S air bag module connector C-110 in the arrow direction
shown, and disconnect the connector.
AC306561AD
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)
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
SHORT SPRING
4 mm OR MORE AC308142AB
weakened.
<2ND SQUIB> terminals 37 and 36 .
C-121 HARNESS SIDE
CONNECTOR
(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
STEP 8. Check the harness for short circuit between

SRS-ECU connector C-121 (terminal No.37 and 36 ) and
passenger's air bag module connector C-110 (terminal
No.1 and 2 ).
CONNECTOR: C-110 Q: Are harness wires between SRS-ECU connector C-121
(terminal No.37 and 36 ) and passenger's air bag module
HARNESS SIDE connector C-110 (terminal No.1 and 2 ) in good
CONNECTOR
(REAR VIEW)
condition?
YES : Go to Step 9.
C-110 (Y) NO : Replace the harness wires between SRS-ECU
connector C-121 and passenger’s air bag module
connector C-110. Then go to Step 9.
FRONT DECK
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
STEP 9. Check for diagnostic trouble code.

MB991910
MB991824
MB991827 00DB076A
DTC B1411: Passenger’s (Front) Air Bag Module (1st Squib) System Fault 2 (Open in the Squib
Circuit)

SRS-ECU
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

nose the CAN main bus line. between the input terminals of the passenger’s air
.
bag module (squib). However, if no DTC reset, the
CIRCUIT OPERATION SRS warning light will be switched off (DTC will be
.
and the front air bag analog G-sensor. If the

impact is over a predetermined level, the TROUBLESHOOTING HINTS
SRS-ECU sends an ignition signal. At this time, if • Open circuit in the passenger's air bag module
the front air bag safing G-sensor is on, the SRS (squib) circuit
air bag will inflate. • Improper connector contact
• The ignition signal is input to the air bag module • Malfunction of the SRS-ECU
via the clock spring to inflate the air bag. • Refer to circuit diagrams GROUP-90
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
C-110.
HARNESS SIDE
CONNECTOR
(REAR VIEW)
C-110 (Y)
FRONT DECK

AC306561AD
RESISTOR: 3 Ω)
CAUTION
CONNECTOR
weakened.
(RESISTOR HARNESS)
PASSENGER'S
YES : Go to Step 4.

SRS-ECU connector C-121 (terminal No.37 and 36) and the
passenger's air bag module connector C-110 (terminal
No.1 and 2).
CONNECTOR: C-110 (1) Unclip passenger’s air bag module connector C-110.
HARNESS SIDE
CONNECTOR
(REAR VIEW)
C-110 (Y)
FRONT DECK
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)
passenger’s air bag module connector C-110 (terminal
No.2)

the diagnostic trouble code. If DTC B1411 set, replace
the SRS-ECU (Refer to P.52B-234). Then go to Step
5.
connector C-121 and passenger’s air bag module

MB991910
MB991824
MB991827 00DB076A
DTC B1412: Passenger’s (Front) Air Bag Module (1st Squib) System Fault for Power Supply Circuit
(Short-Circuited to Power Supply)

SRS-ECU
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

nose the CAN main bus line. between the input terminals of the passenger's air
.
CIRCUIT OPERATION bag module (squib). However, if no DTC resets, the

SRS warning light will be switched off (DTC will be
retained).
and the front air bag analog G-sensor. If the .

SRS-ECU sends an ignition signal. At this time, if • Damaged harness wires and connectors
the front air bag safing G-sensor is on, the SRS • Short to the power supply in the passenger's air
air bag will inflate. bag module (squib) harness
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
C-110.
HARNESS SIDE
CONNECTOR
(REAR VIEW)
C-110 (Y)
FRONT DECK

AC306561AD
RESISTOR: 3 Ω)
CAUTION
CONNECTOR
weakened.
(RESISTOR HARNESS)
connector C-110 (terminal No.1 and 2) by testprobe.
PASSENGER'S
YES : Go to Step 4.
STEP 4. Check the passenger’s air bag module circuit.

Measure the voltage at the SRS-ECU connector C-121.
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
DANGER
HARNESS SIDE
CONNECTOR
(REAR VIEW) (2) Disconnect the passenger's air bag module connector
C-110.
C-110 (Y)
FRONT DECK

CAUTION
weakened.
(5) Measure the voltage between C-121 harness side
AC306561AD connector terminals 37 and 36 and body ground.
Voltage should measure 0 volt.
to Step 6.
NO : Go to Step 5.
STEP 5. Check the harness wires for short circuit to power

supply between SRS-ECU connector C-121 (terminal No.37
and 36) and passenger's air bag module connector C-110
CONNECTOR: C-110 Q: Are the harness wires between SRS-ECU connector
C-121 (terminal No.37 and 36) and passenger's air bag
HARNESS SIDE module connector C-110 (terminal No.1 and 2) in good
CONNECTOR
(REAR VIEW)
condition?
YES : Go to Step 6.
connector C-121 and passenger's air bag module
FRONT DECK
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

MB991910
MB991824
MB991827 00DB076A
DTC B1413: Passenger’s (Front) Air Bag Module (1st Squib) System Fault for Ground Circuit
(Short-Circuited to Ground)

SRS-ECU
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

nose the CAN main bus line. between the input terminals of the passenger's air
.
CIRCUIT OPERATION bag module (squib). However, if no DTC resets, the

SRS warning light will be switched off (DTC will be
retained).
and the front air bag analog G-sensor. If the .

SRS-ECU sends an ignition signal. At this time, if • Damaged harness wires and connectors
the front air bag safing G-sensor is on, the SRS • Short to the ground in the passenger's air bag
air bag will inflate. module (squib) harness
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
C-110.
HARNESS SIDE
CONNECTOR
(REAR VIEW)
C-110 (Y)
FRONT DECK

AC306561AD
RESISTOR: 3 Ω)
CAUTION
CONNECTOR
weakened.
(RESISTOR HARNESS)
connector C-110 (terminal No.1 and 2) by testprobe.
PASSENGER'S
YES : Go to Step 4.
STEP 4. Check the passenger's air bag module circuit.

Measure the resistance at the SRS-ECU connector C-121.
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
DANGER
HARNESS SIDE
CONNECTOR
(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
FRONT DECK side directly, as the connector contact pressure may be
52DB018A CROSSMEMBER weakened.
terminals 37 and 36, and body ground.
YES : Go to Step 5.
NO : Erase the diagnostic trouble code memory, and check
to Step 6.
STEP 5. Check the harness wires for short circuit to

ground between SRS-ECU connector C-121 (terminal
No.37 and 36) and passenger's air bag module connector
C-110 (terminal No.1 and 2).
CONNECTOR: C-110 Q: Are the harness wires between SRS-ECU connector
C-121 (terminal No.37 and 36) and passenger's air bag
HARNESS SIDE module connector C-110 (terminal No.1 and 2) in good
CONNECTOR
(REAR VIEW)
condition?
YES : Go to Step 6.
connector C-121 and passenger's air bag module
FRONT DECK
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

MB991910
MB991824
MB991827 00DB076A
DTC B1417: Front Impact Sensor (LH) Power Supply Circuit System

SRS-ECU
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

nose the CAN main bus line. the front impact sensor (LH) remains less than a pre-
.
CIRCUIT OPERATION determined value for five seconds. However, if the

system returns to normal condition, code number
The front impact sensor includes an analog G sensor
B1417 will be erased automatically and the SRS
and CPU, etc. The CPU monitors the analog G sen-
warning light will go out.
sor output signal. If the CPU judges that the front air
bags should be deployed, it sends a fire signal to the .
SRS-ECU to deploy the front air bags. In addition, TROUBLESHOOTING HINTS

the CPU diagnoses the internal components of the • Damaged wiring harness or connectors
front impact sensor. If a malfunction occurs, it • Malfunction of the front impact sensor (LH)
requests the SRS-ECU to set a diagnostic trouble • Malfunction of the SRS-ECU
code. • Refer to circuit diagrams GROUP-90
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A
STEP 3. Check the front impact sensor (LH) power supply

circuit. Measure the voltage at the front impact sensor (LH)
connector A-23.
CONNECTOR: A-23 (2) Disconnect front impact sensor (LH) connector A-23, and
measure at the wiring harness side.
HARNESS SIDE
A-23 (Y)
AC305210 AT
CAUTION
A-23 HARNESS SIDE weakened.
CONNECTOR
(5) Measure the voltage between A-23 harness side connector
(REAR VIEW)
Voltage should measure 9 volts or more
YES : Replace the front impact sensor (LH) (Refer to
AC308161AC
NO : Go to Step 4.

and 47) and front impact sensor (LH) connector A-23
CONNECTOR: C-121
SRS-ECU
(LH) connector A-23 (terminal No.1 and 2) in good
INSTRUMENT the diagnostic trouble code. If DTC B1417 sets,
HARNESS
(REAR VIEW) to Step 5.
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 connector C-121 and front impact sensor (LH)
CONNECTOR: A-23
HARNESS SIDE
A-23 (Y)
AC305210 AT

MB991910
MB991824
MB991827 00DB076A
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
.

always diagnose the CAN main bus line.
.
front impact sensor (LH) and the SRS-ECU is not
The front impact sensor includes an analog G sensor .
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

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
Check the front impact sensor (LH).
(2) Replace the front impact sensor (LH) with the front impact
sensor (RH).
CONNECTOR
YES : Replace the front impact sensor (LH) with a new one
NO : Go to Step 4.
MB991910
MB991824
MB991827 00DB076A

and 47) and front impact sensor (LH) connector A-23
CONNECTOR: C-121
SRS-ECU
(LH) connector A-23 (terminal No.1 and 2) in good
INSTRUMENT the diagnostic trouble code. If DTC B1418 or B1419
HARNESS
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 connector C-121 and front impact sensor (LH)
CONNECTOR: A-23
HARNESS SIDE
A-23 (Y)
AC305210 AT

MB991910
MB991824
MB991827 00DB076A
DTC B1420: Side-Airbag Module (RH) (Squib) System Fault 1 (Short Circuit between Terminals of the
Squib Circuit)
CONNECTOR: D-26 CONNECTOR : D-32

SRS-ECU
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

If DTC B1420 is set in the combination meter, • Improper engaged connector or defective short
always diagnose the CAN bus lines. spring*
• Short between the side-airbag module (RH)
.
CIRCUIT OPERATION
(squib) circuit terminals
by detecting signals from the left and right side
impact sensors. If the impact is over a predeter-
mined level, the SRS-ECU sends an ignition sig-
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
.
DTC SET CONDITIONS (Refer to P.52B-3). Therefore, if connector D-26 or

This DTC is set if there is abnormal resistance D-32 is damaged or improperly engaged, the short
between the input terminals of the side-airbag mod- spring may not be released when the connector is
ule (RH) (squib). connected.
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
MB991910
MB991824
YES : Go to Step 2
Diagnosis ).
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

CAUTION
MB991958.
NO : Go to Step 5.
MB991824
MB991827 00DB076A
STEP 4. Check SRS-ECU connector D-26.

CONNECTOR: D-26
SRS-ECU YES : Go to Step 5.
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
STEP 5. Check SRS-ECU connector D-26 and side-airbag

module (RH) connector D-32. (Using diagnostic tool
CONNECTOR: D-26
(2) Disconnect connectors D-26 and D-32, and then reconnect
them.
SRS-ECU
D-26 (Y) (4) Erase the diagnostic trouble code memory, and check the
D-26 FLOOR diagnostic trouble code.
HARNESS Q: Is DTC B1420 out put?
CONNECTOR
(REAR VIEW) YES : Go to Step 6.
51 52 B A 53 54
55 56 57 5859 60 61 62 B1420 set because connector D-26 or D-32 was
63 64 65 66 67 68 69 70 24DB063A engaged improperly.
CONNECTOR : D-32
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
STEP 6. Check the side-airbag module (RH). (Using

code.)
CONNECTOR : D-32 (2) Disconnect the side-airbag module (RH) connector D-32.
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
RESISTOR: 3 Ω) CAUTION
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.
D-32 SIDE-AIRBAG (6) Erase the diagnostic trouble code memory, and check the
MODULE (RH) CONNECTOR AC006042BO diagnostic trouble code.
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.
STEP 7. Check the side-airbag module (RH) circuit.

Measure the resistance at the SRS-ECU connector D-26.
CONNECTOR: D-26
(1) Disconnect SRS-ECU connector D-26.
SRS-ECU
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
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
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
63 64 65 66 67 68 69 70
YES : Go to Step 8.
NO : Erase the diagnostic trouble code memory, and check
24DB070A the diagnostic trouble code. If DTC B1420 sets,
to Step 7.
STEP 8. Check the harness wires for short circuit between

SRS-ECU connector D-26 (terminal No.57 and 58) and
side-airbag module (RH) connector D-32 (terminal No.1
and 2).
CONNECTOR: D-26 Q: Are the harness wires between SRS-ECU connector
SRS-ECU
D-26 (terminal No.57 and 58) and side-airbag module
(RH) connector D-32 (terminal No.1 and 2) in good
D-26 (Y) condition?
D-26 FLOOR YES : Go to Step 9.
HARNESS NO : Repair the harness wires between SRS-ECU
CONNECTOR connector D-26 and side-airbag module (RH)
(REAR VIEW)
connector D-32. Then go to Step 9.
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

MB991910
MB991824
MB991827 00DB076A
DTC B1421: Side-Airbag Module (RH) (Squib) System Fault 2 (Open in the Squib Circuit)

SRS-ECU
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

If DTC B1421 is set in the combination meter, This DTC is set if there is abnormal resistance
always diagnose the CAN bus lines. between the input terminals of the side-airbag mod-
.
CIRCUIT OPERATION ule (RH) (squib).

• The SRS-ECU judges how severe a collision is .
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

CAN bus line.
CAUTION
MB991958.
MB991910
MB991824
YES : Go to Step 2
Diagnosis ).
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
CONNECTOR
weakened.
YES : Go to Step 4.
go to Step 5.

SRS-ECU connector D-26 (terminal No.57 and 58) and the
side-airbag module (RH) connector D-32 (terminal No.1
and 2).
CONNECTOR: D-26 (1) Disconnect SRS-ECU connector D-26 and side-airbag
SRS-ECU
module (RH) connector D-32.
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?
to Step 5.
connector D-26 and side-airbag module (RH)

MB991910
MB991824
MB991827 00DB076A
DTC B1422: Side-Airbag Module (RH) (Squib) System Fault Power Supply Circuit (Short-Circuited to
Power Supply)

SRS-ECU
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

.

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
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
MB991910
MB991824
YES : Go to Step 2
Diagnosis-Can Bus Diagnostic Chart ).
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
CONNECTOR
weakened.
YES : Go to Step 4.
go to Step 5.

Measure the voltage at the SRS-ECU connector D-26.
CONNECTOR: D-26 (1) Disconnect SRS-ECU connector D-26.
SRS-ECU
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
HARNESS SIDE
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
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
24DB072A replace the SRS-ECU (Refer to P.52B-234). Then go
to Step 6.
NO : Go to Step 5.

supply between SRS-ECU connector D-26 (terminal No.57
and 58) and side-airbag module (RH) connector D-32
SRS-ECU
D-26 (Y) condition?
HARNESS NO : Replace the harness wires between SRS-ECU
(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

MB991910
MB991824
MB991827 00DB076A
DTC B1423: Side-Airbag Module (RH) (Squib) System Fault Ground Circuit (Short-Circuited to
Ground)

SRS-ECU
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

.

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
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
MB991910
MB991824
YES : Go to Step 2
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
HARNESS SIDE
CONNECTOR
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
CONNECTOR
weakened.
YES : Go to Step 4.
go to Step 6.

SRS-ECU
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
HARNESS SIDE
CONNECTOR (2) Disconnect side-airbag module (RH) connector D-32.
(REAR VIEW)
1 2
D-32 (R)
AC307779 AD
CAUTION
51 52 B A 53 54
55 56 57 5859 60 61 62 weakened.
63 64 65 66 67 68 69 70
terminals 57, 58 and body ground.
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,
to Step 6.

ground between SRS-ECU connector D-26 (terminal No.57
and 58) and side-airbag module (RH) connector D-32
SRS-ECU
D-26 (Y) condition?
HARNESS NO : Replace the harness wires between SRS-ECU
(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

MB991910
MB991824
MB991827 00DB076A
DTC B1426: Side Impact Sensor (RH) System for Fault 1

DTC B1436: Side Impact Sensor (LH) System for Fault 1
CAUTION • Analog G-sensor output is abnormal.

If DTC B1426 or B1436 is set in the SRS-ECU, .
always diagnose the CAN main bus line. TROUBLESHOOTING HINTS

.
Malfunction of side impact sensor (RH) (for DTC

DTC SET CONDITIONS B1426) and side impact sensor (LH) (for DTC
These DTCs are set if the following conditions are B1436)
detected from the analog G-sensor inside the side • Refer to circuit diagrams GROUP-90
impact sensor output: • Refer to configuration diagrams GROUP-80
• Analog G-sensor is not operating.
• Analog G-sensor characteristics are abnormal.
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A
STEP 3. Check the side impact sensor. (Using diagnostic

tool MB991958, read the diagnostic trouble code.)
Replace side impact sensor (RH) (for DTC B1426) and side
impact sensor (LH) (for DTC B1436) (Refer to P.52B-247).
Check the diagnostic trouble code.
Q: Is either DTC B1426 or B1436 set?
YES : Replace the SRS-ECU (Refer to P.52B-234).
DTC B1427: Side Impact Sensor (RH) Power Supply Circuit System
CONNECTOR: D-26 CONNECTOR: D-35

SRS-ECU FRONT SEAT BELT
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

nose the CAN main bus line. the side impact sensor (RH) remains less than a pre-
.
determined value for five seconds. However, if the
CIRCUIT OPERATION system returns to normal condition, code number
The side impact sensor includes an analog G sensor B1427 will be erased automatically and the SRS
and CPU, etc. The CPU monitors the analog G sen- warning light will go out.
sor output signal. If the CPU judges that the side-air-
.
bags should be deployed, it sends a fire signal to the TROUBLESHOOTING HINTS

SRS-ECU to deploy the side-airbags. In addition, the
• Damaged wiring harness or connectors
CPU diagnoses the internal components of the side
• Malfunction of the side impact sensor (RH)
impact sensor. If a malfunction occurs, it requests the
SRS-ECU to set a diagnostic trouble code.
.
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A
STEP 3. Check the side impact sensor (RH) power supply

circuit. Measure the voltage at the side impact sensor (RH)
connector D-35.
CONNECTOR: D-35 (2) Disconnect side impact sensor (RH) connector D-35, and
FRONT SEAT BELT measure at the wiring harness side.
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC308163AC
CAUTION
D-35 HARNESS SIDE weakened.
CONNECTOR (5) Measure the voltage between D-35 harness side connector
(REAR VIEW)
1 2 Voltage should measure 9 volts or more
YES : Replace the side impact sensor (RH) (Refer to
AC201627AQ
NO : Go to Step 4.

circuit between SRS-ECU connector D-26 (terminal No.63
and 64) and side impact sensor (RH) connector D-35
SRS-ECU
D-26 (terminal No.63 and 64) and side impact sensor
D-26 (Y) condition?
D-26 FLOOR YES : Erase the diagnostic trouble code memory, and check
HARNESS the diagnostic trouble code. If DTC B1427 sets,
(REAR VIEW)
to Step 5.
51 52 B A 53 54
55 56 57 5859 60 61 62 NO : Replace the harness wires between SRS-ECU
63 64 65 66 67 68 69 70 24DB063A connector D-26 and side impact sensor (RH)
CONNECTOR: D-35
FRONT SEAT BELT
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC308163AC

MB991910
MB991824
MB991827 00DB076A
DTC B1428: Side-Impact sensor (RH) (Squib) for Power Supply Circuit
DTC B1429: Side-Impact sensor (RH) (Squib) for Communication System

SRS-ECU FRONT SEAT BELT
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

always diagnose the CAN main bus line. side impact sensor (RH) and the SRS-ECU is not
.
CIRCUIT OPERATION possible or communication is faulty.

The side impact sensor includes an analog G sensor .
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
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A
STEP 3. Check any diagnostic trouble code. (Using

code.)
Check the side impact sensor (RH).
(2) Temporarily replace the side impact sensor (RH) with the
side impact sensor (LH).
(4) Erase diagnostic trouble code memory, and check the
CONNECTOR
YES : Replace the side impact sensor (RH) with a new one
NO : Go to Step 4.
MB991910
MB991824
MB991827 00DB076A

and 64) and side impact sensor (RH) connector D-35
SRS-ECU
D-26 (Y) condition?
D-26 FLOOR YES : Erase the diagnostic trouble code memory, and check
HARNESS the diagnostic trouble code. If DTC B1428 or B1429
(REAR VIEW)
Then go to Step 5.
51 52 B A 53 54
55 56 57 5859 60 61 62 NO : Replace the harness wires between SRS-ECU
63 64 65 66 67 68 69 70 24DB063A connector D-26 and side impact sensor (RH)
CONNECTOR: D-35
FRONT SEAT BELT
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC308163AC

MB991910
MB991824
MB991827 00DB076A
DTC B1430: Side-Airbag Module (LH) (Squib) System Fault 1 (Short Circuit between Terminals of the
Squib Circuit)

SRS-ECU
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

If DTC B1430 is set in the combination meter, • Improper engaged connector or defective short
always diagnose the CAN bus lines. spring*
• Short circuit between the side-airbag module
.
CIRCUIT OPERATION
(LH) (squib) circuit terminals
by detecting signals from the left and right side
impact sensors. If the impact is over a predeter-
mined level, the SRS-ECU sends an ignition sig-
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
.
DTC SET CONDITIONS (Refer to P.52B-3). Therefore, if connector D-27 or

This DTC is set if there is abnormal resistance D-24 is damaged or improperly engaged, the short
between the input terminals of the side-airbag mod- spring may not be released when the connector is
ule (LH) (squib). connected.
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
connector.
MB991910 (4) Diagnose the CAN bus line.
MB991824
YES : Go to Step 2
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

CAUTION
MB991958.
NO : Go to Step 5.
MB991824
MB991827 00DB076A
STEP 4. Check SRS-ECU connector D-27.

CONNECTOR: D-27 Q: Is the connector correctly engaged?
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
STEP 5. Check SRS-ECU connector D-27 and side-airbag

module (LH) connector D-24. (Using diagnostic tool
CONNECTOR: D-27 (2) Disconnect connectors D-27 and D-24, and then reconnect
SRS-ECU
them.
D-27 (Y) (4) Erase the diagnostic trouble code memory, and check the
D-27 Floor diagnostic trouble code.
harness Q: Is DTC B1430 out put?
connector
(rear view) YES : Go to Step 6.
1 2 B A 3 4 NO : The procedure is complete. It is assumed that DTC
5 6 7 8 9 10 11 12 B1430 set because connector D-27 or D-24 was
13 14 15 16 17 18 19 20 24DB064A
engaged improperly.
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
STEP 6. Check the side-airbag module (LH). (Using

code.)
(2) Disconnect the side-airbag module (LH) connector D-24.
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991865 (DUMMY
D-24 HARNESS SIDE
CONNECTOR
weakened.
D-24 SIDE-AIRBAG (6) Erase diagnostic trouble code memory, and check the
MODULE (LH) CONNECTOR AC006042 BP diagnostic trouble code.
YES : Go to Step 7.
NO : Replace the seatback frame of the front seat (LH)
go to Step 9.
STEP 7. Check the side-airbag module (LH) circuit.

SRS-ECU DANGER
D-27 (Y)
disconnect the side-airbag module (LH) connector
D-27 Floor D-24 to short the squib circuit.
harness
connector
(2) Disconnect left hand side-airbag module (LH) connector
(rear view) D-24.
1 2 B A 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 24DB064A
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
(REAR VIEW)
1 2 B A 3 4 terminals 9 and 10.
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
Q: Is the circuit normal?
to Step 9.
NO : Go to Step 8.
STEP 8. Check the harness wires for short circuit between

SRS-ECU connector D-27 (terminal No.9 and 10) and
side-airbag module (LH) connector D-24 (terminal No.1 and
2).
SRS-ECU
D-27 (terminal No.9 and 10) and side-airbag module (LH)
connector D-24 (terminal No.1 and 2) in good condition?
D-27 (Y) YES : Go to Step 9.
D-27 Floor NO : Replace the harness wires between SRS-ECU
harness connector C-110 and side-airbag module (LH)
connector connector D-24. Then go to Step 9.
(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
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC

MB991910
MB991824
MB991827 00DB076A
DTC B1431: Side-Airbag Module (LH) (Squib) System Fault 2 (Open in the Squib Circuit)

SRS-ECU
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 ule (LH) (squib).

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
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
MB991910
MB991824
YES : Go to Step 2
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991865 (DUMMY
D-24 HARNESS SIDE
CONNECTOR
weakened.
D-24 SIDE-AIRBAG (6) Erase diagnostic trouble code memory, and then check the
YES : Go to Step 4.
go to Step 5.
STEP 4. Check the harness for open circuit between the

SRS-ECU connector D-27 (terminal No.9 and 10) and the
side-airbag module (LH) connector D-24 (terminal No.1 and
2).
SRS-ECU
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
(2) Disconnect side-airbag module (LH) connector D-24.

CONNECTOR : D-24
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
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?
to Step 5.
connector D-27 and side-airbag module (LH)
STEP 5.Recheck for diagnostic trouble code.

MB991910
MB991824
MB991827 00DB076A
DTC B1432: Side-Airbag Module (LH) (Squib) System Fault Power Supply Circuit (Short-Circuited to
Power Supply)

SRS-ECU
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

.

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
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
MB991910
MB991824
YES : Go to Step 2
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991865 (DUMMY
D-24 HARNESS SIDE
CONNECTOR
weakened.
YES : Go to Step 4.
go to Step 6.

Measure the voltage at the SRS-ECU connector D-27.
SRS-ECU
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
CONNECTOR : D-24
disconnect the side-airbag module (LH) connector
HARNESS SIDE
CONNECTOR (2) Disconnect left hand side-airbag module (LH) connector
(REAR VIEW) D-24.
D-24 (R)
1 2
AC307778 AC
CAUTION
(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
to Step 6.
NO : Go to Step 5.

supply between SRS-ECU connector D-27 (terminal No.9
and 10) and side-airbag module (LH) connector D-24
SRS-ECU
harness connector D-27 and side-airbag module (LH)
(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
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC

MB991910
MB991824
MB991827 00DB076A
DTC B1433: Side-Airbag Module (LH) (Squib) System Fault Ground Circuit (Short-Circuited to
Ground)

SRS-ECU
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

.

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
.
DIAGNOSIS
• MB991958 : diagnostic tool (MUT-III Sub Assembly)

CAN bus line.
CAUTION
MB991958.
MB991910
MB991824
YES : Go to Step 2
Diagnosis-Can Bus Diagnostic Chart ). .
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
MB991865 (DUMMY
D-24 HARNESS SIDE
CONNECTOR
weakened.
YES : Go to Step 4.
go to Step 6.
STEP 4. Check the side-airbag module (LH) circuit.

SRS-ECU
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
(2) Disconnect side-airbag module (LH) connector D-24.

CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC
CAUTION
1 2 B A 3 4
5 6 7 8 9 10 11 12
weakened.
13 14 15 16 17 18 19 20
terminals 9, 10 and body ground.
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,
to Step 6.

ground between SRS-ECU connector D-27 (terminal No.9
and 10) and side-airbag module (LH) connector D-24
SRS-ECU
harness connector D-27 and side-airbag module (LH)
(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
CONNECTOR : D-24
HARNESS SIDE
CONNECTOR
(REAR VIEW)
D-24 (R)
1 2
AC307778 AC

MB991910
MB991824
MB991827 00DB076A
DTC B1437: Side Impact Sensor (LH) Power Supply Circuit System

FRONT SEAT BELT
SRS-ECU
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

If DTC B1437 is set in the SRS-ECU, always diag- This DTC is set if the power supply voltage of the
nose the CAN main bus line. side impact sensor (LH) drops below the rated value
.
for a continuous period of 5 seconds or more. How-
CIRCUIT OPERATION ever, DTC B1437 will be automatically cleared and
The side impact sensor includes an analog G sensor the SRS warning light will switch off if the condition
and CPU, etc. The CPU monitors the analog G sen- returns to normal.
sor output signal. If the CPU judges that the side-air-
.
bags should be deployed, it sends a fire signal to the TROUBLESHOOTING HINTS

SRS-ECU to deploy the side-airbags. In addition, the
• Damaged wiring harnesses or connectors
CPU diagnoses the internal components of the side
• Malfunction of the side impact sensor (LH)
impact sensor. If a malfunction occurs, it requests the
.
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A
STEP 3. Check the side impact sensor (LH) power supply

circuit. Measure the voltage at the side impact sensor (LH)
connector D-20.
CONNECTOR: D-20 (2) Disconnect side impact sensor (LH) connector D-20, and
FRONT SEAT BELT measure at the wiring harness side.
1 2 (4) Turn the ignition switch to the "ON" position.
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC305250 AJ
CAUTION
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.
YES : Replace the side impact sensor (LH) (Refer to
AC201627 AU
NO : Go to Step 4.

and 20) and side impact sensor (LH) connector D-20
SRS-ECU
(LH) connector D-20 (terminal No.1 and 2) in good
D-27 (Y) condition?
D-27 Floor YES : Erase the diagnostic trouble code memory, and check
harness the diagnostic trouble code. If DTC B1437 sets,
connector replace the SRS-ECU (Refer to P.52B-234). Then go
(rear view)
to Step 5.
1 2 B A 3 4
5 6 7 8 9 10 11 12 NO : Replace the harness wires between SRS-ECU
13 14 15 16 17 18 19 20 24DB064A connector D-27 and side impact sensor (LH)
CONNECTOR: D-20
FRONT SEAT BELT
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC305250 AJ

MB991910
MB991824
MB991827 00DB076A
DTC B1438: Side Impact Sensor (LH) (Squib) for Power Supply Circuit
DTC B1439: Side Impact Sensor (LH) (Squib) for Communication System

FRONT SEAT BELT
SRS-ECU
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

always diagnose the CAN main bus line. side impact sensor (LH) and the SRS-ECU is not
.

The side impact sensor includes an analog G sensor .
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
.
DIAGNOSIS

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

code.)
Check the side impact sensor (LH).
(2) Replace the side impact sensor (LH) with the side impact
sensor (RH).
CONNECTOR
YES : Replace the side impact sensor (LH) with a new one
NO : Go to Step 4.
MB991910
MB991824
MB991827 00DB076A

and 20) and side impact sensor (LH) connector D-20
SRS-ECU
(LH) connector D-20 (terminal No.1 and 2) in good
D-27 (Y) condition?
D-27 Floor YES : Erase the diagnostic trouble code memory, and check
harness the diagnostic trouble code. If DTC B1438 or B1439
connector sets, replace the SRS-ECU (Refer to P.52B-234).
(rear view)
Then go to Step 5.
1 2 B A 3 4
5 6 7 8 9 10 11 12 NO : Replace the harness wires between SRS-ECU
13 14 15 16 17 18 19 20 24DB064A connector D-27 and side impact sensor (LH)
CONNECTOR: D-20
FRONT SEAT BELT
1 2
HARNESS SIDE
CONNECTOR
(REAR VIEW)
AC305250 AJ

MB991910
MB991824
MB991827 00DB076A
DTC B1460: Seat Belt Pre-Tensioner (RH) (Squib) System Fault 1 (Short Circuit between Terminals of
the Squib Circuit)

CENTER
SRS-ECU PILLAR
FORWARD
D-26 (Y)
D-26 FLOOR
HARNESS
CONNECTOR
(REAR VIEW) D-33 (B)
51 52 B A 53 54
55 56 57 5859 60 61 62
63 64 65 66 67 68 69 70 24DB063A AC307915 AB
CAUTION TROUBLESHOOTING HITS

If DTC B1460 is set in the SRS-ECU, always diag- • Improper engaged connector or defective short
nose the CAN main bus line. spring*
.
• Short circuit between the driver's seat belt
CIRCUIT OPERATION pre-tensioner (squib) circuit terminals
The SRS-ECU judges how severe a collision is by • Damaged connector(s)
detecting signals from the front impact sensors and • Malfunction of the SRS-ECU
the front air bag analog G-sensor. If the impact is • Refer to circuit diagrams GROUP-90
over a predetermined level, the SRS-ECU sends an • Refer to configuration diagrams GROUP-80
ignition signal. At this time, if the front air bag safing
.
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
• MB991884: Resistor harness (For Pre-tensioner)

CAN bus line.
CAUTION
MB991958.
YES : Go to Step 2.
MB991824
MB991827 00DB076A

Q: Is the DTC set?
YES : Go to Step 3.
MB991824
Malfunctions ).
MB991827 00DB076A

CAUTION
MB991958.
MB991910
YES : Go to Step 4.
NO : Go to Step 5.
MB991824
MB991827 00DB076A
STEP 4. Check the SRS-ECU connector D-26.

CONNECTOR: D-26 Q: Is connector correctly engaged?
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
STEP 5. Check SRS-ECU connector D-26 and driver’s seat

belt pre-tensioner connector D-33. (Using diagnostic tool
CONNECTOR: D-26 (2) Disconnect connectors D-26 and D-33, and then reconnect
SRS-ECU
them. For connector D-33, use a flat-tipped screwdriver to
unlock the locking button at the harness side connector by
D-26 (Y) withdrawing it toward you in two stages, and then
D-26 FLOOR disconnect the connector.
HARNESS (3) Connector the negative battery terminal.
CONNECTOR (4) Erase the diagnostic trouble code memory, and check the
(REAR VIEW) diagnostic trouble code.
51 52 B A 53 54
55 56 57 5859 60 61 62 Q: Is DTC B1460 set?
63 64 65 66 67 68 69 70 24DB063A
YES : Go to Step 6.
CONNECTOR: D-33
CENTER B1460 set because connector D-26 or D-33 was
PILLAR engaged improperly.
FORWARD
HARNESS SIDE
CONNECTOR
(FRONT VIEW)
2 1
D-33 (B)
AC307915 AC
STEP 6. Check the driver's seat belt pre-tensioner. (Using

code.)
(2) Disconnect driver's seat belt pre-tensioner connector D-33.
U

345 Mitsubishi 380 Workshop Service Manual 2005 2008 (Chassis DB)

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345 Mitsubishi 380 Workshop Service Manual 2005 2008 (Chassis DB)

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MITSUBISHI GROUP INDEX

Intake and Exhaust . . . . . . . . . . . . . . 15

Engine and Emission Control . . . . . 17

Interior and SRS . . . . . . . . . . . . . . . . 52

Heater, A/C and Ventilation . . . . . . . 55

GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

HARNESS CONNECTOR INSPECTION INSTRUMENTS . . . . . . . . . . 00E-5

HARNESS CONNECTOR INSPECTION

CONNECTOR CONTINUITY AND VOLTAGE TEST

Observe the symptom carefully. Check if there are also

In determining the probable causes, it is necessary to

Troubleshooting is carried out by making step-by-step

After the problems are corrected, be sure to check that the

INFORMATION FOR DIAGNOSIS

3. Checking with instruments

SELECTOR KNOB ACX00938AB

2. Self-powered test light

CAUTIONS IN EVENT OF BLOWN FUSE

CURRENT DOES CURRENT FLOWS

NORMALLY CLOSED (NC) TYPE

CURRENT CURRENT DOES

CABLES AND WIRES CHECK

GENERAL ELECTRICAL SYSTEM CHECK

STEP 2. Turn the switch ON and disconnect the

HOW TO USE THIS MANUAL. . . . . . 00-3 OPTION CODES . . . . . . . . . . . . . . . . . . . . . 00-21

VEHICLE IDENTIFICATION . . . . . . . 00-18 LUBRICATION AND MAINTENANCE 00-34

HOW TO USE THIS MANUAL

MAINTENANCE, REPAIR AND DANGER, WARNING, AND CAUTION

CAN: Controller Area Network

Indicates the page number.

Indicates procedures to be performed be-

Mark N denotes non-reusable part.

Repair kit or parts sets are shown.

Maintenance and servicing procedures

Classifications of major maintenance / service points

The title of the page

Indicates (by symbols) where

Symbols for lubrication, sealants and adhesives

VERIFY THE COMPLAINT FIND THE PROBLEM

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

CAUTION 4. DIAGNOSTIC TROUBLE CODE CHART

TROUBLESHOOTING TERMINAL VOLTAGE CHECKS

Checks don't have to be carried out in the order CAUTION

10. INSPECTION PROCEDURES USING

HOW TO USE THE INSPECTION PROCEDURES

DTC P0202: Injector Circuit Malfunction - Cylinder 2.

(3) Shows the location of the connector(s) from

B-17X (4) Explains about the operation principle of the

CIRCUIT OPERATION TROUBLESHOOTING HINTS (The most

Diagnostic Tool (MUT-III)

CURRENT TROUBLE HARNESS INSPECTION

MEASURES TO TAKE AFTER

CONNECTOR MEASUREMENT SERVICE POINTS

IF INSPECTING WITH THE CONNECTOR

IF INSPECTING WITH THE CONNECTOR

IF INSPECTING WITH THE CONNECTOR

• From back side of the connector (SRS-ECU harness side

IF INSPECTING WITH THE CONNECTOR

CONNECTOR INSPECTION SERVICE POINTS

STRETCHED OR BROKEN WIRES

HARNESS WIRE BREAKAGE

CONNECTOR PIN INSPECTION

CONNECTOR ENGAGEMENT INSPECTION