Workshop Manual

chassis

'01
 General . . . . . . . . . . . . . . . . . . . . . . . . 00
Engine . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Lubrication . . . . . . . . . . . . . . 12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WORKSHOP MANUAL Engine Cooling . . . . . . . . . . . . . . . . . 14
Intake and Exhaust . . . . . . . . . . . . . 15
FOREWORD Engine Electrical . . . . . . . . . . . . . . . . 16
This Workshop Manual contains procedures for Engine and Emission Control . . . . 17
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Use the following manuals in combination with this
manual as required. Manual Transmission . . . . . . . . . . . . 22
TECHNICAL INFORMATION MANUAL Automatic Transmission . . . . . . . . . 23
IKRE00E1
WORKSHOP MANUAL Propeller Shaft . . . . . . . . . . . . . . . . . . 25
ELECTRICAL WIRING EKRE00E1
BODY REPAIR MANUAL BKRE00E1 Front Axle . . . . . . . . . . . . . . . . . . . . . . 26
ENGINE GROUP PWEE9502-E
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . 27
PARTS CATALOGUE I603F509Dj
Wheel and Tyre . . . . . . . . . . . . . . . . . 31
Power Plant Mount . . . . . . . . . . . . . . 32
All information, illustrations and product descriptions Front Suspension . . . . . . . . . . . . . . .
contained in this manual are current as at the time 33
of publication. We, however, reserve the right to
make changes at any time without prior notice or
Rear Suspension . . . . . . . . . . . . . . . . 34
obligation.
Service Brakes . . . . . . . . . . . . . . . . . . 35
Parking Brakes . . . . . . . . . . . . . . . . . 36
Steering . . . . . . . . . . . . . . . . . . . . . . . . 37
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exterior . . . . . . . . . . . . . . . . . . . . . . . . 51
Interior and Supplemental
Restraint System (SRS) . . . . . . . . 52
Chassis Electrical . . . . . . . . . . . . . . . 54
“GDI” is a trade mark which Mitsubishi Motors
Corporation holds. Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . . 55

E Mitsubishi Motors Corporation August 1999

WARNING REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLE
WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air
bag) or to the driver and passenger (from rendering the SRS inoperative).
(2) The SRS components should not be subjected to temperature of 93 C or more. So, remove
the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side impact sensors
and front seat assemblies (side air bag modules) before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B – Supplemental Restraint System (SRS), before beginning any service or maintenance of
any SRS component or any SRS-related component.

NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
 ENGINE
CONTENTS

ENGINE <4G9-GDI> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A

ENGINE <4G9-MPI> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

 FUEL
CONTENTS

GASOLINE DIRECT INJECTION (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A

FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B

MULTIPOINT FUEL INJECTION (MPI) <4G9> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C

SERVICE BRAKES
CONTENTS

BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A

ANTI-SKID BRAKING SYSTEM (ABS) <4WD> . . . . . . . . . . . . . . . . . . . . . . 35B

 INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS

INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . . . . . 52B

 CHASSIS
ELECTRICAL
CONTENTS

CHASSIS ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54A

SMART WIRING SYSTEM (SWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54B

 GENERAL
Click on the applicable bookmark to selected the required model year
 00-1

GENERAL
CONTENTS

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Scope of Maintenance, Repair and Servicing Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Engine Model Number . . . . . . . . . . . . . . . . . . . . . . 15
Indication of Tightening Torque . . . . . . . . . . . . . . . . . 2
Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . . 15
Explanation of Manual Contents . . . . . . . . . . . . . . . . 4 PRECAUTIONS BEFORE SERVICE . . . . . . . . 17
HOW TO USE SUPPLEMENTAL RESTRAINT SYSTEM
TROUBLESHOOTING/INSPECTION SERVICE (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting Contents . . . . . . . . . . . . . . . . . . . . . . 6 SUPPORT LOCATIONS FOR LIFTING AND
Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to Use the Inspection Procedures . . . . . . . . . 8 Support Positions for a Garage Jack and Axle
Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connector Measurement Service Points . . . . . . . . . 9
Support Positions for a Single-Post Lift or
Connector Inspection . . . . . . . . . . . . . . . . . . . . . . . . 10 Double-Post Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspection Service Points for a Blown Fuse . . . . 11 Support Positions and Support Method for an
Points to Note for Intermittent Malfunctions . . . . 11 H-Bar Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . 12 STANDARD PART/TIGHTENING-TORQUE

TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Vehicle Information Code Plate . . . . . . . . . . . . . . . 12
00-2 GENERAL – How to Use This Manual

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS
AND SERVICING EXPLANATIONS STANDARD VALUE
This manual provides explanations, etc. concerning Indicates the value used as the standard for judging
procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection or
and servicing of the subject model. Note, however, the value to which the part or assembly is corrected
that for engine and transmission-related component and adjusted. It is given by tolerance.
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and LIMIT
installation procedures for major components.
For detailed information concerning the inspection, Shows the standard for judging the quality of a part
checking, adjustment, disassembly and reassembly or assembly on inspection and means the maximum
of the engine, transmission and major components or minimum value within which the part or assembly
after they have been removed from the vehicle, must be kept functionally or in strength. It is a value
please refer to separate manuals covering the established outside the range of standard value.
engine and the transmission.
REFERENCE VALUE
ON-VEHICLE SERVICE Indicates the adjustment value prior to starting the
“On-vehicle Service” is procedures for performing work (presented in order to facilitate assembly and
inspections and adjustments of particularly adjustment procedures, and so they can be
important locations with regard to the construction completed in a shorter time).
and for maintenance and servicing, but other
inspection (for looseness, play, cracking, damage, CAUTION
etc.) must also be performed. Indicates the presentation of information particularly
vital to the worker during the performance of
INSPECTION maintenance and servicing procedures in order to
Under this title are presented inspection and avoid the possibility of injury to the worker, or
checking procedures to be performed by using damage to component parts, or a reduction of
special tools and measuring instruments and by component or vehicle function or performance, etc.
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be INDICATION OF TIGHTENING TORQUE
performed as well. The tightening torque shown in this manual is a
basic value with a tolerance of ±10% except the
following cases when the upper and lower limits
of tightening torque are given.
(1) The tolerance of the basic value is within ±10%.
(2) Special bolts or the like are in use.
(3) Special tightening methods are used.
 GENERAL – How to Use This Manual 00-3

MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.

GDI: Indicates the gasoline direct injection.

DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an
engine.
M/T: Indicates the manual transmission, or models equipped with the manual transmission.
A/T: Indicates the automatic transmission, or models equipped with the automatic transmission.
A/C: Indicates the air conditioner.
00-4 GENERAL – How to Use This Manual

EXPLANATION OF MANUAL CONTENTS

Indicates procedures to be performed

before the work in that section is started,
and procedures to be performed after
the work in that section is finished.

Component Diagram
A diagram of the component parts is pro-
vided near the front of each section in or-
der to give a reader a better understand-
ing of the installed condition of compo-
nent parts.

Indicates (by symbols) where lubrication

is necessary.

Maintenance and Servicing Procedures

The numbers provided within the diagram indi- D Installation steps:
cate the sequence for maintenance and servic- Specified in case installation is impossible
ing procedures. in reverse order of removal steps. Omitted
D Removal steps: if installation is possible in reverse order of
The part designation number corresponds removal steps.
to the number in the illustration to indicate D Reassembly steps:
removal steps. Specified in case reassembly is impossible
D Disassembly steps: in reverse order of disassembly steps.
The part designation number corresponds Omitted if reassembly is possible in reverse
to the number in the illustration to indicate order of disassembly steps.
disassembly steps.

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 stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.

Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for lubrica- : Grease

tion and for application of sealants and adhe- (multipurpose grease unless there is a
sives is provided, by using symbols, in the dia- brand or type specified)
gram of component parts or on the page follow-
ing the component parts page, and explained. : Sealant or adhesive

: Brake fluid or automatic transmission fluid

: Engine oil, gear oil or air conditioner com-

pressor oil

: Adhesive tape or butyl rubber tape

 GENERAL – How to Use This Manual 00-5

Indicates the Indicates the Indicates the Indicates the

group title. section title. group num- page number.
ber.

Denotes non-reus-
able part.

Denotes tightening torque.

For bolts and nuts which do not
have a tightening torque listed,
refer to the “Standard Parts-
tightening-torque Table”.

Repair kit or set parts

are shown. (Only very
frequently used parts
are shown.)

Operating procedures, cautions,

etc. on removal, installation, dis-
assembly and reassembly are
described.

indicates that there is

a continuity between the termi-
nals.
indicates terminals to
which battery voltage is applied.

The title of the page (following

the page on which the diagram
of component parts is present-
ed) indicating the locations of lu-
brication and sealing proce-
dures.
00-6 GENERAL – How to Use Troubleshooting/Inspection Service Points

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS
Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline
described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems
still follow this outline.

TROUBLESHOOTING CONTENTS
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis
flow is different from that given below, or if additional explanation is required, the details of such differences
or additions will also be listed.

Diagnosis method

Gathering information
from the customer.

Check trouble symptom.

Reoccurs Does not reoccur.

Read the diagnosis code Read the diagnosis code

No diagnosis code
or communication Diagnosis code Diagnosis code No diagnosis
with MUT-II not displayed. displayed. code
possible

Refer to the INSPECTION After taking note of the

CHART FOR TROUBLE malfunction code, erase
SYMPTOMS (Refer to the diagnosis code
applicable group.) memory

Recheck trouble symptom.

Read the diagnosis codes.

Diagnosis code No diagnosis
displayed. code

Refer to the INSPECTION CHART FOR DIAGNOSIS INTERMITTENT MALFUNCTIONS (Refer to P.00-12.)
CODES (Refer to applicable group.)

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble
symptoms are shown.

3. DIAGNOSIS FUNCTION
Details which are different from those in the “Diagnosis Function” section on the next page are listed.
4. INSPECTION CHART FOR DIAGNOSIS CODES
5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-9 for how
to use the inspection procedures.)
 GENERAL – How to Use Troubleshooting/Inspection Service Points 00-7
6. INSPECTION CHART FOR TROUBLE SYMPTOMS
If there are trouble symptoms even though the results of inspection using the MUT-II show that all
diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means
of this chart.

7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM

Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection
Chart for Trouble Symptoms. (Refer to P.00-9 for how to use the inspection procedures.)

8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgement values have been provided in this chart as reference information.

9. CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors, inspection items and standard values have been provided
in this chart as reference information.

10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE

When there are inspection procedures using an oscilloscope, these are listed here.

DIAGNOSIS FUNCTION
METHOD OF READING DIAGNOSIS CODES
WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and take a
reading of the diagnosis codes.
Caution
Turn the ignition switch to the LOCK (OFF) position before
MUT-II connecting or disconnecting the MUT-II.

METHOD OF ERASING DIAGNOSIS CODES

WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and erase the diagnosis code.
Caution
Turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting the MUT-II.
WHEN NOT USING THE MUT-II
1. Turn the ignition switch to the LOCK (off) position.
2. After disconnecting the battery cable from the negative (–) battery terminal, wait for 10 seconds or
more and reconnect the cable.
3. Warm up the engine and run at idle for about 15 minutes.
00-8 GENERAL – How to Use Troubleshooting/Inspection Service Points

HOW TO USE THE INSPECTION PROCEDURES

The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors,
components, the ECU and the harnesses between connectors, in that order. These inspection procedures
follow this order, and they first try to discover a problem with a connector or a defective component.

1. Comments on the diagnosis code or trouble

symptom above.
CHECKING PROCEDURE 4

Indicator does not turn on or off even if control Probable cause

mode switch is pressed. 2. Indicates inspection carried out using the
Indicator switch should not be illuminated is MUT-II.
illuminated. Indicates the operation and inspection proce-
dures.
In the above cases, the ECS switch circuit is defective or the indicator Indicates the OK judgement conditions.
circuit is defective.

3. Detailed inspection procedures (methods)

such as component inspection and circuit
inspection are listed on a separate page, and
OK are given here for reference.
MUT-II Data list
17 Control mode selection switch
OK: Voltage changes between approx. 0V → approx.
2.5V → approx. 5V when the switch is operated.
NG
4. Indicates voltage and resistance to be measured at a particular
ECU switch component inspection (Refer to P.33-44.) NG connector.
(Refer to Connector Measurement Service Points.)
OK The connector position can be located in the wiring diagram in the
Measure at switch connector A-44
OK electrical wiring manual by means of this symbol.
Disconnect the connector, and measure at the harness Indicates operation and inspection procedures, inspection terminals
side. and inspection conditions.
Voltage between terminal 6 – earth and terminal 8 Indicates the OK judgement conditions.
– earth
OK: Approx. 5V
OK
Check the following connector. A-44
NG
Repair
OK
5. Inspect the contact condition at each connector terminal.
Check trouble symptom. (Refer to Connector Inspection Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Caution
Replace the ECS-ECU.
After carrying out connector inspection, always be sure to
reconnect the connector as it was before.

6. Confirm that there are trouble symptoms. If trouble symptoms have

disappeared, the connector may have been inserted incorrectly and the
trouble symptom may have disappeared during inspection.
If it seems that trouble symptoms still remain, proceed to the next page
of instructions.

7. If trouble symptoms still remain up to this stage, there is a possibility that there is an
open or short circuit in the harness between the connectors, so check the harness.
Alternatively, the cause may be a defective ECU, so try replacing the ECU and check
if the trouble symptom disappears.

HARNESS INSPECTION
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring manual.
Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses.
For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown
Fuse.”
MEASURES TO TAKE AFTER REPLACING THE ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure
from the beginning.
 GENERAL – How to Use Troubleshooting/Inspection Service Points 00-9
CONNECTOR MEASUREMENT SERVICE POINTS
Turn the ignition switch to the LOCK (OFF) position when
connecting or disconnecting the connectors and turn the
ignition switch ON when measuring, unless otherwise
instructed.

Harness connector WHEN INSPECTING WITH CONNECTOR CONNECTED

(WITH CIRCUIT IN CONDITION OF CONTINUITY)
Waterproof Connectors
Be sure to use the special tool (harness connector). Never
insert a test bar from the harness side, because to do so
will reduce the waterproof performance and result in corrosion.

Ordinary (non-waterproof) Connectors

Extra-thin probe
Check by inserting the test bar from the harness side. Note
that if the connector (control unit, etc.) is too small to permit
insertion of the test bar, it should not be forced; use a special
tool (the extra-thin probe in the harness set for checking for
this purpose.
Test bar

Connector

WHEN INSPECTING WITH CONNECTOR DISCONNECTED

<When Inspecting a Female Pin>
Use the special tool (inspection harness for connector pin
contact pressure in the harness set for inspection).
The inspection harness for connector pin contact pressure
Inspection harness should be used. The test bar should never be forcibly inserted,
for connector pin
contact pressure as it may cause a defective contact.

<When Inspecting a Male Pin>

Touch the pin directly with the test bar.
Caution
At this time, be careful not to short the connector pins
with the test bars. To do so may damage the circuits inside
the ECU.
00-10 GENERAL – How to Use Troubleshooting/Inspection Service Points

Connector disconnected or improperly CONNECTOR INSPECTION

connected
VISUAL INSPECTION
Connector is disconnected or improperly connected
Connector pins are pulled out
Due to harness tension at terminal section
Low contact pressure between male and female terminals
Low connection pressure due to rusted terminals or foreign
matter lodged in terminals

Defective connector contact

Harness wire breakage

at terminal section

Low contact pressure

Good

Bad

CONNECTOR PIN INSPECTION

If the connector pin stopper is damaged, the terminal
connections (male and female pins) will not be perfect even
if the connector body is connected, and the pins may pull
out of the reverse side of the connector. Therefore, gently
pull the harnesses one by one to make sure that no pins
pull out of the connector.

CONNECTOR ENGAGEMENT INSPECTION

Use the special tool (connector pin connection pressure
MB991219
inspection harness of the inspection harness set) to inspect
the engagement of the male pins and females pins. (Pin
drawing force : 1 N or more)
 GENERAL – How to Use Troubleshooting/Inspection Service Points 00-11
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
Remove the fuse and measure the resistance between the
load side of the fuse and the earth. Set the switches of all
0Ω circuits which are connected to this fuse to a condition of
continuity. If the resistance is almost 0 Ω at this time, there
is a short somewhere between these switches and the load.
Battery If the resistance is not 0 Ω, there is no short at the present
time, but a momentary short has probably caused the fuse
to blow.
Fuse The main causes of a short circuit are the following.
Harness being clamped by the vehicle body
Connector
Damage to the outer casing of the harness due to wear
Load inspection or heat
switc Water getting into the connector or circuitry
h Human error (mistakenly shorting a circuit, etc.)
Load

POINTS TO NOTE FOR INTERMITTENT

MALFUNCTIONS
Intermittent malfunctions often occur under certain conditions,
and if these conditions can be ascertained, determining the
cause becomes simple. In order to ascertain the conditions
under which an intermittent malfunction occurs, first ask the
customer for details about the driving conditions, weather
conditions, frequency of occurrence and trouble symptoms,
and then try to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or some other
factor. If vibration is thought to be the cause, carry out the
following checks with the connectors and components to
confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components
which are indicated by inspection procedures or given as
probable causes (which generates diagnosis codes or trouble
symptoms.)
Gently shake the connector up, down and to the left and
right.
Gently shake the wiring harness up, down and to the
left and right.
Gently rock each sensor and relay, etc. by hand.
Gently shake the wiring harness at suspensions and other
moving parts.
NOTE
If determining the cause is difficult, the flight recorder function
of the MUT-II can also be used.
00-12 GENERAL – Vehicle Identification

VEHICLE IDENTIFICATION
VEHICLE INFORMATION CODE PLATE
LOCATION
Vehicle information code plate is riveted on the toeboard inside
the engine compartment.

CODE PLATE DESCRIPTION

The plate shows model code, engine model, transmission
model, and body colour code.
1
2 No. Item Contents Contents
3
4 1 MODEL H66W H66W: Vehicle model
5 LNUEL
LNUEL: Model series

2 ENGINE 4G93 Engine model

3 EXT A01A Exterior code

4 TRANS V5M21 W5M21: Transmission code

AXLE 4875
4875: Rear differential
reduction

5 COLOR A01 11T 03V A01: Body colour code

INT OPT
11T: Interior code

03V: Equipment code

For monotone colour vehicles, the body colour code shall

be indicated. For two-tone or three-way two-tone colour
vehicles, each colour code only shall be indicated in series.
 GENERAL – Vehicle Identification 00-13
MODELS
Model code Engine model Transmission model Fuel supply system

H66 WMNJCLA 4G93-DOHC (1,834 mȏ) V5M21 <5M/T> GDI

WMNJCRA

WMRJCLA V4AW4 <4A/T>

WMRJCRA

MODEL CODE
No. Items Contents

1 Development H6: MITSUBISHI PAJERO

PININ Short wheelbase

1 2 3 4 5 6 7 8 9 2 Engine type 6: 1,800 mȏ petrol engine

3 Sort W: Wagon

4 Body style M: 3-door

5 Transmission type N: 5-speed manual

transmission
R: 4-speed automatic
transmission

6 Trim level J: GL

7 Specification engine C: GDI-DOHC

feature

8 Steering wheel location L: Left hand

R: Right hand

9 Destination A: For Europe

00-14 GENERAL – Vehicle Identification

CHASSIS NUMBER
The chassis number is stamped on the toeboard inside the
engine compartment.

1 2 3 4 5 6 7 8 9

No. Items Contents

1 Steering wheel location JMP Left hand drive

JMR Right hand drive

2 Body style 0 Standard roof

3 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

4 Development order H6 PAJERO PININ Short wheelbase

5 Engine 6 4G93: 1,834 mȏ petrol engine

6 Sort W Wagon

7 Model year Y 2000

8 Plant X Ooe Plant of Pininfarina Works

9 Serial number – –
 GENERAL – Vehicle Identification/Major Specifications 00-15
ENGINE MODEL NUMBER
1. The engine model number is stamped on the cylinder
block as shown below.
Engine model Engine displacement mȏ
4G93 1,834
2. The engine serial number is stamped near the engine
model number.
Engine serial number AA0201 to YY9999

MAJOR SPECIFICATIONS

5 7 4 8
1

2
<L.H. drive
vehicles>

<R.H. drive
vehicles>
00-16 GENERAL – Major Specifications

Items H66WMNJCLA H66WMNJCRA H66WMRJCLA H66WMRJCRA

Vehicle Overall length 1 3,735/3,765*1

di
dimensions
i
Overall width 2 1,695
mm
Overall height (unladen) 3 1,695/1,735*2/1,705*3
Wheelbase 4 2,280
Track-front 5 1,435
Track-rear 6 1,445
Overhang-front 7 755/785*1
Overhang-rear 8 700
Ground clearance 9 200
(unladen)
Vehicle Kerb weight 1,285 1,305
weight
i ht kkg
Max. gross vehicle weight 1,690 1,700
Max. axle weight 740 750
rating-front
Max. axle weight 545 555
rating-rear
Seating capacity 4
Engine
g Model No. 4G93
Total displacement mȏ 1,834
Transmis- Model No. V5M21 V4AW4 V5M21 V4AW4
sion
i
Type 5-speed 4-speed 5-speed 4-speed
manual automatic manual automatic
Fuel system Fuel supply system Gasoline Direct Injection
NOTE:
*1: Vehicles with bumper extension
*2: Vehicles with roof rails
*3: Vehicles with roof spoiler
 GENERAL – Precautions Before Service 00-17
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS is designed to retain enough voltage to deploy the air bags even after the battery has
been disconnected. Serious injury may result from unintended air bag deployment if work is done
on the SRS immediately after the battery cable is disconnected.
(3) Warning/caution labels must be heeded when servicing or handling SRS components.
Warning/caution labels are attached in the following locations.
D Sun visor
D Glove box
D SRS air bag control unit (SRS-ECU)
D Steering wheel
D Steering gear box
D Driver’s and passenger’s air bag modules
D Clock spring
D Side air bag modules
D Side impact sensors
D Instrument panel
D Hood
D Seat belt with pre-tensioner
(4) Always use the designated special tools and test equipment.
(5) Store components removed from the SRS in a clean and dry place.
The air bag modules should be stored on a flat surface and placed so that the deployment surfaces
are facing upward.
Do not place anything on top of them.
(6) Never attempt to disassemble or repair the SRS components (SRS air bag control unit, air bag
modules, clock spring and side impact sensors). If faulty replace them.
(7) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
(8) Be sure to deploy the air bag before disposing of the air bag modules or disposing of a vehicle
equipped with air bag. (Refer to GROUP 52B – Air Bag Module Disposal Procedures.)
2. Observe the following when carrying out operations on places where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat over 93_C, so remove the SRS components
before drying or baking the vehicle after painting.
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.
00-18 GENERAL – Precautions Before Service

SERVICING THE ELECTRICAL SYSTEM

Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative (–)
cable from the battery in order to avoid damage caused by
short-circuiting.
Caution
Before connecting or disconnecting the negative (–) cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of semiconductor
parts being damaged.)

APPLICATION OF ANTI-CORROSION AGENTS

AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will cause
a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover when applying
anti-corrosion agents and undercoats.

PRE-INSPECTION CONDITION
“Pre-inspection condition” refers to the condition that the vehicle
must be in before proper engine inspection can be carried
out. If you see the words “Set the vehicle to the pre-inspection
condition”. in this manual, it means to set the vehicle to the
following condition.
D Engine coolant temperature: 80 to 90_C
D Lamps, electric cooling fan and all accessories: OFF
D M/T: Neutral
D A/T: P range

VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
Approx. equipment is used to wash the vehicle, be sure to note the
40 cm following information in order to avoid damage to plastic
components, etc.
D Spray nozzle distance: Approx. 40 cm or more
D Spray pressure: 3,900 kPa or less
D Spray temperature: 82_C or less
D Time of concentrated spray to one point: within 30 sec.
 GENERAL – Precautions Before Service 00-19

MUT-II
MUT-II
sub-assembly Refer to the “MUT-II REFERENCE MANUAL” or “MUT-II
OPERATING INSTRUCTIONS” for instructions on handling
the MUT-II.

ROM pack

Connect the MUT-II to the diagnosis connector as shown in

the illustration.
Caution
Turn the ignition switch to the LOCK (OFF) position before
connecting or disconnecting the MUT-II.

MUT-II

IN ORDER TO PREVENT VEHICLES FROM FIRE

“Improper installation of electrical or fuel related parts could
cause a fire. In order to retain the high quality and safety
of the vehicle, it is important that any accessories that may
be fitted or modifications/repairs that may be carried out which
involve the electrical or fuel systems, MUST be carried out
in accordance with MMC’s information/Instructions”.

ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will result
in the removal of natural fats from the skin, leading to dryness,
irritation and dermatitis. In addition, used engine oil contains
potentially harmful contaminants which may cause skin cancer.
Adequate means of skin protection and washing facilities must
be provided.

Recommended Precautions
The most effective precaution is to adapt working practices
which prevent, as far as practicable, the risk of skin contact
with mineral oils, for example by using enclosed systems for
handling used engine oil and by degreasing components,
where practicable, before handling them.
00-20 GENERAL – Precautions Before Service

Other precautions:
Avoid prolonged and repeated contact with oils, particularly
used engine oils.
Wear protective clothing, including impervious gloves
where practicable.
Avoid contaminating clothes, particularly underpants, with
oil.
Do not put oily rags in pockets, the use of overalls without
pockets will avoid this.
Do not wear heavily soiled clothing and oil-impregnated
foot-wear. Overalls must be cleaned regularly and kept
separately from personal clothing.
Where there is a risk of eye contact, eye protection should
be worn, for example, chemical goggles or face shields;
in addition an eye wash facility should be provided.
Obtain First Aid treatment immediately for open cuts and
wounds.
Wash regularly with soap and water to ensure all oil is
removed, especially before meals (skin cleansers and nail
brushes will help). After cleaning, the application of
preparations containing lanolin to replace the natural skin
oils is advised.
Do not use petrol, kerosine, diesel fuel, gas oil, thinners
or solvents for cleaning skin.
Use barrier creams, applying them before each work
period, to help the removal of oil from the skin after work.
If skin disorders develop, obtain medical advice without
delay.
 GENERAL – Supplemental Restraint System (SRS) 00-21
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
To improve safety, the SRS is available as optional or the quarter panels, inner monitor any shocks
parts. This system enhances collision safety by coming from the side of the vehicle. The warning
restraining the front occupants in case of an lamp on the instrument panel indicates the
accident. operational status of the SRS. The clock spring
The SRS consists of four air bag modules, SRS is installed in the steering column.
air bag control unit (SRS-ECU), front impact sensor, The SRS side air bags deploy if an impact received
side impact sensors, seat belt pre-tensioner, SRS at the side of the vehicle is stronger than a certain
warning lamp and clock spring. The air bags are set value, in order to protect the front seat occupant’s
located in the centre of the steering wheel, above torso in the event of a collision. Only authorized
the glove box, and built into the front seat back service personnel should do work on or around the
assemblies. Each air bag has a folded air bag and SRS components. Those service personnel should
an inflator unit. The SRS-ECU under the floor read this manual carefully before starting any such
console monitors the system and has a safing work. Extreme care must be used when servicing
G-sensor and an analog G-sensor. The front impact the SRS to avoid injury to the service personnel
sensor are installed on the front side mrmber. The (by inadvertent deployment of the air bags) or the
side impact sensors inside the quater panel inner driver (by rendering the SRS inoperative).

Driver’s air bag module Front passenger’s

air bag module

SRS warning lamp

Clock spring

Diagnosis
connector
SRS-ECU

Seat belts with pre-tensioner

SRS-ECU

Side air bag

module*

Side impact
sensor*

Front impact sensor

NOTE
*: Indicates the parts equipped on the right and left sides.
00-22 GENERAL – Supplemental Restraint System (SRS)

Front passenger’s air bag

Driver’s air
Seat belts with pre-tensioner bag

Side air bag

SRS SERVICE PRECAUTIONS

1. In order to avoid injury to yourself or others NOTE
from accidental deployment of the air bag during If any of these components are diagnosed as
servicing, read and carefully follow all the faulty, they should only be replaced, in
precautions and procedures described in this accordance with the INDIVIDUAL COM-
manual. PONENTS SERVICE procedures in this
2. Do not use any electrical test equipment on manual. (Refer to GROUP 52B.)
or near SRS components, except those
specified on GROUP 52B.
3. Never Attempt to Repair the Following
Components:
SRS air bag control unit (SRS-ECU)
Clock spring
Driver’s and front passenger’s air bag
modules
Side air bag modules
Side impact sensors

4. After disconnecting the negative (–) battery cable, wait

Insulating tape Battery 60 seconds at least before any service and insulate
the disconnected cable with tape. The SRS retain
enough voltage to deploy the air bags for a short time
even after the disconnection of the battery. So, serious
injury may result by accidental air bag deployment
if a work is done on the SRS just after the disconnection
of the battery.
 GENERAL – Supplemental Restraint System (SRS) 00-23
SRS-ECU connector 5. Do not attempt to repair the wiring harness connectors
of the SRS. If the connector(s) are diagnosed as defective,
replace the wiring harness(es). If the harness(es) are
diagnosed as faulty, replace or repair the wiring
harness(es) according to the table that follows.

SRS-ECU Destination of harness Corrective action

Terminal No.

1, 2, 3, 4 Instrument panel wiring harness → Front wiring harness → Front Repair or replace each wiring
impact sensor harness

7 Instrument panel wiring harness → Earth

8 Instrument panel wiring harness → Combination meter

(SRS warning lamp)

9, 10 Instrument panel wiring harness → Front passenger’s air bag

module

11, 12 Instrument panel wiring harness → Clock spring → Driver’s air bag Repair or replace the dash wiring
module) harness. Replace clock spring.

13 Instrument panel wiring harness → Junction block (fuse No.8) Repair or replace each wiring
harness
harness.
16 Instrument panel wiring harness → Junction block (fuse No.6)

20 Instrument panel wiring harness → Diagnosis connector

21, 22 Body wiring harness → Side air bag module (L.H.)

23, 24 Body wiring harness → Side air bag module (R.H.)

27, 28 Body wiring harness → Seat belt with pre-tensioner (R.H.)

29, 30 Body wiring harness → Seat belt with pre-tensioner (L.H.)

34, 35, 36 Body wiring harness → Side impact sensor (L.H.)

40, 41, 42 Body wiring harness → Side impact sensor (R.H.)

00-24 GENERAL – Supplemental Restraint System (SRS)

6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure.
Insert the special tool (probe, MB991222, in the harness set) into the connector from harness side
(rear side), and connect the tester to this probe. If any tool than specified is used, damage to the
harness and other components will result. Furthermore, measurement should not be carried out by
touching the probe directly against the terminals from the front of the connector. The terminals are
plated to increase their conductivity, so that if they are touched directly by the probe, the plating may
break, which will cause drops in reliability.

SRS-ECU harness connector SRS-ECU harness connector (rear view)

MB991222

7. SRS components should not be subjected to temperature over 93 C, so remove the SRS-ECU, driver’s
and front passenger’s air bag modules, clock spring, front impact sensor, side impact sensors and front seat
assemblies (side air bag modules) before drying or baking the vehicle after painting.
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to GROUP 52B.)
9. Make certain that the ignition switch is LOCK (OFF) position when the MUT-II is connected or disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.
 GENERAL – Support Locations for Lifting and Jacking 00-25
SUPPORT LOCATIONS FOR LIFTING AND JACKING
Caution
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.

SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS

GARAGE JACK
Caution
Never support any point other than the specified ones, or deformation will result.

AXLE STANDS

Notch Notch

Rubber Rubber
00-26 GENERAL – Support Locations for Lifting and Jacking

SUPPORT POSITIONS FOR A Caution

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

DOUBLE-POST LIFT
Notch
Notch

SINGLE-POST LIFT
 GENERAL – Support Locations for Lifting and Jacking 00-27

H-bar lift SUPPORT POSITIONS AND SUPPORT METHOD

FOR AN H-BAR LIFT
H-bar lift Caution
When service procedures require removing the rear
suspension, fuel tank, spare tyre and rear bumper, place
additional weight on rear end of vehicle or anchor vehicle
to hoist to prevent tipping of centre of gravity changes.
When H-bar lift is used to lift up vehicles, use of metallic
attachment attached to the H-bar lift may cause damage to
the suspension arm etc. Therefore, lift up the vehicle by the
following procedure.

Chassis-sup- 1. Place the vehicle on the H-bar lift (same direction).

port position 2. Place attachments on the H-bar lift at the designated
(side sill) Attachment chassis-support positions. When making the attachments,
refer to the section concerning making them.
Section A–A Caution
Side sill If support is at any location other than the designated
positions, the body or suspension might be deformed
or otherwise damaged, so care should be taken to
support only at the correct (designated) positions.
H-bar lift
H-bar lift 3. Raise the H-bar lift to the height at which the vehicle is
Attachment
slightly raised and check to be sure that the vehicle is
correctly and sufficiently secured; then raise the vehicle.

A
00-28 GENERAL – Support Locations for Lifting and Jacking

PREPARATION OF “ATTACHMENTS”
Block (A) mm
1. Prepare the blocks (wooden) and nails as shown in the
1,800 figure.
Item Dimensions mm Quantity
90 Block (A) 90 × 95 × 1,800 2
Block (B) 60 × 100 × 95 4
95
Block (C) 140 × 40 × 95 8
Block (B) Block (C) Nail 70 or more 32

15
15 Caution
40 20 40 The wood selected for the blocks must be hard.
40 20
40 2. For the (B) blocks and (C) blocks, use a saw and chisel
60 140
or similar tool to make grooves of the dimensions shown
in the figure.
3. Make four “ATTACHMENTS” such as shown in the figure
100 40 nailing (B) and (C) blocks so that each (B) blocks is
sandwiches between (C) blocks.

Block (C)
100

Block (C)

140 Nail

Block (B)

Finished attachment

Movable according
to vehicle width
 GENERAL – Standard Part/Tightening-Torque Table 00-29
STANDARD PART/TIGHTENING-TORQUE TABLE
Each torque value in the table is a standard value The values in the table are not applicable:
for tightening under the following conditions. (1) If toothed washers are inserted.
(1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
and plated with zinc. (3) If bolts are tightened to plastic or die-cast
(2) The threads and bearing surface of bolts and inserted nuts.
nuts are all in dry condition. (4) If self-tapping screws or self-locking nuts are
used.

Standard bolt and nut tightening torque

Thread size Torque Nm

Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)

M5 0.8 2.5 4.9 5.9

M6 1.0 4.9 8.8 9.8

M8 1.25 12 22 25

M10 1.25 24 44 52

M12 1.25 41 81 96

M14 1.5 72 137 157

M16 1.5 111 206 235

M18 1.5 167 304 343

M20 1.5 226 412 481

M22 1.5 304 559 647

M24 1.5 392 735 853

Flange bolt and nut tightening torque

Thread size Torque Nm

Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)

M6 1.0 4.9 9.8 12

M8 1.25 13 24 28

M10 1.25 26 49 57

M10 1.5 24 44 54

M12 1.25 46 93 103

M12 1.75 42 81 96
NOTES
 GENERAL – Vehicle Identification 00-1
GROUP 00
GENERAL
VEHICLE IDENTIFICATION
MODELS
Model code Engine model Transmission model Fuel supply system

H67 WMNJCLA 4G94-DOHC (1,999 mL) V5M21 <5M/T> GDI

WMNJCRA

WMRJCLA V4AW4 <4A/T>

WMRJCRA

H77 WLNJCLA V5M21 <5M/T>

WLNJCRA

WRNJCLA V4AW4 <4A/T>

WRNJCRA

MODEL CODE

No. Items Contents

1 Development H6: MITSUBISHI PAJERO

PININ Short wheelbase
1 2 3 4 5 6 7 8 9 H7: MITSUBISHI PAJERO
PININ Long wheelbase

2 Engine type 7: 2,000 mL petrol engine

3 Sort W: Wagon

4 Body style M: 3-door

L: 5-door

5 Transmission type N: 5-speed manual

transmission
R: 4-speed automatic
transmission

6 Trim level J: GL

7 Specification engine C: GDI-DOHC

feature
00-2 GENERAL – Vehicle Identification

No. Items Contents

8 Steering wheel location L: Left hand

R: Right hand

9 Destination A: For Europe

CHASSIS NUMBER

1 2 3 4 5 6 7 8 9

No. Items Contents

1 Steering wheel location JMP Left hand drive

JMR Right hand drive

2 Body style 0 Standard roof

3 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

4 Development order H6 PAJERO PININ Short wheelbase

H7 PAJERO PININ Long wheelbase

5 Engine 7 4G94: 1,999 mL petrol engine

6 Sort W Wagon

7 Model year 1 2001

8 Plant X IPF

9 Serial number – –
 GENERAL – Major Specifications 00-3
MAJOR SPECIFICATIONS
<3-door model>

5 7 4 8
1

2
<L.H.drive
vehicles>

<R.H.drive
vehicles>
00-4 GENERAL – Major Specifications

Items H67WMNJCLA H67WMNJCRA H67WMRJCLA H67WMRJCRA

Vehicle Overall length 1 3,735

di
dimensions
i
Overall width 2 1,695
mm
Overall height (unladen) 3 1,690/1,725*1/1,700*2
Wheelbase 4 2,280
Track-front 5 1,435
Track-rear 6 1,445
Overhang-front 7 755
Overhang-rear 8 700
Ground clearance 9 200
(unladen)
Vehicle Kerb weight 1,300 1,320
i ht kg
weight k
Max. gross vehicle weight 1,725
Max. axle weight 745 755
rating-front
Max. axle weight 555 565
rating-rear
Seating capacity 4
Engine
g Model No. 4G94
Total displacement mL 1,999
Transmis- Model No. V5M21 V4AW4
sion
i
Type 5-speed manual 4-speed automatic
Fuel system Fuel supply system Gasoline Dirrect Injection

NOTE:
*1: Vehicles with roof rails
*2: Vehicles with roof spoiler
 GENERAL – Major Specifications 00-5
<5-door model>

5 7 4 8
1

2
<L.H.drive
vehicles>

<R.H.drive
vehicles>
00-6 GENERAL – Major Specifications

Items H77WLNJCLA H77WLNJCRA H77WRNJCLA H77WRNJCRA

Vehicle Overall length 1 4,035

di
dimensions
i
Overall width 2 1,695
mm
Overall height (unladen) 3 1,700/1,735*1/1,720*2
Wheelbase 4 2,450
Track-front 5 1,435
Track-rear 6 1,445
Overhang-front 7 755
Overhang-rear 8 830
Ground clearance 9 200
(unladen)
Vehicle Kerb weight 1,390 1,410
i ht kg
weight k
Max. gross vehicle weight 1,890
Max. axle weight 770 785
rating-front
Max. axle weight 620 625
rating-rear
Seating capacity 5
Engine
g Model No. 4G94
Total displacement mL 1,999
Transmis- Model No. V5M21 V4AW4
sion
i
Type 5-speed manual 4-speed automatic
Fuel system Fuel supply system Gasoline Dirrect Injection

NOTE:
*1: Vehicles with roof rails
*2: Vehicles with roof spoiler
 GENERAL – How to Use This Manual/Vehicle Identification 00-1
GROUP 00
GENERAL
HOW TO USE THIS MANUAL
INDICATION OF TIGHTENING TORQUE
Tightening torques (units: N·m) are set to take into account the central value and the allowable tolerance.
The central value is the target value, and the allowable tolerance provides the checking range for tightening
torques. If bolts and nuts are not provided with tightening torques, refer to P.00-8.
VEHICLE IDENTIFICATION
MODELS
Model code Engine model Transmission model Fuel supply system

H67 WMNJCLA 4G94-DOHC (1,999 mL) V5M21 <5M/T> GDI

WMNJCRA

WMRJCLA V4AW4 <4A/T>

WMRJCRA

H66 WMNDELA 4G93-SOHC (1,834 mL) V5M21 <5M/T> MPI

WMNDERA

WMRDELA V4AW4 <4A/T>

WMRDERA

H77 WLNJCLA 4G94-DOHC (1,999 mL) V5M21 <5M/T> GDI

WLNJCRA

WLRJCLA V4AW4 <4A/T>

WLRJCRA

H76 WLNDELA 4G93-SOHC (1,834 mL) V5M21 <5M/T> MPI

WLNDERA

WLRDELA V4AW4 <4A/T>

WLRDERA
00-2 GENERAL – Vehicle Identification

MODEL CODE

No. Items Contents

1 Development H6: MITSUBISHI PAJERO

PININ Short wheelbase
1 2 3 4 5 6 7 8 9 H7: MITSUBISHI PAJERO
PININ Long wheelbase

2 Engine type 6: 1,800 mL petrol engine

7: 2,000 mL petrol engine

3 Sort W: Wagon

4 Body style M: 3-door

L: 5-door

5 Transmission type N: 5-speed manual

transmission
R: 4-speed automatic
transmission

6 Trim level D: L
J: GL

7 Specification engine E: MPI-SOHC

feature C: GDI-DOHC

8 Steering wheel location L: Left hand

R: Right hand

9 Destination A: For Europe

 GENERAL – Vehicle Identification 00-3
CHASSIS NUMBER

1 2 3 4 5 6 7 8 9

No. Items Contents

1 Steering wheel location JMP Left hand drive

JMR Right hand drive

2 Body style 0 Standard roof

3 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

4 Development order H6 PAJERO PININ Short wheelbase

H7 PAJERO PININ Long wheelbase

5 Engine 6 4G93: 1,834 mL petrol engine

7 4G94: 1,999 mL petrol engine

6 Sort W Wagon

7 Model year 2∗ 2002

8 Plant X IPF

9 Serial number – –

NOTE
∗: Indicates new model.
00-4 GENERAL – Major Specifications

MAJOR SPECIFICATIONS
<3-door model>

5 7 4 8
1

2
<L.H.drive
vehicles>

<R.H.drive
vehicles>
 GENERAL – Major Specifications 00-5
Items H66WMNDELA H66WMNDERA H66WMRDELA H66WMRDERA

Vehicle Overall length 1 3,735

di
dimensions
i
Overall width 2 1,680
mm
Overall height (unladen) 3 1,690/1,725*1/1,700*2
Wheelbase 4 2,280/2,272*3
Track-front 5 1,435
Track-rear 6 1,445
Overhang-front 7 755
Overhang-rear 8 700
Ground clearance 9 200
(unladen)
Vehicle Kerb weight 1,255 1,275
i ht kg
weight k
Max. gross vehicle weight 1,680
Max. axle weight 710 720
rating-front
Max. axle weight 545 555
rating-rear
Seating capacity 4
Engine
g Model No. 4G93
Total displacement mL 1,834
Transmis- Model No. V5M21 V4AW4
sion
i
Type 5-speed manual 4-speed automatic
Fuel system Fuel supply system Electronically controlled multipoint injection

NOTE:
*1: Vehicles with roof rails
*2: Vehicles with roof spoiler
*3: Measure in running condition
00-6 GENERAL – Major Specifications

<5-door model>

5 7 4 8
1

<L.H.drive
vehicles>

<R.H.drive
vehicles>
 GENERAL – Major Specifications 00-7
Items H76WLNDELA H76WLNDERA H76WRNDELA H76WRNDERA

Vehicle Overall length 1 4,035

di
dimensions
i
Overall width 2 1,680
mm
Overall height (unladen) 3 1,700/1,735*1/1,720*2
Wheelbase 4 2,450/2,439*3
Track-front 5 1,435
Track-rear 6 1,445
Overhang-front 7 755
Overhang-rear 8 830
Ground clearance 9 200
(unladen)
Vehicle Kerb weight 1,340 1,360
i ht kg
weight k
Max. gross vehicle weight 1,840
Max. axle weight 735 750
rating-front
Max. axle weight 605 610
rating-rear
Seating capacity 5
Engine
g Model No. 4G93
Total displacement mL 1,843
Transmis- Model No. V5M21 V4AW4
sion
i
Type 5-speed manual 4-speed automatic
Fuel system Fuel supply system Electronically controlled multipoint injection

NOTE:
*1: Vehicles with roof rails
*2: Vehicles with roof spoiler
*3: Measure in running condition
00-8 GENERAL – Standard Part/Tightening Torque Table

STANDARD PART/TIGHTENING TORQUE TABLE

Each torque value in the table is a standard value The values in the table are not applicable:
for tightening under the following conditions. (1) If toothed washers are inserted.
(1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
and plated with zinc. (3) If bolts are tightened to plastic or die-cast
(2) The threads and bearing surface of bolts and inserted nuts.
nuts are all in dry condition. (4) If self-tapping screws or self-locking nuts are
used.

Standard bolt and nut tightening torque

Thread size Torque N·m

Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)

M5 0.8 2.5 ± 0.5 5.0 ± 1.0 6.0 ± 1.0

M6 1.0 5.0 ± 1.0 9.0 ± 2.0 10 ± 2

M8 1.25 12 ± 2 22 ± 4 25 ± 4

M10 1.25 24 ± 4 44 ± 10 53 ± 7

M12 1.25 41 ± 8 83 ± 12 98 ± 12

M14 1.5 73 ± 12 140 ± 20 155 ± 25

M16 1.5 110 ± 20 210 ± 30 235 ± 35

M18 1.5 165 ± 25 300 ± 40 340 ± 50

M20 1.5 225 ± 35 410 ± 60 480 ± 70

M22 1.5 300 ± 40 555 ± 85 645 ± 95

M24 1.5 395 ± 55 735 ± 105 855 ± 125

Flange bolt and nut tightening torque

Thread size Torque N·m

Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)

M6 1.0 5.0 ± 1.0 10 ± 2 12 ± 2

M8 1.25 13 ± 2 24 ± 4 27 ± 5

M10 1.25 26 ± 4 49 ± 9 58 ± 7

M10 1.5 24 ± 4 45 ± 8 55 ± 10

M12 1.25 46 ± 8 95 ± 15 105 ± 15

M12 1.75 43 ± 8 83 ± 12 98 ± 12

NOTE
1. Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
2. Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater
the bolt strength.
 SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN No.: MSB-00E00-505

Date: 2001-09-25 <Model> <M/Y>

Subject: ESTABLISHMENT OF GDI ENGINE IDLE (EC)PAJERO/MON- 01-10
LEARNING FUNCTION TERO(V60,70) 99-10
(EC)GALANT(EA0) 99-10
(EC)SPACE RUN- 98-10
Group: GENERAL Draft No.: 00AL610610 NER/SPACE WAG- 99-10
ON(N60,80,90) 99-10
(EC)CARISMA
CORRECTION INTERNATIONAL (EC)SPACE
CAR
ADMINISTRATION
STAR(H60,70)
T.MASAKI-MANAGER
OFFICE TECHNICAL SERVICE PLANNING (EC)PAJERO PININ
1. Description:
On the GDI engine equipped cars, an idle learning function that will be required after replacement
of the ECU (for engine control) or after resetting of the battery* has been established.
*: Disconnection of ECU (for engine control) battery backup power supply (disconnection of
battery terminals or ECU connectors)

2. Applicable Manuals:
Manual Pub. No. Language Page(s)
2001 PAJERO PWJE0001 (1/2) (English) 00-29
Workshop Manual VOL.1
2001 MONTERO PWJS0002 (1/2) (Spanish)
Workshop Manual VOL.1
2001 PAJERO/MONTERO PWJT0008R (English)
Workshop Manual CD-ROM PWJT0008R (Spanish)
PWJT0008R (French)
PWJT0008R (German)
1999 GALANT PWDE9611-A (English) 00-12
Workshop Manual Supplement PWDS9612-A (Spanish)
PWDF9613-A (French)
PWDG9614-A (German)
PWDD9615-A (Dutch)
PWDW9616-A (Swedish)
1999 SPACE RUNNER/SPACE WAGON PWDE9803 (English) 00-20
Workshop Manual PWDS9804 (Spanish)
PWDF9805 (French)
PWDG9806 (German)
PWDD9807 (Dutch)
PWDW9808 (Swedish)
 Manual Pub. No. Language Page(s)
1998 CARISMA PWDE9502-C (English) 00-4
Workshop Manual Supplement PWDS9503-C (Spanish)
PWDF9504-C (French)
PWDG9505-C (German)
PWDD9506-C (Dutch)
PWDW9507-C (Swedish)
1999 SPACE STAR CMXE99E1 (English) 00-18
Workshop Manual CMXS99E1 (Spanish)
CMXF99E1 (French)
CMXG99E1 (German)
CMXD99E1 (Dutch)
CMXW99E1 (Swedish)
CMXI99E1 (Italian)
1999 PAJERO PININ/MONTERO SPORT CKRE99E1 (English) 00-17
Workshop Manual CKRS99E1 (Spanish)
CKRF99E1 (French)
CKRG99E1 (German)
CKRD99E1 (Dutch)
CKRW99E1 (Swedish)
CKRI99E1 (Italian)

2
3. Details:
Contents of Attachment are to be added to GROUP 00 (GENERAL).

PRECAUTIONS BEFORE SERVICE

LEARNING FUNCTION OF GDI ENGINE
1. Purpose
On the GDI engine equipped cars, when replacement of the ECU (for engine control) or
resetting of the battery* has been performed, an idle learning function of the ECU (for engine
control) will be required.
The idle learning function will be completed by running the engine at idle by the following
procedure.
NOTE:
*: Disconnection of ECU (for engine control) battery backup power supply (disconnection of
battery terminals or ECU connectors)

2. Idle Learning Procedure

(1) Start the engine, and warm up the engine until its coolant temperature reaches 85°C or
higher. When the engine coolant temperature is 85°C or higher, you have only to turn the
ignition switch to the ON position.
(2) Turn the ignition switch to the LOCK (OFF) position, and stop the engine.
(3) After lapse of ten or more seconds, restart the engine.
(4) Run the engine at idle for ten minutes under the following conditions.
• Transmission: Neutral (P range for automatic transmission)
• Air conditioner and heater: Not operational
• Engine coolant temperature: 83°C or higher
(5) Stop the engine
(6) Restart the engine, and run it at idle for ten minutes under the following condition.
• Transmission: Neutral (P range for automatic transmission)
• Air conditioner: Operational (Temperature set at “maximum cool”, fan at high spe ed,
and windows fully opened)
• Engine coolant temperature: 83°C or higher
(7) Repeat steps (5) and (6).
NOTE
1) When the atmospheric temperature is 20°C or more and the air conditioner has
continuously been operated, step (7) may be omitted.
2) During idling operation of the engine in steps (4) and (6), when engine operation switches
from lean operation to stoichiometric operation, engine stall can occur. In this case, clean
the throttle body (throttle valve) thoroughly, and then repeat step (1) and the subsequent
steps.

3
 ENGINE
<4G9-GDI>
Click on the applicable bookmark to selected the required model year
 11A-1

ENGINE
<4G9-GDI>
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 16

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CAMSHAFT AND CAMSHAFT OIL SEAL . . . 17

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 23

Drive Belt Tension Check and Adjustment . . . . . . 6
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 25
Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . 9
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 33
Compression Pressure Check . . . . . . . . . . . . . . . . . 11
Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . 12
11A-2 ENGINE <4G9-GDI> – General Information/Service Specifications

GENERAL INFORMATION
Items 4G93-GDI

Total displacement mȏ 1,834

Bore × Stroke mm 81 × 89
Compression ratio 12.0
Combustion chamber Pentroof + ball-in-piston
Camshaft arrangement DOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake Opening BTDC 15_
Closing ABDC 56_
Exhaust Opening BBDC 55_
Closing ATDC 15_
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type
Auto-lash adjuster Equipped

SERVICE SPECIFICATIONS
Items Standard value Limit
Alternator drive belt tension Vibration frequency Hz 143 – 185 –
(When checked)
Tension N 294 – 490 –
Deflection (Reference value) mm 9.7 – 12.9 –
Alternator drive belt tension Vibration frequency Hz 155 – 175 –
(When adjusted)
Tension N 343 – 441 –
Deflection (Reference value) mm 10.5 – 12.0 –
Alternator drive belt tension Vibration frequency Hz 203 – 234 –
(When replaced)
Tension N 588 – 784 –
Deflection (Reference value) mm 6.7 – 8.5 –
 ENGINE <4G9-GDI> – Service Specifications/Sealants 11A-3

Items Standard value Limit

Power steering oil pump and Vibration frequency Hz 114 – 139 –
A/C compressor drive belt
tension ((When checked)) Tension N 392 – 588 –
Deflection (Reference value) mm 10.0 – 12.0 –
Power steering oil pump and Vibration frequency Hz 121 – 133 –
A/C compressor drive belt
tension ((When adjusted)
j ) Tension N 441 – 539 –
Deflection (Reference value) mm 10.0 – 11.0 –
Power steering oil pump and Vibration frequency Hz 145 – 166 –
A/C compressor drive belt
tension ((When replaced)) Tension N 637 – 834 –
Deflection (Reference value) mm 7.0 – 9.0 –
Basic ignition timing 5_ BTDC ± 3_ –
Ignition timing Approx. 16_BTDC*1 –
Idle speed r/min 600 ± 50*1 –
CO contents % 0.6 or less –
HC contents ppm 200 or less –
Compression pressure kPa – r/min 1,720 – 300 1,337 – 300
Compression pressure difference of all cylinder kPa – Max. 100
Intake manifold vacuum kPa – Min. 60*2
Cylinder head bolt shank length mm – 96.4

Auto-tensioner push rod movement mm Within 1 –

Timing belt tension torque Nm (Reference value) 2.5 – 4.0 –

Auto-tensioner rod protrusion amount mm 3.8 – 4.5 –

NOTE
*1: Indicates the value measured within 4 minutes since the engine was started.
*2: Indicates the value when more than 4 minutes have passed since the engine was started.

SEALANTS
Items Specified sealants Remarks

Beam camshaft cap 3M ATD Part No.8660 or equivalent –

Cylinder head

Cam position sensor support MITSUBISHI GENUINE PART Semi-drying sealant

Oil pan MD970389 or equivalent

Thrust case 3M Stud Locking 4170 or equivalent –

Flywheel or drive plate bolt
11A-4 ENGINE <4G9-GDI> – Special Tools

SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub D Measuring the drive belt tension
assembly D Checking the ignition timing
D Checking the idle speed
D Erasing diagnosis code

MB991668 Belt tension meter Measuring the drive belt tension

set (used together with the MUT-II)

MB990767 End yoke holder D Holding the camshaft sprocket

D Holding the crankshaft sprocket

MD998719 or Crankshaft pulley D Holding the camshaft sprocket

MD998754 holder pin D Holding the crankshaft sprocket

MD998713 Camshaft oil seal Press-in of the camshaft oil seal

installer

MD998781 Flywheel stopper Securing the flywheel or drive plate

MD998776 Crankshaft rear oil Press-in of the crankshaft rear oil seal
seal installer

MB990938 Handle Press-in of the crankshaft rear oil seal

MD998717 Crankshaft front oil Press–in of crankshaft front oil seal

seal installer
 ENGINE <4G9-GDI> – Special Tools 11A-5

Tool Number Name Use

MB991653 Cylinder head bolt Cylinder head bolt removal and installation
wrench

MD998767 Tension pulley Timing belt tension adjustment

socket wrench
11A-6 ENGINE <4G9-GDI> – On-vehicle Service

ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Check the drive belt tension in the following procedure.
Standard value:

Vibration frequency Hz 143 – 185

Tension N 294 – 490
Deflection (Reference value) mm 9.7 – 12.9

15_ MB991668 <When using the MUT-II>

15_ (Microphone)
1. Connect the special tool (belt tension meter set) to the
MUT-II.
2. Connect the MUT-II to the diagnosis connector.
10 – 20 mm 3. Turn the ignition switch to ON and select “Belt Tension
Measurement” from the menu screen.
4. Hold the microphone to the middle of the drive belt between
Alternator pulley the pulleys (at the place indicated by the arrow), about
10 – 20 mm away from the rear surface of the belt and
Crankshaft pulley so that it is perpendicular to the belt (within an angle of
± 15_).
5. Gently tap the middle of the belt between the pulleys (the
place indicated by the arrow) with your finger as shown
in the illustration, and check that the vibration frequency
of the belt is within the standard value.
Caution
(1) The temperature of the surface of the belt should
be as close as possible to normal temperature.
(2) Do not let any contaminants such as water or oil
get onto the microphone.
(3) If strong gusts of wind blow against the
microphone or if there are any loud sources of
noise nearby, the values measured by the
microphone may not correspond to actual values.
(4) If the microphone is touching the belt while the
measurement is being made, the values measured
by the microphone may not correspond to actual
values.
(5) Do not take the measurement while the vehicle’s
engine is running.
 ENGINE <4G9-GDI> – On-vehicle Service 11A-7
Belt tension <When using a tension gauge>
gauge Use a belt tension gauge to check that the belt tension is
within the standard value.

Alternator pulley

Crankshaft pulley

<Belt deflection check>

Apply 98 N of force to the middle of the drive belt between
98 N the pulleys (at the place indicated by the arrow) and check
that the amount of deflection is within the standard value.

Alternator pulley

Crankshaft pulley

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT

1. Loosen the nut of the alternator pivot bolt.
Adjusting bolt 2. Loosen the lock bolt.
Lock bolt
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.

Alternator
Standard value:
pivot nut
Items When adjusted When replaced
Alternator
pivot bolt Vibration frequency Hz 155 – 175 203 – 234
Tension N 343 – 441 588 – 784
Deflection 10.5 – 12.0 6.7 – 8.5
(Reference value) mm

4. Tighten the nut of the alternator pivot bolt.

Tightening torque: 44 Nm
5. Tighten the lock bolt.
Tightening torque: 22 Nm
6. Tighten the adjusting bolt.
Tightening torque: 5 Nm
11A-8 ENGINE <4G9-GDI> – On-vehicle Service

POWER STEERING OIL PUMP AND AIR CONDITIONER

Oil pump pulley COMPRESSOR DRIVE BELT TENSION CHECK AND
Tension ADJUSTMENT
pulley 1. Check if the belt tension is within the standard value using
B one of the methods below.
Crankshaft A
pulley Standard value:
A/C Items When When When
compressor
pulley checked adjusted replaced
Vibration 114 – 139 121 – 133 145 – 166
frequency
Hz
Tension N 392 – 588 441 – 539 637 – 834
Deflection 10.0 – 12.0 10.0 – 11.0 7.0 – 9.0
(Reference
value) mm
<When measuring the vibration frequency>
With your finger tip lightly tap the centre of the belt between
the pulleys in the location shown by the arrow in the
illustration and then measure the belt vibration frequency.
NOTE
Refer to P.11A-7 for information regarding the vibration
frequency measurement method using MUT-II.
<When measuring the tension>
Use a belt tension gauge to measure the belt tension.
<When measuring the deflection>
Apply 98 N of pressure against the location between the
pulleys shown by the arrow in the illustration and then
measure the deflection.
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing nut A.
Tightening torque: 25 Nm
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
 ENGINE <4G9-GDI> – On-vehicle Service 11A-9
IGNITION TIMING CHECK
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Connect the MUT-II to the diagnosis connector.

MUT-II

Condenser 3. Set the timing light to the condenser of the No.1 ignition
coil power supply line (terminal No.3).
4. Start the engine and run at idle.
5. Check that engine idle speed is within the standard value.
Standard value: 600 ± 50 r/min
No.1 ignition coil
NOTE
After 4 minutes or more have passed in the idle running
condition, the idle speed will become 750 r/min.
6. Select No.17 of the MUT-II Actuator test.
NOTE
At this time, the engine speed will become approximately
750 r/min.
7. Check that basic ignition timing is within the standard value.
Standard value: 5_ BTDC ± 3_
8. If the basic ignition timing is outside the standard value,
inspect the GDI system while referring to GROUP 13A
– Troubleshooting.
9. Press the MUT-II clear key (Select a forced driving cancel
mode) to release the Actuator test.
Caution
If the test is not cancelled, a forced driving will continue
for 27 minutes. Driving under this condition may
damage the engine.
10. Check that ignition timing is at the standard value.
Standard value: approx. 16_BTDC
NOTE
(1) The ignition timing will become approximately 5_BTDC
after more than 4 minutes have passed since the basic
ignition timing set mode was released.
(2) The ignition timing may fluctuate within ±7_BTDC.
This is normal.
(3) In higher altitude, the ignition timing is more advanced
than the standard value by approximately 5 degree.
11A-10 ENGINE <4G9-GDI> – On-vehicle Service

IDLE SPEED CHECK

1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn off the ignition switch and then connect the MUT-II
to the diagnosis connector.
3. Check the basic ignition timing.
NOTE
Refer to P.11A-9 concerning the check procedure of the
MUT-II basic ignition timing.
Standard value: 5_ BTDC ± 3_
4. Run the engine at idle for 2 minutes.
5. Check the idle speed. Select item No. 22 and take a reading
of the idle speed.
Standard value: 600 ± 50 r/min
NOTE
(1) After 4 minutes or more have passed in the idle running
condition, the idle speed will become 750 r/min.
(2) The idle speed is controlled automatically by the idle
speed control system.
6. If the idle speed is outside the standard value, inspect the
GDI components by referring to GROUP 13A –
Troubleshooting.

IDLE MIXTURE CHECK

1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Connect the MUT-II to the diagnosis connector.
3. Check that the basic ignition timing is within the standard
value.
NOTE
Refer to P.11A-10 concerning the check procedure of the
MUT-II basic ignition timing.
Standard value: 5_ BTDC ± 3_
4. Run the engine at 2,500 r/min for 2 minutes.
5. Set the CO, HC tester.
 ENGINE <4G9-GDI> – On-vehicle Service 11A-11
6. Check the CO contents and the HC contents at idle.
NOTE
This measurement should be performed in less than
approximately 4 minutes since the engine speed become
the idle speed.
Standard value
CO contents: 0.6% or less
HC contents: 200 ppm or less
7. If there is a deviation from the standard value, check the
following items:
D Diagnosis output
D Fuel pressure
D Injector
D Ignition coil, spark plug
D EGR control system
D Evaporative emission control system
D Compression pressure
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.

COMPRESSION PRESSURE CHECK

1. Before inspection, check that the engine oil, starter and
Crank angle sensor battery are normal. In addition, set the vehicle to the
connector pre-inspection condition.
2. Remove all of the ignition coils and spark plugs.
3. Disconnect the crank angle sensor connector.
NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
4. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
(1) Keep away from the spark plug hole when
cranking.
(2) If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
5. Set compression gauge to one of the spark plug holes.
6. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 300 r/min):
1,720 kPa
Limit (at engine speed of 300 r/min):
Min. 1,337 kPa
11A-12 ENGINE <4G9-GDI> – On-vehicle Service

7. Measure the compression pressure for all the cylinders,

and check that the pressure differences of the cylinders are
below the limit.
Limit: Max. 100 kPa
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 and 7.
(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 crank angle sensor connector.
10. Install the spark plugs and ignition coils.
11. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.

MANIFOLD VACUUM CHECK

Vacuum gauge 1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn off the ignition switch.
3. Connect the engine tachometer or connect the MUT-II
to the diagnosis connector.
4. Disconnect the ventilation hose from the positive crankcase
ventilation (PCV) valve, and then connect a vacuum gauge
to the ventilation hose. Plug the positive crankcase
Positive crankcase Plug ventilation (PCV) valve.
ventilation (PCV) valve
5. Start the engine and run it at idle for 4 minutes or more,
and then check the intake manifold vacuum while the
engine is idling.
Limit: Min. 60 kPa
6. Turn off the ignition switch.
7. Remove the vacuum gauge, and then connect the
ventilation hose to the positive crankcase ventilation (PCV)
valve.
8. Remove the engine tachometer or the MUT-II.
ENGINE <4G9-GDI> – On-vehicle Service 11A-13
LASH ADJUSTER CHECK
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur immediately
after the engine is started, if it does not change in
accordance with the engine speed, or if it changes
in accordance with the engine load, the source of
the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after properly
and oil sludge has caused the lash adjusters to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine is
started, and that the noise changes in accordance with
changes in the engine speed.
If the noise does not occur immediately after the engine is
started, or if it does not change in accordance with the
engine speed, the problem is not being caused by the lash
adjusters, so check for some other cause of the problem.
Moreover, if the noise does not change in accordance with
the engine speed, the cause of the problem is probably not
with the engine. (In these cases, the lash adjusters are
normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N → D).
If the noise level changes, the cause of the noise is probably
parts striking because of worn crankshaft bearings or
connecting rod bearings. (In such cases, the lash adjusters
are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or disappeared, oil sludge
could make the lash adjusters stick. Clean the lash
adjusters. (Refer to the Engine Workshop Manual.) If not
improved, go to step 5.
5. Bleed air from the lash adjusters. (Refer to P.11A-14, LASH
ADJUSTER AIR BLEEDING.)
6. If the noise has not disappeared even after the air bleeding,
clean the lash adjusters. (Refer to the Engine Workshop
Manual.)
11A-14 ENGINE <4G9-GDI> – On-vehicle Service

<LASH ADJUSTER AIR BLEEDING>

NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster will
decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air from inside
the lash adjusters.

1. Check the engine oil and replenish or replace the oil if

necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
Good amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation of
High-pressure chamber the lash adjusters will return to normal.
 ENGINE <4G9-GDI> – On-vehicle Service 11A-15
Drive pattern for air bleeding 2. Run the engine at idle for 1 – 3 minutes to let it warm up.
Gradually open the Close the throttle
3. With no load on the engine, repeat the drive pattern shown
throttle valve. valve. in the illustration at left and check if the abnormal noise
Approx. disappears. (The noise should normally disappear after
3,000 r/min 10 – 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
Idle speed not due to air inside the lash adjusters.)
15 15 4. After the noise has disappeared, repeat the drive pattern
seconds seconds
shown in the illustration at left a further 5 times.
Once 5. Run the engine at idle for 1 – 3 minutes and check that
the noise has disappeared.
11A-16 ENGINE <4G9-GDI> – Crankshaft Pulley

CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Engine Cover and Under Cover Removal D Drive Belt Tension Adjustment (Refer to P.11A-7.)
D Engine Cover and Under Cover Installation

2
177 – 186 Nm

(Engine oil) 5

Removal steps
1. Drive belt (Power steering and A/C) 4. Crankshaft pulley washer
2. Drive belt (Alternator) 5. Crankshaft pulley
AA" "AA 3. Crankshaft pulley bolt

REMOVAL SERVICE POINT

AA" CRANKSHAFT PULLEY BOLT REMOVAL

MD990767
MD998719 or
MD998754

INSTALLATION SERVICE POINT

"AA CRANKSHAFT PULLEY BOLT INSTALLATION
When installing the crankshaft bolt, apply the minimum amount
of engine oil to the bearing surface and thread of the bolt.
 ENGINE <4G9-GDI> – Camshaft and Camshaft Oil Seal 11A-17
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Air Intake Hose and Resonance Tank Removal and D Intake Manifold Removal and Installation
Installation (Refer to GROUP 15 – Air Cleaner and (Refer to GROUP 15.)
Resonance Tank.) D Fuel Pump (High Pressure) and Fuel Pressure
D Timing Belt Removal and Installation Regulator (High Pressure) Removal and Installation
(Refer to P.11A-29.) (Refer to GROUP 13A.)
D Engine Coolant Draining and Supplying
(Refer to GROUP 14 – On-vehicle Service.)

2
1 Apply engine oil to all
3.4 Nm sliding parts during
installation.

3
14
4

21–25 Nm
10–12 Nm
13 21–25 Nm

12–15 Nm 10–12 Nm 10–12 Nm

16 10
12
15 6
8 9
11 35 Nm
5
22 Nm 10–12 Nm

88 Nm
7

Removal steps
1. Earth cable connection 9. Idler pulley
2. Condenser 10. Timing belt rear cover, upper (LH)
3. Rocker cover 11. Timing belt rear cover, lower (RH)
4. Rocker cover gasket 12. Timing belt rear cover, upper (RH)
5. Camshaft position sensor support "BA 13. Beam camshaft cap
6. Camshaft position sensing cylinder 14. Beam camshaft cap gasket
AA" "DA 7. Camshaft sprocket 15. Thrust case
"CA 8. Camshaft oil seal "AA 16. Camshaft
11A-18 ENGINE <4G9-GDI> – Camshaft and Camshaft Oil Seal

Lubrication points
<Seen from underneath
beam camshaft cap>

Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent Sealant: 3M ATD Part No.8660 or equivalent

(Lip section)

(Engine oil)

(Engine oil)

Sealant:
3M Stud locking 4170
or equivalent <Seen from above cylinder head>

Sealant: 3M ATD Part No.8660 or equivalent

 ENGINE <4G9-GDI> – Camshaft and Camshaft Oil Seal 11A-19
REMOVAL SERVICE POINT
MB990767
AA" CAMSHAFT SPROCKET REMOVAL

MD998719

Camshaft sprocket side INSTALLATION SERVICE POINTS

Screw hole
"AA CAMSHAFT INSTALLATION
1. Apply engine oil to journals and cams of the camshafts.
2. Install the camshafts on the cylinder head.
Caution
Be careful not to confuse the intake camshaft with
the exhaust one. There is a screw hole for the cam
position sensing cylinder mounting bolt on the
Exhaust camshaft exhaust-side camshaft.

"BA BEAM CAMSHAFT CAP INSTALLATION

Approx. Approx.
106_ 101_ 1. Place the camshaft dowel pin as shown in the illustration.

Dowel pin
Intake side Exhaust side

2. Tighten the beam camshaft cap mounting bolts to the

28 27 31 32
specified torque in the order shown in the illustration.
Tightening torque:
20 19 23 24 D : 10 – 12 Nm
d : 21 – 25 Nm
12 11 3 15 16

8 7 1 5 6
Intake side Exhaust
side

14 13 2 9 10

22 21 4 17 18

30 29 25 26

Front of engine
11A-20 ENGINE <4G9-GDI> – Camshaft and Camshaft Oil Seal

"CA CAMSHAFT OIL SEAL INSTALLATION

1. Apply engine oil to the entire circumference of the oil seal
lip.
2. Press-fit the oil seal as shown in the illustration.

MD998713

"DA CAMSHAFT SPROCKET INSTALLATION

Use the special tool to secure the camshaft sprocket in the
same way as during removal, and then tighten the bolt to
the specified torque.
Tightening torque: 88 Nm
 ENGINE <4G9-GDI> – Oil Pan 11A-21
OIL PAN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation D Engine Oil Draining and Supplying (Refer to GROUP
D Oil Level Gauge Removal and Installation 12 – On-vehicle Service.)

14

9
φ 4 ± 1 mm 8 48 Nm

19 Nm
Groove Bolt
hole
14
7 Nm 24 Nm
5

7 Nm

13 7 Nm
Sealant: 5
MITSUBISHI GENUINE PART
MD970389 or equivalent 7 Nm 7
18 Nm 11 39 Nm

3 6
93 Nm
10
11
12 Nm

93 Nm
2
4
1

42 Nm
98 – 118 Nm
69 Nm 1 12
4 42 Nm

Removal steps
1. Splash shIeld 8. Oil screen
2. Power steering pressure hose 9. Gasket
clamp 10. Free-wheeling clutch engage switch
3. Steering gear box and shaft connector connection
connection AC" 11. Front differential mount center bolt
AA" 4. Steering gear box installation bolt AC" 12. Front differential mount
AB" 5. Lower oil pan 13. Bell housing cover
6. Drain plug AD" 14. Upper oil pan
"AA 7. Gasket
11A-22 ENGINE <4G9-GDI> – Oil Pan

REMOVAL SERVICE POINTS

AA" STEERING GEAR BOX INSTALLATION BOLT
REMOVAL
Remove the steering gear box installation bolts and lower
the steering gear box.

Lower oil pan AB" LOWER OIL PAN REMOVAL

Place a piece of wood against the lower oil pan, and tap
the piece of wood with a hammer to remove the lower oil
pan.
Caution
Because the upper oil pan used is made from aluminium,
the oil pan remover (MB998727) should not be used.

AC" FRONT DIFFERENTIAL MOUNT CENTER BOLT/

FRONT DIFFERENTIAL MOUNT REMOVAL
1. Support the front differential by a jack, and remove the
front differential mount center bolts and the front differential
mount.
2. Remove the jack and lower the front differential.

AD" UPPER OIL PAN REMOVAL

After removing all installation bolts, install 2 bolts (M6 85)
in the upper oil pan as shown, noting that one located on
the left side and one on the right side. Turn the bolts to remove
the upper oil pan.
Caution
Because the upper oil pan used is made from aluminium,
the oil pan remover (MB998727) should not be used.

Bolt

INSTALLATION SERVICE POINT

"AA DRAIN PLUG GASKET INSTALLATION
Oil pan side
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
Drain plug
gasket
 ENGINE <4G9-GDI> – Crankshaft Oil Seal 11A-23
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION
7 93 – 103 Nm

<M/T>

10

93 – 103 Nm
8

<A/T>
5
3
1

9
4
2 <A/T> <M/T>

Crankshaft
Crankshaft

10 (Engine oil: (Engine oil:

5 bolt washer bolt washer
surface) surface)

Lip section
Lip section
(Bolt thread) (Bolt thread)
8
Engine oil 7

Sealant: 3M Stud locking 4170 or equivalent

Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
D Timing belt (Refer to P.11A-29.) D Transmission assembly
D Crank angle sensor (M/T: Refer to GROUP 22.)
(Refer to GROUP 16.) (A/T: Refer to GROUP 23.)
1. Crankshaft sprocket D Clutch cover and disc <M/T>
2. Key AA" "BA 6. Adapter plate <A/T>
3. Crankshaft sensing blade AA" "BA 7. Flywheel <M/T>
4. Crankshaft spacer AA" "BA 8. Drive plate <A/T>
"CA 5. Crankshaft front oil seal AA" "BA 9. Crankshaft adapter <A/T>
"AA 10. Crankshaft rear oil seal
11A-24 ENGINE <4G9-GDI> – Crankshaft Oil Seal

REMOVAL SERVICE POINT

AA" ADAPTER PLATE<A/T>/FLYWHEEL <M/T>/DRIVE
PLATE <A/T>/CRANKSHAFT ADAPTER <A/T>
REMOVAL
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.

MD998781

INSTALLATION SERVICE POINTS

Crankshaft
rear oil seal Crankshaft "AA CRANKSHAFT REAR OIL SEAL INSTALLATION
MD990938 1. Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
2. Install the oil seal by tapping it as far as the chamfered
position of the oil seal case as shown in the illustration.

MD998776

"AA CRANKSHAFT ADAPTER <A/T>/DRIVE PLATE

<A/T>/FLYWHEEL <M/T>/ADAPTER PLATE<A/T>
INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the drive plate.
2. Apply oil to the bearing surface of the drive plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the special tool to hold the drive plate in the same
manner as removal, and install the bolt.

"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION

CrankShaft
1. Apply a small amount of engine oil to the entire
MD998717 circumference of the oil seal lip.
2. Tap the oil seal unit it is flush with the oil seal case.

MD998717
Oil seal
 ENGINE <4G9-GDI> – Cylinder Head Gasket 11A-25
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Fuel Discharge Prevention (Refer to GROUP 13A D Fuel Pressure Regulator (High Pressure) and Fuel
– On-vehicle Service.) <Pre-removal only> Pump (High Pressure) Removal and Installation
D Engine Coolant Draining and Supplying (Refer to (Refer to GROUP 13A.)
GROUP 14 – On-vehicle Service.) D Water Bypass Pipe Assembly Removal and
D Engine Oil Draining and Supplying (Refer to GROUP Installation (Refer to GROUP 14 – Water Hose and
12 – On-vehicle Service.) Pipe.)
D Intake Manifold Removal and Installation (Refer to D Timing Belt Removal and Installation (Refer to
GROUP 15.) P.11A-29.)

6 3.4 Nm

78 Nm → 0 Nm → 20 Nm
→ +90_ → +90_ 11 7

1
22 Nm
0
12
44 Nm
9
3

8
5

1
26 Nm
13
10–12 Nm 44 Nm
2

35 Nm

10–12 Nm
4

Removal steps
1. Radiator upper hose connection 8. Tension Pulley
2. Idler pulley AA" 9. Power steering oil pump and brack-
3. Timing belt rear cover, upper (LH) et assembly
4. Timing belt rear cover, lower (RH) 10. Heater hose connection
5. Timing belt rear cover, upper (RH) AB" "BA 11. Cylinder head bolt
6. Earth cable connection 12. Cylinder head assembly
7. Rocker cover assembly "AA 13. Cylinder head gasket
11A-26 ENGINE <4G9-GDI> – Cylinder Head Gasket

REMOVAL SERVICE POINTS

AA" POWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pomp and bracket
assembly in a place where it will not be a hindrance when
removing and installing the cylinder head assembly, and tie
it with a cord.

AB" CYLINDER HEAD BOLT REMOVAL

Use the special tool to loosen the bolts in two or three steps
in the order of the numbers shown in the illustration, and
then remove the bolts.

MB991653

Intake side Front of engine

3 5 10 8 2

1 7 9 6 4

Exhaust side

INSTALLATION SERVICE POINTS

"AA CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
2. Install so that the shapes of the cylinder head holes match
the shapes of the respective cylinder head gasket holes.

"BA CYLINDER HEAD BOLT INSTALLATION

Head bolt
Burred side 1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
Head bolt (Engine If it is outside the limit, replace the bolts.
washer oil)
A Limit (A): 96.4 mm
Cylinder 2. The head bolt washer should be installed with the burred
head side caused by tapping out facing upwards.
3. Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
 ENGINE <4G9-GDI> – Cylinder Head Gasket 11A-27
4. Tighten the bolts by the following procedure.
Step Operation Remarks
1 Tighten to 74 Nm. Carry out in the order
shown in the illustration.
2 Fully loosen. Carry out in the reverse
order of that shown in the
illustration.

MB991653 3 Tighten to 20 Nm. Carry out in the order

shown in the illustration.
4 Tighten 90_ of a turn. In the order shown in the
Intake side Front of engine illustration. Mark the head
of the cylinder head bolt
and cylinder head by paint.
8 6 1 3 9 5 Tighten 90_ of a turn. In the order shown in the
illustration. Check that the
painted mark of the head
10 4 2 5 7 bolt is lined up with that of
the cylinder head.
Exhaust side
Caution
1. Always make a tightening angle just 90_. If it is less
than 90_, the head bolt will be loosened.
2. If it is more than 90_, remove the head bolt and repeat
Step 4 Step 5 the procedure from step 1.
90_ 90_

Painted mark Painted mark

11A-28 ENGINE <4G9-GDI> – Timing Belt

TIMING BELT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Cover Removal and Installation D Crankshaft Pulley Removal and Installation (Refer
D Air Intake Duct Removal and Installation to P.11A-17.)
(Refer to GROUP 15 – Air Cleaner and Resonance
Tank.)

10 – 12 Nm 11

48 Nm
20 – 25 Nm

44 Nm 10 – 12 Nm 10
2 7
2 9
4 8
5 12
49 Nm
35 Nm
12 – 15 Nm

12 Nm 49 Nm

6
10 – 12 Nm

Removal steps
1. Timing belt front upper cover 7. Accessory mount
2. Radiator upper installation bolts 8. Front flange
3. Alternator brace "CA D Timing belt tension adjustment
4. Power steering oil pump bracket AA" "BA 9. Timing belt
stay "AA 10. Auto tensioner
5. Crank angle sensor connector 11. Tensioner pulley and arm assembly
6. Timing belt front lower cover 12. Idler pulley
 ENGINE <4G9-GDI> – Timing Belt 11A-29
Timing marks Timing marks REMOVAL SERVICE POINT
AA" TIMING BELT REMOVAL
1. Turn the crankshaft clockwise to align each timing mark.
Caution
The crankshaft must always be turned clockwise.
2. Loosen the tensioner pulley center bolt and remove the
timing belt.
Caution
If the timing belt is to be re-used, use chalk to mark
(on its flat side) an arrow indicating the clockwise
direction.

INSTALLATION SERVICE POINTS

98 – 196 N
"AA AUTO TENSIONER INSTALLATION
1. Apply 98–196 N force to the push rod of the auto tensioner
by pressing it against a metal (cylinder block, etc.), and
A B
measure the movement of the push rod.
Movement
Standard value:
Push rod Within 1 mm
Auto tensioner A: Length when it is free (not pressed)
B: Length when it is pressed
A – B: Movement
2. If it is out of the standard value, change the auto tensioner.
3. Use a press or vice to gently compress the auto tensioner
B A
push rod until pin hole A of the push rod and pin hole
B of the tensioner cylinder are aligned.
Caution
If the compression speed is too fast, the push rod
may become damaged, so be sure to carry out this
operation slowly.
Contact piece
Contact piece

4. Once the holes are aligned, insert the set pin.

NOTE
When replacing the auto tensioner with a new part, the
pin will be in the auto tensioner.
5. Install the auto tensioner to the engine.

Set pin
11A-30 ENGINE <4G9-GDI> – Timing Belt

Camshaft sprocket "BA TIMING BELT INSTALLATION

Timing marks Timing marks
1. Align the timing marks of each camshaft sprocket and
the crankshaft sprocket.
2. Loosen the tensioner pulley center bolt.
3. Move the crankshaft sprocket half a tooth width in the
anti-clockwise direction.

Crankshaft sprocket

Timing
marks

4. Place the timing belt on the exhaust-side camshaft

Paper clip
sprocket, and hold it in the position shown in the illustration
with a paper clip.

Timing marks 5. Place the timing belt on the intake-side sprocket while
using two wrenches to align the timing marks.

Timing marks

6. Hold the belt in the position shown in the illustration with

another paper clip.
 ENGINE <4G9-GDI> – Timing Belt 11A-31
7. Place the belt onto the idler pulley, water pump sprocket,
crankshaft sprocket and tensioner pulley in that order.
8. Remove the two paper clips.
Idler
Tensioner pulley
pulley
Water
pump
sprocket
Crankshaft
sprocket

9. Lift the tensioner pulley in the direction of the arrow and

tighten the tensioner pulley bolt.
10. Check to be sure that all timing marks are aligned.
11. Adjust the timing belt tension.

Fixing bolt "CA TIMING BELT TENSION ADJUSTMENT

MD998767
1. After turning the crankshaft a 1/4 turn anti-clockwise, turn
it clockwise to the position where the timing marks are
Pin hole
aligned.
2. Loosen the fixing bolt of the tensioner pulley and using the
special tool and a torque wrench, apply tension to the timing
belt; then tighten the fixing bolt at the specified torque.
Tensioner
pulley Standard Value:
2.5 – 4.0 Nm [timing belt tension torque (reference
value)]
Caution
When tightening the fixing bolt, ensure that the
tensioner pulley shaft doesn’t rotate with the bolt.

3. Take out the 2 mm Allen wrench from the auto tensioner.

At this time, check to be sure that 2 mm Allen wrench
can be pulled out easily.
Turn the crankshaft clockwise 2 turns, and after leaving
it in this position for 5 minutes or more, check again to
2 mm Allen be sure that the auto tensioner 2 mm Allen wrench can
wrench be pulled out or inserted easily.
11A-32 ENGINE <4G9-GDI> – Timing Belt

NOTE
Even if the 2 mm Allen wrench cannot be easily inserted,
A
then it is satisfactory if the amount of protrusion of the
auto tensioner rod is within the standard value.
Standard value (A): 3.8 – 4.5 mm
If it is outside the standard value, repeat the operations
in steps 1 to 4.
4. Check to be sure that the timing marks on all sprockets
are aligned.
 ENGINE <4G9-GDI> – Engine Assembly 11A-33
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Caution
Mounting locations marked by * should be provisionally tightened, and then fully tightened after
placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal and Post-installation Operation

D Fuel Discharge Prevention (Refer to GROUP 13A D Air Cleaner and Resonance Tank Removal and
– On-vehicle Service.) <Pre-removal only> Installation (Refer to GROUP 15.)
D Engine Coolant Draining and Supplying (Refer to D Transmission Assembly Removal and Installation
GROUP 14 – On-vehicle Service.) (Refer to GROUP 23.)
D Engine Oil Draining and Supplying (Refer to GROUP D Drive Belt Tension Adjustment (Refer to P.11A-7.)
12 – On-vehicle Service.) <Post-installation only>
D Hood Removal and Installation (Refer to GROUP 42.)
D Radiator Assembly Removal and Installation (Refer
to GROUP 14.)

2 13

28 Nm

9
4
3
28 Nm

15
12

11 14
10
4
1
5 Nm

25 Nm*

6
18 Nm
5 Nm
5 8

Removal steps
1. Engine harness connector 8. Drive belt
2. Earth cable connection AA" 9. Power steering oil pump
3. Brake booster vacuum hose AB" 10. A/C compressor
connection 11. Fuel return hose connection
4. Vacuum hose connection 12. Fuel pressure hose connection
5. Battery cable connection 13. Heater hose connection
6. A/T fluid pipe clamp 14. Engine mount installation nut
7. Steering gear box and shaft AC" "AA 15. Engine assembly
connection
11A-34 ENGINE <4G9-GDI> – Engine Assembly

REMOVAL SERVICE POINTS

AA" 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 where it will not
be a hindrance when removing and installing the engine
assembly, and tie it with a cord.

AB" A/C COMPRESSOR REMOVAL

Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.

AC" ENGINE ASSEMBLY REMOVAL

1. Check that all cables, hoses and harness connectors,
etc. are disconnected from the engine.
2. Lift the chain block slowly to remove the engine assembly
upward from the engine compartment.

INSTALLATION SERVICE POINT

"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
 11A-1

ENGINE <4G9>
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3

Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compression Pressure Check . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
CAMSHAFT AND CAMSHAFT OIL SEAL . . . . 4
SEALANT AND ADHESIVE . . . . . . . . . . . . . . . . . 2
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
 General/General Information/Service
11A-2 ENGINE <4G9> – Specifications/Sealant and Adhesive

GENERAL
OUTLINE OF CHANGES
Due to the new addition of the 4G94 engine vehicles, the following service procedures have been established
regarding the sections which differ from that of the previous models with the 4G93 engine. The same
procedures as before are applied except for the items shown below.
 Change in the CO and HC concentration
 Change in compression pressure
 Change of the limits in the intake manifold negative pressure
 Removal and installation of camshaft and camshaft oil seal
 Removal and installation of cylinder head gasket
 Change in the protrusion of the auto tensioner rod
GENERAL INFORMATION
Items 4G94-GDI

Total displacement mL 1,999

Bore × Stroke mm 81.5 × 95.8
Compression ratio 11.0

SERVICE SPECIFICATIONS
Item Standard value Limit
CO concentration % 0.5 or less –
HC concentration ppm 100 or less –
Compression pressure kPa – r/min 1,800 – 200 1,320 – 200
Intake manifold negative pressure kPa – 56
Shank length of cylinder head bolt mm – 96.4
Protrusion of auto tensioner rod mm 4.8 – 5.5 –

SEALANT AND ADHESIVE

Application location Specified sealants Remarks
Beam camshaft cap MITSUBISHI GENUINE PART MD970389 or Semi-drying
y g
Cylinder head equivalent
i l t sealant
l t

Camshaft position sensor support

Camshaft thrust cover 3M Stud Locking 4170 or equivalent –
 ENGINE <4G9> – Special Tools/On-vehicle Service 11A-3
SPECIAL TOOLS
Tools Number Name Use
MB990767 Front hub and Camshaft sprocket held
flange york holder

MD998719 Crankshaft pulley

holder pin

MD998713 Camshaft oil seal Press–fitting camshaft oil seal

installer

MB991653 Cylinder head bolt Removal and installation of cylinder head bolt
wrench

ON-VEHICLE SERVICE
IDLE MIXTURE CHECK
Standard value
CO contents: 0.5% or less
HC contents: 100 ppm or less
COMPRESSION PRESSURE CHECK
Standard value (at engine speed of 200 r/min):
1,800 kPa
Limit (at engine speed of 200 r/min):
Min. 1,320 kPa
MANIFOLD VACUUM CHECK
Limit: Min. 56 kPa
11A-4 ENGINE <4G9> – Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
 Fuel Overflow Prevention Operation <only for pre-removal>
 Fuel Leak Check <only for post-installation>
 Air Bleeding The High-pressure Fuel Line <only for post-installation>
[Refer to GROUP 13A – Fuel Pump (High-pressure).]
 Removal and Installation of Under Cover
 Check and Adjustment of Drive Belt Tension <only for post-installation>
 Draining and Filling of Engine Coolant
 Removal and Installation of Air Intake Hose and Resonance Tank
 ENGINE <4G9> – Camshaft and Camshaft Oil Seal 11A-5

3.0 Nm

9.0 Nm
13
14
15 12

7 (3M ATD Part No. 8121)

4 17
6
9

11 16
6 10
3.5 Nm
3
8
14 Nm 3.5 Nm
5

2
18

19
20
21

Removal steps
E 1. Engine cover 11. Ignition coil connector
2. Power steering oil pressure switch 12. Camshaft position sensor connector
connector 13. Throttle control servo connector
3. A/C compressor magnetic clutch 14. Throttle position sensor connector
connector 15. Purge control solenoid valve
4. Ignition failure sensor connector connector
5. Crank angle sensor connector 16. Breather hose
6. Front wiring harness and injector/EGR 17. PCV hose
wiring harness combination connector  Ignition coil
7. Fuel pressure sensor connector  Intake manifold
8. Detonation sensor connector  Timing belt
9. Engine coolant temperature sensor 18. Intake rocker cover
connector 19. intake rocker cover gasket
10. Engine coolant temperature gauge 20. Exhaust rocker cover
unit connector 21. Exhaust rocker cover gasket
11A-6 ENGINE <4G9> – Camshaft and Camshaft Oil Seal

Apply engine oil to any 19 – 23 Nm

rotating area at the
installation.
10 – 12 Nm
19 – 23 Nm

29

24

10 – 12 Nm

30 33
32

31 22 Nm

22 25

27
26
12 – 15 Nm
34
35
89 Nm
28

23
36 Nm

A 22. Camshaft sprocket 28. O-ring

23. Idler pulley C 29. Beam camshaft cap
24. Timing belt rear upper cover 30. Beam camshaft cap gasket
D 25. Camshaft oil seal B 31. Intake camshaft
 Fuel pump (high-pressure) B 32. Exhaust camshaft
(Refer to GROUP 13A.) 33. Camshaft position sensing cylinder
26. Camshaft position sensor support 34. Rocker arm
27. Camshaft thrust cover A 35. Lash adjuster
 ENGINE <4G9> – Camshaft and Camshaft Oil Seal 11A-7
LUBRICANT AND SEALANT APPLICATION LOCATIONS
<Beam camshaft cap bottom surface observation>
Section A – A
A
φ3 mm
A

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Adhesive:
3M Stud Locking 4170
or equivalent
Engine oil (lip)

Engine oil

Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent

<Cylinder head top surface observation>

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

11A-8 ENGINE <4G9> – Camshaft and Camshaft Oil Seal

REMOVAL SERVICE POINT

MB990767 A CAMSHAFT SPROCKET REMOVAL
Caution
To avoid the danger of damage caused by
interference of the valve and the piston, rotate the
MD998719
crankshaft from No.1 cylinder compression top dead
centre to 90 in the forward direction (clockwise).

INSTALLATION SERVICE POINTS

A LASH ADJUSTER INSTALLATION
Caution
To use the lash adjuster again, be sure to clean and
check it before installation.
(Refer to Engine Workshop Manual.)

Camshaft sprocket side B EXHAUST CAMSHAFT/INTAKE CAMSHAFT

Screw INSTALLATION
hole
1. Apply engine oil to the cam and the journal of the
camshaft.
2. Install the camshaft to the cylinder head.
Caution
Do not mistake the intake side for the exhaust
side. There is a screw hole for the camshaft
Exhaust camshaft position sensing cylinder mounting bolt at the
exhaust side of the camshaft.

Intake side Exhaust side

C BEAM CAMSHAFT CAP INSTALLATION
1. Set the dowel pin of the camshaft at the position shown
in the illustration.
Dowel pin
Approx. 16

Dowel pin Approx. 30

 ENGINE <4G9> – Camshaft and Camshaft Oil Seal 11A-9
2. Tighten the beam camshaft cap mounting bolt to the
27 26 30 31 specified torque in the order of the numbers shown in
the illustration.
19
22 23 Symbol Number Dimensions Tightening
of unit mm (Nominal torque Nm
12 11 3 15 16 diameter ×
nominal length)
 4 8 × 32 19 – 23
8 7 1 5 6
 16 6 × 35 10 – 12
7 8 × 40 19 – 23
14 13 2 9 10
4 8 × 40

21 20 4 17 18

29 28 24 25

Front of the engine

D CAMSHAFT OIL SEAL INSTALLATION

1. Apply engine oil to the circumference of the oil seal
lip.
2. Press-fit the oil seal as shown in the illustration.

MD998713

E ENGINE COVER INSTALLATION

2 4 1. Tighten the mounting bolt temporarily in the order of the
numbers shown in the illustration so that the engine cover
can be moved by hand.
2. Tighten the mounting bolt to the specified torque in the
order of the numbers shown in the illustration.
3 1
Tightening torque: 3.0 Nm
11A-10 ENGINE <4G9> – Cylinder Head Gasket

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
 Removal and Installation of Engine Cover (Refer to P.11A-5.)
 Fuel Overflow Prevention Operation <only for pre-removal>
 Fuel Leak Check <only for post-installation>
 Air Bleeding the High-pressure Fuel Line <only for post-installation>
[Refer to GROUP 13A – Fuel Pump (High-pressure).]
 Removal and Installation of Under Cover
 Check and Adjustment of Drive Belt Tension <only for post-installation>
 Draining and Filling of Engine Coolant
 Removal and Installation of Timing Belt Rear Upper Cover (Refer to P.11A-6.)
 Removal and Installation of Fuel Pump (High-pressure) (Refer to GROUP 13A.)
 Removal and Installation of Exhaust Manifold
 Removal and Installation of Water Pipe
 Removal and Installation of EGR Valve and Support Assembly
 ENGINE <4G9> – Cylinder Head Gasket 11A-11
74 Nm → 0 Nm → 20 Nm → +90 → +90
(when the engine is cold)

(Engine oil)

1 2

22 Nm

3 29 Nm
44 Nm

29 Nm

44 Nm
4

Removal steps
A C 1. Connection of radiator upper hose C B 5. Cylinder head bolt
2. Connection of heater hose 6. Cylinder head assembly
B 3. Power steering oil pump A 7. Cylinder head gasket
4. Power steering oil pump bracket
11A-12 ENGINE <4G9> – Cylinder Head Gasket

REMOVAL SERVICE POINTS

A RADIATOR UPPER HOSE REMOVAL
Put mating marks on the radiator upper hose and the
hose clamp for removal.

B POWER STEERING OIL PUMP REMOVAL

Remove the power steering oil pump with the hose
attached from the bracket.
NOTE
Tie the removed power steering oil pump and the A/C
compressor with strings to set aside so that they will not
hinder the removal and installation of the engine
assembly.

C CYLINDER HEAD BOLT REMOVAL

Intake side Exhaust side
1. Set the dowel pin of the camshaft at the position shown
Dowel pin in the illustration.
Approx. 16

Dowel pin Approx. 30

2. Use the special tool to loosen the bolt in the order of

the numbers shown in the illustration in two to three stages
for removal.

MB991653

3 5 10 8 2

1 7 9 6 4

Front of the engine

 ENGINE <4G9> – Cylinder Head Gasket 11A-13
INSTALLATION SERVICE POINTS
A CYLINDER HEAD GASKET INSTALLATION
1. Remove gasket attached on the mounting surface of
the gasket.
Caution
Be careful not to let foreign objects get inside the
engine coolant and the oil line.
2. Install so that the each hole of the cylinder head is
aligned with each hole of the cylinder head gasket.

B CYLINDER HEAD BOLT INSTALLATION

Sagging side 1. Check that the neck down length of the cylinder head
(Engine oil) bolt is within the limit. If it is outside the limit value,
replace the bolt with a new one.
Limit (A): 96.4 mm
2. Face the sagging side of the bored cylinder head bolt
washer towards the direction shown in the illustration
to install to the cylinder head bolt.
A 3. Apply a little amount of engine oil to the cylinder
head bolt thread and the washer.

4. Use the special tool to tighten the bolt according to the

following procedure (plasticity tightening).
(1) Tighten the bolt to 74 Nm in the order of the
numbers shown in the illustration.
(2) Loosen the bolt completely in the reverse order of
MB991653 the numbers shown in the illustration.
(3) Tighten the bolt to 20 Nm in the order of the
numbers shown in the illustration.

(4) Put the paint mark on the head of the cylinder

head bolt and the cylinder to tighten to the 90 in
the order of the numbers shown in the illustration.
(5) Tighten to the 90 in the order of the numbers
shown in the illustration so that the paint marks
on the head of the cylinder head bolt and cylinder
8 6 1 3 9 head are aligned.
Caution
1. If the tightening angle is less than 90, the
bolt is not sufficiently tightened.
10 4 2 5 7 2. If the tightening angle is beyond the limit,
remove the bolt and start from step 1
Front of the engine again.

Step (4) Step (5)

90 90

Paint mark Paint mark

11A-14 ENGINE <4G9> – Cylinder Head Gasket/Timing Belt

C RADIATOR UPPER HOSE INSTALLATION

1. Insert the radiator upper hose to the convex section
of the water outlet fitting.
2. Align the mating mark on the radiator upper hose with
that of the hose clamp to install.

TIMING BELT
A INSTALLATION SERVICE POINT
Timing belt tension adjustment
Standard value (A): 4.8 – 5.5 mm
 ENGINE
<4G9-MPI>
Click on the applicable bookmark to selected the required model year
 11B-1

ENGINE
<4G9-MPI>
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . . 11

Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Timing Belt Tension Adjustment . . . . . . . . . . . . . . . 11
Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 12
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . . 14
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
CAMSHAFT AND CAMSHAFT OIL SEAL . . . 16
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 22
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 5
Drive Belt Tension Check and Adjustment . . . . . . 5 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 25
Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . 8
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 33
Compression Pressure Check . . . . . . . . . . . . . . . . 10
11B-2 ENGINE <4G9-MPI> – General/General Information/Service Specifications

GENERAL
OUTLINE OF CHANGE
The following contents have been established to correspond to the addition of vehicles with 4G9-MPI
engine.
GENERAL INFORMATION
Items Specification

Total displacement mL 1,834

Bore × Stroke mm 81.0 × 89.0

Compression ratio 10.0

Combustion chamber Pentroof type

Camshaft arrangement SOHC

Number of valve Intake 8

Exhaust 8

Valve timing Intake Opening BTDC 14_

Closing ABDC 50_

Exhaust Opening BBDC 58_

Closing ATDC 10_

Fuel system Electronically controlled multipoint fuel injection

Rocker arm Roller type

Auto-lash adjuster Equipped

SERVICE SPECIFICATIONS
Items Standard value Limit

Alternator drive belt tension Vibration frequency Hz 143 – 185 –

(When checked)
Tension N 294 – 490 –

Deflection (Reference) mm 9.7 – 12.9 –

Alternator drive belt tension Vibration frequency Hz 155 – 175 –

(When adjusted)
Tension N 343 – 441 –

Deflection (Reference) mm 10.5 – 12.0 –

Alternator drive belt tension Vibration frequency Hz 203 – 234 –

(When replaced)
Tension N 588 – 784 –

Deflection (Reference) mm 6.7 – 8.5 –

 ENGINE <4G9-MPI> – Service Specifications/Sealants 11B-3

Items Standard value Limit

Power steering oil pump drive belt Vibration frequency Hz 114 – 139 –
tension <Vehicles without A/C>,
power steering oil pump and A/C Tension N 392 – 588 –
compressor drive belt tension
<Vehicles
V hi l with
i h A/CA/C> (Wh
(When
checked) Deflection (Reference) mm 10.0 – 12.0 –

Power steering oil pump drive belt Vibration frequency Hz 121 – 133 –
tension <Vehicles without A/C>,
power steering oil pump and A/C Tension N 441 – 539 –
compressor drive belt tension
<Vehicles
V hi l with
i h A/C>
A/C (When
(Wh ad-
d
justed) Deflection (Reference) mm 10.0 – 11.0 –

Power steering oil pump drive belt Vibration frequency Hz 145 – 166 –
tension <Vehicles without A/C>,
power steering oil pump and A/C Tension N 637 – 833 –
compressor drive belt tension
<Vehicles
V hi l with
i h A/C
A/C> (Wh
(When re-
placed) Deflection (Reference) mm 7.0 – 9.0 –

Basic ignition timing 5_BTDC ± 3_ –

Ignition timing approx. 5_BTDC –

Idle speed r/min 700 ± 100 –

CO contents % 0.1 or less –

HC contents ppm 100 or less –

Compression pressure (250 r/min) kPa 1370 Min. 1039

Compression pressure difference of all cylinder kPa – Max. 100

Intake manifold vacuum kPa – Min. 60

Cylinder head bolt shank length mm – 96.4

SEALANTS
Items Specified Sealants Remarks

Camshaft position sensor support MITSUBISHI GENUINE PART MD970389 or Semi-drying

equivalent sealant
Oil pan

Flywheel bolt <M/T> 3M Stud Locking 4170 or equivalent –

Drive plate bolt <A/T>

11B-4 ENGINE <4G9-MPI> – Special Tools

SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub D Engine idle speed check
assembly D Basic ignition timing check
D Drive belt tension measurement

MB991668 Belt tension meter Drive belt tension measurement

set (used together with MUT-II)

MB990767 Front hub and D Holding the crankshaft sprocket

flange yoke holder D Holding the camshaft sprocket

MD998719 Pin

MD998443 Auto lash adjuster Holding the lash adjuster

holder

MD998713 Camshaft oil seal Press-in of the camshaft oil seal

installer

MD998727 Oil pan cutter Removal of oil pan

MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate

<A/T>
 ENGINE <4G9-MPI> – Special Tools/On-vehicle Service 11B-5

Tool Number Name Use

MB990938 Installer bar Press-in of the crankshaft rear oil seal

MD998776 Crankshaft rear oil

seal installer

MD998717 Crankshaft front oil Press-in of the crankshaft front oil seal
seal installer

MB991653 Cylinder head bolt Cylinder head bolt removal and installation
wrench

ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Check the drive belt tension by the following procedure.
Standard value:

Vibration frequency Hz 143 – 185

Tension N 294 – 490
Deflection (Reference) mm 9.7 – 12.9
11B-6 ENGINE <4G9-MPI> – On-vehicle Service

15_ <When using the MUT-II>

15_
1. Connect the special tool (MB991668) to the MUT-II.
MB991668
(Micro- 2. Connect the MUT-II to the diagnosis connector.
phone) 3. Turn the ignition switch to ON and select “Belt Tension
10 – 20 mm Measurement” from the menu screen.
4. Hold the microphone to the middle of the drive belt between
Tap lightly the pulleys (at the place indicated by the arrow), about
with a finger. Crank- 10 – 20 mm away from the rear surface of the belt and
Alternator shaft so that it is perpendicular to the belt (within an angle of
pulley pulley
± 15_).
5. Gently tap the middle of the belt between the pulleys (the
place indicated by the arrow) with your finger as shown
in the illustration, and check that the vibration frequency
of the belt is within the standard value.
Caution
(1) The temperature of the surface of the belt should
be as close as possible to normal temperature.
(2) Do not let any contaminants such as water or oil
get onto the microphone.
(3) If strong gusts of wind blow against the
microphone or if there are any loud sources of
noise nearby, the values measured by the
microphone may not correspond to actual values.
(4) If the microphone is touching the belt while the
measurement is being made, the values measured
by the microphone may not correspond to actual
values.
(5) Do not take the measurement while the vehicle’s
engine is running.

<When using a tension gauge>

Belt Use a belt tension gauge to check that the belt tension is
tension within the standard value.
gauge
Crank-
shaft
pulley

Alternator
pulley

Deflection <Belt deflection check>

Approx. Apply approx. 100 N of force to the middle of the drive belt
100 N
Crankshaft
between the pulleys (at the place indicated by the arrow) and
pulley check that the amount of deflection is within the standard
value.

Alternator
pulley
 ENGINE <4G9-MPI> – On-vehicle Service 11B-7
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
Adjusting bolt 1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Lock bolt Standard value:
Items When adjusted When replaced
Vibration frequency Hz 155 – 175 203 – 234
Tension N 343 – 441 588 – 784
Deflection 10.5 – 12.0 6.7 – 8.5
(Reference) mm

4. Tighten the nut of the alternator pivot bolt.

Tightening torque: 44 ± 10 N·m
5. Tighten the lock bolt.
Tightening torque: 23 ± 2 N·m
6. Tighten the adjusting bolt.
Tightening torque: 5.0 ± 1.0 N·m

<Vehicles with A/C> POWER STEERING OIL PUMP DRIVE BELT <Vehicles
Oil pump pulley without A/C>, POWER STEERING OIL PUMP AND A/C
COMPRESSOR DRIVE BELT <Vehicles with A/C> TENSION
Tension CHECK AND ADJUSTMENT
pulley 1. Check if the belt tension is within the standard value using
A B one of the methods below.
Crankshaft
pulley Standard value:
A/C Items When When When
compressor
pulley checked adjusted replaced
Vibration 114 – 139 121 – 133 145 – 166
<Vehicles without A/C> frequency
Hz
Oil pump pulley
Tension N 392 – 588 441 – 539 637 – 833
Deflection 10.0 – 12.0 10.0 – 11.0 7.0 – 9.0
(Reference)
Crankshaft A B mm
pulley
<When measuring the vibration frequency>
Tension With your finger tip lightly tap the centre of the belt between
pulley
the pulleys in the location shown by the arrow in the
illustration and then measure the belt vibration frequency.
NOTE
Refer to P.11B-6 for information regarding the vibration
frequency measurement method using MUT-II.
<When measuring the tension>
Use a belt tension gauge to measure the belt tension.
11B-8 ENGINE <4G9-MPI> – On-vehicle Service

<When measuring the deflection>

Apply approx. 100 N of pressure against the location
between the pulleys shown by the arrow in the illustration
and then measure the deflection.
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing nut A.
Tightening torque: 26 ± 4 N·m
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).

IGNITION TIMING CHECK

1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to LOCK (OFF) position, and then
connect the MUT-II to the diagnosis connector.
3. Set up a timing light.
4. Start the engine and run at idle.
5. Check that engine idle speed is within the standard value.
MUT-II Standard value: approx. 700 r/min
6. Select No.17 of the MUT-II Actuator test.
7. Check that basic ignition timing is within the standard value.
Standard value: 5_ BTDC ± 3_
8. If the basic ignition timing is outside the standard value,
inspect the MPI system while referring to GROUP 13C
– Troubleshooting.
9. Press the MUT-II clear key (Select a forced driving cancel
mode) to release the Actuator test.
Caution
If the test is not cancelled, a forced driving will continue
for 27 minutes. Driving under this condition may
damage the engine.
10. Check that ignition timing is at the standard value.
Standard value: approx. 10_BTDC
NOTE
(1) Ignition timing is variable within about ± 7_, even under
normal operating.
(2) And it is automatically further advanced by about 5_
from standard value at higher altitudes.
11. Remove the timing light.
12. Turn the ignition switch to LOCK (OFF) position, and then
remove the MUT-II.
ENGINE <4G9-MPI> – On-vehicle Service 11B-9

IDLE SPEED CHECK

1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to LOCK (OFF) position, and then
connect the MUT-II to the diagnosis connector.
3. Set up the timing light.
4. Check the ignition timing is within the standard value.
Standard value: approx. 5_ BTDC
MUT-II
5. Run the engine at idle for 2 minutes.
6. Check the idle speed. Select item No. 22 and take a reading
of the idle speed.
Curb idle speed: 700 ± 100 r/min
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
7. If the idle speed is outside the standard value, check the
MPI components by referring to GROUP 13C –
Troubleshooting.
8. Remove the timing light.
9. Turn the ignition switch to the LOCK (OFF) position, and
then remove the MUT-II.
IDLE MIXTURE CHECK
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to LOCK (OFF) position, and then
connect the MUT-II to the diagnosis connector.
3. Set up the timing light.
4. Check that the ignition timing is within the standard value.
Standard value: approx. 5_ BTDC
MUT-II
5. Run the engine at 2,500 r/min for 2 minutes.
6. Set the CO, HC tester.
7. Check the CO contents and the HC contents at idle.
Standard value
CO contents: 0.1 % or less
HC contents: 100 ppm or less
8. If there is a deviation from the standard value, check the
following items:
D Diagnosis output
D Closed-loop control (When the closed-loop control is
normal, the output signal of the oxygen sensor changes
between 0 – 400 mV and 600 – 1,000 mV at idle.)
D Fuel pressure
D Injector
D Ignition coil, spark plug cable, spark plug
D Evaporative emission control system
D Compression pressure
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
9. Remove the timing light.
10. Turn the ignition switch to the LOCK (OFF) position, and
then remove the MUT-II.
11B-10 ENGINE <4G9-MPI> – On-vehicle Service

COMPRESSION PRESSURE CHECK

1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Disconnect the ignition coil and spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
Crank angle sensor connector NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
5. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
(1) Keep away from the spark plug hole when
cranking.
(2) If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.

6. Set compression gauge to one of the spark plug holes.

7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 250 r/min):
1370 kPa
Limit (at engine speed of 250 r/min): min. 1039 kPa
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: max. 100 kPa
9. 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 from (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.
10. Connect the crank angle sensor connector.
11. Install the spark plugs.
12. Install the ignition coils and spark plug cables.
13. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
 ENGINE <4G9-MPI> – On-vehicle Service 11B-11

MANIFOLD VACUUM CHECK

1. Before inspection, set the vehicle to the pre-inspection
Vacuum gauge condition.
2. Turn the ignition switch to LOCK (OFF) position.
3. Connect the engine tachometer or connect the MUT-II
to the diagnosis connector.
4. Disconnect the ventilation hose from the positive crankcase
ventilation (PCV) valve, and then connect a vacuum gauge
Plug to the ventilation hose. Plug the positive crankcase
ventilation (PCV) valve.
5. Check the intake manifold vacuum while the engine is
idling.
Limit: Min. 60 kPa
6. Turn the ignition switch to LOCK (OFF) position.
7. Remove the vacuum gauge, and then connect the
ventilation hose to the positive crankcase ventilation (PCV)
valve.
8. Remove the engine tachometer or the MUT-II.

TIMING BELT TENSION ADJUSTMENT

1. Remove the timing belt upper cover.
2. Turn the crankshaft clockwise to set the No. 1 cylinder
to top dead compression centre.
Caution
As the purpose of this procedure is to apply the proper
amount of tension to the timing belt by means of the
cam drive torque, be sure not to rotate the crankshaft
in the opposite direction.

3. Remove the access cover.

4. Loosen the timing belt tensioner fixing bolt to apply tension
to the belt by means of the force of the tensioner spring.
Caution
The bolt can be loosened 90_ – 180_.
If the belt is loosened more than necessary, the bolt
may fall inside the cover.
5. Tighten the timing belt tensioner fixing bolt.
6. Install the access cover.
7. Install the timing belt upper cover.
11B-12 ENGINE <4G9-MPI> – On-vehicle Service

LASH ADJUSTER CHECK

If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur immediately
after the engine is started, if it does not change in
accordance with the engine speed, or if it changes
in accordance with the engine load, the source of
the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after properly
and oil sludge has caused the lash adjusters to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance with
changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused by
the lash adjusters, so check for some other cause of the
problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example, by
shifting from N → D).
If the noise level changes, the cause of the noise is probably
parts striking because of worn crankshaft bearings or
connecting rod bearings. (In such cases, the lash adjusters
are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or disappeared, oil sludge
could make the lash adjusters stick. Clean the lash
adjusters. (Refer to the Engine Workshop Manual.) If not
improved, go to step 5.
5. Bleed air from the lash adjusters.
6. If the noise has not disappeared even after the air bleeding,
clean the lash adjusters. (Refer to the Engine Workshop
Manual.)
 ENGINE <4G9-MPI> – On-vehicle Service 11B-13
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster will
decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air from inside
the lash adjusters.

1. Check the engine oil and replenish or replace the oil if

necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
Good amount of air may get mixed into the oil.

(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.

(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
High-
pressure chamber will be compressed when the valve
pressure is open and the lash adjuster will over-compress,
chamber resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation of
the lash adjusters will return to normal.
11B-14 ENGINE <4G9-MPI> – On-vehicle Service/Crankshaft Pulley

Drive pattern for air bleeding 2. Run the engine at idle for 1 – 3 minutes to let it warm
Gradually open the Close the throttle
up.
throttle valve. valve. 3. With no load on the engine, repeat the drive pattern shown
Approx. in the illustration at left and check if the abnormal noise
3,000 r/min disappears. (The noise should normally disappear after
10 – 30 repetitions, but if there is no change in the noise
Idle speed level after 30 repetitions or more, the problem is probably
15 15 not due to air inside the lash adjusters.)
seconds seconds
4. After the noise has disappeared, repeat the drive pattern
Once shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 – 3 minutes and check that
the noise has disappeared.
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation
D Drive Belt Tension Adjustment (Refer to P.11B-5.) <only after installation>

2
3

1
182 ± 4 N·m

4
(Engine Oil)

Removal steps
1. Power steering oil pump drive 2. Alternator drive belt
belt <Vehicles without A/C>, AA" "AA 3. Crankshaft pulley
Power steering oil pump and A/C "AA 4. Front flange
compressor drive belt
<Vehicles with A/C>
 ENGINE <4G9-MPI> – Crankshaft Pulley 11B-15
REMOVAL SERVICE POINT
AA" CRANKSHAFT PULLEY REMOVAL

MB990767
MD998719

INSTALLATION SERVICE POINT

Front of engine "AA FRONT FLANGE/CRANKSHAFT PULLEY
INSTALLATION
1. Clean and then degrease the front flange contacting
Crankshaft surface of the crankshaft pulley.
Front
bolt flange NOTE
Degreasing is necessary to prevent decrease in the friction
Crankshaft
Washer between contacting surfaces.
2. Clean the bolt hole in the crankshaft, the crankshaft
contacting surface and washer contacting surface of the
crankshaft pulley, and the washer.
3. Apply an appropriately small amount of oil to the threads
and seating surface of the crankshaft bolt.
4. Use the special tools to stop the crankshaft pulley from
Clean
turning in the same way as was done during removal,
Degrease
and then tighten the crankshaft bolt to the specified torque.
Tightening torque: 182 ± 4 N·m
Crankshaft
pulley
11B-16 ENGINE <4G9-MPI> – Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

14 ± 1 N·m Apply engine oil to all

sliding parts at the time
5 of installation.

6
31 ± 3 N·m

7
22 ± 4 N·m

5
3 10 ± 2 N·m
ø3 mm
2
88 ± 10 N·m
Sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent

Camshaft oil seal removal steps Camshaft removal steps

1. Timing belt upper cover D Cylinder head assembly
AA" "DA 2. Camshaft sprocket and timing belt (Refer to P.11B-25.)
assembly AB" "BA 4. Lash adjuster, rocker arm and shaft
"CA 3. Camshaft oil seal assembly
"AA 5. Camshaft position sensor support
6. Camshaft position sensing cylinder
7. Camshaft

REMOVAL SERVICE POINTS

Timing mark AA" CAMSHAFT SPROCKET AND TIMING BELT
ASSEMBLY REMOVAL
1. Turn the crankshaft clockwise (right turn) to align the timing
mark and to set the No.1 cylinder at compression top
dead center
Caution
The crankshaft should always be turned only
clockwise.
 ENGINE <4G9-MPI> – Camshaft and Camshaft Oil Seal 11B-17
2. Tie the camshaft sprocket and timing belt with a band
cable so that the position of the camshaft sprocket will
not move with respect to the timing belt.

Camshaft
sprocket

3. Use the special tools to remove the camshaft sprocket

with the timing belt attached.
Caution
After removing the camshaft sprocket, be sure not
MB990767
to rotate the crankshaft.

MD998719

AB" LASH ADJUSTER, ROCKER ARM AND SHAFT

ASSEMBLY REMOVAL
MD998443 1. Before removing the lash adjuster, rocker arm and shaft
assembly, install the special tools as shown in the
illustration so that the lash adjusters will not fall out.
2. Loosen the lash adjuster, rocker arm and shaft assembly
mounting bolt, and then remove the lash adjuster, rocker
arm and shaft assembly with the bolt still attached.
Caution
Never disassemble the lash adjuster, rocker arm and
shaft assembly.
INSTALLATION SERVICE POINTS
"AA CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
1. Remove sealant remained on the camshaft position sensor
support.
2. Apply sealant to the flange of the camshaft position sensor
support and install to the cylinder head.
ø3 mm Specified sealant:
MITSUBISHI GENUINE PART MD970389 or
equivalent
3. Tighten the camshaft position sensor support mounting
bolt to the specified torque.
Tightening torque: 14 ± 1 N·m
11B-18 ENGINE <4G9-MPI> – Camshaft and Camshaft Oil Seal

"BA LASH ADJUSTER, ROCKER ARM AND SHAFT

Plug guide ASSEMBLY INSTALLATION
1. Remove the rocker shaft spring.
2. Tighten the lash adjuster, rocker arm and shaft assembly
temporarily with mounting bolts so that all the rocker arms
on the intake side will not push the valves.
3. Install the rocker shaft spring and plug guide so that they
Rocker shaft
can meet at right angle to each other.
spring 4. Tighten the lash adjuster, rocker arm and shaft assembly
mounting bolt to the specified torque.
Tightening torque: 31 ± 3 N·m
5. Install the the lash adjuster, rocker arm and shaft assembly
on the exhaust side, and then tighten the bolt to the
specified torque.
Tightening torque: 31 ± 3 N·m
6. Remove the special tool used for retaining the lash adjuster.

7. Ensure that the notch at the rocker shaft points towards

the direction as shown in the illustration.
Notch

Notch
Front of engine

"CA CAMSHAFT OIL SEAL INSTALLATION

1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.

MD998713

"DA CAMSHAFT SPROCKET AND TIMING BELT

ASSEMBLY INSTALLATION
1. Use the special tools to stop the camshaft sprocket from
turning in the same way as was done during removal,
and then tighten the camshaft sprocket securing bolt to
the specified torque.
Tightening torque: 88 ± 10 N·m
2. Remove the band cable which binds the camshaft sprocket
and timing belt.
 ENGINE <4G9-MPI> – Oil Pan 11B-19
OIL PAN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation D Oil Level Gauge Removal and Installation
D Engine Oil Draining and Supplying

13
15
12

8 19 ± 3 N·m

7 14

10
11 9
48 ± 6 N·m 8.8 ± 1.0 N·m 9.0 ± 3.0 N·m
18 ± 2 N·m
5 39 ± 5 N·m
3 23 ± 4 N·m
93 ± 15 N·m

5
12 ± 2 N·m

2 93 ± 15 N·m
4
1
42 ± 7 N·m

108 ± 10 N·m
1 6
4 42 ± 7 N·m
70 ± 10 N·m

Removal steps
1. Splash shield 8. Bell housing cover
2. Power steering pressure hose 9. Drain plug
clamp <R.H. drive vehicles> "BA 10. Drain plug gasket
3. Steering gear box and shaft AC" "AA 11. Oil pan installation bolts
connection AC" "AA 12. Oil screen
AA" 4. Steering gear box installation bolts AC" "AA 13. Oil screen gasket
AB" 5. Front differential mount center bolt AC" "AA 14. Oil pan
AB" 6. Front differential mount "AA 15. Oil pan gasket
7. Transmission stay

NOTE
Liquid-type gasket is used as the oil pan gasket for the vehicle shipped from the factory or the engine to be
overhauled. If liquid gasket is used during the replacement of the oil pan gasket in the on-vehicle service, the
sealing surfaces affect other parts, thereby resulting in oil leaks. So, be sure to use an oil pan gasket supplied
as a spare part.
11B-20 ENGINE <4G9-MPI> – Oil Pan

REMOVAL SERVICE POINTS

AA" STEERING GEAR BOX INSTALLATION BOLT
REMOVAL
Remove the steering gear box installation bolts and lower
the steering gear box.

AB" FRONT DIFFERENTIAL MOUNT CENTER BOLT/

FRONT DIFFERENTIAL MOUNT REMOVAL
1. Support the front differential by a jack, and remove the
front differential mount center bolts and the front differential
mount.
2. Remove the jack and lower the front differential.

MD998727 AC" OIL PAN INSTALLATION BOLT/OIL SCREEN/OIL

MD998727
SCREEN GASKET/OIL PAN REMOVAL
1. After removing the oil pan installation bolts, use a special
tool to remove the oil pan from the engine.
Caution
Perform this slowly to avoid deformation of the oil
pan flange.

2. With the oil pan removed from the cylinder block, remove
the oil screen installation bolts.
Oil screen 3. Remove the oil pan and the oil screen as a set.

Oil pan
 ENGINE <4G9-MPI> – Oil Pan 11B-21
INSTALLATION SERVICE POINTS
"AA OIL PAN GASKET/OIL PAN/OIL SCREEN
GASKET/OIL SCREEN/OIL PAN INSTALLATION
BOLT INSTALLATION
1. Put the oil screen in the oil pan. With the oil pan gasket
in position, place the oil pan between the cylinder block
and front differential.
2. Install the oil screen gasket and oil screen to the cylinder
block.
3. Install the oil pan to the cylinder block.

"BA DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
Oil pan
side
11B-22 ENGINE <4G9-MPI> – Crankshaft Oil Seal

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION

<M/T> 7

10
98 ± 5 N·m

8 11

<A/T> 7

98 ± 5 N·m
6
4 2
9 10

5
3
<A/T>
1
<M/T>

(Engine oil: Crankshaft

Crankshaft bolt seat and
threaded hole)

(Engine oil:
bolt seat and
threaded
hole)
6 11

(Bolt thread)
(Bolt thread) 9
8 Lip Lip

Sealant: 3M Stud Locking 4170 or equivalent Engine oil

Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
D Timing belt (Refer to P.11B-30.) D Transmission assembly
D Crank angle sensor (Refer to GROUP D Clutch cover and disc <M/T>
16 – Ignition System.) AA" "BA 7. Adapter plate
"DA 1. Crankshaft sprocket AA" "BA 8. Flywheel <M/T>
"DA 2. Spring pin AA" "BA 9. Drive plate <A/T>
"DA 3. Crankshaft sensing blade AA" "BA 10. Crankshaft adapter
"DA 4. Crankshaft spacer "AA 11. Crankshaft rear oil seal
5. Crankshaft key
"CA 6. Crankshaft front oil seal
 ENGINE <4G9-MPI> – Crankshaft Oil Seal 11B-23
REMOVAL SERVICE POINT
AA" ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE
PLATE <A/T>/CRANKSHAFT ADAPTER REMOVAL
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.

MD998781

INSTALLATION SERVICE POINTS

Oil seal
"AA CRANKSHAFT REAR OIL SEAL INSTALLATION
Crankshaft
MB990938 1. Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
2. Install the oil seal by tapping it as far as the chamfered
position of the oil seal case as shown in the illustration.

MD998776

"BA CRANKSHAFT ADAPTER /DRIVE PLATE <A/T>/

FLYWHEEL <M/T>/ADAPTER PLATE
INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the drive plate or flywheel.
2. Apply oil to the bearing surface of the drive plate bolts
or flywheel bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the same special tool as in the removal
procedure to retain drive plate or flywheel, and tighten
drive plate bolts or flywheel bolts to the specified
torque.
Tightening torque: 98 ± 5 N·m

"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION

CrankShaft 1. Apply a small amount of engine oil to the entire
MD998717 circumference of the oil seal lip.
2. Tap the oil seal unit it is flush with the oil seal case.

MD998717
Oil seal
11B-24 ENGINE <4G9-MPI> – Crankshaft Oil Seal

"DA CRANKSHAFT SPACER/CRANKSHAFT SENSING

BLADE/SPRING PIN/CRANKSHAFT SPROCKET
Front of engine INSTALLATION
1. Clean and then degrease the following surfaces and parts:
Crankshaft front surface of oil pump case, sprocket mounting surface
sensing blade
of crankshaft, crankshaft spacer, crankshaft sensing blade,
Crankshaft and crankshaft sprocket.
spacer Crankshaft
NOTE
Degreasing is necessary to prevent decrease in the friction
between contacting surfaces.
2. Clean the crankshaft contacting surface of crankshaft
sprocket.

Degrease
Oil pump case
Clean
Crankshaft
sprocket

3. With spring pin, crankshaft sensing blade and

crankshaft spacer assembled, install crankshaft
Crankshaft sprocket on crankshaft.
sensing blade
Crankshaft
sprocket
Crankshaft
spacer

Front of
engine
Spring pin
 ENGINE <4G9-MPI> – Cylinder Head Gasket 11B-25
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Fuel Discharge Prevention (Refer to GROUP 13C – D Engine Oil Draining and Supplying
On-vehicle Service.) <Pre-removal only> D Exhaust Manifold Removal and Installation
D Kickdown Cable Adjustment <A/T> (Refer to GROUP (Refer to GROUP 15.)
23 – On-vehicle Service.) <Post-installation only> D Thermostat Case Assembly Removal and Installation
D Accelerator Cable Adjustment (Refer to GROUP 17 – (Refer to GROUP 14 – Water Hose and Pipe.)
On-vehicle Service.) <Post-installation only> D Water By-pass Fitting Removal and Installation
D Engine Coolant Draining and Supplying (Refer to GROUP 14 – Water Hose and Pipe.)

19
24
12 ± 2 N·m
5.0 ± 1.0 N·m
27 (Engine oil)
26 1
5.0 ± 1.0 N·m

2
25 9
11 10 16 ± 2 N·m
4
5 8 7
18

13
12 14
15 3
23
16 17

23

21 22

20
Removal steps
1. Accelerator cable connection 14. Idle speed control servo connector
2. Kickdown cable connection <A/T> 15. Purge control solenoid valve
3. Power steering oil pressure switch connector
connector 16. EGR solenoid valve connector
4. A/C compressor magnetic clutch 17. Detonation sensor connector
connector 18. Injector connector
5. Ignition coil connector 19. PCV hose
6. Crank angle sensor connector 20. Vacuum hoses connection
7. Oxygen sensor connector 21. Brake booster vacuum hose
8. Ignition failure sensor connector connection
9. Engine coolant temperature sensor AA" "EA 22. Radiator upper hose connection
connector 23. Water hose connection
10. Engine coolant temperature gauge 24. Heater hose connection
unit connector 25. Fuel return hose connection
11. Camshaft position sensor connector "DA 26. Fuel high-pressure hose connection
12. Capacitor "DA 27. O-ring
13. Throttle position sensor connector
11B-26 ENGINE <4G9-MPI> – Cylinder Head Gasket

30 3.4 ± 0.5 N·m

74 ± 2 N·m to 0 N·m to 20 ± 2 N·m to +90_ to +90_
(Cold engine)

34

(Engine oil)

35

31
32

10 ± 2 N·m

88 ± 10 N·m
22 ± 4 N·m
36

33
44 ± 10 N·m

29

22 ± 4 N·m
44 ± 10 N·m

5.0 ± 1.0 N·m 5.0 ± 1.0 N·m

28

28. Oil cooler pipe connection <A/T> AB" "CA 31. Camshaft sprocket
29. Intake manifold stay 32. Timing belt under upper cover
D Ignition failure sensor (Refer to AC" 33. Power steering oil pump and brack-
GROUP 16 – Ignition System.) et assembly
D Ignition coil (Refer to GROUP 16 – AD" "BA 34. Cylinder head bolt
Ignition System.) 35. Cylinder head assembly
D Timing belt (Refer to P.11B-30.) "AA 36. Cylinder head gasket
30. Rocker cover
 ENGINE <4G9-MPI> – Cylinder Head Gasket 11B-27
REMOVAL SERVICE POINTS
AA" RADIATOR UPPER HOSE REMOVAL
After alignment marks are indicated on radiator upper
hose and hose clamps, remove the hose.

AB" CAMSHAFT SPROCKET REMOVAL

MB990767

MD998719

AC" POWER STEERING OIL PUMP AND BRACKET

ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump and bracket
assembly in a place where it will not be a hindrance when
removing and installing the cylinder head assembly, and tie it
with a cord.

AD" CYLINDER HEAD BOLT REMOVAL

Use the special tool to loosen the bolts in two or three steps
in the order of the numbers shown in the illustration, and
then remove the bolts.
If the washer is caught on valve spring and the bolt is not
removed, pull up the bolt slightly and remove the bolt while
MB991653 tilting the washer by using a magnet, etc.

Front of engine

3 5 10 8 2

1 7 9 6 4
11B-28 ENGINE <4G9-MPI> – Cylinder Head Gasket

INSTALLATION SERVICE POINTS

"AA CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
Caution
Do not insert foreign objects into coolant, oil
passage and cylinders.
2. Install so that the shapes of the respective cylinder head
gasket holes match the shapes of the cylinder block holes.

"BA CYLINDER HEAD BOLT INSTALLATION

Roll-over side 1. Ensure that the length under head of cylinder head
(Engine Oil) bolts is under the limit value. When the measured
value exceeds the limit value, replace the bolt with
new one.
Limit (A): 96.4 mm
2. With roll-over side of punched cylinder head bolt
washer moved in the direction specified in the figure,
A
install it on cylinder head bolt.
3. Apply small quantity of engine oil at the threads of
cylinder head bolts and the washers.
4. Use special tool to tighten bolts according to the following
procedure (tightening for plastic zone).
(1) According to the sequence in the figure, tighten
bolts to the specified torque 74 ± 2 N·m.
(2) In the reverse sequence of the figure, fully loosen
bolts.
MB991653 (3) According to the sequence specified in the figure,
tighten bolts to the specified torque 20 ± 2 N·m.

(4) Indicate paint markings on the heads of cylinder

head bolts and cylinder head, and tighten bolts at
the angle of 90 degrees in the sequence specified
in the figure.
Front of engine (5) When bolts are tightened at the angle of 90
degrees according to the figure, ensure that the
paint markings on the heads of cylinder head
bolts and cylinder head are standing in line.
8 6 1 3 9
Caution
1) When the tightening angle is under 90
10 4 2 5 7 degree, the bolt is not sufficiently
tightened.
2) When the tightening angle exceeds the
specified value, remove the bolt and repeat
the same procedure beginning with Step 1.
Step (4) Step (5)

90_ 90_

Paint marking Paint marking

ENGINE <4G9-MPI> – Cylinder Head Gasket 11B-29
"CA CAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the the camshaft sprocket from
turning in the same way as was done during removal, and
then tighten the bolts to the specified torque.
Tightening torque: 88 ± 10 N·m

"DA O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the delivery pipe.
2. While turning the fuel high-pressure hose to the right and
left, install the delivery pipe, while being careful not to
damage the O-ring. After installing, check that the hose
turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the fuel high-pressure hose
and check the O-ring for damage. After this, re-insert the
delivery pipe and check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting bolt to the
specified torque.
Tightening torque: 5.0 ± 1.0 N·m

"EA RADIATOR UPPER HOSE INSTALLATION

1. Insert the radiator upper hose to the protruded parts of
the water outlet fitting.
2. Align the marks on the radiator upper hose and hose
clamp drawn during removal when installing.
11B-30 ENGINE <4G9-MPI> – Timing Belt

TIMING BELT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation D Crankshaft Pulley Removal and Installation
D Air Intake Pipe Removal and Installation (Refer to P.11B-13.)
(Refer to GROUP 15 – Air Cleaner.)

10 ± 2 N·m
23 ± 2 N·m 8
3
7
12 ± 2 N·m
10
2 44 ± 10 N·m
23 ± 3 N·m

4
2 12 ± 2 N·m

49 ± 9 N·m
49 ± 5 N·m
9
49 ± 9 N·m
5

10 ± 2 N·m

10 ± 2 N·m

Removal steps
1. Timing belt front upper cover "CA 6. Timing belt front lower cover
2. Radiator upper installation bolts 7. Accessory mount
3. Alternator brace "BA D Timing belt tension adjustment
4. Power steering oil pump bracket AA" "AA 8. Timing belt
stay 9. Tensioner spring
5. Crank angle sensor connector 10. Timing belt tensioner
 ENGINE <4G9-MPI> – Timing Belt 11B-31
REMOVAL SERVICE POINT
Timing mark
Camshaft AA" TIMING BELT REMOVAL
sprocket 1. Turn the crankshaft clockwise (right turn) to align each
timing mark and to set the No. 1 cylinder at compression
top dead centre.
Caution
Timing belt Water pump The crankshaft should always be turned only
tensioner sprocket clockwise.

Timing mark

Crankshaft
sprocket

2. Loosen the adjusting bolt.

Timing belt
tensioner 3. Set a screwdriver to the timing belt tensioner and press
it fully back in the direction of the arrow.
4. Provisionally tighten the adjusting bolt.
5. Remove the timing belt.
Caution
Adjusting If the timing belt is to be re-used, use chalk to mark
bolt the flat side of the belt with an arrow indicating the
direction of rotation (right turn).

Timing belt INSTALLATION SERVICE POINTS

tensioner "AA TIMING BELT INSTALLATION
1. Set a screwdriver to the timing belt tensioner and press
it fully back in the direction of the arrow.
2. Provisionally tighten the adjusting bolt.
Adjusting
bolt
11B-32 ENGINE <4G9-MPI> – Timing Belt

Timing mark
3. Align each of the camshaft sprocket and the crankshaft
Camshaft
sprocket sprocket timing marks.
4. Install the timing belt in the following order, while making
sure that the tension side of the belt is not slackened.
(1) Crankshaft sprocket
Belt (2) Water pump sprocket
tension (3) Camshaft sprocket
Timing belt
tensioner
side (4) Tensioner pulley
Water Caution
pump After installing the timing belt, apply force to turn
sprocket
the camshaft sprocket in the reverse direction, and
recheck to be sure that the belt is fully tensioned and
that each timing mark is in the proper position.

Timing
mark Belt
tension
side
Crankshaft
sprocket

Timing belt
"BA TIMING BELT TENSION ADJUSTMENT
tensioner 1. Loosen the adjusting bolt of the temporarily secured timing
belt tensioner by 1/4 – 1/2 turn, and use the force of
the tensioner spring to apply tension to the belt.
2. Turn the crankshaft in the proper rotation direction (right
Adjusting turn) for two rotations, and recheck to be sure that the
bolt
timing marks on each sprocket are aligned.
Caution
As the purpose of this procedure is to apply the proper
amount of tension to the tension side of the timing
belt by using the cam driving torque, turn the
crankshaft only by the amount given above. Be sure
Camshaft not to turn the crankshaft in the opposite direction
sprocket (left turn).
A
3. After checking to be sure that no belt teeth in the section
marked with A are lifted up and that the teeth in each
sprocket are engaged, secure the tensioner pulley.

"CA TIMING BELT FRONT LOWER COVER

INSTALLATION
1. Mount the bolt shown in the illustration first.
2. Mount the other bolts, and tighten them to the
specified torque.
Tightening torque: 10 ± 2 N·m
M6 20 mm
 ENGINE <4G9-MPI> – Engine Assembly 11B-33
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Caution
*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in the unladen condition.

Pre-removal and Post-installation Operation

D Fuel Discharge Prevention (Refer to GROUP 13C – D Hood Removal and Installation
On-vehicle Service.) <Pre-removal only> D Radiator Assembly Removal and Installation
D Kickdown Cable Adjustment <A/T> (Refer to GROUP (Refer to GROUP 14.)
23 – On-vehicle Service.) <Post-installation only> D Under Cover Removal and Installation
D Accelerator Cable Adjustment (Refer to GROUP 17 – D Air Cleaner and Air Intake Pipe Removal and
On-vehicle Service.) <Post-installation only> Installation (Refer to GROUP 15.)
D Drive Belt Tension Check and Adjustment D Front Exhaust Pipe Removal and Installation
<Post-installation only> (Refer to P.11B-5.) (Refer to GROUP 15.)

21
12 ± 2 N·m
5.0 ± 1.0 N·m
24 (Engine oil)
23 1
5.0 ± 1.0 N·m

2
22 9
10 16 ± 2 N·m
11
4
5
18 8 7

13
12 14
15 3
16 17

20

19

Removal steps
1. Accelerator cable connection 12. Capacitor
2. Kickdown cable connection <A/T> 13. Throttle position sensor connector
3. Power steering oil pressure switch 14. Idle speed control servo connector
connector 15. Purge control solenoid valve
4. A/C compressor magnetic clutch connector
connector 16. EGR solenoid valve connector
5. Ignition coil connector 17. Detonation sensor connector
6. Crank angle sensor connector 18. Injector connector
7. Oxygen sensor connector 19. Vacuum hoses connection
8. Ignition failure sensor connector 20. Brake booster vacuum hose
9. Engine coolant temperature sensor connection
connector 21. Heater hose connection
10. Engine coolant temperature gauge 22. Fuel return hose connection
unit connector "BA 23. Fuel high-pressure hose connection
11. Camshaft position sensor connector "BA 24. O-ring
11B-34 ENGINE <4G9-MPI> – Engine Assembly

33

29 ± 3 N·m
28

29 ± 3 N·m

29
26 ± 5 N·m*

32
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m
30
12 ± 2 N·m 26
18 ± 2 N·m
31
27
25

22 ± 4 N·m

25. Oil pressure switch connector AB" 29.

A/C compressor
26. Alternator connector and terminal 30.
Oil cooler pipe connection <A/T>
27. Power steering oil pump drive D
Transmission assembly
belt <Vehicles without A/C>, 31.
Steering gear box and shaft
Power steering oil pump and A/C connection
compressor drive belt 32. Engine mount installation nut
<Vehicles with A/C> AC" "AA 33. Engine assembly
AA" 28. Power steering oil pump

REMOVAL SERVICE POINTS

AA" POWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump with the hose attached
from the engine.
NOTE
Place the removed power steering oil pump where it will not
be a hindrance when removing and installing the engine
assembly, and tie it with a cord.
ENGINE <4G9-MPI> – Engine Assembly 11B-35
AB" A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.

AC" ENGINE ASSEMBLY REMOVAL

1. Check that all cables, hoses and harness connectors,
etc. are disconnected from the engine.
2. Lift the chain block slowly to remove the engine assembly
upward from the engine compartment.

INSTALLATION SERVICE POINTS

"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.

"BA O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the delivery pipe.
2. While turning the fuel high-pressure hose to the right and
left, install the delivery pipe, while being careful not to
damage the O-ring. After installing, check that the hose
turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the fuel high-pressure hose
and check the O-ring for damage. After this, re-insert the
delivery pipe and check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting bolt to the
specified torque.
Tightening torque: 5.0 ± 1.0 N·m
NOTES
 ENGINE
LUBRICATION
Click on the applicable bookmark to selected the required model year
 12-1

ENGINE
LUBRICATION
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4

Engine Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
Engine Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12-2 ENGINE LUBRICATION – General Information

GENERAL INFORMATION
The lubrication method is a fully force-fed, full-flow
filtration type. The oil pump is driven by the
crankshaft via the timing belt.

ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil harmful contaminants which may cause skin cancer.
will result in the removal of natural fats from the Adequate means of skin protection and washing
skin, leading to dryness, irritation and dermatitis. facilities must be provided.
In addition, used engine oil contains potentially

Recommended Precautions
The most effective precaution is to adapt working D Where there is a risk of eye contact, eye
practices which prevent, as far as practicable, the protection should be worn, for example,
risk of skin contact with mineral oils, for example chemical goggles or face shields; in addition
by using enclosed systems for handling used engine an eye wash facility should be provided.
oil and by decreasing components, where D Obtain First Aid treatment immediately for open
practicable, before handling them. cuts and wounds.
Other precautions: D Wash regularly with soap and water to ensure
D Avoid prolonged and repeated contact with oils, all oil is removed, especially before meals (skin
particularly used engine oils. cleansers and nail brushes will help). After
D Wear protective clothing, including impervious cleaning, the application of preparations
gloves where practicable. containing lanolin to replace the natural skin
D Avoid contaminating clothes, particularly oils is advised.
underpants, with oil. D Do not use petrol, kerosine, diesel fuel, gas
D Do not put oily rags in pockets, the use of oil, thinners or solvents for cleaning skin.
overalls without pockets will avoid this. D Use barrier creams, applying them before each
D Do not wear heavily soiled clothing and work period, to help the removal of oil from
oil-impregnated foot-wear. Overalls must be the skin after work.
cleaned regularly and kept separate from D If skin disorders develop, obtain medical advice
personal clothing. without delay.
 ENGINE LUBRICATION – Service Specifications/Sealant/Lubricants/Special Tools 12-3
SERVICE SPECIFICATIONS
Item Standard value

Oil pressure kPa at idle 29 or more

at 3,500 r/min 294 – 686

SEALANT
Item Specified sealant

Oil pressure switch 3M ATD Part No. 8660 or equivalent

LUBRICANTS
Items Specifications

Engine oil (API classification) SG or higher

Engine oil quantity ȏ Oil filter 0.3

Total 3.8

SPECIAL TOOLS
Tool Number Name Use
MB991396 Oil filter wrench Removal and installation of engine oil filter
(When using the oil filter of MD135737)

MD998054 Oil pressure switch Removal and installation of oil pressure switch
wrench
12-4 ENGINE LUBRICATION – On-vehicle Service

ON-VEHICLE SERVICE
ENGINE OIL CHECK
1. Pull out the level gauge slowly and check that the oil
level is in the illustrated range.
2. Check that the oil is not excessively dirty, that there is
no coolant or gasoline mixed in, and that it has sufficient
viscosity.
ENGINE OIL REPLACEMENT
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80_C to 90_C.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
Caution
Use care as oil could be hot.

4. Install a new drain plug gasket so that it faces in the

direction shown in the illustration, and then tighten the
Drain plug gasket drain plug to the specified torque.
NOTE
Install the drain plug gasket so it faces in the direction
shown in the illustration.
Oil pan side

39 Nm

5. Refill with specified quantity of oil.

Barometric temperature
Specified Engine Oil (API classification):
SG or higher
Total quantity (Includes volume inside oil filter and
oil cooler): 3.8 ȏ
6. Install the engine oil filler cap.
7. Check oil level.
 ENGINE LUBRICATION – On-vehicle Service 12-5
OIL FILTER REPLACEMENT
MB991396 or
1. Start the engine and allow it to warm up until the
commercially- temperature of the coolant reaches 80_C to 90_C.
available tool 2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
Caution
Use care as oil could be hot.
4. Remove the under cover.
5. Use the respective tool in the following table to remove
the engine oil filter.
6. Clean the filter bracket side mounting surface.
7. Apply a small amount of engine oil to the O-ring of the
new oil filter.
8. Once the O-ring of the oil filter is touching the flange,
use the respective tool in the following table to tighten
to the specified torque.
9. Install the drain plug and refill engine oil. (Refer to Engine
Oil Replacement on P.12-4.)
10. Race the engine 2 – 3 times, and check to be sure that
O-ring no engine oil leaks from installation section of the oil filter.

Number Tool Tightening torque

MD135737 MB991396 or equivalent tool Approx. 1 turn (14 Nm)

MD136466 Commercially-available tool Approx. 3/4 turn (17 Nm)

MD325714, MD332687 Commercially-available tool Approx. 3/4 turn (17 Nm)

MD322508 Commercially-available tool Approx. 3/4 turn (17 Nm)

OIL PRESSURE CHECK

1. Check engine oil quantity.
Oil pressure 2. Remove the oil pressure switch terminal.
switch

3. Use the special tool (oil pressure switch wrench) to remove

MD998054 the oil pressure switch.
Caution
Since sealant is applied to the thread of oil pressure
switch, take care not to damage the oil pressure switch
when removing it.
12-6 ENGINE LUBRICATION – On-vehicle Service

4. Install the oil pressure gauge.

NOTE
Use a adapter of PT 1/8 thread.
5. Run the engine to warm it.
6. After the engine has been warmed up, check that oil
pressure is within the standard value.
Standard value:
At idle: 29 kPa or more
At 3,500 r/min: 294 – 686 kPa
7. Remove the oil pressure gauge.

8. Apply the specified sealant to the thread of oil pressure

switch.
Specified sealant: 3M ATD Part No. 8660 or equivalent

9. Use the special tool to tighten the oil pressure switch

MD998054 to the specified torque.
Tightening torque: 19 Nm
Caution
Do not start the engine within one hour after the oil
pressure switch has been installed.
10. Install the oil pressure switch terminal.
 ENGINE LUBRICATION – General/On-vehicle Service 12-1

GROUP 12
ENGINE LUBRICATION
GENERAL
OUTLINE OF CHANGE
A quality of the engine oil has been changed.

ON-VEHICLE SERVICE
Specified Engine Oil (ACEA and API classification):
ACEA A1, A2, A3/API SG or higher
NOTES
GASOLINE DIRECT
INJECTION (GDI)
Click on the applicable bookmark to selected the required model year
13A-2

GASOLINE DIRECT
INJECTION (GDI)
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 Engine Coolant Temperature Sensor Check . . 102

Throttle Position Sensor Check . . . . . . . . . . . . . 103
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 7
Accelerator Pedal Position Sensor (1st channel)
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Accelerator Pedal Position Sensor (2nd channel)
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Accelerator Pedal Position Switch Check . . . . 105
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 10 Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . . 105

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 92 Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Throttle Body (Throttle Valve Area) Cleaning . . 92 Throttle Valve Control Servo Check . . . . . . . . . 107

Throttle Position Sensor Adjustment . . . . . . . . . . 92 Purge Control Solenoid Valve Check . . . . . . . . 107

Accelerator Pedal Position Sensor EGR Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . 107

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
FUEL PUMP (HIGH PRESSURE) AND FUEL
Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 95 PRESSURE REGULATOR (HIGH
Fuel Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fuel Pump Connector Disconnection (How to
Reduce Fuel Pressure) . . . . . . . . . . . . . . . . . . . . . . 99 INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Fuel Pump Operation Check . . . . . . . . . . . . . . . . 100
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 114
Component Location . . . . . . . . . . . . . . . . . . . . . . . 101
Engine Control Relay, Fuel Pump Relay, Injector INJECTOR DRIVER . . . . . . . . . . . . . . . . . . . . . . 116
Driver Relay and Throttle Valve Control Servo
Relay Continuity Check . . . . . . . . . . . . . . . . . . . . . 102 THROTTLE VALVE CONTROLLER . . . . . . . . 117
Intake Air Temperature Sensor Check . . . . . . . 102
 GDI – General Information 13A-3
GENERAL INFORMATION
The Gasoline Direct Injection System consists activities such as fuel injection control, idle
of sensors which detect the engine conditions, speed control and ignition timing control. In
the engine-ECU which controls the system addition, the engine-ECU is equipped with
based on signals from these sensors, and several diagnosis modes which simplify
actuators which operate under the control of troubleshooting when a problem develops.
the engine-ECU. The engine-ECU carries out

FUEL INJECTION CONTROL

The injector drive times and injector timing are Fuel injection is normally carried out once for
controlled so that the optimum air/fuel mixture each cylinder for every two rotations of the
is supplied to the engine to correspond to the crankshaft. The firing order is 1-3-4-2. This is
continually-changing engine operation condi- called sequential fuel injection.
tions. When the engine is cold or under a severe load,
A single injector for each cylinder is mounted the “open-loop” control keeps the air/fuel ratio
at the cylinder head. The fuel is sent under at a richer than usual level to maintain
pressure from the fuel tank to the fuel pressure driveability. When the engine is under low or
regulator (low pressure) by the fuel pump (low medium loads, the air/fuel ratio becomes leaner
pressure). The pressure is regulated by the fuel to reduce fuel consumption. When the engine
pressure regulator (low pressure) and the fuel is running at medium or high loads after having
regulated is then sent to the fuel pump (high warmed up, the “closed-loop” control uses the
pressure). The fuel under increased pressure signal from the oxygen sensor to keep the
generated by the fuel pump (high pressure) is air/fuel ratio at the optimum theoretical level.
then regulated by the fuel pressure regulator
(high pressure) and is then distributed to each
of the injectors via the delivery pipes.

THROTTLE VALVE OPENING ANGLE CONTROL

This system controls throttle valve opening target value of the throttle valve opening angle
angle electronically. The engine-ECU deter- to the throttle valve controller. The throttle valve
mines how deeply the accelerator pedal is control servo operates the throttle valve so that
depressed by means of the accelerator position it reaches the target opening angle.
sensor (APS). Then the engine-ECU sends a

IDLE SPEED CONTROL

This system maintains engine idle speed at a within a map value. The map value is
predetermined condition by controlling the air predetermined according to engine coolant
flow that passes through the throttle valve temperature and air-conditioning load. In
according to engine idling condition and engine addition, if the A/C switch is turned on or off
loads at idling. during engine idling, the engine-ECU
The engine-ECU operates the throttle valve compensates the engine speed by operating
control servo so that engine speed is maintained the throttle valve control servo as necessary.

IGNITION TIMING CONTROL

The power transistor located in the ignition is determined by the engine-ECU from the
primary circuit turns ON and OFF to control engine speed, intake air volume, engine coolant
the primary current flow to the ignition coil. This temperature, atmospheric pressure and
controls the ignition timing in order to provide injection timing (intake stroke or compression
the optimum ignition timing with respect to the stroke).
engine operating conditions. The ignition timing
13A-4 GDI – General Information

SELF-DIAGNOSIS FUNCTION
D When an abnormality is detected in one code corresponding to the abnormality is
of the sensors or actuators related to output.
emission control, the engine warning lamp D The RAM data inside the engine-ECU that
(check engine lamp) illuminates as a is related to the sensors and actuators can
warning to the driver. be read by means of the MUT-II. In addition,
D When an abnormality is detected in one the actuators can be force-driven under
of the sensors or actuators, a diagnosis certain circumstances.

OTHER CONTROL FUNCTIONS

1. Fuel Pump Control condenser fan are controlled in response
Turns the fuel pump relay ON so that current to the engine coolant temperature and
is supplied to the fuel pump while the engine vehicle speed.
is cranking or running. 4. Purge Control Solenoid Valve Control
2. A/C Relay Control Refer to GROUP 17.
Turns the compressor clutch of the A/C ON 5. EGR Control Servo Control
and OFF. Refer to GROUP 17.
3. Fan Motor Control
The revolutions of the radiator fan and

GENERAL SPECIFICATIONS
Items Specifications

Throttle body Throttle bore mm 60

Throttle position sensor Variable resistor type

Throttle valve control servo Torque motor type

Engine-ECU Identification model No. E2T71575

Sensors Air flow sensor Karman vortex type

Barometric pressure sensor Semiconductor type

Intake air temperature sensor Thermistor type

Engine coolant temperature sensor Thermistor type

Oxygen sensor Zirconia type

Accelerator pedal position sensor Variable resistor type

Accelerator pedal position switch Rotary contact type, within accelerator pedal position
sensor

Vehicle speed sensor Magnetic resistive element type

Inhibitor switch Contact switch type

Camshaft position sensor Magnetic resistive element type

Crank angle sensor Hall element type

Detonation sensor Piezoelectric type

Fuel pressure sensor Metallic membrane type

Power steering fluid pressure switch Contact switch type

 GDI – General Information 13A-5

Items Specifications

Actuators Engine control relay type Contact switch type

Fuel pump relay type Contact switch type

Injector driver control relay Contact switch type

Injector type and number Electromagnetic type, 4

Injector identification mark DIM 100G

Throttle valve control servo relay Contact switch type

Throttle valve control servo Torque motor type

EGR control servo Stepper motor type

Purge control solenoid valve Duty cycle type solenoid valve

Fuel pressure Regulator pressure kPa 324

regulator (low
pressure)

Fuel pressure Regulator pressure MPa 5

regulator
(high pres-
sure)
13A-6 GDI – General Information

GASOLINE DIRECT INJECTION SYSTEM DIAGRAM

*1 Oxygen sensor D Power supply z1 Injector driver (In- D Engine control relay
*2 Air flow sensor D Ignition switch – IG jector) D Fuel pump relay
*3 Intake air temper- D Ignition switch – ST Engine- z2 EGR valve (Step- D Injector driver relay
ature senor D Accelerator pedal posi- ECU per motor) D Throttle valve control
*4 Throttle position tion sensor (1st z3 Purge control sole- servo relay
sensor (2nd chan- channel) noid valve D A/C relay
nel) D Accelerator pedal posi- D Ignition coil
*5 Camshaft position tion switch D Fan controller
sensor D Vehicle speed sensor D GDI ECO indicator lamp
*6 Crank angle sen- D A/C switch D Engine warning lamp
sor D A/C thermo sensor D Diagnosis output
*7 Barometric pres- D Inhibitor switch D Alternator G terminal
sure sensor D Power steering fluid D Throttle valve controller
*8 Engine coolant pressure switch D A/T-ECU
temperature sen- D Alternator FR terminal
sor D Stop lamp switch
*9 Detonation sensor D Small lamp switch
*10 Fuel pressure sen- D Injector wire open circuit
sor check signal
D Throttle valve controller
D A/T-ECU

*11 Throttle position D Power supply z4 Throttle valve con- D Engine-ECU

sensor (1st chan- D Ignition switch – IG Throttle trol servo
nel) D Accelerator pedal posi- valve
tion sensor (2nd chan- control-
nel) ler
D Engine-ECU

From fuel pump

(low pressure)
*3 Intake air temperature
sensor
To fuel tank *4 Throttle position sensor
(2nd channel)
*11 Throttle position sensor z4 Throttle valve *2 Air flow sensor
(1st channel) control servo
*7 Barometric
*10 Fuel pressure pressure sensor
sensor
*5 Camshaft position
sensor

z2 EGR valve
(Stepper
motor)
High-pressure fuel
regulator assembly
[integrated in fuel Injector
pressure regulator z1 Injector
(high pressure)] driver Canister
Fuel pump *8 Engine coolant
(high pressure) temperature sensor
z3 Purge control
*9 Detonation sensor solenoid valve
*1 Oxygen sensor

*6 Crank angle sensor

 GDI – Service Specifications/Sealant 13A-7
SERVICE SPECIFICATIONS
Item Standard value

Adjustment voltage of throttle position sensor 0.4 – 0.6

(1st channel) V

Adjustment voltage of throttle position sensor 4.2 – 4.8

(2nd channel) V

Resistance of throttle position sensor kΩ 3.5 – 6.5

Adjustment voltages (1st channel) and (2nd channel) of 0.935 – 1.135

accelerator pedal position sensor V

Resistance (1st channel) and (2nd channel) of accelerator 3.5 – 6.5

pedal position sensor kΩ

Intake air temperature sensor at 20_C 2.3 – 3.0

resistance kΩ
at 80_C 0.30 – 0.42

Engine coolant temperature at 20_C 2.1 – 2.7

sensor resistance kΩ
at 80_C 0.26 – 0.36

Fuel pressure High-pressure side MPa 4 – 6.9

Low-pressure side kPa Approximately 324

Injector coil resistance Ω 0.9 – 1.1

Oxygen sensor output voltage (at racing) V 0.6 – 1.0

Oxygen sensor heater resistance Ω 11 – 18

Throttle valve control servo resistance Ω 1.35 – 1.65

SEALANT
Item Specified sealant Remark

Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent Drying sealant
threaded portion
13A-8 GDI – Special Tools

SPECIAL TOOLS
Tool Number Name Use

A MB991223 Harness set D Fuel gauge simple inspection

A: MB991219 A: Test harness A: Connector pin contact pressure inspection
B: MB991220 B: LED harness B: Power circuit inspection
C: Power circuit inspection
C: MB991221 C: LED harness D: Commercial tester connection
D: MB991222 adapter
D: Probe
B

MB991502 MUT-II sub D Reading diagnosis code

assembly D GDI system inspection

MB991348 Test harness set D Measurement of voltage during trouble-

shooting
D Inspection using an analyzer

MB991709 Test harness

MB991519 Alternator harness Measurement of voltage during

connector troubleshooting

MB991536 TPS adjustment Adjustment of throttle position sensor

harness

MB991658 Test harness D Measurement of voltage during

troubleshooting
D Inspection using an analyzer
D Adjustment of accelerator pedal position
sensor
 GDI – Special Tools 13A-9

Tool Number Name Use

MD998464 Test harness Oxygen sensor inspection
(4-pin, square)

MD998478 Test harness D Measurement of voltage during trouble-

(3-pin, triangle) shooting
D Inspection using an analyzer

MB991529 Diagnosis code Reading diagnosis code

check harness

MD998709 Adaptor hose Measurement of fuel pressure

MD998742 Hose adaptor

MB991637 Fuel pressure

gauge set
13A-10 GDI – Troubleshooting

TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
Refer to GROUP 00 – How to Use Troubleshooting/Inspection
Service Points.
NOTE
If the ECU is replaced, the immobilizer-ECU and ignition key
should replaced together with it. Each ECU has an individual
information for immobilizer-ECU, and the individual information
is registered in the immobilizer-ECU.

DIAGNOSIS FUNCTION
ENGINE WARNING LAMP (CHECK ENGINE LAMP)
If an abnormality occurs in any of the following items related
to the Gasoline Direct Injection (GDI) system, the engine
warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illuminates while
the engine is running, check the diagnosis code output.

Engine warning lamp

(check engine lamp)

Engine warning lamp inspection items

Oxygen sensor
Air flow sensor
Intake air temperature sensor
Throttle position sensor (1st channel)
Throttle position sensor (2nd channel)
Engine coolant temperature sensor
Crank angle sensor
Camshaft position sensor
Barometric pressure sensor
Detonation sensor
Injector
Abnormal combustion
Immobilizer system
Abnormal fuel pressure
Brake vacuum sensor
Fuel system malfunction
Accelerator pedal position sensor (1st channel)
Accelerator pedal position sensor (2nd channel)
Electronic-controlled throttle valve system
GDI – Troubleshooting 13A-11
Throttle valve position feedback
Throttle valve control servo motor (1st motor)
Throttle valve control servo motor (2nd motor)
Communication line system with throttle valve controller
Engine-ECU
NOTE
When the electronic-controlled throttle valve system is stopped,
the engine warning lamp flashes.
METHOD OF READING AND ERASING DIAGNOSIS
CODES
Refer to GROUP 00 – How to Use Troubleshooting/Inspection
Service Points.
INSPECTION USING MUT-II DATA LIST AND
ACTUATOR TESTING
1. Carry out inspection by means of the data list and the
actuator test function.
If there is an abnormality, check and repair the chassis
harnesses and components.
2. After repairing, re-check using the MUT-II and check that
the abnormal input and output have returned to normal
as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II.
5. Start the engine again and carry out a road test to confirm
that the problem has disappeared.
13A-12 GDI – Troubleshooting

FAIL-SAFE FUNCTION REFERENCE TABLE

If the diagnosis system detects any sensor malfunction, the vehicle can be driven safely by using a default
control logic instead of the faulty sensors.

Defective part or What to do when a sensor is defective

function

Air flow sensor (1) Disables lean-mixture combustion.

(2) Determines injector basic operating time and basic ignition timing according to map
value, which has been predetermined by throttle position sensor and crank angle
sensor signals.

Intake air temperature Controls as the intake air temperature is 25_C.

sensor

Throttle position (1) Disables lean-mixture combustion.

sensor (1st channel) (2) Controls throttle valve opening angle by closed loop control by using the throttle position
sensor (2nd channel) signal.
(3) Disables the throttle valve opening angle control when the throttle position sensor
(2nd channel) signal is also defective.

Throttle position (1) Disables lean-mixture combustion.

sensor (2nd channel) (2) Controls throttle valve opening angle by closed loop control by using the throttle position
sensor (1st channel) signal.
(3) Disables the throttle valve opening angle control when the throttle position sensor
(1st channel) signal is also defective.

Engine coolant Controls as if the engine coolant temperature is 80_C. (Note that this control will continue
temperature sensor until the ignition switch is turned off even if the sensor signal return to normal.)

Camshaft position Controls according to the conditions before a failure is detected.

sensor

Vehicle speed sensor (1) Disables lean-mixture combustion. However, if a predetermined time elapses at an
engine speed of 1,500 r/min or more, the lean-mixture combustion will return to normal.
(2) Disables lean-mixture combustion during engine idling.

Barometric pressure Controls as if the barometric pressure is 101 kPa.

sensor

Detonation sensor Holds the ignition timing at that for standard petrol.

Injector (1) Disables lean-mixture combustion.

(2) Shuts down exhaust gas recirculation.

Abnormal combustion Disables lean-mixture combustion.

Communication line Disables ignition timing retard control (engine and transmission total control) during shift
with A/T-ECU change.

Alternator FR terminal Disables inhibition control of the alternator output according to electrical load (treats the
alternator as if it is conventional one).

Fuel pressure sensor (1) Controls as if the fuel pressure is 5 MPa (if there is open or short circuit).
(2) Turns off the fuel pump relay (if the fuel pressure is excessively high).
(3) Shuts off the fuel injection (If an excessively low pressure is detected or the engine
speed exceeds 3,000 r/min).
 GDI – Troubleshooting 13A-13

Defective part or What to do when a sensor is defective

function

Accelerator pedal (1) Disables lean-mixture combustion.

position sensor (1st (2) Controls the throttle valve position by using the accelerator pedal position sensor
channel) (2nd channel) signal.
(3) Disables the electronic-controlled throttle valve system if the accelerator pedal position
sensor (2nd channel) signal is also defective.

Accelerator pedal (1) Disables lean-mixture combustion.

position sensor (2nd (2) Controls the throttle valve position by using the accelerator pedal position sensor
channel) (1st channel) signal.
(3) Disables the electronic-controlled throttle valve system if the accelerator pedal position
sensor (1st channel) signal is also defective.

Electronic-controlled (1) Disables the electronic-controlled throttle valve system.

throttle valve system (2) Disables lean-mixture combustion.
(3) Disables engine speed feedback control.

Throttle valve position (1) Disables the electronic-controlled throttle valve system.
feedback (2) Disables lean-mixture combustion.
(3) Disables engine speed feedback control.
However, if the throttle valve opening is great, controls as follows:
(1) Carries out lean-mixture combustion continuously.
(2) Shuts off fuel supply for 2 cylinders continuously.
(3) Shuts off fuel supply when engine speed exceeds 3,000 r/min.

Throttle valve control Disables lean-mixture combustion.

servo motor (1st
motor) malfunction

Throttle valve control (1) Disables the electronic-controlled throttle valve system.
servo motor (2nd (2) Disables lean-mixture combustion.
motor) malfunction (3) Disables engine speed feedback control.

Communication line (1) Error in communication from the throttle valve controller to engine-ECU
with the throttle valve D Disables lean-mixture combustion.
controller D Shuts off fuel supply when engine speed exceeds 3,000 r/min.
(2) Error in communication from the engine-ECU to throttle valve controller
D Disables lean-mixture combustion.
D Shuts off fuel supply when engine speed exceeds 3,000 r/min.
D The throttle valve controller controls the throttle valve opening angle by using
the accelerator pedal position sensor (2nd channel) signal.

NOTE
When the electronic-controlled throttle valve system is stopped, the engine warning lamp flashes.
13A-14 GDI – Troubleshooting

INSPECTION CHART FOR DIAGNOSIS CODES

Code No. Diagnosis item Reference page

11 Oxygen sensor system 13A-15

12 Air flow sensor system 13A-16

13 Intake air temperature sensor system 13A-17

14 Throttle position sensor (2nd channel) system 13A-18

21 Engine coolant temperature sensor system 13A-19

22 Crank angle sensor system 13A-20

23 Camshaft position sensor system 13A-21

24 Vehicle speed sensor system 13A-22

25 Barometric pressure sensor system 13A-23

31 Detonation sensor system 13A-24

41 Injector system 13A-25

44 Abnormal combustion 13A-27

54 Immobilizer system 13A-28

56 Abnormal fuel pressure system 13A-29

61 Communication line with A/T-ECU system 13A-31

64 Alternator FR terminal system 13A-31

66 Brake vacuum sensor system 13A-32

77 Accelerator pedal position sensor (2nd channel) system 13A-33

78 Accelerator pedal position sensor (1st channel) system 13A-34

79 Throttle position sensor (1st channel) system 13A-35

89 Abnormality in fuel pressure system 13A-36

91 Electronic-controlled throttle valve system 13A-36

92 Throttle valve position feedback system 13A-37

94 Communication line system with throttle valve controller 13A-37

95 Malfunction in throttle valve control servo motor (1st motor) system 13A-38

99 Malfunction in throttle valve control servo motor (2nd motor) system 13A-38

NOTE
Code No. 56 may be also output when air is sucked in high-pressure fuel line due to no fuel supply.
 GDI – Troubleshooting 13A-15
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No.11 Oxygen sensor system Probable cause
Range of check D Malfunction of the oxygen sensor
D 3 minutes have passed after engine was started. D Improper connector contact, open circuit or
D Engine coolant temperature is approx. 80°C or more. short-circuited harness wire
D Intake air temperature is 20 – 50°C. D Malfunction of the engine-ECU
D Engine speed is approx. 2,000 – 3,000 r/min.
D Vehicle is moving at constant speed on a flat, level road surface.
Set conditions
D The oxygen sensor output voltage is around 0.6 V for 30 seconds (does
not cross 0.6 V for 30 seconds).
D When the range of check operations given above which accompany starting
of the engine are carried out four time in succession, a problem is detected
after each operation.

NG
Check the oxygen sensor. (Refer to P.13A-105.) Replace
OK
Measure at the oxygen sensor connector A-67. (1) NG NG
Check the following connector: A-36 Repair
D Disconnect the connector, and measure at the
harness side. OK
(1) Voltage between 1 and earth (Ignition switch: ON)
Check trouble symptom.
OK: System voltage
(2) NG
(2) Continuity between 2 and earth NG
OK: Continuity
Check the harness wire between the oxygen
OK
sensor and the engine control relay connector,
and repair if necessary.

NG
Check the following connectors: A-36, Repair
C-19
OK

Check trouble symptom.

NG

Check the harness wire between the engine- NG

Repair
ECU and the oxygen sensor connector.
OK

Replace the engine-ECU.

Measure at the engine-ECU connector C-29.
D Disconnect the connector, and measure at the NG NG
harness side. Check the following connectors: A-67 Repair
D Voltage between 89 and earth (Ignition switch: ON) OK
OK: System voltage
OK Check trouble symptom.
NG
NG
Check the following connector: C-19 Replace Check the harness wire between the engine-
ECU and the oxygen sensor connector, and
OK repair if necessary.

Check trouble symptom.

NG
Check the harness wire between the engine-ECU and NG
the oxygen sensor connector. Replace

OK
Replace the engine-ECU.
13A-16 GDI – Troubleshooting

Code No.12 Air flow sensor system Probable cause

Range of check D Malfunction of the air flow sensor
D Engine speed is 500 r/min or more. D Open circuit or short-circuited harness wire of air
Set conditions flow sensor circuit
D Sensor output frequency is 3.3 Hz or less for 4 seconds. D Malfunction of the engine-ECU

(1) NG (1) NG
Measure at the air flow sensor connec- Measure at the air flow sensor connec- Check the following connector:
tor A-71. tor A-71. A-36
D Connect the connector D Disconnect the connector, and OK NG
(Use the test harness MB991709) measure at the harness side.
(1) Voltage between 3 and earth (1) Voltage between 4 and earth Check trouble symptom. Repair
(Engine: Idling) (Ignition switch: ON) NG
OK: 2.2 – 3.2 V OK: System voltage
(2) Voltage between 7 and earth (2) Voltage between 3 and earth Check the harness wire between the
OK: 0 – 0.1 V (2) NG (Ignition switch: ON) air flow sensor and the engine control
(Engine: Idling) OK: 4.8 – 5.2 V relay, and repair if necessary.
OK: 6 – 9 V (3) Continuity between 5 and earth
(2), (3) NG
(Engine speed: 4,000 OK: Continuity Check the following connectors:
r/min) A-36, C-18, C-19
OK OK
OK NG
Check the following connector:
A-71 Repair
OK NG Check trouble symptom.
NG
Repair
Check the harness wire between the
Check trouble symptom. engine-ECU and the air flow sensor,
NG and repair if necessary.
OK NG
Replace the air flow sensor.
Repair
Measure at the engine-ECU connector Replace the engine-ECU.
C-19.
D Connect the connector NG Check the following connector:
D Voltage between 76 and earth A-71
(Ignition switch: ON)
OK: 6 – 9 V OK NG

OK Repair

Check the following connector:

Check trouble symptom.
C-19
OK NG
NG
Replace the air flow sensor.
Repair
NG
Replace the engine-ECU. Check trouble symptom.
 GDI – Troubleshooting 13A-17
Code No.13 Intake air temperature sensor system Probable cause
Range of check D Malfunction of the intake air temperature sensor
D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the
Set conditions intake air temperature sensor circuit
D Sensor resistance is 0.14 kΩ or less for 4 seconds. D Malfunction of the engine-ECU
or
D Sensor resistance is 50 kΩ or more for 4 seconds.

NG
Check the intake air temperature sensor. (Refer to P.13A-102.) Replace the air flow sensor.
OK
NG
Measure at the air flow sensor connector A-71. Check the following connectors: A-36, C-18, C-19
D Disconnect the connector, and measure at the harness OK NG
side.
D Voltage between 6 and earth Repair
(Ignition switch: ON)
OK: 4.5 – 4.9 V
D Continuity between 5 and earth Check trouble symptom.
OK: Continuity NG
OK
Check the harness wire between the engine-ECU and the intake
Check the following connector: A-71 air temperature sensor.
OK NG OK NG

Repair Repair

NG
Check trouble symptom. Replace the engine-ECU.
13A-18 GDI – Troubleshooting

Code No.14 Throttle position sensor system (2nd channel) Probable cause
The throttle valve controller determines whether a failure is present or not, and D Malfunction of throttle position sensor (2nd channel)
sends a signal indicating its result to the engine-ECU. D Open circuit or short-circuited harness wire in throttle
Range of check position sensor (2nd channel) or poor connector
D Ignition switch: ON contact
D Throttle position sensor (1st channel) is normal D Faulty throttle valve controller
Set conditions D Malfunction of the engine-ECU
D The throttle position sensor (1st channel) output voltage is 1.24 V or more, and
the (2nd channel) output voltage is 4.6 V or more for one second.
or
D The throttle position sensor (1st channel) output voltage is 3.53 V or less, and
the (2nd channel) output voltage is 0.2 V or less for one second.
or
D Throttle position sensor (1st and 2nd channels) output voltages are outside 4
to 6 V.

NG
Check the throttle position sensor. (Re- Replace
fer to P.13A-103.)
OK
NG NG
Measure at throttle position sensor con- Check the following connector: C-48 Repair
nector A-03. OK
D Disconnect the connector, and
NG
measure at the harness side. Check trouble symptom. Check the harness wire between the
D Voltage 1 and earth throttle position sensor and throttle
(Ignition switch: ON) valve controller.
OK: 4.8 – 5.2 V
D Continuity between 3 and earth OK NG
OK: Continuity
Repair
OK
Replace the throttle valve controller.

NG NG
Measure at engine-ECU connector Check the following connector: A-03 Repair
C-19.
D Connect the connector. OK
D Disconnect the throttle valve control
Check trouble symptom.
servo connector (Close the throttle
valve fully by finger). NG
D Voltage between terminal 78 and OK
earth Check the harness wire between the Adjust the throttle position sensor.
(Ignition switch: ON) engine-ECU and throttle position sen- (Refer to P.13A-92.)
OK: 4.0 – 4.8 V sor.
OK NG
Check trouble symptom.
Repair
NG

Replace the engine-ECU.

NG NG
Measure at throttle valve controller con- Check the following connector: A-03 Repair
nector C-48.
OK
D Connect the connector.
D Disconnect the throttle valve control Check trouble symptom.
servo connector (Close the throttle
valve fully by finger). NG
D Voltage between 7 and earth
(Ignition switch: ON) Check the harness wire between the
OK: 0.1 – 1.1 V throttle valve controller and throttle
position sensor, and repair if necessary.
OK

Replace the throttle valve controller.

 GDI – Troubleshooting 13A-19
Code No.21 Engine coolant temperature sensor system Probable cause
Range of check D Malfunction of the engine coolant temperature
D After 60 seconds have passed since the engine have started sensor
Set conditions D Open circuit or short-circuited harness wire of the
D Sensor resistance is 50 Ω or less for 4 seconds. engine coolant temperature sensor circuit
or D Malfunction of the engine-ECU
D Sensor resistance is 72 kΩ or more for 4 seconds.
Range of check
D After engine starts
Set conditions
D After 5 minutes or more have passed since the engine coolant temperature
after filtering has dropped from 40_C or more to less than this temperature

NG
Check the engine coolant temperature sensor. (Refer to Replace
P.13A-102.)
OK

NG
Measure at the engine coolant temperature sensor connector A-69. Check the following connectors: A-36, C-18, C-19
D Disconnect the connector, and measure at the harness OK NG
side.
D Voltage between 1 and earth Repair
(Ignition switch: ON)
OK: 4.5 – 4.9 V
D Continuity between 2 and earth Check trouble symptom.
OK: Continuity NG
OK
Check the harness wire between the engine-ECU and the engine
Check the following connector: A-69 coolant temperature sensor.
OK NG
OK NG
Repair
Repair
NG
Check trouble symptom. Replace the engine-ECU.
13A-20 GDI – Troubleshooting

Code No.22 Crank angle sensor system Probable cause

Range of check D Malfunction of the crank angle sensor
D Engine: During cranking D Open circuit or short-circuited harness wire of the
Set conditions crank angle sensor circuit
D Sensor output voltage does not change for 4 seconds (no pulse signal is D Malfunction of the engine-ECU
being input).

NG (1) NG
Measure at the crank angle sensor con- Measure at the crank angle sensor con- Check the following connector:
nector A-77. nector A-77. A-36
D Connect the connector D Disconnect the connector, and OK
(Use the test harness measure at the harness side. (2) NG NG
MB991658) (1) Voltage between 2 and earth
Repair
D Voltage between 3 (black clip) (Ignition switch: ON)
and earth OK: System voltage (3) NG Check trouble symptom.
(Engine: Cranking) (2) Voltage between 3 and earth
OK: 0.4 – 4.0 V (Ignition switch: ON) NG
D Voltage between 3 (black clip) OK: 4.8 – 5.2 V
and earth (3) Continuity between 1 and earth Check the harness wire between the
(Engine: Idling) OK: Continuity crank angle sensor and the engine con-
OK: 1.5 – 2.5 V trol relay, and repair if necessary.
OK
OK
Check the following connector: Check the following connector:
Replace the engine-ECU. A-77 C-18
OK NG OK NG

Repair Repair

Check trouble symptom. Check trouble symptom.

NG NG

Replace the crank angle sensor. Check the harness wire between the
engine-ECU and the crank angle sen-
sor.
OK NG

Repair

Replace the engine-ECU.

Check the harness wire between the

crank angle sensor and the earth, and
repair if necessary.
 GDI – Troubleshooting 13A-21
Code No.23 Camshaft position sensor system Probable cause
Range of check D Malfunction of the camshaft position sensor
D While engine is cranking or running D Open circuit or short-circuited harness wire of the
Set conditions camshaft position sensor circuit
D Sensor output voltage does not change for 4 seconds (no pulse signal is D Malfunction of the engine-ECU
being input).

NG (1) NG
Measure at the camshaft position sen- Measure at the camshaft position sen- Check the following connector:
sor connector A-66. sor connector A-66. A-36
D Connect the connector (Use the D Disconnect the connector, and OK
test harness MD991709) measure at the harness side. (2) NG NG
D Voltage between 2 and earth (1) Voltage between 3 and earth
Repair
(Engine: Cranking) (Ignition switch: ON)
OK: 0.3 – 3.0 V OK: System voltage (3) NG Check trouble symptom.
D Voltage between 2 and earth (2) Voltage between 2 and earth
(Engine: Idling) (Ignition switch: ON) NG
OK: 0.5 – 3.5 V OK: 4.8 – 5.2 V
(3) Continuity between 1 and earth Check the harness wire between the
OK OK: Continuity camshaft position sensor and the en-
gine control relay, and repair if neces-
Replace the engine-ECU. OK sary.
Check the following connector: Check the following connector:
A-66 C-18
OK NG OK NG

Repair Repair

Check trouble symptom. Check trouble symptom.

NG NG

Replace the camshaft position sensor. Check the harness wire between the
engine-ECU and the camshaft position
sensor.
OK NG

Repair

Replace the engine-ECU.

Check the harness wire between the

camshaft position sensor and the earth,
and repair if necessary.
13A-22 GDI – Troubleshooting

Code No. 24 Vehicles speed sensor system Probable cause

Range of check D Malfunction of the vehicle speed sensor
D Ignition switch: ON D Improper connector contact, open circuit or
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed
after the engine starts. sensor circuit
D Engine speed is 3,000 r/min or more. D Malfunction of the engine-ECU
D Driving under high engine load conditions.
Set conditions
D Sensor output voltage does not change for 4 seconds (no pulse signal input).

No
Does the speedometer operate normally? Check the vehicle speed sensor circuit. (Refer to GROUP 54
– Combination Meter.)
Yes

OK
Measure at engine-ECU connector C-19. Check the following connector: C-19
D Connect the connector. OK NG
D Voltage between terminal 80 and earth
(Ignition switch: ON) Repair
OK: If the vehicle is moved forward without starting the engine,
0 V and system voltage alternates.
Check trouble symptom.
NG
NG
Check the following connectors:
C-28, C-38 <LHD>, C-41 <RHD>, D-02 Replace the engine-ECU.
OK NG
Repair

Check trouble symptom.

NG

Check the harness wire between the vehicle speed sensor and
engine-ECU.
 GDI – Troubleshooting 13A-23
Code No.25 Barometric pressure sensor system Probable cause
Range of check D Malfunction of the barometric pressure sensor
D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the
D Battery voltage is 8 V or more. barometric pressure sensor
Set conditions D Malfunction of the engine-ECU
D Sensor output voltage is 0.2 V or less for 4 seconds. (This condition
corresponds to that the barometric pressure is 53 kPa or less.)
or
D Sensor output voltage is 4.5 V or more for 4 seconds. (This condition
corresponds to that the barometric pressure is 114 kPa or more.)

NG NG
Measure at the air flow sensor connec- Measure at the air flow sensor connec- Check the following connectors:
tor A-71. tor A-71. A-36, C-18, C-19
D Connect the connector. (Use test D Disconnect the connector, and OK NG
harness MB991709) measure at the harness side.
D Voltage between 2 and earth (1) Voltage between 1 and earth Repair
(Ignition switch: ON) (Ignition switch: ON)
OK: 3.7 – 4.3 V OK: 4.8 – 5.2 V
(at altitude of 0 m) (2) Continuity between 5 and earth Check trouble symptom.
3.2 – 3.8 V OK: Continuity NG
(at altitude of 1,200 m)
OK
OK Check the harness wire between the
engine-ECU and the barometric pres-
sure sensor.
OK NG
Check the following connector:
A-71 Repair
OK NG
Replace the engine-ECU.
Repair
NG
Measure at the engine-ECU connector Check trouble symptom. Check the harness wire between the
C-18. engine-ECU and the barometric pres-
D Connect the connector. sure sensor.
D Voltage between 51 and earth OK NG
(Ignition switch: ON)
OK: 3.7 – 4.3 V NG Repair
(at altitude of 0 m) Check the harness wire between the
3.2 – 3.8 V engine-ECU and the barometric pres-
(at altitude of 1,200 m) sure sensor, and repair if necessary. Replace the air flow sensor.
OK OK
OK NG
Check the following connectors: Check trouble symptom. Replace the engine-ECU.
A-71, C-18
NG

Repair
13A-24 GDI – Troubleshooting

Code No.31 Detonation sensor system Probable cause

Range of check D Malfunction of the detonation sensor
D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the
Set conditions detonation sensor
D Amount of change in the sensor output voltage (detonation sensor peak D Malfunction of the engine-ECU
voltage for each half rotation of the crankshaft) is 0.06 V or less for 200
continuous times.

OK NG
Measure at the detonation sensor con- Check the following connector: Repair
nector A-81. C-19
D Disconnect the connector, and OK
measure at the harness side.
D Continuity between 2 and earth NG
Check trouble symptom. Check the harness wire between the
OK: Continuity engine-ECU and the detonation sensor.
NG OK NG
Check the harness wire between the Repair
detonation sensor and the earth, and
repair if necessary.
Replace the detonation sensor.

Check trouble symptom.

NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-25
Code No.41 Injector system Probable cause
Range of check D Malfunction of the injector
D Engine: while cranking, or running D Faulty injector driver relay
D Engine speed: 4,000 r/min or less D Faulty injector driver
D System voltage: 10 V or more D Open circuit or short-circuited harness wire in the
D Fuel shut off, or while forcible activating of injector (actuator test) is in operation. injector drive circuit, or poor connector contact
Set conditions D Malfunction of the engine-ECU
D Injector open circuit check signal is not output from the injector predetermined
time(s).

NG
Check the injector. (Refer to Replace
P.13A-106.)
OK
(1) NG OK
Measure at injector driver relay connec- Check the following connectors: Check trouble symptom.
tor A-44X. C-72, C-74
NG
D Disconnect the connector, and
NG
measure at the harness side.
Check the harness wire between the
(1) Voltage between terminal 4 and
Repair injector driver relay and ignition switch,
earth
and repair if necessary.
(Ignition switch: ON)
OK: System voltage (2) NG OK
(2) Voltage between terminal 3 and Check the following connector: Check trouble symptom.
earth A-36
OK: System voltage NG
NG
OK Check the harness wire between the
Repair injector driver relay and battery, and
repair if necessary.

NG OK
Measure at engine-ECU connector Check the following connector: Check trouble symptom.
C-18. A-44X
NG
D Disconnect the connector, and
NG
measure at the harness side.
Check the harness wire between the
D Voltage between terminal 55 and
Repair injector driver relay and engine-ECU,
earth (Ignition switch: ON)
and repair if necessary.
OK: System voltage
OK
(1) NG OK
Measure at injector driver connector Check the following connector: Check trouble symptom.
A-55. A-44X
NG
D Disconnect the connector, and
NG
measure at the harness side.
Check the harness wire between the
(1) Voltage between 12, 21 and earth
Repair injector driver and injector driver relay,
(Ignition switch: ON)
and repair if necessary.
OK: System voltage
(2) Continuity between 13, 22 and earth
OK: Continuity (2) NG
(3) Resistance between terminals 14 Check the harness wire between the
and 23 injector driver and earth, and repair if
Resistance between terminals 15 necessary.
and 24
Resistance between terminals 16 (3) NG OK
and 25 Check the following connectors: Check trouble symptom.
Resistance between terminals 17 A-61, A-62, A-63, A-64, A-78
and 26 NG
OK: 0.9 – 1.1 Ω NG
Check the harness wire between the
OK Repair injector driver and injector, and repair
if necessary.
To the next page
13A-26 GDI – Troubleshooting

From the previous page

OK
OK NG
Measure at engine-ECU connector Check the following connectors: Repair
C-17,19. C-17, C-19
D Connect the connector. OK
D Voltage between terminal 51 and
earth (Ignition switch: ON) Check trouble symptom.
OK: 4.0 – 5.0 V
D Voltage between terminal 1 and NG
earth
Voltage between terminal 24 and Replace the injector driver.
earth
Voltage between terminal 9 and NG
earth Check trouble symptom. Replace the engine-ECU.
Voltage between terminal 2 and
earth
(Ignition switch: ON)
OK: 8 – 11 V
NG
OK NG
Check the following connector: A-55 Check trouble symptom. Check the harness wire between the
injector driver and engine-ECU, and
NG
repair if necessary.
Repair
 GDI – Troubleshooting 13A-27
Code No.44 Abnormal combustion Probable cause
Range of check D Malfunction of the ignition coil
D While engine is running during lean fuel combustion D Malfunction of the spark plug
Set conditions D Malfunction of the EGR valve
D Abnormal engine speed due to mis-firing is detected by the crank angle D Open circuit or short-circuit in ignition primary
sensor circuit
D Malfunction of the engine-ECU

NG
Check the ignition coil (Refer to GROUP 16 – Ignition System). Replace
OK
(1) NG
Measure at the ignition coil connectors A -09, A-10, A-11, A-12. Check the following connector: C-72, C-74
D Disconnect the connector, and measure at the harness OK NG
side.
(1) Voltage between 1 and earth (Ignition switch: ON) (2) NG Repair
OK: System voltage
(2) Voltage between 3 and earth (Engine: Cranking)
OK: 0.5 – 4.0 V Check trouble symptom.
(3) NG
(3) Continuity between 2 and earth NG
OK: Continuity
OK Check the harness wire between the ignition coil and the ignition
switch, and repair if necessary.
Check the following connectors:
A-09, A-10, A-11, A-12
Check the following connector: C-17
OK NG
OK NG
Repair
Repair

Check trouble symptom.

Check trouble symptom.
NG
NG
Check the following items in the order given. Check the harness wire between the engine-ECU and the ignition
D Spark plugs coil.
D Compression pressure
OK NG
OK
Repair
Check the injector system (Refer to P.13A-25, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE No.41)
OK Replace the engine-ECU.

Check for air leaking into the air intake system. Check the harness wire between the ignition coil and the
D Damaged intake manifold gasket earth, and repair if necessary.
D Damaged vacuum hose
D Damaged air intake hose
D Malfunction of the EGR valve
13A-28 GDI – Troubleshooting

Code No.54 Immobilizer system Probable cause

Range of check D Radio interference of ID codes
D Ignition switch: ON D Incorrect ID code
Set conditions D Malfunction of harness or connector
D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-ECU
D Malfunction of engine-ECU

NOTE
(1) If the ignition switches are close each other when starting the engine, radio interference may cause
this code to be displayed.
(2) This code may be displayed when registering the key ID code.

Yes
Is there another ignition key near the ignition key that is inserted Remove the extra ignition key.
in the ignition switch?
OK NG
Check trouble symptom.
No
Yes Check the immobilizer system. (Refer to GROUP 54 – Ignition
Is a diagnosis code output from the immobilizer-ECU?
Switch and Immobilizer System.)
No

Check the following connector: NG

C-19, C–29, C-62, 1 Replace

OK

Check trouble symptom.

NG

Check the harness wire between the engine-ECU and the OK

Replace the engine-ECU.
immobilizer-ECU.

NG

Replace
 GDI – Troubleshooting 13A-29
Code No.56 Abnormal fuel pressure Probable cause
Range of check D Malfunction of the fuel pressure sensor
D Ignition switch: ON D Open circuit or short-circuited harness wire of the
Set conditions fuel pressure sensor
D Sensor output voltage is 4.8 V or more for four seconds. D Malfunction of the engine-ECU
or D Malfunction of the fuel pump (high pressure)
D Sensor output voltage is 0.2 V or less for four seconds. D Malfunction of the fuel pressure regulator (high
Range of check pressure)
D After the engine is started, the following condition has been detected: D Clogged high-pressure fuel line
(1) Engine speed: 1,000 r/min or more
(2) Fuel pressure: 2 MPa or more
D While engine is running
Set conditions
D Fuel pressure is 6.9 MPa or more for four seconds.
or
D Fuel pressure is 2 MPa or less for four seconds.
This diagnosis code is also output when air is sucked in high-pressure fuel line D Air sucking due to no fuel supply
due to no fuel supply.
In this case, air can be bled by letting the engine run at 2,000 r/min for at
least fifteen seconds. After the air bleeding, the diagnosis code must be erased
by the MUT-II.

OK NG
MUT-II Data list MUT-II Data list D Replace the high-pressure fuel
74 Fuel pressure sensor 74 Fuel pressure sensor regulator (seized regulator).
(Refer to P.13A-75.) (Refer to P.13A-75.) D Replace the high-pressure return
D Ignition switch: ON D Maintain the engine speed at 2,000 pipe (seized pipe).
OK: 0 – 8 MPa r/min for at least fifteen seconds.
OK: 6.9 MPa or less
NG
OK
NG
MUT-II Data list D Replace the fuel pump (high
74 Fuel pressure sensor pressure) (poor pump discharge
(Refer to P.13A-75.) pressure)
D Engine: Idle running for at least D Replace the high-pressure regula-
three minutes tor (fuel leakage at the return side).
OK: 4 MPa or more
OK
Erase diagnosis code No.56. (This
diagnosis code has been output due
to air sucking into high-pressure fuel
line. But that problem has been re-
solved by revving the engine at 2,000
r/min.)

Check trouble symptom. NG Check if input voltage from the fuel

pressure sensor to engine-ECU
OK changes suddenly by performing an
To the next page Normal intermittent malfunction simulation test.
(Refer to GROUP 00 – Points to Note
for Intermittent Malfunction.)
13A-30 GDI – Troubleshooting

From the previos page

Measure at the fuel pressure sensor Measure at the fuel pressure sensor Check the following connectors:
connector A-59. NG connector A-59. NG A-36, A-82, C-18, C-19
D Connect the connector. (Use test D Disconnect the connector, and
harness MB991348) measure at the harness side. OK NG
D Voltage between 2 and earth D Voltage between 1 and earth
OK: 3 V or less (Ignition switch: ON) Repair
(Engine: Cranking) OK: 4.8 – 5.2 V
0.3 – 4.7 V (Engine: Idling) D Continuity between 3 and earth Check trouble symptom.
OK: Continuity
OK NG
OK
Check the harness wire between the
Check the following connectors: engine-ECU and the fuel pressure sen-
A-59, A-82, C-19 sor.
OK NG OK NG

Repair Repair

Replace the engine-ECU.

NG
Check trouble symptom. Check the harness wire between the
engine-ECU and the fuel pressure sen-
NG sor.
Measure at the engine-ECU connector Check the harness wire between the OK
C-19. engine-ECU and the fuel pressure sen- NG
D Connect the connector. sor, and repair if necessary.
D Voltage between 92 and earth Repair
(Engine: idling)
OK: 0.3 – 4.7 V Replace the fuel pressure sensor.
OK
NG
Check the following connectors: Repair
A-59, C-19
OK

Check trouble symptom.

NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-31
Code No.61 Communication wire with A/T-ECU system Probable cause
Range of check D Short circuit in ECU communication circuit
D After 60 seconds have passed since the engine have started D Malfunction of the engine-ECU
Set conditions D Malfunction of the A/T-ECU
D Torque reduction request signal from A/T-ECU is input continuously for 1.5
seconds or more.

NG
Check the following connectors: Repair
C-19, C-25<LHD>, C-26<RHD>, D-04, D-34
OK

Check trouble symptom.

NG
OK
Check the harness wire between the engine-ECU and the Replace the engine-ECU.
A/T-ECU.
NG

Repair Check trouble symptom.

NG

Replace the A/T-ECU.

Code No.64 Alternator FR terminal system Probable cause

Range of check D Open circuit in alternator FR terminal circuit
D Engine speed is 50 r/min or more. D Malfunction of the engine-ECU
Set conditions
D Input voltage from the alternator FR terminal is system voltage for 20
seconds.

NG NG
Measure at the alternator connector Measure at the alternator connector Check the following connectors:
A-79. A-79. A-86, C-18
D Connect the connector. (Use test D Disconnect the connector, and OK NG
harness MB991519) measure at the harness side.
D Voltage between 4 (blue clip) D Voltage between 4 and earth Repair
and earth (Ignition switch: ON)
(Engine: Idling) OK: System voltage
(Radiator fan: Not operating) Check trouble symptom.
(Headlamp: OFF → ON) OK
NG
(Stop lamp: OFF → ON)
Check the following connector:
(Rear defogger switch: OFF → Check the harness wire between the
A-79
ON) engine-ECU and the alternator.
OK: Voltage decreases. OK NG
OK NG
OK
Repair
Repair
Replace the engine-ECU.
Check trouble symptom.
Replace the engine-ECU.
NG

Check the harness wire between the

engine-ECU and the alternator.
OK NG

Repair

Replace the alternator.

13A-32 GDI – Troubleshooting

Code No.66 Brake vacuum sensor system Probable cause

Range of check D Malfunction of the brake vacuum sensor
D Ignition switch: ON D Improper connector contact, open circuit or
Set conditions short-circuited harness wire of the brake vacuum
D Sensor output voltage is 4.8 V or more. sensor
or D Malfunction of the engine-ECU
D Sensor output voltage is 0.2 V or less.

NG NG
Measure at the brake vacuum sensor Measure at the brake vacuum sensor Check the following connectors:
connector A-56. connector A-56. A-36, C-18, C-19
D Connect the connector. (Use test D Disconnect the connector, and OK NG
harness MB991348) measure at the harness side.
D Voltage between 1 and earth D Voltage between 3 and earth Repair
OK: Voltage increases when (Ignition switch: ON)
depressing the brake pedal OK: 4.8 – 5.2 V
several times after the D Continuity between 2 and earth Check trouble symptom.
warmed engine is turned OK: Continuity NG
off from idle speed and the
OK
ignition switch is turned on. Check the harness wire between the
OK Check the following connector: engine-ECU and the brake vacuum
A-56 sensor.
OK NG OK NG

Repair Repair

Replace the engine-ECU.

NG
Check trouble symptom. Check the harness wire between the
engine-ECU and the brake vacuum
sensor.
OK OK
Measure at the engine-ECU connector Check the following connectors: NG
C-19. A-56, C-19
D Connect the connector. Repair
D Voltage between 74 and earth OK NG
OK: Voltage increases when Replace the brake vacuum sensor.
depressing the brake pedal Repair
several times after the
warmed engine is turned Check trouble symptom.
off from idle speed and the
ignition switch is turned on. NG
NG Replace the engine-ECU.

Check the harness wire between the

engine-ECU and the brake vacuum
sensor, and repair if necessary.
 GDI – Troubleshooting 13A-33
Code No.77 Accelerator pedal position sensor (2nd Probable cause
channel) system
Range of check D Malfunction of the accelerator pedal position sensor
D Accelerator pedal position sensor (1st channel) system is normal. (2nd channel)
D Communication between the engine-ECU and throttle valve controller is normal. D Open circuit or short-circuited harness wire in the
Set conditions accelerator pedal position sensor (2nd channel)
D Output voltage of accelerator pedal position sensor (2nd channel) system is system, or poor connector contact
0.2 V or less for one second. D Malfunction of the throttle valve controller
or D Malfunction of the engine-ECU
D Output voltage of the accelerator pedal position sensor (1st channel) is 2.5 V
or less, and output voltage of the accelerator pedal position sensor (2nd channel)
is 4.5 V or more for one second.
or
D Difference between the accelerator pedal position sensor output voltages (1st
and 2nd channels) exceeds 1.0 V (i.e. when the throttle valve opening angle
changes slightly).

NG
Check the accelerator pedal position Replace the accelerator pedal position
sensor (2nd channel). (Refer to P.13A- sensor assembly.
104.)
OK
NG NG
Measure at accelerator pedal position Check the following connector: Repair
sensor (2nd channel) connector C-46. C-48
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between terminal 8 and NG
Check trouble symptom. Check the harness wire between the
earth throttle valve controller and the acceler-
(Ignition switch: ON) ator pedal position sensor (2nd chan-
OK: 4.8 – 5.2 V nel).
D Continuity between terminal 7 and
earth OK NG
OK: Continuity
Repair
OK
Replace the throttle valve controller.
NG NG
Measure at throttle valve controller con- Check the following connector: Repair
nector C-48. C-46
D Connect the connector. OK
D Voltage between terminal 20 and
earth (Ignition switch: ON) NG
Check trouble symptom. Check the harness wire between the
OK: 0.7 – 1.4 V accelerator pedal position sensor (2nd
(Accelerator pedal: fully re- channel) and throttle valve controller.
leased)
4.1 V or more OK NG
(Accelerator pedal: fully de-
pressed) Repair
OK
NG Adjust the accelerator pedal position
MUT-II Data list Check the accelerator pedal position sensor. (Refer to P.13A-94.)
78 Accelerator pedal position sensor sensor (1st channel) system. (Refer to
(1st channel). (Refer to P.13A-75.) P.13A-34, INSPECTION PROCE-
OK DURE FOR DIAGNOSIS CODE 78.) Check trouble symptom.
NG
Replace the throttle valve controller.
Replace the throttle valve controller.
13A-34 GDI – Troubleshooting

Code No.78 Accelerator pedal position sensor (1st Probable cause

channel) system
Range of check D Malfunction of the accelerator pedal position sensor
D Accelerator pedal position sensor (2nd channel) system is normal. (1st channel)
D Communication between the engine-ECU and throttle valve controller is normal. D Open circuit or short-circuited harness wire in the
Set conditions accelerator pedal position sensor (1st channel)
D Output voltage of accelerator position sensor (1st channel) system is 0.2 V or system, or poor connector contact
less for one second. D ON-seizure of the accelerator pedal position switch
or D Malfunction of the throttle valve controller
D Output voltage of the accelerator pedal position sensor (2nd channel) is 2.5 D Malfunction of the engine-ECU
V or less, and (1st channel) output voltage of the accelerator pedal position
sensor is 4.5 V or more for one second.
or
D Difference between the accelerator pedal position sensor (1st and 2nd channels)
output voltages exceeds 1.0 V (i.e. when the throttle valve opening angle changes
slightly).
or
D Although the accelerator pedal position switch is on, 1st-channel output voltage
of the accelerator pedal position sensor exceeds 1.1 V for one second.

NG
MUT-II Data list Check the accelerator pedal position
26 Accelerator pedal position switch switch system. (Refer to P.13A-65.),
(P.13A-73.) INSPECTION PROCEDURE 27.)
OK
NG
Check the accelerator pedal position Replace the accelerator pedal position
sensor (1st channel). (Refer to P.13A- sensor assembly.
104.)
OK
NG NG
Measure at the accelerator pedal posi- Check the following connectors: Repair
tion sensor (1st channel) connector A-36, C-18, C-19
C-46. OK
D Disconnect the connector, and
measure at the harness side. NG
Check trouble symptom. Check the harness wire between the
D Voltage between terminal 2 and accelerator pedal position sensor (1st
earth (Ignition switch: ON) channel) and engine-ECU.
OK: 4.8 – 5.2 V
D Continuity between terminal 5 and OK NG
earth
OK: Continuity Repair
OK
Replace the engine-ECU.

NG NG
Measure at the engine-ECU C-19. Check the following connector: Repair
D Connect the connector. C-46
D Voltage between terminal 94 and OK
earth
(Ignition switch: ON) NG
Check trouble symptom. Check the harness wire between the
OK: 0.935 – 1.135 V accelerator pedal position sensor (1st
(Accelerator pedal: fully re- channel) and engine-ECU.
leased)
4.1 V or more OK NG
(Accelerator pedal: fully de-
pressed) Repair
OK
NG Adjust the accelerator pedal position
MUT-II Data list Check the accelerator pedal position sensor. (Refer to P.13A-94.)
77 Accelerator pedal position sensor sensor (2nd channel) system. (Refer
(2nd channel). (Refer to P.13A-75.) to P.13A-33, INSPECTION PROCE-
DURE FOR DIAGNOSIS CODE 77.) Check trouble symptom.
OK
NG
Replace the engine-ECU.
Replace the engine-ECU.
 GDI – Troubleshooting 13A-35
Code No.79 Throttle position sensor (1st channel) system Probable cause
The throttle valve controller determines a failure, and sends it result to the engine-ECU. D Malfunction of the throttle position sensor (1st channel)
Range of check D Open circuit or short-circuited harness wire in the
D Ignition switch: ON throttle position sensor (1st channel), or poor
D System voltage: 8 V or more connector contact
Set conditions D Malfunction of the throttle valve controller
D Output voltage of the sensor remains 0.2 V for one second. D Malfunction of the engine-ECU
or
D Output voltage of the sensor remains 4.9 V for one second.
or
D Output voltage of the throttle position sensor (1st and 2nd channels) remains
outside 4 – 6 V for four seconds.

Yes
MUT-II Data list Follow INSPECTION PROCEDURE
Is code No. 14, 91 or 92 output? FOR DIAGNOSIS CODE.
No
NG
Check the throttle position sensor. (Re- Replace
fer to P.13A-103.)
OK
NG NG
Measure at throttle position sensor con- Check the following connector: Repair
nector A-03. C-48
D Disconnect the connector, and
OK
measure at the harness side.
D Voltage between terminal 1 and NG
Check trouble symptom. Check the harness wire between the
earth throttle valve controller and throttle
(Ignition switch: ON) position sensor.
OK: 4.8 – 5.2 V
D Continuity between terminal 3 and OK NG
earth
OK: Continuity Repair
OK
Replace the throttle valve controller.

NG NG
Measure at throttle valve controller con- Check the following connector: Repair
nector C-48. A-03
D Connect the connector.
OK
D Disconnect the throttle control servo
connector (Close the throttle valve Check trouble symptom.
fully by finger).
D Voltage between terminal 7 and NG
earth OK
(Ignition switch: ON) Check the harness between the throttle Adjust the throttle position sensor. (Re-
OK: 0.4 – 0.6 V position sensor and throttle valve con- fer to P.13A-92.)
troller.
OK
NG
Check trouble symptom.
Repair NG

Replace the throttle valve controller.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. A-03
D Connect the connector. OK
D Disconnect the throttle control servo
connector (Close the throttle valve NG
Check trouble symptom. Check the harness wire between the
fully by finger). throttle position sensor and engine-
D Voltage between terminal 78 and ECU, and repair if necessary.
earth (Ignition switch: ON)
OK: 3.9 – 4.9 V
OK

Replace the engine-ECU.

13A-36 GDI – Troubleshooting

Code No.89 Abnormal fuel pressure system Probable cause

Range of check D Malfunction of the fuel pump (high pressure)
D Engine: Idling (during stoichio-feedback operation) D Malfunction of the intake air temperature sensor
Set conditions D Malfunction of the barometric pressure sensor
D Fuel injection correction value remains excessively low for ten seconds or more. D Malfunction of the air flow sensor
or D Malfunction of the engine-ECU
D Fuel injection correction value remains excessively high for ten seconds or more.

NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to P.13A-
13 Intake air temperature sensor. (Refer to P.13A-71.) 17, INSPECTION PROCEDURE FOR DIAGNOSIS CODE No.13.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13A-23,
25 Barometric air temperature sensor. (Refer to P.13A-73.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE No.25.)
OK
NG
MUT-II Data list Check the air flow sensor system. (Refer to P.13A-16, INSPEC-
12 Air flow sensor. (Refer to P.13A-71.) TION PROCEDURE FOR DIAGNOSIS CODE No.12.)
OK

Replace the fuel pump (high pressure).

Code No.91 Electronic-controlled throttle valve system Probable cause

Range of check D Short in communication line
D Ignition switch: ON D Malfunction of the engine-ECU
D Error in communication from the engine-ECU to throttle valve controller D Malfunction of the throttle valve controller
Set conditions
D Output voltage of the throttle position sensor (2nd channel) fluctuates significantly
(approx. 1 V or more) from an expected value.
Range of check
D Ignition switch: ON
D Error in communication from the throttle valve controller to engine-ECU
Set conditions
D The throttle valve opening angle (voltage) which the engine-ECU requested of
the throttle valve controller is significantly different from output voltage of the
(2nd channel) throttle position sensor (approx. one volt).

Yes
MUT-II Self-Diag code Follow INSPECTION PROCEDURE FOR DIAGNOSIS CODE.
Is any other diagnosis code than No.94 output?
No
NG
Check the harness wire between the throttle valve controller and Repair
engine-ECU.
OK

Replace the throttle valve controller.

 GDI – Troubleshooting 13A-37
Code No.92 Throttle valve position feedback system Probable cause
The throttle valve controller determines if a failure is present, and sends its result D Malfunction of the throttle position sensor (1st channel)
to the engine-ECU. D Open circuit or short-circuited harness wire in the
Range of check throttle position sensor system (1st channel), or poor
D Ignition switch: ON connector contact
D System voltage: 8 V or more D Malfunction of the throttle valve controller
Set condition
D Motor position feedback system is defective (System detects a motor overcurrent,
or that actual and projected opening angles of the throttle position sensor (1st
channel) are different by 1.0 V or more.

NG
Check the throttle valve control servo. (Refer to P.13A-107.) Replace
OK
NG
Check the following connectors:A-05, C-48 Repair
OK

Check trouble symptom.

NG
NG
Check the harness wire between the throttle control servo and Repair
throttle valve controller.
OK

Replace the throttle body.

Check trouble symptom.

NG

Replace the throttle valve controller.

Code No.94 Communication line system with throttle valve Probable cause
controller
Range of check D Short circuit in communication line
D Ignition switch: ON D Malfunction of the engine-ECU
D System voltage: 8 V or more D Malfunction of the throttle valve controller
D Engine: not cranking
Set condition
D System detects an error in communication line between the engine-ECU and
throttle valve controller.

NG
Check the following connectors: C-19, C-48 Repair
OK

Check trouble symptom.

NG
OK
Check the harness wire between the engine-ECU and throttle Replace the throttle valve controller.
valve controller.
NG
Check trouble symptom.
Repair
NG

Replace the engine-ECU.

13A-38 GDI – Troubleshooting

Code No.95 Malfunction in throttle valve control servo Probable cause

motor (1st motor) system
Range of check D Malfunction of the throttle valve control servo
D Throttle valve control servo relay: ON D Open circuit or short-circuited harness wire in throttle
D System voltage: 8 V or more valve control servo system, or poor connector contact
Set conditions D Malfunction of the throttle valve controller
D Throttle valve control servo drive circuit is shorted to earth.
D Other power source interferences with throttle valve control servo drive circuit.
D Throttle valve control servo drive circuit is open circuit.

NG
Check the throttle valve control servo. (Refer to P.13A-107.) Replace
OK
NG
Check the following connectors: A-05, C-48 Repair
OK

Check trouble symptom.

NG
OK
Check the harness wire between the throttle valve control servo Replace the throttle valve controller.
and throttle valve controller.
NG

Repair

Code No.99 Malfunction in throttle valve control servo Probable cause

motor (2nd motor) system
Range of check D Malfunction of the throttle valve control servo
D Throttle valve control servo relay: ON D Open circuit or short-circuited harness wire in the
D System voltage: 8V or more throttle valve control servo system, or poor connector
Set conditions contact
D Throttle valve control servo drive circuit is shorted to earth. D Malfunction of the throttle valve controller
D Other power source interferes with throttle valve control servo drive circuit.
D Throttle valve control servo drive circuit is open-circuited.

NG
Check the throttle valve control servo. (Refer to P.13A-107.) Replace
OK
NG
Check the following connectors: A-05, C-48 Repair
OK

Check trouble symptom.

NG
OK
Check the harness wire between the throttle valve control servo Replace the throttle valve controller.
and throttle valve controller.
NG

Repair
 GDI – Troubleshooting 13A-39
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptom Inspection Reference page
procedure
No.

Communication Communication with all systems is not possible. 1 13A-41

with MUT-II is
impossible. Communication with engine-ECU only is not possible. 2 13A-42

Engine warning The engine warning lamp does not illuminate right after the 3 13A-42
lamp and ignition switch is turned to the ON position.
related parts
The engine warning lamp remains illuminating and never goes 4 13A-43
out.

Starting No initial combustion (starting impossible) 5 13A-43

Initial combustion but no complete combustion 6 13A-45

(starting impossible)

Long time to start (improper starting)

Idling stability Unstable idling (Rough idling, hunting) 7 13A-47

(Improper idling)
Idling speed is high. (Improper idling speed) 8 13A-49

Idling speed is low. (Improper idling speed)

Idling stability When the engine is cold, it stalls at idling. (Die out) 9 13A-50
(Engine stalls)
When the engine is hot, it stalls at idling. (Die out) 10 13A-51

The engine stalls when starting the car. (Pass out) 11 13A-53

The engine stalls when decelerating. 12 13A-54

Driving Hesitation, sag or stumble 13 13A-55

Poor acceleration

Surge

The feeling of impact or vibration when accelerating 14 13A-56

The feeling of impact or vibration when decelerating 15 13A-57

Knocking 16 13A-57

Dieseling 17 13A-57

Too high CO and HC concentration when idling 18 13A-58

Low alternator output voltage (approx. 12.3 V) 19 13A-59

Fans (radiator fan, A/C condenser fan) are inoperative 20 13A-60

GDI ECO GDI ECO indicator lamp does not illuminate. 21 13A-61
indicator lamp
GDI ECO indicator lamp remains illuminated and does not go 22 13A-61
off.
13A-40 GDI – Troubleshooting

PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)

Items Symptom

Starting Won’t start The starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine won’t start.

Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.

Hard starting Engine starts after cranking a while.

Idling Hunting Engine speed doesn’t remain constant; changes at idle.

stability
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.
This is called rough idle.

Incorrect idle speed The engine doesn’t idle at the usual correct speed.

Engine stall The engine stalls when the foot is taken from the accelerator pedal, regardless
(Die out) of whether the vehicles is moving or not.

Engine stall The engine stalls when the accelerator pedal is depressed or while it is being
(Pass out) used.

Driving Hesitation, Sag “Hesitation” is the delay in response

Hesitation
of the vehicle speed (engine speed) Normal
that occurs when the accelerator is
depressed in order to accelerate Vehicle Initial ac-
from the speed at which the vehicle speed celerator
pedal de-
is now traveling, or a temporary drop pression
in vehicle speed (engine speed) Sag
during such acceleration.
Serious hesitation is called “sag”.

Time

Poor acceleration Poor acceleration is inability to obtain an acceleration corresponding to the

degree of throttle opening, even though acceleration is smooth, or the inability
to reach maximum speed.

Stumble Engine speed increase is delayed

when the accelerator pedal is
initially depressed for accelera-
tion. Vehicle
speed Normal
Initial ac-
celerator
pedal de-
pression

Idling Stumble

Time
 GDI – Troubleshooting 13A-41

Items Symptom

Driving Shock The feeling of a comparatively large impact or vibration when the engine is
accelerated or decelerated.

Surge This is repeated surging ahead during constant speed travel or during variable
speed travel.

Knocking A sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.

Stopping Run on The condition in which the engine continues to run after the ignition switch is
(“Dieseling”) turned to OFF. Also called “Dieseling”.

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1
Communication with MUT-II is not possible. Probable cause
(Communication with all systems is not possible.)
The cause is probably a defect in the power supply system (including earth) for D Malfunction of the connector
the diagnosis line. D Malfunction of the harness wire
D Malfunction of the MUT-II

(1) NG NG
Measure at the diagnostic connector Check the following connectors: Repair
C-35. C-76, C-77
(1) Voltage between 16 and earth OK
OK: System voltage (2) NG
NG
(2) Continuity between 4 and earth Check trouble symptom. Check the harness wire between the
Continuity between 5 and earth power supply and diagnostic connector,
OK: Continuity and repair if necessary.
OK
NG
Replace the MUT-II. Check the following connector: Repair
C-01
OK
NG
Check trouble symptom. Check the earth line, and repair if nec-
essary.
13A-42 GDI – Troubleshooting

INSPECTION PROCEDURE 2
MUT-II communication with engine-ECU is impossible. Probable cause
This may be caused by malfunction of engine-ECU power supply circuit and earth D Malfunction of engine-ECU power supply circuit
circuit. D Malfunction of engine-ECU
D Open circuit between the engine-ECU and diagnosis
connector

NG
Check the following connectors: Repair
C-53 <Vehicles with multi center display>, C-19, C-28, C-35,
C-70
OK

Check trouble symptom.

NG
NG
Check the harness wire between engine-ECU and diagnosis con- Repair
nector.
OK

Check the engine-ECU power supply and earth circuit system. (Refer
to P.13A-62, INSPECTION PROCEDURE 23.)

NOTE
On vehicles with multi center display, if a malfunction cannot be resolved after the procedure above, check
the multi center display and replace if necessary. (Refer to GROUP 54 – Multi center display.)
INSPECTION PROCEDURE 3
The engine warning lamp does not illuminate right after Probable cause
the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Burnt-out bulb
to illuminate for five seconds immediately after the ignition switch is turned to ON. D Defective warning lamp circuit
If the engine warning lamp does not illuminate immediately after the ignition switch D Malfunction of the engine-ECU
is turned to ON, one of the malfunctions listed at right has probably occurred.

NG
MUT-II Data list Check the engine-ECU power supply and earth circuit system.
16 Engine-ECU power supply voltage (Refer to P.13A-72.) (Refer to P.13A-62, INSPECTION PROCEDURE 23.)
OK
OK NG
Measure at the engine-ECU connector C-17. Check the following Repair
D Disconnect the connector, and measure at the harness side. connector: C-17
D Earth the terminal No. 31.
OK
OK: The engine warning lamp illuminates.
NG Check trouble symptom.
NG
NG
Check a burnt-out bulb. Replace Replace the engine-ECU.
OK
NG
Measure at the combination meter connector C-06. Check the engine warning lamp power supply circuit, and repair
D Disconnect the connector, and measure at the harness side. if necessary.
D Voltage between 1 and earth (Ignition switch: ON)
OK: System voltage
OK
NG
Check the following connectors: Repair
C-06, C-07, C-17, C-28
OK
NG
Check trouble symptom. Check the harness wire between combination meter and engine-
ECU, and repair if necessary.
 GDI – Troubleshooting 13A-43
INSPECTION PROCEDURE 4
The engine warning lamp remains illuminating and never Probable cause
goes out.
In cases such as the above, the cause is probably that the engine-ECU is detecting D Short-circuit between the engine warning lamp and
a problem in a sensor or actuator, or that one of the malfunctions listed at right engine-ECU
has occurred. D Malfunction of the engine-ECU

Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES
No
NG
Measure at the combination meter connector C-07. Check the harness wire between combination meter and engine-
D Disconnect the connector, and measure at the harness side. ECU connector, and repair if necessary.
D Disconnect the engine-ECU connector
D Continuity between 46 and earth
OK: No continuity
OK

Replace the engine-ECU.

INSPECTION PROCEDURE 5
No initial combustion (starting impossible) Probable cause
This is caused by incorrect fuel supply into the combustion chamber, and improper D Malfunction of the fuel supply system
ignition circuit. Besides that, foreign material may be contaminated in fuel. D Malfunction of the ignition system
D Malfunction of the engine-ECU

NG
Check system voltage while the engine is cranking. Check the battery. (Refer to GROUP 55 – Battery.)
OK: 8 V or more
OK
Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the engine control relay and ignition switch-IG system.
16 System voltage (Refer to P.13A-72.) (Refer to P.13A-62, INSPECTION PROCEDURE 24.)
OK
No
Does the camshaft rotate when the engine is cranking? Check if the timing belt is broken or damaged.
Yes
NG
MUT-II Actuator test Check the fuel pump (low pressure) system. (Refer to P.13A-66,
07 Fuel pump (low pressure) (Refer to P.13A-76.) INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the crank angle sensor system. (Refer to P.13A-20, IN-
22 Crank angle sensor (Refer to P.13A-72.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 22.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system. (Refer to
21 Engine coolant temperature sensor (Refer to P.13A-72.) P.13A-19, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
OK 21.)

To the next page

13A-44 GDI – Troubleshooting

From the previous page

OK
NG
MUT-II Data list Check the throttle position sensor (2nd channel) system. (Refer
14 Throttle position sensor (2nd channel) (Refer to P.13A-72.) to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 14.)
OK
OK
Inspect engine start ability by cranking the engine while the acceler- Clean around the throttle valve. (Refer to P.13A-92.)
ator pedal is slightly depressed.
NG
NG
Check fuel leakage. (Refer to P.13A-99.) Repair
OK

Measure low fuel pressure between the fuel pump (low pressure) NG
and fuel pump (high pressure). (Refer to P.13A-95.) Repair
OK
NG
Measure at ignition coil connectors A-09, A-10, A-11, A-12. Check abnormal fuel combustion system. (Refer to P.13A-27, IN-
D Connect the connector. SPECTION PROCEDURE FOR DIAGNOSIS CODE 44.)
D Connect a timing light to the No.1 terminal of each connector
in turn.
(Engine cranking)
OK: The timing light flashes.
OK
NG
Check ignition timing while the engine is cranking. Check that the crank angle sensor and timing belt cover are proper-
OK: Approx. 5_ BTDC ly installed.
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

D Spark plug
D Compression pressure
D Foreign material (such as water or kerosine) entered the fuel
lines
OK
NG
Check trouble symptom. Replace the injector.
 GDI – Troubleshooting 13A-45
INSPECTION PROCEDURE 6
Initial combustion takes place, but does not complete Probable cause
(start impossible), too long time to start (poor start)
This may be caused by improper spark plug ignition (poor spark), improper mixture D Malfunction of the fuel supply system
during engine cranking, improper fuel pressure. D Malfunction of the fuel pressure sensor
D Malfunction of the ignition system
D Malfunction of the electronic-controlled throttle vale
system
D Malfunction of the engine-ECU

NG
Check system voltage while the engine is cranking. Check the battery. (Refer to GROUP 55 – Battery.)
OK: 8 V or more
OK
Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Actuator test Check the fuel pump (low pressure) system. (Refer to P.13A-66,
07 Fuel pump (low pressure) (Refer to P.13A-76.) INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the engine coolant temperature system. (Refer to P.13A-
21 Engine coolant temperature sensor (Refer to P.13A-72.) 19, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
OK
NG
MUT-II Data list Check the ignition switch-ST system <M/T>. (Refer to P.13A-63,
18 Cranking signal (Refer to P.13A-72.) INSPECTION PROCEDURE 25.)
Check the ignition switch-ST system and inhibitor switch<A/T>.
OK
(Refer to P.13A-64, INSPECTION PROCEDURE 26.)
NG
MUT-II Data list Check an abnormal fuel pressure system. (Refer to P.13A-29,
74 Fuel pressure sensor (Refer to P.13A-75.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 56.)
NG
NG
Check fuel leakage. (Refer to P.13A-99.) Repair
OK
Yes
Is the engine started normally when it is cranked with the accelera- Clean around the throttle valve. (Refer to P.13A-92.)
tor pedal depressed slightly?
No

MUT-II Data list NG Check the throttle position sensor (2nd channel) system. (Refer
14 Throttle position sensor (2nd channel) (Refer to P.13A-72.) to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS
OK CODE 14.)

Check ignition timing when the engine is cranked. NG Check that the crank angle sensor and timing belt cover are proper-
OK: approx. 5_ BTDC ly installed.
OK

To the next page

13A-46 GDI – Troubleshooting

From the previous page

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

Check all the following items:

D Spark plug
D Compression pressure
D Foreign material (such as water or kerosine) entered the fuel
lines

OK
NG
Check trouble symptom. Replace the injector.
 GDI – Troubleshooting 13A-47
INSPECTION PROCEDURE 7
Unstable idling (rough idle, hunting) Probable cause
This malfunction is probably caused by a faulty ignition system, improper air/fuel D Malfunction of the ignition system
ratio, a faulty electronic-controlled throttle valve system, improper compression D Malfunction of the air/fuel ratio control system
pressure, etc. As many causes can be suspected, diagnose from easier items. D Malfunction of the electronic-control throttle valve
system
D Improper compression pressure
D Air sucking into the air intake system

Yes
Has the battery been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
minutes.
No

Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
Yes
Does the engine idle speed fluctuates excessively (excessive Clean around the throttle valve. (Refer to P.13A-92.)
hunting)?
No
NG
MUT-II Data list Check the throttle position sensor (2nd channel) system. (Refer
14 Throttle position sensor (2nd channel) (Refer to P.13A-72.) to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 14.)
OK
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-75.) P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
92.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system. (Refer to
26 Accelerator pedal position switch (Refer to P.13A-73.) P.13A-65, INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13A-71.) P.13A-17, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
13.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13A-23,
25 Barometric pressure sensor (Refer to P.13A-73.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-72.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system. (Refer to P.13A-68,
08 Purge control solenoid valve (Refer to P.13A-76.) INSPECTION PROCEDURE 30.)
OK

MUT-II Data list NG Check the oxygen sensor system. (Refer to P.13A-15, INSPEC-
11 Oxygen sensor TION PROCEDURE FOR DIAGNOSIS CODE 11.)
OK: 600 – 1,000 mV when the engine is suddenly raced
OK

To the next page

13A-48 GDI – Troubleshooting

From the previous page

OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high pressure)
11 Oxygen sensor and injector. (Refer to P.13A-97.)
OK: 0 – 400 mV and 600 – 1,000 mV alternates when the
engine is idling (wait for four minutes after the engine OK NG
started).
Repair
OK Check that air is sucked in the air intake system.
D Broken intake manifold gasket
D Damaged vacuum hose
D Damaged air intake hose

NG
MUT-II Data list Check the power steering fluid pressure switch system. (Refer
27 Power steering fluid pressure switch (Refer to P.13A-73.) to P.13A-69, INSPECTION PROCEDURE 31.)
OK

MUT-II Data list NG

Check the A/C switch and A/C relay system. (Refer to P.13A-69,
28 A/C switch (Refer to P.13A-73.) INSPECTION PROCEDURE 32.)
OK
NG
MUT-II Data list Check the ignition switch-ST and inhibitor switch. <A/T> (Refer
29 Inhibitor switch (Refer to P.13A-73.) to P.13A-64, INSPECTION PROCEDURE 26.)
OK
NG
MUT-II Data list Check the stop lamp switch. (Refer to P.13A-70, INSPECTION
67 Stop lamp switch (Refer to P.13A-74.) PROCEDURE 33.)
OK
NG
MUT-II Data list Check the small lamp switch system. (Refer to P.13A-70, INSPEC-
31 Small lamp switch (Refer to P.13A-73.) TION PROCEDURE 34.)
OK
NG
MUT-II Data list Check the EGR valve. (Refer to P.13A-67, INSPECTION PROCE-
68 EGR valve (Refer to P.13A-74.) DURE 29.)
OK
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
ly installed.
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Clean around the throttle valve. (Refer to P.13A-92.)

Check trouble symptom.

NG

Check all the following items in that order.

(1) Spark plugs
(2) Exhaust gas emission control system
(3) EGR system
(4) Compression pressure
(5) Foreign material (such as water or kerosine)entered the fuel
line.
(6) Air is sucked in the air intake system, or EGR gas leaks.
D Damaged intake manifold gasket
D Damaged air intake hose
D Damaged vacuum hose
D Faulty EGR valve seat
 GDI – Troubleshooting 13A-49
INSPECTION PROCEDURE 8
Idle speed is high or low (Improper idling) Probable cause
The cause is probably that the intake air amount during idling is too great or too D Malfunction of the electronic-controlled throttle valve
small. system
D Malfunction of the throttle body

Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the throttle position sensor (2nd channel). (Refer to
14 Throttle position sensor (2nd channel) (Refer to P.13A-72.) P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
14.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve. (Refer to P.13A-68, IN-
08 Purge control solenoid valve (Refer to P.13A-76.) SPECTION PROCEDURE 30.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system. (Refer to
26 Accelerator pedal position switch (Refer to P.13A-73.) P.13A-65, INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-72.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
OK
NG
MUT-II Data list Check the A/C switch and A/C relay system. (Refer to P.13A-69,
28 A/C switch (Refer to P.13A-73.) INSPECTION PROCEDURE 32.)
OK
NG
MUT-II Data list Check the ignition switch-ST and inhibitor switch <A/T>. (Refer
29 Inhibitor switch (Refer to P.13A-73.) to P.13A-64, INSPECTION PROCEDURE 26.)
OK
NG
MUT-II Data list Check the stop lamp switch system. (Refer to P.13A-70, INSPEC-
67 Stop lamp switch (Refer to P.13A-74.) TION PROCEDURE 33.)
OK
D Clean around the throttle valve. (Refer to P.13A-92.)
D Adjust the throttle position sensor. (Refer to P.13A-92.)
13A-50 GDI – Troubleshooting

INSPECTION PROCEDURE 9
When the engine is cold, it stalls at idling. (Die out) Probable cause
The cause is probably an incorrect air/fuel ratio or poor intake air amount when D Malfunction of the electronic-control throttle valve
the engine is cold. system
D Malfunction of the throttle body

Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
minutes.
No
Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
Yes
Is the engine idling correct after the engine has been warmed Refer to “Unstable idling (rough idle, hunting).” (Refer to P.13A-47,
up? INSPECTION PROCEDURE 7.)
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
22 Crank angle sensor (Refer to P.13A-72.) P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
Check idling speed when the engine is cold. 92.)
OK
NG
MUT-II Data list Check the accelerator position switch. (Refer to P.13A-65, IN-
26 Accelerator pedal position switch (Refer to P.13A-73.) SPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-72.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
OK
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-67, INSPECTION
68 EGR valve (Refer to P.13A-74.) PROCEDURE 29.)
OK
Yes
Does the engine stall immediately after the accelerator pedal is Clean around the throttle valve. (Refer to P.13A-92.)
released?
No
NG
Measure fuel high pressure between the fuel pump (high pressure) Repair
and injector. (Refer to P.13A-97.)
OK
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
OK ly installed.
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK
OK
Check all the following items: Check trouble symptom.
D Spark plugs
D Compression pressure NG
D Engine oil viscosity
Replace the injector.
 GDI – Troubleshooting 13A-51
INSPECTION PROCEDURE 10
When the engine is hot, it stalls at idling. (Die out) Probable cause
The cause is probably an improper air/fuel ratio, faulty electronic-controlled throttle D Malfunction of the ignition system
valve system, compression pressure. In addition, if the engine stalls suddenly, another D Malfunction of air/fuel ratio control system
possible cause might be a poor connector contact. D Malfunction of electronic-controlled throttle valve
system
D Malfunction of the throttle body
D Poor connector contact
D Improper compression pressure
D Air stuck in the air intake system

Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
No minutes.
Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the throttle position sensor (1st channel) system. (Refer
79 Throttle position sensor (1st channel) (Refer to P.13A-75.) to P.13A-35, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 79.)
OK
No
Is it easy to reproduce the engine stall? While carrying out an intermittent malfunction simulation test. (Re-
fer to GROUP 00 – Points to Note for Intermittent Malfunction.),
Yes check for sudden changes in the following signals.
D Crank angle sensor signal
D Injector drive signal
D Fuel pump (low pressure) drive signal
D Air flow sensor
D Primary ignition signal
D Power supply to the engine-ECU

NG
MUT-II Data list Check the accelerator pedal position switch. (Refer to P.13A-65,
26 Accelerator pedal position switch (Refer to P.13A-73.) INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-17, IN-
13 Intake air temperature sensor (Refer to P.13A-71.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-23, IN-
25 Barometric pressure sensor (Refer to P.13A-73.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-72.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
OK
NG
MUT-II Data list Check the oxygen sensor system. (Refer to P.13A-15, INSPEC-
11 Oxygen sensor TION PROCEDURE FOR DIAGNOSIS CODE 11.)
OK: 600 – 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high pressure)
11 Oxygen sensor and injector. (Refer to P.13A-97.)
OK: 0 – 400 mV and 600 – 1,000 mV alternates when the
OK NG
engine is idling (wait for four minutes after the engine
started).
Repair
OK
Check that air is sucked in the air intake system.
D Broken intake manifold gasket
To the next page
D Damaged vacuum hose
D Damaged air intake hose
13A-52 GDI – Troubleshooting

From the previous page

OK
NG
MUT-II Data list Check the power steering fluid pressure switch system. (Refer
27 Power steering fluid pressure switch (Refer to P.13A-73.) to P.13A-69, INSPECTION PROCEDURE 31.)
OK
NG
MUT-II Data list Check the A/C switch and A/C relay system. (Refer to P.13A-69,
28 A/C switch (Refer to P.13A-73.) INSPECTION PROCEDURE 32.)
OK

MUT-II Data list NG Check the ignition switch-ST and inhibitor switch <A/T>. (Refer
29 Inhibitor switch (Refer to P.13A-73.) to P.13A-64, INSPECTION PROCEDURE 26.)
OK
NG
MUT-II Data list Check the small lamp switch system. (Refer to P.13A-70, INSPEC-
31 Small lamp switch (Refer to P.13A-73.) TION PROCEDURE 34.)
OK
NG
MUT-II Data list Check the air flow sensor system. (Refer to P.13A-16, INSPEC-
34 Air flow sensor reset signal (Refer to P.13A-73.) TION PROCEDURE FOR DIAGNOSIS CODE 12.)
OK
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-67, INSPECTION
68 EGR valve (Refer to P.13A-74.) PROCEDURE 29.)
OK
Yes
Does the engine stall immediately after the accelerator pedal is Clean around the throttle valve. (Refer to P.13A-92.)
released?
No
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
OK ly installed.
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

D Spark plugs
D Compression pressure
D Foreign material (such as water or kerosine) entered the fuel
lines
 GDI – Troubleshooting 13A-53
INSPECTION PROCEDURE 11
The engine stalls when starting the car. (Pass out) Probable cause
The cause is probably poor ignition due to a malfunctioning spark plug (weak spark), D Malfunction of the ignition system
or an incorrect air/fuel ratio when the accelerator is depressed. D Malfunction of the EGR valve
D Air stuck in the air intake system

Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-67, INSPECTION
68 EGR valve (Refer to P.13A-74.) PROCEDURE 29.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system. (Refer to P.13A-68,
08 Purge control solenoid valve (Refer to P.13A-76.) INSPECTION PROCEDURE 30.)
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

(1) Spark plug
(2) Check if air is stuck in the air intake system.
D Damage intake manifold gasket
D Damaged or disconnected vacuum hose
D Damaged air intake hose
13A-54 GDI – Troubleshooting

INSPECTION PROCEDURE 12
The engine stalls when decelerating. Probable cause
The cause is probably an improper air/fuel ratio due to a faulty EGR system, or D Malfunction of the electronic-controlled throttle valve
poor intake air volume due to a faulty electronic-controlled throttle valve system. system
D Malfunction of the EGR valve

Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
No minutes.
Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the accelerator pedal position switch. (Refer to P.13A-65,
26 Accelerator pedal position switch (Refer to P.13A-73.) INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-75.) P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
92.)
OK
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-67, INSPECTION
68 EGR valve (Refer to P.13A-74.) PROCEDURE 29.)
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

D Spark plug
D Clean around the throttle valve (Refer to P.13A-92.)
 GDI – Troubleshooting 13A-55
INSPECTION PROCEDURE 13
Hesitation, sag, stumble, poor acceleration or surge Probable cause
The cause is probably a malfunction of the ignition system, electronic-controlled D Malfunction of the ignition system
throttle valve system, compression pressure, etc. D Malfunction of the air/fuel ratio control system
D Malfunction of the electronic-controlled throttle valve
system
D Improper compression pressure
D Air stuck in the air intake system

Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
NO
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are
properly installed.
OK
NG
MUT-II Data list Check the accelerator pedal position switch. (Refer to P.13A-65,
26 Accelerator pedal position switch (Refer to P.13A-73.) INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-17, IN-
13 Intake air temperature sensor (Refer to P.13A-71.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-23, IN-
25 Barometric pressure sensor (Refer to P.13A-73.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-72.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
OK
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-75.) P.13A-38, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
99.)
OK
NG
MUT-II Data list Check the oxygen sensor system. (Refer to P.13A-15, INSPEC-
11 Oxygen sensor TION PROCEDURE FOR DIAGNOSIS CODE 11.)
OK: 600 – 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high pressure)
11 Oxygen sensor and injector. (Refer to P.13A-97.)
OK: 0 – 400 mV and 600 – 1,000 mV alternates when the OK
engine is idling (wait for four minutes after the engine
started). Check that air is sucked in the air intake system.
OK D Broken intake manifold gasket
D Damaged vacuum hose
D Damaged air intake hose

NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-67, INSPECTION
68 EGR valve (Refer to P.13A-74.) PROCEDURE 29.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve. (Refer to P.13A-68, IN-
08 Purge control solenoid valve (Refer to P.13A-76.) SPECTION PROCEDURE 30.)
OK

To the next page

13A-56 GDI – Troubleshooting

From the previous page

OK
NG
Measure high fuel pressure between the fuel pump (high pressure) Repair
and injector. (Refer to P.13A-97.)
OK
NG Replace the ignition coil.
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK
OK
Check all the following items: Check trouble symptom.
D Spark plug
D EGR system NG
D Compression pressure
D Clogged fuel filter, fuel line Replace the injector.

INSPECTION PROCEDURE 14
The feeling of impact when accelerating Probable cause
The cause is probably an ignition leak being generated in line with an increase D Malfunction of the ignition system
in the spark plug request voltage during acceleration.

Yes
MUT-II Self-Diag code (Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-75.) P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
92.)
OK
OK
Check ignition coil spark for each cylinder. Check all the following items:
(1) Remove the ignition coil. D Spark plug
(2) Install a new spark plug to the removed ignition coil. D Ignition current leak
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured. NG
(4) Earth the spark plug electrode securely. Replace the ignition coil.
(5) Check that the spark plug ignites when the engine is cranked.
 GDI – Troubleshooting 13A-57
INSPECTION PROCEDURE 15
The feeling of impact when decelerating Probable cause
The cause is probably insufficient intake air due to a faulty electronic-controlled D Malfunction of the electronic-controlled throttle valve
throttle valve system. system

Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-75.) P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
92.)
OK

NG
MUT-II Data list Check the accelerator pedal position switch system. (Refer to
26 Accelerator pedal position switch (Refer to P.13A-73.) P.13A-65, INSPECTION PROCEDURE 27.)
OK

Clean around the throttle valve. (Refer to P.13A-92.)

INSPECTION PROCEDURE 16
Knocking Probable cause
The cause is probably incorrect detonation control or improper heat range of the D Malfunction of the detonation sensor
spark plugs. D Improper heat range of the spark plugs

Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
No
Does knocking occur when the vehicle is driven with the detonation Check the detonation sensor system. (Refer to P.13A-24, INSPEC-
sensor disconnected? TION PROCEDURE FOR DIAGNOSIS CODE 31.)
(At this time, use the MUT-II to check whether the ignition timing
is retarded from when the detonation sensor connector is con-
nected.)
Yes

Check all the following items:

D Spark plug
D Foreign material (such as water or kerosine) entered the fuel
lines

INSPECTION PROCEDURE 17
Run-on (dieseling) Probable cause
The cause is probably fuel leak from injector(s) D Malfunction of the injector

Replace the injector.

13A-58 GDI – Troubleshooting

INSPECTION PROCEDURE 18
Too high CO and HC concentration when idling Probable cause
The cause is probably an incorrect air/fuel ratio D Malfunction of air/fuel ratio control system
D Deterioration of the catalyst

Yes
MUT-II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
OK ly installed.
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-72.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-17, IN-
13 Intake air temperature sensor (Refer to P.13A-71.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-23, IN-
25 Barometric pressure sensor (Refer to P.13A-73.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
OK
NG
MUT-II Data list Check the oxygen sensor system. (Refer to P.13A-15, INSPEC-
11 Oxygen sensor TION PROCEDURE FOR DIAGNOSIS CODE 11.)
OK: 600 – 1,000 mV when the engine is suddenly raced
OK
OK
MUT-II Data list Replace the oxygen sensor.
11 Oxygen sensor
OK: 0 – 400 mV and 600 – 1,000 mV alternates when the
engine is idling (wait for four minutes after the engine
started). Check trouble symptom.
NG NG
NG
Measure fuel high-pressure between the fuel pump (high pressure) Repair
and injector. (Refer to P.13A-97.)
OK

Check ignition coil spark for each cylinder.

(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK NG

Check all the following items: Replace the ignition coil.

D Spark plug
D EGR system
D Compression pressure
D Clogged fuel filter or line
OK

To the next page

 GDI – Troubleshooting 13A-59
From the previous page
OK
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-67, INSPECTION
68 EGR valve (Refer to P.13A-74.) PROCEDURE 29.)
OK
NG
MUT-II Actuator test Check purge control solenoid valve system. (Refer to P.13A-68,
08 Purge control solenoid valve (Refer to P.13A-76.) INSPECTION PROCEDURE 30.)
OK
NG
Check trouble symptom. Replace the injector.

Check trouble symptom.

NG
Replace the three-way catalytic converter.

INSPECTION PROCEDURE 19
Low alternator output voltage (approx. 12.3 V) Probable cause
The cause is probably a malfunction of the alternator or one of the problems D Malfunction of the charging system
listed at right. D Open circuit between the alternator G terminal
and the engine-ECU
D Malfunction of the engine-ECU

NG NG
Measure at the alternator connector Measure at the alternator connector Check the harness wire between
A-79. A-79. the alternator and the engine-ECU,
D Connect the connector. (Use the D Disconnect the connector, and and repair if necessary.
test harness MB991519) measure at the harness side.
D Voltage between 1 (black clip) D Disconnect the engine-ECU
and earth connector.
(Engine: Idling) D Continuity between 1 and earth
(Radiator fan: Not operating) OK: No continuity
(Headlamp: OFF → ON) OK
(Stop lamp: OFF → ON)
(Rear defogger switch: OFF → NG
ON) Check the following connectors: Repair
OK: Voltage increased by A-86, C-17
0.2 – 3.5 V.
OK
OK NG
Check trouble symptom. Check the harness wire between
Check the alternator. (Refer to GROUP the alternator and the engine-ECU.
16 – Charging System.)
OK NG

Repair
Replace the engine-ECU.
13A-60 GDI – Troubleshooting

INSPECTION PROCEDURE 20
Fans (radiator fan, A/C condenser fan) are inoperative. Probable cause
The engine-ECU sends a duty signal to the fan controller according to engine coolant D Malfunction of the fan motor relay
temperature, vehicle speed, or A/C switch. D Malfunction of the fan motor
The fan controller controls radiator fan and condenser fan speeds, based on this D Malfunction of the fan controller
signal. (The closer the terminal voltage comes to 5 V, the higher the fan speed D Open or short circuit, or poor connector contact
becomes.) D Malfunction of the engine-ECU

NG
Measure at engine-ECU connector C-17. Check the following connector: A-29
D Disconnect the connector, measure at the harness side. NG
OK
D Voltage between terminal 18 and earth
(Ignition switch: ON) Repair
OK: 4.8 – 5.2 V (The fan runs at high speed.)
D Earth terminal 21.
(Ignition switch: ON)
OK: The fan stops. Check trouble symptom.

OK NG

Check the harness wire between the engine-ECU and fan control-
Check the following connector: C-17 ler.
OK NG OK NG
Repair Repair

Check the radiator fan and condenser fan circuit. (Refer to GROUP
Check trouble symptom. 14 – Troubleshooting.)
NG
NG
MUT-II Data list Check the engine coolant temperature sensor system. (Refer to
21 Engine coolant temperature sensor P.13A-19, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
OK: After the engine has been warmed up, the engine coolant 21.)
temperature during idling is identical to the MUT-II reading.
OK
NG
Check the thermostat. Replace
OK

Replace the engine-ECU.

 GDI – Troubleshooting 13A-61
INSPECTION PROCEDURE 21
GDI ECO indicator lamp does not illuminate. Probable cause
If the GDI ECO indicator lamp does not illuminate after turning switch, the causes D Burned-out GDI ECO indicator lamp bulb
listed in the right column are suspected. D Open circuit or short-circuited harness wire in the
GDI ECO indicator lamp circuit
D Malfunction of the engine-ECU
D Malfunction of the GDI ECO indicator lamp ECU

OK
Measure at engine-ECU connector C-17. Check the following connector: C-17
D Disconnect the connector, and measure at the harness side. OK NG
D Earth terminal 14. (Ignition switch: ON)
OK: The GDI ECO indicator lamp illuminates. Repair
NG

Check trouble symptom.

Check the following connectors: C-29, C-55
NG
OK NG
Replace the engine-ECU.
Repair
Check trouble symptom.
NG

Check the harness wire between the GDI-ECO Indication lamp- NG

ECU and engine-ECU. Repair

OK

Check the relative circuits of GDI ECO indication lamp.

(Refer to GROUP 54A-Troubleshooting.)

INSPECTION PROCEDURE 22
GDI ECO indicator lamp remains illuminated and does not Probable cause
go off.
If the GDI ECO indicator lamp does not go off during high load operation, the causes D Short circuit between the GDI ECO indicator lamp
listed in the right column are suspected. and engine-ECU
D Malfunction of the engine-ECU
D Malfunction of the GDI ECO indicator lamp ECU

NG
Measure at GDI ECO indicator lamp ECU connector C-55. Check the harness wire between the GDI ECO indication lamp-
D Disconnect the connector, and measure at the harness side. ECU and engine-ECU, and repair if necessary.
D Disconnect the engine-ECU connector.
D Continuity between terminal 3 and earth
OK: No continuity
OK

Check the relative circuits of GDI ECO indication lamp.

(Refer to GROUP 54A-Troubleshooting.)
OK

Replace the engine-ECU.

13A-62 GDI – Troubleshooting

INSPECTION PROCEDURE 23
Engine-ECU power supply and earth circuit system Probable cause
The cause is probably a malfunction of the engine-ECU or one of the problems D Open circuit or short-circuited harness wire in the
listed at right. engine-ECU power supply circuit
D Open circuit or short-circuited harness wire in the
engine-ECU earth circuit
D Malfunction of the engine-ECU

(1) NG NG
Measure at the engine-ECU connectors Check the following connectors: Repair
C-18, C-19. C-72, C-74
D Disconnect the connector, and
OK
measure at the harness side.
(1) Voltage between 99 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON) engine-ECU and ignition switch, and
OK: System voltage repair if necessary.
(2) Voltage between 57 and earth (2),(3) NG NG
OK: System voltage OK NG
Check the following connector: Repair
(3) Voltage between 47, 59 and A-36
earth (Ignition switch: ON) Repair
OK: System voltage (When ter- (4) NG OK
minal 57 is shorted to Check the ignition switch. (Refer to
earth) Check the trouble symptoms.
GROUP 54.)
(4) Continuity between 46, 58 and NG
(5) NG
earth
OK: Continuity Check the harness wire between the
(5) Voltage between 60 and earth engine-ECU and engine control relay,
OK: System voltage and repair if necessary.
OK
Check the harness wire between the
Check the following connectors: engine-ECU and earth, and repair if
B-18, C-19 necessary.
OK NG
Check the harness wire between the
Repair engine-ECU and the battery, and repair
if necessary.
Check the trouble symptoms.
NG

Replace the engine-ECU.

INSPECTION PROCEDURE 24
Engine control relay and ignition switch-IG system Probable cause
When the ignition switch ON signal is input to the engine-ECU, the D Malfunction of the ignition switch
engine-ECU turns on the engine control relay. D Malfunction of the engine control relay
This causes system voltage to be supplied to the engine-ECU and to the D Open circuit or short-circuited harness wire of the
sensors and actuators. engine control relay circuit
D Malfunction of the engine-ECU

NG
Check the engine control relay. (Refer Replace
to P.13A-102.)
OK
NG NG
Measure at the engine control relay Check the following connector: Repair
connector A-43X. A-36
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 3, 4 and earth NG
Check the trouble symptoms. Check the harness wire between the
OK: System voltage battery and the engine control relay,
OK and repair if necessary.

Check the engine-ECU power supply

and earth circuit system. (Refer to
P.13A-62, INSPECTION PROCE-
DURE 23.)
 GDI – Troubleshooting 13A-63
INSPECTION PROCEDURE 25
Ignition switch-ST system <M/T> Probable cause
The ignition switch-ST outputs a HIGH signal to the engine-ECU while the D Malfunction of the ignition switch
engine is cranking, and the engine-ECU uses this signal to carry out functions D Open circuit or short-circuited harness wire
such as fuel injection control during starting. between ignition switch
D Malfunction of the engine-ECU

(1) NG NG
Measure at the engine-ECU connector Check the following connector: Repair
C-18. C-27
D Disconnect the connector, and
measure at the harness side. OK
(1) Voltage between 68 and earth
(Ignition switch: START) Check the trouble symptoms.
(2) NG
OK: System voltage NG
(2) Continuity between 67 and earth NG
OK: Continuity Check the harness wire between the Repair
inhibitor switch and the ignition switch
OK connector.
Check the following connector: OK
C-18
Check the ignition switch. (Refer to
OK NG GROUP 54.)

Repair
Check the harness wire between the
engine-ECU connector (terminal
Check the trouble symptoms.
No.91) and the earth, repair if neces-
NG sary.

Replace the engine-ECU.

13A-64 GDI – Troubleshooting

INSPECTION PROCEDURE 26
Ignition switch-ST and inhibitor switch system <A/T> Probable cause
The ignition switch-ST outputs a HIGH signal to the engine-ECU while the D Malfunction of the ignition switch
engine is cranking, and the engine-ECU uses this signal to carry out functions D Malfunction of the inhibitor switch
such as fuel injection control during starting. D Open circuit or short-circuited harness wire
The inhibitor switch inputs the position of the selector lever to the engine-ECU. between ignition switch and inhibitor switch
The engine-ECU uses this signal to carry out idle speed control. D Malfunction of the engine-ECU

NG
Check the inhibitor switch (Refer to Replace
GROUP 23 – On-vehicle Service.)
OK
(1) NG NG
Measure at the inhibitor switch connec- Check the following connectors: Repair
tor B-04. C-18, C-24, D-02
D Disconnect the connector, and
OK
measure at the harness side.
(1) Voltage between 4 and earth NG
Check the trouble symptoms. Check the harness wire between
(Ignition switch: ON)
OK: System voltage the engine-ECU and the inhibitor
(2) Continuity between 1 and earth switch connector.
(2) NG
OK: Continuity Check the following connectors: OK NG
(3) Voltage between 4 and earth A-83, B-01
(Ignition switch: START)
OK NG Repair
Disconnect the engine-ECU
connector. (3) NG
OK: System voltage Repair Replace the engine-ECU.

OK NG
Check the trouble symptoms. Check the harness wire between the
Check the following connector: inhibitor switch connector and the start-
B-04 er S terminal, and repair if necessary.
OK NG NG
Check the following connector: Repair
Repair C-39, D-02
OK
Check the trouble symptoms.
Check the trouble symptoms.
NG
NG
Check the harness wire between the NG
engine-ECU and the inhibitor switch. Check the harness wire between the Repair
inhibitor switch and the ignition switch
OK NG connector.
Repair OK

Check the ignition switch. (Refer to

Replace the engine-ECU. GROUP 54.)
 GDI – Troubleshooting 13A-65
INSPECTION PROCEDURE 27
Accelerator pedal position switch system Probable cause
The accelerator pedal position switch detects that the accelerator pedal is fully closed, D Maladjustment of the accelerator cable
and sends a signal to the engine-ECU. The engine-ECU controls idle speed, based D Maladjustment of the accelerator pedal position switch
on this signal. D Open circuit or short-circuited harness wire in the
accelerator pedal position switch system, or poor
connector contact
D Malfunction of the engine-ECU

NG
Check the accelerator pedal position switch. (Refer to P.13A-105.) Replace the accelerator pedal position sensor assembly.
OK
NG
Measure at accelerator pedal position sensor (1st channel) connec- Check the following connectors: C-18, C-19
tor C-46. NG
OK
D Disconnect the connector, and measure at the harness side.
D Voltage between terminal 4 and earth Repair
(Ignition switch: ON)
OK: 4 V or more
D Continuity between terminal 1 and earth
OK: Continuity Check trouble symptom.
NG
OK
Check the harness wire between the engine-ECU and accelerator
pedal position sensor 1 (1st channel).
OK NG
NG
Check the following connector: C-46 Repair Repair
OK
NG
Check trouble symptom. Replace the engine-ECU.
13A-66 GDI – Troubleshooting

INSPECTION PROCEDURE 28
Fuel pump (low pressure) system Probable cause
The engine-ECU turns on the fuel pump relay while the engine is cranking or running, D Malfunction of the fuel pump relay
and supplies power source to the fuel pump (low pressure). D Malfunction of the fuel pump (low pressure)
D Open circuit or short-circuited harness wire in the
fuel pump (low pressure) circuit, or poor connector
contact
D Malfunction of the engine-ECU

OK
MUT-II Actuator test Normal
07 Fuel pump (Refer to P.13A-76.)
NG
NG
Check the fuel pump relay. (Refer to Replace
P.13A-102.)
OK
NG NG
Measure at fuel pump relay connector Check the following connectors: Repair
A-41X. C-72, C-74
D Disconnect the connector, and
OK
measure at the harness side.
D Voltage between terminals 3, 4 and NG
Check trouble symptom. Check the harness wire between the
earth fuel pump relay and ignition switch.
(Ignition switch: ON)
OK: System voltage OK NG
OK Repair
NG
Measure at engine-ECU connector Check the following connector:
C-17. A-41X Check the ignition switch. (Refer to
D Disconnect the connector, and GROUP 54 – Ignition Switch.)
OK NG
measure at the harness side.
D Voltage between terminal 21 and Repair
earth (Ignition switch: ON)
OK: System voltage NG
Check trouble symptom. Check the harness wire between the
OK fuel pump relay and engine-ECU, and
repair if necessary.
OK NG
Measure at engine-ECU connector Check the following connector: Repair
C-17. C-17
D Disconnect the connector, and
OK
measure at the harness side.
D Short circuit between terminal 21 NG
Check trouble symptom. Replace the engine-ECU.
and earth (Ignition switch: ON)
OK: The fuel pump operates (its
operation sound can be
heard).
NG
(1) NG NG
Measure at fuel pump (low pressure) Check the following connectors: Repair
connector D-17. C-24<LHD>, C-26<RHD>, D-12
D Disconnect the connector, and OK
measure at the harness side.
(1) Voltage between terminal 5 and NG
Check trouble symptom. Check the harness wire between the
earth fuel pump relay and fuel pump (low
(Ignition switch: ON) pressure), and repair if necessary.
OK: System voltage
(2) Continuity between 4 and earth (2) NG
OK: Continuity Check the following connector:
D-12
OK
OK NG

Repair
NG
Check trouble symptom. Check the harness wire between the
NG fuel pump (low pressure) and earth,
Check the following connector: Repair and repair if necessary.
D-17
OK

Check trouble symptom.

NG

Replace the fuel pump (low pressure).

 GDI – Troubleshooting 13A-67
INSPECTION PROCEDURE 29
EGR valve system Probable cause
The engine-ECU controls the EGR valve in order to control the amount of D Malfunction of the EGR valve
exhaust gas mixed in the intake air. D Open circuit or short-circuited harness wire in the
EGR valve circuit
D Malfunction of the engine-ECU

Check the EGR valve. (Refer to NG

GROUP 17 – Emission Control Sys- Replace
tem.)

OK
NG NG
Measure at the EGR valve connector Check the following connectors: Repair
A-60. A-36, A-82
D Disconnect the connector, and
OK
measure at the harness side.
D Voltage between 2, 5 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON) engine control relay and the EGR valve,
OK: System voltage and repair if necessary.
OK
NG NG
Measure at the engine-ECU connector Check the following connectors: Repair
C-17. A-60, A-82
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 5, 6, 32, 34 NG
Check the trouble symptoms. Check the harness wire between the
and earth (Ignition switch: ON) engine-ECU and EGR valve, and repair
OK: System voltage if necessary.
OK
NG
Check the following connector: Repair
C-17
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
13A-68 GDI – Troubleshooting

INSPECTION PROCEDURE 30
Purge control solenoid valve system Probable cause
The engine-ECU controls the purge control solenoid valve in order to control D Malfunction of the purge control solenoid valve
the purge air coming from the canister. D Open circuit or short-circuited harness wire in the
purge control solenoid valve circuit
D Malfunction of the engine-ECU

NG
Check the purge control solenoid valve. Replace
(Refer to GROUP 17 – On-vehicle Ser-
vice.)
OK
NG NG
Measure at the purge control solenoid Check the following connector: Repair
valve connector A-02. A-36
D Disconnect the connector, and
OK
measure at the harness side.
D Voltage between 2 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON) engine control relay and the purge
OK: System voltage control solenoid valve, and repair if
OK necessary.
NG NG
Measure at the engine-ECU connector Check the following connector: Repair
C-17. A-02
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 16 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON) engine-ECU and the purge control sole-
OK: System voltage noid valve, and repair if necessary.
OK
NG
Check the following connector: Repair
C-17
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
 GDI – Troubleshooting 13A-69
INSPECTION PROCEDURE 31
Power steering fluid pressure switch system Probable cause
The power steering fluid pressure switch sends a signal to the engine-ECU according D Malfunction of the power steering fluid pressure switch
to power steering load. D Open circuit or short-circuited harness wire in the
Based on this signal, the engine-ECU controls the throttle control servo so that power steering fluid pressure switch circuit, or poor
idle speed increases when the power steering is in operation. connector contact
D Malfunction of the engine-ECU

NG
Check the power steering fluid pressure switch. (Refer to GROUP Replace
37A – On-vehicle Service.)
OK
NG
Measure at power steering fluid pressure switch connector A-76. Check the following connector: C-18
D Disconnect the connector, and measure at the harness side. OK NG
D Voltage between terminal 1 and earth
(Ignition switch: ON) Repair
OK: System voltage
OK
Check trouble symptom.
Check the following connector: A-76
NG
OK NG
Check the harness wire between the engine-ECU and power steer-
Repair ing fluid pressure switch.
OK NG

Repair

NG
Check trouble symptom. Replace the engine-ECU.

INSPECTION PROCEDURE 32
A/C switch and A/C relay system Probable cause
If the engine-ECU receives a ‘A/C on’ signal, it operates the throttle control servo D Malfunction of the A/C control system
and A/C compressor magnetic clutch so that idle speed increases. D Malfunction of the A/C switch
D Open circuit or short-circuited harness wire in the
A/C switch circuit, or poor connector contact
D Malfunction of the engine-ECU

NG
Service the A/C compressor relay. (Refer to GROUP 55 – On-ve- Replace
hicle Service.)
OK
OK
Measure at engine-ECU connectors C-17, C-19. Check the following connectors: C-17, C-19
D Disconnect the connector, and measure at the harness side. NG
OK
D Voltage between terminals 20, 83 and earth
(Ignition switch: ON) Repair
OK: 0 – 3 V
(A/C switch: OFF)
System voltage
(A/C switch: ON) Check trouble symptom.
D Connect terminal 20 to earth. NG
(Ignition switch: ON, A/C switch: ON)
OK: A/C compressor clutch turns on. Replace the engine-ECU.
NG

Check the A/C system. (Refer to GROUP 55 – On-vehicle Service.)

13A-70 GDI – Troubleshooting

INSPECTION PROCEDURE 33
Stop lamp switch system Probable cause
The engine-ECU determines whether the brake pedal is depressed or not, by means D Malfunction of the stop lamp switch
of the stop lamp switch input signal. D Open circuit or short-circuited harness wire in the
stop lamp circuit, or poor connector contact
D Malfunction of the engine-ECU

NG
Check the stop lamp switch. (Refer to GROUP 35 – Brake Pedal.) Replace
OK
NG
Measure at stop lamp switch connector C-04. Check the following connector: C-29
D Disconnect the connector, and measure at the harness side. OK NG
D Voltage between terminal 2 and earth
OK: System voltage Repair
OK
Check trouble symptom.
NG

Check the harness wire between the battery and stop lamp switch.
NG
Measure at engine-ECU connector C-18. Check the following connectors: C-02, C-04, C-28
D Disconnect the connector, and measure at the harness side. OK NG
D Voltage between terminal 63 and earth
(Ignition switch: ON) Repair
OK: 0 – 3 V (when the brake pedal is not depressed)
System voltage (when the brake pedal is depressed) Check trouble symptom.
OK NG

Check the harness wire between the engine-ECU and stop lamp,
and repair if necessary.
NG
Check the following connector: C-18 Repair
OK

Check trouble symptom.

NG

Replace the engine-ECU.

INSPECTION PROCEDURE 34
Small lamp switch Probable cause
The engine-ECU determines whether the small lamp switch is on or off. D Improper connector contact, open circuit or
According to that information, the engine-ECU controls short-circuited harness wire in the taillamp relay
alternator output current when the vehicle is started. circuit
D Malfunction of the engine-ECU

NG
Measure at the engine-ECU connector C-19. Check the taillamp relay circuit. (Refer to ELECTRICAL WIRING.)
D Disconnect the connector, and measure at the harness
side.
D Voltage between 88 and earth
(Lighting switch: ON)
OK: System voltage
OK
NG
Check the following connector: C-19 Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
 GDI – Troubleshooting 13A-71
DATA LIST REFERENCE TABLE
Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forward.
NOTE
*1: Within four minutes after starting the engine
*2: In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer
than the standard time.
*3: The accelerator pedal position switch normally turns off when the voltage of the accelerator pedal
position sensor (1st channel) is 250 – 550 mV higher than the voltage at the idle position. If the accelerator
pedal position switch turns back on after the accelerator pedal position sensor voltage has risen by
100 mV and the throttle valve has opened, the accelerator pedal position switch and the accelerator
pedal position sensor (1st channel) need to be adjusted.

Item Check items Requirements Normal condition Inspection Refer-

No. procedure ence
No. page

11 Oxygen sensor Engine: After warm- Idling 0 mV*1 Code 13A-15

up No 11
No.11
Sudden racing 600 – 1,000 mV

2,500 r/min 400 mV or less ↔

600 – 1,000 mV
(alternates)

12 Air flow sensor D Engine coolant Idling 20 – 55 Hz Code 13A-16

temperature: 80 No.12
– 95_C
D Lamps, electric 2,500 r/min 65 – 85 Hz
cooling fan and
all accessories:
OFF Racing Frequency in-
D Transmission: creases in re-
Neutral (A/T: P sponse to racing.
range)

13 Intake air tem- Ignition switch: ON Intake air tempera- –20_C Code 13A-17
perature sen- ture: –20_C No.13
sor
Intake air tempera- 0_C
ture: 0_C

Intake air tempera- 20_C

ture: 20_C

Intake air tempera- 40_C

ture: 40_C

Intake air tempera- 80_C

ture: 80_C
13A-72 GDI – Troubleshooting

Item Check items Requirements Normal condition Inspection Refer-

No. procedure ence
No. page

14 Throttle posi- D Engine coolant Release the accel- 4,000 – 4,800 mV Code 13A-18
tion sensor temperature: 80 erator pedal. No.14
(2nd channel) – 95_C
D Ignition switch: Depress the accel- Voltage decreases
ON (Engine erator pedal gradu- in response to the
stopped) ally. pedal depression.

Depress the accel- 100 – 1,100 mV

erator pedal fully.

16 Power supply Ignition switch: ON System voltage Procedure 13A-62

voltage No.23

18 Cranking sig- Transmission: Neu- Engine: Stopped OFF Procedure 13A-63

nal (Ignition tral (A/T: P range) No.25 <M/T>
sswitch
tc – ST)
S ) /
<M/T> 13A 64
13A-64
Engine: Cranking ON Procedure <A/T>
No.26
<A/T>

21 Engine coolant Ignition switch: ON Engine coolant tem- –20_C Code 13A-19
temperature perature: –20_C No.21
sensor
Engine coolant tem- 0_C
perature: 0_C

Engine coolant tem- 20_C

perature: 20_C

Engine coolant tem- 40_C

perature: 40_C

Engine coolant tem- 80_C

perature: 80_C

22 Crank angle D Engine: crank- Compare the engine Accord Code 13A-20
sensor ing speed readings on No.22
D Tachometer: the tachometer and
Connected the MUT-II.

D Engine: Idling Engine coolant tem- 1,200 – 1,400 r/min

D Accelerator perature: –20_C
pedal position
switch: ON Engine coolant tem- 1,100 – 1,300 r/min
D Transmission: perature: 0_C
Neutral (A/T: P
range) Engine coolant tem- 1,000 – 1,200 r/min
perature: 20_C

Engine coolant tem- 750 – 950 r/min

perature: 50_C

Engine coolant tem- 550 – 850 r/min*1

perature: 80_C
 GDI – Troubleshooting 13A-73

Item Check items Requirements Normal condition Inspection Refer-

No. procedure ence
No. page

25 Barometric Ignition switch: ON Altitude: 0 m 101 kPa Code 13A-23

pressure sen- No 25
No.25
sor Altitude: 600 m 95 kPa

Altitude: 1,200 m 88 kPa

Altitude: 1,800 m 81 kPa

26 Accelerator Ignition switch: ON Release the accel- ON Procedure 13A-65

pedal position (Depress and re- erator pedal. No.27
switch lease the accelera-
tor pedal several Depress the accel- OFF
times) erator pedal slightly.

27 Power steering Engine: Idling Steering wheel sta- OFF Procedure 13A-69
fluid pressure tionary No.31
switch
Steering wheel ON
turning

28 A/C switch Engine: Idling (The A/C switch: OFF OFF Procedure 13A-69
A/C com ressor is
compressor No.32
running when the
A/C switch: ON ON
A/C switch is on.)

29 Inhibitor switch Ignition switch: ON Selector lever: P or P, N Procedure 13A-64

<A/T> N No.26

Selector lever: D, 2, D, 2, L, R
L or R

31 Small lamp Engine: Idling Lighting switch: OFF Procedure 13A-70

switch OFF No.34

Lighting switch: ON ON

34 Air flow sensor Engine: After hav- Engine is idling ON Code 13A-16
reset signal ing warmed up No.12
No 12
3,000 r/min OFF

37 Volumetric effi- D Engine coolant Engine is idling 30 – 50% – –

ciency temperature: 80
– 95_C
D Lamps, electric 2,500 r/min 30 – 50%
cooling fan and
all accessories:
OFF Engine is suddenly Volumetric effi-
D Transmission: raced ciency increases in
Neutral response to racing
(A/T: P range)

38 Crank angle D Engine: Cranking [reading is possible Engine speeds dis- – –

sensor at 2,000 r/min or less] played on the
D Tachometer: Connected MUT-II and
tachometer are
identical.
13A-74 GDI – Troubleshooting

Item Check items Requirements Normal condition Inspection Refer-

No. procedure ence
No. page

41 Injector drive D Engine coolant Idling 0.5 – 0.7 ms*1 Code 13A-25
time *2 temperature: 80 No.41
– 95_C
D L
Lamps, l ti
electric
cooling fan and 2,500 r/min 0.4 – 0.8 ms
all accessories:
OFF
D Transmission: Sudden racing Increases
Neutral (A/T: P
range)

44 Ignition D Engine: After Idling 12 – 20_BTDC *2 Code 13A-27

advance warm-up
warm u No.44
D Set a timing
2,500 r/min 20 – 40_BTDC
light.

49 A/C relay Engine: After warm- A/C switch: OFF OFF (compressor Procedure 13A-69
up, idling clutch is not oper- No.32
ating)

A/C switch: ON ON (compressor

clutch is operating)

66 Brake vacuum D Engine coolant Stop the engine Displayed pres- Code 13A-32
sensor temperature: 80 from idling speed, sure increases. No.66
– 95_C and then depress
D Lamps, electric the brake pedal
cooling fan and several times with
all accessories: the ignition switch
OFF on.
D Transmission:
Neutral
(A/T: P range)

67 Stop lamp Ignition switch: ON Brake pedal: OFF Procedure 13A-70

switch Depressed No.33

Brake pedal: ON
Released

68 EGR valve D Engine coolant Idling 0 – 15 STEP Procedure 13A-67

temperature: 80 No.29
– 95_C
D Lamps, electric
cooling fan and
all accessories:
2,500 r/min 0 – 10 STEP
OFF
D Transmission:
Neutral
(A/T: P range)
 GDI – Troubleshooting 13A-75

Item Check items Requirements Normal condition Inspection Refer-

No. procedure ence
No. page

74 Fuel pressure D Engine coolant After 3 minutes 4 – 6.9 MPa Code 13A-29
sensor temperature: 80 have passed at No.56
– 95_C idling condition
D Lamps, electric
cooling fan and
all accessories:
OFF
D Transmission:
Neutral
(A/T: P range)

77 Accelerator Ignition switch: ON Release the accel- 700 – 1,400 mV Code 13A-33
pedal position erator pedal. No.77
sensor (2nd
channel) Depress the accel- Increases in re-
erator pedal gradu- sponse to the ped-
ally. al depression
stroke.

Depress the accel- 4,100 mV or more

erator pedal fully.

78 Accelerator Ignition switch: ON Release the accel- 935 – 1,135 mV Code 13A-34
pedal position erator pedal. No.78
sensor
(1st channel)*3 Depress the accel- Increases in re-
erator pedal gradu- sponse to pedal
ally. depression stroke.

Depress the accel- 4,100 mV or more

erator pedal fully.

79 Throttle posi- D Engine coolant Release the accel- 450 – 800 mV Code 13A-35
tion sensor (1st temperature: 80 erator pedal. No.79
channel) – 95_C
D Ignition switch: Depress the accel- Increases in re-
ON (Engine erator pedal gradu- sponse to pedal
stopped) ally. depression stroke.

Depress the accel- 3,900 – 4,900 mV

erator pedal fully.

Engine: After warm- No load 450 – 1,000 mV

up idling
up,
A/C switch: OFF → Increases by 100 –
ON 600 mV.

Selector lever: N → Increases by 0 –

D range 200 mV.

99 Fuel injection Engine: After warm Idling (for several Lean compression – –
mode up minutes after en-
gine start)

2,500 r/min Stoichio metric

feedback

Sudden racing after Open loop

idle position
13A-76 GDI – Troubleshooting

ACTUATOR TEST REFERENCE TABLE

Item Inspection Drive contents Inspection contents Normal condition Inspection Reference
No. item procedure page
No.

01 Injectors Cut fuel to No. 1 Engine: Idling condition Code No. 13A-25
injector After having becomes different 41
warmed up/Engine (becomes unsta-
02 Cut fuel to No. 2 is idling ble).
injector (Cut the fuel supply
to each injector in
03 Cut fuel to No. 3 turn and check
injector cylinders which
don’t affect idling
idling.))
04 Cut fuel to No. 4
injector

07 Fuel pump Fuel pump Ignition switch: ON Sound of opera- Procedure 13A-66
(low pressure) operates and tion is heard. No. 28
fuel is recirculated.

08 Purge Solenoid valve Ignition switch: ON Sound of opera- Procedure 13A-68

control turns from OFF to tion can be heard No. 30
solenoid valve ON. when solenoid
valve is
driven.

17 Basic ignition Set the engine- Engine: Idling 5_BTDC – –

timing ECU to ignition Timing light is set
timing adjustment
mode

21 Fan controller Drive the fan motor Ignition switch: ON The fan motor Procedure 13A-60
operates No.20

34 Electronic- Close the throttle Ignition switch: ON Operation sound Code 13A-36
controlled valve fully can be heard No.91
throttle valve
system
 GDI – Troubleshooting 13A-77
CHECK AT THE ENGINE-ECU TERMINALS
TERMINAL VOLTAGE CHECK CHART
Engine-ECU Connector Terminal Arrangement

Terminal
Check item Check requirements (engine condition) Normal condition
No.

1 No.1 injector Engine: Warm up, and then depress the Decreases slightly for
accelerator pedal suddenly from the idle speed
speed. short time from 9 – 13 V.
V
9 No.2 injector

24 No.3 injector

2 No.4 injector

3 No.1 ignition coil Engine: 3,000 r/min 0.1 – 2.0 V

13 No.2 ignition coil

12 No.3 ignition coil

4 No.4 ignition coil

6 EGR valve (C) Ignition switch: Immediately after turning ON 5 – 8 V (fluctuates for
approx three seconds)
approx.
5 EGR valve (D)

34 EGR valve (A)

32 EGR valve (B)

8 Alternator G terminal D Engine: Warm up, and then idling Voltage increases by
D Radiator fan: not operating 0.2 – 3.5 V
D Headlamp: OFF → ON
D Stop lamp: OFF → ON
D Rear defogger switch: OFF → ON

14 GDI ECO indicator Engine: idling 0–3V

lamp
Engine: Depress the accelerator pedal suddenly System voltage
from the idle speed.

16 Purge control solenoid D Engine coolant tem- Engine: stopped System voltage
valve perature:
80 – 95°C Engine: Start the Voltage decreases.
D Ignition switch: engine, and then
ON increase engine speed
up to 3,500 r/min.

18 Fan controller Radiator and condenser fans are not operating. 0 – 0.3 V

Radiator and condenser fans are operating. 0.7 V or more

20 A/C relay D Engine: idling System voltage, or

D A/C switch: OFF → ON changes from momentari-
(Compressor is operating) ly 6 V or more to 0 – 3 V
13A-78 GDI – Troubleshooting

Terminal Check item Check requirements (engine condition) Normal condition

No.

21 Fuel pump relay Ignition switch: ON Engine: stopped System voltage

Engine: Idling 0–3V

31 Engine warning lamp Ignition switch: OFF → ON 0 – 3 V → System

voltage (after several
seconds)

41 Sensor power supply Ignition switch: ON 4.5 – 5.5 V

42 Power supply to Ignition switch: ON 4.5 – 5.5 V

accelerator pedal
position sensor

43 Crank angle sensor Engine: Cranking 0.4 – 4.0 V

Engine: Idling 1.5 – 2.5 V

44 Engine coolant Ignition switch: ON Engine coolant 3.2 – 3.8 V

temperature sensor temperature: 0_C

Engine coolant 2.3 – 2.9 V

temperature: 20_C

Engine coolant 1.3 – 1.9 V

temperature: 40_C

Engine coolant 0.3 – 0.9 V

temperature: 80_C

45 Tachometer output Engine: 3,000 r/min 2.0 – 9.0 V

47 Power supply Ignition switch: ON System voltage

59

50 Camshaft position Engine: Cranking 0.3 – 3.0 V

sensor
Engine: Idling 0.5 – 3.5 V

51 Barometric pressure Ignition switch: ON Altitude: 0 m 3.7 – 4.3 V

sensor
Altitude: 1,200 m 3.2 – 3.8 V

52 Alternator FR terminal D Engine: Warm up, and then idling Voltage decrease
D Radiator fan: not operating
D Headlamp: OFF → ON
D Stop lamp: OFF → ON
D Rear defogger switch: OFF → ON

54 Power steering fluid Engine: Warm up, and Steering wheel System voltage
pressure switch then idling stationary

Steering wheel turning 0–3V

55 Injector driver relay Ignition switch: OFF 0 – 0.1 V

Ignition switch: ON 0.5 – 1.0 V

56 Throttle valve control Ignition switch: OFF 0 – 0.3 V

servo relay
Ignition switch: ON 0.5 – 1.0 V
 GDI – Troubleshooting 13A-79

Terminal Check item Check requirements (engine condition) Normal condition

No.

57 Engine control relay Ignition switch: OFF System voltage

Ignition switch: ON 0–3V

60 Back-up power source Ignition switch: OFF System voltage

61 Air flow sensor Engine: Idling 2.2 – 3.2 V

Engine: 2,500 r/min

62 Intake air temperature Ignition switch: ON Intake air temperature: 3.2 – 3.8 V
sensor 0_C

Intake air temperature: 2.3 – 2.9 V

20_C

Intake air temperature: 1.5 – 2.1 V

40_C

Intake air temperature: 0.4 – 1.0 V

80_C

63 Stop lamp switch Depress the brake pedal. System voltage

Release the brake pedal. 0–3V

67 Inhibitor switch <A/T> Ignition switch: ON Selector lever: P or N 0–3V

range

Selector lever: Other 8 – 14 V

than P or N range

68 Ignition switch – ST Engine: Cranking 8 V or more

71 Oxygen sensor Engine: Warm up, and then hold the engine 0 V ↔ 0.8 V alternates
speed at 2,500 r/min (Use a digital voltmeter).

74 Brake vacuum sensor Engine: Stop the engine from idle speed, turn Voltage increases
the ignition switch ON, and then depress the
brake pedal several times.

76 Air flow sensor reset Engine: Idling 0–1V

signal
Engine: 3,000 r/min 6–9V

78 Throttle position Ignition switch: ON Release the accelera- 4.0 – 4.8 V

sensor (2nd channel) tor pedal.

Depress the accelera- 0.1 – 1.1 V

tor pedal fully.

79 Accelerator pedal Ignition switch: ON Release the accelera- 0–1V

position switch tor pedal.

Depress the accelera- 4 V or more

tor pedal slightly.

80 Vehicle speed sensor D Ignition switch: ON 0 V ↔ Battery voltage

D Move the vehicle forward. (alternates repeatedly)
13A-80 GDI – Troubleshooting

Terminal Check item Check requirements (engine condition) Normal condition

No.

83 A/C switch Engine: idling A/C switch: OFF 0–3V

A/C switch: ON System voltage

(Compressor is
operating)

88 Small lamp switch Lighting switch: OFF 0–3V

Lighting switch: ON (Taillamp: ON) System voltage

89 Oxygen sensor heater Engine: Idling 0–3V

Engine: 3,500 r/min System voltage

92 Fuel pressure sensor Engine: Idling 0.3 – 4.7 V

94 Accelerator pedal Ignition switch: ON Release the accelera- 0.935 – 1.135 V

position sensor (1st tor pedal.
channel)
Depress the accelera- 4.1 V or more
tor pedal fully.

96 Injector open circuit Engine: Increase engine speed from idle speed Decreases slightly
check signal to 4,000 r/min. (approx.0.7 V) from
4.5 V – 5.0 V.

97 A/C thermo sensor D Temperature at sensing portion: Approx. 25_C 2.0 – 2.9 V
D Ignition switch: ON

99 Ignition switch – IG Ignition switch: ON System voltage

GDI – Troubleshooting 13A-81
CHECK CHART FOR RESISTANCE AND CONTINUITY
BETWEEN TERMINALS
1. Turn the ignition switch to OFF.
2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity between
the terminals of the engine-ECU harness-side connector
while referring to the check chart.
NOTE
(1) When measuring resistance and checking continuity,
a harness for checking contact pin pressure should
be used instead of inserting a test probe.
(2) Checking need not be carried out in the order given
in the chart.
Caution
If the terminals that should be checked are mistaken,
or if connector terminals are not correctly shorted
to earth, damage may be caused to the vehicle wiring,
sensors, engine-ECU and/or ohmmeter.
Be careful to prevent this!
4. If the ohmmeter shows any deviation from the standard
value, check the corresponding sensor, actuator and
related electrical wiring, and then repair or replace.
5. After repair or replacement, recheck with the ohmmeter
to confirm that the repair or replacement has corrected
the problem.
13A-82 GDI – Troubleshooting

Engine-ECU Harness Side Connector Terminal Arrangement

Terminal No. Check item Standard value, normal condition (check requirements)

6 – 47 EGR valve (C) 15 – 20 Ω (at 20_C)

5 – 47 EGR valve (D)

34 – 47 EGR valve (A)

32 – 47 EGR valve (B)

16 – 47 Purge control solenoid valve 36 – 44 Ω (at 20_C)

44 – 72 Engine coolant temperature sensor 5.1 – 6.5 kΩ (when engine coolant temperature is 0_C)

2.1 – 2.7 kΩ (when engine coolant temperature is 20_C)

0.9 – 1.3 kΩ (when engine coolant temperature is 40_C)

0.26 – 0.36 kΩ (when engine coolant temperature is

80_C)

46 – Body earth Earth Continuity (0 Ω)

58 – Body earth

62 – 72 Intake air temperature sensor 5.3 – 6.7 kΩ (when intake air temperature is 0_C)

2.3 – 3.0 kΩ (when intake air temperature is 20_C)

1.0 – 1.5 kΩ (when intake air temperature is 40_C)

0.30 – 0.42 kΩ (when intake air temperature is 80_C)

67 – Body earth Inhibitor switch <A/T> Continuity (when the selector lever is at P or N range)

No continuity (when the selector lever is at a range other

than P or N)

79 – 72 Accelerator pedal position switch Continuity (when the accelerator pedal is released)

No continuity (when the accelerator pedal is slightly

depressed)

89 – 47 Oxygen sensor heater control 11 – 18 Ω (at 20_C)

 GDI – Troubleshooting 13A-83
CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS
TERMINAL VOLTAGE CHECK CHART
Throttle Valve Controller Terminal Arrangement

Terminal Check items Requirements Normal value

No.

1 Throttle valve control servo D Ignition switch: ON Decreases slightly from

(A+) D Accelerator pedal: Fully opened → system voltage.
fully closed
9 Throttle valve control servo
(B+)

14 Throttle valve control servo D Ignition switch: ON Decreases slightly (approx.

(A–) D Accelerator pedal: Fully closed → 2 V) from system voltage.
fully opened
15 Throttle valve control servo
(B–)

2 Power supply to throttle Ignition switch: ON System voltage

valve control servo

5 Power supply Ignition switch: ON System voltage

6 Sensor voltage Ignition switch: ON 4.5 – 5.5 V

7 Throttle position sensor (1st Ignition switch: Release the 0.45 – 0.8 V
channel) ON accelerator pedal.

Depress the 3.9 – 4.9 V

accelerator pedal
fully.

20 Accelerator pedal position Ignition switch: Release the 0.7 – 1.4 V

sensor (2nd channel) ON accelerator pedal.

Depress the 4 V or more

accelerator pedal
fully.

22 Ignition switch – IG Ignition switch: ON System voltage

13A-84 GDI – Troubleshooting

Analyzer INSPECTION PROCEDURE USING AN ANALYZER

AIR FLOW SENSOR (AFS)
Measurement Method
Special
patterns 1. Disconnect the air flow sensor connector, and connect
pickup the special tool (test harness: MB991709) in between.
(All terminals should be connected.)
2. Connect the analyzer special patterns pickup to air flow
sensor connector terminal 3.
Alternate Method (Test harness not available)
1. Connect the analyzer special patterns pickup to
engine-ECU terminal 61.
Standard Wave Pattern
Observation conditions
Function Special patterns
Pattern height Low
Pattern selector Display
Engine r/min Idle speed
Standard wave pattern
(V) The time (cycle time) T is reduced when
10 T the amount of intake air increases.
T1 T2 Times T1 and T2 are equal.

Time
0

Observation conditions (from conditions above engine speed is increased by racing.)

(V)

10
T

Time
0

Wave Pattern Observation Points

Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
 GDI – Troubleshooting 13A-85
Examples of Abnormal Wave Patterns
D Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when the engine
is not started.
D Example 2
Cause of problem
Damaged rectifier or vortex generation column
Wave pattern characteristics
Unstable wave pattern with non-uniform frequency.
However, when an ignition leak occurs during acceleration,
the wave pattern will be distorted temporarily, even if the
air flow sensor is normal.

Camshaft position sensor connector Analyzer CAMSHAFT POSITION SENSOR AND CRANK ANGLE
SENSOR
Special patterns
pick-up Measurement Method
1. Disconnect the camshaft position sensor connector and
connect the special tool (test harness: MB991709) in
between. (All terminals should be connected.)
2. Connect the analyzer special patterns pickup to camshaft
Crank
position sensor terminal 2.
angle 3. Disconnect the crank angle sensor connector and connect
sensor connector the special tool (test harness: MB991658) in between.
4. Connect the analyzer special patterns pickup to crank
angle sensor terminal 2.
Alternate Method (Test harness not available)
1. Connect the analyzer special patterns pickup to
engine-ECU terminal 50. (When checking the camshaft
position sensor signal wave pattern.)
2. Connect the analyzer special patterns pickup to
engine-ECU terminal 43. (When checking the crank angle
sensor signal wave pattern.)
Standard Wave Pattern
Observation conditions
Function Special patterns

Pattern height Low

Pattern selector Display

Engine r/min Idle speed

13A-86 GDI – Troubleshooting

Standard wave pattern

2 engine revolutions
(1 camshaft revolution)
(V)
75_BTDC T
5_BTDC The time (cycle time) T is
reduced when the engine
speed increases
Crank angle
sensor output 4
wave pattern

Camshaft posi-
tion sensor out-
put wave pat-
tern 4

Time
0
No. 1 No. 3 TDC No. 4 No. 2
TDC: Top dead centre TDC TDC TDC

Wave Pattern Observation Points

Check that cycle time T becomes shorter when the engine speed increases.

Examples of Abnormal Wave Patterns

D Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when the engine
is not started.

D Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.
 GDI – Troubleshooting 13A-87
INJECTORS AND INJECTOR OPEN CIRCUIT CHECK
SIGNAL
Measurement Method
1. Connect the analyzer special patterns pickup to terminal
1 (No.1 injector) of the engine-ECU connector.
2. Connect the analyzer special patterns pickup to terminal
96 (injector open circuit check signal) of the engine-ECU
Analyzer connector.
Special patterns
pickup 3. After checking terminal 1, check terminal 9 (No.2 injector),
terminal 24 (No.3 injector) and terminal 2 (No.4 injector).

Standard Wave Pattern

Observation conditions
Function Special pattern

Pattern height Low

Pattern selector Display

Engine r/min Idle speed

Standard wave pattern

(V)

4
Injector
open circuit
check+
signal 0

Injector
drive signal

4
0
(ms)

Wave Pattern Observation Points

Normal wave
pattern D Check that the injector drive time is identical to the time
displayed on the MUT-II.
D Check that the injector signals become greatly extended
but soon return to their normal wave length when the
engine is suddenly raced.
D Check that the injector open circuit check signal is
synchronized with each rising portion of the injector drive
signal.
13A-88 GDI – Troubleshooting

Analyzer IGNITION COIL AND POWER TRANSISTOR

Power transistor control signal
Measurement Method
1. Disconnect the ignition coil connector, and connect the
special tool (test harness: MB991658) in between. (All
terminals should be connected.)
Special 2. Connect the analyzer special patterns pickup to terminal
patterns 3 of each ignition coil connector in turn.
pickup
Alternate Method (Test harness not available)
1. Connect the analyzer special patterns pickup to
engine-ECU terminal 3 (No. 1 ignition coil), terminal 13
(No. 2 ignition coil), terminal 12(No. 3 ignition coil), terminal
4 (No. 4 ignition coil) respectively.
Standard Wave Pattern
Observation condition
Function Special patterns
Pattern height Low
Pattern selector Display
Engine r/min Approx. 1,200 r/min

Standard wave pattern

(V)
T: Crank angle
T
Compression top dead center

Crank angle
sensor output 4
wave pattern

0
T1: Time calculated by engine-ECU
T1 θ θ: Spark advance angle
Ignition period
Power transistor
control signal
wave pattern

0
OFF ON

Dwell section
Time
 GDI – Troubleshooting 13A-89
Wave Pattern Observation Points
Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern
examples 1 and 2.)

Condition of wave pattern build-up section and maximum voltage Probable cause

Rises from approx. 2V to approx. 4.5V at the top-right Normal

2V rectangular wave Open-circuit in ignition primary circuit

Rectangular wave at power voltage Power transistor malfunction

Examples of Abnormal Wave Patterns

--- Normal wave pattern
D Example 1
Wave pattern during engine cranking
Cause of problem
2V Open-circuit in ignition primary circuit
Wave pattern characteristics
Top-right part of the build-up section cannot be seen, and
voltage value is approximately 2V too low.

D Example 2
--- Normal wave pattern
Wave pattern during engine cranking
VB
Cause of problem
Malfunction in power transistor
Wave pattern characteristics
Power voltage results when the power transistor is ON.
13A-90 GDI – Troubleshooting

Analyzer EGR VALVE (STEPPER MOTOR)

Measurement Method
1. Disconnect the EGR valve connector, and connect the
special tool (test harness: MB991658) in between.
2. Connect the analyzer special patterns pickup to the EGR
valve-side connector terminal 1, terminal 3, terminal 4
and terminal 6 respectively.
Special
patterns
pickup

Alternate Method (Test harness not available)

1. Connect the analyzer special patterns pickup to
engine-ECU terminal 34, connection terminal 32,
connection terminal 6, and connection terminal 5
respectively.
Standard Wave Pattern
Observation conditions
Function Special patterns

Pattern height High

Pattern selector Display

Engine condition Racing

Standard wave pattern

(V)
The wave pattern
appears for an Point B Point A
instant, but soon Coil reverse electromo- Induced electromotive force
30 disappears. tive force (Approx. 3 × from the motor turning
10V)

20

EGR 10
valve
control
signal
wave
pattern
Time
 GDI – Troubleshooting 13A-91
Wave Pattern Observation Points
Check that the standard wave pattern appears when the EGR control servo is operating.
Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal
wave pattern.)

Contrast with standard wave pattern Probable cause

Induced electromotive force does not appear or is extremely small. Motor is malfunctioning

Point B: Height of coil reverse electromotive force

Contrast with standard wave pattern Probable cause

Coil reverse electromotive force does not appear or is extremely small. Short in the coil

Examples of Abnormal Wave Pattern

D Example 1
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Wave pattern characteristics
Induced electromotive force from the motor turning does
not appear.

D Example 2
Open
circuit Cause of problem
side
Open circuit in the line between the EGR valve and the
engine-ECU
Wave pattern characteristics
Current is not supplied to the motor coil on the open circuit
side. (Voltage does not drop to 0 V.)
Nor- Furthermore, the induced electromotive force waveform
mal at the normal side is slightly different from the normal
side
waveform.
13A-92 GDI – On-vehicle Service

ON-VEHICLE SERVICE
Fixed SAS
Caution
(1) Never attempt to tamper the fixed SAS. The fixed SAS
is precisely adjusted at factory.
(2) Should it be tampered, the full closed position of the
throttle valve will be changed. This causes the
engine-ECU to learn a wrong position of the throttle
valve.

THROTTLE BODY (THROTTLE VALVE ARE)

CLEANING
1. Start the engine, and warm it up until engine coolant
temperature reaches 80_C. Then stop the engine.
2. Remove the air intake hose at the throttle body side.
3. Apply cleaning agent to the throttle valve through the intake
port of the throttle valve, and then leave it for approx.
five minutes.
4. Start the engine, race it several times, and then let it run
at idle for approx. one minute.
5. If carbon deposits are not removed from the throttle vale
area, repeat steps 3 and 4.
6. Install the air intake hose.
7. Use the MUT-II or disconnect the negative battery cable
from the battery terminal in order to erase a diagnosis
code. Wait for at least ten seconds, and then let the engine
run at idle again for approx. ten minutes.

Equipment side connector THROTTLE POSITION SENSOR ADJUSTMENT

1. Connect the MUT-II to the diagnosis connector.
Throttle When not using the MUT-II, proceed as follows:
position
sensor

(1) Disconnect the throttle position sensor connector, and

connect the special tool (test harness: MB991536)
between the disconnected connector taking care not
to confuse the terminal to be connected.
(2) Connect digital voltmeter between the terminal No.2
(sensor output: blue clip of special tool) and the
terminal No.3 (sensor earth: white clip of special tool)
of the throttle position sensor connector.
MB991536 Throttle posi-
tion sensor
GDI – On-vehicle Service 13A-93
2. Disconnect the throttle valve control servo connector.
3. Turn the ignition switch to ON (but do not start the engine).
4. Check the output voltage of the throttle position sensor
(1st channel) when the throttle valve is fully closed by
your finger.
Standard value: 0.4 – 0.6 V

5. If not within the standard value, loosen the throttle position

sensor mounting bolts. Then rotate the sensor body to
adjust.
6. Check the output voltage of the throttle position sensor (2nd
channel) when the throttle valve is fully closed by your
finger. When not using the MUT-II, connect digital voltmeter
between the terminal No.4 (sensor output: black clip of
special tool) and the terminal No.3 (sensor earth: white clip
of special tool) of the throttle position sensor connector.
Standard value: 4.2 – 4.8 V
7. If not within the standard value, replace the throttle position
sensor.
8. Turn the ignition switch to OFF.
9. Reconnect the throttle valve control servo connector.
10. Remove the MUT-II. If the MUT-II is not used, remove
the special tool, and then connect the throttle position
sensor connector.
11. If a diagnosis code is displayed, erase the diagnosis code
by using the MUT-II or disconnect the negative battery
cable from the battery terminal and then leave it for at
least ten seconds. After that, reconnect the battery cable.
12. Turn the ignition switch to ON and return it to OFF, and
then leave it for at least ten seconds. In addition, if the
battery cable is disconnected at step 11, let the engine
run at idle for approx. ten minutes.
13A-94 GDI – On-vehicle Service

Accelerator pedal ACCELERATOR PEDAL POSITION SENSOR

position sensor ADJUSTMENT
Equipment Caution
side connector (1) Never attempt to tamper the accelerator pedal position
sensor. The sensor position is precisely adjusted at
factory.
Accelerator (2) Should it be tampered, follow the procedure below:
pedal arm

Accelerator pedal 1. Connect the MUT-II to the diagnosis connector.

position sensor
When not using the MUT-II, proceed as follows:
(1) Disconnect the accelerator pedal position sensor
connector. Connect the special tool (test harness:
MB991658) between the disconnected connectors,
and then connect the digital voltmeter to the terminal
No.3 [output terminal of accelerator pedal position
sensor (1st channel)] and to the terminal No.1 [earth
terminal of accelerator pedal position sensor (1st
channel)].
MB991658

2. Loosen the accelerator pedal position sensor installation

bolts.
3. Contact the accelerator pedal arm to the stopper.
4. Turn the ignition switch to the ON position (but do not
Stopper start the engine).

Accelerator
pedal arm
Accelerator
pedal assembly

Accelerator pedal 5. Rotate the accelerator pedal position sensor with the knock
position sensor pin as the centre, and adjust the output voltage of the
accelerator pedal position sensor (1st channel) to the
standard value.
Standard value: 0.935 – 1.135 V
Knock pin 6. Tighten the accelerator pedal position sensor installation
bolts fully.
 GDI – On-vehicle Service 13A-95

High-pressure
FUEL PRESSURE TEST
fuel hose MEASUREMENT OF FUEL LOW PRESSURE BETWEEN
FUEL PUMP (LOW PRESSURE) AND FUEL PUMP
(HIGH PRESSURE)
Fuel pump
(high pressure) 1. Release residual pressure from the fuel pipe line to prevent
fuel gush out. (Refer to P.13A-99.)
2. Disconnect the high-pressure fuel hose at the fuel pump
(high pressure) side.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.

3. Remove the union joint and bolt from the special tool
MB991637 (adapter hose) and instead attach the special tool (hose
adapter) to the adapter hose.
Gasket 4. Install the special tool (for measuring the fuel pressure)
Fuel
pump MD998709 that was set up in step 3.
(high
pressure) <When using the fuel pressure gauge set (special tool)>
MD998742 (1) Install the special tool (for measuring the fuel pressure)
High-pressure between the high-pressure fuel hose and the fuel pump
fuel hose (high pressure).
(2) Install the fuel pressure gauge set (special tool) on
the special tool (for measuring the fuel pressure)
putting the gasket between them.
(3) Connect the lead wire of the fuel pressure gauge set
(special tool) to the power supply (cigarette lighter
socket) and to the MUT-II.

<When using the fuel pressure gauge>

Fuel pressure gauge (1) Install the fuel pressure gauge on the special tool
O-ring or gasket (for measuring the fuel pressure) putting a suitable
O-ring or gasket between them.
Fuel pump MD998709
(high (2) Install the special tool which was set up in step (1)
pressure) between the high-pressure fuel hose and the fuel pump
MD998742
(high pressure).
High-pressure
fuel hose
13A-96 GDI – On-vehicle Service

5. Connect the MUT-II to the diagnosis connector.

6. Turn the ignition switch to ON. (But do not start the engine.)
7. Select “Item No.07” from the MUT-II Actuator test to drive
the fuel pump (low pressure) at the fuel tank side. Check
that there are no fuel leaks from any parts.
8. Finish the actuator test or turn the ignition switch to OFF.
9. Start the engine and run at idle.
10. Measure fuel pressure while the engine is running at idle.
Standard value: approximately 328 kPa
11. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
12. If fuel pressure is out of the standard value, troubleshoot
and repair according to the table below.

Symptom Probable cause Remedy

D Fuel pressure too low Clogged fuel filter Replace fuel filter
D Fuel pressure drops after racing
Fuel leaking to return side due to poor Replace fuel pressure regulator
fuel pressure regulator (low pressure) (low pressure)
valve seating or settled spring

Low fuel pump (low pressure) delivery Replace the fuel pump (low pressure)
pressure

Fuel pressure too high Binding valve in fuel pressure regula- Replace fuel pressure regulator
tor (low pressure) (low pressure)

Clogged fuel return hose or pipe Clean or replace hose or pipe

13. Stop the engine and check change of fuel pressure gauge
reading. Normal if the reading does not drop within 2
minutes. If it does, observe the rate of drop and
troubleshoot and repair according to the table below.

Symptom Probable cause Remedy

Fuel pressure drops gradually after Leaky fuel pressure regulator (low Replace fuel pressure regulator
engine is stopped pressure) valve seat (low pressure)

Fuel pressure drops sharply Check valve in fuel pump (low Replace the fuel pump (low pressure)
immediately after engine is stopped pressure) is held open
 GDI – On-vehicle Service 13A-97
14. Release residual pressure from the fuel pipe line. (Refer to
P.13A-99.)
15. Remove the fuel pressure gauge and special tools from the
fuel pump (high pressure).
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
16. Replace the O-ring at the end of the high-pressure fuel
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
17. Fit the high-pressure fuel hose to the fuel pump (high
pressure) and tighten the mounting bolt to specified torque.
18. Check for any fuel leaks by following the procedure in
step 7.
19. Disconnect the MUT-II.

MEASUREMENT OF FUEL HIGH PRESSURE BETWEEN

FUEL PUMP (HIGH PRESSURE) AND INJECTORS
NOTE
Measurement of the fuel pressure between the fuel pump
(high pressure) and the injectors should be carried out after
Injector
checking that the fuel pressure between the fuel pump (low
intermediate pressure) and the fuel pump (high pressure) is normal.
harness
connector 1. Connect the MUT-II to the diagnosis connector.
2. Disconnect the injector intermediate harness connector.
3. Turn the ignition switch to ON.
4. Select “Item No.74” from the MUT-II Data list.
5. Crank the engine continuously for 2 seconds or more,
and visually check that there are no fuel leaks from any
parts.
Caution
If any fuel leaks appear, stop cranking immediately
and repair the source of the leak.
6. Crank the engine, and then measure the fuel pressure
immediately after 20 seconds.
Limit: Minimum 1 MPa
Caution
If the fuel pressure is less than 1 MPa, there may
be a partial fuel leak in the high-pressure fuel system.
7. Turn the ignition switch to OFF.
8. Connect the injector intermediate harness connector.
13A-98 GDI – On-vehicle Service

9. Start the engine and run at idle.

10. Measure fuel pressure while the engine is running at idle.
Standard value: approximately 4 – 6.9 MPa
11. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
12. If fuel pressure is out of the standard value, troubleshoot
and repair according to the table below.

Symptom Probable cause Remedy

D Fuel pressure too low Fuel leaking to return side due to poor Replace fuel pressure regulator
D Fuel pressure drops after racing fuel pressure regulator (high pres- (high pressure)
sure) valve seating or settled spring

Low fuel pump (high pressure) Replace the fuel pump

delivery pressure (high pressure)

Fuel pressure too high Binding valve in fuel pressure regula- Replace fuel pressure regulator
tor (high pressure) (high pressure)

Clogged fuel return hose or pipe Clean or replace hose or pipe

13. Stop the engine and turn the ignition switch to OFF.
14. Disconnect the MUT-II.
 GDI – On-vehicle Service 13A-99
FUEL LEAK CHECK
1. Connect the MUT-II to the diagnosis connector.
2. Disconnect the injector intermediate harness connector.
3. Turn the ignition switch to ON.
4. Select “Item No.74” from the MUT-II Data list.
Injector 5. Crank the engine continuously for two seconds or more,
intermediate and visually check that there are no fuel leaks from any
harness parts.
connector
Caution
If any fuel leaks appear, stop cranking immediately
and repair the source of the leak.
6. Crank the engine, and then measure fuel pressure
immediately after 20 seconds.
Limit: Minimum 1 MPa
Caution
If the fuel pressure is less than 1 MPa, there may
be a partial fuel leak in the high-pressure fuel system.
7. Turn off the ignition switch.
8. Reconnect the injector intermediate connector.
9. Remove the MUT-II.

Fuel pump relay FUEL PUMP CONNECTOR DISCONNECTION

(HOW TO REDUCE FUEL PRESSURE)
When removing the fuel pipe, hose, etc., since fuel pressure
in the fuel pipe line is high, do the following operation so
as to release fuel pressure in the line and prevent fuel from
running out.
1. Remove the fuel filler cap to release pressure in the fuel
tank.
2. Remove the fuel pump relay.
3. Connect the MUT-II to the diagnosis connector.
Caution
Turn off the ignition switch before disconnecting or
connecting the MUT-II.
4. Turn off the ignition switch.
5. Select “Item No.74” from the MUT-II Data list.
6. Crank the engine for at least two seconds.
7. If the engine is not be started, use the MUT-II to make
sure that the fuel pressure is 0.5 MPa or less. Then turn
off the ignition switch.
13A-100 GDI – On-vehicle Service

8. If the engine is started, release fuel pressure by the

following procedure:
(1) Turn off the ignition switch, and then stop the engine.
(2) Disconnect one of the ignition coil connectors.
(3) Crank the engine for at least two seconds.
(4) If the engine is not be started, use the MUT-II to make
sure that the fuel pressure is 0.5 MPa or less. Then
turn off the ignition switch.
(5) If the engine is started, stop it by racing and use the
MUT-II to make sure that the fuel pressure is 0.5
MPa or less. Then turn off the ignition switch.
(6) Reconnect the ignition coil connector.
Caution
Clean the spark plug which corresponds to the
disconnected ignition coil connector.
9. Remove the MUT-II.
10. Install the fuel pump relay.

FUEL PUMP OPERATION CHECK

1. Check the operation of the fuel pump by using the MUT-II
to force-drive the fuel pump.
2. If the fuel pump will not operate, check by using the
following procedure, and if it is normal, check the drive
circuit.
(1) Turn off the ignition switch.
(2) Remove the fuel pump relay. Connect the terminal
Fuel pump relay connector No.1 of the harness-side connector to the battery.
Check if the fuel pump operation sound can be heard
at this time.
NOTE
As the fuel pump is an in-tank type, the fuel pump
sound is hard to hear, so remove the fuel filler cap
and check from the tank inlet.
(3) Check the fuel pressure by pinching the fuel hose
with the fingertips.
 GDI – On-vehicle Service 13A-101
COMPONENT LOCATION
Name Symbol Name Symbol
A/C relay A Fuel pressure sensor F
A/C switch P Fuel pump relay A

Accelerator pedal position sensor (1st and 2nd Q Ignition coil I

channels)
Inhibitor switch <A/T> J

Air flow sensor (with intake air temperature N Injectors G

sensor and barometric pressure sensor)
Injector driver B

Camshaft position sensor H Injector driver relay A

Crank angle sensor E Oxygen sensor U
Detonation sensor K Power steering fluid pressure switch M
Diagnosis connector R Purge control solenoid valve C
EGR valve F Throttle position sensor D
Engine control relay A Throttle valve controller S
Engine coolant temperature sensor L Throttle valve control servo D
Engine-ECU S Throttle valve control servo relay T
Engine warning lamp (CHECK ENGINE lamp) O Vehicle speed sensor J

B C D E F G H I J K L M N <LHD> O P

Q R S T

<RHD>
O P U

R Q S T
13A-102 GDI – On-vehicle Service

Equipment side connector

Engine control relay ENGINE CONTROL RELAY, FUEL PUMP
RELAY, INJECTOR DRIVER RELAY AND
THROTTLE VALVE CONTROL SERVO RELAY
CONTINUITY CHECK
Batteryy voltage
g Terminal No.
Injector 1 2 3 4
driver relay
Not supplied
Fuel pump relay
Supplied

Throttle valve control

servo relay

Equipment side connector

Equipment side connector INTAKE AIR TEMPERATURE SENSOR CHECK

1. Disconnect the air flow sensor connector.
2. Measure resistance between terminals 5 and 6.
Standard value:
2.3 – 3.0 kΩ (at 20_C)
0.30 – 0.42 kΩ (at 80_C)
Air flow sensor

Intake air temperature 3. Measure resistance while heating the sensor using a hair
sensor drier.
Normal condition:
Temperature (_C) Resistance (kΩ)
Higher Smaller
4. If the value deviates from the standard value or the
resistance remains unchanged, replace the air flow sensor
assembly.

ENGINE COOLANT TEMPERATURE SENSOR

Engine cool- CHECK
ant tempera-
ture sensor Caution
Equipment
side connector Be careful not to touch the connector (resin section) with
the tool when removing and installing.
1. Remove the engine coolant temperature sensor.
 GDI – On-vehicle Service 13A-103
2. With temperature sensing portion of engine coolant
temperature sensor immersed in hot water, check
resistance.
Standard value:
2.1 – 2.7 kΩ (at 20_C)
0.26 – 0.36 kΩ (at 80_C)
3. If the resistance deviates from the standard value greatly,
replace the sensor.

4. Apply sealant to threaded portion.

Specified sealant:
3M NUT Locking Part No.4171 or equivalent
5. Install the engine coolant temperature sensor and tighten
it to the specified torque.
Tightening torque: 29 Nm

Equipment side connector THROTTLE POSITION SENSOR CHECK

1. Disconnect the throttle position sensor connector.
Throttle 2. Measure the resistance between throttle position sensor
position side connector terminal 1 and terminal 3.
sensor
Standard value: 3.5 – 6.5 kΩ
3. Measure resistance between terminal Nos. 1 and 2 as
well as 1 and 4 of the throttle position sensor connector,
respectively.
Normal condition:
Throttle valve slowly open Changes smoothly in
until fully open from the idle proportion to the opening
position angle of the throttle valve
4. If the resistance is outside the standard value, or if it doesn’t
change smoothly, replace the throttle position sensor.
NOTE
For the throttle position sensor adjustment procedure, refer
to P.13A-92.
13A-104 GDI – On-vehicle Service

Accelerator pedal ACCELERATOR PEDAL POSITION SENSOR

position sensor (1ST CHANNEL) CHECK
Equipment 1. Disconnect the accelerator pedal position sensor
side connector connector.
2. Measure resistance between terminal No.2 (sensor power
supply) and 1 (sensor earth) of the sensor connector.
Accelerator Standard value: 3.5 – 6.5 kΩ
pedal arm
3. Measure resistance between terminal No.2 (sensor power
supply) and 3 (sensor output) of the connector.
Normal condition:
Depress the accelerator Resistance value changes in
pedal slowly. accordance with the
accelerator pedal
depression smoothly.
4. If not within the standard value, or resistance value does
not change smoothly, replace the accelerator pedal position
sensor assembly.
NOTE
After replacement, adjust the accelerator pedal position
sensor. (Refer to P.13A-94.)

Accelerator pedal ACCELERATOR PEDAL POSITION SENSOR

position sensor (2ND CHANNEL) CHECK
Equipment 1. Disconnect the accelerator pedal position sensor
side connector connector.
2. Measure resistance between terminal No.8 (sensor power
supply) and 7 (sensor earth) of the sensor connector.
Accelerator Standard value: 3.5 – 6.5 kΩ
pedal arm
3. Measure resistance between terminal No.8 (sensor power
supply) and 6 (sensor output) of the connector.
Normal condition:
Depress the accelerator Resistance value changes in
pedal slowly. accordance with the
accelerator pedal
depression smoothly.
4. If not within the standard value, or resistance value does
not change smoothly, replace the accelerator pedal position
sensor assembly.
NOTE
After replacement, adjust the accelerator pedal position
sensor. (Refer to P.13A-94.)
 GDI – On-vehicle Service 13A-105
Accelerator pedal ACCELERATOR PEDAL POSITION SWITCH
position sensor CHECK
Equipment 1. Disconnect the accelerator pedal position sensor
side connector connector.
2. Check continuity between terminal No.4 (accelerator pedal
position switch) and 5 (sensor earth) of the connector.
Accelerator Normal condition
pedal arm
Accelerator pedal Continuity
Depressed No continuity
Released Continuity (0 Ω)
3. If defective, replace the accelerator pedal position sensor
assembly.
NOTE
After replacement, adjust the accelerator pedal position
sensor. (Refer to P.13A-94.)

Equipment side connector OXYGEN SENSOR CHECK

1. Disconnect the oxygen sensor connector and connect the
special tool (test harness) to the connector on the oxygen
sensor side.
2. Make sure that there is continuity (11 – 18 Ω at 20_C)
between terminal 1 (red cip of special tool) and terminal
Oxygen sensor 3 (blue clip of special tool) on the oxygen sensor connector.

3. If there is no continuity, replace the oxygen sensor.

4. Warm up the engine until engine coolant is 80_C or higher.
Oxygen
sensor
Red equip-
ment side
connector
Blue

MD998464

5. Use a jumper wire to connect terminal 1 (red clip) of the

Jumper
wire oxygen sensor connector to the battery (+) terminal and
terminal 3 (blue clip) to the battery (–) terminal.
Black Caution
Red
Be very careful when connecting the jumper wire;
incorrect connection can damage the oxygen sensor.
White Blue 6. Connect a digital voltage meter between terminal 2 (black
clip) and terminal 4 (white clip).

MD998464
13A-106 GDI – On-vehicle Service

7. While repeatedly racing the engine, measure the oxygen

sensor output voltage.
Standard value:
Engine Oxygen sensor Remarks
output voltage
When 0.6 – 1.0 V If you make the air/fuel ratio
racing the rich by racing the engine
engine repeatedly, a normal oxy-
gen sensor will output a
voltage of 0.6 – 1.0 V.
8. If the sensor is defective, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 – Exhaust Pipe and Main Muffler.

Injector side connec-

INJECTOR CHECK
tor 1. Disconnect the injector intermediate harness connector.
2. Measure the resistance between each of the terminals.
Standard value: 0.9 – 1.1 Ω (at 20_C)

Injector Measurement terminal

Injector
intermediate
harness
No.1 cylinder 1–2
connector
No.2 cylinder 3–4

No.3 cylinder 5–6

No.4 cylinder 7–8

3. Connect the injector intermediate harness connector.

 GDI – On-vehicle Service 13A-107
Throttle valve THROTTLE VALVE CONTROL SERVO CHECK
control servo Operation Check
Equipment side 1. Disconnect the air intake hose from the throttle body.
connector 2. Turn on the ignition switch.
3. Check that the throttle valve opens or closes in response
to the accelerator pedal depression.
Check of Coil Resistance
1. Disconnect the throttle valve control servo connector.
2. Measure resistance between the throttle valve control
servo connector terminals.
Standard value:

Terminals to be measured Resistance value (Ω)

1–3 1.35 – 1.65 (at 20_C)

2–4

3. Check that there is no continuity between the terminals

and body.

PURGE CONTROL SOLENOID VALVE CHECK

Refer to GROUP 17 – Emission Control System.
EGR VALVE CHECK
Refer to GROUP 17 – Emission Control System.
13A-108 GDI – Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE

REGULATOR (HIGH PRESSURE)
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Fuel Discharge Prevention <before removal only> D Fuel Leak Check <after installation only> (Refer to
(Refer to P.13A-98.) P.13A-98.)
D Engine Cover Removal and Installation
D Resonance Tank Removal and Installation (Refer to
GROUP 15.)

10 – 13
Nm
2 10 – 13
1 Nm
5

4
4 5
3
24 Nm 3 11
10
19 Nm 24
13

5 Nm → 17 18 10 – 13
Nm Nm
9 12
19 Nm
9 Nm
O-ring
5 Nm 21
14 20
7 15
17 19
8 16
23 2, 7, 12,
26 18, 25
22
25 Engine oil

6 19 Nm
9 Nm
 GDI – Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) 13A-109
Fuel pump (High pressure) removal Fuel pressure regulator (High
steps pressure) removal steps
"F A D Fuel pump (high pressure) air bleeding D Intake manifold assembly removal
D Throttle body removal (Refer to (Refer to GROUP 15.)
P.13A-113.) 14. Fuel pressure sensor connector
AA" 1. Fuel pump protector connection
"CA 2. Fuel feed pipe 15. Fuel pressure sensor
"BA 3. Back-up ring A "DA 16. O-ring
"BA 4. O-ring "DA 17. Back-up ring
"BA 5. Back-up ring B "CA 18. Fuel return pipe
6. Fuel pressure hose clamp "BA 19. Back-up ring A
"C A 7. Fuel pressure hose connection "BA 20. O-ring
8. O-ring "BA 21. Back-up ring B
9. Fuel return hose connection 22. Fuel return hose connection
"EA 10. Fuel pump (high pressure) "AA 23. Fuel pressure regulator (high
11. O-ring pressure)
12. Fuel pump return nipple 24. Spacer
13. O-ring 25. Fuel nipple
26. O-ring

REMOVAL SERVICE POINT

AA" FUEL PUMP PROTECTOR REMOVAL
Lift up the transmission with a jack to create clearance between
the engine and front deck, and then remove the fuel pump
protector.
INSTALLATION SERVICE POINTS
"AA FUEL PRESSURE REGULATOR (HIGH
PRESSURE) INSTALLATION
1. Install provisionally the fuel pressure regulator (high
pressure) to the spacer.
2. Install the fuel return pipe, and then tighten the fuel pressure
regulator (high pressure) to the specified torque.

"BA BACK-UP RING B/O-RING/BACK-UP RING A

INSTALLATION
O-ring
Back-up ring A Install the back-up rings and the O-ring as shown in the
illustration.
Caution
1. Install the back-up ring B facing its cutaway surface
Cutaway toward the opposite side of the O-ring as shown in
surface the illustration.
Back-up ring B
2. Confirm the outer diameter of the back-up ring A. Take
care not to install the back-up ring for the fuel pressure
sensor by mistake. (Outer diameter of the back-up
ring A: 14.8 mm)
13A-110 GDI – Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

"CA FUEL RETURN PIPE/FUEL PRESSURE

HOSE/FUEL FEED PIPE INSTALLATION
Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not to let any of the engine oil get inside the
fuel pump (high pressure), fuel pressure regulator (high
pressure) or the delivery pipe assembly.

"DA BACK-UP RING/O-RING INSTALLATION

Back-up ring Install the back-up ring and the O-ring as shown in the
O-ring illustration.
Caution
Take care not to install the back-up ring A for the injector,
fuel feed pipe or fuel return pipe by mistake. (Outer
diameter of the back-up ring for the fuel pressure sensor:
15.1 mm)
Fuel pressure sensor

"EA FUEL PUMP (HIGH PRESSURE) INSTALLATION

1. Apply a small amount of fresh engine oil to the fuel pump
(high pressure) roller and O-ring.
1 3 2. Install temporarily the fuel pump (high pressure) to the
cylinder head.
3. Install the fuel feed pipe, and then tighten the fuel pump
4 2 (high pressure) mounting bolts to 5 Nm in the order shown
in the illustration.
4. Tighten the bolts to 17 Nm in the order shown in the
illustration. The overall difference in tightening torque
between the four bolts should be within 2 Nm.
"FA FUEL PUMP (HIGH PRESSURE) AIR BLEEDING
1. Run the engine at 2,000 r/min for 15 seconds or more
in order to bleed the air.
NOTE
When removing the fuel pump (high pressure), air may
get into the fuel pump (high pressure). If air gets into
the fuel pump (high pressure), diagnosis code No.56 for
abnormal fuel pressure will be output.
2. Use the MUT-II to check the diagnosis code. If the
diagnosis code No.56 for fuel pressure sensor system
defect is output, erase it.
 GDI – Injector 13A-111
INJECTOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Fuel Pressure Regulator (High Pressure) Removal and
Installation (Refer to P.13A-107.)

10 – 13
Nm

4
10 – 13
4 Nm
3 9

2 3
2

6 20 – 25
Nm

7
16 15 14 13 12 11 5
10

O-ring

O-ring

14
1

Engine oil

Removal steps
"DA
1. Fuel feed pipe 9. Insulator
"CA
2. Back-up ring A AB" "BA 10. Fuel injector assembly
"CA
3. O-ring 11. Back-up ring
"CA
4. Back-up ring B 12. O-ring
AA" 5. Injector harness connector 13. Back-up ring
6. Washer 14. Fuel injector
7. Injector holder 15. Gasket
AB" "BA 8. Delivery pipe assembly "AA 16. Corrugated washer
13A-112 GDI – Injector

REMOVAL SERVICE POINTS

AA" INJECTOR HARNESS CONNECTOR
DISCONNECTION
Caution
Disconnect the battery (–) cable from its terminal before
carrying out this operation.

AB" DELIVERY PIPE ASSEMBLY/FUEL INJECTOR

ASSEMBLY REMOVAL
Remove the delivery pipe assembly with the fuel injector
assembly still attached.
Caution
Be careful not to drop the fuel injector assembly when
removing the delivery pipe assembly.

Corrugated washer
INSTALLATION SERVICE POINTS
"AA CORRUGATED WASHER INSTALLATION
Caution
The corrugated washer should always be replaced with
a new part.

"BA FUEL INJECTOR ASSEMBLY/DELIVERY PIPE

ASSEMBLY INSTALLATION
1. Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not to let any of the engine oil get inside
the delivery pipe assembly.
2. While being careful not to damage the O-ring, turn the
fuel injector assembly to the left and right and connect
it to the delivery pipe assembly. After connecting, check
that the fuel injector turns smoothly.
3. If the fuel injector does not turn smoothly, the cause may be
that the O-ring is getting caught. Remove the fuel injector,
check the O-ring for damage and re-connect the fuel
injector to the delivery pipe assembly and then re-check.
 GDI – Injector 13A-113
4. Align the mating marks on the delivery pipe assembly
Fuel injector and the fuel injector, and then install the delivery pipe
assembly with the injector assembly still attached.

Mat-
ing
marks Delivery pipe
assembly

5. Install the delivery pipe and fuel injectors to the cylinder

head, and then tighten them provisionally.
6. Install the injector holders and washers, and then tighten
them to the specified torque.
Caution
Observe the tightening torque.

7. Tighten the delivery pipe and fuel injectors to the specified

torque in the order shown in the illustration.

3 1 2 4

"CA BACK-UP RING B/O-RING/BACK-UP RING A

INSTALLATION
O-ring
Back-up ring A Install the back-up rings and the O-ring as shown in the
illustration.
Caution
Install the back-up ring B facing its cutaway surface toward
Cutaway the opposite side of the O-ring as shown in the illustration.
surface
Back-up ring B

"DA FUEL FEED PIPE INSTALLATION

Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not to let any of the engine oil get inside the
fuel pump (high pressure), fuel pressure regulator (high
pressure) and delivery pipe.
13A-114 GDI – Throttle Body

THROTTLE BODY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying (Refer to
GROUP 14 – On-vehicle Service.)
D Resonance Tank Removal and Installation (Refer
to GROUP 15.)

2
19 Nm
3

3
4

Removal steps
1. Throttle position sensor connector 3. Water hose connection
connection "AA 4. Throttle body assembly
2. Throttle control servo connector con- 5. Throttle body gasket
nection

INSTALLATION SERVICE POINT

"AA THROTTLE BODY INSTALLATION
If the throttle body is replaced, initialize the electronic-controlled
throttle valve system.
Initialization
Turn on the ignition switch, and turn it to LOCK (OFF) position
within one second. Then leave it for at least ten seconds
with the ignition switch in LOCK (OFF) position.
 GDI – Throttle Body 13A-115
DISASSEMBLY AND REASSEMBLY

Disassembly steps
"AA 1. Throttle position sensor
2. Throttle body

REASSEMBLY SERVICE POINTS

"AA THROTTLE POSITION SENSOR
1. Position the throttle position sensor on the throttle body
along the dotted line as shown in the illustration.
2. Rotate the throttle position sensor anticlockwise as shown
in the illustration, and then tighten the screws.
3. Measure resistance value between terminal Nos. 1(sensor
power supply) and 2 (throttle position sensor 1st-channel
output) as well as 1 (sensor power supply) and 4 (throttle
position sensor 2nd-channel output).
Normal condition
Throttle posi-
Sensor power Earth tion sensor Open the throttle valve slowly Resistance value changes
supply (2nd channel) from the idle position to smoothly in response to
output
full-open position. throttle valve opening angle.

4. If the resistance value does not change smoothly, replace

the throttle position sensor.

Throttle position sensor

(1st channel) output
13A-116 GDI – Injector Driver

INJECTOR DRIVER
REMOVAL AND INSTALLATION
5 Nm

5 Nm

Removal steps
AA" 1. Injector driver
2. Bracket

Lock
REMOVAL SERVICE POINT
AA" INJECTOR DRIVER REMOVAL
Press the injector driver connector in the place shown in the
illustration to disconnect the injector driver connector.
Caution
1. Disconnect the battery (–) cable from its terminal
before carrying out this operation.
2. High-tension current is flowing in the harness between
the injector driver and the injector while engine is
running, and the injector driver will become hot after
the vehicle has been driven, so take care when
handling it.
 GDI – Throttle Valve Controller 13A-117

Throttle valve controller THROTTLE VALVE CONTROLLER

INSTALLATION SERVICE POINT
If the throttle valve controller is replaced, initialize the
electronic-controlled throttle valve system.
Initialization
Turn on the ignition switch, and turn it to LOCK (OFF) position
within one second. Then leave it for at least ten seconds
Accelerator cable with the ignition switch in LOCK (OFF) position.
NOTES
13A-2

GASOLINE DIRECT
INJECTION (GDI)
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . 108

Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component Location . . . . . . . . . . . . . . . . . . . . . . . 112
Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . . 112
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
FUEL PUMP (HIGH PRESSURE) . . . . . . . . . . 114
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 121
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 108
 GDI – General/General Information 13A-3
GENERAL
OUTLINE OF CHANGES
Due to the changes shown below, the service procedures regarding the different description from the
previous version have been established.
 On-board Diagnostics System has been adopted to expand the diagnostic items and to change diagnosis
code numbering system.
 Fuel pressure regulator (high-pressure) incorporate fuel pump (high-pressure) has been adopted.
 An oxygen sensor (rear) has been added.
 A ignition failure sensor has been added.
GENERAL INFORMATION
SELF-DIAGNOSIS FUNCTION
Following functions have been added.
 The engine-ECU records the engine operating condition when the diagnosis code is set.
This data is called “freeze frame” data.
This data can be read by using the MUT-II, are can then be used in simulation tests for troubleshooting.

GENERAL SPECIFICATION
Items Specification

Engine-ECU Identification No. E2T71582

13A-4 GDI – General Information

GASOLINE DIRECT INJECTION SYSTEM DIAGRAM

1 Oxygen sensor  Power supply 1 Injector driver  Engine control relay
(front)  Ignition switch-IG (injector)  Fuel pump relay
2 Oxygen sensor  Ignition switch-ST 2 EGR valve  Injector driver relay
(rear)  Accelerator pedal position (stepper motor)  Throttle control
3 Air flow sensor sensor (1st channel) 3 Purge control servo relay
4 Intake air tempera-  Accelerator pedal position solenoid valve  A/C relay
ture sensor switch Engine-
 Ignition coil
5 Throttle position  Vehicle speed sensor ECU
 Fan controller
sensor (2nd chan-  A/C switch 1  Engine warning
nel)  Inhibitor switch <A/T> lamp
 Power steering fluid  GDI ECO indicator
6 Camshaft position
pressure switch lamp
sensor  Alternator FR signal
7 Crank angle sensor  Diagnosis output
 Stop lamp switch  Alternator G termi-
8 Barometric pres-  Small lamp switch
sure sensor nal
 Brake vacuum sensor  Throttle valve
9 Engine coolant tem-  Injector open circuit check
perature sensor controller
signal  Oxygen sensor
10 Detonation sensor  Throttle valve controller heater
11 Fuel pressure sen-  A/C thermo sensor
sor

12 Throttle position  Power supply 4 Throttle valve  Engine-ECU

sensor (1st channel)  Ignition switch-IG Throttle
valve
control servo
 Accelerator pedal position controller
sensor (2nd channel)
 Engine-ECU

4 Intake air temperature sensor

From fuel pump
(low-pressure) 5 Throttle position sensor (2nd channel)
12 Throttle position sensor (1st channel) 3 Air flow sensor
To fuel tank 4 Throttle control servo
8 Barometric pressure
sensor
11 Fuel pressure sensor
6 Camshaft
position sensor

2 EGR valve

Fuel pump Canister

(high-pressure)
Injec- 1 Injector
tor driver
9 Engine coolant temperature sensor

10 Detonation sensor 3 Purge control

solenoid valve
1 Oxygen sensor (front)
2 Oxygen sensor (rear)

7 Crank angle sensor

 GDI – Service Specifications 13A-5
SERVICE SPECIFICATIONS
Items Standard value

Fuel pressure High-pressure side MPa 4 – 6.9

Low-pressure side kPa Approximately 324

Oxygen sensor output voltage (during revving) V 0.6 – 1.0

Oxygen sensor heater resistance (at 20C) Ω Front 4.5 – 8.0

Rear 11 – 18
13A-6 GDI – Troubleshooting

TROUBLESHOOTING
DIAGNOSIS FUNCTION
ENGINE WARNING LAMP (CHECK ENGINE LAMP)
If an abnormality occurs in any of the following items related
to the GDI system, the engine warning lamp will illuminate
or flash. If the lamp remains illuminated or if the lamp illuminates
while the engine is running, check the diagnosis code output.
Engine warning lamp However, the warning lamp will illuminate as bulb check for
(check engine lamp) five seconds whenever the ignition switch is turned to the
ON position.

Engine warning lamp inspection items

Code No. Diagnosis item

– Engine-ECU

P0100 Air flow sensor system

P0105 Barometric pressure sensor system

P0110 Intake air temperature sensor system

P0115 Engine coolant temperature sensor system

P0120 Throttle position sensor (1st channel) system

P0125 Feedback system

P0130 Oxygen sensor (front) system <sensor 1>

P0135 Oxygen sensor heater (front) system <sensor 1>

P0136 Oxygen sensor (rear) system <sensor 2>

P0141 Oxygen sensor heater (rear) system <sensor 2>

P0170 Abnormal fuel system

P0190 Abnormal fuel pressure

P0201 No. 1 injector system

P0202 No. 2 injector system

P0203 No. 3 injector system

P0204 No. 4 injector system

P0220 Accelerator pedal position sensor (1st channel) system

P0225 Throttle position sensor (2nd channel) system

P0300 Ignition coil (power transistor) system

P0301 No. 1 cylinder misfire detected

P0302 No. 2 cylinder misfire detected

P0303 No. 3 cylinder misfire detected

P0304 No. 4 cylinder misfire detected

 GDI – Troubleshooting 13A-7

Code No. Diagnosis item

P0335 Crank angle sensor system

P0340 Camshaft position sensor system

P0403 EGR valve system

P0420 Catalyst malfunction

P0443 Purge control solenoid valve system

P1200 Injector driver system

P1220 Electronic-controlled throttle valve system

P1221 Throttle valve position feedback system

P1223 Communication line with throttle valve controller

P1224 Throttle valve control servo motor (motor 1st phase malfunction) system

P1225 Accelerator pedal position sensor (2nd channel) system

P1228 Throttle valve control servo motor (motor 2nd phase malfunction) system

P1515 Brake vacuum sensor system

NOTE
1. If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
2. After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine
is next turned on and the same malfunction is re-detected. However, for items marked with a “”
in the diagnosis code number column, the engine warning lamp illuminates only on the first detection
of the malfunction.
As for P1220, P1221, P1223, P1224, and P1228, the engine warning lamp flashes. If malfunctions
are detected at the throttle position sensor (1st channel) and the throttle position sensor (2nd channel)
at the same time, or malfunctions are detected at the accelerator pedal position sensor (1st channel)
and the accelerator pedal position sensor (2nd channel) at the same time, the engine warning lamp
will flash.
3. After the engine warning lamp illuminates, it will be switched off under the following conditions.
(1) When the engine-ECU monitored the power train malfunction three times* and met set condition
requirements, it detected no malfunction.
*: In this case, “one time” indicates from engine start to stop.
(2) For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
4. Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates
the sensor mounted at the position second closest to the engine.
13A-8 GDI – Troubleshooting

METHOD OF READING AND ERASING DIAGNOSIS

CODES
Refer to GROUP 00 – How to Use Troubleshooting/Inspection
Service Points.

DIAGNOSIS USING DIAGNOSIS 2 MODE

1. Switch the diagnosis mode of the engine control unit to
DIAGNOSIS 2 mode using the MUT-II.
2. Carry out a road test.
3. Take a reading of the diagnosis code and repair the problem
location.
4. Turn the ignition switch to OFF and then back to ON again.
NOTE
By turning the ignition switch to OFF, the engine-ECU
will switch the diagnosis mode from DIAGNOSIS 2 mode
to DIAGNOSIS 1 mode.
5. Erase the diagnosis codes.

INSPECTION USING MUT-II DATA LIST AND

ACTUATOR TESTING
1. Carry out inspection by means of the data list and the
actuator test function. If there is an abnormality, check
and repair the chassis harnesses and components.
2. After repairing, re-check using the MUT-II and check that
the abnormal input and output have returned to normal
as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II, and then start the engine again and
carry out a road test to confirm that the problem has
disappeared.
GDI – Troubleshooting 13A-9
FREEZE FRAME DATA
When the engine-ECU detects a malfunction and stores a
diagnosis code, it also stores a current status of the engine.
This function is called “Freeze frame data.” By analyzing
this “freeze frame” data with the MUT-II, an effective
troubleshooting can be performed.
The display items of freeze frame data are shown below.
Display item list

Data item Unit

Engine coolant temperature sensor C

Engine speed r/min

Vehicle speed km/h

Long-term fuel compensation (long-term %

fuel trim)

Short-term fuel compensation (short-term %

fuel trim)

Fuel control condi- Open loop OL

tion
Closed loop CL

Open loop owing to OL-DRV.

drive condition

Open loop owing to OL-SYS.

system malfunction

Closed loop based CL-H02S

on one oxygen sen-
sor

Calculation load value %

Diagnosis code during data recording –

NOTE
If malfunctions have been detected in multiple systems, store
one malfunction only, which has been detected first.

READINESS TEST STATUS

The engine-ECU monitors the following main diagnosis items,
judges if these items are in good condition or not, and the
stores its history. This history can be read out by using MUT-II.
(If the ECU has judged a item before, the MUT-II displays
“Complete.”)
In addition, if diagnosis codes are erased or the battery cable
is disconnected, this history will also be erased (the memory
will be reset).
 Catalyst: P0420
 Oxygen sensor: P0130
 Oxygen sensor heater: P0135, P0141
13A-10 GDI – Troubleshooting

FAIL-SAFE FUNCTION REFERENCE TABLE

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

Air flow sensor 1. Suspends lean burn operation.

2. Uses the throttle position sensor signal and engine speed signal (crank angle
sensor signal) to take reading of the basic injector drive time and basic ignition
timing from the pre-set mapping.

Intake air temperature sensor Controls as if the intake air temperature is 25C.

Throttle position sensor (2nd 1. Suspends lean burn operation.

channel) 2. Controls the throttle opening angle feedback (half as much as the opening
rate in the normal condition) by using signals from the throttle position sensor
(1st channel). However, this controlling system is not applied if the throttle
position sensor (1st channel) and throttle position sensor (2nd channel)
combination output voltage is outside 4 – 6 V.
3. Refrains from controlling the throttle opening angle feedback if the throttle
position sensor (1st channel) is also defective.

Engine coolant temperature Controls as if the engine coolant temperature is 80C. (Moreover, the control system
sensor is working until the ignition switch is turned OFF if the sensor signal returns to normal.)

Camshaft position sensor Controls maintaining the condition before determined as failure.
Fuel will be cut-off 4 seconds after a malfunction is detected. (However, only if
No. 1 cylinder TDC has never been detected after the ignition switch is turned
to the ON position)

Vehicle speed sensor 1. Suspends lean burn operation. However, the control is cancelled as a certain
time passes by with the engine speed of 1,500 r/min or more.
2. Suspends lean burn operation during the engine idling.

Barometric pressure sensor Controls as if the barometric pressure is 101 kPa.

Detonation sensor Fixes the ignition timing as that for standard petrol.

Injector 1. Suspends lean burn operation.

2. Suspends the exhaust gas recirculation.

Communication line with Disable ignition timing retard control (engine and transmission total control) during
A/T-ECU shift change.

Ignition coil (incorporating pow- 1. Suspends lean burn operation.

er transistor) 2. Cuts off the fuel supply to cylinders with an abnormal ignition signal.

Fuel pressure sensor 1. Controls as if the fuel pressure is 5 MPa. (In case of open/short circuit)
2. Turns the fuel pump relay off. (In case of abnomality in high pressure)
3. Suspends fuel injection. (when the low pressure is detected and the engine
speed is more than 3,000 r/min)

Alternator FR terminal Refrains from controlling to suppress the alternator output to electrical load.
(Operated as a normal alternator)

Accelerator pedal position sen- 1. Suspends lean burn operation.

sor (2nd channel) 2. Controls the throttle valve position by using signals from the accelerator pedal
position sensor (1st channel). (However, the control system is not applicable
if the difference from the accelerator pedal position sensor (1st channel) output
voltage is 1.0 V or higher.)
3. Suspends the electronic controlled throttle valve system if accelerator pedal
position sensor (1st channel) is also defective.
 GDI – Troubleshooting 13A-11

Malfunctioning item Control contents during malfunction

Accelerator pedal position sen- 1. Suspends lean burn operation.

sor (1st channel) 2. Controls the throttle valve position by using signals from the accelerator pedal
position sensor (2nd channel). (However, this control is not applicable if the
voltage difference between the accelerator pedal position sensor (1st channel)
and accelerator pedal position sensor (2nd channel) is 1.0 V or higher.)
3. Also suspends the electronic-controlled throttle valve system when the
accelerator pedal position sensor (2nd channel) is defective.

Throttle position sensor (1st 1. Suspends lean burn operation.

channel) 2. Controls throttle opening angle feedback by using signals from throttle position
sensor (2nd channel). (However, the controlling system is not applied when
the throttle position sensor (1st channel) and throttle position sensor (2nd
channel) combination output voltage is outside 4 – 6 V.)
3. Refrains from controlling the throttle opening angle feedback when throttle
position sensor (2nd channel) is also defective.

Electronic-controlled throttle 1. Suspends the electronic controlled throttle valve system.

valve system 2. Suspends lean burn operation.
3. Suspends the idle speed feedback control.

Throttle valve position feed- 1. Suspends the electronic controlled throttle valve system.
back 2. Suspends lean burn operation.
3. Suspends the engine speed feedback control.

Communication line between 1. Communication error between the throttle valve controller and the engine-ECU
the throttle valve controller and  Suspends lean burn operation.
the engine-ECU  Cuts the fuel supply when the engine speed reaches 3,000 r/min or more.
 Suspends the cruise-control.
2. Communication error between the throttle valve controller and the engine-ECU
 Suspends lean burn operation.
 Cuts the fuel supply when the engine speed reaches 3,000 r/min or more.
 Suspends the cruise-control.
 The throttle valve controller controls the throttle valve opening angle by
using signals from accelerator pedal position sensor (2nd channel).

Throttle control servo motor 1st Bans lean burn operation.

phase malfunction

Throttle control servo motor 1. Suspends electronic control throttle valve system.
2nd phase malfunction 2. Bans lean burn operation.
3. Bans engine speed feed back control.

Misfiring If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be
shut down.

NOTE
If the electronic-controlled throttle valve system is suspended, the engine warning lamp will illuminate.
13A-12 GDI – Troubleshooting

INSPECTION CHART FOR DIAGNOSIS CODES

Code No. Diagnosis item Reference page

P0100 Air flow sensor system 13A-14

P0105 Barometric pressure sensor system 13A-16

P0110 Intake air temperature sensor system 13A-18

P0115 Engine coolant temperature sensor system 13A-19

P0120 Throttle position sensor 1 (1st channel) system 13A-22

P0125 Feedback system 13A-24

P0130 Oxygen sensor (front) system <sensor 1> 13A-25

P0135 Oxygen sensor heater (front) system <sensor 1> 13A-27

P0136 Oxygen sensor (rear) system <sensor 2> 13A-28

P0141 Oxygen sensor heater (rear) system <sensor 2> 13A-30

P0170 Abnormal fuel system 13A-31

P0190 Abnormal fuel pressure 13A-33

P0201 No. 1 injector system 13A-34

P0202 No. 2 injector system 13A-36

P0203 No. 3 injector system 13A-37

P0204 No. 4 injector system 13A-38

P0220 Accelerator pedal position sensor (1st channel) system 13A-40

P0225 Throttle position sensor (2nd channel) system 13A-43

P0300 Ignition coil (power transistor) system 13A-44

P0301 No. 1 cylinder misfire detected 13A-46

P0302 No. 2 cylinder misfire detected 13A-46

P0303 No. 3 cylinder misfire detected 13A-46

P0304 No. 4 cylinder misfire detected 13A-46

P0325 Detonation sensor system 13A-47

P0335 Crank angle sensor system 13A-47

P0340 Camshaft position sensor system 13A-59

P0403 EGR valve system 13A-50

P0420 Catalyst malfunction 13A-51

P0443 Purge control solenoid valve system 13A-52

P0500 Vehicle speed sensor system 13A-53

P1200 Injector driver system 13A-53

P1220 Electronic-controlled throttle valve system 13A-54

 GDI – Troubleshooting 13A-13

Code No. Diagnosis item Reference page

P1221 Throttle valve position feedback system 13A-55

P1223 Communication line with throttle valve controller 13A-56

P1224 Throttle valve control servo motor (motor 1st phase malfunction) system 13A-57

P1225 Accelerator pedal position sensor (2nd channel) system 13A-58

P1228 Throttle valve control servo motor (motor 2nd phase malfunction) system 13A-60

P1500 Alternator FR terminal system 13A-61

P1515 Brake vacuum sensor system 13A-62

P1600 Communication wire with A/T-ECU system 13A-64

P1610 Immobilizer system 13A-64

NOTE
1. Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
2. Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
3. After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the
engine is started and the same malfunction is re-detected. However, for items marked with a “”,
the diagnosis code is recorded on the first detection of the malfunction.
4. Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates
the sensor mounted at the position second closest to the engine.
13A-14 GDI – Troubleshooting

INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE

Code No. P0100 Air flow sensor system Probable cause
Range of Check  Malfunction of air flow sensor
 Engine speed: 500 r/min or more  Open or short circuit in air flow sensor circuit or
Set Conditions loose connector contact
 The sensor output frequency is 3.3 Hz or less for four seconds.  Malfunction of engine-ECU

OK
MUT-II Data list Transient malfunction
12 Air flow sensor (Refer to (Refer to GROUP 00 – Points to
P.13A-94, DATA LIST REFERENCE Note for Intermittent Malfunctions.)
TABLE.)
NG
NG
Check the following connector: Repair
A-71
OK
(1) NG OK
Measure at air flow sensor Measure at engine-ECU connector Check the following connector:
connector A-71. C-18. C-18
 Disconnect the connector and  Measure the voltage at the
OK NG
measure at the harness side. engine-ECU terminal Repair
(1) Voltage between terminal 3 and  Ignition switch: ON
earth (Ignition switch: ON)  Voltage between terminal 61 and
OK: 4.8 – 5.2 V earth Check the harness between the air
(2) Voltage between terminal 4 and OK: 4.8 – 5.2 V flow sensor and the engine-ECU,
earth (Ignition switch: ON) and repair if necessary.
OK: System voltage NG
(3) Resistance between terminal 5 NG
and earth Check the following connector: Repair
OK: 2 Ω or less C-18
OK

Check the harness between the air NG

flow sensor and the engine-ECU. Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG NG
Check the following connector: Repair
A-36
OK
Check the harness between the air
flow sensor and the engine control
relay, and repair if necessary.
(3) NG NG
Check the following connectors: Repair
A-36, C-19
OK OK

Check the harness between the air NG

Repair
flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

To the next page

 GDI – Troubleshooting 13A-15
From the previous page
OK
NG NG
Measure at air flow sensor Check the following connector: Repair
connector A-71. C-19
 Use test harness (MB991709) to OK
connect the connector, and
measure at the pick-up harness. NG
Check the harness between the air
 Ignition switch: ON Repair
flow sensor and the engine-ECU.
 Voltage between terminal 7 and
earth OK
OK: 7 – 8 V
Replace the air flow sensor.
OK

NG NG
Measure at air flow sensor Check the following connector: Repair
connector A-71. C-19
 Use test harness (MB991709) to
OK
connect the connector, and NG
measure at the pick-up harness. Check the harness between the air Repair
 Selector lever position: P flow sensor and the engine-ECU.
 Voltage between terminal 7 and
earth OK
OK: Engine: Idling
0 – 1 V Check the trouble symptoms.
Engine speed: 3,000 r/min
NG
6 – 9 V
Replace the engine-ECU.
OK

NG
Measure the output wave form at Replace the air flow sensor.
air flow sensor connector A-71 (by
using an analyzer).
 Use test harness (MB991709) to Check the trouble symptoms.
connect the connector, and
measure at the pick-up harness. NG
 Engine: Idling NG
 Voltage between terminal 3 and Check the following connector: Repair
earth C-18
OK: Waveforms should be dis- OK
played on P.13A-84* (In-
spection Procedure Using Check the harnesses between the
an Analyzer) and noise air flow sensor and the engine-ECU
should not be displayed in and between the air flow sensor
the waveform. and the engine control relay, and
OK repair if necessary.

Check the trouble symptoms.

NG

Replace the engine-ECU .

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
13A-16 GDI – Troubleshooting

Code No. P0105 Barometric pressure sensor system Probable cause

Range of Check  Malfunction of barometric pressure sensor
 Two seconds have passed since the ignition switch is turned ON or the  Open or short circuit in barometric pressure
engine starting process is completed. sensor circuit or loose connector contact
 Battery voltage: 8 V or more  Malfunction of engine-ECU
Set Conditions
 The sensor output voltage is 4.5 V or more for four seconds (equivalent to
114 kPa of barometric pressure)
or
 The sensor output voltage is 0.2 V or less (equivalent to 53 kPa of
barometric pressure)

OK
MUT-II Data list Transient malfunction
25 Barometric pressure sensor (Refer to GROUP 00 – Points to
(Refer to P.13A-94, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
Check the following connector: NG
A-71 Repair
OK
(1) NG
Measure at air flow sensor Measure at engine-ECU connector OK Check the following connector:
connector A-71. C-18. C-18
 Disconnect the connector and  Measure the voltage at the OK NG
measure at the harness side. engine-ECU terminal. Repair
(1) Voltage between terminal 1 and  Ignition switch: ON
earth (Ignition switch: ON)  Voltage between terminal 41 and Check the harness between the air
OK: 4.8 – 5.2 V earth flow sensor and the engine-ECU
(2) Resistance between terminal 5 OK: 4.8 – 5.2 V ,and repair if necessary.
and earth
NG
OK: 2 Ω or less
Check the following connector: NG
Repair
C-18
OK

Check the harness between the air NG

Repair
flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG NG
Check the following connector: Repair
A-36, C-19
OK

Check the harness between the air NG Repair

OK
flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
To the next page
 GDI – Troubleshooting 13A-17
From the previous page

OK

(1) NG NG
Measure at air flow sensor Check the following connector: Repair
connector A-71. C-18
 Connect connector terminals No.
1, No. 2 and No. 5 only by using OK
test harness (MB991709), and Check the harness between the air
measure at the pick-up harness. flow sensor and the engine-ECU,
 Ignition switch: ON and repair if necessary.
(1) Voltage between terminal 1 and
earth
OK: 4.8 – 5.2 V
(2) Voltage between terminal 2 and (2) NG
Replace the air flow sensor.
earth
OK: Altitude 0 m: 3.7 – 4.3 V
Altitude 1,200 m:
3.2 – 3.8 V Check the trouble symptoms.
(3) Voltage between terminal 5 and (3) NG NG
earth
OK: 0.5 V or less NG
Check the following connectors: Repair
OK A-36, C-18, C-19
OK

Check the harness between the air

flow sensor and the engine-ECU,
and repair if necessary.

NG
Check the following connectors: Repair
A-36, C-19
OK
Check the harness between the air
flow sensor and the engine-ECU,
and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-18. C-18
 Measure the voltage at the
OK
engine-ECU terminal.
 Ignition switch: ON
 Voltage between terminal 51 and Check the harness between the air
earth flow sensor and the engine-ECU,
OK: Altitude 0 m: 3.7 – 4.3 V and repair if necessary.
Altitude 1,200 m:
3.2 – 3.8 V OK
Check the following connector: NG
Repair
C-18
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

13A-18 GDI – Troubleshooting

Code No. P0110 Intake air temperature sensor system Probable cause
Range of Check  Malfunction of intake air temperature sensor
 Two seconds have passed since the ignition switch is turned ON or the  Open or short circuit in intake air temperature
engine starting process is completed. sensor or loose connector contact
Set Conditions  Malfunction of engine-ECU
 The sensor output voltage is 4.6 V or more for four seconds (equivalent to
–45C of intake air temperature)
or
 The sensor output voltage is 0.2 V or more for four seconds (equivalent to
125C of intake air temperature)

MUT-II Data list OK Transient malfunction

13 Intake air temperature sensor (Refer to GROUP 00 – Points to
OK: Roughly the same as am- Note for Intermittent Malfunctions.)
bient temperature.
NG
NG
Check the intake air temperature Repair
sensor itself.
(Refer to P.13A-102*.)
OK
NG
Check following connector: A-71 Repair
OK
(1) NG NG
Measure at air flow sensor Check the following connectors: Repair
connector A-71. A-36, C-19
 Disconnect the connector and OK
measure at the harness side.
(1) Resistance between terminal 5 Check the harness between the air NG
and earth Repair
flow sensor and the engine-ECU.
OK: 2 Ω or less
(2) Voltage between terminal 6 and OK
earth NG
Check the trouble symptoms. Replace the engine-ECU.
(Ignition switch: ON)
OK: 4.8 – 5.2 V

(2) NG OK
Measure at engine-ECU connector Check the following connector:
C-18. C-18
 Measure the voltage at the NG
engine-ECU terminal. OK
 Disconnect connector A-71. Repair
 Ignition switch: ON
 Voltage between terminal 62 and Check the harness between the air
earth flow sensor and the engine-ECU,
OK: 4.8 – 5.2 V and repair if necessary.

NG

Check the following connector: NG

C-18 Repair

OK
NG
Check the harness between the air Repair
OK flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

To the next page

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
 GDI – Troubleshooting 13A-19
From the previous page
OK
NG NG
Measure at air flow sensor Check the following connectors: Repair
connector A-71. A-36, C-18, C-19
 Use the test harness
(MB991709) to connect only OK
terminals 5 and 6, and then Check the harness between the air
measure at the pick-up harness. flow sensor and the engine-ECU,
 Ignition switch: ON and repair if necessary.
 Voltage between terminal 6 and
earth
OK: Ambient temperature 0C:
3.2 – 3.8 V
Ambient temperature 20C:
2.3 – 2.9 V
Ambient temperature 40C:
1.5 – 2.1 V
Ambient temperature 80C:
0.4 – 1.0 V
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

Code No. P0115 Engine coolant temperature sensor Probable cause

system
Range of Check  Malfunction of engine coolant temperature sensor
 Engine: Two seconds after the engine has been started  Open or short circuit in the engine coolant
Set Conditions temperature sensor circuit or loose connector
 The sensor output voltage is 4.6 V or more for four seconds (equivalent to contact
–45C of engine coolant temperature)  Malfunction of engine-ECU
or
 The sensor output voltage is 0.1 V or less for four seconds (equivalent to
140C of engine coolant temperature)
Range of Check
 Engine: After starting
Set Conditions
 The engine coolant temperature has reduced from over 40C to less than
40C, and that condition has lasted for five minutes or more.
13A-20 GDI – Troubleshooting

OK
MUT-II Data list Transient malfunction
21 Engine coolant temperature (Refer to GROUP 00 – Points to
sensor Note for Intermittent Malfunctions.)
OK: When the engine is cold,
the temperature is roughly
the same as ambient tem-
perature. If warm, it is 80
– 120C.
NG
NG
Measure at engine coolant Replace
temperature sensor connector A-69.
 Disconnect the connector and
measure at the harness side.
 Resistance between terminals 1
and 2
OK: At 20C of engine coolant
temperature: 2.1 – 2.7 kΩ
At 80C of engine coolant
temperature: 0.26 – 0.36
kΩ
OK

Check the following connector: NG

A-69 Repair

OK
(1) NG OK
Measure at engine coolant Measure at engine-ECU connector Check the following connector:
temperature sensor connector A-69. C-18. C-18
 Disconnect the connector and  Measure the voltage at the
measure at the harness side. engine-ECU terminal. OK NG
 Disconnect connector A-69. Repair
(1) Voltage between terminal 1 and
earth  Ignition switch: ON
(Ignition switch: ON)  Voltage between terminal 44 and Check the harness wire between
OK: 4.8 – 5.2 V earth the engine coolant temperature
(2) Resistance between terminal 2 OK: 4.8 – 5.2 V sensor and the engine-ECU, and
and earth repair if necessary.
OK: 2 Ω or less NG

Check the following connector: NG

C-18 Repair

OK
Check the harness wire between
the engine coolant temperature NG
Repair
sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG NG
Check the following connectors: Repair
A-36, C-19
OK OK

Check the harness wire between NG

the engine coolant temperature Repair
sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

To the next page

 GDI – Troubleshooting 13A-21
From the previous page
OK
NG NG
Measure at engine coolant Check the engine coolant Repair
temperature sensor connector A-69. temperature sensor.
 Use test harness (MB991658) to (Refer to P.13A-102*.)
connect the connector, and
measure at the pick-up harness. OK
 Ignition switch: ON NG Repair
Check the following connectors:
 Voltage between terminal 1 and A-36, C-18, C-19
earth
OK: At 0C of engine coolant OK
temperature: 3.2 – 3.8 V
At 20C of engine coolant Check the harness wire between
temperature: 2.3 – 2.9 V the engine coolant temperature
At 40C of engine coolant sensor and the engine-ECU, and
temperature: 1.3 – 1.9 V repair if necessary.
At 80C of engine coolant
temperature: 0.3 – 0.9 V
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
13A-22 GDI – Troubleshooting

Code No. P0120 Throttle position sensor (1st channel) Probable cause
system
The throttle valve controller judges a malfunction, and then transmit the result  Malfunction of throttle position sensor
to the engine-ECU.  Open or short circuit in the throttle position
Range of Check sensor (1st channel) circuit or loose connector
 Ignition switch: ON contact
Set Conditions  Malfunction of throttle valve controller
 The sensor output voltage is 0.2 V or less.  Malfunction of engine-ECU
or
 The sensor output voltage is 4.9 V or more.
or
 The throttle position sensor (1st channel) and throttle position sensor (2nd
channel) combination output voltage is outside 4 – 6 V.
or
 The output voltage of the throttle position sensor (1st channel) is
significantly different (approx. 1V) from the throttle valve opening angle
(voltage), which the engine-ECU request the throttle valve controller.

OK
MUT-II Data list Transient malfunction
79 Throttle position sensor (1st (Refer to GROUP 00 – Points to
channel) (Refer to P.13A-94, Note for Intermittent Malfunctions.)
DATA LIST REFERENCE
TABLE.)
NG
NG
Check the throttle position sensor. Replace
(Refer to P.13A-103*.)
OK
NG
Check the following connector: Repair
A-06
OK
(1) NG OK
Measure at throttle position sensor Measure at throttle valve controller Check the following connector:
connector A-06. connector C-48. C-48
 Disconnect the connector and  Measure voltage at the throttle
measure at the harness side. OK NG
valve controller connector
(1) Voltage between terminal 1 and Repair
terminals.
earth  Ignition switch: ON
(Ignition switch: ON)  Voltage between terminal 6 and Check the harness wire between
OK: 4.8 – 5.2 V earth the throttle position sensor and the
(2) Resistance between terminal 3 OK: 4.8 – 5.2 V throttle valve controller, and repair if
and earth necessary.
OK: 2 Ω or less NG
NG
Check the following connector: Repair
C-48
OK
NG
Check the harness wire between Repair
the throttle position sensor and the
throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.

(2) NG NG
Check the following connector: Repair
C-48
OK
NG
OK Check the harness wire between Repair
the throttle position sensor and the
To the next page throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKPE00E1)
 GDI – Troubleshooting 13A-23
From the previous page
OK
(1) NG NG
Measure at throttle position sensor Check the following connector: Repair
connector A-66. (3) NG C-48
 Use test harness (MB991536) to
connect the connector, and OK
measure at the pick-up harness.
 Ignition switch: ON Check the harness wire between
(1) Voltage between terminal 1 and the throttle position sensor and the
earth throttle valve controller, and repair if
OK: 4.8 – 5.2 V necessary.
(2) Voltage between terminal 2 and (2) NG
earth Adjust the throttle position sensor.
OK: Accelerator pedal fully re- (Refer to P.13A-92*.)
leased: 0.45 – 0.8 V
Accelerator pedal fully de-
pressed: 3.9 – 4.9 V NG
Check the following connector: Repair
(3) Voltage between terminal 3 and
C-48
earth
OK: 0.5 V or less OK

Check the harness wire between

the throttle position sensor and the
OK throttle valve controller, and repair if
necessary.
NG
Measure at throttle valve controller NG Check the following connector: Repair
connector C-48. C-48
 Measure voltage at the throttle OK
valve controller connector
terminals. Check the harness wire between
 Ignition switch: ON the throttle position sensor and the
 Voltage between terminal 7 and throttle valve controller, and repair if
earth necessary.
OK: Accelerator pedal fully re-
leased: 0.45 – 0.8 V OK NG
Accelerator pedal fully de- Check the following connector: Repair
pressed: 3.9 – 4.9 V C-48
OK

Check the trouble symptoms.

NG
Replace the throttle valve controller.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-24 GDI – Troubleshooting

Code No. P0125 Feedback system Probable cause

Range of Check  Malfunction of oxygen sensor (front)
 The engine coolant temperature is approx. 80C or more.  Open or short circuit in the oxygen sensor (front)
 During stoichiometric feedback control circuit or loose connector contact
 The vehicle is not being decelerated.  Malfunction of engine-ECU
Set Conditions
 Oxygen sensor (front) output voltage has been higher or lower than 0.5 V
for at least thirty seconds.

NG
Check the following connector: Repair
A-67
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-36, C-19
 Disconnect the connector and OK
measure at the harness side. NG
 Resistance between terminal 2 Check the harness wire between Repair
and earth the oxygen sensor (front) and the
OK: 2 Ω or less engine-ECU
OK OK
Check the trouble symptoms.
NG

Replace the engine-ECU.

(1) NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-36, C-19
 Use the test harness
OK
(MD998464) to connect the
connector, and measure at the
pick-up harness side. Check the harness wire between
 Engine: 2,500 r/min (after the oxygen sensor (front) and the
warming up) engine-ECU, and repair if necessary.
(1) Voltage between terminal 2 and (2) NG NG
earth Check the oxygen sensor (front). Replace
OK: 0.5 V or less (Refer to P.13A-112.)
(2) Voltage between terminal 4 and
earth OK
OK: 0 V and 0.8 V alternate. NG
Check the following connector: Repair
C-19
OK
OK
Check the harness wire between
the oxygen sensor (front) and the
engine-ECU, and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. C-19
 Measure the voltage at the
engine-ECU terminal. OK
 Engine: 2,500 r/min (after
warming up) Check the harness wire between
 Voltage between terminal 71 and the oxygen sensor (front) and the
earth engine-ECU, and repair if necessary.
OK: 0 V and 0.8 V alternate.
OK
NG
Check the following connector: Repair
C-19
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)

Replace the engine-ECU.

 GDI – Troubleshooting 13A-25
Code No. P0130 Oxygen sensor (front) system Probable cause
<sensor 1>
Range of Check  Malfunction of oxygen sensor (front)
 Three minutes have been passed since the engine has been started.  Open or short circuit in the oxygen sensor (front)
 The engine coolant temperature is approx. 80C or more. circuit or loose connector contact
 Intake air temperature is 20 – 50C  Malfunction of engine-ECU
 Engine speed is 1,200 r/min or more
 Driving on a level surface at constant speed.
Set Conditions
 The oxygen sensor (front) output voltage is 4.5 V or more when the sensor
output voltage is 0.2 V or less and a voltage of 5 V is applied to the
oxygen sensor (front) inside the engine-ECU.
Range of Check
 Engine speed is 3,000 r/min or less
 During driving
 During air/fuel ratio feedback control
Set Conditions
 The oxygen sensor (front) output frequency is five or less per 12 seconds
on average.
13A-26 GDI – Troubleshooting

NG
Check the following connector: Repair
A-55
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-36, C–19
 Disconnect the connector and OK
measure at the harness side. NG
 Resistance between terminal 2 Check the harness wire between Repair
and earth the oxygen sensor (front) and the
OK: 2 Ω or less engine-ECU.
OK OK
Check the trouble symptoms.
NG

Replace the engine-ECU.

(1) NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-36, C-19
 Use the test harness OK
(MD998464) to connect the
connector, and measure at the Check the harness wire between
pick-up harness side. the oxygen sensor (front) and the
 Engine: 2,500 r/min (after engine-ECU, and repair if necessary.
warming up)
(1) Voltage between terminal 2 and
earth
OK: 0.5 V or less
(2) Voltage between terminal 4 and (2) NG NG
earth Check the oxygen sensor (front). Replace
OK: 0 V and 0.8 V alternate. (Refer to P.13A-112.)
OK
OK NG
Check the following connector: Repair
C-19
OK

Check the harness wire between

the oxygen sensor (front) and the
engine-ECU, and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. C-19
 Measure the voltage at the OK
engine-ECU terminal.
 Engine: 2,500 r/min (after Check the harness wire between
warming up) the oxygen sensor (front) and the
 Voltage between terminal 71 and engine-ECU, and repair if necessary.
earth
OK: 0 V and 0.8 V alternate.
OK
NG
Check the following connector: Repair
C-19
OK

OK
Check the trouble symptoms. Transient malfunction
NG (Refer to GROUP 00 – Points to
Note for Intermittent Malfunctions.)
Replace the engine-ECU.
 GDI – Troubleshooting 13A-27
Code No. P0135 Oxygen sensor heater (front) system Probable cause
<sensor 1>
Range of Check  Malfunction of oxygen sensor heater (front)
 The engine coolant temperature is approx. 20C or more.  Open or short circuit in the oxygen sensor heater
 The oxygen sensor heater (front) remains on. (front) circuit or loose connector contact
 The engine speed is 50 r/min or more.  Malfunction of engine-ECU
 Battery voltage is 11 – 16 V.
Set Conditions
 The current, which flows through the oxygen sensor heater (front), is 0.2 A
or less or 3.5 A or more for six seconds.

NG
Measure at oxygen sensor (front) Replace
connector A-67.
 Disconnect the connector and
measure at the harness side.
 Resistance between terminals 1
and 3
OK: 4.5 – 8.0 Ω
OK
NG
Check the following connector: Repair
A-67
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-36, A-43X
 Disconnect the connector and
measure at the harness side. OK
 Ignition switch: ON Check the harness wires between
 Voltage between terminal 1 and the oxygen sensor (front) and the
earth engine control relay, and repair if
OK: System voltage necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. C-19
 Measure the voltage at the OK
engine-ECU terminal.
 Ignition switch: ON Check the harness wire between NG
 Voltage between terminal 89 and the oxygen sensor (front) and the
Repair
earth engine-ECU.
OK: System voltage
OK
OK
Replace the engine-ECU.
NG
Check the following connectors: Repair
A-36, A-43X, C-19
OK
NG
Check the harness wires between Repair
the oxygen sensor (front) and the
engine-ECU and between the
oxygen sensor (front) and the
engine control relay.
OK

OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)

Replace the engine-ECU.

13A-28 GDI – Troubleshooting

Code No. P0136 Oxygen sensor (rear) system Probable cause

<sensor 2>
Range of Check  Malfunction of oxygen sensor (rear)
 Three minutes have been passed since the engine has been started.  Open or short circuit in the oxygen sensor (rear)
 The engine coolant temperature is approx. 80C or more. circuit or loose connector contact
 Intake air temperature is 20 – 50C  Malfunction of engine-ECU
 Engine speed is 1,200 r/min or more
 Driving on a level surface at constant speed.
Set Conditions
 The oxygen sensor (rear) output voltage is 4.5 V or more when the sensor
output voltage is 0.2 V or less and a voltage of 5 V is applied to the
oxygen sensor (rear) inside the engine-ECU.
Range of Check
 Two seconds have passed after the engine-ECU detected an open circuit.
 When the oxygen sensor (front) is in good condition.
Set Conditions
 When the air/fuel ratio is rich, the oxygen sensor (front) output voltage is
0.5 V or more, the oxygen sensor (rear) output voltage is less than 0.1 V,
and the oxygen sensor (rear) output voltage fluctuates within 0.078 V.
 GDI – Troubleshooting 13A-29
NG
Check the following connector: Repair
B-11
OK
NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector B-11. A-36, C-19
 Disconnect the connector and
OK
measure at the harness side. NG
 Resistance between terminal 2 Check the harness wire between Repair
and earth the oxygen sensor (rear) and the
OK: 2 Ω or less engine-ECU.
OK OK
Check the trouble symptoms.
NG

Replace the engine-ECU.

(1) NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector B-11. A-36, C-19
 Use the test harness (MB998464)
to connect the connector, and OK
measure at the pick-up harness
side. Check the harness wire between
 Engine: 2,500 r/min (after the oxygen sensor (rear) and the
warming up) engine-ECU, and repair if necessary.
(1) Voltage between terminal 2 and
earth
OK: 0.5 V or less
(2) Voltage between terminal 4 and (2) NG NG
Check the oxygen sensor (rear). Replace
earth
(Refer to P.13A-113.)
OK: 0 V and 0.8 V alternate.
OK
OK NG
Check the following connector: Repair
C-18
OK

Check the harness wire between

the oxygen sensor (rear) and the
engine-ECU, and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-18. C-18
 Measure the voltage at the
engine-ECU terminal. OK
 Engine: 2,500 r/min (after
Check the harness wire between
warming up)
the oxygen sensor (rear) and the
 Voltage between terminal 53 and
engine-ECU, and repair if necessary.
earth
OK: 0 V and 0.8 V alternate.
OK
NG
Check the following connectors: Repair
A-36, C-18, C-19
OK

OK
Check the trouble symptoms. Transient malfunction
NG (Refer to GROUP 00 – Points to
Note for Intermittent Malfunctions.)
Replace the engine-ECU.
13A-30 GDI – Troubleshooting

Code No. P0141 Oxygen sensor heater (rear) system Probable cause
<sensor 2>
Range of Check  Malfunction of oxygen sensor heater (rear)
 The engine coolant temperature is approx. 20C or more.  Open or short circuit in the oxygen sensor heater
 The oxygen sensor heater (rear) remains on. (rear) circuit or loose connector contact
 The engine speed is 50 r/min or more.  Malfunction of engine-ECU
 Battery voltage is 11 – 16 V.
Set Conditions
 The current, which flows through the oxygen sensor heater (rear), is 0.2 A
or less or 3.5 A or more for six seconds.

NG
Measure at oxygen sensor (rear) Replace
connector B-11.
 Disconnect the connector and
measure at the harness side.
 Resistance between terminals 1
and 3
OK: 11 – 18 Ω
OK
NG
Check the following connector: Repair
B-11
OK

NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector B-11. A-36, A-43X
 Disconnect the connector and
measure at the harness side. OK
 Ignition switch: ON Check the harness wires between
 Voltage between terminal 1 and the oxygen sensor (rear) and the
earth engine control relay, and repair if
OK: System voltage necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. C-19
 Measure the voltage at the
engine-ECU terminal. OK
 Ignition switch: ON
NG
 Voltage between terminal 90 and Check the harness wire between Repair
earth the oxygen sensor (rear) and the
OK: System voltage engine-ECU.
OK OK

Replace the engine-ECU.

NG
Check the following connectors: Repair
A-36, A-43X, C-19
OK
NG
Check the harness wires between Repair
the oxygen sensor (rear) and the
engine-ECU and between the
oxygen sensor (rear) and the engine
control relay.
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)

Replace the engine-ECU .

 GDI – Troubleshooting 13A-31
Code No. P0170 Abnormal fuel system Probable cause
Range of Check  Malfunction of fuel supply system
 Engine: Being learning the air-fuel ratio  Malfunction of oxygen sensor (front)
Set Conditions  Malfunction of intake air temperature sensor
 Ten seconds or more have been passed while the fuel injection amount  Malfunction of barometric pressure sensor
compensation value is too low.  Malfunction of air flow sensor
or  Malfunction of engine-ECU
 Ten seconds or more have been passed while the fuel injection amount
compensation value is too high.

YES
MUT-II Self-Diag Code Refer to P.13A-12, INSPECTION
Is any diagnosis code other than CHART FOR DIAGNOSIS CODES.
No. P0170 output?
NO
NG
Check the air intake from the intake Repair
hose and intake manifold.
OK
NG
Check the exhaust gas leaks from Repair
the exhaust manifold.
OK
NG
Check the throttle body (around the Cleaning
throttle valve), and clean if
necessary. (Refer to P.13A-92*.)
OK

NG NG
MUT-II Data list Check fuel leakage around the fuel Repair
74 Fuel pressure sensor pump (high-pressure) line.
(Refer to 13A-94, DATA LIST
REFERENCE TABLE.) OK
OK Replace the fuel pump
(high-pressure).

NG
MUT-II Data list Refer to the Inspection procedure
11 Oxygen sensor (front) for the sensor, which is indicated by
12 Air flow sensor the abnormal service data.
13 Intake air temperature sensor (Refer to P.13A-12, INSPECTION
21 Engine coolant temperature CHART FOR DIAGNOSIS CODES.)
sensor
25 Barometric pressure sensor
(Refer to 13A-94, DATA LIST
REFERENCE TABLE.)
Reference
If all the service data is normal, go
to “OK.”
If any abnormal service is found, go
to “NG.”
OK

NG
Check the oxygen sensor (front) Replace
(Refer to P.13A-112.)
OK
NG
Check the purge control solenoid Replace
valve (Refer to GROUP 17 –
Emission Control).
OK

To the next page

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-32 GDI – Troubleshooting

From the previous page

OK
NG
Check the EGR valve (Refer to Replace
GROUP 17 – Emission Control.)
OK

NG
Check the fuel pressure between Repair
the fuel pump (low-pressure) and
the fuel pump (high-pressure) (Refer
to P.13A-108.)
OK

NG
Check the fuel lines for fuel leaks. Repair
OK
NG
Check the injectors for clogging or Repair
leaks.
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 – Points to
NG
Note for Intermittent Malfunctions.)
Replace the engine-ECU.
 GDI – Troubleshooting 13A-33
Code No. P0190 Abnormal fuel pressure Probable cause
Range of Check  Malfunction of of fuel pressure sensor
 Ignition switch: ON  Open or short circuit in the fuel pressure sensor
Set Conditions circuit or loose connector contact
 The sensor output voltage is 4.8 V or more, or 0.2 V or less for four  Malfunction of engine-ECU
seconds.
Range of Check  Malfunction of high-pressure fuel pump
 The following conditions are detected temporarily after the engine has been  Clogging of high-pressure fuel lines
started.
(1) Engine speed: 1,000 r/min or more
(2) Fuel pressure: 2 MPa or more
 Engine running
Set Conditions
 The fuel pressure is 6.9 MPa or more, or 2 MPa or less for four seconds.
This diagnosis code will also be output when air is trapped into the  Air trapped due to poor fuel level
high-pressure fuel lines (such as poor fuel level). In that case, the air can be
evacuated by operating the engine for at least 15 seconds at 2,000 r/min. After
the repair, use the MUT-II to erase the diagnosis code.

OK
MUT-II Data list Transient malfunction
74 Fuel pressure sensor (Refer to (Refer to GROUP 00 – Points to
13A-94, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
NG
Check the following connector: Repair
A-59
OK
(1) NG OK
Measure at fuel pressure sensor Measure at engine-ECU connector Check the following connector:
connector A-59. C-18. C-18
 Disconnect the connector, and  Measure the voltage at the OK NG
measure at the harness side. engine-ECU terminal.
Repair
(1) Voltage between terminal 1 and  Ignition switch: ON
earth (Ignition switch: ON)  Voltage between terminal 41 and Check the harness wire between
OK: 4.8 – 5.2 V earth the fuel pressure sensor connector
(2) Resistance between terminal 3 OK: 4.8 – 5.2 V and the engine-ECU, and repair if
and earth necessary.
OK: 2 Ω or less NG

NG
Check the following connector: Repair
C-18
OK
NG
Check the harness wire between the Repair
fuel pressure sensor connector and
the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG NG
Check the following connectors: Repair
A-36, C-19
OK OK
NG
To the next page Check the harness wire between the Repair
fuel pressure sensor connector and
the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
13A-34 GDI – Troubleshooting

From the previous page

OK
(1) NG NG
Measure at fuel pressure sensor Check the following connector: Repair
connector A-59. C-18
 Use test harness (MB991658) to OK
connect the connector, and
measure at the pick-up harness. Check the harness wire between
 Engine: Idling the fuel pressure sensor connector
(1) Voltage between terminal 1 and and the engine-ECU, and repair if
earth necessary.
OK: 4.8 – 5.2 V
(2) Voltage between terminal 2 and
earth (2) NG
OK: 0.3 – 4.7 V Replace the fuel pressure sensor.
(3) Voltage between terminal 3 and
earth
OK: 0.5 V or less Check the trouble symptoms.
NG
NG
Check the following connector: Repair
C-19
OK
Check the harness wire between
the fuel pressure sensor connector
and the engine-ECU, and repair if
necessary.

(3) NG NG
Check the following connectors: Repair
A-36, C-19
OK
OK
Check the harness wire between
the fuel pressure sensor connector
and the engine-ECU, and repair if
necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. C-19
 Measure the voltage at the OK
engine-ECU terminal.
 Engine: Idling Check the harness wire between
 Voltage between terminal 92 and the fuel pressure sensor connector
earth and the engine-ECU, and repair if
OK: 0.3 – 4.7 V necessary.

OK NG
Check the following connector: Repair
C-19
OK

Check the trouble symptoms.

OK

Replace the engine-ECU.

Code No. P0201 No. 1 injector system Probable cause

Range of Check  Malfunction of No. 1 injector
 The engine speed is 4,000 r/min or less.  Open or short circuit in the No. 1 injector circuit
 The battery voltage is 10 V or more. or loose connector contact
 The fuel cut operation or the injector operation (by carrying out the Actuator  Malfunction of engine-ECU
Test) is not in progress.
Set Conditions
 The injector driver is not transmitting a injector open circuit check signal
for four seconds.
 GDI – Troubleshooting 13A-35
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
01 No. 1 injector (Refer to GROUP 00 – Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change. Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.

NG
Check the following connector: Repair
A-78
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
A-78. A-61
 Disconnect the connector and OK
measure at the harness side. NG
 Resistance between terminals 1 Check the harness wire between Repair
and 2 No. 1 injector and the intermediate
OK: 0.9 – 1.1 Ω connector.
OK OK
Replace the No. 1 injector.
NG
Check the following connector: Repair
A-55
OK
NG
Check the harness wire between Repair
the injector driver and the
intermediate connector.
OK
NG
Check the following connector: Repair
C-17
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU A-61
connectors C-17 and C-19. OK
 Engine: Idling
 Voltage between terminal 1 and NG
Check the harness wire between Repair
earth the No. 1 injector and the
OK: A normal waveform should intermediate connector.
be displayed as described
on P.13A-84* (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.

OK

NG
Check the following connector: Repair
A-61
OK
NG
Check the harness wire between Repair
No. 1 injector and the intermediate
connector.
OK
Replace the No. 1 injector.

NG
Check the trouble symptoms. Replace the injector driver.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-36 GDI – Troubleshooting

Code No. P0202 No. 2 injector system Probable cause

Range of Check  Malfunction of No. 2 injector
 The engine speed is 4,000 r/min or less.  Open or short circuit in the No. 2 injector circuit
 The battery voltage is 10 V or more. or loose connector contact
 The fuel cut operation or the injector operation (by carrying out the Actuator  Malfunction of engine-ECU
Test) is not in progress.
Set Conditions
 The injector driver is not transmitting a injector open circuit check signal
for four seconds.

OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
02 No. 2 injector (Refer to GROUP 00 – Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change. Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Check the following connector: Repair
A-78
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
A-78 A-62
 Disconnect the connector and OK
measure at the harness side. NG
 Resistance between terminals 3 Check the harness wire between Repair
and 4 No. 2 injector and the intermediate
OK: 0.9 – 1.1 Ω connector.
OK OK
Replace the No. 2 injector.
NG
Check the following connector: Repair
A-55
OK
NG
Check the harness wire between Repair
the injector driver and the
intermediate connector.
OK
NG
Check the following connector: Repair
B-17
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU A-62
connectors C-17 and C-19. OK
 Engine: Idling NG
 Voltage between terminal 9 and Check the harness wire between Repair
earth the No. 2 injector and the
OK: A normal waveform should intermediate connector.
be displayed as described
on P.13A-84* (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.

OK

NG
Check the following connector: Repair
A-62
OK

To the next page

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-37
From the previous page
OK
NG
Check the harness wire between Repair
No. 2 injector and the intermediate
connector.
OK
Replace the No. 2 injector.

NG
Check the trouble symptoms. Replace the injector driver.

Code No. P0203 No. 3 injector system Probable cause

Range of Check  Malfunction of No. 3 injector
 The engine speed is 4,000 r/min or less.  Open or short circuit in the No. 3 injector circuit
 The battery voltage is 10 V or more. or loose connector contact
 The fuel cut operation or the injector operation (by carrying out the Actuator  Malfunction of engine-ECU
Test) is not in progress.
Set Conditions
 The injector driver is not transmitting a injector open circuit check signal
for four seconds.

OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
03 No. 3 injector (Refer to GROUP 00 – Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change. Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.

NG
Check the following connector: Repair
A-78
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
A-78. A-63
 Disconnect the connector and OK
measure at the harness side. NG
 Resistance between terminals 5 Check the harness wire between Repair
and 6 No. 3 injector and the intermediate
OK: 0.9 – 1.1 Ω connector.
OK OK
Replace the No. 3 injector.
NG
Check the following connector: Repair
A-55
OK
NG
Check the harness wire between Repair
the injector driver and the
intermediate connector.
OK
NG
Check the following connector: Repair
C-17
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK

To the next page

13A-38 GDI – Troubleshooting

From the previous page

OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU A-63
connectors C-17 and C-19.
OK
 Engine: Idling
 Voltage between terminal 24 and NG
Check the harness wire between Repair
earth the No. 3 injector and the
OK: A normal waveform should intermediate connector.
be displayed as described
on P.13A-84* (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.
OK

NG
Check the following connector: Repair
A-63
OK
NG
Check the harness wire between Repair
No. 3 injector and the intermediate
connector.
OK
Replace the No. 3 injector.

NG
Check the trouble symptoms. Replace the injector driver.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
Code No. P0204 No. 4 injector system Probable cause
Range of Check  Malfunction of No. 4 injector
 The engine speed is 4,000 r/min or less.  Open or short circuit in the No. 4 injector circuit
 The battery voltage is 10 V or more. or loose connector contact
 The fuel cut operation or the injector operation (by carrying out the Actuator  Malfunction of engine-ECU
Test) is not in progress.
Set Conditions
 The injector driver is not transmitting a injector open circuit check signal
for four seconds.
 GDI – Troubleshooting 13A-39
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
04 No. 4 injector (Refer to GROUP 00 – Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change. Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.

NG
Check the following connector: Repair
A-78
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
A-78. A-64
 Disconnect the connector and OK
measure at the harness side. NG
 Resistance between terminals 7 Check the harness wire between Repair
and 8 No. 4 injector and the intermediate
OK: 0.9 – 1.1 Ω connector.
OK OK
Replace the No. 4 injector.
NG
Check the following connector: Repair
A-55
OK
NG
Check the harness wire between Repair
the injector driver and the
intermediate connector.
OK
NG
Check the following connector: Repair
C-17
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK

Use an analyzer to measure the NG NG

Check the following connector: Repair
signal waveform at engine-ECU A-64
connectors C-17 and C-19.
OK
 Engine: Idling
 Voltage between terminal 2 and NG
Check the harness wire between Repair
earth the No. 4 injector and the
OK: A normal waveform should intermediate connector.
be displayed as described
on P.13A-84* (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.
OK

NG
Check the following connector: Repair
A-64
OK
NG
Check the harness wire between Repair
No. 4 injector and the intermediate
connector.
OK
Replace the No. 4 injector.

NG
Check the trouble symptoms. Replace the injector driver.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-40 GDI – Troubleshooting

Code No. P0220 Accelerator pedal position sensor (1st Probable cause
channel) system
Range of Check  Malfunction of accelerator pedal position sensor
 Accelerator pedal position sensor (2nd channel) is normal. (1st channel)
 Communication between the engine-ECU and the throttle valve controller is  Open or short circuit in the accelerator pedal
normal. position sensor (1st channel) circuit or loose
Set Conditions connector contact
 The output voltage of accelerator pedal position sensor (1st channel) is 0.2  Accelerator pedal position switch seized ON
V or less for one second.  Malfunction of throttle valve controller
or  Malfunction of engine-ECU
 The output voltage of accelerator pedal position sensor (2nd channel) is 2.5
V or less, and that of accelerator pedal position sensor (1st channel) is 4.5
V or more for one second
or
 The difference between accelerator pedal position sensor (1st channel) and
accelerator pedal position sensor (2nd channel) output voltages is 1.0 V or
more (i.e. the throttle opening angle changes slightly).
or
 The output voltage of accelerator pedal position sensor (1st channel) is
1.875 V or more for one second when the accelerator pedal position switch
is turned on.
 GDI – Troubleshooting 13A-41
MUT-II Data list NG Check the accelerator pedal position
26 Accelerator pedal position switch switch system. (Refer to P.13A-90,
(Refer to P.13A-94, DATA LIST Inspection Procedure 28.)
REFERENCE TABLE.)
OK OK
MUT-II Data list Transient malfunction
78 Accelerator pedal position sensor (Refer to GROUP 00 – Points to
(1st channel) (Refer to P.13A-94, Note for Intermittent Malfunctions.)
DATA LIST REFERENCE
TABLE.)
NG
NG
Check Accelerator pedal position Replace
sensor (1st channel) (Refer to
P.13A-104*.)
OK
NG
Check the following connector: Repair
C-46
OK
(1) NG NG
Measure at accelerator pedal Check the following connector: Repair
position sensor connector C-46. C-18
 Disconnect the connector and OK
measure at the harness side.
(1) Resistance between terminal 1 Check the harness wire between NG
Repair
and earth accelerator pedal position sensor
OK: 2 Ω or less (1st channel) and the engine-ECU.
(2) Voltage between terminal 2 and
earth OK
NG
(Ignition switch: ON) Check the trouble symptoms. Replace the engine-ECU.
OK: 4.8 – 5.2 V

(2) NG OK
Measure at engine-ECU connector Check the following connector:
C-18. C-18
 Measure the voltage at the NG
engine-ECU terminal. OK
Repair
 Ignition switch: ON
 Voltage between terminal 42 and Check the harness wire between
earth accelerator pedal position sensor
OK: 4.8 – 5.2 V (1st channel) and the engine-ECU,
NG and repair if necessary.
NG
OK Check the following connector: Repair
C-18
To the next page OK
NG
Check the harness wire between Repair
accelerator pedal position sensor
(1st channel) and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-42 GDI – Troubleshooting

From the previous page

OK
(1), (2) NG NG
Measure at accelerator pedal Check the following connector: Repair
position sensor connector C-46. C-18
 Connect connector terminals No. OK
1, No. 2 and No. 3 only by using
test harness (MB991658), and Check the harness wire between
measure at the pick-up harness. accelerator pedal position sensor
 Ignition switch: ON (1st channel) and the engine-ECU,
(1) Voltage between terminal 1 and and repair if necessary.
earth
OK: 0.5 V or less
(2) Voltage between terminal 2 and (3) NG
Adjust the accelerator pedal position
earth
sensor. (Refer to P.13A-104.)
OK: 4.8 – 5.2 V
(3) Voltage between terminal 3 and
earth NG
OK: Accelerator pedal fully re- Check the following connector: Repair
leased: 0.935 – 1.135 V C-19
Accelerator pedal fully de- OK
pressed: 4.1 V or higher
Check the harness wire between
OK accelerator pedal position sensor
(1st channel) and the engine-ECU,
and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. C-19
 Measure the voltage at the
OK
engine-ECU termina.
 Ignition switch: ON Check the harness wire between
 Voltage between terminal 94 and accelerator pedal position sensor
earth (1st channel) and the engine-ECU,
OK: Accelerator pedal fully re- and repair if necessary.
leased: 0.935 – 1.135 V
Accelerator pedal fully de- OK NG
pressed: 4.1 V or higher Check the following connector: Repair
C-19
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-43
Code No. 0225 Throttle position sensor (2nd channel) Probable cause
system
The throttle valve controller judges a malfunction, and then transmit the result  Malfunction of throttle position sensor (2nd
to the engine-ECU channel)
Range of Check  Open or short circuit in the throttle position
 Ignition switch: ON sensor (2nd channel) circuit or loose connector
 The throttle position sensor (1st channel) is normal. contact
Set Conditions  Malfunction of the throttle valve controller
 The sensor output voltage is 0.2 V or less for four seconds.  Malfunction of the engine-ECU
or
 The sensor output voltage is 4.85 V or more for four seconds, and the
output voltage of the throttle position sensor (1st channel) is 1.2 V or more.
or
 The throttle position sensor (1st channel) and throttle position sensor (2nd
channel) combination output voltage is outside 4 – 6 V.

OK
MUT-II Data list Intermittent malfunction
14 Throttle position sensor (2nd (Refer to GROUP 00 – Points to
channel) Note for Intermittent Malfunctions.)
OK: Refer to P.13A-94, DATA
LIST REFERENCE TABLE.
NG
NG
Check throttle position sensor (2nd Replace
channel). (Refer to P.13A-102*.)
OK
NG
Check the following connector: Repair
A-06
OK
(1) NG OK
Measure at throttle position sensor Measure at throttle valve controller Check the following connector:
connector A-06. connector C-48. C-48
 Disconnect the connector and  Measure the voltage at the
measure at the harness side. throttle valve controller connector OK NG
Repair
(1) The voltage between terminal 1 terminals.
and earth  Ignition switch: ON
(Ignition switch: ON)  The voltage between terminal 6 Check the harness wire between
OK: 4.8 – 5.2 V and earth the throttle position sensor and the
(2) Resistance between terminal 3 OK: 4.8 – 5.2 V throttle valve controller, and repair if
and earth necessary.
NG
OK: 2 Ω or less
NG
Check the following connector: Repair
C-48
OK
NG
Check the harness wire between Repair
the throttle position sensor and the
throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.

(2) NG NG
Check the following connector: Repair
C-48
OK OK
NG
Check the harness wire between Repair
To the next page
the throttle position sensor and the
throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-44 GDI – Troubleshooting

From the previous page

OK
(1), (2) NG NG
Measure at throttle position sensor Check the following connector: Repair
connector A-06. C-48
 Use test harness (MB991536) to
OK
connect the connector, and
measure at the pick-up harness. Check the harness wire between
 Ignition switch: ON throttle position sensor (2nd channel)
(1) The voltage between terminal 1 and the throttle valve controller.
and earth
OK: 4.8 – 5.2 V (3) NG
(2) The voltage between terminal 3 Adjust the throttle position sensor.
and earth (Refer to P.13A-92*.)
OK: 0.5 V or less
(3) The voltage between terminal 4 NG
and earth Check the following connector: Repair
OK: Accelerator pedal fully re- C-19
leased: 4.0 – 4.8 V OK
Accelerator pedal fully de-
pressed: 0.1 – 1.1 V Check the harness wire between
OK throttle position sensor (2nd
channel) and the engine-ECU, and
repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. C-19
 Measure the voltage at the
OK
engine-ECU terminal.
 Ignition switch: ON Check the harness wire between
 The voltage between terminal 78 throttle position sensor (2nd
and earth channel) and the engine-ECU, and
OK: Accelerator pedal fully re- repair if necessary.
leased: 4.0 – 4.8 V
Accelerator pedal fully de- OK NG
pressed: 0.1 – 1.1 V Check the following connector: Repair
C-19
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)

Code No. P0300 Ignition coil (power transistor) system Probable cause
Range of Check  Malfunction of the ignition coil
 Engine speed is approx. 50 – 4,000 r/min.  Malfunction of the ignition failure sensor
 Engine is not cranking.  Malfunction of spark plug
Set Conditions  Open or short circuit in the primary ignition
 The ignition failure sensor does not send a signal about a certain cylinder circuit or loose connector contact
for four seconds.  Malfunction of engine-ECU
 GDI – Troubleshooting 13A-45
(1) NG
MUT-II Actuator Test Check the following connectors: Repair
01 No. 1 injector Ignition coil connectors, which
02 No. 2 injector correspond to defective cylinders
03 No. 3 injector (A-09, A-10, A-11, A-12).
04 No. 4 injector
OK: The idling condition should OK
change. NG
Reference Check the harness wire between Repair
When the cylinder (defective the ignition coil connector for a
cylinder) where idling condition does defective cylinder and the
not change is detected after intermediate connector.
suspending the injector, go to (1) OK
and inspect the spark plug, the
ignition coil, the connector, and the Check the spark plug and the NG
harness of the defective cylinder. ignition coil for a defective cylinder. Replace
(When more than one cylinder are (Refer to GROUP 16 – Ignition
detected, inspect all of them.) System.)
When all the cylinders are OK, go OK
to (2).
NG
(2) Check the following connector: Repair
C-17
OK
NG
Check the harness wire between Repair
the engine-ECU.
OK

Use an analyzer to measure the signal waveform at engine-ECU connector C-17.

 Engine: Idling
 The voltage between the ignition coil primary signal terminal for a defective cylinder
and earth
OK: A normal waveform should be displayed as described on P.13A-84* (Inspec-
tion Procedure Using an Analyzer).
OK NG

Repair the ignition coil assembly for Replace the engine-ECU.

(1) a defective cylinder and the spark
Use an analyzer to measure the
plug.
signal waveform at the ignition
failure sensor connector A-90.
 Use test harness (MB991536) to
connect the connector, and
measure at the pick-up harness.
 Engine: Idling (3) NG
 The voltage between terminal 2 Check the following connector: Repair
and earth C-18
OK: A normal waveform should OK
be displayed as described NG
on P.13A-84* (INSPEC- Check the harness wires between Repair
TION PROCEDURE US- the ignition failure sensor and the
ING AN ANALYZER). engine-ECU, and between the
Reference ignition failure sensor and earth.
When a normal waveform is
displayed, compare it with that of OK
the ignition coil primary signal at the
engine-ECU terminal to determine Repair the ignition failure sensor.
the cylinder (defective cylinder) with
an abnormal waveform. NG
→When one or more cylinders are Check the trouble symptoms. Replace the engine-ECU.
abnormal, go to (1)
→When all of the cylinders are (4) OK
abnormal, go to (3) Check the trouble symptoms. Intermittent malfunction
→When a normal waveform is NG
(Refer to GROUP 00 – Points to
displayed, go to (4). Note for Intermittent Malfunctions.)
Check the spark plug and the
ignition coil for a defective cylinder.
(Refer to GROUP 16 – Ignition
System.)

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-46 GDI – Troubleshooting

Code No. P0301 No. 1 cylinder misfire detected Probable cause

Code No. P0302 No. 2 cylinder misfire detected
Code No. P0303 No. 3 cylinder misfire detected
Code No. P0304 No. 4 cylinder misfire detected
Range of Check  Malfunction of the ignition system
 The engine speed is 500 – 4,500 r/min.  Abnormal compression
 While the engine is running except deceleration and sudden acceleration.  Malfunction of injector
Set Conditions  Malfunction of engine-ECU
 The number of misfires exceeds a predetermined number per 200 engine
revolutions (Misfire has occurred in only one cylinder).
or
 The number of misfires exceeds a predetermined number per 100 engine
revolutions (Misfire has occurred in only one cylinder).

NG
Check the following connectors: Repair
A-09, A-10, A-11, A-12
OK
(1) NG NG
Measure at ignition coil connectors Check the following connectors: Repair
A-09, A-10, A-11, A-12. A-90, C-72, C-74
 Disconnect the connector and
OK
measure at the harness side.
(1) The voltage between terminal 1
Check the ignition failure sensor NG
and earth Replace
(Refer to GROUP 16 – Ignition
(Ignition switch: ON)
System.)
OK: System voltage
(2) The voltage between terminal 3 OK
and earth
(Engine: Cranking) Check the harness wire between the
OK: 0.5 – 4.0 V ignition coil and the ignition failure
(3) The resistance between terminal sensor, and between the ignition
2 and earth switch and the ignition failure sensor.
OK: 2 Ω or less
(2) NG Check the following connector: NG
C-17 Repair

OK

Check the harness wire between the NG

ignition coil and the engine-ECU. Repair
(3) NG OK
NG
Check the trouble symptoms. Replace the engine-ECU.
OK

Check the ignition coil (Refer to Check the harness wire between
GROUP 16 – Ignition System.) the ignition coil and the earth, and
repair if necessary.

NG
Check the spark plugs. Replace
OK
Check the compression pressure.
NG
(Refer to GROUP 11A – On-vehicle Repair
Service.)
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-47
Code No. P0325 Detonation sensor system Probable cause
Range of Check  Malfunction of the detonation sensor
 Engine: Two seconds after the engine has been started  Open or short circuit in the detonation sensor
Set Conditions circuit or loose connector contact
 Changes in sensor output voltage (detonation sensor peak voltage per 1/3  Malfunction of engine-ECU
crankshaft rotation) in 200 consecutive cycles are 0.08 V or less.

NG
Check the following connector: A-81 Repair
OK
NG
Measure at the detonation sensor connector A-81. Check the harness wire between the detonation sensor and
 Disconnect the connector and measure at the harness earth, and repair if necessary.
side.
 The resistance between terminal 2 and earth
OK: 2 Ω or less
OK
NG
Check the following connector: C-19 Repair
OK
NG
Check the harness wire between the detonation sensor and Repair
the engine-ECU.
OK
OK
Check the trouble symptoms. Intermittent malfunction
(Refer to GROUP 00 – Points to Note for Intermittent
NG Malfunctions.)
Replace the detonation sensor.

Check the trouble symptoms.

NG

Replace the engine-ECU.

Code No. P0335 Crank angle sensor system Probable cause

Range of Check  Malfunction of the crank angle sensor.
 Engine is cranking  Open or short circuit in the crank angle sensor
Set Conditions circuit or loose connector contact.
 Sensor output voltage does not change for 4 seconds (no pulse signal  Malfunction of engine-ECU
input).
13A-48 GDI – Troubleshooting

OK
MUT-II Data list Intermittent malfunction
22 Crank angle sensor (Refer to GROUP 00 – Points to
OK: Refer to P.13A-94, DATA Note for Intermittent Malfunctions.)
LIST REFERENCE TABLE.
NG
NG
Check the following connector: Repair
A-77
OK
(1) NG
Measure at the crank angle sensor Check the harness between the
connector A-77. crank angle sensor and earth, and
 Disconnect the connector and repair if necessary.
measure at the harness side.
(1) The resistance between terminal (2) NG OK
1 and earth Measure at engine-ECU connector Check the following connector:
OK: 2 Ω or less C-18. C-18
(2) The voltage between terminal 3  Measure the voltage at the NG
OK
and earth engine-ECU terminal. Repair
(Ignition switch: ON)  Disconnect the connector A-77
OK: 4.8 – 5.2 V  Ignition switch: ON
Check the harness wire between
(3) The voltage between terminal 2  The voltage between terminal 43 the crank angle sensor and the
and earth and earth. engine-ECU, and repair if necessary.
(Ignition switch: ON) OK: 4.8 – 5.2 V
OK: System voltage NG
NG
Check the following connector: Repair
C-18
OK
NG
Check the harness wire between Repair
the crank angle sensor and the
engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(3) NG NG
Check the following connector: Repair
A-36
OK OK

Check the harness wire between the

crank angle sensor and the engine
control relay, and repair if necessary.

NG NG
Use an analyzer to measure the Check the crank angle sensor vane. Replace
output waveform at the crank angle
OK
sensor connector A-77.
 Use the test harness
Replace the crank angle sensor.
(MB991658) to connect the
connector, and measure at the
pick-up harness side.
 Engine: Idling Check the trouble symptoms.
 The voltage between terminal 3 NG
and earth NG
OK: A normal waveform should Check the following connectors: Repair
be displayed as described A-36, C-18
on P.13A-84* (Inspection
Procedure Using an Ana- OK
lyzer). Its maximum value
should be 4.8 V or more, Check the harness wires between
and its minimum value the crank angle sensor and the
should be 0.6 V or less engine-ECU, crank angle sensor
with no noise in waveform. and the engine control relay, and
the crank angle sensor and earth.
Then, repair if necessary.
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-49
Code No. P0340 Camshaft position sensor system Probable cause
Range of Check  Malfunction of the camshaft position sensor
 After the engine was started  Open or short circuit in the camshaft position
Set Conditions sensor circuit or loose connector contact.
 The sensor output voltage does not change for 4 seconds (no pulse signal  Malfunction of engine-ECU
input).

Check the following connector: NG

A-66 Repair
OK
(1) NG NG
Measure at camshaft position Check the following connector: Repair
sensor connector A-66. A-36
 Disconnect the connector and OK
measure at the harness side.
(1) The voltage between terminal 3 Check the harness wire between
and earth the camshaft position sensor
(Ignition switch: ON) connector and the engine control
OK: System voltage relay, and repair if necessary.
(2) The voltage between terminal 2
and earth (2) NG
OK
(Ignition switch: ON) Measure at engine-ECU connector Check the following connector:
OK: 4.8 – 5.2 V C-18. C-18
(3) The resistance between terminal  Measure the voltage at the
OK NG
1 and earth engine-ECU terminal. Repair
OK: 2 Ω or less  Disconnect connector A-66.
 Ignition switch: ON Check the harness wire between the
 The voltage between terminal 50 camshaft position sensor connector
and earth and the engine-ECU, and repair if
OK: 4.8 – 5.2 V necessary.

NG
NG
Check the following connector: Repair
C-18
OK
NG
Check the harness wire between Repair
the intermediate connector and the
engine-ECU.
OK
OK NG
Check the trouble symptoms. Replace the engine-ECU.

(3) NG
Check the harness wire between the
camshaft position sensor connector
and earth, and repair if necessary.

NG NG
Use an analyzer to measure the Check the camshaft position sensing Replace
output waveform at camshaft cylinder.
position sensor connector A-66.
 Use test harness (MB991709) to OK
connect the connector, and Replace the camshaft position
measure at the pick-up harness. sensor.
 Engine: Idling
 The voltage between terminal 2
and earth
OK: A normal waveform should Check the trouble symptoms.
be displayed as described NG
on P.13A-84* (Inspection NG
Procedure Using an Ana- Check the following connectors: Repair
lyzer), its maximum value A-36, C-18
should be 4.8 V or more, OK
and its minimum value
should be 0.6 V or less Check the harness wires between the camshaft position sensor connector and the
with no noise in waveform. engine-ECU, the camshaft position sensor connector and the engine control relay, and
the camshaft position sensor connector and earth. Then, repair if necessary.
OK
OK Intermittent malfunction
Check the trouble symptoms. (Refer to GROUP 00 – Points to Note for Intermittent Malfunctions.)
NG
Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-50 GDI – Troubleshooting

Code No. P0403 EGR valve system Probable cause

Range of Check  Malfunction of the EGR valve
 Ignition switch: OFF to ON  Open or short circuit in the EGR valve circuit or
 EGR valve is in operation after the engine starting process is complete. loose connector contact
Set Conditions  Malfunction of engine-ECU
 Off–surge voltage is not generated from the motor coil while the EGR valve
control motor is running.

NG
Measure at EGR valve connector Replace
A-60.
 Disconnect the connector, and
measure at the EGR valve side.
 The resistance between terminals
1 and 2
 The resistance between terminals
2 and 3
 The resistance between terminals
4 and 5
 The resistance between terminals
5 and 6
OK: 10 – 20 Ω
OK
NG
Check the following connector: Repair
A-60
OK
NG NG
Measure at EGR valve connector Check the following connector: A-36 Repair
A-60.
OK
 Disconnect the connector and
measure at the harness side. Check the harness wire between the
 Ignition switch: ON EGR valve and the engine control
 The voltage between terminal 2 relay, and repair if necessary.
and earth
 The voltage between terminal 5
and earth
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connectors: Repair
C-17. A-82, C-17
 Measure the voltage at the
OK
engine-ECU terminal.
NG
 The voltage between terminal 5 Check the harness wire between the Repair
and earth. EGR valve and the engine-ECU.
 The voltage between terminal 6
and earth. OK
 The voltage between terminal 32
and earth. Replace the engine-ECU.
 The voltage between terminal 34
and earth.
OK: The voltage changes as follows
for three seconds when the
ignition switch is turned ON.
(When using a circuit tester)
5 V and 8 V alternates
(When using an analyzer)
1 V or less and system voltage
alternates
OK
NG
Check the following connectors: Repair
A-36, A-82, C-17
OK
NG
Check the harness wires between Repair
the EGR valve and the engine
control relay, and between the EGR
valve and the engine-ECU.
OK
OK Intermittent malfunction
Check the trouble symptoms.
(Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)

Replace the engine-ECU.

 GDI – Troubleshooting 13A-51
Code No. P0420 Catalyst malfunction Probable cause
Range of Check  Malfunction of catalyst
 The engine speed is 3,000 r/min or less.  Malfunction of the oxygen sensor (front)
 During driving  Malfunction of the oxygen sensor (rear)
 During air/fuel ratio feedback control  Malfunction of engine-ECU
Set Conditions
 The ratio between the oxygen sensor (rear) and the oxygen sensor (front)
output frequencies reaches 0.8 per 12 seconds on average.

NG
Check the exhaust manifold. (Are there any cracks?) Repair
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system <sensor 2>
59 Oxygen sensor (rear) (Refer to P.13A-28, INSPECTION PROCEDURE FOR
 Transmission: 2nd gear DIAGNOSTIC TROUBLE CODE P0136.)
 Drive with wide open throttle
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system <sensor 1>
11 Oxygen sensor (front) (Refer to P.13A-25, INSPECTION PROCEDURE FOR
OK: 600 – 1,000 mV when racing suddenly DIAGNOSTIC TROUBLE CODE P0130.)
OK
NG
MUT-II Data list Replace the oxygen sensor (front).
11 Oxygen sensor (front)
 Transmission: 2nd gear
OK: Changeover between 0 – 400 mV and 600 – 1,000
mV occur 15 times in 10 seconds.
OK

Replace the oxygen sensor (rear).

Check the trouble symptoms.

NG

Replace the catalytic converter.

Check the trouble symptoms.

NG

Replace the engine-ECU.

13A-52 GDI – Troubleshooting

Code No. P0443 Purge control solenoid valve system Probable cause
Range of Check  Malfunction of the purge control solenoid valve
 Ignition switch: ON  Open or short circuit in the purge control solenoid
 Battery voltage is 10 V or more. valve circuit or loose connector contact
Set Conditions  Malfunction of engine-ECU
 The solenoid coil surge voltage (battery voltage + 2 V) is not detected
when the purge control solenoid valve is turned from on to off.

OK
MUT-II Actuator Test Intermittent malfunction
08 Purge control solenoid valve (Refer to GROUP 00 – Points to
OK: Operating sound can be Note for Intermittent Malfunctions.)
heard and the valve vibrates.
NG
NG
Measure at the purge control Replace
solenoid valve connector A-02.
 Disconnect the connector, and
measure at the solenoid valve
side.
 The resistance between
terminals 1 and 2
OK: 28 – 36 Ω (at 20C)
OK
NG
Check the following connector: Repair
A-02
OK
NG
Measure at the purge control Check the following connector: NG
Repair
solenoid valve connector A-02. A-36
 Disconnect the connector and
measure at the harness side. NG
 Ignition switch: ON Check the harness wire between
 The voltage between terminal 2 the purge control solenoid valve and
and earth the engine control relay, and repair
OK: System voltage if necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-17. C-17
 Measure the voltage at the
engine-ECU terminal. OK
 Ignition switch: ON Check the harness wire between NG
 The voltage between terminal 16 the purge control solenoid valve and Repair
and earth the engine-ECU.
OK: System voltage
OK
OK
Replace the engine-ECU.
NG
Check the following connectors: Repair
A-36, C-17
OK
NG
Check the harness wires between Repair
the purge control solenoid valve and
the engine control relay, and
between the purge control solenoid
valve and the engine-ECU.
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-53
Code No. P0500 Vehicle speed sensor system Probable cause
Range of Check  Malfunction of the vehicle speed sensor
 Engine: Two seconds after the engine was started  Open or short circuit in the vehicle speed sensor
 Idle switch: OFF circuit or loose connector contact
 Engine speed: 2,500 r/min or more  Malfunction of engine-ECU
 During high engine load
Set Conditions
 The sensor output voltage does not change for 4 seconds (no pulse signal
input).

NO
Does the speedometer operate normally? Check the vehicle speed sensor
(Refer to GROUP 54 – Combination Meter.)
YES

NG
Use an analyzer to measure the output waveform of the Check the following connectors:
vehicle speed sensor at engine-ECU connector C-19. B-08, C-19, C-28, C-38 <LHD>, C-41 <RHD>, D-02
 Driving the vehicle OK NG
 The voltage between terminal 80 and earth
OK: A normal waveform should be displayed as de- Repair
scribed in OSCILLOSCOPE INSPECTION PROCE- Check the harness wire between vehicle speed sensor and
DURE, and noise should not be displayed in the the engine-ECU, and repair if necessary.
waveform. (Refer to GROUP 23 – Troubleshooting.)
OK
NG
Check the following connector: C-19 Repair
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

Code No. P1200 Injector driver system Probable cause

Range of Check  Malfunction of the injector driver
 Engine speed: 4,000 r/mimn or less  Open or short circuit, or loose connector contact
 Battery voltage: 10 V or more  Malfunction of engine-ECU
 The fuel cut operation and the injector operation (by carrying out the
Actuator test) are not in progress.
 During high engine load
Set Conditions
 Injector open circuit check signal is not output from the injector driver.

NG
Check the following connector: C-19 Repair
OK
NG
Check the harness wire between the injector driver and the Repair
engine-ECU
OK
NG
Use an analyzer to measure the signal waveform at Replace the injector driver.
engine-ECU connectors C-17, C-19.
 Engine: Idling
 The voltage between terminal 96 and earth, terminal 1
and earth
OK: A normal waveform should be displayed as de-
scribed on P.13A-84* (INSPECTION PROCEDURE
USING AN ANALYZER).
OK

OK
Check the trouble symptoms. Intermittent malfunction
(Refer to GROUP 00 – Points to Note for Intermittent
NG
Malfunctions.)
Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-54 GDI – Troubleshooting

Code No. P1220 Electronic-controlled throttle valve Probable cause

system
Range of Check  Short in communication line
 Ignition switch: ON  Malfunction of the engine-ECU
 Error in communication between the engine-ECU and the throttle valve  Malfunction of the throttle valve controller
controller
Set Conditions
 Output voltage of throttle position sensor (2nd channel) fluctuates
significantly (approx. 1 V or more) from an expected value, based on that
of the accelerator pedal position sensor (2nd channel).
Range of Check
 Ignition switch: ON
 Error in communication between the throttle valve controller and the
engine-ECU
Set Conditions
 The output voltage of the throttle position sensor (2nd channel) is
significantly different (approx. 1 V) from the throttle valve opening angle
(voltage), which the engine-ECU request the throttle valve controller.

Check the following connectors: NG

C-19, C-48 Repair

OK
NG
Check the harness wire between the throttle valve controller Repair
and the engine-ECU.
OK

Check the trouble symptoms.

NG

Replace the throttle valve controller.

Check the trouble symptoms.

NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-55
Code No. P1221 Throttle valve position feedback system Probable cause
The throttle valve controller judges a malfunction, and then transmit the result  Malfunction of throttle position sensor (1st
to the engine-ECU. channel)
Range of Check  Open or short circuit in the throttle position
 Ignition switch: ON sensor (1st channel) circuit or loose connector
 Battery voltage: 10 V or more contact
Set Conditions  Malfunction of the throttle valve controller
 Failure in the motor position feedback
(The engine-ECU detects that the current in the motor is excessive and the
opening angle difference between the target value of throttle position sensor
(1st channel) and the actual value of throttle position sensor (1st channel)
is 1.0 V or more)

YES
MUT-II Self-Diag Code Refer to Code No. P0120, Throttle position sensor (1st
Is code No. P0120 set? channel) system (Refer to P.13A-22.)
NO
YES
MUT-II Self-Diag Code Refer to Code No. P1224, Throttle valve control servo motor
Is Code No. P1224 set? (motor 1st phase malfunction) system (Refer to P.13A-57.)
NO
YES
MUT-II Self-Diag Code Refer to Code No. P1228, Throttle valve control servo motor
Is Code No. P1228 set? (motor 2nd phase malfunction) system (Refer to P.13A-60.)
NO

Adjust the throttle position sensor. (Refer to P.13A-92*.)

OK
NG
Check the throttle valve control servo. (Refer to P.13A-107*.) Replace the throttle body assembly.
OK
NG
Check the following connectors: A-05, A-06, C-48 Repair
NG
NG
Check the harness wires between the throttle position sensor Repair
and the throttle valve controller, and between the throttle
valve control servo and the throttle valve controller.
OK

Check the trouble symptoms.

NG

Replace the throttle valve controller.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-56 GDI – Troubleshooting

Code No. P1223 Communication line system with the Probable cause
throttle valve controller
Range of Check  Short in communication line
 Ignition switch: ON  Malfunction of engine-ECU
 Battery voltage: 8 V or more.  Malfunction of throttle valve controller
 Engine: Not cranking
Set Conditions
 System detects an error in communication line between the engine-ECU
and the throttle valve controller, and between the throttle valve controller
and the engine-ECU.

YES
MUT-II Self-Diag Code Refer to Code No. P1220,
Is Code No. P1220 output? Electronic-controlled throttle valve system
(Refer to P13A-54.)
NO
NG
Check the following connector: Repair
C-48
OK
(1) NG NG
Measure at throttle valve controller Check the following connector: Repair
connector C-48. A-36
 Measure voltage at the throttle
OK
valve controller connector
terminals. Check the harness wire between the
 Ignition switch: ON throttle valve controller and the engine
(1) The voltage between terminal 5 control relay, and repair if necessary.
and earth
OK: System voltage (2) NG
(2) The voltage between terminal 3 Check the following connector: NG
and earth A-36 Repair
The voltage between terminal 4
and earth OK
The voltage between terminal 16
and earth Check the harness wire between the
OK: 0.5 V or less throttle valve controller and earth, and
repair if necessary.
OK

NG
Check the following connector: Repair
C-19
OK
NG
Check the harness wire between Repair
the throttle valve controller and the
engine-ECU.
OK

Check the trouble symptoms.

NG

Replace the throttle valve controller.

Check the trouble symptoms.

NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-57
Code No. P1224 Throttle valve control servo motor Probable cause
(Motor 1st phase malfunction) system
Range of Check  Malfunction of the throttle valve control servo
 Throttle valve control servo relay: ON  Open circuit or short-circuited harness wire in
 System voltage: 8 V or more. throttle valve control servo system, or poor
Set Conditions connector contact
 Throttle valve control servo drive circuit is shorted to earth.  Malfunction of the throttle valve controller
 Other power source interferences with throttle valve control servo drive
circuit.
 Throttle valve control servo drive circuit is open circuit.

NG
Check the throttle valve control Replace the throttle body assembly.
servo (Refer to P.13A-107*.)
OK
NG
Check the following connector: Repair
C-48
OK
NG
Measure at throttle valve controller NG
Check the following connector: A-05 Repair
connector C-48.
 Measure voltage at the throttle OK
valve controller connector NG
terminals. Check the harness wire between the Repair
 Ignition switch: ON throttle valve control servo and the
 The voltage between terminal 1, throttle valve controller.
9 and earth OK
(Accelerator pedal: Fully open to
fully closed)
OK: The battery voltage tempo- Check the trouble symptoms
rarily shows a slight de- NG
crease.
 The voltage between terminal Replace the throttle valve controller.
14, 15 and earth
(Accelerator pedal: Fully closed
to fully open)
OK: The battery voltage show a
slight (approximately 2 V)
decrease.
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-58 GDI – Troubleshooting

Code No. P1225 Accelerator pedal position sensor (2nd Probable cause
channel) system
Range of Check  Malfunction of accelerator pedal position sensor
 Accelerator pedal position sensor (2nd channel) is normal. (2nd channel)
 Communication between the engine-ECU and the throttle valve controller is  Open or short circuit in accelerator pedal position
normal. sensor (2nd channel) circuit or loose connector
Set Conditions contact
 Output voltage of the accelerator pedal position sensor (2nd channel) is 0.2  Malfunction of the throttle valve controller
V or less for one second  Malfunction of engine-ECU
or
 Output voltage of the accelerator pedal position sensor (1st channel) is 2.5
V or less, and output voltage of the accelerator pedal position sensor (2nd
channel) is 4.5 V or more for one second.
or
 Difference between the accelerator pedal position sensor (1st and 2nd
channels) output voltages exceeds 1.0 V (i.e. when the throttle valve
opening angle changes slightly).

OK
MUT-II Data list Intermittent malfunction
77 Accelerator pedal position sensor (Refer to GROUP 00 – Points to
(2nd channel) (Refer to Note for Intermittent Malfunctions.)
P.13A-94, DATA LIST
REFERENCE TABLE.)
NG
NG
Check the accelerator pedal position Replace
sensor (Refer to P.13A-104*.)
OK
NG
Check the following connector: Repair
B-94
OK
(1) NG NG
Measure at accelerator pedal Check the following connector: Repair
position sensor connector C-46. C-48
 Disconnect the connector and
measure at the harness side. OK
NG
(1) The resistance between terminal Check the harness wire between Repair
7 and earth accelerator pedal position sensor
OK: 2 Ω or less (2nd channel) and the throttle valve
(2) The voltage between terminal 8 controller.
and earth
(Ignition switch: ON) OK
OK: 4.8 – 5.2 V NG
Check the trouble symptoms. Replace the throttle valve controller.
(2) NG OK
Measure at throttle valve controller Check the following connector:
connector C-48. C-48
 Measure voltage at the throttle
OK NG
valve controller connector Repair
terminals.
 Ignition switch: ON
Check the harness wire between
 The voltage between terminal 6
accelerator pedal position sensor
and earth
(2nd channel) and the throttle valve
OK: 4.8 – 5.2 V
controller, and repair if necessary.
NG
NG
Check the following connector: Repair
C-48
OK
OK
NG
To the next page Check the harness wire between Repair
accelerator pedal position sensor
(2nd channel) and the throttle valve
controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-59
From the previous page
OK
(1) NG
Measure at accelerator pedal Adjust the accelerator pedal position
position sensor connector C-46. sensor (Refer to P.13A-94*).
 Use test harness (MB991658) to
connect terminals No. 6, No. 7,
No. 8 only, and measure at the NG
Check the following connector: C-48 Repair
pick-up harness side.
 Ignition switch: ON OK
(1) The voltage between terminal 6
and earth Check the harness wire between
OK: Accelerator pedal fully re- accelerator pedal position sensor (2nd
leased: 0.7 – 1.4 V channel) and the throttle valve controller,
Accelerator pedal fully de- and repair if necessary.
pressed: 4.1 V or higher (2), (3) NG NG
(2) The voltage between terminal 7 Check the following connector: C-48 Repair
and earth
OK
OK: 0.5 V or more
(3) The voltage between terminal 8
and earth Check the harness wire between
OK: 4.8 – 5.2 V accelerator pedal position sensor (2nd
channel) and the throttle valve controller,
and repair if necessary.
OK
NG NG
Measure at throttle valve controller Check the following connector: C-48 Repair
connector C-48. OK
 Measure voltage at the throttle
valve controller connector Check the harness wire between
terminals. accelerator pedal position sensor (2nd
 Ignition switch: ON channel) and the throttle valve controller,
 The resistance between 20 and and repair if necessary.
earth
OK: Accelerator pedal fully re-
OK NG
leased: 0.7 – 1.4 V Check the following connector: C-48 Repair
Accelerator pedal fully de-
pressed: 4.1 V or higher OK

Check the trouble symptoms.

NG

Replace the throttle valve controller.

13A-60 GDI – Troubleshooting

Code No. P1228 Throttle valve control servo motor Probable cause
(Motor 2nd phase malfunction) system
Range of Check  Malfunction of the throttle valve control servo
 Throttle valve control servo relay: ON  Open circuit or short-circuited harness wire in
 System voltage: 8 V or more throttle valve control servo system, or poor
Set Conditions connector contact
 Throttle valve control servo drive circuit is shorted to earth.  Malfunction of the throttle valve controller
 Other power source interferes with throttle valve control servo drive circuit.
 Throttle valve control servo drive circuit is open-circuit.

NG
Check the throttle valve control Replace the throttle body assembly.
servo (Refer to P.13A-107*).
OK
NG
Check the following connector: Repair
C-48
OK
NG NG
Measure at throttle valve controller Check the following connector: A-05 Repair
connector C-48.
 Measure voltage at the throttle OK
valve controller connector NG
Check the harness wire between the Repair
terminals.
 Ignition switch: ON throttle valve control servo and the
 The voltage between terminal 1, throttle valve controller.
9 and earth OK
(Accelerator pedal: Fully open to
fully closed) Check the trouble symptoms.
OK: The battery voltage tempo-
rarily shows a slight de- NG
crease.
 The voltage between terminal Replace the throttle valve controller.
14, 15 and earth
(Accelerator pedal: Fully closed
to fully open)
OK: The battery voltage show a
slight (approximately 2 V)
decrease.
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-61
Code No. P1500 Alternator FR terminal system Probable cause
Range of Check  Open circuit in alternator FR terminal circuit
 Engine speed: 50 r/min or more  Malfunction of engine-ECU
Set Conditions
 Input voltage from the alternator FR terminal is system voltage for 20
seconds.

NG
Check the following connector: Repair
A-86
OK
NG NG
Measure at intermediate connector Measure at engine-ECU connector Check the following connector:
A-86. C-18. C-18
 Use test harness (MB991658) to  Measure the voltage at the
connect the connector, and engine-ECU terminal. OK NG
Repair
measure at the pick-up harness.  Ignition switch: ON
 Ignition switch: ON  The voltage between terminal 52 Check the harness wire between
 The voltage between terminal 6 and earth the intermediate connector and the
and earth OK: 9 – 10 V engine-ECU, and repair if necessary.
OK: 9 – 10 V
NG

NG
Check the following connector: Repair
C-18
OK
NG
Check the harness wire between Repair
OK the intermediate connector and the
engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

NG NG
Measure at intermediate connector Check the following connector: Repair
A-86. A-79
 Use test harness (MB991658) to OK
connect the connector, and
measure at the pick-up harness. Check the harness wire between NG
 Engine: Idling (After warming up) the alternator and the intermediate Repair
 Radiator fan: Not operating connector.
 The voltage between terminal 2 OK
and earth
OK: The voltage drops when Check the following connector: NG
the headlamps are turned C-18 Replace
on. OK

Check the harness wire between NG

the intermediate connector and the Repair
engine-ECU.
OK

Check the trouble symptoms.

NG

Replace the alternator.

OK

OK
Check the trouble symptoms. Intermittent malfunction
(Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)
Replace the engine-ECU.
13A-62 GDI – Troubleshooting

Code No. P1515 Brake vacuum sensor system Probable cause

Range of Check  Malfunction of the brake vacuum sensor
 Ignition switch: ON  Improper connector contact, open circuit or
Set Conditions short-circuited harness wire of the brake vacuum
 Sensor output voltage is 4.8 V or more. sensor
or  Malfunction of the engine-ECU
 Sensor output voltage is 0.2 V or less.

OK
MUT-II Data list Intermittent malfunction (Refer to
66 Brake vacuum sensor GROUP 00 – Points to Note for
OK: (Refer to P.13A-94, DATA intermittent Malfunctions.)
LIST REFERENCE TABLE.)
NG
NG
Check the following connector: Repair
A-70
OK
(1) NG NG
Measure at brake vacuum sensor Measure at engine-ECU connector Check the following connector:
connector A-56 C-18. C-18
 Disconnect the connector and  Measure the voltage at the
measure at the harness side. OK NG
engine-ECU terminals.
(1) The voltage between terminal 3  Ignition switch: ON Repair
and earth  The voltage between terminal 41 Check the harness wire between
(Ignition switch: ON) and earth the brake vacuum sensor and the
OK: 4.8 – 5.2 V OK: 4.8 – 5.2 V engine-ECU, and repair if necessary.
(2) Continuity between terminal 2
and earth OK
OK: 2Ω or less
NG
Check the following connector: Repair
C-18
OK
NG
Check the harness wire between Repair
the brake vacuum sensor and the
engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG NG
Check the following connectors: Repair
A-36, C-19
OK
OK NG
Check the harness wire between Repair
To the next page. the brake vacuum sensor and the
engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
 GDI – Troubleshooting 13A-63
From the previous page
OK
(1) NG NG
Measure at brake vacuum sensor Check the following connector: Repair
connector A-56. C-18
 Use test harness (MB991348) to
connect terminals, and measure at OK
the pick-up harness side.
 Engine: Idling Check the harness wire between
(1) The voltage between 3 and earth the brake vacuum sensor and the
OK: 4.8 – 5.2 V engine-ECU, and repair if necessary.
(2) The voltage between 1 and earth (2) NG
OK: 0.9 – 1.5 V Replace the brake vacuum sensor.
(3) The continuity between 2 and
earth
OK: 2 Ω or less
Check the trouble symptoms.
NG
Check the following connector: NG
Repair
C-19
OK
Check the harness wire between
the brake vacuum sensor and the
engine-ECU, and repair if necessary.
(3) NG
Check the following connectors: NG
A-36, C-19 Repair
OK
OK
Check the harness wire between
the brake vacuum sensor and the
engine-ECU, and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-19. C-19
 Measure the voltage at the
OK
engine-ECU terminal.
 Engine: Idling Check the harness wire between
 The voltage between 74 and the brake vacuum sensor and the
earth engine-ECU, and repair if necessary.
OK: 0.9 – 1.5 V
OK

Check the following connectors:

A-36, C-18, C-19
OK
Check the trouble symptom.
NG

Replace the engine-ECU.

13A-64 GDI – Troubleshooting

Cord No. P1600 Communication wire with A/T-ECU Probable cause

system
Range of Check  Short circuit in ECU communication circuit
 After 60 seconds have passed since the engine have started  Malfunction of the engine-ECU
Set Conditions  Malfunction of the A/T-ECU
 Torque reduction request signal from A/T-ECU is input continuously for 1.5
seconds or more.

Check the following connectors: NG

C-19, C-25<LHD>, C-26<RHD>, D-34, D-45 Repair

OK
Check trouble symptom.
NG
OK
Check the harness wire between the engine-ECU and the A/T-ECU. Replace the engine-ECU.
NG

Replace Check trouble symptom.

NG

Replace the A/T-ECU.

Cord No. P1610 Immobilizer system Probable cause

Range of Check  Open or short circuit, or loose connector contact
 Ignition switch: ON  Malfunction of the immobilizer-ECU
Set Conditions  Malfunction of the engine-ECU
 Improper communication between the engine-ECU and the immobilizer-ECU

NOTE
(1) If the registered ignition keys are close each other when starting the engine, radio interference may
cause this code to be displayed.
(2) This code may be displayed when registering the key ID code.
NG
Check the following connectors: Repair
1, C-19, C-29, C-62
OK
NG
Check the harness wire between Replace
the immobilizer-ECU and the
engine-ECU.
OK

Check the trouble symptoms.

NG

Replace the immobilizer-ECU.

Check the trouble symptoms.

NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-65
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptom Inspection Reference page
procedure
No.

Communication Communication with all systems is not possible. 1 13A-66

with MUT-II is
impossible. Communication with engine-ECU only is not possible. 2 13A-66

Engine warning The engine warning lamp does not illuminate right after the 3 13A-67
lamp and ignition switch is turned to the ON position.
related parts
The engine warning lamp remains illuminating and never goes 4 13A-67
out.

Starting No initial combustion (starting impossible) 5 13A-78

Initial combustion but no complete combustion 6 13A-70

(starting impossible)

Long time to start (improper starting)

Idling stability Unstable idling (Rough idling, hunting) 7 13A-71

(Improper idling)
Idling speed is high. (Improper idling speed) 8 13A-73

Idling speed is low. (Improper idling speed)

Idling stability When the engine is cold, it stalls at idling. (Die out) 9 13A-74
(Engine stalls)
When the engine is hot, it stalls at idling. (Die out) 10 13A-75

The engine stalls when starting the car. (Pass out) 11 13A-77

The engine stalls when decelerating. 12 13A-78

Driving Hesitation, sag or stumble 13 13A-79

Poor acceleration

Surge

The feeling of impact or vibration when accelerating 14 13A-80

The feeling of impact or vibration when decelerating 15 13A-81

Knocking 16 13A-81

Dieseling 17 13A-81

Too high CO and HC concentration when idling 18 13A-82

Low alternator output voltage (approx. 12.3 V) 19 13A-83

Fans (radiator fan, A/C condenser fan) are inoperative 20 13A-84

GDI ECO indi- GDI ECO indicator lamp does not illuminate. 21 13A-85
cator lamp sys-
tem GDI ECO indicator lamp remains illuminated and does not go off. 22 13A-85
13A-66 GDI – Troubleshooting

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1
Communication with MUT-II is not possible. Probable cause
(Communication with all systems is not possible.)
The cause is probably a defect in the power supply system (including earth) for  Malfunction of the connector
the diagnosis line.  Malfunction of the harness wire
 Malfunction of MUT-II

NG NG
Measure at the diagnostic connector Check the following connectors: Repair
(16-pin) B-35. C-76, C-77
 Voltage between 16 and earth OK
OK: System voltage
NG
OK Check trouble symptom. Check the harness wire between the
power supply and diagnostic connector
(16-pin), and repair if necessary.
NG
Measure at the diagnostic connector Check the following connector: NG
C-01 Repair
(16-pin) C-35.
 Continuity between 4 and earth
 Continuity between 5 and earth OK
OK: Continuity
Check trouble symptom.
OK
NG
Replace the MUT-II.
Check the harness wire between the
diagnostic connector (16-pin) and
earth, and repair if necessary.

INSPECTION PROCEDURE 2
MUT-II communication with engine-ECU (engine- Probable cause
A/T-ECU) is impossible.
One of the following causes may be suspected.  Malfunction of engine-ECU power supply circuit
 No power supply to engine-ECU  Malfunction of engine-ECU
 Defective earth circuit of engine-ECU  Open circuit between the engine-ECU and diagnosis
 Defective engine-ECU connector
 Improper communication line between engine-ECU and MUT-II

NG
Check the following connectors: Repair
C-19, C-28, C-35, C-53, C-70
OK

Check trouble symptom.

NG
NG
Check the harness wire between engine-ECU and diagnosis con- Repair
nector.
OK

Check the engine-ECU power supply and earth circuit system.

(Refer to P.13A-86, INSPECTION PROCEDURE 23.)

NOTE
On vehicles with multi center display, if a malfunction cannot be resolved after the procedure above, check the multi
center display and replace if necessary. (Refer to GROUP 54 – Multi Center display.)
 GDI – Troubleshooting 13A-67
INSPECTION PROCEDURE 3
The engine warning lamp does not illuminate right after Probable cause
the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-ECU <M/T> or engine-A/T-ECU <A/T>  Burnt-out bulb
causes the engine warning lamp to illuminate for five seconds immediately after  Defective warning lamp circuit
the ignition switch is turned to ON. If the engine warning lamp does not illuminate  Malfunction of the engine-ECU <M/T>
immediately after the ignition switch is turned to ON, one of the malfunctions listed  Malfunction of the engine-A/T-ECU <A/T>
at right has probably occurred.

NG
MUT-II Data list Check the engine-ECU (engine-A/T-ECU) power supply and earth
16 engine-ECU (engine-A/T-ECU) power supply voltage (Refer circuit system.
to P.13A-94.) (Refer to P.13A-86, INSPECTION PROCEDURE 23.)
OK
OK NG
Measure at the engine-ECU connector C-17. Check the following Repair
 Disconnect the connector, and measure at the harness side. connector: C-17
 Earth the terminal No. 31. OK
OK: The engine warning lamp illuminates.
NG
Check trouble symptom.
NG NG
Check a burnt-out bulb. Replace
Replace the engine-ECU
OK

NG
Measure at the combination meter connector C-06. Check the engine warning lamp power supply circuit, and repair
 Disconnect the connector, and measure at the harness side. if necessary.
 Voltage between 1 and earth (Ignition switch: ON)
OK: System voltage
OK
NG
Check the following connectors: Repair
C-07, C-17, C-28
OK
NG
Check trouble symptom. Check the harness wire between combination meter and engine-
ECU, and repair if necessary.

INSPECTION PROCEDURE 4
The engine warning lamp remains illuminating and never Probable cause
goes out.
In cases such as the above, the cause is probably that the engine-ECU is detecting  Short-circuit between the engine warning lamp and
a problem in a sensor or actuator, or that one of the malfunctions listed at right engine-ECU
has occurred.  Malfunction of the engine-ECU

Yes
MUT-II Self-Diag code Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Measure at the combination meter connector C-07. Check the harness wire between combination meter and engine-
 Disconnect the connector, and measure at the harness side. ECU connector, and repair if necessary.
 Disconnect the engine-ECU connector
 Continuity between 46 and earth
OK: No continuity

OK

Replace the engine-ECU

13A-68 GDI – Troubleshooting

INSPECTION PROCEDURE 5
No initial combustion (starting impossible) Probable cause
This is caused by incorrect fuel supply into the combustion chamber, and improper  Malfunction of the fuel supply system
ignition circuit. Besides that, foreign material may be contaminated in fuel.  Malfunction of the ignition system
 Malfunction of the engine-ECU

NG
Check system voltage while the engine is cranking. Check the battery. (Refer to GROUP 55 – Battery.)
OK: 8 V or more
OK
Yes
MUT-II Self-Diag code Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the engine control relay and ignition switch-IG system.
16 System voltage (Refer to P.13A-94.) (Refer to P.13A-87, INSPECTION PROCEDURE 24.)
OK
No
Does the camshaft rotate when the engine is cranking? Check if the timing belt is broken or damaged.
Yes
NG
MUT-II Actuator test Check the fuel pump (low pressure) system.
07 Fuel pump (low pressure) (Refer to P.13A-100.) (Refer to P.13A-91, INSPECTION PROCEDURE 29.)
OK
NG
MUT-II Data list Check the crank angle sensor system. (Refer to P.13A-47, IN-
22 Crank angle sensor (Refer to P.13A-94.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0335.)
OK NG
Check the engine coolant temperature sensor system.
MUT-II Data list (Refer to P.13A-19, INSPECTION PROCEDURE FOR DIAGNO-
21 Engine coolant temperature sensor (Refer to P.13A-94.) SIS CODE P0115.)
OK
NG
MUT-II Data list Check the throttle position sensor (1st channel) system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-22, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P0120.)
OK
Inspect engine start ability by cranking the engine while the Clean around the throttle valve. (Refer to P.13A-92*.)
accelerator pedal is slightly depressed.
NG
NG
Measure at injector driver connector A-55. Check the injector driver system.
 Disconnect the connector, and measure at the connector side. (Refer to P.13A-88, INSPECTION PROCEDURE 25.)
 Voltage between each of terminals 12, 21 and earth
(Ignition switch: ON)
OK: System voltage
OK
NG
Check fuel leakage. (Refer to P.13A-99*.) Repair
OK
NG
Measure low fuel pressure between the fuel pump (low pressure) Repair
and fuel pump (high pressure). (Refer to P.13A-108.)
OK
NG
Measure at ignition coil connectors A-09, A-10, A-11, A-12. Check the ignition coil (incorporating power transitor) system.
 Connect the connector. (Refer to P.13A-44, INSPECTION PROCEDURE FOR DIAGNO-
 Connect a timing light to the No. 1 terminal of each connector SIS CODE P0300.)
in turn.
(Engine cranking)
OK: The timing light flashes.
OK
NG
Check ignition timing while the engine is cranking. Check that the crank angle sensor and timing belt cover are proper-
OK: Approx. 5 BTDC ly installed.
OK

To the next page

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-69
From the previous page
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

 Spark plug
 Compression pressure
 Foreign material (such as water or kerosine) entered the fuel
lines
OK
NG
Check trouble symptom. Replace the injector.
13A-70 GDI – Troubleshooting

INSPECTION PROCEDURE 6
Initial combustion takes place, but does not complete Probable cause
(start impossible), too long time to start (poor start)
This may be caused by improper spark plug ignition (poor spark), improper mixture  Malfunction of the fuel supply system
during engine cranking, improper fuel pressure.  Malfunction of the fuel pressure sensor
 Malfunction of the ignition system
 Malfunction of the electronic-controlled throttle valve
system
 Malfunction of the engine-ECU <M/T>
 Malfunction of the engine-A/T-ECU <A/T>

NG
Check system voltage while the engine is cranking. Check the battery. (Refer to GROUP 55 – Battery.)
OK: 8 V or more
OK
Yes
MUT-II Self-Diag code Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Actuator test Check the fuel pump (low pressure) system.
07 Fuel pump (low pressure) (Refer to P.13A-100.) (Refer to P.13A-91, INSPECTION PROCEDURE 29.)
OK
NG
MUT-II Data list Check the engine coolant temperature system. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115.)
OK
NG Check the ignition switch-ST system. <M/T>
MUT-II Data list (Refer to P.13A-89, INSPECTION PROCEDURE 26.)
18 Cranking signal (Refer to P.13A-94.) Check the ignition switch-ST system and inhibitor switch sytem.
<A/T> (Refer to P.13A-89, INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check an abnormal fuel pressure system. (Refer to P.13A-33,
74 Fuel pressure sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0190.)
OK
NG
Check fuel leakage. (Refer to P.13A-99*.) Repair
OK
Yes
Is the engine started normally when it is cranked with the accelera- Clean around the throttle valve. (Refer to P.13A-92*.)
tor pedal depressed slightly?
No
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P1221.)
NG
Check ignition timing when the engine is cranked. Check that the crank angle sensor and timing belt cover are proper-
OK: approx. 5 BTDC ly installed.
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

 Spark plug
 Compression pressure
 Foreign material (such as water or kerosine) entered the fuel
lines
OK
NG
Check trouble symptom. Replace the injector.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-71
INSPECTION PROCEDURE 7
Unstable idling (rough idle, hunting) Probable cause
This malfunction is probably caused by a faulty ignition system, improper air/fuel  Malfunction of the ignition system
ratio, a faulty electronic-controlled throttle valve system, improper compression  Malfunction of the air/fuel ratio control system
pressure, etc. As many causes can be suspected, diagnose from easier items.  Malfunction of the electronic-control throttle valve
system
 Improper compression pressure
 Air sucking into the air intake system

Yes
Has the battery been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
minutes.
No
Yes
MUT-II Self-Diag code Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
Yes
Does the engine idle speed fluctuates excessively (excessive Clean around the throttle valve. (Refer to P.13A-92*.)
hunting)?
No
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P1221.)
NG
MUT-II Data list Check the accelerator pedal position switch system. (Refer to
26 Accelerator pedal position switch (Refer to P.13A-94.) P.13A-90, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system.
13 Intake air temperature sensor (Refer to P.13A-94.) (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P0110.)
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13A-16,
25 Barometric pressure sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system. (Refer to P.13A-52,
08 Purge control solenoid valve (Refer to P.13A-100.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0443.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13A-28, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
 Transmission: 2nd gear <M/T>, L range <A/T>
 Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-25, IN-
11 Oxygen sensor (front) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: 600 – 1,000 mV when the engine is suddenly raced
OK

To the next page

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-72 GDI – Troubleshooting

From the previous page

OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high pressure)
11 Oxygen sensor (front) and injector. (Refer to P.13A-108.)
OK: 0 – 400 mV and 600 – 1,000 mV alternates when the OK
engine is idling (wait for four minutes after the engine NG
started).
Repair
OK Check that air is sucked in the air intake system.
 Broken intake manifold gasket
 Damaged vacuum hose
 Damaged air intake hose
NG
MUT-II Data list Check the power steering fluid pressure switch system. (Refer
27 Power steering fluid pressure switch (Refer to P.13A-94.) to P.13A-92, INSPECTION PROCEDURE 30.)
OK

MUT-II Data list NG Check the A/C switch and A/C relay system. (Refer to P.13A-92,
28 A/C switch (Refer to P.13A-94.) INSPECTION PROCEDURE 31.)
OK
NG Check the stop lamp switch. (Refer to P.13A-93, INSPECTION
MUT-II Data list
67 Stop lamp switch (Refer to P.13A-94.) PROCEDURE 32.)
OK
MUT-II Data list NG Check the small lamp switch system. (Refer to P.13A-93, INSPEC-
31 Small lamp switch (Refer to P.13A-94.) TION PROCEDURE 33.)
OK
NG
MUT-II Data list Check the EGR valve. (Refer to P.13A-50, INSPECTION PROCE-
68 EGR valve (Refer to P.13A-94.) DURE FOR DIAGNOSIS CODE P0403.)

OK
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
OK ly installed.

Clean around the throttle valve. (Refer to P.13A-92*.)

Check trouble symptom.

NG
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK
Check all the following items in that order.
(1) Spark plugs
(2) Exhaust gas emission control system
(3) EGR system
(4) Compression pressure
(5) Foreign material (such as water or kerosine) entered the fuel
line.
(6) Air is sucked in the air intake system, or EGR gas leaks.
 Damaged intake manifold gasket
 Damaged air intake hose
 Damaged vacuum hose
 Faulty EGR valve seat

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-73
INSPECTION PROCEDURE 8
Idle speed is high or low (Improper idling) Probable cause
The cause is probably that the intake air amount during idling is too great or too  Malfunction of the electronic-controlled throttle valve
small. system
 Malfunction of the throttle body

Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P1221.)
NG
MUT-II Actuator test Check the purge control solenoid valve. (Refer to P.13A-52, IN-
08 Purge control solenoid valve (Refer to P.13A-100.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0443.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system.
26 Accelerator pedal position switch (Refer to P.13A-94.) (Refer to P.13A-90, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115.)
OK
NG
MUT-II Data list Check the A/C switch and A/C relay system.
28 A/C switch (Refer to P.13A-94.) (Refer to P.13A-92, INSPECTION PROCEDURE 31.)
OK
NG
MUT-II Data list Check the stop lamp switch system.
67 Stop lamp switch (Refer to P.13A-94.) (Refer to P.13A-93, INSPECTION PROCEDURE 32.)
OK

 Clean around the throttle valve. (Refer to P.13A-92*.)

 Adjust the throttle position sensor. (Refer to P.13A-92*.)

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-74 GDI – Troubleshooting

INSPECTION PROCEDURE 9
When the engine is cold, it stalls at idling. (Die out) Probable cause
The cause is probably an incorrect air/fuel ratio or poor intake air amount when  Malfunction of the electronic-control throttle valve
the engine is cold. system
 Malfunction of the throttle body

Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
No minutes.
Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
Yes
Is the engine idling correct after the engine has been warmed up? Refer to “Unstable idling (rough idle, hunting).
(Refer to P.13A-71, INSPECTION PROCEDURE 7.)
No
NG
MUT-II Data list Check the throttle valve position feedback system.
22 Crank angle sensor (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
Check idling speed when the engine is cold. SIS CODE P1221.)
OK
NG
MUT-II Data list Check the accelerator position switch.
26 Accelerator pedal position switch (Refer to P.13A-94.) (Refer to P.13A-90, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115.)
OK
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-50, INSPECTION
68 EGR valve (Refer to P.13A-94.) PROCEDURE FOR DIAGNOSIS CODE P0403.)
OK
Yes
Does the engine stall immediately after the accelerator pedal is Clean around the throttle valve.
released? (Refer to P.13A-91*.)
No

Measure fuel high pressure between the fuel pump (high pressure) NG
and injector. (Refer to P.13A-108.) Repair
OK
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
OK ly installed.
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK
OK
Check all the following items: Check trouble symptom.
 Spark plugs NG
 Compression pressure
 Engine oil viscosity
Replace the injector.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-75
INSPECTION PROCEDURE 10
When the engine is hot, it stalls at idling. (Die out) Probable cause
The cause is probably an improper air/fuel ratio, faulty electronic-controlled throttle  Malfunction of the ignition system
valve system, compression pressure. In addition, if the engine stalls suddenly, another  Malfunction of air/fuel ratio control system
possible cause might be a poor connector contact.  Malfunction of electronic-controlled throttle valve
system
 Malfunction of the throttle body
 Poor connector contact
 Improper compression pressure
 Air stuck in the air intake system

Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
No minutes.
Yes
MUT-II Self-Diag code Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P1221.)
No
Is it easy to reproduce the engine stall? While carrying out an intermittent malfunction simulation test. (Re-
fer to GROUP 00 – Points to Note for Intermittent Malfunction.),
Yes check for sudden changes in the following signals.
 Crank angle sensor signal
 Injector drive signal
 Fuel pump (low pressure) drive signal
 Air flow sensor
 Primary ignition signal
 Power supply to the engine-ECU

NG
MUT-II Data list Check the accelerator pedal position switch.
26 Accelerator pedal position switch (Refer to P.13A-94.) (Refer to P.13A-90, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-18, IN-
13 Intake air temperature sensor (Refer to P.13A-94.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-16, IN-
25 Barometric pressure sensor (Refer to P.13A-94.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115.)
OK

MUT-II Data list NG Check the oxygen sensor (rear) system. (Refer to P.13A-28, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
 Transmission: 2nd gear <M/T>, L range <A/T>
 Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-25, IN-
11 Oxygen sensor (front) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: 600 – 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high pressure)
11 Oxygen sensor (front) and injector. (Refer to P.13A-108.)
OK: 0 – 400 mV and 600 – 1,000 mV alternates when the OK NG
engine is idling (wait for four minutes after the engine
started). Repair
OK Check that air is sucked in the air intake system.
 Broken intake manifold gasket
To the next page
 Damaged vacuum hose
 Damaged air intake hose
13A-76 GDI – Troubleshooting

From the previous page

OK
NG
MUT-II Data list Check the power steering fluid pressure switch system.
27 Power steering fluid pressure switch (Refer to P.13A-94.) (Refer to P.13A-92, INSPECTION PROCEDURE 30.)
OK
NG
MUT-II Data list Check the A/C switch and A/C relay system.
28 A/C switch (Refer to P.13A-94.) (Refer to P.13A-92, INSPECTION PROCEDURE 31.)
OK
NG
MUT-II Data list Check the small lamp switch system.
31 Small lamp switch (Refer to P.13A-94.) (Refer to P.13A-93, INSPECTION PROCEDURE 33.)
OK
NG
MUT-II Data list Check the air flow sensor system. (Refer to P.13A-14, INSPEC-
34 Air flow sensor reset signal (Refer to P.13A-94.) TION PROCEDURE FOR DIAGNOSIS CODE P0100.)

OK
NG
MUT-II Data list Check the EGR valve. (Refer to P.13A-50, INSPECTION PROCE-
68 EGR valve (Refer to P.13A-94.) DURE FOR DIAGNOSIS CODE P0403.)
OK
Yes
Does the engine stall immediately after the accelerator pedal is Clean around the throttle valve. (Refer to P.13A-92*.)
released?
No
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
OK ly installed.

Check ignition coil spark for each cylinder.

(1) Remove the ignition coil. NG
(2) Install a new spark plug to the removed ignition coil. Replace the ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

 Spark plugs
 Compression pressure
 Foreign material (such as water or kerosine) entered the fuel
lines

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-77
INSPECTION PROCEDURE 11
The engine stalls when starting the car. (Pass out) Probable cause
The cause is probably poor ignition due to a malfunctioning spark plug (weak spark),  Malfunction of the ignition system
or an incorrect air/fuel ratio when the accelerator is depressed.  Malfunction of the EGR valve
 Air stuck in the air intake system

Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the EGR valve. (Refer to P.13A-50, INSPECTION PROCE-
68 EGR valve (Refer to P.13A-94.) DURE FOR DIAGNOSIS CODE P0403.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system. (Refer to P.13A-52,
08 Purge control solenoid valve (Refer to P.13A-100.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0443.)
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

(1) Spark plug
(2) Check if air is stuck in the air intake system.
 Damage intake manifold gasket
 Damaged or disconnected vacuum hose
 Damaged air intake hose
13A-78 GDI – Troubleshooting

INSPECTION PROCEDURE 12
The engine stalls when decelerating. Probable cause
The cause is probably an improper air/fuel ratio due to a faulty EGR system, or  Malfunction of the electronic-controlled throttle valve
poor intake air volume due to a faulty electronic-controlled throttle valve system. system
 Malfunction of the EGR valve

Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
No minutes.
Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the accelerator pedal position switch.
26 Accelerator pedal position switch (Refer to P.13A-94.) (Refer to P.13A-90, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P1221.)
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-50, INSPECTION
68 EGR valve (Refer to P.13A-94.) PROCEDURE FOR DIAGNOSIS CODE P0403.)
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK

Check all the following items:

 Spark plug
 Clean around the throttle valve (Refer to P.13A-92*.)

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 GDI – Troubleshooting 13A-79
INSPECTION PROCEDURE 13
Hesitation, sag, stumble, poor acceleration or surge Probable cause
The cause is probably a malfunction of the ignition system, electronic-controlled  Malfunction of the ignition system
throttle valve system, compression pressure, etc.  Malfunction of the air/fuel ratio control system
 Malfunction of the electronic-controlled throttle valve
system
 Improper compression pressure
 Air stuck in the air intake system

Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
OK ly installed.
NG
MUT-II Data list Check the accelerator pedal position switch.
26 Accelerator pedal position switch (Refer to P.13A-94.) (Refer to P.13A-90, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-18, IN-
13 Intake air temperature sensor (Refer to P.13A-94.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-16, IN-
25 Barometric pressure sensor (Refer to P.13A-94.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115.)
OK
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P1221.)
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13A-28, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
 Transmission: 2nd gear <M/T>, L range <A/T>
 Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-25, IN-
11 Oxygen sensor (front) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: 600 – 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high pressure)
11 Oxygen sensor (front) and injector. (Refer to P.13A-108.)
OK: 0 – 400 mV and 600 – 1,000 mV alternates when the OK
engine is idling (wait for four minutes after the engine
started). Check that air is sucked in the air intake system.
OK  Broken intake manifold gasket
 Damaged vacuum hose
 Damaged air intake hose

NG
MUT-II Data list Check the EGR valve. (Refer to P.13A-50, INSPECTION PROCE-
68 EGR valve (Refer to P.13A-94.) DURE FOR DIAGNOSIS CODE P0403.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve. (Refer to P.13A-52, IN-
08 Purge control solenoid valve (Refer to P.13A-100.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0443.)
OK
To the next page
13A-80 GDI – Troubleshooting

From the previous page

OK
NG
Measure high fuel pressure between the fuel pump (high pressure) Repair
and injector. (Refer to P.13A-108.)
OK
NG Replace the ignition coil.
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK
OK
Check all the following items: Check trouble symptom.
 Spark plug
 EGR system NG
 Compression pressure
 Clogged fuel filter, fuel line Replace the injector.

INSPECTION PROCEDURE 14
The feeling of impact when accelerating Probable cause
The cause is probably an ignition leak being generated in line with an increase  Malfunction of the ignition system
in the spark plug request voltage during acceleration.

Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P1221.)
OK
OK
Check ignition coil spark for each cylinder. Check all the following items:
(1) Remove the ignition coil.  Spark plug
(2) Install a new spark plug to the removed ignition coil.  Ignition current leak
(3) Disconnect the injector intermediate connector.
Caution NG
Never touch the connector terminal as approx. 100 V is Replace the ignition coil.
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
 GDI – Troubleshooting 13A-81
INSPECTION PROCEDURE 15
The feeling of impact when decelerating Probable cause
The cause is probably insufficient intake air due to a faulty electronic-controlled  Malfunction of the electronic-controlled throttle valve
throttle valve system. system

Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-94.) (Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P1221.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system.
26 Accelerator pedal position switch (Refer to P.13A-94.) (Refer to P.13A-90, INSPECTION PROCEDURE 28.)
OK

Clean around the throttle valve. (Refer to P.13A-92*.)

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)

INSPECTION PROCEDURE 16
Knocking Probable cause
The cause is probably incorrect detonation control or improper heat range of the  Malfunction of the detonation sensor
spark plugs.  Improper heat range of the spark plugs

Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
No
Does knocking occur when the vehicle is driven with the detonation Check the detonation sensor system. (Refer to P.13A-47, INSPEC-
sensor disconnected? TION PROCEDURE FOR DIAGNOSIS CODE P0325.)
(At this time, use the MUT-II to check whether the ignition timing
is retarded from when the detonation sensor connector is con-
nected.)
Yes
Check all the following items:
 Spark plug
 Foreign material (such as water or kerosine) entered the fuel
lines

INSPECTION PROCEDURE 17
Run-on (dieseling) Probable cause
The cause is probably fuel leak from injector(s)  Malfunction of the injector

Replace the injector.

13A-82 GDI – Troubleshooting

INSPECTION PROCEDURE 18
Too high CO and HC concentration when idling Probable cause
The cause is probably an incorrect air/fuel ratio  Malfunction of air/fuel ratio control system
 Deterioration of the catalyst

Yes
MUT-II Self-Diag code (Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
Check ignition timing. (Refer to GROUP 11A – Engine Adjustment.) Check that the crank angle sensor and timing belt cover are proper-
ly installed.
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-19,
21 Engine coolant temperature sensor (Refer to P.13A-94.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-18, IN-
13 Intake air temperature sensor (Refer to P.13A-94.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-16, IN-
25 Barometric pressure sensor (Refer to P.13A-94.) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13A-28, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
 Transmission: 2nd gear <M/T>, L range <A/T>
 Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG Check the oxygen sensor (front) system. (Refer to P.13A-25, IN-
MUT-II Data list
11 Oxygen sensor (front) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: 600 – 1,000 mV when the engine is suddenly raced
OK
OK
MUT-II Data list Replace the oxygen sensor (front).
11 Oxygen sensor (front)
OK: 0 – 400 mV and 600 – 1,000 mV alternates when the
engine is idling (wait for four minutes after the engine Check trouble symptom.
started). NG
NG
NG
Measure fuel high-pressure between the fuel pump (high pressure) Repair
and injector. (Refer to P.13A-108.)
OK
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK NG

Check all the following items: Replace the ignition coil.

 Spark plug
 EGR system
 Compression pressure
 Clogged fuel filter or line
OK

To the next page

 GDI – Troubleshooting 13A-83
From the previous page
OK
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-50, code No.
68 EGR valve (Refer to P.13A-94.) P0403.)
OK
NG
MUT-II Actuator test Check purge control solenoid valve system. (Refer to P.13A-52,
08 Purge control solenoid valve (Refer to P.13A-100.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0443.)
OK
NG
Check trouble symptom. Replace the injector.

Check trouble symptom.

NG
Replace the three-way catalytic converter.

INSPECTION PROCEDURE 19
Low alternator output voltage (approx. 12.3 V) Probable cause
The cause is probably a malfunction of the alternator or one of the problems  Malfunction of the charging system
listed at right.  Open circuit between the alternator G terminal
and the engine-ECU
 Malfunction of the engine-ECU

NG NG
Measure at the alternator connector Measure at the alternator connector Check the harness wire between
A-79. A-79. the alternator and the engine-ECU,
 Connect the connector. (Use the  Disconnect the connector, and and repair if necessary.
test harness MB991519) measure at the harness side.
 Voltage between 1 (black clip)  Disconnect engine-ECU
and earth connector C-17.
(Engine: Idling)  Continuity between 1 and earth
(Radiator fan: Not operating) OK: No continuity
(Headlamp: OFF → ON) OK
(Stop lamp: OFF → ON)
(Rear defogger switch: OFF → NG
ON) Check the following connectors: Repair
OK: Voltage increased by A-79, A-86, C-17
0.2 – 3.5 V. OK
OK
Replace the engine-ECU.
Check the alternator. (Refer to GROUP
16 – Charging System.)
13A-84 GDI – Troubleshooting

INSPECTION PROCEDURE 20
Fans (radiator fan, A/C condenser fan) are inoperative. Probable cause
The engine-ECU sends a duty signal to the fan controller according to engine coolant  Malfunction of the fan motor relay
temperature, vehicle speed, or A/C switch load.  Malfunction of the fan motor
The fan controller controls radiator fan and condenser fan speeds, based on this  Malfunction of the fan controller
signal. (The closer the terminal voltage comes to 5 V, the higher the fan speed  Open or short circuit, or poor connector contact
becomes.)  Malfunction of the engine-ECU

NG
Measure at engine-ECU connector C-17. Check the following connectors: A-29, C-17
 Disconnect the connector, measure at the harness side. OK NG
 Voltage between terminal 18 and earth
(Ignition switch: ON) Repair
OK: 4.8 – 5.2 V (The fan runs at high speed.)
 Earth terminal 18. Check trouble symptom.
(Ignition switch: ON)
OK: The fan stops. NG

OK Check the harness wire between the engine-ECU and fan controller.
OK
Check the following connector: C-17 NG
OK NG
Repair
Repair
Check the radiator fan and condenser fan circuit. (Refer to GROUP
Check trouble symptom. 14 – Troubleshooting.)
NG
NG
MUT-II Data list Check the engine coolant temperature sensor system. (Refer to
21 Engine coolant temperature sensor P.13A-19, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
OK: After the engine has been warmed up, the engine coolant 0115.)
temperature during idling is identical to the MUT-II reading.
OK
NG
Check the thermostat. Replace
OK

Replace the engine-ECU.

 GDI – Troubleshooting 13A-85
INSPECTION PROCEDURE 21
GDI ECO indicator lamp does not illuminate. Probable cause
If the GDI ECO indicator lamp does not illuminate after turning switch, the causes  Burned-out GDI ECO indicator lamp bulb
listed in the right column are suspected.  Open circuit or short-circuited harness wire in the
GDI ECO indicator lamp circuit
 Malfunction of the engine-ECU
 Malfunction of the GDI ECO indicator lamp ECU

OK
Measure at the engine-ECU connector C-17. Check the following connector: C-17
 Disconnect the connector, and measure at the harness side.
 Earth terminal 14. (Ignition switch: ON) OK NG
OK: The GDI ECO indicator lamp illuminates. Repair
NG
Check trouble symptom.
Check the following connector: C-29, C-55 NG
OK NG
Replace the engine-ECU.
Repair

Check trouble symptom.

NG

Check the harness wire between the GDI-ECO Indication lamp-

ECU and engine-ECU.

INSPECTION PROCEDURE 22
GDI ECO indicator lamp remains illuminated and does not Probable cause
go off.
If the GDI ECO indicator lamp does not gooff during high load operation, the causes  Short circuit between the GDI ECO indicator lamp
listed in the right column are suspected. and engine-ECU
 Malfunction of the engine-ECU
 Malfunction of the GDI ECO indicator lamp ECU

NG
Measure at GDI ECO indicator lamp ECU connector C-55. Check trouble harness wire between the GDI ECO indication lamp-
 Disconnect the connector, and measure at the harness side. ECU and engine-ECU, and repair if necessary.
 Disconnect the engine-ECU connector.
 Continuity between terminal 3 and earth
OK: No continuity
OK

Check the relative circuits of GDI ECO indication lamp.

(Refer to GROUP 54A-Troubleshooting.)
OK

Replace the engine-ECU.

13A-86 GDI – Troubleshooting

INSPECTION PROCEDURE 23
Engine-ECU power supply and earth circuit system Probable cause
The cause is probably a malfunction of the engine-ECU or one of the problems  Open circuit or short-circuited harness wire in the
listed at right. engine-ECU power supply circuit
 Open circuit or short-circuited harness wire in the
engine-ECU earth circuit
 Malfunction of the engine-ECU

(1) NG NG
Measure at the engine-ECU connectors Check the following connectors: Repair
C-18, C-19. C-72, C-74
 Disconnect the connector, and
OK
measure at the harness side.
(1) Voltage between 99 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON)
engine-ECU and ignition switch, and
OK: System voltage
repair if necessary.
(2) Voltage between 57 and earth
OK: System voltage (2), (3) NG Check the following connector: OK NG
(3) Voltage between 47, 59 and A-36
earth (Ignition switch: ON) Repair
NG
OK: System voltage (When ter- OK
Repair Check the ignition switch. (Refer to
minal 57 is shorted to
GROUP 54.)
earth) Check the trouble symptoms.
(4) Continuity between 46, 58 and
earth NG
OK: Continuity
(5) Voltage between 60 and earth Check the harness wire between the
OK: System voltage engine-ECU and engine control relay,
and repair if necessary.

(4) NG Check the harness wire between the

engine-ECU and earth, and repair if
necessary.

(5) NG Check the harness wire between the

engine-ECU and the battery, and repair
if necessary.

OK

Check the following connectors:

C-18, C-19
OK NG

Repair
Check the trouble symptoms.
NG

Replace the engine-ECU.

 GDI – Troubleshooting 13A-87
INSPECTION PROCEDURE 24
Engine control relay and ignition switch-IG system Probable cause
When the ignition switch ON signal is input to the engine-ECU, the  Malfunction of the ignition switch
engine-ECU turns on the engine control relay.  Malfunction of the engine control relay
This causes system voltage to be supplied to the engine-ECU and to the  Open circuit or short-circuited harness wire of the
sensors and actuators. engine control relay circuit
 Malfunction of the engine-ECU

NG
Check the engine control relay. (Refer Replace
to P.13A-102*.)
OK
NG
Measure at the engine control relay Check the harness wire between the
connector A-43X. battery and the engine control relay,
 Disconnect the connector, and and repair if necessary.
measure at the harness side.
 Voltage between 3, 4 and earth
OK: System voltage
OK

Check the engine-ECU power supply

and earth circuit system.
(Refer to P.13A-86, INSPECTION
PROCEDURE 23.)

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-88 GDI – Troubleshooting

INSPECTION PROCEDURE 25
Injector driver relay system Probable cause
When the ignition switch ON signal is input to the engine-ECU, engine-ECU  Malfunction of the injector driver relay
turns on the injector driver relay.  Improper connector contact, open circuit or
This causes system voltage to be supplied to the injector driver. short-circuited harness wire
 Malfunction of the engine-ECU

Check the injector driver relay. (Refer to P.13A-102*.) NG

Replace
OK
(1) NG
Measure at the injector driver relay connector A-44X. Check the following connector: A-36
 Disconnect the connector, and measure at the harness side.
(1) Voltage between 3 and earth OK NG
OK: System voltage Repair
(2) Voltage between 4 and earth (Ignition switch: ON)
OK: System voltage Check the trouble symptoms.
NG
Check the harness wire between the injector driver relay and
the battery, repair if necessary.

(2) NG
Check the following connectors: C-72, C-74
OK NG
OK
Repair
Check the trouble symptoms.
NG

Check the harness wire between the injector driver relay and
the ignition switch, repair if necessary.

NG
Measure at the engine-ECU connector C-18. Check the following connector: A-44X
 Disconnect the connector, and measure at the harness side.
OK NG
 Voltage between 55 and earth
(Ignition switch: ON)
OK: System voltage Repair
OK Check the trouble symptoms.
NG
Check the following connector: C-18
Check the harness wire between the injector driver relay and
OK NG the engine-ECU, and repair if necessary.

Repair
NG
Check the trouble symptoms. Check the following connector: A-44X
NG OK NG

Measure at the injector driver connector A-55. Repair

 Connect the connector.
 Voltage between 12, 21 and earth (Ignition switch: ON) Check the trouble symptoms.
OK: System voltage NG
OK
Check the harness wire between the injector driver relay and
Check the injector driver system. the injector driver, repair if necessary.
(Refer to P.13A-53, INSPECTION PROCEDURE FOR
DIAGNOSIS CODE P1200.)

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE99E1)
 GDI – Troubleshooting 13A-89
INSPECTION PROCEDURE 26
Ignition switch-ST system <M/T> Probable cause
The ignition switch-ST outputs a HIGH signal to the engine-ECU while the  Malfunction of the ignition switch
engine is cranking.  Open circuit or short-circuited harness wire of the
The engine-ECU uses this signal to carry out functions such as fuel injection ignition switch circuit
control during starting.  Malfunction of the engine-ECU

(1) NG NG
Measure at the engine-ECU connector Check the following connector: Repair
C-18. C-27
 Disconnect the connector, and OK
measure at the harness side.
(1) Voltage between 68 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: START) engine-ECU and the ignition switch.
OK: 8 V or more (2) NG
(2) Continuity between 67 and earth Check the harness wire between the OK NG
OK: Continuity engine-ECU connector (terminal
No.91) and the earth, repair it neces- Repair
OK sary.
NG Check the ignition switch. (Refer to
Check the following connector: Repair GROUP 54.)
C-18
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

INSPECTION PROCEDURE 27
Ignition switch-ST and inhibitor switch system <A/T> Probable cause
The ignition switch-ST outputs a HIGH signal to the engine-ECU while the  Malfunction of the ignition switch
engine is cranking, and the engine-ECU uses this signal to carry out functions  Malfunction of the inhibitor switch
such as fuel injection control during starting.  Open circuit or short-circuited harness wire
The inhibitor switch inputs the position of the selector lever to the engine-ECU. between ignition switch and inhibitor switch
The engine-ECU uses this signal to carry out idle speed control.  Malfunction of the engine-ECU
13A-90 GDI – Troubleshooting

Check the inhibitor switch (Refer to NG

Replace
GROUP 23 – On-vehicle Service).
OK

(1) NG NG
Measure at the inhibitor switch connec- Check the following connectors: Repair
tor B-04. C-18, C-24 <LHD>, C-26 <RHD>,
 Disconnect the connector, and D-02
measure at the harness side. OK
(1) Voltage between 4 and earth NG Check the harness wire between the
(Ignition switch: ON) Check the trouble symptoms. engine-ECU and the inhibitor switch
OK: System voltage connector.
(2) Continuity between 1 and earth (2) NG Check the following connectors: NG
OK
OK: Continuity A-83, B-01
(3) Voltage between 4 and earth Repair
(Ignition switch: START) OK NG
Disconnect the engine-ECU con- Replace the engine-ECU
(3) NG Repair
nector. NG
OK: System voltage Check the trouble symptoms. Check the harness wire between the
inhibitor switch connector and the start-
OK
er S terminal, and repair if necessary.
NG
Check the following connector: Check the following connectors: Repair
B-04 C-39, D-02

OK NG OK
Repair
Check the trouble symptoms.
Check the trouble symptoms.
NG
NG NG
Check the harness wire between the Repair
Check the harness wire between the inhibitor switch and the ignition switch
engine-ECU and the inhibitor switch. connector.
OK NG OK

Repair Check the ignition switch (Refer to

GROUP 54.)
Replace the engine-ECU.

INSPECTION PROCEDURE 28
Accelerator pedal position switch system Probable cause
The accelerator pedal position switch detects that the accelerator pedal is fully closed,  Maladjustment of the accelerator cable
and sends a signal to the engine-ECU. The engine-ECU controls idle speed, based  Maladjustment of the accelerator pedal position switch
on this signal.  Open circuit or short-circuited harness wire in the
accelerator pedal position switch system, or poor
connector contact
 Malfunction of the engine-ECU

NG
Check the accelerator pedal position switch. (Refer to P.13A-105*.) Replace the accelerator pedal position sensor assembly.
OK
NG
Measure at accelerator pedal position sensor connector C-46. Check the following connectors: A-36, C-19
 Disconnect the connector, and measure at the harness side. OK NG
 Voltage between terminal 4 and earth
(Ignition switch: ON) Repair
OK: 4 V or more
 Continuity between terminal 5 and earth
OK: Continuity Check trouble symptom.
OK NG

Check the harness wire between the engine-ECU and accelerator

pedal position sensor.
OK NG
NG
Check the following connector: C-46 Repair Repair
OK
NG
Check trouble symptom. Replace the engine-ECU.

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE99E1)
 GDI – Troubleshooting 13A-91
INSPECTION PROCEDURE 29
Fuel pump (low pressure) system Probable cause
The engine-ECU turns on the fuel pump relay while the engine is cranking or running,  Malfunction of the fuel pump relay
and supplies power source to the fuel pump (low pressure).  Malfunction of the fuel pump (low pressure)
 Open circuit or short-circuited harness wire in the
fuel pump (low pressure) circuit, or poor connector
contact
 Malfunction of the engine-ECU

OK
MUT-II Actuator test Normal
07 Fuel pump (Refer to P.13A-100.)
NG
NG
Check the fuel pump relay. (Refer to Replace
P.13A-102*.)
OK
NG NG
Measure at fuel pump relay connector Check the following connectors: Repair
A-41X. C-72, C-74
 Disconnect the connector, and OK
measure at the harness side. NG
 Voltage between terminals 3, 4 and Check trouble symptom. Check the harness wire between the
earth (Ignition switch: ON) fuel pump relay and ignition switch.
OK: System voltage
OK NG
OK
NG Repair
Measure at engine-ECU connector Check the following connector:
C-17. A-41X Check the ignition switch. (Refer to
 Disconnect the connector, and OK NG GROUP 54 – Ignition Switch.)
measure at the harness side.
 Voltage between terminal 21 and Repair
earth (Ignition switch: ON) NG
OK: System voltage Check trouble symptom. Check the harness wire between the
fuel pump relay and engine-ECU, and
OK repair if necessary.

OK NG
Measure at engine-ECU connector Check the following connector: Repair
C-17. C-17
 Disconnect the connector, and
OK
measure at the harness side. NG
 Short circuit between terminal 21 Check trouble symptom. Replace the engine-ECU.
and earth (Ignition switch: ON)
OK: The fuel pump operates (its
operation sound can be
heard).
NG
(1) NG NG
Measure at fuel pump (low pressure) Check the following connectors: Repair
connector D-17. C-24 <LHD>, C-26 <RHD>, D-12
 Disconnect the connector, and OK
measure at the harness side. NG
(1) Voltage between terminal 5 and Check trouble symptom. Check the harness wire between the
earth (Ignition switch: ON) fuel pump relay and fuel pump (low
OK: System voltage (2) NG pressure), and repair if necessary.
(2) Continuity between 4 and earth Check the following connector:
OK: Continuity D-12
OK NG
OK
Repair
NG
Check trouble symptom. Check the harness wire between the
NG fuel pump (low pressure) and earth,
Check the following connector: Repair and repair if necessary.
D-17
OK

Check trouble symptom.

NG

Replace the fuel pump (low pressure).

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A-92 GDI – Troubleshooting

INSPECTION PROCEDURE 30
Power steering fluid pressure switch system Probable cause
The power steering fluid pressure switch sends a signal to the engine-ECU according  Malfunction of the power steering fluid pressure switch
to power steering load.  Open circuit or short-circuited harness wire in the
Based on this signal, the engine-ECU controls the throttle control servo so that power steering fluid pressure switch circuit, or poor
idle speed increases when the power steering is in operation. connector contact
 Malfunction of the engine-ECU

NG
Check the power steering fluid pressure switch. (Refer to GROUP Replace
37A – On-vehicle Service.)
OK
NG
Measure at power steering fluid pressure switch connector A-76. Check the following connector: C-18
 Disconnect the connector, and measure at the harness side. OK NG
 Voltage between terminal 1 and earth
(Ignition switch: ON) Repair
OK: System voltage
OK Check trouble symptom.
NG
Check the following connector: A-76
OK NG Check the harness wire between the engine-ECU and power steer-
ing fluid pressure switch.
OK NG
Repair
Repair
NG
Check trouble symptom. Replace the engine-ECU

INSPECTION PROCEDURE 31
A/C switch and A/C relay system Probable cause
If the engine-ECU receives a ‘A/C on’ signal, it operates the throttle control servo  Malfunction of the A/C control system
and A/C compressor magnetic clutch so that idle speed increases.  Malfunction of the A/C switch
 Open circuit or short-circuited harness wire in the
A/C switch circuit, or poor connector contact
 Malfunction of the engine-ECU

NG
Service the A/C compressor relay. (Refer to GROUP 55 – On-ve- Replace
hicle Service.)
OK
OK
Measure at engine-ECU connectors C-17, C-19. Check the following connectors:
 Disconnect the connector, and measure at the harness side. C-17, C-19
 Voltage between terminals 20, 83 and earth OK NG
(Ignition switch: ON)
OK: 0 – 3 V
(A/C switch: OFF) Repair
System voltage
(A/C switch: ON)
Check trouble symptom.
 Connect terminal 20 to earth.
(Ignition switch: ON, A/C switch: ON) NG
OK: A/C compressor clutch turns on.
Replace the engine-ECU.
NG

Check the A/C system. (Refer to GROUP 55 – On-vehicle Service.)

 GDI – Troubleshooting 13A-93
INSPECTION PROCEDURE 32
Stop lamp switch system Probable cause
The engine-ECU determines whether the brake pedal is depressed or not, by means  Malfunction of the stop lamp switch
of the stop lamp switch input signal.  Open circuit or short-circuited harness wire in the
stop lamp circuit, or poor connector contact
 Malfunction of the engine-ECU

NG
Check the stop lamp switch. (Refer to GROUP 35 – Brake Pedal.) Replace
OK
NG
Measure at stop lamp switch connector C-04. Check the following connector: C-29
 Disconnect the connector, and measure at the harness side. NG
OK
 Voltage between terminal 2 and earth
OK: System voltage Repair
OK
Check trouble symptom.
NG

Check the harness wire between the battery and stop lamp switch.
NG
Measure at engine-ECU connector C-18. Check the following connectors: C-02, C-04, C-28
 Disconnect the connector, and measure at the harness side. OK NG
 Voltage between terminal 63 and earth
(Ignition switch: ON) Repair
OK: 0 – 3 V (when the brake pedal is not depressed)
System voltage (when the brake pedal is depressed) Check trouble symptom.
OK NG

Check the harness wire between the engine-ECU and stop lamp,
and repair if necessary.
NG
Check the following connector: C-18 Repair
OK

Check trouble symptom.

NG

Replace the engine-ECU.

INSPECTION PROCEDURE 33
Small lamp switch system Probable cause
The engine-ECU determines whether the small lamp switch is on or off.  Improper connector contact, open circuit or
According to that information, the engine-ECU controls alternator output current short-circuited harness wire in the taillamp circuit
when the vehicle is started.  Malfunction of the engine-ECU

NG
Measure at the engine-ECU connector C-19. Check the taillamp circuit. (Refer to ELECTRICAL WIRING.)
 Disconnect the connector, and measure at the harness
side.
 Voltage between 88 and earth
(Lighting switch: ON)
OK: System voltage
OK

NG
Check the following connector: C-19 Repair
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

13A-94 GDI – Troubleshooting

DATA LIST REFERENCE TABLE

Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forward.
NOTE
*1: Within four minutes after starting the engine
*2: In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10 %
longer than the standard time.
*3: The accelerator pedal position switch normally turns off when the voltage of the accelerator pedal
position sensor (1st channel) is 200 – 600 mV higher than the voltage at the idle position. If the accelerator
pedal position switch turns back on after the accelerator pedal position sensor voltage has risen by
100 mV and the throttle valve has opened, the accelerator pedal position switch and the accelerator
pedal position sensor (1st channel) need to be adjusted.
Item Check items Requirements Normal condition Inspection Reference
No. procedure page
No.

11 Oxygen sensor Engine: After Idling 0 mV*1 Code No. 13A-25

(front) warm-up P0130
Sudden racing 600 – 1,000 mV

2,500 r/min 400 mV or less and

600 – 1,000 mV
alternates.

12 Air flow sensor  Engine coolant Idling 24 – 50 Hz Code No. 13A-14

temperature: P0100
80 – 95C
 Lamps, electric 2,500 r/min 70 – 90 Hz
cooling fan and
all accessories:
OFF Racing Frequency in-
 Transmission: creases in re-
Neutral sponse to racing.
(A/T: P range)

13 Intake air tem- Ignition switch: ON Intake air tempera- –20C Code No. 13A-18
perature sen- ture: –20C P0110
sor
Intake air tempera- 0C
ture: 0C

Intake air tempera- 20C

ture: 20C

Intake air tempera- 40C

ture: 40C

Intake air tempera- 80C

ture: 80C
 GDI – Troubleshooting 13A-95

Item Check items Requirements Normal condition Inspection Reference

No. procedure page
No.

14 Throttle posi-  Engine coolant Release the accel- 4,000 – 4,800 Code No. 13A-43
tion sensor temperature: erator pedal. P0225
(2nd channel) 80 – 95C
 Ignition switch: Depress the accel- Voltage decreases
ON (Engine erator pedal gradu- in response to the
stopped) ally. pedal depression.

Depress the accel- 100 – 1,100 mV

erator pedal fully.

16 Power supply Ignition switch: ON System voltage Procedure 13A-86

voltage No. 23

18 Cranking sig- Transmission: Engine: Stopped OFF Procedure 13A-89

nal (Ignition Neutral No.26 <M/T>
switch – ST) (A/T: P range) <M/T> 13A-89
Procedure <A/T>
Engine: Cranking ON No.27
<A/T>

21 Engine coolant Ignition switch: ON Engine coolant –20C Code No. 13A-19
temperature temperature: P0115
sensor –20C

Engine coolant 0C

temperature: 0C

Engine coolant 20C

temperature: 20C

Engine coolant 40C

temperature: 40C

Engine coolant 80C

temperature: 80C

22 Crank angle  Engine: Crank- Compare the engine Accord Code No. 13A-47
sensor ing speed readings on P0335
 Tachometer: the tachometer and
Connected the MUT-II.

 Engine: Idling Engine coolant 1,200 – 1,400 r/min

 Accelerator temperature:
pedal position –20C
switch: ON
Engine coolant 1,100 – 1,300 r/min
temperature: 0C

Engine coolant 1,000 – 1,200 r/min

temperature: 20C

Engine coolant 850 – 1,050 r/min

temperature: 40C

Engine coolant 550 – 750 r/min*1

temperature: 80C

24 Vehicle speed Drive at 40 km/h Approximately Code No. 13A-53

sensor 40 km/h P0500
13A-96 GDI – Troubleshooting

Item Check items Requirements Normal condition Inspection Reference

No. procedure page
No.

25 Barometric Ignition switch: ON Altitude: 0 m 101 kPa Code No. 13A-16

pressure sen- P0105
sor Altitude: 600 m 95 kPa

Altitude: 1,200 m 88 kPa

Altitude: 1,800 m 81 kPa

26 Accelerator Ignition switch: ON Release the accel- ON Procedure 13A-90

pedal position (Depress and re- erator pedal. No. 28
switch lease the accelera-
tor pedal several Depress the accel- OFF
times) erator pedal slight-
ly.

27 Power steering Engine: Idling Steering wheel sta- OFF Procedure 13A-92
fluid pressure tionary No. 30
switch
Steering wheel ON
turning

28 A/C switch Engine: Idling (The A/C switch: OFF OFF Procedure 13A-92
compressor
A/C com ressor is No. 31
running when the
A/C switch: ON ON
A/C switch is on.)

29 Inhibitor switch Ignition switch: ON Selector lever: P or P, N Procedure 13A-89

<A/T> N No. 27

Selector lever: D, 2, D, 2, L, R
L or R

31 Small lamp Engine: Idling Lighting switch: OFF Procedure 13A-93

switch OFF No. 33

Lighting switch: ON ON

34 Air flow sensor Engine: After hav- Engine is idling ON Code No. 13A-14
reset signal ing warmed up P0100
3,000 r/min OFF

37 Volumetric effi-  Engine coolant Engine is idling 30 – 50 % – –

ciency temperature:
80 – 95C
 Lamps, electric 2,500 r/min 10 – 30 %
cooling fan and
all accessories:
OFF Engine is suddenly Volumetric effi-
 Transmission: raced ciency increases in
Neutral response to racing
(A/T: P range)

38 Crank angle  Engine: Cranking [reading is possible Engine speeds dis- – –

sensor at 2,000 r/min or less] played on the
 Tachometer: Connected MUT-II and
tachometer are
identical.
 GDI – Troubleshooting 13A-97

Item Check items Requirements Normal condition Inspection Reference

No. procedure page
No.

41 Injector drive  Engine coolant Idling 0.35 – 0.55 ms*1 – –

time*2 temperature:
80 – 95C
 L l ti
Lamps, electric
cooling fan and 2,500 r/min 0.4 – 0.6 ms
all accessories:
OFF
 Transmission: Sudden racing Increases
Neutral
(A/T: P range)

44 Ignition  Engine: After Idling 8 – 24BTDC*1 Code No. 13A-44

advance warm-up
warm u P0300
 Set a timing
2,500 r/min 15 – 35BTDC
light.

49 A/C relay Engine: After A/C switch: OFF OFF (compressor Procedure 13A-92
warm-up, idling clutch is not oper- No. 31
ating)

A/C switch: ON ON (compressor

clutch is operating)

59 Oxygen sensor  Transmission: 3,500 r/min 600 – 1,000 mV Code No. 13A-28
(rear) 2nd gear P0136
(A/T: L range)
 Drive with
throttle widely
open

66 Brake vacuum  Engine coolant Stop the engine Displayed pres- Code No. 13A-62
sensor temperature: from idling speed, sure increases. P1515
80 – 95C and then depress
 Lamps, electric the brake pedal
cooling fan and several times with
all accessories: the ignition switch
OFF on.
 Transmission:
Neutral
(A/T: P range)

67 Stop lamp Ignition switch: ON Brake pedal: De- OFF Procedure 13A-93
switch pressed No. 32

Brake pedal: Re- ON

leased

68 EGR valve  Engine coolant Idling 2 – 17 STEP Code No. 13A-50

temperature: P0403
80 – 95C
 Lamps, electric
cooling fan and
all accessories:
2,500 r/min 0 – 9 STEP
OFF
 Transmission:
Neutral
(A/T: P range)
13A-98 GDI – Troubleshooting

Item Check items Requirements Normal condition Inspection Reference

No. procedure page
No.

74 Fuel pressure  Engine coolant Engine: Idling 4 – 6.9 MPa Code No. 13A-33
sensor temperature: P0190
80 – 95C
 Lamps, electric
cooling fan and
all accessories:
OFF
 Transmission:
Neutral
(A/T: P range)

77 Accelerator Ignition switch: ON Release the accel- 700 – 1,400 mV Code No. 13A-58
pedal position erator pedal. P1225
sensor (2nd
channel)*3 Depress the accel- Increases in re-
erator pedal gradu- sponse to the ped-
ally. al depression
stroke.

Depress the accel- 4,100 mV or more

erator pedal fully.

78 Accelerator Ignition switch: ON Release the accel- 985 – 1,135 mV Code No. 13A-40
pedal position erator pedal. P0220
sensor
(1st channel)*3 Depress the accel- Increases in re-
erator pedal gradu- sponse to pedal
ally. depression stroke.

Depress the accel- 4,100 mV or more

erator pedal fully.

79 Throttle posi-  Engine coolant Release the accel- 450 – 800 mV Code No. 13A-22
tion sensor (1st temperature: erator pedal. P0120
channel) 80 – 95C
 Ignition switch: Depress the accel- Increases in re-
ON (Engine erator pedal gradu- sponse to pedal
stopped) ally. depression stroke.

Depress the accel- 3,900 – 4,900 mV

erator pedal fully.

Engine: After No load 450 – 1,000 mV

warm-up,
warm-up idling
A/C switch: Increases by
OFF → ON 100 – 600 mV.

Selector lever: Increases by

N → D range 0 – 200 mV.

81 Long-term fuel Engine: Warm, 2,500 r/min without any –10 – 10 % Code No. 13A-31
compensation load (during closed loop) P0170

82 Short-term fuel Engine: Warm, 2,500 r/min without any –25 – 25 % Code No. 13A-31
compensation load (during closed loop) P0170
 GDI – Troubleshooting 13A-99

Item Check items Requirements Normal condition Inspection Reference

No. procedure page
No.

85 Fuel pressure  Engine coolant Engine: Idling 4,000 – 6,900 kPa Code 13A-33
sensor temperature: No.P0190
80 – 95C
 Lamps, electric
cooling fan and
all accessories:
OFF
 Transmission:
Neutral
(A/T: P range)

87 Calculation Engine: Warm Engine: Idling 15 – 35 % – –

load value
2,500 r/min 15 – 35 %

88 Fuel control Engine: Warm 2,500 r/min Closed loop Code No. 13A-24
condition P0125
When engine is Open loop – drive
suddenly raced condition

99 Fuel injection Engine: After warm Idling (after four Lean compression – –
mode up minutes or more
have passed since
engine start)

2,500 r/min Stoichiometric

metric feedback

Sudden racing after Open loop

idle position

A1 Oxygen sensor Engine: Idling 0V Code No. 13A-25

(front) After warm-up P0130
Sudden racing 0.6 – 1.0 V

2,500 r/min 0.4 V or less and

0.6 – 1.0 V alter-
nates

A2 Oxygen sensor  Transmission: 3,500 r/min 0.6 – 1.0 V Code No. 13A-28
(rear) 2nd gear P0136
<M/T>, L range
<A/T>
 Drive with
throttle widely
open

8A Throttle posi-  Engine coolant Release the accel- 8 – 16 % Code No. 13A-22
tion sensor (1st temperature: erator pedal. P0120
channel) 80 – 95C
(Throttle valve  Ignition switch: Depress the accel- Increase in re-
opening angle) ON (Engine: erator pedal gradu- sponse to pedal
stopped) ally. depression stroke.

Depress the accel- 80 – 100 %

erator pedal fully.

Engine: After No load 8 – 18 %

warm-up,
warm-up idling
A/C switch: Rises by 2 – 10 %
OFF → ON
13A-100 GDI – Troubleshooting

ACTUATOR TEST REFERENCE TABLE

Item Inspection Drive contents Inspection contents Normal condition Inspection Reference
No. item procedure page
No.

01 Injectors Cut fuel to No. 1 Engine: Idling condition Code No. 13A-34
injector After having becomes different P0201
warmed up/Engine (becomes unsta
unsta-
02 Cut fuel to No. 2 is idling ble). Code No. 13A-36
injector (Cut
( the fuel supplyy P0202
t each
to h injector
i j t in i
03 Cut fuel to No. 3 turn and check Code No. 13A-37
injector cylinders
y which P0203
d ’ affect
don’t ff idling.)
idli )
04 Cut fuel to No. 4 Code No. 13A-38
injector P0204

07 Fuel pump Fuel pump Ignition switch: ON Sound of opera- Procedure 13A-91
(low pressure) operates and tion is heard. No. 29
fuel is recirculated.

08 Purge Solenoid valve Ignition switch: ON Sound of opera- Code No. 13A-52
control turns from OFF to tion can be heard P0443
solenoid valve ON. when solenoid
valve is
driven.

17 Basic ignition Set the engine- Idling after engine 5BTDC – –

timing ECU to ignition warm up
timing adjustment
mode

21 Fan controller Drive the fan motor Ignition switch: ON The fan motor Procedure 13A-84
operates No. 20

34 Electronic- Stop the throttle Ignition switch: ON Throttle valve is Code No. 13A-54
controlled control servo. opened slightly. P1220
throttle valve
system
 GDI – Troubleshooting 13A-101
CHECK AT THE ENGINE-ECU TERMINALS
TERMINAL VOLTAGE CHECK CHART
Engine-ECU Connector Terminal Arrangement

Terminal No. Check item Check requirements (engine condition) Normal condition

1 No. 1 injector Engine: Warm up, and then depress Decreases slightly for short
the accelerator pedal suddenly from time from 9 – 13 V
9 No. 2 injector the idle speed.

24 No. 3 injector

2 No. 4 injector

3 No. 1 ignition coil Engine: 3,000 r/min 0.3 – 3.0 V

13 No. 2 ignition coil

12 No. 3 ignition coil

4 No. 4 ignition coil

5 EGR valve (D) Ignition switch: Immediately after 5 – 8 V (fluctuates for

turning ON approx.
approx three seconds)
6 EGR valve (C)

32 EGR valve (B)

34 EGR valve (A)

8 Alternator G terminal  Engine: Warm up, and then idling Voltage increases by
 Radiator fan: Not operating 0.2 – 3.5 V
 Headlamp: OFF → ON
 Stop lamp: OFF → ON
 Rear defogger switch: OFF → ON

14 GDI ECO indication lamp Ignition switch: OFF → ON 0 – 3 V (System voltage

after five seconds)

Engine: When the accelerator pedal is System voltage

suddenly depressed while the engine
is idling

16 Purge control solenoid  Engine cool- Engine: Stopped System voltage

valve ant tempera-
ture: Engine: Start the Voltage decreases
80 – 95C engine, and then
 Ignition increase engine
switch: ON speed up to 3,500
r/min.
13A-102 GDI – Troubleshooting

Terminal No. Check item Check requirements (engine condition) Normal condition

18 Fan controller Radiator and condenser fans are not 0 – 0.3 V

operating.

Radiator and condenser fans are 0.7 V or more

operating.

20 A/C relay  Engine: Idling System voltage, or changes

 A/C switch: OFF → ON from momentarily 6 V or
(Compressor is operating) more to 0 → 3 V

21 Fuel pump relay Ignition switch: Engine: Stopped System voltage

ON
Engine: Idling 0–3V

31 Engine warning lamp Ignition switch: OFF → ON 0 – 3 V → System voltage

(after several seconds)

41 Sensor power supply Ignition switch: ON 4.5 – 5.5 V

42 Power supply to Ignition switch: ON 4.5 – 5.5 V

accelerator pedal position
sensor (1st channel)

43 Crank angle sensor Engine: Cranking 0.4 – 4.0 V

Engine: Idling 1.5 – 2.5 V

44 Engine coolant tempera- Ignition switch: Engine coolant 3.2 – 3.5 V

ture sensor ON temperature: 0C

Engine coolant 2.3 – 2.9 V

temperature:
20C

Engine coolant 1.5 – 2.1 V

temperature:
40C

Engine coolant 0.4 – 1.0 V

temperature:
80C

45 Engine ignition signal Engine: 3,000 r/min 0.3 – 3.0 V

47 Power supply Ignition switch: ON System voltage

59

50 Camshaft position sensor Engine: Cranking 0.4 – 3.0 V

Engine: Idling 0.5 – 2.0 V

51 Barometric pressure Ignition switch: Altitude: 0 m 3.7 – 4.3 V

sensor ON
Altitude: 1,200 m 3.2 – 3.8 V

52 Alternator FR terminal  Engine: Warm up, and then idling Voltage decreases
 Radiator fan: Not operating
 Headlamp: OFF → ON
 Stop lamp: OFF → ON
 Rear defogger: OFF → ON
 GDI – Troubleshooting 13A-103

Terminal No. Check item Check requirements (engine condition) Normal condition

53 Oxygen sensor (rear)  Transmission: 2nd gear 0.6 – 1.0 V

 Engine speed: 3,500 r/min or more
 Driving with the throttle valve widely
open

54 Power steering fluid Engine: Warm Steering wheel System voltage

pressure switch up, and then stationary
idling
Steering wheel 0–3V
turning

55 Injector driver relay Ignition switch: OFF 0 – 0.1 V

Ignition switch: ON 0.5 – 1.0 V

56 Throttle valve control Ignition switch: OFF 0 – 0.3 V

servo relay
Ignition switch: ON 0.5 – 1.0 V

57 Engine control relay Ignition switch: OFF 0–3V

Ignition switch: ON System voltage

60 Back-up power source Ignition switch: OFF System voltage

61 Air flow sensor Engine: Idling 2.2 – 3.2 V

Engine: 2,500 r/min

62 Intake air temperature Ignition switch: Intake air temper- 3.2 – 3.8 V
sensor ON ature: 0C

Intake air temper- 2.3 – 2.9 V

ature: 20C

Intake air temper- 1.5 – 2.1 V

ature: 40C

Intake air temper- 0.4 – 1.0 V

ature: 80C

63 Stop lamp switch Depress the brake pedal. System voltage

Release the brake pedal. 0–3V

68 Ignition switch-ST Engine: Cranking 8 V or more

71 Oxygen sensor (front) Engine: Warm up, and then hold the 0 ↔ 0.8 V alternates.
engine speed at 2,500 r/min (Use a
digital voltmeter).

74 Brake vacuum sensor Engine: Stop the engine from idle Voltage increases
speed, turn the ignition switch ON,
and then depress the brake pedal
several times.

76 Air flow sensor reset Engine: Idling 0–1V

signal
Engine: 3,000 r/min 6–9V
13A-104 GDI – Troubleshooting

Terminal No. Check item Check requirements (engine condition) Normal condition

78 Throttle position sensor Ignition switch: Release the 4.0 – 4.8 V

(2nd channel) ON accelerator pedal.

Depress the 0.1 – 1.1 V

accelerator pedal
fully.

79 Accelerator pedal position Ignition switch: Release the 0–1V

switch ON accelerator pedal.

Depress the 4 V or more

accelerator pedal
fully.

80 Vehicle speed sensor  Ignition switch: ON 0 ↔ system voltage

 Move the vehicle forward. alternates.

83 A/C switch Engine: Idling A/C switch: OFF 0–3V

A/C switch: ON System voltage

(Compressor is
operating)

88 Small lamp switch Lighting switch: OFF 0–3V

Lighting switch: ON (Taillamp: ON) System voltage

89 Oxygen sensor heater Engine: Idling 0–3V

(front)
Engine: 3,500 r/min System voltage

90 Oxygen sensor heater Engine: Idling 0–3V

(rear)
Engine: 3,500 r/min System voltage

92 Fuel pressure sensor Engine: Idling 0.3 – 4.7 V

94 Accelerator pedal position Ignition switch: Release the acceler- 0.935 – 1.135 V*1
sensor (1st channel) ON ator pedal.

Depress the 4.1 V or more*2

accelerator pedal
fully.

96 Injector open circuit check Engine: Increase engine speed from Decreases slightly (approx.
signal idle speed to 4,000 r/min. 0.7 V) from 4.5 V – 5.0 V.

97 A/C thermo sensor  Temperature at sensing portion: 2.0 – 2.9 V

Approx 25°C
 Ignition switch: ON

99 Ignition switch-IG Ignition switch: ON System voltage

NOTE
Check if the difference in output between *1 and *2 is 4 V or more.
GDI – Troubleshooting 13A-105
CHECK CHART FOR RESISTANCE AND CONTINUITY
BETWEEN TERMINALS
1. Turn the ignition switch to OFF.
2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity between
the terminals of the engine-ECU harness-side connector
while referring to the check chart.
NOTE
(1) When measuring resistance and checking continuity,
a harness for checking contact pin pressure should
be used instead of inserting a test probe.
(2) Checking need not be carried out in the order given
in the chart.
Caution
If the terminals that should be checked are mistaken,
or if connector terminals are not correctly shorted
to earth, damage may be caused to the vehicle wiring,
sensors, engine-ECU and/or ohmmeter.
Be careful to prevent this!
4. If the ohmmeter shows any deviation from the standard
value, check the corresponding sensor, actuator and
related electrical wiring, and then repair or replace.
5. After repair or replacement, recheck with the ohmmeter
to confirm that the repair or replacement has corrected
the problem.
13A-106 GDI – Troubleshooting

Engine-ECU Harness Side Connector Terminal Arrangement

Terminal No. Check item Standard value, normal condition (check require-
ments)

5 – 47 EGR valve (D) 15 – 20 Ω (at 20C)

6 – 47 EGR valve (C)

32 – 47 EGR valve (B)

34 – 47 EGR valve (A)

16 – 47 Purge control solenoid valve 30 – 34 Ω (at 20C)

44 – 72 Engine coolant temperature sensor 5.1 – 6.5 kΩ (when engine coolant temperature is
0C)

2.1 – 2.7 kΩ (when engine coolant temperature is

20C)

0.9 – 1.3 kΩ (when engine coolant temperature is

40C)

0.26 – 0.36 kΩ (when engine coolant temperature is

80C)

46 – Body earth Earth Continuity (0 Ω)

58 – Body earth

62 – 72 Intake air temperature sensor 5.3 – 6.7 kΩ (when intake air temperature is 0C)

2.3 – 3.0 kΩ (when intake air temperature is 20C)

1.0 – 1.5 kΩ (when intake air temperature is 40C)

0.30 – 0.42 kΩ (when intake air temperature is 80C)

79 – 49 Accelerator pedal position switch Continuity (when the accelerator pedal is released)

No continuity (when the accelerator pedal is slightly

depressed)

89 – 47 Oxygen sensor heater control (front) 4.5 – 8.0 Ω (at 20C)

90 – 47 Oxygen sensor heater (rear) 11 – 18 Ω (at 20C)

 GDI – Troubleshooting 13A-107
CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS
TERMINAL VOLTAGE CHECK CHART
Throttle Valve Controller Terminal Arrangement

Terminal Check items Requirements Normal value

No.

1 Throttle valve control servo  Ignition switch: ON Decreases slightly from

(A+)  Accelerator pedal: Fully opened → system voltage.
fully closed
9 Throttle valve control servo
(B+)

14 Throttle valve control servo  Ignition switch: ON Decreases slightly (approx.

(A–)  Accelerator pedal: Fully closed → 2 V) from system voltage.
fully opened
15 Throttle valve control servo
(B–)

2 Power supply to throttle Ignition switch: ON System voltage

valve control servo
19

5 Power supply Ignition switch: ON System voltage

6 Sensor voltage Ignition switch: ON 4.5 – 5.5 V

7 Throttle position sensor (1st Ignition switch: Release the 0.45 – 0.8 V
channel) ON accelerator pedal.

Depress the 3.9 – 4.9 V

accelerator pedal
fully.

20 Accelerator pedal position Ignition switch: Release the 0.7 – 1.4 V*1
sensor (2nd channel) ON accelerator pedal.

Depress the 4.1 V or more*1

accelerator pedal
fully.

NOTE:
Check that the voltage difference between *1 and *2 is 4 V or more.
13A-108 GDI – On-vehicle Service

Fixed SAS ON-VEHICLE SERVICE

Caution
(1) Never attempt to tamper the fixed SAS. The fixed SAS
is precisely adjusted at factory.
(2) Should it be tampered, the full closed position of the
throttle valve will be changed. This causes the
engine-ECU to learn a wrong position of the throttle
valve.

FUEL PRESSURE TEST

High-pressure MEASUREMENT OF FUEL LOW PRESSURE BETWEEN
fuel hose
FUEL PUMP (LOW PRESSURE) AND FUEL PUMP
(HIGH PRESSURE)
1. Release residual pressure from the fuel pipe line to prevent
fuel gush out.
NOTE
Refer to the ’00 PAJERO PININ Workshop Manual (Pub.
Fuel pump No. CKRE00E1) GROUP 13A – On-vehicle Service.
(high-pressure)
2. Disconnect the high-pressure fuel hose at the fuel pump
(high pressure) side.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.

3. Remove the union joint and bolt from the special tool
MB991637 (adapter hose) and instead attach the special tool (hose
adapter) to the adapter hose.
Gasket 4. Install the special tool (for measuring the fuel pressure)
Fuel
pump MD998709 that was set up in step 3.
(high
pressure) <When using the fuel pressure gauge set (special tool)>
MD998742 (1) Install the special tool (for measuring the fuel pressure)
High-pressure between the high-pressure fuel hose and the fuel pump
fuel hose (high pressure).
(2) Install the fuel pressure gauge set (special tool) on
the special tool (for measuring the fuel pressure)
putting the gasket between them.
(3) Connect the lead wire of the fuel pressure gauge set
(special tool) to the power supply (cigarette lighter
socket) and to the MUT-II.
 GDI – On-vehicle Service 13A-109
<When using the fuel pressure gauge>
Fuel pressure gauge (1) Install the fuel pressure gauge on the special tool
O-ring or gasket (for measuring the fuel pressure) putting a suitable
O-ring or gasket between them.
Fuel pump MD998709
(high (2) Install the special tool which was set up in step (1)
pressure) between the high-pressure fuel hose and the fuel pump
MD998742
(high pressure).
High-pressure
fuel hose

5. Connect the MUT-II to the diagnosis connector.

Caution
Turn off the ignition switch before disconnecting or
connecting the MUT-II.
6. Turn the ignition switch to ON. (But do not start the engine.)
7. Select “Item No. 07” from the MUT-II Actuator test to drive
the fuel pump (low pressure) at the fuel tank side. Check
that there are no fuel leaks from any parts.
8. Finish the actuator test or turn the ignition switch to OFF.
9. Start the engine and run at idle.
10. Measure fuel pressure while the engine is running at idle.
Standard value: approximately 324 kPa
11. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
12. If fuel pressure is out of the standard value, 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 poor Replace fuel pressure regulator
fuel pressure regulator (low pressure) (low pressure)
valve seating or settled spring

Low fuel pump (low pressure) delivery Replace the fuel pump (low pressure)
pressure

Fuel pressure too high Binding valve in fuel pressure regula- Replace fuel pressure regulator
tor (low pressure) (low pressure)

Clogged fuel return hose or pipe Clean or replace hose or pipe

13A-110 GDI – On-vehicle Service

13. Stop the engine and check change of fuel pressure gauge
reading. Normal if the reading does not drop within 2
minutes. If it does, observe the rate of drop and
troubleshoot and repair according to the table below.
Symptom Probable cause Remedy

Fuel pressure drops gradually after Leaky fuel pressure regulator (low Replace fuel pressure regulator
engine is stopped pressure) valve seat (low pressure)

Fuel pressure drops sharply Check valve in fuel pump (low Replace the fuel pump (low pressure)
immediately after engine is stopped pressure) is held open

14. Release residual pressure from the fuel pipe line.

NOTE
Refer to the ’00 PAJERO PININ Workshop Manual (Pub.
No. CKRE00E1) GROUP 13A – On-vehicle Service.
15. Remove the fuel pressure gauge and special tools from the
fuel pump (high pressure).
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
16. Replace the O-ring at the end of the high-pressure fuel
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
17. Fit the high-pressure fuel hose to the fuel pump (high
pressure) and tighten the mounting bolt to specified torque.
18. Check for any fuel leaks by following the procedure in
step 7.
19. Disconnect the MUT-II.

MEASUREMENT OF FUEL HIGH PRESSURE BETWEEN

FUEL PUMP (HIGH PRESSURE) AND INJECTORS
NOTE
Measurement of the fuel pressure between the fuel pump
(high pressure) and the injectors should be carried out after
checking that the fuel pressure between the fuel pump (low
Injector inter- pressure) and the fuel pump (high pressure) is normal.
mediate harness
connector 1. Connect the MUT-II to the diagnosis connector.
2. Disconnect the injector intermediate harness connector.
3. Turn the ignition switch to ON.
4. Select “Item No. 74” from the MUT-II Data list.
5. Crank the engine continuously for 2 seconds or more,
and visually check that there are no fuel leaks from any
parts.
Caution
If any fuel leaks appear, stop cranking immediately
and repair the source of the leak.
6. Check if the fuel pressure is more than 1 MPa immediately
after 20 seconds have passed since cranking was finished.
7. If the fuel pressure is lower than 1 MPa, it means that
there is likely to be a leak in the high-pressure fuel system,
so this system should be checked.
 GDI – On-vehicle Service 13A-111
8. Turn the ignition switch to OFF.
9. Connect the injector intermediate harness connector.
10. Start the engine and run at idle.
11. Measure fuel pressure while the engine is running at idle.
Standard value: 4 – 6.9 MPa

12. Check to see that fuel pressure at idle does not drop even
after the engine has been raced several times.
13. If fuel pressure is out of the standard value, troubleshoot
and repair according to the table below.

Symptom Probable cause Remedy

 Fuel pressure too low Fuel leaking to return side due to poor Replace the fuel pump (high pres-
 Fuel pressure drops after racing fuel pressure regulator valve seating sure)
or settled spring in the fuel pump (high
pressure).

Low fuel pump (high pressure) Replace the fuel pump

delivery pressure (high pressure)

Fuel pressure too high Clogged fuel pressure regulator valve Replace the fuel pump (high pres-
in the fuel pump (high pressure) sure)

Clogged fuel return hose or pipe Clean or replace hose or pipe

14. Stop the engine and turn the ignition switch to OFF.
15. Disconnect the MUT-II.
13A-112 GDI – On-vehicle Service

COMPONENT LOCATION
Name Symbol Name Symbol

Fuel pressure sensor C Oxygen sensor (front) B

Ignition failure sensor A Oxygen sensor (rear) D

A B

C
D

Equipment side OXYGEN SENSOR CHECK

connector
<Oxygen sensor (front)>
1. Disconnect the oxygen sensor connector and connect the
special tool (test harness) to the connector on the oxygen
sensor side.
2. Make sure that there is continuity (4.5 – 8.0 Ω at 20C)
between terminal 1 (red clip of special tool) and terminal
Oxygen sensor 3 (blue clip of special tool) on the oxygen sensor connector.
(front)

3. If there is no continuity, replace the oxygen sensor.

4. Warm up the engine until engine coolant is 80C or higher.
Red
Blue

MD998464
 GDI – On-vehicle Service 13A-113
5. Use a jumper wire to connect terminal 1 (red clip) of the
oxygen sensor connector to the battery (+) terminal and
White Black
terminal 3 (blue clip) to the battery (–) terminal.
Caution
Red Be very careful when connecting the jumper wire;
incorrect connection can damage the oxygen sensor.
Blue 6. Connect a digital voltage meter between terminal 2 (black
clip) and terminal 4 (white clip).
7. While repeatedly racing the engine, measure the oxygen
MD9998464 sensor output voltage.
Standard value:
Engine Oxygen sensor Remarks
output voltage
When racing 0.6 – 1.0 V If you make the air/fuel
the engine ratio rich by racing the
engine repeatedly, a nor-
mal oxygen sensor will
output a voltage of 0.6 –
1.0 V.
8. If the sensor is defective, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 – Exhaust Pipe and Main Muffler.

<Oxygen sensor (rear)>

Equipment side connector
1. Disconnect the oxygen sensor connector and connect the
special tool (test harness set) to the connector on the
oxygen sensor side.
2. Make sure that there is continuity (11 – 18 Ω at 20C)
between terminal 1 (red clip of special tool) and terminal
3 (blue clip of special tool) on the oxygen sensor connector.
3. If there is no continuity, replace the oxygen sensor.
Oxygen sensor (rear) NOTE
(1) If the MUT-II does not display the standard value
although no abnormality is found by the above
mentioned continuity test and harness check, replace
the oxygen sensor (rear).
(2) For removal and installation of the oxygen sensor,
refer to GROUP 15 – Exhaust Pipe and Main Muffler.
Blue

Red

MD998464
13A-114 GDI – Fuel Pump (High Pressure)

FUEL PUMP (HIGH PRESSURE)

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
 Engine Cover Removal and Installation (Refer to  High-pressure Fuel Line Air Bleeding
GROUP 11A – Camshaft and Camshaft Oil Seal.) <after installation only> (P.13A-116.)
 Prevention of Fuel Discharge <before removal only>  Resonance Tank Removal and Installation
 Fuel Leak Check <after installation only>

Apply engine oil to all

O-rings during installation.

10 – 13 Nm
1

5
10 – 13 Nm
8
7
6

10
5.0 Nm
23 Nm 10 – 12 Nm

3
9 4
5.0 Nm → 17 Nm
2

Removal steps
A 1. Fuel pump protector B 6. Back-up ring A
2. Furl return hose connection B 7. O-ring
C 3. Fuel pressure hose connection B 8. Back-up ring B
C 4. O-ring A 9. Fuel pump (high-pressure)
B 5. Fuel pipe 10. O-ring
 GDI – Fuel Pump (High Pressure) 13A-115
REMOVAL SERVICE POINT
A FUEL PUMP PROTECTOR REMOVAL
Jack up the transmission, and create sufficient clearance
between the engine and the front deck. Then remove the
fuel pump protector.

INSTALLATION SERVICE POINTS

A FUEL PUMP (HIGH-PRESSURE) INSTALLATION
1. Apply clean engine oil to the O-ring and the roller of the
fuel pump (high-pressure).
2. Insert the fuel pump (high-pressure) into the cylinder head
mounting hole squarely, and finger-tighten the mounting
bolts. The mounting bolts should be tightened securely
at step B.

B BACK-UP RING B/O-RING/BACK-UP RING A/FUEL

Back-up ring A
(either side)
PIPE INSTALLATION
A
1. Install the back-up rings and the O-ring as shown in the
O-ring illustration.
Caution
(1) Install the back-up ring B facing its cutaway
surface toward the opposite side of the O-ring
Cutaway
A surface as shown in the illustration.
Back-up
Section A – A
(2) Confirm the outer diameter of the back-up ring
ring B A. Take care not to install the back-up ring for
the fuel pressure sensor by mistake. (Outer
diameter of the back-up ring A: 14.8 mm)
2. Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not to let any of the engine oil get inside
the fuel pump (high-pressure) or the delivery pipe
assembly.
3. Install the fuel pipe into the fuel pump (high pressure) and
the delivery pipe ports squarely. Insert the pipe securely,
being careful not to twisting it, and then tighten the mounting
bolts to the specified torque.
Tightening torque: 10 – 13 Nm
13A-116 GDI – Fuel Pump (High Pressure)

4. Tighten the fuel pump (high-pressure) mounting bolts to

5.0 Nm in the order shown.
5. Tighten the mounting bolts to 17 Nm in the sequence
1 3 shown as second stage. The final tightening torques should
not vary more than 2.0 Nm.

4 2

C O-RING/FUEL PRESSURE HOSE INSTALLATION

1. Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not to let any of the engine oil get inside
the fuel pump (high pressure).
2. While being careful not to damage the O-ring, turn the
fuel pressure hose to the left and right and connect it
to the fuel pump (high pressure). After connecting, check
that the hose turns smoothly.
3. If the hose does not turn smoothly, the cause may be
that the O-ring is getting caught. Disconnect the hose,
check the O-ring for damage and re-connect the hose
to the fuel pump (high pressure) and then re-check.
4. Tighten the fuel pressure hose mounting bolts to the
specified toque.
Tightening torque: 5.0 Nm

AIR-BLEEDING HIGH-PRESSURE FUEL LINE

1. Run the engine at 2000 r/min for at least 15 seconds
in order to bleed air from the high-pressure fuel line.
NOTE
If air is trapped in the high-pressure fuel line due to the
removal of fuel pipe, diagnosis code No. P.0190 will be
set as abnormal fuel pressure.
2. Finally confirm diagnosis code by using the MUT-II. If
diagnosis code, which indicates defective fuel pressure
sensor system, has been set, erase the code.
 GDI – Injector 13A-117
INJECTOR
REMOVAL AND INSTALLATION
Caution
1. Disconnect the negative battery cable prior to the service work.
2. The injector driver may be hot immediately after each operation, and high voltage and current
flows between the injector driver and the injectors while the engine is running. Handle the
injector driver carefully.

Pre-removal and Post-installation Operation

 Engine Cover Removal and Installation (Refer to  Fuel Leak Check <after installation only>
GROUP 11A – Camshaft and Camshaft Oil Seal.)  High-pressure Fuel Line Air Bleeding
 Prevention of Fuel Discharge <before removal only> <after installation only> (P.13A-116.)

10 – 13 Nm
Apply engine oil to all
O-rings during installation.
22 – 26 Nm
1
7
10
10 2
9 3
9
8 8 5
4

10 – 13 Nm

14 13

20 – 25 Nm
11
18 12
19
20 6
21
17 16
15

Fuel pressure sensor removal steps

1. Fuel pressure sensor connector C 10. Back-up ring B
A E 2. Flange B 11. Injector washer
E 3. Fuel pressure sensor B 12. Injector holder
D 4. O-ring B B 13. Delivery pipe assembly
D 5. Back-up ring B 14. Insulator
Injector removal steps B 15. Injector gasket
B B 16. Injector assembly
 Intake manifold (Refer to GROUP 15.) A 17. Corrugated washer
6. Injector connector A 18. Back-up ring A
C 7. Fuel pipe A 19. O-ring
C 8. Back-up ring A A 20. Back-up ring B
C 9. O-ring 21. Injector
13A-118 GDI – Injector

REMOVAL SERVICE POINT

Fuel pressure A FLANGE REMOVAL
sensor
If the fuel pressure sensor is reused, make mating marks
Flange on the sensor and the flange before removal.
NOTE
The sealing performance and the installation rigidity of the
fuel pressure sensor can be secured by deforming the flange
Mating mark when the sensor is installed. Therefore, the flange must be
reinstalled on the same side and phase as it is removed.
In addition, if the fuel pressure sensor is replaced, it should
be always replaced together with the flange.
B DELIVERY PIPE ASSEMBLY/INJECTOR
ASSEMBLY REMOVAL
Remove the delivery pipe assembly with the injector assembly
still attached.
Caution
Be careful not to drop the injector assembly when
removing the delivery pipe assembly.

Back-up ring A INSTALLATION SERVICE POINTS

(either side) A BACK-UP RING B/O-RING/BACK-UP RING A
A
/CORRUGATED WASHER INSTALLATION
O-ring
1. Install the back-up rings and the O-ring as shown in the
illustration.
Caution
Cutaway (1) Install the back-up ring B facing its cutaway
A surface surface toward the opposite side of the O-ring
Back-up
ring B Section A – A as shown in the illustration.
(2) Confirm the outer diameter of the back-up ring
A. Take care not to install the back-up ring for
the fuel pressure sensor by mistake. (Outer
diameter of the back-up ring A: 14.8 mm)
2. Apply petroleum jelly to the corrugated washer to prevent
it from falling off, and install it in the direction shown.
Caution
The corrugated washer should always be replaced
with a new part. If the corrugated washer is reused,
fuel or gas leak may occur.
Corrugated
washer

B FUEL INJECTOR ASSEMBLY/INJECTOR

GASKET/INSULATOR/DELIVERY PIPE
ASSEMBLY/INJECTOR HOLDER/INJECTOR
WASHER INSTALLATION
1. Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not to let any of the engine oil get inside
the delivery pipe assembly.
 GDI – Injector 13A-119
2. Insert the injector assembly into the mounting hole on the
delivery pipe squarely. Then check that the fuel injector
turns smoothly.
3. If the injector does not turn smoothly, the cause may be that
the O-ring is getting caught. Remove the fuel injector, check
the O-ring for damage and re-connect the injector to the
Mating delivery pipe assembly and then re-check.
mark
4. Align the injector assembly mating mark with the delivery
pipe mating mark.
5. Install the injector gasket and the insulator to the cylinder
head.
6. Assemble the delivery pipe and injector assembly to the
cylinder head, then finger-tighten the mounting bolts.
7. Assemble the injector holder and the injector washer, then
tighten the mounting bolts to the specified torque.
Tightening torque: 20 – 25 Nm
3 1 2 4
8. Tighten the delivery pipe and injector assembly mounting
bolts to the specified torque in the order shown.
Tightening torque: 10 – 13 Nm

C BACK-UP RING B/O-RING/BACK-UP RING A/FUEL

Back-up ring A
(either side)
PIPE INSTALLATION
A
1. Install the back-up rings and the O-ring as shown in the
O-ring illustration.
Caution
(1) Install the back-up ring B facing its cutaway
surface toward the opposite side of the O-ring
Cutaway as shown in the illustration.
A surface
Back-up (2) Confirm the outer diameter of the back-up ring
ring B Section A – A A. Take care not to install the back-up ring for
the fuel pressure sensor by mistake. (Outer
diameter of the back-up ring A: 14.8 mm)
2. Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not to let any of the engine oil get inside
the fuel pump (high-pressure) or the delivery pipe
assembly.
3. Install the fuel pipe into the fuel pump (high pressure) and
the delivery pipe ports squarely. Insert the pipe securely,
being careful not to twisting it, and then tighten the mounting
bolts to the specified torque.
Tightening torque: 10 – 13 Nm
D BACK-UP RING/O-RING INSTALLATION
Assemble the back-up ring and the O-ring as shown.
O-ring
A Caution
Be careful not to confuse this back-up ring with back-up
ring A for the injector or the fuel pipe. (Back-up ring outer
diameter: 15.1 mm)
A
Section A – A
Back-up ring
(either side)
13A-120 GDI – Injector

E FUEL PRESSURE SENSOR/FLANGE

INSTALLATION
1. Apply a small amount of fresh engine oil to the O-ring.
Caution
Be careful not to allow the engine oil to enter the
delivery pipe.

2. Make the part number on the fuel pressure sensor face

as shown.
Fuel pressure sensor
If the fuel pressure sensor is reused, align the mating
marks to install it to the delivery pipe.
Caution
If the fuel pressure sensor is replaced, always replace
it together with the flange.

Parts number
 GDI – Throttle Body 13A-121
THROTTLE BODY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
 Engine Coolant Draining and Supplying
 Resonance Tank Removal and Installation

19 Nm

19 Nm
2

3 5

1
19 Nm

4
6
3

Removal steps
1. Throttle position sensor connector 5. Throttle body stay
2. Throttle control servo connector B 6. Throttle body assembly
3. Water hose connection A 7. Throttle body gasket
4. Brake booster vacuum hose
connection
13A-122 GDI – Throttle Body

INSTALLATION SERVICE POINTS

A THROTTLE BODY GASKET INSTALLATION
Install the throttle body gasket with its projection facing as
shown in the illustration.
Projection

B THROTTLE BODY ASSEMBLY INSTALLATION

If the throttle body assembly is replaced, initialize the
electronic-controlled throttle valve system.
Initialization
Turn on the ignition switch, and turn it to LOCK (OFF) position
within one second. Then leave it for at least ten seconds
with the ignition switch in LOCK (OFF) position.
 GDI – Throttle Body 13A-123
DISASSEMBLY AND REASSEMBLY

Disassembly steps
A 1. Throttle position sensor
2. Throttle body

REASSEMBLY SERVICE POINT

A THROTTLE POSITION SENSOR INSTALLATION
1. Position the throttle position sensor on the throttle body
along the dotted line as shown in the illustration.
2. Rotate the throttle position sensor anticlockwise as shown
in the illustration, and then tighten the screws.

3. Measure resistance value between terminal Nos. 1 (sensor

Throttle posi-
power supply) and 2 (throttle position sensor 1st-channel
Earth tion sensor output) as well as 1 (sensor power supply) and 4 (throttle
Sensor power
supply (2nd channel) position sensor 2nd-channel output).
output
Normal condition

Open the throttle valve slowly Resistance value changes

from the idle position to smoothly in response to
full-open position. throttle valve opening angle.
Throttle position sensor
(1st channel) output 4. If the resistance value does not change smoothly, replace
the throttle position sensor.
 SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN No.: MSB-00E13-001

Date: 2001-06-03 <Model> <M/Y>

Subject: AVAILABILITY OF DRIVE CYCLE PATTERNS (EC)GALANT(EA0) 01-10
FOR 2001 MODEL CARS (EC)SPACE STAR
(EC) SPACE
RUNNER/SPACE
WAGON(N80, N90)
(EC)PAJERO
Group: FUEL Draft No.: 00AL602317 SPORT
(K80W,K90W)
(EC)PAJERO/
MONTERO
(V60, V70)
INFORMATION INTERNATIONAL (EC)CARISMA
CAR
ADMINISTRATION T.MASAKI-MANAGER
(EC)PAJERO PININ
OFFICE TECHNICAL SERVICE PLANNING (H60,H70)
1. Description:
On the 2001 model cars equipped with the on-board diagnostics system, the drive cycle patterns
have been made available.
Performing the running test of the car using these drive cycle patterns makes it possible to
monitor all the diagnosis codes that are required for operation of the car in order to determine if
the applicable system is operating properly or not.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
2001 GALANT PWDE9611-B (English) 4G64-GDI:13I-8
Workshop Manual Supplement PWDS9612-B (Spanish) 4G63-MPI:13A-7
PWDF9613-B (French) 6A13-MPI:13A-97
PWDG9614-B (German)
PWDD9615-B (Dutch)
PWDW9616-B (Swedish)
2001 SPACE RUNNER/ SPACE WAGON PWDE9803-C (English) 4G64-GDI:13A-9
Workshop Manual Supplement PWDS9804-C (Spanish) 4G63-MPI:13D-12
PWDF9805-C (French)
PWDG9806-C (German)
PWDD9807-C (Dutch)
PWDW9808-C (Swedish)
2001 CARISMA PWDE9502-E (English) 4G93-GDI:13J-8
Workshop Manual Supplement PWDS9503-E (Spanish) 4G92-MPI:13A-7
PWDF9504-E (French)
PWDG9505-E (German)
PWDD9506-E (Dutch)
PWDW9507-E (Swedish)
2001 SPACE STAR CMXE99E1-A (English) 4G93-GDI:13A-9
Workshop Manual Supplement 4G13-MPI:13B-7
2001 COLT PWME9511-C (English) 4G13-MPI:13A-7
Workshop Manual Supplement PWMS9512-C (Spanish) 4G93-MPI:13A-88
PWMF9513-C (French)
PWMG9514-C (German)
PWMD9515-C (Dutch)
PWMW9516-C (Swedish)
2001 PAJERO PWJE0001(1/2) (English) 6G74-GDI:13A-12
Workshop Manual VOL1
2001 MONTERO PWJS0002(1/2) (Spanish)
Workshop Manual VOL1
2001 PAJERO/MONTERO PWJT0008R (English)
Workshop Manual CD-ROM (Spanish)
(French)
(German)
2001 PAJERO SPORT PWJE9812-B (English) 6G72-MPI:13A-8
Workshop Manual Supplement PWJS9813-B (Spanish)
PWJF9814-B (French)
PWJG9815-B (German)
2001 PAJERO PININ CKRE99E1-A (English) 4G93-GDI: 13A-9
Workshop Manual Supplement

2
3. Details:2001 GALANT Workshop Manual Supplement 4G64
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G64
GDI - Troubleshooting

DRIVE CYCLE
Performing the running test of the car using the following five drive cycle patterns makes it possible to
monitor all the diagnosis codes that are required for operation of the car in order to determine if the
applicable system is operating properly or not.
In other words, doing such a drive allows to regenerate any kind of trouble which involves illuminating the
Engine Warning Lamp (Check Engine Lamp) and to verify the repair procedure has eliminated the trouble
[the Engine Warning Lamp (Check Engine Lamp) is no longer illuminated].

Caution
Two technicians should always be in the vehicle when carrying out a test drive.

NOTE
Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diagnosis
code if it has been output.

DRIVE CYCLE PATTERN LIST

PROCEDURE MONITOR ITEM DIAGNOSIS CODE
1 Catalytic converter monitor P0420
2 Heated oxygen sensor <front> monitor P0130
3 Fuel trim monitor P0170
4 Feed back monitor P0125
5 Other monitor P0136, P0201, P0202, P0203, P0204, P0300,
P0301, P0302, P0303, P0304, P0325

NOTE
The vehicle speed sensor (P0500) and the power steering fluid pressure switch (P0551) are used to
determine if the system is operating properly or not through use of the Data List function of the MUT-II.

3
2001 GALANT Workshop Manual Supplement 4G64
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G64
GDI - Troubleshooting

PROCEDURE 1
Monitor item CATALYTIC CONVERTER MONITOR (P0420)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 10 minutes or more.

5 minutes or more

100 km/h or more

5 minutes or more

100 – 120 km/h

Vehicle
speed

Stopping and
braking permitted

Time

Engine start Ignition switch ”LOCK”

(OFF) position
Y6005BY

Inspection • Atmospheric temperature :-10 °C or more

conditions • Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 km/h or more.
3. Travel for 5 minutes or more while keeping the vehicle speed is 100 km/h or more.
4. Decelerate until the vehicle speed is 100 – 120 km/h or less.
5. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 100 –
120 km/h and travel for 5 minutes or more.
• Stopping and braking during this operation are permitted.
6. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

4
2001 GALANT Workshop Manual Supplement 4G64
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G64
GDI - Troubleshooting

PROCEDURE 2
OXYGEN SENSOR <FRONT> MONITOR (P0130)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 5 minutes or more.

5 minutes or more

80 – 100 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 80 – 100 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 80 –
100 km/h and travel for 5 minutes or more.
• Stopping and braking during this operation are permitted. Keep the accelerator pedal
opening degree constant for 1 minute or more after each acceleration.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

5
2001 GALANT Workshop Manual Supplement 4G64
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G64
GDI - Troubleshooting

PROCEDURE 3
monitor item FUEL TRIM MONITOR (P0170)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 15 minutes or more.

15 minutes or more

80 – 110 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 80 – 110 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 80 –
110 km/h and travel for 15 minutes or more.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

6
2001 GALANT Workshop Manual Supplement 4G64
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G64
GDI - Troubleshooting

PROCEDURE 4
monitor item FEED BACK MONITOR (PO125)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 5 minutes or more.

5 minutes or more

100 – 120 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 – 120 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 100 –
120 km/h and travel for 5 minutes or more.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

7
2001 GALANT Workshop Manual Supplement 4G64
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G64
GDI - Troubleshooting

PROCEDURE 5
monitor item OTHER MONITOR
Diagnosis P0136, P0201, P0202, P0203, P0204, P0300, P0301, P0302, P0303, P0304, P0325
code No.
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 6 minutes or more.

5 minutes or more

60 km/h or more

Vehicle
speed 30 seconds or more
Engine: Idling
Transmission: Neutral

Time

Engine start
Ignition switch ”LOCK”
(OFF) position
Y6009BY
Inspection • Engine coolant temperature : 85 °C or more
conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 60 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at
60km/h or more and travel for 5 minutes or more.
4. Return the vehicle to the shop
5. After stopping the vehicle, continue idling for 30 seconds, and then turn the ignition switch to
”LOCK” (OFF) position.
• A/C switch : OFF
• Light and all accessories : OFF
• Transmission : Neutral

8
2001 CARISMA Workshop Manual Supplement 4G93
2001 SPACE STAR Workshop Manual Supplement 4G93
GDI - Troubleshooting

DRIVE CYCLE
Performing the running test of the car using the following five drive cycle patterns makes it possible to
monitor all the diagnosis codes that are required for operation of the car in order to determine if the
applicable system is operating properly or not.
In other words, doing such a drive allows to regenerate any kind of trouble which involves illuminating the
Engine Warning Lamp (Check Engine Lamp) and to verify the repair procedure has eliminated the trouble
[the Engine Warning Lamp (Check Engine Lamp) is no longer illuminated].

Caution
Two technicians should always be in the vehicle when carrying out a test drive.

NOTE
Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diagnosis
code if it has been output.

DRIVE CYCLE PATTERN LIST

PROCEDURE MONITOR ITEM DIAGNOSIS CODE
1 Catalytic converter monitor P0420
Catalyst temperature sensor <M/T> monitor P0425
(DX only)
2 Heated oxygen sensor <front> monitor P0130
3 Fuel trim monitor P0170
4 Feed back monitor P0125
5 Other monitor P0136, P0201, P0202, P0203, P0204, P0300,
P0301, P0302, P0303, P0304, P0325

NOTE
The vehicle speed sensor (P0500) and the power steering fluid pressure switch (P0551) are used to
determine if the system is operating properly or not through use of the Data List function of the MUT-II.

9
2001 CARISMA Workshop Manual Supplement 4G93
2001 SPACE STAR Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 1
monitor item CATALYTIC CONVERTER MONITOR (P0420)
CATALYTIC TEMPERATURE SENSOR <M/T> MONITOR (P0425)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 12 minutes or more.
*: 1 minute or less

Vehicle
speed 5 minutes or more 3 minutes or more 3 minutes or more

100 km/h or more 100 – 120 km/h 100 – 120 km/h

Time

Stop: 25 – 30 seconds Stop: 25 – 30 seconds Ignition switch

Engine start
”LOCK” (OFF)
position

Y6004BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 km/h.
3. Travel for 5 minutes or more while keeping the vehicle speed is 100 km/h or more.
4. Decelerate until the vehicle speed is 0 km/h within 1 minute and stop for 25 – 30 seconds.
5. Accelerate until the vehicle speed at 100 – 120 km/h within 1 minute.
6. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at
100 - 120 km/h and travel for 3 minutes or more.
7. Repeat the above procedure 4 – 6.
8. Return the vehicle to the shop, then turn the ignition switch ”LOCK” (OFF) position.

10
2001 CARISMA Workshop Manual Supplement 4G93
2001 SPACE STAR Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 2
monitor item OXYGEN SENSOR <FRONT> MONITOR (P0130)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 7 minutes or more.

*: 1 minute or less

3 minutes or more 3 minutes or more

100 – 120 km/h 100 – 120 km/h

Vehicle
speed

Time

Stop: 25 – 30 seconds
Engine start Ignition switch
”LOCK” (OFF)
position
Y6006BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 – 120 km/h within 1 minute.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 100 –
120 km/h and travel for 3 minutes or more.
4. Decelerate until the vehicle speed is 0 km/h within 1 minute and stop for 25 – 30 seconds.
5. Repeat the above procedure 2 – 3.
6. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

11
2001 CARISMA Workshop Manual Supplement 4G93
2001 SPACE STAR Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 3
monitor item FUEL TRIM MONITOR (P0170)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 13 minutes or more.
*: 1 minute or less

Vehicle
speed

3 minutes or more 3 minutes or more 3 minutes or more 3 minutes or more

100 – 120 km/h 100 – 120 km/h 100 – 120 km/h 100 – 120 km/h

Time
Stop: 25 – 30 seconds Stop: 25 – 30 seconds Stop: 25 – 30 seconds
Engine start Ignition switch
”LOCK” (OFF)
position
Y6007BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 – 120 km/h within 1 minute.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 100 –
120 km/h and travel for 3 minutes or more.
4. Decelerate until the vehicle speed is 0 km/h within 1 minute and stop for 25 – 30 seconds.
5. Repeat the above procedure 2 - 4 two times and 2 - 3 one time.
6. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

12
2001 CARISMA Workshop Manual Supplement 4G93
2001 SPACE STAR Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 4
monitor item FEED BACK MONITOR (P0125)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 5 minutes or more.

1 minute
or less
5 minutes or more

90 – 110 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Engine start Ignition switch

”LOCK” (OFF)
position
Y6008BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 90 – 110 km/h within 1 minute.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 90 –
110 km/h and travel for 5 minutes or more.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

13
2001 CARISMA Workshop Manual Supplement 4G93
2001 SPACE STAR Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 5
OTHER MONITOR
Diagnosis P0136, P0201, P0202, P0203, P0204, P0300, P0301, P0302, P0303, P0304, P0325
code No.
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 6 minutes or more.

5 minutes or more

60 km/h or more

Vehicle
speed 30 seconds or more
Engine: Idling
Transmission: Neutral

Time

Engine start
Ignition switch ”LOCK”
(OFF) position
Y6009BY
Inspection • Engine coolant temperature : 85 °C or more
conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 60 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at
60km/h or more and travel for 5 minutes or more.
4. Return the vehicle to the shop
5. After stopping the vehicle, continue idling for 30 seconds, and then turn the ignition switch to
”LOCK” (OFF) position.
• A/C switch : OFF
• Light and all accessories : OFF
• Transmission : Neutral

14
2001 PAJERO/MONTERO WAGON Workshop Manual 6G74
GDI - Troubleshooting

DRIVE CYCLE
Performing the running test of the car using the following five drive cycle patterns makes it possible to
monitor all the diagnosis codes that are required for operation of the car in order to determine if the
applicable system is operating properly or not.
In other words, doing such a drive allows to regenerate any kind of trouble which involves illuminating the
Engine Warning Lamp (Check Engine Lamp) and to verify the repair procedure has eliminated the trouble
[the Engine Warning Lamp (Check Engine Lamp) is no longer illuminated].

Caution
Two technicians should always be in the vehicle when carrying out a test drive.

NOTE
Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diagnosis
code if it has been output.

DRIVE CYCLE PATTERN LIST

PROCEDURE MONITOR ITEM DIAGNOSIS CODE
1 Catalytic converter monitor P0420
Heated oxygen sensor <front> monitor P0130
2 Fuel trim monitor P0170
3 Feed back monitor P0125
4 Other monitor P0136, P0201, P0202, P0203, P0204, P0205,
P0206, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0325

NOTE
The vehicle speed sensor (P0500) and the power steering fluid pressure switch (P0551) are used to
determine if the system is operating properly or not through use of the Data List function of the MUT-II.

15
2001 PAJERO/MONTERO Workshop Manual 6G74
GDI - Troubleshooting

PROCEDURE 1
monitor item CATALYTIC CONVERTER MONITOR (P0420)
OXYGEN SENSOR <FRONT> MONITOR (P0130)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 10 minutes or more.

5 minutes or more

100 km/h or more 100 – 120 km/h

5 minutes or more

60 – 80 km/h
Vehicle
speed

Stopping and braking

permitted

Time

Engine start Ignition switch

”LOCK” (OFF)
position
Y6005BY

Inspection • Atmospheric temperature : -10 °C or more

conditions • Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 km/h or more.
3. Travel for 5 minutes or more while keeping the vehicle speed is 100 km/h or more.
4. Decelerate until the vehicle speed is 60 - 80 km/h or less.
5. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 60 - 80
km/h and travel for 5 minutes or more.
• Stopping and braking during this operation are permitted.
6. Return the vehicle to the shop, then turn the ignition switch ”LOCK” (OFF) position.

16
2001 PAJERO/MONTERO Workshop Manual 6G74
GDI - Troubleshooting

PROCEDURE 2
monitor item FUEL TRIM MONITOR (P0170)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 15 minutes or more.

15 minutes or more

80 – 110 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 80 – 110 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 80 –
110 km/h and travel for 15 minutes or more.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

17
2001 PAJERO/MONTERO Workshop Manual 6G74
GDI - Troubleshooting

PROCEDURE 3
monitor item FEED BACKK MONITOR (P0125)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 5 minutes or more.

5 minutes or more

100 – 120 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 – 120 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 100 –
120 km/h and travel for 5 minutes or more.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

18
2001 PAJERO/MONTERO Workshop Manual 6G74
GDI - Troubleshooting

PROCEDURE 4
monitor item OTHER MONITOR
Diagnosis P0136, P0201, P0202, P0203, P0204, P0205, P0206, P0300, P0301, P0302, P0303, P0304,
code No. P0305, P0306, P0325
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 6 minutes or more.

5 minutes or more

60 km/h or more

Vehicle
speed 30 seconds or more
Engine: Idling
Transmission: Neutral

Time

Engine start
Ignition switch ”LOCK”
(OFF) position
Y6009BY
Inspection • Engine coolant temperature : 85 °C or more
conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 60 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 60
km/h or more and travel for 5 minutes or more.
4. Return the vehicle to the shop
5. After stopping the vehicle, continue idling for 30 seconds, and then turn the ignition switch to
”LOCK” (OFF) position.
• A/C switch : OFF
• Light and all accessories: OFF
• Transmission : Neutral

19
2000 PAJERO/PININ Workshop Manual Supplement 4G93
GDI - Troubleshooting

DRIVE CYCLE
Performing the running test of the car using the following five drive cycle patterns makes it possible to
monitor all the diagnosis codes that are required for operation of the car in order to determine if the
applicable system is operating properly or not.
In other words, doing such a drive allows to regenerate any kind of trouble which involves illuminating the
Engine Warning Lamp (Check Engine Lamp) and to verify the repair procedure has eliminated the trouble
[the Engine Warning Lamp (Check Engine Lamp) is no longer illuminated].

Caution
Two technicians should always be in the vehicle when carrying out a test drive.

NOTE
Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diagnosis
code if it has been output.

DRIVE CYCLE PATTERN LIST

PROCEDURE MONITOR ITEM DIAGNOSIS CODE
1 Catalytic converter monitor P0420
2 Heated oxygen sensor <front> monitor P0130
3 Fuel trim monitor P0170
4 Feed back monitor P0125
5 Other monitor P0136, P0201, P0202, P0203, P0204, P0300,
P0301, P0302, P0303, P0304, P0325

NOTE
The vehicle speed sensor (P0500) and the power steering fluid pressure switch (P0551) are used to
determine if the system is operating properly or not through use of the Data List function of the MUT-II.

20
2000 PAJERO/PININ Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 1
monitor item CATALYTIC CONVERTER MONITOR (P0420)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 10 minutes or more.

5 minutes or more

100 km/h or more 100 – 120 km/h

5 minutes or more

90 – 110 km/h
Vehicle
speed

Stopping and braking

permitted

Time

Engine start Ignition switch

”LOCK” (OFF)
position
Y6005BY

Inspection • Atmospheric temperature : -10 °C or more

conditions • Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 km/h or more.
3. Travel for 5 minutes or more while keeping the vehicle speed is 100 km/h or more.
4. Decelerate until the vehicle speed is 90 –110 km/h or less.
5. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 90 -
110 km/h and travel for 5 minutes or more.
• Stopping and braking during this operation are permitted.
6. Return the vehicle to the shop, then turn the ignition switch ”LOCK” (OFF) position.

21
2000 PAJERO/PININ Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 2
OXYGEN SENSOR <FRONT> MONITOR (P0130)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 5 minutes or more.

5 minutes or more

80 – 100 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 80 – 100 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 80 –
100 km/h and travel for 5 minutes or more.
• Stopping and braking during this operation are permitted. Keep the accelerator pedal
opening degree constant for 1 minute or more after each acceleration.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

22
2000 PAJERO/PININ Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 3
Monitor item FUEL TRIM MONITOR (P0170)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 15 minutes or more.

15 minutes or more

80 – 110 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 80 – 100 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 80 –
110 km/h and travel for 15 minutes or more.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

23
2000 PAJERO/PININ Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 4
Monitor item FEED BACK MONITOR (P0125)
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 5 minutes or more.

5 minutes or more

100 – 120 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : 85 °C or more

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 100 – 120 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 100 –
120 km/h and travel for 15 minutes or more.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

24
2000 PAJERO/PININ Workshop Manual Supplement 4G93
GDI - Troubleshooting

PROCEDURE 5
monitor item OTHER MONITOR
Diagnosis P0136, P0201, P0202, P0203, P0204, P0300, P0301, P0302, P0303, P0304, P0325
code No.
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 6 minutes or more.

5 minutes or more

60 km/h or more

Vehicle
speed 30 seconds or more
Engine: Idling
Transmission: Neutral

Time

Engine start
Ignition switch ”LOCK”
(OFF) position
Y6009BY
Inspection • Engine coolant temperature : 85 °C or more
conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 60 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 60
km/h or more and travel for 5 minutes or more.
4. Return the vehicle to the shop
5. After stopping the vehicle, continue idling for 30 seconds, and then turn the ignition switch to
”LOCK” (OFF) position.
• A/C switch : OFF
• Light and all accessories: OFF
• Transmission : Neutral

25
2001 GALANT Workshop Manual Supplement 4G63, 6A13
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G63
2001 CARISMA Workshop Manual Supplement 4G92
2001 SPACE STAR Workshop Manual Supplement 4G13
2001 COLT Workshop Manual Supplement 4G13, 4G93
2001 PAJERO SPORT Workshop Manual Supplement 6G72
GDI - Troubleshooting

DRIVE CYCLE
Performing the running test of the car using the following five drive cycle patterns makes it possible to
monitor all the diagnosis codes that are required for operation of the car in order to determine if the
applicable system is operating properly or not.
In other words, doing such a drive allows to regenerate any kind of trouble which involves illuminating the
Engine Warning Lamp (Check Engine Lamp) and to verify the repair procedure has eliminated the trouble
[the Engine Warning Lamp (Check Engine Lamp) is no longer illuminated].

Caution
Two technicians should always be in the vehicle when carrying out a test drive.

NOTE
Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diagnosis
code if it has been output.

DRIVE CYCLE PATTERN LIST

PROCEDURE MONITOR ITEM DIAGNOSIS CODE (DTC)
1 2 3
1 Catalytic converter monitor P0420* , P0421* , P0431* ,
2 Heated oxygen sensor <front> monitor P0130
3 Other monitor P0136, P0201, P0202, P0203, P0204,
3
P0205* , P0300, P0301, P0302, P0303,
3 3 4
P0304, P0305* , P0306* , P0325*

NOTE
*1: 4G63
*2: 4G13, 4G92, 4G93, 6A13, 6G72
*3: 6A13, 6G72
*4: 4G13, 4G63, 4G92, 4G93, 6A13

26
2001 GALANT Workshop Manual Supplement 4G63, 6A13
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G63
2001 CARISMA Workshop Manual Supplement 4G92
2001 SPACE STAR Workshop Manual Supplement 4G13
2001 COLT Workshop Manual Supplement 4G13, 4G93
2001 PAJERO SPORT Workshop Manual Supplement 6G72
GDI - Troubleshooting

PROCEDURE 1
CATALYTIC CONVERTER MONITOR
Diagnosis P0420, P0421, P0431
code No.
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 16 minutes or more.

6 minutes or more

90 km/h or more 10 minutes or more

55 – 80 km/h

Vehicle
speed
Stopping and braking
permitted

Time

Engine start Ignition switch

”LOCK” (OFF)
position
Y6001BY

Inspection • Atmospheric temperature : -10 °C or more

conditions • Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 90 km/h or more.
3. Travel for 6 minutes or more while keeping the vehicle speed is 90 km/h or more.
4. Decelerate until the vehicle speed is 80 km/h or less.
5. While traveling at 55 – 80 km/h for 10 minutes or more, fully close the throttle at least once in 2
minutes and decelerate for 10 seconds or more.
• Do not repeat deceleration too often.
• Vehicle speed may go below 55 km/h after the deceleration.
• Stopping and braking during this operation are permitted.
(If stopped or drive at 55 km/h or less for more than 5 minutes the monitoring may be
stopped. In this case please restart monitoring from the beginning.)
6. After completing the above deceleration, bring the vehicle speed back to 55 – 80 km/h and keep
it in the range until starting the deceleration again.
• Repeat the above deceleration at least 5 times.
7. Return the vehicle to the shop, the turn the ignition switch ”LOCK” (OFF) position.

27
2001 GALANT Workshop Manual Supplement 4G63, 6A13
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G63
2001 CARISMA Workshop Manual Supplement 4G92
2001 SPACE STAR Workshop Manual Supplement 4G13
2001 COLT Workshop Manual Supplement 4G13, 4G93
2001 PAJERO SPORT Workshop Manual Supplement 6G72
GDI - Troubleshooting

PROCEDURE 2
OXYGEN SENSOR <FRONT> MONITOR
Diagnosis P0130
code No.
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 16 minutes or more.

16 minutes or more

55 – 80 km/h

Vehicle
speed
Stopping and
braking permitted

Time

Ignition switch ”LOCK”

Engine start (OFF) position
Y6002BY

Inspection • Engine coolant temperature : After engine warm up.

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 55 – 80 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 55 –80
km/h and travel for 16 minutes or more.
• Stopping and braking during this operation are permitted.
4. Return the vehicle to the shop, then turn the ignition switch “LOCK” (OFF) position.

28
2001 GALANT Workshop Manual Supplement 4G63, 6A13
2001 SPACE RUNNER/SPACE WAGON Workshop Manual Supplement 4G63
2001 CARISMA Workshop Manual Supplement 4G92
2001 SPACE STAR Workshop Manual Supplement 4G13
2001 COLT Workshop Manual Supplement 4G13, 4G93
2001 PAJERO SPORT Workshop Manual Supplement 6G72
GDI - Troubleshooting

PROCEDURE 3
OTHER MONITOR
Diagnosis P0136, P0201, P0202, P0203, P0204, P0205, P0206, P0300, P0301, P0302, P0303, P0304,
code No. P0305, P0306, P0325, P0500, P0551
Drive cycle One trip monitor [from start to ignition switch to “LOCK” (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 21 minutes or more.

16 minutes or more

55 km/h or more

Vehicle
speed 5 minutes or more
Engine: Idling
Transmission: Neutral

Time

Engine start Ignition switch ”LOCK”

(OFF) position
Y6003BY

Inspection • Engine coolant temperature : After engine warm up.

conditions • Atmospheric temperature : -10 °C or more
• Condition of A/T :Selector lever D range, overdrive switch “ON” position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 55 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 55
km/h or more and travel for 16 minutes or more.
4. Return the vehicle to the shop
5. After stopping the vehicle, continue idling for 5 minutes, and then turn the ignition switch to
”LOCK” (OFF) position.

29
 FUEL SUPPLY
Click on the applicable bookmark to selected the required model year
 13B-1

FUEL SUPPLY
CONTENTS

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fuel Pump Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13B-2 FUEL SUPPLY – Fuel Tank

FUEL TANK
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Fuel Draining D Fuel Supplying.
D Reduce the Inner Pressure of Fuel Line and Hose D Checking for Fuel Leaks
(Refer to GROUP 13 – On-vehicle Service.) D Rear Propeller Shaft Installation
D Center Exhaust Pipe Removal (Refer to GROUP 25.)
(Refer to GROUP 15.) D Center Exhaust Pipe Installation
D Rear Propeller Shaft Removal (Refer to GROUP 15.)
(Refer to GROUP 25.)

10 2 – 3 Nm
5
6 16
15
11
20 10
12
23 21 5 9
4
2 – 3 Nm

19 13
17 18
22
2 – 3 Nm 7
12
2 – 3 Nm 14
3
19

1
8

13 – 16 Nm

Removal steps
1. Parking brake cable clamp 12. Vapour hose
mounting nut 13. Fuel check valve
2. Filler hose 14. Fuel tank harness
3. Leveling hose 15. Fuel pump module
"AA 4. High pressure tube connection 16. Retainer plate
5. Vapour hose connection 17. Packing
6. Return hose connection 18. Pipe and gauge assembly
7. Harness connector connection 19. Valve assembly
8. Fuel tank assembly 20. Fuel filler cap
"AA 9. High pressure tube 21. Filler neck protector
10. Return hose 22. Filler neck assembly
"AA 11. Suction tube 23. Packing
 FUEL SUPPLY – Fuel Tank 13B-3
INSTALLATION SERVICE POINT
A
SUCTION TUBE/HIGH PRESSURE TUBE
CONNECTION
Caution
After the connection, pull the high pressure tube and
suction tube gently in the direction of removal to check
that they are firmly connected.

Fuel pump INSPECTION

Fuel hose module
FUEL PUMP MODULE/PIPE AND GAUGE ASSEMBLY
Fuel tube Fuel tube REPLACEMENT
1. Remove the rear seat cushion.
2. Remove the service hole cover.
3. Disconnect the harness connector, fuel hose and tube.
4. Unscrew the mounting nuts, and then remove the pipe
and gauge assembly and fuel pump module.
5. Install the pipe and gauge assembly and fuel pump module.
Harness
connector Tighten the mounting nuts to the specified torque.
Specified torque: 2 – 3 Nm
Fuel tube Fuel hose 6. Connect the fuel hose, fuel tube and harness connector.
Caution
After the connection, pull the high pressure tube and
suction tube gently in the direction of removal to check
that they are firmly connected.
7. Install the service hole cover.
Pipe and
gauge 8. Install the rear seat cushion.
Harness assembly
connector

FUEL GAUGE UNIT CHECK

Refer to GROUP 54 – Combination Meter.
13B-4 FUEL SUPPLY – Fuel Tank

DISASSEMBLY AND REASSEMBLY

FUEL PUMP MODULE

13

2
12
7
10
11
6

9
7

1
8
5

Disassembly steps
1. Fuel gauge unit 9. Stopper
2. Gauge harness 10. Fuel pressure regulator
3. Bracket (low-pressure) and assist pump
4. Cushion assembly
5. Fuel pump (low-pressure) A
11. O-ring
6. Fuel tube 12. Fuel hose
A
7. Grommet 13. Fuel filter assembly
8. Housing

REASSEMBLY SERVICE POINT

A
O-RING/GROMMET INSTALLATION
Apply a fuel to O-ring and grommet before installing them,
to prevent them from being damaged or twisted.
13B-2 FUEL SUPPLY – General/Fuel Tank

GROUP 13B
FUEL SUPPLY
GENERAL
OUTLINE OF CHANGES
The following service procedures have been established due to the addition of the vehicles with 4G93-MPI
engine.

FUEL TANK
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Fuel Draining D Fuel Supplying.
D Reduce the Inner Pressure of Fuel Line and Hose D Checking for Fuel Leaks
(Refer to GROUP 13C – On-vehicle Service.) D Rear Propeller Shaft Installation
D Center Exhaust Pipe Removal D Center Exhaust Pipe Installation
(Refer to GROUP 15.) (Refer to GROUP 15.)
D Rear Propeller Shaft Removal
 FUEL SUPPLY – Fuel Tank 13B-3
2.5 ± 0 .5 N · m
10
6 16
15 11
20
21 5 12 9
23 4 2.5 ± 0 .5 N · m

12
13 18
22 17
19 12
2.5 ± 0 . 5 N · m
7
3 19 14
2.5 ± 0 . 5 N ·m

1 8
15 ± 1 N ·m

Removal steps
1. Parking brake cable clamp 12. Vapour hose
mounting nut 13. Fuel check valve
2. Filler hose 14. Fuel tank harness
3. Leveling hose 15. Fuel pump module
"AA 4. High pressure tube connection 16. Retainer plate
5. Vapour hose connection 17. Packing
6. Return hose connection 18. Pipe and gauge assembly
7. Harness connector connection 19. Valve assembly
8. Fuel tank assembly 20. Fuel filler cap
"AA 9. High pressure tube 21. Filler neck protector
10. Return hose 22. Filler neck assembly
11. Suction hose 23. Packing

INSTALLATION SERVICE POINT

"AA HIGH PRESSURE TUBE CONNECTION
Caution
After the connection, pull the high pressure tube gently
in the direction of removal to check that is firmly
connected.
13B-4 FUEL SUPPLY – Fuel Tank

INSPECTION
Return hose
FUEL PUMP MODULE/PIPE AND GAUGE ASSEMBLY
Suction REPLACEMENT
hose
1. Remove the rear seat cushion.
2. Remove the service hole cover.
3. Disconnect the harness connector, fuel hose and tube.
4. Unscrew the mounting nuts, and then remove the pipe
High and gauge assembly and fuel pump module.
pressure 5. Install the pipe and gauge assembly and fuel pump module.
tube Harness
connector Tighten the mounting nuts to the specified torque.
Fuel pump
module Tightening torque: 2.5 ± 0.5 N⋅m
Suction hose 6. Connect the fuel hose, fuel tube and harness connector.
Caution
After the connection, pull the high pressure tube and
suction tube gently in the direction of removal to check
that they are firmly connected.
Pipe and 7. Install the service hole cover.
gauge 8. Install the rear seat cushion.
Harness assembly
connector
 FUEL SUPPLY – Fuel Tank 13B-5
DISASSEMBLY AND REASSEMBLY
FUEL PUMP MODULE
13

12

2
7

11
10 6
1

9
5

8 4

Disassembly steps
1. Fuel gauge unit 8. Housing
2. Gauge harness 9. Stopper
3. Bracket 10. Assist pump assembly
4. Cushion 11. Fuel hose (suction)
5. Fuel pump 12. Fuel hose (return)
6. Fuel tube 13. Fuel filter assembly
"AA 7. Grommet

REASSEMBLY SERVICE POINT

"AA GROMMET INSTALLATION
Apply a fuel to grommet before installing them, to prevent
them from being damaged or twisted.
NOTES
MULTIPOINT FUEL
INJECTION (MPI)
<4G9>
Click on the applicable bookmark to selected the required model year
 13C-1

MULTIPOINT FUEL
INJECTION (MPI)
<4G9>
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fuel Pump Operation Check . . . . . . . . . . . . . . . . . 100

Component Location . . . . . . . . . . . . . . . . . . . . . . . . 101
Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Control Relay and Fuel Pump Relay Continuity
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 2 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Intake Air Temperature Sensor Check . . . . . . . . . 102
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5
Engine Coolant Temperature Sensor
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Throttle Position Sensor Check . . . . . . . . . . . . . . . 103
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . . . 103
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 8 Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 96 Idle Speed Control (ISC) Servo (Stepper Motor)
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Throttle Body (Throttle Valve Area) Purge Control Solenoid Valve Check . . . . . . . . . 108
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
EGR Control Solenoid Valve Check . . . . . . . . . . . 108
Throttle Position Sensor Adjustment . . . . . . . . . . . 96
Basic Idle Speed Adjustment . . . . . . . . . . . . . . . . . . 97 INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 98 THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 111
Fuel Pump Connector Disconnection
(How to Reduce the Fuel Pressure) . . . . . . . . . . . 100
13C-2 MPI <4G9> – General Information

GENERAL
OUTLINE OF CHANGES
The following contents have been established to correspond to the addition of vehicles with 4G9-MPI
engine.
GENERAL INFORMATION
The Multipoint Fuel Injection System consists activities such as fuel injection control, idle
of sensors which detect the engine conditions, speed control and ignition timing control. In
the engine-ECU which controls the system addition, the engine-ECU is equipped with
based on signals from these sensors, and several diagnosis modes which simplify
actuators which operate under the control of troubleshooting when a problem develops.
the engine-ECU. The engine-ECU carries out

FUEL INJECTION CONTROL

The injector drive times and injector timing are crankshaft. The firing order is 1-3-4-2. This is
controlled so that the optimum air/fuel mixture called sequential fuel injection. The engine-ECU
is supplied to the engine to correspond to the provides a richer air/fuel mixture by carrying
continually-changing engine operation condi- out “open-loop” control when the engine is cold
tions. or operating under high load conditions in order
A single injector is mounted at the intake port to maintain engine performance. In addition,
of each cylinder. Fuel is sent under pressure when the engine is warm or operating under
from the fuel tank by the fuel pump, with the normal conditions, the engine-ECU controls the
pressure being regulated by the fuel pressure air/fuel mixture by using the oxygen sensor
regulator. The fuel thus regulated is distributed signal to carry out “closed-loop” control in order
to each of the injectors. to obtain the theoretical air/fuel mixture ratio
Fuel injection is normally carried out once for that provides the maximum cleaning
each cylinder for every two rotations of the performance from the three way catalyst.

IDLE AIR CONTROL

The idle speed is kept at the optimum speed the engine coolant temperature and air
by controlling the amount of air that bypasses conditioner load. In addition, when the air
the throttle valve in accordance with changes conditioner switch is turned off and on while
in idling conditions and engine load during idling. the engine is idling, the ISC motor operates
The engine-ECU drives the idle speed control to adjust the throttle valve bypass air amount
(ISC) motor to keep the engine running at the in accordance with the engine load conditions
pre-set idle target speed in accordance with in order to avoid fluctuations in the engine speed.

IGNITION TIMING CONTROL

The power transistor located in the ignition engine operating conditions. The ignition timing
primary circuit turns ON and OFF to control is determined by the engine-ECU from the
the primary current flow to the ignition coil. This engine speed, intake air volume, engine coolant
controls the ignition timing in order to provide temperature and atmospheric pressure.
the optimum ignition timing with respect to the

SELF-DIAGNOSIS FUNCTION
D When an abnormality is detected in one code corresponding to the abnormality is
of the sensors or actuators related to output.
emission control, the engine warning lamp D The RAM data inside the engine-ECU that
(check engine lamp) illuminates as a is related to the sensors and actuators can
warning to the driver. be read by means of the MUT-II. In addition,
D When an abnormality is detected in one the actuators can be force-driven under
of the sensors or actuators, a diagnosis certain circumstances.
 MPI <4G9> – General Information 13C-3
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control condenser fan are controlled in response
Turns the fuel pump relay ON so that current to the engine coolant temperature and
is supplied to the fuel pump while the engine vehicle speed.
is cranking or running. 4. Purge Control Solenoid Valve Control
2. A/C Relay Control Refer to GROUP 17.
Turns the compressor clutch of the A/C ON 5. EGR Control Solenoid Valve Control
and OFF. Refer to GROUP 17.
3. Fan Motor Control
The revolutions of the radiator fan and
GENERAL SPECIFICATIONS
Items Specifications
Throttle body Throttle bore mm 50
Throttle position sensor Variable resistor type

Idle speed control servo Stepper motor type

(Stepper motor type by-pass air control system)
Engine-ECU Identification model No. E2T74481
Sensors Air flow sensor Karman vortex type

Barometric pressure sensor Semiconductor type

Intake air temperature sensor Thermistor type

Engine coolant temperature sensor Thermistor type

Oxygen sensor Zirconia type

Vehicle speed sensor Magnetic resistive element type

Inhibitor switch Contact switch type

Camshaft position sensor Magnetic resistive element type

Crank angle sensor Hall element type

Detonation sensor Piezoelectric type

Power steering fluid pressure switch Contact switch type

Actuators Control relay type Contact switch type

Fuel pump relay Contact switch type

Injector type and number Electromagnetic type, 4

Injector identification mark CDH 210

EGR control solenoid valve Duty cycle type solenoid valve

Purge control solenoid valve Duty cycle type solenoid valve

Fuel pressure Regulator pressure kPa 329

regulator
13C-4 MPI <4G9> – General Information

CONTROL SYSTEM DIAGRAM

L1 Oxygen sensor D Power supply l1 Injector D Engine control relay

<front> D Ignition switch-IG l2 Idle speed control D Fuel pump relay
L2 Air flow sensor D Ignition switch-ST Engine- servo D A/C relay
L3 Intake air temperature D Vehicle speed sensor ECU l3 EGR control solenoid D Ignition coil
sensor D A/C switch valve D Fan motor relay
L4 Throttle position D A/C thermo sensor l4 Purge control D Engine warning lamp
sensor D Inhibitor switch solenoid valve D Tachometer
L5 Camshaft position D Power steering fluid D Diagnosis output
sensor pressure switch D Alternator G terminal
L6 Crank angle sensor D Alternator FR termi- D A/T-ECU
L7 Engine coolant nal
temperature sensor D A/T-ECU
L8 Barometric pressure
sensor
L9 Detonation sensor
L10Oxygen sensor
<rear>

L3 Intake air temperature

L4 Throttle position sensor
sensor
l2 Idle speed L2 Air flow sensor
control servo
L8 Barometric pressure
L5 Camshaft position
sensor
sensor
Air

M E A
Air cleaner
Fuel pressure From
To fuel regulator fuel
tank pump
PCV valve
EGR valve
L1 Oxygen sensor Canister
<front>

l1 Injector
L7 Engine coolant
temperature sensor
L9 Detonation sensor l4 Purge control solenoid valve
L10Oxygen sensor
<rear> l3 EGR controlsolenoid valve

Catalytic converter
L6 Crank angle sensor
 MPI <4G9> – Service Specifications/Sealant 13C-5
SERVICE SPECIFICATIONS
Items Specifications

Basic idle speed r/min 700 ± 50

Throttle position sensor adjusting voltage mV 535 – 735

Throttle position sensor resistance kΩ 3.5 – 6.5

Idle speed control servo coil resistance Ω 27 – 33 (at 20_C)

Intake air temperature sensor –20_C 13 – 17

resistance kΩ
0_C 5.3 – 6.7

20_C 2.3 – 3.0

40_C 1.0 – 1.5

60_C 0.56 –0.76

80_C 0.30 – 0.42

Engine coolant temperature –20_C 14 – 17

sensor resistance kΩ
0_C 5.1 – 6.5

20_C 2.1 – 2.7

40_C 0.9 – 1.3

60_C 0.48 – 0.68

80_C 0.26 – 0.36

Oxygen sensor output voltage (at racing) V 0.6 – 1.0

Fuel pressure kPa Vacuum hose disconnection 324 – 343 at curb idle

Vacuum hose connection Approx. 265 at curb idle

Injector coil resistance Ω 13 – 16 (at 20_C)

SEALANT
Item Specified sealant Remark

Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent Drying sealant
threaded portion
13C-6 MPI <4G9> – Special Tools

SPECIAL TOOLS
Tool Number Name Use

A MB991223 Harness set D Check at the ECU terminals

A: MB991219 A: Test harness A: Connector pin contact pressure inspection
B: MB991220 B: LED harness B: Power circuit inspection
C: Power circuit inspection
C: MB991221 C: LED harness D: Commercial tester connection
D: MB991222 adapter
D: Probe
B

MB991502 MUT-II sub D Reading diagnosis code

assembly D MPI system inspection

MB991348 Test harness set D Measurement of voltage during trouble-

shooting
D Inspection using an analyzer

MB991709 Test harness D Measurement of voltage during trouble-

shooting
D Inspection using an analyzer
D Adjustment of throttle position sensor

MB991519 Alternator harness Measurement of voltage during troubleshoot-

connector ing

MD998478 Test harness D Measurement of voltage during trouble-

(3-pin, triangle) shooting
D Inspection using an analyzer
 MPI <4G9> – Special Tools 13C-7

Tool Number Name Use

MD998709 Adaptor hose Measurement of fuel pressure

MD998742 Hose adaptor

MB991637 Fuel pressure

gauge set

MD998706 Injector test set Checking the spray condition of injectors

MB991607 Injector test

harness

MD998741 Injector test

adaptor

MB991608 Clip
13C-8 MPI <4G9> – Troubleshooting

TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
Refer to GROUP 00 – How to Use Troubleshooting/Inspection
Service Point.
Engine warning lamp
(check engine lamp) NOTE
If the engine-ECU for vehicles for GCC is replaced, the
immobilizer-ECU and ignition key should be replaced together
with it.

DIAGNOSIS FUNCTION
ENGINE WARNING LAMP (CHECK ENGINE LAMP)
If an abnormality occurs in any of the following items related
to the MPI system, the engine warning lamp will illuminate
or flash. If the lamp remains illuminated or if the lamp illuminates
while the engine is running, check the diagnosis code output.
However, the warning lamp will illuminate as bulb check for
five seconds whenever the ignition switch is turned to the
ON position.

Engine warning lamp inspection items

Code No. Diagnosis item
– Engine-ECU
P0100 Air flow sensor system
P0105 Barometric pressure sensor system
P0110 Intake air temperature sensor system
P0115 Engine coolant temperature sensor system
P0120 Throttle position sensor system
P0125 Feedback system
P0130 Oxygen sensor (front) system <sensor 1>
P0135 Oxygen sensor heater (front) system <sensor 1>
P0136 Oxygen sensor (rear) system <sensor 2>
P0141 Oxygen sensor heater (rear) system <sensor 2>
P0170 Abnormal fuel system
P0201 No. 1 injector system
P0202 No. 2 injector system
P0203 No. 3 injector system
P0204 No. 4 injector system
P0300L Ignition coil (power transistor) system
P0301 No. 1 cylinder misfire detected
P0302 No. 2 cylinder misfire detected
P0303 No. 3 cylinder misfire detected
P0304 No. 4 cylinder misfire detected
P0325 Detonation sensor system
 MPI <4G9> – Troubleshooting 13C-9
Code No. Diagnosis item
P0335 Crank angle sensor system
P0340 Camshaft position sensor system
P0403 EGR valve system
P0420 Catalyst malfunction
P0443 Purge control solenoid valve system
P0500 Vehicle speed sensor system
P0505 Idle speed control system
P0551 Power steering fluid pressure switch system
P1603 Battery backup line system

NOTE
1. If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
2. After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine
is next turned on and the same malfunction is re-detected. However, for items marked with a “L”
in the diagnosis code number column, the engine warning lamp illuminates only on the first detection
of the malfunction.
3. After the engine warning lamp illuminates, it will be switched off under the following conditions.
(1) When the engine-ECU monitored the power train malfunction three times* and met set condition
requirements, it detected no malfunction.
*: In this case, “one time” indicates from engine start to stop.
(2) For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
4. Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates
the sensor mounted at the position second closest to the engine.
13C-10 MPI <4G9> – Troubleshooting

METHOD OF READING AND ERASING DIAGNOSIS

CODES
Refer to GROUP 00 – How to Use Troubleshooting/Inspection
Service Points.

INSPECTION USING MUT-II DATA LIST AND ACTUATOR

TESTING
1. Carry out inspection by means of the data list and the
actuator test function. If there is an abnormality, check
and repair the chassis harnesses and components.
2. After repairing, re-check using the MUT-II and check that
the abnormal input and output have returned to normal
as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II, and then start the engine again and
carry out a road test to confirm that the problem has
disappeared.
 MPI <4G9> – Troubleshooting 13C-11
FAIL-SAFE FUNCTION REFERENCE TABLE
When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by
means of the pre-set control logic to maintain safe conditions for driving.

Malfunctioning item Control contents during malfunction

Air flow sensor 1. Uses the throttle position sensor signal and engine speed signal (crank angle sensor
signal) to take reading of the basic injector drive time and basic ignition timing from
the pre-set mapping.
2. Fixes the ISC servo in the appointed position so idle control is not performed.

Intake air temperature Controls as if the intake air temperature is 25_C.

sensor

Throttle position No increase in fuel injection amount during acceleration due to the throttle position sensor
sensor (TPS) signal.

Engine coolant Controls as if the engine coolant temperature is 80_C.

temperature sensor

Camshaft position sen- Injects fuel to all cylinders simultaneously.

sor (However, after the ignition switch is turned to ON, the No.1 cylinder top dead centre is not
detected at all.)

Barometric pressure Controls as if the barometric pressure is 101 kPa.

sensor

Detonation sensor Switches the ignition timing from ignition timing for super petrol to ignition timing for standard
petrol.

Ignition coil, power Cuts off the fuel supply to cylinders with an abnormal ignition.
transistor

Oxygen sensor (front) Air/fuel ratio feedback control (closed loop control) is not performed.

Oxygen sensor (rear) Performs the feedback control (closed loop control) of the air/fuel ratio by using only the signal
of the oxygen sensor (front) installed on the front of the catalytic converter.

Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works as a
normal alternator)

Misfiring If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be shut
down.
13C-12 MPI <4G9> – Troubleshooting

INSPECTION CHART FOR DIAGNOSIS CODES

Code No. Diagnosis item Reference page

P0100 Air flow sensor system 13C-14

P0105 Barometric pressure sensor system 13C-16

P0110 Intake air temperature sensor system 13C-18

P0115 Engine coolant temperature sensor system 13C-20

P0120 Throttle position sensor 1 system 13C-22

P0125 Feedback system 13C-24

P0130 Oxygen sensor (front) system 13C-25

P0135 Oxygen sensor heater (front) system 13C-26

P0136 Oxygen sensor (rear) system 13C-27

P0141 Oxygen sensor heater (rear) system 13C-28

P0170 Abnormal fuel system 13C-29

P0201 No. 1 injector system 13C-30

P0202 No. 2 injector system 13C-30

P0203 No. 3 injector system 13C-30

P0204 No. 4 injector system 13C-30

P0300L Ignition coil (power transistor) system 13C-31

P0301 No. 1 cylinder misfire detected 13C-32

P0302 No. 2 cylinder misfire detected 13C-32

P0303 No. 3 cylinder misfire detected 13C-32

P0304 No. 4 cylinder misfire detected 13C-32

P0325 Detonation sensor system 13C-33

P0335 Crank angle sensor system 13C-33

P0340 Camshaft position sensor system 13C-35

P0403 EGR valve system 13C-36

P0420 Catalyst malfunction 13C-37

P0443 Purge control solenoid valve system 13C-38

P0500 Vehicle speed sensor system 13C-39

P0505 Idle speed control system 13C-40

P0551 Power steering fluid pressure switch system 13C-43

P1603 Battery backup circuit malfunction 13C-44

P1610 Immobilizer system 13C-45

 MPI <4G9> – Troubleshooting 13C-13
NOTE
1. Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
2. Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
3. After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the
engine is started and the same malfunction is re-detected. However, for items marked with a “L”,
the diagnosis code is recorded on the first detection of the malfunction.
4. Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates
the sensor mounted at the position second closest to the engine.
13C-14 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE

Code No. P0100 Air flow sensor system Probable cause
Range of Check D Malfunction of air flow sensor
D Engine speed: 500 r/min or more D Open or short circuit in air flow sensor circuit or
Set Conditions loose connector contact
D The sensor output frequency is 3.3 Hz or less for 4 seconds. D Malfunction of engine-ECU

OK
MUT-II Data list Transient malfunction
12 Air flow sensor (Refer to (Refer to GROUP 00 – Points to
P.13C-74, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
NG
Check the following connector: Repair
A-71
OK
(1) NG OK
Measure at air flow sensor Measure at engine-ECU connector Check the following connector:
connector A-71. C-90. C-90
D Disconnect the connector and D Measure the voltage at the
OK NG
measure at the harness side. engine-ECU terminal. Repair
(1) Voltage between terminal 3 and D Ignition switch: ON
earth (Ignition switch: ON) D Voltage between terminal 90 and
OK: 4.8 – 5.2 V earth Check the harness between the air
(2) Voltage between terminal 4 and OK: 4.8 – 5.2 V flow sensor and the engine-ECU,
earth (Ignition switch: ON) and repair if necessary.
OK: System voltage NG
(3) Resistance between terminal 5 NG
and earth Check the following connector: Repair
OK: 2 Ω or less C-90
OK

Check the harness between the air NG

flow sensor and the engine-ECU. Repair

OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG
Check the harness between the air
flow sensor and the engine control
relay, and repair if necessary.

(3) NG NG
Check the following connectors: Repair
A-36, C-88
OK
Check the harness between the air NG
Repair
flow sensor and the engine-ECU.
OK OK
NG
To the next page Check the trouble symptoms. Replace the engine-ECU.
 MPI <4G9> – Troubleshooting 13C-15
From the previous page
OK
NG NG
Measure at air flow sensor Check the following connector: Repair
connector A-71. A-71
D Use test harness (MB991709) to OK
connect the connector, and
measure at the pick-up harness. Check the harness between the air NG Repair
D Ignition switch: ON flow sensor and the engine-ECU.
D Voltage between terminal 7 and
earth OK
OK: 7 – 8 V Replace the air flow sensor.
OK
NG NG
Measure at air flow sensor Check the following connector: Repair
connector A-71. A-71
D Use test harness (MB991709) to OK
connect the connector, and NG
Check the harness between the air Repair
measure at the pick-up harness.
D Voltage between terminal 7 and flow sensor and the engine-ECU.
earth OK
OK: Engine: Idling
0 – 1 V Check the trouble symptoms.
Engine speed: 3,000 r/min
NG
6 – 9 V
Replace the engine-ECU.
OK

NG
Measure the output waveform at air Replace the air flow sensor.
flow sensor connector A-71 (by
using an analyzer).
D Use test harness (MB991709) to Check the trouble symptoms.
connect the connector, and NG
measure at the pick-up harness. NG
D Engine: Idling Check the following connectors: Repair
D Voltage between terminal 3 and A-71, C-90
earth OK
OK: Waveforms should be dis-
played on P.13C-87 (In- Check the harnesses between the
spection Procedure Using air flow sensor and the engine-ECU
an Analyzer) and noise and between the air flow sensor
should not be displayed in and the engine control relay, and
the waveform. repair if necessary.
OK
Check the trouble symptoms.
NG
Replace the engine-ECU.
13C-16 MPI <4G9> – Troubleshooting

Code No. P0105 Barometric pressure sensor system Probable cause

Range of Check D Malfunction of barometric pressure sensor
D Two seconds have passed since the ignition switch is turned ON or the D Open or short circuit in barometric pressure
engine starting process is completed. sensor circuit or loose connector contact
D Battery voltage: 8 V or more D Malfunction of engine-ECU
Set Conditions
D The sensor output voltage is 4.5 V or more for 4 seconds (equivalent to
114 kPa of barometric pressure)
or
D The sensor output voltage is 0.2 V or less (equivalent to 53 kPa of
barometric pressure)

OK
MUT-II Data list Transient malfunction
25 Barometric pressure sensor (Refer to GROUP 00 – Points to
(Refer to P.13C-74, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
Check the following connector: NG
A-71 Repair
OK
(1) NG
Measure at air flow sensor Measure at engine-ECU connector OK Check the following connector:
connector A-71. C-90. C-90
D Disconnect the connector and D Measure the voltage at the OK NG
measure at the harness side. engine-ECU terminal. Repair
(1) Voltage between terminal 1 and D Ignition switch: ON
earth (Ignition switch: ON) D Voltage between terminal 81 and Check the harness between the air
OK: 4.8 – 5.2 V earth flow sensor and the engine-ECU,
(2) Resistance between terminal 5 OK: 4.8 – 5.2 V and repair if necessary.
and earth
NG
OK: 2 Ω or less
Check the following connector: NG
Repair
C-90
OK
Check the harness between the air NG
Repair
flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG NG
Check the following connector: Repair
C-90, A-36
OK

OK Check the harness between the air NG Repair

flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
To the next page
 MPI <4G9> – Troubleshooting 13C-17
From the previous page

OK
(1) NG NG
Measure at air flow sensor Check the following connector: Repair
connector A-71. (3) NG
C-90
D Connect connector terminals No.
1, No. 2 and No. 5 only by using OK
test harness (MB991709), and Check the harness between the air
measure at the pick-up harness. flow sensor and the engine-ECU,
D Ignition switch: ON and repair if necessary.
(1) Voltage between terminal 1 and
earth
OK: 4.8 – 5.2 V (2) NG
(2) Voltage between terminal 2 and Replace the air flow sensor.
earth
OK: Altitude 0 m: 3.7 – 4.3 V
Altitude 1,200 m: Check the trouble symptoms.
3.2 – 3.8 V NG
(3) Voltage between terminal 5 and
NG
earth Check the following connector: Repair
OK: 0.5 V or less C-90
OK OK
Check the harness between the air
flow sensor and the engine-ECU,
and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-90. C-90
D Measure the voltage at the
engine-ECU terminal. OK
D Ignition switch: ON
Check the harness between the air
D Voltage between terminal 81 and
flow sensor and the engine-ECU,
earth
and repair if necessary.
OK: Altitude 0 m: 3.7 – 4.3 V
Altitude 1,200 m:
3.2 – 3.8 V OK NG
Check the following connector: Repair
C-90
OK
Check the trouble symptoms.
NG
Replace the engine-ECU.
13C-18 MPI <4G9> – Troubleshooting

Code No. P0110 Intake air temperature sensor system Probable cause
Range of Check D Malfunction of intake air temperature sensor
D 2 seconds have passed since the ignition switch is turned ON or the D Open or short circuit in intake air temperature
engine starting process is completed. sensor or loose connector contact
Set Conditions D Malfunction of engine-ECU
D The sensor output voltage is 4.6 V or more for four seconds (equivalent to
–45_C of intake air temperature)
or
D The sensor output voltage is 0.2 V or more for four seconds (equivalent to
125_C of intake air temperature)

OK
MUT-II Data list Transient malfunction
13 Intake air temperature sensor (Refer to GROUP 00 – Points to
OK: Roughly the same as am- Note for Intermittent Malfunctions.)
bient temperature.
NG
NG
Check the intake air temperature Repair
sensor itself.
(Refer to P.13C-102.)
OK
NG
Check the following connector: Repair
A-71
OK
(1) NG NG
Measure at air flow sensor Check the following connector: Repair
connector A-71. C-90
D Disconnect the connector and OK
measure at the harness side.
(1) Resistance between terminal 5 Check the harness between the air NG
and earth Repair
flow sensor and the engine-ECU.
OK: 2 Ω or less
OK
(2) Voltage between terminal 6 and
earth NG
Check the trouble symptoms. Replace the engine-ECU.
(Ignition switch: ON)
OK: 4.8 – 5.2 V

(2) NG OK
Measure at connector C-90. Check the following connector:
D Measure the voltage at the C-90
engine-ECU terminal. NG
D Disconnect connector A-71. OK
Repair
D Ignition switch: ON
D Voltage between terminal 72 and
earth Check the harness between the air
OK: 4.8 – 5.2 V flow sensor and the engine-ECU,
and repair if necessary.
NG

Check the following connector: NG

C-90 Repair

OK
OK NG
Check the harness between the air Repair
flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

To the next page

 MPI <4G9> – Troubleshooting 13C-19
From the previous page
OK
NG NG
Measure at air flow sensor Check the following connectors: Repair
connector A-71. A-36, A-71, C-88
D Use the test harness
(MB991709) to connect only OK
terminals 5 and 6, and then Check the harness between the air
measure at the pick-up harness. flow sensor and the engine-ECU,
D Ignition switch: ON and repair if necessary.
D Voltage between terminal 6 and
earth
OK: Ambient temperature 0_C:
3.2 – 3.8 V
Ambient temperature 20_C:
2.3 – 2.9 V
Ambient temperature 40_C:
1.5 – 2.1 V
Ambient temperature 80_C:
0.4 – 1.0 V
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
13C-20 MPI <4G9> – Troubleshooting

Code No. P0115 Engine coolant temperature sensor Probable cause

system
Range of Check D Malfunction of engine coolant temperature sensor
D Engine: Two seconds after the engine has been started D Open or short circuit in the engine coolant
Set Conditions temperature sensor circuit or loose connector
D The sensor output voltage is 4.6 V or more for four seconds (equivalent to contact
–45_C or lower of engine coolant temperature) D Malfunction of engine-ECU
or
D The sensor output voltage is 0.1 V or less for four seconds (equivalent to
140_C or higher of engine coolant temperature)
Range of Check
D Engine: After starting
Set Conditions
D The engine coolant temperature has reduced from over 40_C to less than
40_C, and that condition has lasted for five minutes or more.

OK
MUT-II Data list Transient malfunction
21 Engine coolant temperature (Refer to GROUP 00 – Points to
sensor Note for Intermittent Malfunctions.)
OK: When the engine is cold,
the temperature is roughly
the same as ambient tem-
perature. If warm, it is 80
– 120_C.
NG
NG
Measure at engine coolant Replace
temperature sensor connector A-69.
D Disconnect the connector and
measure at the harness side.
D Resistance between terminals 1
and 2
OK: At 20_C of engine coolant
temperature: 2.1 – 2.7 kΩ
At 80_C of engine coolant
temperature: 0.26 – 0.36
kΩ
OK

Check the following connector: NG

A-69 Repair

OK

To the next page

 MPI <4G9> – Troubleshooting 13C-21
From the previous page
OK
(1) NG OK
Measure at engine coolant Measure at engine-ECU connector Check the following connector:
temperature sensor connector A-69. C-90. C-90
D Disconnect the connector and D Measure the voltage at the
measure at the harness side. engine-ECU terminal. OK NG
D Disconnect connector A-69. Repair
(1) Voltage between terminal 1 and
earth D Ignition switch: ON
(Ignition switch: ON) D Voltage between terminal 83 and Check the harness wire between
OK: 4.8 – 5.2 V earth the engine coolant temperature
(2) Resistance between terminal 2 OK: 4.8 – 5.2 V sensor and the engine-ECU, and
and earth repair if necessary.
NG
OK: 2 Ω or less
Check the following connector: NG
C-90 Repair

OK
Check the harness wire between
the engine coolant temperature NG
Repair
sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG NG
Check the following connector: Repair
C-90
OK
OK

Check the harness wire between NG

the engine coolant temperature Repair
sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

NG NG
Measure at engine coolant Check the engine coolant Repair
temperature sensor connector A-69. temperature sensor.
D Use test harness (MB991658) to (Refer to P.13C-102.)
connect the connector, and
measure at the pick-up harness. OK
NG
D Ignition switch: ON Check the following connectors: Repair
D Voltage between terminal 1 and A-69, C-90
earth
OK: At 0_C of engine coolant OK
temperature: 3.2 – 3.8 V
At 20_C of engine coolant Check the harness wire between
temperature: 2.3 – 2.9 V the engine coolant temperature
At 40_C of engine coolant sensor and the engine-ECU, and
temperature: 1.3 – 1.9 V repair if necessary.
At 80_C of engine coolant
temperature: 0.3 – 0.9 V
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
13C-22 MPI <4G9> – Troubleshooting

Code No. 0120 Throttle position sensor system Probable cause

Range of Check D Malfunction of throttle position sensor
D Excluding 2 seconds after the ignition switch is turned ON or immediately D Open or short circuit in the throttle position
after the engine start. sensor circuit or loose connector contact
Set Conditions D Malfunction of the engine-ECU
D The sensor output voltage is 0.2 V or less for four seconds.
or
D Volume efficiency is 60 percent or lower.
D Engine speed is lower than 1000 r/min.
D The sensor output voltage is 2.0 V or more.
D AFS: Normal

OK
MUT-II Data list Intermittent malfunction
14 Throttle position sensor (Refer to GROUP 00 – Points to
OK: Refer to P.13C-74, DATA Note for Intermittent Malfunctions.)
LIST REFERENCE TABLE.
NG
NG
Check throttle position sensor. Replace
(Refer to P.13C-103.)
OK
NG
Check the following connector: Repair
A-06
OK
(1) NG OK
Measure at throttle position sensor Measure at engine-ECU connector Check the following connector:
connector A-06. C-90. C-90
D Disconnect the connector and D Measure the voltage at the
OK NG
measure at the harness side. engine-ECU connector terminals. Repair
(1) The voltage between terminal 1 D Ignition switch: ON
and earth D The voltage between terminal 81
(Ignition switch: ON) and earth Check the harness wire between
OK: 4.8 – 5.2 V OK: 4.8 – 5.2 V the throttle position sensor and the
(2) Resistance between terminal 4 engine-ECU, and repair if necessary.
NG
and earth NG
OK: 2 Ω or less Check the following connector: Repair
C-90
OK
NG
Check the harness wire between Repair
the throttle position sensor and the
engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(2) NG NG
Check the following connector: Repair
C-90
OK
OK
To the next page NG
Check the harness wire between Repair
the throttle position sensor and the
engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
 MPI <4G9> – Troubleshooting 13C-23
From the previous page
OK
(1), (2) NG NG
Measure at throttle position sensor Check the following connector: Repair
connector A-06. C-90
D Use test harness (MB991536) to
OK
connect the connector, and
measure at the pick-up harness. Check the harness wire between
D Ignition switch: ON throttle position sensor and the
(1) The voltage between terminal 1 engine-ECU.
and earth
OK: 4.8 – 5.2 V
(2) The voltage between terminal 4 (3) NG
and earth Adjust the throttle position sensor.
OK: 0.5 V or less (Refer to P.13C-96.)
(3) The voltage between terminal 2
and earth NG
OK: Accelerator pedal fully re- Check the following connector: Repair
leased: 0.3 – 1.0 V C-90
Accelerator pedal fully de-
pressed: 4.5 – 5.5 V OK
Check the harness wire between
OK throttle position sensor and the
engine-ECU, and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-90. C-90
D Measure the voltage at the OK
engine-ECU terminal.
D Ignition switch: ON Check the harness wire between
D The voltage between terminal 84 throttle position sensor and the
and earth engine-ECU, and repair if necessary.
OK: Accelerator pedal fully re-
leased: 0.3 – 1.0 V
Accelerator pedal fully de- OK NG
pressed: 4.5 – 5.5 V Check the following connector: Repair
C-90
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

13C-24 MPI <4G9> – Troubleshooting

Code No. P0125 Feedback system Probable cause

Range of Check D Malfunction of oxygen sensor (front)
D The engine coolant temperature is approx. 80_C or more. D Open or short circuit in the oxygen sensor (front)
D During stoichiometric feedback control circuit or loose connector contact
D The vehicle is not being decelerated. D Malfunction of engine-ECU
Set Conditions
D Oxygen sensor (front) output voltage has been higher or lower than 0.5 V
for at least thirty seconds.

NG
Check the following connector: Repair
A-67
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-67, C-90
D Disconnect the connector and OK
measure at the harness side. NG
D Resistance between terminal 2 Check the harness wire between Repair
and earth the oxygen sensor (front) and the
OK: 2 Ω or less engine-ECU.
OK OK
Check the trouble symptoms.
NG
Replace the engine-ECU.

(1) NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-67, C-90
D Use the test harness OK
(MD998464) to connect the
connector, and measure at the Check the harness wire between
pick-up harness side. the oxygen sensor (front) and the
D Engine: 2,500 r/min (after engine-ECU, and repair if necessary.
warming up)
(1) Voltage between terminal 2 and
earth
OK: 0.5 V or less (2) NG NG
(2) Voltage between terminal 4 and Check the oxygen sensor (front). Replace
earth (Refer to P.13C-103.)
OK: 0 V and 0.8 V alternate. OK
NG
OK Check the following connectors: Repair
A-67, C-90
OK
Check the harness wire between
the oxygen sensor (front) and the
engine-ECU, and repair if necessary.

NG NG
Measure at engine-ECU connector Check the following connectors: Repair
C-90. A-67, C-90
D Measure the voltage at the OK
engine-ECU terminal.
D Engine: 2,500 r/min (after Check the harness wire between
warming up) the oxygen sensor (front) and the
D Voltage between terminal 76 and engine-ECU, and repair if necessary.
earth
OK: 0 V and 0.8 V alternate.
OK
NG
Check the following connector: Repair
C-90
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 – Points to
NG
Note for Intermittent Malfunctions.)
Replace the engine-ECU.
 MPI <4G9> – Troubleshooting 13C-25
Code No. P0130 Oxygen sensor (front) system Probable cause
<sensor 1>
Range of Check D Malfunction of oxygen sensor (front)
D Three minutes have been passed since the engine has been started. D Open or short circuit in the oxygen sensor (front)
D The engine coolant temperature is approx. 80_C or more. circuit or loose connector contact
D Engine speed is 1,200 r/min or more D Malfunction of engine-ECU
D Driving on a level surface at constant speed.
Set Conditions
D The oxygen sensor (front) output voltage is 4.5 V or more when the sensor
output voltage is 0.2 V or less and a voltage of 5 V is applied to the
oxygen sensor (front) inside the engine-ECU.
Range of Check
D Engine speed is 3,000 r/min or less
D During driving
D During air/fuel ratio feedback control
Set Conditions
D The oxygen sensor (front) output frequency is five or less per 12 seconds
on average.

NG
Check the following connector: Repair
A-67
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-67, C-90
D Disconnect the connector and OK
measure at the harness side. NG
D Resistance between terminal 2 Check the harness wire between Repair
and earth the oxygen sensor (front) and the
OK: 2 Ω or less engine-ECU.
OK OK
Check the trouble symptoms.
NG

Replace the engine-ECU.

(1) NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-67, C-90
D Use the test harness
(MD998464) to connect the OK
connector, and measure at the Check the harness wire between
pick-up harness side. the oxygen sensor (front) and the
D Engine: 2,500 r/min (after engine-ECU, and repair if necessary.
warming up)
(1) Voltage between terminal 2 and (2) NG NG
Check the oxygen sensor (front). Replace
earth
(Refer to P.13C-103.)
OK: 0.5 V or less
(2) Voltage between terminal 4 and OK
earth NG
OK: 0 V and 0.8 V alternate. Check the following connectors: Repair
A-67, C-90
OK OK

Check the harness wire between

the oxygen sensor (front) and the
engine-ECU, and repair if necessary.

Measure at engine-ECU connector NG Check the following connectors:

C-90. A-67, C-90
D Measure the voltage at the
engine-ECU terminal. OK
D Engine: 2,500 r/min (after NG
Check the harness wire between Repair
warming up) the oxygen sensor (front) and the
D Voltage between terminal 76 and engine-ECU, and repair if necessary.
earth
OK: 0 V and 0.8 V alternate.
OK
OK OK
Check the following connector: Check the trouble symptoms. Transient malfunction
C-90 (Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)
NG
Replace the engine-ECU.
Repair
13C-26 MPI <4G9> – Troubleshooting

Code No. P0135 Oxygen sensor heater (front) system Probable cause
<sensor 1>
Range of Check D Malfunction of oxygen sensor heater (front)
D The engine coolant temperature is approx. 20_C or more. D Open or short circuit in the oxygen sensor heater
D The oxygen sensor heater (front) remains on. (front) circuit or loose connector contact
D The engine speed is 50 r/min or more. D Malfunction of engine-ECU
D Battery voltage is 11 – 16 V.
Set Conditions
D The current, which flows through the oxygen sensor heater (front), is 0.2 A
or less or 3.5 A or more for six seconds.

NG
Measure at oxygen sensor (front) Replace
connector A-67.
D Disconnect the connector and
measure at the harness side.
D Resistance between terminals 1
and 3
OK: 4.5 – 8.0 Ω
OK
NG
Check the following connector: Repair
A-67
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector A-67. A-36, A-43X
D Disconnect the connector and OK
measure at the harness side.
D Ignition switch: ON Check the harness wires between
D Voltage between terminal 1 and the oxygen sensor (front) and the
earth engine control relay, and repair if
OK: System voltage necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connectors: Repair
C-89. A-67, C-89
D Measure the voltage at the OK
engine-ECU terminal.
D Ignition switch: ON Check the harness wire between
D Voltage between terminal 60 and the oxygen sensor (front) and the
earth engine-ECU, and repair if necessary.
OK: System voltage

OK
NG
Check the following connector Repair
C-89
OK
NG
Check the harness wires between Repair
the oxygen sensor (front) and the
engine-ECU and between the
oxygen sensor (front) and the
engine control relay.
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)
Replace the engine-ECU.
 MPI <4G9> – Troubleshooting 13C-27
Code No. P0136 Oxygen sensor (rear) system <sensor Probable cause
2>
Range of Check D Malfunction of oxygen sensor (rear)
D Three minutes have been passed since the engine has been started. D Open or short circuit in the oxygen sensor (rear)
D The engine coolant temperature is approx. 80_C or more. circuit or loose connector contact
D Intake air temperature is 20 – 50_C D Malfunction of engine-ECU
D Engine speed is 1,200 r/min or more
D Driving on a level surface at constant speed.
Set Conditions
D The oxygen sensor (rear) output voltage is 4.5 V or more when the sensor
output voltage is 0.2 V or less and a voltage of 5 V is applied to the
oxygen sensor (rear) inside the engine-ECU.
Range of Check
D Two seconds have passed after the engine-ECU detected an open circuit.
D When the oxygen sensor (front) is in good condition.
Set Conditions
D When the air/fuel ratio is rich, the oxygen sensor (front) output voltage is
0.5 V or more, the oxygen sensor (rear) output voltage is less than 0.1 V,
and the oxygen sensor (rear) output voltage fluctuates within 0.078 V.

NG
Check the following connector: Repair
B-11
OK
NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector B-11. C-90, B-11, D-47, C-26<RHD>,
D Disconnect the connector and C-25<LHD>
measure at the harness side. OK
D Resistance between terminal 1 OK
and earth Check the harness wire between Check the trouble symptoms.
OK: 2 Ω or less the oxygen sensor (rear) and the
NG
engine-ECU.
OK
NG Replace the engine-ECU.
Repair
(1) NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector B-11. C-90, B-11, D-47, C-26<RHD>,
D Measure the voltage at the C-25<LHD>
oxygen sensor (rear) terminal.
D Engine: 2,500 r/min (after OK
warming up)
(1) Voltage between terminal 1 and Check the harness wire between
earth the oxygen sensor (rear) and the
OK: 0.5 V or less engine-ECU, and repair if necessary.
(2) Voltage between terminal 3 and (2) NG NG
earth Check the oxygen sensor (rear). Replace
OK: 0 V and 0.8 V alternate. (Refer to P.13C-104.)

OK
OK OK
Check the following connectors: Check the harness wire between
C-90, B-11, D-47, C-26<RHD>, the oxygen sensor (rear) and the
C-25<LHD> engine-ECU, and repair if necessary.
NG

Repair
NG NG
Measure at engine-ECU connector Check the following connectors: Repair
connector C-90. C-90, B-11, D-47, C-26<RHD>,
D Measure the voltage at the C-25<LHD>
engine-ECU terminal.
D Engine: 2,500 r/min (after OK
warming up) Check the harness wire between
D Voltage between terminal 75 and the oxygen sensor (rear) and the
earth engine-ECU, and repair if necessary.
OK: 0 V and 0.8 V alternate.

OK OK OK
Check the following connectors: Check the trouble symptoms. Transient malfunction
C-90, B-11, D-47, C-26<RHD>, (Refer to GROUP 00 – Points to
C-25<LHD> NG Note for Intermittent Malfunctions.)

NG Replace the engine-ECU.

Repair
13C-28 MPI <4G9> – Troubleshooting

Code No. P0141 Oxygen sensor heater (rear) system Probable cause
<sensor 2>
Range of Check D Malfunction of oxygen sensor heater (rear)
D The engine coolant temperature is approx. 20_C or more. D Open or short circuit in the oxygen sensor heater
D The oxygen sensor heater (rear) remains on. (rear) circuit or loose connector contact
D The engine speed is 50 r/min or more. D Malfunction of engine-ECU
D Battery voltage is 11 – 16 V.
Set Conditions
D The current, which flows through the oxygen sensor heater (rear), is 0.2 A
or less or 3.5 A or more for six seconds.

NG
Measure at oxygen sensor (rear) Replace
connector B-11.
D Disconnect the connector and
measure at the harness side.
D Resistance between terminals 2
and 4
OK: 11 – 18 Ω
OK
NG
Check the following connector: Repair
B-11
OK
NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector B-11. D-47, C-24, A-36, A-43X
D Disconnect the connector and OK
measure at the harness side.
D Ignition switch: ON Check the harness wires between
D Voltage between terminal 2 and the oxygen sensor (rear) and the
earth engine control relay, and repair if
OK: System voltage necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connectors: Repair
C-89. B-11, C-89, C-24
D Measure the voltage at the OK
engine-ECU terminal.
D Ignition switch: ON Check the harness wire between
D Voltage between terminal 54 and the oxygen sensor (rear) and the
earth engine-ECU, and repair if necessary.
OK: System voltage

OK
NG
Check the following connector: Repair
C-89
OK
NG
Check the harness wires between Repair
the oxygen sensor (rear) and the
engine-ECU and between the
oxygen sensor (rear) and the engine
control relay.
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)
Replace the engine-ECU.
 MPI <4G9> – Troubleshooting 13C-29
Code No. P0170 Abnormal fuel system Probable cause
Range of Check D Incorrect fuel pressure
D Engine: Being learning the air-fuel ratio D Malfunction of fuel supply system
Set Conditions D Malfunction of oxygen sensor (front)
D Ten seconds or more have been passed while the fuel injection amount D Malfunction of intake air temperature sensor
compensation value is too low. D Malfunction of barometric pressure sensor
or D Malfunction of air flow sensor
D Ten seconds or more have been passed while the fuel injection amount D Malfunction of engine-ECU
compensation value is too high.

NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13C-74.) P.13C-18, INSPECTION PROCEDURE FOR DIAGNOSTIC
TROUBLE CODE P0110.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system. (Refer to
21 Engine coolant temperature sensor (Refer to P.13C-75.) P.13C-20, INSPECTION PROCEDURE FOR DIAGNOSTIC
TROUBLE CODE P0115.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13C-16,
25 Barometric pressure sensor (Refer to P.13C-76.) INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE
CODE P0105.)
OK
NG
Check the injector (Refer to P.13C-106.) Replace
OK
NG
Check the following connectors: Repair
A-61, A-62, A-63, A-64, A-36
OK
NG
Check the harness wire between the engine-ECU and the injector Repair
connector.
OK

Check the fuel pressure (Refer to P.13C-98.)

OK More than
zero NG
MUT-II Data list Check if air was drawn into Repair
81 Long-term fuel compensation (Refer to P.13C-77.) the intake system.
D Is fuel trim more or less than zero? OK
Less than zero No
No MUT-II Data list D Check for clogging of
MUT-II Data list D Check for fuel leaks 12 Volume air flow sensor the injector.
12 Volume air flow sensor from injector. (Refer to P.13C-74.) D Check for clogging of
(Refer to P.13C-74.) D Check for entry of D Does the tester indi- the fuel filter and fuel
D Does the tester indi- foreign matter (water, cate less than the line.
cate more than the kerosene, etc.) into standard value? D Check the fuel pump
standard value? the fuel. (insufficient discharge
Yes
rate.)
Yes OK D Check for exhaust
Replace the volume air
flow sensor. leaks (oxygen sensor
Replace the volume air Replace the engine-ECU.
installation section,
flow sensor.
cracks in exhaust
manifold, cracks in
front pipe, etc.).
D Check for entry of
foreign matter (water,
kerosene, etc.) into
the fuel.
OK
Replace the engine-ECU.
13C-30 MPI <4G9> – Troubleshooting

Code No. P0201 No. 1 injector system Probable cause

Code No. P0202 No. 2 injector system
Code No. P0203 No. 3 injector system
Code No. P0204 No. 4 injector system
Range of Check D Malfunction of the injector
D Engine speed is approx. 50 – 1,000 r/min D Improper connector contact, open circuit or short-cir-
D The throttle position sensor output voltage is 1.15 V or less. cuited harness wire of the injector circuit
D Actuator test by MUT-II is not carried out. D Malfunction of engine-ECU
Set Conditions
D Surge voltage of injector coil is not detected for 4 seconds.

OK
MUT-II Actuator Test Intermittent malfunction
01 No. 1 injector (Refer to GROUP 00 – Points to Note for Intermittent Malfunctions.)
02 No. 2 injector
03 No. 3 injector
04 No. 4 injector
OK: The idling condition should change
NG
NG
Check the following connectors: Repair
A-61, A-62, A-63, A-64
OK
NG
Check the injector. (Refer to P.13C-106.) Replace
OK
NG
Measure at the injector connector A-61, A-62, A-63, A-64. Check the harness wire between the engine control relay and the
D Disconnect the connector, and measure at the harness side. injector connector, and repair if necessary.
D Voltage between 1 and earth (Ignition switch: ON)
OK: System voltage
OK
NG
Check the following connector: C-87 Repair
OK
NG
Measure at the engine-ECU connector C-87. Check the harness wire between the engine-ECU and the injector
D Disconnect the connector, and measure at the harness side. connector, and repair if necessary.
D Voltage between 1, 2, 14, 15 and earth (Ignition switch: ON)
OK: System voltage
OK

Check the trouble symptoms.

NG
OK
Use an analyzer to measure the signal waveform at injector Intermittent malfunction
connector A-61, A-62, A-63, A-64. (Refer to GROUP 00 – Points to Note for Intermittent Malfunctions.)
D Use a test harness (MB991348) to connect the connector, and
measure at the pick-up harness side.
D Engine: Idling
D The voltage between terminal 2 and earth
OK: A normal waveform should be displayed as de-
scribed on P.13C-87 (INSPECTION PROCEDURE
USING AN ANALYZER).
NG

Replace the engine-ECU.

 MPI <4G9> – Troubleshooting 13C-31
Code No. P0300 Ignition coil (power transistor) system Probable cause
Range of Check D Malfunction of the ignition coil
D Engine speed is approx. 50 – 4,000 r/min. D Malfunction of the ignition failure sensor
D Engine is not cranking. D Malfunction of spark plug
Set Conditions D Open or short circuit in the primary ignition
D The ignition failure sensor does not send a signal about a certain cylinder circuit or loose connector contact
for 4 seconds. D Malfunction of engine-ECU

(1) NG
MUT-II Actuator Test Check the following connectors: Repair
01 No. 1 injector The ignition coil connectors, which
02 No. 2 injector correspond to defective cylinders
03 No. 3 injector (A-13, A-14).
04 No. 4 injector OK
OK: The idling condition should
NG
change. Check the spark plug and the Replace
Reference ignition coil for a defective cylinder.
When the cylinder (defective (Refer to GROUP 16 – Ignition
cylinder) where idling condition does System.)
not change is detected after
suspending the injector, go to (1) OK
and inspect the spark plug, the NG
ignition coil, the connector, and the Check the following connector: Repair
harness of the defective cylinder. C-87
(When more than one cylinder are OK
detected, inspect all of them.)
When all the cylinders are OK, go Use an analyzer to measure the signal waveform at engine-ECU connector C-87
to (2). connector.
(2) D Engine: Idling
D The voltage between the ignition coil primary signal terminal for a defective
cylinder and earth
OK: A normal waveform should be displayed as described on P.13C-87 (Inspec-
tion Procedure Using an Analyzer).
OK NG

Repair the ignition coil assembly for Replace the engine-ECU.

a defective cylinder and the spark
plug.

(1)
Use an analyzer to measure the
signal waveform at the ignition
failure sensor connector A-90. (3) NG
D Use test harness (MB991536) to Check the following connector: Repair
connect the connector, and C-89
measure at the pick-up harness.
D Engine: Idling OK
D The voltage between terminal 2 NG
Check the harness wires between Repair
and earth
OK: A normal waveform should the ignition failure sensor and the
be displayed as described engine-ECU, and between the
on P.13C-87 (INSPECTION ignition failure sensor and earth.
PROCEDURE USING AN OK
ANALYZER).
Reference Repair the ignition failure sensor.
When a normal waveform is
displayed, compare it with that of NG
the ignition coil primary signal at the Check the trouble symptoms. Replace the engine-ECU.
engine-ECU terminal to determine
the cylinder (defective cylinder) with
an abnormal waveform.
→When one or more cylinders are (4) OK
abnormal, go to (1) Check the trouble symptoms. Intermittent malfunction
→When all of the cylinders are (Refer to GROUP 00 – Points to
abnormal, go to (3) NG Note for Intermittent Malfunctions.)
→When a normal waveform is
Check the spark plug and the
displayed, go to (4).
ignition coil for a defective cylinder.
(Refer to GROUP 16 – Ignition
System.)
13C-32 MPI <4G9> – Troubleshooting

Code No. P0301 No. 1 cylinder misfire detected Probable cause

Code No. P0302 No. 2 cylinder misfire detected
Code No. P0303 No. 3 cylinder misfire detected
Code No. P0304 No. 4 cylinder misfire detected
Range of Check D Malfunction of the ignition system
D The engine speed is 500 – 4,500 r/min. D Abnormal compression
D While the engine is running except deceleration and sudden acceleration. D Malfunction of injector
Set Conditions D Malfunction of engine-ECU
D The number of misfires exceeds a predetermined number per 200 engine
revolutions (Misfire has occurred in only one cylinder).
or
D The number of misfires exceeds a predetermined number per 100 engine
revolutions (Misfire has occurred in only one cylinder).

NG
Check the following connectors: Repair
A-13, A-14
OK
(1) NG NG
Measure at ignition coil connectors Check the following connectors: Repair
A-13, A-14. A-13, A-14, A-90
D Disconnect the connector and
OK
measure at the harness side.
(1) The voltage between terminal 1
Check the ignition failure sensor NG
and earth Replace
(Refer to GROUP 16 – Ignition
(Ignition switch: ON)
System.)
OK: System voltage
(2) The voltage between terminal 3 OK
and earth
(Engine: Cranking) Check the harness wire between the
OK: 0.5 – 4.0 V ignition coil and the ignition failure
(3) The resistance between terminal sensor, and between the ignition
2 and earth switch and the ignition failure sensor.
OK: 2 Ω or less
(2) NG Check the following connectors: NG
A-13, A-14, C-87 Repair

OK

Check the harness wire between the NG

ignition coil and the engine-ECU. Repair
(3) NG
OK
NG
OK Check the trouble symptoms. Replace the engine-ECU.

Check the ignition coil (Refer to

GROUP 16 – Ignition System.) Check the harness wire between
the ignition coil and the earth, and
repair if necessary.
NG
Check the spark plugs. Replace
OK
Check the compression pressure.
NG
(Refer to GROUP 11B – On-vehicle Repair
Service.)
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

 MPI <4G9> – Troubleshooting 13C-33
Code No. P0325 Detonation sensor system Probable cause
Range of Check D Malfunction of the detonation sensor
D Engine: Two seconds after the engine has been started D Open or short circuit in the detonation sensor
Set Conditions circuit or loose connector contact
D Changes in sensor output voltage (detonation sensor peak voltage per 1/2 D Malfunction of engine-ECU
crankshaft rotation) in 200 consecutive cycles are 0.06 V or less.

NG
Check the following connector: A-81 Repair
OK
NG
Measure at the detonation sensor connector A-81. Check the harness wire between the detonation sensor and
D Disconnect the connector and measure at the harness earth, and repair if necessary.
side.
D The resistance between terminal 2 and earth
OK: 2 Ω or less
OK
NG
Check the following connector: C-90 Repair
OK
NG
Check the harness wire between the detonation sensor and Repair
the engine-ECU.
OK
OK
Check the trouble symptoms. Intermittent malfunction
(Refer to GROUP 00 – Points to Note for Intermittent
NG Malfunctions.)
Replace the detonation sensor.

Check the trouble symptoms.

NG

Replace the engine-ECU.

Code No. P0335 Crank angle sensor system Probable cause

Range of Check D Malfunction of the crank angle sensor.
D Engine is cranking D Open or short circuit in the crank angle sensor
Set Conditions circuit or loose connector contact.
D Sensor output voltage does not change for 4 seconds (no pulse signal D Malfunction of engine-ECU
input).

OK
MUT-II Data list Intermittent malfunction
22 Crank angle sensor (Refer to GROUP 00 – Points to
OK: Refer to P.13C-74, DATA Note for Intermittent Malfunctions.)
LIST REFERENCE TABLE.
NG
NG
Check the following connector: Repair
A-77
OK

To the next page

13C-34 MPI <4G9> – Troubleshooting

From the previous page

OK
(1) NG
Measure at the crank angle sensor Check the harness between the
connector A-77. crank angle sensor and earth, and
D Disconnect the connector and repair if necessary.
measure at the harness side.
(1) The resistance between terminal (2) NG OK
1 and earth Measure at engine-ECU connector Check the following connector:
OK: 2 Ω or less C-90. C-90
(2) The voltage between terminal 3 D Measure the voltage at the NG
OK
and earth engine-ECU terminal. Repair
(Ignition switch: ON) D Disconnect the connector A-77
OK: 4.8 – 5.2 V D Ignition switch: ON
Check the harness wire between
(3) The voltage between terminal 2 D The voltage between terminal 89 the crank angle sensor and the
and earth and earth engine-ECU, and repair if necessary.
(Ignition switch: ON) OK: 4.8 – 5.2 V
OK: System voltage NG
NG
Check the following connector: Repair
C-90
OK
NG
Check the harness wire between Repair
the crank angle sensor and the
engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
(3) NG NG
Check the following connectors: Repair
A-36, A-43X
OK OK

Check the harness wire between the

crank angle sensor and the engine
control relay, and repair if necessary.

NG NG
Use an analyzer to measure the Check the crank angle sensor vane. Replace
output waveform at the crank angle
OK
sensor connector A-77.
D Use the test harness
Replace the crank angle sensor.
(MB991658) to connect the
connector, and measure at the
pick-up harness side.
D Engine: Idling Check the trouble symptoms.
D The voltage between terminal 3 NG
and earth NG
OK: A normal waveform should Check the following connectors: Repair
be displayed as described A-77, C-90
on P.13C-87 (Inspection
Procedure Using an Ana- OK
lyzer). Its maximum value
should be 4.8 V or more, Check the harness wires between
and its minimum value the crank angle sensor and the
should be 0.6 V or less engine-ECU crank angle sensor and
with no noise in waveform. the engine control relay, and the
crank angle sensor and earth. Then,
OK repair if necessary.

Check the trouble symptoms.

NG

Replace the engine-ECU.

 MPI <4G9> – Troubleshooting 13C-35
Code No. P0340 Camshaft position sensor system Probable cause
Range of Check D Malfunction of the camshaft position sensor
D After the engine was started D Open or short circuit in the camshaft position
Set Conditions sensor circuit or loose connector contact.
D The sensor output voltage does not change for 4 seconds (no pulse signal D Malfunction of engine-ECU
input).

NG
Check the following connector: Repair
A-66
OK
(1) NG NG
Measure at camshaft position Check the following connectors: Repair
sensor connector A-66. A-66, A-43X
D Disconnect the connector and OK
measure at the harness side.
(1) The voltage between terminal 3 Check the harness wire between
and earth the camshaft position sensor
(Ignition switch: ON) connector and the engine control
OK: System voltage relay, and repair if necessary.
(2) The voltage between terminal 2
and earth (2) NG
Measure at engine-ECU connector OK
(Ignition switch: ON) Check the following connector:
OK: 4.8 – 5.2 V C-90. C-90
(3) The resistance between terminal D Measure the voltage at the NG
OK
1 and earth engine-ECU terminal. Repair
OK: 2 Ω or less D Disconnect connector A-66.
D Ignition switch: ON Check the harness wire between
D The voltage between terminal 2 the camshaft position sensor
and earth connector and the engine-ECU, and
OK: 4.8 – 5.2 V repair if necessary.

NG
NG
Check the following connector: Repair
C-90
OK
NG
Check the harness wire between Repair
the intermediate connector and the
OK engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.

(3) NG
Check the harness wire between the
camshaft position sensor connector
and earth, and repair if necessary.

NG NG
Use an analyzer to measure the Check the camshaft position sensing Replace
output waveform at camshaft cylinder.
position sensor connector A-66.
D Use test harness (MB991709) to
connect the connector, and Replace the camshaft position
measure at the pick-up harness. sensor.
D Engine: Idling
D The voltage between terminal 2 OK
and earth
OK: A normal waveform should Check the trouble symptoms.
be displayed as described NG
on P.13C-87 (Inspection NG
Procedure Using an Ana- Check the following connector: Repair
lyzer), its maximum value A-66
should be 4.8 V or more, OK
and its minimum value
should be 0.6 V or less Check the harness wires between the camshaft position sensor connector and the
with no noise in waveform. engine-ECU, the camshaft position sensor connector and the engine control relay, and
the camshaft position sensor connector and earth. Then, repair if necessary.
OK
OK
Check the trouble symptoms. Intermittent malfunction
NG (Refer to GROUP 00 – Points to Note for Intermittent Malfunctions.)

Replace the engine-ECU.

13C-36 MPI <4G9> – Troubleshooting

Code No. P0403 EGR control solenoid valve system Probable cause
Range of Check D Malfunction of the EGR control solenoid valve
D Ignition switch: ON D Open or short circuit in the EGR control solenoid
D Battery voltage is 10 V or more. valve circuit or loose connector contact
Set Conditions D Malfunction of engine-ECU
D The solenoid coil surge voltage (battery voltage + 2 V) is not detected
when the purge control solenoid valve is turned from on to off.

OK
MUT-II Actuator Test Intermittent malfunction
10 EGR control solenoid valve (Refer to GROUP 00 – Points to
OK: Operating sound can be Note for Intermittent Malfunctions.)
heard and the valve vibrates.
NG
NG
Measure at the EGR control Replace
solenoid valve connector A-03.
D Disconnect the connector, and
measure at the solenoid valve
side.
D The resistance between
terminals 1 and 2
OK: 28 – 36 Ω (at 20_C)
OK
NG
Check the following connector: Repair
A-03
OK
NG
Check the following connector: NG
Measure at the EGR control Repair
solenoid valve connector A-03. A-36
D Disconnect the connector and NG
measure at the harness side.
D Ignition switch: ON Check the harness wire between
D The voltage between terminal 1 the EGR control solenoid valve and
and earth the engine control relay, and repair
OK: System voltage if necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-87. C-87
D Measure the voltage at the OK
engine-ECU terminal.
D Ignition switch: ON Check the harness wire between NG
D The voltage between terminal 6 the EGR control solenoid valve and Repair
and earth the engine-ECU.
OK: System voltage
OK

OK Replace the engine-ECU.

NG
Check the following connector: Repair
C-87
OK
NG
Check the harness wires between Repair
the EGR control solenoid valve and
the engine control relay, and
between the purge control solenoid
valve and the engine-ECU.
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

 MPI <4G9> – Troubleshooting 13C-37
Code No. P0420 Catalyst malfunction Probable cause
Range of Check D Malfunction of catalyst
D The engine speed is 3,000 r/min or less. D Malfunction of the oxygen sensor (front)
D During driving D Malfunction of the oxygen sensor (rear)
D During air/fuel ratio feedback control D Malfunction of engine-ECU
Set Conditions
D The ratio between the oxygen sensor (rear) and the oxygen sensor (front)
output frequencies reaches 0.8 per 12 seconds on average.

NG
Check the exhaust manifold. (Are there any cracks?) Repair
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system <sensor 2>
59 Oxygen sensor (rear) (Refer to P.13C-27, INSPECTION PROCEDURE FOR
D Transmission: 2nd gear <M/T>, L range <A/T> DIAGNOSTIC TROUBLE CODE P0136.)
D Drive with wide open throttle
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system <sensor 1>
11 Oxygen sensor (front) (Refer to P.13C-25, INSPECTION PROCEDURE FOR
OK: 600 – 1,000 mV when racing suddenly DIAGNOSTIC TROUBLE CODE P0130.)
OK
NG
MUT-II Data list Replace the oxygen sensor (front).
11 Oxygen sensor (front)
D Transmission: 2nd gear <M/T>, L range <A/T>
OK: Changeover between 0 – 400 mV and 600 – 1,000
mV occur 15 times in 10 seconds.
OK

Replace the oxygen sensor (rear).

Check the trouble symptoms.

NG

Replace the catalytic converter.

Check the trouble symptoms.

NG

Replace the engine-ECU.

13C-38 MPI <4G9> – Troubleshooting

Code No. P0443 Purge control solenoid valve system Probable cause
Range of Check D Malfunction of the purge control solenoid valve
D Ignition switch: ON D Open or short circuit in the purge control solenoid
D Battery voltage is 10 V or more. valve circuit or loose connector contact
Set Conditions D Malfunction of engine-ECU
D The solenoid coil surge voltage (battery voltage + 2 V) is not detected
when the purge control solenoid valve is turned from on to off.

OK
MUT-II Actuator Test Intermittent malfunction
08 Purge control solenoid valve (Refer to GROUP 00 – Points to
OK: Operating sound can be Note for Intermittent Malfunctions.)
heard and the valve vibrates.
NG
NG
Measure at the purge control Replace
solenoid valve connector A-02.
D Disconnect the connector, and
measure at the solenoid valve
side.
D The resistance between
terminals 1 and 2
OK: 28 – 36 Ω (at 20_C)
OK
NG
Check the following connector: Repair
A-02
OK
NG
Measure at the purge control Check the following connector: NG
Repair
solenoid valve connector A-02. A-36, A-43X
D Disconnect the connector and
NG
measure at the harness side.
D Ignition switch: ON Check the harness wire between
D The voltage between terminal 2 the purge control solenoid valve and
and earth the engine control relay, and repair
OK: System voltage if necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-87. A-02, C-87
D Measure the voltage at the
OK
engine-ECU terminal.
D Ignition switch: ON Check the harness wire between NG
D The voltage between terminal 9 the purge control solenoid valve and Repair
and earth the engine-ECU.
OK: System voltage
OK

OK Replace the engine-ECU.

NG
Check the following connector: Repair
C-87
OK
NG
Check the harness wires between Repair
the purge control solenoid valve and
the engine control relay, and
between the purge control solenoid
valve and the engine-ECU.
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

 MPI <4G9> – Troubleshooting 13C-39
Code No. P0500 Vehicle speed sensor system Probable cause
Range of Check D Malfunction of the vehicle speed sensor
D Engine: Two seconds after the engine was started D Open or short circuit in the vehicle speed sensor
D Idle switch: OFF circuit or loose connector contact
D Engine speed: 2,500 r/min or more D Malfunction of engine-ECU
D During high engine load
Set Conditions
D The sensor output voltage does not change for 4 seconds (no pulse signal
input).

NO
Does the speedometer operate normally? Check the vehicle speed sensor
(Refer to GROUP 54 – Combination Meter.)
YES
NG
Use an analyzer to measure the output waveform of the Check the following connectors:
vehicle speed sensor at engine-ECU connector C-90. B-08, D-02, C-41<RHD>, C-38<LHD>, C-28, C-90
D Driving the vehicle OK NG
D The voltage between terminal 86 and earth
OK: A normal waveform should be displayed as de- Repair
scribed in OSCILLOSCOPE INSPECTION PROCE-
DURE, and noise should not be displayed in the Check the harness wire between the engine-ECU, and repair
waveform. (Refer to GROUP 23 – Troubleshooting.) if necessary.

OK
NG
Check the following connector: C-90 Repair
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

13C-40
Code No. P0505 Idle speed control (ISC) system Probable cause
Check Area D Malfunction of idle speed control (ISC) servo
D Vehicle speed has reached 1.5 km/h at least once. D Improper connector contact, open circuit or
D Under the closed loop idle speed control. short-circuit harness wire
Judgment Criteria D Malfunction of engine-ECU
D Actual idle speed has continued to be higher than the target idle speed by
300 r/min or more for 10 sec.
Check Area
D Vehicle speed has reached 1.5 km/h at least once.
D During idle speed closed loop control.
D The highest temperature at the last drive is 45_C or less.
D Engine coolant temperature is approx. 80_C or more.
D Battery voltage is 10 V or more.
D Intake air temperature is –10_C or more.
Judgment Criteria
D Actual idle speed has been minimum 200 r/min higher than the target idle
speed for 10 seconds.
Check Area
D During idle speed closed loop control.
D Engine coolant temperature is about 80_C or higher.
D Battery voltage is 10 V or higher.
D Power steering switch is off.
D Intake air temperature is –10_C or more.
D Volume efficiency is 40 percent or lower.
D Barometric pressure is 76 kPa or higher.
Judgment Criteria
D Actual idle speed has been minimum 100 r/min higher than the target idle
speed for 10 seconds.
 MPI <4G9> – Troubleshooting 13C-41
Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION
Is any diagnosis code other than CHART FOR DIAGNOSIS CODES.
No. P0505 output?
No
NG
Check intake air hose and intake Repair
manifold for air intake.
OK
NG
Check the throttle body (around the Clean around the throttle valve.
throttle valve) for contamination. (Refer to P.13C-96.)
OK
NG
Check the idle speed control (ISC) Replace
servo. (Refer to P.13C-107.)
OK
NG
Check the following connector: Repair
A-04
OK
NG
Measure at the idle speed control Check the following connector:
servo connector A-04. A-04, A-36, A-43X
D Disconnect the connector, and OK
measure at the harness side.
D Ignition switch: ON Check the harness wire between the
D The voltage between terminal 2 engine control relay and the idle speed
and earth control servo, and repair if necessary.
D The voltage between terminal 5
and earth
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-87. A-04, C-87
D Use test harness (MB991709) to
connect the connector, and mea- OK
NG
sure at the pick-up harness side. Check the harness wire between the Repair
D The voltage between terminal 4 and idle speed control servo and the engine-
earth ECU.
D The voltage between terminal 5 and
earth OK
D The voltage between terminal 17
Replace the engine-ECU.
and earth
D The voltage between terminal 18
and earth
OK: The voltage changes as fol-
lows for three seconds when
the ignition switch is turned
ON.
(When using a circuit tester)
5 V and 8 V alternates
(When using an analyzer)
1 V or less and system volt-
age alternates.
OK
To the next page
13C-42 MPI <4G9> – Troubleshooting

From the previous page

OK
NG
Check the following connector: Repair
A-04
OK
NG
Check the harness wire between Repair
the engine control relay and the idle
speed control servo, and between
the idle speed control servo and the
engine-ECU.
OK
OK
Check the trouble symptoms. Intermittent malfunction
(Refer to GROUP 00 – Points to
NG Note for Intermittent Malfunctions.)
Replace the engine-ECU.
 MPI <4G9> – Troubleshooting 13C-43
Code No. P0551 Power Steering fluid Pressure Switch Probable cause
System
Check Area D Power steering fluid pressure switch failed.
D Intake air temperature is –10_C or higher. D Open or shorted power steering fluid pressure
D Barometric pressure is 76 kPa or higher. switch circuit or loose connector
D Engine coolant temperature is 30_C or more. D Malfunction of engine-ECU
D Repeat *1 drive and *2 stop ten times or more.
*1: Engine speed is 2,500 r/min or higher, volumetric efficiency is 55 % or
higher and vehicle speed is 5 km/h or higher for 4 seconds or more.
*2: Vehicle speed is 1.5 km/h or lower.
Judgment Criteria
D Power steering pressure switch remains on.

OK
MUT-II Data list Transient malfunction (Refer to GROUP 00 – Points to Note
27 Power steering fluid pressure switch for Intermittent Malfunctions.)
(Refer to P.13C-74, DATA LIST REFERENCE TABLE.)
NG
NG
Check the power steering pressure switch. Replace
(Refer to GROUP 37A – On-vehicle Service.)
OK
NG
Check the following connector: A-76 Repair
OK
NG NG
Measure at the power steering pressure switch connector Check the following Repair
A-76. connectors: A-76, C-88
D Disconnect the connector and measure at the harness
side. OK
D Voltage between 1 and ground (Ignition switch: ON)
Check the trouble
OK: Battery positive voltage
symptom.
OK
NG NG
Check the following Repair
NG
connector: A-76 Check the harness wire Repair
OK between engine-ECU
and power steering
Check the trouble pressure switch
symptom. connector.
OK OK
Replace the engine-ECU. Replace the engine-
ECU.
13C-44 MPI <4G9> – Troubleshooting

Code No. P1603 Battery backup line system Probable cause

Range of Check D Open circuit or short-circuit in the battery backup
D Ignition switch: ON line, or loose connector contact
Set Conditions D Malfunction of the engine-ECU
D Backup RAM data which was set when the ignition switch was turned off
the previous time has not been retained.

YES
Were the battery terminals Turn the ignition switch to the
disconnected immediately before LOCK (OFF) position, wait for 10
reading the diagnosis codes? seconds, and then turn it back to
the ON position.
NG

YES MUT-II diagnosis codes NO

D Is code No. P1603 output? End

NG OK
Measure at the engine-ECU Measure
Replace at the ECU connector Check the following connector:
connector C-90. C-90. A-36, C-90
D Measure the engine-ECU D Disconnect the connector and
measure at the harness side. OK NG
terminal voltage. Repair
D Ignition switch: ON D Voltage between 80 and earth
D Voltage between 80 and earth OK: System voltage Check the harness between the
OK: System voltage battery and the engine-ECU, and
NG repair if necessary.
Check the harness between the
battery and the engine-ECU, and
repair if necessary.

OK

Check the following connectors:

C-90
OK
OK
Check the trouble symptoms. Transient malfunction (Refer to
GROUP 00 – Points to Note for
NG Transient Malfunctions.)

Replace the engine-ECU.

 MPI <4G9> – Troubleshooting 13C-45
Code No. P1610 Immobilizer system Probable cause
Range of Check D Open or short circuit, or loose connector contact
D Ignition switch: ON D Malfunction of the immobilizer-ECU
Set Conditions D Malfunction of the engine-ECU
D Improper communication between the engine-ECU and the immobilizer-ECU

NOTE
(1) If the registered ignition keys are close each other when starting the engine, radio interference may
cause this code to be displayed.
(2) This code may be displayed when registering the key ID code.
NG
Check the following connectors: Repair
C-62, C-29, A-43X
OK
NG
Check the harness wire between Replace
the immobilizer-ECU and the
engine-ECU.
OK
Check the trouble symptoms.
NG
Replace the immobilizer-ECU.

Check the trouble symptoms.

NG

Replace the engine-ECU.

13C-46 MPI <4G9> – Troubleshooting

INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom Inspection Reference page
procedure
No.

Communication Communication with all systems is not possible. 1 13C-47

with MUT-II is
impossible. Communication with engine-ECU only is not possible. 2 13C-47

Engine warning The engine warning lamp does not illuminate right after the 3 13C48
lamp and ignition switch is turned to the ON position.
related parts
The engine warning lamp remains illuminating and never goes 4 13C-48
out.

Starting No initial combustion (starting impossible) 5 13C-49

Initial combustion but no complete combustion 6 13C-50

(starting impossible)

Long time to start (improper starting) 7 13C-51

Idling stability Unstable idling (Rough idling, hunting) 8 13C-52

(Improper idling)
Idling speed is high. (Improper idling speed) 9 13C-54

Idling speed is low. (Improper idling speed) 10 13C-54

Idling stability When the engine is cold, it stalls at idling. (Die out) 11 13C-55
(Engine stalls)
When the engine becomes hot, it stalls at idling. (Die out) 12 13C-56

The engine stalls when starting the car. (Pass out) 13 13C-58

The engine stalls when decelerating. 14 13C-58

Driving Hesitation, sag or stumble 15 13C-59

The feeling of impact or vibration when accelerating 16 13C-60

The feeling of impact or vibration when decelerating 17 13C-60

Poor acceleration 18 13C-61

Surge 19 13C-63

Knocking 20 13C-64

Dieseling 21 13C-64

Too high CO and HC concentration when idling 22 13C-65

Idling speed is improper when A/C is operating 23 13C-66

Fans (radiator fan, A/C condensor fan) are inoperative 24 13C-67

 MPI <4G9> – Troubleshooting 13C-47
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1
Communication with MUT-II is not possible. Probable cause
(Communication with all systems is not possible.)
The cause is probably a defect in the power supply system (including earth) for D Malfunction of the connector
the diagnosis line. D Malfunction of the harness wire

NG NG
Measure at the diagnostic connector Check the following connectors: Repair
(16-pin) C-35. C-76, C-77
D Voltage between 16 and earth OK
OK: Battery voltage NG
OK Check the trouble symptom. Check the harness wire between the
power supply and diagnostic connector
NG (16-pin), and repair if necessary.
Measure at the diagnostic connector Check the following connectors: C-01
(16-pin) C-35.
OK
D Continuity between 4 and earth
D Continuity between 5 and earth NG
Check the harness wire between the Repair
OK: Continuity diagnostic connector (16-pin) and
OK earth, and repair if necessary.

Replace the MUT-II.

INSPECTION PROCEDURE 2
MUT-II communication with engine-ECU is impossible. Probable cause
One of the following causes may be suspected. D Malfunction of engine-ECU power supply circuit
D No power supply to engine-ECU. D Malfunction of engine-ECU
D Defective earth circuit of engine-ECU. D Open circuit between the engine-ECU and diagnosis
D Defective engine-ECU. connector
D Improper communication line between engine-ECU and MUT-II

NG
Check the following connectors: Repair
C-35, B-70, C-53, C-28, C-89
OK
Check the trouble symptom.
NG
NG
Check the harness wire between engine-ECU and diagnosis con- Repair
nector.
OK

Check the engine-ECU power supply and earth circuit system.

(Refer to P.13C-68, INSPECTION PROCEDURE 25.)
13C-48 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 3
The engine warning lamp does not illuminate right after Probable cause
the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Burnt-out bulb
to illuminate for five seconds immediately after the ignition switch is turned to ON. D Defective warning lamp circuit
If the engine warning lamp does not illuminate immediately after the ignition switch D Malfunction of the engine-ECU
is turned to ON, one of the malfunctions listed at right has probably occurred.

NG
MUT-II Data list Check the engine-ECU power supply and earth circuit.
16 engine-ECU power supply voltage (Refer to P.13C-75.) (Refer to P.13C-68, INSPECTION PROCEDURE 25.)
OK
OK NG
Measure at the engine-ECU connector C-88. Check the following Repair
D Disconnect the connector, and measure at the harness side. connector: C-88
D Earth the terminal No. 36.
OK
OK: The engine warning lamp illuminates.
NG Check the trouble symptom.
NG NG
Check a burnt-out bulb. Replace
Replace the engine-ECU.
OK
NG
Measure at the combination meter connector C-07. Check the engine warning lamp power supply circuit, and repair
D Disconnect the connector, and measure at the harness side. if necessary.
D Voltage between 46 and earth (Ignition switch: ON)
OK: System voltage
OK
NG
Check the following connectors: Repair
C-07, C-28, C-88
OK
NG
Check the trouble symptom. Check the harness wire between combination meter and engine-
ECU, and repair if necessary.

INSPECTION PROCEDURE 4
The engine warning lamp remains illuminating and never Probable cause
goes out.
In cases such as the above, the cause is probably that the engine-ECU is detecting D Short-circuit between the engine warning lamp and
a problem in a sensor or actuator, or that one of the malfunctions listed at right engine-ECU
has occurred. D Malfunction of the engine-ECU

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Measure at the combination meter connector C-07. Check the harness wire between combination meter and engine-
D Disconnect the connector, and measure at the harness side. ECU connector, and repair if necessary.
D Disconnect the engine-ECU connector
D Continuity between 46 and earth
OK: No continuity
OK
Replace the engine-ECU.
 MPI <4G9> – Troubleshooting 13C-49
INSPECTION PROCEDURE 5
No initial combustion (starting impossible) Probable cause
In cases such as the above, the cause is probably that a spark plug is defective, D Malfunction of the ignition system
or that the supply of fuel to the combustion chamber is defective. D Malfunction of the fuel pump system
In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel. D Malfunction of the injectors
D Malfunction of the engine-ECU
D Malfunction of the immobilizer system
D Foreign materials in fuel

NG
Check battery voltage when cranking. Check the battery. (Refer to GROUP 54 – Battery.)
OK: 8 V or higher
OK
Yes
Is immobilizer-ECU diagnosis code displayed? Check the immobilizer.
(Refer to GROUP 54 – Ignition Key and Immobilizer.)
No
NG
MUT-II Data list Check the power supply and ignition switch-IG system.
16 Power supply voltage (Refer to P.13C-75.) (Refer to P.13C-69, INSPECTION PROCEDURE 26.)
OK
No
Does the camshaft rotate at the engine cranking? Check timing belt for breakage.
(When oil filler cap is removed.)
Yes
Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
No
MUT-II Data list Check the crank angle sensor system. (Refer to P.13A-113, IN-
22 Crank angle sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0335.)
OK: Cranking speed is displayed
OK
NG
MUT-II Actuator test Check the fuel pump system.
07 Fuel pump (Refer to P.13C-79.) (Refer to P.13C-69, INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
No
Can any sound be heard from the injectors when cranking? Check the injector system. (Refer to P.13C-30, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203,
Yes P0204.)
No
Measure at the ignition coil connectors A-13 and A-14 Check the ignition circuit system. (Refer to P.13C-72, INSPECTION
D Connectors connected PROCEDURE 30.)
D Check by connecting the timing light to terminal 1 of each
connector (Engine: Cranking)
OK: The timing light flashes.
OK

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Check if the injectors are clogged.
D Check if foreign materials (water, alcohol, etc.) got into fuel.
D Check the compression pressure.
D Check the immobilizer system.
13C-50 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 6
Initial combustion but no complete combustion Probable cause
(starting impossible)
In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the ignition system
sparks but the sparks are weak, or the initial mixture for starting is not appropriate. D Malfunction of the injector system
D Foreign materials in fuel
D Poor compression
D Malfunction of the engine-ECU

NG
Check battery voltage when cranking. Check the battery. (Refer to GROUP 54 – Battery.)
OK: 8 V or higher
OK
Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODE.
No
NG
MUT-II Actuator test Check the fuel pump system.
07 Fuel pump (Refer to P.13C-79.) (Refer to P.13C-69, INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-12, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Data list Check the ignition switch-ST system.
18 Ignition switch-ST (Refer to P.13C-75.) (Refer to P.13C-71, INSPECTION PROCEDURE 28.)
OK
NG
Can any sound be heard from the injectors when cranking? Check the injector system. (Refer to P.13C-30, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203, P0204.)
OK
Yes NG
Is starting good if the engine is cranked with the accelerator pedal Check ISC servo for op- Check the ISC servo sys-
slightly depressed? eration sound. tem. (Refer to P.13C-40,
(Refer to P.13C-107.) INSPECTION PROCE-
No DURE FOR DIAGNOSIS
OK
CODE P0505.)

D Clean the throttle valve area. (Refer to P.13C-96.)

NG
Check the ignition timing when cranking. Check that the crank angle sensor is installed properly.
OK: Approx. 5_BTDC
OK

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Check if the injectors are clogged.
D Check the compression pressure.
D Check fuel lines for clogging.
D Check if foreign materials (water, alcohol, etc.) got into fuel.
 MPI <4G9> – Troubleshooting 13C-51
INSPECTION PROCEDURE 7
It takes too long time to start. (Incorrect starting) Probable cause
In cases such as the above, the cause is probably that the spark is weak and D Malfunction of the ignition system
ignition is difficult, the initial mixture for starting is not appropriate, or sufficient D Malfunction of the injector system
compression pressure is not being obtained. D Inappropriate gasoline use
D Poor compression

NG
Check battery voltage when cranking Check the battery. (Refer to GROUP 54 – Battery.)
OK: 8 V or higher
OK
Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODE.
No
NG
MUT-II Actuator test Check the fuel pump system.
07 Fuel pump (Refer to P.13C-79.) (Refer to P.13C-69, INSPECTION PROCEDURE 27.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P0115.)
NG
MUT-II Data list Check the ignition switch-ST system.
18 Ignition switch-ST (Refer to P.13C-75.) (Refer to P.13C-71, INSPECTION PROCEDURE 28.)
OK
NG
Can any sound be heard from the injectors when cranking? Check the injector system. (Refer to P.13C-30, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203,
OK P0204.)
NG
Check the ignition timing when cranking. Check that the crank angle sensor is installed properly.
OK: Approx. 5_BTDC
OK

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Check if the injectors are clogged.
D Check the compression pressure.
D Check if foreign materials (water, alcohol, etc.) got into fuel.
13C-52 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 8
Unstable idling (Rough idling, hunting) Probable cause
In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of the ignition system
idle speed control (ISC) or compression pressure is defective. D Malfunction of air-fuel ratio control system
Because the range of possible causes is broad, inspection is narrowed down to D Malfunction of the ISC system
simple items. D Malfunction of the purge control solenoid valve system
D Malfunction of the EGR solenoid valve system
D Poor compression
D Drawing air into exhaust system

Yes
Were the battery terminals disconnected? After warming-up, let the engine run at idling for 10 minutes.
No
Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
Yes
Does idling speed fluctuate excessively? Clean the throttle body. (Refer to P.13C-96.)
No
Check the trouble symptom.

NG

Inspect the intake of air into the air intake system

D Broken intake manifold gasket
D Broken air intake hose
D Broken vacuum hose
D Positive crankcase ventilation valve does not operate.

NG
Check the ISC servo for operation sound. (Refer to P.13C-107.) Check the ISC system. (Refer to P.13C-40, INSPECTION PROCE-
DURE FOR DIAGNOSIS CODE P0505.)
OK
NG
Check the injector for operation sound. Check the injector system. (Refer to P.13C-30, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203, P0204.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13C-74.) P.13C-18. INSPECTION PROCEDURE FOR DIAGNOSIS CODE
P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13C-16,
25 Barometric pressure sensor (Refer to P.13C-76.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system
08 Purge control solenoid valve (Refer to P.13C-79.) (Refer to P.13C-38, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0443.)
OK
NG
MUT-II Actuator test Check the EGR control solenoid valve system. (Refer to P.13C-36,
10 EGR control solenoid valve (Refer to P.13C-79.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0403.)
OK
To the next page
 MPI <4G9> – Troubleshooting 13C-53
From the previous page
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13C-27, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
D Transmission: 2nd gear <M/T>, L range <A/T>
D Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13C-25, IN-
11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: 600 – 1,000 mV during sudden racing
OK
NG OK
MUT-II Data list Check the fuel pressure. 1. Inspect the intake of
11 Oxygen sensor (Refer to P.13C-98.) air into the air intake
OK: Changes between 0 – 400 mV and 600 – 1,000 mV system.
during idling D Broken intake
manifold gasket
OK D Broken vacuum
NG
Check the power steering hose
MUT-II Data list
fluid pressure switch sys- D PCV valve does
27 Power steering fluid pressure switch (Refer to P.13C-76.)
tem. (Refer to P.13C-43, not operate.
OK
INSPECTION PROCE- D Broken air intake
DURE FOR DIAGNOSIS hose
CODE P0551.) 2. Check the injector for
clog.
NG
MUT-II Data list Check the A/C switch and A/C relay system.
28 A/C switch (Refer to P.13C-76.) (Refer to P.13C-72, INSPECTION PROCEDURE 29.)
OK
NG
MUT-II Data list Check the ignition switch-ST.
29 Inhibitor switch (Refer to P.13C-76.) (Refer to P.13C-71, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Adjust the basic idle speed. (Refer to P.13C-97.)
45 ISC Servo position (Refer to P.13C-77.)
OK
NG
Check the ignition timing. Check that the crank angle sensor is installed properly.
(Refer to GROUP 11B – On-vehicle Service.)
OK

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Check the purge control system.
D Check the EGR control system.
D Check the compression pressure.
D Check if foreign materials (water, alcohol, etc.) got into fuel.
13C-54 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 9
Idling speed is high. (Improper idling speed) Probable cause
In such cases as the above, the cause is probably that the intake air volume during D Malfunction of the ISC servo system
idling is too great. D Malfunction of the throttle body

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Check the ISC servo for operation sound. (Refer to P.13C-107.) Check the ISC system. (Refer to P.13C-40, INSPECTION PROCE-
DURE FOR DIAGNOSIS CODE P0505.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Data list Check the A/C switch and A/C relay system.
28 A/C switch (Refer to P.13C-76.) (Refer to P.13C-72, INSPECTION PROCEDURE 29.)
OK

Basic idle adjustment (Refer to P.13C-97.)

NG
Check the trouble symptom. Clean the throttle valve area. (Refer to P.13C-96.)

INSPECTION PROCEDURE 10
Idling speed is low. (Improper idling speed) Probable cause
In cases such as the above, the cause is probably that the intake air volume during D Malfunction of the ISC servo system
idling is too small. D Malfunction of the throttle body

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Check the ISC servo for operation sound. (Refer to P.13C-107.) Check the ISC system. (Refer to P.13C-40, INSPECTION PROCE-
DURE FOR DIAGNOSIS CODE P0505.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Data list Check the ignition switch ST.
29 Inhibitor switch (Refer to P.13C-76.) (Refer to P.13C-71, INSPECTION PROCEDURE 28.)
OK

Basic idle adjustment (Refer to P.13C-97.)

NG
Check the trouble symptom. Clean the throttle valve area. (Refer to P.13C-96.)
 MPI <4G9> – Troubleshooting 13C-55
INSPECTION PROCEDURE 11
When the engine is cold, it stalls at idling. (Die out) Probable cause
In such cases as the above, the cause is probably that the air/fuel mixture is D Malfunction of the ISC servo system
inappropriate when the engine is cold, or that the intake air volume is insufficient. D Malfunction of the throttle body
D Malfunction of the injector system
D Malfunction of the ignition system

Yes
Were the battery terminals disconnected? After warming-up, let the engine run at idling for 10 minutes.
No
Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
Yes
Does the engine stall right after the accelerator pedal is released? Clean the throttle valve
area.
No (Refer to P.13C-96.)
No
Is engine-idling stable after the warming-up? Check if the unstable idling (Rough idling, hunting).
Yes (Refer to P.13C-52, INSPECTION PROCEDURE 8.)
NG
Check the ISC servo for operation sound. (Refer to P.13C-107.) Check the ISC system. (Refer to P.13C-40, INSPECTION PROCE-
OK DURE FOR DIAGNOSIS CODE P0505.)
NG
Check the injector for operation sound. Check the injector system. (Refer to P.13C-30, INSPECTION PRO-
OK CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203, P0204.)
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Actuator test Check the EGR control solenoid valve system. (Refer to P.13C-36,
10 EGR control solenoid valve (Refer to P.13C-79.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0403.)
OK

Check the fuel pressure. (Refer to P.13C-98.)

OK
NG
Check the ignition timing. Check that the crank angle sensor is installed properly.
(Refer to GROUP 11B – On-vehicle Service.)
OK

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Check the compression pressure.
D Check the engine oil viscosity.
13C-56 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 12
When the engine is hot, it stalls at idling. (Die out) Probable cause
In such cases as the above, the cause is probably that ignition system, air/fuel D Malfunction of the ignition system
mixture, idle speed control (ISC) or compression pressure is defective. D Malfunction of air-fuel ratio control system
In addition, if the engine suddenly stalls, the cause may also be a defective connector D Malfunction of the ISC system
contact. D Drawing air into intake system
D Improper connector contact

Yes
Were the battery terminals disconnected? After warming-up, let the engine run at idling for 10 minutes.
No
Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Check the ISC servo for operation sound. (Refer to P.13C-107.) Check the ISC system. (Refer to P.13C-40, INSPECTION PROCE-
DURE FOR DIAGNOSIS CODE P0505.)
OK
NG
Check the injector for operation sound. Check the injector system. (Refer to P.13C-30, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203, P0204.)
OK
Yes
Does the engine stall right after the accelerator pedal is released? Clean the throttle valve area.
No (Refer to P.13C-96.)

No
Does the engine stall easily again? While carrying out an intermittent malfunction simulation test (Refer
to GROUP 00 – Points to Note for Intermittent Malfunctions.),
OK check for sudden changes in the signals shown below.
D Crank angle sensor signal D Primary and secondary
D Air flow sensor signal ignition signal
D Injector drive signal D Fuel pump drive signal
D Engine-ECU power
supply voltage

NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13C-74.) P.13C-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13C-15,
25 Barometric pressure sensor (Refer to P.13C-76.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Actuator test Check the EGR control solenoid valve system. (Refer to P.13C-36,
10 EGR control solenoid valve (Refer to P.13C-79.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0403.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13C-27, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
D Transmission: 2nd gear <M/T>, L range <A/T>
D Driving with throttle widely open
OK: 600 – 1,000 mV
OK
To the next page
 MPI <4G9> – Troubleshooting 13C-57
From the previous page
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13C-25, IN-
11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: Changes between 600 – 1,000 mV during sudden racing
OK
NG OK
MUT-II Data list Check the fuel pressure. 1. Inspect the intake of
11 Oxygen sensor (Refer to P.13C-98.) air into the air intake
OK: Changes between 0 – 400 mV and 600 – 1,000 mV system
during idling D Broken intake
OK manifold gasket
NG D Broken vacuum
MUT-II Data list Check the power steering hose
27 Power steering fluid pressure switch (Refer to P.13C-76.) fluid pressure switch sys- D PCV valve does
tem. (Refer to P.13C-43, not operate.
OK INSPECTION PROCE- D Broken air intake
DURE FOR DIAGNOSIS hose
CODE P0551.) 2. Check the injector for
clog.
NG
MUT-II Data list Check the A/C switch and A/C relay system.
28 A/C switch (Refer to P.13C-76.) (Refer to P.13C-72, INSPECTION PROCEDURE 29.)
OK
NG
MUT-II Data list Check the ignition switch-ST.
29 Inhibitor switch (Refer to P.13C-76.) (Refer to P.13C-71, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Adjust the basic idle speed. (Refer to P.13C-97.)
45 ISC servo position (Refer to P.13C-107.)
OK
NG
Check the ignition timing. Check that the crank angle sensor is installed properly.
(Refer to GROUP 11B – On-vehicle Service.)
OK

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Check if the injectors are clogged.
D Check the compression pressure.
13C-58 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 13
The engine stalls when starting the car. (Pass out) Probable cause
In cases such as the above, the cause is probably misfiring due to a weak spark, D Drawing air into intake system
or an inappropriate air/fuel mixture when the accelerator pedal is depressed. D Malfunction of the ignition system

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
MUT-II Actuator test Check the EGR control solenoid valve system. (Refer to P.13C-36,
10 EGR control solenoid valve (Refer to P.13C-79.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0403.)
OK

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Check if air was drawn into the intake system.
Broken intake manifold gasket
Broken or disconnected vacuum hose
Improper operation of the PCV valve
Broken air intake hose

INSPECTION PROCEDURE 14
The engine stalls when decelerating. Probable cause
In cases such as the above, the cause is probably that the intake air volume is D Malfunction of the ISC system
insufficient due to a defective idle speed control (ISC) servo system.

Yes
Were the battery terminals disconnected? After warming-up, let the engine run at idling for 10 minutes.
No
Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
OK
NG
MUT-II Data list Check the throttle position sensor system. (Refer to P.13C-22,
14 Throttle position sensor (Refer to P.13C-75.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0120.)
OK
Yes
MUT-II Data list Check the vehicle speed sensor system. (Refer to P.13C-40, IN-
45 ISC servo position SPECTION PROCEDURE FOR DIAGNOSIS CODE P0500.)
D Is the idle speed control (ISC) servo position drops to 0 –
2 steps when decelerating (engine r/min less than 1,000)?
No
NG
MUT-II Actuator test Check the EGR control solenoid valve system. (Refer to P.13C-36,
10 EGR control solenoid valve (Refer to P.13C-79.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0403.)
OK

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Clean the throttle valve area.
 MPI <4G9> – Troubleshooting 13C-59
INSPECTION PROCEDURE 15
Hesitation, sag or stumble Probable cause
In cases such as the above, the cause is probably that ignition system, air/fuel D Malfunction of the ignition system
mixture or compression pressure is defective. D Malfunction of air-fuel ratio control system
D Malfunction of the fuel supply system
D Malfunction of the EGR control solenoid valve system
D Poor compression

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Check the injectors for operation sound. Check the injector system. (Refer to P.13C-30, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203, P0204.)
OK
NG
Check the ignition timing. Check that the crank angle sensor is installed properly.
(Refer to GROUP 11B – On-vehicle Service.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13C-75.) P.13C-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13C-16,
25 Barometric pressure sensor (Refer to P.13C-76.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P0115.)
NG
MUT-II Data list Check the throttle position sensor system. (Refer to P.13C-22,
14 Throttle position sensor (Refer to P.13C-75.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0120.)
OK
NG
MUT-II Actuator test Check the EGR control solenoid valve system.
10 EGR control solenoid valve (Refer to P.13C-79.) (Refer to P.13C-36, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0403.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13C-27, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
D Transmission: 2nd gear <M/T>, L range <A/T>
D Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13C-25, IN-
11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: Changes between 600 – 1,000 mV during sudden racing
OK
To the next page
13C-60 MPI <4G9> – Troubleshooting

From the previous page

OK
NG OK
MUT-II Data list Check the fuel pressure. 1. Inspect the intake of
11 Oxygen sensor (Refer to P.13C-98.) air into the air intake
OK: Changes between 0 – 400 mV and 600 – 1,000 mV system
during idling D Broken intake
OK manifold gasket
D Broken vacuum
Check the fuel pressure. (Refer to P.13A-78.) hose
D PCV valve does
OK not operate.
D Broken air intake
Check the following items. hose
D Check the ignition coil, spark plugs, spark plug cables. 2. Check the injector for
D Check the EGR control system. clog.
D Check the compression pressure.
D Check the fuel filter or fuel line for clogging.

INSPECTION PROCEDURE 16
The feeling of impact or vibration when accelerating Probable cause
In cases such as the above, the cause is probably that there is an ignition leak D Malfunction of the ignition system
accompanying the increase in the spark plug demand voltage during acceleration.

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No

Check the following items.

D Check the ignition coil, spark plugs, spark plug cables.
D Check for occurrence of ignition leak.

INSPECTION PROCEDURE 17
The feeling of impact or vibration when decelerating. Probable cause
Malfunction of the ISC system is suspected. D Malfunction of the ISC system

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Check the ISC servo for operation sound. (Refer to P.13C-107.) Check the ISC system. (Refer to P.13C-40, INSPECTION PROCE-
OK DURE FOR DIAGNOSIS CODE P0505.)
NG
MUT-II Data list Check the throttle position sensor system. (Refer to P.13C-22,
14 Throttle position sensor (Refer to P.13C-75.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0120.)
OK

Clean the throttle valve area. (Refer to P.13C-96.)

 MPI <4G9> – Troubleshooting 13C-61
INSPECTION PROCEDURE 18
Poor acceleration Probable cause
Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. D Malfunction of the ignition system
are suspected. D Malfunction of air-fuel ratio control system
D Malfunction of the fuel supply system
D Poor compression pressure
D Clogged exhaust system

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Check the injectors for operation sound. Check the injector system. (Refer to P.13C-30, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203, P0204.)
OK
NG
Check the ignition timing. Check that the crank angle sensor is installed properly.
(Refer to GROUP 11B – On-vehicle Service.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13C-74.) P.13C-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
OK P0110.)
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13C-16,
25 Barometric pressure sensor (Refer to P.13C-76.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Data list Check the throttle position sensor system. (Refer to P.13C-22,
14 Throttle position sensor (Refer to P.13C-75.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0120.)
OK
NG
MUT-II Actuator test Check the EGR control solenoid valve system.
10 EGR control solenoid valve (Refer to P.13C-79.) (Refer to P.13C-36, INSPECTION PROCEDURE FOR DIAGNO-
OK SIS CODE P0403.)
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13C-27, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
D Transmission: 2nd gear <M/T>, L range <A/T>
D Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13C-25, IN-
11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: Changes between 600–1,000 mV during sudden racing
OK

To the next page

13C-62 MPI <4G9> – Troubleshooting

From the previous page

OK
NG OK
MUT-II Data list Check the fuel pressure. 1. Inspect the intake of
11 Oxygen sensor (Refer to P.13C-98.) air into the air intake
OK: Changes between 0 – 400 mV and 600 – 1,000 mV system
during idling D Broken intake
manifold gasket
OK D Broken vacuum
Check the fuel pressure. (Refer to P.13C-98.) hose
D PCV valve does
OK not operate.
D Broken air intake
Check the following items. hose
D Check the ignition coil, spark plugs, spark plug cables. 2. Check the injector for
D Check the compression pressure. clog.
D Check the fuel filter or fuel line for clogging.
D Broken air intake hose
D Clogged air cleaner
 MPI <4G9> – Troubleshooting 13C-63
INSPECTION PROCEDURE 19
Surge Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of the ignition system
D Malfunction of air-fuel ratio control system
D Malfunction of the EGR control solenoid valve system

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Check the injectors for operation sound. Check the injector system. (Refer to P.13C-32, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE P0201, P0202, P0203, P0204.)
OK
NG
Check the ignition timing. Check that the crank angle sensor is installed properly.
(Refer to GROUP 11C – On-vehicle Service.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13C-74.) P.13C-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13C-16.
25 Barometric pressure sensor (Refer to P.13C-76.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Data list Check the throttle position sensor system. (Refer to P.13C-22,
14 Throttle position sensor (Refer to P.13C-75.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0120.)
OK
NG
MUT-II Actuator test Check the EGR control solenoid valve system.
10 EGR control solenoid valve (Refer to P.13C-79.) (Refer to P.13C-36, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0403.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13C-27, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
D Transmission: 2nd gear <M/T>, L range <A/T>
D Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13C-25, IN-
11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: Changes between 600 – 1,000 mV during sudden racing
OK
NG OK
MUT-II Data list Check the fuel pressure. 1. Inspect the intake of
11 Oxygen sensor (Refer to P.13C-98.) air into the air intake
OK: Changes between 0 – 400 mV and 600 – 1,000 mV system
during idling D Broken intake
manifold gasket
OK D Broken vacuum
hose
Check the fuel pressure. (Refer to P.13C-98.) D PCV valve does
OK not operate.
D Broken air intake
Check the following items. hose
D Check the ignition coil, spark plugs, spark plug cables. 2. Check the injector for
D Check the EGR control system. clog.
13C-64 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 20
Knocking Probable cause
In cases as the above, the cause is probably that the detonation control is defective D Defective detonation sensor
or the heat value of the spark plug is inappropriate. D Inappropriate heat value of the spark plug

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
No
Does knocking occur when driving with the sensor disconnected? Check the detonation sensor system. (Refer to P.13C-33, INSPEC-
At this time, use the MUT-II to check if the timing is retarded TION PROCEDURE FOR DIAGNOSIS CODE P0325.)
compared to when the detonation sensor connector is connected.
Yes

Check the following items.

D Spark plugs
D Check if foreign materials (water, alcohol, etc.) got into fuel.

INSPECTION PROCEDURE 21
Dieseling Probable cause
Fuel leakage from injectors is suspected. D Fuel leakage from injectors

Check the injectors for fuel leakage.

 MPI <4G9> – Troubleshooting 13C-65
INSPECTION PROCEDURE 22
Too high CO and HC concentration when idling Probable cause
Abnormal air-fuel ratio is suspected. D Malfunction of the air-fuel ratio control system
D Deteriorated catalyst

Yes
MUT-II Self-Diag code Refer to P.13C-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
No
NG
Check the ignition timing. Check that the crank angle sensor is installed properly.
(Refer to GROUP 11B – On-vehicle Service.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor. (Refer to P.13C-75.) (Refer to P.13C-20, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE P0115.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13C-74.) P.13C-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
OK P0110.)
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13C-16,
25 Barometric pressure sensor (Refer to P.13C-76.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13C-27, IN-
59 Oxygen sensor (rear) SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.)
D Transmission: 2nd gear <M/T>, L range <A/T>
D Driving with throttle widely open
OK: 600 – 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13C-25, IN-
11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.)
OK: 600 – 1,000 mV when racing suddenly.
OK
OK
MUT-II Data list Replace the oxygen sensor.
11 Oxygen sensor
OK: Repeat 0 – 400 mV and 600 – 1,000 mV alternately
when idling.
Check the trouble symptom.
NG NG
Check the fuel pressure. (Refer to P.13C-98.)
OK

Check the following items.

D Check the injectors for operation sound.
D Check the injectors for fuel leakage.
D Check the ignition coil, spark plugs, spark plug cables.
D Check the compression pressure.
D Check the positive crankcase ventilation system.
D Check the purge control system.
D Check the EGR control system.

Check the trouble symptom.

NG

Replace the catalytic converter.

13C-66 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 23
Idling speed is improper when A/C is operating Probable cause
If the engine-ECU detects that the air conditioner is on, it activates the idle D Malfunction of the A/C control system
speed control (ISC) servo to control idle-up operation. D Improper connector contact, open circuit or
The A/C-ECU judges if the load caused by air conditioner operation is high or short-circuited harness wire
low, and converts it to voltage signal (high or low voltage) and inputs the D Malfunction of the engine-ECU
signal to the engine-ECU.
Based on this voltage signal, the engine-ECU controls the idle-up speed (for
high or low load).

OK
Measure at the engine-ECU connector C-87 Check the following connector:
D Connect the connector. C-87
D Voltage between 8 and earth (Engine: at idle, outside air
OK NG
temperature: 25_C or more)
OK: 0 – 3 V [When A/C is MAX. COOL condition (when Repair
the load by A/C is high)]
System voltage [When A/C is MAX. HOT condition
(when the load by A/C is low)] Check the trouble symptom.
NG NG

Check the A/C system. (Refer to GROUP 55 – On-vehicle Service.) Replace the engine-ECU.
 MPI <4G9> – Troubleshooting 13C-67
INSPECTION PROCEDURE 24
Fans (radiator fan, A/C condenser fan) are inoperative Probable cause
The engine-ECU outputs a duty signal to the fan controller depending on the D Malfunction of the fan motor relay
engine coolant temperature, vehicle speed, and air conditioner switch condition. D Malfunction of the fan motor
Based on this signal, the fan controller controls the radiator fan and condenser D Malfunction of the fan controller
fan speeds (The more the average voltage at the terminal approaches 5 V, the D Improper connector contact, open circuit or
higher the fan speed become.) short-circuited harness wire
D Malfunction of the engine-ECU

NG NG
Measure at the engine-ECU connector C-87. Check the following Repair
D Disconnect the connector, and measure at the harness connector: C-87
side.
OK
D Voltage between 21 and earth (Ignition switch: ON)
OK: 4.8 – 5.2 V (Fan rotates at high speed.) Check the trouble symp-
D Connect a jumper cable between 21 and earth (Ignition tom.
switch: ON)
OK: Fan stops NG
NG
OK Check the harness wire Repair
NG between the engine-ECU
Check the following Repair and the fan controller
connector: A-91X connector.
OK

Check the trouble symp- OK

tom.
Check the radiator fan
NG and condenser fan cir-
cuit. (Refer to GROUP 14
– Troubleshooting.)

NG
MUT-II Data list Check the engine coolant temperature sensor system. (Refer to
21 Engine coolant temperature sensor P.13C-20, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
OK: After the engine has been warmed up, the engine P0115.)
coolant temperature during idling is identical to the
MUT-II reading.
OK
NG
Check the thermostat. Replace
OK

Replace the engine-ECU.

13C-68 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 25
Engine-ECU power supply and earth circuit system Probable cause
The engine-ECU may be defective, or that one of the malfunctions listed at right D Improper connector contact, open circuit or
has occurred. short-circuited harness wire in the engine-ECU power
supply circuit.
D Open circuit or short-circuited harness wire in the
engine-ECU earth circuit
D Malfunction of the engine-ECU

(1) NG NG
Measure at the engine-ECU connector C-90, C-88, C-87, C-89 Check the following Repair
D Disconnect the connector and measure at the harness side connectors:
(1) Voltage between 82 and earth (Ignition switch: ON) C-90, C-72, C-74
OK: System voltage (2), (3) NG OK
(2) Voltage between 38 and earth
OK: System voltage Check the trouble symptom.
(3) Voltage between 12, 25 and earth (Ignition switch: ON)
OK: System voltage (when the terminal 38 is earthed) (4) NG OK
(4) Continuity between 13, 26 and earth NG
OK: Continuity Check the harness wire Repair
(5) Voltage between 80 and earth between engine-ECU
OK: System voltage and ignition switch
(5) NG connector.
OK

Check the ignition switch.

OK (Refer to GROUP 54 – Ignition Switch.)
NG
Check the following Repair
connectors:
C-87, C-88, C-89, C-90
Check the harness wire between engine-ECU and control relay
OK connector, and repair if necessary.
Check the trouble symptom.
NG Check the harness wire between engine-ECU and earth, and
repair if necessary.
Replace the engine-ECU.
NG
Check the following Repair
connectors: A-36, C-90

OK

Check the trouble symptom.

NG

Check the harness wire between engine-ECU and battery,

and repair if necessary.
 MPI <4G9> – Troubleshooting 13C-69
INSPECTION PROCEDURE 26
Power supply system and ignition switch-IG system Probable cause
When an ignition switch ON signal is input to the engine-ECU, the engine-ECU D Malfunction of the ignition switch
turns the control relay ON. This causes battery voltage to be supplied to the D Malfunction of the control relay
engine-ECU, injectors and air flow sensor. D Improper connector contact, open circuit or
short-circuited harness wire
D Disconnected engine-ECU earth wire
D Malfunction of the engine-ECU

NG
Check the control relay. (Refer to P.13C-102.) Replace
OK
NG NG
Measure at the control relay connector A-43X. Check the following Repair
D Disconnect the connector, and measure at the harness side. connector: C-61, A-36, A-43X
D Voltage between 3, 4 and earth OK
OK: System voltage
OK Check the trouble symptom.
NG
Check the engine-ECU power supply and earth circuit.
(Refer to P.13C-68, INSPECTION PROCEDURE 25.) Check the harness wire between battery and control relay connec-
tor, and repair if necessary.

INSPECTION PROCEDURE 27
Fuel pump system Probable cause
The engine-ECU turns the control relay ON when the engine is cranking or running, D Malfunction of the fuel pump relay
and this supplies power to drive the fuel pump. D Malfunction of the fuel pump
D Improper connector contact, open circuit or
short-circuited harness wire
D Malfunction of the engine-ECU

OK
MUT-II Actuator test Normal
07 Fuel pump (Refer to P.13C-79.)
NG
NG
Check the fuel pump relay. (Refer to Replace
P.13C-102.)

OK
To the next page
13C-70 MPI <4G9> – Troubleshooting

From the previous page

OK
NG
Measure at fuel pump relay connector NG Check the following connectors:
Repair
A-41X. C-72, C-74
D Disconnect the connector, and OK
measure at the harness side. NG
D Voltage between terminals 3, 4 and Check the trouble symptom. Check the harness wire between the
earth fuel pump relay and ignition switch.
(Ignition switch: ON) OK NG
OK: System voltage
OK Repair
NG
Measure at the engine-ECU Check the following connector: Check the ignition switch. (Refer to
connector C-87. C-87, A-41X GROUP 54 – Ignition Switch and Immo-
D Disconnect the connector, and OK NG
bilizer System.)
measure at the harness side.
D Voltage between terminal 22 and Repair
earth (Ignition switch: ON) NG
OK: System voltage Check the trouble symptom. Check the harness wire between the
fuel pump relay and engine-ECU, and
repair if necessary.
OK
OK NG
Measure at the engine-ECU Check the following connector: Repair
connector C-87. C-87
D Disconnect the connector, and
OK
measure at the harness side. NG
D Short circuit between terminal 22 Check the trouble symptom. Replace the engine-ECU.
and earth (Ignition switch: ON)
OK: The fuel pump operates (its
operation sound can be
heard).
NG
(1) NG NG
Measure at fuel pump connector D-17. Check the following connectors: Repair
D Disconnect the connector, and D-17, C-24<LHD>, C-26<RHD>, A-41X
measure at the harness side. OK
(1) Voltage between terminal 1 and NG
earth Check the trouble symptom. Check the harness wire between the
(Ignition switch: ON) fuel pump relay and fuel pump, and
OK: System voltage repair if necessary.
(2) Continuity between 2 and earth (2) NG
OK: Continuity Check the following connector:
D-12
OK
OK NG

Repair
NG
Check the trouble symptom. Check the harness wire between the
NG fuel pump and earth, and repair if neces-
Check the following connector: Repair sary.
D-17
OK
NG
Check the trouble symptom. Replace the fuel pump.
 MPI <4G9> – Troubleshooting 13C-71
INSPECTION PROCEDURE 28
Ignition switch-ST system Probable cause
The ignition switch-ST outputs a HIGH signal to the engine-ECU while the D Malfunction of the ignition switch
engine is cranking. D Malfunction of the inhibitor switch <A/T>
The engine-ECU uses this signal to carry out functions such as fuel injection D Open circuit or short-circuited harness wire of the
control during starting. ignition switch circuit
D Malfunction of the engine-ECU

<M/T>
NG NG
Measure at the engine-ECU connector Check the following connectors: Repair
C-90. C-90, A-86, C-27, C-61
D Disconnect the connector, and OK
measure at the harness side. NG
D Voltage between 71 and earth Check the trouble symptoms. Check the harness wire between the
(Ignition switch: START) engine-ECU and the ignition switch.
OK: 8 V or more
OK NG
OK
NG Repair
Check the following connector: Repair
C-90 Check the ignition switch.
(Refer to GROUP 54.)
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

<A/T>
NG
Check the inhibitor switch Replace
D Continuity between 9 and 10
(Refer to GROUP 23 – On-vehicle service.)
OK
NG
Measure at the inhibitor switch connector B-04. Check the following connector: B-04, C-02, C-39, C-61
D Disconnect the connector, and measure at the harness
side. OK NG
D Voltage between 10 and earth (Ignition switch: START) Repair
OK: System voltage
OK Check the trouble symptoms.
NG

Check the harness wire between inhibitor switch and ignition switch.
OK NG
Repair

Check the ignition switch (Refer to GROUP 54 – Ignition Switch.)

NG
Measure at the engine-ECU connector C-90. Check the following connectors: A-86, B-01, B-04 C-90
D Disconnect the connector, and measure at the harness
side. OK NG
D Voltage between 71 and earth Repair
(Selector lever position: P or N)
(Ignition switch: START) Check the trouble symptoms.
OK: System voltage
NG
OK NG
Repair Check the harness wire between inhibitor switch and engine-ECU,
and repair if necessary.
Check the following connector: C-90
OK

Check the trouble symptoms.

NG

Replace the engine-ECU.

13C-72 MPI <4G9> – Troubleshooting

INSPECTION PROCEDURE 29
A/C switch and A/C relay system Probable cause
When an A/C ON signal is input to the engine-ECU, the engine-ECU carries out D Malfunction of A/C control system
control of the idle speed control (ISC) servo, and also operates the A/C compressor D Malfunction of A/C switch
magnetic clutch. D Improper connector contact, open circuit or
short-circuited harness wire
D Malfunction of the engine-ECU

NG
Check the A/C compressor relay. Replace
(Refer to GROUP 55 – On-vehicle Service.)
OK
NG
Measure at the engine-ECU connector C-87. Check the A/C system. (Refer to GROUP 55 – Troubleshooting.)
D Disconnect the connector, and measure at the harness side.
D Voltage between 8 and earth OK NG
(Ignition switch: ON) Check the following Replace
OK: 0 – 3 V (A/C switch: OFF) connector: C-87
System voltage (A/C switch: ON) OK
D Short circuit between 8 and earth
(Ignition switch: ON, A/C switch: ON) Check the trouble symptom.
OK: A/C compressor clutch turns on.
NG

Replace the engine-ECU.

INSPECTION PROCEDURE 30
Ignition circuit system Probable cause
The engine-ECU interrupts the ignition coil primary current by turning the D Malfunction of ignition coil.
power transistor inside the engine-ECU ON and OFF. D Malfunction of ignition failure sensor.
D Improper connector contact, open circuit or
short-circuited harness wire
D Malfunction of the engine-ECU

NG
Check the ignition coil. (Refer to Replace
GROUP 16 – Ignition System.)
OK
NG
Check the ignition failure sensor. Replace
(Refer to GROUP 16 – Ignition
System.)
OK
NG NG
Measure at the ignition failure sensor connector A-90. Check the following Repair
D Disconnect the connector and measure at the harness side. connectors: C-72, C-74
Voltage between 4 and ground (Ignition switch: ON) OK
OK: System voltage
OK Check the trouble symptom.
NG
To the next page NG
Check the harness wire Repair
between the ignition fail-
ure sensor and ignition
switch connector.
OK

Check the ignition switch. (Refer to GROUP 54 – Ignition Switch.)

 MPI <4G9> – Troubleshooting 13C-73
From the previous page
OK
(1) NG NG
Measure at the ignition coil connectors Check the following connector: Repair
A-13, A-14. A-13, A-14, A-90
D Disconnect the connector, and OK
measure at the harness side. NG
(1) Voltage between 1 and earth Check the trouble symptom. Check the harness wire between the
(Ignition switch: ON) ignition coil and ignition failure sensor
OK: Battery positive voltage connector, and repair if necessary.
(2) Voltage between 3 and earth (2) NG NG
(Engine: Cranking) Check the following connector: Repair
OK: 0.5 – 4.0 V C-87, A-90
(3) Continuity between 2 and earth
OK
OK: Continuity
Check the trouble symptom.
NG
NG
Check the harness wire between Repair
the engine-ECU and ignition coil
connector.
OK

Replace the engine-ECU.

(3) NG
Check the harness wire between
the ignition coil connector and
OK ground, and repair if necessary.
NG
Check the following connectors: Repair
A-13, A-14
OK

Check the trouble symptom.

NG
(1) NG
Measure at the ignition failure sensor connector A-90. There is an open or short-circuit the ignition signal output harness
D Disconnect the connector and measure at the harness side. of the ignition failure sensor, so check and repair the harness.
(1) Voltage between 2 and earth (Ignition switch: ON)
OK: 4 V or more (2) NG
Check the harness wire between the ignition failure sensor and
(2) Continuity between 1 and earth
earth, and repair if necessary.
OK: Continuity
OK
NG NG
Measure at the engine-ECU connector C-89. Check the following Repair
D Measure with the connector connected. connectors: C-89,
D Voltage between 58 and earth A-90
(Engine: Cranking or 3,000 r/min) OK
OK: 0.3 – 3.0 V
OK Check the trouble symptom.
NG
Replace the engine-ECU. NG
Check the harness wire Repair
between the engine-ECU
and the ignition failure
sensor connector.
OK

Replace the ignition failure sensor.

13C-74 MPI <4G9> – Troubleshooting

DATA LIST REFERENCE TABLE

Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forward.
NOTE
*1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes
10 % higher than the standard frequency.
*2. The injector drive time represents the time when the cranking speed is at 250 r/min or below when
the power supply voltage is 11 V.
*3. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10 %
longer than the standard time.
*4. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes
30 steps greater than the standard value.
L It will not be displayed when service data of the check mode is selected.

Item Inspection Inspection contents Normal condition Inspection Reference

No. item procedure page
No.

11 Oxygen Engine: After having When at 4,000 r/min, 200 mV or less Code No. 13C-25
sensor warmed up engine is suddenly P0130
(front) Air/fuel mixture is made decelerated
decelerat
leaner when decelerat-
ing, and is made richer When engine is sud- 600 – 1,000 mV
when racing. denly raced

Engine: After having Engine is idling 400 mV or less

warmed up (Changes)
The oxygen sensor 600 – 1,000 mV
signal is used to check
the air/fuel mixture 2,500 r/min
ratio, and control con-
dition is also checked
by the ECU.
12 Air flow sen- D Engine coolant Engine is idling 12 – 38 Hz – –
sor*1 temperature:
80 – 95_C
D Lamps, electric 2,500 r/min 58 – 98 Hz
cooling fan and all
accessories: OFF Engine is raced Frequency in-
D Transmission: creases in re-
Neutral sponse to racing
(A/T: P range)

13 Intake air Ignition switch: ON or When intake air tem- –20_C Code No. 13C-18
temperature with engine running perature is –20_C P0110
sensor
When intake air tem- 0_C
perature is 0_C

When intake air tem- 20_C

perature is 20_C

When intake air tem- 40_C

perature is 40_C

When intake air tem- 80_C

perature is 80_C
 MPI <4G9> – Troubleshooting 13C-75

Item Inspection Inspection contents Normal condition Inspection Reference

No. item procedure page
No.

14 Throttle Ignition switch: ON Set to idle position 535 – 735 mV Code No. 13C-22
position P0120
sensor Gradually open Increases in pro-
portion to throttle
opening angle

Open fully 4,750 mV or more

16 Power sup- Ignition switch: ON System voltage Procedure 13C-68

ply voltage No. 25

18 Cranking Ignition switch: ON Engine: Stopped OFF Procedure 13C-71

signal No. 28
(ignition
Engine: Cranking ON
switch-ST)

21 Engine cool- Ignition switch: ON or When engine cool- –20_C Code No. 13C-20
ant tempera- with engine running ant temperature is P0115
ture sensor –20_C

When engine cool- 0_C

ant temperature is
0_C

When engine cool- 20_C

ant temperature is
20_C

When engine cool- 40_C

ant temperature is
40_C

When engine cool- 80_C

ant temperature is
80_C

22 Crank angle D Engine: Cranking Compare the engine Accord Code No. 13C-33
sensor D Tachometer: speed readings on P0335
Connected the tachometer and
the MUT-II.

D Engine: Idling When engine cool- 1,380 – 1,580

D Idle position ant temperature is r/min
switch: ON –20_C

When engine cool- 1,320 – 1,520

ant temperature is r/min
0_C

When engine cool- 1,200 – 1,400

ant temperature is r/min
20_C

When engine cool- 1,100 – 1,300

ant temperature is r/min
40_C

When engine cool- 600 – 800 r/min

ant temperature is
80_C
13C-76 MPI <4G9> – Troubleshooting

Item Inspection Inspection contents Normal condition Inspection Reference

No. item procedure page
No.

24 Vehicle Drive at 40 km/h Approximately Code No. 13C-39

speed 40 km/h P0500
sensor

25 Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code No. 13C-16

pressure P0105
sensor At altitude of 600 m 95 kPa

At altitude of 1,200 m 88 kPa

At altitude of 1,800 m 81 kPa

27 Power steer- Engine: Idling Steering wheel sta- OFF Code No. 13C-43
ing fluid tionary P0551
pressure
switch Steering wheel turn- ON
ing

28 A/C switch Engine: Idling A/C switch: OFF OFF Procedure 13C-72
No.
No 29
A/C A/C com- OFF
switch: pressor
ON does not
operate

A/C com- ON
pressor
operates

29 Inhibitor Ignition switch: ON P or N P or N Procedure 13C-71

switch No.
No 28
<A/T> D, 2, L or R D, 2, L or R

41 Injectors*2 Engine: Cranking When engine cool- 14 – 21 ms – –

ant temperature is
0_C (injection is car-
ried out for all cylin-
ders simultaneously)

When engine cool- 30 – 45 ms

ant temperature is
20_C

When engine cool- 6.9 – 10.4 ms

ant temperature is
80_C

Injectors*3 D Engine coolant Engine is idling 1.6 – 2.8 ms

temperature:
80 – 95_C
D Lamps, electric 2,500 r/min 1.4 – 2.6 ms
cooling fan and all
accessories: OFF
D Transmission: When engine is sud- Increases
Neutral denly raced
(A/T: P range)
 MPI <4G9> – Troubleshooting 13C-77

Item Inspection Inspection contents Normal condition Inspection Reference

No. item procedure page
No.

44 Ignition coils D Engine: After hav- Engine is idling 2 – 18_BTDC Code No. –
and power ing warmed up P0300
transistors D Timing lamp is set.
(The timing lamp
is set in order to 2,500 r/min 23 – 43_BTDC
check actual igni-
tion timing.)

45 ISC (step- D Engine coolant A/C switch: OFF 2 – 25 STEP – –

per) motor temperature:
position*4 80 – 95_C
D Lamps,
Lam s, electric
cooling fan and all A/C switch: Increases by 10 –
accessories: OFF OFF → ON 70 steps
D Transmission:
Neutral
((A/T: P range)
g )
D Idle
Idl position
iti
switch: ON D A/C switch: OFF Increases by 5 –
D Engine: Idling D Select lever: 50 steps
D When A/C switch N range → D
is ON, A/C com- range
pressor should be
operating

49 A/C relay Engine: After having A/C switch: OFF OFF Proce- 13C-72
warmed up/Engine is dure No.
No
idling A/C A/C com- OFF 29
switch: pressor is
ON not driven

A/C com- ON Proce- 13C-72

pressor is dure No.
driven 29

59 Oxygen D Transmission: 3,500 r/min 600 – 1,000 mV Code No. 13C-27

sensor 2nd gear <M/T>, P0316
(rear) L range <A/T>
D Drive with throttle
widely open

24L Vehicle Drive at 40 km/h Approximately 40 Code No. 13C-39

speed sen- km/h P0500
sor

81L Long-term Engine: Warm, 2,500 r/min without any load –12.5 – 12.5 % Code No. 13C-29
fuel com- (during closed loop) P0170
pensation

82L Short-term Engine: Warm, 2,500 r/min without any load –25 – 25 % Code No. 13C-29
fuel com- (during closed loop) P0170
pensation

87L Calculation Engine: Warm Engine: Idling 10 – 30 % – –

load value
2,500 r/min 17 – 37 %

88L Fuel control Engine: Warm 2,500 r/min Closed loop Code No. 13C-24
condition P0125
When engine is sud- Open loop – drive
denly raced condition
13C-78 MPI <4G9> – Troubleshooting

Item Inspection Inspection contents Normal condition Inspection Reference

No. item procedure page
No.

A1 Oxygen Engine: After warm-up Idling 0.2 V or less Code No. 13C-25
L sensor P0130
(sensor 1) Sudden racing 0.6 – 1.0 V

2,500 r/min 0.4 V or less and

0.6 – 1.0 V alter-
nates

A2 Oxygen D Transmission: 3,500 r/min 0.6 – 1.0 V Code No. 13C-27

L sensor 2nd gear <M/T>, P0136
(sensor 2) L range <A/T>
D Drive with throttle
widely open

8A Throttle D Engine coolant Release the acceler- 6 – 20 % Code No. 13C-22

L position temperature: ator pedal. P0120
sensor 80 – 95_C
(Throttle D Ignition switch: Depress the acceler- Increase in re-
valve open- ON ator pedal gradually sponse to pedal
ing angle) (Engine: Stopped) depression
stroke.

Depress the acceler- 80 – 100 %

ator pedal fully.
 MPI <4G9> – Troubleshooting 13C-79
ACTUATOR TEST REFERENCE TABLE
Item Inspection Drive contents Inspection contents Normal condition Inspection Reference
No. item procedure page
No.

01 Injectors Cut fuel to No. Engine: After having warmed Idling condition Code No. 13C-30
1 injector up/Engine is idling becomes different P0201
(Cut the fuel supply to each (becomes unsta
unsta-
02 Cut fuel to No. injector in turn and check ble). Code No. 13C-30
2 injector cylinders
y which don’t affect P0202
idli )
idling.)
03 Cut fuel to No. Code No. 13C-30
3 injector P0203

04 Cut fuel to No. Code No. 13C-30

4 injector P0204

07 Fuel pump Fuel pump D Engine: Pinch the Pulse is felt. Procedure 13C-69
operates and Cranking return hose No. 27
fuel is recircu- D Fuel with fingers
lated. pump: to feel the
Forced pulse of the
driving fuel being
Inspect recirculated.
according
to both Listen near Sound of opera-
the above the fuel tank tion is heard.
conditions. for the
sound of
fuel pump
operation.

08 Purge Solenoid valve Ignition switch: ON Sound of opera- Code No. 13C-38
control turns from tion can be heard P0443
solenoid OFF to ON. when solenoid
valve valve is driven.

10 EGR con- Solenoid valve Ignition switch: ON Sound of opera- Code No. 13C-36
trol sole- turns from tion can be heard P0403
noid valve OFF to ON. when solenoid
valve is driven.

17 Basic igni- Set to ignition Engine: Idling 5_BTDC – –

tion timing timing adjust- Timing light is set
ment mode

21 Fan relay Drive the fan Ignition switch: ON Radiator fan and Proce- 13C-67
motor condenser fan dure No.
operate at high 24
speed
13C-80 MPI <4G9> – Troubleshooting

Needle-nosed wire probe

CHECK AT THE ENGINE-ECU TERMINALS
TERMINAL VOLTAGE CHECK CHART
1. Connect a needle-nosed wire probe (test harness:
MB991223 or paper clip) to a voltmeter probe.
2. Insert the needle-nosed wire probe into each of the
engine-ECU connector terminals from the wire side, and
measure the voltage while referring to the check chart.
NOTE
(1) Make the voltage measurement with the engine-ECU
connectors connected.
(2) You may find it convenient to pull out the engine-ECU
to make it easier to reach the connector terminals.
(3) The checks can be carried out off the order given
in the chart.
Caution
Short-circuiting the positive (+) probe between a
connector terminal and earth could damage the vehicle
wiring, the sensor, engine-ECU or all of them. Be
careful to prevent this!
3. If voltmeter shows any division from standard value, check
the corresponding sensor, actuator and related electrical
wiring, then repair or replace.
4. After repair or replacement, recheck with the voltmeter
to confirm that the repair has corrected the problem.
 MPI <4G9> – Troubleshooting 13C-81
Engine-ECU Connector Terminal Arrangement

Terminal Check item Check condition (Engine condition) Normal condition

No.

1 No. 1 injector While engine is idling after having From 11 – 14 V, momentarily

warmed up,
up suddenly depress the drops slightly
14 No. 2 injector accelerator pedal.

2 No. 3 injector

15 No. 4 injector

4 Stepper motor coil <A> Engine: Soon after the warmed up System voltage ´ 0 V
engine is started (Changes repeatedly)
17 Stepper motor coil <B>

5 Stepper motor coil <C>

18 Stepper motor coil <D>

6 EGR control solenoid valve Ignition switch: ON System Voltage

While engine is idling, suddenly depress From system voltage,

the accelerator pedal. momentarily drops

8 A/C relay D Engine: Idle speed System voltage or

D A/C switch: OFF → ON momentarily
(A/C compressor is operating) 6 V or more → 0 – 3 V

9 Purge control solenoid Ignition switch: ON System voltage

valve
Running at 3,000 r/min while engine is 0–3V
warming up after having been started.

10 Ignition coil – No. 1, Engine r/min: 3,000 r/min 0.3 – 3.0 V

No. 4 (power transistor)

23 Ignition coil – No. 2,

No. 3 (power transistor)

12 Power supply Ignition switch: ON System voltage

25

19 Air flow sensor reset Engine: Idle speed 0–1V

signal
Engine r/min: 3,000 r/min 6–9V

20 Condenser motor relay Radiator fan is not operating (Engine System voltage
(HI) coolant temperature is 90_C or less)

Radiator fan is not operating (Engine 0–3V

coolant temperature is 105_C or less)
13C-82 MPI <4G9> – Troubleshooting

Terminal Check item Check condition (Engine condition) Normal condition

No.

21 Radiator motor relay (LO) Radiator fan and condenser fan are not System voltage
operating (Engine coolant temperature
is 90_C or less)

Radiator fan and condenser fan are not 0–3V

operating (Engine coolant temperature
is 90 – 105_C or less)

22 Fuel pump relay Ignition switch: ON System voltage

Engine: Idle speed 0–3V

33 Alternator G terminal D Engine: Warm, idle Voltage rises by 0.2 – 3.5 V.

(radiator fan: OFF)
D Headlamp: OFF to ON
D Rear defogger switch: OFF to ON
D Brake lamp: ON

41 Alternator FR terminal D Engine: Warm, idle Voltage drops by 0.2 – 3.5 V.

(radiator fan: OFF)
D Headlamp: OFF to ON
D Rear defogger switch: OFF to ON
D Brake lamp: ON

36 Engine warning lamp Ignition switch: “LOCK” (OFF) position 0 – 3 V → 9 – 13 V

→ ON (After several seconds have
elapsed)

37 Power steering fluid Engine: Idling after When steering System voltage
pressure switch warming up wheel is stationary

When steering 0–3V

wheel is turned

38 Control relay Ignition switch: “LOCK” (OFF) position System voltage

(Power supply)
Ignition switch: ON 0–3V

45 A/C switch 1 Engine: Idle speed Turn the A/C 0–3V

switch OFF

Turn the A/C System voltage

switch ON (A/C
compressor is
operating)

58 Tachometer signal Engine r/min: 3,000 r/min 0.3 – 3.0 V

60 Oxygen sensor (front) Engine: Idling after warming up 0–3V

heater
Engine r/min: 5,000 r/min System voltage

54 Oxygen sensor (rear) Engine: Idling after warming-up 0–3V

heater
Engine r/min: 5,000 r/min System voltage

71 Ignition switch – ST Engine: Cranking 8 V or more

 MPI <4G9> – Troubleshooting 13C-83

Terminal Check item Check condition (Engine condition) Normal condition

No.

72 Intake air temperature Ignition switch: ON When intake air 3.2 – 3.8 V
sensor temperature is
0_C

When intake air 2.3 – 2.9 V

temperature is
20_C

When intake air 1.5 – 2.1 V

temperature is
40_C

When intake air 0.4 – 1.0 V

temperature is
80_C

75 Oxygen sensor (rear) D Transmission: 2nd gear <M/T>, 0.6 – 1.0 V

L range <A/T>
D Engine r/min: 3,500 r/min or more
D Driving with the throttle valve
widely open

76 Oxygen sensor (front) Engine: Running at 2,500 r/min after 0 ´ 0.8 V

warmed up (Check using a digital type (Changes repeatedly)
voltmeter)

77 A/C thermo sensor D Ignition switch: ON 2.2 V

D Temperature at sensor: 25_C (1.5
kΩ)

80 Backup power supply Ignition switch: “LOCK” (OFF) position System voltage

81 Sensor impressed Ignition switch: ON 4.5 – 5.5 V

voltage

82 Ignition switch – IG Ignition switch: ON System voltage

83 Engine coolant Ignition switch: ON When engine 3.2 – 3.8 V

temperature sensor coolant tempera-
ture is 0_C

When engine 2.3 – 2.9 V

coolant tempera-
ture is 20_C

When engine 1.3 – 1.9 V

coolant tempera-
ture is 40_C

When engine 0.3 – 0.9 V

coolant tempera-
ture is 80_C

84 Throttle position Ignition switch: ON Set throttle valve 0.3 – 1.0 V

sensor to idle position

Fully open throttle 4.5 – 5.5 V

valve
13C-84 MPI <4G9> – Troubleshooting

Terminal Check item Check condition (Engine condition) Normal condition

No.

85 Barometric pressure Ignition switch: ON When altitude is 3.7 – 4.3 V

sensor 0m

When altitude is 3.2 – 3.8 V

1,200 m

86 Vehicle speed sensor D Ignition switch: ON 0´5V

D Move the vehicle slowly forward (Changes repeatedly)

88 Camshaft position Engine: Cranking 0.4 – 3.0 V

sensor
Engine: Idle speed 0.5 – 2.0 V

89 Crank angle sensor Engine: Cranking 0.4 – 4.0 V

Engine: Idle speed 1.5 – 2.5 V

90 Air flow sensor Engine: Idle speed 2.2 – 3.2 V

Engine r/min: 2,500 r/min

CHECK CHART FOR RESISTANCE AND CONTINUITY

BETWEEN TERMINALS
1. Turn the ignition switch to “LOCK” (OFF) position.
2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity between
the terminals of the engine-ECU harness-side connector
while referring to the check chart.
NOTE
(1) When measuring resistance and checking continuity,
a harness for checking contact pin pressure should
be used instead of inserting a test probe.
(2) Checking need not be carried out in the order given
in the chart.
 MPI <4G9> – Troubleshooting 13C-85
Caution
If the terminals that should be checked are mistaken,
or if connector terminals are not correctly shorted
to earth, damage may be caused to the vehicle wiring,
sensors, engine-ECU and/or ohmmeter.
Be careful to prevent this!
4. If the ohmmeter shows any deviation from the standard
value, check the corresponding sensor, actuator and
related electrical wiring, and then repair or replace.
5. After repair or replacement, recheck with the ohmmeter
to confirm that the repair or replacement has corrected
the problem.

Engine-ECU Harness Side Connector Terminal Arrangement

Terminal Inspection item Normal condition (Check condition)

No.

1 – 12 No. 1 injector 13 – 16 Ω (At 20_C)

14 – 12 No. 2 injector

2 – 12 No. 3 injector

15 – 12 No. 4 injector

4 – 12 Stepper motor coil (A) 28 – 33 Ω (At 20_C)

17 – 12 Stepper motor coil (B)

5 – 12 Stepper motor coil (C)

18 – 12 Stepper motor coil (D)

6 – 12 EGR control solenoid valve 29 – 35 Ω (At 20_C)

9 – 12 Purge control solenoid valve 29 – 35 Ω (At 20_C)

13 – Body Engine-ECU earth Continuity (0 Ω)

earth

26 – Body Engine-ECU earth

earth

60 – 12 Oxygen sensor (front) heater 4.5 – 8.0 Ω (At 20_C)

54 – 12 Oxygen sensor (rear) heater 11 – 18 Ω (At 20_C)

13C-86 MPI <4G9> – Troubleshooting

Terminal Inspection item Normal condition (Check condition)

No.

72 – 92 Intake air temperature sensor 5.3 – 6.7 kΩ (When intake air temperature is 0_C)

2.3 – 3.0 kΩ (When intake air temperature is 20_C)

1.0 – 1.5 kΩ (When intake air temperature is 40_C)

0.30 – 0.42 kΩ (When intake air temperature is 80_C)

83 – 92 Engine coolant temperature sensor 5.1 – 6.5 kΩ (When coolant temperature is 0_C)

2.1 – 2.7 kΩ (When coolant temperature is 20_C)

0.9 – 1.3 kΩ (When coolant temperature is 40_C)

0.26 – 0.36 kΩ (When coolant temperature is 80_C)

 MPI <4G9> – Troubleshooting 13C-87
Analyzer INSPECTION PROCEDURE USING AN ANALYZER
AIR FLOW SENSOR (AFS)
Measurement Method
Special
patterns 1. Disconnect the air flow sensor connector, and connect
pickup the special tool (test harness: MB991709) in between.
(All terminals should be connected.)
2. Connect the analyzer special patterns pickup to air flow
sensor connector terminal 3.
Alternate Method (Test harness not available)
1. Connect the analyzer special patterns pickup to
engine-ECU terminal 90.
Standard Wave Pattern
Observation conditions

Function Special patterns

Pattern height Low
Pattern selector Display
Engine r/min Idle speed
Standard wave pattern
(V) The time (cycle time) T is reduced when
10 T the amount of intake air increases.
T1 T2 Times T1 and T2 are equal.

Time
0

Observation conditions (from conditions above engine speed is increased by racing.)

(V)

10
T

Time
0

Wave Pattern Observation Points

Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
13C-88 MPI <4G9> – Troubleshooting

Examples of Abnormal Wave Patterns

D Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when the engine
is not started.
D Example 2
Cause of problem
Damaged rectifier or vortex generation column
Wave pattern characteristics
Unstable wave pattern with non-uniform frequency.
However, when an ignition leak occurs during acceleration,
the wave pattern will be distorted temporarily, even if the
air flow sensor is normal.

Camshaft position sensor connec- Analyzer CAMSHAFT POSITION SENSOR AND CRANK ANGLE
tor SENSOR
Special patterns
pick-up Measurement Method
1. Disconnect the camshaft position sensor connector and
connect the special tool (test harness: MB991659) and
jumper wire in between. (All terminals should be
connected.)
2. Connect the analyzer special patterns pickup to camshaft
position sensor terminal 2.
Crank angle sensor connector 3. Disconnect the crank angle sensor connector and connect
the special tool (test harness: MB991658) in between.
4. Connect the analyzer special patterns pickup to crank
angle sensor terminal 3.
Alternate Method (Test harness not available)
1. Connect the analyzer special patterns pickup to
engine-ECU terminal 88. (When checking the camshaft
position sensor signal wave pattern.)
2. Connect the analyzer special patterns pickup to
engine-ECU terminal 89. (When checking the crank angle
sensor signal wave pattern.)
Standard Wave Pattern
Observation conditions
Function Special patterns

Pattern height Low

Pattern selector Display

Engine r/min Idle speed

 MPI <4G9> – Troubleshooting 13C-89
Standard wave pattern

2 engine revolutions
(1 camshaft revolution) The time (cycle time) T is
(V)
reduced when the engine
75_BTDC speed increases
5_BTDC

Crank angle
sensor output
wave pattern

0
131° 49° 56° 34°

Camshaft posi-
tion sensor out-
put wave pat-
tern

Time
0
No. 1 TDC No. 3 TDC No. 4 TDC No. 2 TDC
TDC: Top dead centre

Wave Pattern Observation Points

Check that cycle time T becomes shorter when the engine speed increases.

Examples of Abnormal Wave Patterns

D Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when the engine
is not started.

D Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.
13C-90 MPI <4G9> – Troubleshooting

Examples of Abnormal Wave Patterns

D Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when the engine
is not started.

D Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.

INJECTOR
Analyzer
Measurement Method
1. Disconnect the injector connector, and then connect the
special tool (test harness: MB991348) in between.
(Both the power supply side and engine-ECU side should
be connected.)
2. Connect the analyzer special patterns pickup to terminal
2 of the injector connector.

Alternate Method (Test harness not available)

1. Connect the analyzer special patterns pickup to
engine-ECU terminal 1. (When checking the No. 1
cylinder.)
2. Connect the analyzer special patterns pickup to
engine-ECU terminal 14. (When checking the No. 2
cylinder.)
3. Connect the analyzer special patterns pickup to
engine-ECU terminal 2. (When checking the No. 3
cylinder.)
4. Connect the analyzer special patterns pickup to
engine-ECU terminal 15. (When checking the No. 4
cylinder.)
 MPI <4G9> – Troubleshooting 13C-91
Standard Wave Pattern
Observation conditions
Function Special patterns

Pattern height Variable

Variable knob Adjust while viewing the wave pattern

Pattern selector Display

Engine r/min Idle speed

Standard wave pattern

(V)

Point A

50

Solenoid back electromotive force

(Approx. 7×10 V)

Point B
Injector drive time

Power voltage

0 Drive signal: ON Drive signal: OFF

Time

Wave Pattern Observation Points

Point A: Height of solenoid back electromotive force
Contrast with standard wave pattern Probable cause

Solenoid coil back electromotive force is low or doesn’t Short in the injector solenoid
appear at all.

Point B: Injector drive time

D The injector drive time will be synchronized with the MUT-II

tester display.
D When the engine is suddenly raced, the drive time will
be greatly extended at first, but the drive time will soon
match the engine speed.

--- When idling

–– When racing
13C-92 MPI <4G9> – Troubleshooting

IDLE SPEED CONTROL (ISC) SERVO (STEPPER

Analyzer
MOTOR)
Measurement Method
1. Disconnect the ISC servo connector, and connect the
Special
patterns special tool (test harness: MB991709) in between.
pickup 2. Connect the analyzer special patterns pickup to the ISC
servo-side connector terminal 1, terminal 3, terminal 4
and terminal 6 respectively.

Alternate Method (Test harness not available)

1. Connect the analyzer special patterns pickup to
engine-ECU terminal 4, connection terminal 5, connection
terminal 17, and connection terminal 18 respectively.
Standard Wave Pattern
Observation conditions
Function Special patterns

Pattern height High

Pattern selector Display

Engine condition When the engine coolant temperature is 20_C or below, turn the ignition switch from LOCK
(OFF) position to ON (without starting the engine).

While the engine is idling, turn the A/C switch to ON.

Immediately after starting the warm engine

Standard wave pattern

(V)
The wave pattern
appears for an Point B Point A
instant, but soon Coil reverse electromotive Induced electromotive force
30 disappears. force (Approx. 3 × 10V) from the motor turning

20

10
Stepper
motor
control
signal
wave
pattern
Time
 MPI <4G9> – Troubleshooting 13C-93
Wave Pattern Observation Points
Check that the standard wave pattern appears when the stepper motor is operating.
Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal
wave pattern.)

Contrast with standard wave pattern Probable cause

Induced electromotive force does not appear or is extremely small. Motor is malfunctioning

Point B: Height of coil reverse electromotive force

Contrast with standard wave pattern Probable cause

Coil reverse electromotive force does not appear or is extremely small. Short in the coil

Examples of Abnormal Wave Pattern

D Example 1
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Wave pattern characteristics
Induced electromotive force from the motor turning does
not appear.

D Example 2
Open
circuit Cause of problem
side
Open circuit in the line between the stepper motor and
the engine-ECU.
Wave pattern characteristics
Current is not supplied to the motor coil on the open circuit
side. (Voltage does not drop to 0 V.)
Nor- Furthermore, the induced electromotive force waveform
mal at the normal side is slightly different from the normal
side
waveform.
13C-94 MPI <4G9> – Troubleshooting

Analyzer IGNITION COIL AND POWER TRANSISTOR

D Ignition coil primary signal
Refer to GROUP 16 – Ignition system.
D Power transistor control signal
Measurement Method
1. Disconnect the ignition coil connector, and connect the
Special special tool (test harness: MB991348) in between. (All
patterns terminals should be connected.)
pickup 2. Connect the analyzer special patterns pickup to terminal
3 of each ignition coil connector in turn.
Alternate Method (Test harness not available)
1. Connect the analyzer special patterns pickup to
engine-ECU terminal 10 (No. 1 – No. 4), terminal 23 (No.
2 – No. 3) respectively.
Standard Wave Pattern
Observation condition
Function Special patterns
Pattern height Low
Pattern selector Display
Engine r/min Approx. 1,200 r/min

Standard wave pattern

(V) T

5_BTDC
6 75_BTDC
Compression top dead center

Crank angle
sensor output 2
wave pattern
0
T1 θ
Ignition period
4

Power transistor 2
control signal
wave pattern
0
OFF ON
(ms)

T :Crank angle Dwell section

T1: Time computed by the engine-ECU
θ : Spark advance angle
 MPI <4G9> – Troubleshooting 13C-95
Wave Pattern Observation Points
Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern
examples 1 and 2.)

Condition of wave pattern build-up section and maximum voltage Probable cause

Rises from approx. 2 V to approx. 4.5 V at the top-right Normal

2 V rectangular wave Open-circuit in ignition primary circuit

Rectangular wave at power voltage Power transistor malfunction

Examples of Abnormal Wave Patterns

--- Normal wave pattern
D Example 1
Wave pattern during engine cranking
Cause of problem
2V Open-circuit in ignition primary circuit
Wave pattern characteristics
Top-right part of the build-up section cannot be seen, and
voltage value is approximately 2 V too low.

D Example 2
--- Normal wave pattern
Wave pattern during engine cranking
VB
Cause of problem
Malfunction in power transistor
Wave pattern characteristics
Power voltage results when the power transistor is ON.
13C-96 MPI <4G9> – On-vehicle Service

ON-VEHICLE SERVICE
THROTTLE BODY (THROTTLE VALVE AREA)
CLEANING
15 mm
1. Disconnect the air intake hose from the throttle body.
15 mm 2. Apply some detergent to a clean cloth.
3. Use the clean cloth with detergent to wipe the area around
the throttle valve until it is clean.
Throttle valve Caution
molybdenum coating
(1) Do not let any of the detergent get directly onto
the throttle valve.
(2) Take care not to let any detergent get into the
motor through the bypass passage. Furthermore,
do not let it get to the sensor through the shaft.
(3) Do not wipe the molybdenum coating which is
located around the throttle valve shaft.
4. Connect the air intake hose.
5. Adjust the standard idle speed.

Equipment THROTTLE POSITION SENSOR ADJUSTMENT

side connector 1. Turn the ignition switch to LOCK (OFF) position.
2. Connect the MUT-II to the diagnosis connector.
When not using the MUT-II, proceed as follows:
Throttle position
sensor

(1) Disconnect the throttle position sensor connector, and

connect the special tool (throttle position sensor test
harness: MB991536) between the disconnected
connector taking care not to confuse the terminal to
be connected.
(2) Connect digital voltmeter between the terminal No.2
(sensor output: blue clip of special tool) and the
terminal No.4 (sensor earth: black clip of special tool)
MB991536 Throttle position of the throttle position sensor connector.
sensor

3. Turn the ignition switch to ON (but do not start the engine).

4. Check the output voltage of the throttle position sensor.
Standard value: 535 – 735 mV
MPI <4G9> – On-vehicle Service 13C-97
5. If not within the standard value, loosen the throttle position
sensor mounting bolts. Then rotate the sensor body to
adjust.
6. Turn the ignition switch to LOCK (OFF) position.
7. Remove the MUT-II. If the MUT-II is not used, remove
the special tool, and then connect the throttle position
sensor connector.
8. If a diagnosis code is displayed, erase the diagnosis code
by using the MUT-II or disconnect the negative battery
cable from the battery terminal and then leave it for at
least ten seconds. After that, reconnect the battery cable,
and then let the engine run at idle for approx. ten minutes.
BASIC IDLE SPEED ADJUSTMENT
NOTE
(1) The standard idling speed has been adjusted by the
speed adjusting screw (SAS) by the manufacturer,
and there should usually be no need for readjustment.
(2) If the adjustment has been changed by mistake, the
idle speed may become too high or the idle speed
may drop too low when loads from components such
as the A/C are placed on the engine. If this occurs,
adjust by the following procedure.
(3) The adjustment, if made, should be made after first
confirming that the spark plugs, the injectors, the idle
speed control servo, the compression pressure, etc.,
are all normal.
1. Before inspection and adjustment, set the vehicle to the
pre-inspection condition.
2. Turn the ignition switch to LOCK (OFF) position.
3. Connect the MUT-II to the diagnosis connector (16-pin).
NOTE
When the MUT-II is connected, the diagnosis control
terminal should be earthed.
4. Start the engine and run at idle.
5. Select the item No.30 of the MUT-II Actuator test.
NOTE
This holds the ISC servo at the basic step to adjust the
basic idle speed.
6. Check the idle speed.
Standard value: 700 ± 50 r/min
NOTE
(1) The engine speed may be 20 to 100 r/min lower than
indicated above for a new vehicle [driven
approximately 500 km or less], but no adjustment is
necessary.
(2) If the engine stalls or the engine speed is low even
though the vehicle has been driven approximately 500
km or more, it is probable that deposits are adhered
to the throttle valve, so clean it. (Refer to P.13C-96.)
13C-98 MPI <4G9> – On-vehicle Service

7. If not within the standard value range, turn the speed

adjusting screw (SAS) to make the necessary adjustment.
8. Press the MUT-II clear key, and release the ISC servo
from the Actuator test mode.
NOTE
Unless the ISC servo is released, the Actuator test mode
will continue 27 minutes.
9. Turn the ignition switch to LOCK (OFF) position.
10. Disconnect the MUT-II.
11. Start the engine again and let it run at idle speed for
about 10 minutes; check that the idling condition is normal.

FUEL PRESSURE TEST

High-pressure 1. Release residual pressure from the fuel pipe line to prevent
fuel hose fuel gush out. (Refer to P.13C-70.)
2. Disconnect the high-pressure fuel hose at the delivery
pipe side.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
Delivery pipe

3. Remove the union joint and bolt from the special tool
MB991637
(adapter hose) and instead attach the special tool (hose
adapter) to the adapter hose.
Gasket 4. Install the special tool (for measuring the fuel pressure)
MD998709 that was set up in step 3.
<When using the fuel pressure gauge set (special tool)>
Delivery (1) Install the special tool (for measuring the fuel pressure)
pipe MD998742
High-pressure between the high-pressure fuel hose and the delivery
fuel hose pipe.
(2) Install the fuel pressure gauge set (special tool) on
the special tool (for measuring the fuel pressure)
putting the gasket between them.
(3) Connect the lead wire of the fuel pressure gauge set
(special tool) to the power supply (cigarette lighter
socket) and to the MUT-II.
 MPI <4G9> – On-vehicle Service 13C-99

Fuel pressure gauge set

<When using the fuel pressure gauge>
(1) Install the fuel pressure gauge on the special tool
O-ring or gasket (for measuring the fuel pressure) putting a suitable
MD998709
O-ring or gasket between them.
(2) Install the special tool which was set up in step (1)
Delivery between the high-pressure fuel hose and the delivery
pipe MD999742 pipe.
High-pressure 5. Connect the MUT-II to the diagnosis connector.
fuel hose 6. Turn the ignition switch to ON. (But do not start the engine.)
7. Select “Item No.07” from the MUT-II Actuator test to drive
the fuel pump. Check that there are no fuel leaks from
any parts.
8. Finish the actuator test or turn the ignition switch to LOCK
(OFF) position.
9. Start the engine and run at idle.
10. Measure fuel pressure while the engine is running at idle.
Standard value: Approx. 265 kPa

11. Disconnect the vacuum hose from the fuel pressure

regulator and measure fuel pressure with the hose end
closed by a finger.
Standard value: 324–349 kPa
12. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
13. Racing the engine repeatedly, hold the fuel return hose
lightly with fingers to feel that fuel pressure is present
in the return hose.
NOTE
If the fuel flow rate is low, there will be no fuel pressure
in the return hose.
14. If any of fuel pressure measured in steps 10 to 13 is
out of specification, troubleshoot and repair according to
the table below.

Symptom Probable cause Remedy

D Fuel pressure too low Clogged fuel filter Replace fuel filter
D Fuel pressure drops after racing
D No fuel pressure in fuel return Fuel leaking to return side due to poor Replace fuel pressure regulator
hose fuel regulator valve seating or settled
spring

Low fuel pump delivery pressure Replace fuel pump

Fuel pressure too high Binding valve in fuel pressure Replace fuel pressure regulator
regulator

Clogged fuel return hose or pipe Clean or replace hose or pipe

Same fuel pressure when vacuum Damaged vacuum hose or clogged Replace vacuum hose or clean nipple
hose is connected and when nipple
disconnected
13C-100 MPI <4G9> – On-vehicle Service

15. Stop the engine and check change of fuel pressure gauge
reading. Normal if the reading does not drop within 2
minutes. If it does, observe the rate of drop and
troubleshoot and repair according to the table below.

Symptom Probable cause Remedy

Fuel pressure drops gradually after Leaky injector Replace injector

engine is stopped
Leaky fuel regulator valve seat Replace fuel pressure regulator

Fuel pressure drops sharply Check valve in fuel pump is held open Replace fuel pump
immediately after engine is stopped

16. Release residual pressure from the fuel pipe line.

(Refer to P.13C-70.)
17. Remove the fuel pressure gauge and special tool from
the delivery pipe.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
18. Replace the O-ring at the end of the fuel high pressure
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
19. Fit the fuel high pressure hose over the delivery pipe and
tighten the bolt to specified torque.
Tightening torque: 9.0 ± 2.0 Nm
20. Check for any fuel leaks by following the procedure in
step 7.
21. Disconnect the MUT-II.

Fuel pump relay FUEL PUMP CONNECTOR DISCONNECTION

(HOW TO REDUCE THE FUEL PRESSURE)
When removing the fuel pipe, hose, etc., since fuel pressure
in the fuel pipe line is high, do the following operation so
as to release the fuel pressure in the line and prevent fuel
from running out.
1. Remove the fuel pump relay.
2. After starting the engine and letting it run until it stops
naturally, turn the ignition switch to LOCK (OFF) position.
3. Install the fuel pump relay.

FUEL PUMP OPERATION CHECK

Refer to GROUP 13A – On-vehicle Service.
 MPI <4G9> – On-vehicle Service 13C-101
COMPONENT LOCATION
Name Symbol Name Symbol
A/C relay A Engine warning lamp (check engine lamp) O
A/C switch Q Idle speed control servo B

Air flow sensor (With intake air temperature J Ignition coil N

sensor and barometric pressure sensor)
Ignition failure sensor E

Camshaft position sensor F Inhibitor switch <A/T> G

Control relay and fuel pump relay A Injectors D
Crank angle sensor L Oxygen sensor (front) I
Detonation sensor K Oxygen sensor (rear) S
Diagnosis connector P Power steering fluid pressure switch M
EGR control solenoid valve C Purge control solenoid valve C
Engine coolant temperature sensor H Throttle position sensor B
Engine-ECU R Vehicle speed sensor T

A B C D E F G H I J

K L M N

O P Q R S TT
13C-102 MPI <4G9> – On-vehicle Service

CONTROL RELAY AND FUEL PUMP RELAY

Equipment side connector CONTINUITY CHECK
Control relay
1 2
Battery
y voltage
g Terminal No.
3 4
1 2 3 4
Not supplied
Fuel pump relay Supplied

INTAKE AIR TEMPERATURE SENSOR CHECK

Equipment side
connector 1. Disconnect the air flow sensor connector.
Air flow sensor 2. Measure resistance between terminals 5 and 6.
Standard value:
13 – 17 kΩ (at –20_C)
5.7 – 6.7 kΩ (at 0_C)
2.3 – 3.0 kΩ (at 20_C)
1.0 – 1.5 kΩ (at 40_C)
0.56 – 0.76 kΩ (at 60_C)
0.30 – 0.42 kΩ (at 80_C)

Intake air temperature 3. Measure resistance while heating the sensor using a hair
sensor drier.
Normal condition:
Temperature (_C) Resistance (kΩ)
Higher Smaller
4. If the value deviates from the standard value or the
resistance remains unchanged, replace the air flow sensor
assembly.

ENGINE COOLANT TEMPERATURE SENSOR

CHECK
Engine coolant Caution
temperature sensor Be careful not to touch the connector (resin section) with
the tool when removing and installing.
1. Remove the engine coolant temperature sensor.

2. With temperature sensing portion of engine coolant

temperature sensor immersed in hot water, check
resistance.
 MPI <4G9> – On-vehicle Service 13C-103
Standard value:
14 – 17 kΩ (at –20_C)
5.1 – 6.5 kΩ (at 0_C)
2.1 – 2.7 kΩ (at 20_C)
0.9 – 1.3 kΩ (at 40_C)
0.48 – 0.68 kΩ (at 60_C)
0.26 – 0.36 kΩ (at 80_C)
3. If the resistance deviates from the standard value greatly,
replace the sensor.

4. Apply sealant to threaded portion.

Specified sealant:
3M Nut Locking Part No.4171 or equivalent
5. Install the engine coolant temperature sensor and tighten
it to the specified torque.
Tightening torque: 29 ± 9 N·m

Equipment THROTTLE POSITION SENSOR CHECK

side connector 1. Disconnect the throttle position sensor connector.
2. Measure the resistance between the throttle position
sensor side connector terminal 1 and terminal 4.
Standard value: 3.5 – 6.5 kΩ
Throttle position
sensor 3. Measure the resistance between the throttle position
sensor side connector terminal 2 and terminal 4.
Normal condition:
Throttle valve slowly open Changes smoothly in
until fully open from the idle proportion to the opening
position angle of the throttle valve
4. If the resistance is outside the standard value, or if it doesn’t
change smoothly, replace the throttle position sensor.
NOTE
For the throttle position sensor adjustment procedure, refer
to P.13C-96.

OXYGEN SENSOR CHECK

Equipment side connector
<Oxygen sensor (front)>
1. Disconnect the oxygen sensor connector and connect the
1 2 special tool (test harness) to the connector on the oxygen
3 4 sensor side.
2. Make sure that there is continuity (4.8 – 8.0 Ω at 20_C)
between terminal 1 (red clip of special tool) and terminal
3 (blue clip of special tool) on the oxygen sensor connector.
Oxygen sensor (front)
13C-104 MPI <4G9> – On-vehicle Service

3. If there is no continuity, replace the oxygen sensor.

4. Warm up the engine until engine coolant is 80_C or higher.

Oxygen
Red sensor
equipment
side connector
Blue

MD998464

5. Use the jumper wire to connect terminal 1 (red clip) of

Jumper the oxygen sensor connector to the battery (+) terminal
wire and terminal 3 (blue clip) to the battery (–) terminal.
Black Caution
Red Be very careful when connecting the jumper wire;
incorrect connection can damage the oxygen sensor.
White Blue 6. Connect a digital voltage meter between terminal 2 (black
clip) and terminal 4 (white clip).
7. While repeatedly racing the engine, measure the oxygen
MD998464 sensor output voltage.
Standard value:
Engine Oxygen sensor Remarks
output voltage
When 0.6 – 1.0 V If you make the air/fuel ratio
racing the rich by racing the engine
engine repeatedly, a normal oxy-
gen sensor will output a
voltage of 0.6 – 1.0 V.
8. If the sensor is defective, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 – Exhaust Pipe and Main Muffler.

<Oxygen sensor (rear)>

Equipment side connector
1. Disconnect the oxygen sensor connector and connect the
1 2
special tool (test harness) to the connector on the oxygen
3 4
sensor side.
2. Make sure that there is continuity (11 – 18 Ω at 20_C)
between terminal 1 (red clip of special tool) and terminal
3 (blue clip of special tool) on the oxygen sensor connector.
Oxygen sensor (rear)
 MPI <4G9> – On-vehicle Service 13C-105
3. If there is no continuity, replace the oxygen sensor.
4. Warm up the engine until engine coolant is 80_C or higher.

Oxygen
Red sensor
equipment
side connector
Blue

MD998464

5. Use the jumper wire to connect terminal 1 (red clip) of

Jumper the oxygen sensor connector to the battery (+) terminal
wire and terminal 3 (blue clip) to the battery (–) terminal.
Black Caution
Red Be very careful when connecting the jumper wire;
incorrect connection can damage the oxygen sensor.
White Blue 6. Connect a digital voltage meter between terminal 2 (black
clip) and terminal 4 (white clip).
7. While repeatedly racing the engine, measure the oxygen
MD998464 sensor output voltage.
Standard value:
Engine Oxygen sensor Remarks
output voltage
When 0.6 – 1.0 V If you make the air/fuel ratio
racing the rich by racing the engine
engine repeatedly, a normal oxy-
gen sensor will output a
voltage of 0.6 – 1.0 V.
8. If the sensor is defective, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 – Exhaust Pipe and Main Muffler.
13C-106 MPI <4G9> – On-vehicle Service

Injectors INJECTOR CHECK

Measurement of Resistance between Terminals
1. Remove the injector connector.
2. Measure the resistance between terminals.
Standard value: 13 – 16 Ω (at 20_C)
3. Install the injector connector.

Checking the Injection Condition

1. Following the steps below, bleed out the residual pressure
within the fuel pipe line to prevent flow of the fuel.
(Refer to P.13C-100.)
2. Remove the injector.
3. Arrange the special tool (injector test set), adaptor, fuel
pressure regulator and clips as shown in the illustration
below.

High-pressure fuel hose MD998741

Return hose

MB991607

Pressure regulator
(MD116395)
Injector
MD998706

Clip (MB991608)
Battery

4. Connect the MUT-II to the diagnosis connector.

5. Turn the ignition switch to ON. (But do not start the engine.)
6. Select “Item No.7” from the MUT-II Actuator test to drive
the fuel pump.

Main hose 7. Activate the injector and check the atomized spray
Return hose
condition of the fuel.
The condition can be considered satisfactory unless it is
extremely poor.

Injector

Battery
 MPI <4G9> – On-vehicle Service 13C-107
8. Stop the actuation of the injector, and check for leakage
from the injector’s nozzle.
Standard value: 1 drop or less per minute
9. Activate the injector without activating the fuel pump; then,
when the spray emission of fuel from the injector stops,
disconnect the special tool and restore it to its original
condition.
10. Disconnect the MUT-II.

IDLE SPEED CONTROL (ISC) SERVO

Idle speed (STEPPER MOTOR) CHECK
control servo
Checking the Operation Sound
1. Check that the engine coolant temperature is 20_C or
below.
NOTE
Disconnecting the engine coolant temperature sensor
connector and connecting the harness-side of the
connector to another engine coolant temperature sensor
that is at 20_C or below is also okay.
2. Check that the operation sound of the stepper motor can
be heard after the ignition is switched ON. (But do not
start the engine.)
3. If the operation sound cannot be heard, check the stepper
motor’s activation circuit.
If the circuit is normal, it is probable that there is a
malfunction of the stepper motor or of the engine control
unit.

Checking the Coil Resistance

1. Disconnect the idle speed control servo connector.
2. Measure the resistance between terminal 2 and either
terminal 1 or terminal 3 of the connector at the idle speed
control servo side.
Standard value: 27 – 33 Ω (at 20_C)
3. Measure the resistance between terminal 5 and either
terminal 6 or terminal 4 of the connector at the idle speed
control servo side.
Standard value: 27 – 33 Ω (at 20_C)
13C-108 MPI <4G9> – On-vehicle Service

Operation Check
1. Remove the throttle body.
2. Remove the stepper motor.
3. Connect the special tool (test harness: MB991709) to the
idle speed control servo connector.
4. Connect the positive (+) terminal of a power supply (approx.
6 V) to the terminals 2 and 5.
5. With the idle speed control servo as shown in the
illustration, connect the negative (–) terminal of the power
supply to each clip as described in the following steps,
and check whether or not a vibrating feeling (a feeling
of very slight vibration of the stepper motor) is generated
as a result of the activation of the stepper motor.
(1) Connect the negative (–) terminal of the power supply
to the red and black clip.
(2) Connect the negative (–) terminal of the power supply
to the blue and black clip.
(3) Connect the negative (–) terminal of the power supply
to the blue and yellow clip.
(4) Connect the negative (–) terminal of the power supply
to the red and yellow clip.
(5) Connect the negative (–) terminal of the power supply
to the red and black clip.
(6) Repeat the tests in sequence from (5) to (1).
6. If, as a result of these tests, vibration is detected, the
stepper motor can be considered to be normal.

PURGE CONTROL SOLENOID VALVE CHECK

<Vehicles with catalytic converter>
Refer to GROUP 17 – Emission Control System.
EGR CONTROL SOLENOID VALVE CHECK
Refer to GROUP 17 – Emission Control System.
 MPI <4G9> – Injector 13C-109
INJECTOR
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Fuel Discharge Prevention (Refer to P.13C-100) D Air Cleaner and Air Intake Pipe Installation
D Air Cleaner and Air Intake Pipe Removal (Refer to GROUP 15.)
(Refer to GROUP 15.) D Accelerator Cable Adjustment
(Refer to GROUP 17 – On-vehicle Service.)

12 ± 1 N·m
5.0 ± 1.0 N·m 11
3
11

4 O-ring
15 5, 8
5 14
13
14
9.0 ± 2.0 N·m
7
8
9.0 ± 2.0 N·m

12 O-ring
15
10 9.0 ± 2.0 N·m

Engine oil

6
2
9

Removal steps
1. Accelerator cable connection 9. Fuel hose
2. PCV hose 10. Fuel return pipe
3. Injector connector AA" 11. Delivery pipe
4. Injector harness clamp 12. Insulator
"AA 5. High-pressure fuel hose connection 13. Insulator
6. Fuel return hose connection AA" "AA 14. Injector
7. Vacuum hose connection 15. Grommet
"AA 8. Fuel pressure regulator
13C-110 MPI <4G9> – Injector

REMOVAL SERVICE POINT

AA" DELIVERY PIPE/INJECTOR REMOVAL
Remove the delivery pipe (with the injectors attached to it).
Caution
Care must be taken, when removing the delivery pipe,
not to drop the injector.

INSTALLATION SERVICE POINT

"AA INJECTOR/FUEL PRESSURE REGULATOR/
HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a drop of new engine oil to the O-ring.
Caution
Be sure not to let engine oil in the delivery pipe.
2. While turning the injector, high-pressure fuel hose and
fuel pressure regulator to the right and left, install the
delivery pipe, while being careful not to damage the O-ring.
After installing, check that the hose turns smoothly.
3. If it does not turn smoothly, the O-ring may be trapped,
remove the injector, high-pressure fuel hose or fuel
pressure regulator and then re-insert it into the delivery
pipe and check once again.
4. Tighten the high-pressure fuel hose and fuel pressure
regulator to the specified torque.
Tightening torque:
9.0 ± 2.0 N·m (Fuel pressure regulator)
5.0 ± 1.0 N·m (High-pressure fuel hose)
 MPI <4G9> – Throttle Body 13C-111
THROTTLE BODY
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Engine Coolant Draining D Air Cleaner and Air Intake Pipe Installation
(Refer to GROUP 14 – On-vehicle Service.) (Refer to GROUP 15.)
D Air Cleaner and Air Intake Pipe Removal D Engine Coolant Supplying
(Refer to GROUP 15.) (Refer to GROUP 14 – On-vehicle Service.)
D Accelerator Cable Adjustment
(Refer to GROUP 17 – On-vehicle Service.)

24 ± 3 N·m 1

6 19 ± 3 N·m
7 2

9.0 ± 1.0 N·m

8
11 ± 1 N·m

10
4 3

19 ± 3 N·m

5
9

Removal steps
1. Accelerator cable connection 6. Stay
2. Throttle position sensor connector 7. Throttle cable bracket
3. Idle speed control servo connector 8. Harness Clamp
4. Vacuum hose connection 9. Throttle body
5. Water hose connection 10. Throttle body gasket
13C-112 MPI <4G9> – Throttle Body

DISASSEMBLY AND REASSEMBLY

5 1

Disassembly steps
"AA 1. Throttle position sensor NOTE
2. Idle speed control body assembly 1. The speed adjusting screw is correctly adjusted at the
3. O-ring factory and should not be removed.
4. Throttle body 2. If the speed adjusting screw has been removed, carry
5. Speed adjusting screw out fixed SAS adjustment.
6. O-ring 3. If the speed adjusting screw should happen to have
been removed, carry out speed adjusting screw
adjustment.
 MPI <4G9> – Throttle Body 13C-113
CLEANING THROTTLE BODY PARTS
1. Clean all throttle body parts.
Do not use solvent to clean the following parts:
D Throttle position sensor
D Accelerator pedal position sensor
D Idle speed control body assembly
If these parts are immersed in solvent, their insulation
will deteriorate.
Wipe them with cloth only.
2. Check if the vacuum port or passage is clogged. Use
compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINT
"AA THROTTLE POSITION SENSOR (TPS)
INSTALLATION
1. Install the TPS to the throttle body as shown by (1) in
the illustration.
2. Turn the TPS so that it is at the position shown by (2)
in the illustration, and then tighten the screw.

3. Connect a multimeter between terminal (4) (TPS power

No connection supply) and terminal (3) (TPS output) of the TPS connector,
and check that the resistance increases gradually as the
Earth TPS power supply throttle valve is opened slowly to the fully-open position.
4. If there is an abnormality, replace the TPS.

TPS output
NOTES
 ENGINE
COOLING
Click on the applicable bookmark to selected the required model year
 14-1

ENGINE
COOLING
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Engine Coolant Replacement . . . . . . . . . . . . . . . . . . 9

Concentration Measurement . . . . . . . . . . . . . . . . . 10
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
Fan Controller Check . . . . . . . . . . . . . . . . . . . . . . . 10
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fan Control Relay Continuity Check . . . . . . . . . . . 11

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 3 WATER HOSE AND WATER PIPE . . . . . . . . . . 15

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 8 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Engine Coolant Leak Checking . . . . . . . . . . . . . . . . . 8
Radiator Cap Valve Opening Pressure Check . . . 8
 General Information/
14-2 ENGINE COOLING – Service Specifications/Lubricant

GENERAL INFORMATION
The cooling system is designed to keep every part The water pump is of the centrifugal type and is
of the engine at appropriate temperature in whatever driven by the timing belt from the crankshaft.
condition the engine may be operated. The radiator is the corrugated fin, down flow type
The cooling method is of the water-cooled, pressure and is cooled by the electrical radiator fan.
forced circulation type in which the water pump The cooling fans are controlled by a fan controller
pressurizes coolant and circulates it throughout the and the engine-ECU depending on driving
engine. If the coolant temperature exceeds the conditions.
prescribed temperature, the thermostat opens to
circulate the coolant through the radiator as well
so that the heat absorbed by the coolant may be
radiated into the air.

Items Specifications

Radiator Performance kJ/h M/T 152,791

A/T 169,535

A/T oil cooler Performance kJ/h 5,652

NOTE
*: Vehicles with optional radiator

SERVICE SPECIFICATIONS
Items Standard value Limit

Radiator cap opening pressure kPa 74 – 103 64

Range of coolant antifreeze concentration of radiator % 30 – 60 –

Thermostat Valve opening temperature of thermostat _C 82$ 1.5 –

Full-opening temperature of thermostat _C 95 –

Valve lift (at 95_C) mm 8.5 or more –

LUBRICANT
Items Quantity ȏ

MITSUBISHI GENUINE COOLANT or equivalent 6

 ENGINE COOLING – Sealants/Special Tool/Troubleshooting 14-3
SEALANTS
Items Specified sealant Remarks

Cylinder block drain plug 3M Nut Locking Part No. 4171 or equivalent Drying sealant

Water pump Mitsubishi Genuine Parts No. MD970389 or Semi-drying sealant

equivalent
Water fitting

Water outlet fitting

Water by-pass fitting

SPECIAL TOOL
Tool Number Name Use
MB991223 Harness set Measurement of terminal voltage
A
A: MB991219 A: Test harness A: Connector pin contact pressure inspection
B: MB991220 B: LED harness B: Power circuit inspection
C: MB991221 C: LED harness C: Power circuit inspection
D: MB991222 adapter D: Commercial tester connection
D: probe
B

TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptoms Inspection procedure Reference page
No.

Radiator fan and condenser fan do not operate. <Vehicles with A/C> 1 14-4
Radiator fan does not operate. <Vehicles without A/C>

Radiator fan and condenser fan do not change speed or stop. 2 14-6
<Vehicles with A/C>
Radiator fan does not change speed or stop. <Vehicles without A/C>

Radiator fan does not operate. <Vehicles with A/C> 3 14-7

Condenser fan does not operate. <Vehicles with A/C> 4 14-7

14-4 ENGINE COOLING – Troubleshooting

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1
Radiator fan and condenser fan do not operate. Probable cause
<Vehicles with A/C>
Radiator fan does not operate. <Vehicles without A/C>
The cause could be a malfunction of the fan controller power supply or earth circuit. D Malfunction of fusible link
The cause could also be a malfunction of the fan controller or the engine-ECU. D Malfunction of fan control relay
D Malfunction of fan controller
D Malfunction of engine-ECU
D Malfunction of wiring harness or connector

<Vehicles with A/C>

NG
D Fusible link (7) check Replace
D Fan control relay check (Refer to P.14-11.)
OK
(1) NG
Measure at the fan control relay connector A-42X. Check the harness wire between fan control relay and fusible
D Remove the relay, and measure at the harness side connector. link (7), and repair if necessary.
(1) Voltage between 2 and body earth (2) NG
OK: System voltage Check the harness wire between fan control relay and engine
(2) Voltage between 3 and body earth (Ignition switch: ON) control relay, and repair if necessary.
OK: System voltage
(3) Continuity between 1 and body earth (3) NG
Check the harness wire between fan control relay and body earth,
OK: Continuity and repair if necessary.
OK
(1) NG
Measure at the fan controller connector A-29. Check the harness wire between fan controller and fan control
D Disconnect the connector, and measure at the harness side relay, and repair if necessary.
connector. (2) NG
(1) Voltage between 3 and body earth (Ignition switch: ON) Check the harness wire between fan controller and body earth,
OK: System voltage and repair if necessary.
(2) Continuity between 1 and body earth
OK: Continuity
OK
NG
Measure at the engine-ECU connectors C-17. Check the harness wire between fan controller and engine-ECU.
D Connect the connector. OK NG
D Voltage between 18 and body earth
(Engine: idling, A/C switch: ON) Repair
OK: 0.7 V or more (When A/C compressor is operating)
OK
Engine-ECU terminal voltage check (Refer to GROUP 13 – Trou-
bleshooting.)
OK NG

Replace

Check the automatic compressor-ECU, and repair if necessary.

(Refer to GROUP 55 – Troubleshooting.)

Measure at the engine-ECU connectors C-17.

D Connect the connector.
D Pull out the terminal No.18 to disconnect it (Ignition switch: ON)
OK: The radiator fan motor and condenser fan motor operate.
YES NO

Engine-ECU terminal voltage check (Refer to GROUP 13 – Trou- Replace the radiator fan motor and fan controller assembly.
bleshooting.)
 ENGINE COOLING – Troubleshooting 14-5
<Vehicles without A/C>
NG
D Fusible link (7) check Replace
D Fan control relay check (Refer to P.14-11.)
OK
(1) NG
Measure at the fan control relay connector A-42X. Check the harness wire between fan control relay and fusible
D Remove the relay, and measure at the harness side connector. link (7), and repair if necessary.
(1) Voltage between 2 and body earth (2) NG
OK: System voltage Check the harness wire between fan control relay and engine
(2) Voltage between 3 and body earth (Ignition switch: ON) control relay, and repair if necessary.
OK: System voltage
(3) Continuity between 1 and body earth (3) NG
Check the harness wire between fan control relay and body earth,
OK: Continuity and repair if necessary.
OK
(1) NG
Measure at the fan controller connector A-29. Check the harness wire between fan controller and fan control
D Disconnect the connector, and measure at the harness side relay, and repair if necessary.
connector. (2) NG
(1) Voltage between 3 and body earth (Ignition switch: ON) Check the harness wire between fan controller and body earth,
OK: System voltage and repair if necessary.
(2) Continuity between 1 and body earth
OK: Continuity
OK
NG
Measure at the engine-ECU connectors C-17. Check the harness wire between fan controller and engine-ECU.
D Connect the connector. OK NG
D Voltage between 18 and body earth (Engine: idling)
OK: 0.7 V or more (When radiator fan is operating) Repair
OK
Engine-ECU terminal voltage check (Refer to GROUP 13 – Trou-
bleshooting.)

Measure at the engine-ECU connectors C-17.

D Connect the connector.
D Pull out the terminal No.18 to disconnect it (Ignition switch: ON).
OK: The radiator fan motor operates.
YES NO

Engine-ECU terminal voltage check (Refer to GROUP 13 – Trou- Replace the radiator fan motor and fan controller assembly.
bleshooting.)
14-6 ENGINE COOLING – Troubleshooting

Inspection Procedure 2
Radiator fan and condenser fan do not change speed or Probable cause
stop. <Vehicles with A/C>
Radiator fan does not change speed or stop.
<Vehicles without A/C>
The fan controller carries out step-free control of the radiator fan motor and the D Malfunction of fan control relay
condenser fan motor speeds using signals transmitted from the engine-ECU. D Malfunction of fan controller
D Malfunction of engine-ECU
D Malfunction of wiring harness or connector

<Vehicles with A/C>

NG
Fan control relay check (Refer to P.14-11.) Replace
OK
NG
D Check the harness wire between fan control relay and engine Repair
control relay.
D Check the harness wire between fan control relay and body
earth.
D Check the harness wire between fan control relay and fan
controller.
OK
NG
Measure at the engine-ECU connectors C-17. Check the harness wire between fan controller and engine-ECU.
D Connect the connector. NG
D Voltage between 18 and body earth
(Engine: idling, engine coolant temperature: 80_C or less) Repair
OK
OK: 0 – 0.3 V (Engine: idling, A/C switch: ON)
OK: 0.7 V or more (When A/C compressor is operating)
Engine-ECU terminal voltage check (Refer to GROUP 13 – Trou-
OK bleshooting.)
NG

OK Replace

Check the automatic compressor-ECU, and repair if necessary.

(Refer to GROUP 55 – Troubleshooting.)

NG
Fan controller check (Refer to P.14-10.) Replace the radiator fan motor and fan controller assembly.
OK

Measure at the engine-ECU connectors C-17.

D Connect the connector.
D Pull out the terminal No.18 to disconnect it (Ignition switch: ON)
OK: The radiator fan motor and condenser fan motor operate.
D Connect the terminal No.18 to the body earth (Ignition switch: ON)
OK: The radiator fan motor and condenser fan motor stop.
YES NO

Engine-ECU terminal voltage check (Refer to GROUP 13 – Trou- Replace the radiator fan motor and fan controller assembly.
bleshooting.)
 ENGINE COOLING – Troubleshooting 14-7
<Vehicles without A/C>

NG
Fan control relay check (Refer to P.14-11.) Replace
OK
NG
D Check the harness wire between fan control relay and engine Repair
control relay.
D Check the harness wire between fan control relay and body
earth.
D Check the harness wire between fan control relay and fan
controller.
OK
NG
Measure at the engine-ECU connectors C-17. Check the harness wire between fan controller and engine-ECU.
D Connect the connector. OK NG
D Voltage between 18 and body earth
(Engine: idling, engine coolant temperature: 80_C or less) Repair
OK: 0 – 0.3 V (Engine: idling)
OK: 0.7 V or more (When radiator fan is operating)
Engine-ECU terminal voltage check (Refer to GROUP 13 – Trou-
bleshooting.)
OK
NG
Fan controller check (Refer to P.14-10.) Replace the radiator fan motor and fan controller assembly.

OK

Measure at the engine-ECU connectors C-17.

D Connect the connector.
D Pull out the terminal No.18 to disconnect it (Ignition switch: ON)
OK: The radiator fan motor operates.
D Connect the terminal No.18 to the body earth (Ignition switch: ON)
OK: The radiator fan motor stops.
YES NO

Engine-ECU terminal voltage check (Refer to GROUP 13 – Trou- Replace the radiator fan motor and fan controller assembly.
bleshooting.)

Inspection Procedure 3
Radiator fan does not operate. <Vehicles with A/C> Probable cause
The cause could be a malfunction of the radiator fan motor or an open circuit between D Malfunction of radiator fan motor
the fan controller and the radiator fan motor. D Open circuit between fan controller and radiator fan
motor

Replace the radiator fan motor and fan controller assembly.

Inspection Procedure 4
Condenser fan does not operate. <Vehicles with A/C> Probable cause
The cause could be a malfunction of the condenser fan motor or of the fan controller. D Malfunction of condenser fan motor
D Malfunction of fan controller
D Malfunction of wiring harness or connector

NG NG
Condenser fan motor check (Refer to Condenser fan motor connector Repair
GROUP 55.)
OK
OK NG
Check the trouble symptom. Replace the condenser fan motor.
Replace the radiator fan motor and fan
controller assembly.
14-8 ENGINE COOLING – On-vehicle Service

ON-VEHICLE SERVICE
Cap adapter ENGINE COOLANT LEAK CHECKING
1. Confirm that the coolant level is up to the filler neck. Install
Adapter a radiator cap tester, adapter and cap adapter to the filler
neck, and apply 160 kPa pressure, and then check for
leakage from the radiator hose or connections.
Caution
(1) Be sure to completely clean away any moisture
from the places checked.
(2) When the tester is taken out, be careful not to
spill any coolant from it.
(3) Be careful, when installing and removing the tester
and when testing, not to deform the radiator filler
neck.
2. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP VALVE OPENING PRESSURE

CHECK
1. Use a cap adapter to attach the cap to the radiator cap
Cap adapter
tester.
2. Increase the pressure until the indicator of the gauge stops
moving.
Standard value: 75 – 105 kPa
Limit: 65 kPa
3. Replace the radiator cap if the reading does not remain
at or above the limit.
NOTE
Be sure that the cap is clean before testing, since rust
or other foreign material on the cap seal will cause an
improper indication.
 ENGINE COOLING – On-vehicle Service 14-9
ENGINE COOLANT REPLACEMENT
1. Drain the engine coolant by removing the drain plug and
then the radiator cap.
2. Remove the drain plug from the cylinder block to drain
the engine coolant.
3. Remove the reserve tank to drain the engine coolant.
4. When the engine coolant has drained, pour in water from
Cylinder block drain plug
the radiator cap to clean the engine coolant line.
39 Nm 5. Coat the thread of the cylinder block drain plug with the
specified sealant and tighten to the specified torque.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
6. Securely tighten the radiator drain plug.
7. Install the reserve tank.
8. Slowly pour the engine coolant into the mouth of the radiator
until the radiator is full, and pour also into the reserve
tank up to the FULL line.
Recommended antifreeze:
MITSUBISHI GENUINE COOLANT or equivalent
Quantity: 6
Caution
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze can
cause the corrosion of the aluminium components.
9. Install the radiator cap securely.
10. Start the engine and warm the engine until the thermostat
opens. (Touch the radiator hose with your hand to check
that warm water is flowing.)
11. After the thermostat opens, race the engine several times,
and then stop the engine.
12. Cool down the engine, and then pour engine coolant into
the reserve tank until the level reaches the FULL line.
If the level is low, repeat the operation from step 11.
14-10 ENGINE COOLING – On-vehicle Service

CONCENTRATION MEASUREMENT
Measure the temperature and specific gravity of the engine
coolant to check the antifreeze concentration.
Standard value: 30–60% (allowable concentration range)
RECOMMENDED ANTIFREEZE
Antifreeze Allowable concentration
MITSUBISHI GENUINE COOLANT 30 – 60%
or equivalent

Caution
If the concentration of the antifreeze is below 30 %, the
anti-corrosion property will be adversely affected. In
addition, if the concentration is above 60 %, both the
anti-freezing and engine cooling properties will decrease,
affecting the engine adversely. For these reasons, be sure
to maintain the concentration level within the specified
range.

Fan controller FAN CONTROLLER CHECK

1. Disconnect the condenser fan motor connector.
2. Start the engine and run it at idle.
3. Turn the A/C switch to ON and maintain the coolant
temperature at 80_C or less.
4. When measuring the voltage between the fan
controller-side connector terminals, check that the value
changes repeatedly as indicated by (1) – (3) below.
(1) 0 V
(2) 8.2 ± 2.6 V
(3) Battery voltage ± 2.6 V
5. If the voltage does not repeatedly change as indicated,
replace the radiator fan motor and the fan controller
assembly.
 ENGINE COOLING – On-vehicle Service 14-11
FAN CONTROL RELAY CONTINUITY
CHECK
Battery voltage Terminal No.

1 2 3 4

When current is not

supplied
Fan control relay
When current is
supplied
14-12 ENGINE COOLING – Thermostat

THERMOSTAT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying
(Refer to P.14-9.)
D Engine Cover and Under Cover Removal and
Installation
D Air Cleaner Removal and Installation
(Refer to GROUP 15.)

22 – 25 Nm

3 2 1

Removal steps
AA" "BA 1. Radiator lower or upper hose con-
nection
2. Water inlet or outlet fitting
"AA 3. Thermostat

REMOVAL SERVICE POINT

AA" RADIATOR LOWER OR UPPER HOSE
DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.
 ENGINE COOLING – Thermostat 14-13
INSTALLATION SERVICE POINTS
Jiggle valve
"AA THERMOSTAT INSTALLATION
Install the thermostat so that the jiggle valve is facing straight
up.
Caution
Make absolutely sure that no oil is adhering to the rubber
ring of the thermostat. In addition, be careful not to fold
Rubber ring
over or scratch the rubber ring when inserting. If the rubber
ring is damaged, replace the thermostat.

"BA RADIATOR LOWER OR UPPER HOSE

CONNECTION
1. Insert each hose as far as the projection of the water
inlet fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

INSPECTION
THERMOSTAT CHECK
1. Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value:
Valve opening temperature: 82 1.5_C

2. Check that the amount of valve lift is at the standard value

when the water is at the full-opening temperature.
Standard value:
Full-opening temperature: 95_C
Amount of valve lift: 8.5 mm or more
Valve lift NOTE
Measure the valve height when the thermostat is fully
closed, and use this measurement to calculate the valve
height when the thermostat is fully open.
14-14 ENGINE COOLING – Water Pump

WATER PUMP
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying
(Refer to P.14-9.)
D Timing Belt Removal and Installation
(Refer to GROUP 11.)
D Idler Pulley Removal and Installation
(Refer to GROUP 11A.)

10 – 12 Nm

Sealant:
Mitsubishi Genuine Part No.
MD970389 or equivalent

2
24 Nm

Removal steps
1. Timing belt rear cover
"AA 2. Water pump

INSTALLATION SERVICE POINT

"AA WATER PUMP INSTALLATION
Squeeze out the sealant from the tube evenly and apply it
so that there is not too much sealant and no places without
sealant.
Specified Sealant:
Mitsubishi Genuine Parts No. MD970389 or equivalent
 ENGINE COOLING – Water Hose and Water Pipe 14-15
WATER HOSE AND WATER PIPE
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Suppling D Exhaust Manifold Removal and Installation
(Refer to P.14-9.) (Refer to GROUP 15.)
D Engine Cover Removal and Installation
D Air Cleaner Removal and Installation
(Refer to GROUP 15.)

11

13 12

10 – 12 Nm
10 – 12 Nm

14
10
13
22 – 25 Nm

22 – 25 Nm
8

9
15
16 9
7
12 – 15 Nm

22 – 25 Nm
9

6
5, 8, 16 4
5
2
4 22 – 25 Nm
Sealant:
Mitsubishi Genuine Part No. 1
MD970389 or equivalent 3 22 – 25 Nm

Removal steps
AA" "BA 1. Radiator lower hose connection D EGR valve
2. Thermostat case assembly (Refer to GROUP 17.)
3. Water pipe 10. Water hose
"CA 4. O-ring 11. Water hose
5. Water fitting 12. Water pipe
6. Heater hose connection 13. Water hose
7. Water pipe assembly 14. Water pipe
"AA 8. Water by-pass fitting "BA 15. Radiator upper hose connection
"CA 9. O-ring "AA 16. Water outlet fitting
14-16 ENGINE COOLING – Water Hose and Water Pipe

REMOVAL SERVICE POINT

AA" RADIATOR UPPER HOSE/RADIATOR LOWER
HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.

INSTALLATION SERVICE POINTS

"AA WATER OUTLET FITTING/WATER BY-PASS
FITTING/WATER FITTING INSTALLATION
1. Use a gasket scraper or wire brush to eliminate completely
foreign materials adhered to the gasket surface.
2. Apply the specified sealant continuously.
Specified sealant:
Mitsubishi Genuine Parts No. MD970389 or
equivalent
3. Install the water fitting, water bypass fitting and the water
outlet fitting while the sealant is wet (within 15 minutes
after applying the sealant). Do not apply sealant to the
positions other than the required.

"BA RADIATOR UPPER HOSE/RADIATOR LOWER

HOSE CONNECTION
1. Insert each hose as far as the projection of the water
inlet fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

Thermostat case assembly or cylinder block "CA O-RING INSTALLATION

Insert the O-ring to the water inlet pipe assembly, and coat
the outer circumference of the O-ring with water or engine
coolant.
Caution
Do not allow engine oil or other greases to adhere to
the O-ring
O-ring
Water inlet pipe assembly
ENGINE COOLING – Water Hose and Water Pipe 14-17
INSPECTION
WATER PIPE AND HOSE CHECK
Check the water pipe and hose for cracks, damage, clog and
replace them if necessary.
14-18 ENGINE COOLING – Radiator

RADIATOR
REMOVAL AND INSTALLATION
Pre-removal Operations Post-installation Operations
D Engine Coolant Draining (Refer to P.14-9.) D Air Cleaner Installation (Refer to GROUP 15.)
D Engine Cover and Under Cover Removal D Engine cover and Under Cover Installation
D Air Cleaner Removal (Refer to GROUP 15.) D Engine Coolant Supplying (Refer to P.14-9.)
D A/T Fluid Supplying
(Refer to GROUP 23 – On-vehicle Service.)

12 Nm
12 Nm
7
8 6 12
2 12 Nm
8
13 15 14

1
5
3

10 5 10
4 11

Radiator removal steps Radiator fan motor, fan controller

1. Drain plug assembly removal steps
2. Radiator cap 12. Radiator fan motor assembly
AA" "AA 3. Radiator upper hose 13. Fan
AA" "AA 4. Radiator lower hose 14. Radiator fan motor and fan control-
AB" 5. A/T oil cooler hose connection ler assembly
6. Rubber hose 15. Shroud
7. Condense tank
8. Upper insulator
9. Radiator assembly
10. Lower insulator
11. Condenser fan motor assembly
12. Radiator fan motor assembly
ENGINE COOLING – Radiator 14-19
REMOVAL SERVICE POINTS
AA" RADIATOR UPPER HOSE/RADIATOR LOWER
HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.

AB" A/T OIL COOLER HOSE REMOVAL

After removing the hose from the radiator, plug the hose and
the radiator nipple to prevent dust or foreign particles from
getting in.

INSTALLATION SERVICE POINT

"AA RADIATOR LOWER HOSE/RADIATOR UPPER
HOSE CONNECTION
1. Insert each hose as far as the projection of the water
inlet fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
NOTES
 ENGINE COOLING – General/Water Hose and Water Pipe 14-1
GROUP 14
ENGINE COOLING
GENERAL
OUTLINE OF CHANGES
The following service procedures have been established due to the addition of vehicles with 4G9-MPI engine.
Other service procedures are the same as the vehicles with GDI engine.
WATER HOSE AND WATER PIPE
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Suppling D Exhaust Manifold Removal and Installation
D Air Cleaner Removal and Installation (Refer to GROUP 15.)
(Refer to GROUP 15.)

10

11
14 ± 1 N·m

12
10
24 ± 1 N·m
24 ± 1 N·m

9
13 7
14
14 ± 1 N·m

9 24 ± 1 N·m

6
3 5
2
24 ± 1 N·m
4
4
24 ± 1 N·m 1

Removal steps
1. Radiator lower hose connection 8. Water by-pass fitting
2. Thermostat case assembly 9. O-ring
3. Water pipe 10. Water hose
4. O-ring 11. Water pipe
5. Water fitting 12. Water hose
6. Heater hose connection 13. Radiator upper hose connection
7. Water pipe assembly 14. Water outlet fitting
14-2 ENGINE COOLING – Radiator

RADIATOR
REMOVAL AND INSTALLATION
Pre-removal Operations Post-installation Operations
D Engine Coolant Draining D Air Cleaner Installation
D Engine Cover and Under Cover Removal D Engine Cover and Under Cover Installation
D Air Cleaner Removal D Engine Coolant Supplying
D A/T Fluid Supplying

12 ± 2 N·m
12 ± 2 N·m 7 12 ± 2 N·m
6
8
2 12
8
13
15
14

1
5
3

9
10
10 5
4
11

Radiator removal steps Radiator fan motor assembly removal

1. Drain plug steps
2. Radiator cap 12. Radiator fan motor assembly
3. Radiator upper hose 13. Fan
4. Radiator lower hose 14. Radiator fan motor
5. A/T oil cooler hose connection 15. Shroud
6. Rubber hose
7. Condense tank
8. Upper insulator
9. Radiator assembly
10. Lower insulator
11. Condenser fan motor assembly
12. Radiator fan motor assembly
 ENGINE COOLING – Radiator 14-3
INSPECTION
RADIATOR FAN MOTOR CHECK
1. Check to be sure that the radiator fan rotates when battery
voltage is applied between terminals (as shown in the
figure).
2. Check to see that abnormal noises are not produced,
while motor is turning.

RADIATOR FAN RELAY CONTINUITY CHECK

Battery voltage Terminal No.

1 2 3 4

When current is not

supplied

Radiator fan relay When current is

supplied
NOTES
 INTAKE AND
EXHAUST
Click on the applicable bookmark to selected the required model year
 15-1

INTAKE AND
EXHAUST
CONTENTS

SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 2 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 6

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 EXHAUST PIPE AND MAIN MUFFLER . . . . . . 7

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CATALYTIC CONVERTER

. . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 4
15-2 INTAKE AND EXHAUST – Service Specification/Special Tool

SERVICE SPECIFICATION
Items Standard value Limit

Distortion of the intake manifold installation surface mm 0.15 or less 0.20

SPECIAL TOOL
Tool Number Name Use
MD998770 Oxygen sensor Removal and installation of oxygen sensor
wrench
 INTAKE AND EXHAUST – Air Cleaner 15-3
AIR CLEANER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover Removal and Installation

10 Nm

8
1

5
9
9 Nm

2
10 4

Air cleaner removal steps Resonance tank removal steps

1. Air intake hose 8. Resonance tank
2. Resonator 9. Air hose
3. Air duct 10. Insulator
4. Air flow sensor connector connection
5. Air cleaner cover
6. Air cleaner element
7. Air cleaner
15-4 INTAKE AND EXHAUST – Intake Manifold

INTAKE MANIFOLD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying D Ignition Coil Removal and Installation
(Refer to GROUP 14 – On-vehicle Service.) (Refer to GROUP 16.)
D Engine Cover and Under Cover Removal and D Throttle Body Removal and Installation
Installation (Refer to GROUP 13A.)
D Resonance Tank Removal and Installation
(Refer to P.15-3.)

20 Nm
16
20
24 Nm
17 21 2
18

19 Nm 9 Nm 19
9 10 – 12 Nm 3
10
11 1
5 8

11 12
10 – 12 Nm
7 10 – 12 Nm

10 – 12 Nm 6

28 Nm 13

27 – 34 Nm

14 34 Nm

34 Nm
15

Removal steps
1. Engine coolant temperature sensor 10. PCV hose connection
connector connection 11. Vacuum hose connection
2. Condenser connector connection 12. Fuel hose clamp
3. Camshaft position sensor connector 13. Intake manifold stay
connection 14. A/T fluid level gauge guide
4. Injector harness connector connection 15. Front exhaust pipe connection
5. Purge control solenoid connector AA" 16. Fuel pump protector
connection 17. EGR valve support connection
6. EGR valve connector connection 18. Gasket
7. Harness connector bracket 19. Branch tube
8. Water hose and pipe 20. Intake manifold assembly
9. Brake booster vacuum hose 21. Intake manifold gasket
INTAKE AND EXHAUST – Intake Manifold 15-5
REMOVAL SERVICE POINT

A FUEL PUMP PROTECTOR REMOVAL
Lift up the transmission with a jack to create clearance between
the engine and the front deck, and remove the fuel pump
protector.

INSPECTION
Check the following points; replace the part if a problem is
found.
INTAKE MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
15-6 INTAKE AND EXHAUST – Exhaust Manifold

EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover and Under Cover Removal and Air Cleaner Removal and Installation
Installation (Refer to P.15-3.)

5
8

18 Nm

29 Nm

13 Nm

2
6
29 Nm 7
98 Nm

12 – 15
Nm

13 Nm
3

4
34 Nm
34 Nm

Removal steps
1. Front exhaust pipe connection 6. Exhaust manifold cover
2. Exhaust manifold bracket 7. Exhaust manifold
3. Engine oil level gauge guide 8. Exhaust manifold gasket
4. Washer tank filler tube
5. A/C pressure switch connector
connection
 INTAKE AND EXHAUST – Exhaust Pipe and Main Muffler 15-7
EXHAUST PIPE AND MAIN MUFFLER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover and Under Cover Removal and Installation

13 Nm 4
1

13 Nm
7
12 34 Nm
6
13 Nm
49 Nm 11
3

34 Nm 5 34 Nm
49 Nm 2
10
13
14
9

Main muffler removal steps Pre-muffler removal steps

1. Main muffler 8. Pre-muffler
3. Gasket 11. Gasket
4. Hanger Center exhaust pipe removal steps
Center exhaust pipe removal steps
A A
9. Oxygen sensor
2. Center exhaust pipe 10. Front exhaust pipe
3. Gasket 11. Gasket
5. Gasket 12. Gasket
6. Protector 13. Heat protector
7. Hanger 14. Hanger

REMOVAL SERVICE POINT

A OXYGEN SENSOR REMOVAL

INSTALLATION SERVICE POINT

A
OXYGEN SENSOR INSTALLATION

MD998770
NOTES
15-1 INTAKE AND EXHAUST – General/Exhaust Pipe and Main Muffler

GROUP 15
INTAKE AND EXHAUST
GENERAL
OUTLINE OF CHANGE
Due to the introduction of the oxygen sensor (rear), the following service procedure has been added.
The other service procedures are the same as before.

EXHAUST PIPE AND MAIN MUFFLER

REMOVAL AND INSTALLATION

Removal step
A 1. Oxygen sensor (rear)

REMOVAL SERVICE POINT

A OXYGEN SENSOR (REAR) REMOVAL
MD998770

Oxygen sensor (rear)

 INTAKE AND EXHAUST – General/Service Specification/Air Cleaner 15-1
GROUP 15
INTAKE AND EXHAUST
GENERAL
OUTLINE OF CHANGES
The following service procedures have been established due to the addition of vehicle with 4G9-MPI engine.
Other contents are the same as 4G9-GDI engine.
SERVICE SPECIFICATION
Items Standard value Limit

Distortion of the intake manifold installation surface mm 0.15 or less 0.20

AIR CLEANER
REMOVAL AND INSTALLATION
<4G9-MPI>
12 ± 2 N·m
11

4.0 ± 1.0 N·m 3.9 ± 1.0 N·m

5
6 8.8 ± 1.0 N·m
7
12
2
13
3.9 ± 1.0 N·m
1 3
4
9.0 ± 1.0 N·m

10

Removal steps
1. Air intake hose and resonator 8. Air cleaner element
2. Air intake hose 9. Air duct
3. Resonator 10. Air cleaner
4. Air flow sensor connector 11. Breather hose connection
5. Air flow sensor and air cleaner cover 12. Air intake pipe
6. Air flow sensor 13. Air hose
7. Air cleaner cover
15-2 INTAKE AND EXHAUST – Intake Manifold

INTAKE MANIFOLD
REMOVAL AND INSTALLATION
<4G9-MPI>
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying D Throttle Body and Throttle Cable Bracket Removal
D Under Cover Removal and Installation and Installation
D Air Cleaner Removal and Installation (Refer to GROUP 13C.)
(Refer to P.15-2.)

7
12 ± 1 N·m 6
1
10 2
3 5 4

12 7
9.0 ± 1.0 N·m

11

9
22 23
22 ± 4 N·m 15

24 13 9.0 ± 1.0 N·m

14
8 20 ± 2 N·m
Delivery pipe
16
18
20 ± 2 N·m
31 ± 3 N·m

O-ring
21 20 17
10
24 ± 1 N·m
5.0 ± 1.0 N·m 19 Engine oil
5.0 ± 1.0 N·m

Removal steps
1. Noise condenser connector AB" 12. Delivery pipe, injector and fuel
2. Purge control solenoid valve pressure regulator assembly
connector 13. PCV hose connection
3. EGR solenoid valve connector 14. Vacuum hose connection
4. Crank angle sensor connector 15. Solenoid valve and bracket assembly
5. Detonation sensor connector 16. Radiator upper hose
6. Injector connector 17. Water outlet fitting
7. Control harness clamp 18. Battery harness clamp
8. Intake manifold vacuum hose 19. A/T oil cooler pipe clamp <A/T>
connection 20. Earth cable connection
9. Brake booster vacuum hose 21. Intake manifold stay
connection 22. Intake manifold assembly
"AA 10. Fuel pressure hose 23. Intake manifold gasket
11. Return hose 24. EGR valve
 INTAKE AND EXHAUST – Intake Manifold 15-3
REMOVAL SERVICE POINT
AA" FUEL PUMP PROTECTOR REMOVAL
Lift up the transmission with a jack to create clearance between
the engine and the front deck, and remove the fuel pump
protector.

AB" DELIVERY PIPE, INJECTOR AND FUEL

PRESSURE REGULATOR ASSEMBLY REMOVAL
Remove the delivery pipe (with the injectors and fuel pressure
regulator attached to it).
Caution
Care must be taken, when removing the delivery pipe,
not to drop the injector.

INSTALLATION SERVICE POINT

Delivery pipe
"AA HIGH-PRESSURE FUEL HOSE INSTALLATION
1. When connecting the high-pressure fuel hose to the
delivery pipe, apply a small amount of new engine oil
to the O-ring and then insert the high-pressure fuel hose,
being careful not to damage the O-ring.
O-ring Caution
Be careful not to let any engine oil get into the delivery
High-pressure fuel hose pipe.
2. While turning the high-pressure fuel hose to the left and
right, install it to the delivery pipe.
3. Check to be sure that the high-pressure fuel hose turns
smoothly.
If it does not turn smoothly, the O-ring may be trapped,
remove the high-pressure fuel hose and then re-insert
it into the delivery pipe and check once again.
INSPECTION
Check the following points; replace the part if a problem is
found.
INTAKE MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum)
outlet port, and for obstruction of the water passage or
gas passage.
3. Using a straight edge and thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
15-4 INTAKE AND EXHAUST – Exhaust Manifold

EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
<4G9-MPI>
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation D Power Steering Oil Pump Bracket Removal and
D Air Cleaner Removal and Installation Installation
(Refer to P.15-2.)

13 ± 1 N·m

7
5
18 ± 2 N·m

29 ± 3 N·m
13 ± 1 N·m
29 ± 3 N·m
35 ± 5 N·m

2
14 ± 1 N·m 35 ± 6 N·m 1
3 35 ± 5 N·m

Removal steps
1. Front exhaust pipe connection 5. Exhaust manifold cover
2. Exhaust manifold bracket 6. Exhaust manifold
3. Engine oil level gauge guide 7. Exhaust manifold gasket
4. Washer tank filler tube
 INTAKE AND EXHAUST – Exhaust Pipe and Main Muffler 15-5
EXHAUST PIPE AND MAIN MUFFLER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Under Cover Removal and Installation

<4G9-MPI>

1 2

2 13 ± 2 N·m

3
50 ± 10 N·m 4

Front exhaust pipe removal steps

1. Front exhaust pipe 3. Heat protector
2. Gasket 4. Hanger
NOTES
 ENGINE
ELECTRICAL
Click on the applicable bookmark to selected the required model year
 16-1

ENGINE
ELECTRICAL
CONTENTS

CHARGING SYSTEM . . . . . . . . . . . . . . . . 2 IGNITION SYSTEM . . . . . . . . . . . . . . . . . 27

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . 27

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . 28

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 28

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . 29

Alternator Output Line Voltage Drop Test . . . . 4 Ignition Coil (With Built-in Power Transistor)
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Output Current Test . . . . . . . . . . . . . . . . . . . . . . . . 5
Spark Plug Check and Cleaning . . . . . . . . . 30
Regulated Voltage Test . . . . . . . . . . . . . . . . . . . . . 7
Camshaft Position Sensor Check . . . . . . . . . 30
Waveform Check Using An Analyzer . . . . . . . . 9
Crank Angle Sensor Check . . . . . . . . . . . . . . . 30
Alternator Relay Continuity Check . . . . . . . . . 10
Detonation Sensor Check . . . . . . . . . . . . . . . . 30
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . 31
STARTING SYSTEM . . . . . . . . . . . . . . . . 17
CRANK ANGLE SENSOR . . . . . . . . . . . . . . . 32
GENERAL INFORMATION . . . . . . . . . . . . . . . 17
CAMSHAFT POSITION SENSOR . . . . . . . . 32
SERVICE SPECIFICATIONS . . . . . . . . . . . . . 17
DETONATION SENSOR . . . . . . . . . . . . . . . . 33
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . 18
16-2 ENGINE ELECTRICAL – Charging System

CHARGING SYSTEM
GENERAL INFORMATION
The charging system uses the alternator output to
keep the battery charged at a constant level under
various electrical loads.

Voltage OPERATION
Rotation of the excited field coil generates AC voltage in the
stator.
This alternating current is rectified through diodes to DC voltage
having a waveform shown in the illustration at left. The average
Approx. 14.4 V output voltage fluctuates slightly with the alternator load
condition.

Time

When the ignition switch is turned on, current flows approx. 14.4 V, the field current is cut off. When
in the field coil and initial excitation of the field coil the battery voltage drops below the regulated
occurs. voltage, the voltage regulator regulates the output
When the stator coil begins to generate power after voltage to a constant level by controlling the field
the engine is started, the field coil is excited by current.
the output current of the stator coil. In addition, when the field current is constant, the
The alternator output voltage rises as the field alternator output voltage rises as the engine speed
current increases and it falls as the field current increases.
decreases. When the battery voltage (alternator S
terminal voltage) reaches a regulated voltage of

SYSTEM DIAGRAM

B
Stator coil

Engine-ECU

Field coil G
S
L +
Voltage
regulator FR Ignition
Charging switch Battery
warning lamp
–
 ENGINE ELECTRICAL – Charging System 16-3
ALTERNATOR SPECIFICATIONS
Items Specifications

Type Battery voltage sensing

Rated output V/A 12/100

Voltage regulator Electronic built-in type

SERVICE SPECIFICATIONS
Items Standard value Limit

Alternator output line voltage drop (at 30 A) V – Max. 0.3

Regulated voltage ambient – 20_C 14.2 – 15.4 –

temp at voltage regulator V
temp.
20_C 13.9 –14.9 –

60_C 13.4 – 14.6 –

80_C 13.1 – 14.5 –

Output current – 70% of normal output current

SPECIAL TOOL
Tool Number Name Use
MB991519 Alternator test Checking the alternator (S terminal voltage)
harness
16-4 ENGINE ELECTRICAL – Charging System

ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

+ –

Alternator Ammeter
Voltmeter

Battery
Terminal B + –

This test determines whether the wiring from the output wire. (Connect the (+) lead of the
alternator “B” terminal to the battery (+) terminal ammeter to the “B” terminal, and then connect
(including the fusible line) is in a good condition the (–) lead of the ammeter to the disconnected
or not. output wire.)
(1) Always be sure to check the following before NOTE
the test. An inductive-type ammeter which enables
D Alternator installation measurements to be taken without disconnect-
D Alternator drive belt tension ing the alternator output wire should be
D Fusible link recommended. Using this equipment will lessen
D Abnormal noise from the alternator while the possibility of a voltage drop caused by a
the engine is running loose “B” terminal connection.
(2) Turn the ignition switch to the LOCK (OFF)
position. (5) Connect a digital-type voltmeter between the
(3) Disconnect the negative battery cable. alternator “B” terminal and the battery (+)
(4) Disconnect the alternator output wire from the terminal. (Connect the (+) lead of the voltmeter
alternator “B” terminal and connect a DC test to the “B” terminal and the connect the (–) lead
ammeter with a range of 0–100 A in series of the voltmeter to the battery (+) cable.)
between the “B” terminal and the disconnected
 ENGINE ELECTRICAL – Charging System 16-5
(6) Reconnect the negative battery cable. (11)If the value displayed on the voltmeter is above
(7) Connect a tachometer or the MUT-II. the limit value, there is probably a malfunction
(8) Leave the hood open. in the alternator output wire, so check the wiring
(9) Start the engine. between the alternator “B” terminal and the
(10)With the engine running at 2,500 r/min, turn battery (+) terminal (including fusible link).
the headlamps and other lamps on and off to If a terminal is not sufficiently tight or if the
adjust the alternator load so that the value harness has become discolored due to
displayed on the ammeter is slightly above 30 overheating, repair and then test again.
A. (12)After the test, run the engine at idle.
Adjust the engine speed by gradually (13)Turn off all lamps and the ignition switch.
decreasing it until the value displayed on the (14)Remove the tachometer or the MUT-II.
ammeter is 30 A. Take a reading of the value (15)Disconnect the negative battery cable.
displayed on the voltmeter at this time. (16)Disconnect the ammeter and voltmeter.
Limit: max. 0.3 V (17)Connect the alternator output wire to the
alternator “B” terminal.
NOTE (18)Connect the negative battery cable.
When the alternator output is high and the value
displayed on the ammeter does not decrease
until 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is max.
0.4 V.

OUTPUT CURRENT TEST

Load

Voltmeter
Ammeter
Charging warning lamp

Ignition switch

Alternator relay – + + –

B
FR
L
S
G
Battery
Alternator
Engine
-ECU
16-6 ENGINE ELECTRICAL – Charging System

This test determines whether the alternator output (10)Turn the light switch on to turn on headlamps
current is normal. and then start the engine.
(1) Before the test, always be sure to check the (11)Immediately after setting the headlamps to high
following. beam and turning the heater blower switch to
D Alternator installation the high revolution position, increase the engine
D Battery speed to 2,500 r/min and read the maximum
NOTE current output value displayed on the ammeter.
The battery should be slightly discharged. Limit: 70% of normal current output
The load needed by a fully-charged battery NOTE
is insufficient for an accurate test. D For the nominal current output, refer to the
D Alternator drive belt tension Alternator Specifications.
D Fusible link D Because the current from the battery will
D Abnormal noise from the alternator while soon drop after the engine is started, the
the engine is running. above step should be carried out as quickly
(2) Turn the ignition switch to the LOCK (OFF) as possible in order to obtain the maximum
position. current output value.
(3) Disconnect the negative battery cable. D The current output value will depend on
(4) Disconnect the alternator output wire from the the electrical load and the temperature of
alternator “B” terminal. Connect a DC test the alternator body.
ammeter with a range of 0–100 A in series D If the electrical load is small while testing,
between the “B” terminal and the disconnected the specified level of current may not be
output wire. (Connect the (+) lead of the output even though the alternator is normal.
ammeter to the “B” terminal. Connect the (–) In such cases, increase the electrical load
lead of the ammeter to the disconnected output by leaving the headlamps turned on for
wire.) some time to discharge the battery or by
Caution using the lighting system in another vehicle,
Never use clips but tighten bolts and nuts and then test again.
to connect the line. Otherwise loose D The specified level of current also may not
connections (e.g. using clips) will lead to be output if the temperature of the alternator
a serious accident because of high current. body or the ambient temperature is too high.
In such cases, cool the alternator and then
NOTE test again.
An inductive-type ammeter which enables (12)The reading on the ammeter should be above
measurements to be taken without disconnect- the limit value. If the reading is below the limit
ing the alternator output wire should be value and the alternator output wire is normal,
recommended. remove the alternator from the engine and check
(5) Connect a voltmeter with a range of 0–20 V the alternator.
between the alternator “B” terminal and the (13)Run the engine at idle after the test.
earth. (Connect the (+) lead of the voltmeter (14)Turn the ignition switch to the LOCK (OFF)
to the “B” terminal, and then connect the (–) position.
lead of the voltmeter to the earth.) (15)Remove the tachometer or the MUT-II.
(6) Connect the negative battery cable. (16)Disconnect the negative battery cable.
(7) Connect a tachometer or the MUT-II. (17)Disconnect the ammeter and voltmeter.
(8) Leave the hood open. (18)Connect the alternator output wire to the
(9) Check that the reading on the voltmeter is equal alternator “B” terminal.
to the battery voltage. (19)Connect the negative battery cable.
NOTE
If the voltage is 0 V, the cause is probably an
open circuit in the wire or fusible link between
the alternator “B” terminal and the battery (+)
terminal.
 ENGINE ELECTRICAL – Charging System 16-7
REGULATED VOLTAGE TEST

Load
Ignition Charging warning
switch lamp MB991519
Alternator

FR
Alternator relay L
S
G

Yellow
Engine-
ECU Ammeter

Voltmeter
Battery

– +
+ –
16-8 ENGINE ELECTRICAL – Charging System

This test determines whether the voltage regulator NOTE

is correctly controlling the alternator output voltage. If the voltage is 0 V, the cause is probably an
(1) Always be sure to check the following before open circuit in the wire or fusible link between
the test. the alternator “S” terminal and the battery (+)
D Alternator installation terminal.
D Check that the battery installed in the vehicle (10)Turn all lamps and accessories off.
is fully charged. (11)Start the engine.
D Alternator drive belt tension (12)Increase the engine speed to 2,500 r/min.
D Fusible link (13)Read the value displayed on the voltmeter when
D Abnormal noise from the alternator while the alternator output current alternator becomes
the engine is running 10 A or less.
(2) Turn the ignition switch to the LOCK (OFF) (14)If the voltage reading conforms to the value
position. in the voltage regulation, then the voltage
(3) Disconnect the negative battery cable. regulator is operating normally.
(4) Use the special tool (Alternator test harness: If the voltage is not within the standard value,
MB991519) to connect a digital voltmeter there is a malfunction of the voltage regulator
between the alternator S terminal and earth. or of the alternator.
(Connect the (+) lead of the voltmeter to the (15)After the test, lower the engine speed to the
“S” terminal, and then connect the (−) lead of idle speed.
the voltmeter to a secure earth or to the battery (16)Turn the ignition switch to the LOCK (OFF)
(−) terminal.) position.
(5) Disconnect the alternator output wire from the (17)Remove the tachometer or the MUT-II.
alternator “B” terminal. (18)Disconnect the negative battery cable.
(6) Connect a DC test ammeter with a range of (19)Disconnect the ammeter and voltmeter.
0–100 A in series between the “B” terminal (20)Connect the alternator output wire to the
and the disconnected output wire. (Connect the alternator “B” terminal.
(+) lead of the ammeter to the “B” terminal. (21)Remove the special tool, and return the
Connect the (–) lead of the ammeter to the connector to the original condition.
disconnected output wire.) (22)Connect the negative battery cable.
(7) Reconnect the negative battery cable.
(8) Connect a tachometer or the MUT-II.
(9) Turn the ignition switch to the ON position and
check that the reading on the voltmeter is equal
to the battery voltage.

Voltage Regulation Table

Standard value:
Inspection terminal Voltage regulator ambient temperature _C Voltage V

Terminal “S” – 20 14.2 – 15.4

20 13.9 – 14.9

60 13.4 – 14.6

80 13.1 – 14.5
 ENGINE ELECTRICAL – Charging System 16-9
Special WAVEFORM CHECK USING AN ANALYZER
patterns Analyzer
Alternator pickup
MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to the alternator
B terminal.

B terminal

STANDARD WAVEFORM
Observation Conditions
FUNCTION SPECIAL PATTERNS

PATTERN HEIGHT VARIABLE

VARIABLE knob Adjust while viewing the wave-

form.

PATTERN SELECTOR RASTER

Engine speed Curb idle speed

0.4

0.2
Voltage at
alternator 0
B terminal
– 0.2

– 0.4

Time

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.
In addition, when the voltage waveform reaches an excessively
high value (approx. 2 V or higher at idle), it often indicates
an open circuit due to a brown fuse between alternator “B”
terminal and battery, but not a defective alternator.
16-10 ENGINE ELECTRICAL – Charging System

EXAMPLES OF ABNORMAL WAVEFORMS

NOTE
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob
on the analyzer.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveforms Problem Abnormal waveforms Problem cause
cause
Example 1 Open diode Example 4 Short in stator
coil

Example 2 Short in diode Example 5 Open

supplementary
diode

Example 3 Broken wire

in stator coil

At this time, the charging warning lamp

is illuminated.

ALTERNATOR RELAY CONTINUITY CHECK

1. Remove the alternator relay from the relay box inside
the instrument panel.
2. Set the analogue-type circuit tester to the Ω range and
check that there is continuity when the (+) terminal of
the tester is connected to terminal 2 of the alternator relay
and the (–) terminal is connected to terminal 4.
Alternator
3. Next, check that there is no continuity when the (+) terminal
relay is connected to terminal 4 and the (–) terminal is connected
to terminal 2.
4. If the continuity checks in steps 2 and 3 show a defect,
replace the alternator relay.
2
1

4
3
 ENGINE ELECTRICAL – Charging System 16-11
ALTERNATOR
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Under Cover Removal D Drive Belt Tension Adjustment
D Under Cover Installation

20 – 25 Nm 3

1
4
2

44 Nm
5

44 Nm

Disassembly steps
1. Drive belt (Power steering, A/C) 4. Alternator connector
2. Drive belt (Alternator) 5. Alternator
3. Alternator brace
16-12 ENGINE ELECTRICAL – Charging System

DISASSEMBLY AND REASSEMBLY

4
3

5
7 6

12
10
9

8
14

13

11

Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Alternator pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Slinger
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
ENGINE ELECTRICAL – Charging System 16-13
DISASSEMBLY SERVICE POINTS
AA" FRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdriver, etc., in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
The stator coil could be damaged so do not insert the
screwdriver too far.

AB" ALTERNATOR PULLEY REMOVAL

Face the pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care so that the rotor is not damaged.

AC" STATOR/REGULATOR ASSEMBLY REMOVAL

Soldered
1. Use a soldering iron (180 to 250 W) to unsolder the stator.
This work should complete within approximately four
seconds to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly,
remove the soldered sections of the rectifier.
Caution
(1) Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
(2) Use care that no undue force is exerted to the
lead wires of the diodes.
16-14 ENGINE ELECTRICAL – Charging System

REASSEMBLY SERVICE POINTS

Wire "AA REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.

Rear bracket

Brush

Wire

"BA ROTOR INSTALLATION

Wire
After installing the rotor, remove the wire used to fix the brush.

INSPECTION
ROTOR CHECK
1. Check the continuity between the rotor coil slip rings, and
replace the rotor if the resistance value is not at the
standard value.
Standard value: 3 – 5 Ω

2. Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
ENGINE ELECTRICAL – Charging System 16-15
STATOR CHECK
1. Check the continuity between the coil leads, and if there
is continuity, replace the stator.

2. Check the continuity between the coil and core, and if

there is continuity, replace the stator.

RECTIFIER CHECK
1. Inspect the (+) heat sink by checking the continuity between
the (+) heat sink and stator coil lead wire connection
terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

2. Inspect the (–) heat sink by checking the continuity between

the (–) heat sink and stator coil lead wire connection
terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

3. Check the diode trio by connecting an ohmmeter to both

ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the rectifier.
16-16 ENGINE ELECTRICAL – Charging System

BRUSH CHECK
1. Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Protrusion Limit: 2 mm or less
length

Soldered 2. The brush can be removed if the solder of the brush lead
wire is removed.
3. When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
 ENGINE ELECTRICAL – Starting System 16-17

STARTING SYSTEM
GENERAL INFORMATION
If the ignition switch is turned to the “START” M-terminal to conduct. Thus, current flows to engage
position, current flows in the pull-in and holding coils the starter motor.
provided inside magnetic switch, attracting the When the ignition switch is returned to the “ON”
plunger. When the plunger is attracted, the lever position after starting the engine, the starter clutch
connected to the plunger is actuated to engage is disengaged from the ring gear.
the starter clutch. An overrunning clutch is provided between the pinion
On the other hand, attracting the plunger will turn and the armature shaft, to prevent damage to the
on the magnetic switch, allowing the B-terminal and starter.

SYSTEM DIAGRAM
Holding coil Plunger

Pull-in coil Lever

Over-running
clutch

Pinion shaft
Ignition
switch

Armature

Battery

Brush
Yoke

STARTER MOTOR SPECIFICATIONS

Items Specifications
Type Reduction drive with planetary gear
Rated output kW/V 1.2/12
No. of pinion teeth 8

SERVICE SPECIFICATIONS
Items Standard value Limit
Pinion gap mm 0.5 – 2.0 –
Commutator outer diameter mm 29.4 28.8
Commutator runout mm – 0.05
Commutator undercut mm 0.5 0.2
16-18 ENGINE ELECTRICAL – Starting System

STARTER MOTOR
Switch
S INSPECTION
B M PINION GAP ADJUSTMENT
1. Disconnect field coil wire from M-terminal of magnetic
Battery switch.
Field coil wire
2. Connect a 12-volt battery between S-terminal and
M-terminal.
3. Set switch to “ON”, and pinion will move out.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning.

4. Check pinion to stopper clearance (pinion gap) with a

thickness gauge.
Standard value: 0.5 – 2.0 mm

Stopper
Pinion gap

Pinion

5. If pinion gap is out of specification, adjust by adding or

removing gaskets between magnetic switch and front
bracket.
 ENGINE ELECTRICAL – Starting System 16-19
MAGNETIC SWITCH PULL-IN TEST
S 1. Disconnect field coil wire from M-terminal of magnetic
switch.
M 2. Connect a 12-volt battery between S-terminal and
Battery
M-terminal.
Caution
Field coil wire
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning.
3. If pinion moves out, then pull-in coil is good. If it doesn’t,
replace magnetic switch.

MAGNETIC SWITCH HOLD-IN TEST

S 1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12-volt battery between S-terminal and body.
Battery
Caution
This test must be performed quickly (in less than 10
Field coil wire seconds) to prevent coil from burning.
3. Manually pull out the pinion as far as the pinion stopper
position.
4. If pinion remains out, everything is in order. If pinion moves
in, hold-in circuit is open. Replace magnetic switch.

Carbon-pile rheostat FREE RUNNING TEST

1. Place starter motor in a vise equipped with soft jaws and
S connect a fully-charged 12-volt battery to starter motor
B M A as follows:
Ammeter 2. Connect a test ammeter (100-ampere scale) and carbon
Starter pile rheostat in series with battery positive post and starter
motor V
Battery motor terminal.
Voltmeter 3. Connect a voltmeter (15-volt scale) across starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable from battery negative post to starter
motor body.
6. Adjust the rheostat until the battery voltage shown by the
voltmeter is 11-volt.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly
and freely.
Current: max. 90 A
16-20 ENGINE ELECTRICAL – Starting System

MAGNETIC SWITCH RETURN TEST

1. Disconnect field coil wire from M-terminal of magnetic
switch.
M 2. Connect a 12-volt battery between M-terminal and body.
Battery
Caution
This test must be performed quickly (in less than 10
Field coil wire
seconds) to prevent coil from burning.
3. Pull pinion out and release. If pinion quickly returns to
its original position, everything is in order. If it doesn’t,
replace magnetic switch.
Caution
Be careful not to get your fingers caught when pulling
out the pinion.
 ENGINE ELECTRICAL – Starting System 16-21
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Cover and Under Cover Removal and
Installation
D Front Propeller Shaft Removal and Installation
(Refer to GROUP 25.)

1
26 – 33 Nm

5
11 10 – 12 Nm 8

7
28 Nm

34 Nm
10
4 10 – 12 Nm

6
34 Nm
9
26 – 33 Nm 10 – 12 Nm
3
26 – 33 Nm
5 Nm

2 5 Nm

Disassembly steps
1. Starter harness connection 7. Water pipe clamp
2. A/T oil pipe clamp 8. Injector harness connector
3. Earth cable connection connection
4. Intake manifold stay 9. Harness connector bracket
5. Oxygen sensor connector 10. Detonation sensor connector
connection connection
6. Front exhaust pipe connection AB" 11. Starter motor assembly
AA" "AA D Transmission mount crossmember
16-22 ENGINE ELECTRICAL – Starting System

REMOVAL SERVICE POINTS

AA" TRANSMISSION MOUNT CROSSMEMBER
REMOVAL
1. Remove the transmission mount crossmember. (Refer to
GROUP 32.)
2. Lower the jack holding the engine and transmission
assembly to create clearance enough to remove the starter
motor installation bolts.

AB" STARTER MOTOR ASSEMBLY REMOVAL

Pull the starter motor assembly out of space between the
intake manifold and cylinder block.

INSTALLATION SERVICE POINT

"AA TRANSMISSION MOUNT CROSSMEMBER
INSTALLATION
Refer to GROUP 32.
 ENGINE ELECTRICAL – Starting System 16-23
DISASSEMBLY AND REASSEMBLY

13
14
16

12 11
15

1 21
4

20
19
18
3
17
8 5
22 7

10

Disassembly steps
1. Screw 12. Packing A
AA" 2. Magnetic switch 13. Packing B
3. Screw 14. Plate
4. Through bolt 15. Planetary gear
5. Rear bracket 16. Lever
6. Brush holder AC" "AA 17. Snap ring
7. Brush AC" "AA 18. Stop ring
8. Rear bearing 19. Overrunning clutch
AB" 9. Armature 20. Internal gear
10. Yoke assembly 21. Planetary gear holder
AB" 11. Ball 22. Front bracket
16-24 ENGINE ELECTRICAL – Starting System

S-terminal
DISASSEMBLY SERVICE POINTS
Magnetic
switch AA" MAGNETIC SWITCH REMOVAL
M-terminal Disconnect the field coil wire from M-terminal of the magnetic
switch.
Field coil
wire

AB" ARMATURE AND BALL REMOVAL

When removing the armature, do not lose the ball placed
at the end as a bearing.

AC" SNAP RING/STOP RING REMOVAL

Socket 1. Using an appropriate wrench socket, push the stop ring
toward the overrunning clutch.
Stop ring
Pinion gear

Overrunning
clutch

2. Remove the snap ring with snap ring pliers and then remove
Snap ring pliers the stop ring and overrunning clutch.
Snap ring

Pinion gear

Over-
running
clutch

STARTER MOTOR PARTS CLEANING

1. Do not immerse the parts in cleaning solvent. Immersing
the yoke and field coil assembly and/or armature will
damage insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The
overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
 ENGINE ELECTRICAL – Starting System 16-25
REASSEMBLY SERVICE POINTS
"AA STOP RING/SNAP RING INSTALLATION
Using an appropriate tool, pull the stop ring over the snap
ring.
Stop ring
Overrunning
Stop ring clutch

Snap ring

INSPECTION
COMMUTATOR
1. Place the armature in a pair of “V” blocks and check the
runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm

2. Measure the commutator outer diameter.

Standard value: 29.4 mm
Limit: 28.8 mm

3. Check the undercut depth between segments.

Undercut Standard value: 0.5 mm
Segment Limit: 0.2 mm
Mica

OVERRUNNING CLUTCH
1. Check that the pinion locks when it is turned anti-clockwise
and moves smoothly when it is turned clockwise.
2. Check the pinion for wear or damage.
Free

Lock
16-26 ENGINE ELECTRICAL – Starting System

BRUSH
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length.
Limit: Wear limit line
2. In case the contacting surface has been corrected or the
Wear limit line brush has been replaced, correct the contacting surface
by winding sandpaper around the commutator.

ARMATURE COIL SHORT-CIRCUIT TEST

Growler
1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
Caution
Clean the armature surface thoroughly before
checking.

3. Check the insulation between each commutator segment

and armature coil core.
If there is no continuity, the insulation is in order.

ARMATURE COIL OPEN-CIRCUIT INSPECTION

Check the continuity between segments. If there is continuity,
the coil is in order.
 ENGINE ELECTRICAL – Ignition System 16-27

IGNITION SYSTEM
GENERAL INFORMATION
This system is equipped with four ignition coils with The engine-ECU determines which ignition coil
built-in power transistors for each of the cylinders. should be controlled by means of the signals from
Interruption of the primary current flowing in the the camshaft position sensor and the crank angle
primary side of an ignition coil generates a high sensor. It also detects the crankshaft position, in
voltage in the secondary side of the ignition coil. order to provide ignition at the most appropriate
The high voltage thus generated is applied to the timing in response to the engine operation
spark plugs to generate sparks. conditions.
The engine-ECU turns the power transistors inside When the engine is cold or running at high altitudes,
the ignition coils alternately on and off. This causes the ignition timing is slightly advanced to provide
the primary currents in the ignition coils to be optimum performance. Furthermore, if knocking
alternately interrupted and allowed to flow to fire occurs, the ignition timing is gradually retarded until
the cylinders in the order 1 – 3 – 4 – 2. knocking ceases.

SYSTEM DIAGRAM

Ignition switch Battery

Air flow sensor
Barometric pressure sensor
Intake air temperature sensor
Engine coolant temperature
sensor
Accelerator pedal position
switch Engine-
Camshaft position sensor ECU
Crank angle sensor
Ignition switch-ST Ignition coil
Detonation sensor

Vehicle speed sensor

Inhibitor switch
Spark plug

A/T-ECU
Cylinder No. 1 2 3 4
To tachometer
16-28 ENGINE ELECTRICAL – Ignition System

IGNITION COIL SPECIFICATIONS

Items Specifications

Type Molded 4-coil

SPARK PLUG SPECIFICATIONS

Items Specifications

NGK IZFR6B

SERVICE SPECIFICATIONS
SPARK PLUG
Items Standard value Limit

Spark plug gap mm 0.5 – 0.6 0.75

Spark plug insulation resistance MΩ – 1

SPECIAL TOOL
Tool Number Name Use
MD998773 Detonation sensor Detonation sensor removal and installation
wrench
 ENGINE ELECTRICAL – Ignition System 16-29
ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER
TRANSISTOR) CHECK
Check by the following procedure, and replace if there is a
malfunction.

PRIMARY COIL AND POWER TRANSISTOR

CONTINUITY CHECK
1.5 V
+ – NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative (–) prove of the circuit tester to
– + terminal 1.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning and power transistor
from breakage.
Voltage:
g 1.5V Terminal No.
1 2 3
When current is
flowing

When current is
not flowing

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. So, check the secondary coil
in the following procedure.
1. Disconnect the ignition coil connector.
2. Remove the ignition coil and install a new spark plug to
the ignition coil.
3. Connect the ignition coil connector.
4. Earth the side electrode of the spark plug and crank the
engine.
5. Check that spark is produced between the electrodes of the
spark plug.
6. If no spark is produced, replace the ignition coil with a
new one and recheck.
7. 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.
16-30 ENGINE ELECTRICAL – Ignition System

SPARK PLUG CHECK AND CLEANING

CAUTION
1. Do not adjust the gap for iridium plugs.
2. The iridium tips may become damaged when iridium
plugs are cleaned. Accordingly, if the plugs are sooty
and need to be cleaned, use a plug cleaner in order
to protect the terminals, and do not clean for more
than 20 seconds. Tools such as wire brushes must
never be used.
3. The terminals of iridium plugs may become blackened,
even when the plugs are functioning normally.
However, the carbon which is deposited onto these
plugs burns off more easily than for conventional
spark plugs, so such blackening is not normally a
problem. Measure the insulation resistance of the
spark plug to judge if the plug is still usable or not.
(1) Check the plug gap, and replace the plug if the gap is
greater than the limit value.
Standard Valve : 0.5 – 0.6 mm
Limit : 0.75 mm

(2) Measure the insulation resistance of the spark plug, and

replace the plug if the resistance is below the limit value.
Limit : 1 MΩ

CAMSHAFT POSITION SENSOR CHECK

Refer to GROUP 13A – Troubleshooting.
CRANK ANGLE SENSOR CHECK
Refer to GROUP 13A – Troubleshooting.
DETONATION SENSOR CHECK
Check the detonation sensor circuit if self-diagnosis code,
No. 31 is shown.
NOTE
For information concerning the self-diagnosis codes, refer to
GROUP 13A – Troubleshooting .
 ENGINE ELECTRICAL – Ignition System 16-31
IGNITION COIL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Cover Removal and Installation
D Resonance Tank Removal and Installation
(Refer to GROUP 15.)
D Air Cleaner Assembly and Air Intake Hose Removal
and Installation

10 Nm
2

25 Nm

Disassembly steps
1. Ignition Coil Connector
2. Ignition Coil
3. Spark Plug
16-32 ENGINE ELECTRICAL – Ignition System

CRANK ANGLE SENSOR

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Timing Belt Front Lower Cover Removal and Installation
(Refer to GROUP 11.)

Crank angle sensor

9 Nm

CAMSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover Removal and Installation

9 Nm

Camshaft
position
sensor
 ENGINE ELECTRICAL – Ignition System 16-33
DETONATION SENSOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Cover Removal and Installation

10 – 12 Nm

20 – 25 Nm

10 – 12 Nm

Disassembly steps
1. Water pipe clamp
AA" "AA 2. Detonation sensor

REMOVAL SERVICE POINT

AA" DETONATION SENSOR REMOVAL

INSTALLATION SERVICE POINT

"AA DETONATION SENSOR INSTALLATION

MD998773
NOTES
 ENGINE ELECTRICAL – Ignition System 16-1

GROUP 16
ENGINE ELECTRICAL
IGNITION SYSTEM
GENERAL
OUTLINE OF CHANGES
The 4G93-GDI engine has been replaced with the 4G94-GDI engine. Due to this, the following service
adjustment procedures have been changed. Other procedures are the same as the conventional 4G93-GDI
engine.
 An ignition failure sensor has been added.
 The spark plug type has been changed.

GENERAL INFORMATION
SPARK PLUG SPECIFICATION
Items Specifications

NGK IZFR5B

SERVICE INFORMATION
IGNITION FAILURE SENSOR
Items 4G94-GDI

Resistance Ω 0.1 or less

ON-VEHICLE SERVICE
IGNITION FAILURE SENSOR CHECK
NOTE
An analog-type circuit tester should be used.
Check that the resistance between terminals 3 and 4 is at
the standard value.
Standard value: 0.1 Ω or less
16-2 ENGINE ELECTRICAL – Ignition System

IGNITION FAILURE SENSOR

REMOVAL AND INSTALLATION

5.0 Nm

Removal steps
1. Ignition failure sensor connector
2. Ignition failure sensor
 16-1

ENGINE
ELECTRICAL
CONTENTS

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 15

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 16

Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ignition Coil (with Built-in Power Transistor)
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL INFORMATION . . . . . . . . . . . . . . . . 2
Resistive Cord Check . . . . . . . . . . . . . . . . . . . . . 16
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spark Plug Check and Cleaning . . . . . . . . . . . . 17
Ignition Failure Sensor Check . . . . . . . . . . . . . . 17
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . 8
Camshaft Position Sensor Check . . . . . . . . . . . 17
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Crank Angle Sensor Check . . . . . . . . . . . . . . . . 17
Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . 8 Detonation Sensor Check . . . . . . . . . . . . . . . . . . 17
Waveform Check Using an Analyzer . . . . . . . . 18
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . 14 IGNITION COIL AND IGNITION FAILURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CRANK ANGLE SENSOR . . . . . . . . . . . . . . . . 23
Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . 14
CAMSHAFT POSITION SENSOR . . . . . . . . . 23
GENERAL INFORMATION . . . . . . . . . . . . . . . 14
DETONATION SENSOR . . . . . . . . . . . . . . . . . 24
SERVICE SPECIFICATIONS . . . . . . . . . . . . . 15
16-2 ENGINE ELECTRICAL – Charging System

CHARGING SYSTEM
GENERAL
OUTLINE OF CHANGES
The following contents have been established to correspond to the addition of vehicles with 4G9-MPI
engine. Other specifications are the same as for the 4G9-GDI engine.

GENERAL INFORMATION
ALTERNATOR SPECIFICATIONS
Items 4G9-MPI

Type Battery voltage sensing

Rated output V/A 12/85

Voltage regulator Electronic built-in type

ALTERNATOR
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Under Cover Removal D Drive Belt Tension Adjustment
D Under Cover Installation

<4G9– MPI>

23 ± 2 N·m 3

1 4
2

44 ± 10 N·m
44 ± 10 N·m
5

Disassembly steps
1. Drive belt (Power steering, A/C) 4. Alternator connector
2. Drive belt (Alternator) 5. Alternator
3. Alternator brace
 ENGINE ELECTRICAL – Charging System 16-3
DISASSEMBLY AND REASSEMBLY

4
3

5
7 6

12
10
9

8
14

13

11

Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Alternator pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Slinger
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
16-4 ENGINE ELECTRICAL – Charging System

DISASSEMBLY SERVICE POINTS

AA" FRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdriver, etc., in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
The stator coil could be damaged so do not insert the
screwdriver too far.

AB" ALTERNATOR PULLEY REMOVAL

Face the pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care so that the rotor is not damaged.

AC" STATOR/REGULATOR ASSEMBLY REMOVAL

Soldered
1. Use a soldering iron (180 to 250 W) to unsolder the stator.
This work should complete within approximately four
seconds to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly,
remove the soldered sections of the rectifier.
Caution
(1) Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
(2) Use care that no undue force is exerted to the
lead wires of the diodes.
 ENGINE ELECTRICAL – Charging System 16-5
REASSEMBLY SERVICE POINTS
Wire "AA REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.

Rear bracket

Brush

Wire

"BA ROTOR INSTALLATION

Wire
After installing the rotor, remove the wire used to fix the brush.

INSPECTION
ROTOR CHECK
1. Check the continuity between the rotor coil slip rings, and
replace the rotor if the resistance value is not at the
standard value.
Standard value: 3 – 5 Ω

2. Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
16-6 ENGINE ELECTRICAL – Charging System

STATOR CHECK
1. Check the continuity between the coil leads, and if there
is continuity, replace the stator.

2. Check the continuity between the coil and core, and if

there is continuity, replace the stator.

RECTIFIER CHECK
1. Inspect the (+) heat sink by checking the continuity between
the (+) heat sink and stator coil lead wire connection
terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

2. Inspect the (– ) heat sink by checking the continuity between

the (– ) heat sink and stator coil lead wire connection
terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

3. Check the diode trio by connecting an ohmmeter to both

ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the rectifier.
 ENGINE ELECTRICAL – Charging System 16-7
BRUSH CHECK
1. Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Protrusion Limit: 2 mm or less
length

Soldered 2. The brush can be removed if the solder of the brush lead
wire is removed.
3. When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
16-8 ENGINE ELECTRICAL – Starting System

STARTING SYSTEM
GENERAL
OUTLINE OF CHANGES
The following service procedures have been established due to the adoption of the 4G9-MPI engine. The
other service procedures are the same as for the 4G9-GDI engine.
SERVICE SPECIFICATION
Items Standard value Limit

Commutator runout mm 0.05 0.1

Commutator outer diameter mm 29.4 28.8

Commutator undercut mm 0.5 0.2

Brush length mm – 7.0

STARTER
REMOVAL AND INSTALLATION
<4G9-MPI>
Pre-removal and Post-installation Operation
D Battery Removal and Installation
D Under Cover Removal and Installation
D Front Propeller Shaft Removal and Installation

30 ± 3 N·m

5
4

31 ± 3 N·m

3
5.0 ± 1.0 N·m

2 5.0 ± 1.0 N·m

 ENGINE ELECTRICAL – Starting System 16-9
Disassembly steps
1. Starter motor connector AA" "AA D Transmission mount crossmember
2. A/T oil cooler pipe clamp <A/T> D Detonation sensor connector
3. Earth cable connection
4. Intake manifold stay 5. Starter motor assembly
D Front catalytic converter
(Refer to GROUP 17.)

REMOVAL SERVICE POINTS

AA" TRANSMISSION MOUNT CROSSMEMBER
REMOVAL
1. Remove the transmission mount crossmember. (Refer to
GROUP 32.)
2. Lower the jack holding the engine and transmission
assembly to create clearance enough to remove the starter
motor installation bolts.

INSTALLATION SERVICE POINT

"AA TRANSMISSION MOUNT CROSSMEMBER
INSTALLATION
Refer to GROUP 32.
16-10 ENGINE ELECTRICAL – Starting System

DISASSEMBLY AND REASSEMBLY

12
13
15

11
10

14

1 20

4
19
18
17
16 3

7 5
21

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

S-terminal
DISASSEMBLY SERVICE POINTS
Magnetic
switch AA" MAGNETIC SWITCH REMOVAL
M-terminal Disconnect the field coil wire from M-terminal of the magnetic
switch.
Field coil
wire

AB" ARMATURE AND BALL REMOVAL

When removing the armature, do not lose the ball placed
at the end as a bearing.

AC" SNAP RING/STOP RING REMOVAL

Socket 1. Using an appropriate wrench socket, push the stop ring
toward the overrunning clutch.
Stop ring
Pinion gear

Overrunning
clutch

2. Remove the snap ring with snap ring pliers and then remove
Snap ring pliers the stop ring and overrunning clutch.
Snap ring

Pinion gear

Over-
running
clutch

STARTER MOTOR PARTS CLEANING

1. Do not immerse the parts in cleaning solvent. Immersing
the yoke and field coil assembly and/or armature will
damage insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The
overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
16-12 ENGINE ELECTRICAL – Starting System

REASSEMBLY SERVICE POINTS

"AA STOP RING/SNAP RING INSTALLATION
Using an appropriate tool, pull the stop ring over the snap
ring.
Stop ring
Overrunning
Stop ring clutch

Snap ring

INSPECTION
COMMUTATOR
1. Place the armature in a pair of “V” blocks and check the
runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm

2. Measure the commutator outer diameter.

Standard value: 29.4 mm
Limit: 28.8 mm

3. Check the undercut depth between segments.

Undercut Standard value: 0.5 mm
Segment Limit: 0.2 mm
Mica

OVERRUNNING CLUTCH
1. Check that the pinion locks when it is turned anti-clockwise
and moves smoothly when it is turned clockwise.
2. Check the pinion for wear or damage.
Free

Lock
 ENGINE ELECTRICAL – Starting System 16-13
BRUSH
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length.
Minimum limit: 7.0 mm
2. In case the contacting surface has been corrected or the
brush has been replaced, correct the contacting surface
by winding sandpaper around the commutator.

ARMATURE COIL SHORT-CIRCUIT TEST

Growler
1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
Caution
Clean the armature surface thoroughly before
checking.

3. Check the insulation between each commutator segment

and armature coil core.
If there is no continuity, the insulation is in order.

ARMATURE COIL OPEN-CIRCUIT INSPECTION

Check the continuity between segments. If there is continuity,
the coil is in order.
16-14 ENGINE ELECTRICAL – Ignition System

IGNITION SYSTEM
GENERAL
OUTLINE OF CHANGES
The following service procedures have been established to correspond to the addition of vehicles with
4G9-MPI engine. Other service procedures are the same as for the 4G9-GDI engine.

GENERAL INFORMATION
This system is equipped with two ignition coils (A causes the primary currents in the ignition coils to
and B) with built-in power transistors for the No. be alternately interrupted and allowed to flow to
1 and No. 4 cylinders and the No. 2 and No. 3 fire the cylinders in the order 1– 3– 4– 2.
cylinders respectively. The engine-ECU determines which ignition coil
Interruption of the primary current flowing in the should be controlled by means of the signals from
primary side of ignition coil A generates a high the camshaft position sensor which is incorporated
voltage in the secondary side of ignition coil A. in the camshaft and from the crank angle sensor
The high voltage thus generated is applied to the which is incorporated in the crankshaft. It also
spark plugs of No. 1 and No. 4 cylinders to generate detects the crankshaft position in order to provide
sparks. At the time that the sparks are generated ignition at the most appropriate timing in response
at both spark plugs, if one cylinder is at the to the engine operation conditions. It also detects
compression stroke, the other cylinder is at the the crankshaft position in order to provide ignition
exhaust stroke, so that ignition of the compressed at the most appropriate timing in response to the
air/fuel mixture occurs only for the cylinder which engine operation conditions.
is at the compression stroke. When the engine is cold or operated at high altitudes,
In the same way, when the primary current flowing the ignition timing is slightly advanced to provide
in ignition coil B is interrupted, the high voltage optimum performance.
thus generated is applied to the spark plugs of No. When the automatic transmission shifts gears, the
2 and No. 3 cylinders. ignition timing is also retarded in order to reduce
The engine-ECU turns the two power transistors output torque, thereby alleviating shifting shocks.
inside the ignition coils alternately on and off. This

SYSTEM DIAGRAM
To tachometer

Engine-ECU Ignition switch Battery

Intake air temperature sensor
Engine coolant temperature
sensor
Ignition
Camshaft position sensor failure Ignition coil A
sensor
Crank angle sensor
Ignition switch-ST
Detonation sensor
Vehicle speed sensor Ignition coil B
Air flow sensor
Barometric pressure sensor
Inhibitor switch

Spark plug

Cylinder No.3 2 4 1
 ENGINE ELECTRICAL – Ignition System 16-15
IGNITION COIL SPECIFICATIONS
Items Specifications

Type Molded 2-coil

SPARK PLUG SPECIFICATIONS

Items Specifications

NGK BKR5E-11

DENSO K16PR-U11

SERVICE SPECIFICATIONS
IGNITION COIL
Items Standard value

Secondary coil resistance kΩ 8.5 – 11.5

SPARK PLUG
Items Standard value

Spark plug gap mm 1.0 – 1.1

RESISTIVE CORD
Items Limit

Resistance kΩ Max.22

IGNITION FAILURE SENSOR

Items Standard value

Resistance Ω 0.1 or less

SPECIAL TOOL
Tool Number Name Use
MD998773 Detonation sensor Detonation sensor removal and installation
wrench
16-16 ENGINE ELECTRICAL – Ignition System

ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER
TRANSISTOR) CHECK
Check by the following procedure, and replace if there is a
malfunction.
SECONDARY COIL RESISTANCE CHECK
Measure the resistance between the high-voltage terminals
of the ignition coil.
Standard value: 8.5 – 11.5 kΩ
PRIMARY COIL AND POWER TRANSISTOR
CONTINUITY CHECK
1.5 V
+ –
NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative (– ) prove of the circuit tester to
terminal 1.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning and power transistor
from breakage.
Voltage:
g 1.5V Terminal No.
1 2 3
When current is
flowing

When current is
not flowing

RESISTIVE CORD CHECK

Measure the resistance of the all spark plug cables.
1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Max. 22 kΩ
 ENGINE ELECTRICAL – Ignition System 16-17
SPARK PLUG CHECK AND CLEANING
1. Remove the ignition coils and spark plug cables.
Caution
When pulling off the spark plug cable from the plug
always hold the cable cap, not the cable.
2. Remove the spark plugs.
3. Check for burned out electrode or damaged insulator.
Check for even burning.
4. Remove carbon deposits with wire brush or plug cleaner.
Remove sand from plug screw with compressed air.
5. Use a plug gap gauge to check that the plug gap is within
the standard value range.
Plug gap gauge
Standard value: 1.0 – 1.1 mm
If the plug gap is not within the standard value range,
Measurement direction adjust by bending the earth electrode.
6. Clean the engine plug holes.
Caution
Be careful not to allow foreign matter in cylinders.
7. Install the spark plugs.
8. Install the ignition coils and spark plug cables.

IGNITION FAILURE SENSOR CHECK

NOTE
An analog-type circuit tester should be used.
Check that the resistance between terminals 3 and 4 is at
the standard value.
Standard value: 0.1 Ω or less

CAMSHAFT POSITION SENSOR CHECK

Refer to GROUP 13C – Troubleshooting. <4G9-MPI>
CRANK ANGLE SENSOR CHECK
Refer to GROUP 13C – Troubleshooting. <4G9-MPI>
DETONATION SENSOR CHECK
Check the detonation sensor circuit if self-diagnosis code,
No. 31 is shown.
NOTE
For information concerning the self-diagnosis codes, refer to
GROUP 13C – Troubleshooting <4G9-MPI>.
16-18 ENGINE ELECTRICAL – Ignition System

WAVEFORM CHECK USING AN ANALYZER

Ignition Secondary Voltage Waveform Check

MEASUREMENT METHOD
1. Clamp the secondary pickup around the spark plug cable.
NOTE
(1) The peak ignition voltage will be reversed when the
spark cables No. 2 and No. 4, or No. 1 and No. 3
cylinders are clamped.
(2) Because of the two-cylinder simultaneous ignition
system, the waveforms for two cylinders in each group
appear during waveform observation (No. 1 cylinder
– No. 4 cylinder, No. 2 cylinder – No. 3 cylinder).
However, waveform observation is only applicable for
the cylinder with the spark plug cable clamped by
the secondary pickup.
(3) Identifying which cylinder waveform is displayed can
be difficult. For reference, remember that the waveform
of the cylinder attached to the secondary pickup will
be displayed as stable.
2. Clamp the spark plug cable with the trigger pickup.
NOTE
Clamp the trigger pickup to the same spark plug cable
clamped by the secondary pickup.
 ENGINE ELECTRICAL – Ignition System 16-19
STANDARD WAVEFORM
Observation Conditions

Function Secondary

Pattern height High (or Low)

Pattern selector Raster

Engine revolutions Curb idle speed

kV Spark line (point A)

Ignition voltage
(point D)

Wave damping
reduction section
(point B)
Dwell
section
Secondary
ignition
voltage
waveform
Point C

Time

Observation Condition (The only change from above condition is the pattern selector.)

Pattern selector Display

kV

No. 4 cylinder No. 1 cylinder No. 3 cylin-

No. 2 cylinder der ignition
ignition noise noise

Secondary
ignition
voltage Time
waveform 0

2 Neutral section
16-20 ENGINE ELECTRICAL – Ignition System

WAVEFORM OBSERVATION POINTS

Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).

Spark line Plug gap Condition of Compression Concentration of Ignition timing Spark plug
electrode force air mixture cable

Length Long Small Normal Low Rich Advanced Leak

Short Large Large wear High Lean Retarded High

resistance

Height High Large Large wear High Lean Retarded High

resistance

Low Small Normal Low Rich Advanced Leak

Slope Large Plug is fouled – – – –

Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)

Number of vibrations Coil and condenser

Three or more Normal

Except above Abnormal

Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)

Number of vibrations Coil

5– 6 or higher Normal

Except above Abnormal

Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.

Ignition Plug gap Condition of Compression Concentration of Ignition timing Spark plug cable
voltage electrode force air mixture

High Large Large wear High Lean Retarded High resistance

Low Small Normal Low Rich Advanced Leak

 ENGINE ELECTRICAL – Ignition System 16-21
EXAMPLES OF ABNORMAL WAVEFORMS

Abnormal waveform Wave characteristics Cause of problem

Example 1 Spark line is high and short. Spark plug gap is too large.

01P0215

Example 2 Spark line is low and long, and is Spark plug gap is too small.
sloping.
Also, the second half of the spark line
is distorted. This could be a result of
misfiring.

Example 3 Spark line is low and long, and is Spark plug gap is fouled.
sloping. However, there is almost no
spark line distortion.

Example 4 Spark line is high and short. Spark plug cable is nearly falling off.
Difficult to distinguish between this (Causing a dual ignition)
and abnormal waveform example 1.

Example 5 No waves in wave damping section. Layer short in ignition coil

16-22 ENGINE ELECTRICAL – Ignition System

IGNITION COIL AND IGNITION FAILURE SENSOR

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Air Cleaner Assembly and Air Intake Hose Removal
and Installation

<4G9-MPI>

10 ± 2 N ·m

10 ± 2 N ·m
1
2 5
6
1
5.0 ± 1 .0 N · m

3
7

2
4 3 8

25 ± 5 N · m

Disassembly steps
1. Ignition coil connector 5. Oxygen sensor connector
2. Spark plug cable 6. Ignition failure sensor connector
3. Ignition coil 7. Ignition failure sensor
4. Spark plug 8. Ignition failure sensor bracket
 ENGINE ELECTRICAL – Ignition System 16-23
CRANK ANGLE SENSOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Timing Belt Front Lower Cover Removal and Installation
(Refer to GROUP 11.)

<4G9-MPI>

Crank angle sensor

9.8 ± 2 .0 N ·m

CAMSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Air Cleaner Assembly and Air Intake Hose Removal
and Installation

<4G9-MPI>

9.8 ± 2 .0 N ·m

Camshaft
position
sensor
16-24 ENGINE ELECTRICAL – Ignition System

DETONATION SENSOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation

<4G9-MPI>

23 ± 2 N ·m

4 3
31 ± 3 N ·m
5.0 ± 1 . 0 N · m
2
5.0 ± 1 .0 N ·m
1

Disassembly steps
1. Earth cable connection 3. Intake manifold stay
2. A/T oil cooler pipe clamp <A/T> AA" "AA 4. Detonation sensor

REMOVAL SERVICE POINT

AA" DETONATION SENSOR REMOVAL

INSTALLATION SERVICE POINT

"AA DETONATION SENSOR INSTALLATION
MD998773
 ENGINE AND
EMISSION
CONTROL
Click on the applicable bookmark to selected the required model year
 17-1

ENGINE AND
EMISSION
CONTROL
CONTENTS

ENGINE CONTROL SYSTEM . . . . . . . . 3 Vacuum Hose Installation . . . . . . . . . . . . . . . . . . . 7

SERVICE SPECIFICATION . . . . . . . . . . . . . . . 3 CRANKCASE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 3 General Information . . . . . . . . . . . . . . . . . . . . . . . . 8
Accelerator Cable Check and Adjustment ...3 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Location . . . . . . . . . . . . . . . . . . . . . . . 8
ACCELERATOR CABLE AND PEDAL . . . . 4
Positive Crankcase Ventilation System
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PCV Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . 9

EVAPORATIVE EMISSION CONTROL

GENERAL INFORMATION . . . . . . . . . . . . . . . . 5
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Emission Control Device Reference
Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Information . . . . . . . . . . . . . . . . . . . . . . 10
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 6 Component Location . . . . . . . . . . . . . . . . . . . . . 10
Purge Control System Check . . . . . . . . . . . . . . 11
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 6
Purge Port Vacuum Check . . . . . . . . . . . . . . . . . 11
VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . . . 6 Purge Control Solenoid Valve Check . . . . . . 12
Vacuum Hose Piping Diagram . . . . . . . . . . . . . . 6
CONTINUED ON NEXT PAGE
Vacuum Circuit Diagram . . . . . . . . . . . . . . . . . . . . 7
Vacuum Hose Check . . . . . . . . . . . . . . . . . . . . . . . 7
17-2

EXHAUST GAS RECIRCULATION (EGR) Exhaust Gas Recirculation (EGR) ControL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Information . . . . . . . . . . . . . . . . . . . . . . 13 EGR Valve (Stepper Motor) Check . . . . . . . . 14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Location . . . . . . . . . . . . . . . . . . . . . 13 CATALYTIC CONVERTER . . . . . . . . . . . . . . .17
 ENGINE AND EMISSION CONTROL – Engine Control System 17-3

ENGINE CONTROL SYSTEM

SERVICE SPECIFICATION
Items Standard value

Accelerator cable play mm 1–2

ON-VEHICLE SERVICE
ACCELERATOR CABLE CHECK AND
ADJUSTMENT
1. Check the accelerator cable play when the accelerator
pedal is released.
Standard value: 1 – 2 mm
Adjusting
nut 2. If the play is not within the standard value, turn the adjusting
nut to adjust the play to the standard value.
17-4 ENGINE AND EMISSION CONTROL – Engine Control System

ACCELERATOR CABLE AND PEDAL

REMOVAL AND INSTALLATION
Post-installation Operation
D Accelerator Pedal Position Sensor Check and
Adjustment (Refer to GROUP 13A – On-vehicle
Service.)
D Kickdown Cable Adjustment (Refer to GROUP
23 – On-vehicle Service.)

7
10 Nm 8

12 Nm
4
5

9
6

Removal steps
1. Kickdown cable connection 6. Accelerator pedal pad
2. Spring nut 7. Accelerator pedal position sensor
3. Bushing 8. Accelerator pedal bracket
4. Return spring 9. Accelerator pedal stopper
5. Accelerator pedal
 ENGINE AND EMISSION CONTROL – Emission Control System 17-5

EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The emission control system consists of the following subsystems:
D Crankcase emission control system
D Evaporative emission control system
D Exhaust emission control system

Items Name Specification

Crankcase emission Positive crankcase ventilation (PCV) valve Variable flow type
control system (Purpose: HC reduction)

Evaporative emission Canister Equipped

control system Purge control solenoid valve Duty cycle type solenoid valve
(Purpose: HC reduction)

Exhaust emission Air-fuel ratio control device–GDI system Oxygen sensor feedback type
control system (Purpose: CO, HC, NOx reduction)

Exhaust gas recirculation system Equipped

D EGR valve Stepper motor type
(Purpose: NOx reduction)

Catalytic converter Monolith type

(Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE REFERENCE TABLE

Related parts Crankcase Evaporative Air/fuel Catalytic Exhaust gas Reference
emission emission ratio converter recircula- page
control control control tion
system system system system

PCV valve × 17-9

Purge control solenoid valve × 17-12

GDI system component × × GROUP 13A

Catalytic converter × 17-17

EGR valve × 17-14

17-6 ENGINE AND EMISSION CONTROL – Emission Control System

SERVICE SPECIFICATIONS
Items Standard value

Purge control solenoid valve coil resistance (at 20_C) Ω 36 – 44

EGR valve (stepper motor) coil resistance (at 20_C) Ω 10 – 20

SPECIAL TOOL
Tool Number Name Use
MB991658 Test harness set Inspection of EGR valve

VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM

From fuel pump (low-pressure)

To fuel tank

Air cleaner

Air
P

EGR valve
(stepper
PCV motor)
Fuel pressure valve
regulator (high- Canister
pressure)
Injector

Fuel pump (high- Purge control

pressure) solenoid valve

Oxygen sensor

Catalytic converter
 ENGINE AND EMISSION CONTROL – Emission Control System 17-7
VACUUM CIRCUIT DIAGRAM

Intake manifold Throttle body

To
combustion From air
chamber cleaner

Canister
Purge control
solenoid valve
(ON: OPEN)
Vacuum hose colour
B: Black
R: Red

VACUUM HOSE CHECK

1. Using the piping diagram as a guide, check to be sure
that the vacuum hoses are correctly connected.
2. Check the connection condition of the vacuum hoses,
(removed, loose, etc.) and check to be sure that there
are no bends or damage.
VACUUM HOSE INSTALLATION
1. When connecting the vacuum hoses, they should be
securely inserted onto the nipples.
2. Connect the hoses correctly, using the vacuum hose piping
diagram as a guide.
17-8 ENGINE AND EMISSION CONTROL – Emission Control System

CRANKCASE EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The crankcase emission control system prevents The PCV valve lifts the plunger according to the
blow-by gases from escaping inside the crankcase intake manifold vacuum so as to regulate the flow
into the atmosphere. of blow-by gas properly. In other words, the blow-by
Fresh air is sent from the air cleaner into the gas flow is regulated during low load engine
crankcase through the breather hose. The air operation to maintain engine stability, while the flow
becomes mixed with the blow-by gases inside the is increased during high load operation to improve
crankcase. the ventilation performance.
The blow-by gas inside the crankcase is drawn into
the intake manifold through the positive crankcase
ventilation (PCV) valve.

SYSTEM DIAGRAM

Ventilation hose

PCV
valve Breather hose

COMPONENT LOCATION
PCV valve

PCV valve
ENGINE AND EMISSION CONTROL – Emission Control System 17-9
POSITIVE CRANKCASE VENTILATION SYSTEM
CHECK
1. Remove the ventilation hose from the PCV valve.
2. Remove the PCV valve from the rocker cover.
3. Reinstall the PCV valve at the ventilation hose.
4. Start the engine and run at idle.

5. Place a finger at the opening of the PCV valve and check

that vacuum of the intake manifold is felt.
NOTE
PCV valve At this moment, the plunger in the PCV valve moves back
and forth.
6. If vacuum is not felt, clean the PCV valve or replace it.

PCV VALVE CHECK

1. Insert a thin rod into the PCV valve from the side shown
in the illustration (rocker cover installation side), and move
the rod back and forth to check that the plunger moves.
2. If the plunger does not move, there is clogging in the
PCV valve. In this case, clean or replace the PCV valve.
17-10 ENGINE AND EMISSION CONTROL – Emission Control System

EVAPORATIVE EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The evaporative emission control system prevents sent to the combustion chamber.
fuel vapours generated in the fuel tank from escaping When the engine coolant temperature is low or when
into the atmosphere. the intake air quantity is small (when the engine
Fuel vapours from the fuel tank flow through the is at idle, for example), the engine control unit turns
fuel tank pressure control valve and vapour the purge solenoid off to shut off the fuel vapour
pipe/hose to be stored temporarily in the canister. flow to the intake manifold.
When driving the vehicle, fuel vapours stored in This does not only insure the driveability when the
the canister flow through the purge solenoid and engine is cold or running under low load but also
purge port and go into the intake manifold to be stabilize the emission level.

SYSTEM DIAGRAM
Throttle body

Engine-ECU

Canister
Air flow sensor
From fuel tank
Engine coolant
temperature sensor
Purge control Intake air
solenoid valve Control temperature sensor
(ON: Open) relay Barometric pressure
sensor

Battery

COMPONENT LOCATION
Purge control solenoid valve
Purge control
solenoid valve
 ENGINE AND EMISSION CONTROL – Emission Control System 17-11
PURGE CONTROL SYSTEM CHECK
1. Disconnect the vacuum hose (red stripe) from the throttle
body and connect it to a hand vacuum pump.
2. Plug the nipple from which the vacuum hose was removed.
Plug
3. When the engine is cold or hot, apply a vacuum of 53
kPa, and check the condition of the vacuum.
When engine is cold
(Engine coolant temperature: 40_C or less)
Vacuum hose
(red stripe) Engine condition Normal condition
At idle Vacuum is maintained
3,000 r/min
When engine is hot
(Engine coolant temperature: 80_C or higher)
Engine condition Normal condition
At idle Vacuum is maintained
3,000 r/min (fore Vacuum will leak.
approximately 3 minutes
after the engine is started.)

PURGE PORT VACUUM CHECK

1. Disconnect the vacuum hose (red stripe) from the throttle
body purge vacuum nipple and connect a hand vacuum
pump to the nipple.

Vacuum hose
(red stripe)

Vacuum 2. Start the engine.

3. Check that vacuum is produced almost constantly
regardless of engine revolution.
4. When the vacuum is not produced, clean the hose as
it may be clogged.

Engine speed (r/min)

17-12 ENGINE AND EMISSION CONTROL – Emission Control System

PURGE CONTROL SOLENOID VALVE CHECK

A
NOTE
When disconnecting the vacuum hose, always make a mark
B so that it can be reconnected at original position.
1. Disconnect the vacuum hose (black stripe, red stripe) from
the solenoid valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the solenoid
Battery valve (refer to the illustration at left).
4. Check airtightness by applying a vacuum with voltage
applied directly from the battery to the purge control
solenoid valve and without applying voltage.

Jumper wire Nipple B Normal condition

Connected Open Vacuum leaks

Closed Vacuum maintained

Disconnected Open Vacuum maintained

5. Measure the resistance between the terminals of the

solenoid valve.
Standard value: 36 – 44 Ω (at 20_C)
 ENGINE AND EMISSION CONTROL – Emission Control System 17-13
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION
The exhaust gas recirculation (EGR) system lowers port of the cylinder head to the combustion chamber
the nitrogen oxide (NOx) emission level. When the through the intake manifold to decrease the air/fuel
air/fuel mixture combustion temperature is high, a mixture combustion temperature, resulting in
large quantity of nitrogen oxides (NOx) is generated reduction of NOx.
in the combustion chamber. Therefore, this system The EGR flow rate is controlled by the EGR valve
recirculates part of emission gas from the exhaust so as not to decrease the driveability.

OPERATION
The EGR valve is being closed and dose not D The engine coolant temperature is low.
recirculate exhaust gases under one of the following D The engine is at idle.
conditions. Otherwise, the EGR valve is opened D The throttle valve is widely opened.
and recirculate exhaust gases.

SYSTEM DIAGRAM
Throttle body

Engine-ECU

Air flow sensor

Engine coolant tem-
perature sensor
Control
relay Crank angle sensor
EGR valve
(Stepper
motor) Throttle position sensor
Battery

COMPONENT LOCATION
EGR valve
Throttle
body

EGR valve
17-14 ENGINE AND EMISSION CONTROL – Emission Control System

EXHAUST GAS RECIRCULATION (EGR)

CONTROL SYSTEM CHECK
Refer to GROUP 13A – Troubleshooting.

EGR VALVE (STEPPER MOTOR) CHECK

Throttle Checking the Operation Sound
body
1. Check that the operation sound of the stepper motor can
be heard from the EGR valve when the ignition switch
is turned to ON (without starting the engine).
2. If the operation sound cannot be heard, check the stepper
motor drive circuit.
NOTE
If the circuit is normal, the cause is probably a malfunction
EGR valve of the stepper motor or of the engine-ECU.
Checking the Coil Resistance
1. Disconnect the EGR valve connector.
2. Measure the resistance between the EGR valve-side
connector terminal No.2 and terminal No.1 or terminal
No.3.
Standard value: 10 – 20 Ω (at 20_C)
3. Measure the resistance between the EGR valve-side
connector terminal No.5 and terminal No.4 or terminal
No.6.
Standard value: 10 – 20 Ω (at 20_C)
 ENGINE AND EMISSION CONTROL – Emission Control System 17-15
Operation Check
1. Remove the EGR valve.
2. Connect the special tool (test harness set) to the EGR
valve-side connector.
3. Connect terminal No.2 and terminal No.5 to the positive
(+) terminal of power supply of approximately 6 V.
4. Connect each clip to the negative (–) terminal of power
supply in the order given below to test if any vibration
EGR valve occurs (as though the stepper motor is shaking slightly)
due to the operation of the stepper motor.

(1) Connect terminal No.1 and terminal No.4 to the

negative (–) terminal of the power supply.
(2) Connect terminal No.3 and terminal No.4 to the
negative (–) terminal of the power supply.
(3) Connect terminal No.3 and terminal No.6 to the
negative (–) terminal of the power supply.
(4) Connect terminal No.1 and terminal No.6 to the
negative (–) terminal of the power supply.
Battery
(5) Connect terminal No.1 and terminal No.4 to the
MB991658 negative (–) terminal of the power supply.
(6) Repeat the test in the order from (5) to (1).
5. If the results of testing show that the vibration could be
felt, the stepper motor is normal.

Cleaning the EGR Valve

Remove the EGR valve, and then check if the EGR valve
is stuck and carbon is accumulated in it. If so, use a wire
brush to clean the EGR valve.
Caution
Do not use a cleaning solvent. Solvent will penetrate to
the motor and malfunction of EGR valve will result.
17-16 ENGINE AND EMISSION CONTROL – Emission Control System

EGR VALVE
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying (Refer to
GROUP 14 – On-vehicle Service.)
D Engine Cover Removal and Installation

24 Nm

7
19 Nm 4
7

10 – 12 Nm
5

10 2 24 Nm

19 Nm
8

Removal steps
AA" 1. Fuel pump protector 6. EGR valve and support assembly
2. EGR valve harness connector 7. EGR pipe gasket
connection 8. EGR valve
3. Water hose 9. EGR valve gasket
4. Water pipe 10. Water hose
5. Water hose

REMOVAL SERVICE POINT

AA" FUEL PUMP PROTECTOR REMOVAL
Lift up the transmission with a jack to create clearance between
the engine and front deck, and then remove the fuel pump
protector.
 ENGINE AND EMISSION CONTROL – Emission Control System 17-17
CATALYTIC CONVERTER
GENERAL INFORMATION
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
sensor signal, oxidizes carbon monoxides (CO) and provides the highest purification against the three
hydrocarbons (HC) and reduces nitrogen oxides constituents, namely, CO, HC and NOx.
(NOx).

REMOVAL AND INSTALLATION

49 Nm

34 Nm
3

49 Nm

1 49 Nm

Removal steps
1. Oxygen sensor harness connector 2. Front exhaust pipe
connection 3. Catalytic converter
NOTES
 17-1

ENGINE AND
EMISSION
CONTROL
CONTENTS

EMISSION CONTROL SYSTEM Vacuum Hose Piping Diagram . . . . . . . . . . . . . . 2

Vacuum Circuit Diagram . . . . . . . . . . . . . . . . . . . . 3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . 2 EVAPORATIVE EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 2 Purge Control System Check . . . . . . . . . . . . . . . 3
Purge Port Vacuum Check . . . . . . . . . . . . . . . . . . 4
VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . . . 2
Purge Control Solenoid Valve Check . . . . . . . . 4
17-2 ENGINE AND EMISSION CONTROL – Emission Control System

EMISSION CONTROL SYSTEM

GENERAL
OUTLINE OF CHANGE
The flow rate of the purge control solenoid valve has been increased and the vacuum line routing has
been changed. Due to these changes, the following service procedures have been established. Other
items are the same as before.

SERVICE SPECIFICATION
Items Standard value

EGR control solenoid valve coil resistance (at 20 C) Ω 30 – 34

VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
From fuel pump
(low pressure)
To fuel tank
Throttle control servo
Air cleaner

Air
M

EGR valve
(Stepper
motor)
Positive
Fuel pump crankcase
ventilation Canister
(high
pressure) (PCV) valve

Purge control
solenoid valve
(ON: Open)
Oxygen sensor (front)
Oxygen sensor (rear)

Catalytic converter
 ENGINE AND EMISSION CONTROL – Emission Control System 17-3
VACUUM CIRCUIT DIAGRAM

Intake manifold Throttle body

To
combustion
chamber From air
cleaner

EGR control Canister

solenoid
valve (ON:
Vacuum hose colour OPEN)
B: Black
R: Red

Plug
EVAPORATIVE EMISSION CONTROL
SYSTEM
PURGE CONTROL SYSTEM CHECK
1. Disconnect the vacuum hose (black) from the intake
manifold and connect it to a hand vacuum pump.
2. Plug the nipple from which the vacuum hose was removed.
Vacuum 3. When the engine is cold or hot, apply a vacuum of 53
hose kPa, and check the condition of the vacuum.
(black)
When engine is cold
(Engine coolant temperature: 40C or less)
Engine condition Normal condition
At idle Vacuum is maintained
3,000 r/min
When engine is hot
(Engine coolant temperature: 80C or higher)
Engine condition Normal condition
 At idle Vacuum is maintained
 Within 4 minutes
after the engine
has been started
 3,000 r/min Vacuum will leak.
 Within 3 minutes
after the engine
has been started
17-4 ENGINE AND EMISSION CONTROL – Emission Control System

Purge port PURGE PORT VACUUM CHECK

vacuum
nipple 1. Disconnect the vacuum hose (black) from the intake
manifold purge vacuum nipple and connect a hand vacuum
pump to the nipple.

Vacuum 2. Start the engine and check that the vacuum remains fairly
constant after racing the engine.
NOTE
If vacuum changes, it is possible that the intake manifold
purge port may be clogged and require cleaning.

Engine r/min

PURGE CONTROL SOLENOID VALVE CHECK

NOTE
A
When disconnecting the vacuum hose, always make a mark
B so that it can be reconnected at original position.
B 1. Disconnect the vacuum hose (black stripe, red stripe) from
the solenoid valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the solenoid
Battery
valve (refer to the illustration at left).
4. Check airtightness by applying a vacuum with voltage
applied directly from the battery to the purge control
solenoid valve and without applying voltage.
Battery voltage Normal condition
Applied Vacuum leaks
Not applied Vacuum maintained

5. Measure the resistance between the terminals of the

solenoid valve.
Standard value: 30 – 34 Ω (at 20C)
 17-1

ENGINE AND
EMISSION
CONTROL
CONTENTS

ENGINE CONTROL SYSTEM . . . . . . . . . . . . 2 CRANKCASE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . 2 Component Location . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE SPECIFICATION . . . . . . . . . . . . . . . . 2 EVAPORATIVE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 8
Accelerator Cable Check and Adjustment System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
<4G9-MPI> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Component Location . . . . . . . . . . . . . . . . . . . . . . . . 8
ACCELERATOR CABLE AND PEDAL . . . . . . 3 Purge Control System Check . . . . . . . . . . . . . . . . 9
EMISSION CONTROL SYSTEM Purge Port Vacuum Check . . . . . . . . . . . . . . . . . . . 9
<MPI> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Purge Control Solenoid Valve Check . . . . . . . . 10

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 EXHAUST GAS RECIRCULATION (EGR)

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL INFORMATION . . . . . . . . . . . . . . . . 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 5
Component Location . . . . . . . . . . . . . . . . . . . . . . . 11
VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exhaust Gas Recirculation (EGR) Control
Vacuum Hose Piping Diagram . . . . . . . . . . . . . . . . 5 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Vacuum Circuit Diagram . . . . . . . . . . . . . . . . . . . . . 6 EGR Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 12

Vacuum Hose Check . . . . . . . . . . . . . . . . . . . . . . . . 6 EGR Port Vacuum Check . . . . . . . . . . . . . . . . . . 13

Vacuum Hose Installation . . . . . . . . . . . . . . . . . . . . 6 EGR Control Solenoid Valve Check . . . . . . . . . 13

CATALYTIC CONVERTER . . . . . . . . . . . . . . . 14
17-2 ENGINE AND EMISSION CONTROL – Engine Control System

ENGINE CONTROL SYSTEM

GENERAL
OUTLINE OF CHANGES
The following service procedures have been established due to the addition of vehicles with 4G9-MPI
engine. The other contents are the same as the 4G9-GDI engine.
SERVICE SPECIFICATION
Items Standard value

Accelerator cable play mm 1– 2

Adjusting nut ON-VEHICLE SERVICE

ACCELERATOR CABLE CHECK AND
ADJUSTMENT <4G9-MPI>
1. Check the accelerator cable play when the accelerator
pedal is released.
Standard value: 1 – 2 mm
2. If the play is not within the standard value, turn the adjusting
nut to adjust the play to the standard value.
 ENGINE AND EMISSION CONTROL – Engine Control System 17-3
ACCELERATOR CABLE AND PEDAL
REMOVAL AND INSTALLATION
<4G9-MPI>
Post-installation Operation
Accelerator Cable Adjustment (Refer to P.17-2.)

<L.H. drive vehicles>

5.0 ± 1.0 N·m

<R.H. drive vehicles>

5.0 ± 1.0 N·m 4 5
2
1 4

5 12 ± 2 N·m

2 6 6
3 3

8
6 12 ± 2 N·m
6
4
5.0 ± 1.0 N·m
7

8
Removal steps
1. Accelerator cable 5. Accelerator pedal bracket
2. Push-on spring nut 6. Bushing
3. Accelerator arm assembly 7. Pedal pad
4. Spring "AA 8. Accelerator pedal stopper

INSTALLATION SERVICE POINT

AA" ACCELERATOR PEDAL STOPPER INSTALLATION
Heat up the claw of the accelerator pedal pad with a drier
and etc. before installation.
NOTE
Apply some soapsuds to the claw to facilitate installation if
there is any difficulty.
17-4 ENGINE AND EMISSION CONTROL – Emission Control System <MPI>

EMISSION CONTROL SYSTEM <MPI>

GENERAL
OUTLINE OF CHANGES
The following contents have been established to correspond to the addition of vehicles with 4G9-MPI
engine. The other contents are the same as before.

GENERAL INFORMATION
The emission control system consists of the following subsystems:
D Crankcase emission control system
D Evaporative emission control system
D Exhaust emission control system

Items Name Specification

Crankcase emission Positive crankcase ventilation (PCV) valve Variable flow type
control system (Purpose: HC reduction)

Evaporative emission Canister Equipped

control system Purge control solenoid valve Duty cycle type solenoid valve
(Purpose: HC reduction)

Exhaust emission Air-fuel ratio control device – MPI system Oxygen sensor feedback type
control system (Purpose: CO, HC, NOx reduction)

Exhaust gas recirculation system Equipped

D EGR valve Single type
D EGR control solenoid valve Duty cycle type solenoid valve
(Purpose: NOx reduction)

Catalytic converter Monolith type

(Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE REFERENCE TABLE

Related parts Crankcase Evaporative Air/fuel Catalytic Exhaust Reference
emission emission ratio converter gas page
control control control recircula-
system system system tion system

PCV valve × 17-9*

Purge control solenoid valve × 17-9

MPI system component × × GROUP 13B

Catalytic converter × 17-14

EGR valve × 17-12

EGR control solenoid valve × 17-13

NOTE
*: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> 17-5
SERVICE SPECIFICATIONS
Items Standard value

Purge control solenoid valve coil resistance (at 20_C) Ω 36 – 44

EGR control solenoid valve coil resistance (at 20_C) Ω 36 – 44

VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM

Air

M E A
Air cleaner

PCV valve
EGR valve
OFF Canister
OFF ON
Oxygen sensor
<front> ON
EGR control
Purge control
solenoid valve
solenoid valve
Oxygen sensor
<rear>
17-6 ENGINE AND EMISSION CONTROL – Emission Control System <MPI>

VACUUM CIRCUIT DIAGRAM

Intake manifold Throttle body

To From air
combustion
chamber cleaner

M P A

G
Fuel
Y
pressure G
regulator R

G Canister

B
EGR valve

Purge control
EGR control solenoid
solenoid valve valve
(ON: OPEN) (ON: OPEN)

Vacuum hose colour

B: Black
G: Green
L: Light blue
R: Red
Y: Yellow

VACUUM HOSE CHECK

1. Using the piping diagram as a guide, check to be sure
that the vacuum hoses are correctly connected.
2. Check the connection condition of the vacuum hoses,
(removed, loose, etc.) and check to be sure that there
are no bends or damage.
VACUUM HOSE INSTALLATION
1. When connecting the vacuum hoses, they should be
securely inserted onto the nipples.
2. Connect the hoses correctly, using the vacuum hose piping
diagram as a guide.
 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> 17-7
CRANKCASE EMISSION CONTROL SYSTEM
SYSTEM DIAGRAM

Ventilation hose

Breather hose
PCV valve

COMPONENT LOCATION
PCV valve
17-8 ENGINE AND EMISSION CONTROL – Emission Control System <MPI>

EVAPORATIVE EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The evaporative emission control system prevents sent to the combustion chamber.
fuel vapours generated in the fuel tank from escaping When the engine coolant temperature is low or when
into the atmosphere. the intake air quantity is small (when the engine
Fuel vapours from the fuel tank flow through the is at idle, for example), the engine control unit turns
fuel tank pressure control valve and vapour the purge solenoid off to shut off the fuel vapour
pipe/hose to be stored temporarily in the canister. flow to the intake manifold.
When driving the vehicle, fuel vapours stored in This does not only insure the driveability when the
the canister flow through the purge solenoid and engine is cold or running under low load but also
purge port and go into the intake manifold to be stabilize the emission level.

SYSTEM DIAGRAM

Engine-ECU
Throttle body

From fuel tank Air flow sensor

OFF
Engine coolant
Canister temperature sensor
ON
Purge control Intake air
solenoid valve temperature sensor
Control
relay Barometric pressure
sensor

COMPONENT LOCATION
Purge control solenoid valve
 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> 17-9
PURGE CONTROL SYSTEM CHECK
Plug 1. Disconnect the vacuum hose (red stripe) from the throttle
body and connect it to a hand vacuum pump.
2. Plug the nipple from which the vacuum hose was removed.
3. When the engine is cold or hot, apply a vacuum of 53
kPa, and check the condition of the vacuum.
When engine is cold
(Engine coolant temperature: 40_C or less)
Engine condition Normal condition
At idle Vacuum is maintained
3,000 r/min
When engine is hot
(Engine coolant temperature: 80_C or higher)
Engine condition Normal condition
At idle Vacuum is maintained
3,000 r/min (fore Vacuum will leak.
approximately 3 minutes
after the engine is started.)

Purge port
PURGE PORT VACUUM CHECK
vacuum nipple 1. Disconnect the vacuum hose (red stripe) from the throttle
body purge vacuum nipple and connect a hand vacuum
pump to the nipple.

Vacuum 2. Start the engine and check that the vacuum remains fairly
constant after racing the engine.
NOTE
If vacuum changes, it is possible that the throttle body
purge port may be clogged and require cleaning.

Engine speed (r/min)

17-10 ENGINE AND EMISSION CONTROL – Emission Control System <MPI>

PURGE CONTROL SOLENOID VALVE CHECK

A
NOTE
When disconnecting the vacuum hose, always make a mark
B so that it can be reconnected at original position.
1. Disconnect the vacuum hose (black, red stripe) from the
solenoid valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the solenoid
Battery valve (refer to the illustration at left).
4. Check airtightness by applying a vacuum with voltage
applied directly from the battery to the purge control
solenoid valve and without applying voltage.
Battery voltage Normal condition
Applied Vacuum leaks
Not applied Vacuum maintained
5. Measure the resistance between the terminals of the
solenoid valve.
Standard value: 36 – 44 Ω (at 20_C)
 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> 17-11
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION
The exhaust gas recirculation (EGR) system lowers port of the cylinder head to the combustion chamber
the nitrogen oxide (NOx) emission level. When the through the intake manifold to decrease the air/fuel
air/fuel mixture combustion temperature is high, a mixture combustion temperature, resulting in
large quantity of nitrogen oxides (NOx) is generated reduction of NOx.
in the combustion chamber. Therefore, this system The EGR flow rate is controlled by the EGR valve
recirculates part of emission gas from the exhaust so as not to decrease the driveability.

OPERATION
The EGR valve is being closed and does not D The engine coolant temperature is low.
recirculate exhaust gases under one of the following D The engine is at idle.
conditions. Otherwise, the EGR valve is opened D The throttle valve is widely opened.
and recirculates exhaust gases.

SYSTEM DIAGRAM

EGR valve
Engine-ECU
OFF ON
EGR Air flow sensor
control
solenoid Engine coolant
valve temperature sensor

Control Crank angle sensor

relay

Battery

COMPONENT LOCATION
EGR control solenoid valve EGR valve
17-12 ENGINE AND EMISSION CONTROL – Emission Control System <MPI>

Three-way EXHAUST GAS RECIRCULATION (EGR)

terminal CONTROL SYSTEM CHECK
1. Disconnect the vacuum hose (green stripe) from the EGR
valve, and then connect a hand vacuum pump via the
three-way terminal.
2. When the engine is hot or cold, check the condition of
vacuum by racing the engine.
Vacuum hose
(Green stripe) EGR valve When engine is cold
(Engine coolant temperature: 20_C or less)
Throttle valve Normal vacuum condition
Open quickly No vacuum will generate
(the same as barometric pressure.)

When engine is hot

(Engine coolant temperature: 80_C or higher)
Throttle valve Normal vacuum condition
Open quickly It will momentarily rise over 13 kPa

3. Disconnect the three-way terminal.

Plug Vacuum hose 4. Connect the hand vacuum pump to the EGR valve.
(Green stripe) 5. Check whether the engine stalls or the idling is unstable
when a vacuum of 30 kPa or higher is applied during
idling.

EGR valve

EGR VALVE CHECK

1. Remove the EGR valve and inspect for sticking, carbon
deposits, etc. If found, clean with a suitable solvent so
that the valve seats correctly.
2. Connect a hand vacuum pump to the EGR valve.
3. Apply 67 kPa of vacuum, and check that the vacuum
is maintained.
4. Apply a vacuum and check the passage of air by blowing
through one side of the EGR passage.
Vacuum Passage of air
5.0 kPa or less Air is not blown out
27 kPa or more Air is blown out
5. Replace the gasket, and tighten to the specified torque.
Tightening torque: 22 ± 5 N·m
 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> 17-13
EGR PORT VACUUM CHECK
1. Disconnect the vacuum hose (Green) from the throttle
body EGR vacuum nipple and connect a hand vacuum
pump to the nipple.

Vacuum 2. Start the engine and check that, after raising the engine
speed by racing the engine, purge vacuum raises according
to engine speed.
NOTE
If there is a problem with the change in vacuum, the throttle
body EGR port may be clogged and require cleaning.

Engine speed (r/min)

EGR CONTROL SOLENOID VALVE CHECK

NOTE
When disconnecting the vacuum hose, always make a mark
so that it can be reconnected at original position.
1. Disconnect the vacuum hose (yellow stripe, green stripe)
from the solenoid valve.
2. Disconnect the harness connector.

3. Connect a hand vacuum pump to the nipple (A) of the

A solenoid valve (refer to the illustration at left).
4. Check airtightness by applying a vacuum with voltage
applied directly from the battery to the EGR control solenoid
valve and without applying voltage.
Battery voltage Normal condition
B
Not applied Vacuum maintained
Battery Applied Vacuum leaks

5. Measure the resistance between the terminals of the

solenoid valve.
Standard value: 36 – 44 Ω (at 20_C)
17-14 ENGINE AND EMISSION CONTROL – Emission Control System <MPI>

CATALYTIC CONVERTER
REMOVAL AND INSTALLATION

50 ± 10 N·m

50 ± 10 N·m 50 ± 10 N·m

50 ± 10 N·m
5
1
4

50 ± 10 N·m
3
13 ± 2 N·m

50 ± 10 N·m

Front catalytic converter removal Catalytic converter removal steps

steps 1. Front pipe
1. Front pipe 4. Oxygen sensor (rear)
2. Oxygen sensor (front) 5. Catalytic converter
3. Front catalytic converter
 CLUTCH
Click on the applicable bookmark to selected the required model year
 21-1

CLUTCH
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5

Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 7
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Inspection and Adjustment . . . . . . . . 2
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
21-2 CLUTCH – General Information/Service Specifications/Lubricants/On-vehicle Service

GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
Items Standard value
Clutch pedal height mm 212 – 215 <L.H. drive vehicles>
202 – 205 <R.H. drive vehicles>
Clutch pedal clevis pin play mm 1–3
Clutch pedal free play mm 6 – 13
Distance between the clutch pedal and the toeboard 110 or more
when the clutch is disengaged mm

LUBRICANTS
Items Specified lubricants Quantity
Clutch fluid Brake fluid DOT3 or DOT4 As required
Push rod assembly Rubber grease
Release cylinder push rod MITSUBISHI genuine grease
Part No. 0101011

Clutch pedal height Clutch pedal clevis ON-VEHICLE SERVICE

pin play
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height and the clutch pedal clevis
pin play.
Standard value (A):
A B
212 – 215 <L.H. drive vehicles>
202 – 205 <R.H. drive vehicles>
Standard value (B): 1 – 3 mm
 CLUTCH – On-vehicle Service 21-3
3. If the clutch pedal height and the clutch pedal clevis pin
Setting nut play are outside the standard value, turn the setting nut
to adjust them to the standard value.
Caution
Do not push in the master cylinder push rod at this
time, otherwise the clutch will not operate properly.

Clutch pedal
12 Nm

Clutch pedal free Distance between the 4. After completing the adjustments, confirm that the clutch
play clutch pedal and the pedal free play (measured at the face of the pedal pad)
toeboard when the
clutch is disengaged and the distance between the clutch pedal (the face of
the pedal pad) and the toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6 – 13 mm
Standard value (D): 110 mm or more
C D
5. If the clutch pedal free play and the distance between
the clutch pedal and the toeboard when the clutch is
disengaged do not agree with the standard values, it is
probably the result of either air in the hydraulic system
or a faulty master cylinder, release cylinder or clutch. Bleed
the air, or disassemble and inspect the master cylinder,
release cylinder or clutch.
6. Turn back the carpet, etc.

BLEEDING
Clutch release cylinder Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified fluid and other fluid.
21-4 CLUTCH – Clutch Pedal

CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Clutch Pedal Adjustment (Refer to P.21-2.)

L.H. drive vehicles R.H. drive vehicles

12 Nm 2 2
12 Nm
4
4
1 1
12 Nm 12 Nm
3 6 3
7
7

Removal steps
1. Snap pin 5. Stopper <R.H. drive vehicles>
2. Clevis pin 6. Pedal pad
3. Clutch master cylinder mounting nut 7. Clutch pedal assembly
4. Master cylinder member mounting bolt
 CLUTCH – Clutch Control 21-5
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Clutch Fluid Draining D Clutch Fluid Supplying
D Clutch Line Bleeding (Refer to P.21-3.)
D Clutch Pedal Adjustment (Refer to P.21-2.)

<L.H. drive vehicles>

13 Nm 6 1
Release fork
Release cylinder
push rod 13 8
7
5 Nm
5

Specified grease:
3
MITSUBISHI genuine
grease Part No. 0101011 4
11 2
19 Nm
5
15 Nm 12 Nm
10
12

11, 13

9
13 5 Nm 20 – 25 Nm
12 Nm

Clutch master cylinder assembly 7. Reservoir tank

removal steps 8. Breather hose
1. Clevis pin Clutch release cylinder assembly
2. Clutch pipe connection removal steps
3. Breather hose connection 9. Clutch pipe connection
4. Clutch master cylinder assembly 10. Clutch release cylinder assembly
5. Sealer
Clutch line removal steps
Reservoir tank removal steps
11. Clutch pipe
3. Breather hose connection 12. Bracket
5. Bolt 13. Clutch hose
6. Reservoir bracket
21-6 CLUTCH – Clutch Control

<R.H. drive vehicles>

2
Release 4
cylinder Release fork
push rod

Specified grease: 3
MITSUBISHI genuine
grease Part No. 0101011 7 12 Nm

15 Nm 19 Nm
6
8

9 12 Nm
5 Nm 20 – 25 Nm

Clutch master cylinder assembly Clutch release cylinder assembly

removal steps removal steps
1. Clevis pin 5. Clutch pipe connection
2. Clutch pipe connection 6. Clutch release cylinder assembly
3. Clutch master cylinder assembly Clutch line removal steps
4. Sealer
7. Clutch pipe
8. Bracket
9. Clutch hose
 CLUTCH – Clutch Control 21-7
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
Caution
Do not disassemble piston assembly.
6

12 Nm
8
5 9
9
9
3

4
7 1
2
10 7

11

4 2
1
2

Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease

Disassembly steps
1. Piston stopper ring 8. Reservoir tank <R.H. drive vehicles>
2. Piston assembly 9. Seal
"AA 3. Push rod assembly 10. Master cylinder body <L.H. drive
4. Boot vehicles>
5. Nipple <L.H. drive vehicles> 11. Master cylinder body <R.H. drive
6. Reservoir cap <R.H. drive vehicles> vehicles>
7. Spring pin

INSTALLATION SERVICE POINT

"AA PUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown dimension
to make the adjustment of clutch pedal easier.

<L.H. drive vehicles> 103 mm

<R.H. drive vehicles> 126 mm
NOTES
 MANUAL
TRANSMISSION
Click on the applicable bookmark to selected the required model year
 22-1

MANUAL
TRANSMISSION
CONTENTS

LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Transfer Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . 3

SEALANTS AND ADHESIVES . . . . . . . . . . . . . . 2 TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . 4

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2 TRANSMISSION AND TRANSFER

Transmission Oil Check . . . . . . . . . . . . . . . . . . . . . . . 2
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission Oil Change . . . . . . . . . . . . . . . . . . . . . . 2 4WD INDICATOR CONTROL UNIT . . . . . . . . . . 9
Transfer Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
22-2 MANUAL TRANSMISSION – Lubricant/Sealants and Adhesives/On-vehicle Service

LUBRICANT
Items Specified lubricants Quantity ȏ

Transmission oil Hypoid gear oil SAE 75W – 90 or 75W – 85W 2.4
conforming to API GL-4
Transfer oil 2.2

SEALANTS AND ADHESIVES

Items Specified sealant Remarks

Contact surface between transmission and 3M ATD Part No.8660 or equivalent Semi-drying sealant
transmission control lever, thread (except
outer surface) of stopper bracket assembly
installation bolts and transfer control lever
gasket

Thread of stopper bracket assembly 3M Stud Locking No.4170 or equivalent Anaerobic sealant
installation bolts and thread of transfer
control lever assembly installation bolts

ON-VEHICLE SERVICE
Oil filler TRANSMISSION OIL CHECK
plug hole
Transmission oil 1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the oil filler
plug hole.
3. Check that the transmission oil is not noticeably dirty, and
that it has a suitable viscosity.
4. Tighten the oil filler plug to the specified torque.
Tightening torque: 29 – 34 Nm

TRANSMISSION OIL CHANGE

1. Remove the oil drain plug to drain oil.
2. Tighten the oil drain plug to the specified torque.
Tightening torque: 39 Nm
Oil filler
plug 3. Remove the oil filler plug and fill with specified oil till the
level comes to the lower portion of oil filler plug hole.
Specified oil:
Oil drain plug Hypoid gear oil SAE 75W – 90 or 75W – 85W
conforming to API GL-4
Quantity: 2.4 ȏ
4. Tighten the oil filler plug to the specified torque.
Tightening torque: 29 – 34 Nm
 MANUAL TRANSMISSION – On-vehicle Service 22-3
TRANSFER OIL CHECK
1. Remove the oil filler plug.
Oil filler
plug hole
2. Oil level should be at the lower portion of the oil filler
plug hole.
3. Check that the transfer oil is not noticeably dirty, and it
has a suitable viscosity.
Oil level 4. Install the oil filler plug, and then tighten it to the specified
torque.
Tightening torque: 29 – 34 Nm

TRANSFER OIL CHANGE

1. Remove the oil drain plug to drain oil.
2. Install the oil drain plug, and then tighten it to the specified
Oil filler plug Oil drain plug torque.
Tightening torque: 29 – 34 Nm
3. Remove the oil filler plug, and then fill with specified oil
till the level comes to the lower portion of oil filler plug
hole.
Specified oil:
Hypoid gear oil SAE 75W – 90 or 75W – 85W
conforming to API GL-4
Quantity: 2.2 ȏ
4. Install the oil filler plug, and then tighten it to the specified
torque.
Specified torque: 29 – 34 Nm
22-4 MANUAL TRANSMISSION – Transmission Control

TRANSMISSION CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Move the transmission control lever and transfer control Check that the transmission control lever and the
lever to the following positions. transfer control lever are moved to each position
D Transmission control lever: Neutral smoothly and correctly.
D Transfer control lever: 4H

4 19 Nm 10
1

7 14

19 Nm
19 Nm

2 8

9
3
6
13
12
5
11

19 Nm

Transmission control lever Transfer control lever assembly

assembly removal steps removal steps
D Front floor console and rear floor D Rear floor console (Refer to GROUP
console (Refer to GROUP 52A.) 52A.)
1. Harness connection 8. Retainer
2. Retainer 9. Transfer lever inner boots
3. Shift lever cover "BA 10. Transfer control lever assembly
AA" 4. Transmission control lever 11. Gasket
assembly "AA 12. Stopper plate
5. Control lever bushing 13. Gasket
"CA 6. Stopper bracket assembly 14. Transfer control lever
7. Transmission control lever
 MANUAL TRANSMISSION – Transmission Control 22-5
SEALANT APPLICATION POINTS

A
B

A: Sealant:
3M ATD Part No.8660 or equivalent
B: Sealant:
Sealant: 3M Stud Locking No.4170 or
3M ATD Part No.8660 or equivalent equivalent

Sealant:
3M Stud Locking
No.4170 or equivalent

Both sides of gasket

Sealant:
3M ATD Part No.8660
or equivalent
22-6 MANUAL TRANSMISSION – Transmission Control

Transmission REMOVAL SERVICE POINT

mount cross-
A TRANSMISSION CONTROL LEVER ASSEMBLY
member instal-
lation bolt REMOVAL
1. Support the transfer with a transmission jack, and then
remove the transmission mount crossmember installation
bolt.
2. Lower the transmission until the transmission control lever
assembly installation bolts can be removed.
3. Remove the bolts, and then remove the transmission
control lever assembly.

INSTALLATION SERVICE POINTS

A
STOPPER PLATE INSTALLATION
Install the stopper plate as shown in the illustration.
Front of
vehicle

B
TRANSFER CONTROL LEVER ASSEMBLY

INSTALLATION
1. Eliminate adhesive adhered to the transfer control lever
assembly installation bolts.
2. Use a tap (M8 1.25) to eliminate adhesive adhered
to the threaded holes of the control housing, and then
clean the holes with a compressed air.
3. Apply the specified adhesive to the transfer control lever
assembly installation bolts, and then install the transfer
control lever assembly.
Specified adhesive:
3M Stud Locking No.4170 or equivalent
MANUAL TRANSMISSION – Transmission Control 22-7
C
STOPPER BRACKET ASSEMBLY INSTALLATION
A
1. Eliminate sealant and adhesive adhered to the stopper
bracket assembly installation bolts.
2. Use a tap (M8 1.25) to eliminate adhesive adhered
to the threaded holes of the stopper bracket assembly
installation nuts, and then clean the holes with a
compressed air.
B 3. Apply the specified sealant to the stopper bracket assembly
installation bolts (A shown in the illustration) and the
specified adhesive to the threaded part of the stopper
bracket assembly installation bolts (B shown in the
illustration), and then install the stopper bracket assembly.
Specified sealant (A):
3M ATD Part No.8660 or equivalent
Specified adhesive (B):
3M Stud Locking No.4170 or equivalent
22-8 MANUAL TRANSMISSION – Transmission and Transfer Assembly

TRANSMISSION AND TRANSFER ASSEMBLY

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Transmission Oil and Transfer Oil Draining and Front Exhaust Pipe and Catalytic Converter Removal
Refilling (Refer to P.22-2, 3.) and Installation (Refer to GROUP 17 – Emission
Transmission Control Lever Assembly and Transfer Control.)
Control Lever Assembly Removal and Installation Shift Lever Operation Check <only after installation>
(Refer to P.22-4.) Instruments Operation Check <only after installation>
Front Propeller Shaft and Rear Propeller Shaft
Removal and Installation (Refer to GROUP 25.)

5 30 Nm

48 Nm
2
48 Nm 5

1
19 Nm

7
48 Nm

48 Nm
6
3

48 Nm

Removal steps
1. Clutch release cylinder installation 5. Transmission assembly upper cou-
bolts pling bolts
2. Starter motor installation bolts 6. Transmission assembly lower cou-
3. Oil pan connection bolts pling bolts
Adapter (Refer to GROUP 32 – 7. Transmission and transfer assembly
Transmission mount.)
4. Transmission harness connector
connection
 MANUAL TRANSMISSION – 4WD Indicator Control Unit 22-9
4WD INDICATOR CONTROL UNIT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Seat Assembly (Driver’s side) and Rear Seat Cushion Front Floor Console and Rear Floor Console Removal
Removal and Installation (Refer to GROUP 52A – and Installation (Refer to GROUP 52A.)
Seat.)
Front Scuff Plate (Right) and Quarter Trim (Right)
Removal and Installation (Refer to GROUP 52A –
Trims.)

5 Nm

1
3
2

Removal steps
1. Rear heater duct (right) 3. 4WD indicator control unit
Turn up the carpet. 4. Bracket
2. Harness connector connection
22-10 MANUAL TRANSMISSION – 4WD Indicator Control Unit

NSPECTION
4WD INDICATOR CONTROL UNIT CHECK
Measure terminal voltage on each condition. Connect the harness to the control unit. Insert the probe
from the back side of the connector and measure the voltage between the terminal No.8 (earth terminal)
and each terminal.

Front wheel lamp

VCU lock lamp

Rear wheel lamp

Termi- Check item Check condition Check condition 2: Normal

nal No. 1: Ignition switch Transfer lever position condition

1 High/Low detection switch ON Move from 4HLC to System voltage*

4LLC or vice versa

4HLC, 4LLC 0V

2 4WD operation detection switch ON 2H System voltage*

4H 0V

3 Ignition switch OFF – 0V

ON – System voltage

4 4WD indicator VCU lock lamp ON 4H System voltage

lamp
4HLC 1.5 V or lower

5 VCU lock detection switch ON 4H System voltage*

4HLC 0V

6 Free wheel engage switch ON 2WD condition System voltage*

4WD condition 0V

7 VCU lock operation detection switch ON 4H System voltage*

4HLC 0V

9 4WD indicator Rear wheel ON Move from 4HLC to 0V

lamp 4LLC or vice versa

4HLC, 4LLC System voltage*

10 4WD indicator Front wheel ON 2WD condition 0V

lamp
4WD condition System voltage*

NOTE
System voltage marked with * is low slightly (from 1 V to 2 V).
 MANUAL TRANSMISSION – General/General Information 22-1
GROUP 22
MANUAL TRANSMISSION
GENERAL
OUTLINE OF CHANGE
Due to the addition of the vehicles with the 4G93-MPI engine, the V5M21 type transmission has been
adopted. This transmission is basically the same as that of the vehicles with 4G94 engine except for
the following items.
D A full-time 4WD model has been added.
D Due to the adoption of a full-time 4WD, the transfer control lever and the 4WD indicator control unit
have been discontinued.

GENERAL INFORMATION
TRANSFER
SECTIONAL VIEW
Center differential
(planetary gear type)
Input shaft Viscous coupling unit

Rear output shaft

Random chain

Front output shaft

22-2 MANUAL TRANSMISSION – General Information

CENTRE DIFFERENTIAL (PLANETARY GEAR TYPE)

The planetary gear type has been adopted for the center differential.
Driving power transmitted from the transmission to the input shaft passes on the pinion gear of the center
differential. Then, driving power is transmitted to the front output shaft via the drive sprocket and to the
rear output shaft via the pinion carrier.
The drive sprocket and the pinion carrier are driven by the pinion gear simultaneously while 50% of driving
power is distributed to the drive sprocket (front output shaft) and the remaining 50% of driving power
is distributed to the pinion carrier (rear output shaft).
VCU is installed between the drive sprocket and the rear output shaft so that driving power can be properly
distributed if there are any discrepancies in driving power between the front output shaft and the rear
output shaft.

Front output shaft Center differential

Pinion carrier
Pinion gear

VCU

Engine T/M

Rear output shaft

Input shaft
Drive sprocket

Rear output shaft

Input shaft

50 %

50 %

Pinion gear
Drive sprocket Pinion carrier
 AUTOMATIC
TRANSMISSION
Click on the applicable bookmark to selected the required model year
 23-1

AUTOMATIC
TRANSMISSION
CONTENTS

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 Converter Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . 44

Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . 45
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SEALANTS AND ADHESIVES . . . . . . . . . . . . . . 2 Selector Lever Operation Check . . . . . . . . . . . . . 47
Transmission Control Cable Adjustment . . . . . . . 49
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION CONTROL* . . . . . . . . . . . . . . . 50
TROUBLESHOOTING <A/T> . . . . . . . . . . . . . . . . 4
A/T KEY INTERLOCK AND SHIFT LOCK
TROUBLESHOOTING <A/T KEY INTERLOCK MECHANISMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
AND SHIFT LOCK MECHANISMS> . . . . . . . . . 32
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . 56
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 34
Essential Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 TRANSMISSION OIL COOLER . . . . . . . . . . . . . 59
Transfer Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A/T-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Transfer Oil Replacement . . . . . . . . . . . . . . . . . . . . 39
A/T Control Component Location . . . . . . . . . . . . . 40 4WD INDICATOR CONTROL UNIT . . . . . . . . . 60
A/T Control Component Check . . . . . . . . . . . . . . . 41

WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B – Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, 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 (*).
 Service Specifications/
23-2 AUTOMATIC TRANSMISSION – Lubricants/Sealants and Adhesives

SERVICE SPECIFICATIONS
Items Standard value

Clearance between inner cable stopper and dust cover end surface mm 0.8 – 1.5

Input shaft speed sensor resistance (at 20_C) Ω 620 $ 60

Output shaft speed sensor resistance (at 20_C) Ω 430 $ 43

A/T fluid temperature sensor resistance Ω at 25_C 1,100

at 120_C 57

Coil resistance of solenoid valve No.1 (at 25_C) Ω 13 $ 2

Coil resistance of solenoid valve No.2 (at 25_C) Ω 13 $ 2

Coil resistance of solenoid valve No.3 (at 25_C) Ω 13 $ 2

Stall speed r/min 2,320 – 2,620

Line pressure kPa at idle speed D range 373 – 422

R range 520 – 579

at stall speed D range 765 – 863

R range 1,383 – 1,628

LUBRICANTS
Items Specified lubricant Quantity ȏ

Transmission fluid DEXRON II or equivalent 7.2

Transfer oil Hypoid gear oil SAE 75W-90 or 2.3

75W-85W conforming to API GL-4

SEALANTS AND ADHESIVES

Items Specified sealant Remarks

Transfer control lever gasket 3M ATD Part No.8660 or equivalent Semi-drying sealant

Transfer control lever assembly 3M Stud Locking No.4170 or Anaerobic sealant

installation bolt equivalent
 AUTOMATIC TRANSMISSION – Special Tools 23-3
SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub Checking of the diagnosis code
assembly

MD998330 Oil pressure gauge Measurement of oil pressure

(including (2,942 kPa)
MD998331)

MD998920 Adapter Connection of oil pressure gauge

23-4 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

TROUBLESHOOTING <A/T>
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Gathering information from custom-
er.

NG
Check automatic transmission fluid Replace automatic transmission
fluid.
OK

Check trouble symptoms.

Communication with
MUT-II not possible
Read the diagnosis code (GROUP Inspection procedure No. 1 in
00 – How to Use Troubleshooting/In- Inspection Chart For Trouble
spection Service Points.) Symptoms (Refer to P.23-16.)
Diagnosis code NO diagnosis code displayed
displayed
Erase the diagnosis code (GROUP
00 – How to Use Troubleshooting/In-
spection Service Points.)

Carry out the essential service

(Refer to P.23-34.)

Abnormality exists (no diagnosis code)

Road test (Refer to P.23-6.)

Abnormality exists No abnormality

(diagnosis code
Recheck diagnosis codes which
present)
were read before the road test.

Diagnosis No diagnosis
code displayed code displayed

To INSPECTION CHART FOR To INSPECTION CHART FOR

DIAGNOSIS CODES TROUBLE SYMPTOMS
(Refer to P.23-9.) (Refer to P.23-15.)

Search for cause.

Found Not found
NG
Repair INTERMITTENT MALFUNCTION
(GROUP 00 – Points to Note for
Intermittent Malfunctions.)
OK
NG OK
Confirmation test (road test) Completed
AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-5
DIAGNOSIS FUNCTION
N RANGE LAMP
The N range lamp flashes at a frequency of approximately
1 Hz if there is an abnormality in any of the items in the
table below which are related to the A/T system. Check the
diagnosis code output if the N range lamp is flashing at a
frequency of approximately 1 Hz.
N range lamp flashing items
Input shaft speed sensor
Output shaft speed sensor
Each solenoid valve
Caution
If the N range lamp is flashing at a frequency of
approximately 2 Hz (faster than at 1 Hz), it means that
the A/T fluid temperature is too high. Stop the vehicle
in a safe place and wait until the N range lamp switches
off.

METHOD OF READING THE DIAGNOSIS CODE

Use the MUT-II or the N range lamp to take a reading of
the diagnosis codes. (Refer to GROUP 00 – How to Use
Troubleshooting/Inspection Service Points.)
23-6 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

ROAD TEST
No. State prior to test Test and operation Judgement value Check item Inspection item if there
and operation is an abnormality
1 Ignition switch: Ignition switch Data list No. 14 APS (Power Code No.13, 14
ON (1) ON (1) Approx. 5V supply voltage) APS system (P.23-10)
g
Engine: Stopped (2) OFF (2) 0V
Overdrive switch Data list No. 35 Overdrive Overdrive switch
(1) ON (1) OD switch system (P.23-25)
(2) OFF (2) OD-OFF
Selector lever Data list No. 37 Inhibitor switch Inhibitor switch
position (1) P, R, D system (P.23-25)
(1) P (2) P, R, D
(2) R (3) N
(3) N (4) P, R, D
(4) D (5) 2
(5) 2 (6) L
(6) L
Brake pedal Data list No. 28 Stop lamp Stop lamp switch
(1) Depressed (1) ON switch system (P.23-26)
(2) Released (2) OFF
2 Ignition switch: Starting test with Starting should be Starting Does not move
ST selector lever P or possible possible or (P.23-17)
E i
Engine: S
Stopped d N position impossible
Lockup malfunction
(P.23-24)
3 Engine: Warmed Drive for 15 Data list No. 15 A/T fluid A/T fluid temperature
up minutes or more so Gradually rises to temperature sensor system
that the automatic 70 – 90_C sensor (P.23-10)
fluid temperature
becomes 70 –
90_C.
4 Engine: Idling Accelerator pedal Data list No. 13 APS (Throttle Code No.13, 14
Selector lever (1) Released (1) 0 – 5 % opening angle) APS system (P.23-10)
position: N (2) Half depressed (2) Gradually rises
(3) Fully from (1)
depressed (3) 85 – 100 %
(approx
(approx.
Data list No. 22 Wide open Wide open throttle
2 seconds)
(1) OFF throttle switch switch system
(2) ON (P.23-11)
Selector lever Should be no Does not move Does not move
position abnormal shifting forward and reverse
(1) N → D shocks (P.23-17)
(2) N → R Time lag should be Does not move
within 2 seconds forward only (P.23-18)
Does not reverse only
(P.23-18)
Shocks when Large shocks
shifting (P.23-22)
5 Engine: Idling Accelerator pedal Data list No. 27 Solenoid valve Code No.41, 42
(Vehicle stopped) (1) Released (1) 1st No.1 Solenoid valve No.1
Selector lever system (P.23-13)
position: D Solenoid valve Code No.43, 44
No.2 Solenoid valve No.2
system (P.23-13)
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-7
No. State prior to test Test and operation Judgement value Check item Inspection item if there
and operation is an abnormality
6 Selector lever Shift position and Data list No. 27 Solenoid valve Code No.41, 42
position: D vehicle speed (1) 1st No.1 Solenoid valve No.1
Overdrive switch: (1) Idling (2) 1st system (P.23-13)
OFF (Vehicle (3) 3rd Solenoid valve Code No.43, 44
stopped) (4) 2nd No.2 Solenoid valve No.2
(2) Driving at system (P.23-13)
5 km/h
(3) Driving at Data list No. 31 Input shaft Input shaft speed
constant (3) 1,800 – 2,000 speed sensor sensor system
speed of rpm (P.23-11)
50 km/h
k /h
Data list No. 32 Output shaft Output shaft speed
(20 seconds
or more) (3) 1,800 – 2,000 speed sensor sensor system
rpm (P.23-11)
(4) Driving at
constant Data list No. 41 Solenoid valve Code No.41, 42
speed of (2) ON No.1 Solenoid valve No.1
40 km/h with (3) OFF system (P.23-13)
the selector (4) ON
lever in 2
position Data list No. 43 Solenoid valve Code No.43, 44
(2) OFF No.2 Solenoid valve No.2
(3) ON system (P.23-13)
(4) ON
Data list No. 47 Solenoid valve Code No.47, 48
(1) OFF No.3 Solenoid valve No.3
(2) OFF Malfunction system (P.23-13)
(3) ON when shifting Shifting point
(4) Accelerates abnormality (P.23-20)
smoothly and
no abnormal Slippage (vibration)
shocks should (P.23-23)
occur.
7 Selector lever Shift position and Data list No. 27 Solenoid valve Code No.41, 42
position: D vehicle speed (1) 4th No.1 Solenoid valve No.1
Overdrive switch: (1) Driving at system (P.23-13)
ON constant Solenoid valve Code No.43, 44
speed of No.2 Solenoid valve No.2
50 km/h system (P.23-13)
(20 seconds
or more) Data list No. 41 Solenoid valve Code No.41, 42
(1) OFF No.1 Solenoid valve No.1
system (P.23-13)
Data list No. 43 Solenoid valve Code No.43, 44
(1) OFF No.2 Solenoid valve No.2
system (P.23-13)
23-8 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

No. State prior to test Test and operation Judgement value Check item Inspection item if there
and operation is an abnormality
8 Selector lever Monitor data list For (1), (2) and (3), Malfunction Upshifting does not
position: D No. 13, 27, and 32 the reading should when shifting occur (P.23-19)
Overdrive switch: with the MUT
MUT-II. II. be the same as the
ON (1) Accelerate to specified output Downshifting does not
4th gear at APS shaft speed occur (P.23-20)
opening
o e g a angle
ge ((vehicle
e c e sspeed)
eed)
of 30 %. and no abnormal Shifting point
(2) Gently shocks should abnormality (P.23-20)
decelerate to a occur.
standstill
standstill. F (4),
For (4) (5) and d (6),
(6)
(3) Accelerate to Upshifting occurs
downshifting spontaneously
4th gear at APS should occur
opening angle (P.23-19)
immediately
of 50 %.
% after the shifting
(4) While driving at operation is made. Incorrect drive gear
50 km/h in 4th position (P.23-21)
gear, set the
overdrive Malfunction Large shocks
switch to OFF when driving (P.23-22)
position. the vehicle
Whil d
(5) While i i at
driving Slippage (vibration)
50 km/h in 3rd (P.23-23)
gear, move the
selector lever
to 2 position. Lockup malfunction
(6) While driving at (P.23-24)
20 km/h in 2nd
gear, move the Abnormal engine
selector lever braking (P.23-24)
to L position.

SHIFT PATTERN
D range (Overdrive switch: ON)
Throttle opening (%)
1 2 1 2 2 3 2 3 3 4 3 4
100

80

60

40

20

0 1,000 2,000 3,000 4,000 5,000 6,000

Output shaft speed (r/min)

0 50 100 150
Vehicle speed (km/h)
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-9
INSPECTION CHART FOR DIAGNOSIS CODE
Code Diagnosis item Reference page

13 Accelerator pedal position sensor system Sensor malfunction, 23-10

(Throttle opening voltage) open circuit, short circuit

14 Accelerator pedal position sensor system Open circuit, 23-10

(Throttle power supply voltage) short circuit

15 A/T fluid temperature sensor system Open circuit 23-10

16 A/T fluid temperature sensor system Short circuit 23-10

22 Wide open throttle switch Open circuit, 23-11

short circuit

31 Input shaft speed sensor system Open circuit 23-11

32 Output shaft speed sensor system Open circuit 23-11

38 Vehicle speed sensor system Open circuit 23-12

41 Solenoid valve No.1 system Open circuit 23-13

42 Solenoid valve No.1 system Short circuit 23-13

43 Solenoid valve No.2 system Open circuit 23-13

44 Solenoid valve No.2 system Short circuit 23-13

47 Solenoid valve No.3 system Open circuit 23-13

48 Solenoid valve No.3 system Short circuit 23-13

55 Abnormal communication with engine-ECU Open circuit 23-14

23-10 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

INSPECTION PROCEDURES FOR DIAGNOSIS CODES

Code No. 13, 14 Accelerator pedal position sensor (APS) Probable cause
If the APS output voltage (APS opening voltage) is 4.8 V or higher when the engine Malfunction of the accelerator pedal position sensor
is idling, the output voltage is judged to be too high and diagnosis code No. 13 Malfunction of harness or connector
is output. If the APS output voltage (APS opening voltage) is 0.335 V or lower Malfunction of the A/T-ECU
when the engine is idling, the output voltage is judged to be too low and diagnosis
code No. 13 is output.
If the APS output voltage (APS power supply voltage) is 3.0 V or lower or if it
is 5.7 V or higher when the engine is idling, the APS is judged to be faulty and
diagnosis code No. 14 is output.

NG
Accelerator pedal position sensor Replace
check (Refer to GROUP 13A – On-ve-
hicle Service.)
OK

NG
Check the following connectors: Repair
<L.H. drive vehicles> C-46, C-25, D-34,
D-04
<R.H. drive vehicles> C-46, C-26, D-34,
D-04
OK

NG NG
Check the trouble symptoms. Check the harness wire between accel- Repair
erator pedal position sensor and
A/T-ECU.
OK

Replace the A/T-ECU.

Code No. 15, 16 A/T fluid temperature sensor system Probable cause
If the A/T fluid temperature sensor output is 10°C or less (5.6 kΩ or more) even Malfunction of the A/T fluid temperature sensor
after running the engine for 15 minutes or more, it is judged that there is an open Malfunction of harness or connector
circuit in the A/T fluid temperature sensor and diagnosis code No. 15 is output. Malfunction of the A/T-ECU
If the A/T fluid temperature sensor output is 240°C or more (10 Ω or less), it is
judged that there is a short circuit in the A/T fluid temperature sensor and diagnosis
code No. 16 is output.

NG
A/T fluid temperature sensor check Replace
(Refer to P.23-43.)
OK

NG
Check the following connectors: Repair
B-03, D-04
OK

NG
Check the trouble symptoms. Check the harness wire between A/T Repair
fluid temperature sensor and A/T-ECU.
OK

Replace the A/T-ECU.

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-11
Code No. 22 Wide open throttle switch system Probable cause
If the wide open throttle switch does not turn OFF when the accelerator pedal is D Malfunction of wide open throttle switch
not depressed, there is a short circuit in the wide open throttle switch and diagnosis D Malfunction of connector
code No. 25 is output. D Malfunction of the A/T-ECU

NG
Wide open throttle switch inspection Replace
j(Refer to P.23-51.)
OK
NG NG
Measure at wide open throttle switch Check the following connector: Repair
connector C-58. D-04
D Disconnect the connector and OK
measure at the harness side.
D Voltage between terminal 1 and Check trouble symptom.
earth (ignition switch: ON)
OK System voltage NG
OK
NG
Check the following connectors: Repair
C-58, D-34, D-04 NG
OK Check the harness between the wide Repair
open throttle switch and A/T-ECU con-
Check the trouble symptoms. nectors.
NG OK
Check the harness between the wide
open throttle switch and A/T-ECU con- Replace the A/T-ECU
nectors, and repair if necessary.

Code No. 31, 32 Input shaft speed sensor system, output Probable cause
shaft speed sensor system
If no output pulse is detected from the input shaft speed sensor for 120 seconds D Malfunction of the input shaft speed sensor or output
or more while driving in 3rd gear at a speed of 60 km/h or more, there is judged shaft speed sensor
to be an open circuit in the input shaft speed sensor and diagnosis code No. 31 D Malfunction of harness or connector
is output. D Malfunction of the sensor rotor
If no output pulse is detected from the output shaft speed sensor for 120 seconds D Malfunction of A/T-ECU
or more while driving in 3rd gear at a speed of 60 km/h or more, there is judged D Electrical noise
to be an open circuit in the output shaft speed sensor and diagnosis code No.
32 is output.

L: Refer to the Transmission Workshop Manual.

NG
Input shaft speed sensor and output Replace the input shaft speed sensor
shaft speed sensor check (Refer to and output shaft speed sensor.
P.23-41, 42.)
OK
Check the trouble symptoms.
NG NG
Check the following connectors: Repair
D-04, B-03 NG
OK Check the sensor rotor.K Replace
OK
Check the trouble symptoms. NG
OK Check the trouble symptoms. Eliminate a source of electrical noise.

NG
Check the harness wire between input Repair
shaft speed sensor, output shaft speed
sensor and A/T-ECU.
OK

Replace the A/T-ECU.

23-12 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

Code No. 38 Vehicle speed sensor system Probable cause

If no output pulse is detected from the vehicle speed sensor for 120 seconds or D Malfunction of the vehicle speed sensor
more continuously while driving at a speed of 60 km/h or more, there is judged D Malfunction of harness or connector
to be an open circuit in the vehicle speed sensor and diagnosis code No. 38 is D Malfunction of the A/T-ECU
output. D Malfunction of the ignition switch

NG
Vehicle speed sensor check (Refer to Replace
GROUP 54 – Combination meter.)
OK

Measure at the vehicle speed sensor (1) NG Check the following connectors: NG
Repair
connector B-08. <L.H. drive vehicles> D-02, C-38, C-02,
D Disconnect the connector and C-76, C-74
measure at the harness side. (2) NG <R.H. drive vehicles> D-02, C-41, C-76,
(1) Voltage between 1 and earth C-74
(Ignition switch: ON)
OK: System voltage OK
(3) NG
(2) Voltage between 3 and earth
Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.8 – 5.2 V NG
(3) Continuity between 2 and earth NG
OK: Continuity Check the harness wire between igni- Repair
tion switch and vehicle speed sensor.
OK
OK
Check the following connectors: Check the ignition switch. (Refer to
B-08, D-02, D-04 GROUP 54.)
OK NG
NG
Repair Check the following connectors: Repair
D-02, D-04
Check the trouble symptoms.
OK
NG
Check the trouble symptoms.
Check the harness wire between NG
A/T-ECU and vehicle speed sensor. NG
OK NG Check the harness wire between Repair
A/T-ECU and vehicle speed sensor.
Repair OK

Replace the A/T-ECU. Replace the A/T-ECU.

Check the harness wire between

vehicle speed sensor and earth, and
repair if necessary.
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-13
Code No. 41, 42 Solenoid valve No.1 system Probable cause
If the resistance value for a solenoid valve No.1 is too large, it is judged that there D Malfunction of solenoid valve No.1
is an open circuit in the solenoid valve No.1 and the diagnosis code No.41 is output. D Malfunction of harness or connector
If the resistance value for a solenoid valve No.1 is too small, it is judged that there D Malfunction of the A/T-ECU
is a short-circuit in the solenoid valve No.1 and the diagnosis code No.42 is output.

NG
Solenoid valve No.1 check (Refer to P.23-42.) Replace
OK
NG
Check the following connectors: B-03, D-04 Repair
OK
NG
Check the harness wire between A/T-ECU and solenoid valve Repair
No.1.
OK
NG
Check the trouble symptoms. Replace the A/T-ECU.

Code No. 43, 44 Solenoid valve No.2 system Probable cause

If the resistance value for a solenoid valve No.2 is too large, it is judged that there D Malfunction of solenoid valve No.2
is an open circuit in the solenoid valve No.2 and the diagnosis code No.43 is output. D Malfunction of harness or connector
If the resistance value for a solenoid valve No.2 is too small, it is judged that there D Malfunction of the A/T-ECU
is a short-circuit in the solenoid valve No.2 and the diagnosis code No.44 is output.

NG
Solenoid valve No.2 check (Refer to P.23-42.) Replace
OK
NG
Check the following connectors: B-03, D-04 Repair
OK
NG
Check the harness wire between A/T-ECU and solenoid valve Repair
No.2.
OK
NG
Check the trouble symptoms. Replace the A/T-ECU.

Code No. 47, 48 Solenoid valve No.3 system Probable cause

If the resistance value for a solenoid valve No.3 is too large, it is judged that there D Malfunction of solenoid valve No.3
is an open circuit in the solenoid valve No.3 and the diagnosis code No.47 is output. D Malfunction of harness or connector
If the resistance value for a solenoid valve No.3 is too small, it is judged that there D Malfunction of the A/T-ECU
is a short-circuit in the solenoid valve No.3 and the diagnosis code No.48 is output.

NG
Solenoid valve No.3 check (Refer to P.23-42.) Replace
OK
NG
Check the following connectors: B-03, D-04 Repair
OK
NG
Check the harness wire between A/T-ECU and solenoid valve Repair
No.3.
OK
NG
Check the trouble symptoms. Replace the A/T-ECU.
23-14 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

Code No. 55 Abnormal communication with engine-ECU Probable cause

If normal communication is not possible for a continuous period of 1 second or D Malfunction of harness or connector
more when the ignition switch is at the ON position and the battery voltage is 10 D Malfunction of the engine-ECU
V or more, diagnosis code No. 55 is output. Diagnosis code No. 55 is also output D Malfunction of the A/T-ECU
if the data being received is abnormal for a continuous period of 1 second under
the same conditions.

NO
MUT-II Self-Diag code Replace the A/T-ECU.
D Is the diagnosis code No.61 output?
YES
NG
Check the following connectors: Repair
<L.H. vehicles> C-19, C-25, D-34, D-04
<R.H. vehicles> C-19, C-26, D-34, D-04
OK

Check the trouble symptoms.

NG
NG
Check the harness wire between engine-ECU and A/T-ECU. Repair

OK

Replace the engine-ECU.

NG
Check the trouble symptoms. Replace the A/T-ECU.
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-15
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptom Inspection procedure Reference page
No.

Communication with the MUT-II is not possible 1 23-16

Does not move Does not move forward and reverse 2 23-17

Does not move forward only 3 23-18

Does not reverse only 4 23-18

Malfunction when Upshifting does not occur 5 23-19

shifting
Downshifting does not occur 6 23-20

Shifting point abnormality 7 23-20

Upshifting occurs spontaneously 8 23-21

Incorrect drive gear position 9 23-21

Large shocks 10 23-22

Slippage (vibration) 11 23-23

Lockup malfunction 12 23-24

Abnormal engine braking 13 23-24

Electronic circuit Inhibitor switch system 14 23-25

systems
Overdrive switch system 15 23-25

Stop lamp switch system 16 23-26

23-16 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1
Communication with the MUT-II is not possible Probable cause
If communication with the MUT-II is not possible, the cause is probably a malfunction D Malfunction of self-diagnosis system
in the self-diagnosis system or the A/T-ECU is not functioning. D Malfunction of A/T-ECU power circuit
D Malfunction of A/T-ECU earth circuit
D Malfunction of A/T-ECU
D Malfunction of harness and connector

No
Is communication with other systems Check and repair the self-diagnosis
possible using the MUT-II? system with the MUT-II
Yes
OK NG
Measure at A/T-ECU connector D-04 Check the following connectors: Repair
D Disconnect the connector and <L.H. drive vehicles> D-04, D-34, C-37,
measure at the harness side. C-70, C-35
D Voltage between terminals (9) and <R.H. drive vehicles> D-04, D-34, C-39,
(24) and the earth C-70, C-35
OK: System voltage
OK
D Continuity between terminal (25)
and earth Check the trouble symptoms.
OK: Continuity
NG
NG
Replace the A/T-ECU.

NG
Check the following connectors: Repair
<L.H. drive vehicles> D-02, C-24, C-78,
C-74, D-34, C-68, C-72
<R.H. drive vehicles> D-02, C-26, C-78,
C-74, D-34, C-68, C-72
OK
NG
Check the trouble symptoms. D Check and repair the harness wire Check the trouble symptoms
between the A/T-ECU and the NG
power supply.
D Check and repair the harness wire Replace the A/T-ECU.
between the A/T-ECU and the earth.
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-17
INSPECTION PROCEDURE 2
Does not move forward and reverse Probable cause
When the engine is idling, the vehicle does not move forward and reverse even D Malfunction of transmission control cable
if the selector lever is shifted from N to D, 2, L or R positionj. In such cases, the D Abnormal line pressure
cause is probably abnormal line pressure, or a malfunction of the transmission control D Malfunction of power train
cable, torque converter, oil pump, parking mechanism or the power train. D Malfunction of oil pump
D Malfunction of valve body
D Malfunction of parking mechanism
D Malfunction of torque converter
D Malfunction of A/T-ECU

L: Refer to the Transmission Workshop Manual.

NG
Transmission control cable assembly Repair, replace
check
OK
NG
Check the engine control system, igni- Repair, replace
tion system, fuel system, engine me-
chanical system.
OK
Yes Is the source of the abnormal noise
Is abnormal noise generated in D the torque converter or thetransmis- Replace the torque converter L
range? sion? Torque
converter
No Transmission

Check the power train. L

D Disassemble the transmission,
check the condition of the planetary
gear and other parts, and repair or
replace any parts as necessary.
No
Can the propeller shaft be turned by Malfunction of parking mechanism L
hand in all ranges except P range?
Yes
NG
Check the line pressure. Repair or replace the valve body. L
(Refer to P. 23-45.)
OK
Check the trouble symptoms
NG

Check and repair or replace the oil

pump. L

Replace the torque converter. L Check the trouble symptoms.

NG

Replace the A/T-ECU.

23-18 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

INSPECTION PROCEDURE 3
Does not move forward only Probable cause
When the engine is idling, the vehicle does not move forward even if the selector D Malfunction of forward clutch
lever is shifted from N to D, 2 or L range. In such cases, the cause is probably D Malfunction of direct clutch
a malfunction of the clutch or brake. D Malfunction of one-way clutch No. 2
D Malfunction of brake No. 1, No. 2, No. 3
D Malfunction of A/T-ECU

L: Refer to the Transmission Workshop Manual.

No
Does not vehicle move forward in D, Check the forward clutch. L
2 and L range?
Yes
No
Does not vehicle move forward in D Check one-way clutch No. 2. L
and 2 range?
Yes
No
Does not vehicle move forward in 2 Check the brake No. 3. L
range?
Yes
2nd
Which is the drive gear in D range? Check the brake No. 1, No. 2. L
3rd

Check the direct clutch. L Check the trouble symptoms.

NG

Replace the A/T-ECU.

INSPECTION PROCEDURE 4
Does not reverse only Probable cause
When the engine is idling, the vehicle does not reverse even if the selector lever D Malfunction of brake No. 1, No. 3
is shifted from N to R range. In such cases, the cause is probably a malfunction D Malfunction of direct clutch
of a clutch, brake or the valve body. D Malfunction of valve body
D Malfunction of planetary gear
D Malfunction of A/T-ECU

L: Refer to Transmission Workshop Manual.

2nd
Check the drive gear in D range. Check the brake No. 1. L
1st 3rd
Check the planetary gear. L

No
Does the A/T shift up to 2nd gear? Malfunction of 1-2 shift valve. L
Yes
NG
Is there any slippage in 3rd gear in Check the direct clutch. L
D range?
OK

Check the brake No. 3. L Check the trouble symptoms.

NG

Replace the A/T-ECU.

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-19
INSPECTION PROCEDURE 5
Upshifting does not occur Probable cause
Upshifting does not occur under conditions when upshifting should occur. Check D Malfunction of solenoid valve No. 1, No. 2
shifting from 1→2, 2→3 and 3→4 respectively. D Malfunction of A/T-ECU
D Malfunction of power train internal parts

L: Refer to the Transmission Workshop Manual.

No
Is a normal diagnostic code output? To Inspection Chart For Each Diagnosis
Yes Code (Refer to P. 23-9.)

No No
Does not the A/T shift from 1→2? Does the A/T shift to 2nd gear in 2 Malfunction of 1-2 shift valve. L
range? Malfunction of solenoid valve No.
Yes
Yes 2.L

Check the brake No. 2 system. L

Check one-way clutch No. 1.L

No No
Does not the A/T shift from 2→3? Does the vehicle reverse in R range? Check the direct clutch system.
Yes L
Yes

Malfunction of 2-3 shift valve.L

Malfunction of solenoid valve No. 1.L

No
A/T does not shift from 3→4. Does the vehicle move in 1st gear in Malfunction of solenoid valve No.
D range? 2. L
Yes
NG
Inspection Procedure 15 – Overdrive Repair
Switch System (Refer to P. 23-25.)
OK

Malfunction of 3-4 shift valve. L Check the trouble symptoms.

NG

Replace the A/T-ECU.

23-20 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

INSPECTION PROCEDURE 6
Downshifting does not occur Probable cause
Downshifting does not occur under conditions when downshifting should occur. Check D Malfunction of solenoid No. 1, No. 2
shifting from 2→1, 3→2 and 4→3 respectively. D Malfunction of A/T-ECU
D Malfunction of power train internal parts

L: Refer to the Transmission Workshop Manual.

No
Is a normal diagnosis code output? To Inspection Chart For Diagnosis
Yes Code (Refer to P. 23-9.)
(DRIVE 1ST)
No
Does not the A/T shift from 4→3? Which gear is engaged when the A/T Malfunction of solenoid valve No.
Yes is shifted from D range to 2 range 2 L
(accelerator OFF) while in 3rd gear?
(DRIVE 2ND, 4TH)

Malfunction of 3-4 shift valve L

(DRIVE 4TH)
No
Does not the A/T shift from 3→2? Does the vehicle move in 1st gear in Malfunction of 2–3 shift valve L
D range?
Yes
(DRIVE 1ST)

Malfunction of solenoid valve No. 1 L

No
A/T does not shift from 2→1. Does the A/T shift from 3→4 in D range? Malfunction of solenoid valve No.
2 L
Yes
No
Does the vehicle move forward in L Malfunction of 1–2 shift valve L
range?
Yes
No
Does the vehicle reverse in R range? Check the brake No. 1. L
Yes

Check the brake No. 2. L Check the trouble symptoms.

NG

Replace the A/T-ECU.

INSPECTION PROCEDURE 7
Shifting point abnormality Probable cause
Shifting occurs at points which are different from the shift pattern. Note that the D Malfunction of A/T fluid temperature sensor
shift pattern will vary in different modes and at high A/T fluid temperatures. D Malfunction of A/T-ECU

No
Is a normal diagnosis code output? To Inspection Chart For Diagnosis
Yes Code (Refer to P. 23-9.)
NG
MUT-II SERVICE DATA Code No. 15, 16 – A/T fluid temperature
D 15 – A/T fluid temperature sensor sensor system (Refer to P. 23-10.)
OK: 70 – 90_C after engine
warmed-up
OK

Replace the A/T-ECU.

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-21
INSPECTION PROCEDURE 8
Upshifting occurs spontaneously Probable cause
Upshifting occurs in ranges where upshifting should not occur, e. g. upshifting to D Malfunction of inhibitor switch
2nd gear in L range, 3rd gear in 2 range or 4th gear in D range when overdrive D Malfunction of overdrive switch
is disconnected. D Malfunction of A/T-ECU

NG
MUT-II SERVICE DATA Inspection Procedure 14 – Inhibitor
D 37 – Inhibitor switch switch system (Refer to P. 23-25.)
OK: MUT-II display and selector
lever position should match
OK
NG
MUT-II SERVICE DATA Inspection Procedure 15 – Overdrive
D 35 – Overdrive switch switch system (Refer to P. 23-25.)
OK: MUT-II display and mode
selected should match
OK

Replace the A/T-ECU.

INSPECTION PROCEDURE 9
Incorrect drive gear position Probable cause
Vehicle starts off in 2nd, 3rd or 4th gear when in D range. Often occurs when starting D Malfunction of inhibitor switch
off is not smooth. D Malfunction of direct clutch
D Malfunction of planetary gear
D Malfunction of valve body
D Malfunction of forward clutch
D Malfunction of solenoid valve No. 1
D Malfunction of A/T-ECU

L: Refer to the Transmission Workshop Manual.

NG
MUT-II SERVICE DATA Inspection Procedure 14 – Inhibitor
D 37 – Inhibitor switch switch system (Refer to P. 23-25.)
OK: MUT-II display and selector
lever position should match
OK
Yes
Does the vehicle move forward in 2nd Inspection Procedure 6 – Downshifting
gear? does not occur (Refer to P. 23-20.)
No
Yes Yes
Does the vehicle move forward in 3rd Does the vehicle reverse in R range? Check the direct clutch. L
gear? (D range) No
No
Check the planetary gear. L

Yes
Does the vehicle move forward in 3rd Malfunction of 2–3 shift valve L
gear? (2, L range) Malfunction of solenoid valve No. 1L
No
Yes Yes
Does the vehicle move forward in 4th Does the vehicle reverse in R range? Malfunction of solenoid valve No.
gear? No 1 L
No
Malfunction of 2–3 shift valve L
Check the forward clutch. L

Check the trouble symptoms.

NG

Replace the A/T-ECU.

23-22 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

INSPECTION PROCEDURE 10
Large shocks Probable cause
Shocks accompany shifting from N→D, N→R and during each upshift and downshift. D Malfunction of direct clutch
D Malfunction of brake No. 3
D Malfunction of stop lamp switch
D Malfunction of inhibitor switch
D Malfunction of forward clutch
D Malfunction of valve body
D Malfunction of A/T-ECU

L: Refer to the Transmission Workshop Manual.

Yes NG
Is there a large shock when shifting Check the time lag (within 2 seconds). Check the direct clutch clear-
from N→R? ance. L
OK
Check the brake No. 3 clearance.
No
L
Check each accumulator. L
Yes NG
Is there a large shock when shifting MUT-II SERVICE DATA Inspection Procedure 16 – Stop
from N→D? D 28 – Stop lamp switch lamp switch system (Refer to P.
OK: ON when brake pedal is de- 23-26.)
No
pressed
OFF when brake pedal is re-
leased
NG
Check the kickdown cable. Repair OK
OK
NG
Check each modulator valve. L MUT-II SERVICE DATA Inspection Procedure 14 – Inhibi-
Check each check ball. L D 37 – Inhibitor switch tor switch system (Refer to P.
Check each accumulator. L OK: MUT-II display and selector 23-25.)
lever position should match.
OK
NG
Check the time lag (within 2 seconds) Check the forward clutch clear-
OK ance. L

Check each accumulator. L

Check the trouble symptoms.

NG

Replace the A/T-ECU.

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-23
INSPECTION PROCEDURE 11
Slippage (vibration) Probable cause
Occurs when a clutch or brake does not fully engage due to low hydraulic pressure D Malfunction of torque converter
or a worn facing. Appears as vibration when the problem is slight. D Malfunction of direct clutch
D Malfunction of forward clutch
D Malfunction of one-way clutch No. 1, No. 2
D Malfunction of overdrive brake
D Malfunction of brake No. 1, No. 2, No. 3
D Malfunction of overdrive one-way clutch
D Malfunction of A/T-ECU

L: Refer to the Transmission Workshop Manual.

Yes NG
Does slippage occur both when moving Check the torque converter. Replace the torque converter. L
forward and reversing?
OK
No
Check the overdrive clutch system. L
Check the overdrive one-way clutch
system. L

Yes NG
Does slippage occur in R range? Check slippage in 3rd gear in D range. Check the direct clutch system.
OK L
No

Check the brake No. 3 system. L

Yes NG
Does slippage occur in 1st gear? Check for slippage in L range. Check the forward clutch system.
OK L
No

Check the one-way clutch No. 2 sys-

tem. L

Yes NG
Does slippage occur in 2nd gear? Check for slippage in 2nd gear in 2 Check the brake No. 2 system.
range. L
No
OK

Check the brake No. 2 system. L

Check one-way clutch No. 1. L

Yes
Does slippage occur in 3rd gear? Check the direct clutch system. L
No

Check the overdrive brake system. L Check the trouble symptoms.

NG

Replace the A/T-ECU.

23-24 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

INSPECTION PROCEDURE 12
Lockup abnormality Probable cause
When lockup does not operate even though in the lockup range, and also when D Malfunction of torque converter
lockup is operating and the engine is idling but then stalls. D Malfunction of valve body
D Malfunction of A/T-ECU

L: Refer to the Transmission Workshop Manual.

No
Is a normal diagnosis code output? To Inspection Chart For Diagnosis
Code (Refer to P. 23-9.)
Yes

NG
Check the solenoid valve No. 3. Replace the solenoid valve No. 3. L
OK
NG
Check the lockup control valve. Replace the lockup control valve. L
OK

Replace the torque converter. L Check the trouble symptoms.

NG

Replace the A/T-ECU.

INSPECTION PROCEDURE 13
Abnormal engine braking Probable cause
Engine braking effectiveness is poor after downshifting has occurred. D Malfunction of overdrive clutch
D Malfunction of brake No. 1, No. 3
D Malfunction of valve body
D Malfunction of A/T-ECU

L: Refer to the Transmission Workshop Manual.

Yes
Poor braking in 1st, 2nd and 3rd gears Check the overdrive clutch system. L
No
Yes OK
Poor braking in 1st gear Check the slippage in R range Malfunction of low modulator valve. L
No NG

Check the brake No. 3 system. L

Check the brake No. 1 system. L Check the trouble symptoms.

NG

Replace the A/T-ECU.

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-25
INSPECTION PROCEDURE 14
Inhibitor switch system Probable cause
If the engine does not start in P or N range, the cause is probably a problem in D Malfunction of inhibitor switch
the inhibitor switch system. D Malfunction of harness or connector
D Malfunction of A/T-ECU

OK
MUT-II SERVICE DATA Completed
D 37 – Inhibitor switch
OK: MUT-II display and selector
lever position should match
NG
NG
Check the inhibitor switch. (Refer to Replace
P.23-37.)
OK
NG
Measure at inhibitor switch connector Check the ignition switch. (Refer to
B-04. GROUP 54 – Ignition Switch.)
D Disconnect the connector and
measure at the harness side.
D Voltage between terminal 1 and
earth (Ignition switch: ON)
OK: System voltage
OK
NG
Check the following connectors: Repair
B-04, D-04
OK
NG NG
Check the trouble symptoms. Check the harness wire between the Repair
inhibitor switch and the A/T-ECU.
OK

Replace the A/T-ECU.

INSPECTION PROCEDURE 15
Overdrive switch system Probable cause
If downshifting does not occur when overdrive switch is turned off while driving D Malfunction of overdrive switch
in 4th gear, or if shifting to 4th gear is not possible, the cause is probably a problem D Malfunction of harness or connector
in the overdrive switch system. D Malfunction of A/T-ECU
D Malfunction of ignition switch

OK
MUT-II SERVICE DATA Completed
D 35 – Overdrive switch
OK: MUT-II display and overdrive
switch OD/OD-OFF position
should match.
NG
NG
Check the overdrive switch. (Refer to Replace
P.23-51.)
OK
OK NG
Measure at overdrive switch connector Check the following connectors: Repair
D-35. D-35, D-34, D-04
D Disconnect the connector and OK
measure at the harness side
D Voltage between terminal 3 and Check the trouble symptoms.
earth (Ignition switch: ON)
OK: System voltage
NG
NG Check the harness wire between the Repair
overdrive switch and the A/T-ECU.
Check the ignition switch. (Refer to
GROUP 54 – Ignition Switch.) OK

Replace the A/T-ECU.

23-26 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

INSPECTION PROCEDURE 16
Stop lamp switch system Probable cause
If large shocks occur during squat control, the cause is probably a problem with D Malfunction of stop lamp switch
the stop lamp switch. D Malfunction of harness or connector
D Malfunction of A/T-ECU

OK
MUT-II SERVICE DATA Check the stop lamp switch
D 28 – Stop lamp switch (Refer to GROUP 35 – Brake Pedal)
OK: ON when the brake pedal is
depressed and OFF when the
brake pedal is released
NG
NG
Check the following connectors: Repair
<L.H. drive vehicles> C-04, C-02, C-29,
C-24, D-02, D-04
<R.H. drive vehicles> C-04, C-02, C-41,
D-02, D-04
OK

Check the trouble symptoms.

NG
Check the harness wire between the Repair
stop lamp switch and the A/T-ECU.
OK

Replace the A/T-ECU.

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-27
SERVICE DATA REFERENCE TABLE
Item Inspection item Inspection conditions Normal value
No.

13 Accelerator Engine: Idle Accelerator pedal: Fully 0–5%

pedal position Selector lever position: N released
sensor (throttle
opening voltage) Accelerator pedal: Depressed Gradually rises from
the above value

Accelerator pedal: Fully 85 – 100 %

depressed (up to 2 seconds)

14 Accelerator Ignition switch: ON Ignition switch: ON Approx. 5 V

edal position
pedal osition Engine: Sto
Stopped
ed
sensor (power
Ignition switch: OFF 0V
supply voltage)

15 A/T fluid Driving with engine Drive for 15 minutes or more Gradually increases
temperature warmed up until the A/T fluid temperature is to 70 – 90_C
sensor 70 – 90_C.

22 Wide open Accelerator pedal position Released OFF

throttle switch
Depressed ON

27 Shift position Accelerator pedal: Fully Shifting from N to D 1st→3rd→1st

signal released
Engine: Idle (Vehicle
stopped)
Selector lever position: N
Brake pedal: Depressed

Selector lever position: L Idle (Vehicle stopped) 1st

Selector lever position: 2 Idle (Vehicle stopped) 1st

Driving at 40 km/h (20 seconds 2nd

or more)

Selector lever position: D Driving at constant speed of 50 3rd

Overdrive switch: OFF km/h (20 seconds or more)

Selector lever position: D Driving at constant speed of 50 4th

Overdrive switch: OFF km/h (20 seconds or more)

28 Stop lamp switch Ignition switch: ON Brake pedal: Depressed ON

Engine: Stopped
Brake pedal: Released OFF

31 Input shaft speed Selector lever position: D Driving at constant speed of 50 1,800 – 2,000 r/min
sensor Overdrive switch: OFF km/h

32 Output shaft Selector lever position: D Driving at constant speed of 50 1,800 – 2,000 r/min
speed sensor Overdrive switch: OFF km/h

35 Overdrive switch Ignition switch: ON Overdrive switch: OFF OD-OFF

Engine: Stopped
Overdrive switch: ON OD
23-28 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

Item Inspection item Inspection conditions Normal value

No.

37 Inhibitor switch Ignition switch: ON Selector lever position: P P, R, D

Engine: Stopped
Selector lever position: R P, R, D

Selector lever position: N N

Selector lever position: D P, R, D

Selector lever position: 2 2

Selector lever position: L L

38 Vehicle speed Selector lever Idling in 1st gear (Vehicle 0 r/min

sensor position: L, D stopped)
Overdrive switch: OFF
Driving at constant speed of 50 450 – 550 r/min
km/h (3rd gear)

41 Solenoid valve Selector lever position: D Driving at constant speed of 5 ON

No. 1 Overdrive switch: ON km/h (1st gear)

Driving at constant speed of 50 OFF

km/h (4th gear)

43 Solenoid valve Selector lever position: D Driving at constant speed of 5 OFF

No. 2 Overdrive switch: OFF km/h (1st gear)

Driving at constant speed of 50 ON

km/h (3rd gear)

47 Solenoid valve Selector lever position: D Driving at constant speed of 5 OFF

No. 3 Overdrive switch: ON km/h (1st gear)

Driving at constant speed of 50 ON

km/h (4th gear)

53 N range switch Ignition switch: ON Selector lever position: N ON

Engine: Stopped
Selector lever position: Other OFF
than N

55 2 range switch Selector lever position: 2 ON

Selector lever position: Other OFF

than 2

56 L range switch Selector lever position: L ON

Selector lever position: Other OFF

than L

61 Free-wheeling Ignition switch: ON Transfer lever position: Other 4WD

engage switch Engine: Stopped than 4WD

Transfer lever position: 4WD 2WD

63 Dual-pressure Engine: Stopped A/C switch: ON ON

switch Selector lever position: N
A/C switch: OFF OFF
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-29
REFERENCE FOR FAIL-SAFE/BACKUP FUNCTIONS
When malfunctions of the main sensors or actuators are detected by the diagnosis system, the vehicle
is controlled by means of the pre-set control logic to maintain safe conditions for driving.

Malfunctioning item Control contents during malfunction

Output shaft speed If there is an open circuit in the output shaft speed sensor, upshifting to 4th gear and lockup
sensor control is stopped.

Inhibitor switch If there is an open circuit in the N, 2 or L signal line, driving is possible in the case of 2 and L
(same as D range) so that control can be performed as if the range is D range, and driving is
not possible in N range. If more than one of the N, 2 or L signals are input, the order of priority
for control is L→2→N.

Accelerator pedal If the output is 0.335 V or less or 4.8 V or more during idling condition, gear shifting control when
position sensor throttle is fully closed is carried out.

Solenoid valve No. 3 If a problem is detected, lockup is stopped over the whole range and the solenoid is turned off
to prevent the engine from stalling during idling.

Solenoid valve No. 1, If a problem is detected, each solenoid stops operating and is turned off. The gear shifting logic
No. 2 when a problem is detected is given in the table below

Selector le- Normal When the solenoid When the solenoid When the solenoid
ver valve No. 1 has broken valve No. 2 has broken valves No. 1 and No. 2
position have broken

Gear S1 S2 Gear S1 S2 Gear S1 S2 Gear S1 S2

D 1 f × 3 ×→f 1 f O/D

2 f f 3 f O/D f→× O/D

3 × f 3 f O/D × O/D

O/D × × O/D × O/D × O/D

2 1 f × 3 ×→f 1 f 3

2 f f 3 f 3 f→× 3

3 × f 3 f 3 × 3

L 1 f × 1 × 1 f 1

2 f f 2 f 1 f 1

f : Energized (ON)
× : Not energized (OFF)
23-30 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

A/T-ECU TERMINAL VOLTAGE REFERENCE CHART

Terminal Inspection item Inspection conditions Standard value

No.

1 Solenoid valve No. 1 When in 1st or 2nd gear System voltage

When in 3rd or 4th gear 0V

2 Solenoid valve No. 2 When in 2nd or 3rd gear System voltage

When in 1st or 4th gear 0V

3 Wide open throttle switch Accelerator pedal: Released 4.5 – 5.5 V

Accelerator pedal: Depressed Less than 0.4 V

4 Output shaft speed sensor – –

earth

5 Stop lamp switch Brake pedal: Depressed System voltage

Brake pedal: Released 0V

6 Free-wheeling engage Transfer lever position: Other than 4WD System voltage
switch
Transfer lever position: 4WD 0V

8 Inhibitor switch (L) Selector lever position: L System voltage

Selector lever position: Other than L 0V

9 Back-up power supply Ignition switch: OFF System voltage

10 Solenoid valve No. 3 When lockup clutch is operating System voltage

When lockup clutch is not operating 0V

11 Diagnosis control terminal – –

12 A/T fluid temperature – –

sensor earth

13 Output shaft speed sensor Vehicle: Stopped Approx. 2.5 V

Vehicle: Driving Other than 2.5 V

14 Dual-pressure switch A/C switch: OFF 0V

A/C switch: ON System voltage

15 Input shaft speed sensor – –

earth

16 Input shaft speed sensor Ignition switch: OFF 0V

Ignition switch: ON 2.5 V

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-31

Terminal Inspection item Inspection conditions Standard value

No.

19 Communication with input Engine: Idling Other than 0 V

signals from engine-ECU Selector lever position: D

21 Communication with output Engine: Idling Other than 0 V

signals to engine-ECU Selector lever position: D

23 Inhibitor switch (2) Selector lever position: 2 System voltage

Selector lever position: Other than 2 0V

24 Power supply Ignition switch: OFF 0V

Ignition switch: ON System voltage

25 Earth Engine: Idling 0V

27 Vehicle speed sensor Vehicle: Slowly moving forward Alternates between

0↔Approx. 5 V

28 A/T fluid temperature ATF temperature: 120_C Approx. 0.3 V

sensor
ATF temperature: 150_C Approx. 0.15 V

29 Overdrive switch Overdrive switch: ON System voltage

Overdrive switch: OFF 0V

30 Accelerator pedal position Accelerator pedal: Released Approx. 1 V

sensor (throttle opening
voltage) Accelerator pedal: Fully depressed Approx. 4 V

31 Accelerator pedal position Ignition switch: ON Approx. 5 V

sensor (power supply
voltage) Ignition switch: OFF 0V

32 Diagnostic output terminal – –

33 N range lamp Ignition switch: ON System voltage

Ignition switch: OFF 0V

34 Inhibitor switch (N) Selector lever position: N System voltage

Selector lever position: Other than N 0V

 Troubleshooting <A/T Key Interlock and Shift
23-32 AUTOMATIC TRANSMISSION – Lock Mechanisms>

TROUBLESHOOTING <A/T KEY INTERLOCK AND SHIFT LOCK

MECHANISMS>
INSPECTION CHART FOR TROUBLE SYMPTOMS
Problem Inspection Reference page
Procedure No.

Selector lever can be moved from P to R without depressing brake pedal 1 23-32
when ignition key is at positions other than LOCK (OFF).

Selector lever cannot be moved from P to R with brake pedal depressed 2 23-32
when ignition key is at positions other than LOCK (OFF).

Selector lever can be moved from P to R with brake pedal depressed when 3 23-33
ignition key is at LOCK (OFF) position.

Selector lever cannot be moved from P to R smoothly. 4 23-33

Selector lever cannot be moved from R to P. 5 23-33
Ignition key cannot be turned to LOCK (OFF) position when selector lever 6 23-33
is at P position.

Ignition key can be turned to LOCK (OFF) position when selector lever is at 7 23-33
positions other than P.

INSPECTION CHART FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1
Selector lever can be moved from P to R without Probable cause
depressing brake pedal when ignition key is at positions
other than LOCK (OFF).
Lock cam or shift lock cable may be defective. D Malfunction of lock cam
D Malfunction of shift lock cable

Check items described in the column “Probable cause”.

INSPECTION PROCEDURE 2
Selector lever cannot be moved from P to R with brake Probable cause
pedal depressed when ignition key is at positions other
than LOCK (OFF).
Selector lever assembly, shift lock cable, key interlock cable, transmission control D Malfunction of selector lever assembly
cable or lock cam may be defective. D Malfunction of shift lock cable
D Malfunction of key interlock cable
D Malfunction of transmission control cable
D Malfunction of lock cam

Check items described in the column “Probable cause”.

 Troubleshooting <A/T Key Interlock and Shift
AUTOMATIC TRANSMISSION – Lock Mechanisms> 23-33
INSPECTION PROCEDURE 3
Selector lever can be moved from P to R with brake pedal Probable cause
depressed when ignition key is at LOCK (OFF) position.
Lock cam or key interlock cable may be defective. D Malfunction of lock cam
D Malfunction of key interlock cable

Check items described in the column “Probable cause”.

INSPECTION PROCEDURE 4
Selector lever cannot be moved from P to R smoothly. Probable cause
Key interlock cable, shift lock cable, lock cam, or selector lever assembly may be D Malfunction of key interlock cable
defective. D Malfunction of shift lock cable
D Malfunction of lock cam
D Malfunction of selector lever assembly

Check items described in the column “Probable cause”.

INSPECTION PROCEDURE 5
Selector lever cannot be moved from R to P. Probable cause
Selector lever assembly or transmission control cable may be defective. D Malfunction of selector lever assembly
D Malfunction of transmission control cable

Check items described in the column “Probable cause”.

INSPECTION PROCEDURE 6
Ignition key cannot be turned to LOCK (OFF) position Probable cause
when selector lever is at P position.
Lock cam, key interlock cable or key cylinder slider may be defective. D Malfunction of lock cam
D Malfunction of key interlock cable
D Malfunction of key cylinder slider

Check items described in the column “Probable cause”.

INSPECTION PROCEDURE 7
Ignition key can be turned to LOCK (OFF) position when Probable cause
selector lever is at positions other than P.
Lock cam, key cylinder cover or key interlock cable may be defective. D Malfunction of lock cam
D Malfunction of key cylinder cover
D Malfunction of key interlock cable

Check items described in the column “Probable cause”.

23-34 AUTOMATIC TRANSMISSION – On-vehicle Service

ON-VEHICLE SERVICE
ESSENTIAL SERVICE
AUTOMATIC TRANSMISSION FLUID CHECK
Caution
When the transmission has been replaced or overhauled,
or driving has been carried out under the severe condition,
the A/T fluid cooler line flushing should always be carried
out and also, the A/T fluid should always be replaced.
1. Drive the vehicle until the A/T fluid temperature rises to
the normal temperature (70 – 90_C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the
torque converter and the hydraulic circuits with A/T fluid,
and then move the selector lever to the N position.
4. After wiping off any dirt around the oil level gauge, remove
the oil level gauge and check the condition of the A/T
fluid.
NOTE
If the A/T fluid smells as if it is burning, it means that
the A/T fluid has been contaminated by the particles from
the bushes and friction materials, a transmission overhaul
and flushing the A/T fluid cooler line may be necessary.

5. Check that the A/T fluid level is at the HOT mark on the
oil level gauge. If the A/T fluid level is lower than this,
pour in more A/T fluid until the level reaches the HOT
mark.
Automatic transmission fluid:
DEXRON II or equivalent
NOTE
If the A/T fluid level is low, the oil pump will draw in air
along with the A/T fluid, which will cause bubbles to form
inside the hydraulic circuit. This will in turn cause the
hydraulic pressure to drop, which will result in late shifting
and slipping of the clutches and brakes.
If there is too much A/T fluid, the gears can churn it up
into foam and cause the same conditions that can occur
with low A/T fluid levels.
In either case, air bubbles can cause overheating and
oxidation of the A/T fluid which can interfere with normal
valve, clutch, and brake operation. Foaming can also result
in A/T fluid escaping from the transmission vent hole, in
which case it may be mistaken for a leak.
6. Securely insert the oil level gauge.
AUTOMATIC TRANSMISSION – On-vehicle Service 23-35
AUTOMATIC TRANSMISSION FLUID REPLACEMENT
Caution
When the transmission has been replaced or overhauled,
the A/T fluid cooler line flushing should always be carried
out before installing the A/T fluid cooler hose.
If you have a A/T fluid changer, use this changer to replace
the A/T fluid. If you do not have a A/T fluid changer, replace
the A/T fluid by the following procedure.
1. Disconnect the hose shown in the illustration which
connects the transmission and the A/T fluid cooler (inside
the radiator).
2. Start the engine and let the A/T fluid drain out.
Running conditions: N range with engine idling
Caution
The engine should be stopped within one minute after
it is started. If the A/T fluid has all drained out before
then, the engine should be stopped at that point.
Discharge volume: Approx. 3.4

3. Remove the drain plug from the bottom of the transmission

case to drain the A/T fluid.
Discharge volume: Approx. 0.8
4. Install the drain plug via a new gasket, and tighten it to
the specified torque.
Tightening torque: 20.1 Nm
5. Pour the new A/T fluid in through the oil filler tube.
Adding volume: Approx. 4.2
Caution
Stop pouring if the full volume of A/T fluid cannot
be poured in.
6. Repeat the procedure in step 2.
NOTE
Drain the A/T fluid from the cooler hose 6.0 at least
in steps 2 and 5. Then drain the A/T fluid a little and
check the A/T fluid for dirt.
If it has been contaminated, repeat the steps 5 and 6.
7. Pour the new A/T fluid in through the oil filler tube.
Adding volume: Approx. 3.4
23-36 AUTOMATIC TRANSMISSION – On-vehicle Service

8. Reconnect the hose which was disconnected in step 1

above, and firmly replace the oil level gauge.
9. Start the engine and run it at idle for 1 – 2 minutes.
10. Move the selector lever through all positions, and then
move it to the N position.

11. Check that the A/T fluid level is at the COLD mark on
the oil level gauge. If the level is lower than this, pour
in more A/T fluid.
12. Drive the vehicle until the A/T fluid temperature rises to
the normal temperature (70 – 90_C), and then check the
A/T fluid level again.
The A/T fluid level must be at the HOT mark.
NOTE
The COLD level is for reference only; the HOT level should
be regarded as the standard level.
13. Firmly insert the oil level gauge into the oil filler tube.

AUTOMATIC TRANSMISSION FLUID COOLER LINE

FLUSHING
Caution
When the transmission has been replaced or overhauled,
or A/T fluid is contaminated, the A/T fluid cooler line
flushing should always be carried out.
1. Disconnect the hose shown in the illustration which
connects the transmission and the A/T fluid cooler (inside
the radiator).
2. Start the engine and let the A/T fluid drain out.
Running conditions: N range with engine idling
Caution
The engine should be stopped within one minute after
it is started. If the A/T fluid has all drained out before
then, the engine should be stopped at that point.
Discharge volume: Approx. 3.4
3. Pour the new A/T fluid in through the oil filler tube.
Adding volume: Approx. 3.4
Caution
Stop pouring if the full volume of A/T fluid cannot
be poured in.
 AUTOMATIC TRANSMISSION – On-vehicle Service 23-37
4. Repeat the procedure in step 2.
NOTE
Drain the A/T fluid from the cooler hose 6.0 at least
in step 2. Then drain the A/T fluid a little and check the
A/T fluid for dirt.
If it has been contaminated, repeat the steps 3 and 4.
5. Follow the automatic transmission fluid replacement
procedure from the step 3.

KICKDOWN CABLE CHECK AND ADJUSTMENT

1. Release the accelerator pedal.
A 2. Loosen the adjusting nut or adjusting bolt. Move the outer
cable of the kickdown cable to adjust the clearance (A)
between the inner cable stopper and dust cover end to
the standard value, and then tighten the adjusting nut
or adjusting bolt to secure the kickdown cable.
Adjusting Standard value: 0.8 – 1.5 mm
Dust bolt
Inner cable cover Caution
stopper Adjust the accelerator cable assembly after the
kickdown cable adjustment.

INHIBITOR SWITCH CONTINUITY CHECK

Inhibitor switch
Posi- Terminal No.
ti
tion
1 2 3 4 5 6 7 8 9 10
P
R
N
D
2
L
23-38 AUTOMATIC TRANSMISSION – On-vehicle Service

INHIBITOR SWITCH AND CONTROL CABLE

ADJUSTMENT
Mounting bolt
N position 1. Set the manual control lever to the N position.
reference 2. Loosen the inhibitor switch mounting bolt.
line 3. Turn the inhibitor switch to align the N position reference
line on the inhibitor switch with the scratched line on the
N position adjusting plate.
4. Tighten the mounting bolt to the specified torque.
N position adjust-
ing plate Tightening torque: 5.4 Nm

VCU LOCK DETECTION SWITCH CONTINUITY CHECK

Check the continuity between the terminal of the brown
connector installed in the side of transfer case (shown in the
illustration) and the transfer case.
Transfer lever position Continuity
4H No continuity
4HLc Continuity

2WD/4WD DETECTION SWITCH CONTINUITY CHECK

Check the continuity between the terminal of the white
connector installed in the side of transfer case (shown in the
illustration) and the transfer case.
Transfer lever position Continuity
2H Continuity
4H No continuity

VCU LOCK OPERATION DETECTION SWITCH

CONTINUITY CHECK
Check the continuity between the terminal of the brown
connector installed in the top of transfer case (shown in the
illustration) and the transfer case.
Transfer lever position Continuity
4H No continuity
4HLc Continuity

4WD OPERATION DETECTION SWITCH CONTINUITY

CHECK
Check the continuity between the terminal of the white
connector installed in the top of transfer case (shown in the
illustration) and the transfer case.
Transfer lever position Continuity
2H No continuity
4H Continuity
 AUTOMATIC TRANSMISSION – On-vehicle Service 23-39
HIGH/LOW DETECTION SWITCH CONTINUITY CHECK
Check the continuity between the terminal of the black
connector installed in the top of transfer case (shown in the
illustration) and the transfer case.
Transfer lever position Continuity
4HLc Continuity
Between 4HLc and 4LLc No continuity
4LLc Continuity

TRANSFER OIL CHECK

Oil filler plug 1. Remove the oil filler plug.
hole 2. Check that the oil level is at the lower portion of the oil
filler plug hole.
3. Check that the oil is not noticeably dirty, and that it has
a suitable viscosity.
Oil level 4. Tighten the oil filler plug to the specified torque.
Tightening torque: 29 – 34 Nm

TRANSFER OIL REPLACEMENT

1. Remove the oil drain plug to drain oil.
2. Tighten the oil drain plug to the specified torque.
Oil drain plug
Oil filler plug
Tightening torque: 29 – 34 Nm
3. Remove the oil filler plug and fill with specified oil till the
level comes to the lower portion of oil filler plug hole.
Specified oil:
Hypoid gear oil SAE 75W - 90 or 75W - 85W
conforming to API GL-4
Quantity: 2.2
4. Tighten the oil filler plug to the specified torque.
Tightening torque: 29 – 34 Nm
23-40 AUTOMATIC TRANSMISSION – On-vehicle Service

A/T CONTROL COMPONENT LOCATION

Name Symbol Name Symbol

Accelerator pedal position sensor (APS) K Inhibitor switch D

Input shaft speed sensor C

A/T-ECU N Output shaft speed sensor F

A/T fluid temperature sensor E Overdrive switch H
Diagnosis connector M Solenoid valves E
Dual-pressure switch A Stop lamp switch J
Engine-ECU I Vehicle speed sensor G
Free wheeling engage switch B Wide open throttle position switch L

B C D E F G

H I H I

J K L M N N M J L K
 AUTOMATIC TRANSMISSION – On-vehicle Service 23-41
A/T CONTROL COMPONENT CHECK
OVERDRIVE SWITCH CHECK
Refer to P.23-51.
WIDE OPEN THROTTLE SWITCH CHECK
Refer to P23-51.
ACCELERATOR PEDAL POSITION SENSOR (APS)
CHECK
Refer to GROUP 13A – On-vehicle Service.
INHIBITOR SWITCH CHECK
Refer to P.23-37.
STOP LAMP SWITCH CHECK
Refer to GROUP 35 – On-vehicle Service.
VEHICLE SPEED SENSOR CHECK
Refer to GROUP 54 – On-vehicle Service.
DUAL-PRESSURE SWITCH CHECK
Refer to GROUP 55 – On-vehicle Service.
FREE WHEELING ENGAGE SWITCH CHECK
Refer to GROUP 26 – On-vehicle Service.

INPUT SHAFT SPEED SENSOR CHECK

1. Disconnect the input shaft speed sensor connector.

Input shaft speed sensor

2. Measure the resistance between terminals 9 and 10 of

the input shaft speed sensor connector.
Standard value: 620 ± 60 Ω (at 20 _C)
3. If the resistance is not within the standard value, replace
the input shaft speed sensor.
23-42 AUTOMATIC TRANSMISSION – On-vehicle Service

OUTPUT SHAFT SPEED SENSOR CHECK

Output shaft speed sensor
1. Disconnect the output shaft speed sensor connector.

2. Measure the resistance between terminals 3 and 4 of

the output shaft speed sensor connector.
Standard value: 430 ± 43 Ω (at 20 _C)
3. If the resistance is not within the standard value, replace
the output shaft speed sensor.

SOLENOID VALVE CHECK

1. Disconnect the solenoid valve connector.

Solenoid valve No. 3

Solenoid valves
No. 1 and No. 2

2. Measure the solenoid valve resistance.

Standard value:

Item Measurement Resistance

terminal

Solenoid valve No. 1 Between terminal 6 13 ± 2 Ω

and earth (at 25_C)

Solenoid valve No. 2 Between terminal 7

and earth

Solenoid valve No. 3 Between terminal 8

and earth

3. If the resistance is not within the standard value, replace

the solenoid valve assembly.
 AUTOMATIC TRANSMISSION – On-vehicle Service 23-43
A/T FLUID TEMPERATURE SENSOR CHECK
1. Disconnect the A/T fluid temperature sensor connector.

A/T fluid temperature sensor

2. Measure the resistance between terminals 1 and 2 of

the A/T fluid temperature sensor connector.
Standard value
Temperature (_C) Resistance
25 1,100 Ω
120 57 Ω

3. If the resistance is not the standard value, replace the

A/T fluid temperature sensor.
23-44 AUTOMATIC TRANSMISSION – On-vehicle Service

Engine CONVERTER STALL TEST

tachometer
In this test, the engine maximum speed when the torque
converter stalls with the selector lever in the “D” or “R” range
is measured to check operation of the torque converter, starter
and one-way clutch and check holding performance of the
transmission clutch (including brake).
Caution
Do not stand in front or at rear of the vehicle during this
test.
1. Check the transmission fluid level. The fluid temperature
should be at the level after normal operation (70 – 90_C).
The engine coolant temperature should also be at the
level after normal operation (80 – 95_C).
2. Apply chocks to the rear wheels (right and left).
3. Mount an engine tachometer.
4. Apply fully the parking and service brakes.
5. Start the engine.
6. With the selector lever in the “D” range, fully depress
the accelerator pedal and read off the engine maximum
speed.
NOTE
When doing so, do not keep the engine running with throttle
full open for more than 5 seconds. If two or more stall
tests are needed, place the selector lever in the “N” position
and run the engine at about 1,000 r/min to allow the
transmission fluid to cool before another stall test.
Standard value: 2,320 – 2,620 r/min
7. Place the selector lever in the “R” range and perform
the test as above.

JUDGEMENT OF STALL TEST RESULTS

Stall speed in “D” and “R” range is equal to each other (1) Engine output is low.
but lower than the nominal value. (2) Starter one-way clutch is faulty. (Faulty torque
converter is suspected if it is lower than nominal by
more than 600 r/min)

Stall speed in “D” range is higher than nominal. (1) Overdrive clutch slipping
(2) Overdrive one-way clutch faulty
(3) Forward clutch slipping
(4) One-way clutch No. 2 faulty
(5) Low line pressure

Stall speed in “R” range is higher than nominal. (1) Overdrive clutch slipping
(2) Overdrive one-way clutch faulty
(3) Direct clutch slipping
(4) Brake No. 3 slipping
(5) Low line pressure
 AUTOMATIC TRANSMISSION – On-vehicle Service 23-45
HYDRAULIC PRESSURE TEST
The hydraulic pressure test is important in determining the
MD998920 causes of transmission failures. Before conducting the test,
fluid level and condition and throttle cable adjustment, etc.
must be checked for defects or abnormalities. When conducting
the test, the engine and transmission should be at correct
MD998331 operating temperatures, (engine coolant 80 – 95_C,
transmission fluid 70 – 90_C.)
MD998330 LINE PRESSURE TEST
1. Place the vehicle on a chassis dynamometer.
2. Remove the plug from the line pressure take off port.
3. Install special tools as shown in the figure and place the
meter inside vehicle.
4. Apply the parking brake.
5. Start the engine.
6. Place the selector lever in the “D” range.
7. Depress the brake pedal firmly by the left foot and operate
the accelerator pedal by the right foot to measure the
line pressure at each engine r/min. If the measured
pressure is not nominal, check adjustment of the throttle
cable and readjust if necessary before conducting the
test again.
8. Place the selector lever in the “R” range and test as above.
Standard value:

Items Line pressure kPa

“D” range “R” range

At idle 373 – 422 520 – 579

At stall 765 – 863 1,383 – 1,628

JUDGEMENT BY LINE PRESSURE

Hydraulic pressure higher than nominal in all ranges (1) Regulator valve faulty
(2) Throttle valve faulty
(3) Throttle cable incorrectly adjusted

Hydraulic pressure lower than nominal in all ranges (1) Oil pump faulty
(2) Regulator valve faulty
(3) Throttle valve faulty
(4) Throttle cable incorrectly adjusted
(5) Overdrive clutch faulty

Hydraulic pressure lower than nominal in “D” range (1) Large fluid leaks in “D” range hydraulic circuit
(2) Forward clutch faulty
(3) Overdrive clutch faulty

Hydraulic pressure lower than nominal in “R” range (1) Large fluid leaks in “R” range hydraulic circuit
(2) Brake No. 3 faulty
(3) Direct clutch faulty
(4) Overdrive clutch faulty
23-46 AUTOMATIC TRANSMISSION – On-vehicle Service

HYDRAULIC CIRCUIT

1 2 3 4 5 6 7

PRND2L

8 9 10

14
15 12
13

11
17 20 21
16
18 23

19
22

28 26 24
27 25

29

1. Overdrive clutch 16. Cut-back valve

2. Overdrive brake 17. Throttle valve
3. Forward clutch 18. Secondary regulator valve
4. Direct clutch 19. Lockup control valve
5. Brake No. 1 20. Primary regulator valve
6. Brake No. 2 21. Reverse clutch sequence valve
7. Brake No. 3 22. 3-4 shift valve
8. Manual valve 23. Intermediate modulator valve
9. 2-3 shift valve 24. Accumulator C1
10. Solenoid valve No. 1 25. Accumulator C2
11. Solenoid valve No. 2 26. Accumulator B2
12. Low coast modulator valve 27. Oil cooler bypass valve
13. 1-2 shift valve 28. Oil pump
14. Pressure relief valve 29. Oil strainer
15. Solenoid valve No. 3
 AUTOMATIC TRANSMISSION – On-vehicle Service 23-47
SELECTOR LEVER OPERATION CHECK
1. Apply the parking brake lever.
2. Move the selector lever from N position to each of D,
2 and L positions to check that the selector lever moves
smoothly.
3. Check that the engine starts when the selector lever is
in each of N and P positions, and that the engine does
not start when the selector lever is in positions other than
N and P.
4. Start the engine and release the parking brake. Check
that the vehicle moves forward when the selector lever
is moved from N position to each of D, 2 and L positions,
and moves backward when the selector lever is moved
Turn the ignition switch to any position to R position.
other than LOCK (OFF), and operate 5. Stop the engine.
the selector lever with the brake pedal
depressed and the push button pushed. 6. Turn the ignition switch to ON position. Check that the
Operate the selector lever without backup lamp illuminates and the buzzer sounds when
pushing the push button. the selector lever is moved from P position to R position.
Operate the selector lever with the NOTE
push button pushed.
Because of the inclusion of an A/T mis-operation prevention
device, the select or lever cannot be moved from the P
position to an other position unless you turn the ignition
key to a position other than LOCK (OFF) and depress
the brake pedal first.

KEY INTERLOCK MECHANISM CHECK

1. Carry out the following inspection:

Inspection Requirements Normal condition

procedure

1 Brake pedal: Ignition key: LOCK The selector lever push button can not be pushed, and the
Depressed (OFF) or removed selector lever should not be moved from P position.

2 Ignition key: Other than If the selector lever push button is pushed, the selector
above lever can be moved from P position.

3 Brake pedal: Selector lever: Other The ignition key can not be turned to LOCK (OFF)
Not depressed than P position.

4 Selector lever: P The ignition key can be turned to LOCK (OFF) position.
23-48 AUTOMATIC TRANSMISSION – On-vehicle Service

2. If there is a problem on the inspection above, adjust the

key interlock cable as follows:
12 Nm (1) Remove the rear floor console. (Refer to GROUP 52A.)
Lock cam (2) Move the selector lever to P position.
(3) Turn the ignition key to LOCK (OFF) position.
A
(4) Loosen the key interlock cable fixing nut.
(5) Tighten the key interlock cable fixing nut to the specified
torque with the lock cam pushed in the direction A
(shown in the illustration).
Tightening torque: 12 Nm
(6) Install the rear floor console. (Refer to GROUP 52A.)

SHIFT LOCK MECHANISM CHECK

1. Carry out the following inspection:

Inspection Requirements Normal condition

procedure

1 Brake pedal: Ignition key: ACC If the selector lever push button is not pushed, the
Depressed selector lever can not be moved from P position.

2 If the selector lever push button is pushed, the

selector lever can be moved from P position.

3 Brake pedal: If the selector lever push button is pushed, the

Not depressed selector lever can be moved from R position to P
position.
 AUTOMATIC TRANSMISSION – On-vehicle Service 23-49
2. If there is a problem on the inspection above, adjust the shift
Red marking lock cable as follows:
Lock cam (1) Remove the rear floor console. (Refer to GROUP 52A.)
Shift lock cable
(2) Move the selector lever to P position.
(3) Loosen the shift lock cable fixing nut.
(4) Move the shift lock cable to position the shift lock
cable end above the red marking painted on the lock
cam, and then tighten the shift lock cable fixing nut
to the specified torque.
12 Nm
Tightening torque: 12 Nm
(5) Install the rear floor console. (Refer to GROUP 52A.)

Transmission Front of vehicle TRANSMISSION CONTROL CABLE

N ADJUSTMENT
90°C
1. Move the selector lever to N position, and set the
transmission lever to N position.

Transmission lever

2. Loosen the fixing bolt. Adjust the adjuster lever position

so that the transmission control cable will be tight, and
Fixing bolt then tighten the fixing bolt.

Transmission
Adjuster lever control cable
23-50 AUTOMATIC TRANSMISSION – Transmission Control

TRANSMISSION CONTROL
REMOVAL AND INSTALLATION
Caution
Do not strike the SRS-ECU when removing and installing the transmission control cable, key interlock
cable, shift lever assembly and the A/T-ECU.

Apply sealant
to both sides

9, 11

Sealant: Sealant:
3M Stud Locking 3M ATD Part No.8663 13
No.4170 or equivalent or equivalent

12 Nm
12 Nm
1

12 Nm
15 – 22 Nm

3 6
2
6

5 12
7
11
8
10

12 Nm

Selector lever assembly and Transfer control lever assembly

transmission control cable assembly removal steps
removal steps D Front floor console assembly
D Rear floor console assembly (Refer to GROUP 52A.)
(Refer to GROUP 52A.) 6. Retainer plate
1. Key interlock cable connection "AA 7. Transfer lever inner boot
2. Shift lock cable connection 8. Transfer control lever assembly
3. Transmission control cable connection 9. Gasket
(selector lever side) 10. Stopper plate
4. Selector lever assembly 11. Gasket
5. Transmission control cable connection 12. Transfer control lever
(transmission side) Wide open throttle switch removal
13. Wide open throttle switch
 AUTOMATIC TRANSMISSION – Transmission Control 23-51
INSTALLATION SERVICE POINT
"AA TRANSFER LEVER INNER BOOT INSTALLATION
Install the transfer lever inner boot as shown in the illustration.
Front of
vehicle

Front of vehicle INSPECTION

Slide the connector in the direction of arrow shown in the
illustration to remove it from the bracket.
POSITION INDICATOR LAMP CHECK
Check requirement
q Terminal No.
1 2
Always

OVERDRIVE SWITCH CHECK

Switch position Terminal No.
3 4 5
Connector
ON
OFF

Bracket

WIDE OPEN THROTTLE SWITCH CHECK

Switch position Terminal No.
OFF 1 2
ON
OFF
ON
23-52 AUTOMATIC TRANSMISSION – Transmission Control

SELECTOR LEVER ASSEMBLY

DISASSEMBLY AND REASSEMBLY

15 Nm
3
15 Nm

6 2

5
4
9
8
12 Nm

1
10

18
11
12

14

13 15 17

16

Disassembly steps
AA" 1. Position indicator socket assembly 10. Adjuster lever
2. Bulb 11. Lock cam
3. Shift knob 12. Pin
4. Push button 13. Ball spring
5. Stopper 14. Ball support
6. Spring 15. Ball
7. Overdrive switch 16. Packing
8. Indicator panel assembly 17. Selector lever assembly
"AA 9. Sleeve 18. Stopper
 AUTOMATIC TRANSMISSION – Transmission Control 23-53
DISASSEMBLY SERVICE POINT
Terminal AA" POSITION INDICATOR SOCKET ASSEMBLY
REMOVAL
Use a flat-tipped screwdriver, etc. to remove the terminal of
shift knob side from the position indicator socket assembly
connector.

Screwdriver

REASSEMBLY SERVICE POINT

16.0 – 16.7 mm
Sleeve "AA SLEEVE INSTALLATION
Shift the selector lever to the N position, and then turn the
sleeve so that the clearance between the sleeve and lever
assembly end is within the dimension shown in the illustration.

Selector
lever
assembly
23-54 AUTOMATIC TRANSMISSION – A/T Key Interlock and Shift Lock Mechanisms

A/T KEY INTERLOCK AND SHIFT LOCK MECHANISMS

REMOVAL AND INSTALLATION

6
2
12 Nm
4

1
7

12 Nm

Key interlock cable removal steps Shift lock cable removal steps
D Front floor console (Refer to GROUP D Front floor console (Refer to GROUP
52A.) 52A.)
D Instrument under cover (Refer to "AA 5. Shift lock cable connection
GROUP 52A.) (selector lever side)
D Lower column cover (Refer to GROUP 6. Shift lock cable connection
37A – Steering Wheel and Shaft.) (brake pedal side)
"CA 1. Key interlock cable connection 7. Shift lock cable
(selector lever side)
2. Cover
"BA 3. Key interlock cable connection
(steering lock cylinder side)
4. Key interlock cable
 AUTOMATIC TRANSMISSION – A/T Key Interlock and Shift Lock Mechanisms 23-55
INSTALLATION SERVICE POINTS
Red marking
Lock cam
"AA SHIFT LOCK CABLE (SELECTOR LEVER SIDE)
Shift lock cable INSTALLATION
1. Move the selector lever to P position.
2. Move the shift lock cable to position the shift lock cable
end above the red marking painted on the lock cam, and
then tighten the shift lock cable fixing nut to the specified
torque.
12 Nm
Tightening torque: 12 Nm
3. Check that the shift lock mechanism operates normally.
(Refer to P. 23-49.)

"BA KEY INTERLOCK CABLE (STEERING LOCK

CYLINDER SIDE) INSTALLATION
Turn the ignition key to LOCK (OFF) position, and then install
the key interlock cable.

"CA KEY INTERLOCK CABLE (SELECTOR LEVER

SIDE) INSTALLATION
12 Nm 1. Move the selector lever to P position.
Lock cam
2. Turn the ignition key to LOCK (OFF) position.
A 3. Connect the key interlock cable end to the lock cam.
4. Install the key interlock cable temporarily.
5. Tighten the key interlock cable fixing nut to the specified
torque with the lock cam pushed in the direction A (shown
in the illustration).
Tightening torque: 12 Nm
6. Check that the key interlock mechanism operates normally.
(Refer to P. 23-48.)
23-56 AUTOMATIC TRANSMISSION – Transmission Assembly

TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Caution
Mounting locations marked by * should be provisionally tightened, and then fully tightened after
placing the vehicle horizontally and loading the full weight of the transmission on the vehicle body.

Pre-removal and Post-installation Operation

D Transfer Control Lever Assembly Removal and D Front Exhaust Pipe and Catalytic Converter Removal
Installation (Refer to P.23-50.) and Installation (Refer to GROUP 15.)
D Under Cover Removal and Installation D Vacuum Actuator Assembly Removal and Installation
D Transmission Fluid and Transfer Oil Draining and (Refer to GROUP 26 – Main Shaft.)
Filling (Refer to P.23-35, 39.) D Kick-down Cable Adjustment <Only after installation>
D Front and Rear Propeller Shaft Removal and (Refer to P.23-37.)
Installation (Refer to GROUP 25.) D Accelerator Cable Assembly Check and Adjustment
D Air Cleaner Removal and Installation (Refer to <Only after installation> (Refer to GROUP 17 –
GROUP 15 – Air Cleaner and Resonance Tank.) On-vehicle Service.)

26 – 33 Nm 9
10

12 11
1

13
16 Nm

8 7

Removal steps
1. Kick-down cable connection 9. VCU lock operation detection switch
2. Oil level gauge assembly connector
3. Transmission control cable connection 10. High/Low detection switch connector
4. Dust shield guard 11. 4WD operation detection switch
AA" 5. Starter motor connector
6. Vehicle speed sensor connector 12. Harness connector
7. VCU lock detection switch connector 13. Inhibitor switch connector
8. 2WD/4WD detection switch connector
 AUTOMATIC TRANSMISSION – Transmission Assembly 23-57

23

49 Nm
24

14

22
23

15 49 Nm 49 Nm

20

18 21
21
34 – 41 Nm

17 18
49 Nm

16
19
93 Nm
18

49 Nm 17

16

49 Nm

14. Oil cooler hose 18. Transmission mount bushing

D Oil pan removal 19. Transmission mount crossmember
(Refer to GROUP 11A.) 20. Transmission mount insulator
AB" 15. Drive plate connection bolt assembly
D Support the transmission with a "BA 21. Transmission mount stopper
transmission jack 22. Adapter
16. Washer 23. Transmission upper part coupling bolts
17. Spacer "AA 24. Transmission assembly
23-58 AUTOMATIC TRANSMISSION – Transmission Assembly

REMOVAL SERVICE POINTS

AA" STARTER MOTOR REMOVAL
Remove the starter motor with the starter motor harnesses
still connected, and secure it inside the engine compartment.

AB" DRIVE PLATE CONNECTION BOLTS REMOVAL

1. Remove the connection bolts (6 places) while turning the
crankshaft.
2. Press in the torque converter to the transmission side
so the torque converter does not remain on the engine
side.

INSTALLATION SERVICE POINTS

"AA TRANSMISSION ASSEMBLY INSTALLATION
Press in the torque converter to the transmission side
25.9 mm completely, and then install the transmission assembly to the
engine.

Front of "BA TRANSMISSION MOUNT STOPPER INSTALLATION

vehicle 1. Install the transmission mount stopper so that the arrow
faces the direction shown.
NOTE
Disregard F and R stamped as a shared part.
Transmission
mount insulator
assembly
Transmission
mount stopper

2. The sizes of the mounting bolts are different. So be sure

Diameter B A not to confuse them.
A Bolt Diameter x Length mm
Length
A 10 x 50
C
Starter motor B B 10 x 60

C 10 x 40
4G9 only
 AUTOMATIC TRANSMISSION – Transmission Oil Cooler 23-59
TRANSMISSION OIL COOLER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Transmission Fluid Draining and Supplying
(Refer to P.23-35.)
D Under Cover Removal and Installation

5 6
4
3

44 Nm

Removal steps
1. Return hose D Transmission assembly (Refer to
2. Feed hose P.23-56.)
3. Oil cooler pipe assembly 5. Oil return pipe
4. Hose assembly 6. Oil feed pipe
23-60 AUTOMATIC TRANSMISSION – A/T-ECU/4WD Indicator Control Unit

A/T-ECU
REMOVAL AND INSTALLATION
Caution
Do not strike the G sensor when removing and installing the A/T-ECU.

Pre-removal and Post-installation Operation

Rear Floor Console Removal and Installation

Removal steps
1. Floor console bracket
2. A/T-ECU

4WD INDICATOR CONTROL UNIT

REMOVAL AND INSTALLATION
Refer to GROUP 22.
 23-1

AUTOMATIC
TRANSMISSION
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING <A/T> . . . . . . . . . . . . . . . . 2

Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23-2 AUTOMATIC TRANSMISSION – General/Troubleshooting <A/T>

GENERAL
OUTLINE OF CHANGES
The following service procedures for items which are different from before have been established to correspond
to the following changes:
 The A/T-ECU has been changed.
 The shift pattern has been changed.

TROUBLESHOOTING <A/T>
SHIFT PATTERN
D range (Overdrive switch: ON)
Throttle opening (%)
1 2 2 3 3 4
100
1 2 2 3 3 4
80

60

40

20

Output shaft speed r/min 0 1,000 2,000 3,000 4,000 5,000 6,000

Vehicle speed km/h 0 50 100 150

INSPECTION CHART FOR DIAGNOSIS CODE

Code Diagnosis item Reference page

13 Accelerator pedal position sensor system Sensor malfunction/ 23-3

(Throttle opening voltage) open circuit/short circuit

14 Accelerator pedal position sensor system Open circuit/short circuit 23-3

(Throttle power supply voltage)

15 A/T fluid temperature sensor system Open circuit 23-4

16 A/T fluid temperature sensor system Short circuit 23-4

22 Wide open throttle system Open circuit/short circuit 23-4

29 Inhibitor switch system Open circuit 23-5

30 Inhibitor switch system Short circuit 23-5

31 Input shaft speed sensor system Open circuit 23-6

32 Output shaft speed sensor system Open circuit 23-6

38 Vehicle speed sensor system Open circuit 23-7

41 Solenoid valve No. 1 system Open circuit 23-8

42 Solenoid valve No. 1 system Short circuit 23-8

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-3

Code Diagnosis item Reference page

43 Solenoid valve No. 2 system Open circuit 23-8

44 Solenoid valve No. 2 system Short circuit 23-8

47 Solenoid valve No. 3 system Open circuit 23-8

48 Solenoid valve No. 3 system Short circuit 23-8

55 Abnormal communication with engine-ECU Open circuit 23-9

INSPECTION PROCEDURES FOR DIAGNOSIS CODES

Code No. 13, 14 Accelerator pedal position sensor (APS) Probable cause
If the APS output voltage (APS opening voltage) is 4.8 V or higher when the engine  Malfunction of the accelerator pedal position sensor
is idling, the output voltage is judged to be too high and diagnosis code No. 13  Malfunction of harness or connector
is output. If the APS output voltage (APS opening voltage) is 0.335 V or lower  Malfunction of the A/T-ECU
when the engine is idling, the output voltage is judged to be too low and diagnosis
code No. 13 is output.
If the APS output voltage (APS power supply voltage) is 3.0 V or lower or if it
is 5.7 V or higher when the engine is idling, the APS is judged to be faulty and
diagnosis code No. 14 is output.

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

NG
Accelerator pedal position sensor check Replace
(Refer to GROUP 13A – On-vehicle Service.)*
OK
NG
Check the following connectors: Repair
<L.H. drive vehicles> C-46, C-25, D-34, D-46
<R.H. drive vehicles> C-46, C-26, D-34, D-46
OK
NG
Check the trouble symptoms. Harness check
 Between accelerator pedal position sensor and A/T-ECU
OK NG
Repair

Replace the A/T-ECU.

23-4 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

Code No. 15, 16 A/T fluid temperature sensor system Probable cause
If the A/T fluid temperature sensor output is 10C or less (5.6 kΩ or more) even  Malfunction of the A/T fluid temperature sensor
after running the engine for 15 minutes or more, it is judged that there is an open  Malfunction of harness or connector
circuit in the A/T fluid temperature sensor and diagnosis code No. 15 is output.  Malfunction of the A/T-ECU
If the A/T fluid temperature sensor output is 240C or more (10 kΩ or less), it is
judged that there is a short circuit in the A/T fluid temperature sensor and diagnosis
code No. 16 is output.

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

NG
A/T fluid temperature sensor check (Refer to P.23-43.)* Replace
OK
NG
Check the following connectors: B-03, D-45 Repair
OK
NG
Check the trouble symptoms. Harness check
 Between A/T fluid temperature sensor and A/T-ECU
OK NG
Repair
Replace the A/T-ECU.

Code No. 22 Wide open throttle switch system Probable cause

If the wide open throttle switch dose not turn OFF with the accelerator pedal is  Malfunction of the wide open throttle switch
not depressed, there is a short circuit in the wide open throttle switch and diagnosis  Malfunction of harness or connector
code No. 22 is output.  Malfunction of the A/T-ECU

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

NG
Wide open throttle switch check (Refer to P.23-51).* Replace
OK
NG
Measure at wide open throttle switch connector C-58. Check the following connector: D-46
 Disconnect the connector and measure at the harness side. OK NG
 Voltage between terminal 1 and earth
(ignition switch: ON) Repair
OK: System voltage
Check the trouble symptoms.
OK
NG OK
Check the following connectors: C-58, D-34, D-46 Repair
OK
Harness check
Check the trouble symptoms.  Between the wide open throttle switch and the A/T-ECU
connectors.
OK
OK NG
Harness check
 Between the wide open throttle switch and the A/T-ECU Repair
connectors, and repair if necessary. Replace the A/T-ECU.
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-5
Code No. 29, 30 Inhibitor switch system Probable cause
If the inhibitor switch has not sent any signal for 2 seconds while the ignition switch  Malfunction of the inhibitor switch
is on, it is judged that there is an open circuit in the inhibitor switch and diagnosis  Malfunction of harness or
code No.29 is set.  Malfunction of the A/T-ECU
If the inhibitor switch has sent at least two signals simultaneously for 2 seconds
while the ignition switch is on, it is judged that there is an short circuit in the inhibitor
switch and diagnosis code No.30 is set.

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

MUTĆII SERVICE DATA OK

 37 Inhibitor switch End
OK: The MUT-II should display a correct selector lever posi-
tion.
NG
NG
Inhibitor switch check (Refer to P.23-37).* Replace
OK
NG
Measure at inhibitor switch connector B-04. Check the following connectors: D-02, C-26, C-74, C-78
 Disconnect the connector and measure at the harness side. OK NG
 Voltage between terminal 8 and earth
(ignition switch: ON) Repair
OK: System voltage
Check the trouble symptoms.
OK
OK
Check the following connectors: B-04, D-46
OK NG Harness check
 Between the inhibitor switch and the ignition switch
Repair
OK NG
Check the trouble symptoms. Repair
NG
Check the ignition switch. (Refer to GROUP 54 - ignition switch.)*
Harness check NG
 Between the inhibitor switch and the A/T-ECU Repair

OK

Replace the A/T-ECU.

23-6 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

Code No. 31, 32 Input shaft speed sensor system, output Probable cause
shaft speed sensor system
If no output pulse is detected from the input shaft speed sensor for 120 seconds  Malfunction of the input shaft speed sensor
or more while driving in 3rd gear at a speed of 60 km/h or more, there is judged  Malfunction of the output shaft speed sensor
to be an open circuit in the input shaft speed sensor and diagnosis code No. 31  Malfunction of harness or connector
is output. If not output pulse is detected from the output shaft speed sensor for  Malfunction of the sensor rotor
120 seconds or more while driving in 3rd gear at a speed of 60 km/h or more,  Malfunction of A/T-ECU
there is judged to be an open circuit in the output shaft speed sensor and diagnosis  Electrical noise
code No. 32 is output.

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

: Refer to the Transmission Workshop Manual

NG
Input shaft speed sensor check (Refer to P.23-41).* Replace the input shaft speed sensor and output shaft speed sensor.
Output shaft speed sensor check (Refer to P.23-42).*
OK
Check the trouble symptoms.
NG NG
Check the following connectors: B-03, D-46 Repair
OK NG
Check the sensor rotor.
Repair
OK NG
Check the trouble symptoms.
Repair
OK
Check the trouble symptoms.
Harness check NG
 Between the input shaft speed sensor and the A/T-ECU
 Between the output shaft speed sensor and the A/T-ECU
OK NG Eliminate a source of electrical noise.

Repair
Replace the A/T-ECU.
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-7
Code No. 38 Vehicle speed sensor system Probable cause
If no output pulse is detected from the vehicle speed sensor for 120 seconds or  Malfunction of the vehicle speed sensor
more continuously while driving at a speed of 60 km/h or more, there is judged  Malfunction of harness or connector
to be an open circuit in the vehicle speed sensor and diagnosis code No. 38 is  Malfunction of the A/T-ECU
output.  Malfunction of the ignition switch

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

NG
Vehicle speed sensor check Replace
(Refer to GROUP 54 – Combination meter.)*
OK
(1) NG
Measure at the vehicle speed sensor connector B-08. Check the following connectors:
 Disconnect the connector, and measure at the harness side. <L.H. drive vehicles> D-02, C-38, C-02, C-76, C-74
(1) Voltage between 1 and earth (Ignition switch: ON) (2) NG <R.H. drive vehicles> D-02, C-41, C-76, C-74
OK: System voltage NG
OK
(2) Voltage between 3 and earth (Ignition switch: ON)
OK: 4.8 - 5.2 V (3) NG Repair
(3) Continuity between 2 and earth Check trouble symptom.
OK: Continuity
NG

Harness check
 Between the vehicle speed sensor and ignition switch
connector.
OK OK NG
Check the following connectors: B-08, D-02, D-46 Repair

OK NG Check the ignition switch. (Refer to GROUP 54 - Ignition switch.)*

Repair
Check trouble symptom. Check the following connectors: D-02, D-46
NG OK NG
Repair
Harness check
 Between the A/T-ECU and the vehicle speed sensor. Check trouble symptom.
OK NG NG
Repair Harness check
Replace the A/T-ECU.  Between the A/T-ECU and the vehicle speed sensor.
OK NG
Repair
Replace the A/T-ECU.

Harness check
 Between the vehicle speed sensor and the earth, and
repair if necessary.
23-8 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

Code No. 41, 42 Solenoid valve No.1 system Probable cause

If the resistance value for a solenoid valve No.1 is too large, it is judged that there  Malfunction of solenoid valve No.1
is an open circuit in the solenoid valve No.1 and the diagnosis code No.41 is output.  Malfunction of harness or connector
If the resistance value for a solenoid valve No.1 is too small, it is judged that there  Malfunction of the A/T-ECU
is a short-circuit in the solenoid valve No.1 and the diagnosis code No.42 is output.

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

NG
Solenoid valve No.1 check (Refer to P.23-42.)* Replace
OK
NG
Check the following connectors: B-03, D-45 Repair
OK
NG
Check the harness wire between A/T-ECU and solenoid valve No.1. Repair
OK
NG
Check the trouble symptoms. Replace the A/T-ECU.

Code No. 43, 44 Solenoid valve No.2 system Probable cause

If the resistance value for a solenoid valve No.2 is too large, it is judged that there  Malfunction of solenoid valve No.2
is an open circuit in the solenoid valve No.2 and the diagnosis code No.43 is output.  Malfunction of harness or connector
If the resistance value for a solenoid valve No.2 is too small, it is judged that there  Malfunction of the A/T-ECU
is a short-circuit in the solenoid valve No.2 and the diagnosis code No.44 is output.

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

NG
Solenoid valve No.2 check (Refer to P.23-42.)* Replace
OK
NG
Check the following connectors: B-03, D-45 Repair
OK
NG
Check the harness wire between A/T-ECU and solenoid valve No.2. Repair
OK
NG
Check the trouble symptoms. Replace the A/T-ECU.

Code No. 47, 48 Solenoid valve No.3 system Probable cause

If the resistance value for a solenoid valve No.3 is too large, it is judged that there  Malfunction of solenoid valve No.3
is an open circuit in the solenoid valve No.3 and the diagnosis code No.47 is output.  Malfunction of harness or connector
If the resistance value for a solenoid valve No.3 is too small, it is judged that there  Malfunction of the A/T-ECU
is a short-circuit in the solenoid valve No.3 and the diagnosis code No.48 is output.

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

NG
Solenoid valve No.3 check (Refer to P.23-42.)* Replace
OK
NG
Check the following connectors: B-03, D-45 Repair
OK
NG
Check the harness wire between A/T-ECU and solenoid valve No.3. Repair
OK
NG
Check the trouble symptoms. Replace the A/T-ECU.
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-9
Code No. 55 Abnormal communication with engine-ECU Probable cause
If normal communication is not possible for a continuous period of 1 second or  Malfunction of harness or connector
more when the ignition switch is at the ON position and the battery voltage is 10  Malfunction of the engine-ECU
V or more, diagnosis code No. 55 is output. Diagnosis code No. 55 is also output  Malfunction of the A/T-ECU
if the data being received is abnormal for a continuous period of 1 second under
the same conditions.

NO
MUT-II Self-Diag code Replace the A/T-ECU.
 Is the diagnosis code No.61 output?
YES
NG
Check the following connectors: Repair
<L.H. vehicles> C-19, C-25, D-34, D-45
<R.H. vehicles> C-19, C-26, D-34, D-45
OK

Check the trouble symptoms.

NG
NG
Check the harness wire between engine-ECU and A/T-ECU. Repair
OK

Replace the engine-ECU.

NG
Check the trouble symptoms. Replace the A/T-ECU.

INSPECTION CHART FOR TROUBLE SYMPTOMS

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

Trouble symptom Inspection procedure Reference page

No.

Communication with the MUT-II is not possible 1 23-10

Does not move Does not move forward and reverse 2 23-17*

Does not move forward only 3 23-18*

Does not reverse only 4 23-18*

Malfunction when Upshifting does not occur 5 23-19*

shifting
Downshifting does not occur 6 23-20*

Shifting point abnormality 7 23-20*

Upshifting occurs spontaneously 8 23-21*

Incorrect drive gear position 9 23-21*

Large shocks 10 23-22*

Slippage (vibration) 11 23-23*

Lockup malfunction 12 23-24*

Abnormal engine braking 13 23-24*

Electronic circuit Overdrive switch system 14 23-11

systems
Stop lamp switch system 15 23-11
23-10 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1
Communication with the MUT-II is not possible Probable cause
If communication with the MUT-II is not possible, the cause is probably a malfunction  Malfunction of self-diagnosis system
in the self-diagnosis system or the A/T-ECU is not functioning.  Malfunction of A/T-ECU power circuit
 Malfunction of A/T-ECU earth circuit
 Malfunction of A/T-ECU
 Malfunction of harness and connector

NO
Is communication with other systems possible using the MUT-II? Check and repair the self-diagnosis
YES system with the MUT-II

OK
Measure at A/T-ECU connector D-45 Check the following connectors:
 Disconnect the connector and measure at the harness side. <L.H. drive vehicles> D-46, D-34, C-37, C-70, C-35
 Voltage between terminals 5 and 14 and the earth <R.H. drive vehicles> D-46, D-34, C-39, C-70, C-35
(ignition switch: ON) OK NG
OK: System voltage
 Continuity between terminal 19 and earth Repair
OK: Continuity
Check the trouble symptoms.
NG
OK
Check the following connectors:
<L.H. drive vehicles> D-45, C-24, C-78, C-74, D-34, C-68, C-72 Replace the A/T-ECU.
<R.H. drive vehicles> D-45, C-26, C-78, C-74, D-34, C-68, C-72
OK NG
Repair
Check the trouble symptoms.  Check and repair the harness wire between the A/T-ECU
and the power supply.
 Check and repair the harness wire between the A/T-ECU
and the earth.
OK NG
Repair
Check the trouble symptoms
NG
Replace the A/T-ECU.
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-11
INSPECTION PROCEDURE 14
Overdrive switch system Probable cause
If downshifting does not occur when overdrive switch is turned off while driving  Malfunction of overdrive switch
in 4th gear, or if shifting to 4th gear is not possible, the cause is probably a problem  Malfunction of harness or connector
in the overdrive switch system.  Malfunction of A/T-ECU
 Malfunction of ignition switch

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

OK
MUT-II SERVICE DATA Completed
 35 – Overdrive switch
OK: MUT-II display and overdrive switch OD/OD-OFF posi-
tion should match.
NG

Check the overdrive switch. (Refer to P.23-51.)*

OK NG
Repair
OK
Measure at overdrive switch connector D-35. Check the following connectors: D-35, D-34, D-46
 Disconnect the connector and measure at the harness side OK NG
 Voltage between terminal 3 and earth
(Ignition switch: ON) Repair
OK: System voltage
Check the trouble symptoms.

Check the harness wire between the overdrive switch and the
A/T-ECU.
OK NG
NG
Repair
Check the ignition switch. (Refer to GROUP 54 – Ignition Switch.)*
Replace the A/T-ECU.

INSPECTION PROCEDURE 15
Stop lamp switch system Probable cause
If large shocks occur during squat control, the cause is probably a problem with  Malfunction of stop lamp switch
the stop lamp switch.  Malfunction of harness or connector
 Malfunction of A/T-ECU

*: Refer to ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).

OK
MUT-II SERVICE DATA Check the stop lamp switch
 28 – Stop lamp switch (Refer to GROUP 35 – Brake Pedal)*
OK: ON when the brake pedal is depressed and OFF when
the brake pedal is released
NG
NG
Check the following connectors: Repair
<L.H. drive vehicles> C-04, C-02, C-29, C-24, D-02, D-45
<R.H. drive vehicles> C-04, C-02, C-41, D-02, D-45
OK

Check the trouble symptoms.

OK
NG
Check the harness wire between the stop lamp switch and the Repair
A/T-ECU.
OK

Replace the A/T-ECU.

23-12 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

SERVICE DATA REFERENCE TABLE

Item No. 37 has been changed since the A/T-ECU has been changed. The other SERVICE DATA are
the same as before.
Item Inspection item Inspection conditions Normal value
No.

37 Inhibitor switch Ignition switch: ON Selector lever position: P P

Engine: Stopped
Selector lever position: R R

Selector lever position: N N

Selector lever position: D D

Selector lever position: 2 2

Selector lever position: L L

A/T-ECU TERMINAL VOLTAGE REFERENCE CHART

Terminal Inspection item Inspection conditions Standard value

No.

1 Solenoid valve No. 1 When in 1st or 2nd gear System voltage

When in 3rd or 4th gear 0V

2 Solenoid valve No. 2 When in 2nd or 3rd gear System voltage

When in 1st or 4th gear 0V

3 Free-wheeling engage Transfer lever position: Other than 4WD System voltage
switch
Transfer lever position: 4WD 0V

5 Back-up power supply Ignition switch: OFF System voltage

6 Solenoid valve No. 3 When lockup clutch is operating System voltage

When lockup clutch is not operating 0V

11 Communication with input Engine: Idling Other than 0 V

signals from engine-ECU Selector lever position: D

13 A/T fluid temperature ATF temperature: 120C Approx. 0.3 V

sensor
ATF temperature: 150C Approx. 0.15 V

14 Power supply Ignition switch: OFF 0V

Ignition switch: ON System voltage

17 Communication with output Engine: Idling Other than 0 V

signals to engine-ECU Selector lever position: D
 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-13

Terminal Inspection item Inspection conditions Standard value

No.

18 Stop lamp switch Brake pedal: Depressed System voltage

Brake pedal: Released 0V

19 Earth Engine: Idling 0V

20 A/T fluid temperature – –

sensor earth

21 Diagnostic output terminal – –

23 Input shaft speed sensor Ignition switch: OFF 0V

Ignition switch: ON 2.5 V

24 Output shaft speed sensor Vehicle: Stopped Approx. 2.5 V

Vehicle: Driving Other than 2.5 V

25 Overdrive switch Overdrive switch: ON System voltage

Overdrive switch: OFF 0V

26 Inhibitor switch P Selector lever position: P System voltage

Selector lever position: Other than P 0V

27 Inhibitor switch R Selector lever position: R System voltage

Selector lever position: Other than R 0V

30 Input shaft speed sensor – –

earth

31 Output shaft speed sensor – –

earth

33 Wide open throttle switch Accelerator pedal: Released 4.5 – 5.5 V

Accelerator pedal: Depressed Less than 0.4 V

34 Dual-pressure switch A/C switch: OFF 0V

A/C switch: ON System voltage

37 N range lamp Ignition switch: ON System voltage

Ignition switch: OFF 0V

38 Inhibitor switch N Selector lever position: N System voltage

Selector lever position: Other than N 0V

39 Inhibitor switch D Selector lever position: D System voltage

Selector lever position: Other than D 0V

41 Diagnosis control terminal – –

42 Accelerator pedal position Ignition switch: ON Approx. 5 V

sensor (power supply
voltage) Ignition switch: OFF 0V
23-14 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>

Terminal Inspection item Inspection conditions Standard value

No.

43 Accelerator pedal position Accelerator pedal: Released Approx. 1 V

sensor (throttle opening
voltage) Accelerator pedal: Fully depressed Approx. 4 V

44 Vehicle speed sensor Vehicle: Slowly moving forward Alternates between

0↔Approx. 5 V

47 Inhibitor switch 2 Selector lever position: 2 System voltage

Selector lever position: Other than 2 0V

48 Inhibitor switch L Selector lever position: L System voltage

Selector lever position: Other than L 0V

 23-1

AUTOMATIC
TRANSMISSION
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4

Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Kickdown Cable Check and Adjustment . . . . . . . . . 4

TROUBLESHOOTING <A/T> . . . . . . . . . . . . . . . . 2
23-2 AUTOMATIC TRANSMISSION – General/Troubleshooting <A/T>

GENERAL
OUTLINE OF CHANGES
Since the vehicles with the 4G93-MPI engine have been added, the V4AW4 type transmission has been
adopted. This transmission is basically the same as that of the vehicles with 4G94 engine.
Due to the changes shown below, some new service procedures have been added.
D On the vehicles with 4G93-MPI engine, the APS has been used for the transmission control (input
signal of the throttle opening angle). Due to this, the road test, the inspection procedures for diagnosis
codes, and the service data have been reviewed.
D On the vehicles with 4G93-MPI engine, the shift pattern has been established. On the vehicles with
4G94 engine, the shift pattern has been changed.
D On the vehicles with 4G93-MPI engine, the kick-down cable adjustment procedure has been established.
D A full-time 4WD model has been added to the vehicles with 4G93-MPI engine (Refer to GROUP 22
– Manual Transmission).
D Due to the addition of a full-time 4WD model, the transfer control lever and the 4WD indicator control
unit on the vehicles with 4G93-MPI engine have been discontinued.
D On all models, the quantity of the transfer oil has been changed from 2.3 litre to 2.2 litre.
D On all models, the wide open throttle switch has been discontinued.

TROUBLESHOOTING <A/T>
ROAD TEST
No. State prior to test Test and operation Judgement value Check item Inspection item if there
and operation is an abnormality

1 Ignition switch: ON Ignition switch Data list No.12 APS (Power supply Code No.11, 12
Engine: Stopped (1) ON (1) Approx. 5V voltage) APS system (P.23-4)
(2) OFF (2) 0V
4 Engine: Idling Accelerator pedal Data list No.11 APS (Throttle Code No.11, 12
Selector lever (1) Released (1) 0 - 5 % opening angle) APS system (P.23-4)
position: N (2) Half depressed (2) Gradually
(3) Fully depressed rises from (1)
(approx. 2 (3) 85 - 100 %
seconds)

SHIFT PATTERN
<4G93 – MPI>
D range (Overdrive switch: ON)
Throttle opening (%)
100
1 2 2 3 3 4
1 2 2 3 3 4
80

60

40

20

Output shaft speed r/min 0 1,000 2,000 3,000 4,000 5,000 6,000

Vehicle speed km/h 0 50 100

 AUTOMATIC TRANSMISSION – Troubleshooting <A/T> 23-3
<4G94>
D range (Overdrive switch: ON)
DOWNSHIFT PATTERN
Throttle opening (%)
100
1 2 2 3 3 4
1 2 2 3 3 4
80

60

40

20

Output shaft speed r/min 0 1,000 2,000 3,000 4,000 5,000 6,000

Vehicle speed km/h 0 50 100 150

INSPECTION CHART FOR DIAGNOSIS CODE

Code Diagnosis item Reference page

11 Accelerator pedal position sensor system (APS) Sensor malfunction/ 23-3

(Throttle opening voltage) open circuit/short circuit

12 Accelerator pedal position sensor system (APS) Open circuit/short circuit 23-3
(Throttle power supply voltage)

INSPECTION PROCEDURES FOR DIAGNOSIS CODES

Code No.11, 12 Accelerator pedal position sensor (APS) Probable cause
If the APS output voltage (APS opening voltage) is 4.8 V or higher when the engine D Malfunction of the accelerator pedal position sensor
is idling, the output voltage is judged to be too high and diagnosis code No. 13 D Malfunction of harness or connector
is output. If the APS output voltage (APS opening voltage) is 0.335 V or lower D Malfunction of the A/T-ECU
when the engine is idling, the output voltage is judged to be too low and diagnosis
code No. 13 is output.
If the APS output voltage (APS power supply voltage) is 3.0 V or lower or if it
is 5.7 V or higher when the engine is idling, the APS is judged to be faulty and
diagnosis code No. 14 is output.

NG
Accelerator pedal position sensor check Replace
(Refer to GROUP 13C – On-vehicle Service.)
OK
NG
Check the following connectors: Repair
<L.H. drive vehicles> C-46, C-25, D-34, D-46
<R.H. drive vehicles> C-46, C-26, D-34, D-46
OK
NG
Check the trouble symptoms. Harness check
D Between accelerator pedal position sensor and A/T-ECU.
OK NG

Repair
Replace the A/T-ECU.
23-4 AUTOMATIC TRANSMISSION – Troubleshooting <A/T>/On-vehicle Service

SERVICE DATA REFERENCE TABLE

Item Inspection item Inspection conditions Normal value
No.

11 Accelerator pedal Engine: Idle Accelerator pedal: Fully released 0– 5%

position sensor Selector lever position: N
(Throttle opening Accelerator pedal: Depressed Gradually rises from
voltage) the adove value

Accelerator pedal: Fully depressed 85 – 100 %

(up to 2 seconds)

12 Accelerator pedal Ignition switch: ON Ignition switch: ON Approx. 5

position
osition sensor Engine: Sto
Stopped
ed
(Power supply Ignition switch: OFF 0V
voltage)

ON-VEHICLE SERVICE
16 ± 2 N·m KICKDOWN CABLE CHECK AND ADJUSTMENT
A 1. Release the accelerator pedal.
2. Loosen the adjusting nut and locking nut. Move the outer
cable of the kickdown cable to adjust the clearance (A)
Adjusting nut
between the inner cable stopper and dust cover end to
the standard value, and then tighten the adjusting nut
Locking nut
to secure the kickdown cable.
Inner cable stopper Dust cover 3. Tighten the locking nut to the specified torque.
Standard value: 0.8 – 1.5 mm
Caution
Adjust the accelerator cable assembly after the
kickdown cable adjustment.
 PROPELLER
SHAFT
Click on the applicable bookmark to selected the required model year
 25-1

PROPELLER
SHAFT
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 3

LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25-2 PROPELLER SHAFT – General Information/Service Specifications/Lubricant/Special Tool

GENERAL INFORMATION
A two-joint propeller shaft was used for both the front and rear.
SERVICE SPECIFICATIONS
Items Standard value Limit
Propeller shaft runout mm Front – 0.5
Rear – 0.4
Length of rear propeller shaft mm 630 ± 1.5 –
Clearance of snap ring Front 0 – 0.06 –
groove mm
Rear 0.02 – 0.06 –

LUBRICANT
Items Specified lubricant Quantity
Front propeller shaft sleeve Hypoid gear oil SAE 75W–90 or 75W–85W or 80W As required
yoke conforming to API GL–4

SPECIAL TOOL
Tool Number Name Use
MB990840 Universal joint Disassembly and reassembly of the universal
remover and joint
installer
 PROPELLER SHAFT – Propeller Shaft 25-3
PROPELLER SHAFT
REMOVAL AND INSTALLATION
Caution
Do not reuse the rear propeller shaft already shrunk due to a big impact. The rear propeller shaft
has impact-absorption mechanism (shrinkage).

Pre-removal Operation Post-installation Operation

D Shift the lever to “2H” Transfer Gear Oil Supplying
D Transfer Gear Oil Draining (M/T: Refer to GROUP 22 – On-vehicle Service.)
(M/T: Refer to GROUP 22 – On-vehicle Service.) (A/T: Refer to GROUP 23 – On-vehicle Service.)
(A/T: Refer to GROUP 23 – On-vehicle Service.)

2
Gear Oil: Hypoid gear oil SAE 75W–90 or
75W–85W or 80W conforming to API GL–4

49 – 59 Nm

49 – 59 Nm

Removal steps
AA" "AA 1. Front propeller shaft assembly
AA" "AA 2. Rear propeller shaft assembly
25-4 PROPELLER SHAFT – Propeller Shaft

REMOVAL SERVICE POINT

A FRONT PROPELLER SHAFT ASSEMBLY/REAR
PROPELLER SHAFT ASSEMBLY REMOVAL
1. Make mating marks on the differential companion flange
and flange yoke, and then remove the propeller shaft
assembly.
2 Cover the transmission and transfer not to allow foreign
materials to enter.
INSTALLATION SERVICE POINT
A
REAR PROPELLER SHAFT ASSEMBLY/FRONT
PROPELLER SHAFT ASSEMBLY INSTALLATION
When reusing the propeller shaft, align the mating marks made
during the removal and install the propeller shaft assembly
to the companion flange.
Caution
1. Wipe out oil and grease on the threads of the mounting
bolts and nuts before tightening, or they will loosen.

2. Do not damage the oil seal lips of the transmission

and transfer.

Oil seal

INSPECTION
PROPELLER SHAFT RUNOUT
Limit:
Front propeller shaft: 0.5 mm
Rear propeller shaft: 0.4 mm

REAR PROPELLER SHAFT

1. Measure length A.
A
Standard value:
630 ± 1.5 mm
2. If the standard value is not met, replace the rear propeller
shaft.
 PROPELLER SHAFT – Propeller Shaft 25-5
DISASSEMBLY AND REASSEMBLY
3
2

1 2
6

1 2
5

3 4

3 2
3 1

Universal joint repair kit

Disassembly steps

A B
1. Snap ring 4. Flange yoke

B A
2. Journal bearing 5. Sleeve yoke
3. Journal 6. Propeller shaft

DISASSEMBLY SERVICE POINTS

A SNAP RING REMOVAL
Make mating marks on the flange yoke, sleeve yoke and
propeller shaft. Then, remove the snap rings.

Mating marks
25-6 PROPELLER SHAFT – Propeller Shaft

MB990840

B JOURNAL BEARING REMOVAL
1. Using the special tools, press in the journal bearing to
remove the journal bearing on the opposite side.
2. Set the special tools reverse to press in the journal. Then,
pull out the journal bearing pressed in step 1.
Caution
Do not tap the journal bearing to remove. Tapping
the journal bearing will upset the balance of the
MB990840 propeller shaft.

MB990840

MB990840

MB990840

MB990840 REASSEMBLY SERVICE POINTS

A
JOURNAL BEARING INSTALLATION
Groove for snap ring
1. Using the special tool, press in the journal bearing to the
yoke until the snap ring groove can be seen completely.

2. Using the special tools, press in the journal bearing on the

opposite side to the yoke.
MB990840 Caution
Press in the journal bearing straight, or the journal
could damage the inside of the journal bearing.
3. Align the mating marks on the yoke and propeller shaft. On
the propeller shaft side, install the journal bearing in the
MB990840 same steps of 1 and 2.

B
SNAP RING INSTALLATION

MB990840 1. Install the snap ring to one side of the journal.
2. Using the special tool, press in the journal bearing toward
the snap ring from the opposite side which the snap ring
has been installed on.
Snap ring
 PROPELLER SHAFT – Propeller Shaft 25-7
3. Install the snap ring on the opposite side and measure the
clearance of the snap ring groove with a thickness gauge.
Snap ring
Standard value:
A Front propeller shaft (A) 0 – 0.06 mm
Rear propeller shaft (A) 0.02 – 0.06 mm
Caution
Always use snap rings of the same thickness on both
sides.

4. If the standard value(s) are not met, use other snap rings
to adjust the clearance.
Items Thickness mm Identification
colour
Front propeller shaft, 1.28 –
R
Rear propeller
ll shaft
h ft 1.31 Yellow
1.34 Blue
1.37 Purple
Rear propeller shaft 1.40 Brown
NOTES
 PROPELLER SHAFT – General/Service Specifications 25-1

GROUP 25
PROPELLER SHAFT
GENERAL
OUTLINE OF CHANGE
Specifications for 5 door models have been added.

SERVICE SPECIFICATIONS
Items Standard value Limit
Propeller shaft runout mm Front – 0.5
Rear – 0.4
Length of rear propeller shaft mm 790 ± 1.5 –
Clearance of snap ring Front 0 – 0.06 –
groove mm
Rear 0.02 – 0.06 –
 PROPELLER SHAFT – General/Service Specifications 25-1
GROUP 25
PROPELLER SHAFT
GENERAL
OUTLINE OF CHANGE
Specifications for 1800-MPI models have been added.

SERVICE SPECIFICATIONS
Items Standard value Limit
Propeller shaft runout mm Front – 0.5
Rear – 0.4
Length of rear propeller shaft mm 642.5 ± 1.5 <3 door models> –
814.5 ± 1.5 <5 door models>
Clearance of snap ring Front 0 – 0.06 –
groove mm
Rear 0.02 – 0.06 –
NOTES
 FRONT AXLE
Click on the applicable bookmark to selected the required model year
 26-1

FRONT AXLE
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Solenoid Valve Operation Check . . . . . . . . . . . . . 12

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4 HUB AND KNUCKLE ASSEMBLY . . . . . . . . . . 14

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SEALANTS AND ADHESIVES . . . . . . . . . . . . . . 5 MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . 28

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 10 FREE-WHEELING CLUTCH ASSEMBLY . . . . 45

Wheel Bearing Axial Play Check . . . . . . . . . . . . . 10
SOLENOID VALVE, VACUUM PIPES AND
Front Axle Total Backlash Check . . . . . . . . . . . . . 10 VACUUM TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Front Axle Gear Oil Level Check . . . . . . . . . . . . . . 11
Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . 11 FRONT DIFFERENTIAL MOUNT . . . . . . . . . . . 50
Differential Carrier Oil Seal Replacement . . . . . . 11
26-2 FRONT AXLE – General Information

GENERAL INFORMATION
The front axle consists of the hub assembly, drive D For vehicles with ABS, the ABS rotor for
shaft, inner shaft, front differential, and detecting the wheel speed has been pressed
free-wheeling clutch. in the B.J. joint.
The features are: D The axle is supported by the ball bearing and
D The free-wheeling mechanism enables 2WD the front hub, which is pressed in the knuckle
and 4WD to be switched over during driving, axle housing.
thus improving fuel efficiency and reducing D The ball bearing is of a double-row angular
vibration at the 2WD mode. contact ball bearing which features high thrust
D The drive shaft uses a B.J.-D.O.J.-type constant load resistance.
velocity ball joint which has high power D The differential carrier is supported elastically
transmission efficiency and reduces vibration at three points, thus reducing vibration and
and noise. noise.

FRONT AXLE
Item Specifications
Wheel bearing Type Double-row angular contact ball bearing
Bearing (O.D. I.D.) mm 74 40
Drive shaft Joint type Outer B.J.
Inner D.O.J.
Shaft length*1 Shaft diameter Right side 316 24*2, 293 24*3
mm
Left side 435 24*2, 428 24*3
Inner shaft Shaft length Shaft diameter mm 383 25
Bearing (O.D. I.D.) mm 62 35

NOTE
*1: shows the distance between the centres of the joints.
*2: A/T
*3: M/T
FRONT DIFFERENTIAL
Item Specifications

Drive gear type Hypoid gear

Reduction ratio 4.875
Differential gear type Straight bevel gear
Number of teeth Drive gear 39
Drive pinion 8
Side gear 14
Pinion gear 10
Bearing (O.D. I.D.) mm Side 72.0 35.0*1, 80.0 45.0*2
Front 62.0 25.0*1, 64.0 30.0*2
Rear 72.0 35.0*1, 76.0 36.5*2

NOTE
*1: A/T
*2: M/T
 FRONT AXLE – General Information 26-3
CONSTRUCTION DIAGRAM

Front differential

Free-wheeling clutch
Differential mount
bracket (LH)

Differential mount
crossmember

Drive shaft (RH)

Drive shaft (LH)

Ball joint

Drive shaft
Knuckle
(LH) Brake disc
Differential side D.O.J. B.J.

(RH) Plastic BJ boot ABS rotor

Differential side Hub

Ball bearing

Dust cover
26-4 FRONT AXLE – Service Specifications/Lubricants

SERVICE SPECIFICATIONS
Items Standard value Limit

Front axle total backlash mm – 5

Wheel bearing axial play mm – 0.2

Solenoid valve resistance Ω 36 – 46 –

Hub rotation starting torque Nm 1.6 –

Setting of D.O.J. boot length mm 80 ± 3 –

Special tool (MB991561) opening With B.J. boot band (small) 2.9 –
dimension mm crimped

With B.J. boot band (large) 3.2 –

crimped

B.J. boot crimping dimension mm 2.4 – 2.8 –

Clearance between B.J. boot (large) and step on B.J. housing mm 0.1 – 1.55 –

Final drive gear backlash mm 0.11 – 0.16 –

Drive gear runout mm – 0.05

Differential gear backlash mm 0 – 0.076 0.2

Drive pinion turning Without oil seal When replacing 0.88 – 1.17*1, –
torque Nm (with anti-rust agent) 0.29 – 0.49*2

When replacing or reusing 0.39 – 0.49*1 –

(with gear oil applied) 0.147 – 0.245*2

With oil seal When replacing 0.98 – 1.27*1 –

(with anti-rust agent) 0.49 – 0.69*2

When replacing or reusing 0.49 – 0.58*1 –

(with gear oil applied) 0.343 – 0.441*2

NOTE
*1: A/T
*2: M/T

LUBRICANTS
Items Specified lubricants Quantity

Gear oil Front differential Hypoid gear oil API classification GL-5 0.83 ȏ
or higher SAE viscosity No
No.90,
90 80W
Free-wheeling clutch 0.12 ȏ

D.O.J. Repair kit grease <A/T> 85 g

<M/T> 100 g

B.J. Repair kit grease <A/T> 85 g

<M/T> 110 g
 FRONT AXLE – Sealants and Adhesives/Special Tools 26-5
SEALANTS AND ADHESIVES
Items Specified sealants and adhesives Remarks

Front housing assembly and free- 3M ATD Part No.8661 or equivalent Semi-drying sealant
wheeling hosing assembly

Front housing assembly and differen-

tial carrier

Vent plug

Differential cover

Drive gear and differential case 3M Stud Locking 4170 or equivalent Anaerobic sealant
mating surface

SPECIAL TOOLS
Tool Number Name Use
MB991618 Hub bolt remover Hub bolt removal

MB990767 Front hub and Hub fixing

flange yoke holder

MB991115 Oil seal installer D Front axle hub oil seal press-fitting (Used
together with MB990938)
D Housing tube dust seal press-fitting

MB991406 or Steering linkage Ball joint disconnection

MB991113 puller

MB990241 Axle shaft puller Drive shaft removal

A: MB990242 A: Puller shaft
B
B: MB990244 B: Puller bar

MB991354 Puller body

26-6 FRONT AXLE – Special Tools

Tool Number Name Use

MB991056 or Knuckle arm Hub removal
MB991355 bridge

A: MB991017 A, B: Front hub D Hub removal and press-fitting.

A
B: MB990998 remover and in- D Wheel bearing provisional holding
C: MB991000 staller (MB991000, which belongs to MB990998,
C: Spacer should be used as a spacer.)
B
C

MB990810 Side bearing puller D Side bearing inner race removal

D Companion flange removal

MB990925 Bearing and oil D Outer wheel bearing inner race installation
seal installer set D Oil seal installation
D Front housing assembly oil seal installation
D Drive pinion front and rear bearing outer
race removal and installation
D Final drive gear backlash check

A MB991045 Bush remover Wheel bearing pressing-in

A: MB991050 installer (Used together with base B)
A: Base (B)

MB991387 Bush remover Outer oil seal pressing-in

installer

MB991389 Bush remover Inner oil seal pressing-in

base

MB991561 Boot band clipping Plastic boot band installation

tool
 FRONT AXLE – Special Tools 26-7

Tool Number Name Use

MB990673 Front bearing Bearing removal
remover

MB990663 Rear axle shaft Bearing installation

bearing and retain-
er ring installer

MB990909 Working base Differential carrier fixing

assembly

MB990850 End yoke holder Companion flange removal and installation

MB990560 Rear axle shaft Drive pinion bearing inner race removal
bearing remover

MB990835 Dummy pinion set D Drive pinion rotation starting torque check
A: MB990836 A: Drive D Drive pinion height measurement <A/T>
B: MB990392 pinion gauge
assembly
B B: Cylinder gauge
A

MB990326 Pre-load socket Drive pinion turning torque measurement

MB990901 Pinion height Pinion height adjustment <M/T>

A: MB990903 gauge set

MB991170 Cylinder gauge Pinion height adjustment <M/T>

26-8 FRONT AXLE – Special Tools

Tool Number Name Use

MB990829 Pinion and side D Drive pinion rear bearing inner race
bearing installer pressing-in
D Side bearing inner race pressing-in

MB990727 Oil seal installer Drive pinion oil seal pressing-in

MB991015 Knuckle oil seal Oil seal pressing-in

installer

MB990799 Ball joint remover Free-wheeling clutch gear and bearing installa-
and installer tion

MD999547 Oil seal installer Front differential mount insulator <front>

removal

MD999570 Crankshaft front oil Front differential mount insulator <rear>

seal installer removal

MB990947 Lower arm bushing Front differential mount insulator <front>

arbour pressing-in

MB990847 Rear suspension

bushing remover
and installer base

MB990981 Mount bushing

remover and
installer ring
 FRONT AXLE – Special Tools 26-9

Tool Number Name Use

MB991318 Lower arm bushing Front differential mount insulator <rear>
arbour pressing-in

MB991183 Bushing arbour

MB990843 Drag link bushing

remover and
installer

GENERAL Engine lifter Supporting the engine assembly when the

SERVICE differential carrier is removed and installed
TOOL
MZ203827

MB990925
Tool box
C Brass bar

B
A Bar (snap-in type)
Installer adapter

Type Tool number O.D. mm Type Tool number O.D. mm

A MB990926 39 A MB990933 63.5

MB990927 45 MB990934 67.5

MB990928 49.5 MB990935 71.5

MB990929 51 MB990936 75.5

MB990930 54 MB990937 79

MB990931 57 B MB990938 –

MB990932 61 C MB990939 –
26-10 FRONT AXLE – On-vehicle Service

ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
1. Remove the disc brake caliper 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 axial play while moving the hub in the axial
direction.
Limit: 0.2 mm
4. If axial play exceeds the limit, disassemble the hub and
knuckle to inspect each component.

FRONT AXLE TOTAL BACKLASH CHECK

If the propeller shaft is rotated by hand while the ignition
switch is OFF, the front wheel actuator will lock the front
wheels. To prevent this, follow the procedures below:
1. Turn the ignition switch to the OFF position, and then
place the transfer shift lever in the 2H position to lock
the front wheels.
Caution
Do not jack up the vehicle.
2. Rotate the propeller shaft until a click is heard to lock
the free-wheeling differential.
Mating marks 3. Rotate the propeller shaft fully clockwise, and then make
mating marks on the companion flange dust cover and
the gear carrier.

4. Rotate the propeller shaft fully anticlockwise, and measure

the difference between the mating marks with a scale.
Limit: 5 mm
5. If the measured value exceeds the limit value, check
the following.
D Final drive gear backlash
D Differential gear backlash
D Play in the serrations and spline of the side gears,
drive shaft, inner shaft and drive flange
 FRONT AXLE – On-vehicle Service 26-11
FRONT AXLE GEAR OIL LEVEL CHECK
Top up the specified gear oil if the gear oil level does not
reach the bottom of the filler plug.
Specified gear oil:
Hypoid gear oil API classification GL-5 or
higher, SAE viscosity No.90, 80W
NOTE
SAE 90 for 10 °C or higher, SAE80 for 10 °C or
lower
Capacity:
Front differential: Approx. 0.83 ȏ
Free-wheeling clutch: 0.12 ȏ

HUB BOLT REPLACEMENT

MB990767
1. Rotate the hub to align each hub bolt with the cutout
MB991618 section of the dust cover, and push out each hub bolt
while locking the hub with the special tool.

2. To press in the hub bolt, install each hub bolt at the

cutout section of the dust cover, and tighten the hub
MB990767 bolt with the hub nut as shown.

DIFFERENTIAL CARRIER OIL SEAL

Flat-tipped screwdriver
Oil seal REPLACEMENT
1. Remove the front housing assembly. (Refer to P.26-26.)
2. Remove the drive shaft <RH>. (Refer to P.26-19.)
3. Use a flat-tipped screwdriver or the like to remove the
oil seal.
26-12 FRONT AXLE – On-vehicle Service

4. Use the special tools to install a new oil seal.

MB990938

MB991115

5. Apply multi-purpose grease to the oil seal lip, and then

install the right drive shaft (Refer to P.26-19) and the
front housing assembly (Refer to P.26-26).
Caution
(1) Be careful not to scratch the oil seal lip.
(2) Always replace the circlip, which is installed on
the D.O.J.-side spline of the right drive shaft, with
a new one.

SOLENOID VALVE OPERATION CHECK

1. Remove the vacuum hoses (blue stripe, yellow stripe)
from the solenoid valves.
2. Disconnect the harness connectors.
Solenoid valve A

Solenoid valve B

3. Connect a hand vacuum pump to solenoid valve A, and

carry out the following inspections.
(1) When battery voltage is not applied to any terminals,
the negative pressure is not be held.
(2) The negative pressure is not held when battery voltage
is applied to solenoid valve A. However, when the
Check valve
vacuum hose of solenoid valve B is restricted by
Vacuum tank bending it, the pressure is held.
(3) The negative pressure is held when battery voltage
is applied to solenoid valves A and B.

Solenoid
valve A

Vacuum
hose
Solenoid valve B
 FRONT AXLE – On-vehicle Service 26-13
4. Connect a hand vacuum pump to solenoid valve B. Apply
negative pressure and carry out the following inspections.
(9) When battery voltage is not applied to any terminals,
Check valve the negative pressure is held.
Vacuum tank (10)When battery voltage is applied to solenoid valve
B, the negative pressure is not held.
(11) When battery voltage is applied to solenoid valve
A, the negative pressure is not held.
5. Measure the resistance of solenoid valves A and B.
Solenoid
valve A Standard value: 36 – 46 Ω

Solenoid valve B
26-14 FRONT AXLE – Hub and Knuckle Assembly

HUB AND KNUCKLE ASSEMBLY

REMOVAL AND INSTALLATION
Post-installation Operation
Press the Dust Cover with a Finger to Check Whether
the Dust Cover is Cracked or Damaged.

10 108 – 127 Nm

9
59 – 71 Nm

59 – 71 Nm

1
11
3

90 – 110 Nm

9 Nm
8 6 196 – 255 Nm
2 5

Removal steps
1. Disc brake assembly AB" 8. Tie rod end and hub/knuckle
2. Brake disc assembly connection
3. Wheel speed sensor <Vehicles with AC" 9. Drive shaft and hub/knuckle
ABS> assembly connection
4. Dust cover 10. Strut assembly and hub/knuckle
AA" "AA 5. Castle nut assembly connection
"AA 6. Washer 11. Hub/knuckle assembly
AB" 7. Lower arm and hub/knuckle
assembly connection

REMOVAL SERVICE POINTS

AA" CASTLE NUT REMOVAL
Caution
Never apply the vehicle weight to the wheel bearing while
the castle nut is loosened. If the vehicle weight is applied,
the wheel bearing will be damaged.

MB990767
 FRONT AXLE – Hub and Knuckle Assembly 26-15

MB991113 or
AB" TIE ROD END/LOWER ARM REMOVAL
MB991406 Caution
1. Only loosen the ball joint nut, but do not remove it.
Nut
Use the special tool.
Cord 2. Suspend the special tool with a cord to prevent it
from dropping.

Ball joint

MB990244 AC" DRIVE SHAFT REMOVAL

(three
pieces) Use the special tools when the drive shaft can not be separated
MB990767 from the knuckle easily due to seizure.

MB991354
MB990242

INSTALLATION SERVICE POINTS

Washer
"AA WASHER/CASTLE NUT INSTALLATION
1. Face the chamfered side of the washer against the castle
nut.

2. Use the special tool to tighten the castle nut securely.

196 – 255 Nm
Caution
Never apply the vehicle weight to the wheel bearing
while the castle nut is loosened. If the vehicle weight
is applied, the wheel bearing will be damaged.
3. If the split pin hole is not aligned with the castle nut slit,
always tighten the nut further within a torque of 255 Nm,
and assemble the split pin in the first aligned slit and
MB990767 the hole.
26-16 FRONT AXLE – Hub and Knuckle Assembly

DISASSEMBLY AND REASSEMBLY

Lip

1
3 2
4 1
6
5
2
4

Disassembly steps Reassembly steps

1. Inner oil seal 6. Knuckle
AA" 2. Hub "AA 4. Wheel bearing
3. Snap ring 3. Snap ring
AB" 4. Wheel bearing "BA 5. Outer oil seal
5. Outer oil seal 2. Hub
6. Knuckle "CA D Hub rotation starting torque check
"DA D Wheel bearing axial play check
"EA 1. Inner oil seal

DISASSEMBLY SERVICE POINTS

MB991056 or
MB991355
MB991017 AA" HUB REMOVAL
Caution
When the hub is removed, the wheel bearing may be
damaged. Therefore, if the hub is withdrawn, the wheel
bearing should be always be replaced with a new one.
Tighten the nut while
MB991000 holding the bolt,
(MB990998)

AB" WHEEL BEARING REMOVAL

Wheel bearing
outer inner 1. Pry the outer oil seal at the shown positions with a
race screwdriver so that the jaws of the special tool can hook
the wheel bearing outer inner race.

Outer oil seal

 FRONT AXLE – Hub and Knuckle Assembly 26-17
2. Use the special tool to remove the wheel bearing outer
MB990810 inner race from the hub.
Caution
Be careful not to drop the hub when the outer inner
race is pressed out.

Outer inner
race

3. Assemble the removed outer inner race to the wheel

MB990938 bearing, and then use the special tools to remove the
wheel bearing.
Outer inner race
MB990932

MB991056 or MB991355

REASSEMBLY SERVICE POINTS

MB990938
"AA WHEEL BEARING INSTALLATION
MB991050 Caution
When the wheel bearing is pressed in, its outer race should
be pushed in.

MB991387 "BA OUTER OIL SEAL INSTALLATION

"CA HUB ROTATION STARTING TORQUE CHECK

MB991000 1. Tighten the special tools to the specified torque to press
MB991017 (MB990998)
the hub into the knuckle.
2. Rotate the hub so that the hub is lubricated sufficiently.
Bolt

196 – 255 Nm
Tighten the nut
while holding the
bolt.
26-18 FRONT AXLE – Hub and Knuckle Assembly

3. Use the special tool to measure the hub rotation starting

torque.
Limit: within 1.6 Nm
4. Make sure that the hub rotation starting torque is within
the limit, and the hub turns smoothly.

MB990326

"DA WHEEL BEARING AXIAL PLAY CHECK

MB991000
(MB990998) 1. Clamp the knuckle in a vise, and measure the axial play
while moving the hub in the axial direction.
196 – 255 Nm Limit: 0.2 mm
2. If the limit value can not be obtained after tightening
the special tool within 196 – 255 Nm, the wheel bearing,
the knuckle and the hub may be improperly assembled.
Disassemble these parts to replace the bearing, and then
MB991017
assemble them again.

MB991389 "EA INNER OIL SEAL INSTALLATION

 FRONT AXLE – Drive Shaft 26-19
DRIVE SHAFT
REMOVAL AND INSTALLATION
Caution
On the vehicles with ABS, when the drive shaft is removed or installed, be careful not to interfere
with the ABS rotor installed to the B.J. outer race to prevent the rotor from damage.

Pre-removal Operation Post-installation Operation

D Disengage the Stabilizer Link from the Strut Bar D Press the Dust Cover with a Finger to Check
(Refer to GROUP 33 – Strut Bar and Lower Arm.) Whether the Dust Cover is Cracked or Damaged.
D Brake Disc Removal (Refer to P.26-14.) D Engage the Stabilizer Link with the Strut Bar (Refer
to GROUP 33 – Strut Bar and Lower Arm.)
D Brake Disc Installation (Refer to P.26-14.)

6 <LH> 59 – 71 Nm

2
59 – 71 Nm

6 <RH> 7
3
1
196 – 255 Nm

Removal steps
AA" "AA 1. Castle nut AB" 5. Lower arm and hub/knuckle
"AA 2. Washer assembly connection
AB" 3. Tie rod end and hub/knuckle AC" 6. Drive shaft
assembly connection 7. Circlip
4. Wheel speed sensor

REMOVAL SERVICE POINTS

AA" CASTLE NUT REMOVAL
Caution
Never apply the vehicle weight to the wheel bearing while
the castle nut is loosened. If the vehicle weight is applied,
the wheel bearing will be damaged.

MB990767
26-20 FRONT AXLE – Drive Shaft

MB991113 or
AB" TIE ROD END AND HUB/KNUCKLE
MB991406 ASSEMBLY/LOWER ARM AND HUB/KNUCKLE
ASSEMBLY DISCONNECTION
Nut
Caution
Cord 1. Only loosen the ball joint nut, but do not remove it.
Use the special tool.
2. Tie the special tool with a cord not to let it fall off.

Ball joint

D.O.J. AC" DRIVE SHAFT REMOVAL

1. For the left side drive shaft, pry the D.O.J. stepped part
with a tyre lever, and then withdraw the drive shaft from
the free-wheeling hub assembly.
Caution
Always use a tyre lever. When the drive shaft is
Stepped part withdrawn from the B.J. assembly, the D.O.J. may
be damaged.
Tyre lever
2. For the right side drive shaft, install the drive shaft with
the castle nut loosely. Then pull the strut, the hub/knuckle
assembly and the lower arm towards you, and then
MB990244 withdraw the drive shaft from the front differential.
(Three) Caution
MB990767
Be sure to maintain the drive shaft horizontally not
to bend the D.O.J. at extreme angle when the drive
shaft is withdrawn.
3. If it is difficult to withdraw the drive shaft from the
hub/knuckle assembly, use the special tools.

MB991354
MB990242

Caution
MB991000 Do not apply the vehicle weight to the wheel bearing
(MB990998) as possible while the drive shaft is removed. If it is
impossible, use the special tool to hold the the wheel
MB991017
bearing as shown in the illustration.

INSTALLATION SERVICE POINT

"AA WASHER/CASTLE NUT INSTALLATION
Refer to P. 26-15.
 FRONT AXLE –    26-21
DISASSEMBLY AND REASSEMBLY
Caution
The B.J. assembly is non-serviceable and requires replacement if defective. B.J. boot can be replaced.

12
4 <RH>
3
5 6
13

13
4 <LH> 2 11
1

4
11

Grease: Repair kit grease

Grease: Repair kit grease Quantity:
<A/T> B.J.: 85 g (40 g for joint, 45 g for boot)
D.O.J.: 85 g (50 g for joint, 35 g for boot)
<M/T> B.J.: 110 g (55 g for joint, 55 g for boot)
D.O.J.: 100 g (60 g for joint, 40 g for boot)
Caution
The joint is filled with a special grease. Do not mix the grease with an old one or other grease.

   
  
    
 
 
   



B.J. boot repair kit D.O.J. boot repair kit D.O.J. repair kit
26-22 FRONT AXLE – Drive Shaft

Disassembly steps AA" "AA 7. D.O.J. boot

"BA 1. D.O.J. boot band (small) 8. B.J. boot band (small)
"BA 2. D.O.J. boot band (large) 9. B.J. boot band (large)
3. Circlip 10. B.J. boot
4. D.O.J. outer race 11. B.J. assembly
5. Snap ring 12. Circlip
6. Inner race, cage, ball assembly 13. Dust cover

DISASSEMBLY SERVICE POINT

AA" D.O.J. BOOT REMOVAL
Wrap a plastic tape around the B.J. assembly spline to
prevent the boot from damage.

REASSEMBLY SERVICE POINTS

"AA D.O.J. BOOT INSTALLATION
Wrap a plastic tape around the B.J. assembly spline to
prevent damage, and then install the boot.

"BA D.O.J. BOOT BAND/BOOT BAND INSTALLATION

1. Slide the D.O.J. outer race so that the distance between
the boot bands meet the standard value in order to adjust
the air amount inside the D.O.J. boot.
Standard value (A): 80 ± 3 mm
2. Remove the boot partially from the D.O.J. outer race
in order to bleed the air from the boot.
A

B.J. BOOT (PLASTIC BOOT) REPLACEMENT

1. Remove the boot bands (small and large).
NOTE
The boot bands are non-reusable parts.
2. Remove the plastic boot.
 FRONT AXLE – Drive Shaft 26-23
3. Position the plastic boot small end so that one drive shaft
groove is visible.

MB991561 4. Turn the adjusting bolt of the special tool so that the
Stopper opening distance (W) meets the standard value.
Standard value (W): 2.9 mm
<More than 2.9 mm>
Tighten the adjusting bolt.
(W)
<Less than 2.9 mm>
Loosen the adjusting bolt
Adjusting bolt NOTE
(1) Turning the adjusting bolt changes the opening
distance (W) by approx. 0.7 mm.
(2) Do not turn the adjusting bolt more than one turn.

5. Butt the boot band (small) against the boot end projection
Boot so that a certain clearance (A) is obtained.
A

Boot band (small)

Projection

6. Use the special tool to crimp the boot band (small).

Caution
(1) Secure the drive shaft in an upright position and
clamp the part of the B.J. boot band to be crimped
securely in the jaws of the special tool.
(2) Crimp the B.J. boot band until the special tool
stopper closes.

MB991561
26-24 FRONT AXLE – Drive Shaft

7. Check that the crimping amount (B) of the B.J. boot band
is at the standard value.
B
Standard value (B): 2.4 – 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 4 according
to the following formula, and then repeat the
operation in step 6.
W = 5.5 mm – B
Example: If B = 2.9 mm, then W = 2.6 mm.
<If the crimping amount is smaller than 2.4 mm>
Remove the B.J. boot band, readjust the value
of (W) in step 4 according to the following
formula, and then repeat the operations in
steps 5 and 6 using a new B.J. boot band.
W = 5.5 mm – B
Example: If B = 2.3 mm, then W = 3.2 mm.
8. Check that the B.J. boot band is not sticking out past
the place where it has been installed.
If the B.J. boot band is sticking out, remove it and then
repeat the operations in steps 4 to 7 using a new B.J.
boot band.

9. Fill the inside of the B.J. boot with the specified amount
of the specified grease.
Specified grease: Repair kit grease
Amount to use:
<A/T> 85 g (50 g for joint, 35 g for boot)
<M/T> 110 g (55 g for joint, 55 g for boot)

10. Position the boot so that the difference between the boot
C big end and the housing stepped part (C) meets the
standard value.
Standard value (C) : 0.1 – 1.55 mm
11. Follow the same procedure as in step 4 to adjust the
size of the opening (W) on the special tool so that it
is at the standard value.
Standard value (W): 3.2 mm

12. Place the B.J. boot band (large) against the projection
at the edge of the boot, and then secure it so that there
Boot Projection is a clearance left as shown by (D) in the illustration.
Boot band (large) 13. Use the special tool to crimp the B.J. boot band (large)
in the same way as in step 6.

D
 FRONT AXLE – Drive Shaft 26-25
14. Check that the crimping amount (E) of the B.J. boot band
is at the standard value.
Standard value (E): 2.4 – 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 11 according
to the following formula, and then repeat the
operation in step 13.
E
W = 5.8 mm – E
Example: If E = 2.9 mm, then W = 2.9 mm.
<If the crimping amount is smaller than 2.4 mm>
Remove the B.J. boot band, readjust the value
of (W) in step 11 according to the following
formula, and then repeat the operations in
steps 12 and 13 using a new B.J. boot band.
W = 5.8 mm – E
Example: If E = 2.3 mm, then W = 3.5 mm.
15. Check that the B.J. boot band is not sticking out past
the place where it has been installed.
If the B.J. boot band is sticking out, remove it and then
repeat the operations in steps 12 to 14 using a new B.J.
boot band.
26-26 FRONT AXLE – Main Shaft

MAIN SHAFT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Drive Shaft Removal and Installation (Refer to
P.26-19.)
D Free-wheeling Clutch Housing Assembly Removal
and Installation (Refer to P.26-45.)
D Gear Oil Draining and Refilling (Refer to P.26-11.)

17 Nm

3
88 Nm

9
5

7 8
98 – 118 Nm
4

(Apply to the lip)

(Apply to the lip)

Sealant:
3M ATD Part No.8661 or equivalent 6

Removal steps
1. Vacuum pipe assembly "CA 6. Oil seal
2. Vacuum hose assembly AA" "BA 7. Bearing
3. Vacuum actuator assembly 8. Main shaft
4. Inner shaft assembly "AA 9. Oil seal
5. Front housing assembly
 FRONT AXLE – Main Shaft 26-27
REMOVAL SERVICE POINT
MB990673 AA" BEARING REMOVAL
Install the special tool as shown in the illustration, and use
a press to drive out the bearing from the main shaft.

MB990938
INSTALLATION SERVICE POINTS
MB990926
"AA OIL SEAL INSTALLATION

"BA BEARING INSTALLATION

MB990663

"CA OIL SEAL INSTALLATION

MB990938
MB990927
26-28 FRONT AXLE – Differential Carrier

DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Caution
To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then
fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D Drive Shaft Removal and Installation D Gear Oil Draining and Refilling (Refer to P.26-11.)
(Refer to P.26-19.)
D Stabilizer Bar Removal and Installation
(Refer to GROUP 33A.)

1
93 Nm*
49 – 59 Nm
5

103 Nm 103 Nm

3
4 93 Nm*
2

88 Nm

59 – 69 Nm 59 – 69 Nm
49 Nm

98 – 118 Nm*

Sealant:
3M ATD Part No.8661 or
equivalent
Removal steps
AA" D Support the Engine Assembly 4. Differential mount bracket assembly
1. Front propeller shaft connection <RH>
2. Front differential assembly and 5. Differential carrier
differential mount crossmember 6. Differential mount crossmember
assembly assembly
3. Free-wheeling clutch assembly
 FRONT AXLE – Differential Carrier 26-29
MZ203827 REMOVAL SERVICE POINT
AA" ENGINE ASSEMBLY SUPPORT
Use the special tool to raise the engine assembly until the
mount insulators are free from load.

DISASSEMBLY




 
















  



  
 

Disassembly steps 16. Drive pinion front shim

D Inspection before disassembly (For drive pinion height adjustment)
1. Cover 17. Drive pinion
2. Vent plug AG" 18. Oil seal
3. Bearing cap AG" 19. Drive pinion rear bearing inner race
AA" 4. Differential case assembly AG" 20. Drive pinion rear bearing outer
5. Side bearing spacer race
6. Side bearing outer race AH" 21. Drive pinion front bearing outer
AB" 7. Side bearing inner race race
AC" 8. Drive gear 22. Oil seal
AD" 9. Self-locking nut 23. Differential carrier
10. Washer AI" 24. Lock pin
AE" 11. Drive pinion assembly 25. Pinion shaft
12. Companion flange 26. Pinion gear
13. Drive pinion spacer 27. Pinon washer
14. Drive pinion rear shim 28. Side gear
(For drive pinion rotation torque 29. Side gear spacer
adjustment) 30. Filler plug
AF" 15. Drive pinion front bearing inner 31. Drain plug
race 32. Differential case
26-30 FRONT AXLE – Differential Carrier

INSPECTION BEFORE DISASSEMBLY

1. Remove the cover.
MB990909
2. Hold the special tool in a vise, and install the differential
carrier assembly to the special tool.

DRIVE GEAR BACKLASH

1. With the drive pinion locked in place, use a dial gauge
to measure the drive gear backlash in four or more places
on the drive gear.
Standard value: 0.11 – 0.16 mm
2. If the backlash is not within the standard value, adjust
the backlash of the final drive gear (Refer to P.26-42).
3. After adjustment, inspect the drive gear tooth contact.

DRIVE GEAR RUNOUT

1. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
2. When runout exceeds the limit value, check for foreign
object between drive gear rear side and differential case,
or for loose drive gear installation bolts.
3. When check (2) gives normal results, reposition drive
gear and differential case and remeasure.
4. If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.

Wedge
DIFFERENTIAL GEAR BACKLASH
1. While locking the side gear with the wedge, measure
the differential gear backlash with a dial indicator on the
pinion gear.
Standard value: 0 – 0.076 mm
Limit: 0.2 mm
Side gear
spacer Repeat the same procedure for other pinion gear.
Side
gear
spacer
 FRONT AXLE – Differential Carrier 26-31
2. If the backlash exceeds the limit, adjust the differential
gear backlash (Refer to P.26-41).
3. If adjustment is impossible, replace the side gear and
pinion gear as a set.

DRIVE GEAR TOOTH CONTACT

Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.

2. Insert the special tool between the differential carrier and

the differential case, and then rotate the companion flange
MB990939 by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque (approximately 2.5 –
2.9 Nm) is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and
drive pinion.
26-32 FRONT AXLE – Differential Carrier

Standard tooth contact pattern Problem Solution

1 Narrow tooth side Tooth contact pattern resulting from

2 Drive-side tooth surface (the side excessive pinion height
applying power during forward
movement)
3 Wide tooth side
4 Coast-side tooth surface (the 2 1 4
side applying power during re- 2 1 4
verse movement)

3 3

Increase the thickness of the drive

The drive pinion is positioned too far
pinion rear shim, and position the
from the centre of the drive gear.
2 1 4 drive pinion closer to the centre of the
drive gear. Also, for backlash adjust-
ment, position the drive gear farther
from the drive pinion.

3 Tooth contact pattern resulting from

insufficient pinion height.

2 1 4 2 1 4

3 3

Decrease the thickness of the drive

The drive pinion is positioned too
pinion rear shim, and position the
close to the centre of the drive gear.
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.

NOTE
Checking the tooth contact pattern is the way to If, even after adjustments have been made, the
confirm that the adjustments of the pinion height correct tooth contact pattern cannot be obtained,
and backlash have been done properly. Continue it means that the drive gear and the drive pinion
to adjust the pinion height and backlash until the have become worn beyond the allowable limit.
tooth contact pattern resembles the standard Replace the gear set.
pattern.
 FRONT AXLE – Differential Carrier 26-33
DISASSEMBLY SERVICE POINTS
AA" DIFFERENTIAL CASE ASSEMBLY REMOVAL
Remove the differential case assembly with a hammer handle
or the like.
Caution
When taking out the differential case assembly, be careful
not to drop and damage the side bearing outer races.
NOTE
Keep the right and left side bearing outer races and side
bearing spacers separate, so that they do not become mixed
at the time of reassembly.

MB990810
AB" SIDE BEARING INNER RACE REMOVAL
NOTE
There are two notches provided (at the differential case side)
for the jaws of the special tool; use the special tool at that
MB990811
position.
If the special tool jaws cannot be inserted between the
differential case and the bearing inner race, file the jaw tips
as necessary.

AC" DRIVE GEAR REMOVAL

1. Make the mating marks on the differential case and the
drive gear.
2. Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.
Mating marks

AD" SELF-LOCKING NUT REMOVAL

MB990850
26-34 FRONT AXLE – Differential Carrier

MB990810 AE" DRIVE PINION ASSEMBLY REMOVAL

1. Make mating marks on the drive pinion and the companion
flange.
Caution
The mating mark must not be on the coupling surface
of the companion flange and the front propeller shaft.
Companion 2. Use the special tool to drive out the drive pinion.
flange

AF" DRIVE PINION FRONT BEARING INNER RACE

REMOVAL

MB990560

MB990939 AG" OIL SEAL/DRIVE PINION REAR BEARING INNER

RACE/DRIVE PINION REAR BEARING OUTER
RACE REMOVAL

AH" DRIVE PINION FRONT BEARING OUTER RACE

MB990939 REMOVAL

A I" LOCK PIN DRIVE OUT

Punch
 FRONT AXLE – Differential Carrier 26-35
REASSEMBLY

 








 


Differential gear set Final drive gear set










78 – 88 Nm
   


186 Nm

34 – 39 Nm*




 49 Nm








 59 – 69 Nm
35 Nm 





Reassembly steps
1. Differential carrier 15. Self-locking nut
"AA 2. Oil seal 16. Differential case
"BA 3. Drive pinion front bearing outer "FA D Differential gear backlash adjustment
race 17. Side gear spacer
"CA 4. Drive pinion rear bearing outer 18. Side gear
race 19. Pinion washer
"DA D Drive pinion height adjustment 20. Pinion gear
5. Drive pinion 21. Pinion shaft
6. Drive pinion front shim (for drive "GA 22. Lock pin
pinion height adjustment) "HA 23. Drive gear
7. Drive pinion front bearing inner "IA 24. Side bearing inner race
race 25. Side bearing outer race
8. Drive pinion spacer "JA D Final drive gear backlash adjustment
"EA D Drive pinion rotation torque adjustment 26. Side bearing spacer
9. Drive pinion rear shim (for drive 27. Differential case assembly
pinion rotation torque adjustment) 28. Bearing cap
10. Drive pinion assembly 29. Vent plug
11. Drive pinion rear bearing inner race 30. Cover
12. Oil seal 31. Drain plug
13. Companion flange 32. Filler plug
14. Washer

NOTE
The fasteners marked by * should be tightened when the
differential gear oil is applied.
26-36 FRONT AXLE – Differential Carrier

LUBRICATION, SEALANT AND ADHESIVE POINTS

(Apply to the (Apply

entire circumfer- to the
ence of the lip entire
Sealant: circum-
3M ATD Part No. 8661 or ference
equivalent of the lip

f 2 – 3 mm

Sealant: Adhesive:
3M ATD Part No. 8661 or 3M Stud Locking 4170 or
equivalent equivalent

REASSEMBLY SERVICE POINTS

MB990938 "AA OIL SEAL INSTALLATION

MB991115
 FRONT AXLE – Differential Carrier 26-37
"BA DRIVE PINION FRONT BEARING OUTER RACE
INSTALLATION
MB990938

MB990926

MB990938 "CA DRIVE PINION REAR BEARING OUTER RACE

INSTALLATION
MB990929

"DA DRIVE PINION HEIGHT ADJUSTMENT

Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special
MB990836 tool.
(MB990835)
<A/T> 2. Install the special tool, drive pinion front and rear bearing
MB990903
<M/T> inner races to the gear carrier.

MB990835
<A/T> Washer

3. Tighten the nut of the special tool while measuring the

MB990903 <M/T> rotation torque of the drive pinion. Gradually keep
MB990835 <A/T> tightening the nut of the special tool until the rotation
torque of the drive pinion (without oil seal) is at the standard
value.
Standard value:
Bearing division Bearing lubrication Rotation torque
Nm
New None (With 0.88 – 1.17*1
anti-rust agent) 0.29 – 0.49*2
New or reused Gear oil applied 0.39 – 0.49*1
0.147 – 0.245*2
NOTE
*1: A/T
*2: M/T
26-38 FRONT AXLE – Differential Carrier

MB990326 NOTE
The special tool cannot be turned a full revolution, so
turn it several times within the range of movement to
run in the bearing, and then measure the rotation torque.

MB991170 <M/T> 4. Clean the side bearing hub.

Notch
MB990392 <A/T> 5. Install the special tools to the side bearing hub of the
gear carrier, and then install the bearing cap.
NOTE
A
Always check that the notch is in the shown position
and that the special tools are touching firmly against the
side bearing hub.
6. Use a thickness gauge to measure the clearance (A)
Thickness MB990903 <M/T> between the special tools.
gauge MB990836 <A/T>

7. Remove the special tools.

8. Use a micrometer to measure the special tool in the places
C (B, C) shown in the illustration.

9. Install the bearing cap, and then use a cylinder gauge

Bearing cap and micrometer to measure the inside diameter (D) of
the bearing cap as shown in the illustration.
10. Calculate the thickness (E) of the required drive pinion
front shim by the following formula, and then select a
D shim which most closely matches this thickness.
E = A + B + C–1/2D–86.0

11. Fit the selected drive pinion front shim(s) to the drive
Drive
pinion, and press-fit the drive pinion front bearing inner
pinion MB990829 race by using the special tool.
front
shim

MB990829
 FRONT AXLE – Differential Carrier 26-39
"EA DRIVE PINION ROTATION TORQUE
ADJUSTMENT
Adjust the drive pinion rotation torque by using the following
procedure:
1. Insert the drive pinion into the gear carrier, and then install
the drive pinion spacer, the drive pinion rear shim, the
drive pinion rear bearing inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.

2. Use the special tool to hold companion flange, and then

186 Nm tighten the self-locking nut to the specified torque.

MB990850

MB990326 3. Measure the drive pinion rotation torque (without the oil
seal) by using the special tool.
Standard value:
Bearing division Bearing lubrication Rotation torque Nm
New None (With 0.88 – 1.17*1
anti-rust agent) 0.29 – 0.49*2
New/reused Gear oil applied 0.39 – 0.49*1
0.147 – 0.245*2

NOTE
*1: A/T
*2: M/T

4. If the drive pinion rotation torque is not within the range

of the standard value, adjust it by replacing the drive
pinion rear shim(s) or the drive pinion spacer.
NOTE
When selecting the drive pinion rear shims, if the number
A of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacers. Also, select the
Identification drive pinion spacer from the following two types.
colour
26-40 FRONT AXLE – Differential Carrier

Drive pinion spacer Identification colour

height (A) mm
46.67*1 White
47.01*1 –
57.72*2 –
57.08*2 Red
NOTE
*1: M/T
*2: A/T
5. Remove the companion flange and drive pinion again.
Then, after inserting the drive pinion rear bearing inner
race into the gear carrier, use the special tool to press-fit
MB990727 the oil seal.

6. Install the drive pinion assembly and companion flange

with mating marks properly aligned, and use the special
186 Nm tool to hold the companion flange, and then tighten the
MB990850 self-locking nut to the specified torque.

MB990326 7. Measure the drive pinion rotation torque (with the oil seal)
by using the special tool.
Standard value:
Bearing division Bearing lubrication Rotation torque Nm
New None (With 0.98 – 1.27*1
anti-rust agent) 0.49 – 0.69*2
New/reused Gear oil applied 0.49 – 0.58*1
0.343 – 0.441*2
NOTE
*1: A/T
*2: M/T
8. If the drive pinion rotation torque is not within the standard
value, check the tightening torque of the companion flange
self-locking nut and the oil seal installation condition.
 FRONT AXLE – Differential Carrier 26-41
"FA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
Follow the procedures below to adjust the differential gear
backlash.
1. Assemble the side gears, side gear spacers, pinion gears
and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE
Do not drive in the lock pin yet.

Wedge
3. Insert a wedge between the side gear and the pinion
shaft to lock the side gear.
4. Measure the differential gear backlash with a dial indicator
on the pinion gear.
Standard value: 0 – 0.076 mm
Limit: 0.2 mm
Side gear
thrust spacer Repeat the steps above for the other pinion gear.
Side gear 5. If the differential gear backlash exceeds the limit, adjust
thrust spacer
the backlash by changing the side gear spacers.
6. If adjustment is not possible, replace the side gears and
pinion gears as a set.
7. Confirm that the differential gear backlash is correct, and
that the differential gear turns smoothly.

"GA LOCK PIN INSTALLATION

1. Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
2. Stake the lock pin with a punch at two points.

"HA DRIVE GEAR INSTALLATION

1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes
of the drive gear by turning a tap (M10 x 1.25), and then
clean the threaded holes by applying compressed air.

M10 1.25 (pitch)

26-42 FRONT AXLE – Differential Carrier

3. Clean the drive gear attaching surface, and then apply

the specified adhesive to the threaded holes of the drive
gear.
Specified sealant:
3M Stud Locking 4170 or equivalent
4. Install the drive gear onto the differential case with the
mating marks properly aligned.
5. Tighten the drive gear attaching bolts provisionally, and
then tighten them to the specified torque in a diagonal
sequence.
Tightening torque: 78 – 88 Nm

"IA SIDE BEARING INNER RACE INSTALLATION

Metal Use the special tool to press the side bearing inner race
Metal into the differential case.

MB990829
MB990829

"JA DRIVE GEAR BACKLASH ADJUSTMENT

Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than
those removed, to the side bearing outer races, and then
mount the differential case assembly into the gear carrier.
NOTE
Select side bearing spacers with the same thickness for
both the drive gear sides.

2. Push the differential case assembly to one side, and

measure the clearance between the gear carrier and the
side bearing spacer with a thickness gauge.
 FRONT AXLE – Differential Carrier 26-43
3. Measure the thickness of the side bearing spacers on
one side, select two pairs of spacers which correspond
to that thickness plus one half of the clearance plus 0.05
mm, and then install one pair each to the drive pinion
side and the drive gear side.

Clearance/2 + 0.05 mm
= Thickness of the spacer on one
side

4. Install the selected side bearing spacers and differential

case assembly, as shown in the illustration, to the gear
carrier.

5. Tap the side bearing spacers with the special tool to fit
them to the side bearing outer race.

MB990939

6. Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.

7. With the drive pinion locked in place, measure the drive

gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.11 – 0.16 mm
26-44 FRONT AXLE – Differential Carrier

If backlash is too small 8. Change the side bearing spacers as illustrated, and then
Thinner
adjust the drive gear backlash.
Thicker
spacer spacer NOTE
When increasing the number of side bearing spacers,
decrease the same number of the side bearing spacers
for opposite side.
9. Check the drive gear and drive pinion for tooth contact.
Thicker Thinner If poor contact is evident, make adjustment. (Refer to
spacer spacer P. 26-31.)
If backlash is too large

10. Measure the drive gear runout at the shoulder on the

reverse side of the drive gear.
Limit: 0.05 mm
11. If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential case,
and remeasure.
12. If adjustment is not possible, replace the differential case
or replace the drive gear and drive pinion as a set.
 FRONT AXLE – Free-wheeling Clutch Assembly 26-45
FREE-WHEELING CLUTCH ASSEMBLY
REMOVAL AND INSTALLATION
Caution
To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then
fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D Gear Oil Draining and Refilling (Refer to P.26-11.)
D Drive Shaft Removal and Installation
(Refer to P.26-19.)

5 2 – 3 mm
1
4 Sealant:
3M ATD Part No.8661 or equivalent
35 Nm

49 – 59 Nm
49 Nm 93 Nm*

59 – 69 Nm 3
103 Nm

Removal steps
AA" 1. Pin 4. Free-wheeling clutch housing
2. Free-wheeling engage switch assembly
assembly 5. Collar
3. Differential mount bracket assembly
<LH>

Collar Dust cover

REMOVAL SERVICE POINT
AA" PIN REMOVAL
1. Remove the one side of the dust cover from the vacuum
actuator assembly.
2. Align the pin with the pin hole of the collar, and then
Pin drive out the pin with a punch.
26-46 FRONT AXLE – Free-wheeling Clutch Assembly

INSPECTION
FREE-WHEELING ENGAGE SWITCH CONTINUITY
CHECK

Shaft Shaft (switch) position Terminal number

OFF ON
1 2

Pushed (ON)
Contact point Electrode Released (OFF)

DISASSEMBLY AND REASSEMBLY

4 5
5 3
6
2

1
8

13
10
11
12
7 9

11
13

(Apply to the lip)

Disassembly steps
"DA 1. Clutch sleeve 8. Circlip
2. Snap ring AA" "BA 9. Bearing
3. Shift fork assembly 10. Bearing
"CA 4. Spring pin 11. Clutch gear
5. Shift rod "AA 12. Oil seal
6. Shift fork 13. Free-wheeling clutch housing
7. Clutch gear assembly
 FRONT AXLE – Free-wheeling Clutch Assembly 26-47
DISASSEMBLY SERVICE POINT
AA" BEARING REMOVAL
Position the bearing inner race on a support. Then use a
press to separate the clutch gear from the bearing.
Support

MB990938 MB991015 REASSEMBLY SERVICE POINTS

"AA OIL SEAL INSTALLATION

MB990799 "BA BEARING INSTALLATION

Use the special tool to press-fit the bearing to the shoulder
of the clutch gear.

Spring pin "CA SPRING PIN INSTALLATION

Insert the spring pin into the pin hole (with chamfered surface)
of the shift rod, and then tap the spring pin in as shown
in the illustration.

0 – 1 mm Shift rod
Shift fork

"DA CLUTCH SLEEVE INSTALLATION

Face the clutch sleeve tapered side towards the drive shaft
to install the clutch sleeve.
Drive shaft Differential carrier
side side

Taper side
26-48 FRONT AXLE – Solenoid Valve, Vacuum Pipes and Vacuum Tank

SOLENOID VALVE, VACUUM PIPES AND VACUUM TANK

REMOVAL AND INSTALLATION

1
7

6
3

2
1

4 1

1
1 8
5

10
9

12
17 Nm

11
1

1. Vacuum hose Vacuum actuator assembly removal

"AA 2. Vacuum hose <blue stripe> steps
"AA 3. Vacuum hose <yellow stripe> "AA 9. Vacuum hose <blue stripe>
4. Vacuum pipe assembly connection
5. Vacuum pipe assembly "AA 10. Vacuum hose <yellow stripe>
6. Solenoid valve assembly connection
"BA 7. Check valve AA" 11. Pin
8. Vacuum tank assembly 12. Vacuum actuator assembly
 FRONT AXLE – Solenoid Valve, Vacuum Pipes and Vacuum Tank 26-49
REMOVAL SERVICE POINT
Collar Dust cover
AA" PIN REMOVAL
1. Remove the one side of the dust cover from the vacuum
actuator assembly.
2. Align the pin with the pin hole of the collar, and then
Pin drive out the pin with a punch.

INSTALLATION SERVICE POINTS

" AA VACUUM HOSE INSTALLATION
Connect the vacuum hoses, the solenoid valve and the
vacuum pipes according to their identification colours.

" BA CHECK VALVE INSTALLATION

Face the arrow mark to the vacuum side.

Solenoid
Vacuum side valve side

Arrow mark indicating

ventilation direction
26-50 FRONT AXLE – Front Differential Mount

FRONT DIFFERENTIAL MOUNT

REMOVAL AND INSTALLATION
Caution
1. To remove the differential mount crossmember assembly, support the front differential assembly
with a jack.
2. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.

103 Nm
4
3
42 Nm

98 – 118 Nm*

2
1
42 Nm 93 Nm*
103 Nm

Differential mount bracket assembly 2. Differential mount bracket assembly

(front) removal steps <Rear – LH>
D Free-wheeling clutch assembly 3. Differential mount bracket
removal (Refer to P. 26-45.) <Rear – RH>
1. Differential mount bracket assembly Differential mount crossmember
<front> assembly removal steps
Differential mount bracket assembly D Front propeller shaft removal (Refer
(LH, RH) removal steps to GROUP 25.)
D Drive shaft assembly removal 4. Differential mount crossmember
(Refer to P. 26-19.) assembly
 FRONT AXLE – Front Differential Mount 26-51

MD999547
DIFFERENTIAL MOUNT INSULATOR
REPLACEMENT
FRONT
1. Use the special tool to drive out the insulator.

MB990947 2. Use the special tools and a press to press-fit the insulators
MB990847
so that their hollow portion points to the shown direction
and the insulator protrudes evenly (Distance A is equal
MB990981
to distance B).

REAR
1. Use the special tool to drive out the insulator.
MD999570

MB991318 2. Use the special tools and a press to press-fit the insulators
so that their hollow portion points to the shown direction
MB991183
and the insulator protrudes evenly (Distance C is equal
MB990843 to distance D).

D
NOTES
26-1 FRONT AXLE – General/General Information

GROUP 26
FRONT AXLE
GENERAL
OUTLINE OF CHANGE
 The front differential reduction gear ratio has been changed due to the introduction of 2000-mL engine.
 The service procedure has been changed since the wheel bearing has been changed from the previous
oil seal separate type to the integrated type.

Inner oil seal

<abolished>
Snap ring

Wheel bearing Knuckle

<Oil seal inte- Outer oil seal
grated> <abolished>
Hub

 The solenoid valve for the free-wheeling mechanism has been changed.
Waterproof type connector
New Old

GENERAL INFORMATION
FRONT DIFFERENTIAL
Item New Old
Reduction ratio 4.636*1, 4.900*2 4.875

Number Drive gear 51*1, 49*2 39

of teeth
Drive pinion 11*1, 10*2 8

NOTE
*1: M/T, *2: A/T
 FRONT AXLE – Hub and Knuckle Assembly 26-2
HUB AND KNUCKLE ASSEMBLY
DISASSEMBLY AND REASSEMBLY

2
3

4
1

Disassembly steps B A 3. Wheel bearing

D  Hub rotation starting torque check 4. Knuckle
C  Wheel bearing axial play check
NOTE
A 1. Hub
The disassembly service points are the same as
B 2. Snap ring before.

REASSEMBLY SERVICE POINTS

Only the service procedure below has been added. The other
service procedures are the same as before.
B SNAP RING INSTALLATION
The notch in the snap ring should face down.
Caution
The sealing performance between the snap ring and the
Snap ring
bearing seal can be ensured by making the snap ring
face down. If the snap ring notches face toward the
different direction, the sealing performance may be
impaired.
 26-1

FRONT AXLE
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 5

Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Front Axle Total Backlash Check . . . . . . . . . . . . . . . 5

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 FRONT AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . 7

LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . 9

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 VACUUM PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

26-2 FRONT AXLE – General/General Information

GENERAL
OUTLINE OF CHANGE
The following service procedures have been established due to the addition of the vehicles with 1800-MPI
engine. Other service procedures are the same as before.
GENERAL INFORMATION
FRONT AXLE
Item 1800-MPI
Drive shaft Shaft length* Shaft diameter Right side 316 24
mm
Left side 435 24
Front axle shaft Shaft length Shaft diameter mm 389 25
Bearing (O.D. I.D.) mm 62 35

NOTE
*: shows the distance between the centres of the joints.

FRONT DIFFERENTIAL
Item 1800-MPI

Reduction ratio 4.636*1, 5.111*2

Number of teeth Drive gear 51*1, 46*2
Drive pinion 11*1, 9*2
Bearing (O.D. I.D.) mm Side 72.0 35.0
Front 62.0 25.0
Rear 72.0 35.0

NOTE
*1: M/T
*2: A/T
 FRONT AXLE – General Information/Service Specifications/Lubricant 26-3
CONSTRUCTION DIAGRAM

Front axle assembly

Differential mount
bracket (LH) Differential mount
crossmember

Front differential

Drive shaft (RH)

Drive shaft (LH)

SERVICE SPECIFICATIONS
Items Standard value Limit

Drive pinion turning Without oil seal When replacing 0.88 – 1.17 –
torque N·m (with anti-rust agent)

When replacing or reusing 0.39 – 0.49 –

(with gear oil applied)

With oil seal When replacing 0.98 – 1.27 –

(with anti-rust agent)

When replacing or reusing 0.49 – 0.58 –

(with gear oil applied)

LUBRICANT
Items Specified lubricants Quantity

D.O.J./B.J. Repair kit grease 85 g

26-4 FRONT AXLE – Special Tools

SPECIAL TOOLS
Tool Number Name Use
MB991115 Oil seal installer Front axle oil seal press-fitting (Used together
with MB990938)

MB990673 Front bearing Bearing removal

remover

MB990663 Rear axle shaft Bearing installation

bearing and retain-
er ring installer

MB990850 End yoke holder Companion flange removal and installation

MB990835 Dummy pinion set D Drive pinion rotation starting torque check
A: MB990836 A: Drive D Drive pinion height measurement
B: MB990392 pinion gauge
assembly
B B: Cylinder gauge
A

MB990326 Pre-load socket Drive pinion turning torque measurement

MB990829 Pinion and side D Drive pinion rear bearing inner race
bearing installer pressing-in
D Side bearing inner race pressing-in

MB990727 Oil seal installer Drive pinion oil seal pressing-in

 FRONT AXLE – Special Tools/On-vehicle Service 26-5

MB990925
Tool box
C Brass bar

B
A Installer bar (snap-in type)
Installer adapter

Type Tool number O.D. mm Type Tool number O.D. mm

A MB990926 39 A MB990933 63.5

MB990927 45 MB990934 67.5

MB990928 49.5 MB990935 71.5

MB990929 51 MB990936 75.5

MB990930 54 MB990937 79

MB990931 57 B MB990938 –

MB990932 61 C MB990939 –

Mating marks ON-VEHICLE SERVICE

FRONT AXLE TOTAL BACKLASH CHECK
1. Place the transmission shift lever in the neutral position,
apply the parking brake and then jack up the vehicle.
2. Manually turn the propeller shaft clockwise as far as it
will go and make mating marks on the companion flange
dust cover and the differential carrier.

3. Manually turn the propeller shaft anti-clockwise as far as it

will go and measure the movement of the mating marks.
Limit: 5 mm
4. If the backlash exceeds the limit, remove the differential
carrier assembly, and then carry out the following checks.
D Final drive gear backlash
D Differential gear backlash
D Play in the serrations and spline of the side gears,
drive shaft, inner shaft and drive flange
26-6 FRONT AXLE – Drive Shaft

DRIVE SHAFT
DISASSEMBLY AND REASSEMBLY
Caution
The B.J. assembly is non-serviceable and requires replacement if defective. B.J. boot can be replaced.

12
4 <RH>
3
5 6
13

13
4 <LH> 2 11
1

4
11

Grease: Repair kit grease

Grease: Repair kit grease Quantity: B.J.: 85 g (40 g for joint, 45 g for boot)
D.O.J.: 85 g (50 g for joint, 35 g for boot)

Caution
The joint is filled with a special grease. Do not mix the grease with an old one or other grease.

12 3 13 4
5 2 35
1 12 3 5 6
7 7
2 2
1 13 12 1
8
9
10

B.J. boot repair kit D.O.J. boot repair kit D.O.J. repair kit
 FRONT AXLE – Drive Shaft/Front Axle Shaft 26-7
Disassembly steps 9. B.J. boot band (large)
"BA 1. D.O.J. boot band (small) 10. B.J. boot
"BA 2. D.O.J. boot band (large) 11. B.J. assembly
3. Circlip 12. Circlip
4. D.O.J. outer race 13. Dust cover
5. Snap ring NOTE
6. Inner race, cage, ball assembly Removal and installation service points are the same
AA" "AA 7. D.O.J. boot as before.
8. B.J. boot band (small)

FRONT AXLE SHAFT

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Drive Shaft Removal and Installation
D Gear Oil Draining and Refilling

88 ± 10 N·m

9
2 10
8
6
108 ± 10 N·m
7
5
3 4

9 4

(Apply to
the lip)

Sealant: (Apply to the lip)

3M ATD Part No.8661 or equivalent

Removal steps
D Front differential assembly and 5. Snap ring
differential mount crossmember 6. Front axle shaft
assembly(Refer to P.26-9) 7. Clip
1. Vacuum pipe assembly "BA 8. Oil seal
2. Vacuum hose assembly AA" "AA 9. Bearing
3. Front axle assembly 10. Front housing assembly
"CA 4. Oil seal
26-8 FRONT AXLE – Front Axle Shaft

REMOVAL SERVICE POINT

MB990673 AA" BEARING REMOVAL
Install the special tool as shown in the illustration, and use
a press to drive out the bearing from the main shaft.

INSTALLATION SERVICE POINTS

"AA BEARING INSTALLATION
MB990663

MB990938
"BA OIL SEAL INSTALLATION

MB990927

"CA OIL SEAL INSTALLATION

MB990938
MB991115
 FRONT AXLE – Differential Carrier 26-9
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Caution
To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully
tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D Drive Shaft Removal and Installation
D Stabilizer Bar Removal and Installation
D Gear Oil Draining and Refilling

93 ± 15 N·m*

54 ± 4 N·m

1
103 ± 15 N·m
3 2
88 ± 5 N·m
4
5

49 ± 9 N·m
88 ± 10 108 ± 10 N·m*
64 ± 4 N·m N·m
93 ± 15 N·m*

Sealant:
3M ATD Part No.8661 or
equivalent
Removal steps
AA" D Support the Engine Assembly 5. Differential carrier
1. Front propeller shaft connection 6. Differential mount crossmember
2. Front differential assembly and assembly
differential mount crossmember NOTE
assembly
Removal service points are the same as before.
3. Front axle assembly
4. Differential mount bracket assembly
<RH>
26-10 FRONT AXLE – Differential Carrier

DISASSEMBLY AND REASSEMBLY

Service procedures except following are the same as before.
MB990836 REASSEMBLY SERVICE POINTS
(MB990835) "DA DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special
MB990835 tool.
Washer 2. Install the special tool, drive pinion front and rear bearing
inner races to the gear carrier.

3. Tighten the nut of the special tool while measuring the

MB990835
rotation torque of the drive pinion. Gradually keep
tightening the nut of the special tool until the rotation torque
of the drive pinion (without oil seal) is at the standard
value.
Standard value:
Bearing division Bearing lubrication Rotation torque
N·m
New None (With 0.88 – 1.17
anti-rust agent)
New or reused Gear oil applied 0.39 – 0.49

MB990326 NOTE
The special tool cannot be turned a full revolution, so
turn it several times within the range of movement to run
in the bearing, and then measure the rotation torque.

4. Clean the side bearing hub.

Notch MB990392 5. Install the special tools to the side bearing hub of the
gear carrier, and then install the bearing cap.
NOTE
A
Always check that the notch is in the shown position and
that the special tools are touching firmly against the side
bearing hub.
6. Use a thickness gauge to measure the clearance (A)
Thickness MB990836 between the special tools.
gauge
 FRONT AXLE – Differential Carrier 26-11
7. Remove the special tools.
8. Use a micrometer to measure the special tool in the places
C (B, C) shown in the illustration.

9. Install the bearing cap, and then use a cylinder gauge

Bearing cap and micrometer to measure the inside diameter (D) of
the bearing cap as shown in the illustration.
10. Calculate the thickness (E) of the required drive pinion
front shim by the following formula, and then select a
D shim which most closely matches this thickness.
E = A + B + C – 1/2D – 86.0

11. Fit the selected drive pinion front shim(s) to the drive pinion,
Drive
and press-fit the drive pinion front bearing inner race by
pinion MB990829 using the special tool.
front
shim

MB990829

"EA DRIVE PINION ROTATION TORQUE

ADJUSTMENT
Adjust the drive pinion rotation torque by using the following
procedure:
1. Insert the drive pinion into the gear carrier, and then install
the drive pinion spacer, the drive pinion rear shim, the
drive pinion rear bearing inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.

2. Use the special tool to hold companion flange, and then

186 ± 29 N·m tighten the self-locking nut to the specified torque.

MB990850
26-12 FRONT AXLE – Differential Carrier

MB990326 3. Measure the drive pinion rotation torque (without the oil
seal) by using the special tool.
Standard value:
Bearing division Bearing lubrication Rotation torque
N·m
New None (With 0.88 – 1.17
anti-rust agent)
New/reused Gear oil applied 0.39 – 0.49

4. If the drive pinion rotation torque is not within the range

of the standard value, adjust it by replacing the drive pinion
rear shim(s) or the drive pinion spacer.
NOTE
When selecting the drive pinion rear shims, if the number
A of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacers. Also, select the drive
Identification pinion spacer from the following two types.
colour
Drive pinion spacer Identification colour
height (A) mm
57.72 –
57.08 Red

5. Remove the companion flange and drive pinion again.

Then, after inserting the drive pinion rear bearing inner
race into the gear carrier, use the special tool to press-fit
MB990727 the oil seal.

6. Install the drive pinion assembly and companion flange

with mating marks properly aligned, and use the special
186 ± 29 N·m
tool to hold the companion flange, and then tighten the
MB990850 self-locking nut to the specified torque.
 FRONT AXLE – Differential Carrier/Vacuum Pipes 26-13
MB990326 7. Measure the drive pinion rotation torque (with the oil seal)
by using the special tool.
Standard value:
Bearing division Bearing lubrication Rotation torque
N·m
New None (With 0.98 – 1.27
anti-rust agent)
New/reused Gear oil applied 0.49 – 0.58

8. If the drive pinion rotation torque is not within the standard

value, check the tightening torque of the companion flange
self-locking nut and the oil seal installation condition.

VACUUM PIPES
REMOVAL AND INSTALLATION

3 1

1
2

1
Removal step
1. Vacuum hose 3. Vacuum pipe assembly
2. Vacuum pipe assembly 4. Breather cap
NOTES
 REAR AXLE
Click on the applicable bookmark to selected the required model year
 27-1

REAR AXLE
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Rear Axle Total Backlash Check . . . . . . . . . . . . . . . 6

Gear Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
Wheel Bearing Axial Play Check . . . . . . . . . . . . . . . 7
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Axle Housing Oil Seal Replacement . . . . . . . . . . . . 7

SEALANTS AND ADHESIVES . . . . . . . . . . . . . . 4 AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . 15

27-2 REAR AXLE – General Information

GENERAL INFORMATION
The rear axle is a banjo-type semi-floating type and D For vehicles with ABS, the ABS rotor is
provides the following characteristics: press-fitted to the axle shaft.
D The rear wheel bearing is of an anti-mud D In order to improve stream-crossing
enhanced type. performance, a vent plug is fitted to the upper
D In order to improve driveability at muddy road, part of the axle housing.
helical LSD are available as optional equipment.

Item Conventional differential Helical LSD

Drive gear type Hypoid gear Hypoid gear

Reduction ratio 4.875 4.875

Limited slip differential type – Torque sensitive type

Differential gear type Side gear Straight bevel gear  2 Helical gear  2
(Type  quantity)
Pinion gear Straight bevel gear  2 Long pinion  4, Short
pinion  4

Number of teeth Drive gear 39 39

Drive pinion 8 8

Side gear 14 14

Pinion gear 10 10

Bearing (O.D.  I.D.) mm Side 80.0  45.2 80.0  45.2

Front 68.3  30.2 68.3  30.2

Rear 76.2  36.5 76.2  36.5

 REAR AXLE – General Information/Service Specifications/Lubricants 27-3
CONSTRUCTION DIAGRAM

Brake disc
Wheel bearing
Vent plug

Oil seal
Axle housing

Differential

Axle shaft Axle shaft

ABS rotor

SERVICE SPECIFICATIONS
Items Standard value Limit

Rear axle total backlash mm – 4.2

Wheel bearing axial play mm – 0.025

Final drive gear backlash mm 0.08 – 0.13 –

Drive gear runout mm – 0.05

Differential gear backlash mm 0.01 – 0.25 0.2

Drive pinion Without When replacing with a new 0.59 – 0.88 –

turning torque oil seal bearing (with rust-prevention oil)
Nm
When using a new bearing or 0.39 – 0.49 –
when reusing (gear oil application)

With oil When replacing with a new 0.83 – 1.13 –

seal bearing (with rust-prevention oil)

When using a new bearing or 0.64 – 0.74 –

when reusing (gear oil application)

LUBRICANTS
Items Specified lubricant Quantity

Gear oil Hypoid gear oil Approx. 1.7 ȏ

API classification GL-5 or higher SAE viscosity
No. 90, 80W
27-4 REAR AXLE – Sealants and Adhesives/Special Tools

SEALANTS AND ADHESIVES

Items Specified sealants and adhesives Specified sealants and
adhesives

Bearing case 3M ATD Part No. 8661 or equivalent Semi-drying sealant

Axle housing (Differential carrier instal-

lation surface)

Drive gear threaded holes 3M Stud Locking 4170 or equivalent Anaerobic sealant

SPECIAL TOOLS
Tool Number Name Use

A MB990590 Rear axle shaft oil D Axle shaft removal

A: MB990211 seal remover D Axle housing oil seal removal
B B: MB990212 A: Slide hammer
B: Adapter

MB990241 Axle shaft puller Axle shaft removal

A: MB990242 A: Puller shaft
B
B: MB990244 B: Puller bar

MB991354 Puller body

MB990560 Rear axle shaft Rotor removal

bearing remover

MB991284 Axle shaft bearing Axle shaft wheel bearing removal

puller set

MB990909 Working base Differential carrier fixing

 REAR AXLE – Special Tools 27-5

Tool Number Name Use

MB991367 Special spanner Side bearing nut removal and installation

MB991385 Pin

MB990810 Side bearing puller D Side bearing inner race removal

D Companion flange removal

MB990811 Side bearing cup Side bearing inner race removal

MB990850 End yoke holder D Self-locking nut removal

D Drive pinion turning torque adjustment

MB990339 Bearing puller Drive pinion rear bearing inner race removal

MB990648 Bearing remover

MB991171 Drive pinion setting Drive pinion height adjustment

A: MB990819 gauge set
C
B: MB991170 A: Drive pinion
C: MB991169 gauge
B B: Cylinder gauge
A C: Drive pinion
gauge attach-
ment
27-6 REAR AXLE – Special Tools/On-vehicle Service

Tool Number Name Use

MB990685 Torque wrench Drive pinion turning torque adjustment

MB990326 Preload socket

MB990802 Bearing installer D Drive pinion rear bearing inner race

press-fitting
D Side bearing inner race press-fitting

MB990727 Oil seal installer Drive pinion oil seal press-fitting

MB991171 Bearing and oil D Oil seal press-fitting

A A: MB990926 to seal installer set D Bearing inner and outer race removal and
MB990937 A: Installer adapter press-fitting
C For the details of installer, refer to GROUP 26
B: MB990938 B: Bar
B – Special Tool.
C: MB990939 C: Brass bar

Mating marks ON-VEHICLE SERVICE

REAR AXLE TOTAL BACKLASH CHECK
1. Place the transmission shift lever and the transfer shift
lever in the neutral position, apply the parking brake and
then jack up the vehicle.
2. Manually turn the propeller shaft clockwise as far as it
will go and make mating marks on the companion flange
dust cover and the differential carrier.

3. Manually turn the propeller shaft anti-clockwise as far as it

will go and measure the movement of the mating marks.
Limit: 4.2 mm
4. If the backlash exceeds the limit, remove the differential
carrier assembly, and then carry out the following checks.
Final drive gear backlash (Refer to P.27-16.)
Differential gear backlash (Refer to P.27-16.)
 REAR AXLE – On-vehicle Service 27-7
GEAR OIL LEVEL CHECK
1. Remove the filler plug.
Gear oil
2. Check that the gear oil level is between the upper limit
(the bottom of a filler plug) and the lower limit.
3. If the gear oil level is not between the upper limit and
Upper limit 8 mm the lower limit, add the specified gear oil until the gear
oil level reaches the bottom of the filler plug.
Lower limit Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity No. 90, 80W
4. Install the filler plug, and then tighten it to the specified
torque.
Tightening torque: 49 Nm

WHEEL BEARING AXIAL PLAY CHECK

1. Place a dial gauge against the axle shaft as shown in
the illustration, and then move the axle shaft in the axial
direction and check the axial play.
Limit: 0.025 mm
2. If the axial play exceeds the limit, check the backing plate
to axle housing tightening torque. If it is correct, replace
the bearing.

AXLE HOUSING OIL SEAL REPLACEMENT

1. Use the special tools to remove the axle shaft assembly.
(Refer to P.27-11.)

MB990244 (Three)
MB990211 MB991354

2. Use the special tools to remove the oil seal.

MB990212 3. Apply multipurpose grease to the oil seal contact surface
MB990211
of the axle housing.
27-8 REAR AXLE – On-vehicle Service

4. Use the special tools to install a new oil seal in position.

MB990930 5. Apply multipurpose grease to the lip section of the oil
seal.
6. Install the axle shaft assembly. (Refer to P.27-11.)

MB990938
 REAR AXLE – Axle Assembly 27-9
AXLE ASSEMBLY
REMOVAL AND INSTALLATION
Caution
1. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.
2. Be careful not to strike the pole piece at the tip of the wheel speed sensor against the other
parts when removing and installing the wheel speed sensor.

Pre-removal Operation Post-installation Operation

D Brake Fluid Draining (Refer to GROUP 35A – D Brake Fluid Filling and Air Bleeding (Refer to
On-vehicle Service.) GROUP 35A – On-vehicle Service.)
D Differential Gear Oil Draining D Parking Brake Lever Stroke Adjustment (Refer to
GROUP 36 – On-vehicle Service.)
D Differential Gear Oil Filling (Refer to P.27-7.)

11
9
16

59 Nm* 12

10
101 Nm* 8
81 Nm*

13

14
60 Nm

2
49 Nm
15
15 Nm
3

18

1
59 Nm
6
49 – 59 Nm
17 4
7
5
Removal steps
AA" 1. Rear propeller shaft connection 10. Coil spring (Refer to GROUP 34 –
2. Caliper assembly Rear Suspension Assembly.)
3. Brake disc 11. Silencer sheet
4. Parking brake shoe assembly (Re- 12. Bump stopper
fer to GROUP 36 – Parking Brake 13. Lower spring pad
Drum.) AC" 14. Lateral rod connection
5. Parking brake cable connection 15. Rear brake pipe and hose connec-
6. Wheel speed sensor <Vehicles with tion
ABS> 16. Upper arm connection
7. O-ring <Vehicles with ABS> 17. Lower arm connection
8. Spring support AD" 18. Axle assembly
AB" 9. Shock absorber connection
27-10 REAR AXLE – Axle Assembly

REMOVAL SERVICE POINTS

AA" REAR PROPELLER SHAFT DISCONNECTION
Make mating marks on the companion flange and the flange
yoke, and then disconnect the propeller shaft from the
companion flange.
Caution
Use a wire, etc. to suspend the propeller shaft from the
body to prevent it from falling.
AB" SHOCK ABSORBER DISCONNECTION
Support the axle housing with a jack before removing the
shock absorber lower mounting nut.
AC" LATERAL ROD DISCONNECTION
Disconnect the lateral rod from the axle assembly, and then
use a wire, etc. to suspend the lateral rod to prevent it from
falling.
AD" AXLE ASSEMBLY REMOVAL
Take out the axle assembly toward the rear of vehicle.
Caution
Take out the axle assembly carefully and slowly. The axle
assembly is heavy and unstable and may fall.
 REAR AXLE – Axle Shaft 27-11
AXLE SHAFT
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Brake Fluid Draining (Refer to GROUP 35A – On-vehicle D Brake Fluid Filling and Air Bleeding (Refer to
Service.) GROUP 35A – On-vehicle Service.)
D Parking Brake Lever Stroke Adjustment (Refer to
GROUP 36 – On-vehicle Service.)

15 Nm 1 88 Nm

(Oil lip part) 2

12

7
10

5
11
9
4

Removal steps
1. Brake tube 7. O-ring <Vehicles with ABS>
2. Caliper assembly AA" 8. Axle shaft assembly
3. Brake disc "BA 9. Packing(s)
4. Parking brake shoe (Refer to "BA 10. Shim(s)
Group 36 – Parking brake drum.) "BA 11. Packing(s)
5. Parking brake cable connection AB" "AA 12. Oil seal
6. Wheel speed sensor <Vehicles with
ABS>

REMOVAL SERVICE POINTS

AA" AXLE SHAFT ASSEMBLY REMOVAL
Use the special tools to remove the axle shaft assembly.
Caution
Be careful not to damage the oil seal when pulling the axle
shaft.

MB990211 MB990244 (Three)

MB991354
27-12 REAR AXLE – Axle Shaft

AB" OIL SEAL REMOVAL

MB990212 Use the special tools to remove the oil seal.
MB990211

INSTALLATION SERVICE POINTS

MB990930
"AA OIL SEAL INSTALLATION
Use the special tools to tap in the oil seal.

MB990938

"BA PACKING/SHIM INSTALLATION

1. When only removing and reinstalling the axle shaft, the
same thickness and number of shims as before should
be used.
2. When replacing the axle shaft or the wheel bearing, select
the packing(s) and shim(s) to adjust the bearing outer
retainer tightening condition by the following procedure.
(1) Insert the axle shaft assembly into the axle housing
without packing(s) and shim(s). Temporarily tighten
the installation nuts to half of specified torque (until
the bearing outer race contacts the axle housing)
evenly in diagonal order in two steps.
(2) Use a thickness gauge to measure the clearance
between the axle housing and the backing plate, and
then select the packing(s) and shim(s) according to
the following table.
NOTE
New packing is 0.27 mm to 0.33 mm in thickness,
and new shim is 0.3 mm in thickness.
Clearance mm Number of Number of
packing shim
0.2 0 0
0.2 – 0.5 1 0
0.5 – 0.75 2 0
0.75 – 1.0 2 1
1.0 – 1.25 2 2
 REAR AXLE – Axle Shaft 27-13
(3) If using the shim(s), sandwich the shim(s) between the
Shims packings as shown in the illustration.
3. Install the axle shaft assembly. Tighten the nuts in a
diagonal order to the specified torque.
Tightening torque: 29 Nm

Packings

DISASSEMBLY AND REASSEMBLY

1
2
3

Disassembly steps
AA" 1. ABS rotor <Vehicles with ABS> "AA 4. Bearing outer retainer
AB" "AA 2. Bearing inner retainer 5. Axle shaft
AC" "AA 3. Wheel bearing

MB990560
DISASSEMBLY SERVICE POINTS
AA" ABS ROTOR REMOVAL
Use the special tool to press out the ABS rotor.

AB" BEARING INNER RETAINER REMOVAL

1. Use a grinder to shave off a part of the bearing inner
retainer until its thickness becomes 1 to 1.5 mm.

Bearing inner
retainer
27-14 REAR AXLE – Axle Shaft

2. Use a chisel to cut the shaven part of the bearing inner

retainer, and then remove the bearing inner retainer.
Caution
Be careful not to damage the axle shaft.

MB991284 AC" WHEEL BEARING REMOVAL

Use the special tool to remove the wheel bearing.

Metal plate
REASSEMBLY SERVICE POINT
(Toward the wheel) Black seal (Toward
the centre of vehicle)
"AA BEARING OUTER RETAINER/WHEEL BEARING/
BEARING INNER RETAINER INSTALLATION
1. Install the bearing outer retainer, wheel bearing and the
bearing inner retainer to the axle shaft in that order, as
shown in the illustration.
2. Press-fit the bearing inner retainer to the axle shaft.
Caution
Wheel bearing Install the wheel bearing as shown in the illustration.
 REAR AXLE – Differential Carrier 27-15
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Differential Gear Oil Draining D Brake Fluid Filling and Air Bleeding (Refer to
D Axle Shaft Removal (Refer to P.27-11.) GROUP 35A – On-vehicle Service.)
D Brake Fluid Draining (Refer to GROUP 35A – D Axle Shaft Installation (Refer to P.27-11.)
On-vehicle Service.) D Differential Gear Oil Filling (Refer to P.27-7.)

Section A – A
φ 2 – 3 mm

49 Nm
A

A
Flange surface of axle housing 49 – 59 Nm 2
Sealant: 3
3M ATD Part No. 8661 or
equivalent

25 – 29 Nm

59 Nm

Removal steps
AA" "AA 1. Rear propeller shaft connection
AB" 2. Differential carrier assembly
3. Vent plug

REMOVAL SERVICE POINTS

AA" REAR PROPELLER SHAFT DISCONNECTION
Make mating marks on the companion flange and the flange
yoke, and then disconnect the propeller shaft from the
companion flange.
Caution
Use a wire, etc. to suspend the propeller shaft from the
body to prevent it from falling.
27-16 REAR AXLE – Differential Carrier

AB" DIFFERENTIAL CARRIER REMOVAL

Loosen the differential carrier mounting nuts to the end of
each stud bolt, and then strike the lower part of differential
carrier with a piece of timber several times to separate the
differential carrier from the axle housing.
Caution
1. Do not remove the differential carrier mounting nuts
so that the differential carrier will not fall when
separating it from the axle housing.
2. Do not strike the companion flange.

INSTALLATION SERVICE POINT

"AA REAR PROPELLER SHAFT CONNECTION
Connect the propeller shaft so that the mating marks on the
flange yoke and the companion flange of differential carrier
are aligned.

INSPECTION BEFORE DISASSEMBLY

For the inspection procedure except for the standard values
below, refer to GROUP 26 – Inspection Before Disassembly.
FINAL DRIVE GEAR BACKLASH
Standard value: 0.08 – 0.13 mm
DIFFERENTIAL GEAR BACKLASH
Standard value: 0.01 – 0.25 mm
 REAR AXLE – Differential Carrier 27-17
DISASSEMBLY
Caution
Do not disassemble the limited slip differential case assembly (helical gear type), because it is
not possible to assemble.

<Conventional differential>
1
2 5 6 4
13 12
9
10
11
8
3 13
7 14
29 11 6 5
28 12
27 10
19 25 26

24
22 23 1
20 21 2
3 18
17
16

30 <Helical LSD>
1
2 4
5
6
7
15
6
5

1
2

Disassembly steps
D Inspection before disassembly 17. Washer
(Refer to P.27-17.) AF" 18. Drive pinion assembly
1. Locking plate AF" 19. Companion flange
AA" 2. Side bearing nut 20. Drive pinion front shim
3. Bearing cap (for drive pinion turning torque
AB" 4. Differential case assembly adjustment)
5. Side bearing outer race 21. Drive pinion spacer
AC" 6. Side bearing inner race AG" 22. Drive pinion rear bearing inner race
AD" 7. Drive gear 23. Drive pinion rear shim
8. Lock pin (for drive pinion height adjustment)
9. Pinion shaft 24. Drive pinion
10. Pinion gear AH" 25. Oil seal
11. Pinion washer AH" 26. Drive pinion front bearing inner
12. Side gear race
13. Side gear spacer AH" 27. Drive pinion front bearing outer
14. Differential case race
15. Limited slip differential case AI" 28. Drive pinion rear bearing outer race
assembly 29. Differential carrier
AE" 16. Self-locking nut 30. Dynamic damper
27-18 REAR AXLE – Differential Carrier

MB991367 DISASSEMBLY SERVICE POINTS

MB991385
AA" SIDE BEARING NUT REMOVAL
Use the special tools to remove the side bearing nuts.
NOTE
Keep the right and left side bearing nuts separate, so that
they will not be confused when assembling.

AB" DIFFERENTIAL CASE ASSEMBLY REMOVAL

Use the handle of hammer to pry up the differential case
assembly.
Caution
Remove the differential case assembly, slowly and
carefully so that the side bearing outer races are not
dropped.
NOTE
Keep the right and left side bearing outer races separate,
so that they will not be confused when assembling.

AC" SIDE BEARING INNER RACE REMOVAL

MB990810
Use the special tools to pull out the side bearing inner race.
NOTE
MB990811 Position the two prongs of the special tool under the bottom
of the side bearing inner race through the two notches in
the differential case.

AD" DRIVE GEAR REMOVAL

1. Make the mating marks to the differential case and the
drive gear in order to position the drive gear correctly
when assembling it.
2. Loosen the drive gear attaching bolts in diagonal sequence
Mating marks
to remove the drive gear.

AE" SELF-LOCKING NUT REMOVAL

Use the special tool to hold the companion flange, and then
remove the self-locking nut.

MB990850
 REAR AXLE – Differential Carrier 27-19
MB990810 AF" DRIVE PINION ASSEMBLY/COMPANION FLANGE
REMOVAL
1. Make the mating marks on the drive pinion and the
companion flange in order to position the companion flange
correctly when assembling it.
Caution
Companion Do not make mating mark on the surface that contacts
flange with the propeller shaft.
2. Use the special tool to remove the companion flange.

MB990339 AG" DRIVE PINION REAR BEARING INNER RACE

REMOVAL
Use the special tools to remove the drive pinion rear bearing
inner race.

MB990648

MB990939 AH" OIL SEAL/DRIVE PINION FRONT BEARING

INNER RACE/DRIVE PINION FRONT BEARING
OUTER RACE REMOVAL
Use the special tool to remove the drive pinion front bearing
Drive pinion
rear bearing outer race, drive pinion front bearing inner race and oil seal.
outer race
Drive pinion
front bearing
outer race Drive pinion
front bearing
inner race
Oil seal

AI" DRIVE PINION REAR BEARING OUTER RACE

MB990939 REMOVAL
Use the special tool to remove the drive pinion rear bearing
outer race.
27-20 REAR AXLE – Differential Carrier

REASSEMBLY
29 19 Nm <Conventional differential>
28 2524 26
17 1821
20 19
22
27 1723
1 68 – 78 Nm 19 1524
2 25
20 18 19 Nm
12 11 10 3

4
65 29
8 7 28
78 – 88 Nm
27 9
14 13
216 Nm

30

23 20
18 17 <Helical LSD>
4
14
19 Nm
17 29 26
18 28 25
20 24 23
16
24
Differential gear set Final drive gear set 25
19 Nm
12
29
28
23
11
Adhesive: 3M Stud Locking
4170 or equivalent

Reassembly steps
1. Differential carrier 14. Self-locking nut
"AA 2. Drive pinion rear bearing outer race 15. Differential case
"BA 3. Drive pinion front bearing outer 16. Limited slip differential case
race assembly
"CA D Drive pinion height adjustment "EA D Differential gear backlash adjustment
4. Drive pinion 17. Side gear spacer
5. Drive pinion rear shim 18. Side gear
(for drive pinion height adjustment) 19. Pinion washer
6. Drive pinion rear bearing inner race 20. Pinion gear
7. Drive pinion spacer 21. Pinion shaft
"DA D Drive pinion turning torque adjustment 22. Lock pin
8. Drive pinion front shim "FA 23. Drive gear
(for drive pinion turning torque "GA 24. Side bearing inner race
adjustment) 25. Side bearing outer race
9. Drive pinion assembly 26. Differential case assembly
10. Drive pinion front bearing inner "HA 27. Bearing cap
race "IA D Drive gear backlash adjustment
11. Oil seal 28. Side bearing nut
12. Companion flange 29. Locking plate
13. Washer 30. Dynamic damper
 REAR AXLE – Differential Carrier 27-21
REASSEMBLY SERVICE POINTS
MB990938 "AA DRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
MB990936
Use the special tools to tap in the drive pinion rear bearing
outer race.

"BA DRIVE PINION FRONT BEARING OUTER RACE

MB990938 PRESS-FITTING
MB990934 Use the special tools to tap in the drive pinion front bearing
outer race.

"CA DRIVE PINION HEIGHT ADJUSTMENT

For drive pin-
Adjust the drive pinion height by the following procedures:
ion attach- 1. Apply multipurpose grease to the washer of special tool.
ment, use 2. Install the special tools and drive pinion front and rear
MB991169. bearing inner races to the differential carrier in the
sequence shown in the illustration.

MB990819
Washer

3. Gradually tighten the nut of the special tool while checking

MB990819 the drive pinion turning torque until the standard value
of drive pinion turning torque (without oil seal) is obtained.
Standard value:
Bearing Bearing lubrication Turning
torque Nm
New None 0.59 – 0.88
(with anti-rust agent)
New or reusing Gear oil applied 0.39 – 0.49

MB990685
MB990326
27-22 REAR AXLE – Differential Carrier

MB991170 Cutout section 4. Clean the side bearing seat thoroughly.

5. Set the special tool on the side bearing seats, and position
the cutout section as shown in the illustration. Then confirm
that the special tool contacts with the side bearing seats
completely.
6. Use a thickness gauge to measure the clearance (A)
A between the special tools.

MB991169
Thickness
gauge

7. Remove special tools MB990720, MB990858, MB991169

and MB991170.
C
8. Use a micrometer to measure dimensions (B) and (C)
of the special tools.

9. Install the bearing cap, and then use a cylinder gauge

and the micrometer to measure the inside diameter (D)
of the bearing cap as shown in the illustration.
10. Calculate the thickness (F) of the drive pinion rear shim
from the following equation, and select the shim that is
Cylinder gauge closest in thickness to this value.
F = A + B + C – 1/2 D – 100

11. Fit the selected drive pinion rear shim(s) to the drive pinion,
and press-fit the drive pinion rear bearing inner race by
MB990802
using the special tool.
Drive
pinion
rear shim

MB990802

"DA DRIVE PINION TURNING TORQUE ADJUSTMENT

Adjust the drive pinion turning torque by using the following
procedure:
1. Insert the drive pinion into the differential carrier, and then
install the drive pinion spacer, the drive pinion front shim,
the drive pinion front bearing inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.
 REAR AXLE – Differential Carrier 27-23
2. Use the special tool to hold the companion flange, and then
tighten the companion flange self-locking nut to the
216 Nm
specified torque.
MB990850

3. Use the special tool to measure the drive pinion turning

MB990685 MB990326
torque (without the oil seal).
Standard value:
Bearing Bearing lubrication Turning
torque Nm
New None 0.59 – 0.88
(with anti-rust agent)
New or reusing Gear oil applied 0.39 – 0.49

4. If the drive pinion turning torque is not within the standard

value, adjust the turning torque by replacing the drive
pinion front shim(s) or the drive pinion spacer.
NOTE
A When selecting the drive pinion front shims, if the number
Identification of shims is large, reduce the number of shims to a minimum
colour
by selecting the drive pinion spacer.
Select either of the following drive pinion spacers.
Height (A) of drive pinion spacer mm Identification colour
56.67 –
57.01 White

5. Remove the companion flange and drive pinion once again.

Insert the drive pinion front bearing inner race into the
differential carrier, and then use the special tool to tap
MB990727 in the oil seal into the differential carrier.
27-24 REAR AXLE – Differential Carrier

6. Install the drive pinion assembly and the companion flange

with mating marks properly aligned. Install the new
216 Nm
self-locking nut, then use the special tool to hold the
MB990850 companion flange, and tighten the self-locking nut to the
specified torque.

7. Use the special tool to check that the drive pinion turning
MB990685 MB990326
torque (with the oil seal) is within the standard value.
Standard value:
Bearing Bearing lubrication Turning
torque Nm
New None 0.83 – 1.13
(with anti-rust agent)
New or reusing Gear oil applied 0.64 – 0.74
8. If the drive pinion turning torque is not within the standard
value, check the tightening torque of the companion flange
self-locking nut and the oil seal installation condition.

"EA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT

Adjust the differential gear backlash by the following
procedures:
1. Assemble the side gears, side gear spacers, pinion gears
and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE
Do not drive in the lock pin yet.

Attachment 3. Insert a wooden wedge between the side gear and the
Wedge pinion shaft to lock the side gear.
4. Measure the differential gear backlash with a dial indicator
on the pinion gear.
NOTE
Pinion shaft The measurement should be made for both pinion gears
individually.
Standard value: 0.01 – 0.25 mm
Side gear spacer
Limit: 0.2 mm
 REAR AXLE – Differential Carrier 27-25
5. If the differential gear backlash exceeds the limit, adjust
the backlash by replacing the side gear spacers.
6. If adjustment is not possible, replace the side gears and
pinion gears as a set.
7. After adjustment, check that the backlash does not exceed
the limit and the differential gear turns smoothly.

"FA DRIVE GEAR INSTALLATION

1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes of
the drive gear by using a tap, and then clean the threaded
holes by applying compressed air.
3. Install the drive gear onto the differential case with the
mating marks properly aligned.
Tightening torque: 78 – 88 Nm
Tap (M101.25)

"GA SIDE BEARING INNER RACE INSTALLATION

Contact Use the special tool to press-fit the side bearing inner races
Contact plate plate
into the differential case.

MB990802
MB990802

"HA BEARING CAP INSTALLATION

Install the bearing caps with the mating marks properly aligned,
and then tighten the bearing caps installation bolts to the
specified torque.

69 – 78 Nm

MB991367 "IA DRIVE GEAR BACKLASH ADJUSTMENT

MB991385
Adjust the drive gear backlash by the following procedures:
1. Use the special tools to tighten the side bearing nut to
the position where a preload will start to be applied to
the side bearing.
27-26 REAR AXLE – Differential Carrier

2. With the drive pinion locked in place, measure the drive

gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumference of
the drive gear.
Standard value: 0.08 – 0.13 mm

If backlash is too small 3. If the drive gear backlash is not within the standard value,
use the special tools (MB991367 and MB991385) to tighten
Loosen Tighten or loosen the side bearing nuts as shown in the illustration,
in order to adjust the backlash.
NOTE
First loosen the side bearing nut, then tighten the side
Tighten Loosen bearing nut the same amount as when it was loosened.

If backlash is too large

4. Use the special tools to turn down both right and left side
MB991367 bearing nuts on half the distance between centres of two
neighboring holes, in order to apply the preload to the
side bearing.

MB991385

5. Measure the drive gear runout at the shoulder on the

reverse side of the drive gear.
Limit: 0.05 mm
6. If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential case,
and remeasure.
7. If adjustment is not possible, replace the differential case
or limited slip differential case, or replace the drive gear
and drive pinion as a set.

MB092153 MB092154
8. Select either of the lock plates, and then install it.
9. Check the drive gear tooth contact. If poor contact is
evident, adjust the drive gear tooth contact. (Refer to
GROUP 26 – Differential carrier.)
27-1 REAR AXLE – General/General Information

GROUP 27
REAR AXLE
GENERAL
OUTLINE OF CHANGE
 The rear differential reduction gear ratio has been changed due to the introduction of 2000-mL engine.
 A rear stabilizer bracket has been added to the rear axle housing due to the introduction of the rear
stabilizer bar. Because of this, the service procedure has been added. <5-door models>
GENERAL INFORMATION
REAR DIFFERENTIAL
Item New Old

Reduction ratio 4.636*1, 4.900*2 4.875

Number Drive gear 51*1, 49*2 39

of teeth
Drive pinion 11*1, 10*2 8

NOTE
*1: M/T
*2: A/T
CONSTRUCTION DIAGRAM

Axle housing

Rear stabilizer bracket

 REAR AXLE – Axle Assembly<5-door models> 27-2
AXLE ASSEMBLY<5-DOOR MODELS>
REMOVAL AND INSTALLATION
Caution
1. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.
2. Be careful not to strike the pole piece at the tip of the wheel speed sensor against the other
parts when removing and installing the wheel speed sensor.

Pre-removal Operation Post-installation Operation

 Brake Fluid Draining (Refer to GROUP 35A –  Brake Fluid Filling and Air Bleeding (Refer to
On-vehicle Service.) GROUP 35A – On-vehicle Service.)
 Differential Gear Oil Draining  Parking Brake Lever Stroke Adjustment (Refer to
GROUP 36 – On-vehicle Service.)
 Differential Gear Oil Filling

11
17 9

59 Nm* 12

10
15
101 Nm* 8 49 Nm
81 Nm*

13

14
60 Nm

2
49 Nm
16
3
15 Nm

19

1
59 Nm
6
49-59 Nm 7
18 4
5

Removal steps
A 1. Rear propeller shaft connection 11. Silencer sheet
2. Caliper assembly 12. Bump stopper
3. Brake disc 13. Lower spring pad
4. Parking brake shoe assembly (Refer C 14. Lateral rod connection
to GROUP 36 – Parking Brake 15. Rear stabilizer bar connection
Drum.) (Refer to GROUP 34 – Rear
5. Parking brake cable connection stabilizer.)
6. Wheel speed sensor <Vehicles with 16. Rear brake pipe and hose connection
ABS> 17. Upper arm connection
7. O-ring <Vehicles with ABS> 18. Lower arm connection
8. Spring support <Vehicles without D 19. Axle assembly
ABS>
B 9. Shock absorber connection NOTE
10. Coil spring (Refer to GROUP 34 – The removal service points are the same as before.
Rear Suspension Assembly.)
 27-1

REAR AXLE
CONTENTS

GENERAL ................................ 2 AXLE ASSEMBLY <1800-MPI> . . . . . . . . . . . . . . 3

Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . 2
AXLE SHAFT <1800-MPI> . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
DIFFERENTIAL CARRIER <1800-MPI> . . . . . . . 5
27-2 REAR AXLE – General/General Information

GENERAL
OUTLINE OF CHANGE
The service procedures have been established due to the addition of vehicles with 1800-MPI engine.
The other service procedures are the same as before.
GENERAL INFORMATION
Item 1800-MPI

Reduction ratio 4.636*1, 5.111*2

Number of teeth Drive gear 51*1, 46*2

Drive pinion 11*1, 9*2

Bearing (O.D.  I.D.) mm Side 73.4  41.3

Front 64.3  30.2

Rear 76.2  36.5

NOTE
*1: M/T
*2: A/T
CONSTRUCTION DIAGRAM

Mud plug
Vent plug Wheel bearing
Oil seal
Axle housing

Axle shaft

Differential

Axle shaft
ABS rotor

Brake drum
 REAR AXLE – Axle Assembly <1800-MPI> 27-3
AXLE ASSEMBLY <1800-MPI>
REMOVAL AND INSTALLATION
Caution
1. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.
2. Be careful not to strike the pole piece at the tip of the wheel speed sensor against the other
parts when removing and installing the wheel speed sensor.

Pre-removal Operation Post-installation Operation

D Brake Fluid Draining D Brake Fluid Filling and Air Bleeding
D Differential Gear Oil Draining D Parking Brake Lever Stroke Adjustment(Refer to
GROUP36 – On Vehicle Service.)
D Differential Gear Oil Filling

10
15 8

64 ± 9 N·m* 11

9
3
101 ± 12 7
81 ± 12 N·m* N·m*

96 ± 12 N·m*
12

13

49 ± 9
N·m
14
15 ± 1 N·m 2
17
1
59 ± 9 N·m 5
54 ± 4 N·m
16 6
4
Removal steps
AA" 1. Rear propeller shaft connection 10. Silencer sheet
2. Brake drum 11. Bump stopper
3. Shoe and lining assembly (Refer to 12. Lower spring pad
GROUP 35A – Rear Drum Brake.) AC" 13. Lateral rod connection
4. Parking brake cable connection 14. Rear brake pipe and hose connec-
5. Wheel speed sensor<Vehicles with tion
ABS> 15. Upper arm connection
6. O-ring<Vehicles with ABS> 16. Lower arm connection
7. Load sensing proportioning valve AD" 17. Axle assembly
spring support<Vehicles without NOTE
ABS> Removal service points are the same as before.
AB" 8. Shock absorber connection
9. Coil spring
27-4 REAR AXLE – Axle Shaft <1800-MPI>

AXLE SHAFT <1800-MPI>

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Brake Fluid Draining D Brake Fluid Filling and Air Bleeding
D Parking Brake Lever Stroke Adjustment

(Oil lip part)

2 12
15 ± 1 N·m
8
10

5
6 1

11
4 9
30 ± 4 N·m

Removal steps
1. Brake drum AA" 8. Axle shaft assembly
2. Rear brake pipe connection "BA 9. Packing(s)
3. Shoe and lining assembly (Refer to "BA 10. Shim(s)
GROUP 35A – Rear Drum Brake.) "BA 11. Packing(s)
4. Parking brake cable connection AB" "AA 12. Oil seal
5. Wheel speed sensor<Vehicles with NOTE
ABS> Removal and installation service points are the same
6. O-ring<Vehicles with ABS>
7. Plug as before.
 REAR AXLE – Differential Carrier <1800-MPI> 27-5
DIFFERENTIAL CARRIER <1800-MPI>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Differential Gear Oil Draining and Refilling
D Axle Shaft Removal and Installation (Refer to
P.27-4.)
D Brake Fluid Draining, Refilling and Air Bleeding

Section A – A
φ 2 – 3 mm 49 ± 9 N·m

A 54 ± 4 N·m

A
Flange surface of axle housing
3
Sealant: 1
3M ATD Part No. 8661
or equivalent

3 2

27 ± 2 N·m 59 ± 9 N·m

Sealant:
3M ATD Part No. 8661
or equivalent

Removal steps
AA" "AA 1. Rear propeller shaft connection NOTE
AB" 2. Differential carrier assembly Removal and installation service points are the same
3. Vent plug
as before.

DISASSEMBLY AND REASSEMBLY

REASSEMBLY SERVICE POINTS
Service procedures except following are the same as before.
A "CA DRIVE PINION HEIGHT ADJUSTMENT
Identification
colour If the drive pinion turning torque is not within the standard
value, adjust the turning torque by replacing the drive pinion
front shim(s) or the drive pinion spacer.
27-6 REAR AXLE – Differential Carrier <1800-MPI>

NOTE
When selecting the drive pinion front shims, if the number
of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacer.
Select either of the following drive pinion spacers.
Height (A) of drive pinion spacer mm Identification colour
46.67 White
47.01 –
WHEEL AND TYRE
Click on the applicable bookmark to selected the required model year
 31-1

WHEEL AND TYRE

CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4

Tyre Inflation Pressure Check . . . . . . . . . . . . . . . . . . 4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
Tyre Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 3 Wheel Runout Check . . . . . . . . . . . . . . . . . . . . . . . . . 4

WHEEL AND TYRE . . . . . . . . . . . . . . . . . . . . . . . . 4

31-2 WHEEL AND TYRE – General Information/Service Specifications

GENERAL INFORMATION
The wheels and tyres of the following specifications
have been established.

SPECIFICATIONS
Items Specification

Wheel Type Steel

Aluminium*

Size 16 × 6JJ

Amount of wheel offset mm 46

Pitch circle diameter (P.C.D.) mm 114.3

Tyre Size 215/65R16 98S

NOTE
*: Optional items

SERVICE SPECIFICATIONS
Items Limit

Tread depth of tyre mm 1.6

Wheel runout (Radial runout) mm Steel wheel 1.2 or less

Aluminium wheel 1.0 or less

Wheel runout (Lateral runout) mm Steel wheel 1.2 or less

Aluminium wheel 1.0 or less

 WHEEL AND TYRE – Troubleshooting 31-3
TROUBLESHOOTING
Symptom Probable cause Remedy Reference page

Rapid wear at Under-inflation Adjust the tyre 31-4.

shoulders or lack of rotation pressure.

Rapid wear at Over-inflation or

centre lack of rotation

Cracked treads Under-inflation Adjust the tyre 31-4.

pressure.

Wear on one Excessive cam- Inspect the cam- Refer to GROUP

side ber ber. 33A – On-vehicle
Service.

Feathered edge Incorrect toe-in Adjust the toe-in.

Bald spots Unbalanced Adjust the imbal- –

wheel anced wheels.

Scalloped wear Lack of rotation of tyres or worn or Rotate the tyres Refer to GROUP
out-of-alignment suspension and check the 33A – On-vehicle
front suspension Service.
alignment.
31-4 WHEEL AND TYRE – On-vehicle Service/Wheel and Tyre

ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK
NOTE
For information on tyre inflation pressure, refer to the label
attached near the driver’s side door striker.

TYRE WEAR CHECK

Measure the tread depth of tyres.
Limit: 1.6 mm
If the remaining tread depth is less than the limit, replace
the tyre.
NOTE
When the tread depth of tyres is reduced to 1.6 mm or less,
wear indicators will appear.

WHEEL RUNOUT CHECK

Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with
Radial a dial indicator.
Limit:
Item Steel wheel Aluminium wheel
Radial runout mm 1.2 1.0
Lateral Lateral runout mm 1.2 1.0
If wheel runout exceeds the limit, replace the wheel.

Spare tyre WHEEL AND TYRE

Spare tyre INSTALLATION SERVICE POINT
cover
Tighten the wheel nut to the specified torque.
Tightening torque: 98 Nm
When installing the spare tyre and spare tyre cover to the
spare tyre carrier, tighten the wheel nut, lock cylinder and
bolt to the specified torque.
Tightening torque: 46 Nm
31-1 WHEEL AND TYRE – General/General Information

GROUP 31
WHEEL AND TYRE
GENERAL
OUTLINE OF CHANGE
A newly designed aluminium wheel has been added. Its appearance has been improved by attaching
a balance weight on the rim inside surface.

Adhesive type balance weight

GENERAL INFORMATION
SPECIFICATIONS
Items Specification
Wheel Type Aluminium type*
Size 16  6J
Amount of wheel offset mm 46
Pitch circle diameter (P.C.D.) mm 114.3
NOTE
*: Optional items
POWER PLANT
MOUNT
Click on the applicable bookmark to selected the required model year
 32-1

POWER PLANT
MOUNT
CONTENTS

ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . 2 TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . 3

32-2 POWER PLANT MOUNT – Engine Mounting

ENGINE MOUNTING
REMOVAL AND INSTALLATION
Caution
Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the
full weight of the engine on the vehicle body.

Pre-removal and Post-installation Operation

Crossmember Removal and Installation (Refer to
GROUP 33.)

25 Nm*

44 Nm 44 Nm 25 Nm*

25 Nm

25 Nm

Removal steps
1. Engine mount bracket
2. Engine mount insulator
 POWER PLANT MOUNT – Transmission Mounting 32-3
TRANSMISSION MOUNTING
REMOVAL AND INSTALLATION
Caution
Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the
full weight of the transmission on the vehicle body.

Pre-removal and Post-installation Operation

Jack up the Engine and Transmission Assembly until
there is no weight on the Engine Mount Bracket Insulator.

93 Nm*

3
5

2
4 49 Nm

1
49 Nm

6
49 Nm

Removal steps
1. Washer 5. Transmission mount insulator assembly
2. Spacer "AA 6. Transmission mount stopper
3. Transmission mount bushing 7. Adaptor
4. Transmission mount crossmember
assembly

Front of INSTALLATION SERVICE POINT

vehicle
"AA TRANSMISSION MOUNT STOPPER INSTALLATION
Install the transmission mount stopper so that the arrow faces
the direction shown.
NOTE
Transmission Disregard F and R stamped as a shared part.
mount insula-
tor assembly
Transmission
mount stopper
NOTES
 POWER PLANT MOUNT – General/Engine Mounting 32-1

GROUP 32
POWER PLANT MOUNT
GENERAL
OUTLINE OF CHANGE
The following service procedures have been added due to the change of the engine mount and transmission
mount.

ENGINE MOUNTING
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Crossmember Removal and Installation

49 Nm

49 Nm
4

49 Nm 49 Nm
3

49 Nm
49 Nm

49 Nm
2

Removal steps
1. Engine mount insulator Assembly 3. Engine mount bracket (L.H.)
(L.H.) 4. Engine mount bracket (R.H.)
2. Engine mount insulator Assembly
(R.H.)
32-2 POWER PLANT MOUNT – Transmission Mounting

TRANSMISSION MOUNTING
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Jack up the Engine and Transmission Assembly until
there is no weight on the Engine Mount Bracket Insulator.

<M/T> 4

<A/T> 4

49 Nm

49 Nm

49 Nm

3
2
1

49 Nm
2
1

49 Nm

Removal steps
1. Collar 4. Transmission mount insulator
2. Transmission mount bushing Assembly
3. Transmission mount crossmember
Assembly
 POWER PLANT MOUNT – General/Engine Mounting 32-1
GROUP 32
POWER PLANT MOUNT
GENERAL
OUTLINE OF CHANGE
The following service procedures have been established due to the addition of vehicles with 4G9-MPI
engine. The other service procedures are the same as the vehicles with GDI engine.
ENGINE MOUNTING
REMOVAL AND INSTALLATION
Caution
Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the
full weight of the engine on the vehicle body.

Pre-removal and Post-installation Operation

Crossmember Removal and Installation
(Refer to GROUP 33.)

26 ± 5 N·m*

49 ± 10 N·m
49 ± 10 N·m

Removal steps
1. Engine mount bracket <RH>
2. Engine mount insulator
NOTES
 FRONT
SUSPENSION
Click on the applicable bookmark to selected the required model year
 33A-1

FRONT
SUSPENSION
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . . 6

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 STRUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 7

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STRUT BAR AND LOWER ARM . . . . . . . . . . . 10

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 13

Wheel Alignment Check and Adjustment . . . . . . . . 4
CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 15
33A-2 FRONT SUSPENSION – General Information

GENERAL INFORMATION
The front suspension is a McPherson strut with coil
spring. The shock absorber is gas-filled hydraulic
double-acting type.

COIL SPRING
Items Specification

Wire diameter × average diameter × free length mm 14 × 160 × 365

CONSTRUCTION DIAGRAM

Strut insulator
assembly

Suspension
crossmember Strut assembly
(shock absorber)
Stabilizer bar

Lower arm

Strut bar
Stabilizer link
 FRONT SUSPENSION – Service Specifications/Special Tools 33A-3
SERVICE SPECIFICATIONS
Items Standard value

Toe-in At the centre of tyre tread mm 3±2

Toe-angle (per wheel) 0_07’ ± 05’

Toe-out angle on turns 21_04’

(inner wheel when outer wheel at 20_)

Camber 0_30’ ± 30’*

Caster 3_00’ ± 30’*

Side slip mm (per 1 m) 0±3

Kingpin inclination 11_04’

Lower arm ball joint rotation starting torque Nm 1.0 – 5.9

Stabilizer link ball joint turning torque Nm 1.7 – 3.1

NOTE
*: difference between right and left wheels: less than 30’
SPECIAL TOOLS
Tools Number Name Use
MB991004 Wheel alignment Wheel alignment measurement
gauge attachment <Vehicles with aluminium wheels>

A: MB991237 A: Spring com- Coil spring compression

pressor body
A B: MB991238
B: Arm set
B

MB991176 Spring seat holder Disassembly and assembly of the strut assem-
bly

MB991406 or Steering linkage Tie rod end disconnection

MB991113 puller

MB990799 Ball joint remover & Lower arm bushing press-in and press-out
installer
33A-4 FRONT SUSPENSION – Special Tools/On-vehicle Service

Tools Number Name Use

MB990996 Lower arm bushing Lower arm bushing press-in and press-out
arbor

MB990997 Lower arm bushing

installer support

B99099

MB990326 Preload socket D Lower arm ball joint rotation starting torque
measurement
D Stabilizer link ball joint rotation torque
measurement

MB990968 Torque wrench

GENERAL Engine lifter Supporting the engine assembly during

SERVICE TOOL removal and installation of the crossmember
MZ203827

ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
Measure the wheel alignment with the vehicle parked on a
level surface.
The front suspension, steering system, and wheels should
be serviced to normal condition prior to measurement of wheel
alignment.
 FRONT SUSPENSION – On-vehicle Service 33A-5
TOE-IN
Standard value:
At the centre of tyre tread 3 ± 2 mm
Clip Toe angle (per wheel) 0_07’ ± 05’
1. If the toe-in is not within the standard value, adjust the
toe-in by undoing the clip 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 turned
toward the rear of the vehicle.
2. Use a turning radius gauge to check that the steering
angle is at the standard value.
(Refer to GROUP 37A – On-vehicle Service.)
TOE-OUT ANGLE ON TURNS
To check the steering linkage, especially after the vehicle has
been involved in an accident or if an accident is presumed,
it is advisable to check the toe-out angle on turns in addition
to the wheel alignment.
Conduct this test on the left turn as well as on the right turn.
Standard value (inner wheel when outer wheel
at 20_): 21_04’

CAMBER, CASTER AND KINGPIN INCLINATION

MB991004 Standard value:
Item Specification
Camber (difference between right and left wheel: 0_30’ ± 30’
less than 30’)
Caster (difference between right and left wheel: 3_00’ ± 30’
less than 30’)
Kingpin inclination 11_04’
NOTE
1. Camber and caster are preset at the factory and cannot
be adjusted.
2. If camber is not within the standard value, check and
replace bent or damaged parts.
3. For vehicles with aluminium type wheels, attach the
camber/caster/kingpin gauge to the drive shaft by using
the special tool. Tighten the special tool to the same torque
226 Nm as the drive shaft nut.
33A-6 FRONT SUSPENSION – On-vehicle Service

Caution
To prevent the wheel bearing from damage, never
subject the wheel bearings to the vehicle load when
the drive shaft nuts are loosened.

SIDE SLIP
Measure the side slip with a side slip tester.
Standard value: 0 ± 3 mm

BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing
it with finger.
2. If the dust cover is cracked or damaged, replace the lower
arm assembly or stabilizer link.
NOTE
Cracks or damage of the dust cover may cause damage
of the ball joint.
 FRONT SUSPENSION – Strut Assembly 33A-7
STRUT ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Injector Driver Removal <right side> D Injector Driver Installation <right side>
(Refer to GROUP 13A.) (Refer to GROUP 13A.)
D Check the Dust Cover for Cracks or Damage by
Pushing it with Fingers.
D Wheel Alignment Check and Adjustment
(Refer to P.33A-4.)

4 19 Nm

108 – 127 Nm
1

Removal steps
1. Front wheel speed sensor harness 3. Knuckle connection
bracket <Vehicles with ABS> 4. Strut installation nut
2. Brake hose bracket 5. Strut assembly
33A-8 FRONT SUSPENSION – Strut Assembly

DISASSEMBLY AND REASSEMBLY

59 – 69 Nm
1

3
2

7 5

Disassembly steps
1. Dust cover 5. Upper spring pad
AA" "AA 2. Self-locking nut 6. Bump rubber
3. Strut insulator assembly 7. Coil spring
4. Upper spring seat assembly AB" 8. Strut assembly

MB991238 DISASSEMBLY SERVICE POINT

AA" SELF-LOCKING NUT REMOVAL
1. Use the special tools to compress the coil spring.
Caution
Install the special tools evenly, and so that the
maximum length will be attained within the installation
range.
MB991237
 FRONT SUSPENSION – Strut Assembly 33A-9
2. Holding the upper spring seat with the special tool, loosen
the self-locking nut.
Caution
MB991176 Do not use an impact wrench as it will cause the bolt
of the special tool to be seized.

MB991237

AB" STRUT ASSEMBLY REMOVAL

To discard the strut assembly, place the assembly horizontally
with its piston rod extended. Then drill a hole approx. 3 mm
in diameter at the location shown in the illustration and
discharge the gas.
Caution
The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill. Therefore,
be sure to wear goggles.

REASSEMBLY SERVICE POINT

"AA SELF-LOCKING NUT INSTALLATION
Pipe 1. While the coil spring is being compressed by the special
tools, provisionally tighten the self-locking nut.
2. Line up the hole in the strut assembly lower spring seat
with the hole in the upper spring seat.
NOTE
Using a pipe as shown facilitates the alignment.

3. Correctly align both ends of the coil spring with the grooves
in the spring seat, and then loosen the special tools.
4. Using the special tool, tighten the self-locking nut to the
MB991176 specified torque.
Tightening torque: 59 – 69 Nm

5. Apply multipurpose grease to the bearing of the strut

insulator.
Caution
When applying the grease, take care that grease does
not adhere to the insulator’s rubber.
33A-10 FRONT SUSPENSION – Strut Bar and Lower Arm

STRUT BAR AND LOWER ARM

REMOVAL AND INSTALLATION
Caution
*: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal Operation Post-installation Operation

Under Cover Removal D Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
D Wheel Alignment Check and Adjustment (Refer
to GROUP 33A-4.)
D Under Cover Installation

7
8 9

10

52 Nm* 2
11

59 – 71 Nm
1 49 Nm
5
49 Nm 1
103 Nm*
3

6
4

54 – 69 Nm
49 Nm

59 Nm

Lower arm removal steps Strut bar removal steps

1. Strut bar bracket installation bolt 1. Strut bar bracket installation bolt
2. Strut bar installation bolt 2. Strut bar installation bolt
3. Fixture 7. Washer
"BA 4. Stabilizer link connection "AA 8. Strut bar bushing A
AA" 5. Lower arm assembly and knuckle 9. Strut bar bracket
connection "AA 10. Strut bar bushing B
6. Lower arm assembly 11. Strut bar
 FRONT SUSPENSION – Strut Bar and Lower Arm 33A-11
REMOVAL SERVICE POINT
AA" LOWER ARM ASSEMBLY AND KNUCKLE
MB991406 or
MB991113 DISCONNECTION
Caution
Ball joint
1. Loosen the nut but do not remove it.
Cord
2. Support the special tool with a cord to prevent it from
coming off.

Nut

INSTALLATION SERVICE POINTS

"AA STRUT BAR BUSHING B AND STRUT BAR
BUSHING A INSTALLATION
Install the bushings A and B as shown in the illustration
confirming there shapes.

Strut bar Strut bar

bushing A bushing B

"BA STABILIZER LINK INSTALLATION

Use a hexagonal wrench to hold the stabilizer link stud so
that it does not turn, and then tighten the nut.
Hexagonal
wrench

INSPECTION
LOWER ARM BALL JOINT ROTATION STARTING
MB990326 TORQUE CHECK
1. After shaking the ball joint stud several times, install the
nut to the stud and use the special tools to measure the
rotation starting torque of the ball joint.
MB990968 Standard value: 1.0 – 5.9 Nm
2. When the measured value exceeds the standard value,
replace the lower arm assembly.
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 reuse that ball joint.
33A-12 FRONT SUSPENSION – Strut Bar and Lower Arm

LOWER ARM BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing
it with finger.
2. If the dust cover is cracked or damaged, replace the lower
arm assembly.
NOTE
Cracks or damage of the dust cover may cause damage
of the ball joint. When it is damaged during service work,
replace the dust cover.

LOWER ARM BALL JOINT DUST COVER

MB990800 REPLACEMENT
Only when the dust cover is damaged accidentally during
Dust service work, replace the dust cover as follows:
cover 1. Remove the dust cover.
2. Apply multipurpose grease to the lip and inside of the
dust cover.
3. Using the special tool, press the dust cover until it contacts
the snap ring.
4. Check the dust cover for cracks or damage by pushing
it with finger.
Driving out Press-fitting LOWER ARM BUSHING REPLACEMENT
Use the special tools to drive out and press in the bushing.
MB990996
MB990996

MB990997 MB990997

MB990799 MB990799
 FRONT SUSPENSION – Stabilizer Bar 33A-13
STABILIZER BAR
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Under Cover Removal D Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
D Under Cover Installation

54 – 69 Nm
3
4

54 – 69 Nm

49 Nm

Removal steps
"AA 1. Fixture "BA 3. Stabilizer link
"AA 2. Bushing "AA 4. Stabilizer bar

INSTALLATION SERVICE POINTS

"AA STABILIZER BAR/BUSHING/FIXTURE
INSTALLATION
Position the stabilizer bar so that the right end of the
identification colour is aligned with the left end of the bushing
as shown, and tighten the stabilizer bar fixture mounting bolt.
Identification
colour
Front side of
vehicle

"BA STABILIZER LINK INSTALLATION

Use a hexagonal wrench to hold the stabilizer link stud so
that it will not turn, and then tighten the nut.
Hexagonal
wrench
33A-14 FRONT SUSPENSION – Stabilizer Bar

MB990968 INSPECTION
MB990326 STABILIZER LINK BALL JOINT TURNING TORQUE
CHECK
1. After shaking the ball joint stud several times, install the
nut to the stud and use the special tools to measure the
turning torque of the ball joint.
Standard value: 1.7 – 3.1 Nm
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 reuse that ball joint.

STABILIZER LINK BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing
it with 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
of the ball joint. When it is damaged during service work,
replace the dust cover.

STABILIZER LINK BALL JOINT DUST COVER

REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Remove the clip ring and the dust cover.
2. Apply multipurpose grease to the inside of the dust cover.
3. Wrap plastic tape around the stabilizer link stud, and then
install the dust cover to the stabilizer link.
Clip ring 4. Secure the dust cover by the clip ring.
5. Check the dust cover for cracks or damage by pushing
it with finger.
 FRONT SUSPENSION – Crossmember 33A-15
CROSSMEMBER
REMOVAL AND INSTALLATION
Caution
*: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D Steering Gear Box and Linkage Removal and D Stabilizer Bar Removal and Installation(Refer to
Installation (Refer to GROUP 37A.) P.33A-13.)
D Strut Bar and Lower Arm Disconnection D Front Differential Mounting Bracket Removal and
(Refer to P.33A-10.) Installation (Refer to GROUP 26 – Differential Carrier.)

103 Nm*

1 103 Nm*

103 Nm 1
103 Nm

2
2

Removal steps
AA" D Engine assembly holding 2. Crossmember installation bolts
1. Lower arm installation bolts 3. Crossmember

MZ203827 REMOVAL SERVICE POINT

AA" ENGINE ASSEMBLY HOLDING
Use the general service tool to lift the engine assembly until
the engine weight will not be applied to the engine mount
insulators.
NOTES
 FRONT SUSPENSION – General/General Information 33A-1

GROUP 33A
FRONT SUSPENSION
GENERAL
OUTLINE OF CHANGE
 The coil spring specifications have been changed. <3-door models>
 The coil spring specifications have been added. <5-door models>

GENERAL INFORMATION
COIL SPRING<3-door models>
Items New Old
Wire diameter  average diameter  free length mm 14  160  365*1 14  160  365
14  160  376*2 14  160  365

COIL SPRING<5-door models>

Items Specifiations
Wire diameter  average diameter  free length mm 14  160  376*1
14  160  386*2

NOTE
*1: L.H.D. Vehicles, R.H.D. Vehicles L.H. side
*2: R.H.D. Vehicles R.H. side
 FRONT SUSPENSION – General/General Information 33A-1
GROUP 33A
FRONT SUSPENSION
GENERAL
OUTLINE OF CHANGE
The specification of front coil spring has been established due to the addition of vehicles with 1800-MPI
engine.

GENERAL INFORMATION
COIL SPRING
Items 1800-MPI
L.H. drive vehicles R.H. drive vehicles
Wire dia. × O.D. × free length mm 14 × 160 × 365 14 × 160 × 365 <L.H.>
14 × 160 × 376 <R.H.>
NOTES
 SERVICE BULLETIN
PUBLICATION GROUP, AFTER SALES SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV

SERVICE BULLETIN No.: ESB-99E33-503

Date: 2000-04-15 <Model> <M/Y>

Subject: CORRECTION TO FRONT SUSPENSION (EC) PAJERO 99-10
CAMBER VALUE PININ (H6,H7)
Group: FRONT SUSPENSION

CORRECTION
O. Kai - E.V.P. & G.M.
After Sales Service Dept.

1. Description:
This Service Bulletin informs you that the camber value of the front suspension has been
corrected.

2. Applicable Manuals:
Manual Pub. No. Language Page(s)
’99 PAJERO PININ CKRE00E1 (English) 33A-3, 5
Workshop Manual CKRS00E1 (Spanish)
CKRF00E1 (French)
CKRG00E1 (German)
CKRD00E1 (Dutch)
CKRI00E1 (Italian)
3. Details:
 FRONT SUSPENSION – Service Specifications/Special Tools 33A-3

SERVICE SPECIFICATIONS
Items Standard value
Toe-in At the centre of tyre tread mm 3±2
Toe-angle (per wheel) 0°07’ ± 05’
Toe-out angle on turns 21°04’
(inner wheel when outer wheel at 20°) -0°30’ ± 30’* <Correct>
Camber 0°30’ ± 30’* <Incorrect>
Caster 3°00’ ± 30’*
Side slip mm (per 1 m) 0±3
Kingpin inclination 11°04’
Lower arm ball joint rotation starting torque Nm 1.0 – 5.9
Stabilizer link ball joint turning torque Nm 1.7 – 3.1

NOTE
*: difference between right and left wheels: less than 30’

SPECIAL TOOLS
Tools Number Name Use
MB991004 Wheel alignment Wheel alignment measurement
gauge attachment <Vehicles with aluminium wheels>

B991004

A: MB991237 A: Spring Coil spring compression

compressor
B: MB991238 body

B: Arm set
00003796

MB991176 Spring seat holder Disassembly and assembly of the strut assembly

B991176

MB991406 or Steering linkage Tie rod end disconnection

MB991113 puller

B991113

MB990799 Ball joint remover & Lower arm bushing press-in and press-out
installer

B990799

2
FRONT SUSPENSION – On-vehicle Service 33A-5

TOE-IN

Standard value:
At the centre of tyre tread 3 ± 2 mm
Toe angle (per wheel) 0°07’ ± 05’
Clip 1. If the toe-in is not within the standard value, adjust the toe-in
by undoing the clip 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 turned toward
the rear of the vehicle.
2. Use a turning radius gauge to check that the steering angle is
A12C0001
at the standard value.
(Refer to GROUP 37A – On-vehicle Service.)

TOE-OUT ANGLE ON TURNS

To check the steering linkage, especially after the vehicle has been
involved in an accident or if an accident is presumed, it is advisable
to check the toe-out angle on turns in addition to the wheel
alignment.
Conduct this test on the left turn as well as on the right turn.

Standard value (Inner wheel when outer wheel at 20°): 21°04’

CAMBER, CASTER AND KINGPIN INCLINATION

Standard value: -0°30’ ± 30’ <Correct>

Item Specification
Camber (difference between right and left wheel: 0°30’ ± 30’*
less than 30’) <Incorrect>
Caster (difference between right and left wheel: 3°00’ ± 30’
less than 30’)
Kingpin inclination 11°04’

A12S0057 NOTE
1. Camber and caster are preset at the factory and cannot be
adjusted.
2. If camber is not within the standard value, check and replace
bent or damaged parts.
3. For vehicles with aluminium type wheels, attach the
camber/caster/kingpin gauge to the drive shaft by using the
special tool. Tighten the special tool to the same torque
226 Nm as the drive shaft nut.

3
 REAR
SUSPENSION
Click on the applicable bookmark to selected the required model year
 34-1

REAR
SUSPENSION
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 REAR SUSPENSION ASSEMBLY . . . . . . . . . . . 4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
34-2 REAR SUSPENSION – General Information

GENERAL INFORMATION
The rear suspension is a 5-link coil spring type axle
suspension, which assures comfortable ride and
outstanding steering stability.

COIL SPRING
Items Specification

Wire diameter × outer diameter × free length mm 11 × 131 × 306

CONSTRUCTION DIAGRAM

Bump rubber
Coil spring

Upper control arm Lateral rod

Shock absorber

Lower control arm

 REAR SUSPENSION – Special Tools 34-3
SPECIAL TOOLS
Tool Number Name Use
MB990847 Rear suspension bushing D Upper arm rear bushing
remover and installer base driving out and press-fitting
D Lower arm rear bushing
driving out and press-fitting

MB990947 Lower arm bushing arbor

MB990832 Lower arm rear bushing Upper arm rear bushing driving
remover and installer ring out and press-fitting

MB991154 Upper arm bushing guide

MB991155 Lower arm bushing guide Lower arm rear bushing driving
out and press-fitting

MB990831 Upper arm bushing

remover and installer ring

MB990958 Bushing remover and in- D Upper arm front bushing

staller driving out and press-fitting
D Lower arm front bushing
driving out and press-fitting

MB990983 Bushing remover and in-

staller arbor
34-4 REAR SUSPENSION – Rear Suspension Assembly

REAR SUSPENSION ASSEMBLY

REMOVAL AND INSTALLATION
Caution
*: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.

1 64 Nm*

10 7

81 Nm*
5
4 96 Nm*
96 Nm*
64 Nm*
101 Nm*
9

8
3

103 – 123 Nm*

96 Nm* 96 Nm*

1. Shock absorber 7. Bump stopper

2. Lower arm 8. Lower spring pad
3. Lateral rod Upper arm removal steps
4. Shock absorber installation bolt
5. Coil spring
Coil spring removal steps 9. Rear wheel speed sensor installa-
4. Shock absorber installation bolt tion bolt <Vehicles with ABS>
"AA 5. Coil spring 10. Upper arm
6. Silencer sheet

INSTALLATION SERVICE POINT

"AA COIL SPRING INSTALLATION
Install the coil spring so that its end with identification colour
faces upward.
 REAR SUSPENSION – Rear Suspension Assembly 34-5
LATERAL ROD BUSHING REPLACEMENT
1. Use a press to press in and out the bushing.
2. Apply ample amount of soapy water to the outer surface
of the bushing and inner surface of the lateral rod pipe,
and then press-fit the bushing so that both ends protrude
evenly.

Driving out Press- UPPER ARM BUSHING/LOWER ARM BUSHING

fitting REPLACEMENT
A A UPPER ARM REAR BUSHING, LOWER ARM REAR
BUSHING
B
D 1. Use the special tools and a press to press in and out
the bushing.
C
B SPECIAL TOOL
C
Item Upper arm rear bushing Lower arm rear bushing

A MB990947 MB990947
Upper arm Lower arm
B MB990832 MB990831

C MB990847 MB990847

D MB991154 MB991155

2. Apply ample amount of soapy water to the outer surface

of bushing and inner surface of arm pipe, and then press-fit
the bushing so that both ends protrude evenly.

UPPER ARM FRONT BUSHING, LOWER ARM FRONT

Bushing MB990983 BUSHING
Cham-
fered 1. Use a press and the special tools to press in and out
portion
the bushing.
NOTE
Press in the bushing from the chamfered side of the arm
MB990958
pipe.

2. Install the bushing so that both ends protrude evenly.

NOTES
34-1 REAR SUSPENSION – General/General Information

GROUP 34
REAR SUSPENSION
GENERAL
OUTLINE OF CHANGE
 The coil spring specification has been added. <5-door models>
 The service procedures have been added due to the introduction of the rear stabilizer. <5-door models>
 The bushing of the upper control arm has been reshaped.

GENERAL INFORMATION
COIL SPRING<5-door models>
Items Specification
Wire diameter  average diameter  free length mm 11  131  305

CONSTRUCTION DIAGRAM

Stabilizer link bracket

Stabilizer link
Upper control arm

A
A

Section A–A
Stabilizer bar
New Old
Bushing Bushing
 REAR SUSPENSION – Service Specification/Special Tool/Stabilizer Bar 34-2
SERVICE SPECIFICATION
Items Standard value

Stabilizer link ball joint turning torque Nm 1.7 – 3.1

SPECIAL TOOL
Tool Number Name Use
MB990326 Preload socket Stabilizer link ball joint turning torque measure-
ment

STABILIZER BAR
REMOVAL AND INSTALLATION
Post-installation Operations
Press the dust cover with your finger to check that
there are no cracks or damage in the dust cover.

83 Nm
1

44 Nm
1

44 Nm

4
3
5
49 Nm

Removal steps
1. Stabilizer link assembly
2. Stabilizer link bracket
A 3. Stabilizer bracket
A 4. Bushing
A 5. Stabilizer bar
34-3 REAR SUSPENSION – Stabilizer Bar

INSTALLATION SERVICE POINT

A STABILIZER BAR/BUSHING/STABILIZER
Front of vehicle BRACKET INSTALLATION
Align the identification mark of stabilizer bar with the left end
of the bushing, before tightening the mounting bolts.

Identification mark

INSPECTION
MB990326
STABILIZER LINK BALL JOINT TURNING TORQUE
CHECK
1. After shaking the ball joint stud several times, install the
nut to the stud and use the special tools to measure the
turning torque of the ball joint.
Standard value: 1.7 – 3.1 Nm
MB990968 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 reuse that ball joint.

STABILIZER LINK BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing
it with 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
of the ball joint. When it is damaged during service work,
replace the dust cover.

STABILIZER LINK BALL JOINT DUST COVER

REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Remove the clip ring and the dust cover.
2. Apply multipurpose grease to the inside of the dust cover.
3. Wrap plastic tape around the stabilizer link stud, and then
install the dust cover to the stabilizer link.
4. Secure the dust cover by the clip ring.
Clip ring 5. Check the dust cover for cracks or damage by pushing
it with finger.
BASIC BRAKE
SYSTEM
Click on the applicable bookmark to selected the required model year
35A-2

BASIC BRAKE
SYSTEM
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 Brake Fluid Level Sensor Check . . . . . . . . . . . . . 10

Disc Brake Pad Check and Replacement . . . . . . 11
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4
Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . 12
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Disc Thickness Check . . . . . . . . . . . . . . . . . 12
Brake Disc Run-out Check and Correction . . . . 13
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MASTER CYLINDER AND BRAKE
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brake Pedal Check and Adjustment . . . . . . . . . . . . 6 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake Booster Operating Test . . . . . . . . . . . . . . . . . . 7
FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . . 20
Check Valve Operation Check . . . . . . . . . . . . . . . . . 8
Load Sensing Spring Length Check and REAR DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . 25
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Load Sensing Proportioning Valve Function LOAD SENSING PROPORTIONING
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
 BASIC BRAKE SYSTEM – General Information 35A-3
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.

Items Specifications

Master cylinder Type Tandem type

I.D. mm 22.2

Brake booster Type Vacuum type, single

Effective dia. of power cylinder mm 230

Boosting ratio 4.5

Load sensing proportioning Type Dual type

valve
Decompression ratio 0.25

Front disc brakes Type Floating caliper, 1-piston, ventilated disc

Disc effective dia. × thickness mm 236 × 22

Wheel cylinder I.D. mm 57.2

Pad thickness mm 10.0

Clearance adjustment Automatic

Rear disc brakes Type Floating caliper,1-piston, solid disc

Disc effective dia. × thickness 222 × 9.4

Wheel cylinder I.D. mm 34.93

Pad thickness mm 10.0

Clearance adjustment Automatic

Brake fluid DOT3 or DOT4

CONSTRUCTION DIAGRAM

Load sensing
proportioning
valve
Hydraulic unit

Brake booster
Master cylinder
35A-4 BASIC BRAKE SYSTEM – Service Specifications

SERVICE SPECIFICATIONS
Items Standard value Limit

Brake pedal height mm L.H. drive vehicles 201 – 204 –

R.H. drive vehicles 201.7 – 204.7 –

Brake pedal play mm 3 –8 –

Brake pedal to floorboard clearance when the brake pedal is depressed mm 105 or more –

Brake booster push rod protrusion amount mm L.H. drive vehicles with ABS 22.7 – 22.9 –

L.H. drive vehicles without 23.93 – 24.18 –

ABS and R.H. drive vehicles

Load sensing proportion- When load sensing spring length is 199 mm (when 4.2 – 6.0 (9.8) –
ing valve output fluid unladen)
pressure (Input fluid pres-
sure) MPa When load sensing spring length is 217 mm (when 9.7 – 10.5 (9.8) –
laden)
14.5 – 16.3 (16.7) –

Output fluid pressure difference between left and right – 0.39

MPa

Load sensing spring length <Distance between spring ends> mm 194 – 198 –

Front disc brake Pad thickness mm 10.0 2.0

Disc thickness mm 22 0
22.0 20 4
20.4

Disc runout mm – 0.06

Drag force N 69 –

Rear disc brake Pad thickness mm 10.0 2.0

Disc thickness mm 9.4 7.8

Disc runout mm – 0.08

Drag force N 34 –

Front hub end play mm – 0.2

Rear hub end play mm – 0.025

 BASIC BRAKE SYSTEM – Lubricants/Sealant/Special Tools 35A-5
LUBRICANTS
Items Specified Lubricant Quantity

Brake fluid DOT3 or DOT4 As required

Vacuum sensor grommet Silicone grease

Brake booster seal

Piston boot, piston seal Repair kit grease

Guide pin, lock pin

Piston, wheel cylinder body DOT3 or DOT4

SEALANT
Items Specified sealant Remarks

Fitting 3M ATD Part No. 8661 or equivalent Semi-drying sealant

SPECIAL TOOLS
Tool Number Name Use

A MB990964 Brake tool set Pushing-in of the disc brake piston

A: MB990520

A: MB990998 A: Front hub re- When bearing provisional holding

B: MB991000 mover and installer MB991000, which belongs to MB990998,
B: Spacer should be used as a spacer.
A
B

MB991568 Push rod adjusting Adjustment of the brake booster push rod
socket protrusion amount
35A-6 BASIC BRAKE SYSTEM – On-vehicle Service

ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
Operating rod
BRAKE PEDAL HEIGHT
Stop lamp switch
1. Turn up the carpet, etc. under the brake pedal.
Operating 2. Measure the brake pedal height as illustrated.
rod lock nut
Standard value (A):
A <L.H. drive vehicles> 201 – 204 mm
<R.H. drive vehicles> 201.7 – 204.7 mm
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it approx.
1/4 turns anticlockwise.
(3) Remove the pin, and then adjust so that the brake
pedal height meets the standard value by turning the
clevis.
NOTE
When the clevis is turned 180°, the pedal height is
changed approximately 2.3 mm.

(4) Screw in the stop lamp switch until it touches the

Stopper
stopper. At this time, support the brake pedal to the
highest position by hand.
(5) Lock the stop lamp switch by turning it approx. 1/4
turns clockwise, and confirm that the clearance
between the switch plunger and the stopper is as
shown.
(6) Connect the connector at the stop lamp switch.
Caution
0.5 – 1.0 mm
Check that the stop lamp does not illuminate when
the brake pedal is not depressed.
4. For A/T, check the key interlock and shift lock mechanisms.
(Refer to GROUP 23 – On-vehicle Service.)
5. Return the carpet, etc.

BRAKE PEDAL FREE PLAY

1. With the engine stopped, depress the brake pedal two
or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value (B): 3 – 8 mm
B
 BASIC BRAKE SYSTEM – On-vehicle Service 35A-7
2. If the brake pedal play is not within the standard value,
check the following, and adjust or replace if necessary:
D Excessive play between the brake pedal and the clevis
pin, or between the clevis pin and the brake booster
operating rod
D Brake pedal height
D Installation position of the stop lamp switch, etc.

CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR

BOARD
1. Turn up the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value (C): 105 mm or more
3. If the clearance is outside the standard value, check for
air trapped in the brake line, thickness of the disc brake
pad or the drum brake lining and dragging in the parking
brake.
Adjust and replace defective parts as required.
4. Return the carpet, etc.

Good No good
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster operation, carry
out the following tests:
1. Run the engine for one or two minutes, and then stop
it.
If the pedal depresses fully 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.

2. With the engine stopped, step on the brake pedal several

When engine is When engine is
stopped started times.
Then start the engine while the brake pedal is stepped
on.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective.
35A-8 BASIC BRAKE SYSTEM – On-vehicle Service

Good No good 3. With the engine running, step on the brake pedal and
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.
If the above three tests are okay, the booster performance
can be determined as good.
If one of the above three tests is not okay at least, the check
valve, vacuum hose, or booster will be defective.

CHECK VALVE OPERATION CHECK

1. Remove the vacuum hose. (Refer to P.35A-15, 16.)
Caution
The check valve should not be disassembled from
the vacuum hose as they are united as one part.
2. Check the operation of the check valve by using a vacuum
pump.
Vacuum pump Accept/reject criteria
connection
Connection at the brake A negative pressure (vacuum) is
Valve Spring booster side (A) created and held.
Connection at the intake A negative pressure (vacuum) is
Booster A B Intake manifold side (B) not created.
side manifold
side Caution
If the check valve is defective, always replace it as
an assembly unit together with the vacuum hose.

LOAD SENSING SPRING LENGTH CHECK

AND ADJUSTMENT
1. Park the vehicle on a level ground. The vehicle should
be unloaded and supported only by wheels.
Caution
Never support the vehicle with jacks or other similar
means.

2. With the lever pressed all the way to the load sensing
Load sensing spring proportioning valve side, check whether or not the length
Spring support (shown in the figure) of the spring (the length between
Lever its ends) is the standard value.
Standard value (A): 194 – 198 mm
A 3. If the spring length is not within the standard value, loosen
the bolt attaching the support and adjust the distance by
moving the support.
 BASIC BRAKE SYSTEM – On-vehicle Service 35A-9
Pressure gauge LOAD SENSING PROPORTIONING VALVE
FUNCTION TEST
1. Connect pressure gauges to the input and output ports
of the load sensing proportioning valve.
2. Bleed the system. (Refer to P.35A-10.)
3. Disconnect the spring at the support side.

Load sensing pro-

portioning valve

Load sensing pro- 4. Place the spring so that it is in parallel with the load sensing
portioning valve Load sensing spring proportioning valve, and then pull in the direction indicated
A by arrow A so that its length H shown in the figure (the
Parallel
length between its ends) is as noted below.
NOTE
At this time the lever is pressed all the way to the load
sensing proportioning valve side.

H
Lever

5. Check at this time whether or not the output fluid’s pressure,

relative to the load sensing proportioning valve’s input fluid
pressure, is within the standard value.
Standard value:
Spring length Input fluid Output fluid pressure
H mm pressure MPa MPa
199*1 9.8 4.2 – 6.0
217*2 9.8 9.7 – 10.5
16.7 14.5 – 16.3
NOTE
*1 and *2 indicate the applicable lengths for unladen
and laden vehicles respectively.
6. Measure each output fluid pressure at both valves, and
check that the difference between the two is at the limit
value or less.
Limit: 0.39 MPa
7. After making the check, install the spring. Disconnect the
pressure gauges from the load sensing proportioning valve
and bleed air.
35A-10 BASIC BRAKE SYSTEM – On-vehicle Service

BLEEDING
Caution
Specified brake fluid: DOT3 or DOT4
Always use the specified brake fluid. Avoid using a mixture
of the specified brake fluid and other fluid.

MASTER CYLINDER BLEEDING

The master cylinder used has no check valve, so if bleeding
is carried out by the following procedure, bleeding of air from
the brake pipeline will become easier. (When brake fluid is
not contained in the master cylinder.)
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with
a finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 – 4 three or four times to fill the inside
of the master cylinder with brake fluid.

BRAKE PIPE LINE BLEEDING

4 (2) Bleed the air in the sequence shown in the figure.
1 (3)

2 (4) 3 (1)
( ): R.H. drive vehicles

BRAKE FLUID LEVEL SENSOR CHECK

The brake fluid level sensor is in good condition if there is
no continuity when the float surface is above “MIN” and if
MAX there is continuity when the float surface is below “MIN”.
MIN
 BASIC BRAKE SYSTEM – On-vehicle Service 35A-11
DISC BRAKE PAD CHECK AND REPLACEMENT
NOTE
The brake pads have wear indicators that contact the brake
disc when the brake pad thickness reaches approximately
2 mm and emit a squealing sound to warn the driver.

FRONT REAR 1. Check the brake pad thickness through the caliper body
check port.
Standard value: 10.0 mm
Limit: 2.0 mm
2. When the thickness is less than the limit, always replace
the pads at an axle set.

3. Remove the guide lock pin bolt. Pivot the caliper assembly
and hold it with wires.

FRONT REAR 4. Remove the following parts from the caliper support.
3 3 1. Pad and wear indicator assembly
2. Pad assembly
2 1 3. Clip
4 4 2
5 4. Inner shim
5 5. Outer shim
1

3 3

5. In order to measure the brake drag force after pad

installation, measure the rotary-sliding resistance of the
hub with the pads removed. (Refer to P.35A-20, 25.)
6. Install the pads and caliper assembly, and then check
the brake drag force. (Refer to P.35A-21, 26.)
35A-12 BASIC BRAKE SYSTEM – On-vehicle Service

DISC BRAKE ROTOR CHECK

Caution
When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within
the allowable service values in order to maintain normal brake operation.
Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.

Inspection items Remarks

Scratches, rust, saturated lining materials D If the vehicle is not driven for a certain period, the sections of
and wear the discs that are not in contact with lining will become rusty, causing
noise and shuddering.
D If grooves resulting from excessive disc wear and scratches are
not removed prior to installing a new pad assembly, there will
momentarily be inappropriate contact between the disc and the
lining (pad).

Run-out or drift Excessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.

Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.

Inset or warping (flatness) Overheating and improper handling while servicing will cause inset or
warping.

BRAKE DISC THICKNESS CHECK

1. Using a micrometer, measure disc thickness at eight
positions, approximately 45_ apart and 10 mm in from
the outer edge of the disc.
Brake disc thickness
Item Standard value Limit
Front 22.0 20.4
Rear 9.4 7.8

Thickness variation (at least 8 positions)

The difference between any thickness measurements
should not be more than 0.015 mm.
2. If the disc is beyond the limits for thickness, remove it
and install a new one. If thickness variation exceeds the
specification, replace the brake disc or grind it with
on-the-car type brake lathe (“MAD, DL-8700PF” or
equivalent).
BASIC BRAKE SYSTEM – On-vehicle Service 35A-13
BRAKE DISC RUN-OUT CHECK AND
CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Place a dial gauge approximately 5 mm from the outer
circumference of the brake disc, and measure the run-out
of the disc.
Limit: <Front> 0.06 mm or less,
<Rear> 0.08 mm or less
3. If the brake disc run-out exceeds the limit, correct it as
follows:
(1) Chalk phase marks on the wheel stud and the brake
Chalk marks
disc, which run-out is excessive as shown.

(2) Remove the brake disc. Then place a dial gauge as

shown, and measure the end play by pushing and
pulling the wheel hub.
Limit: <Front> 0.2 mm, <Rear> 0.025 mm
(3) If the end play exceeds the limit, disassemble the
hub and knuckle assembly to check each part.
(4) If the end play does not exceed the limit, dephase
the brake disc and secure it. Then recheck the brake
disc run-out.

4. If the run-out cannot be corrected by changing the phase

of the brake disc, replace the brake disc or grind it with
the on-the-car type brake lathe (”MAD, DL-8700PF” or
equivalent).
35A-14 BASIC BRAKE SYSTEM – Brake Pedal

BRAKE PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Brake Pedal Adjustment (Refer to P.35A-6.)

14 Nm

10

3 2 1

4
7 8 9
12 Nm

Removal steps
1. Harness connector 7. Split pin <A/T>
2. Stop lamp switch 8. Shift lock cable connection <A/T>
3. Adjuster 9. Pedal pad
4. Pedal stopper 10. Brake pedal and pedal support
5. Snap pin member
6. Pin assembly

INSPECTION
STOP LAMP SWITCH CHECK
1. Connect an ohmmeter between the stop lamp switch
connector terminals.
No continuity Continuity 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.

4 mm
 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-15
MASTER CYLINDER AND BRAKE BOOSTER
REMOVAL AND INSTALLATION
<L.H. drive vehicles with ABS>
Pre-removal Operation Post-installation Operation
Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
D Brake Pedal Adjustment (Refer to P.35A-6.)

6 10
12
14 11

14.7 – 17.7 Nm 14

Specified Sealant: 3M ATD Grease: Silicone grease

Part No.8661 or equivalent

9
15 Nm

10
1 4 11
12 Nm
8
5
7
13

2 14 Nm
15 Nm

12
3 Silicon grease
35A-16 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster

<L.H. drive vehicles without ABS and R.H. drive vehicles>

Pre-removal Operation Post-installation Operation
Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
D Brake Pedal Adjustment (Refer to P.35A-6.)

10

11 12

14 4 12

Grease: Silicone grease Specified Sealant: 3M ATD Grease: Silicone grease

Part No.8661 or equivalent

9
10
15 Nm 11

1 2

8
5 13
12 Nm 7
1
4
14 Nm
15 Nm

12
3

<L.H. drive vehicles> <R.H. drive vehicles>

6 6

14.7 – 17.7 Nm 14

14 14.7 – 17.7 Nm
 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-17
Master cylinder removal steps
1. Brake pipe connection "AA 6. Vacuum hose
2. Brake fluid level sensor connector (With built-in check valve)
3. Bracket <L.H. drive vehicles> 7. Snap pin
4. Master cylinder 8. Pin assembly
"CA 5. Seal 9. Vacuum sensor connector
Brake booster removal steps 10. Vacuum sensor
11. Grommet
1. Brake pipe connection 12. Brake booster
2. Brake fluid level sensor connector 13. Sealer
3. Bracket <L.H. drive vehicles>
4. Master cylinder Fitting removal
"CA 5. Seal 14. Fitting
"BA D Push rod protrusion amount check and
adjustment

INSTALLATION SERVICE POINTS

"AA VACUUM HOSE CONNECTION
Insert the vacuum hose to the fitting with its paint mark facing
forward <L.H. drive vehicles>/upward <R.H. drive vehicles>
until the hose end reaches the edge of the hexagonal part
of the fitting, and then secure the hose by using the hose
clip.

"BA PUSH ROD PROTRUSION AMOUNT CHECK AND

ADJUSTMENT
1. Measure dimension (A).
Standard value (A) :
<L.H. drive vehicles with ABS> 22.7 – 22.9 mm
A <L.H. drive vehicles without ABS and R.H. drive
vehicles> 23.93 – 24.18 mm
NOTE
When a negative pressure of 66.7 kPa is applied to the
brake booster, the push rod should protrude 22.2 – 22.4
mm <L.H. drive vehicles with ABS>/23.48 – 23.73 mm
Measuring distance A <L.H. drive vehicles without ABS and R.H. drive vehicles>.

Block gauge
35A-18 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster

2. If the protrusion amount is not within the standard value

range, adjust the push rod length by turning the push
rod. Use the special tool to turn the push rod while holding
the rod spline with angle-nose pliers.

Angle-nose pliers

MB991568

<L.H. drive vehicles with ABS> "CA SEAL INSTALLATION

Master cylinder 1. Apply silicone grease to the seal.
2. Install the seal to the master cylinder as shown.

Seal

<L.H. drive vehicles without ABS and R.H.

drive vehicles>
Master cylinder

Seal

INSPECTION
VACUUM SENSOR CHECK
Refer to GROUP 13A – Troubleshooting.
NOTE
The vacuum sensor is monitored by the engine-ECU. Diagnosis
code is output when the vacuum sensor has a malfunction.
 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-19
MASTER CYLINDER <L.H. drive vehicles without ABS and R.H. drive vehicles>
DISASSEMBLY AND REASSEMBLY

4 8 6
9

5
7
10
5 11
12

12

10
11 10
6
9 8 7
11
12 Brake fluid: DOT3 or DOT4
Master cylinder kit

Disassembly steps
1. Reservoir cap 7. Piston guide
2. Pin 8. Cylinder cup
3. Reservoir tank 9. Plate
4. Brake fluid level sensor 10. Primary piston assembly
5. Reservoir seal 11. Secondary piston assembly
AA" 6. Stopper ring 12. Master cylinder body

DISASSEMBLY SERVICE POINT

AA" STOPPER RING REMOVAL
Push the primary piston assembly and remove the stopper
ring.
35A-20 BASIC BRAKE SYSTEM – Front Disc Brake

FRONT DISC BRAKE

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Brake Fluid Draining Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)

49 Nm
90 – 110 Nm
2
1

Removal steps
1. Brake hose connection
2. Gasket
"AA 3. Disc brake assembly
4. Brake disc

MB991000 INSTALLATION SERVICE POINT

(MB990998) "AA DISC BRAKE ASSEMBLY INSTALLATION
1. In order to measure the brake drag force after pad
installation, measure the rotary-sliding resistance of the
hub by the following procedure with the pads removed.
Bolt
(1) Withdraw the drive shaft. (Refer to GROUP 26 – Front
Axle.)
(2) Attach the special tool to the front hub assembly as
shown in the illustration, and tighten it to the specified
torque.
Tightening torque: 196 – 255 Nm
(3) Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
2. Install the caliper support to the knuckle, and then assemble
the pad clip and the pad to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
BASIC BRAKE SYSTEM – Front Disc Brake 35A-21
3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
MB990520

7. Use a spring balance to measure the rotary-sliding

resistance of the hub.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value: 69 N
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the lock pin and the
guide pin slide smoothly.
35A-22 BASIC BRAKE SYSTEM – Front Disc Brake

DISASSEMBLY AND REASSEMBLY

15 15

13 12
26 Nm

1
11 15
2
Clip kit
3 15
26 Nm
9 14
8
7
10
6

3
5
4

1 2
3 11 13 9
9 3
8 7
10 7 6

2
3
5 14 5
4 12 4

Brake caliper kit Pad set Shim kit Seal and boot kit

Disassembly steps
1. Guide pin lock bolt AA" 8. Piston
2. Guide pin AB" 9. Piston seal
3. Boot 10. Caliper body
4. Bushing 11. Pad and wear indicator assembly
5. Bushing retainer 12. Pad assembly
6. Caliper support (including pad, clip, 13. Inner shim
and shim) 14. Outer shim
AA" 7. Piston boot 15. Clip
 BASIC BRAKE SYSTEM – Front Disc Brake 35A-23
LUBRICATION POINTS

Piston seal Grease: Repair kit grease

Caution
The piston seal inside the
seal and boot kit is coated
with special grease, so do
not wipe this grease off.

Brake fluid: DOT3 or DOT4

Grease: Repair kit grease

Grease: Repair kit grease
35A-24 BASIC BRAKE SYSTEM – Front Disc Brake

DISASSEMBLY SERVICE POINTS

AA" PISTON BOOT/PISTON REMOVAL
Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.
Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be sure
to apply compressed air gradually.

AB" PISTON SEAL REMOVAL

1. Remove the piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.
Specified brake fluid: DOT3 or DOT4

INSPECTION
D Check the cylinder for wear, damage or rust.
D Check the piston surface for wear, damage or rust.
D Check the caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check the
backing metal for damage.

PAD WEAR CHECK

Measure thickness at the thinnest and worn area of the pad.
Replace the pad assembly if the pad thickness is less than
the limit value.
Standard value: 10 mm
Limit: 2.0 mm
Caution
1. Always replace the brake pads as an axle set.
2. If an excessive difference is found in the thickness
between the right and left brake pads, check moving
parts.
 BASIC BRAKE SYSTEM – Rear Disc Brake 35A-25
REAR DISC BRAKE
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-10.)

55 – 65 Nm
1

15 Nm
2

Removal steps
1. Brake hose connection
"AA 2. Disc brake assembly
3. Brake disc

INSTALLATION SERVICE POINT

"AA DISC BRAKE ASSEMBLY INSTALLATION
1. In order to measure the brake drag force after pad
installation, use a spring balance to measure the
rotary-sliding resistance of the hub with the pads removed.
2. Install the caliper support to the backing plate, and then
assemble the pad clip and the pad to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
35A-26 BASIC BRAKE SYSTEM – Rear Disc Brake

3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
MB990520

7. Use a spring balance to measure the rotary-sliding

resistance of the hub.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value: 34 N
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the lock pin and the
guide pin slide smoothly.
 BASIC BRAKE SYSTEM – Rear Disc Brake 35A-27
DISASSEMBLY AND REASSEMBLY

15
43 Nm 1 15

8 Nm 11
12
13
5 14

15

Clip set
9 8
7
6
2 15
4
3
10
5

5
1
9 11 14
10 9 7 5
3
2
3
5 8
7 13 6
6 12 Grease 5

Brake caliper kit Pad set Shim set Seal and boots kit

Disassembly steps
"AA 1. Guide pin AB" 9. Piston seal
"AA 2. Lock pin 10. Caliper body
3. Bushing 11. Pad and wear indicator assembly
4. Caliper support (pad, clip, shim) 12. Pad assembly
5. Pin boot 13. Inner shim
6. Boot ring 14. Outer shim
AA" 7. Piston boot 15. Clip
AA" 8. Piston
35A-28 BASIC BRAKE SYSTEM – Rear Disc Brake

LUBRICATION POINTS

Piston
seal

Grease: Repair kit grease

Caution
The piston seal inside the seal
and boot kit is coated with
special grease, so do not wipe
this grease off.

Brake fluid: DOT3 or DOT4

Grease: Repair kit grease

Grease: Repair kit grease
 BASIC BRAKE SYSTEM – Rear Disc Brake 35A-29
DISASSEMBLY SERVICE POINTS
AA" PISTON BOOT/PISTON REMOVAL
Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.
Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be sure
to apply compressed air gradually.

AB" PISTON SEAL REMOVAL

1. Remove the piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.
Specified brake fluid: DOT3 or DOT4

REASSEMBLY SERVICE POINT

Lock pin
"AA LOCK PIN/GUIDE PIN INSTALLATION
“L”
Install the guide pin and lock pin as illustrated that each head
mark of the guide pin and the lock pin matches the indication
Front mark (“G” or “L”) located on the caliper body.

Guide pin
“G”

INSPECTION
D Check the cylinder for wear, damage or rust.
D Check the piston surface for wear, damage or rust.
D Check the caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check the
backing metal for damage.
35A-30 BASIC BRAKE SYSTEM – Rear Disc Brake

PAD WEAR CHECK

Measure thickness at the thinnest and worn area of the pad.
Replace the pad assembly if the pad thickness is less than
the limit value.
Standard value: 10 mm
Limit: 2.0 mm
Caution
1. Always replace the brake pads as an axle set.
2. If an excessive difference is found in the thickness
between the right and left brake pads, check moving
parts.
 BASIC BRAKE SYSTEM – Load Sensing Proportioning Valve 35A-31
LOAD SENSING PROPORTIONING VALVE
REMOVAL AND INSTALLATION
Caution
Do not disassemble the load sensing proportioning valve.

Pre-removal Operation Post-installation Operation

Brake Fluid Draining D Brake Fluid Supplying
D Brake Line Bleeding (Refer to P.35A-10.)

2
5
1
15 Nm 3

15 Nm

3 4

Removal steps
"AA 1. Spring support 4. Load sensing proportioning valve
2. Load sensing spring 5. Bracket
3. Brake pipe connection

INSTALLATION SERVICE POINT

Load sensing spring
"AA SPRING SUPPORT INSTALLATION
Spring
Lever support 1. Install the load sensing spring, and then tighten the spring
support to the axle assembly temporarily.
2. Insert the lever of the load sensing proportioning valve
fully into the valve side and hold it. Then adjust the spring
support so that the spring length (the distance between
the two ends of the spring) is at the standard value.
Standard value (A): 194 – 198 mm
NOTES
 35A-1

BASIC BRAKE
SYSTEM
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE <1800-MPI> . . . . . . . . . 3

Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Lining Thickness Check . . . . . . . . . . . . . . . . . 3
Brake Drum Inside Diameter Check . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
Brake Lining and Brake Drum Contact Check . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
MASTER CYLINDER AND BRAKE
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BOOSTER <1800-MPI> . . . . . . . . . . . . . . . . . . . . . 4

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 6

 General/General Information/
35A-2 BASIC BRAKE SYSTEM – Service Specifications/Lubricants/Special Tool

GENERAL
OUTLINE OF CHANGE
The following service procedures have been established due to the adoption of the rear drum brake.
<1800-MPI>

GENERAL INFORMATION
Items 1800-MPI

Rear drum brakes Type Leading trailing

Drum I.D. mm 228

Wheel cylinder I.D. mm 22.2

Lining thickness mm 4.9

Clearance adjustment Automatic

SERVICE SPECIFICATIONS
Items Standard value Limit

Rear drum brake Lining thickness mm 4.9 1.0

Drum inside diameter mm 228.6 230.6

LUBRICANTS
Items Specified Lubricant Quantity

Backing plate Brake grease SAE J310, NLGI No.1 As required

Shoe and lining assembly

Automatic adjuster assembly

SPECIAL TOOL
Tool Number Name Use

A MB990964 Brake tool set D Pushing-in of the disc brake piston

A: MB990520 D Installation of drum brake wheel cylinder
B piston cup
B: MB990619
BASIC BRAKE SYSTEM – On-vehicle Service <1800-MPI> 35A-3
ON-VEHICLE SERVICE <1800-MPI>
BRAKE LINING THICKNESS CHECK
1. Remove the brake drum.
2. Measure the thickness of the brake lining at the place
A worn the most.
Standard value (A): 4.9 mm
Limit (A): 1.0 mm
3. Replace the shoe and lining assembly as an axle set
if brake lining thickness is less than the limit. For information
concerning the procedures for installation of the shoe and
lining assembly, refer to P.35A-26.
Caution
If there is a significant difference in the thickness
of the shoe and lining assemblies on the left and right
sides, check the sliding condition of the piston.

BRAKE DRUM INSIDE DIAMETER CHECK

1. Remove the brake drum.
2. Measure the inside diameter of the brake drum at two
A or more locations.
Standard value (A) : 228.6 mm
Limit (A) : 230.6 mm
3. Replace the brake drum when the inside diameter exceeds
the limit value or the brake drum is worn unevenly.

BRAKE LINING AND BRAKE DRUM CONTACT

CHECK
1. Remove the shoe and lining assembly. (Refer to P.35A-6.)
2. Chalk inner surface of brake drum and rub with shoe and
lining assembly.
3. Replace shoe and lining assembly or brake drums if there
are any irregular contact area.
4. Clean off chalk after check.
35A-4 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster <1800-MPI>

MASTER CYLINDER AND BRAKE BOOSTER <1800-MPI>

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-11.)*
D Brake Pedal Adjustment (Refer to P.35A-7.)*

11 5 9

Specified Sealant: 3M ATD Grease: Silicone grease

Part No.8661 or equivalent
1

15 ± 1 N·m 2

8
5 10
9.8 ± 2.0 N·m
1 7
4
14 ± 2 N·m
15 ± 1 N·m

9
3

<L.H. drive vehicles> <R.H. drive vehicles>

6
6
16 ± 1 N·m
16 ± 1 N·m 11
11
 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster <1800-MPI> 35A-5
Master cylinder removal steps
1. Brake pipe connection "BA D Push rod protrusion amount check and
2. Brake fluid level sensor connector adjustment
3. Bracket <L.H. drive vehicles> "AA 6. Vacuum hose
4. Master cylinder (With built-in check valve)
"CA 5. Seal 7. Snap pin
Brake booster removal steps 8. Pin assembly
9. Brake booster
1. Brake pipe connection 10. Sealer
2. Brake fluid level sensor connector
3. Bracket <L.H. drive vehicles> Fitting removal
4. Master cylinder 11. Fitting
"CA 5. Seal

NOTE
(1) *: Refer to PAJERO PININ ’00 Workshop Manual
(Pub. No. CKRE00E1).
(2) The installation service points are the same as before.
35A-6 BASIC BRAKE SYSTEM – Rear Drum Brake

REAR DRUM BRAKE

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Loosening the Parking Brake Cable Adjusting Nut. D Parking Brake Lever Stroke Adjustment
(Refer to GROUP 36 – On-vehicle Service) (Refer to GROUP 36 – On-vehicle Service)
D Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-11.)*

9.8 ± 1.9 N·m

11
18 2 4 3 15
14
13
19 12

8
15 ± 1 N·m 16 7
6

17

10 9 1
8
7
6 5

4
3 17
17 14 4

Specified grease: Brake grease SAE J310, NLGI No.1

Removal steps AA" "BA 12. Retainer

1. Brake drum "AA 13. Wave washer
2. Shoe-to-shoe spring 14. Parking lever
3. Adjuster lever 15. Shoe and lining assembly
4. Auto-adjuster assembly 16. Shoe hold-down pin
5. Retainer spring 17. Backing plate (Refer to GROUP 27
6. Shoe hold-down cup – Rear Axle Shaft.)
7. Shoe hold-down spring Wheel cylinder removal steps
8. Shoe hold-down cup 1. Brake drum
9. Shoe-to-shoe spring 18. Brake pipe connection
10. Shoe and lining assembly 19. Wheel cylinder assembly
11. Shoe and lever assembly

NOTE
*: Refer to PAJERO PININ ’00 Workshop Manual
(Pub. No. CKRE00E1).
 BASIC BRAKE SYSTEM – Rear Drum Brake 35A-7
REMOVAL SERVICE POINT
Pin of shoe and lining assembly
AA" RETAINER REMOVAL
Use a flat-tipped screwdriver or the like to open up the retainer
joint, and remove the retainer.

Retainer

INSTALLATION SERVICE POINTS

"AA WAVE WASHER INSTALLATION
Wave washer Shoe and lining
assembly Install the wave washer in the direction shown in the illustration.

Pin

Parking lever

"BA RETAINER INSTALLATION

Pin of shoe and lining assembly
Use pliers or the like to crimp the retainer or the pin positively.

Retainer

INSPECTION
BRAKE LINING THICKNESS CHECK
Refer to P.35A-3.
BRAKE DRUM INSIDE DIAMETER CHECK
Refer to P.35A-3.
BRAKE LINING AND BRAKE DRUM CONTACT CHECK
Refer to P.35A-3.
35A-8 BASIC BRAKE SYSTEM – Rear Drum Brake

WHEEL CYLINDER
DISASSEMBLY AND REASSEMBLY

1 4 4 1
Grease
7
6
2
2

Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Wheel cylinder repair kit

5 7.9 ± 0.9 N·m

2
6
4 3 1
1

3 4
2

Disassembly steps
1. Boots "AA 4. Piston cups
2. Piston assembly 5. Spring
"AA 3. Pistons 6. Wheel cylinder body

REASSEMBLY SERVICE POINT

"AA PISTON CUPS/PISTONS REASSEMBLY
MB990619
1. Use trichloroethylene, alcohol or the specified brake fluid
to clean the piston.
Specified brake fluid: DOT3 or DOT4
2. Apply the specified brake fluid to the piston cups and
the outer circumference of the special tool.
3. Set the piston cup on the special tool with the lip of the
cup facing up, fit the cup onto the special tool.
4. Slide the piston cup down the outside of the tool into
the piston groove carefully, making sure that the piston
cup is twisted or slanted.
INSPECTION
Check the piston and wheel cylinder walls for rust or damage,
Piston
and if there is any abnormality, replace the entire wheel cylinder
assembly.

Have the lip facing

upwards.
 SERVICE BULLETIN
PUBLICATION GROUP, AFTER SALES SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV

SERVICE BULLETIN No.: ESB-01E35-001

Date: 2001-07-03 <Model> <M/Y>

Subject: REPLACEMENT AND CLEANING FOR BRAKE (EC)CARISMA 98-10
BOOSTER VACUUM NIPPLE ON 4G93 GDI (EC)SPACE STAR
EQUIPPED VEHICLES (EC)PAJERO PININ
Group: SERVICE BRAKE draftno.: 01AL005

INFORMATION
O. Kai - E.V.P. & G.M.
After Sales Service Dept.

1. Description:
On 4G93-GDI engine-equipped vehicles for Europe, the vacuum nipple of the brake booster must
be replaced and cleaned periodically. This Service Bulletin covers the replacement and cleaning
procedures which should be added in On-Vehicle Service as shown below.

2. Applicable Manuals:
Manual Pub. No. Language Page(s)
’98 CARISMA GDI PWDE9502-C (English) 35A-1
Workshop Manual chassis PWDS9503-C (Spanish) 35A-1
PWDF9504-C (French) 35A-1
PWDG9505-C (German) 35A-1
PWDD9505-C (Dutch) 35A-1
PWDW9506-C (Swedish) 35A-1
PWDI96E1-C (Italian) 35A-1
’99 SPACE STAR CMXE99E1 (English) 35A-14
Workshop Manual chassis CMXS99E1 (Spanish) 35A-14
CMXF99E1 (French) 35A-14
CMXG99E1 (German) 35A-14
CMXD99E1 (Dutch) 35A-14
CMXW99E1 (Swedish) 35A-14
CMXI99E1 (Italian) 35A-14
’00 PAJERO PININ CKRE00E1 (English) 35A-13
Workshop Manual chassis
’00 MONTERO io CKRS00E1 (Spanish) 35A-13
Workshop Manual chassis
’00 PAJERO PININ CKRF00E1 (French) 35A-13
Workshop Manual chassis CKRG00E1 (German) 35A-13
CKRD00E1 (Dutch) 35A-13
CKRW00E1 (Swedish) 35A-13
CKRI00E1 (Italian) 35A-13
3. Details: ’98 CARISMA GDI Workshop Manual chassis
35A-1 BASIC BRAKE SYSTEM - General /On-vehicle Service <Added>

GROUP 35A
BASIC BRAKE SYSTEM
GENERAL
OUTLINE OF CHANGES
The following maintenance service points have been established to correspond to the addition of a pressure
sensor. Maintenance service procedures not listed below are the same as before.

<Added>

Intake manifold Brake ON-VEHICLE SERVICE

booster
hose
BRAKE BOOSTER VACUUM NIPPLE
REPLACEMENT
Nipple 1. Remove the brake booster hose from the intake manifold.
2. Replace the nipple with a new one, using a sealing agent
and tighten to 15 – 18 N.m

AY0140BY Specified sealant:

3M ATD Part No.8661 or equivalent

Caution
Take care when applying the thread sealant as too
much could block the nipple.

3. After replacement, re-install the brake booster hose.

2
3. Details: ’99 SPACE STAR Workshop Manual chassis
35A-14 BASIC BRAKE SYSTEM - On-vehicle Service

BRAKE LINING THICKNESS CHECK 35100300241

1. Remove the brake drum.

2. Measure the wear of the brake lining at the place worn
the most.
Standard value: 4.38 mm
Limit: 1.0 mm
Replace the shoe and lining assembly if brake lining
thickness is less than the limit if it is not worn evenly.
For information concerning the procedures for installation
14W0096
of the shoe and lining assembly, refer to P.35A-22.
Caution
(1) Whenever the shoe and lining assembly is
replaced, replace both RH and LH assemblies as a
set to prevent car from pulling to one side when
braking.
(2) If there is a significant difference in the thickness
of the shoe and lining assemblies on the left and
right sides, check the sliding condition of the
piston.

BRAKE DRUM INSIDE DIAMETER CHECK 35100320049

1. Remove the brake drum.

2. Measure the inside diameter of the brake drum at two or
more locations
Standard value: 203 mm
14X0366
Limit: 205 mm
3. Replace brake drums, shoe and lining assembly when
wear exceeds the limit value or is badly imbalanced.

BRAKE LINING AND BRAKE DRUM

CONNECTION CHECK 35100310053

1. Remove the brake drum.

2. Remove the shoe and lining assembly.
(Refer to P.35A-22.)
3. Chalk inner surface of brake drum and rub with shoe and
lining assembly.
4. Replace shoe and lining assembly or brake drums if there
14U007
are any irregular contact area.
NOTE
Clean off chalk after check.
<Added>
Intake manifold
BRAKE BOOSTER VACUUM NIPPLE
Brake booster hose REPLACEMENT
1. Remove the brake booster hose from the intake manifold.
2. Replace the nipple with a new one, using a sealing agent
Nipple and tighten to 15 – 18 N.m
Specified sealant:
3M ATD Part No.8661 or equivalent.
Caution
Take care when applying the thread sealant as too
AY0141BY
much could block the nipple.
3. After replacement, re-install the brake booster hose.

3
3. Details: ’00 PAJERO PININ Workshop Manual chassis
BASIC BRAKE SYSTEM - On-vehicle Service 35A-13
BRAKE DISC RUN-OUT CHECK AND CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Place a dial gauge approximately 5 mm from the outer circumference
of the brake disc, and measure the run-out of the disc.
Limit: <Front> 0.06 mm or less,
<Rear> 0.08 mm or less
3. If the brake disc run-out exceeds the limit, correct it as follows:

14F812
(1) Chalk phase marks on the wheel stud and the brake disc, which
run-out is excessive as show

Chalk marks

A14A0398

(2) Remove the brake disc. Then place a dial gauge as shown, and
measure the end play by pushing and pulling the wheel hub.
Limit: <Front> 0.2 mm, <Rear> 0.025 mm
(3) If the end play exceeds the limit, disassemble the hub and knuckle
assembly to check each part.
(4) If the end play does not exceed the limit, dephase the brake disc
and secure it. Then recheck the brake disc run-out.

14H0052
4. If the run-out cannot be corrected by changing the phase of the brake
disc, replace the brake disc or grind it with the on-the-car type brake
lathe (”MAD, DL-8700PF” or equivalent.
<Added>
BRAKE BOOSTER VACUUM NIPPLE
Intake minifold REPLACEMENT <SCREW TYPE NIPPLE>
1. Remove the brake booster hose from the intake manifold.
Brake booster hose 2. Replace the nipple with a new one, using a sealing agent and
tighten to 15 – 18 N.m.
Nipple Specified sealant:
3M ATD Part No.8661 or equivalent
Caution
AY0142BY
Take care when applying the thread sealant as too much
could block the nipple.
3. After replacement, re-install the brake booster hose.

Brake booster hose MB991876 BRAKE BOOSTER VACUUM NIPPLE CLEANING

<PRESS FIT TYPE NIPPLE>
1. Remove the brake booster hose from the intake manifold.
2. Insert special tool into the nipple and remove the carbon deposit
Nipple by rotating and reciprocating of the special tool.
Caution
The special tool should be inserted more than 50 mm and
AY0143BY confirm that it goes through into the intake manifold.
3. Make sure that no parts of the special tool remain in the manifold.
4. After cleaning, re-install the brake booster hose.

4
 ANTI-SKID
BRAKING SYSTEM
(ABS) <4WD>
Click on the applicable bookmark to selected the required model year
 35B-1

ANTI-SKID
BRAKING SYSTEM
(ABS) <4WD>
CONTENTS
Click on the applicable bookmark to selected the required model year

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 Brake Fluid Level Sensor Check

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 Bleeding . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Disc Brake Pad Check and Replacement
LUBRICANTS . . . . . . . . . . Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

SEALANTS . . . . . . . . . . . . Refer to GROUP 35A Disc Brake Rotor Check . . . Refer to GROUP 35A
Brake Disc Thickness Check
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Brake Disc Run-out Check and Correction
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Wheel Speed Sensor Output Voltage Check
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Brake Pedal Check and Adjustment ABS Warning Lamp Relay Continuity Check
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake Booster Operating Test Hydraulic Unit Check . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Remedy for a Flat Battery . . . . . . . . . . . . . . . . . . . 25
Check Valve Operation Check
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
BRAKE PEDAL . . . . . . . . Refer to GROUP 35A
Load Sensing Spring Length Check and
Adjustment . . . . . . . . . . . . . . . Refer to GROUP 35A MASTER CYLINDER AND BRAKE
Load Sensing Proportioning Valve Function BOOSTER . . . . . . . . . . . . Refer to GROUP 35A
Test . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
CONTINUED ON NEXT PAGE
35B-2

FRONT DISC BRAKE . . Refer to GROUP 35A HYDRAULIC UNIT AND ABS-ECU . . . . . . . . . 26

REAR DISC BRAKE . . . . Refer to GROUP 35A WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . 29

LOAD SENSING PROPORTIONING G SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

VALVE . . . . . . . . . . . . . . . . . Refer to GROUP 35A
 ABS <4WD> – General Information/Service Specifications 35B-3
GENERAL INFORMATION
The ABS consists of components such as the wheel identified and the trouble symptoms will be
speed sensors, stop lamp switch, hydraulic unit memorized by the diagnosis function.
assembly (integrated with the ABS-ECU) and the In addition, reading of diagnosis codes and service
ABS warning lamp. If a problem occurs in the data and actuator testing are possible by using the
system, the malfunctioning components can be MUT-II.

WHEEL SPEED SENSOR

Type Magnet coil type

ABS rotor teeth 43

CONSTRUCTION DIAGRAM

ABS warning
lamp
Hydraulic unit
assembly Diagnosis
(integrated with connector
the ABS-ECU)

G-sensor
Wheel speed sensor
Wheel speed sensor Stop lamp switch

SERVICE SPECIFICATIONS
Items Standard value

Wheel speed sensor internal resistance kΩ 1.30 – 1.58

Wheel speed sensor insulation resistance kΩ 100 or more

G sensor output voltage V When labeled surface is faced to vertical direction 2.4 – 2.6

When labeled surface is faced straight down 3.3 – 3.7

35B-4 ABS <4WD> – Special Tools

SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub For checking of ABS
assembly (Diagnosis code display when using the
MUT-II)

MB991529 Diagnosis code For checking of ABS

check harness (Diagnosis code display when using the ABS
warning lamp)

MB991547 ABS check For measuring of ABS-ECU terminal voltage

harness

MB991348 Test harness set For checking of G sensor

 ABS <4WD> – Troubleshooting 35B-5
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.
NOTES WITH REGARD TO DIAGNOSIS
1. The phenomena listed in the following table are not abnormal.

Phenomenon Explanation of phenomenon

System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside
the engine compartment, but this is because the system operation check is being performed,
and is not an abnormality.

ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is the generated along with vibration of the brake pedal. (scraping)
3. When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)

System check sound When depressing the brake pedal during driving, a shock is sometime felt.

2. For road surfaces such as snow-covered roads and gravel roads, the braking distance for vehicles
with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the customer
to drive safely on such roads by lowering the vehicle speed and not being too overconfident.
3. Diagnosis detection condition can vary depending on the diagnosis code.
Make sure that checking requirements listed in the “Comment” are satisfied when checking the trouble
symptom again.
Caution
Use the special tool (MB991547) when checking the terminal voltage and resistance of ABS-ECU.
35B-6 ABS <4WD> – Troubleshooting

ABS WARNING LAMP INSPECTION

Check that the ABS warning lamp illuminates as follows.
1. When the ignition key is turned to “ON”, the ABS warning
lamp illuminates for approximately 3 seconds and then
switches off.
2. When the ignition key is turned to “START”, the ABS
warning lamp remains illuminated.
3. When the ignition key is turned from “START” back to
“ON”, the ABS warning lamp illuminates for approximately
3 seconds and then switches off.
ABS warning lamp NOTE
The ABS warning lamp may remain on until the vehicle
reaches a speed of several km/h. This is limited to cases
Approx. 3 s Approx. 3 s where diagnosis code Nos.21 to 24, 53 or 55 have been
ABS recorded because of a previous problem occurring. In
warn- Illuminated this case, the ABS-ECU keeps the warning lamp
ing Not illumi- illuminated until the problem corresponding to that
lamp nated diagnosis code can be detected.
START
Ignition ON 4. If the illumination is other than the above, check the
switch ACC, diagnosis codes.
LOCK

DIAGNOSIS FUNCTION
READING DIAGNOSIS CODES
Read a diagnosis code by the MUT-II or ABS warning lamp.
(Refer to GROUP 00 – How to Use Troubleshooting/Inspection
Service Points.)
NOTE
Connect the MUT-II to the diagnosis connector (16-pin).
ERASING DIAGNOSIS CODES
When using the MUT-II
Connect the MUT-II to the diagnosis connector (16-pin) and
erase the diagnosis code.
Caution
Turn the ignition key to the LOCK (OFF) position before
connecting or disconnecting the MUT-II.
 ABS <4WD> – Troubleshooting 35B-7
When not using the MUT-II
1. Stop the engine.
2. Use the special tool to earth terminal (1) (diagnosis control
terminal) of the diagnosis connector.
3. Turn on the stop lamp switch. (Depress the brake pedal.)
MB991529
4. After carrying out steps 1. to 3., turn the ignition switch
to ON. Within 3 seconds after turning the ignition switch
to ON, turn off the stop lamp switch (release the brake
pedal). Then, turn the stop lamp switch on and off a total
of 10 times.
NOTE
If the ABS-ECU function has been stopped because of
fail-safe operation, it will not be possible to erase the
diagnosis codes.
ON
Ignition switch
LOCK (OFF)

ON
Stop lamp switch
OFF

1 second

ON
ABS warning lamp
OFF

ABS-ECU memory
Within 3 Within
1
Within
1
Within Within
1 1
Within Within Within Within
1
Within Within
1
1 1 1 1
seconds second second second second second second second second second second

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Erasing of
ABS-ECU
diagnosis
codes
complete.
35B-8 ABS <4WD> – Troubleshooting

INSPECTION CHART FOR DIAGNOSIS CODES

Diagnosis code No. Inspection item Reference page

11 Front right wheel speed sensor (Open circuit or short circuit) 35B-9

12 Front left wheel speed sensor (Open circuit or short circuit) 35B-9

13 Rear right wheel speed sensor (Open circuit or short circuit) 35B-9

14 Rear left wheel speed sensor (Open circuit or short circuit) 35B-9

15 Wheel speed sensor (Abnormal output signal) 35B-10

16* ABS-ECU power supply system (Abnormal voltage drop or rise) 35B-11

21 Front right wheel speed sensor 35B-9

22 Front left wheel speed sensor 35B-9

23 Rear right wheel speed sensor 35B-9

24 Rear left wheel speed sensor 35B-9

32 G sensor system 35B-12

33 Stop lamp switch system 35B-13

41 Front right solenoid valve The diagnosis codes are output 35B-13
when there is no response to the
42 Front left solenoid valve drive signals for respective solenoid
valves or the ABS ECU power
ABS-ECU
43 Rear right solenoid valve supply system is defective.
44 Rear left solenoid valve

51 Valve relay problem (stays on) 35B-26, 27

(Replace the
hydraulic unit and
ABS-ECU.)

52 Valve relay problem (stays off) or ABS-ECU power supply system 35B-13
problem

53 Motor relay problem (stays off) or ABS-ECU power supply system

problem

54 Motor relay problem (stays on) 35B-26, 27

(Replace the
hydraulic unit and
ABS-ECU.)

55 Motor system (seized pump motor) or ABS-ECU power supply system 35B-13
problem

63 ABS-ECU 35B-26, 27
(Replace the
hydraulic unit and
ABS-ECU.)

NOTE
*: Turning the ignition switch to ACC will erase the diagnosis code No.16.
 ABS <4WD> – Troubleshooting 35B-9
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code Nos.11, 12, 13 and 14 Wheel speed sensor Probable cause
(open circuit or short circuit)
Code Nos.21, 22, 23 and 24 Wheel speed sensor
Code Nos. 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit D Malfunction of wheel speed sensor
or short-circuit in the (+) wire or (–) wire in any one of the four wheel speed sensors. D Malfunction of wiring harness or connector
D Malfunction of hydraulic unit and ABS-ECU
Code Nos. 21, 22, 23 and 24 are output in the following cases. D Malfunction of wheel speed sensor
D When there is no input from any one of the four wheel speed sensors when D Malfunction of wiring harness or connector
travelling at several km/h or more, even though open circuit can not be verified. D Malfunction of ABS rotor
D When a chipped or blocked-up ABS rotor is detected and if the anti-lock system D Too much gap between the sensor and the ABS rotor
operates continuously because a malfunctioning sensor or a warped ABS rotor D Malfunction of hydraulic unit and ABS-ECU
is causing sensor output to drop. D Malfunction of wheel bearing

NG
Wheel speed sensor installation check Repair
OK
NG
Measure at the ABS-ECU connector A-58. Wheel speed sensor check (Refer to P.35B-30.)
D Disconnect the connector, and measure at the harness side OK NG
connector.
D Resistances between 17 and 18, 15 and 14, 2 and 1, 4 and Replace
5
OK: 1.30 – 1.58 kΩ
Check the following connectors:
OK A-58, C-25<L.H. drive vehicles>, C-24<R.H. drive vehicles>, A-24,
A-85, D-24, D-28
Wheel speed sensor output voltage check (Refer to P.35B-22.)
OK NG
OK NG
NG
Wheel speed sensor Replace Check the trouble symp-
check tom. Repair
(Refer to P.35B-30.) NG
OK
NG Check the harness wire, and repair if necessary.
ABS rotor check Replace D Between each wheel speed sensor and ABS-ECU
(Refer to P.35B-30.)
OK

Wheel bearing check

(Refer to GROUP 26 and
GROUP 27 – On-vehicle
Service.)

Check the following connector: A-58

OK NG

Check the trouble symp- Repair

tom.
NG

Replace the hydraulic unit and ABS-ECU.

35B-10 ABS <4WD> – Troubleshooting

Code No.15 Wheel speed sensor (Abnormal output signal) Probable cause
This code is output if the output signal of any wheel speed sensor is abnormal D Unequal tyre size
(other than an open circuit or short circuit). D Improper installation of wheel speed sensor
D Malfunction of wheel speed sensor
D Malfunction of wiring harness or connector
D Malfunction of ABS rotor
D Malfunction of wheel bearing
D Malfunction of hydraulic unit and ABS-ECU

NO
Are four tyres equal in size? Equalize sizes on all tyres.
YES

Check the trouble symptom.

NG

NG
Check the wheel speed sensor installation condition. Repair
OK

NG
Check the wheel speed sensor output voltage. (Refer to P.35B-22.) Check the wheel speed sensor. (Refer to P.35B-30.)
OK OK NG

Replace
Check the following connector: A-58
OK NG Check the ABS rotor. (Refer to P.35B-30.)
OK NG
Repair
Check the trouble symp-
tom. Replace
NG
Check the wheel bearing. (Refer to GROUP 26 and GROUP
27 – On-vehicle Service.)
Replace the hydraulic unit and ABS-ECU.
OK NG

Check the trouble symp-

tom. Replace

NG
Check the harness wire, and repair if necessary.
D Between each wheel speed sensor and ABS-ECU
 ABS <4WD> – Troubleshooting 35B-11
Code No.16 ABS-ECU power supply system (abnormal Probable cause
voltage drop or rise)
This code is output if the ABS-ECU power supply voltage drops below or rises D Malfunction of battery
above the rated values. D Malfunction of wiring harness or connector
Furthermore, turning the ignition switch to ACC will erase this code. D Malfunction of hydraulic unit and ABS-ECU

Caution
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage
returns to standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, C-40 <R.H. drive
D Disconnect the connector, and measure at the harness side vehicles>, C-02 <R.H. drive vehicles>, C-78 <L.H. drive vehicles>,
connector. C-76 <R.H. drive vehicles>, C-74
D Start the engine. Voltage between 10 and body earth
OK NG
OK: System voltage
OK
Check the trouble symp- Repair
Check the following connector: A-58 tom.
OK NG
NG
Check the trouble symp- Repair
tom.
Check the harness wire, and repair if necessary.
NG D Between ignition switch and ABS-ECU
Replace the hydraulic unit and ABS-ECU.
35B-12 ABS <4WD> – Troubleshooting

Code No.32 G sensor system Probable cause

This code is output in the following cases. D Malfunction of G sensor
D G sensor output voltage is less than 0.5 V or more than 4.5 V. (An open or D Malfunction of wiring harness or connector
short circuit is present in the G sensor circuit.) D Malfunction of hydraulic unit and ABS-ECU
D G sensor output voltage does not change. (G sensor output voltage is abnormal.)

NG
G sensor check (Refer to P.35B-31.) Replace
OK

NG
Measure at the G sensor connector D-29. Check the following connector: D-29
D Disconnect the connector, and measure at the harness side
connector. OK NG
D Ignition switch: ON
D Voltage between 1 and body earth Check the trouble symp- Repair
OK: System voltage tom.
NG
OK
Check the harness wire, and repair if necessary.
D Between ignition switch and G sensor

NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, C-25 <L.H. drive
D Disconnect the connector, and measure at the harness side vehicles>, D-29
connector.
D Ignition switch: ON OK NG
D Voltage between 7 and 20
OK: 2.4 – 2.6 V (When labeled surface is faced to vertical Check the trouble symp- Repair
direction) tom.

OK NG

Check the following connector: A-58 Check the harness wire, and repair if necessary.
OK NG D Between G sensor and ABS-ECU

Check the trouble symp- Repair

tom.
NG

Replace the hydraulic unit and ABS-ECU.

 ABS <4WD> – Troubleshooting 35B-13
Code No.33 Stop lamp switch system Probable cause
This code is output in the following cases. D Malfunction of stop lamp switch
D If the stop lamp switch is continuously on for 15 minutes or more even though D Malfunction of wiring harness or connector
the ABS system is not operating. D Malfunction of hydraulic unit and ABS-ECU
D If there is an open circuit in the stop lamp switch input circuit harness.

NO
Does the stop lamp turn on and off normally? Check the stop lamp switch installation condition.
YES (Refer to GROUP 35A – On-vehicle Service.)
OK NG
Measure at the ABS-ECU connector A-58.
D Disconnect the connector, and measure at the harness side Repair
connector.
D Stop lamp switch: ON Check the stop lamp switch. (Refer to GROUP 35A – Brake Pedal.)
D Voltage between 3 and body earth
OK: System voltage OK NG
OK NG
Replace
Check the following Check the following
connector: A-58 connectors: Check the following connectors: C-28 <L.H. drive vehicles>,
A-58, C-28 <L.H. drive C-41 <R.H. drive vehicles>, C-02, C-04, C-29
OK NG vehicles>, C-41 <R.H. OK NG
drive vehicles>
Repair
OK NG Check the trouble symp- Repair
Check the trouble symp- tom.
tom. Repair
Check the trouble symp- NG
NG
tom.
Replace the hydraulic NG Check the harness wire, and repair if necessary.
unit and ABS-ECU. D Between battery and stop lamp switch
Check the harness wire, D Between stop lamp switch and ABS-ECU
and repair if necessary.
D Between stop lamp
switch and ABS-ECU

Code Nos.41, 42, 43 and 44 Solenoid valve Probable cause

Code No.52 Valve relay problem (stays off)
Code No.53 Motor relay problem (stays off)
Code No.55 Motor system (seized pump motor)
These codes are output if there is an open circuit or short-circuit in the ABS-ECU D Malfunction of wiring harness or connector
power supply circuit (power supply circuit for solenoid valve and motor), or the internal D Malfunction of hydraulic unit and ABS-ECU
circuit in the hydraulic unit and ABS-ECU is defective.

NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, C-24 <R.H. drive
D Disconnect the connector, and measure at the harness side vehicles>
connector.
D Voltage between 22 and body earth, and between 24 and OK NG
body earth
OK: System voltage Check the trouble symp-
tom. Repair
OK
NG

Check the following connector: A-58 Check the harness wire, and repair if necessary.
D Between fusible link No.1 and ABS-ECU
OK NG

Repair
Check the trouble symp-
tom.
NG

Replace the hydraulic unit and ABS-ECU.

35B-14 ABS <4WD> – Troubleshooting

INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptoms Inspection procedure Reference page
No.

Communication between the MUT-II and the whole system is not 1 35B-14
possible.

Communication between the MUT-II and the ABS-ECU is not possible. 2 35B-15

When the ignition key is turned to “ON” (engine stopped), the ABS warning 3 35B-16
lamp does not illuminate.

Even after the engine is started, the ABS warning lamp remains 4 35B-17
illuminated.

Faulty ABS operation 5 35B-18

Caution
1. If steering movements are made when driving at high speed, or when driving on road surfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, when getting information from the customer,
check if the problem occurred while driving under such conditions as these.
2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1
Communication between the MUT-II and the whole system Probable cause
is not possible.
The cause may be a malfunction of the power supply circuit or the earth circuit D Malfunction of diagnosis connector
of the diagnosis connector. D Malfunction of wiring harness or connector

NG
Measure at the diagnosis connector C-35. Check the following connectors: C-35, C-76, C-77
D Voltage between 16 and body earth
OK NG
OK: System voltage
OK Check the trouble symp- Repair
tom.
NG

Check the harness wire, and repair if necessary.

D Between fusible link No.2 and diagnosis connector

NG
Measure at the diagnosis connector C-35. Check the following connector: C-35
D Continuity between 4 and body earth, and between 5 and
OK NG
body earth
OK: Continuity Check the trouble symp- Repair
OK tom.
NG
Check the trouble symptom.
NG Check the harness wire, and repair if necessary.
D Between diagnosis connector and earth
Replace the MUT-II.
 ABS <4WD> – Troubleshooting 35B-15
Inspection Procedure 2
Communication between MUT-II and the ABS-ECU is not Probable cause
possible.
The cause may be an open circuit in the ABS-ECU power supply circuit or an open D Blown fuse
circuit in the diagnosis output circuit. D Malfunction of wiring harness or connector
D Malfunction of hydraulic unit and ABS-ECU

NG
Measure at the diagnosis connector C-35 and the ABS-ECU con- Check the following connectors: A-58, C-28 <L.H. drive
nector A-58. vehicles>, C-40 <R.H. drive vehicles>, C-70, C-35
D Disconnect the connectors, and measure at the harness side
connectors. OK NG
D Continuity between the following terminals
ABS-ECU side – Diagnosis connector side Check the trouble symp- Repair
19 – 1 tom.
9 – 7 NG
OK: Continuity
Check the harness wire, and repair if necessary.
OK D Between ABS-ECU and diagnosis connector

NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, C-40 <R.H. drive
D Disconnect the connector, and measure at the harness side vehicles>, C-02 <R.H. drive vehicles>, C-78 <L.H. drive vehicles>,
connector. C-76 <R.H. drive vehicles>, C-74
D Ignition switch: ON
D Voltage between 10 and body earth OK NG
OK: System voltage
Repair
Check the trouble symp-
OK tom.
NG

Check the harness wire, and repair if necessary.

D Between ignition switch and ABS-ECU

Measure at the ABS-ECU connector A-58. NG

Check the following connector: A-58
D Disconnect the connector, and measure at the harness side
connector. OK NG
D Continuity between 21 and body earth, and between 23 and
body earth Check the trouble symp- Repair
OK: Continuity tom.
NG
OK

Check the following connector: A-58 Check the harness wire, and repair if necessary.
D Between ABS-ECU and earth
OK NG
Check the trouble symp- Repair
tom.
NG

Replace the hydraulic unit and ABS-ECU.

35B-16 ABS <4WD> – Troubleshooting

Inspection Procedure 3
When the ignition key is turned to “ON” (engine stopped), Probable cause
the ABS warning lamp does not illuminate.
The cause may be an open circuit in the lamp power supply circuit, a blown lamp, D Blown fuse
a malfunction of the ABS warning lamp relay or an open circuit between the ABS D Burn out ABS warning lamp bulb
warning lamp and the earth. D Malfunction of ABS warning lamp relay
D Malfunction of wiring harness or connector
D Malfunction of hydraulic unit and ABS-ECU

NG
Fuse check Refer to GROUP 00 – Inspection Service Points for Blown Fuse.
Multi-purpose fuse No.6
OK
NG
Measure at the ABS warning lamp relay connector A-57. Check whether the ABS warning lamp bulb is burnt out.
D Disconnect the connector, and measure at the harness side
OK NG
connector.
D Ignition switch: ON Replace the ABS warning
D ABS warning lamp condition when terminal 3 is earthed. lamp bulb.
OK: Illuminates
OK
Check the following connectors: A-57,
ABS warning lamp relay check (Refer to P.35B-23.) C-27 <L.H. drive vehicles>, C-40 <R.H. drive vehicles>,
C-07, C-06, C-02 <L.H. drive vehicles>, C-76, C-74
OK NG
OK NG
Replace the ABS warning
lamp relay. Check the trouble symp- Repair
tom.

NG

Check the harness wire.

D Between ignition switch and combination meter
D Between combination meter and ABS warning lamp relay
OK NG

Repair

Replace the combination meter.

NG
Measure at the ABS warning lamp relay connector A-57. Check the following connector: A-57
D Disconnect the connector, and measure at the harness side
connector. OK NG
D Ignition switch: ON
D Continuity between 1 and body earth Check the trouble symp- Repair
OK: Continuity tom.
OK NG

Replace the hydraulic unit and ABS-ECU. Check the harness wire, and repair if necessary.
D Between ABS warning lamp relay and earth
 ABS <4WD> – Troubleshooting 35B-17
Inspection Procedure 4
Even after the engine is started, the ABS warning lamp Probable cause
remains illuminated.
The cause is probably a short-circuit in the ABS warning lamp illumination circuit. D Malfunction of combination meter
D Malfunction of ABS warning lamp relay
D Malfunction of wiring harness (short circuit)
D Malfunction of hydraulic unit and ABS-ECU

NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible (ABS-ECU
power supply is normal) and the diagnosis code is a normal diagnosis code.
YES
Does the ABS warning lamp stay illuminated when the combination Replace the combination meter.
meter connector C-07 is disconnected and the ignition switch
is turned to ON?
NO
NG
ABS warning lamp relay check (Refer to P.35B-23.) Replace the ABS warning lamp relay.
OK
YES
Does the ABS warning lamp stay illuminated when the ABS warning Check the harness wire, and repair if necessary.
lamp relay connector A-57 is disconnected and the ignition switch D Between combination meter and ABS warning lamp relay
is turned to ON?
NO
NG
Measure at the ABS warning lamp relay connector A-57. Check the following connector: A-57
D Disconnect the connector, and measure at the harness side
OK NG
connector.
D Ignition switch: ON Check the trouble symp-
D Voltage between 5 and body earth Repair
tom.
OK: System voltage
NG
OK
Check the harness wire, and repair if necessary.
D Between ignition switch and ABS warning lamp relay

NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, A-57
D Ignition switch: ON OK NG
D Voltage between 8 and body earth
OK: System voltage Check the trouble symp- Repair
OK tom.
NG
Replace the hydraulic unit and ABS-ECU.
Check the harness wire, and repair if necessary.
D Between ABS warning lamp relay and ABS-ECU
35B-18 ABS <4WD> – Troubleshooting

Inspection Procedure 5
Faulty ABS operation Probable cause
This varies depending on the driving conditions and the road surface conditions, D Improper installation of wheel speed sensor
so problem diagnosis is difficult. However, if a normal diagnosis code is displayed, D Malfunction of wiring harness or connector
carry out the following inspection. D Malfunction of wheel speed sensor
D Malfunction of ABS rotor
D Foreign material adhering to wheel speed sensor
D Malfunction of wheel bearing
D Malfunction of hydraulic unit and ABS-ECU

NG
Wheel speed sensor installation check Repair
OK
OK
Wheel speed sensor output voltage check (Refer to P.35B-22.) Hydraulic unit check (Refer to P.35B-24.)
NG
NG
Wheel speed sensor check (Refer to P.35B-30.) Replace the wheel speed sensor.
OK
NG
ABS rotor check (Refer to P.35B-30.) Repair
OK
NG
Wheel bearing check (Refer to GROUP 26 and GROUP 27 – Repair
On-vehicle Service.)
OK
NG
Check the following connectors: Repair
A-58, C-25 <L.H. drive vehicles>, C-24 <R.H. drive vehicles>,
A-24, A-85, D-24, D-28
OK

Check the trouble symptom.

NG
NG
Measure at the ABS-ECU connector A-58. Check the harness wire.
D Disconnect the connector, and measure at the harness side D Between each wheel speed sensor and ABS-ECU
connector.
D Resistances between 17 and 18, 15 and 14, 4 and 5, 2 and
1
OK: 1.30 – 1.58 kΩ
(The sensor harness and connector should be moved while
these inspections are carried out.)
OK
NG Repair
Check the following connector: A-58
OK
Check the trouble symptom.
NG
Replace the hydraulic unit and ABS-ECU.
 ABS <4WD> – Troubleshooting 35B-19
DATA LIST REFERENCE TABLE
The following items can be read by the MUT-II from the ABS-ECU input data.

1. When the system is normal

Item No. Check item Checking requirements Normal value

11 Front-right wheel speed sensor Perform a test run Vehicle speeds

displayed on the
12 Front-left wheel speed sensor speedometer
MUT II are
and MUT-II
13 Rear-right wheel speed sensor identical.
14 Rear-left wheel speed sensor

16 ABS-ECU power supply Ignition switch: ON 9.2 – 17.5 V

voltage

32 G sensor Vehicle is stopped. 2.4 – 2.6 V

Vehicle is running. 0.5 – 4.5 V

33 Stop lamp switch Depress the brake pedal. ON

Release the brake pedal. OFF

2. When the ABS-ECU shut off ABS operation.

When the diagnosis system stops the ABS-ECU, the MUT-II display data will be unreliable.

ACTUATOR TEST REFERENCE TABLE

The MUT-II activates the following actuators for testing.
NOTE
1. If the ABS-ECU runs down, actuator testing cannot be carried out.
2. Actuator testing is only possible when the vehicle is stationary.

ACTUATOR TEST SPECIFICATIONS

Activation pattern
No. Item
End of forced
Start of action 01 Solenoid valve for Solenoid valves and pump
forced front-right wheel motors in the hydraulic unit
A action
Solenoid (simple inspection mode)
valve B 1s 02 Solenoid valve for front-left
C 2s wheel
0.05 s 0.01 s 03 Solenoid valve for rear-right
Pump ON wheel
motor OFF 04 Solenoid valve for rear-left
wheel

NOTE
A: Hydraulic pressure increase
B: Hydraulic pressure holds
C: Hydraulic pressure decrease
35B-20 ABS <4WD> – Troubleshooting

CHECK AT ABS-ECU
TERMINAL VOLTAGE CHECK CHART
1. Disconnect the ABS-ECU connector. (Refer to P. 35B-27.)
2. Use the special tool to measure the voltage between each
terminal and earth (terminal No.23).
3. The terminal layout is shown in the illustration.
Earth terminal

Check connector

MB991547

Body side harness

ABS-ECU

Terminal No. Check item Checking requirements Normal condition

3 Stop lamp switch input Ignition switch: ON Stop lamp switch: ON System voltage

Stop lamp switch: OFF 1 V or less

7 Input
In ut from G sensor Ignition switch: ON 2.4 – 2.6 V
Vehicle is horizontal
8 ABS warning lamp Ignition switch: ON When the lamp is 2 V or less
relay transistor output switched off

When the lamp is illu- System voltage

minated

9 MUT-II When the MUT-II is connected Serial communication

with MUT-II

When the MUT-II is not connected 1 V or less

10 ABS-ECU power Ignition switch: ON System voltage

supply
Ignition switch: START 0V

19 Diagnosis changeover When the MUT-II is connected 0V

input
When the MUT-II is not connected Approx. 12 V

20 G sensor earth Always 0V

22 Solenoid valve power Always System voltage

supply

24 Motor power supply Always System voltage

 ABS <4WD> – Troubleshooting 35B-21
RESISTANCE AND CONTINUITY BETWEEN
HARNESS-SIDE CONNECTOR TERMINALS
1. Turn the ignition key to the LOCK (OFF) position.
2. Disconnect the ABS-ECU connector. (Refer to P. 35B-27.)
3. Use the special tool to check the resistance and continuity
between the terminals indicated in the table below.
4. The terminal layout is shown in the illustration.

Check connector

MB991547

Body side harness

ABS-ECU

ABS–ECU terminal No. Signal Normal condition

1–2 Wheel speed sensor (rear left) 1.30 – 1.58 kΩ

4–5 Wheel speed sensor (rear right)

14 – 15 Wheel speed sensor (front left)

17 – 18 Wheel speed sensor (front right)

21 – Body earth Earth Continuity

23 – Body earth Earth

35B-22 ABS <4WD> – On-vehicle Service

ON-VEHICLE SERVICE
WHEEL SPEED SENSOR OUTPUT VOLTAGE
CHECK
1. Lift up the vehicle and release the parking brake.
2. Disconnect the ABS-ECU connector and then connect
the special tool to the harness side connector. (Refer to
P. 35B-27.)
3. Rotate the wheel to be measured at approximately 1/2–1
Check connector rotation per second, and check the output voltage using a
circuit tester or an oscilloscope.
MB991547
Wheel speed Front Front Rear left Rear
sensor left right right
Terminal No. 15 17 2 4
14 18 1 5
Output voltage
Body side harness
ABS-ECU When measuring with a circuit tester:
42 mV or more
When measuring with an oscilloscope:
120 mV p-p or more
4. The followings are suspected if the output voltage is lower
than the value described above. Check the wheel speed
sensor, and replace if necessary.
D Too large clearance between the pole piece of the
wheel speed sensor and ABS rotor
D Faulty wheel speed sensor

Inspecting Waveforms With An Oscilloscope

Use the following method to observe the output voltage
When turning by hand waveform from each wheel speed sensor with an oscilloscope.
D Start the engine, and rotate the rear wheels by engaging
1st gear (vehicles with manual transmission) or D range
(vehicles with automatic transmission). Turn the front
wheels manually so that they rotate at a constant speed.
NOTE
1. The waveform measurements can also be taken while
the vehicle is actually moving.
When idling (5 – 6 km/h), 1st gear (M/T) 2. The output voltage will be small when the wheel speed
or D range (A/T) is low, and similarly it will be large when the wheel speed
is high.

10.0 ms/DIV 1
V/DIV
 ABS <4WD> – On-vehicle Service 35B-23
Points In Waveform Measurement
Symptom Probable causes Remedy

Too small or zero waveform Faulty wheel speed sensor Replace sensor
amplitude

Waveform amplitude fluctuates Axle hub eccentric or with large runout Replace hub
excessively (this is no problem
roblem if
the minimum amplitude is 100 mV
Faulty ABS-ECU earth Repair
or more)

Noisy or disturbed waveform Open circuit in sensor Replace sensor

Open circuit in harness Correct harness

Incorrectly mounted wheel speed sensor Mount correctly

ABS rotor with missing or damaged teeth Replace ABS rotor

Caution
Because the wheel speed sensor cables move together with the front and rear suspension, they vibrate
greatly when driving over poor road surfaces. As a result, the sensor harnesses should also be shaken
when monitoring of output waveforms of the wheel speed sensors in order to simulate conditions such
as driving over poor road surfaces.

<L.H. drive vehicles> ABS WARNING LAMP RELAY CONTINUITY

CHECK
Hydraulic unit
and ABS-ECU
Battery voltage Terminal No.

1 2 3 5

Power is not
supplied

Power is supplied

<R.H. drive vehicles>

Hydraulic unit
and ABS-ECU
35B-24 ABS <4WD> – On-vehicle Service

HYDRAULIC UNIT CHECK

1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points
or place the wheels which are checked on the rollers of the braking force tester.
Caution
(1) The roller of the braking force tester and the tyre should be dry during testing.
(2) When testing the front brakes, apply the parking brake, and when testing the rear brakes,
stop the front wheels by chocking them.
2. Turn the ignition key to the LOCK (OFF) position and set the MUT-II.
Caution
Turn the ignition key to the LOCK (OFF) position before connecting or disconnecting the MUT-II.
3. After checking that the shift lever <M/T> or the selector lever <A/T> is in neutral, start the engine.
4. Use the MUT-II to force-drive the actuator.
NOTE
(1) During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be
cancelled.
(2) When the ABS has been interrupted by the fail-safe function, the MUT-II actuator testing cannot
be used.
5. Turn the wheel by hand and check the change in braking force when the brake pedal is depressed.
When using the braking force tester, depress the brake pedal until the braking force is at the following
values, and check that the braking force decreases when the actuator is force-driven.

Front wheel 785 – 981 N

Rear wheel 588 – 784 N

The result should be as shown in the following diagram.

Depressed
Pedal operation
Released
MUT-II actuator test
(Item No. 01, 02, 03, 04) start
Increase in pressure
Solenoid valve
position Steady pressure
2 seconds
Reduction in pressure
1 seconds
Approx. 0.05 seconds
Checking the Lock
brake force
Drag force when the pedal is free
 ABS <4WD> – On-vehicle Service 35B-25
6. If the result of inspection is abnormal, correct according to the “Diagnosis Table”.
Diagnosis Table
No. Operation Judgement Judgement Probable cause Remedy
– Normal – Abnormal

01 (1) Depress brake pedal Brake force Wheel does not Clogged brake Check and clean
to lock wheel. released for 3 lock when brake line other than brake line
(2) Using the MUT-II, seconds after pedal is de- hydraulic unit
select the wheel to be locking
locking. pressed
pressed.
02 checked and force the Clogged hydrau- Replace hydrau-
actuator to operate. lic circuit in lic unit assembly
(3) Turn the selected hydraulic unit
wheel manually to
03 check the change of Brake force is Incorrect hydrau- Connect correct-
brake force. not released lic unit brake ly
tube connection

04 Hydraulic unit Replace hydrau-

solenoid valve lic unit assembly
not functioning
correctly

7. After inspection, disconnect the MUT-II immediately after turning the ignition switch to OFF.

REMEDY FOR A FLAT BATTERY

When booster cables are used to start the engine when the
battery is completely flat and then the vehicle is immediately
driven without waiting for the battery to recharge itself to some
extent, the engine may misfire, and driving might not be
possible.
This happens because ABS consumes a great amount of
current for its self-check function; the remedy is to either allow
the battery to recharge sufficiently, or to disconnect the
ABS-ECU connector, thus disabling the anti-skid brake system.
The ABS warning lamp will illuminate when the ABS-ECU
connector is disconnected.
After the battery has sufficiently recharged, connect the
ABS-ECU connector and restart the engine; then check to
be sure the ABS warning lamp is not illuminated.

DISCONNECTING ABS-ECU CONNECTOR

Lock lever
Move the lock lever of the ABS-ECU connector as shown
in the illustration, and then disconnect the ABS-ECU connector.

Hydraulic unit and

ABS-ECU
35B-26 ABS <4WD> – Hydraulic Unit and ABS-ECU

HYDRAULIC UNIT AND ABS-ECU

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Brake Fluid Draining D Brake Fluid Supplying and Brake Line Bleeding
D Air Cleaner Removal (Refer to GROUP 15.) (Refer to GROUP 35A – On-vehicle Service.)
D Hydraulic Unit Inspection (Refer to P.35B-24.)
D Air Cleaner Installation (Refer to GROUP 15.)

<L.H. drive vehicles>

3
3
4

15 Nm

1
 ABS <4WD> – Hydraulic Unit and ABS-ECU 35B-27
<R.H. drive vehicles>

3
3

15 Nm

Removal steps
1. ABS warning lamp relay AB" 4. Hydraulic unit and ABS-ECU
AA" 2. Harness connector 5. Hydraulic unit bracket assembly
"AA 3. Brake pipe connection

REMOVAL SERVICE POINTS

Lock lever
AA" HARNESS CONNECTOR DISCONNECTION
Move the lock lever of the ABS-ECU connector as shown
in the illustration, and then disconnect the harness connector.

Hydraulic unit
and ABS-ECU
35B-28 ABS <4WD> – Hydraulic Unit and ABS-ECU

AB" HYDRAULIC UNIT AND ABS-ECU REMOVAL

Caution
1. The hydraulic unit assembly is heavy, and so care
should be taken when removing it.
2. The hydraulic unit assembly is not to be disassembled;
its nuts and bolts should absolutely not be loosened.
3. The hydraulic unit assembly must not be dropped
or otherwise subjected to impact shocks.
4. The hydraulic unit assembly must not be turned upside
down or laid on its side.
INSTALLATION SERVICE POINT
5 1 2
6 "AA BRAKE PIPE CONNECTION
Connect the pipes to the hydraulic unit assembly as shown
3 in the illustration.
1. To the proportioning valve (Rear brake, LH)
4 2. To the proportioning valve (Rear brake, RH)
3. From the master cylinder (Primary)
4. From the master cylinder (Secondary)
5. To the front brake (RH)
6. To the front brake (LH)
 ABS <4WD> – Wheel Speed Sensor 35B-29
WHEEL SPEED SENSOR
REMOVAL AND INSTALLATION
Post-installation Operation
Wheel Speed Sensor Output Voltage Check
(Refer to P.35B-22.)

<FRONT> <REAR> 3

1
4

AA" 1. Front wheel speed sensor

2. Front ABS rotor (Refer to GROUP NOTE
26 – Drive Shaft.) The front ABS rotor is integrated with the drive shaft. Do
AA" 3. Rear wheel speed sensor not disassemble it.
4. Rear ABS rotor (Refer to GROUP
27 – Axle Shaft.)

REMOVAL SERVICE POINT

AA" FRONT WHEEL SPEED SENSOR/REAR WHEEL
SPEED SENSOR REMOVAL
Caution
Do not strike the pole piece at the tip of the wheel speed
sensor against the ABS rotor tooth surface or other parts
when removing the wheel speed sensor.
Pole piece
35B-30 ABS <4WD> – Wheel Speed Sensor

INSPECTION
CHECK OF RESISTANCE BETWEEN WHEEL SPEED
SENSOR TERMINALS
Caution
The pole piece can become magnetized because of the
magnet built into the wheel speed sensor, with the result
that metallic foreign material easily adheres to it. Moreover,
the pole piece may not be able to function to correctly
sense the wheel rotation speed if it is damaged.

1. Measure the resistance between the wheel speed sensor

terminals.
Standard value: 1.30 – 1.58 kΩ
If the internal resistance of the wheel speed sensor is
not within the standard value, replace with a new wheel
speed sensor.
2. Check the wheel speed sensor cable for breakage, damage
or disconnection; replace with a new one if a problem
is found.
NOTE
When checking for cable damage, remove the cable clamp
part from the body and then bend and pull the cable near
the clamp to check whether or not temporary disconnection
occurs.

WHEEL SPEED SENSOR INSULATION INSPECTION

1. Remove all connections from the wheel speed sensor,
and then measure the resistance between terminals 1
and 2 and the body of the wheel speed sensor.
Standard value: 100 kΩ or more
2. If the speed sensor insulation resistance is outside the
standard value range, replace with a new speed sensor.

ABS ROTOR CHECK

Check whether ABS rotor teeth are broken or deformed, and,
if so, replace the B.J. assembly or the ABS rotor.
 ABS <4WD> – G Sensor 35B-31
G SENSOR
REMOVAL AND INSTALLATION
Caution
Do not drop the G sensor or subject it to any shocks.

Pre-removal and Post-installation Operation

Rear floor console removal and installation
(Refer to Group 52A.)

5 Nm

G sensor

INSPECTION
1. Remove the G sensor.
Label
2. Connect the special tool between the disconnected
connectors, and then place the G sensor horizontally as
shown in the illustration.
3. Turn on the ignition switch, and then measure the voltage
between terminal No.2 and body earth.
Standard value: 2.4 – 2.6 V
MB991348

4. Face the labeled surface straight down with the special

Label tool still connected. Measure the voltage between terminal
No.2 and body earth with the labeled surface faced straight
down.
Standard value: 3.3 – 3.7 V
5. If not within the standard value, check the power supply
line and earth condition, and then replace the G sensor.
NOTES
 35B-1

ANTI-SKID
BRAKING SYSTEM
(ABS) <4WD>
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 14

Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wheel Speed Sensor Output Voltage Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
HYDRAULIC UNIT AND ABS-ECU . . . . . . . . . 15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5
35B-2 ABS <4WD> – General/General Information

GENERAL
OUTLINE OF CHANGES
 The hydraulic unit (integrated with the ABS-ECU) has been reshaped. In addition, the troubleshooting
has been changed due to the change on the ABS-ECU connector.
 The Electronic Brake-force Distribution (EBD) has been adopted. The EBD makes it possible to maintain
the maximum amount of braking force for the rear wheels even when the vehicle’s load is unevenly
distributed

GENERAL INFORMATION
EBD CONTROL
In ABS, electronic control method is used whereby laden condition and the condition of the road
the rear wheel brake hydraulic pressure during brak- surface, the system reduces the required pedal
ing is regulated by rear wheel control solenoid valves depression force, particularly when the vehicle
in accordance with the vehicle’s rate of deceleration is heavily laden or driving on road surfaces with
and the front and rear wheel slippage which are high frictional coefficients.
calculated from the signals received from the various  Because the duty placed on the front brakes
wheel sensors. EBD control is a control system has been reduced, the increases in pad temper-
which provides a high level of control for both vehicle ature can be controlled during front brakes ap-
braking force and vehicle stability. The system has plying to improve the wear resistance character-
the following features. istics of the pad.
 Because the system provides the optimum rear  Control valves such as the proportioning valve
wheel braking force regardless of the vehicle are no longer required.

HYDRAULIC UNIT
New Old
Hydraulic unit

Hydraulic unit
 ABS<4WD> – General Information 35B-3
ABS-ECU
EBD HYDRAULIC PRESSURE CONTROL
The procedures are the same as that used in PAJERO except for the items shown below.
Item PAJERO-PININ PAJERO
EBD control condition When the difference between the rear When the difference between the
wheel speed and the vehicle speed rear wheel speed and the front
exceeds the set value. wheel speed exceeds the set
value.

<PAJERO-PININ>

Front wheel
Rear wheel speed sensor
speed sensor
Vehicle speed

EBD control
Set value of
EBD slip ratio

Speed

Set value of
ABS slip ratio

ABS control (Rear wheel)

ABS control (Front wheel)

Time

<PAJERO>

Front wheel
Rear wheel speed sensor
speed sensor
Vehicle speed

Set value of
EBD slip ratio

Speed

Set value of
EBD control ABS slip ratio

ABS control (Rear wheel)

ABS control (Front wheel)

Time
35B-4 ABS<4WD> – General Information

FAIL-SAFE FUNCTION
The procedures are the same as that used in PAJERO except for the items shown below.
Item PAJERO-PININ PAJERO
Warning lamp during fail-safe opera- ABS warning lamp Brake warning lamp
tion

Diagnosis
g Item Action during fail-safe operation
code
d No.
N ABS control EBD control ABS warn-
ing lamp
11 Open circuit or short-circuit in If faulty wheels include If faulty wheels include Illuminated
wheel speed sensor (FR) two rear wheels: two rear wheels:
12 Open circuit or short-circuit in C t l stopped
Control t d iin allll C t l stopped
Control t d
wheel speed sensor (FL) wheels Other than the above:
Other than the above: Control carried out
13 Open circuit or short-circuit in Control stopped in faulty
wheel speed sensor (RR) wheels
14 Open circuit or short-circuit in
wheel speed sensor (RL)
15 Problem with any one of the
four wheel speed sensors
16 Abnormal drop or rise in Control stopped Control stopped Illuminated
ABS-ECU power supply volt-
age
21 Wheel speed sensor (FR) If faulty wheels include If faulty wheels include Illuminated
system two rear wheels: two rear wheels:
22 Wheel speed sensor (FL) C t l stopped
Control t d iin allll C t l stopped
Control t d
system wheels Other than the above:
Other than the above: Control carried out
23 Wheel speed sensor (RR) Control stopped in faulty
system wheels
24 Wheel speed sensor (RL)
system
32 G sensor system Control stopped Control carried out Illuminated
33 Stop lamp switch system Control stopped Control carried out Illuminated
41 Solenoid valve (FR) system System
y interrupted System
y interrupted Illuminated
42 Solenoid valve (FL) system
43 Solenoid valve (RR) system
44 Solenoid valve (RL) system
51 Valve relay ON problem Control stopped Control carried out Illuminated
52 Valve relay OFF problem System interrupted System interrupted Illuminated
53 Motor relay OFF problem Control stopped Control carried out Illuminated
54 Motor relay ON problem System interrupted Control carried out Illuminated
55 Motor system Control stopped Control carried out Illuminated
63 ABS-ECU abnormality System interrupted System interrupted Illuminated

NOTE
Control stopped: Control is not carried out until the ignition switch is turned to the “LOCK” (OFF) position.
However, if the problem returns to normal, control is carried out again.
System interrupted: Control is not carried out until the valve relay turns off and the ignition switch is turned
to the “LOCK” (OFF) position.
 ABS <4WD> – Troubleshooting 35B-5
TROUBLESHOOTING
INSPECTION CHART FOR DIAGNOSIS CODES

Diagnosis code No. Inspection item Reference page

11 Front right wheel speed sensor (Open circuit or short circuit) 35B-6

12 Front left wheel speed sensor (Open circuit or short circuit) 35B-6

13 Rear right wheel speed sensor (Open circuit or short circuit) 35B-6

14 Rear left wheel speed sensor (Open circuit or short circuit) 35B-6

15 Wheel speed sensor (Abnormal output signal) –

16* ABS-ECU power supply system (Abnormal voltage drop or rise) 35B-7

21 Front right wheel speed sensor 35B-6

22 Front left wheel speed sensor 35B-6

23 Rear right wheel speed sensor 35B-6

24 Rear left wheel speed sensor 35B-6

32 G sensor system 35B-7

33 Stop lamp switch system –

41 Front right solenoid valve The diagnosis codes are output 35B-8
when there is no response to the
42 Front left solenoid valve drive signals for respective solenoid
valves or the ABS-ECU
ABS ECU power
43 Rear right solenoid valve supply system is defective.
44 Rear left solenoid valve

51 Valve relay problem (stays on) –

52 Valve relay problem (stays off) or ABS-ECU power supply system 35B-8
problem

53 Motor relay problem (stays off) or ABS-ECU power supply system

problem

54 Motor relay problem (stays on) –

55 Motor system (seized pump motor) or ABS-ECU power supply system 35B-8
problem

63 ABS-ECU –

NOTE
*: Turning the ignition switch to ACC will erase the diagnosis code No.16.
35B-6 ABS <4WD> – Troubleshooting

INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code Nos.11, 12, 13 and 14 Wheel speed sensor Probable cause
(open circuit or short circuit)
Code Nos.21, 22, 23 and 24 Wheel speed sensor
Code Nos. 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit  Malfunction of wheel speed sensor
or short-circuit in the (+) wire or (–) wire in any one of the four wheel speed sensors.  Malfunction of wiring harness or connector
 Malfunction of hydraulic unit and ABS-ECU
Code Nos. 21, 22, 23 and 24 are output in the following cases.  Malfunction of wheel speed sensor
 When there is no input from any one of the four wheel speed sensors when  Malfunction of wiring harness or connector
travelling at several km/h or more, even though open circuit can not be verified.  Malfunction of ABS rotor
 When a chipped or blocked-up ABS rotor is detected and if the anti-lock system  Too much gap between the sensor and the ABS rotor
operates continuously because a malfunctioning sensor or a warped ABS rotor  Malfunction of hydraulic unit and ABS-ECU
is causing sensor output to drop.  Malfunction of wheel bearing

NG
Wheel speed sensor installation check Repair
OK
NG
Measure at the ABS-ECU connector A-58. Wheel speed sensor check
 Disconnect the connector, and measure at the harness side OK NG
connector.
 Resistances between 26 and 27, 4 and 5, 2 and 1, 24 and Replace
23
OK: 1.30 – 1.58 kΩ
Check the following connectors:
OK A-58, C-25<L.H. drive vehicles>, C-24<R.H. drive vehicles>, A-24,
A-85, D-24, D-28
Wheel speed sensor output voltage check (Refer to P.35B-14.)
OK NG
OK NG
NG
Wheel speed sensor Replace Check the trouble symp-
check tom. Repair
NG
OK
NG Check the harness wire, and repair if necessary.
ABS rotor check Replace  Between each wheel speed sensor and ABS-ECU

OK

Wheel bearing check

(Refer to GROUP 26 and
GROUP 27 – On-vehicle
Service.)

Check the following connector: A-58

OK NG

Check the trouble symp- Repair

tom.
NG

Replace the hydraulic unit and ABS-ECU.

 ABS <4WD> – Troubleshooting 35B-7
Code No.16 ABS-ECU power supply system (abnormal Probable cause
voltage drop or rise)
This code is output if the ABS-ECU power supply voltage drops below or rises  Malfunction of battery
above the rated values.  Malfunction of wiring harness or connector
Furthermore, turning the ignition switch to ACC will erase this code.  Malfunction of hydraulic unit and ABS-ECU

Caution
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage
returns to standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, C-40 <R.H. drive
 Disconnect the connector, and measure at the harness side vehicles>, C-02 <R.H. drive vehicles>, C-78 <L.H. drive vehicles>,
connector. C-76 <R.H. drive vehicles>, C-74
 Start the engine. Voltage between 32 and body earth
OK NG
OK: System voltage
OK
Check the trouble symp- Repair
Check the following connector: A-58 tom.
OK NG
NG
Check the trouble symp- Repair
tom.
Check the harness wire, and repair if necessary.
NG  Between ignition switch and ABS-ECU
Replace the hydraulic unit and ABS-ECU.
35B-8 ABS <4WD> – Troubleshooting

Code No.32 G sensor system Probable cause

This code is output in the following cases.  Malfunction of G sensor
 G sensor output voltage is less than 0.5 V or more than 4.5 V. (An open or  Malfunction of wiring harness or connector
short circuit is present in the G sensor circuit.)  Malfunction of hydraulic unit and ABS-ECU
 G sensor output voltage does not change. (G sensor output voltage is abnormal.)

NG
G sensor check Replace
OK

NG
Measure at the G sensor connector D-29. Check the following connector: D-29
 Disconnect the connector, and measure at the harness side
connector. OK NG
 Ignition switch: ON
 Voltage between 1 and body earth Check the trouble symp- Repair
OK: System voltage tom.
NG
OK
Check the harness wire, and repair if necessary.
 Between ignition switch and G sensor

NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, C-25 <L.H. drive
 Disconnect the connector, and measure at the harness side vehicles>, D-29
connector.
 Ignition switch: ON OK NG
 Voltage between 9 and 6
OK: 2.4 – 2.6 V (When labeled surface is faced to vertical Check the trouble symp- Repair
direction) tom.

OK NG

Check the following connector: A-58 Check the harness wire, and repair if necessary.
OK NG  Between G sensor and ABS-ECU

Check the trouble symp- Repair

tom.
NG

Replace the hydraulic unit and ABS-ECU.

Code Nos.41, 42, 43 and 44 Solenoid valve Probable cause

Code No.52 Valve relay problem (stays off)
Code No.53 Motor relay problem (stays off)
Code No.55 Motor system (seized pump motor)
These codes are output if there is an open circuit or short-circuit in the ABS-ECU  Malfunction of wiring harness or connector
power supply circuit (power supply circuit for solenoid valve and motor), or the internal  Malfunction of hydraulic unit and ABS-ECU
circuit in the hydraulic unit and ABS-ECU is defective.

NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, C-24 <R.H. drive
 Disconnect the connector, and measure at the harness side vehicles>
connector.
 Voltage between 34 and body earth, and between 12 and OK NG
body earth
OK: System voltage Check the trouble symp-
tom. Repair
OK
NG

Check the following connector: A-58 Check the harness wire, and repair if necessary.
 Between fusible link No.1 and ABS-ECU
OK NG

Repair
Check the trouble symp-
tom.
NG

Replace the hydraulic unit and ABS-ECU.

 ABS <4WD> – Troubleshooting 35B-9
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptoms Inspection procedure Reference page
No.

Communication between the MUT-II and the whole system is not 1 –

possible.

Communication between the MUT-II and the ABS-ECU is not possible. 2 35B-10

When the ignition key is turned to “ON” (engine stopped), the ABS warning 3 –
lamp does not illuminate.

Even after the engine is started, the ABS warning lamp remains 4 35B-11
illuminated.

Faulty ABS operation 5 35B-12

Caution
1. If steering movements are made when driving at high speed, or when driving on road surfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, when getting information from the customer,
check if the problem occurred while driving under such conditions as these.
2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.
35B-10 ABS <4WD> – Troubleshooting

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 2
Communication between MUT-II and the ABS-ECU is not Probable cause
possible.
The cause may be an open circuit in the ABS-ECU power supply circuit or an open  Blown fuse
circuit in the diagnosis output circuit.  Malfunction of wiring harness or connector
 Malfunction of hydraulic unit and ABS-ECU

NG
Measure at the diagnosis connector C-35 and the ABS-ECU con- Check the following connectors: A-58, C-28 <L.H. drive
nector A-58. vehicles>, C-40 <R.H. drive vehicles>, C-70, C-35
 Disconnect the connectors, and measure at the harness side
connectors. OK NG
 Continuity between the following terminals
ABS-ECU side – Diagnosis connector side Check the trouble symp- Repair
19 – 1 tom.
21 – 7 NG
OK: Continuity
Check the harness wire, and repair if necessary.
OK  Between ABS-ECU and diagnosis connector

NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, C-40 <R.H. drive
 Disconnect the connector, and measure at the harness side vehicles>, C-02 <R.H. drive vehicles>, C-78 <L.H. drive vehicles>,
connector. C-76 <R.H. drive vehicles>, C-74
 Ignition switch: ON
 Voltage between 32 and body earth OK NG
OK: System voltage
Repair
Check the trouble symp-
OK tom.
NG

Check the harness wire, and repair if necessary.

 Between ignition switch and ABS-ECU

Measure at the ABS-ECU connector A-58. NG

Check the following connector: A-58
 Disconnect the connector, and measure at the harness side
connector. OK NG
 Continuity between 33 and body earth, and between 11 and
body earth Check the trouble symp- Repair
OK: Continuity tom.
NG
OK

Check the following connector: A-58 Check the harness wire, and repair if necessary.
 Between ABS-ECU and earth
OK NG
Check the trouble symp- Repair
tom.
NG

Replace the hydraulic unit and ABS-ECU.

 ABS <4WD> – Troubleshooting 35B-11
Inspection Procedure 4
Even after the engine is started, the ABS warning lamp Probable cause
remains illuminated.
The cause is probably a short-circuit in the ABS warning lamp illumination circuit.  Malfunction of combination meter
 Malfunction of ABS warning lamp relay
 Malfunction of wiring harness (short circuit)
 Malfunction of hydraulic unit and ABS-ECU

NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible (ABS-ECU
power supply is normal) and the diagnosis code is a normal diagnosis code.
YES
Does the ABS warning lamp stay illuminated when the combination Replace the combination meter.
meter connector C-07 is disconnected and the ignition switch
is turned to ON?
NO
NG
ABS warning lamp relay check Replace the ABS warning lamp relay.
OK
YES
Does the ABS warning lamp stay illuminated when the ABS warning Check the harness wire, and repair if necessary.
lamp relay connector A-57 is disconnected and the ignition switch  Between combination meter and ABS warning lamp relay
is turned to ON?
NO
NG
Measure at the ABS warning lamp relay connector A-57. Check the following connector: A-57
 Disconnect the connector, and measure at the harness side
OK NG
connector.
 Ignition switch: ON Check the trouble symp-
 Voltage between 5 and body earth Repair
tom.
OK: System voltage
NG
OK
Check the harness wire, and repair if necessary.
 Between ignition switch and ABS warning lamp relay

NG
Measure at the ABS-ECU connector A-58. Check the following connectors: A-58, A-57
 Ignition switch: ON OK NG
 Voltage between 22 and body earth
OK: System voltage Check the trouble symp- Repair
OK tom.
NG
Replace the hydraulic unit and ABS-ECU.
Check the harness wire, and repair if necessary.
 Between ABS warning lamp relay and ABS-ECU
35B-12 ABS <4WD> – Troubleshooting

Inspection Procedure 5
Faulty ABS operation Probable cause
This varies depending on the driving conditions and the road surface conditions,  Improper installation of wheel speed sensor
so problem diagnosis is difficult. However, if a normal diagnosis code is displayed,  Malfunction of wiring harness or connector
carry out the following inspection.  Malfunction of wheel speed sensor
 Malfunction of ABS rotor
 Foreign material adhering to wheel speed sensor
 Malfunction of wheel bearing
 Malfunction of hydraulic unit and ABS-ECU

NG
Wheel speed sensor installation check Repair
OK
OK
Wheel speed sensor output voltage check (Refer to P.35B-14.) Hydraulic unit check
NG
NG
Wheel speed sensor check Replace the wheel speed sensor.
OK
NG
ABS rotor check Repair
OK
NG
Wheel bearing check (Refer to GROUP 26 and GROUP 27 – Repair
On-vehicle Service.)
OK
NG
Check the following connectors: Repair
A-58, C-25 <L.H. drive vehicles>, C-24 <R.H. drive vehicles>,
A-24, A-85, D-24, D-28
OK

Check the trouble symptom.

NG
NG
Measure at the ABS-ECU connector A-58. Check the harness wire.
 Disconnect the connector, and measure at the harness side  Between each wheel speed sensor and ABS-ECU
connector.
 Resistances between 26 and 27, 4 and 5, 24 and 23, 2 and
1
OK: 1.30 – 1.58 kΩ
(The sensor harness and connector should be moved while
these inspections are carried out.)
OK
NG Repair
Check the following connector: A-58
OK
Check the trouble symptom.
NG
Replace the hydraulic unit and ABS-ECU.
 ABS <4WD> – Troubleshooting 35B-13
CHECK AT ABS-ECU
TERMINAL VOLTAGE CHECK CHART
1. Measure the voltages between the respective terminal
and earth.
2. The terminal layout is shown in the illustration.

Terminal No. Check item Checking requirements Normal condition

3 Stop lamp switch input Ignition switch: ON Stop lamp switch: ON System voltage

Stop lamp switch: OFF 1 V or less

6 G sensor earth Always 0V

9 Input
In ut from G sensor Ignition switch: ON 2.4 – 2.6 V
Vehicle is horizontal
12 Solenoid valve power Always System voltage
supply

19 Diagnosis changeover When the MUT-II is connected 0V

input
When the MUT-II is not connected Approx. 12 V

21 MUT-II When the MUT-II is connected Serial communication

with MUT-II

When the MUT-II is not connected 1 V or less

22 ABS warning lamp Ignition switch: ON When the lamp is 2 V or less

relay transistor output switched off

When the lamp is illu- System voltage

minated

32 ABS-ECU power Ignition switch: ON System voltage

supply
Ignition switch: START 0V

34 Motor power supply Always System voltage

RESISTANCE AND CONTINUITY BETWEEN

HARNESS-SIDE CONNECTOR TERMINALS
1. Turn the ignition key to the LOCK (OFF) position.
2. Disconnect the ABS-ECU connector.
3. Check the resistance and continuity between the terminals
indicated in the table below.
4. The terminal layout is shown in the illustration.
35B-14 ABS <4WD> – Troubleshooting/On-vehicle Service

ABS-ECU terminal No. Signal Normal condition

1–2 Wheel speed sensor (rear left) 1.30 – 1.58 kΩ

23 – 24 Wheel speed sensor (rear right)

4–5 Wheel speed sensor (front left)

26 – 27 Wheel speed sensor (front right)

11 – Body earth Earth Continuity

33 – Body earth Earth

ON-VEHICLE SERVICE
WHEEL SPEED SENSOR OUTPUT VOLTAGE
CHECK
1. Lift up the vehicle and release the parking brake.
2. Disconnect the ABS-ECU connector.
3. Rotate the wheel to be measured at approximately 1/2–1
rotation per second, and check the output voltage using a
circuit tester or an oscilloscope.
Wheel speed Front Front Rear left Rear
sensor left right right
Terminal No. 4 26 2 24
5 27 1 23

Output voltage
When measuring with a circuit tester:
42 mV or more
When measuring with an oscilloscope:
120 mV p-p or more
4. The followings are suspected if the output voltage is lower
than the value described above. Check the wheel speed
sensor, and replace if necessary.
 Too large clearance between the pole piece of the
wheel speed sensor and ABS rotor
 Faulty wheel speed sensor
 ABS <4WD> – Hydraulic Unit and ABS-ECU 35B-15
HYDRAULIC UNIT AND ABS-ECU
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
 Brake Fluid Draining  Brake Fluid Supplying and Brake Line Bleeding
 Air Cleaner Removal (Refer to GROUP 15.) (Refer to GROUP 35A – On-vehicle Service.)
 Hydraulic Unit Inspection
 Air Cleaner Installation (Refer to GROUP 15.)

<L.H. drive vehicles>

3

4
15 Nm

3
2

1
35B-16 ABS <4WD> – Hydraulic Unit and ABS-ECU

<R.H. drive vehicles>

15 Nm

3
3
2

1 5

Removal steps
1. ABS warning lamp relay 5. Hydraulic unit bracket assembly
A 2. Harness connector
A 3. Brake pipe connection NOTE
B 4. Hydraulic unit and ABS-ECU The removal service points are the same as before.

3 2 1 INSTALLATION SERVICE POINT

4 A BRAKE PIPE CONNECTION
6
Connect the pipes to the hydraulic unit assembly as shown
in the illustration.
1. To the front brake (L.H.)
2. To the proportioning valve (Rear brake, R.H.)
3. To the proportioning valve (Rear brake, L.H.)
4. From the master cylinder (Primary)
5 5. From the master cylinder (Secondary)
6. To the front brake (R.H.)
PARKING BRAKES
Click on the applicable bookmark to selected the required model year
 36-1

PARKING BRAKES
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Parking Brake Switch Check . . . . . . . . . . . . . . . . . . . 4

Lining Runing-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . 5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PARKING BRAKE CABLE . . . . . . . . . . . . . . . . . . 6
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3
Parking Brake Lever Stroke Check and PARKING BRAKE DRUM . . . . . . . . . . . . . . . . . . . 8
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
36-2 PARKING BRAKES – General Information/Service Specifications/Lubricants

GENERAL INFORMATION
The parking brake is of a mechanical control type
acting on the rear wheels. A lever is used to apply
the parking brake.

CONSTRUCTION DIAGRAM

Parking brake lever

Parking brake cable

SERVICE SPECIFICATIONS
Items Standard value Limit

Parking brake lever stroke 3 – 5 notches –

Rear brake lining thickness mm 2.8 1.0

Rear drum inside diameter mm 168.0 169.0

LUBRICANTS
Items Specified lubricants

Backing plate Multipurpose grease

Shoe and lining assembly

Adjuster
 PARKING BRAKES – On-Vehicle Service 36-3

Parking brake lever ON-VEHICLE SERVICE

PARKING BRAKE LEVER STROKE CHECK
AND ADJUSTMENT
1. Pull the parking brake lever with a force of approx. 196
N and count the number of notches.
Adjusting nut
Standard value: 3 – 5 notches

2. If the parking brake lever stroke is not the standard value,

adjust as described below.
(1) Remove the rear floor console, and then loosen the
adjusting nut to move it to the cable rod end so that
the cable will be free.
(2) Remove the rear wheels.

(3) Remove the adjustment hole plug, and then use a

Adjuster flat-tip (–) screwdriver to turn the adjuster in the
direction of the arrow (the direction which expands
the shoe) so that the disc will not rotate.
Return the adjuster five notches in the direction
opposite to the direction of the arrow.

(4) Turn the adjusting nut to adjust the parking brake lever
Parking brake lever stroke to the standard value. After adjusting, check that
there is no space between the adjusting nut and the
parking brake lever.
Caution
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
Adjusting nut rear brakes may drag.
(5) Release the parking brake and turn the rear wheels
to check that the rear brakes are not dragging.
36-4 PARKING BRAKES – On-Vehicle Service

PARKING BRAKE SWITCH CHECK

Check for continuity between the parking brake switch terminal
and the switch mounting bolt.

When parking brake lever is pulled Continuity

When parking brake lever is released No continuity

Pull LINING RUNNING-IN

Carry out running-in by the following procedure when replacing
the parking brake linings or the rear brake disc rotors, or when
Spring balance brake performance is insufficient.
Caution
Carry out running-in in a place with good visibility, and
pay careful attention to safety.
Approx.
40 mm 1. Adjust the parking brake stroke to the specified value.
Standard value [Operation force: Approx. 196 N] : 3
– 5 notches
2. Hook a spring balance onto the centre of the parking brake
lever grip and pull it with a force of 98 – 147 N in a direction
perpendicular to the handle.
3. Drive the vehicle at a constant speed of 35 – 50 km/h
for 100 metres.
4. Release the parking brake and let the brakes cool for
5 – 10 minutes.
5. Repeat the procedure in steps 2. to 4. 4 – 5 times.
 PARKING BRAKES – Parking Brake Lever 36-5
PARKING BRAKE LEVER
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Rear Floor Console Removal D Parking Brake Lever Stroke Adjustment
(Refer to GROUP 52A.) (Refer to P.36-3.)
D Rear Floor Console Installation
(Refer to GROUP 52A.)

1
2

Ratchet plate
A Section A – A Section B – B

A
B

Ratchet
pawl
B

Removal steps
1. Adjusting nut 4. Parking brake lever assembly
2. Nut holder 5. Parking brake switch
3. Parking brake front cable assembly
connection
36-6 PARKING BRAKES – Parking Brake Cable

PARKING BRAKE CABLE

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Rear Floor Console Removal D Parking Brake Lever Stroke Check and Adjustment
(Refer to GROUP 52A.) (Refer to P.36-3.)
D Rear Floor Console Installation
(Refer to GROUP 52A.)

12

55 – 65 Nm

13 1
2

12

11
3
6

10 7

4
9
8 5

Removal steps
AA" 1. Rear brake caliper assembly AB" 8. Shoe hold-down cup
2. Rear brake disc 9. Shoe hold-down spring
"BA 3. Shoe-to-anchor spring 10. Shoe hold-down pin
4. Adjusting screw spring 11. Shoe and lining assembly
"AA 5. Adjuster 12. Clip
6. Strut 13. Parking brake cable
7. Strut return spring
 PARKING BRAKES – Parking Brake Cable 36-7
REMOVAL SERVICE POINTS
AA" REAR BRAKE CALIPER ASSEMBLY REMOVAL
Remove the rear brake caliper assembly and support it with
wire or similar.

AB" SHOE HOLD-DOWN CUP REMOVAL

Shoe hold-down cup Extend the shoe and lining assembly, and remove the shoe
hold-down cup.

INSTALLATION SERVICE POINTS

"AA ADJUSTER INSTALLATION
Install the adjuster so that the shoe adjusting bolt of left hand
wheel is attached towards the front of the vehicle, and the
shoe adjusting bolt of right hand wheel is towards the rear
of the vehicle.

Shoe adjusting
bolt

"BA SHOE-TO-ANCHOR SPRING INSTALLATION

Install the shoe-to-anchor springs in the order shown in the
illustration.
Caution
The load on the respective shoe-to-anchor springs is
different, so the spring in the figure has been painted.
Rear NOTE
The figure shows the left wheel; for the right wheel, the position
1 2 (Painted)
is symmetrical.
36-8 PARKING BRAKES – Parking Brake Drum

PARKING BRAKE DRUM

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Drive Shaft Removal (Refer to GROUP 27B.) D Drive Shaft Installation (Refer to GROUP 27B.)
D Parking Brake Lever Stroke Check and Adjustment
(Refer to P.36-3.)

55 – 65 Nm
1

2
9 10

8
5 7
6
11 12
13
10
8 4 3
7

13 10

10 4

Brake grease: Multipurpose grease

Removal steps
1. Rear brake caliper assembly 7. Shoe hold-down cup
(Refer to P.36-7) (Refer to P.36-7)
2. Shoe-to-anchor spring 8. Shoe hold-down spring
(Refer to P.36-7) 9. Shoe hold-down pin
3. Adjusting screw spring 10. Shoe and lining assembly
4. Adjuster (Refer to P.36-7) 11. Clip
5. Strut 12. Parking brake cable
6. Strut return spring 13. Backing plate
PARKING BRAKES – Parking Brake Drum 36-9
INSPECTION
BRAKE LINING AND BRAKE DRUM CHECK
1. Measure the thickness of the brake lining at several places.
Standard value: 2.8 mm
Limit: 1.0 mm
2. If the thickness of the brake lining has worn down to the
limit value or more, replace the shoe and lining assemblies
on both sides of the vehicle.

3. Measure the inside diameter of the brake disc in two places

or more.
Standard value: 168.0 mm
Limit: 169.0 mm
4. If the inside of the brake disc has worn down to the limit
value or more, or if it is excessively worn on one side,
replace the brake disc.
NOTES
 PARKING BRAKES – General/Service Specifications/On-vehicle Service 36-1
GROUP 36
PARKING BRAKES
GENERAL
OUTLINE OF CHANGE
The following service procedures have been established due to the adoption of rear drum brake. <1800-MPI>
D Parking brake lever stroke check and adjustment
D Parking brake cable removal and installation

SERVICE SPECIFICATIONS
Items 1800-MPI

Standard value Limit

Parking brake lever stroke 5 – 7 notches –

Rear brake lining thickness mm 4.9 1.0

Rear drum inside diameter mm 228.6 230.6

Parking brake lever

ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE CHECK
AND ADJUSTMENT <1800-MPI>
LEVER STROKE CHECK (WITH FORCE OF 196 N
APPLIED)

Adjusting nut Standard value: 5 – 7 notches

LEVER STROKE ADJUSTMENT
1. Loosen the adjusting nut up to the cable end to free the
cable.
2. Depress the brake pedal hard two or three times.
NOTE
Depressing the brake pedal allows the shoe clearance
to be adjusted correctly.
3. Adjust the parking brake lever stroke. Then, jack up the
vehicle in its rear. Release the parking brake and rotate
the rear tyres to check that no drag exists.
36-2 PARKING BRAKES – Parking Brake Cable <1800-MPI>

PARKING BRAKE CABLE <1800-MPI>

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Rear Floor Console Removal D Parking Brake Lever Stroke Check
(Refer to P.36-1.)
D Rear Floor Console Installation

10

11

10
1

9
4 3

7 5
6

3
9 9 12
3

Brake grease: Multipurpose grease

Removal steps
1. Brake drum 7. Shoe hold-down spring
2. Shoe-to-lever spring 8. Shoe hold-down pin
3. Auto-adjuster assembly 9. Shoe and lining assembly
4. Shoe-to-shoe spring 10. Clip
5. Retainer spring 11. Parking brake cable
6. Shoe hold-down cup 12. Backing plate
 STEERING
Click on the applicable bookmark to selected the required model year
 37A-1

STEERING
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Oil Pump Belt Tension Check . . . . . . . . . . . . . . . . . . 8

Power Steering Fluid Level Check . . . . . . . . . . . . . 9
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4
Power Steering Fluid Replacement . . . . . . . . . . . . . 9
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power Steering System Bleeding . . . . . . . . . . . . . . . 9
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SEALANT AND ADHESIVE . . . . . . . . . . . . . . . . . 4
Power Steering Oil Pressure Switch Check . . . . 11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . 11

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 7 STEERING WHEEL AND SHAFT* . . . . . . . . . . 12

Steering Wheel Free Play Check . . . . . . . . . . . . . . . 7
POWER STEERING GEAR BOX AND
Steering Angle Check . . . . . . . . . . . . . . . . . . . . . . . . . 7 LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tie Rod End Ball Joint Starting Torque
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 POWER STEERING OIL PUMP . . . . . . . . . . . . 29
Stationary Steering Effort Check . . . . . . . . . . . . . . . 8
POWER STEERING OIL HOSES . . . . . . . . . . . 32
Steering Wheel Returnability Check . . . . . . . . . . . . 8

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from
rendering the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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-ECU, SRS warning lamp, 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 (*).
37A-2 STEERING – General Information

GENERAL INFORMATION
A 4-spoke type steering wheel has been mounted. The steering system uses a vane oil pump with
The power steering is an integral rack and pinion a fluid flow control system, so that steering effort
type that combines the steering gear and linkage varies with engine speed.
into one light-weight and compact assembly.

Item Specifications
Steering gear and linkage Type Integral type
Gear type Rack and pinion
Oil pump Type Vane type
mȏ/rev
Displacement mȏ/rev. 72
7.2
Relief set pressure Mpa 8.3 – 9.0

CONSTRUCTION DIAGRAM

<L.H. drive vehicles>

Oil pump Steering wheel

Oil reservoir Pressure hose

Suction hose

Return hose
Steering column and shaft

Steering gear box and linkage

 STEERING – General Information 37A-3
<R.H. drive vehicles>

Steering wheel

Steering column and shaft

Oil pump

Oil reservoir

Suction hose

Return hose
Pressure hose

Steering gear box and linkage

37A-4 STEERING – Service Specifications/Lubricants/Sealant and Adhesive

SERVICE SPECIFICATIONS
Item Standard value Limit
Steering wheel free play mm with engine running – 30 or less
with engine stopped 0 – 10 –
Steering angle Inner wheel 34_40’ ± 2_ –
Outer wheel 32_10’
32 10 –
<For reference>
Ball joint turning torque Nm 0.5 – 2.5 –
Stationary steering effort N Steering effort 27 or less 30 or less
Fluctuation allowance 5.9 or less –
Oil pump relief pressure MPa 88
8.8 –
Pressure under no-load condition MPa 0.2 – 0.7 –
Steering gear retention hydraulic pressure MPa 88
8.8 –
Oil pressure switch operating pressure MPa OFF → ON 1.5 – 2.0 –
ON→ OFF 0.7 – 2.0 –
Pinion total rotation torque Nm Total rotation torque 0.6 – 1.5 –
Torque variation 0.5 or less –
Tie rod joint swing resistance N (Tie rod joint swing torque Nm) 5 – 17 (1.5 – 4.9) –
Special tool aperture dimension (MB991561) mm 2.9 –
Band crimped width mm 2.4 – 2.8 –

LUBRICANTS
Item Specified lubricant Quantity
Power steering Automatic transmission fluid DEXRON or DEXRON II Approx. 0.6 ȏ
Tie rod bellows Silicone grease As required
Pinion and valve assembly Repair kit grease As required
Rack assembly Repair kit grease As required

SEALANT AND ADHESIVE

Item Specified sealant Remarks
R k support
Rack su ortt cover end
d plug
llug 3M ATD P
Partt N
No. 8661 or equivalent
i l t S i d i sealant
Semi-drying l t
Gear housing mounting rubber 3M ATD Part No. 8155 or equivalent Quick fix adhesive
 STEERING – Special Tools 37A-5
SPECIAL TOOLS
Tool Number Name Use
MB990635, Steering linkage Tie rod end disconnection
MB991113 or puller
MB991406

MB990326 Preload socket Ball joint turning torque measurement

MB990993 Power steering oil Oil pressure measurement

pressure gauge
adapter
(pump side)

MB990994 Power steering oil

pressure gauge
adapter
(hose side)

MB990662 Oil pressure gauge

assembly

MB990803 Steering wheel Steering wheel disconnection

puller

MB991006 Preload socket Total pinion torque measurement

MB991621 Rack support D Rack support cover removal

cover wrench D Total pinion torque adjustment
37A-6 STEERING – Special Tools

Tool Number Name Use

MB991197 Bar (long type) Gear housing oil seal press fitting

MB991199 Oil seal installer

MB991213 Oil seal protector Rack assembly installation

MB990925 Bearing and oil Oil seal and bearing press fitting
seal installer set (Refer to GROUP 26 – Special Tools.)

MB991203 Oil seal and Valve housing oil seal and bearing press
bearing installer fitting

MB991317 Seal ring installer Pinion seal ring compression

MB990941 Torque tube Valve housing lower oil seal press fitting
bearing installer

MB991561 Boot band Bellows band installation

crimping tool

MB990776 Front axle base Dust cover press fitting

 STEERING – On-vehicle Service 37A-7
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK
1. With the engine running (hydraulic pressure operating),
put the front wheels in straight-ahead position.
2. Lightly turn the steering wheel left and right to measure
circumferential play on the steering wheel before the
wheels start to move.
Limit: 30 mm or less

3. When the play exceeds the limit, check steering shaft

connections and steering linkage for looseness. Repair
or replace if necessary.
4. If the play still exceeds the limit, put the steering wheel
in straight-ahead position with the engine stopped. Then,
load 5 N in the circumferential direction on the steering
wheel and measure circumferential play.
Standard value: 0 – 10 mm
5. In case the play exceeds the standard value again, remove
the steering gear box and linkage. Then, check and adjust
total pinion torque. (Refer to P.37A-18.)

STEERING ANGLE CHECK

1. Put the front wheels on a turning radius gauge and measure
steering angle.
Standard value:
Inner wheels 34_40’ ± 2_
Outer wheels <For reference> 32_10’

2. If the standard values are not met, toe-in is probably

incorrect. Adjust the toe-in, seeing GROUP 33A –
On-vehicle Service, and recheck the steering angle.

MB990635, TIE ROD END BALL JOINT STARTING TORQUE

MB991113 or Cord CHECK
MB991406
1. Use the special tool to disconnect the tie rod and knuckle.
Nut
Caution
(1) In order not to damage the ball joint thread, the
tie rod end mounting nut must be only loosened
but not removed from the ball joint. Also, be sure
to use the special tool.
(2) Tie the special tool with a cord so as not to fall
Ball joint
off.
37A-8 STEERING – On-vehicle Service

2. After swinging the ball joint stud several times, install the
MB990326
nut on the stud. Then, measure ball joint turning torque
with the special tool.
Standard value: 0.5 – 2.5 Nm
3. When the torque is over the standard value, replace the
tie rod end.
4. When the torque is below the standard value, check the
ball joint for looseness or ratcheting. If none of these found,
the ball joint is still serviceable.

STATIONARY STEERING EFFORT CHECK

1. With the vehicle stopped on a flat, paved surface, put
the steering wheel in straight–ahead position.
2. Start the engine and keep it at 1,000±100 r/min.
3. Attach a spring balance to the steering wheel outer bar.
Measure steering effort required to turn the steering wheel
from the straight-ahead position to the left and right (within
a range of 1.5 turns). Also see that no significant fluctuation
is present in the steering effort.
Standard value:

Steering effort 27 N or less <Limit: 30 N or less>

Fluctuation 5.9 N or less

4. If the standard values are not met, check and adjust the
related parts.

STEERING WHEEL RETURNABILITY CHECK

Check returnability as follows on road test:
1. Make both gradual and sudden turns and see by your
70_ 70_ own feeling that the steering effort and returnability have
no difference between the left and right turns.
2. At a speed of about 35 km/h, turn the steering wheel
90_, keep it there for 1 to 2 seconds and release. When
the steering wheel returns more than 70_, it has a good
returnability.
NOTE
You may have momentary increase in effort when turning
the steering wheel quickly, which is normal. This happens
due to insufficient job of the oil pump when the engine
is running at low speed such as idling.

OIL PUMP BELT TENSION CHECK

Refer to GROUP 11A – On-vehicle Service.
 STEERING – On-vehicle Service 37A-9
POWER STEERING FLUID LEVEL CHECK
Fluid level change: Within 5 mm
1. Park the vehicle on a flat, level surface and start the engine.
Without the vehicle moving, turn the steering wheel several
times until the fluid reaches 50 to 60_C.
2. With the engine running, turn the wheel fully left and right
several times.
3. Check the fluid in the oil reservoir for foaming or milkiness.
4. Check difference in fluid level between the engine stopped
While engine While engine and running. If the difference is 5 mm or more, bleed
running stopped air.

POWER STEERING FLUID REPLACEMENT

1. Jack up the vehicle and support the front wheels with
rigid racks.
2. Disconnect the return hose.
3. Connect a vinyl hose to the return hose and drain fluid
Return hose into a container.
Vinyl hose
4. Disconnect the ignition coil connectors. (Refer to
GROUP16 – Ignition System.)
5. Cranking the engine several times intermittently with the
starter, turn the steering wheel fully left and right to drain
the fluid.
6. Connect the return hose and secure it with the clip.
7. Fill the oil reservoir with specified fluid up to between
“MAX” and “MIN” marks, and then bleed air.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
Caution
Do not use ATF-SP II as it damages the components
of the power steering.
POWER STEERING SYSTEM BLEEDING
1. Jack up the vehicle and support the front wheels with
rigid racks.
2. Disconnect the ignition coil connectors. Cranking the
engine with the starter several times intermittently (during
15 to 20 seconds), turn the steering wheel left and right
fully five or six times.
Caution
(1) During the bleeding, refill the fluid so that the level
is always above “MIN” mark on the oil reservoir.
(2) Be sure to bleed air only while cranking. If the
bleeding is done with the engine running, the air
will be broken up and absorbed into the fluid.
3. Connect the ignition coil connectors and idle the engine.
4. Turn the steering wheel left and right fully until no bubbles
comes out in the oil reservoir.
5. See that the fluid is not milky and that the fluid level is
between “MAX” and “MIN” marks.
6. See that the fluid level changes little when the steering
wheel is turned left and right.
7. Check difference in fluid levels between the engine stopped
and running.
37A-10 STEERING – On-vehicle Service

8. If the level changes more than 5 mm, the air is badly bled.
Fluid level change: Within 5 mm So, bleed air again.
Caution
(1) If the fluid level rises suddenly after the engine
is stopped, the bleeding is incomplete.
(2) Incomplete bleeding causes abnormal noises from
the pump and the flow-control valve. This could
lessen the life of the pump and the other parts.
While engine While engine
running stopped

Pressure OIL PUMP PRESSURE TEST

Temperature gauge
(MB990662) Shut-off valve 1. Disconnect the pressure hose from the oil pump, and then
gauge
connect the special tools.
2. Bleed air. Without the vehicle moving, turn the steering
wheel several times to raise the fluid temperature to 50
Oil reservoir to 60_C.
Adapter 3. Start the engine and idle at 1,000±100 r/min.
(MB990993) 4. Fully close the shut-off valve of the pressure gauge and
measure the oil pump relief pressure.
Standard value: 8.3 – 9.0 MPa
5. If the standard value is not met, disassemble and assemble
Oil the oil pump again. Then, remeasure oil pressure.
pump 6. With the pressure gauge shut–off valve fully open, check
the hydraulic pressure in unladen condition.
Standard value: 0.2 – 0.7 MPa
Adapter
(MB990994) 7. If the standard value is not met, the oil line or steering
gear is probably defective. So, repair and measure oil
pressure again.
8. Turn the steering wheel fully either left or right and check
the retention hydraulic pressure.
Standard value: 8.3 – 9.0 MPa
9. If the pressure is below the standard value, disassemble
and reassemble the steering gear. If above, disassemble
and reassemble the components of the oil pump flow
control valve. Then, measure oil pressure again.
10. Remove the special tools, and tighten the pressure hose
to the specified torque.
Tightening torque: 57 Nm
11. Bleed the system.
 STEERING – On-vehicle Service 37A-11
POWER STEERING OIL PRESSURE SWITCH
Adapter Shut-off valve CHECK
(MB990993) Pressure
gauge 1. Disconnect the pressure hose from the oil pump and
Temperature (MB990662) connect the special tools.
gauge 2. Bleed air. Without the vehicle moving, turn the steering
wheel several times to raise the fluid temperature to 50
to 60_C.
3. Idle the engine.
4. Disconnect the oil pressure switch connector and set an
ohmmeter in position.
5. Gradually close the shut-off valve in the pressure gauge
to increase hydraulic pressure. Check that the hydraulic
Oil pressure activating the switch meets the standard value.
pump
Standard value: 1.5 – 2.0 MPa

Reservoir Adapter 6. Gradually open the shut-off valve and reduce the hydraulic
(MB990994) pressure. Check that the hydraulic pressure deactivating
the switch meets the standard value.
Standard value: 0.7 – 2.0 MPa
7. Remove the special tools and tighten the pressure hose
to the specified torque.
Tightening torque: 57 Nm
8. Bleed the system.

BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing
it with finger.
2. If the dust cover is cracked or damaged, replace the tie
rod end.
NOTE
A cracked or damaged dust cover may damage the ball
joint.
37A-12 STEERING – Steering Wheel and Shaft

STEERING WHEEL AND SHAFT

REMOVAL AND INSTALLATION
Caution:
1. Before removing the air bag module and clock spring, refer to GROUP 52B – Service Precautions
and Air Bag Module and Clock Spring.
2. Use an earth bolt for one of the steering shaft assembly mounting bolts. The earth bolt has
mark “E” on its head.

Pre-removal Operation Post-installation Operation

Instrument Under Cover Removal D Instrument Under Cover Installation
(Refer to GROUP 52A.) (Refer to GROUP 52A.)
D Checking Steering Wheel Position with Wheels
Straight Ahead

Standard bolt Earth bolt

41 Nm

5
12 Nm 22 Nm 1
4
1
2

9 Nm

9 6
8

12 Nm
18 Nm
3

Removal steps
1. Air bag module <Refer to GROUP 7. Key interlock cable <A/T>
52B> 8. Steering column shaft assembly
AA" 2. Steering wheel
3. Lower column cover
4. Upper column cover NOTE
5. Clock spring and column switch as- When the air bag module assembly must be
sembly <Refer to GROUP 52B> removed, refer to GROUP 52B – Air Bag Modules
6. Cover <A/T> and Clock Spring.
 STEERING – Steering Wheel and Shaft 37A-13
REMOVAL SERVICE POINTS
AA" STEERING WHEEL REMOVAL
MB990803
37A-14 STEERING – Steering Wheel and Shaft

DISASSEMBLY AND REASSEMBLY

<L.H. drive vehicles> <R.H. drive vehicles>

2
2 1
1

17 Nm
5

AW1122AL BW0581AL

Disassembly steps
AA" "AA 1. Special bolt 4. Shaft assembly
"AA 2. Steering lock bracket <L.H. drive vehicles>
"AA 3. Steering lock cylinder assembly 5. Steering column shaft assembly

Left-hand tap DISASSEMBLY SERVICE POINT

Special bolt
AA" SPECIAL BOLT REMOVAL
Steering
lock bracket 1. In the special bolt, drill a hole deep enough for the tap
to stand.
2. Using a left-hand tap, remove the special bolt.

Steering lock body

REASSEMBLY SERVICE POINT

"AA STEERING LOCK CYLINDER ASSEMBLY/
STEERING LOCK BRACKET/SPECIAL BOLT
INSTALLATION
1. When installing the steering lock cylinder assembly and
steering lock bracket to the steering column assembly,
temporarily install the steering lock in alignment with the
column boss.
2. Check that the steering lock works properly. Then, tighten
the special bolts until the heads twists off.
 STEERING – Power Steering Gear Box and Linkage 37A-15
POWER STEERING GEAR BOX AND LINKAGE
REMOVAL AND INSTALLATION
Caution: SRS
On vehicles with SRS, before removing steering gear box, refer to GROUP 52B. Also, put the front
wheels in straight–ahead position and remove the ignition key. Failure to do so may damage the
SRS clock spring and render the SRS air bag inoperative, which results serious driver injury.

Pre-removal Operation Post-installation Operation

D Power Steering Fluid Draining (Refer to P.37A-9.) D Check the Dust Cover for Cracks or Damage by
D Under Cover Removal Pushing it with Finger.
D Under Cover Installation
D Power Steering Fluid Supplying and bleeding
(Refer to P.37A-9.)
D Checking Steering Wheel Position with Wheels
Straight Ahead
D Front Wheel Alignment Check and Adjustment
(Refer to GROUP 33A – On-vehicle Service.)

<L.H. drive vehicles>

15 Nm 6
3
12 Nm
15 – 33 Nm 5

9 10
4
34 Nm
8 18 Nm
1

11 13
2 12

70 Nm 2
37A-16 STEERING – Power Steering Gear Box and Linkage

<R.H. drive vehicles>

3 15 – 33 Nm 18 Nm

1
15 Nm 4

10 13
7 5
12 Nm
2
5
34 Nm 6
8
9
12
12 Nm
11
70 Nm
2

Removal steps
1. Steering gear and joint connecting bolt 7. Nut <R.H drive vehicles>
2. Splash shield 8. Pressure tube
3. Split pin 9. Return tube
AA" 4. Tie rod end and knuckle 10. O-ring
connection 11. Cylinder clamp
"BA 5. Return hose 12. Gear housing clamp
"AA 6. Pressure hose AB" 13. Steering and gear linkage
 STEERING – Power Steering Gear Box and Linkage 37A-17
MB990635, REMOVAL SERVICE POINTS
MB991113 or Cord
MB991406 AA" TIE ROD END AND KNUCKLE DISCONNECTION

Nut Caution
(1) In order not to damage the ball joint thread, the tie
rod end mounting nut must be only loosened but not
removed from the ball joint. Be sure to use the special
tool.
(2) Tie the special tool with a cord so as not to fall off.
Ball joint

AB" STEERING GEAR BOX AND LINKAGE REMOVAL

Caution
Do not damage the boots when removing the steering
gear box and linkage.

INSTALLATION SERVICE POINTS

"AA PRESSURE HOSE CONNECTION
Connect the pressure hose and pressure tube with their mating
marks aligned.

Mating marks

"BA RETURN HOSE CONNECTION

Hose clip Connect the return hose so that the claws of the hose clip
are positioned as shown.
Return tube

Return hose
37A-18 STEERING – Power Steering Gear Box and Linkage

INSPECTION
GEAR BOX PINION TOTAL ROTATION TORQUE CHECK
MB991006 1. Using the special tool, turn the pinion gear at a speed
of one rotation per 4 to 6 seconds to measure total rotation
torque.
Standard values:
Total rotation torque: 0.6 – 1.5 Nm
Torque fluctuation: 0.5 Nm or less
NOTE
(1) Remove the bellows from the rack housing before
measuring.
(2) Measure the total rotation torque by turning the special
tool left and right 180_ from the neutral position.
2. If the standard values are not met, adjust the pinion total
rotation torque. (Refer to P.37-26.)
3. In case the adjustment is impossible, disassemble and
check the components, and repair if necessary.
Caution
Secure the steering gear box and linkage in their
mounting positions only. Otherwise, deformation or
damage could result.
TIE ROD SWING RESISTANCE CHECK
1. Swing the tie rod 10 times hardly.
2. With the tie rod end downwards as shown, use a spring
scale to measure swing resistance (swing torque).
Standard value: 5 – 17 N (1.5 – 4.9 Nm)
3. If the measured value is above the standard value, replace
the tie rod.
4. If below, check the ball joint for looseness or ratcheting.
The tie rod is still serviceable when the ball joint swings
smoothly.

TIE ROD END BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing
it with finger.
2. If the dust cover is cracked or damaged, replace the tie
rod end. (Refer to P.37A-19, 20.)
NOTE
A cracked or damaged dust cover may damage the ball
joint. Replace the dust cover when it is damaged during
service work.
 STEERING – Power Steering Gear Box and Linkage 37A-19
DISASSEMBLY AND REASSEMBLY
<L.H. drive vehicles>
Steering gear seal set
2
6
2 25 Nm 26 27
29
30
21 2
9
35
19
36 1 17
2 9 34
37 34 20
19 35 9
15 15
18
59 Nm 17 14 6
16
10
4 11 12 Flare nut
13 13 Nm
22 Nm³ć30_ 1
5
7
3
49 – 59 Nm

88 Nm
6
9
8 23

22
26
25
27
29
24
30
32
31
33
28

Disassembly steps
1. Feed pipe AD" "FA 19. Upper oil seal
2. O-ring 20. Valve housing
"MA 3. Locking nut 21. Dust cover
"MA 4. Tie rod end AE" "EA 22. Circlip
5. Clip AF" 23. Rack stopper
"LA 6. Band AF" "DA 24. Rack bushing assembly
7. Bellows AF" "DA 25. Rack bushing
"KA 8. Tie rod AF" "DA 26. Oil seal
"KA 9. Tab washer AF" 27. O-ring
"JA D Total pinion torque adjustment AF" "CA 28. Rack assembly
"IA 10. Locking nut 29. Piston ring
AA" "IA 11. Rack support cover 30. O-ring
12. Rack support spring 31. Circlip
13. Rack support 32. Pistion
14. Valve assembly 33. Rack
AB" "HA 15. Lower oil seal 34. Gasket
AB" 16. Pinion and valve assembly AG" "BA 35. Oil seal
AC" "GA 17. Seal ring "AA 36. Gear housing mounting rubber
AD" "FA 18. Upper bearing 37. Gear Housing
37A-20 STEERING – Power Steering Gear Box and Linkage

<R.H. drive vehicles>

Steering gear seal set

21 25 Nm
19
17 2
1
20
19 15 2
18
9
2 6 6
34 9
14
17 35 30
29
27
16 15 2 26

34
Flare nut
37 35 13 Nm
36 28 1
7 33 31
32 24
29
11 12 13 30 25
10 27
59 Nm 22 Nm³ć30_
26
23 22

9
88 Nm
8
6
7 4
5
3
49 – 59 Nm

Disassembly steps
1. Feed pipe AD" "FA 19. Upper oil seal
2. O-ring 20. Valve housing
"MA 3. Locking nut 21. Dust cover
"MA 4. Tie rod end AE" "EA 22. Circlip
5. Clip AF" 23. Rack stopper
"LA 6. Band AF" "DA 24. Rack bushing assembly
7. Bellows AF" "DA 25. Rack bushing
"KA 8. Tie rod AF" "DA 26. Oil seal
"KA 9. Tab washer AF" 27. O-ring
"JA D Total pinion torque adjustment AF" "CA 28. Rack assembly
"IA 10. Locking nut 29. Piston ring
AA" "IA 11. Rack support cover 30. O-ring
12. Rack support spring 31. Circlip
13. Rack support 32. Pistion
14. Valve assembly 33. Rack
AB" "HA 15. Lower oil seal 34. Gasket
AB" 16. Pinion and valve assembly AG" "BA 35. Oil seal
AC" "GA 17. Seal ring "AA 36. Gear housing mounting rubber
AD" "FA 18. Upper bearing 37. Gear Housing
 STEERING – Power Steering Gear Box and Linkage 37A-21
Lubrication and Sealing Points

Grease: Repair kit grease

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

Fluid:
Automatic transmission fluid
DEXRON or DEXRON II

Grease: Silicone grease

Fluid: Fluid:
Automatic transmission fluid Automatic transmission fluid
DEXRON or DEXRON II DEXRON or DEXRON II
37A-22 STEERING – Power Steering Gear Box Box and Linkage

DISASSEMBLY SERVICE POINTS

AA" RACK SUPPORT COVER REMOVAL

MB991621

AB" OIL SEAL/PINION AND VALVE ASSEMBLY

REMOVAL
With a plastic hammer, lightly tap the pinion and valve assembly
in its spline to remove the lower oil seal and pinion and valve
assembly from the valve housing.

AC" SEAL RING REMOVAL

Cut the seal ring to remove from the pinion and valve assembly.
Caution
When cutting the seal ring, be careful not to damage the
pinion and valve assembly.

AD" UPPER BEARING/UPPER OIL SEAL REMOVAL

Using a socket, pull out the upper oil seal and bearing from
the valve housing.

Socket

Rack stopper AE" CIRCLIP REMOVAL

1. Turn the rack stopper clockwise until the circlip end comes
out of the slot in the rack housing.
2. Turn the rack stopper anticlockwise to remove the circlip.
Caution
Do not turn the rack stopper anticlockwise first.
Circlip Otherwise, the circlip will get caught in the slot in
the housing, which makes the rack stopper unable
to turn.
 STEERING – Power Steering Gear Box Box and Linkage 37A-23
AF" RACK STOPPER/RACK BUSHING ASSEMBLY/
RACK BUSHING/OIL SEAL/O-RING/RACK
REMOVAL
1. Remove the rack stopper, rack bushing, oil seal and O-ring
together by pulling out the rack gently.

2. Partially bend the oil seal to remove from the rack bushing.
Caution
Use care not to damage the oil seal press-fitting
Rack bushing surface of the rack bushing.

AG" OIL SEAL REMOVAL

Gear housing
Use a pipe or the like to pull out the oil seal.
Pipe

Oil seal

<L.H. drive vehicle> REASSEMBLY SERVICE POINTS

Gear housing "AA GEAR HOUSING MOUNTING RUBBER
mounting rubber
Slit INSTALLATION
1. Install the gear housing mounting rubber on the rack
housing so that the dimension shown is achieved.
NOTE
The gear housing mounting rubber can be installed
regardless of the installation direction of the slit.
37.5 mm 2. Apply specified adhesive to the slit of the gear housing
mounting rubber.
<R.H. drive vehicle> Specified adhesive:
Gear housing 3M ATD Part No.8155 or equivalent
mounting rubber

Slit
37.5 mm
37A-24 STEERING – Power Steering Gear Box Box and Linkage

"BA OIL SEAL INSTALLATION

MB991199
Gear housing MB991197

Oil seal

"CA RACK ASSEMBLY INSTALLATION

Vent hole
1. Apply repair kit grease to the teeth of the rack assembly.
Caution
Use care not to close the vent hole in the rack with
grease.

Seal ring, O-ring

2. Cover the serrations of the rack assembly with the special

Oil seal tool.
3. Apply specified fluid to the outer surfaces of the special
tool, seal ring and O-ring.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
MB991213 4. Slowly insert the rack covered with the special tool from
the power cylinder side of the gear housing.
Caution
Carefully push in the rack with the oil seal centre and
the special tool end matched. This is to avoid the
retainer spring coming off.

"DA OIL SEAL/RACK BUSHING/RACK BUSHING

ASSEMBLY INSTALLATION
MB990925 1. Apply specified fluid to the outer surface of the oil seal.
(MB990927)
Using the special tool, press in the oil seal until it is flush
Oil seal with the bushing end face.
O-ring
Specified fluid:
Rack Automatic transmission fluid
bushing
DEXRON or DEXRON II
 STEERING – Power Steering Gear Box and Linkage 37A-25
Caution
Do not use Dia Queen ATF SPII and ATF SPII M as
they damage the components of the power steering.

2. Apply the specified fluid to the oil seal inner surface and
Rack the O-ring.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
Caution
Plastic tape Do not use Dia Queen ATF SPII and ATF SPII M as
they damage the components of the power steering.
Rack bushing
3. Wrap the rack end with plastic tape, and push the rack
bushing onto the rack.

"EA CIRCLIP INSTALLATION

Circlip
Circlip Align the mark on the rack stopper and the slot in the cylinder.
Then, insert the circlip into the rack stopper hole through the
cylinder hole. Turn the rack stopper clockwise and insert the
circlip firmly.

Slot Slot

"FA UPPER OIL SEAL/UPPER BEARING

MB990925
MB990925 INSTALLATION
(MB990938)
(MB990938)

MB991203 MB991203
Upper oil Bearing
seal

"GA SEAL RING INSTALLATION

After installation, using the special tool or by hand, compress
MB991317
seal rings that expand during installation.
37A-26 STEERING – Power Steering Gear Box and Linkage

Approx. 1 mm "HA LOWER OIL SEAL INSTALLATION

MB990941
Oil Using the special tool, press the oil seal into the valve housing.
seal The upper surface of the oil seal must project outwards about
1 mm from the housing end surface.
Caution
Housing When the oil seal is flush with or lower than the housing
edge, reassemble the components. Otherwise, oil leaks
will result.

"IA RACK SUPPORT COVER/LOCKING NUT

INSTALLATION
1. Apply specified sealant to the rack cover support thread.
Specified fluid:
3M ATD Part No.8661 or equivalent
2. Using the special tool, tighten the rack support cover to
22 Nm.
MB991621 3. Return the rack support cover by about 30_.
4. Tighten the locking nut to the specified torque, using the
special tool to prevent the rack support cover from spinning.

"JA PINION TOTAL ROTATION TORQUE ADJUSTMENT

1. Using the special tool, measure total rotation torque by
MB991006
turning the pinion gear at a speed of one rotation per
4 to 6 seconds.
Standard value:
Total rotation torque: 0.6 – 1.5 Nm
Torque fluctuation: 0.5 Nm or less

2. If the total rotation torque or torque fluctuation does not

meet the standard values, adjust by returning the rack
support cover within a range of 0 to 30_.
Caution
(1) Adjust around the maximum limit of the standard
values.
(2) See that no ratcheting or catching are present
when operating the rack towards the shaft
direction.
(3) Measure the total pinion torque through the whole
stroke of the rack.
3. If the adjustment is impossible in the given range, check
the components of the rack support cover, and replace
if necessary.
 STEERING – Power Steering Gear Box and Linkage 37A-27
"KA TAB WASHER/TIE ROD INSTALLATION
After installing the tie rod to the rack, fold the tab washer
end (2 locations) to the tie rod notch.

MB991561
"LA BELLOWS BAND INSTALLATION
Stopper 1. Turn the adjusting bolt of the special tool to adjust the
opening dimension (W) to the standard value.
W Standard value (W): 2.9 mm
<When more than 2.9 mm>
Screw in the adjusting bolt.
<When less than 2.9 mm>
Adjusting bolt
Loosen the adjusting bolt.
NOTE
(1) The dimension (W) is adjusted by about 0.7 mm per
one turn.
(2) Do not turn the adjusting bolt more than one turn.
2. Use the special tool to crimp the bellows band.
MB991561
Caution
(1) Hold the rack housing, and use the special tool
to crimp the bellows band securely.
(2) Crimp the bellows band until the special tool
touches the stopper.

3. See that the crimped width (A) meets the standard value.
Standard value (A): 2.4 – 2.8 mm
<When more than 2.8 mm>
A
Readjust the dimension (W) of step (1) to the value
calculated by the following equation, and repeat step
(2).
W = 5.5 mm – A [Example: If (A) is 2.9 mm, (W)
is 2.6 mm.]
<When less than 2.4 mm>
Remove the bellows band, readjust the dimension
(W) of step (1) to the value calculated by the following
equation, and use a new bellows band to repeat steps
(2) to (3).
W = 5.5 mm – A [Example: If (A) is 2.3 mm, (W)
is 3.2 mm.]
37A-28 STEERING – Power Steering Gear Box and Linkage

"MATIE ROD END/LOCKING NUT INSTALLATION

Edge of bellows Locking nut Screw in the tie rod end until the dimension shown is achieved.
assembly groove
Then, temporarily tighten with the locking nut.
NOTE
The locking nut must be tightened securely only after the power
steering gear box and linkage are installed to the vehicle and
toe–in is adjusted.
212 mm

TIE ROD END BALL JOINT DUST COVER

REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply grease inside a new dust cover.
MB990776 2. Using the special tool, press in the dust cover to the tie
rod end.
3. Check the dust cover for cracks or damage by pushing
it with finger.
 STEERING – Power Steering Oil Pump 37A-29
POWER STEERING OIL PUMP
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Power Steering Fluid Draining (Refer to P.37A-9.) D Power Steering Fluid Supplying and Bleeding
(Refer to P.37A-9.)
D Drive Belt Tension Adjusting
(Refer to GROUP 11A.)

57 Nm
2 7
7 3
21 Nm 5
10 4

28 Nm

49 Nm
6
8

1 28 Nm

44 Nm

44 Nm

25 Nm
9

Removal steps
D Air intake duct "AA 6. Suction hose
1. Drive belt 7. Oil pump assembly
2. Pressure switch connector 8. Oil pump stay
3. Eye bolt 9. Tensioner pulley
4. Pressure hose 10. Oil pump bracket
5. Gasket

INSTALLATION SERVICE POINT

Oil pump
"AA SUCTION HOSE INSTALLATION
Install so that the mark on the suction hose is positioned as
shown.

Suction hose
37A-30 STEERING – Power Steering Oil Pump

DISASSEMBLY AND REASSEMBLY

Caution
Never disassemble the terminal assembly unable to be reassembled.

27 Nm
1 2

5
4 25 – 29 Nm
3
11

12
16 12 Nm
17

7
8
9

15 10
14
13

NOTE 59 Nm

: Automatic transmission fluid DEXRON or DEXRON II

4
5
12 3
17 8
5
5
10
14 7
2 9 6

Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit

Disassembly steps
1. Pump cover "BA 10. Oil seal
2. O-ring 11. Terminal assembly
"EA 3. Vanes "AA 12. O-ring
"DA 4. Cam ring 13. Inner plug
5. Snap ring "AA 14. O-ring
6. Pulley and shaft 15. Flow control spring
"CA 7. Rotor 16. Suction connector
8. Side plate "AA 17. O-ring
"AA 9. O-ring
 STEERING – Power Steering Oil Pump 37A-31

Inner plug Side plate

REASSEMBLY SERVICE POINTS
"AA O-RING INSTALLATION

No. ID × Width mm
1
1 21.0 × 1.9
2 14.8 × 2.4
3 14.8 × 1.9
2
4 3.8 × 1.9
Suction connector 5 15.8 × 2.4
mounting portion of
Terminal assembly oil pump body

3
5

MB990938 "BA OIL SEAL INSTALLATION

MB991203

"CA ROTOR INSTALLATION

Punch mark Install the rotor with its punch mark towards the side plate.

"DA CAM RING INSTALLATION

Install the cam ring with its identification mark towards the
Identification side plate.
mark
37A-32 STEERING – Power Steering Oil Pump/Power Steering Oil Hoses

"EA VANE INSTALLATION

Round
edge Install the vane to the rotor with its round edge outwards
(towards cam ring).

Vane

POWER STEERING OIL HOSES

REMOVAL AND INSTALLATION
Pre–removal and Post–installation Operations
D Power Steering Fluid Draining and Supplying, and D Air Intake Hose, Resonator, Air Duct, Air Cleaner
Bleeding (Refer to P.37A–9.) Cover Removal and Installation
D Under Cover Removal and Installation (Refer to GROUP 15.)
 STEERING – Power Steering Oil Hoses 37A-33
<L.H. drive vehicles>
12 Nm 57 Nm
3 4
6

15 Nm
2
5
8

10
34 Nm
12 Nm
9

<R.H. drive vehicles> 12 Nm

57 Nm
4
3
6
1

15 Nm

10 5
12 Nm
8 2
34 Nm

7
12 Nm

Removal steps
"CA 1. Return hose 6. Gasket
"BA 2. Suction hose 7. Clip
3. Oil reservoir 8. Return tube
D Splash shield (Refer to P.37A-15, 16.) 9. Pressure tube
4. Eye bolt 10. O-ring
"AA 5. Pressure hose
37A-34 STEERING – Power Steering Oil Hoses

INSTALLATION SERVICE POINTS

"AA PRESSURE HOSE INSTALLATION
Install with the marks on the pressure hose and pressure
tube aligned.

Mating mark

"BA SUCTION HOSE INSTALLATION

Alignment
1. Install with the mark at the end of the hose (oil reservoir
mark on Oil reservoir side) and the alignment mark on the oil reservoir aligned.
oil reservoir

Suction hose

2. Install so that the mark at the end of the hose(oil pump

Oil pump side) is positioned as shown.

Suction hose

"CA RETURN HOSE INSTALLATION

Hose clip Install so that the hose clip claws are placed as shown.

Return tube

Return hose
 BODY
Click on the applicable bookmark to selected the required model year
 42-1

BODY
CONTENTS

HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 18
FENDER* . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 18
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . 19
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Door Fit Adjustment . . . . . . . . . . . . . . . . . . . . . . 19
FUEL FILLER DOOR . . . . . . . . . . . . . . . . 6 Door Window Glass Adjustment . . . . . . . . . . . 19
Defective Power Window Adjustment and
WINDOW GLASS . . . . . . . . . . . . . . . . . . . 8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power Window Safety Mechanism
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 8
Door Outside Handle Play Check . . . . . . . . . 20
WINDOW REPAIR . . . . . . . . . . . . . . . . . . . . . . . 8 Power Window Operation Current Check . . . 21
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Circuit Breaker (Incorporated in the Power
Window Motor) Check . . . . . . . . . . . . . . . . . . . . 21
QUARTER WINDOW GLASS . . . . . . . . . . . . 14
Door Inside Handle Play Check and
BACK DOOR GLASS . . . . . . . . . . . . . . . . . . . 16 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONTINUED ON NEXT PAGE
SERVICE SPECIFICATIONS . . . . . . . . . . . . . 18

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from
rendering the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors 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 (*).
42-2

DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22 BACK DOOR HANDLE AND LATCH . . . . . 37

DOOR TRIM AND WATERPROOF KEYLESS ENTRY SYSTEM . . . . . . . . . . 38
FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DOOR GLASS AND REGULATOR . . . . . . . 26 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 38
DOOR HANDLE AND LATCH . . . . . . . . . . . 30 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . 38
How to Replace a Battery
WINDOW GLASS RUNCHANNEL AND of the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 38
DOOR OPENING WEATHERSTRIP . . . . . . 32
Encrypted Code Registration Method . . . . . . 39
BACK DOOR . . . . . . . . . . . . . . . . . . . . . . 33 Hazard Lamp Answerback Adjustment . . . . . 40

SERVICE SPECIFICATION . . . . . . . . . . . . . . 33 KEYLESS ENTRY SYSTEM . . . . . . . . . . . . . 41

SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . 42
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 33 SERVICE SPECIFICATION . . . . . . . . . . . . . . 42
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 33 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 42
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . 33 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . 46
Back Door Fit Adjustment . . . . . . . . . . . . . . . . 33 Water Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Back Door Handle Play Check . . . . . . . . . . . . 33 Sunroof Fit Adjustment . . . . . . . . . . . . . . . . . . . 46
BACK DOOR ASSEMBLY . . . . . . . . . . . . . . . . 34 SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
BACK DOOR TRIM AND WATERPROOF
FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
 BODY – Hood 42-3

HOOD
REMOVAL AND INSTALLATION

3 7

2 1
6

2
9 Nm

8
12 Nm

Adjustment of hood step and Adjustment of clearance Adjustment of hood height

hood striker linkage around hood

Hood latch removal steps Hood removal steps

D Front grille (Refer to GROUP 51.) 4. Hood silencer
1. Hood latch 5. Hood weatherstrip
Hood lock release cable removal D Washer hose
steps (Refer to GROUP 51.)
6. Hood
2. Hood lock release handle 7. Hood bumper
3. Hood lock release cable 8. Hood support rod
42-4 BODY – Hood/Fender

Clip positions
A Section A – A

6
A Clip
4

: Clip positions
6

FENDER
SEALANT
Item Specified sealant Remark

Splash shield 3M ATD Part No. 8625 or equivalent Ribbon sealer

 BODY – Fender 42-5
FENDER
REMOVAL AND INSTALLATION
Caution: SRS
Do not strike the front impact sensor when removing or installing the fender.

Pre-removal and Post-installation Operation

D Front Bumper Removal and Installation
(Refer to GROUP 51.)

A
A
5

4
3

Section A – A Section B – B
Side outer
2
2 B
5 panel
5
B
40 mm

2
Clip
6 mm
W0260AL
: Clip positions
Sealant: 3M ATD Part No. 8625 or equivalent

Removal steps
1. Mud guard "AA 4. Side turn signal lamp
2. Splash shield (Refer to GROUP 54.)
3. Grille filler panel 5. Fender
42-6 BODY – Fender/Fuel Filler Door

INSTALLATION SERVICE POINT

AA" SIDE TURN SIGNAL LAMP REMOVAL
Hook Engage the hook with the fender panel.

Fender panel
Front of Vehicle

FUEL FILLER DOOR

REMOVAL AND INSTALLATION
Pre–removal and Post–installation Operations
D Rear Floor Console Removal and Installation
(Refer to GROUP 52A.) D Quarter Trim, Lower (R.H.) Removal and Installation
D Front Seat (Driver’s side), Rear Seat Removal (Refer to GROUP 52A.)
and Installation (Refer to GROUP 52A.)

1
2

Removal steps
AA" "AA 1. Rivet 4. Fuel filler door lock release cable
2. Fuel filler door panel assembly 5. Lid lock release handle
3. Fuel filler door lock assembly
 BODY – Fuel Filler Door 42-7
REMOVAL SERVICE POINT
AA" RIVET REMOVAL
Use a drill (Ø4.0 – 5.5 mm) to break the rivet by drilling a
hole, and then remove the rivet.
Rivet
Fuel filler
door panel
assembly Drill

Riveter INSTALLATION SERVICE POINT

"AA RIVET INSTALLATION
Use a riveter shown to install rivets as follows:
1. Insert a rivet in the body panel and fuel filler door panel
assembly.
2. Insert the riveter to the rod (A shown) of a rivet.
3. Pressing the flange surface of the rivet with the riveter,
Fuel filler door handle the riveter.
panel assembly Body
A panel 4. The rod is cut at its thinnest point and the rivet is held
1
in position.

Rivet
2

Riveter 3

Flange surface
4

Rivet
42-8 BODY – Window Glass

WINDOW GLASS
ADHESIVE
Items Specified adhesive

Windshield 3M ATD Part No. 8609 Super Fast Urethane Auto Glass
Sealant or equivalent
Quarter window glass

Back door glass

SPECIAL TOOLS
Tool Number Name Use
MB990480 Window glass Removal and installation of windshield
holder

MB990449 Window moulding Removal of roof drip moulding

remover

WINDOW REPAIR
The following glass parts are installed with a liquid urethane
adhesive method:
D Windshield
D Quarter window glass
D Back door window glass
ITEMS NEEDED
Name Remarks

Adhesive 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
equivalent

Primer 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent

Spacers Available as service part

Dam Available as service part

Anti-rust solvent For rust prevention

(or Tectyl 506T...Valvoline Oil Company)

Isopropyl alcohol For grease removal from bonded surface

Steel piano wire Dia. × length...0.6mm × 1m For cutting adhesive

Adhesive gun For pressing-out adhesive

 BODY – Window Glass 42-9
HANDLING OF AUTO WINDOW SEALER
Keep the sealant in a cool place, not exposed to the direct
rays of the sun. Do not place any heavy article on the sealant
nor press it, otherwise it will become deformed. Avoid storing
the sealant for more than 6 months, because it will lose its
sealing effect.
BODY PINCH-WELD FLANGE SERVICING
Before servicing the body pinch-weld flange, remove old
adhesive completely. If the flange requires painting, bake it
after painting is completed.

WORKING PROCESS
Window glass installation procedure

Body side Window glass side

Reusing the glass Replacing the glass

Cleaning of adhesion surface Cleaning of adhesion surface Cleaning of adhesion surface

Cut off the residual adhesive until the Completely cut off all of the residual Clean off any dirt adhering to the adhe-
thickness is less than 2 mm. Clean the adhesive. Clean the adhesion surface sion surface with isopropyl alcohol, and
adhesion surface with isopropyl alco- with isopropyl alcohol, and let dry for let dry for 3 minutes or more.
hol, and let dry for 3 minutes or more. 3 minutes or more.

Attaching of clip, spacer and dual

lock fastener Gluing of window spacer, glass stoppers and dual lock fastener
Attach the clip, spacer and dual lock Glue the window spacer, glass stoppers and dual lock fastener along the standard position
fastener to set the positions for the glass on the glass outer circumference.
to be installed.

Application of primer
Application of primer Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After
Apply to the adhesion surface of the application, let dry for 3 to 30 minutes.
body and let dry for 3 minutes or more.

Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.

Installing the glass

After applying the adhesive, lightly press the glass evenly so that it adheres
completely.

Cleaning
After removing any adhesive that is sticking out or adhering to the body or
glass with a spatula, etc., clean off with isopropyl alcohol.

Checking for water leaks

Carry out a shower test to check that no water will leak through.
42-10 BODY – Window Glass

WINDSHIELD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
D Front Pillar Trim Removal and Installation
(Refer to GROUP 52A.)
D Headlining Removal and Installation
(Refer to GROUP 52A.)

Section A – A Section B – B Section C – C mm

A Primer 15
14
6 15 7
A
Primer

C C 9 1
B 15 7
Primer
B

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent

6 8

5 5
4 7
5 2

Removal steps
AA" 1. Roof drip moulding (Refer to "AA 5. Windshield spacer
GROUP 51.) "AA 6. Windshield upper moulding
2. Roof drip moulding clip "AA 7. Clip
3. Windshield lower moulding "AA 8. Glass stopper
AB" "AA 4. Windshield
 BODY – Window Glass 42-11
REMOVAL SERVICE POINTS
MB990449 AA" ROOF DRIP MOULDING REMOVAL
Use the special tool to lever out the moulding.
Caution
If the moulding has become warped, it should not be
reused.

AB" WINDSHIELD REMOVAL

1. In order to protect the body (paint surface), apply cloth
tape to all body areas around the installed windshield.
2. Using a sharp-point drill, make hole in the windshield
adhesive.
3. Pass the piano wire from the inside of the vehicle through
the hole.
4. Pull the piano wire alternately from the inside and outside
along the windshield to cut the adhesive.
Caution
Do not let the piano wire touch the edge of the
windshield.
MB990480
5. Make alignment marks on the windshield and body.
6. Use the special tool to remove the windshield.

7. Use a knife to cut away remaining adhesive to 2 mm

thick or less around the entire circumference of the body
flange.
8. Smooth the flange surface.
Caution
(1) Use care not to remove more adhesive than
necessary, or the adhesive could weaken.
(2) Be careful also not to damage the paintwork on
the body surface with the knife. If the paintwork
is damaged, repair the damaged area with repair
paint or anti-rust agent.
9. When reusing windshield, remove the remaining adhesive
on the windshield completely. Then, decrease the
windshield with isopropyl alcohol.
10. Decrease the body flange in the same way.
Caution
Before the next job, leave the decreased parts for 3
minutes or more to dry. Also, do not touch any cleaned
surface.
42-12 BODY – Window Glass

INSTALLATION SERVICE POINTS

"AA GLASS STOPPER/CLIP/WINDSHIELD UPPER
MOULDING/WINDSHIELD SPACER/WINDSHIELD
INSTALLATION
1. When installing new windshield, temporarily position the
windshield on the body. Make alignment marks on the
windshield and body.
2. Use isopropyl alcohol to degrease the inside of windshield
circumference, and also the body flanges.
3. Apply primer soaked in a sponge evenly to the specified
positions on the windshield and body flange.
4. Dry 3 minutes or more.
5. Install the glass stoppers and windshield spacers as shown
to prevent the inside of windshield from warp or separation.

Glass stopper and windshield spacer installation position

Glass end line Windshield spacer

Ceramic line
14 mm
14 mm Glass
Align glass stopper end end line
with notch in ceramic.

Ceramic line
Glass stopper
Ceramic line
Windshield

Glass
Windshield spacer end line
Ceramic line

25 mm
Align windshield spacer 25 mm
end with notch in ceramic.

Windshield Ceramic line

spacer
Glass end line

Caution
(1) Be sure to apply the primer to strengthen adhesion
evenly around the entire position. Note that too
thick application weakens the adhesion.
(2) Never touch the surfaces where the primer is
applied.
6. Install the windshield upper moulding to the windshield.
 BODY – Window Glass 42-13
7. 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

15 mm

8. Install the clip to the clip stud.

9. After applying the adhesive, align the alignment marks
Clip stud on the windshield and body. Then, press the windshield
gently to seat.
10. Use a spatula or the like to remove any excessive adhesive.
Then clean the surface with isopropyl alcohol. Install the
windshield moulding before the adhesive hardens.
11. Wait 30 minutes or more, and then test for water leakage.
Caution
Clip (1) Do not move the vehicle unless necessary. If doing
so, move it very gently.
(2) When testing for water leakage, do not pinch the
end of the hose to spray the water.
42-14 BODY – Window Glass

QUARTER WINDOW GLASS

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Quarter Trim, Lower (R.H.) Removal and
Installation (Refer to GROUP 52A.)
D Headlining Removal and Installation
(Refer to GROUP 52A.)

Section B – B mm
Section A – A
3, 7
Primer
12.5
3, 7
B
15
12.5 2, 6
B

C Primer
C

A A D
Section C – C Section D – D
Primer
Primer
D
3
15 12.5
12.5
18.5 3, 7

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent

W0390AL
00008893

Removal steps
AA" "AA 1. Quarter window glass
"AA 2. Dual lock fastener
"AA 3. Window dam
 BODY – Window Glass 42-15
REMOVAL SERVICE POINT
AA" QUARTER WINDOW GLASS REMOVAL
Remove the quarter window glass in the same manner as
for the windshild. (Refer to P.42-11.)

INSTALLATION SERVICE POINT

"AA WINDOW DAM/DUAL LOCK FASTENER/
QUARTER WINDOW GLASS INSTALLATION
1. Use a isopropyl alcohol to decrease the glass and body
surfaces where the window dam and dual lock fasteners
are installed.
2. Install the window dam.

Dual lock fastener 3. Install the dual lock fasteners to the body flange in the
installation positions specified positions.
4. Install the dual lock fasteners to the windshield in the
positions corresponding to the ones on the body flange
where the dual lock fasteners have been installed.
5. Apply the primer and adhesive.
6. Install the glass in the same manner as for the windshield.
(Refer to P.42-12.)

Glass end line

Dual lock
fastener

Align the dual

lock fastener end
Side panel and the marking.
flange end line

: Dual lock fastener installation positions

42-16 BODY – Window Glass

BACK DOOR GLASS

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D High-mounted Stop Lamp Assembly Removal and
Installation (Refer to GROUP 52A.)
D Back Door Trim Removal and Installation (Refer
to P.42-34.)

mm
Section A – A Section B – B

5
12.5
5
B
Primer
5.5 Primer
B 12.5

Section C – C
C Primer

A A C
12.5
5.5
5

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent

2
5

Removal steps
1. Harness connector "AA 4. Glass stopper
AA" "AA 2. Back door glass "AA 5. Window dam
"AA 3. Dual lock fastener
 BODY – Window Glass 42-17
REMOVAL SERVICE POINT
AA" BACK DOOR GLASS REMOVAL
Remove the back door glass in the same manner as for the
windshield. (Refer to P42-11.)

INSTALLATION SERVICE POINT

"AA WINDOW DAM/DUAL LOCK FASTENER/GLASS
STOPPER/BACK DOOR GLASS INSTALLATION
1. Use a isopropyl alcohol to decrease the glass and body
surfaces where the window dam, dual lock fasteners and
glass stoppers are installed.
2. Install the window dam.

Glass stopper installation holes 3. Install the dual lock fasteners to the concavities on the
Concavity Concavity body panel and the glass stoppers to the hole on the
body panel respectively.
4. Install the dual lock fasteners to the windshield in the
positions corresponding to the ones on the body panel
where the dual lock fasteners have been installed.
5. Apply the primer and adhesive.
6. Install the glass in the same manner as for the windshield.
(Refer to P.42–12.)
Dual lock fastener
42-18 BODY – Door

DOOR
SERVICE SPECIFICATIONS
Items Standard value

Door outside handle play mm 3.7 or more

Power window operating current A 5.3 ± 2 (power supply 14.5 V ± 0.3 V at 23_C)

Door inside handle play mm 5.3 or more

Glass pad and glass Between glass holder and glass rear end (A) 55.0
holder installation
position mm Between glass holders (B) 419.0 – 421.0

Between glass holder and glass front end (C) 55.0

SEALANT
Items Specified sealant Remark

Waterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer

SPECIAL TOOLS
Tool Number Name Use
MB990784 Ornament remover Door trim removal

MB990480 Window glass Power window regulator and motor assembly

holder removal

MB990900 or Door hinge Adjustment of door fit

MB991164 adjusting wrench

TROUBLESHOOTING
The power window and central door locking is controlled by the Smart Wiring System (SWS). For
troublesshooting, refer to GROUP 54B – Troubleshooting.
 BODY – Door 42-19
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENT
MB990900 or
MB991164 1. If clearance between the door and body is uneven, affix
protective tape to the fender around the hinge and to
the edge of the door. Then use the special tool to loosen
the door hinge mounting bolts on the body, and adjust
the clearance around the door so that it becomes even.
2. If the door and body are not flush with each other, use
the special tool to loosen the door hinge mounting bolts
on the door. Then align the door.
Caution
Do not load more than 98 Nm on the special tool.

3. If the door opening and closing is heavy, adjust the meshing

of the striker and the door latch (forward and backward)
Striker Shim by adding shims to the striker and by moving the striker
up and down or to the left and right.

DOOR WINDOW GLASS ADJUSTMENT

Check that the door glass moves securely along the door
glass runchannel when the window glass is fully raised and
fully lowered. If the glass does not move correctly, adjust as
follows:
1. Remove the door trim and the waterproof film. (Refer to
P.42-23.)
2. Close the door window glass. Loosen the channel guide
Channel guide
mounting bolts, and then adjust the inclination of glass.
42-20 BODY – Door

DEFECTIVE POWER WINDOW ADJUSTMENT

Runchannel AND REPLACEMENT
Door
sash If the window glass wrongly, automatically lowers while being
raised, adjust or replace as follows:
1. Remove the door trim and the waterproof film. (Refer to
P.42-23.)
2. Remove the window regulator assembly from the door
Lower sash
window glass, and then raise and lower the door window
glass by hand to check the operation force.
NOTE
Insert soft stuff like cushion to prevent damage to the
glass if it falls down.
3. If the door window glass does not move up and down
smoothly, do as follows:
D Check the installation condition of the runchannel.
D Straighten twist in the door sash.
D Check the installation condition of the lower sash or
the center sash.
NOTE
The lower sash cannot normally be adjusted, but it may
be possible to adjust the sash span slightly within the
range allowed by manufacturing tolerances by pushing
the lower sash outwards while re-installing it.
4. If repair or adjustment is impossible, replace the door
assembly.

POWER WINDOW SAFETY MECHANISM

CHECK
1. Place a wooden board about 10 mm thick as shown. Then,
raise the window glass.
2. Check that the window lowers by about 150 mm when
the window clamps the board. If this doesn’t happen, do
troubleshooting. (Refer to GROUP 54B.)

Section A – DOOR OUTSIDE HANDLE PLAY CHECK

A
1. Measure the door outside handle play.
A Standard value (B): 3.7 mm or more
2. If the play is not within the standard value, check the
door outside handle or the door latch assembly. Replace,
A if necessary.

B
 BODY – Door 42-21
POWER WINDOW OPERATION CURRENT
CHECK
1. Remove the power window fuse and connect a circuit
tester as shown.
2. Measure the operation current. When the power window
switch is turned to UP, much current flows at the beginning
and end of the operation. So, measure the operation current
in between these points.
Standard value:
5.3 $ 2 A (power supply voltage 14.5 $ 0.3 V
at 23_C)
3. If the operation current is not within the standard value,
do troubleshooting. (Refer to GROUP 54B.)

CIRCUIT BREAKER (INCORPORATED IN

POWER WINDOW MOTOR) CHECK
1. Turn the power window switch to UP to close the window
glass. Keep the switch at the fully-closed position for
another 10 seconds.
2. Release the power window switch and immediately turn
it to DOWN. Under this condition if the window glass starts
to lower within 60 seconds, the circuit breaker can be
judged good.

Section A – A DOOR INSIDE HANDLE PLAY CHECK AND

ADJUSTMENT
A A 1. Measure the door inside handle play.
B Standard value (B): 5.3 mm or more
2. If the play is not within the standard value, remove the
door trim. (REfer to P.42-23.)
3. Adjust the door inside handle play with the clip connecting
the inside handle and the rod.
42-22 BODY – Door

DOOR ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Door Fit Adjustment (Refer to P.42-19.)

4, 5

6 7
21 Nm 4

12 Nm

23 Nm
8 9
15 Nm

5 2 3

Door assembly removal steps Striker removal steps

1. Harness connector 6. Striker
2. Door check connecting bolt 7. Striker shim
3. Door assembly Door switch removal steps
4. Door upper hinge
5. Door lower hinge 8. Door switch cap
9. Door switch

INSPECTION
DOOR SWITCH CONTINUITY CHECK
Driver’s side
Switch Terminal number
position 1 2 3 (Earth)
Released (ON)
Depressed (OFF)
 BODY – Door 42-23
Passenger’s side
Switch Terminal number
position
iti
1 2 (Earth)
Released (ON)
Depressed (OFF)

DOOR TRIM AND WATERPROOF FILM

REMOVAL AND INSTALLATION

6
18
18

Sealant:
3M ATD Part No. 8625 or equivalent
17

16

<Vehicles with 12 5
power windows>
13
2
1 3
<Vehicles without
4 power windows> 11
14

15

7 10
14 10 8
9

Removal steps
AA" 1. Power window and remote- "BA 9. Regulator handle
controlled mirror switch assembly 10. Cap
2. Power window switch panel 11. Door trim
assembly 12. Grip bracket
3. Power window switch 13. Door grip
4. Remote-controlled mirror switch 14. Front arm restraint cover
AB" 5. Door inside handle cover 15. Door lamp lense
6. Delta cover, inner 16. Speaker
AC" "BA 7. Clip 17. Power window switch bracket
"BA 8. Escutcheon "AA 18. Waterproof film
42-24 BODY – Door

CLIP AND CLAW POSITIONS

View A

View E View B View D

View C

View A View B Section A – A

Delta cover,
inner Delta
cover,
Clip inner,
door trim

Door trim
A
A
A Door
A panel

View C Section B – B View D Section C – C

Door trim Claw

Door trim
B

Claw
B C

Cap Cap
C Door lamp lense

View E Section D – D Section E – E

Power window and remote-controlled
D D mirror switch assembly
E

Claw
E

Power window and remote-controlled- Front arm Clip

mirror switch assembly Front arm
restraint cover restraint cover
NOTE
: Clips positions
: Claws positions
 BODY – Door 42-25
REMOVAL SERVICE POINTS
MB990784
AA" POWER WINDOW AND REMOTE-CONTROLLED
MIRROR SWITCH ASSEMBLY/POWER WINDOW
SWITCH PANEL ASSEMBLY REMOVAL
1. Use the special tool to pry out the power window and
remote-controlled mirror switch assembly, first at the front
and then at the rear. (Refer to P.42-24, CLAW AND CLIP
POSITIONS.)

Power window and remote-controlled switch assembly 2. Use a flat-tipped screwdriver to disengage the lower claws
of the power window and remote-controlled mirror switch
Flat-tipped assembly as shown in the illustration, and then remove
screw driver the power window and remote-controlled mirror switch
Door assembly.
trim

Claw

Switch bracket
Claw

MB990784 AB" DOOR INSIDE HANDLE COVER REMOVAL

Use the special tool to pry out the rear part of door inside
A A
handle cover, and then slide the door inside handle cover
in the direction of arrow shown to remove it.
A A

Section A – A

Door trim Claw

AC" CLIP REMOVAL

Use a cloth to remove the clip as shown in the illustration.

Waterproof film INSTALLATION SERVICE POINTS

"AA WATERPROOF FILM INSTALLATION
Inner panel Apply the specified sealant to the shown positions of waterproof
water drain
hole film, and then attach the waterproof film.
Specified sealant: 3M ATD Part No. 8625 or equivalent
Caution
Be sure to apply the sealant below the inner panel water
drain holes so as not to plug them.
42-26 BODY – Door

"BA REGULATOR HANDLE/ESCUTCHEON/CLIP

INSTALLATION
Horizontal line 1. Install the clip and escutcheon to the regulator handle.
2. Close the front door window glass fully, and then install
the regulator handle as shown in the illustration.
30_

Front of vehicle

DOOR GLASS AND REGULATOR

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Door Mirror Removal (Refer to GROUP 51.) D Door Window Glass Adjustment (Refer to P.42-19.)
D Door Trim and Waterproof Film Removal D Door Trim and Waterproof Film Installation
(Refer to P.42-23.) (Refer to P.42-23.)
D Door Mirror Installation (Refer to GROUP 51.)

2 8

6 7
6 5 10

1 5

8
7
9

Door window glass removal steps Power window regulator and motor
"DA D limit switch set-up assembly removal steps
1. Door window inner weather strip AA" 7. Power window regulator and motor
2. Door belt line moulding assembly assembly
3. Door window glass runchannel "BA 8. Power window motor assembly
"CA 4. Door window glass "BA 9. Power window regulator assembly
"CA 5. Glass holder "AA 10. Rear lower sash
"CA 6. Door glass pad
 BODY – Door 42-27
REMOVAL SERVICE POINT
AA" POWER WINDOW REGULATOR AND MOTOR
MB990480 ASSEMBLY REMOVAL
1. Remove the door window glass assembly installation bolts.
2. Lift up the door window glass assembly, and then install
the special tool to the window glass as shown in the
illustration to prevent the window glass falling.
Caution
If a film, etc. is attached to the door window glass,
install the special tool to the outside of window glass
in order to prevent the film peeling.
3. Remove the power window regulator and motor assembly.

INSTALLATION SERVICE POINTS

"AA REAR LOWER SASH INSTALLATION
Be sure to insert the rear lower sash to the window rear sash
(at door) securely.

"BA POWER WINDOW MOTOR ASSEMBLY/POWER

Power window WINDOW REGULATOR ASSEMBLY
motor assembly Arm INSTALLATION
Adjust the power window motor assembly and power window
regulator assembly positions as follows:
1. Connect the power window motor assembly connector
and the power window switch connector to the wiring
harness of body side.
Bracket 2. Turn on the power window switch to operate the power
30° or less window motor for 3 seconds in the direction which the
window glass closes.
3. Disconnect the power window motor assembly connector
and the power window switch connector from the wiring
harness of body side.
4. Assemble the power window motor assembly and the
power window regulator so that the arm and bracket are
positioned as shown in the illustration, and then install
the power window motor assembly.
42-28 BODY – Door

Caution
When installing the power window regulator, do not
set it in the window glass fully-closed position. If
installing the power window regulator in that condition,
the window glass safety mechanism will not functions
correctly.

"CA DOOR WINDOW GLASS/GLASS HOLDER/DOOR

GLASS PAD INSTALLATION
1. Install the door glass pads and glass holders to the window
glass in the positions shown.
Glass holders
Standard value (A): 55.0 mm
Standard value (B): 419.0 – 421.0 mm
Standard value (C): 55.0 mm
2. Install the glass to the window regulator assembly.
A B C
Caution
Do not activate the window regulator assemble before
installing the glass as the resetting in the limit switch
is cancelled.

"DALIMIT SWITCH SETTING

1. Fully close the window glass.
NOTE
The limit switch learning operation is complete once the
window glass is fully closed.
2. Check that the limit switch operates normally.
(Refer to P.42-20.)

INSPECTION
POWER WINDOW MAIN SWITCH CONTINUITY CHECK
NOTE
Since the power window main switch uses the SWS system, check the continuity with the input signal
check method. Refer to GROUP 54B – Troubleshooting.
 BODY – Door 42-29
POWER WINDOW SUB SWITCH CONTINUITY CHECK
Switch Terminal No.
position
iti
1 4 6
UP

DOWN

Power window POWER WINDOW RELAY CONTINUITY CHECK

relay
Battery
y Terminal No.
voltage
lt
1 3 4 5
Not applied
Applied
42-30 BODY – Door

DOOR HANDLE AND LATCH

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Door Trim Removal (Refer to P.42-23.) D Door Inside Handle Play Check (Refer to P.42-21.)
D Door Outside Handle Play Check (Refer to P.42-20.)
D Door Trim Installation (Refer to P.42-23.)

2
3

1
6 Nm

6 5

12 Nm
4

Door handle and door latch Door check removal steps

assembly removal steps D Waterproof film (Refer to P.42-23.)
"CA 1. Door inside handle "AA 6. Door check
D Waterproof film (Refer to P.42-23.)
2. Door outside handle
3. Door lock key cylinder
"BA 4. Rear lower sash
5. Door latch assembly

INSTALLATION SERVICE POINTS

"AA DOOR CHECK INSTALLATION
Identification mark Install with the following identification marks upward.

Items Identification mark

Left door 21L

Right door 21R

 BODY – Door 42-31
"BA REAR LOWER SASH INSTALLATION
Be sure to install the rear lower sash to the window rear sash
(at door) securely.

Inner cable Clip "CA DOOR INSIDE HANDLE INSTALLATION

Outer 1. Install the inside lock cable to the door inside handle as
cable end
follows:
(1) Install the inner cable end in the inside lock cable
to the clip in the door inside handle.
(2) Turn the inside lock knob to the door lock position.
(3) Install the outer cable end to the door inside handle
securely.
Door inside handle (4) Install the clip to the inner cable.
Inside handle rod
2. Install the inside handle rod to the door inside handle.
3. Install the door inside handle to the door.

<Left side>
INSPECTION
DOOR LOCK ACTUATOR CHECK
Lock
View A Unlock <Left side>
Rod position Terminal No. Rod operation
4 6
LOCK LOCK to UNLOCK
UNLOCK UNLOCK to LOCK
A <Right side>
<Right side>
Rod position Terminal No. Rod operation
View B Unlock Lock 1 2 3 4 6
LOCK LOCK to UNLOCK
UNLOCK UNLOCK to LOCK
LOCK
UNLOCK

DOOR LOCK KEY CYLINDER SWITCH CONTINUITY

CHECK <Vehicles with central door locking system>
Passenger’s side only
Switch Terminal No.
position
1 2 3
LOCK
Neutral (OFF)
UNLOCK
42-32 BODY – Door

WINDOW GLASS RUNCHANNEL AND DOOR OPENING

WHETHERSTRIP
REMOVAL AND INSTALLATION

5
Sectional view of
4
3 clip position

2
1

Sectional view of
clip position

Door inner opening weatherstrip Door window glass runchannel

removal steps removal steps
D Scuff plate (Refer to GROUP 52A.) 3. Door window glass runchannel
D Cowl side trim (Refer to GROUP 52A.) 4. Door window glass lower
D Center pillar lower trim (Refer to runchannel
GROUP 52A.) Door beltline moulding removal
1. Door inner opening weatherstrip
steps
Door outer opening weatherstrip D Outside rear view mirror (Refer to
removal GROUP 51.)
AA" 2. Door outer opening weatherstrip 5. Door beltline moulding

REMOVAL SERVICE POINT

15 mm AA" DOOR OUTER OPENING WEATHERSTRIP
4 mm REMOVAL
Make a tool as shown and remove the door opening
8 mm weatherstrip.
Thickness
1mm
 BODY – Back Door 42-33

BACK DOOR
SERVICE SPECIFICATION
Item Standard value

Back door handle play mm 2.0 – 8.0

SEALANT
Item Specified sealant Remark

Waterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer

SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Back door trim removal

TROUBLESHOOTING
The central door locking (back door) is controlled by the Smart Wiring System (SWS). For troublesshooting,
refer to GROUP 54B – Troubleshooting.

ON-VEHICLE SERVICE
BACK DOOR FIT ADJUSTMENT
1. If the striker and latch mesh badly, move the striker forward
and backward or right and left to adjust.
2. If uneven clearance is present between back door and
body, reposition the hinge and striker and/or change the
thickness of shim (change the number of shim) to adjust
the clearance.

Section A – A BACK DOOR HANDLE PLAY CHECK

1. Measure the back door handle play.
A
Standard value (B): 2.0 – 8.0 mm
2. If the back door handle play is not within the standard
value, check the back door handle and door latch assembly.
A Replace if necessary.

B
42-34 BODY – Back Door

BACK DOOR ASSEMBLY

REMOVAL AND INSTALLATION
Pre–removal Operation Post–installation Operation
D High–mounted Stop Lamp Removal D High–mounted Stop Lamp Installation
(Refer to GROUP 54A.) (Refer to GROUP 54A.)
D Spare Tyre Carrier Removal (Refer to GROUP 51.) D Spare Tyre Carrier Installation
(Refer to GROUP 51.)
D Back Door Fit Adjustment (Refer to P.42-33.)

3 4

2
22 Nm
5
9

1
6
7
10

6
3 5

Removal steps
D Back door trim and waterproof film 5. Door check
(Refer to P.42-36.) 6. Back door lower hinge
1. Harness connector 7. Shim
2. Back door assembly 8. Damper mail
3. Back door upper hinge "BA 9. Striker
4. Shim "AA 10. Back door opening weatherstrip
 BODY – Back Door 42-35
INSTALLATION SERVICE POINT
"AA BACK DOOR OPENING WEATHERSTRIP
INSTALLATION
Align the marking section on the back door opening
weatherstrip with the centre of the body.

Striker centre Latch centre "BA STRIKER INSTALLATION

Install the striker so that the striker centre does not deviate
more than 1.5 mm from the latch centre.
+1.5 mm

– 1.5 mm

Striker
Latch
42-36 BODY – Back Door

BACK DOOR TRIM AND WATERPROOF FILM

REMOVAL AND INSTALLATION

1 2

View A

View A Section A – A
Clip 1

A
Door panel

1
Sealant:
: Clip positions 3M ATD Part No. 8625 or equivalent

Removal steps
1. Back door trim
2. Waterproof film
 BODY – Back Door 42-37
BACK DOOR HANDLE AND LATCH
REMOVAL AND INSTALLATION
Post-installation Operation
Back Door Handle Play Check (Refer to P.42-33.)

1
2

1
3

Back door handle and lock key Back door latch removal steps
cylinder removal steps D Back door trim and waterproof film
D Back door trim and waterproof film (Refer to P.42-36.)
(Refer to P.42-36.) 3. Back door lock actuator
1. Back door handle 4. Back door latch assembly
2. Back door lock key cylinder

Unlock INSPECTION
View A
BACK DOOR LOCK ACTUATOR CHECK

Rod position Terminal No. Rod operation

4 6
Lock
LOCK LOCK to UNLOCK

UNLOCK UNLOCK to LOCK

A
42-38 BODY – Back Door/Keyless Entry System

BACK DOOR LATCH CONTINUITY CHECK

Switch Terminal No.
position
4 6
Back door opend
Back door closed

DOOR LOCK KEY CYLINDER SWITCH CONTINUITY

CHECK <Vehicles with central door locking system>
Switch Terminal No.
position
1 2 3
LOCK
Neutral (OFF)
UNLOCK

KEYLESS ENTRY SYSTEM

TROUBLESHOOTING
The keyless entry system is controlled by the Smart Wiring System (SWS). For troublesshooting, refer
to GROUP 54B – Troubleshooting.

Battery ON-VEHICLE SERVICE

Open HOW TO REPLACE A BATTERY OF THE
Claw TRANSMITTER
1. Remove the set screw to remove the battery from the
transmitter.
2. Install a battery with its (+) side face-down.
Battery required for replacement:
Screw Coin type battery CR2032
O-ring
3. Insert the claw first, and with care not to displace the
O-ring, assemble the transmitter.
4. Check to see if the keyless entry system operates.
NOTE
(1) Do not let water or dust stick to the inside of the
transmitter when it is open. Also, do not touch the
precision electronic device.
(2) If the O-ring is displaced during the assembly of the
transmitter, water or dust penetrates in it causing
trouble.
 BODY – Keyless Entry System 42-39
ENCRYPTED CODE REGISTRATION METHOD
Each individual encrypted code is registered inside the
transmitter, and so it is necessary to register these codes
with the EEPROM inside the ETACS-ECU in the following
cases.
D When either the transmitter or ETACS-ECU is replaced;
D If a second transmitter is to be used;
D 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 memory
area of the EEPROM (four different transmitters can be used).
When the code for the first transmitter is registered, the
previously-registered codes for four transmitters are cleared.
Therefore, if you are using more than two transmitters or are
adding a second transmitter, the codes for all the transmitters
must be registered at the same time.
1. Check that the doors lock normally when the ignition key
is inserted into the door key cylinder and turned.
2. Insert the ignition key in the ignition switch.
3. Connect the MUT-II to the diagnosis connector.
NOTE
This sets the system in encrypted code registration standby
mode. If MUT-II is not used, connect terminal No.1 of
the diagnosis connector to earth.
Caution
Always turn the ignition switch to LOCK (OFF) position
before connecting and disconnecting the MUT-II or
earth.

4. Within 10 seconds after connecting the MUT-II or earth,

press the hazard switch six times.
MUT-II connected
NOTE
(1) The doors will lock and unlock once after pressing
Within 10 seconds the hazard switch six times, and the system will switch
to registration mode.
1 2 3 4 5 6 (2) The hazard switch alternates between ON and OFF
Hazard ON
switch each time pressing the hazard switch (Refer to
OFF illustration).
5. Press the lock switch or unlock switch of the transmitter
switch, and then press it two times within 10 seconds
of the first press. This will register the code.
6. After registration is completed, the doors will be
automatically locked and unlocked once.
7. If you are using more than two transmitters or have added
a second transmitter, the same registration procedure
should be carried out for the remaining transmitters, and
it should be carried out within one minute after registration
of the code for the first transmitter has been completed.
The registration procedure are all the same for all
transmitters.
42-40 BODY – Keyless Entry System

8. Registration mode will be terminated under the following

conditions.
D When the encrypted codes for four transmitters have
been registered;
D When one minute has passed after registration mode
started;
D When the MUT-II is disconnected (earth is released);
D When the ignition key is removed;
9. After registration mode has been completed, carry out
the followings to make sure that the keyless entry system
operates.
D Pull the ignition key out.
D Close all of the doors.

HAZARD LAMP ANSWERBACK ADJUSTMENT

The following functions can be adjusted by operating input switches. The adjustments will be stored in
the ECU memory even after a battery cable is disconnected:
D Switching of keyless entry answerback function (From activation to desactivation, or viceversa)
D Initialization of all the ETACS functions (From desactivation to activation)
1. Entry conditions to the adjustment mode
The ETACS-ECU sounds a buzzer once when all of the following conditions are satisfied, and then
enters the adjustment mode:
D Hazard warning lamp switch: OFF
D Diagnosis control: ON (Connect the MUT-II or earth the diagnosis connector No.1 terminal.)
D Key reminder switch: OFF
D Ignition switch: LOCK (OFF)
D Driver’s door switch: OFF (Close the driver’s door.)
D If all of the conditions above are satisfied, the windshield washer switch will be turned on for
more than 10 seconds.
2. Exit conditions from the adjustment mode
The ETACS-ECU cancels the adjustment mode when any of the following conditions is satisfied:
D Diagnosis control: ON (Disconnect the MUT-II or disconnect the diagnosis connector No.1 terminal
from the earth.)
D Key reminder switch: ON (Pull out the ignition key.)
D Ignition switch: Other than LOCK (OFF)
D Driver’s door switch: ON (Open the driver’s door.)
D After the ETACS-ECU has entered the adjustment mode, no adjustment is made within 3 minutes
(If any adjustment is made within 3 minutes, the ETACS-ECU monitors a adjustment operation
for other 3 minutes.)
D Other warning buzzer(s) sounds
 BODY – Keyless Entry System 42-41
3. Adjustment of functions
Function Adjustment procedure

Keyless entry answerback function When the transmitter lock switch is turned on twice continuously within 2
seconds, the lock answerback function toggles on and off.
D If the function toggles on, the buzzer sounds once (default condition).
D If the function toggles off, the buzzer sounds twice,
When the transmitter unlock switch is turned on twice continuously within 2
seconds, the unlock answerback function toggles on and off.
D If the function toggles on, the buzzer sounds once (default condition).
D If the function toggles off, the buzzer sounds twice,

Initialization of all the ETACS func- When the windshield washer switch remains on for more than 20 seconds, the
tions (From desactivation to activa- buzzer sounds twice and then all of the following functions will be initialized.
tion) D Automatic lighting sensor sensitivity
D Automatic headlamp switch-off function
D Vehicle-speed dependent wiper
D Outside mirror automatic rest function
The buzzer will sound in 10 seconds (indicating that the ETACS-ECU enters
the adjustment mode), but the washer switch must remains off for 20 seconds
in order to initialize all the functions.
If the windshield washer switch remains on for more than 20 seconds without
entering the adjustment mode, the system enters the adjustment mode in 10
seconds, but does not initialize all of the functions.

KEYLESS ENTRY SYSTEM

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Side Cover Removal and Installation
(See GROUP 52A – Instrument Panel.)

ETACS-ECU
42-42 BODY – Sunroof

SUNROOF
SERVICE SPECIFICATION
Items Standard value

Roof lid glass operating current A (at 20_C) 7 or less

TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptom Inspection procedure Reference page

The sunroof does not operate when the ignition switch is turned 1 42-43
to ON.

The motor does not reverse its direction when a load of 140 N 2 42-44
or more is applied while the sunroof is closing.

The timer does not operate during 30 seconds after the ignition 3 42-44
switch is turned to LOCK (OFF) position.

Opening or closing of the sunroof is possible immediately after 4 42-44

turning the ignition switch to LOCK (OFF) position, but the timer
function does not operate continuously for another 30 seconds
if the driver’s side door is opened within 30 seconds.
 BODY – Sunroof 42-43
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1
The sunroof does not operate when the ignition switch is Probable cause
turned to ON.
The cause may be a malfunction of a sunroof switch, sunroof-ECU power supply D Malfunction of sunroof switch
circuit or earth circuit. D Malfunction of sunroof-ECU
D Malfunction of wiring harness or connector

NG
Measure at the sunroof-ECU connector D-06. Check the following connectors: C-74, C-76, C-02, C-43, D-06
D Disconnect the connector and measure at the harness side.
OK NG
D Ignition switch: ON
D Voltage between 2 and body earth
OK: System voltage Repair
Check trouble symptoms.
NG
OK
Check the harness wire, and repair if necessary.
D Between ignition switch (IG2) and sunroof-ECU

(1) NG
Measure at the sunroof-ECU connector D-06. Check the following connectors: C-27, D-06
D Disconnect the connector and measure at the harness side.
OK NG
(1) Voltage between 1 and body earth
(2) Voltage between 3 and body earth (2) NG Repair
OK: System voltage Check trouble symptoms.
OK NG
Check the harness wire, and repair if necessary.
D Between fusible link No.3 and sunroof-ECU

Check the following connectors: C-72, C-73, D-06

OK NG

Repair
Check trouble symptoms.
NG

Check the harness wire, and repair if necessary.

D Between fusible link No.3 and sunroof-ECU

NG
Measure at the sunroof-ECU connector D-06. Check the following connectors: D-06, C-73, C-75, C-01
D Disconnect the connector and measure at the harness side.
D Continuity between 5 and body earth OK NG
OK: Continuity
Repair
OK Check trouble symptoms.
NG

Check the harness wire, and repair if necessary.

D Between ignition switch (IG2) and sunroof-ECU
NG
Check the sunroof switch continuity. (Refer to P.42-49.) Replace
OK
NG
Measure at the sunroof-ECU connector D-06. Check the following connectors: D-06, D-08, C-73, C-75, C-01
D Disconnect the connector and measure at the harness side.
(1) Continuity between 7 and body earth OK NG
OK: Continuity [Sunroof switch (UP) : ON]
(2) Continuity between 6 and body earth Repair
OK: Continuity [Sunroof switch (CLOSE) : ON] Check trouble symptoms.
(3) Continuity between 8 and body earth NG
OK: Continuity [Sunroof switch (OPEN) : ON]
Check the harness wire, and repair if necessary.
OK D Between sunroof-ECU and sunroof switch
D Between sunroof switch and earth
Replace the sunroof-ECU.
42-44 BODY – Sunroof

INSPECTION PROCEDURE 2
The motor does not reverse its direction when a load of 140 Probable cause
N or more is applied while the sunroof is closing.
The sunroof-ECU monitors the load conditions from the amount of current flowing D Malfunction of sunroof-ECU
to the motor. If more than the constant amount of current is flowing, the direction
of motor operation is reversed to prevent jamming.
If the motor does not reverse direction even when an excessive load is being applied,
the cause may be a malfunction of the sunroof-ECU.

Replace the sunroof-ECU.

INSPECTION PROCEDURE 3
The timer does not operate during 30 seconds after the Probable cause
ignition switch is turned to LOCK (OFF) position.
The sunroof-ECU has a timer function which operates during 30 seconds after the D Malfunction of wiring harness or connector
ignition switch is turned to LOCK (OFF) position. If the timer does not operate, D Malfunction of sunroof-ECU
the cause may be a malfunction of the sunroof-ECU or of the wiring harness or
connector.

NG
Measure at the sunroof-ECU connector D-06. Check the following connectors: C-74, C-76, C-02, C-43, D-06
D Disconnect the connector and measure at the harness side.
OK NG
D Ignition switch: ON
D Voltage between 2 and body earth
OK: System voltage Repair
Check trouble symptoms.
NG
OK
Check the harness wire, and repair if necessary.
D Between ignition switch (IG2) and sunroof-ECU

Replace the sunroof-ECU.

INSPECTION PROCEDURE 4
Opening or closing of the sunroof is possible immediately Probable cause
after turning the ignition switch to LOCK (OFF) position,
but the timer function does not operate continuously for
another 30 seconds if the driver’s side door is opened
within 30 seconds.
The operation period for the sunroof timer is extended when an on signal is output D Malfunction of wiring harness or connector
from the driver’s-side door switch. Because of this, if the timer operation period D Malfunction of driver’s door switch
is not extended, the cause may be a malfunction of the door switch input circuit. D Malfunction of sunroof-ECU

NG
Check the driver’s door switch continu- Replace
ity. (Refer to P.42-22.)
OK
NG
Check the following connectors: Repair
C-82, C-68, D-27, D-05
OK
NG NG
Check trouble symptoms. Check the harness wire between driv- Repair
er’s door switch and sunroof-ECU.
OK
Replace the sunroof-ECU.
 BODY – Sunroof 42-45
SUNROOF-ECU TERMINAL VOLTAGE CHART

Terminal No. Check Item Check Condition Normal Condition

1 ECU power supply Always System voltage

2 Sensor power supply Ignition switch: ON System voltage

5 Earth Always 0V

6 Sunroof switch (CLOSE, Sunroof switch ON 0V

DOWN input) (close position or down
position) OFF System voltage

7 Sunroof switch (UP input) Sunroof switch ON 0V

(up position)
OFF System voltage

8 Sunroof switch (OPEN Sunroof switch ON 0V

input) (open position)
OFF System voltage

9 Driver’s door switch Driver’s door Open Continuity

Close No continuity
42-46 BODY – Sunroof

ON-VEHICLE SERVICE
WATER TEST
Check if there are any leaks in the sunroof by the following
procedure.
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 when the
hose is held vertically facing upwards.

3. Hold the end of the hose approximately 30 cm above

the roof and let the water run onto the weatherstrip for
Hose
5 minutes or more.
Approx. 30cm
4. While doing this, check if any water leaks through into
the passenger compartment from around the roof lid glass.

SUNROOF FIT ADJUSTMENT

1. Fully close the roof lid glass.
2. Fully open the sunshade.
3. Loosen the roof lid glass assembly mounting screws, and
then slide the roof lid glass assembly along the slot in
the mechanish assembly to adjust the height of the roof
lid glass.
4. After adjustment, check to be sure that the sunroof operates
smoothly.
 BODY – Sunroof 42-47
SUNROOF
REMOVAL AND INSTALLATION
Post-installation Operation
D Sunroof Water Test (Refer to P.42-46.)
D Sunroof Fit Adjustment (Refer to P.42-46.)

1 Section A – A

Claw 3

3 4

A
NOTE A 2
: Claw positions

1. Roof lid glass assembly Sunroof motor assembly removal

Sunroof switch removal steps steps
2. Sunroof switch cover D Headlining (Refer to GROUP 52A.)
3. Sunroof switch AB" "BA 5. Sunroof motor assembly
Drain hose removal steps Sunroof assembly removal steps
D Headlining (Refer to GROUP 52A.) D Headlining (Refer to GROUP 52A.)
D Splash shield (Rear drain hose) AA" "AA 4. Drain hose
D Cowl side trim and instrument lower 6. Room lamp bracket
panel (Refer to GROUP 52A.) 7. Sunroof assembly
D Engine-ECU, throttle servo relay and
throttle controller (Driver’s-side drain
hose)
AA" "AA 4. Drain hose
42-48 BODY – Sunroof

REMOVAL SERVICE POINTS

AA" DRAIN HOSE REMOVAL
Tie a cord to the end of the drain hose, and wind tape around
it so that there is no unevenness. Then pull the drain hose
out from the passenger compartment.
Drain hose
Cord

AB" SUNROOF MOTOR ASSEMBLY REMOVAL

Caution
Always close the roof lid glass fully before removing the
sunroof motor. If the fully-closed positions of the roof
lid glass and the sunroof motor are not the same, the
sunroof will not operate properly.
NOTE
If there is a problem with the sunroof motor so that the roof
lid glass cannot close fully, use an Allen key to turn the gear
section of the sunroof motor to fully close the roof lid glass.

INSTALLATION SERVICE POINTS

"AA DRAIN HOSE INSTALLATION
1. Tie the cord that was used during removal to the end
of the drain hose, and wind tape around it so that there
is no unevenness.
2. Pull the cord to pull through the drain hose
Cord Drain hose

3. Install the grommet, and then position the drain hose so

that it protrudes from the grommet as shown in the
Grommet illustration.

20 – 30 mm
 BODY – Sunroof 42-49
"BA SUNROOF MOTOR ASSEMBLY INSTALLATION
If the fully-closed position of the sunroof motor assembly is
incorrect, set the sunroof motor to the fully-closed position
by the following procedure, and then install the sunroof motor.
1. Set the sunroof to full tilt-up position by using the close
switch. The roof lid glass moves full tilt position only step
by step with about 30 mm steps.
2. Hold the close switch for about 3 seconds at full tilt positon.
Do not release the switch at hard stop position before
initialization is compleyed.
3. Set the sunroof to full close position by using the close
switch.
4. Set the sunroof to full open position by using the open
switch. Do not stop the sunroof while it is moving.
5. Set the sunroof to full close position by using the close
switch. Do not stop the sunroof while it is moving.
NOTE
Sunroof-ECU will initialize when the sunroof motor stops.

INSPECTION
ROOF LID GLASS OPERATION CURRENT CHECK
1. Remove the sunroof fuse and connect a circuit analyser
as shown in the illustration.
2. Press the sunroof switch to operate the sunroof, and then
measure the operation current while the roof lid glass
is moving (except when the sunroof starts to operate,
when it is fully open, when it is fully closed and when
it is fully tilted up).
Standard value: 7 A or less (at 20_C)
3. If the operation current is not within the standard value,
check the following points.
D Installation condition, warping or jamming of sunroof
assembly
D Sticking of drive cable
D Tilt of roof lid glass

Slide close, SUNROOF SWITCH CONTINUITY CHECK

Tilt down Tilt up
Switch position Terminal No.
Open
3 4 5 6
Open
Off
Tilt up
Slide close, Tilt down
42-50 BODY – Sunroof

DISASSEMBLY AND REASSEMBLY

9
11

9
6

1
2

4
9
10
5

11

3 10

Disassembly steps
1. Roof lid glass assembly 7. Sunshade assembly
2. Weatherstrip 8. Drive unit cover
3. Sunroof motor assembly 9. Mechanish assembly
4. Roof wind deflector panel 10. Drive unit assembly
5. Rail end 11. Frame assembly
6. Roof drip channel
 42-1

BODY
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FRONT DOOR TRIM AND WATERPROOF

FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OUTLINE OF CHANGES . . . . . . . . . . . . . . . . . 2
REAR DOOR TRIM AND WATERPROOF
WINDOW GLASS . . . . . . . . . . . . . . . . . . . 2 FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT DOOR GLASS
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 2
AND REGULATOR . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 2
REAR DOOR GLASS
QUARTER WINDOW GLASS . . . . . . . . . . . . . 3 AND REGULATOR . . . . . . . . . . . . . . . . . . . . . . 13
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REAR DOOR HANDLE AND LATCH . . . . . 16
WINDOW GLASS RUNCHANNEL AND
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 6 DOOR OPENING WEATHERSTRIP . . . . . . 18
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 7
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REAR DOOR ASSEMBLY . . . . . . . . . . . . . . . . 7
42-2 BODY – General/Window glass

GENERAL
OUTLINE OF CHANGES
Due to the introduction of 5-door models, the following service procedures have been added. The
other items are the same as before.
 Quarter window glass removal and installation
 Rear door assembly removal and installation
 Front door trim removal and installation
 Rear door trim and waterproof film removal and installation
 Front door glass and regulator installation service points
 Rear door glass and regulator removal and installation
 Rear door handle and latch removal and installation
 Sunroof removal and installation

WINDOW GLASS
ADHESIVE
Items Specified adhesive

Quarter window glass 3M ATD Part No. 8609 Super Fast Urethane Auto Glass
Sealant or equivalent

SPECIAL TOOLS
Tool Number Name Use
MB990480 Quarter window Removal and installation of quarter window
glass glass
 BODY – Window Glass 42-3
QUARTER WINDOW GLASS
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
 Quarter Trim, Lower (R.H.) Removal and
Installation (Refer to GROUP 52A.)
 Headlining Removal and Installation
(Refer to GROUP52A.)

mm

Section A – A Section B – B
C
3
B C
B 1
A
A D
D
B
B E Primer
34.5 1

E Section D – D Section E – E
Section C – C Primer 1
1
2
12.5 12.5

Primer
Primer
1 12.5

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent

3 2

Removal steps
A A 1. Quarter window glass
A 2. Dual lock fastener
A 3. Clip
42-4 BODY – Window Glass

REMOVAL SERVICE POINT

A QUARTER WINDOW GLASS REMOVAL
1. Apply cloth tape to protect quarter window glass.
2. Make mating marks on the quarter window glass and body.

Cloth tape

3. Use glass adhesive knife to cut away adhesive.

Keep glass adhesive knife at right angles with body flange
(from inside the vehicle),and put the blade at body flange.
Then cut away adhesive along the body flange.

Glass adhesive knife

MB990480 4. Use special tool MB990480 to remove the quarter window

glass.
 BODY – Window Glass 42-5
5. Use a knife to cut away the remaining adhesive so that the
thickness is within 2 mm around the entire circumference of
the body flange.
6. Finish the flange surfaces so that they are smooth.
Caution
(1) Use care not to remove more adhesive than
necessary, or the adhesive could weaken.
(2) Be careful also not to damage the paintwork on
the body surface with the knife. If the paintwork
is damaged, repair the damaged area with repair
paint or anti-rust agent.
7. When reusing quarter window glass, remove the remaining
adhesive on the quarter window glass completely. Then,
decrease the windshield with isopropyl alcohol.
8. Decrease the body flange in the same way.
Caution
Before the next job, leave the decreased parts for 3
minutes or more to dry. Also, do not touch any cleaned
surface.

INSTALLATION SERVICE POINT

A CLIP/DUAL LOCK FASTENER/
QUARTER WINDOW GLASS INSTALLATION
1. Carry out the following procedure to re-install quarter
window glass.
(1) Fit the clip into the body.

(2) Cut away the clip fitting convex on the quarter window
Fitting convex on the glass.
quarter window glass NOTE
If you fail to cut away the convexes, the glass may
be fitted improperly.
2. Use a unleaded gasoline to degrease the glass and the
vehicle body, which the dual-lock fasteners are adhered
to.
42-6 BODY – Window Glass/Door

Dual lock fastener 3. Install the dual lock fasteners to the body flange in the
installation positions specified positions.
4. Install the dual lock fasteners to the windshield in the
positions corresponding to the ones on the body flange
where the dual lock fasteners have been installed.
5. Apply the primer and adhesive.
6. Install the glass in the same manner as for the windshield.

Dual lock
fastener Glass end line

Side panel Align the dual

flange end lock fastener end
line and the marking.
: Dual lock fastener
installation positions

DOOR
SERVICE SPECIFICATIONS
Items Standard value

Glass pad and glass Between glass holder and glass Front 50.0
holder installation rear end
position Rear –
mm
Between glass holders Front 419.0 – 421.0

Rear –

Between glass holder and glass Front 45.0

front end
Rear 53.0

SEALANT
Items Specified sealant Remark

Waterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer

SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Door trim removal
 BODY – Door 42-7
TROUBLESHOOTING
The power window and central door locking is controlled by ETACS-ECU. For troubleshooting, refer to
GROUP 54B – Troubleshooting.
REAR DOOR ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Door Fit Adjustment

4, 5

4 7

30 Nm

2 11 Nm
5 3
21 Nm
8

1
9
11 Nm

Door assembly removal steps Striker removal steps

1. Harness connector 6. Striker
2. Door check connecting bolt 7. Striker shim
3. Door assembly Door switch removal steps
4. Door upper hinge
5. Door lower hinge 8. Door switch cap
9. Door switch

INSPECTION
DOOR SWITCH CONTINUITY CHECK

Switch Terminal number

position
iti
2 Earth
Released (ON)
Depressed (OFF)
42-8 BODY – Door

FRONT DOOR TRIM AND WATERPROOF FILM

CLIP AND CLAW POSITIONS

View A

View B

View A View B
Section A – A
Delta cover, Delta cover,
inner inner, door trim

Clip

Door
A trim
A
Door
A A panel

NOTE
Clips
Claws
 BODY – Door 42-9
REAR DOOR TRIM AND WATERPROOF FILM
REMOVAL AND INSTALLATION

14

14

Sealant:
13 3M ATD Part No. 8625 or equivalent

10 4
11

9
2 <Vehicles without
4
1 power windows>
3
9

<Vehicles with
power windows>
8
5 6
8 7

12

12
Removal steps
1. Power window switch panel 8. Cap
assembly 9. Door trim
2. Power window switch panel 10. Grip bracket
3. Power window switch 11. Door grip
A 4. Door inside handle cover 12. Door lamp lense
B B 5. Clip 13. Power window switch bracket
B 6. Escutcheon A 14. Waterproof film
B 7. Regulator handle
42-10 BODY – Door

View D

View B

View A

View C
View A View B
Section A – A Section B – B
Rear
Clip door trim Claw
B
Rear door
trim

B
Rear Door panel Cap
A door trim Cap

View C View D
Section C – C Section D – D
Claw Rear arm restraint cover
D D
C
Rear
door
trim
Door
Door lamp lamp
lense lense Claw
C Power window
switch panel
assembly

NOTE
Clips
Claws
 BODY – Door 42-11
Inside handle A REMOVAL SERVICE POINTS
A DOOR INSIDE HANDLE COVER REMOVAL
1. Insert the special tool between the inside handle upper
part and the inside handle cover, and then disengage
the upper claw of the inside handle.
MB990784 2. Disengage the lower claw of the inside handle in the same
manner as for the upper claw.
3. Remove the door trim.
A
4. Remove the inside handle cover from the door trim.
Inside handle
Section A – A cover

Claw

Inside
Inside handle
handle cover

Claw

B CLIP REMOVAL

Use a cloth to remove the clip as shown in the illustration.

Waterproof film INSTALLATION SERVICE POINTS

A WATERPROOF FILM INSTALLATION
Apply the specified sealant to the shown positions of waterproof
film, and then attach the waterproof film.
Specified sealant: 3M ATD Part No. 8625 or equivalent
Caution
Be sure to apply the sealant below the inner panel water
drain holes so as not to plug them.

B REGULATOR HANDLE/ESCUTCHEON/CLIP

INSTALLATION
Horizontal line 1. Install the clip and escutcheon to the regulator handle.
2. Close the front door window glass fully, and then install
the regulator handle as shown in the illustration.
30

Front of vehicle
42-12 BODY – Door

FRONT DOOR GLASS AND

REGULATOR
Glass pads and DOOR WINDOW GLASS/GLASS HOLDER/DOOR
glass holders
GLASS PAD INSTALLATION
1. Install the door glass pads and glass holders to the window
glass in the positions shown.
Standard value (A): 50.0 mm
A C
Standard value (B): 419.0 – 421.0 mm
B
Standard value (C): 45.0 mm
2. Install the glass to the window regulator assembly.
Caution
Do not activate the window regulator assemble before
installing the glass as the resetting in the limit switch
is cancelled.

INSPECTION
POWER WINDOW MAIN SWITCH CONTINUITY CHECK
NOTE
Since the power window main switch uses the SWS system, check the continuity with the input signal
check method. Refer to GROUP 54B – Troubleshooting.
 BODY – Door 42-13
REAR DOOR GLASS AND REGULATOR
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
 Door Trim and Waterproof Film Removal (Refer  Door Window Glass Adjustment
to P.42-9.)  Door Trim and Waterproof Film Installation (Refer
to P.42-9.)

4
3
1 13
2

12
10

11

6 8 5
7

11
9
10

Door window glass removal steps Power window regulator and motor
1. Door window inner weather strip assembly removal steps
2. Door belt line moulding assembly 9. Power window regulator and motor
3. Door window glass runchannel assembly
4. Rear center sash A 10. Power window motor assembly
5. Rear lower sash A 11. Power window regulator assembly
B 6. Rear door window glass 12. Stationary window glass
B 7. Glass holder 13. Stationary window glass weather
B 8. Door glass pad strip
42-14 BODY – Door

INSTALLATION SERVICE POINTS

A POWER WINDOW MOTOR ASSEMBLY/POWER
WINDOW REGULATOR ASSEMBLY
INSTALLATION
Adjust the power window motor assembly and power window
regulator assembly positions as follows:
1. Connect the power window motor assembly connector
and the power window switch connector to the wiring
harness of body side.
2. Turn on the power window switch to operate the power
window motor for 3 seconds in the direction which the
window glass closes.
3. Disconnect the power window motor assembly connector
and the power window switch connector from the wiring
Bracket Arm
harness of body side.
4. Assemble the power window motor assembly and the
power window regulator so that the arm and bracket are
30° or less positioned as shown in the illustration, and then install
the power window motor assembly.
Power window Caution
motor assembly When installing the power window regulator, do not
set it in the window glass fully-closed position. If
installing the power window regulator in that condition,
the window glass safety mechanism will not functions
correctly.

B REAR DOOR WINDOW GLASS/GLASS

HOLDER/DOOR GLASS PAD INSTALLATION
1. Install the door glass pad and glass holder to the window
glass in the position shown.
Glass pad and Standard value (A): 53.0 mm
glass holder
2. Install the glass to the window regulator assembly.
Caution
Do not activate the window regulator assemble before
A installing the glass as the resetting in the limit switch
is cancelled.
 BODY – Door 42-15
INSPECTION
POWER WINDOW SUB SWITCH CONTINUITY CHECK

Switch Terminal No.

position
iti
1 4 6
UP

DOWN

Power window relay POWER WINDOW RELAY CONTINUITY CHECK

Battery
y Terminal No.
voltage
lt
1 3 4 5
Not applied
Applied
42-16 BODY – Door

REAR DOOR HANDLE AND LATCH

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Door Trim Removal (Refer to P.42-9.)  Door Inside Handle Play Check
 Door Outside Handle Play Check
 Door Trim Installation (Refer to P.42-9.)

3
1

6 Nm

Door handle and door latch Door check removal steps

assembly removal steps  Waterproof film (Refer to P.42-9.)
B 1. Door inside handle A 4. Door check
 Waterproof film (Refer to P.42-9.)
2. Door outside handle
3. Door latch assembly

INSTALLATION SERVICE POINTS

A DOOR CHECK INSTALLATION
Identification mark Install with the following identification marks upward.

Items Identification mark

Left door 26L

Right door 26R

 BODY – Door 42-17
Clip B DOOR INSIDE HANDLE INSTALLATION
Outer Inner cable
cable end 1. Install the inside lock cable to the door inside handle as
follows:
(1) Install the inner cable end in the inside lock cable
to the clip in the door inside handle.
(2) Turn the inside lock knob to the door lock position.
(3) Install the outer cable end to the door inside handle
securely.
Door inside handle (4) Install the clip to the inner cable.
Inside handle rod
2. Install the inside handle rod to the door inside handle.
3. Install the door inside handle to the door.

INSPECTION
<Left side> DOOR LOCK ACTUATOR CHECK
Lock Rod position Terminal No. Rod operation

View A 2 3
LOCK LOCK to UNLOCK
UNLOCK UNLOCK to LOCK

Unlock
A
<Right side>

Lock

View B

Unlock
B
42-18 BODY – Door

WINDOW GLASS RUNCHANNEL AND DOOR OPENING

WHETHERSTRIP
REMOVAL AND INSTALLATION
<FRONT DOOR>

5
4
3 Sectional view of
clip position
2
1

Sectional view of
clip position

Door inner opening weatherstrip Door window glass runchannel

removal steps removal steps
 Scuff plate (Refer to GROUP 52A.) 3. Door window glass runchannel
 Cowl side trim (Refer to GROUP 52A.) 4. Door window glass lower
 Center pillar lower trim (Refer to runchannel
GROUP 52A.) Door beltline moulding removal
1. Door inner opening weatherstrip
steps
Door outer opening weatherstrip  Outside rear view mirror
removal 5. Door beltline moulding
A 2. Door outer opening weatherstrip
 BODY – Door 42-19
<REAR DOOR>

5 4
2
Sectional view of
clip position
3 1

Sectional view of
clip position

A 1. Door outer opening weatherstrip Door beltline inner weatherstrip

Door window glass runchannel removal steps
removal steps  Door trim (Refer to P.42-9.)
2. Door window glass runchannel 4. Door beltline inner weatherstrip
 Door lower sash (Refer to P.42-13.) Door beltline moulding removal
3. Door window glass lower 5. Door beltline moulding
runchannel

REMOVAL SERVICE POINT

15 mm A DOOR OUTER OPENING WEATHERSTRIP
4 mm REMOVAL
Make a tool as shown and remove the door opening
8 mm weatherstrip.
Thickness
1mm
42-20 BODY – Sunroof

SUNROOF
TROUBLESHOOTING
The timer does not operate for 30 seconds after the Probable cause
ignition switch is turned to LOCK (OFF) position. (When
the ignition switch is turned on, the sunroof operates.)
The sunroof-ECU has a timer function which operates during 30 seconds after the  Malfunction of wiring harness or connector
ignition switch is turned to LOCK (OFF) position. If the timer does not operate,  Malfunction of sunroof-ECU
the cause may be a malfunction of the ETACS-ECU, sunroof-ECU or of the wiring  Malfunction of the ETACS-ECU
harness or connector.

No
Does the central door locking system Carry out the troubleshooting regarding
operate properly? the central door locking system.

Yes

No
Is a diagnosis code sent to the Carry out the troubleshooting regarding
ETACS-ECU? the ETACS–ECU.
Yes

NG
MUT-II input signal check Check the input signal circuits.
 Ignition switch (IG1)
 Front door switch (driver’s side)
OK

NG NG
Measure at the sunroof-ECU connector Check the following connectors: Repair
D-06 and ETACS-ECU connector C-83. C-83, C-02, C-43, D-06
 Disconnect the connector and
measure at the harness side. OK
 Continuity between 10 (for D-06) and Check trouble symptoms.
21 (for C-83)
OK: Continuity NG
OK
Check the harness wire between the
ETACS-ECU and the sunroof-ECU, and
repair if necessary.

NG
Replace the sunroof-ECU. Check trouble symptoms.
NG

Replace the ETACS-ECU.

 BODY – Sunroof 42-21
SUNROOF
REMOVAL AND INSTALLATION
Post-installation Operation
 Sunroof Water Test
 Sunroof Fit Adjustment

2
3 5

1. Roof lid glass assembly Sunroof motor assembly removal

Sunroof switch removal steps steps
2. Sunroof switch cover  Headlining
3. Sunroof switch B B 5. Sunroof motor assembly
Drain hose removal steps Sunroof assembly removal steps
 Headlining  Headlining
 Splash shield (Rear drain hose) A A 4. Drain hose
 Cowl side trim and instrument lower 6. Room lamp bracket
panel 7. Sunroof assembly
 Engine-ECU, throttle valve control
relay and throttle valve controller
(Driver’s-side drain hose)
A A 4. Drain hose
42-22 BODY – Sunroof

REMOVAL SERVICE POINTS

A DRAIN HOSE REMOVAL
Tie a cord to the end of the drain hose, and wind tape around
it so that there is no unevenness. Then pull the drain hose
out from the passenger compartment.
Drain hose
Cord

B SUNROOF MOTOR ASSEMBLY REMOVAL

Caution
Always close the roof lid glass fully before removing the
sunroof motor. If the fully-closed positions of the roof
lid glass and the sunroof motor are not the same, the
sunroof will not operate properly.
NOTE
If there is a problem with the sunroof motor so that the roof
lid glass cannot close fully, use an Allen key to turn the gear
section of the sunroof motor to fully close the roof lid glass.

INSTALLATION SERVICE POINTS

A DRAIN HOSE INSTALLATION
1. Tie the cord that was used during removal to the end
of the drain hose, and wind tape around it so that there
is no unevenness.
2. Pull the cord to pull through the drain hose
Cord Drain hose

3. Install the grommet, and then position the drain hose so

that it protrudes from the grommet as shown in the
Grommet illustration.

20–30 mm
BODY – Sunroof 42-23
B SUNROOF MOTOR ASSEMBLY INSTALLATION
If the fully-closed position of the sunroof motor assembly is
incorrect, set the sunroof motor to the fully-closed position
by the following procedure, and then install the sunroof motor.
1. Remove the sunroof motor assembly with the connector
still connected.
2. Set the roof lid glass to the fully-closed position.
3. Continue to push the sunroof close switch until the sunroof
motor stops turning. Then install the sunroof motor
assembly.
NOTE
Sunroof-ECU will initialize when the sunroof motor stops.
42-24 BODY – Sunroof

DISASSEMBLY AND REASSEMBLY

11
15

5
1

2
6
7 8

4 12
10

14
13 11

15
3

Disassembly steps
1. Roof lid glass assembly 9. Cable guide casing
2. Weatherstrip 10. Side deflector
3. Sunroof motor 11. Drive cable assembly
4. Roof wind deflector panel 12. Seal
5. Roof drip channel 13. Seal
6. Panel stopper 14. Clamp
7. Sunshade assembly 15. Guide rail sub assembly
8. Guide rail stopper
 42-1

BODY
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 8

Power Window Safety Mechanism
OUTLINE OF CHANGES . . . . . . . . . . . . . . . . . . 2 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DOOR TRIM AND WATERPROOF
FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 2
DOOR GLASS AND REGULATOR . . . . . . . . 9
42-2 BODY – General/Door

GENERAL
OUTLINE OF CHANGES
The following service procedures have been added. The other items are the same as before.
D Troubleshooting
D On-vehicle service
D Door trim and waterproof film inspection
D Door glass and regulator inspection

DOOR
TROUBLESHOOTING
The central door locking is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to
GROUP 54B – Troubleshooting.

DIAGNOSIS FUNCTION
INPUT SIGNAL CHECK POINTS <VEHICLES WITH ETACS-ECU>
1. Connect the MUT-II or a voltmeter to the diagnosis connector to check input signal. (Refer to GROUP
00 – How to Use Troubleshooting/Inspection Service Points.)
2. The following input signals can be checked:
Door lock actuator
D LOCK
D UNLOCK
NOTE
If all the input signals cannot be check by using the MUT-II, the diagnosis circuit may be defective.
INSPECTION CHART FOR TROUBLE SYMPTOMS
POWER WINDOWS
Symptom Inspection Reference
procedure page

None of power window switches can operate any of windows. 1 42-3

Power window main switch can not operate any of windows. (However, each power 2 42-4
window sub-switch can operate window.)

Power window main switch can not operate driver’s window. (However, power window 3 42-4
main switch can operate window except driver’s window.)

Power window main switch can not operate passenger’s window. (However, 4 42-5
passenger’s power window sub-switch can operate passenger’s window.)

Power window main switch can not operate rear door windows. (However, rear power 5 42-5
window sub-switches can operate rear door windows.)

Passenger’s power window sub-switch can not operate passenger’s window. 6 42-6
(However, power window main switch can operate passenger’s window.)

Rear power window sub-switches can not operate rear door windows. (However, 7 42-7
power window main switch can operate rear door windows.)
 BODY – Door 42-3
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Inspection Procedure 1
None of power window switches can operate any of Probable cause
windows.
Power window relay, power window relay drive circuit or ETACS-ECU may be defective. D Malfunction of power window relay
D Malfunction of ETACS-ECU
D Malfunction of junction block
D Malfunction of wiring harness or connector

NG
Check power window relay continuity. Replace

OK
NG NG
Measure at ETACS-ECHO connector Check the following connectors: Repair
C-82. C-71, C-72, C-82
D Disconnect the connector and
measure at harness side. OK
D Voltage between 8 and body earth
OK: System voltage Check trouble symptoms.
NG
OK
NG
Check the harness wire between fusible Repair
link No.4 and junction block.
OK
NG
Check trouble symptoms. Replace the junction block.

NG NG
Check continuity at power window relay Check the following connectors: Repair
connector C-71 and junction block con- C-71, C-74
nector C-74.
D Disconnect the connector and OK
measure at harness side. NG
D Continuity between terminal 4 of Check trouble symptoms. Replace the junction block.
C-71 and terminal 1 of C-74
OK: Continuity
OK

Replace the ETACS-ECU.

42-4 BODY – Door

Inspection Procedure 2
Power window main switch can not operate any of Probable cause
windows. (However, each power window sub-switch can
operate window.)
Power window main switch or its power supply circuit or earth circuit may be defective. D Malfunction of power window main switch
D Malfunction of wiring harness or connector

NG NG
Measure at power window main switch Check the following connectors: Repair
connector E-10. C-74, C-45, C-21, E-10
D Disconnect connector and measure
OK
at harness side.
NG
D Ignition switch: ON Check trouble symptoms. Check harness wire between junction
D Voltage between 2 and body earth block and power window main switch,
<3-door models> and repair if necessary.
D Voltage between 3 and body earth
<5-door models>
OK: System voltage
OK
NG
Check power window main switch conti- Replace
nuity. (Refer to P.42-8.)
OK
NG NG
Measure at power window main switch Check the following connectors: Repair
connector E-10. E-10, C-45, C-21
D Disconnect connector and measure NG
at harness side. OK
D Continuity between 3 and body
earth <3-door models> Check trouble symptoms. Check harness wire between power
D Continuity between 4 and body window main switch and body earth,
earth <5-door models> and repair if necessary.
OK: Continuity

Inspection Procedure 3
Power window main switch can not operate driver’s Probable cause
window. (However, power window main switch can
operate window except driver’s window.)
Power window main switch, power window motor, or harness or connector between D Malfunction of power window main switch
power window main switch and power window motor may be defective. D Malfunction of power window motor
D Malfunction of wiring harness or connector

NG
Check power window main switch continuity. (Refer to P.42-8.) Replace
OK
NG
Check power window motor. (Refer to P.42-9.) Repair
OK
NG
Check the following connectors: Repair
E-10, E-12, E-03
OK
NG
Check trouble symptoms. Check harness wire between power window main switch and
power window motor, and repair if necessary.
 BODY – Door 42-5
Inspection Procedure 4
Power window main switch can not operate passenger’s Probable cause
window. (However, passenger’s power window sub-
switch can operate passenger’s window.)
There may be short circuit or open circuit in communication line from the power D Malfunction of power window main switch
window main switch to passenger’s power window sub-switch, or passenger’s power D Malfunction of passenger’s power window sub-switch
window sub-switch or power window main switch may be defective. D Malfunction of wiring harness or connector

NG
Check power window main switch continuity. (Refer to P.42-8.) Replace
OK
NG
Check passenger’s power window sub-switch continuity. (Refer Replace
to P.42-9.)
OK
NG
Check the following connectors: Repair
E-10, C-45, C-21, E-04, E-09
OK

Check harness wire between power window main switch and

passenger’s power window sub-switch, and repair if necessary.

Inspection Procedure 5
Power window main switch can not operate rear door Probable cause
windows. (However, rear power window sub-switches can
operate rear door windows.)
There may be short circuit or open circuit in communication line from the power D Malfunction of power window main switch
window main switch to rear power window sub-switch, or rear power window sub-switch D Malfunction of rear power window sub-switch
or power window main switch may be defective. D Malfunction of wiring harness or connector

NG
Check power window main switch continuity. (Refer to P.42-8.) Replace
OK
NG
Check rear power window sub-switch continuity. (Refer to P.42-9.) Replace
OK
NG
Check the following connectors: Repair
E-10, C-45, C-21, C-39, C-41, D-09, D-25, E-19, E-23
OK

Check harness wire between power window main switch and

rear power window sub-switch, and repair if necessary.
42-6 BODY – Door

Inspection Procedure 6
Passenger’s power window sub-switch can not operate Probable cause
passenger’s window. (However, power window main
switch can operate passenger’s window.)
Power supply circuit or earth circuit of the passenger’s power window sub-switch, D Malfunction of passenger’s power window sub-switch
passenger’s power window sub-switch or passenger’s power window motor may D Malfunction of passenger’s power window motor
be defective. D Malfunction of wiring harness or connector

NG NG
Measure at passenger’s power window Check the following connectors: Repair
sub-switch connectors E-04 and E-09. C-45, C-21, E-04, E-09, E-10
D Disconnect connector and measure
OK
at harness side.
NG
D Ignition switch: ON Check trouble symptoms. Check harness wire between power
D Voltage between 4 and body earth window main switch and passenger’s
OK: System voltage power window sub-switch, and repair
OK if necessary.
NG
Check passenger’s power window mo- Replace
tor. (Refer to P.42-9.).
OK
NG
Check passenger’s power window sub- Replace
switch continuity. (Refer to P.42-9.).
OK
NG
Check the following connectors: Repair
E-04, E-09, E-03, E-12
OK

Check harness wire between passen-

ger’s power window sub-switch and
passenger’s power window motor, and
repair if necessary.
 BODY – Door 42-7
Inspection Procedure 7
Rear power window sub-switches can not operate rear Probable cause
door windows. (However, power window main switch can
operate rear door windows.)
Power supply circuit or earth circuit of the rear power window sub-switches, rear D Malfunction of rear power window sub-switches
power window sub-switches or rear power window motors may be defective. D Malfunction of rear power window motors
D Malfunction of wiring harness or connector

NG NG
Measure at rear power window sub- Check the following connectors: Repair
switch connectors E-19 and E-23. C-39, C-41, D-09, D-25, E-19, E-23
D Disconnect connector and measure
at harness side. OK
D Ignition switch: ON
D Voltage between 4 and body earth NG
OK: System voltage Check trouble symptoms. Check harness wire between power
window main switch and rear power
OK window sub-switch, and repair if neces-
NG sary.
Check rear power window motor. (Refer Replace
to P.42-9.).
OK
NG
Check rear power window sub-switch Replace
continuity. (Refer to P.42-9.).
OK
NG
Check the following connectors: Repair
E-23, E-24, E-19, E-18
OK

Check harness wire between rear pow-

er window sub-switch and rear power
window motor, and repair if necessary.
42-8 BODY – Door

ON-VEHICLE SERVICE
POWER WINDOW SAFETY MECHANISM
CHECK <FRONT DRIVER’S SIDE POWER
WINDOW>
1. Place a wooden board about 10 mm thick as shown. Then,
raise the window glass.
2. Check that the window lowers by about 150 mm when
the window clamps the board. If this doesn’t happen, do
troubleshooting. (Refer to GROUP 54B.)

DOOR TRIM AND WATERPROOF FILM

INSPECTION
POWER WINDOW MAIN SWITCH CONTINUITY CHECK

<3-door models> <5-door models>

<3-door models>
Switch position Terminal No.

Passenger side

3 4 5 9

Unlock UP

OFF

DOWN

Lock UP

OFF

DOWN
 BODY – Door 42-9
<5-door models>
Switch position Terminal No.

Front door Rear door

Driver side Passenger side Driver side Passenger side

3 5 7 8 1 3 5 14 3 5 6 13 2 3 5 9

Un- UP
lock

OFF

DOWN

Lock UP

OFF

DOWN

POWER WINDOW SUB SWITCH CONTINUITY CHECK

Switch Terminal No.

position
iti
1 2 4 5 6
UP

OFF

DOWN

DOOR GLASS AND REGULATOR

INSPECTION
POWER WINDOW MOTOR CHECK
1. Connect the battery directly to the motor terminals.
2. Check that the motor rotates smoothly.
3. Reconnect the battery to the motor terminals vice versa.
4. Check that the motor rotates in the reverse direction.
5. If malfunction is present, replace the window regulator assembly.
NOTES
 SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN No.: ESB-00E51-501

Date: 2001-08-28 <Model> <M/Y>

Subject: CORRECTION TO MAINTENANCE (EC)PAJERO PININ/ 00-10
PROCEDURE FOR BACK DOOR GLASS MONTERO iO
Group: EXTERIOR Draft No.: 00SY091416 (H60, H70)

CORRECTION INTERNATIONAL
CAR
ADMINISTRATION O. Kai - E.V.P. & G.M.
OFFICE After Sales Service Dept.

1. Description:
This Service Bulletin informs you that correction has been made to the maintenance procedure for
back door glass.

2. Applicable Manuals:
Manual Pub. No. Language Page(s)
’00 PAJERO PININ CKRE00E1 (English) 42-16, 17
Workshop Manual Chassis CKRF00E1 (French)
CKRG00E1 (German)
CKRD00E1 (Dutch)
CKRI00E1 (Italian)
’00 MONTERO iO CKRS00E1 (Spanish)
Workshop Manual Chassis
3. Details:
42-16 BODY – Window Glass

BACK DOOR GLASS

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
• High-mounted Stop Lamp Assembly Removal and See next page.
Installation (Refer to GROUP 52A).
• Back Door Trim Removal and Installation (Refer to
P. 42-34).
<Incorrect>
Section A - A mm
Section B - B

12.5

Primer
5.5 Primer
12.5

Section C - C

Primer

18H0004

12.5
5.5

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent

W0393AL
00008895

Removal steps
1. Harness connector ►A◄ 4. Glass stopper
◄A►►A◄ 2. Back door glass ►A◄ 5. Window dam
►A◄ 3. Dual lock fastener <Deleted>

2
<Correct>

Section A - A mm
Section B - B

12.5

Primer
5.5 Primer
12.5

Section C - C

Primer

12.5
5.5
AY0365AL

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent

AY0093AL

3
 BODY – Window Glass 42-17
REMOVAL SERVICE POINT
◄A► BACK DOOR GLASS REMOVAL
Remove the back door glass in the same manner as for the
windshield. (Refer to P 42-11.)

INSTALLATION SERVICE POINT

►A◄ WINDOW DAM/DUAL LOCK FASTENER/GLASS
STOPPER/BACK DOOR GLASS INSTALLATION
1. Use a isopropyl alcohol to decrease the glass and body
surfaces where the window dam, dual lock fasteners and glass
stoppers are installed.
2. Install the window dam.

3. Install the dual lock fasteners to the concavities on the body

Glass stopper installation holes
Concavity Concavity panel and the glass stoppers to the hole on the body panel
respectively.
4. Install the dual lock fasteners to the windshield in the positions
corresponding to the ones on the body panel where the dual
lock fasteners have been installed.
5. Apply the primer and adhesive.
6. Install the glass in the same manner as for the windshield.
Dual lock fastener (Refer to P.42 – 12.)
AW0394AL

<Incorrect>

See next page.

4
<Correct>

REMOVAL SERVICE POINT

Cloth tape
Moulding ◄A► BACK DOOR GLASS REMOVAL
Back door glass
1. Put matchmarks on the back door and the back door glass.
2. For protection of painted surface of the back door, apply cloth
tape all around the back door on which the back door glass is
fitted.
Adhesive
Piano wire
Back door panel 3. Using a pointed drill, make a hole in the bonded portion of the
back door.
AY0063AL
4. From inside the vehicle, pass the piano wire through the hole.

5. Put the piano wire along the bonded surface from outside the
Moulding
Back door panel vehicle, and hold it at its end.
Piano wire 6. Slowly pull the piano wire inside the vehicle in the direction in
which the piano wire outside the vehicle is held, and remove
the adhesive in the numerical order as shown.
(1) From left up to left down direction, pull the piano wire
inside the vehicle, and remove the adhesive.
(2) From left up to right up direction, pull the piano wire inside
the vehicle, and remove the adhesive.
(3) From right up to right down to left down direction, pull the
Hold like this. Back door glass piano wire inside the vehicle, and remove the adhesive.
(4) Pass the piano wire outside the vehicle through the inside
of the vehicle, pull both ends of the piano wire toward the
inside of the vehicle, and remove the adhesive.
Caution
When the adhesive is removed, do not alternately pull the
piano wires. This may give damage to the moulding.
Adhesive
AY0118AL 7. Remove the back door glass from the back door panel.
8. Remove the body to windshield adhesive by the same
procedure as for the windshield. (Refer to P.42 – 11.)

INSTALLATION SERVICE POINT

►A◄ GLASS STOPPER/DUAL LOCK FASTENER/BACK
DOOR GLASS INSTALLATION
1. Using unleaded gasoline, degrease the glass and body surface
on which the dual lock fasteners and the glass stoppers are
installed.

Glass stopper installation holes 2. Install the dual lock fasteners correctly on the specified
Concavity Concavity locations of the body flange (convexities on the body panel).
3. Install the dual lock fasteners and the glass stoppers on the
back door glass at the positions that correspond to those of the
body flange on which the dual lock fasteners and the glass
stoppers are installed.
4. Using the sponge saturated with primer, apply primer evenly to
the specified areas around entire surface of the back door glass
Dual lock fastener and the body.
AW0394AL
5. Install the back door glass by the same procedures as for the
windshield. (Refer to P.42 – 12.)

5
 EXTERIOR
Click on the applicable bookmark to selected the required model year
 51-1

EXTERIOR
CONTENTS

FRONT BUMPER . . . . . . . . . . . . . . . . . . . . 2 REAR WIPER AND WASHER . . . . . . . . 14

REAR BUMPER . . . . . . . . . . . . . . . . . . . . . 4 SERVICE SPECIFICATION . . . . . . . . . . . . . . 14
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 14
EXTERIOR PARTS . . . . . . . . . . . . . . . . . . 5
REAR WIPER AND WASHER . . . . . . . . . . . 15
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXTERIOR PARTS . . . . . . . . . . . . . . . . . . . . . . . 6 HEADLAMP WASHER . . . . . . . . . . . . . . 17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 17
MOULDING AND GARNISH . . . . . . . . . 7
HEADLAMP WASHER . . . . . . . . . . . . . . . . . . 17
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 7
MOULDING AND GARNISH . . . . . . . . . . . . . . 8 MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

WINDSHIELD WIPER AND OUTSIDE DOOR MIRROR . . . . . . . . . . 21

WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE SPECIFICATIONS . . . . . . . . . . . . . 10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 10
WINDSHIELD WIPER AND WASHER . . . . 11
51-2 EXTERIOR – Front Bumper

FRONT BUMPER
REMOVAL AND INSTALLATION

1
B 3
A

B
A

4 2
6

NOTE
: Clip positions
Section A – A Section B – B

1 1

Clip Clip

Removal steps
AA" 1. Radiator grille 5. Headlamp washer hose connection
2. Splash shield installation clips <Vehicles with headlamp washer>
3. Headlamp 6. Front bumper assembly
4. Fog lamp connector
 EXTERIOR – Front Bumper 51-3
REMOVAL SERVICE POINT
Section A – A
AA" RADIATOR GRILLE REMOVAL
Radiator Clip Remove the radiator grille by pushing the tab of the radiator
grille
grille clips in the direction of the arrows with a flat-tipped
screwdriver, while lightly pulling the radiator grille towards you.

A
A

Radiator
grille

DISASSEMBLY AND REASSEMBLY

Section A – A

Clip

A 1

5 6 2
3

Disassembly steps
1. Front bumper reinforcement 3. Fog lamp cover
assembly <Vehicles without fog lamp>
D Headlamp washer assembly 4. Bumper net
<Vehicles with headlamp washer> 5. Licence plate bracket
(Refer to P.51-17) 6. Front bumper face
2. Fog lamp
51-4 EXTERIOR – Rear Bumper

REAR BUMPER
REMOVAL AND INSTALLATION

5 6 7

3 4

Removal steps
1. Rear mud guard 6. Bumper center reinforcement
2. Rear splash shield assembly
3. Rear combination lamp or rear fog 7. Bumper side reinforcement
lamp connection assembly
4. Rear bumper assembly
5. Bumper step reinforcement
assembly
 EXTERIOR – Rear Bumper/Exterior Parts 51-5
DISASSEMBLY AND REASSEMBLY

5
1

4.9 Nm

4.9 Nm

Disassembly steps
1. Bracket <R.H. drive vehicles> 4. Rear fog assembly
2. Bracket <L.H. drive vehicles> <L.H. drive vehicles>
3. Rear combination lamp assembly 5. Rear bumper face
<R.H. drive vehicles>

EXTERIOR PARTS
SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Removal of roof rack cover.
51-6 EXTERIOR – Exterior Parts

EXTERIOR PARTS
REMOVAL AND INSTALLATION

Section A – A Section B – B Section C – C Section D – D

1
1
1
2

4
4 4 4
Section E – E

5 Nm 5 Nm
1 1
3 Body
A
4 2
4
B 5 E
5 Nm E
B C
A 3 A
1 1
2 D
D

A
C
6

23 Nm

23 Nm

Roof rail removal steps Spare tyre carrier removal steps

AA" 1. Roof rack cover (front, rear) D Spare tyre cover
2. Roof rack cover (side) (Refer to GROUP 31.)
3. Center bracket D Spare tyre
4. Roof bar D Back door trim and waterproof film
(Refer to GROUP 42.)
Roof spoiler removal steps 7. Spare tyre carrier
5. cover
6. Roof spoiler
 EXTERIOR – Exterior Parts/Moulding and Garnish 51-7
REMOVAL SERVICE POINT
Slit Claw (rear)
AA" ROOF RACK COVER (FRONT, REAR) REMOVAL
1. Insert the special tool into the slit.
NOTE
The roof rack assembly has the slit.
2. Insert the special tool as far as possible and remove the
Claw (front) claw (front) by prying the roof rack cover toward you.
View A 3. Remove the claw (rear).
MB990784
Caution
View A Spread out the roof rack cover sufficiently and pull
it upward, otherwise the claws will be broken.
Outside of vehicle
Slit

Claw (front) Claw (rear)

MOULDING AND GARNISH

SPECIAL TOOL
Tool Number Name Use
MB990449 Window moulding Removal of roof drip moulding.
remover
51-8 EXTERIOR – Moulding and Garnish

MOULDING AND GARNISH

REMOVAL AND INSTALLATION
Section A – A Section B – B Section C – C Section D – D

2 Clip 4
2 Clip Clip
Clip
5

Windshield

2 <Vehicles with roof rail>

1
2

<Vehicles without roof rail>

B
A
A

C
C
B 5

NOTE
: Clip positions
: Bolt positions 4 View B 5
View A
4

Adhesive: double-sided tape [5 mm width and 0.8 mm thickness]

Roof drip moulding removal steps Side protector moulding removal

D Roof rail assembly <Vehices with roof AB" "AA 4. Side protector moulding
rail> (Refor to P.51-6) Rear licence plate garnish removal
1. Roof drip cover steps
AA" 2. Roof drip moulding
3. Windshield moulding D Back door trim (Refer to GROUP 42
(Refer to GROUP 42 – Windshield.) – Back door.)
5. Rear licence plate garnish
 EXTERIOR – Moulding and Garnish 51-9
REMOVAL SERVICE POINT
AA" ROOF DRIP MOULDING REMOVAL
Use the special tool to lever out the moulding.
Caution
If the moulding has become warped, it should not be
reused.

MB990449

AB" SIDE PROTECT MOULDING REMOVAL

Protection tape 1. Attach protection tape all the way along the edges of the
double-sided tape which is still adhering to the body.

Double-sided tape

2. Use a resin spatula to scrape off the double-sided tape.

3. Peel off the protection tape.
Double-sided tape 4. Wipe the body surface and clean it with a rag moistened
with isopropyl alcohol.

INSTALLATION SERVICE POINTS

"AA SIDE PROTECT MOULDING INSTALLATION
Double-sided tape affixing to the side protect
moulding (when reusing)
1. Scrape off the double-sided tape with a resin spatula or
gasket scraper.

2. Wipe off the side protect moulding adhesion surface and

clean it with a shop towel moistened with isopropyl alcohol.
3. Affix the specified double sided tape to the side protect
moulding. (Refer to P.51-8.)
Specified adhesive tape:
Double-sided tape: 5 mm width and 0.8 mm
thickness
51-10 EXTERIOR – Moulding and Garnish/Windshield Wiper and Washer

4. Remove strip paper from the pressure sensitive

double-sided tape.
NOTE
Affix double-sided tape to the end of strip paper for ease
of strip paper removal. (Refer to P.51-8.)
5. Install the side protect moulding.
Adhesive tape
Backing paper NOTE
If it is hard to affix the double-sided tape in winter, heat
the application surfaces at both the vehicle body and the
side protect moulding.
Body 40 – 60 C
Side protect moulding 20 – 30 C
Apply pressure fully to the side protect moulding.

WINDSHIELD WIPER AND WASHER

SERVICE SPECIFICATIONS
Items Standard value

Park position of windshield wiper arm and blade assembly (Distance Driver’s side 20 $ 5
between wiper blade and windshield lower moulding) mm < L.H. drive vehicles>
30 $ 5
< R.H. drive vehicles >

Passenger’s side 20 $ 5
<L.H. drive vehicles >
30 $ 5
<R.H. drive vehicles >

TROUBLESHOOTING
The windshield wiper and washer is controlled by the Smart Wiring System (SWS). For troublesshooting,
refer to GROUP 54B – Troubleshooting.
 EXTERIOR – Windshield Wiper and Washer 51-11
WINDSHIELD WIPER AND WASHER
REMOVAL AND INSTALLATION

6
A A
A B
B B
B
A
A A
2
3
13 Nm

C C 5
5
4 3
C
C C
6 13 Nm C C C
C
C
C
C
1
4
8

Section A – A

7 6

1 Claw
10
11
Section B – B Section C – C
1

9 5
12 6

Cli Clip
p

1. Washer hose connection Washer tank removal steps

2. Washer nozzle D Air cleaner
Wiper motor and linkage removal D Intake duct
steps 1. Washer hose connection
"AA 3. Wiper arm and blade assembly 9. Headlamp washer motor
4. Washer <Vehicles with headlamp washer>
5. Front deck garnish 10. Front washer motor
<R.H. drive vehicles> 11. Rear washer motor
6. Front deck garnish 12. Washer tank assembly
<L.H. drive vehicles> NOTE
AA" 7. Wiper motor For removal and installation of the column switch
8. Linkage assembly assembly (wiper and washer switch), refer to GROUP
37A – Steering Wheel and Shaft.
51-12 EXTERIOR – Windshield Wiper and Washer

REMOVAL SERVICE POINT

AA" WIPER MOTOR REMOVAL
1. Remove the wiper motor mounting bolts.
2. Use a flat-tipped screwdriver to separate the wiper motor
Linkage crank arm from the linkage assembly, and then remove
assembly the wiper motor.
Caution
Because the installation angle of the crank arm and
the wiper motor has been set, do not remove them
unless it is necessary to do so. If they must be
removed, remove them only after marking their
mounting positions.

INSTALLATION SERVICE POINTS

"AA WIPER ARM AND BLADE ASSEMBLY
INSTALLATION
Install the wiper blade so that the wipers stops at the specified
A A stop position (standard value) as shown in the illustration.
Standard value (A): 20 ± 5 mm <L.H. drive vehicles>
30 ± 5 mm <R.H. drive vehicles>
Windshield lower moulding end

INSPECTION
WIPER MOTOR CHECK
Disconnect the wiring harness connector, and then check the
wiper motor operation with the wiper motor remaining installed
to the body.
Wiper Motor Operation Speed
Connect a battery to the wiper motor as shown in the illustration
and check the operation speed.
Stop Position
Operation speed check 1. Connect a battery to the wiper motor as shown in the
(A) of the illustration. While the wiper motor operates at
low speed, disconnect the battery to stop the wiper motor.
2. Connect the terminals via a jumper wire and a battery
Low speed High speed
to the wiper motor as shown in the (B) of the illustration.
After the motor starts turning at low speed, it should stop
Stop position check
at the automatic stop position.

(A) Low
speed (B) Automatic stop
 EXTERIOR – Windshield Wiper and Washer 51-13
WASHER MOTOR CHECK
1. With the washer motor installed to the washer tank, fill
the washer tank with water.
2. Check that the water squirts out strongly when battery
voltage is applied to terminal (2) and terminal (1) is earthed.

WASHER FLUID EJECTION POINT CHECK

50 mm Adjust the ejection angle by moving the nozzle.
50 mm
Item Distance mm Item Distance mm
110 mm 50 mm A 350 E 320
B 475 F 200
Area to be ejected Area to be ejected
C 165 G 310
L.H. drive vehicles <Driver’s side> D 200 H 200
<Passen- A B
ger’s side>
C D

E G
F H

Ceramic end line

R.H. drive vehicles
<Driver’s side> <Passen-
B A
ger’s side>
D C

G E
H F

Ceramic end line

51-14 EXTERIOR – Rear Wiper and Washer

REAR WIPER AND WASHER

SERVICE SPECIFICATION
Items Standard value

Park position of rear wiper arm and blade assembly (Distance between wiper blade and back 33 $ 5
door glass ceramic end line) mm

TROUBLESHOOTING
The rear wiper and washer is controlled by the Smart Wiring System (SWS). For troublesshooting, refer
to GROUP 54B – Troubleshooting.
 EXTERIOR – Rear Wiper and Washer 51-15
REAR WIPER AND WASHER
REMOVAL AND INSTALLATION

8 Nm

4 3

Wiper motor assembly removal Rear washer hose removal steps

steps D Rear seat (Refer to GROUP 52A.)
D Back door trim (Refer to GROUP 42.) D Scuff plate and quarter trim (Refer to
1. Cover GROUP 52A.)
"AA 2. Wiper arm and blade assembly D Headlining (Refer to GROUP 52A.)
"BA 3. Grommet 6. Washer nozzle
4. Wiper motor assembly 7. Washer hose
Washer tank and washer motor NOTE
removal For removal and installation of the column switch
assembly (wiper and washer switch), refer to GROUP
5. Washer tank and washer motor 37A – Steering Wheel and Shaft.
(Refer to P.51-11.)
51-16 EXTERIOR – Rear Wiper and Washer

Back
INSTALLATION SERVICE POINT
A
door "AA WIPER ARM AND BLADE ASSEMBLY
glass
ceramic INSTALLATION
end line Install so that the wiper blade is positioned at the shown position
when the wiper arm stops.
Standard value (A): 33 ± 5 mm

Notch "BA GROMMET INSTALLATION

Align the mating mark of grommet and the notch of installation
Mating mark
hole.
Grommet

INSPECTION
WIPER MOTOR CHECK
Disconnect the wiring harness connector, and check the wiper
motor operation with the wiper motor remaining installed to
the body.
Wiper Motor Operation
Connect a battery to the wiper motor as shown in the illustration
and check the motor operation.
Wiper Motor Stop Position
Operation check 1. Operate the wiper motor, and then disconnect the battery
to stop the wiper motor while the wiper motor is operating.
2. Reconnect the battery as shown in the illustration, and
Battery confirm that after the motor starts turning, it stops at the
automatic stop position.
Stop position check

Battery

WASHER MOTOR CHECK

1. With the washer motor installed to the washer tank, fill
the washer tank with water.
2. Check that the water squirts out strongly when system
voltage is applied to terminal 2 and terminal 1 is earthed.
 EXTERIOR – Rear Wiper and Washer/Headlamp Washer 51-17
WASHER FLUID EJECTION POINT CHECK
Moulding 50 mm Adjust the ejection angle by moving the nozzle.
end line 50 mm

50 mm

Ceramic end line

HEADLAMP WASHER
TROUBLESHOOTING
The headlamp washer is controlled by the Smart Wiring System (SWS). For troublesshooting, refer to
GROUP 54B – Troubleshooting.
HEADLAMP WASHER
REMOVAL AND INSTALLATION

8
3 6 7

4
1
3 3

2
2
2
3
2 2
5

4 2

Nozzle and check valve removal Washer tank removal steps

steps Draining of washer fluid
Draining of washer fluid Air cleaner
Front bumper (Refer to P.51-2.) Intake duct
1. Check valve 6. Washer hose
2. Washer hose 7. Washer tank assembly
3. Joint 8. Headlamp washer motor
4. Bracket
5. Nozzle
51-18 EXTERIOR – Headlamp Washer

INSPECTION
CHECK VALVE CHECK
Apply pressure to the inlet of the check valve to check its
opening pressure.
Opening pressure: 78 kPa

HEADLAMP WASHER MOTOR CHECK

1. With the washer motor installed to the washer tank, fill
the washer tank with water.
2. Connect battery (+) and (–) cables to terminals (1) and
(2) respectively to see that the washer motor runs and
water is injected.
 EXTERIOR – Marks 51-19

MARKS
REMOVAL AND INSTALLATION

6
2
1 7

3 4
4 5
3

1. Three diamonds mark "AA 5. Vehicle name decal

2. “GDI” mark "AA 6. Three diamonds mark
3. Pininfarina mark "AA 7. “GDI” mark
4. Pininfarina logo mark

INSTALLATION SERVICE POINT

"AA INSTALLATION OF MARKS
1. APPLICATION POSITION
(5) Vehicle name decal
<Vehices except for Spain>
Align the application tape end with this slit.

Back door end line

Slit

<Vehicles for Spain>

Align the application tape end with this slit.

Back door end line

Slit
51-20 EXTERIOR – Marks

(6) Three diamonds mark

Key cylinder
Back door end line

165 mm
56 mm

(7) GDI mark

Window moulding end line

121 mm
Back door end line

42 mm

2. INSTALLATION PROCEDURE
(1) Clean the mark installation surfaces on the body with
unleaded petrol.
(2) Peel off the backing paper from the reverse side of the
marks, and then attach the marks to the vehicle body
so that they fit properly into position.
Caution
When attaching the marks, the surrounding
temperature should be 20–38 C and the air should
be completely free from dust.
If the surrounding temperature is lower than 20 C,
the marks and the places on the body where the marks
are to be attached should be heated to 20–38 C.
When the marks are attached, care should be used
not to allow bubble to enter between tape and the
body.
 EXTERIOR – Outside Door Mirror 51-21

OUTSIDE DOOR MIRROR

REMOVAL AND INSTALLATION

4
5

<Electric remote-con-
trolled door mirror>

A 4 5
A

2
<Manual-controlled
door mirror >
1

A
A
A

A 3

Section A – A
7

Clip
1
6

Door mirror removal steps Electric remote-controlled mirror

1. Delta inner cover switch removal steps
2. Clip 6. Power window and remote-
3. Boot controlled mirror switch assembly
4. Mirror assembly (Refer to GROUP 42 – Door trim
AA" "AA 5. Mirror and water proof film.)
7. Electric remote-controlled mirror
switch
51-22 EXTERIOR – Outside Door Mirror

Section A – A REMOVAL SERVICE POINT

Flat-tipped AA" MIRROR REMOVAL
screwdriver Mirror
Using a hand, push the upper part of mirror to tilt it. Apply
a protection tape as shown in the illustration. Insert a flat-tipped
screwdriver between a notch behind the mirror and the pivot
plate, and then pry off the lower part of mirror from the pivot
Pivot plate plate.

A A
A A

Protection
tape
Notches

Section A – A INSTALLATION SERVICE POINT

Mirror
"AA MIRROR INSTALLATION
While holding the pivot plate with a flat-tipped screwdriver,
push the mirror to engage the clips at its lower part with the
pivot plate.
Pivot plate
Flat-tipped
screwdriver

A
A
A A
 EXTERIOR – Outside Door Mirror 51-23
INSPECTION
ELECTRIC REMOTE-CONTROLLED MIRROR
OPERATION CHECK
Battery connection terminal Direction of
operation
ti
1 2 3 6 7
UP
DOWN
LEFT
RIGHT
Vehicles with
heater mirror

ELECTRIC REMOTE-CONTROLLED MIRROR SWITCH

CONTINUITY CHECK

Switch Switch Terminal No.

position
Left mirror Right mirror

1 6 9 10 11 1 2 3 6 9

Adjustment switch UP

DOWN

RIGHT

LEFT
NOTES
 EXTERIOR – General/Rear bumper 51-1

GROUP 51
EXTERIOR
GENERAL
OUTLINE OF CHANGES
 Due to the introduction of 5-door models, the rear bumper service procedure has been added.
 Due to the introduction of 5-door models, the service procedures for the roof drip moulding and the
side protector moulding have been added.
 Due to the change on the front deck garnish, the service procedure has been changed.
 The side protector moulding for 5-door models has a “Pininfarina” mark and “Pininfarina” logo mark.
Due to this, the service procedure has been established.
 Due to the change on the GDI mark, the service procedure has been changed.
REAR BUMPER
DISASSEMBLY AND REASSEMBLY
1

View A
Location of rear bumper pad)
A
2 1 Notch
Vertical line

2
Press line 2
1 4

3
Disassembly steps
 Rear combination lamp assembly and 1. Rear bumper face side bracket
rear combination lamp assembly 2. Rear bumper pad
bracket <R.H. drive vehicles> 3. Rear bumper cover
 Rear fog assembly and rear fog 4. Rear bumper face
assembly bracket <L.H. drive
vehicles>
51-2 EXTERIOR – Moulding

MOULDING
REMOVAL AND INSTALLATION
Section A – A Section B – B Section C – C Section D – D

2 Clip 3 Clip 3
2 Clip
Clip

Windshield

2 <Vehicles with roof rail> 1

2 <Vehicles without roof rail>

B
B
A A

D
C
D
C

3
View E

3
Adhesive: double-sided tape [5 mm width and 0.8 mm thickness]

Roof drip moulding removal steps NOTE

 Roof rail assembly For the removal and installation service points of the
1. Roof drip cover roof drip moulding and the side protector moulding, refer
A 2. Roof drip moulding to the Basic Manual.
Side protector moulding removal
B A 3. Side protector moulding
 EXTERIOR – Garnish 51-3
GARNISH
REMOVAL AND INSTALLATION
View A

B C

B C
1

Section B – B Section C – C
1 1
NOTE
: Clip positions
Claw Clip : Claw positions

Adhesive: double-sided tape [5 mm width and 0.8 mm thickness]

Front deck garnish removal steps NOTE

 Wiper arm and blade assembly For the removal and installation service points of the
A A 1. Front deck garnish side protector moulding, refer to the Basic Manual.
51-4 EXTERIOR – Marks

MARKS
REMOVAL AND INSTALLATION

1,2

A 1. Pininfarina mark A 3. GDI mark

A 2. Pininfarina logo mark

INSTALLATION SERVICE POINT

A MARK INSTALLATION
(1) PININFARINA MARK,(2) PININFARINA LOGO MARK

Side protect moulding

2
 EXTERIOR – Marks 51-5
(3) GDI MARK
Window moulding end line

Back door end line

124 ± 1 mm

Align the application tape end

with the back door end line.

1. Clean the mark installation surfaces on the body with

unleaded petrol.
2. Peel off the backing paper from the reverse side of the
marks, and then attach the marks to the vehicle body
so that they fit properly into position.
Caution
When attaching the marks, the surrounding
temperature should be 20 – 38C and the air should
be completely free from dust.
If the surrounding temperature is lower than 20C,
the marks and the places on the body where the marks
are to be attached should be heated to 20 – 38C.
NOTES
 EXTERIOR – General/Marks 51-1
GROUP 51
EXTERIOR
GENERAL
OUTLINE OF CHANGES
The following service procedures have been changed due to the addition of marks.
MARKS
REMOVAL AND INSTALLATION

"AA 1. Pininfarina logo mark <Vehicles for

MPI>
51-2 EXTERIOR – Marks

INSTALLATION SERVICE POINT

"AA INSTALLATION OF MARK
1. APPLICATION POSITION
(1) Pininfarina mark

Front fender panel end line

10 mm

342 mm

R end line

2. INSTALLATION PROCEDURE
(1) Clean the mark installation surfaces on the body with
unleaded petrol.
(2) Peel off the backing paper from the reverse side of the
marks, and then attach the marks to the vehicle body
so that they fit properly into position.
Caution
When attaching the marks, the surrounding
temperature should be 20 – 38_C and the air should
be completely free from dust.
If the surrounding temperature is lower than 20_C,
the marks and the places on the body where the marks
are to be attached should be heated to 20 – 38_C.
When the marks are attached, care should be used
not to allow bubble to enter between tape and the
body.
 INTERIOR
Click on the applicable bookmark to selected the required model year
52A-2

INTERIOR
CONTENTS

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Front Seat* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTRUMENT PANEL* . . . . . . . . . . . . . . . . . . . . . . 3
Rear Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . 7
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Front Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSIDE REAR VIEW MIRROR . . . . . . . . . . . . . . 11

HEADLINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from
rendering the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and
interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or
maintenance) are indicated in the table of contents by an asterisk (*).
 INTERIOR – Special Tool/Instrument Panel 52A-3
SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Removal of switch, trim, etc.

INSTRUMENT PANEL
REMOVAL AND INSTALLATION
For installation of the instrument panel, the bolts and screws described below are used. They are indicated
by symbols in the illustration.

Name Symbol Size mm (D × L) Colour Shape

Tapping screw a 5 12 –

b 5 20 –

c 5 16 –

d 5 16 Black

Washer-assembled screw e 5 10 –

Washer-assembled bolt f 6 16 –

g 8 20 –

h 5 12 –

i 6 16 –

D = Thread diameter
L = Effective thread length
52A-4 INTERIOR – Instrument Panel

Caution: SRS
1. For the passenger side air bag module removal/installation, always observe the service procedures
of GROUP 52B – Air Bag Module.
2. Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel.

Pre-removal and Post-installation Operation

Steering Column Mounting Bolt Removal and
Installation

c 5
c
6
3 13
c 4 c
c 14
e 7
c e
8

17 h 8
f i
5 Nm
f
20
1 22 f h
16 19 18 17
23 f
f 21
f

a f f
b 12
5 Nm
c
2 9 15

d a
10

11
Removal steps
1. Column cover 15. Glove box
2. Under cover 16. Switch panel assembly
3. Meter hood B <Vehicles with fog lamp>
4. Combination meter 17. Instrument panel side cover
5. Meter hood A D Scuff plate (Refer to P.52A-9.)
6. Multi-center display hood D Cowl side trim (Refer to P.52A-9.)
7. Multi-center display D Floor console (Refer to P.52A-7.)
8. Multi-display bracket D Front pillar trim (Refer to P.52A-9.)
9. Center panel 18. Rheostat connector
10. Radio and tape player 19. Leveling switch connector
11. Heater control assembly or auto- 20. Fog lamp switch connector
matic A/C control panel assembly <Vehicles with fog lamp>
12. Glove box striker 21. Hazard lamp switch connector
13. Instrument tray <Vehicles without 22. Instrument panel assembly
front air bag module> 23. Knee protector bracket
14. Passenger’s side air bag module
<Vehicles with front air bag
module>
 INTERIOR – Instrument Panel 52A-5
CLIP AND CLAW POSITIONS

A
B A

D C B
B
C A
D
E E A
B
B

F
H
G
H G F
K F
K J
J
I I

NOTE
: Clip positions
: Claw positions

Section A – A Section B – B Section C – C Section D – D

Instrument panel Instrument panel Instrument panel

Garnish

Clip Claw
Claw Claw

Section E – E Section F – F Section G – Section H – H

G
Instrument Clip Claw
Claw
panel
Column
Column cover
Instrument
panel cover Claw

Section I – I Section J – J Section K – K

Clip
Instrument panel

Claw

Garnish

Clip
Instrument panel
52A-6 INTERIOR – Instrument Panel

DISASSEMBLY AND REASSEMBLY

10

9 a
a a a a
11
a
7 a
a a
A a a a
a
A 4 a
8 a
6 11

3 A a
A

6
2

a
a a 12

1
1
1 2
Section A – A
12 Claw

NOTE
: Claw positions 6

Disassembly steps
1. Garnish 8. Center air outlet case
2. Parcel box 9. Instrument panel reinforcement
3. Connector holder 10. Center support panel
4. Distribution duct 11. Instrument panel side support
5. Defroster duct bracket
6. Side air outlet assembly 12. Instrument panel
7. Center air outlet
 INTERIOR – Floor Console 52A-7
FLOOR CONSOLE
REMOVAL AND INSTALLATION

11
13

10

14
12

9
1
5
4

2
6

3 5 Nm

5 Nm
7
8

Removal steps
1. Selector nob <M/T> 9. Front floor console
2. Rear floor console 10. Box with lid
3. Transfer lever cover <M/T> 11. Heated seat switch
4. Rear ashtray assembly <Vehicles with heated seat>
5. Holder 12. A/T panel or M/T panel
6. Ashtray bracket 13. Switch panel
7. G sensor <Vehicles with ABS> <Vehicles with heated seat>
8. Floor console bracket 14. Front ashtray assembly
<Vehicles with ABS>
52A-8 INTERIOR – Floor Console

CLIP AND CLAW POSITIONS

D
F
E E
H D
G

G
H
A
BA
C
B
C

NOTE
: Clip positions
: Claw positions

Section A – A Section B – B Section C – C

Rear floor console
Front floor console

Rear floor console

Claw Claw Clip

Claw

Section D – D Section E – E

Claw
Section H – H
Front floor
console
Clip
Front floor
Clip console

Instrument
Section F – F Section G – G panel

Instrument
Claw panel
Front floor
console

Clip

Claw
 INTERIOR – Trims 52A-9
TRIMS
REMOVAL AND INSTALLATION

17

3 14
44 Nm 44 Nm
4
15
13
5

8 16
11

10 12

2 9
44 Nm
1 7

1. Scuff plate 8. Luggage room hook

2. Cowl side trim 9. Front seat belt connection
3. Front door opening trim 10. Quarter trim
4. Assist grip 11. Quarter box
5. Front pillar trim 12. Hook
6. Rear step plate 13. Front seat belt connection
<Vehicles without luggage floor 14. Center pillar trim
box> 15. Rear door opening trim
D Rear seat 16. Rear seat belt connection
(Refer to P.52A-15.) 17. Rear pillar trim
7. Luggage floor box <Option>
52A-10 INTERIOR – Trims

CLIP AND CLAW POSITIONS

E G
D G
E F F
D
A HH
B A
B

C
C
I I
J J
I I

K K

NOTE
: Clip positions
: Claw positions
For door trim, refer to GROUP 42.

Section A – A Section B – B Section C – C Section D – D

Front pillar trim

Clip Front pillar trim Clip

Instrument
Front panel
pillar Clip
trim
Center pillar trim
Section E – E Section F – F Section G – G Section H – H
Clip Clip
Head-
Center lining
pillar
trim
Rear pillar trim
Clip Rear pillar trim
Claw

Section I – I Section J – J Section K – K

Center pillar
trim
Clip
Rear step plate
Claw

Quarter trim
Quarter trim
Quarter trim Claw
 INTERIOR – Inside Rear View Mirror/Headlining 52A-11

Button INSIDE REAR VIEW MIRROR

REMOVAL SERVICE POINT
Remove by pushing in the direction of the arrow in the
illustration.

HEADLINING
REMOVAL AND INSTALLATION
10
11
6

7
9

5 8
1
8

1
8
4 <Front passenger’s side only>

Removal steps
1. Assist grip D Rear pillar trim (Refer to P.52A-9.)
2. Sun visor assembly 7. Trim clip <Vehicles without
3. Sun visor holder sunroof>
4. Front room lamp assembly 8. Clip
5. Sunroof switch cover 9. Trim clip
<Vehicles with sunroof> 10. Sunroof drip moulding
6. Rear room lamp assembly <Vehicles with sunroof>
D Front pillar trim (Refer to P.52A-9.) 11. Headlining
D Center pillar trim (Refer to P.52A-9.)
52A-12 INTERIOR – Seat

SEAT
FRONT SEAT
REMOVAL AND INSTALLATION
Caution: SRS
Before removal of the seat equipped with the side air bag module, refer to GROUP 52B – SRS
Service Precautions and Air Bag Module.
Front floor
console box

2 1

6
44 Nm

44 Nm
3 44 Nm
6
29 Nm

4 29 Nm 44 Nm
3 5

4 5
3 3

1. Heated seat switch 4. Heated seat harness connector

<Vehicles with heated seat> <Vehicles with heated seat>
2. Headrestraint 5. Side air bag module harness
Front seat assembly removal steps connector <Vehicles with SRS side
air bag>
3. Front seat anchor cover "AA 6. Front seat assembly

INSTALLATION SERVICE POINT

"AA FRONT SEAT ASSEMBLY INSTALLATION
Temporarily tighten the mounting nuts and bolts, and then
tighten them to the specified torque. Note that the bolts shown
in the illustration should be tightened with no load on the
seat cushion.
INTERIOR – Seat 52A-13
INSPECTION
HEATED SEAT SWITCH CONTINUITY CHECK
Switch Terminal No.
position
1 3 4 5 – 8 9 2 – 6
Driver’s HI
seat
switch

LO

Passen- HI
ger’s seat
switch
LO

NOTE
To inspect the diode, match the polarity of the circuit tester
with the (+) (–) polarities in the table.
HEATER CHECK
Measure the resistance between terminals.
Standard value:
Between terminals 1 and 3: Approx. 5.4 Ω
Between terminals 1 and 2: Approx. 4.2 Ω
Between terminals 2 and 3: Approx. 9.6 Ω
52A-14 INTERIOR – Seat

DISASSEMBLY AND REASSEMBLY

12 <Front view of front seat back>

15 16 13
14

18

17

<Front view of front seat cushion>

8 10

11
4
B B
3 7
Section A–A Section B–B
19
B
5
B
2
7
Claw 19
19 Claw
1
NOTE
A
: Hog ring positions
A
: Claw positions
1
6

Disassembly steps 10. Front seat cushion pad

1. Front seat side shield cover 11. Front seat cushion frame
2. Height adjuster lever 12. Front seat back assembly
3. Inner seat belt AA" 13. Headrestraint guide
4. Reclining adjuster lever 14. Front seat back cover
5. Front seat hinge cover 15. Front seat back pad
6. Front cover 16. Front seat back frame
7. Recliner cover 17. Release lever knob
8. Front seat cushion assembly 18. Release lever trim
9. Front seat cushion cover 19. Seat slide adjuster
 INTERIOR – Seat 52A-15
REMOVAL SERVICE POINT
AA" HEADRESTRAINT GUIDE REMOVAL

REAR SEAT
REMOVAL AND INSTALLATION

82 Nm 3

23 Nm 23 Nm

2
4

1. Headrestraint 2. Rear seat cushion assembly

Rear seat assembly removal steps 3. Rear seat back assembly
4. Rear seat stopper
52A-16 INTERIOR – Seat

DISASSEMBLY AND REASSEMBLY

3

6
5

4 8

1 7

<Back view of rear seat cushion> <Front view of rear seat back>

<Front view of rear seat cushion>

NOTE
: Hog ring positions

Disassembly steps
1. Rear seat cushion cover 5. Rear seat back pad
2. Rear seat cushion pad 6. Rear seat back frame assembly
AA" 3. Headrestraint guide 7. Rear seat center hinge
4. Rear seat back cover 8. Folding knob assembly
 INTERIOR – Seat Belt 52A-17
SEAT BELT
FRONT SEAT BELT
REMOVAL AND INSTALLATION
Caution: SRS
Before removal of the seat belt pre-tensioner, refer to GROUP 52B – SRS Service Precautions and
Seat Belt with Pre-tensioner.

44 Nm

1
44 Nm
44 Nm 44 Nm

Outer seat belt removal steps Inner seat belt removal

1. Outer seat belt connection 4. Inner seat belt
D Quarter trim (Refer to P.52A-9.)
2. Outer seat belt
3. Front noise protector
52A-18 INTERIOR – Seat Belt

REAR SEAT BELT

REMOVAL AND INSTALLATION

1
2

44 Nm

44 Nm

2 44 Nm

44 Nm

Removal steps D Rear pillar trim (Refer to P.52A-9.)

D Rear seat cushion assembly D Quarter trim (Refer to P.52A-9.)
(Refer to P.52A-15.) 3. Outer seat belt
1. Sash guide cover 4. Rear noise protector
2. Outer seat belt connection 5. Inner seat belt
D Luggage floor box <Option>
(Refer to P.52A-9.)
 INTERIOR – General/Trims <5–door models> 52A-1
GROUP 52A
INTERIOR
GENERAL
OUTLINE OF CHANGE
 Due to the introduction of 5-door models, the service procedures for the trims, the headlining, the
seat and the seat belts have been added. The other items are the same as before.
TRIMS <5-DOOR MODELS>
REMOVAL AND INSTALLATION

21 44 Nm

22 20 19
9
11
3
4
5 10

14
44 Nm 15 16

17

8
18

6
12
7
13
2 1
44 Nm

1. Front scuff plate  Rear seat (Refer to ’00 PAJERO PININ

2. Cowl side trim Workshop Manual <pub.No.
3. Front door opening trim CKRE00E1> Group 52A)
4. Assist grip (front) 13. Luggage floor box <Option>
5. Front pillar trim 14. Luggage room hook
6. Rear scuff plate 15. Net hook <Option>
7. Front seat belt connection 16. Cover
8. Center pillar lower trim 17. Quarter lower trim
9. Rear door opening trim 18. Hook
10. Front seat belt connection 19. Back door opening trim
11. Center pillar upper trim 20. Rear pillar trim
12. Rear step plate 21. Rear seat belt connection
22. Quarter pillar upper trim
52A-2 INTERIOR – Trims <5–door models>

CLIP AND CLAW POSITIONS

H
H
E
F FE
D
D
A E E
I G G
B A
I
B I
E I
C E J
J
C

K
K
L
L

NOTE
: Clip positions
: Claw positions
For door trim, refer to GROUP 42.

Section A – A Section B – B Section C – C Section D – D

Headlining Front pillar Head-
Clip Front pillar trim trim lining

Clip
Instrument
Front panel
pillar Clip
trim
Center pillar trim
Section E – E Section F – F Section G – G
Section H – H
Clip Rear pillar trim
Clip Clip
Pillar trim

Headlining
Rear pillar trim
Clip Head-
lining
Quarter pillar
upper trim
Section I – I Section J – J Section K – K Section L – L
Center pillar Rear step plate
trim
Clip
Rear step plate
Claw

Quarter trim
Quarter trim
Quarter trim Claw Clip
 INTERIOR – Headlining <5-door models> 52A-3
HEADLINING <5-DOOR MODELS>
REMOVAL AND INSTALLATION
10
11 7

9
1 9
6 9
1

9
5 2
4

Removal steps
1. Assist grip  Quarter pillar upper trim
2. Grip (rear) (Refer to P.52A-1.)
3. Sun visor assembly  Rear pillar trim (Refer to P.52A-1.)
4. Sun visor holder 8. Trim clip <Vehicles without
5. Front room lamp assembly sunroof>
6. Sunroof switch 9. Clip
<Vehicles with sunroof> 10. Sunroof drip moulding
7. Rear room lamp assembly <Vehicles with sunroof>
 Front pillar trim (Refer to P.52A-1.) 11. Headlining
 Center pillar trim (Refer to P.52A-1.)
52A-4 INTERIOR – Seat <5-door models>

SEAT <5-DOOR MODELS>

REAR SEAT
DISASSEMBLY AND REASSEMBLY
3

6 5

4 7

13 Nm
1

8
A A
B
10 B

NOTE
: Clip position
: Claw position

<Back view of rear seat cushion> Section A – A Section B – B

Claw 10
1 10 Claw 8

Disassembly steps
1. Rear seat cushion cover 6. Rear seat back pad
2. Rear seat cushion pad 7. Folding knob assembly
A 3. Headrestraint guide 8. Reclining adjuster cover
4. Rear seat back cover 9. Rear seat center hinge
5. Rear seat back panel 10. Rear seat back frame assembly

REMOVAL SERVICE POINT

A HEADRESTRAINT GUIDE REMOVAL
 INTERIOR – Seat Belt <5-door models> 52A-5
SEAT BELT <5-DOOR MODELS>
FRONT SEAT BELT
REMOVAL AND INSTALLATION
Caution: SRS
Before removal of the seat belt pre-tensioner, refer to GROUP 52B – SRS Service Precautions and
Seat Belt with Pre-tensioner.

3
44 Nm
2 44 Nm

44 Nm

5
2
44 Nm
44 Nm

Outer seat belt removal steps Inner seat belt removal

1. Sash guide cover 5. Inner seat belt
2. Outer seat belt connection
 Center pillar lower trim
(Refer to P.52A-1.)
 Center pillar upper trim
(Refer to P.52A-1.)
3. Adjustable seat belt anchor
4. Outer seat belt
52A-6 INTERIOR – Seat Belt <5-door models>

REAR SEAT BELT

REMOVAL AND INSTALLATION

1
2

44 Nm

4 3

44 Nm 44 Nm

2 5
44 Nm

6
5

Removal steps  Quarter lower trim

 Rear seat cushion assembly (Refer to P.52A-1.)
(Refer to P.52A-1.)  Quarter pillar upper trim
1. Sash guide cover (Refer to P.52A-1.)
2. Outer seat belt connection 3. Outer seat belt
 Luggage floor box <Option> 4. Rear noise protector
(Refer to P.52A-1.) 5. Rear center seat belt
6. Inner seat belt
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
Click on the applicable bookmark to selected the required model year
 52B-1

SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SRS AIR BAG CONTROL UNIT

(SRS-ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SRS SERVICE PRECAUTIONS . . . . . . . . . . . . . . 4
AIR BAG MODULES AND CLOCK
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7 SEAT BELT WITH PRE-TENSIONER . . . . . . . 44

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 8 SIDE IMPACT SENSOR . . . . . . . . . . . . . . . . . . . 46

SRS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 23 AIR BAG MODULE AND SEAT BELT

PRE-TENSIONER DISPOSAL
POST-COLLISION DIAGNOSIS . . . . . . . . . . . . . 27 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Undeployed Air Bag Module and Seat Belt
INDIVIDUAL COMPONENT SERVICE . . . . . . . 30 Pre-tensioner Disposal . . . . . . . . . . . . . . . . . . . . . . . 48
Deployed Air Bag Module or Operated Seat Belt
WARNING/CAUTION LABELS . . . . . . . . . . . . . . 31 Pre-tensioner Disposal Procedures . . . . . . . . . . . 60

FRONT IMPACT SENSORS . . . . . . . . . . . . . . . . 32

CAUTION
D Carefully read and observe the information in the SERVICE PRECAUTIONS (P.52B-4.) prior to any service.
D For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting
(P.52B-8.) section.
D If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the
procedures in the INDIVIDUAL COMPONENT SERVICE section (P.52B-30.) for the components involved.
D If you have any questions about the SRS, please contact your local distributor.
52B-2 SRS – General Information

GENERAL INFORMATION
To improve safety, the SRS and seat belts with lamp on the instrument panel indicates the
pre-tensioner are available as optional parts. These operational status of the SRS. The clock spring
systems enhance collision safety by restraining the is installed in the steering column.
front passengers in case of an accident. The SRS The SRS side air bag deploys if an impact received
works with the pre-tensioner simultaneously when at the side of the vehicle is stronger than a certain
a collision is detected. set value, in order to protect the upper bodies of
The SRS consists of four air bag modules, SRS front seat passengers in the event of a collision.
air bag control unit (SRS-ECU), front impact The seat belt pre-tensioner is built into the front
sensors, side impact sensors, SRS warning lamp seat belt retractor. Only authorized service
and clock spring. The air bags are located in the personnel should do work on or around the SRS
centre of the steering wheel, above the glove box, components and seat belt with pre-tensioner. Those
and built into the front seat back assemblies. Each service personnel should read this manual carefully
air bag has a folded air bag and an inflator unit. before starting any such work. Extreme care must
The SRS-ECU under the floor console monitors be used when servicing the SRS to avoid injury
the system and has a safing G sensor and an analog to the service personnel (by inadvertent deployment
G sensor. The front impact sensors are installed of the air bags or inadvertent operation of the seat
on the front side member. The side impact sensor belt with pre-tensioner) or the driver (by rendering
inside the quarter panels, inner monitors any shocks the SRS or the seat belt with pre-tensioner
coming from the side of the vehicle. The warning inoperative).
 SRS – General Information 52B-3

Driver’s air bag

module
Front passenger’s
air bag module

SRS warning lamp

Clock spring

Driver’s air bag Diagnosis

Seat belts with connector
Front
pre-tensioner passenger’s SRS-ECU
air bag

Seat belt pre-tensioner

Side air bag

SRS-ECU

Side air bag

module*

Side impact sensor*

Front impact sensor

NOTE
*: Indicates the parts equipped on the right and left sides.
52B-4 SRS – SRS Service Precautions

SRS SERVICE PRECAUTIONS

1. In order to avoid injury to yourself or others NOTE
from accidental deployment of the air bag during If any of these components are diagnosed as
servicing, read and carefully follow all the faulty, they should only be replaced, in
precautions and procedures described in this accordance with the INDIVIDUAL COM-
manual. PONENTS SERVICE procedures in this
2. Do not use any electrical test equipment on manual. (Refer to P.52B-30.)
or near SRS components, except those
specified on P.52B-7.
3. Never Attempt to Repair the Following
Components:
D SRS air bag control unit (SRS-ECU)
D Front impact sensor
D Clock spring
D Driver’s and front passenger’s air bag
modules
D Side air bag module
D Side impact sensor
D Seat belt with pre-tensioner

4. After disconnecting the negative (–) battery cable, wait

Insulating tape Battery 60 seconds at least before any service and insulate
the disconnected cable with tape. The SRS retain
enough voltage to deploy the air bag for a short time
even after disconnection of the battery. So, serious
injury may result by accidental air bag deployment
if a work is done on the SRS just after the disconnection
of the battery.

5. Do not attempt to repair the wiring harness connectors

SRS-ECU connector
of the SRS. If the connector(s) are diagnosed as defective,
replace the wiring harness(es). If the harness(es) are
diagnosed as faulty, replace or repair the wiring
harness(es) according to the following table.
 SRS – SRS Service Precautions 52B-5

SRS-ECU Destination of harness Corrective action

Terminal No.

1, 2, 3, 4 Instrument panel wiring harness → Front wiring harness → Front Repair or replace each wiring
impact sensor harness.

7 Instrument panel wiring harness → Earth

8 Instrument panel wiring harness → Combination meter

(SRS warning lamp)

9, 10 Instrument panel wiring harness → Front passenger’s air bag

module

11, 12 Instrument panel wiring harness → Clock spring → Driver’s air bag Repair or replace the dash wiring
module harness. Replace clock spring.

13 Instrument panel wiring harness → Junction block (fuse No.8) Repair or replace each wiring
harness
harness.
16 Instrument panel wiring harness → Junction block (fuse No.6)

20 Instrument panel wiring harness → Diagnosis connector

21, 22 Body wiring harness → Side air bag module (L.H.)

23, 24 Body wiring harness → Side air bag module (R.H.)

27, 28 Body wiring harness → Seat belt with pre-tensioner (R.H.)

29, 30 Body wiring harness → Seat belt with pre-tensioner (L.H.)

34, 35, 36 Body wiring harness → Side impact sensor (L.H.)

40, 41, 42 Body wiring harness → Side impact sensor (R.H.)

6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure.
Insert the special tool (probe, MB991222, in the harness set) into connector from harness side (rear
side), and connect the tester to this probe. If any tool than special is used, damage to the harness
and other components will result. Furthermore, measurement should not be carried out by touching
the probe directly against the terminals from the front of the connector. The terminals are plated to
increase their conductivity, so that if they are touched directly by the probe, the plating may break,
which will cause drops in reliability.
SRS-ECU harness connector

SRS-ECU harness connector (rear view)

MB991222
52B-6 SRS – SRS Service Precautions/Special Tools

7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the
front impact sensor, SRS-ECU, air bag module (driver’s side and front passenger’s side), clock spring,
side impact sensors, front seat assemblies (side air bag module), and seat belts with pre-tensioner
before drying or baking the vehicle after painting.
D Front impact sensor, SRS-ECU, air bag module, clock spring, side impact sensor: 93_C or more
D Seat belt with pre-tensioner: 90_C or more
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to P.52B-8.)
9. Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.

SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub D Reading diagnosis codes
assembly D Erasing diagnosis code
D Reading trouble period
D Reading erase times

MB991613 SRS check Checking the SRS electrical circuitry

harness

A MB991223 Harness set Checking the continuity and measuring the

A: MB991219 A: Check harness voltage at the SRS-ECU harness connector
B: MB991220 B: LED harness
C: MB991221 C: LED harness
D: MB991222 adapter
D: Probe
B

MB990803 Steering wheel Steering wheel removal

puller
 SRS – Special Tools/Test Equipment 52B-7

Tool Number Name Use

MR372530 SRS air bag Deployment of driver’s side air bag module
adapter harness inside the vehicle

MB686560 SRS air bag Deployment of front passenger’s side air bag
adapter harness module inside or outside the vehicle

MR203491 or SRS air bag Deployment of driver’s side air bag module
MB628919 adapter harness outside the vehicle

TEST EQUIPMENT
Tool Name Use
Digital multi-meter Checking the SRS electrical circuitry
Use a multi-meter for which the maximum
test current is 2 mA or less at the minimum
range of resistance measurement
52B-8 SRS – Troubleshooting

TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
DIAGNOSIS CODES CHECK
Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check
diagnosis codes.
(Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.)
ERASING DIAGNOSIS CODE
Connect the MUT-II to the diagnosis connector and erase the diagnosis code.
Caution
Turn off the ignition switch before connecting or disconnecting the MUT-II.

SRS WARNING LAMP INSPECTION

1. Check to be sure that the SRS warning lamp illuminates
when the ignition switch is in the ON position.
2. Check to be sure that it illuminates for approximately 7
seconds and then switches off.
3. If the above is not the cause, inspect the diagnosis codes.

SRS warning lamp

INSPECTION CHART FOR DIAGNOSIS CODES

Inspect according to the inspection chart that is appropriate for the malfunction code.

Code No. Diagnosis item Reference page

11, 12, 13 Front impact sensor system 52B-10

14 Analog G-sensor system in the SRS-ECU 52B-11

15,16 Front impact safing G-sensor system inside SRS-ECU 52B-11

17 Side impact safing G-sensor system inside SRS-ECU 52B-11

21*2, 22*2, 61*2, 62*2 Driver’s side air bag module (squib) system 52B-12

24*2, 25*2, 64*2, 65*2 Front passenger’s side air bag module (squib) system 52B-13

26*2, 27*2, 66, 67 Driver’s side pre-tensioner (squib) system 52B-14

28*2, 29*2, 68, 69 Front passenger’s side pre-tensioner (squib) system 52B-15

31, 32 SRS-ECU capacitor system 52B-11

34*1 Connector lock system 52B-16

35 SRS-ECU (deployed air bag) system 52B-16

 SRS – Troubleshooting 52B-9
Code No. Diagnosis item Reference page

41*1 Power circuit system (fuse No.6 circuit) 52B-16

42*1 Power circuit system (fuse No.8 circuit) 52B-16

43*1 SRS warning lamp drive circuit Lamp does not illuminate. 52B-17
system
Lamp does not switch off. 52B-17

44*1 SRS warning lamp drive circuit system 52B-17

45 Internal circuit system of non-volatile memory (EEPROM) inside 52B-11

SRS-ECU

51, 52 Driver’s side air bag module (squib ignition drive circuit) system 52B-11

54, 55 Front passenger’s side air bag module (squib ignition drive circuit) 52B-11
system

56, 57 Driver’s side pre-tensioner (squib ignition drive circuit) system 52B-11

58, 59 Front passenger’s side pre-tensioner (squib ignition drive circuit) system 52B-11

71*2, 72*2, 75, 76 Side air bag module (R.H.) (squib) system 52B-18

73, 74 Side air bag module (R.H.) (squib ignition drive circuit) system 52B-11

79, 93 Side impact sensor (L.H.) communication system 52B-19

81*2, 82*2, 85, 86 Side air bag module (L.H.) (squib) system 52B-19

83, 84 Side air bag module (L.H.) (squib ignition drive circuit) system 52B-11

89, 96 Side impact sensor (R.H.) communication system 52B-20

91*1 Side impact sensor (L.H.) power supply circuit system 52B-21

92 Side impact sensor (L.H.) system 52B-21

94*1 Side impact sensor (R.H.) power supply circuit system 52B-21

95 Side impact sensor (R.H.) system 52B-21

NOTE
(1) *1: If the vehicle condition returns to normal, the diagnosis code will be automatically erased, and the SRS warning
lamp will return to normal.
(2) *2: If the trouble(s) are extinguished, the SRS warning lamp go out with diagnosis code history stored.
(3) If the vehicle has a discharged battery it will store the diagnosis codes 41 or 42. When these diagnosis codes are
displayed, check the battery.
52B-10 SRS – Troubleshooting

INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE

Code No.11, 12 or 13 Front impact sensor system Probable cause
These diagnostic trouble codes are output if there is abnormal resistance between D Malfunction of front impact sensor
the input terminals of the front impact sensors. D Malfunction of wiring harness of connectors
The trouble causes for each diagnosis code No. are as follows. D Malfunction of SRS-ECU

Code No. Trouble Symptom

11 D Short circuit in front impact sensor or harness

D Short circuit in front impact sensor harness leading to the vehicle body ground
D Short circuit in front impact sensor harness leading to the power supply

12 D Open circuit in either left or right front impact sensor or harness

D Short circuit in front impact sensor harness leading to the power supply

13 D Open circuit in both left or right front impact sensor or harness

D Short circuit in front impact sensor harness leading to the power supply

Front impact sensor check. (Refer to P.52B-33)

NG NG
Measure at SRS-ECU connector C-32. Check the following connectors: Repair
D Disconnect the connector and measure at the harness side. A-51, A-49, C-28, C-32
D Connect negative (–) battery terminal.
OK
D Ignition switch: ON
D Resistance between terminal 1 and 2 Check trouble symptoms.
OK: 820 ± 82 Ω
D Resistance between terminal 3 and 4 NG
OK: 820 ± 82 Ω
Check the harness wire between the SRS-ECU and front impact
sensor, and repair if necessary.
OK

Replace the SRS-ECU.

 SRS – Troubleshooting 52B-11
Code No.14, 15, 16, 17, 31, 32, 45, 51, 52, 54, 55, 56, 57, 58, Probable cause
59, 73, 74, 83, 84 System inside SRS-ECU
These diagnostic trouble codes are output when a fault is detected in the SRS-ECU. D Malfunction of SRS-ECU
The defective parts and trouble causes for each diagnosis code No. are as follows.

Code No. Defective parts Trouble causes

14 Analog G-sensor D Analog G-sensor is not operating

D Analog G-sensor characteristics are abnormal
D Analog G-sensor output is abnormal

15 Front impact safing G-sensor D Short circuit in the safing G-sensor

16 D Open circuit in the safing G-sensor

17 Side impact safing G-sensor D Safing G sensor is not operating

D Safing G sensor characteristics are abnormal
D Safing G sensor output is abnormal

31 Capacitor D Voltage at the capacitor terminal is higher than the specified value
for five seconds or more

32 D Voltage at the capacitor terminal is lower than the specified value

for five seconds or more (this is not detected if diagnosis code
No.41 or 42 indicating battery voltage drop has been output.)

45 Non-volatile memory (EE- D Non-volatile memory (EEPROM) is abnormal

PROM)

51 Driver’s side air bag module D Short circuit in the squib ignition drive circuit
(squib ignition drive circuit)
52 D Open circuit in the squib ignition drive circuit

54 Front passenger’s side air D Short circuit in the squib ignition drive circuit
bag module (squib ignition
55 drive circuit) D Open circuit in the squib ignition drive circuit

56 Driver’s side pre-tensioner D Short circuit in the squib ignition drive circuit
(squib ignition drive circuit)
57 D Open circuit in the squib ignition drive circuit

58 Front passenger’s side pre- D Short circuit in the squib ignition drive circuit
tensioner (squib ignition drive
59 circuit) D Open circuit in the squib ignition drive circuit

73 Side air bag module (R.H.) D Short circuit in the squib ignition drive circuit
(squib ignition drive circuit)
74 D Open circuit in the squib ignition drive circuit

83 Side air bag module (R.H.) D Short circuit in the squib ignition drive circuit
(squib ignition drive circuit)
84 D Open circuit in the squib ignition drive circuit

Replace the SRS-ECU.

52B-12 SRS – Troubleshooting

Code No.21, 22, 61, 62 Probable cause

Driver’s air bag module (squib) system
Abnormal resistance is present between input terminals of driver’s air bag module D Malfunction of clock spring
(squib). See table below for what each code tells. D Partially open as clock spring is not in neutral position
However, once trouble is extinguished, SRS-warning lamp will go out. (Diagnosis D Defective wiring harnesses or connectors
code will remain stored) D Malfunction of driver’s air bag module (squib)
D Malfunction of SRS-ECU

Code No. Trouble causes

21 D Short in driver’s air bag module (squib) or harness short

D Short in clock spring
D Defective connector*

22 D Open in driver’s side air bag module (squib) or open harness

D Open in clock spring
D Disconnected driver’s air bag module (squib) connector
D Partially open as clock spring is not in neutral position
D Poor connector contact*

61 D Driver’s air bag module (squib) harness shorted to power supply

62 D Driver’s air bag module (squib) harness short to the earth

NOTE
*: The shorting bars, which short positive (+) and negative (–) wires to prevent the air bags from accidental deployment
during the disconnection of the connector, are set in the squib circuit connectors. In a defective connector, the short-bar
may be still working even after the connection of the connector.
NG
Check clock spring. (Refer to P.52B-42.) Replace
NO

MUT-II Self-diag code

Resistance (3 Ω) D Connect clock spring connector No.1 C-65 and the harness side connector
(2-pin).
D Remove the cover from the No. 2 connector of the clock spring, and
then insert the probes (MB991222) and connect check harness to the
SRS check harness probe.
(MB991613)
Resistance (3 Ω) Caution
Never insert the probe directly to the terminals from the front of
the connector.
Check harness D Disconnect the resistance connector from the SRS check harness
(MB991613) and connect to the check harness.
D Connect the negative (–) battery terminal.
D Erase diagnosis code memory.
Is code Nos.21, 22, 61 or 62 displayed?
2 Check harness

1
Instrument panel
wiring harness Probe
connector (2-pin) (MB991222)

Cover 2
YES NO

Check the following connectors: C-32, C-65 Replace driver’s air bag module (squib).
OK NG

Check trouble symptoms. Repair

NG
Check wiring harness between clock spring and SRS-ECU.
OK NG

Replace SRS-ECU. Repair

 SRS – Troubleshooting 52B-13
Code No.24, 25, 64, 65 Probable cause
Front passenger’s air bag module (squib) system
Abnormal resistance is present between input terminals of front passenger’s air D Defective wiring harnesses or connectors
bag module (squib). See table below for what each code tells. D Malfunction of front passenger’s air bag module
However, once trouble is extinguished, SRS-warning lamp will go out. (Diagnosis (squib)
code will remain stored) D Malfunction of SRS-ECU

Code No. Trouble causes

24 D Short in front passenger’s air bag module (squib) or short harness
25 D Open in front passenger’s air bag module (squib) or open harness
D Poor connector contact*
64 D Short-circuit in front passenger’s air bag module (squib) harness to power supply
65 D Short-circuit in front passenger’s air bag module (squib) harness to earth

NOTE
*: The shorting bars, which short positive (+) and negative (–) wires to prevent the air bags from accidental deployment
during the disconnection of the connector, are set in the squib circuit connectors. In a defective connector, the short-bar
may be still working even after the connection of the connector.
YES
Check the following connectors: C-15, C-32
SRS check harness (MB991613)
OK NG

Check trouble symptoms. Repair

Resistance (3 Ω) NG
Instrument panel wiring harness
Check wiring harness between the front passenger’s air bag
module and SRS-ECU.
OK NG

Replace SRS-ECU. Repair

1

Front passenger’s air bag

module connector NO
Replace the front passenger’s air bag module (squib).

MUT-II Self-diag code

D Disconnect front passenger’s air bag module connector C-15,
and connect the harness side connector to SRS check
harness (MB991613) connector No.1.
D Connect negative (–) battery terminal.
D Erase diagnosis code memory.
Is code Nos.24, 25, 64 or 65 output?
52B-14 SRS – Troubleshooting

Code No.26, 27, 66 or 67 Driver’s side pre-tensioner (squib) Probable cause

system
These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of wiring harnesses or connectors
terminals of the driver’s side pre-tensioner (squib). D Malfunction of driver’s side pre-tensioner (squib)
The trouble causes for each diagnosis code No. are as follows. D Malfunction of SRS-ECU

Code No. Trouble causes

26 D Short in driver’s side pre-tensioner (squib) or harness short

27 D Open circuit in driver’s side pre-tensioner (squib) or open harness

D Malfunction of connector contact

66 D Short in driver’s side pre-tensioner (squib) harness leading to the power supply

67 D Short in driver’s side pre-tensioner (squib) harness leading to the earth

MUT-II Self-diag code

SRS check harness D Disconnect the driver’s side pre-tensioner connector D-41 <L.H. drive
(MB991613) vehicles>, D-38 <R.H. drive vehicles>
Resistance (3 Ω) D Insert the probe (MB991222) from the rear of the harness side connector
and connect the check harness to the probe.
Caution
Never insert the probe directly to the terminals from the front of
the connector.
Resistance (3 Ω)
D Disconnect the resistance connector from the SRS check harness
(MB991613) and connect to the check harness.
Check harness D Connect the negative (–) battery terminal.
D Erase diagnosis code memory.
Is code No.26, 27, 66 or 67 displayed?

Probe
Body wiring harness (MB991222)

Check harness

YES NO

Check the following connectors: D-36, D-41 <L.H. drive Replace the driver’s side pre-tensioner.
vehicles>, D-38 <R.H. drive vehicles>
OK NG

Check trouble symptoms. Repair

NG
Check wiring harness between the driver’s side pre-tensioner and
SRS-ECU.
OK NG

Replace SRS-ECU. Repair

 SRS – Troubleshooting 52B-15
Code No.28, 29, 68 or 69 Front passenger’s side Probable cause
pre-tensioner (squib) system
These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of wiring harnesses or connectors
terminals of the front passenger’s side pre-tensioner (squib). D Malfunction of front passenger’s side pre-tensioner
The trouble causes for each diagnosis code No. are as follows. (squib)
D Malfunction of SRS-ECU

Code No. Trouble causes

28 D Short in front passenger’s side pre-tensioner (squib) or harness short

29 D Open circuit in front passenger’s side pre-tensioner (squib) or open harness

D Malfunction of connector contact

68 D Short in front passenger’s side pre-tensioner (squib) harness leading to the power
supply

69 D Short in front passenger’s side pre-tensioner (squib) harness leading to the earth

MUT-II Self-diag code

SRS check harness D Disconnect the front passenger’s side pre-tensioner connector D-38 <L.H.
(MB991613) drive vehicles>, D-41 <R.H. drive vehicles>
Resistance (3 Ω) D Insert the probe (MB991222) from the rear of the harness side connector
and connect the check harness to the probe.
Caution
Never insert the probe directly to the terminals from the front of
the connector.
Resistance (3 Ω)
D Disconnect the resistance connector from the SRS check harness
(MB991613) and connect to the check harness.
Check harness D Connect the negative (–) battery terminal.
D Erase diagnosis code memory.
Is code No.28, 29, 68 or 69 displayed?

Probe
Body wiring harness (MB991222)

Check harness

YES NO

Check the following connectors: D-36, D-38 <L.H. drive Replace the front passenger’s side pre-tensioner.
vehicles>, D-41 <R.H. drive vehicles>
OK NG

Check trouble symptoms. Repair

NG
Check wiring harness between the front passenger’s side pre-ten-
sioner and SRS-ECU.
OK NG

Replace SRS-ECU. Repair

52B-16 SRS – Troubleshooting

Code No.34 Connector lock system Probable cause

SRS-ECU is poorly connected. D Defective connectors
However, when vehicle condition returns to normal, this code will be automatically D Malfunction of SRS-ECU
erased, and the SRS warning lamp will go out.

Yes
Is SRS-ECU connector C-32 connected properly? Check the following connectors: C-32
No OK NG

Repair Replace SRS-ECU. Repair

Code No.35 SRS-ECU (deployed air bag) system Probable cause

This code is displayed after deployment of air bags. If displayed before deployment, D Malfunction of SRS-ECU
the code indicates malfunction probably present in SRS-ECU.

Replace the SRS-ECU.

Code No.41 Power circuit system (fuse No.6 circuit) Probable cause
Code No.42 Power circuit system (fuse No.8 circuit)
Code No.41 is displayed if voltage between IG1 terminal (SRS–ECU, terminal 12) D Defective wiring harnesses or connectors
and earth is lower than specified for five successive seconds or more. D Malfunction of SRS-ECU
Code No.42 is displayed if voltage between IG1 terminal (SRS–ECU, terminal 9)
and earth is lower than specified for five successive seconds or more.
However, once trouble is extinguished, these codes will be automatically erased,
and SRS warning lamp will go out.
If codes 41 and 42 are displayed together, check the battery first as vehicle may
have discharged battery.

NG
Measure at SRS-ECU connector C-32. Check the following connectors: C-32, C-75, C-76
D Disconnect connector, and measure at harness side. NG
OK
D Connect negative (–) battery terminal.
D Ignition switch: ON Check trouble symptoms. Repair
D Voltage between terminal 16 and body earth (code No.41)
OK: 9 V or more NG
D Voltage between terminal 13 and body earth (code No.42)
Check harness wire between SRS-ECU and ignition switch IG1.
OK: 9 V or more
Repair if necessary.
OK

Replace SRS-ECU.
 SRS – Troubleshooting 52B-17
Code No.43 SRS warning lamp drive circuit system Probable cause
(Lamp does not come on)
Open circuit is present for 5 successive seconds or more in SRS warning lamp D Defective wiring harnesses or connectors
drive circuit. D Blown bulb
However, once trouble is extinguished, this code, if displayed due to open circuit, D Malfunction of SRS-ECU
will be automatically erased. D Malfunction of combination meter

NG
Check SRS warning lamp. Check bulb for being blown.
D Connect negative (–) battery terminal. OK NG
D Ignition switch: ON
D Does lamp come on when SRS-ECU connector C-32 is Repair
disconnected?
OK: Lamp illuminates Check the following connectors: C-02, C-06, C-07, C-32
OK OK NG
Replace SRS-ECU. Check trouble symptoms. Repair
NG
Check wiring harness between SRS-ECU, combination meter
and ignition switch IG1.
OK NG

Replace combination Repair

meter.

Code No.43 SRS warning lamp drive circuit system Probable cause
(Lamp does not go out.)
Harness between SRS warning lamp and SRS-ECU is being shorted to earth. D Defective wiring harnesses or connectors
However, once trouble is extinguished, this code will be automatically erased, and D Malfunction of SRS-ECU
SRS warning lamp will go out. D Malfunction of combination meter

NO
Check SRS warning lamp. Check the following connectors: C-07, C-32
D Connect negative (–) battery terminal.
OK NG
D Ignition switch: ON
D Does lamp go out when combination meter connector C-07 Check trouble symptoms. Repair
is disconnected?
NG
NO
Check wiring harness between SRS-ECU and combination meter.
Replace SRS-ECU.
OK NG

Replace SRS-ECU. Repair

Code No.44 SRS warning lamp drive circuit system Probable cause
Short is present in SRS warning lamp drive circuit, or output transistor in SRS-ECU D Defective wiring harnesses or connectors
is defective. D Malfunction of SRS-ECU
However, once trouble is extinguished, this code will be automatically erased, and
SRS warning lamp will go out.

OK
Check SRS warning lamp drive circuit system. Replace SRS-ECU.
(Refer to P.52B-17)
52B-18 SRS – Troubleshooting

Code No.71, 72, 75, 76 Probable cause

Side air bag module (R.H.) (squib) system
Abnormal resistance is present between input terminals of SRS-ECU for side air D Malfunction of wiring harnesses or connectors
bag module (R.H.) (squib). See table below for what each code tells. D Malfunction of side air bag module (R.H.) (squib)
However, as for code Nos. 71 and 72, once trouble is extinguished, SRS warning D Malfunction of SRS-ECU
lamp will go out. (Diagnosis code will remain stored)

Code No. Trouble causes

71 D Short in side air bag module (R.H.) (squib) or harness short

72 D Open in side air bag module (R.H.) (squib) or open harness

D Poor connector contact

75 D Side air bag module (R.H.) (squib) harness short to power supply

76 D Side air bag module (R.H.) (squib) harness short to earth

MUT-II Self-diag code

SRS check harness D Disconnect the side air bag module (R.H.) connector D-01
(MB991613) D Insert the probe (MB991222) from the rear of the harness side connector
Resistance (3 Ω) and connect the check harness to the probe.
Caution
Never insert the probe directly to the terminals from the front of
the connector.
Resistance (3 Ω) D Disconnect the resistance connector from the SRS check harness
(MB991613) and connect to the check harness.
D Connect the negative (–) battery terminal.
Check harness D Erase diagnosis code memory.
Is code No.71, 72, 75 or 77 displayed?

Probe
Body wiring harness (MB991222)

Check harness

YES NO

Check the following connectors: D-01, D-36 Replace the seat back assembly (R.H.)
OK NG

Check trouble symptoms. Repair

NG
Check wiring harness between the side air bag module (R.H.)
and SRS-ECU.
OK NG

Replace SRS-ECU. Repair

 SRS – Troubleshooting 52B-19
Code No.79 or No.93 Probable cause
Side impact sensor (L.H.) communication system
These diagnosis code are output if communication between the side impact sensor D Malfunction of wiring harnesses or connectors
(L.H.) and the SRS–ECU is not possible (code No.79) or abnormal (code No.93). D Malfunction of side impact sensor (L.H.)
D Malfunction of SRS-ECU

NO
MUT-II Self-diag code Check the following connectors: D-26, D-36
D Switch over the right side impact sensor (R.H.) and the side
OK NG
impact sensor (L.H.)
D Erase diagnosis code memory. Check trouble symptoms. Repair
Are code Nos.79 and 93 erased and code Nos.89 and 96 output?
NG
YES
Check the harness wire between the side impact sensor (L.H.)
Replace the side impact sensor (L.H.). and SRS-ECU.
OK NG

Replace the SRS-ECU. Repair

Code No.81, 82, 85, 86 Probable cause

Side air bag module (L.H.) (squib) system
Abnormal resistance is present between input terminals of SRS-ECU for side air D Defective wiring harnesses or connectors
bag module (L.H.) (squib). See table below for what each code tells. D Malfunction of side air bag module (L.H.) (squib)
However, as for code Nos. 81 and 82, once trouble is extinguished, SRS warning D Malfunction of SRS-ECU
lamp will go out. (Diagnosis code will remain stored)

Code No. Trouble causes

81 D Short in side air bag module (L.H.) (squib) or harness short

82 D Open circuit in side air bag module (L.H.) (squib) or open harness
D Poor connector contact

85 D Side air bag module (L.H.) (squib) harness short to power supply

86 D Side air bag module (L.H.) (squib) harness short to earth

52B-20 SRS – Troubleshooting

MUT-II Self-diag code

SRS check harness D Disconnect the side air bag module (L.H.) connector D-32
(MB991613) D Insert the probe (MB991222) from the rear of the harness side connector
Resistance (3 Ω) and connect the check harness to the probe.
Caution
Never insert the probe directly to the terminals from the front of
the connector.
Resistance (3 Ω) D Disconnect the resistance connector from the SRS check harness
(MB991613) and connect to the check harness.
D Connect the negative (–) battery terminal.
Check harness D Erase diagnosis code memory.
Is code No.81, 82, 85 or 86 displayed?

Probe
Body wiring harness (MB991222)

Check harness

YES NO

Check the following connectors: D-32, D-36 Replace the seat back assembly (L.H.)
OK NG

Check trouble symptoms. Repair

NG
Check wiring harness between the side air bag module (L.H.)
and SRS-ECU.
OK NG

Replace SRS-ECU. Repair

Code No.89 or No.96 Side impact sensor (R.H.) Probable cause

communication system
These diagnosis codes are output if communication between the side impact sensor D Malfunction of wiring harnesses or connectors
(R.H.) and the SRS–ECU is not possible (code No.89) or abnormal (code No.96) D Malfunction of side impact sensor (R.H.)
D Malfunction of SRS-ECU

NO
MUT-II Self-diag code Check the following connectors: D-10, D-36
D Switch over the side impact sensor (R.H.) and the side impact
OK NG
sensor (L.H.).
D Erase diagnosis code memory. Check trouble symptoms. Repair
Are code Nos.89 and 96 erased and code Nos.79 and 93 output?
NG
YES
Check the harness wire between the side impact sensor (L.H.)
Replace the side impact sensor (R.H.). and SRS-ECU.
OK NG

Replace the SRS-ECU. Repair

 SRS – Troubleshooting 52B-21
Code No.91 Side impact sensor (L.H.) power supply circuit Probable cause
system
Power supply voltage of side impact sensor (L.H.) is lower than specified for five D Defective wiring harnesses or connectors
successive seconds or more. D Malfunction of side impact sensor (L.H.)
However, once trouble is extinguished, this code will be automatically erased, and D Malfunction of SRS-ECU
SRS warning lamp will go out.

NG
Measure at side impact sensor (L.H.) connector D-26. Check the following connectors: D-26, D-36
D Disconnect connector and measure at the harness side.
OK NG
D Connect negative (–) battery terminal.
D Ignition switch: ON Check trouble symptoms. Repair
D Voltage between terminal No.1 and body earth.
OK: 9 V or more NG
OK Check harness wire between side impact sensor (L.H.) and SRS-
ECU.
Replace side impact sensor (L.H.).
OK NG

Replace SRS-ECU. Repair

Code No.92, 95 Side impact sensor system Probable cause

Code No.92 is displayed when malfunction is present inside side impact sensor D Malfunction of side impact sensor (L.H.) (Code No.92)
(L.H.). D Malfunction of side impact sensor (R.H.) (Code No.95)
Code No.95 is displayed when malfunction is present inside side impact sensor
(R.H.).
See INSPECTION CHART 6, below, for what each code tells.

Code No. Defective parts Trouble

92 Side impact analog G-sensor D Not working

D Having abnormal
95 D Having abnormal output

Replace side impact sensor (L.H.) (code No.92).

Replace side impact sensor (R.H.) (code No.95).

Code No.94 Side impact sensor (R.H.) power supply circuit Probable cause
system
Power supply voltage of side impact sensor (R.H.) is lower than specified for D Defective wiring harnesses or connectors
successive five seconds or more. D Malfunction of side impact sensor (R.H.)
However, once trouble is extinguished, this code will be automatically erased, and D Malfunction of SRS-ECU
SRS warning lamp will go out.

NG
Measure at side impact sensor (R.H.) connector D-10. Check following connectors: C-10, D-31
D Disconnect connector and measure at harness side.
OK NG
D Connect negative (–) battery terminal.
D Ignition switch: ON Check trouble symptoms. Repair
D Voltage between terminal (1) and body earth
OK: 9 V or more NG
OK Check harness wire between side impact sensor (R.H.) and
SRS-ECU.
Replace side impact sensor (R.H.).
OK NG

Replace SRS-ECU. Repair

52B-22 SRS – Troubleshooting

INSPECTION CHART FOR TROUBLE SYMPTOMS

Get an understanding of the trouble symptoms and check according to the inspection procedure chart.

Trouble Inspection procedure No(s). Reference page

Communication with MUT-II is impossible. 1 52B-22

SRS warning lamp does not come on. See diagnosis code No.43. 52B-17

SRS warning lamp does not go out. See diagnosis code Nos.43, 44. 52B-17

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1
Communication with MUT-II is impossible. Probable cause
When communication with all systems is impossible, diagnosis circuit is suspected D Defective wiring harness(es) or connector(s)
as faulty. D Malfunction of SRS-ECU
When only communication with SRS air bags is impossible, open in diagnosis output
circuit or power supply circuit including earth circuit may be present.

No
Can MUT–II communicate with other systems? Check MUT-II diagnosis circuit, and repair if necessary.
Yes

(1)NG
Measure at SRS-ECU connector C-32. Check following connector: C-32
D Disconnect connector and measure at harness side. OK NG
(1) Conductivity between terminal (7) and body earth
OK: Conductive Check trouble symptoms. Repair
D Connect negative (–) battery terminal.
NG
D Ignition switch: ON
(2) Voltage between terminal (13) and body earth Check harness wire between SRS-ECU and earth, and repair
OK: 9 V or more if necessary.
(3) Voltage between terminal (16) and body earth (2), (3)NG
OK: 9 V or more
OK
Check following connectors: B-32, C-35 Check following connectors: C-32, C-74, C-75
OK NG OK NG

Check trouble symptoms. Repair Check trouble symptoms. Repair

NG NG
Check harness wire between SRS-ECU and diagnosis connector. Check harness wire between SRS-ECU and ignition switch IG1,
OK NG repair if necessary.

Replace SRS-ECU. Repair

 SRS – SRS Maintenance 52B-23
SRS MAINTENANCE
The SRS must be inspected by an authorized dealer 10 years
after the date of vehicle registration.

SRS WARNING LAMP CHECK

Turn the ignition switch to the “ON” position. Does the SRS
warning lamp illuminate for about 7 seconds, turn off and
then remain extinguished for at least 5 seconds? If yes, SRS
system is functioning properly. If no, consult page 52B-8.

SRS warning lamp

Insulating tape SRS COMPONENT VISUAL CHECK

Battery Turn the ignition key to LOCK (OFF) position, disconnect the
negative battery cable and tape the terminal.
Caution
Wait at least 60 seconds after disconnecting the battery
cable before doing any further work. (Refer to P.52B-4.)

Battery (–) cable

SRS-ECU
SRS CONTROL UNIT (SRS-ECU)
1. Check SRS-ECU case and brackets for dents, cracks,
deformation or rust.
Caution
The SRS may not activate if the SRS-ECU is not
installed properly, which could result in serious injury
or death to the vehicle’s driver or front passenger.
2. Check connector for damage, and terminals for
deformation or rust.
Replace SRS-ECU if it fails visual check.
(Refer to P.52B-34.)
Front side member FRONT IMPACT SENSORS
Front impact
1. Check the front side member for deformation or rest.
sensor 2. Check the front impact sensor for dents, cracks,
deformation or rust.
3. Check the sensor harnesses for binding, the connectors
for damage, and the terminals for deformation.

Forward
52B-24 SRS – SRS Maintenance

AIR BAG MODULES, STEERING WHEEL AND CLOCK

<Driver’s side>
Inflator case
SPRING
Connector 1. Remove the air bag modules, steering wheel and clock
spring. (Refer to P.52B-36.)
Caution
The removed air bag modules should be stored in
a clean, dry place with the cover face up.
2. Check cover for dents, cracks or deformation.
3. Check connector for damage, terminals deformities, and
harness for binds.
<Front passenger’s side> 4. Check air bag inflator case for dents, cracks or deformities.
5. Check harness and connectors for damage, and terminals
for deformation.

Connector Inflator case

Case 6. Check clock spring connectors and protective tube for

damage, and terminals for deformation.
7. Visually check the clock spring case for damage.
8. Align the mating marks of the clock spring and, after turning
the vehicle’s front wheels to straight-ahead position, install
the clock spring to the column switch.
Mating Mark Alignment
Turn the clock spring clockwise fully, and then turn back
Protective tubes
Mating
it approx. 3 times counterclockwise to align the mating
marks marks.
Caution
If the clock spring’s mating mark is not properly
aligned, the steering wheel may not be completely
rotational during a turn, or the flat cable within the
clock spring may be severed, obstructing normal
operation of the SRS and possibly leading to serious
injury to the vehicle’s driver or front passenger.
9. Install the steering column covers, steering wheel and
the air bag module.
10. Check steering wheel for noise, binds of difficult operation.
 SRS – SRS Maintenance 52B-25
11. Check steering wheel for excessive free play.
REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS
THAT INSPECTION. (Refer to P.52B-41.)
Caution
The SRS may not activate if any of the above
components is not installed properly, which could
result in serious injury or death to the vehicle’s driver
or front passenger.

FRONT SEAT BACK ASSEMBLY (SIDE AIR BAG

MODULE)
Side air bag module
deployment section 1. Check that there is no abnormality in the seat air bag
module deployment section.
2. Check that there is no connector damage, bent terminals
or clamping of the harness.

Quarter SIDE IMPACT SENSORS

panel, 1. Check that there is no bending or corrosion in the quarter
inner
panel, inner.
2. Check that there is no denting, breakage, bending or
corrosion of the side impact sensor.
3. Check that there is no clamping of the harness, connector
damage or bent terminals.
Side NOTE
impact The illustration at left shows the side impact sensor (R.H.).
sensor The position of the side impact sensor (L.H.) is symmetrical
to this.
Caution
The SRS may not activate if the side impact sensors
are not installed properly, which could result in serious
injury or death to the vehicle’s driver or front
passenger.
52B-26 SRS – SRS Maintenance

INSTRUMENT PANEL WIRING HARNESS/FRONT WIRING HARNESS/ASSIST

WIRING HARNESS/BODY WIRING HARNESS

Instrument panel wiring harness

Body wiring harness

Front wiring harness

1. Check connector for poor connection.

2. Check harnesses for binds, connectors for damage, and
terminals for deformation.
REPLACE ANY CONNECTORS OR HARNESS THAT
FAIL THE VISUAL INSPECTION. (Refer to P.52B-4.)
Caution
The SRS may not activate if SRS harnesses or
connectors are damaged or improperly connected,
which could result in serious injury or death to the
vehicle’s driver or front passenger.

POST-INSTALLATION INSPECTION
Reconnect the negative battery terminal. Turn the ignition
switch to the “ON” position. Does the SRS warning lamp
illuminate for about 7 seconds, turn off and then remain
extinguished for at least 5 seconds? If yes, SRS system is
functioning properly. If no, consult page 52B-8.

SRS warning lamp

 SRS – Post-collision Diagnosis 52B-27
POST-COLLISION DIAGNOSIS
Whether or not the air bags have deployed, check and service
the vehicle after collision as follows:

SRS-ECU MEMORY CHECK

1. Connect the MUT-II to the diagnosis connector. (Refer
to GROUP 00 – How to Use Troubleshooting/Inspection
Service Points.)
Caution
Refer to that the ignition switch is LOCK (OFF) when
connecting or disconnecting MUT-II.
2. Read (and write down) all displayed diagnosis codes.
(Refer to P.52B-8.)
NOTE
If battery power supply has been shut down by the collision,
the MUT-II cannot communicate with the SRS-ECU. Check
and, repair if necessary, the instrument panel wiring
harness before the next job.
3. Use the the MUT-II to read the data list (how long trouble(s)
have continued and how often memory have been erased).
Data list

No Service Data Item Applicability

92 Number indication how often the memory is cleared. Maximum time to be stored: 250

93 How long problem have lasted (How long it takes Maximum time to be stored: 9,999 minutes
from the occurrence of the problem till the first air bag (approximately 7 days)
squib igniting signal)

94 How long problem(s) have lasted (How long it takes

from the first air bag squib igniting signal till now.)

4. Erase the diagnosis codes and after waiting 5 seconds

or more read (and write down) all displayed diagnosis
codes. (Refer to P.52B-8.)

REPAIR PROCEDURE
WHEN AIR BAGS (DRIVER’S SIDE AND FRONT
PASSENGER’S SIDE) DEPLOY OR SEAT BELT
PRE-TENSIONER OPERATES IN A COLLISION.
1. Replace the following parts with new ones.
D SRS-ECU (Refer to P.52B-34.)
D Driver’s side air bag module (Refer to P.52B-36.)
D Front passenger’s side air bag module (Refer to
P.52B-36.)
D Front impact sensor (Refer to P.52B-32.)
D Seat belt with pre-tensioner (Refer to P.52B-44.)
52B-28 SRS – Post-collision Diagnosis

2. Check the following parts and replace if there are any

malfunctions.
D Clock spring (Refer to P.52B-36.)
D Steering wheel, steering column and intermediate joint
(1) Check wiring harness (built into steering wheel)
and connectors for damage, and terminals for
deformation.
(2) Install air bag module to check fit or alignment
with steering wheel.
(3) Check steering wheel for noise, binds or difficult
operation and excessive free play.
3. Check harnesses for binding, connectors for damage, poor
connections, and terminals for deformation.
(Refer to P.52B-4.)

DEPLOYED SIDE AIR BAGS

1. Replace the following parts with new ones:
D SRS-ECU (Refer to P.52B-34.)
D Side impact sensors (Refer to P.52B-46.)
D Front seat back assemblies (Refer to P.52B-36.)
2. Check harnesses for binding, connectors for damage, poor
connections, and terminals for deformation. (Refer to
P.52B-4.)

UNDEPLOYED AIR BAGS IN LOW-SPEED COLLISION

Check the SRS components. If visible damage such as dents,
cracks, or deformation are found on the SRS components,
replace them with new ones. Concerning parts removed for
inspection, replacement with new parts and cautions in
working, refer to INDIVIDUAL COMPONENT SERVICE,
P.52B-30.

SRS-ECU
SRS-ECU
1. Check the SRS-ECU case and bracket for dents, cracks
or deformation.
2. Check the connector for damage, and terminals for
deformation.
3. Check the SRS-ECU and bracket for proper installation.
 SRS – Post-collision Diagnosis 52B-29
Front side member FRONT IMPACT SENSORS
Front impact
1. Check the front side member for deformation or rest.
sensor 2. Check the front impact sensor for dents, cracks,
deformation or rust.
3. Check the sensor harnesses for binding, the connectors
for damage, and the terminals for deformation.

Forward

<Driver’s side> Driver’s and passenger’s air bag modules

1. Check the covers for dents, cracks or deformation.
Inflator case 2. Check the connectors for damage, the terminals
Connector
deformities, and the harness for binds.
3. Check the air bag inflator cases for dents, cracks or
deformities.
4. Check the air bag modules for proper installation.

<Front passenger’s side>

Connector Inflator case

Clock spring
Case 1. Check the clock spring connectors and protective tubes
for damage, and terminals for deformation.
2. Visually check the case for damage.
Steering wheel, steering column and intermediate joint
1. Check the driver’s air bag module for proper installation
to the steering wheel.
Protective
tubes

2. Check the steering wheel for noise, binds or difficult

operation and excessive free play.
Harness connector (Instrument panel wiring harness)
Check the harness for binds, the connector for damage and
the terminals for deformation. (Refer to P.52B-4.)
52B-30 SRS – Post-collision Diagnosis/Individual Component Service

Front seat back assembly (side air bag module)

Side air bag module 1. Check the side air bag module deployment section in the
deployment section seat for dents and deformation.
2. Check the harness for binds, the connector for damage
and the terminals for deformation.

Quarter
Side impact sensor
panel,
inner 1. Check the quarter panel, inner for deformation or rust.
2. Check the side impact sensors for dents, cracks,
deformation and rust.
3. Check the connector for damage and the terminals for
deformation.
NOTE
Side The figures show side impact sensors (L.H.).
impact
sensor Harness connector (Instrument panel wiring harness
and side air bag wiring harness)
Check the harness for binds, the connector for damage and
the terminals for deformation. (Refer to P.52B-4.)

Seat belt with pre-tensioner

1. Check the seat belt for damage or deformation.
2. Check the pre-tensioner for cracks or deformation.
3. Check that the unit is installed correctly to the vehicle
body.

INDIVIDUAL COMPONENT SERVICE

If the SRS components and seat belt with pre-tensioner are to be removed or replaced as a result of
maintenance, troubleshooting, etc., follow each procedure (P.52B-32 – P.52B-47.)
Caution
1. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove
the front impact sensor, SRS-ECU, air bag modules (driver’s side and front passenger’s side),
front seat assemblies (side air bag module), clock spring, side impact sensors and seat belts
with pre-tensioner before drying or baking the vehicle after painting.
D Front impact sensor, SRS-ECU, Air bag module, clock spring, side impact sensor: 93_C
or more
D Seat belt with pre-tensioner: 90_C or more
Recheck SRS system operability after re-installing them.
2. If the SRS components and seat belts with pre-tensioner are removed for the purpose of check,
sheet metal repair, painting, etc., they should be stored in a clean, dry place until they are
reinstalled.
 SRS – Warning/Caution Labels 52B-31
WARNING/CAUTION LABELS
Caution labels on the SRS are attached in the vehicle the SRS. If the label(s) are dirty or damaged, replace
as shown. Follow label instructions when servicing with new one(s).
Steering wheel Driver’s air bag module Clock spring

Sun visor SRS-ECU Glove box

Front passenger’s Steering gear box Instrument panel

air bag module

Side impact sensor Seat belt with pre-tensioner Hood

Quarter
panel,
inner
52B-32 SRS – Front Impact Sensors

FRONT IMPACT SENSORS

Caution
1. Disconnect the battery (–) terminal and wait 3. Do not drop or subject the front impact
for 60 seconds or more before starting work. sensor to impact or vibration.
Furthermore, the disconnected battery If denting, cracking, deformation, or rust are
terminal should be covered with tape to discovered in the front impact sensor,
insulate it. (Refer to P.52B-4.) replace it with a new front impact sensor.
2. Never attempt to disassemble or repair the Discard the old one.
front impact sensor. If faulty, replace it. 4. After deployment of an air bag, replace the
front impact sensor with a new one.

REMOVAL AND INSTALLATION

Pre-removal Operation
D Turn Ignition Key to LOCK (OFF) position.
D Disconnect the Negative (–) Battery Terminal.

Front side member

4.9 Nm

Removal steps Installation steps

1. Under cover "AA D Pre-installation inspection
2. Front impact sensor "BA 2. Front impact sensor
1. Under cover
D Negative (–) battery cable connection
"CA D Post-installation inspection

INSTALLATION SERVICE POINTS

"AA PRE-INSTALLATION INSPECTION
To mount the new front impact sensor, visually check it and
measure the resistance between the terminals. (Refer to the
previous item “INSPECTION”)
 SRS – Front Impact Sensors 52B-33
"BAFRONT IMPACT SENSOR INSTALLATION
Front side member
Label 1. Securely connect the connector.
2. Position the front impact sensor facing toward the front
of the vehicle as shown by the arrow on the label, and
install it securely.
Caution
The SRS may not activate properly if a front impact
Front impact sensor is not installed properly, which could result
sensor Connector in serious injury or death to the vehicle’s driver.
Forward

"CA POST-INSTALLATION INSPECTION

1. Reconnect the negative battery terminal.
2. Turn the ignition key to the “ON” position.
3. Does the “SRS” warning lamp illuminate for about 7
seconds, and then remain extinguished for at least 5
seconds after turning OFF?
4. If yes, SRS system if functioning properly.
If no, consult page 52B-8.

SRS warning lamp

INSPECTION
1. Check the front impact sensor for dents, cracks,
deformation or rust.
Caution
If a dent, crack, deformation or rust is detected, replace
with a new sensor.
2. Measure the resistance between terminals and check
whether it is within the standard value.
Standard value: 820 ± 82 Ω
Caution
Always replace the sensor with a new one if the
resistance is not within the standard value.
3. Check front side member for deformation or rust.
4. Check the continuity between the terminal and bracket.
If there is a continuity, the insulation is malfunctioned,
and replace the sensor with a new one.
52B-34 SRS – SRS-ECU

SRS AIR BAG CONTROL UNIT (SRS-ECU)

Caution
1. Disconnect the negative (–) battery terminal 3. Do not drop or subject the SRS-ECU to
and wait for 60 seconds or more before impact or vibration.
starting work. Also, the disconnected battery If denting, cracking, deformation, or rust are
terminal should be insulated with tape. found in the SRS-ECU, replace it with a new
(Refer to P.52B-4.) one. Discard the old one.
2. Never attempt to disassemble or repair the 4. After deployment of the air bags, replace
SRS-ECU. If faulty, just replace with a new the SRS-ECU with a new one.
one. 5. Never use an ohmmeter on or near the
SRS-ECU, and use only the special test
equipment described on P.52B-7.

REMOVAL AND INSTALLATION

Pre-removal Operation
D Turn Ignition Key to LOCK (OFF) Position.
D Disconnect the Negative (–) Battery Terminal.

5 Nm

1
1
4
2

Removal steps Installation steps

D Floor console (Refer to GROUP 52A.) 4. SRS-ECU bracket
1. Bracket mounting bolts "AA 3. SRS-ECU
2. Bracket mounting bolt "BA 2. Bracket mounting bolt
(Earth bolt) (Earth bolt)
3. SRS-ECU 1. Bracket mounting bolt
4. SRS-ECU bracket D Floor console (Refer to GROUP 52A.)
D Negative (–) battery cable connection
"CA D Post-installation inspection
 SRS – SRS-ECU 52B-35
INSTALLATION SERVICE POINTS
"AA SRS-ECU INSTALLATION
Caution
Be sure to install the SRS-ECU properly. Otherwise, the
SRS air bags do not activate, which results in serious
injury or death of vehicle’s occupants.

"BA BRACKET MOUNTING BOLT (EARTH BOLT)

INSTALLATION
Earth bolt head mark Before installation, Refer to that the bolt is stamped mark
“E” on the head.

"CA POST-INSTALLATION CHECK

1. Turn the ignition switch to ON.
2. Does the SRS warning lamp illuminate for about 7 seconds
and then go out for more than 5 seconds?
3. Yes: The SRS warning lamp is working properly
No: Go to Troubleshooting. (Refer to P.52B-8.)

SRS warning lamp

INSPECTION
1. Check the SRS-ECU and brackets for dents, cracks or
deformation.
2. Check connector for damage, and terminals for
deformation.
Caution
If a dent, crack, deformation or rust are present, replace
the SRS-ECU with a new one.
NOTE
To check the SRS-ECU in other items than described
above, go to Troubleshooting. (Refer to P.52B-8.)
52B-36 SRS – Air Bag Modules and Clock Spring

AIR BAG MODULES AND CLOCK SPRING

Caution
1. Disconnect the negative (–) battery terminal 5. Do not store the air bag modules in a place
and wait for 60 seconds or more before more than 93_C.
starting work. Also, the disconnected battery 6. When the driver’s and front passenger’s air
terminal should be insulated with tape. bags have been deployed, replace the
(Refer to P.52B-4.) driver’s and passenger’s air bag modules
2. Never attempt to disassemble or repair the with new ones.
air bag modules and clock spring. 7. Put on gloves and safety glasses when
If faulty, just replace with new one(s). handling deployed air bags.
3. Do not drop the air bag modules or clock 8. When discarding the undeployed air bag
spring or allow contact with water, grease module(s), be sure to deploy the air bag(s)
or oil. in advance as specified in the service
Replace if a dent, crack, deformation or rust procedure.
are present. (Refer to to P.52B-48.)
4. Store the air bag modules on a flat surface
with the deployment surface facing up.
Do not place anything on top of them.
 SRS – Air Bag Modules and Clock Spring 52B-37
REMOVAL AND INSTALLATION
<Driver’s air bag module, clock spring>
Pre-removal Operation
D Put Steering Wheel and Front Wheels in
Straight-ahead Position. Remove Ignition Key.
D Disconnect the Negative (–) Battery Terminal.

A A
Column switch

2
1 41 Nm 0.69 Nm

3 B B
3

Section A – A Section B – B
9 Nm

Claw Claw
9 Nm
NOTE
: Claws

Driver’s air bag module removal Driver’s air bag module installation
steps steps
AA" 1. Driver’s air bag module "AA D Pre-installation inspection
AB" 2. Steering wheel "CA 2. Steering wheel
1. Driver’s air bag module
D Negative (–) battery cable connection
"DA D Post-installation check

Clock spring removal steps Clock spring installation steps

AA" 1. Drive’s air bag module "AA D Pre-installation check
AB" 2. Steering wheel "BA 3. Clock spring
D Lower column cover D Lower column cover
AC" 3. Clock spring "CA 2. Steering wheel
1. Driver’s air bag module
D Negative (–) battery cable connection
"DA D Post-installation inspection
52B-38 SRS – Air Bag Modules and Clock Spring

<Front passenger’s air bag module>

Sections A – A and C – C
A
2 Instrument panel
A
2
B C
C

Claw

Section B – B

Instrument Claw
1
panel

NOTE
: Claws

Removal steps Installation steps

1. Glove box "AA D Pre-installation inspection
AD" 2. Passenger’s air bag module 2. Passenger’s air bag module
1. Glove box
D Negative (–) battery cable connection
"DA D Post-installation inspection
 SRS – Air Bag Modules and Clock Spring 52B-39
<Front seat back assembly with side air bag module (Vehicles with side air bag)>

Side air bag module

Removal Installation steps

AE" 1. Front seat back assembly "AA D Pre-installation inspection
1. Front seat back assembly
D Negative (–) battery cable connection
"DA D Post-installation inspection

Air bag module

REMOVAL SERVICE POINTS
Connector AA" DRIVER’S AIR BAG MODULE REMOVAL
After removing the clip shown in the illustration, disconnect
the connector.
Caution
1. The air bag module must not be measured with such
equipment as an ohmmeter, nor disassembled.
2. The removed air bag module should be stored in a
clean, dry place with the deployment surface facing
Clip up.

AB" STEERING WHEEL REMOVAL

MB990803
Caution
Do not hammer on the steering wheel. Doing so may
damage the collapsible column mechanism.

AC" CLOCK SPRING REMOVAL

Caution
The removed clock spring should be stored in a clean,
dry place.
52B-40 SRS – Air Bag Modules and Clock Spring

AD"PASSENGER’S AIR BAG MODULE REMOVAL

Caution
The removed air bag module should be stored in a clean,
dry place with the deployment surface facing up.

AE"FRONT SEAT BACK ASSEMBLY REMOVAL

Refer to GROUP 52A – Seat.
Caution
1. When the side air bag module is required replacing,
replace the front seat back assembly.
2. The removed front seat back assembly should be
stored in clean, dry place with its back touching the
ground.

INSTALLATION SERVICE POINTS

"AA PRE-INSTALLATION INSPECTION
1. Even new air bag modules and a clock spring require
inspection before installation. (Refer to P.52B-41.)
Caution
When discarding the air bag module or seat back
assembly, deploy the air bag as specified in the service
procedure. (Refer to P.52B-48.)
2. Connect the negative (–) battery terminal.
3. Connect the MUT-II to the diagnosis connector (16-pin).
Caution
Turn the ignition switch to LOOK (OFF) position when
connecting and disconnecting the MUT-II.
4. Turn the ignition switch to ON.
5. Read a diagnostic code to Refer to that the SRS is operating
properly except an open in the air bag module circuit.
6. Turn the ignition switch to LOCK (OFF) position.
Disconnect the negative (–) battery cable and insulate
with tape.
Caution
Wait at least 60 seconds after the disconnection of the
battery cable before any further job. (Refer to P.52B-4.)
"BA CLOCK SPRING INSTALLATION
Align the mating marks on the clock spring as mentioned in
the next step. Then, after putting the front wheels in
straight-ahead position, install the clock spring to the column
switch.
 SRS – Air Bag Modules and Clock Spring 52B-41
Clock Spring Centring
Fully turn the clock spring clockwise and then turn it back
about 3 times counterclockwise to align the mating marks.
Caution
Unless the mating marks are properly aligned, the steering
wheel gets stuck amid a turn or the flat cable in the clock
spring is cut. These hinder the SRS air bag from proper
operation, resulting in serious injury to the vehicle’s driver.
Mating marks

"CA STEERING WHEEL INSTALLATION

1. Refer to first that the clock spring has been centred
properly. Then, install the steering wheel.
Caution
Be sure, when installing the steering wheel, not to
have the clock spring harness caught or tangled.
2. After the installation, check the steering wheel for proper
operation by turning it fully right and left.

"DA POST-INSTALLATION CHECK

1. Lightly turn the steering wheel right and left to Refer to
that noise and malfunction are not present.
2. Turn the ignition switch to “ON”.
3. Does the SRS warning lamp illuminate for about 7 seconds
and then go out for 5 seconds or more?
4. Yes: The SRS is working properly.
No: Go to Troubleshooting (Refer to P.52-8.)

SRS warning lamp

<Driver’s side> INSPECTION

DRIVER’S AND PASSENGER’S AIR BAG MODULE
Inflator case
Connector INSPECTION
If any malfunction is found in the following inspection, replace
the air bag module(s) with new one(s).
Discard the old one(s) after deployment as specified in the
service procedure. (Refer to P.52B-48.)
Caution
Never measure circuit resistance in the air bag modules
(squib) even with the specified tester. Measuring the circuit
<Front passenger’s side>
resistance with a tester causes accidental air bag
deployment due to current that flows or static, resulting
in serious personal injury.
1. Check the cover for dents, cracks or deformation.
2. Check the connectors for damage, terminals for
deformation, and harness for binds.
3. Check the air bag inflator cases for dents, cracks or
deformation.
4. Install the driver’s air bag module to the steering wheel
and check fit or alignment with the steering wheel.
Inflator
Connector case 5. Install the front passenger’s air bag module to instrument
panel and crossmember and check fit and alignment.
52B-42 SRS – Air Bag Modules and Clock Spring

Caution
If dents, cracks, deformation, or rust are present in
the air bag module(s), replace with new one(s).
Discard the old one(s) as specified in the service
procedure. (Refer to P.52B-48.)

Case 1 CLOCK SPRING CHECK

If any malfunction is found in the following inspections, replace
the clock spring with a new one.
1. Check the connectors and protective tubes for damage,
and terminals for deformation.
2. Visually check the case for damage.
3 3. Refer to that the clock spring has continuity between
connector No.2 and terminal No.4 of connector No.1.
Protective tubes
2

4. Remove the cover from the No. 3 connector of the clock

spring, and then insert the probes (MB991222).
Caution
The probe must not be inserted directly to the terminals
from the front of the connector.
5. Connect a digital multimeter to the probe (MB991222),
3 as shown, to check that.
Standard value: 0.62 ± 0.12 Ω

Digital
multimeter

Clock spring
2
Probe
(MB991222)

Cover
3

FRONT SEAT BACK ASSEMBLY WITH SIDE AIR BAG

MODULE
Side air bag module
deployment section If any malfunction is found in the following inspections, replace
the front seat back assembly.
To discard the removed front seat back assembly, deploy the
side air bag first as specified in the service procedure. (Refer
to P.52B-48.)
SRS – Air Bag Modules and Clock Spring 52B-43
Caution
Never measure circuit resistance in the air bag modules
(squib) even with the specified tester. Measuring the circuit
resistance with a tester causes accidental air bag
deployment due to current that flows or static, resulting
in serious personal injury.
1. Check the side air bag module deployment section for
dents and deformation.
2. Check the harness and connector for damage and the
terminals for deformation.
52B-44 SRS – Seat Belt with Pre-tensioner

SEAT BELT WITH PRE-TENSIONER

Caution
1. Never attempt to disassemble or repair the 4. Do not expose the seat belt with
seat belt with pre-tensioner. If faulty, replace pre-tensioner to temperatures over 90_C.
it. 5. After operating the seat belt pre-tensioner,
2. Be extremely careful when handling the seat replace the seat belt pre-tensioner with a
belt with pre-tensioner. Do not subject it to new part.
shocks, drop it, bring it close to strong 6. Gloves and protective goggles should be
magnets or allow contact with water, grease worn when handling a pre-tensioner once
or oil. Always replace it with a new part if it has been used.
any dents, cracks or deformation is found. 7. If disposing of a seat belt with pre-tensioner
3. Do not place anything on top of the seat which has not yet been used, its
belt pre-tensioner. pre-tensioner should be operated first before
disposal. (Refer to P.52B-48.)

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
D Turn Ignition Key to LOCK (OFF) Position
D Disconnect the Negative (–) Battery Terminal.

44 Nm

1 44 Nm

44 Nm

Removal steps Installation steps

1. Outer seat belt connection "AA D Post-installation inspection
D Quarter Trim (Refer to GROUP 52A.) 2. Seat belt with pre-tensioner
2. Seat belt with pre-tensioner D Quarter Trim (Refer to GROUP 52A.)
1. Outer seat belt connection
D Negative (–) battery cable connection
"BA D Pre-installation inspection
NOTE
The figure shows the seat belt with pre-tensioner
(R.H.)
 SRS – Seat Belt with Pre-tensioner 52B-45
INSTALLATION SERVICE POINTS
"AA PRE-INSTALLATION INSPECTION
When installing a new seat belt with pre-tensioner refer to
“INSPECTION”.
Caution
Disposal of the pre-tensioner must be carried out as stated
in the procedure. (Refer to P.52B-48.)

"BA POST-INSTALLATION INSPECTION

1. Reconnect the negative battery terminal.
2. Turn the ignition key to the “ON” position.
3. Does the “SRS” warning lamp illuminate for about 7
seconds, and then remain extinguished for at least 5
seconds after turning OFF?
4. If yes, SRS system is functioning properly. If no, consult
page 52B-8.

SRS warning lamp

INSPECTION
SEAT BELT WITH PRE-TENSIONER CHECK
If any part is found to be faulty during the inspection, it must
be replaced with a new one.
Dispose of the old one according to the specified procedure.
(Refer to P.52B-48.)
D Check seat belt pre-tensioner for dents, cracks or
deformation.
52B-46 SRS – Side Impact Sensor

SIDE IMPACT SENSOR

Caution
1. Disconnect the negative (–) battery terminal 3. Do not drop or subject the side impact
and wait for 60 seconds or more before sensors to impact or vibration.
starting work. Also, the disconnected battery If denting, cracking, deformation, or rust are
terminal should be insulated with tape. found in the side impact sensors, replace
(Refer to P.52B-4.) it with new ones. Discard the old ones.
2. Never attempt to disassemble or repair the 4. After deployment of the air bags, replace
side impact sensors. If faulty, just replace the side impact sensors with new ones.
with new ones. 5. Never use an ohmmeter on or near the side
impact sensors, and use only the special
test equipment described on P.52B-7.

REMOVAL AND INSTALLATION

Pre-removal Operation
D Turn Ignition Switch to LOCK (OFF) Position.
D Disconnect the Negative (–) Battery Terminal.

Quarter panel, inner

5 Nm

Removal steps Installation steps

D Front seat belt (Refer to GROUP 52A.) "AA D Pre-installation inspection
1. Front noise protector "BA 2. Side impact sensor
2. Side impact sensor 1. Front noise protector
D Front seat belt (Refer to GROUP 52A.)
D Negative (–) battery cable connection
"CA D Post-installation inspection
NOTE
The figure shows the side impact sensor (R.H.).

"AA PRE-INSTALLATION INSPECTION

Even new side impact sensor requires inspection before
installation. (Refer to Inspection.)
 SRS – Side Impact Sensor 52B-47
"BA SIDE IMPACT SENSOR INSTALLATION
Caution
The side impact sensor, unless properly installed, does
not operate properly, thereby resulting in serious injury
or death of the vehicle’s occupants.

"CA POST-INSTALLATION INSPECTION

1. Turn the ignition switch to ON.
2. Does the SRS warning lamp illuminate for about 7 seconds
and go off for 5 seconds or more?
3. YES: The system is working properly.
NO: Go to Troubleshooting. (Refer to P.52B-8.)

SRS warning lamp

INSPECTION
If any malfunction is found in the following inspections, replace
the side impact sensor(s) with new one(s).
1. Check the side impact sensors for dents, cracks,
deformation and rust.
2. Check the connector for damage and the terminals for
deformation.
3. Check the center pillar or quarter panel, inner for
deformation and rust.
NOTE
For other inspections than described above, go to
Troubleshooting. (P.52B-8.)
52B-48 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures

AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL

PROCEDURES
Before disposing of a vehicle which is equipped pre-tensioner themselves, the following procedures
with air bags or seat belts with pre-tensioner, or must be used to deploy the air bags or operate
when disposing of the air bags or seat belt the seat belt pre-tensioners before disposal.

UNDEPLOYED AIR BAG MODULE AND SEAT

BELT PRE-TENSIONER DISPOSAL
Caution
1. If the vehicle is to be scrapped or otherwise disposed
of, deploy the air bags inside the vehicle, and operate
the seat belt pre-tensioners outside the vehicle. If the
vehicle will continue to be operated and only the air
bag modules and seat belt pre-tensioner are to be
disposed of, deploy the air bags and operate the seat
belt pre-tensioners outside the vehicle.
2. Since a large amount of smoke is produced when
the air bag are deployed or the seat belt pre-tensioner
is operated, avoid residential areas whenever possible.
3. Since there is a loud noise when the air bags are
deployed and when the seat belt pre-tensioners are
operated, avoid residential areas whenever possible.
If anyone is nearby, give warning of the impending
noise.
4. Suitable ear protection should be worn by personnel
performing these procedures or by people in the
immediate area.
DEPLOYMENT INSIDE THE VEHICLE
1. Move the vehicle to an isolated spot.
2. Disconnect the negative (–) and positive (+) battery cables
from the battery terminals, and then remove the battery
from the vehicle.
Caution
Wait at least 60 seconds after disconnecting the battery
cables before doing any further work.
(Refer to P.52B-4.)
3. Deploy each air bag module as specified in the service
procedures that follows.
 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 52B-49
Driver’s air bag module
(1) Remove the steering column cover, lower.
(Refer to GROUP 52A – Instrument Panel.)
Clock spring (2) Disconnect the clock spring 2-pin connector and
2-pin connector instrument panel wiring harness connector (2-pin,
yellow).
NOTE
Once disconnected from the instrument panel wiring
Instrument panel wiring
harness connector harness, both electrodes of the clock spring connector
(2-pin yellow) short automatically. This prevents the driver’s air bag
from accidental deployment caused by static, etc.
Shorted (3) Connect deployment harnesses longer than 6 m to
each SRS air bag adapter harness and insulate the
Deployment harnesses connections with plastic tape.
Also, connect the deployment harnesses in the other
SRS air bag ends to short, thereby preventing the driver’s air bag
adapter 6 m or longer
harness from accidental deployment caused by static etc.
MB372530

Insulation
tape

(4) Connect the SRS air bag adapter harness to the clock
Clock spring spring 2-pin connector and route the deployment
2-pin connector SRS air bag harnesses out of the vehicle.
adapter harness
MB372530

Deployment
harnesses

(5) Close all the doors with the windows fully closed and
Cover put a cover over the vehicle to minimize report.
Caution
The cover is required as the glass, if already
damaged, may break.
(6) Separate the deployment harnesses as far from the
Deployment vehicle as possible and connect to the terminals of
harnesses
the battery removed from the vehicle. Then deploy.
Caution
1) Before deploying the air bag, see that no one
is in and near the vehicle. Also, put on safety
glasses.
2) The deployment makes the inflator of the
driver’s air bag very hot. Before handling the
inflator, wait more than 30 minutes for cooling.
3) If the air bag module fails to deploy although
the procedure is respected, do not go near
the module. Contact your local distributor.
(7) After deployment of the driver’s air bag module, discard
as specified in the procedure (Refer to P.52B-60).
Front passenger’s air bag module
52B-50 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures

(1) Remove the glove box.

(Refer to GROUP 52A – Instrument Panel.)
(2) Disconnect the front passenger’s air bag module 2-pin
connector (red) and instrument panel wiring harness
connector (2-pin, red).
NOTE
Once disconnected from the instrument panel wiring
Front passen- Instrument panel harness, both electrodes of the front passenger’s air
ger’s air bag wiring harness
module 2-pin connector (2-pin, red) bag module short automatically. This prevents the front
connector (red) passenger air bag from accidental deployment caused
by static, etc.
(3) Connect deployment harnesses longer than 6 m to
Shorted each SRS air bag adapter harness and insulate the
connections with plastic tape.
Deployment harnesses Also, connect the deployment harnesses in the other
SRS air bag ends to short, thereby preventing the front passenger’s
adapter harness 6 m or longer air bag from accidental deployment caused by static
MB686560
etc.
Insulation
tape

(4) Connect the SRS air bag adapter harness to the front
SRS air bag passenger’s air bag module 2-pin connector and route
adapter harness
MB686560 the deployment harnesses out of the vehicle.

Front passenger’s
air bag module 2-pin
Deployment connector (red)
harnesses

(5) Close all the doors with the windows fully closed and
Cover put a cover over the vehicle to minimize report.
Caution
The cover is required as the glass, if already
damaged, may break.
(6) Separate the deployment harnesses as far from the
Deployment vehicle as possible and connect to the terminals of
harnesses
the battery removed from the vehicle. Then deploy.
Caution
1) Before deploying the air bag, see that no one
is in and near the vehicle. Also, put on safety
glasses.
2) The deployment makes the inflator of the front
passenger’s air bag very hot. Before handling
the inflator, wait more than 30 minutes for
cooling.
3) If the air bag module fails to deploy although
the procedure is respected, do not go near
the module. Contact your local distributor.
 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 52B-51
(7) After deployment of the front passenger’s air bag
module, discard as specified in the procedure (Refer to
P.52B-60).

Side air bag module

Side air bag module
wiring harness (1) Disconnect the side air bag module wiring harness
connector (2-pin, yellow) connector (2-pin, yellow) and body wiring harness
connector (2-pin).
Body wiring Caution
harness
connector (2-pin) The side air bag modules both in the driver’s and
passenger’s sides should be deployed.
NOTE
Once disconnected from the side air bag wiring
harness, both electrode of the side air bag module
connector short automatically. This prevents the side
air bag from accidental deployment caused by static
Deployment harnesses etc.
Shorted
(2) Prepare two wires longer than 6 m for deployment
and connect the terminals in one end to short-circuit.
This is to prevent accidental deployment caused by
static etc.
(3) Touch the vehicle’s body with bare hands to discharge
static in you.
6 m or longer Caution
Never fail to do Step (3) in order to prevent
accidental deployment caused by static.
Deployment (4) Using pliers, cut the side air bag module connector
harnesses from the harnesses. Connect the deployment
Shorted
harnesses to each harness that has been cut and
insulate the connections with plastic tape.
(5) Route the deployment harnesses out of the vehicle.

Insulation tape AX0243AL

(6) Close all the doors with the windows fully closed and
Cover put a cover over the vehicle to minimize report.
Caution
The cover is required as the glass, if already
damaged, may break.

Deployment
harnesses
52B-52 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures

(7) Disconnect the deployment wires as far from the

vehicle as possible and connect the wires to the
terminals of the battery removed from the vehicle.
Deploy the side air bag module.
Caution
1) Before deploying the air bag in this manner,
first check to be sure that there is no one in
or near the vehicle. Wear safety glasses.
2) The deployment of the side air bag makes the
inflator very hot. Before handling the inflator,
wait more than 30 minutes for cooling.
3) If the air bag module fails to deploy when the
procedures above are followed, do not go near
the module. Contact your local distributor.
(8) Remove the deployed side air bag module from the
seat back assembly and discard as specified in the
procedure (Refer to P.52B-60).

Seat belt pre-tensioner

Seat belt pre-tensioner (1) Remove the quarter trim. (Refer to GROUP 52A)
2-pin connector (yellow) (2) Remove the connection between the seat belt
pre-tensioner 2-pin connector (yellow) and the body
wiring harness connector (2-pin).
Body wiring NOTE
harness con- If the seat belt pre-tensioner connector is disconnected
nector (2-pin)
from the body wiring harness, both electrodes of the
seat belt pre-tensioner connector will be automatically
shorted to prevent unintended operation of the seat
belt pre-tensioner due to static electricity, etc.

(3) Prepare two wires longer than 6 m for deployment

Deployment harnesses and connect the terminals in one end to short-circuit.
Shorted This is to prevent accidental operation caused by static
etc.
(4) Touch the vehicle’s body with bare hands to discharge
static in you.
Caution
Never fail to do Step (3) in order to prevent
accidental operation caused by static.
6 m or longer
 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 52B-53
(5) Using pliers, cut the seat belt pre-tensioner connector
Deployment Seat belt pre- from the harnesses. Connect the deployment
harnesses tensioner harnesses to each harness that has been cut and
insulate the connections with plastic tape.
(6) Route the deployment harness out of the vehicle.

Shorted

Insulation
tape

(7) Fully close all door windows, close the doors and
Cover place a cover over the vehicle to minimize the amount
of noise.
Caution
If the glass is damaged, it may break, so the car
must be covered.
Deployment harnesses
(8) Disconnect the deployment harnesses as far from the
vehicle as possible and connect the wires to the
terminals of the battery removed from the vehicle.
Operate the seat belt pre-tensioner.
Caution
1) Before operating the seat belt pre-tensioner
in this manner, first check to be sure that there
is no one in or near the vehicle. Wear safety
glasses.
2) The operation of the seat belt pre-tensioner
makes the inflator very hot. Before handling
the inflator, wait more than 30 minutes for
cooling.
3) If the seat belt pre-tensioner fails to operate
when the procedures above are followed, do
not go near the seat belt pre-tensioner. Contact
your local distributor.
(9) After operation of the seat belt pre-tensioner, discard
as specified in the procedure (Refer to P.52B-60).
52B-54 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures

DEPLOYMENT OUTSIDE THE VEHICLE

Caution
1. This should be carried out in a wide, flat area at least
6 m away from obstacles and other people.
2. Do not deploy outside if wind is high. Even in a soft
wind, ignite to windward of the air bag modules, front
seat back assembly with side air bag module or seat
belt pre-tensioner.
1. Disconnect the negative (–) and positive (+) battery cables
from the battery terminals, and then remove the battery
from the vehicle.
Caution
Wait at least 60 seconds after disconnecting the battery
cables before doing any further work. (Refer to
P.52B-4.)
2. Deploy each air bag module, seat belt pre-tensioner in
the following procedures.

Driver’s air bag module

(1) Remove the driver’s air bag module from the vehicle.
(Refer to P.52B-36.)
Caution
The driver’s air bag module should be stored on
a flat surface and placed so that the air bag
deployment surfaces are facing upward. Do not
place anything on top of them.

(2) Connect two wires, each six meters or longer, to the

Connection two leads of SRS air bag adapter harness and cover
Deployment harnesses
the connections with insulation tape. The other ends
SRS air bag of the two wires should be connected to each other
adapter harness (short-circuited), to prevent sudden unexpected
MR203491 or deployment of the driver’s air bag.
MB628919 6m
long or
more

Insulation tape

(3) Install a nut to the bolt behind the driver’s air bag
module and tie thick wire for securing to the wheel.
 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 52B-55
(4) Take the SRS air bag adapter harness that is
connected to the wires, pass it beneath the old tyre
Driver’s air bag module
wheel assembly, and connect it to the drive’s air bag
module.
(5) With the driver’s air bag module upwards, place it in the
Deployment wheel of old tyre and secure with the wire tied to the
harnesses bolt.
Caution
Slack the deployment harnesses below the wheel.
If deployment harnesses are tight, the reaction
when the air bag deploys could damage the
adaptor harness.

(6) Place three old tyres without wheels on top of the

tyre secured to the driver’s air bag module.
Tyres without wheels

Deployment harnesses

(7) Disconnect the deployment harnesses as far from the

driver’s air bag module as possible and connect the
wires to the terminals of the battery removed from
the vehicle. Then deploy.
Caution
1) Before the deployment, be sure that no one
is near the driver’s air bag module.
2) The deployment of the driver’s air bag makes
the inflator very hot. Before handling the
Deployment harnesses inflator, wait more than 30 minutes for cooling.
3) If the driver’s air bag module fails to deploy
when the procedures above are followed, do
not go near the module. Contact your local
distributor.
(8) After deployment of the driver’s air bag module, discard
as specified in the procedure (Refer to P.52B-60).
52B-56 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures

Front passenger’s air bag module

(1) Remove the front passenger’s air bag module from
the vehicle. (Refer to P.52B-36.)
Caution
Once disconnected, both electrodes of the front
passenger’s air bag module connector short
automatically to prevent accidental deployment
caused by static etc. Still, in consideration of the
accidental deployment, store the air bag module
on flat place with deployment surface facing up.
Also, do not put anything on it.
(2) Connect deployment wires 6 m or longer with the
Shorted
SRS air bag adapter harness respectively. Insulate
the connection with tape.
Insulation tape Also, connect the other ends of the deployment
SRS air bag harness each other to short, thereby preventing the
6 m long
adapter harness or more front passenger’s air bag from accidental deployment
MR686560 caused by static etc.
Deployment
harnesses

(3) Route the SRS air bag adapter harness with the
Front passenger’s air bag module deployment harnesses beneath an old tyre and wheel
assembly. Then, connect the harnesses to the front
passenger’s air bag module.
(4) Route a thick wire through the holes in the front
passenger’s air bag module bracket. With the
deployment surface facing up, secure the front
passenger’s air bag module to the old tyre and wheel
assembly.
Deployment Caution
harnesses
1) The deployment harnesses must not be tight
below the wheel. Otherwise, the adapter
harness could get damaged at deployment.
2) Place the connector of the SRS air bag adapter
harness so that it is not clamped by the tyre
at deployment.

(5) Put three old tyres without wheels on the tyre secured
to the front passenger’s air bag module. Secure all
Tyres without wheels the tyres with ropes (4 locations).
NOTE
The tyres must be bound because the passenger’s
air bag inflates more than the driver’s air bag.

Deployment harnesses
 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 52B-57
(6) Disconnect the deployment harnesses as far from the
front passenger’s air bag module as possible and
connect the harnesses to the battery removed from
the vehicle.
Caution
1) Before the deployment, see that no one is near
the front passenger’s air bag module.
2) The deployment makes the inflator of the front
passenger’s air bag very hot. Before handling
Deployment harnesses the inflator, wait more than 30 minutes for
cooling.
3) If the front passenger’s air bag module fails
to deploy although the procedure is respected,
do not go near the module. Contact your local
distributor.
(7) After deployment of the front passenger’s air bag
module, discard as specified in the procedure (Refer
to P.52B-60).

Side air bag module

(1) Remove the front seat back assembly with side air
bag module from the vehicle. (Refer to P.52B-36.)
Caution
Once disconnected, both electrodes of the side
air bag module connector short automatically to
prevent accidental deployment caused by static
etc. Still, in consideration of the accidental
deployment, store the air bag module on flat place
with deployment surface facing up. Also, do not
put anything on it.

(2) Prepare two wires longer than 6 m for deployment and

Deployment harnesses connect the terminals in one end to short-circuit. This
Shorted is to prevent accidental deployment caused by static
etc.
(3) Touch the vehicle’s body with bare hands to discharge
static in you.
Caution
Never fail to do Step (3) in order to prevent
accidental deployment caused by static.
6 m or longer

Front seat back assembly (4) Using pliers, cut the side air bag module connector
Insulation from the harnesses. Connect the deployment
tape
harnesses to each harness that has been cut and
insulate the connections with plastic tape.

Shorted

Deployment harnesses
52B-58 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures

(5) Disconnect the deployment harnesses as far from the

front seat back assembly possible and connect the
harnesses to the battery removed from the vehicle.
Then, deploy.
Caution
1) Before the deployment, see that no one is near
the front seat back assembly.
2) The deployment makes the inflator of the side
Deployment air bag very hot. Before handling the inflator,
harnesses wait more than 30 minutes for cooling.
3) If the side air bag module fails to deploy
although the procedure is respected, do not
go near the module. Contact your local
distributor.
(6) Remove the deployed side air bag module from the
seat back assembly and discard as specified in the
procedure (Refer to P.52B-60.).

Seat belt pre-tensioner

(1) Remove the seat belt pre-tensioner from the vehicle.
(Refer to P.52B-44.)
Caution
The seat belt pre-tensioner should be stored on
a flat surface and placed so that the air bag
operation surfaces are facing upward. Do not place
anything on top of them.

(2) Prepare two wires longer than 6 m for deployment and

Deployment harnesses connect the terminals in one end to short-circuit. This
Shorted is to prevent accidental operation caused by static etc.
(3) Touch the vehicle’s body with bare hands to discharge
static in you.
Caution
Never fail to do Step (3) in order to prevent
accidental operation caused by static.
6 m or longer

Seat belt pre-tensioner (4) Using pliers, cut the seat belt pre-tensioner connector
from the harnesses. Connect the deployment
harnesses to each harness that has been cut and
insulate the connections with plastic tape.
(5) Pass the wires through the hole on the seat belt
retractor bracket and secure them to the front (raised
part) of the old tyre wheel assembly on two places.
Shorted
Insulation
tape
Deployment harnesses
 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 52B-59
Caution
Tyre without Pull the seat belt out the outside of the tyre, and
wheels
then place one tyre without a wheel on top of the
existing tyre.

(6) Place three old tyres without wheels on top of the

tyre secured to the seat belt pre-tensioner.
Tyres without wheels

Deployment harnesses

(7) Disconnect the deployment harnesses as far from the

seat belt pre-tensioner as possible and connect the
wires to the terminals of the battery removed from
the vehicle, and operate.
Caution
1) Before the operation, be sure that no one is
near the seat belt pre-tensioner.
2) The operation of the seat belt pre-tensioner
makes itself very hot. Before handling the seat
Deployment harnesses belt pre-tensioner, wait more than 30 minutes
for cooling.
3) If the seat belt pre-tensioner fails to deploy
when the procedures above are followed, do
not go near the seat belt pre-tensioner. Contact
your local distributor.
(8) After operation of the seat belt pre-tensioner, discard
as specified in the procedure (Refer to P.52B-60).
52B-60 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures

DEPLOYED AIR BAG MODULE OR OPERATED

SEAT BELT PRE-TENSIONER DISPOSAL
PROCEDURES
After deployment or operation, the air bag module and the
seat belt pre-tensioner should be disposed of in the same
manner as any other scrap parts, adhering to local laws and/or
legislation that may be in force except that the following points
should be carefully noted during disposal.
1. The inflator will be quite hot immediately following
deployment, so wait at least 30 minutes to allow it cool
before attempting to handle it.
2. Do not put water or oil on the air bag after deployment
or on the seat belt pre-tensioner after operation.
3. There may be, adhered to the deployed air bag module
or the operated seat belt pre-tensioner, material that could
irritate the eye and/or skin, so wear gloves and safety
glasses when handling a deployed air bag module or a
operated seat belt pre-tensioner.
Caution
If after following these precautions, any material does
get into the eyes or on the skin, immediately rinse
the affected area with a large amount of clean water.
If any irritation develops, seek medical attention.

4. Tightly seal the air bag module and seat belt pre-tensioner
Strong in a strong vinyl bag for disposal.
vinyl bag Air bag module 5. Be sure to always wash your hands after completing this
and seat belt operation.
pre-tensioner
 52B-1

SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SEAT BELT WITH PRE-TENSIONER . . . . . . . . 2

Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SIDE IMPACT SENSOR . . . . . . . . . . . . . . . . . . . . 3

CAUTION
 Carefully read and observe the information in the SERVICE PRECAUTIONS (Refer to ’00 PAJERO PININ Workshop
Manual <Pub.No.CKRE00E1> P.52B-4.) prior to any service.
 For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting
(Refer to ’00 PAJERO PININ Workshop Manual <Pub.No.CKRE00E1> P.52B-8.) section.
 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 (Refer to ’00 PAJERO PININ Workshop Manual
<Pub.No.CKRE00E1> P.52B-30.) for the components involved.
 If you have any questions about the SRS, please contact your local distributor.
52B-2 SRS – General/Seat Belt with Pre-tensioner

GENERAL
OUTLINE OF CHANGE
 Due to the introduction of 5-door models, the removal and installation procedures for seat belt with
pre-tensioner and side impact sensor have been added. The other items are the same as before.

SEAT BELT WITH PRE-TENSIONER

Caution 4. Do not expose the seat belt with
1. Never attempt to disassemble or repair the pre-tensioner to temperatures over 90C.
seat belt with pre-tensioner. If faulty, replace 5. After operating the seat belt pre-tensioner,
it. replace the seat belt pre-tensioner with a
2. Be extremely careful when handling the seat new part.
belt with pre-tensioner. Do not subject it to 6. Gloves and protective goggles should be
shocks, drop it, bring it close to strong worn when handling a pre-tensioner once
magnets or allow contact with water, grease it has been used.
or oil. Always replace it with a new part if 7. If disposing of a seat belt with pre-tensioner
any dents, cracks or deformation is found. which has not yet been used, its
3. Do not place anything on top of the seat pre-tensioner should be operated first before
belt pre-tensioner. disposal. (Refer to ’00 PAJERO PININ
Workshop Manual <Pub. No. CKRE00E1>
P.52B-48.)

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
 Turn Ignition Key to LOCK (OFF) Position
 Disconnect the Negative (–) Battery Terminal.

44 Nm
2
1

44 Nm
2

Removal steps Installation steps

1. Sash guide cover A  Post-installation inspection
2. Outer seat belt connection 3. Seat belt with pre-tensioner
 Center pillar lower trim  Center pillar lower trim
(Refer to P.52A-1.) (Refer to P.52A–1.)
3. Seat belt with pre-tensioner 2. Outer seat belt connection
1. Sash guide cover
 Negative (–) battery cable connection
B  Pre-installation inspection
NOTE
The figure shows the seat belt with pre-tensioner
(R.H.).
For service points, refer to Basic Manual.
 SRS – Side Impact Sensor 52B-3
SIDE IMPACT SENSOR
Caution
1. Disconnect the negative (–) battery terminal 3. Do not drop or subject the side impact
and wait for 60 seconds or more before sensors to impact or vibration.
starting work. Also, the disconnected battery If denting, cracking, deformation, or rust are
terminal should be insulated with tape. found in the side impact sensors, replace
(Refer to ’00 PAJERO PININ Workshop it with new ones. Discard the old ones.
Manual <Pub. No. CKRE00E1> P.52B-4.) 4. After deployment of the air bags, replace
2. Never attempt to disassemble or repair the the side impact sensors with new ones.
side impact sensors. If faulty, just replace 5. Never use an ohmmeter on or near the side
with new ones. impact sensors, and use only the special
test equipment described on ’00 PAJERO
PININ Workshop Manual
<Pub. No. CKRE00E1> P.52B-7.

REMOVAL AND INSTALLATION

Pre-removal Operation
 Turn Ignition Switch to LOCK (OFF) Position.
 Disconnect the Negative (–) Battery Terminal.

1
Front of Vehicle
5 Nm

Center pillar

Removal steps Installation steps

 Front seat belt (Refer to GROUP 52A.) A  Pre-installation inspection
1. Side impact sensor B 1. Side impact sensor
 Front seat belt (Refer to GROUP 52A.)
 Negative (–) battery cable connection
C  Post-installation inspection
NOTE
The figure shows the side impact sensor (R.H.).
For service points, refer to Basic Manual.
 CHASSIS
ELECTRICAL
Click on the applicable bookmark to selected the required model year
54A-2

CHASSIS
ELECTRICAL
CONTENTS

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 8

SERVICE SPECIFICATION . . . . . . . . . . . . . . . 5 IGNITION SWITCH AND IMMOBILIZER

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 5
Fluid Level and Specific Gravity Check . . . . . . 5 COMBINATION METERS . . . . . . . . . . . . 17
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SERVICE SPECIFICATIONS . . . . . . . . . . . . . 17
Battery Testing Procedure . . . . . . . . . . . . . . . . . . . 7
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
IGNITION SWITCH AND IMMOBILIZER SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 18
SYSTEM* . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 19
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONTINUED ON NEXT PAGE

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from
rendering the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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-ECU, SRS warning lamp, 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 (*).
 54A-3

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 24 REAR COMBINATION LAMP, REAR FOG

Speedometer Check . . . . . . . . . . . . . . . . . . . . . . 24 LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tachometer Check . . . . . . . . . . . . . . . . . . . . . . . 24
HIGH-MOUNTED STOP LAMP
Fuel Gauge Unit Check . . . . . . . . . . . . . . . . . . 25 AND LICENCE PLATE LAMP . . . . . . . . 42
Fuel Level Warning Switch Check . . . . . . . . . 26
Engine Coolant Temperature Gauge Unit Check COLUMN SWITCH . . . . . . . . . . . . . . . . . . 43
26

COMBINATION METERS . . . . . . . . . . . . . . . . 27
RHEOSTAT . . . . . . . . . . . . . . . . . . . . . . . . 44
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 44
OUTSIDE THERMO SENSOR . . . . . . 29
RHEOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SERVICE SPECIFICATIONS . . . . . . . . . . . . . 29
HAZARD WARNING LAMP
HEADLAMP, FRONT TURN-SIGNAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LAMP AND FRONT FOG LAMP . . . . 30
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 45
SERVICE SPECIFICATIONS . . . . . . . . . . . . . 30
HAZARD WARNING LAMP SWITCH . . . . . 45
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 30

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 30 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . 31 CIGARETTE LIGHTER . . . . . . . . . . . . . . 46

Headlamp Aiming . . . . . . . . . . . . . . . . . . . . . . . . 31
ACCESSORY SOCKET . . . . . . . . . . . . . 47
Headlamp Intensity Measurement . . . . . . . . . . 32
Front Fog Lamp Aiming . . . . . . . . . . . . . . . . . . 33 RADIO AND TAPE PLAYER . . . . . . . . . . 48
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . 34
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 48
HEADLAMP, FRONT TURN-SIGNAL LAMP Quick-reference Troubleshooting Chart . . . . . 48
AND FRONT FOG LAMP . . . . . . . . . . . . . . . 35
RADIO AND TAPE PLAYER . . . . . . . . . . . . . 61
SIDE TURN-SIGNAL LAMP . . . . . . . . . 37
CD AUTOCHANGER . . . . . . . . . . . . . . . . . . . . 62
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 37
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . 63
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 37

SIDE TURN-SIGNAL LAMP . . . . . . . . . . . . . 38 ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . 64

ROOM LAMP . . . . . . . . . . . . . . . . . . . . . . . 38 REAR WINDOW DEFOGGER . . . . . . . 65

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 38 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . 65

Printed-heater Line Check . . . . . . . . . . . . . . . . 65
REAR COMBINATION LAMP, REAR Rear Window Defogger Relay Continuity
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . 38 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 38 REAR WINDOW DEFOGGER SWITCH . . . 66

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 38 CONTINUED ON NEXT PAGE

54A-4

MULTI-CENTER DISPLAY <MIDDLE MULTI-CENTER DISPLAY <HIGH

GRADE> . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 GRADE> . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 67 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 80

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 67 MULTI-CENTER DISPLAY . . . . . . . . . . . . . . 108

MULTI-CENTER DISPLAY . . . . . . . . . . . . . . 79
 CHASSIS ELECTRICAL – Battery 54A-5

BATTERY
SERVICE SPECIFICATION
Item Specification

Specific gravity of the battery fluid 1.220 – 1.290 [20_C]

ON-VEHICLE SERVICE
FLUID LEVEL AND SPECIFIC GRAVITY CHECK
Good
1. Inspect whether or not the battery fluid is between the
UPPER LEVEL and LOWER LEVEL marks.
Caution
(1) If the battery fluid is below the LOWER LEVEL,
Thermometer
the battery could explode in using.
(2) If the battery fluid is over the UPPER LEVEL,
leakage could result.

Hydrometer
2. Use a hydrometer and thermometer to check the specific
gravity of the battery fluid.
Standard value: 1.220 – 1.290 [20_C]
The specific gravity of the battery fluid varies with the
temperature, so use the following formula to calculate
the specific gravity for 20_C. Use the calculated value
to determine whether or not the specific gravity is
satisfactory.
D20 = (t – 20) 0.0007 + Dt
D20: Specific gravity of the battery fluid calculated
for 20_C.
Dt: Actually measured specific gravity
t: Actually measured temperature
54A-6 CHASSIS ELECTRICAL – Battery

CHARGING
1. When charging a battery while still installed in the vehicle,
disconnect the battery cables to prevent damage to
electrical parts.
2. The current normally used for charging a battery should
be approximately 1/10th of the battery capacity. When
performing a quick-charging due to lack of time, etc., the
charging current should never exceed the battery capacity
as indicated in amperes.
Battery Capacity Normal charg- Quick-charg-
type (5 HR) ing current ing current
65D23L 52 Ah 5.2 A 53 A
3. Determining if charging is completed.
(1) If the specific gravity of the battery fluid reaches 1.250
– 1.290 and remains constant for at least one hour.
(2) If the voltage of each cell reaches 2.5 – 2.8 V and
remains constant for at least one hour.
Caution
(1) Remove the battery caps during charging.
(2) Be careful since the battery fluid level may rise
during charging.
(3) Keep all sources of fire away while charging
because there is a danger of explosion.
(4) Be careful not to do anything that could generate
sparks while charging.
(5) When charging is completed, replace the battery
caps, pour clean water over the battery to remove
any sulfuric acid and dry.
(6) Perform the charging in the well-ventilated place.
(7) Do not raise the battery fluid temperature more
than approximately 45_C (In case of quick-
charging: approximately 55_C).
 CHASSIS ELECTRICAL – Battery 54A-7
BATTERY TESTING PROCEDURE
TEST STEP
(1) Turn headlamps on for 15 seconds.
(2) Turn headlamps off for 2 minutes to allow battery voltage
to stabilize.
(3) Disconnect cables.
OK
NG
Read open circuit voltage. Charge battery at 5 amps. (see LOAD TEST RATE CHART)
OK: Open circuit voltage is more than 12.4 V
OK
Retest

NG
(1) Connect a load tester to the battery. Replace battery
(2) Load the battery at the recommended discharge rate (see
LOAD TEST RATE CHART) for 15 seconds.
(3) Read voltage after 15 seconds, then remove load.
(4) Compare the measured value with the minimum voltage (see
LOAD TEST CHART).
OK: Higher than minimum voltage
OK

Normal

LOAD TEST RATE CHART

Battery type 65D23L

Charging time when fully discharged h [5-amp rated current charging] 11

Load test (Amps) 300

LOAD TEST CHART

Temperature _C 21 and 16 10 4 –1 –7 –12 –18
above

Minimum voltage V 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
54A-8 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System

IGNITION SWITCH AND IMMOBILIZER SYSTEM

SPECIAL TOOL
Tool Number Name Use
MB991502 MUT-II sub D Immobilizer system check
assembly (Diagnosis display using the MUT-II)
D Registration of the encrypted code

A MB991223 Harness set D Fuel gauge simple check

A: MB991219 A: Test harness A: Connector pin contact pressure check
B: MB991220 B: LED harness B: Power circuit check
C: MB991221 C: LED harness C: Power circuit check
D: MB991222 adapter D: Commercial tester connection
B D: Probe

TROUBLESHOOTING
Caution
The encrypted code should always be re-registered when replacing the immobilizer-ECU.

STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Refer to GROUP 00 – How To Use Troubleshooting/Inspection Service Points.

DIAGNOSIS FUNCTION
DIAGNOSIS CODES CHECK
Refer to GROUP 00 – How To Use Troubleshooting/Inspection Service Points.
ERASING DIAGNOSIS CODES
Refer to GROUP 00 – How To Use Troubleshooting/Inspection Service Points.
Caution
The diagnosis codes which result from disconnecting the battery cables cannot be erased.

INSPECTION CHART FOR DIAGNOSIS CODES

Diagnosis code No. Inspection items Reference
page

11 Transponder communication system 54A-9

12 Encrypted code are not the same or are not registered 54A-9
 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System 54A-9
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No. 11 Transponder communication system Probable cause
The encrypted code of the transponder is not sent to the immobilizer-ECU immediately D Malfunction of the transponder
after the ignition switch is turned to the ON position. D Malfunction of the ignition key ring antenna
D Malfunction of the immobilizer-ECU

OK
Does the engine start using the spare Replace the ignition key that does not
ignition key which has had the en- work.
crypted code registered?
NG
Code No. 12 occurs
Diagnosis codes check To INSPECTION PROCEDURE FOR
DIAGNOSIS CODE No. 12
Code No. 11 occurs
(Refer to P.54A-9.)

Replace the immobilizer-ECU. Register the password (secret code)

and encrypted code (Refer to
P.54A-15.)

Code No. 12 Encrypted code are not the same or are not Probable cause
registered
The encrypted code which is sent from the transponder is not the same as the D The encrypted code in the ignition key being used
encrypted code which is registered in the immobilizer-ECU. has not been properly registered.
D Malfunction of the immobilizer-ECU

NG
Re-register the encrypted code. Check trouble symptoms. Replace the immobilizer-ECU.
(Refer to P.54A-15.)

Register the password (secret code)

and encrypted code (Refer to
P.54A-15.)

INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom Inspection procedure No. Reference page

Communication with MUT-II is impossible. – GROUP 13B, 13C

– Troubleshooting

Diagnosis code No. 54 has been generated by the engine-ECU. 1 54A-10

Encrypted code cannot be registered using the MUT-II. 2 54A-10

Engine does not start (Cranking but no initial combustion). 3 54A-11

Malfunction of the immobilizer-ECU power supply and earth circuit 4 54A-11

54A-10 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1
Diagnosis code No. 54 has been generated by the Probable cause
engine-ECU.
There is a problem with communication between the engine-ECU and the D Malfunction of harness or connector
immobilizer-ECU. D Malfunction of the immobilizer-ECU
D Malfunction of the engine-ECU

NG
Check the following connectors: Repair
C-19, C-29, C-62
OK

Check trouble symptoms.

NG
NG
Check the harness wire between en- Repair
gine-ECU and immobilizer-ECU.
NO
OK
Check the immobilizer-ECU power sup- Check trouble symptoms.
ply and earth circuit. (Refer to INSPEC-
NG
TION PROCEDURE 4.)
Replace the immobilizer-ECU.

NG
Check trouble symptoms. Replace the engine-ECU.

Register the password (secret code)

and encrypted code (Refer to
P.54A-15.)

Inspection Procedure 2
Encrypted code cannot be registered using the MUT-II. Probable cause
The cause is probably that there is no encrypted code registered in the D Malfunction of the transponder
immobilizer-ECU, or there is a malfunction of the immobilizer-ECU. D Malfunction of the ignition key ring antenna
D Malfunction of harness or connector
D Malfunction of the immobilizer-ECU

NO
No ignition key can be registered. Replace the ignition key that cannot
be registered.
YES

NO
Is a normal diagnosis code output? To INSPECTION CHART FOR DIAG-
NOSIS CODE (Refer to P.54A-8.)
YES

OK
Check the immobilizer-ECU power Check trouble symptoms.
source and earth circuit. (Refer to IN-
NG
SPECTION PROCEDURE 4.)
Replace the immobilizer-ECU. Register the password (secret code)
and encrypted code (Refer to
P.54A-15.)
 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System 54A-11
Inspection Procedure 3
Engine does not start (cranking but no initial combustion). Probable cause
If the fuel injectors are not operating, there might be a problem with the MPI system D Malfunction of the MPI system
in addition to a malfunction of the immobilizer system. D Malfunction of the immobilizer-ECU
It is normal for this to occur if an attempt is made to start the engine using a key
that has not been properly registered.

NG
Check the system voltage during crank- Check the battery
ing. (Refer to P.54A-5.)
OK: 8V or more
OK
NO
Is a normal diagnosis code output from To INSPECTION CHART FOR DIAG-
the immobilizer-ECU? NOSIS CODE (Refer to P.54A-8.)
YES
NO
Is a normal diagnosis code output from Refer to GROUP 13B or 13C – Trouble-
the engine-ECU? shooting.
YES

To inspection procedure for when there

is no initial combustion. (Refer to
GROUP 13A – Troubleshooting.)
NG

Check trouble symptoms.

NG
OK NG
Check the immobilizer-ECU power sup- Check trouble symptoms. Replace the immobilizer-ECU.
ply and earth circuit (Refer to INSPEC-
TION PROCEDURE 4.)
Register the password (secret code)
and encrypted code (Refer to
P.54A-15.)

Inspection Procedure 4
Malfunction of the immobilizer-ECU power supply and earth circuit

(1)NG NG
Measure at the immobilizer-ECU con- Check the following connector: Repair
nector 1. A-43X, C-29, C-62,
D Disconnect the connector and
OK
measure at the harness side.
D Turn the ignition switch to ON NG
Check trouble symptoms. Check the harness wire between immo-
position.
bilizer-ECU and engine control relay
(1) Voltage between 1 and earth
and repair if necessary.
OK: System voltage
(2) Continuity between 4 and earth
OK: Continuity
(2)NG

OK NG
Check the following connector: Check trouble symptoms. Check the harness wire between immo-
C-02, C-62 bilizer-ECU and body earth and repair
NG if necessary.

Repair
54A-12 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System

CHECK AT IMMOBILIZER-ECU
TERMINAL VOLTAGE CHECK CHART

Terminal No. Signal Checking requirements Terminal voltage

1 Immobilizer-ECU power supply Ignition switch: ON System voltage

2 – – –

3 Engine-ECU – –

4 Immobilizer-ECU earth Always 0V

 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System 54A-13
IGNITION SWITCH AND IMMOBILIZER SYSTEM
REMOVAL AND INSTALLATION
Caution: SRS
Before removal of air bag module and clock spring, refer to GROUP 52B – Service Precautions
and Air Bag Module and Clock Spring.

Pre-removal and Post-installation Operation

Clock Spring and Column Switch Removal and
Installation (Refer to GROUP 52B – Air Bag Modules
and Clock Spring.)

5
4 6
7
A B
A B C
A
A
1 C
2

Section A – A Section B – B Section C – C

Instrument panel
3 3
Tab

Tab
Clip
2 2
1

Removal steps
1. Instrument under cover AA" 5. Steering lock cylinder
2. Column cover, lower 6. Immobilizer-ECU
3. Column cover, upper 7. Key reminder switch
4. Ignition switch
54A-14 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System

REMOVAL SERVICE POINTS

AA" STEERING LOCK CYLINDER REMOVAL
1. Insert the key in the steering lock cylinder and turn it to
the “ACC” position.
2. Using a cross-tip (+) screwdriver (small) or a similar tool,
push the lock pin of the steering lock cylinder inward and
then pull the steering lock cylinder toward you.

Cross-tip (+) screwdriver

INSPECTION
IGNITION SWITCH CONTINUITY CHECK
1. Remove the column cover lower and upper.
2. Disconnect the wiring connector from the ignition switch.
3. Operate the switch, and check the continuity between
the terminals.
Ignition
g keyy Terminal No.
position
iti
1 2 4 5 6
LOCK
ACC
ON
START

KEY REMINDER SWITCH CONTINUITY CHECK

Disconnect the key reminder switch connector with the switch
attached to the vehicle, and then check the continuity between
the terminals.
Ignition
g keyy Terminal No.
4 6
Removed
Inserted
CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System 54A-15
ENCRYPTED CODE REGISTRATION METHOD
AND RESETTING THE CODE TO THE FACTORY
SETTING
Register the encrypted code in the immobilizer-ECU and then
reset the code to the factory setting after parts have been
replaced.

Replacement part Encrypted code

Ignition key Necessary

Immobilizer-ECU Necessary

Engine-ECU* Necessary

NOTE
*: If the engine-ECU is replaced, the immobilizer-ECU and
ignition key should be replaced together with it.
Each engine-ECU has an individual information for
immobilizer-ECU, and the individual information is registered
in the immobilizer-ECU and ignition key.

ENCRYPTED CODE REGISTRATION METHOD

If using an ignition key that has just been newly purchased,
or if the immobilizer-ECU has been replaced, you will need
to register the encrypted codes for each ignition key being
used into the immobilizer-ECU. (A maximum of eight different
encrypted codes can be registered.)
Moreover, when the immobilizer-ECU has been replaced, you
will need to use the MUT-II to input the vehicle secret code
and to register the password (secret code) that the user
specifies into the immobilizer-ECU. (Refer to the “MUT-II
REFERENCE MANUAL” or “MUT-II OPERATING IN-
STRUCTIONS”)
Caution
If registering of the encrypted codes is carried out after
all previously-registered codes have been erased, you
should have ready all of the ignition keys that have already
been registered.

1. Connect the MUT-II to the diagnosis connector.

Caution
Turn the ignition switch to LOCK (OFF) position before
connection or disconnection of the MUT-II.
2. Check that the diagnosis code No.54 is not being generated
by the engine-ECU. If it is being generated check according
to the Troubleshooting Procedures.
3. Use the ignition key that is to be registered to turn on
MUT-II the ignition switch.
54A-16 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System

4. Use the MUT-II to register the encrypted code. To register

the second or subsequent key, leave the MUT-II connected
and remove the first registered key. Within 5 seconds
insert the key to be registered and turn on the ignition
switch.
NOTE
After 5 seconds have elapsed, the key registration must
be repeated from the beginning because the key
registration mode terminates.
5. This completes the registration operation. Turn the ignition
switch to LOCK (OFF) position and wait for approx. 10
seconds.
6. Check that the engine can be started with each of the
ignition keys.
7. Check the diagnosis output from engine-ECU, and erase
code No.54 if it appears.
 CHASSIS ELECTRICAL – Combination Meters 54A-17

COMBINATION METERS
SERVICE SPECIFICATIONS
Items Items Standard value

Speedometer indication error km/h(mph) 40 (20) 40 – 48 (20 – 25)

80 (40) 80 – 92 (40 – 47)

120 (60) 120 – 136 (60 – 69)

160 (80) 160 – 180 (80 – 91)

– (100) – (100 – 114)

Tachometer indication error r/min 700 ± 100

3,000 +150
–100

5,000 +325
–125

6,000 +375
–125

Fuel gauge unit resistance Ω Main Float point F 1–3

Float point E 49.7 – 51.7

Sub Float point F 1– 3

Float point E 55.3 – 57.3

Fuel gauge unit float height mm Main A (Float point F) 44.5 – 52.5

B (Float point E) 220.3 – 228.3

Sub A (Float point F) 30.4 – 36.4

B (Float point E) 238.5 – 244.5

Engine coolant temperature gauge unit resistance (at 70_C) Ω 104 ± 13.5

Fuel gauge resistance Ω Power supply and earth 233.3

Power supply and fuel gauge 108.3

Fuel gauge and earth 125.0

Engine coolant temperature gauge Power supply and earth 178.9

resistance Ω
Power supply and engine coolant tempera- 54
ture gauge

Engine coolant temperature gauge and 232.9

earth
54A-18 CHASSIS ELECTRICAL – Combination Meters

SEALANT
Items Specified sealant Remark

Engine coolant temperature gauge 3M Adhesive nut locking No. 4171 or Drying sealant
unit threaded portion equivalent

SPECIAL TOOLS
Tool Number Name Use
A MB991223 Harness set D Fuel gauge simple check
A: MB991219 A: Test harness A: Connector pin contact pressure check
B: MB991220 B: LED harness B: Power circuit check
C: MB991221 C: LED harness C: Power circuit check
D: MB991222 adapter D: Commercial tester connection
B
D: Probe

MB990784 Ornament remover Removal of meter hood

 CHASSIS ELECTRICAL – Combination Meters 54A-19
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptom Inspection Reference
procedure page

Speedometer does not work. 1 54A-19

Tachometer does not work. 2 54A-20

Fuel gauge does not operate. 4 54A-21

Engine coolant temperature gauge does not operate. 5 54A-22

GDI ECO indication lamp does not illumination 6 54A-23

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1
Speedometer does not work. Probable cause
The cause may be a defective vehicle speed sensor circuit system or a defective D Malfunction of vehicle speed sensor
speedometer. Vehicle speed sensor is co-used among the engine-ECU and A/T-ECU. D Malfunction of speedometer
D Malfunction of harness or connector

YES
MUT-II Self-Diag. Code Check the vehicle speed sensor circuit. (Refer to P.54A-20,
Is the diagnosis code No.24 for GDI system output? Inspection Procedure 3.)
NO
OK
Check the following connectors: Check trouble symptom.
B-08, D-02, C-38 <L.H. drive vehicles>, C-41 <R.H. drive NG
vehicles>, C-02, C-05
NG
Check the harness wire between the vehicle speed sensor and
Repair combination meter, and repair if necessary.
OK NG
Repair

Replace the combination meter.

54A-20 CHASSIS ELECTRICAL – Combination Meters

Inspection Procedure 2
Tachometer does not work. Probable cause
The ignition signal may not be input from the engine, or there may be a malfunction D Malfunction of tachometer
in the power supply or earth circuit. D Malfunction of harness or connector

YES
MUT-II Self-Diag. Code Check the ignition coil and power transistor unit system. (Refer
Is the diagnosis code No.44 for GDI system output? to GROUP 13A – Troubleshooting, INSPECTION PROCEDURE
FOR DIAGNOSIS CODE 44.)
OK
OK
Measure at the combination meter connectors C-06 and C-07. Replace the tachometer.
D Disconnect the connector, and measure at the harness side.
D Turn the ignition switch ON position. (1) NG
Check the following connectors: C-07, C-18, C-28
(1) Voltage between the terminal No.45 and body earth
OK: 5 V OK NG
(2) Continuity between terminal No.52 and body earth (2) NG
OK: Continuity Repair
(3) Voltage between the terminal No.1 and body earth
OK: System voltage Check trouble symptom.
NG
(3) NG
Check the harness wire between the combination meter and en-
Check the following connectors: C-06, C-02 <L.H. drive gine-ECU, and repair if necessary.
vehicles>, C-76, C-74
OK NG Check the following connector: C-07
OK NG
Repair
Repair
Check trouble symptom.
Check trouble symptom.
NG
NG
Check the harness wire between the ignition switch (IG1) and com-
bination meter, and repair if necessary. Check the harness wire between the combination meter and body
earth, and repair if necessary.

Inspection Procedure 3
Vehicle speed sensor circuit system inspection

NG
Vehicle speed sensor inspection (Refer to P.54A-27.) Replace
OK
(1) NG
Measure at the vehicle speed sensor connector B-08. Check the following connectors: B-08, D-02, C-38 <L.H. drive
D Disconnect the connector, and measure at the harness side. vehicles>, C-41 <R.H. drive vehicles>, C-02, C-05
D Turn the ignition switch to ON position. NG
NG
(1) Voltage between the terminal No.3 and body earth
OK: 4.5 V or more Repair
(2) Continuity between terminal No.2 and body earth (2) NG Check trouble symptom.
OK: Continuity
(3) Voltage between the terminal No.1 and body earth NG
OK: System voltage
Check the harness wire between the vehicle speed sensor and
(3) NG combination meter, and repair if necessary.

Check the following connectors: B-08, D-02, C-38 <L.H. drive

vehicles>, C-41 <R.H. drive vehicles>, C-02, C-76, C-74
Check the following connector: B-08
OK NG
OK NG
Repair
Repair
Check trouble symptom. Check trouble symptom.
NG NG
Check the harness wire between the vehicle speed sensor and Check the harness wire between the vehicle speed sensor and
power supply, and repair if necessary. body earth, and repair if necessary.
 CHASSIS ELECTRICAL – Combination Meters 54A-21
Inspection Procedure 4
Fuel gauge does not operate. Probable cause
If speedometer and tachometer operate normally, the harness from power supply D Malfunction of fuel gauge unit
to combination meter is normal. D Malfunction of fuel gauge
D Malfunction of harness or connector

NO
Do the speedometer and tachometer operate normally? Check the speedometer and tachometer circuit. (Refer to
YES P.54A-18.)

Check the fuel gauge circuit. OK Replace the fuel gauge unit.
D Disconnect the fuel gauge unit connector D-17.
D Use the special tool to connect a test lamp (12 V – 3.4 W)
to the harness-side connector. (Refer to Fig. 1.) (1) NG
D Ignition switch: ON Check the following connectors: D-17, D-23, D-12, C-38 <L.H.
(1) Test lamp condition drive vehicles>, C-40 <R.H. drive vehicles>, C-02, C-05
OK: Illuminates OK NG
(2) Fuel gauge needle condition
OK: Moves to the middle position. Repair
Check trouble symptom.
(2) NG NG
Replace the fuel gauge.
Check the harness between the combination meter and fuel gauge,
and repair if necessary.

Fig. 1
Fuel gauge Earth
Test lamp
(12V–3.4W)

MB991219
54A-22 CHASSIS ELECTRICAL – Combination Meters

Inspection Procedure 5
Engine coolant temperature gauge does not operate. Probable cause
If speedometer and tachometer operate normally, the harness from power supply D Malfunction of engine coolant temperature gauge unit
to combination meter is normal. D Malfunction of engine coolant temperature gauge
D Malfunction of harness or connector

NO
Do the speedometer and tachometer operate normally? Check the speedometer and tachometer circuit. (Refer to
YES P.54A-19.)

OK Replace the engine coolant temperature gauge unit.

Check the engine coolant temperature gauge circuit.
D Disconnect the engine coolant temperature gauge unit
connector A-68.
D Use the special tool to connect a test lamp (12 V – 3.4 W) (1) NG Check the following connectors: A-68, C-29, C-06
to the harness-side connector. (Refer to Fig. 1.)
D Ignition switch: ON OK NG
(1) Test lamp condition
OK: Illuminates Check trouble symptom. Repair
(2) Engine coolant temperature gauge needle condition
OK: Moves to the middle position. NG
(2) NG
Check the harness between the combination meter and engine
Replace the engine coolant temperature gauge. coolant temperature gauge, and repair if necessary.

Fig. 1 Connector
Test lamp (12V–3.4W)

Earth
 CHASSIS ELECTRICAL – Combination Meters 54A-23
Inspection Procedure 6
GDI ECO indication lamp does not illuminate. Probable cause
GDI ECO indication lamp is illuminated by GDI ECO indication lamp-ECU. D ECO indication lamp bulb blown
When it does not illuminates, GDI ECO indication lamp bulb may be blown, or D Malfunction of combination meter
combination meter, power supply circuit of GDI ECO indication lamp-ECU or GDI D Malfunction of GDI ECO indication lamp
ECO indication lamp-ECU may be malfunctioning. D Malfunction of engine-ECU
D Damaged harness or connectors

NG
Other illumination lamps normally darken with rheostat. Check the rheostat. (Refer to P.54A-44.)
OK
NG Check bulb for being blown.
Check GDI ECO indication lamp at GDI ECO indication lamp-ECU
connector C-55 OK
D Disconnect connector and measure at harness side.
D Ignition switch: ON Check following connectors: C-55, C-07
D Connect between terminal 2 and body earth OK NG
OK: Lamp illuminate
OK Check trouble symptom. Repair

NG

Check the harness wires between combination meter and GDI

ECO indication lamp-ECU.

NG Check following connectors: C-02 <L.H. drive vehicles>, C-76,

Measure at GDI ECO indication lamp-ECU connector C-55
D Disconnect connector and measure at harness side. C-74
D Ignition switch: ON OK NG
D Voltage between terminal 1 and body earth
OK: System voltage Repair
Check trouble symptom.
OK NG

Check the harness wires between ignition switch (IG) and GDI
ECO indication lamp-ECU.

Measure at GDI ECO indication lamp-ECU connector C-55 NG

D Disconnect connector at measure harness side. Check following connector: C-55
D Continuity between terminal 8 and body earth OK NG
OK: Continuity
OK Check trouble symptom. Repair

NG

Check harness wire between GDI ECO indication lamp-ECU and

body earth.

NG
Check following connectors: C-55, C-83, C-29,C-17 Repair
OK
Check trouble symptoms.
NG

Check harness wire between GDI ECO indication lamp-ECU and

engine-ECU, between GDI ECO indication lamp-ECU and rheostat.
NG
Replace GDI ECO indication lamp-ECU.

Check trouble symptoms.

NG
Replace engine-ECU.
54A-24 CHASSIS ELECTRICAL – Combination Meters

ON-VEHICLE SERVICE
SPEEDOMETER CHECK
1. Adjust the pressure of the tyres to the specified level.
(Refer to GROUP 31 – Service Specifications.)
2. Set the vehicle onto a speedometer tester.
3. Use wheel chocks to hold the front wheels, and apply
the parking brake firmly.
Wheel chocks

Tension bar 4. To prevent the front wheels from moving from side to
side, attach tension bars to the tie-down hooks, and secure
both ends to anchor plates.
5. To prevent the vehicle from launching, attach a chain or
Front
wire to the rear retraction hook, and make sure the end
of the chain or wire is secured firmly.
Anchor plate 6. Check if the speedometer indicator range is within the
standard values.
Caution
Do not operate the clutch suddenly. Do not
increase/decrease speed rapidly while testing.
Standard values:
Standard indication km/h Allowable range km/h (mph)
(mph)
40 (20) 40 – 48 (20 – 25)
80 (40) 80 – 92 (40 – 47)
120 (60) 120 – 136 (60 – 69)
160 (80) 160 – 180 (80 – 91)
– (100) – (100 – 114)

Paper clip Engine tachometer TACHOMETER CHECK

1. Insert a paper clip in the engine speed detection connector
from the harness side, and attach the engine speedometer.
NOTE
For tachometer check, use of a fluxmeter-type engine
Engine speedometer is recommended. (Because a fluxmeter only
speed needs to be clipped to the high tension cable.)
detection
terminal 2. Compare the readings of the engine speedometer and the
tachometer at every engine speed, and check if the
variations are within the standard values.
Standard values:
700 r/min: ±100 r/min
3,000 r/min: +150 r/min
–100 r/min
5,000 r/min: +325 r/min
–125 r/min
6,000 r/min: +375 r/min
–125 r/min
 CHASSIS ELECTRICAL – Combination Meters 54A-25
<Main> <Sub> FUEL GAUGE UNIT CHECK
Remove the fuel gauge unit from the fuel tank.
(Refer to GROUP 13C.)
FUEL GAUGE UNIT RESISTANCE
1. Check that resistance value between the fuel gauge
terminal and earth terminal is at standard value when
fuel gauge unit float is at point F (highest) and point E
(lowest).
Standard value:

Items Standard value Ω

Main Float point F 1 –3

Float point E 49.7 – 51.7

Point F (highest) Sub Float point F 1–3
Point E (lowest) Float point E 55.3 – 57.3

2. Check that resistance value changes smoothly when float

moves slowly between point F (highest) and point E
(lowest).
FUEL GAUGE UNIT FLOAT HEIGHT
1. Move float and measure the height A at point F (highest)
and B at point E (lowest) with float arm touching stopper.
A
Standard value:

Items Standard value mm

Point F B
(highest) Point E (lowest)
Main Float point F 44.5 – 52.5

Float point E 220.3 – 228.3

Sub Float point F 30.4 – 36.4

Float point E 238.5 – 244.5

2. Check that resistance value changes smoothly when float

moves slowly between point F (highest) and point E
(lowest).

FUEL LEVEL SENSOR (THERMISTOR)

Thermistor
Earth 1. Connect the battery to the main fuel gauge unit connector
via test lamp (12 V – 3.4 W) as shown in the illustration.
54A-26 CHASSIS ELECTRICAL – Combination Meters

Thermistor 2. Condition is good if the test lamp goes off when the
thermistor is immersed in water and comes on when it
is taken out of water.
Illuminated Caution
After finishing this test, wipe the unit dry and install
it in the fuel tank.

Not
illuminated

FUEL LEVEL WARNING SWITCH CHECK

1. Remove the sub fuel gauge unit pipe assembly. (Refer
to GROUP 13B – Fuel Tank.)
Fuel level NOTE
warning switch Pipe assembly Moving up and down of the float makes the reed switch
of fuel level warning switch turned on and off.
Stopper
2. Check the continuity between the terminals.
Float
Float position Terminal No.
3 4
When float is in contact with upper stopper
When float is in contact with lower stopper

ENGINE COOLANT TEMPERATURE GAUGE UNIT

CHECK
1. Bleed the engine coolant. (Refer to GROUP 14 –
On-vehicle Service.)
2. Remove the engine coolant temperature gauge unit.
3. Immerse the unit in 70_C water to measure the resistance.
Standard value: 104 ± 13.5 Ω

4. After checking, apply the specified adhesive around the

thread of engine coolant temperature gauge unit.
Specified sealant:
3M Adhesive Nut Locking No. 4171 or equivalent
5. Add engine coolant. (Refer to GROUP 14 – On-vehicle
Service.)

11 ± 1 Nm
 CHASSIS ELECTRICAL – Combination Meters 54A-27
COMBINATION METERS
REMOVAL AND INSTALLATION

Section A – A
Instrument panel
Clip

3 1

1
A
A
A
A
A

Clip position

Combination meter removal steps Vehicle speed sensor removal

1. Meter hood 3. Vehicle speed sensor
2. Combination meter

INSPECTION
Vehicle VEHICLE SPEED SENSOR INSPECTION
speed
Terminal number sensor 1. Lift up the vehicle.
2. Remove the vehicle speed sensor, and then connect the
vehicle speed sensor and a resistance (3 – 10 kΩ) as
Resistance
(3 – 10 kΩ) shown in the illustration.
3. Use a circuit tester to check that the voltage between
Circuit terminal 2 and terminal 3 changes when turning a shaft
tester Battery of the vehicle speed sensor (4 pulses per each one turn).
54A-28 CHASSIS ELECTRICAL – Combination Meters

FUEL GAUGE RESISTANCE CHECK

Fuel gauge
1. Remove the power supply tightening screw.
2. Use an ohmmeter to measure the resistance value between
the terminals.
Standard value:
Power supply – Earth: 233.3 Ω
Power supply Power supply – Fuel gauge: 108.3 Ω
Fuel gauge – Ground: 125.0 Ω
Earth
Caution
When inserting the testing probe into the power supply
terminal, be careful not to touch the printed board.

Engine coolant ENGINE COOLANT TEMPERATURE GAUGE

temperature gauge RESISTANCE CHECK
1. Remove the power supply tightening screw.
2. Use an ohmmeter to measure the resistance value between
the terminals.
Standard value:
Earth Power supply Power supply – Earth: 178.9 Ω
Power supply – Engine coolant temperature gauge:
54 Ω
Engine coolant temperature gauge – Earth:
232.9 Ω
Caution
When inserting the testing probe into the power supply
terminal, be careful not to touch the printed board.
 CHASSIS ELECTRICAL – Outside Thermo Sensor 54A-29

OUTSIDE THERMO SENSOR

SERVICE SPECIFICATIONS
Items Standard value

Internal resistance of outside thermo sensor Ω At 25 _ Approx. 1,700

OUTSIDE THERMO SENSOR

REMOVAL AND INSTALLATION

Outside thermo sensor

INSPECTION
Thermometer OUTSIDE THERMO SENSOR INTERNAL RESISTANCE
CHECK
Check the internal resistance of the outside thermo sensor
are at the standard value at temperatures of 25 _C.

Sensor
Standard value:
Approx. 1,700 Ω (at 25 _C)
Dryer
54A-30 CHASSIS ELECTRICAL – Headlamp, Front Turn-signal Lamp and Front Fog Lamp

HEADLAMP, FRONT TURN-SIGNAL LAMP AND

FRONT FOG LAMP
SERVICE SPECIFICATIONS
Items Standard value Limit

Headlamp aiming for low Vertical direction 60 mm below horizontal (H) –

beam
Horizontal direction Position where the 15_ sloping section –
intersects the vertical line (V)

Headlamp intensity cd – 30,000 or more

Front fog lamp aiming Vertical direction 100 mm below horizontal (H) –

Horizontal direction Parallel to direction of vehicle travel –

SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Removal of switch garnish

TROUBLESHOOTING
The headlamp, turn-signal lamp and front fog lamp are controlled by the smart wiring system (SWS).
For troubleshooting, refer to GROUP 54B – Troubleshooting.
 CHASSIS ELECTRICAL – Headlamp, Front Turn-signal Lamp and Front Fog Lamp 54A-31
ON-VEHICLE SERVICE
HEADLAMP AIMING
<USING A BEAM SETTING EQUIPMENT>
1. The headlamps should be aimed with the proper beam
setting equipment, and in accordance with the equipment
manufacture’s instructions.
NOTE
If there are any regulations pertinent to the aiming of
headlamps in the area where the vehicle is to be used,
adjust so as to meet those requirements.
2. Alternately turn the adjusting screw to adjust the headlamp
aiming. (Refer to P.54A-32.)

<USING A SCREEN>
1. Inflate the tyres to the specified pressures and there should
be no other load in the vehicles other than driver or
substituted weight of approximately 75 kg placed in driver’s
position.
2. Put the headlamp leveling switch in “0” position.
Lamp centre 3. Set the distance between the screen and the centre marks
of the headlamps as shown in the illustration.

Screen Headlamp centre line

Vehicle centre line

5m
54A-32 CHASSIS ELECTRICAL – Headlamp, Front Turn-signal Lamp and Front Fog Lamp

(V) 4. Check if the beam shining onto the screen is at the standard
value.
Distance of Standard value:
vertical direction Lamp centre
(Vertical direction)
(H) 60 mm below horizontal (H)
15 (Horizontal direction)
Position where the 15_ sloping section intersects
High intensity zone
the vertical line (V)
NOTE
The illustration shows L.H. drive vehicles. For R.H. drive
vehicles, it is symmetrical.
Horizontal Vertical direction 5. Alternately turn the adjusting screw to adjust the headlamp
direction adjustment aiming.
adjustment
Caution
Be sure to adjust the aiming adjustment screw in the
tightening direction.

HEADLAMP INTENSITY MEASUREMENT

Using a photometer, and following its manufacture’s instruction
manual, measure the headlamp intensity and check to be
sure that the limit value is satisfied.
Limit: 30,000 cd or more
NOTE
1. When measuring the intensity, maintain an engine speed
of 2,000 r/min, with the battery in the charging condition.
2. There may be special local regulations pertaining to
headlamp intensity, be sure to make any adjustments
necessary to satisfy such regulations.
3. If an illuminometer is used to make the measurements,
convert its values to photometer values by using the
following formula.
I = Er2 Where:
I=intensity (cd)
E=illumination (lux)
r=distance (m) from headlamps to illuminometer
 CHASSIS ELECTRICAL – Headlamp, Front Turn-signal Lamp and Front Fog Lamp 54A-33
FRONT FOG LAMP AIMING
1. Measure the centre of the front fog lamps, as shown in
the illustration.
2. Set the distance between the screen and the centre of
the front fog lamps as shown in the illustration.
Lamp centre
3. Inflate the tyres to the specified pressures and there should
be no other load in the vehicles other than driver or
substituted weight of approximately 75 kg placed in the
driver’s position.
4. With the engine running at 2,000 r/min, aim the front fog
lamp.

Screen Fog lamp centre line

Vehicle centre line

5m

5. Check if the beam shining onto the screen is at the standard

Lamp centre
value.
Distance of
vertical direction Standard value:
(Vertical direction)
100 mm below horizontal (H)
(Horizontal direction)
Parallel to direction of vehicle travel
High intensity zone
Centre of high
intensity zone

Adjusting screw NOTE

The horizontal direction is non-adjustable. If the deviation
of the light beam axis exceeds the standard value, check
to be sure that the mounting location or some other point
is not defective.
Caution
When making the aiming adjustment, be sure to mask
those lamps which are not being adjusted.
54A-34 CHASSIS ELECTRICAL – Headlamp, Front Turn-signal Lamp and Front Fog Lamp

BULB REPLACEMENT
Spring <Headlamp Bulb>
1. Disconnect the connector.
2. Remove the socket cover.
3. Remove the bulb mounting spring, and then withdraw the
bulb.
4. Install new bulb, and then connect the connector securely.
Caution
Do not touch the surface of the bulb with hands or dirty
gloves. If the surface does become dirty, clean it with
alcohol or thinner, and let it dry thoroughly before
installing.

<Position Lamp Bulb>

Remove the lamp socket by turning it anti-clockwise, then
pull out the bulb from the socket.
Position lamp bulb

<Front fog lamp Bulb>

Fog lamp cover
1. Remove the front fog lamp.
2. Remove the front fog lamp cover.
3. Remove the front bulb mounting spring, and then withdraw
the bulb.
4. Disconnect the connector, and then replace the bulb.
Spring
Caution
(1) Always use the genuine part for replacement.
(2) Do not touch the surface of the bulb with hands
or dirty gloves. If the surface does become dirty,
clean it with alcohol or thinner, and let it dry
thoroughly before installing.
(3) Be sure to install the socket cap. If the socket
cap is improperly installed, the lens will be fogged
or water may enter the lamp unit.
 CHASSIS ELECTRICAL – Headlamp, Front Turn-signal Lamp and Front Fog Lamp 54A-35
HEADLAMP, FRONT TURN-SIGNAL LAMP AND FRONT FOG
LAMP
REMOVAL AND INSTALLATION

7 6

5 Nm

5 Nm
5

A A

9
A A
2
3 1

Section A – A 8
Claw
Instrument
panel 8

1
BX0283AL

Fog lamp switch and headlamp Front fog lamp removal steps
leveling switch removal steps 8. Splash shield front part mounting
1. Switch panel clips and screws
2. Fog lamp switch 9. Front fog lamp
3. Headlamp leveling switch
Headlamp removal steps NOTE
For removal and installation of the column switch (lighting
AA" 4. Radiator grille switch), refer to GROUP 37A – Steering Wheel and Shaft.
5. Headlamp
6. Front turn-signal lamp socket
7. Front turn-signal lamp bulb
54A-36 CHASSIS ELECTRICAL – Headlamp, Front Turn-signal Lamp and Front Fog Lamp

REMOVAL SERVICE POINT

Section A – A
AA" RADIATOR GRILLE REMOVAL
Radiator grille Clip
1. Pull the radiator grille toward you gently, and press the
clip tab with a flat-tipped screwdriver toward the arrow
to remove the radiator grille.
2. Remove the clips from the body, and install them to the
radiator grille temporarily for reinstallation.

Radiator grille

INSPECTION
HEADLAMP LEVELING SWITCH CONTINUITY CHECK
1. Check the continuity between terminals 4 and 5
(illumination circuit).
2. Operating the headlamp leveling switch, check that the
resistance between terminals 4 and 5 meets the condition
below.

Switch position Resistance value

0 12 kΩ

1 5.1 kΩ

2 2.7 kΩ

3 1.5 kΩ

4 620 Ω

FOG LAMP SWITCH CONTINUITY CHECK

Switch position Terminal No.

1 2 3 ILL 4

Released

Pressed
 Headlamp, Front Turn-signal Lamp and
CHASSIS ELECTRICAL – Front Fog Lamp/Side Turn-signal Lamp 54A-37
FRONT FOG LAMP RELAY CONTINUITY CHECK

Battery voltage Terminal No.

1 3 4 5

Not supplied

Supplied

Front fog lamp relay

SIDE TURN-SIGNAL LAMP

SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Removal of side turn-signal lamp

TROUBLESHOOTING
The side turn-signal lamp is controlled by the smart wiring system (SWS).
For troubleshooting, refer to GROUP 54B – Troubleshooting.
 Side Turn-signal Lamp/Room Lamp/Rear
54A-38 CHASSIS ELECTRICAL – Combination Lamp, Rear Fog Lamp

Front of vehicle
SIDE TURN-SIGNAL LAMP
REMOVAL SERVICE POINT
SIDE TURN-SIGNAL LAMP REMOVAL
Use a special tool to remove the lock from the fender panel,
and then remove the side turn-signal lamp.

MB990784

ROOM LAMP
TROUBLESHOOTING
The room lamp is controlled the smart wiring system (SWS).
For troubleshooting, refer to GROUP 54B – Troubleshooting.

REAR COMBINATION LAMP, REAR FOG LAMP

SPECIAL TOOLS
Tool Number Name Use
MB990784 Ornament remover Removal of side turn-signal lamp

TROUBLESHOOTING
The tail lamp, turn-signal lamp and rear fog lamp are controlled by the smart wiring system (SWS). For
troubleshooting, refer to GROUP 54B – Troubleshooting.
 CHASSIS ELECTRICAL – Rear Combination Lamp, Rear Fog Lamp 54A-39
REAR COMBINATION LAMP, REAR FOG LAMP
REMOVAL AND INSTALLATION <L.H. drive vehicles>
Section A – A
Claw
A A
Instrument
panel

1 A A
BX0283AL
2 1

Section B – B
Gronmet

Body 3
panel

4 7
8
5 5
2.5 ± 0.2 Nm
6

Fog lamp switch removal steps Rear fog lamp removal steps
1. Switch panel D Rear mad guard
2. Fog lamp switch (Refer to GROUP 51)
Rear combination lamp removal D Rear splash shield
steps 6. Rear fog lamp
7. Bracket
D Quarter Trim Removal and Installation 8. Socket
(Refer to GROUP 52A)
3. Rear combination lamp
4. Socket assembly
5. Bulb
54A-40 CHASSIS ELECTRICAL – Rear Combination Lamp, Rear Fog Lamp

REMOVAL AND INSTALLATION <R.H. drive vehicles>

Section A – A Section B – B
Gronmet
A A Claw
Instrument
panel

Body 3
panel
A A 1
BX0283AL
2 1

7
9
6

6 5

9
7
7
B
B 9
2.5 ± 0.2 Nm 4
3

Fog lamp switch removal steps 4. Rear combination lamp (Turn-signal

1. Switch panel and tail lamp)
2. Fog lamp switch 5. Rear combination lamp (Rear fog
lamp, turn-signal lamp and tail
Rear combination lamp removal lamp)
steps 6. Bracket
D Quarter trim removal and installation 7. Socket assembly
(Refer to GROUP 52A) 8. Socket
3. Rear combination lamp (Stop and 9. Bulb
back up lamp)
 CHASSIS ELECTRICAL – Rear Combination Lamp, Rear Fog Lamp 54A-41
INSPECTION
FOG LAMP SWITCH CONTINUITY CHECK

Terminal No.
3 ILL 4 5 6
Relased

Pressed

INSPECTION
REAR FOG LAMP RELAY CONTINUITY CHECK

Batteryy voltage
g Terminal No.
1 3 4 5
Not supplied

Supplied
Rear fog
lamp relay
54A-42 CHASSIS ELECTRICAL – High-mounted Stop Lamp and Licence Plate Lamp

HIGH-MOUNTED STOP LAMP AND LICENCE

PLATE LAMP
REMOVAL AND INSTALLATION
Section A – A
Tab

A 1
A
1
A

2
3
4

10
9

5
8
7

High-mounted stop lamp removal D Licence plate lamp garnish (Refer to

steps GROUP 42 – Back Door.)
1. High-mounted stop lamp cover 5. Licence plate lamp assembly
2. Socket assembly 6. Lens
3. Bulb 7. Packing
4. High-mounted stop lamp 8. Licence plate lamp
9. Bulb
Licence plate lamp removal steps 10. Socket assembly
D Back door trim and waterproof film
(Refer to GROUP 42.)
 CHASSIS ELECTRICAL – Column Switch 54A-43

COLUMN SWITCH
REMOVAL AND INSTALLATION

A
A
2
A
A

B
B

B
B
1

Section A – A Section B – B

2
2

1 Tab Tab
1

Removal steps
1. Column cover, lower 3. Wiper and washer switch
2. Column cover, upper 4. Lighting switch
 Rheostat <Vehicles for
54A-44 CHASSIS ELECTRICAL – Australia and New Zealand>

RHEOSTAT
SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Removal of switch garnish

RHEOSTAT
REMOVAL AND INSTALLATION
Section A – A
Claw
Instrument
panel

A A

A A 1
2

Removal steps
1. Switch panel
2. Rheostat

INSPECTION
1. Connect the battery and the test bulb (40W) as shown
40W in the illustration.
2. Operate the rheostat, and if the brightness changes
smoothly without switching off, then the rheostat function
is normal.
 CHASSIS ELECTRICAL – Hazard Warning Lamp Switch 54A-45

HAZARD WARNING LAMP SWITCH

SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Removal of center panel

HAZARD WARNING LAMP SWITCH

REMOVAL AND INSTALLATION
2

1 A
A
Section A – A
Clip Instrument panel

: shows clips.

Removal steps
1. Center panel
2. Hazard warning lamp switch

INSPECTION
Switch position Terminal No.
1 2 3 4
OFF
ILL
ON
ILL
54A-46 CHASSIS ELECTRICAL – Horn/Cigarette Lighter

Horn relay HORN

INSPECTION
HORN RELAY CONTINUITY CHECK

Batteryy voltage
g Terminal No.
1 3 4 5
Not supplied
Supplied

CIGARETTE LIGHTER
REMOVAL AND INSTALLATION

3
4

5
1

Removal steps
1. Plug 3. Bulb
2. Floor console (Refer to GROUP 4. Socket case
52A) 5. Socket
 CHASSIS ELECTRICAL – Cigarette Lighter/Accessory Socket 54A-47
INSPECTION
D Take out the plug, and check for a worn edge on the
Element element spot connection, and for shreds of tobacco or
Spot
other material on the element.
D Using a circuit tester, check the continuity of the element.

ACCESSORY SOCKET
INSPECTION
ACCESSORY SOCKET RELAY CONTINUITY CHECK

Batteryy voltage
g Terminal No.
1 3 4 5
Accessory
socket Not supplied
relay
Supplied
54A-48 CHASSIS ELECTRICAL – Radio and Tape Player

RADIO AND TAPE PLAYER

TROUBLESHOOTING
QUICK-REFERENCE TROUBLESHOOTING CHART
Items Problem symptom Relevant chart

Noise Noise appears at certain places when travelling. A-1

Mixed with noise, only at night. A-2

Broadcasts can be heard but FM/MW/LW has a lot of noise. A-3

There is noise when starting the engine. A-4

Some noise appears when there is vibration or shocks during A-5

travelling.

Ever-present noise. A-6

Radio When switch is set to ON, no power is available. B-1

No sound from one speaker. B-2

There is noise but no reception for FM/MW/LW or no sound from B-3

FM/MW/LW

Insufficient sensitivity. B-4

Distortion on FM/MW/LW. B-5

Too few automatic select stations. B-6

Insufficient memory (preset stations are erased). B-7

Tape player Cassette tape will not be inserted. C-1

No sound. C-2

No sound from one speaker. C-3

Sound quality is poor, or sound is weak. C-4

Cassette tape will not be ejected. C-5

Uneven revolution. Tape speed is fast or slow. C-6

Faulty auto reverse. C-7

Tape gets caught in mechanism. C-8

 CHASSIS ELECTRICAL – Radio and Tape Player 54A-49
CHART
A. NOISE
A-1 Noise appears at certain places when travelling.

No Yes
Is there a particular structure? Do the following measures eliminate OK
the noise?
Yes
1. Change to a different station with
a strong signal to boost resistance
to interference.
Find out the following information from
the user: 2. Suppress high tones to reduce
noise.
1. Place 3. Extend antenna completely.
2. Locality conditions (valley, moun-
tain, etc.) No
3. Name and frequency of stations
affected by noise

If due to vehicle noise: If due to external noise:

It may not be possible to prevent noise In almost all cases, prevention on the
if the signal is weak. receiver side is impossible. Weak sig-
nals especially are susceptible to inter-
ference.

If there is more noise than other radios, find out the noise
conditions and the name and frequency of the receiving
stations from the user, and consult with the service centre.
54A-50 CHASSIS ELECTRICAL – Radio and Tape Player

A-2 Mixed with noise, only at night.

The following factors can be considered as possible to a different station or the appearance of a
causes of noise appearing at night. beating sound* may occur.
1. Factors due to signal conditions: Due to the Beat sound*: Two signals close in frequency
fact that long-distance signals are more easily interfere with each other, creating a repetitious
received at night, even stations that are received high-pitched sound. This sound is generated
without problem during the day may experience not only by sound signals but by electrical waves
interference in a general worsening of reception as well.
conditions. The weaker a station is the more 2. Factors due to vehicle noise: Alternator noise
susceptible it is to interference, and a change may be a cause.

No
Is the noise still obvious even with the
lamps OFF?
Yes
Yes
Do the following measures eliminate OK
the noise?
D Tune to a station with a strong
signal.
D Tune to a station with a strong signal Yes
without completely extending the Does the noise fade away when the OK
antenna. vehicle harness is moved away from
the radio chassis? (if the harness is
No not in the proper position.)
No

If there is more noise than other radios, consult a service

centre.
 CHASSIS ELECTRICAL – Radio and Tape Player 54A-51
A-3 Broadcasts can be heard but FM/MW/LW has a lot of noise.

(1) (2)
Noise occurs when the engine is stopped. Noise occurs when the engine in running.
Yes

Do the following measures eliminate the noise? Inspect the vehicle’s noise suppressor. (Refer to A-4.)
D Tune to a station with a strong signal. Yes
D Extend the antenna completely. OK
D Adjust the sound quality to suppress high tones.
No
No
Is the radio body earth mounted securely? Securely tighten the nuts for the body
earth.
Yes
No
Is the antenna plug properly connected to the radio? Correctly attach the antenna plug.
Yes
No
Is the antenna itself in good condition or is it properly Clean the antenna plug and earth wire
mounted? mounting area. Mount the antenna se-
curely.
Yes

Yes
Is the noise eliminated? OK
No

If there is more noise than other radios, consult a service

centre.
54A-52 CHASSIS ELECTRICAL – Radio and Tape Player

A-4 There is noise when starting the engine.

Noise type Conditions Cause Remedy

Sounds are in
parentheses ( ).

FM/MW/LW: D Increasing the engine speed D Mainly due to the spark D Check or replace the
Ignition noise causing the popping sound to plugs. earth cable. (Refer to
(Popping, snap- speed up, and volume D Due to the engine noise. Fig. 1 on P.54A-59.)
ping, cracking, decreases. D Check or replace the
buzzing) D Disappears when the ignition noise capacitor.
switch is turned to ACC.

Other electrical – Noise may appear as electri- Repair or replace electrical

components cal components become old- components.
er.

Static electricity D Disappears when the vehicle Occurs when parts or wiring Return parts or wiring to their
(Cracking, crin- is completely stopped. move for some reason and proper position.
kling) D Severe when the clutch is contact metal parts of the
engaged. body.

D Various noises are produced Due to detachment from the Tighten the mounting bolts
depending on the body part of body of the front hood, securely. Cases where the
the vehicle. bumpers, exhaust pipe and problem is not eliminated by
muffler, suspension, etc. a single response to one
area are common, due to
several body parts being
imperfectly earthed.

Caution passes A.C. current, impedance (resistance

1. Connecting a high tension cable to the noise against A.C.) decreases, and current flow is
filter may destroy the noise filter and should facilitated. A noise suppressing condenser
never be done. which takes advantage of this property is
2. Check that there is no external noise. Since inserted between the power line for the noise
failure caused by this may result in source and the earth. This suppresses noise
misdiagnosis due to inability to identify the by earthing the noise component (A.C. or pulse
noise source, this operation must be signal) to the body of the vehicle.
performed. 2. Coil
3. Noise prevention should be performed by The coil passes D.C. current, but impedance
suppressing strong sources of noise step rises as the number of waves increases relative
by step. to the A.C. current. A noise suppressing coil
NOTE which takes advantage of this property is
1. Capacitor inserted into the power line for the noise source,
The capacitor does not pass D.C. current, but and works by preventing the noise component
as the number of waves increases when it from flowing or radiating out of the line.

Fig. 1

Earth
cable
 CHASSIS ELECTRICAL – Radio and Tape Player 54A-53
A-5 Some noise appears when there is vibration or shocks during travelling.

No
Are connectors properly connected? Ensure proper connection.
Yes
No
Does noise appear when the radio switch is turned on while the Static electricity noise:
vehicle is stopped and the radio is struck while tuned away from Body static electric from the shock absorber rubber bushings used
a station? to prevent vibration, tyres, etc. occurs because of separation from
the earth, causing a buzzing noise. Since no measures can be
Yes
taken on the radio side, other steps should be taken to discharge
the static electricity of the vehicle body.

No
Is the radio correctly earthed? (Is the mounting screw tightened Tighten the screw securely.
securely?)
Yes
No
Is the antenna correctly earthed? (If noise appears when the anten- If rust is present at the antenna earth screw, clean and tighten
na is moved, this means the earth is not securely connected.) the earth securely.
Yes

Repair or replace radio.

A-6 Ever-present noise.

Noise is often created by the following factors, and For this reason, if there are still problems with noise
often the radio is OK when it is checked individually. even after the measures described in steps A-1
D Travelling conditions of the vehicle to A-8 have been taken, get information on the
D Terrain of area travelled through factors listed above as well as determining whether
D Surrounding buildings the problem occurs with FM/MW/LW, the station
D Signal conditions names, frequencies, etc., and contact a service
D Time period centre.
54A-54 CHASSIS ELECTRICAL – Radio and Tape Player

B. RADIO
B-1 No power is supplied when the switch is set to ON.

Yes
Is dedicated fuse No. 6 blown or is the circuit open? Replace fuse or repair harness.
No
No
Is the connector at the back of the radio connected properly? Connect connector securely.
Yes
No
Disconnect and check the connector at the rear of the radio. Is Repair harness.
the ACC power (12 V) being supplied to the radio?
Yes

Repair or replace radio.

B-2 No sound from one speaker.

Yes
Check to see if there is any sound when Repair or replace radio.
attached to another radio.
No
Yes
Remove the connector on the back of It conducts electricity but is shorted out. Repair speaker harness.
the radio and check the speaker har-
ness for conductance.
No
Yes
Check the speaker for conductance. Repair speaker harness and ensure
proper connection of relay connectors.
No

Repair or replace speaker.

 CHASSIS ELECTRICAL – Radio and Tape Player 54A-55
B-3 There is noise but no reception for FM/MW/LW or no sound from FM/MW/LW.

Yes
Is the check being conducted under
special electrical field conditions?
No Example: In an underground
garage or inside a building.

Yes
Is proper performance obtained when OK
the vehicle is moved?
No
Yes
Does tuning solve the problem? OK
No
No
Are the antenna plug and radio unit properly connected? Reconnect
Yes
Yes
Does the problem disappear if connected to another radio? Repair or replace radio.
No

Replace the antenna.

B-4 Insufficient sensitivity.

Yes
Is the check being conducted under
special electrical field conditions?
No Example: In an underground
garage or inside a building.

Yes
Is proper performance obtained when OK
the vehicle is moved?
No
Yes
Does tuning solve the problem? OK
No
Yes
Is the problem limited to the reception of a specific radio Electrical field condition related
station from a specific position?
No
No
Is the antenna plug properly connected to the unit? Ensure proper connection.
Yes
Yes
Does the problem disappear when a different radio is Repair or replace radio.
connected?
No

Replace the antenna.

54A-56 CHASSIS ELECTRICAL – Radio and Tape Player

B-5 Distortion on FM/MW/LW.

Occasional Yes
How much distortion is there? Distortion in the vicinity of the radio sta- Excessive antenna input
tion
Constant
No
Yes
Are the speaker cords in contact with the cone paper? Remove cords away from cone paper.
No
Yes
Remove the speakers and check for torn cone paper or foreign Repair or replace speakers.
objects.
No
Yes
Check for deformation with speaker installed. Install speaker securely.
No

Repair or replace radio.

B-6 Too few automatic select stations.

Yes
Is the check being conducted under
special electrical field conditions?
No Example: In an underground
garage or inside a building

Yes
Is proper performance obtained when OK
the vehicle is moved?
No
No
Is the antenna plug properly connected to the equipment? Ensure proper connection.
Yes
Yes
Does the equipment work properly if the radio is changed? Repair or replace radio.
No

Replace the antenna.

 CHASSIS ELECTRICAL – Radio and Tape Player 54A-57
B-7 Insufficient memory (preset stations are erased).

Yes
Is dedicated fuse No. 5 blown or is the circuit open? Replace fuse or repair harness.
No
No
Disconnect and check the connector at the rear of the radio. Repair harness.
Is the memory backup (battery) power being supplied?
Yes

Repair or replace radio.

C. TAPE PLAYER
C-1 Cassette tape will not be inserted.

Yes
Are there any foreign objects in the tape player? Remove the object(s)*1
No
*1
Attempting to force a foreign object (e.g., a coin or clip, etc.) out
of the tape player may damage the mechanism. The player should
be taken to a service dealer for repair.
Yes
Does the tape player work if another tape is inserted? Replace tape*2
No
*2
Repair or replace tape player. Ensure that the tape label is not loose, that the tape itself is not
deformed and that the tape is tightly wound. Also, tape of C-120
or greater length often get caught in the mechanism and should
not be used.

C-2 No sound (even after a tape has been inserted).

Yes
Is dedicated fuse No. 6 blown or is the circuit open? Replace fuse or repair harness.
No
No
Is connector at rear of radio connected tightly? Connect connector firmly.
Yes
Yes
Disconnect connector at rear of radio. Is ACC power being supplied Repair or replace tape player.
to the radio?
No

Repair harness.
54A-58 CHASSIS ELECTRICAL – Radio and Tape Player

C-3 No sound from one speaker.

Yes
Clean the tape player head and check again. OK
No
Yes
Replace the tape player and check again. Repair or replace tape player.
No
Yes
Remove the connector on the back of the radio and check It conducts electricity but is Repair harness.
the speaker harness for conductance. shorted out.
No
Yes
Check the speaker for conductance. Repair harness.
No

Repair or replace speaker.

C-4 Sound quality is poor, or sound is weak.

Yes
Does the player play properly when another tape* is inserted? OK
No
*:
D Ensure that the tape label is not loose, that the tape
itself is not deformed and that the tape is tightly wound.
D Tapes of C-120 or greater length often get caught
in the mechanism and should not be used.
Yes
Does the player play properly when the tape player head is cleaned? OK
No
Yes
Is proper operation obtained when the tape player is replaced? Repair or replace tape player.
No
Repair or replace speaker.

C-5 Cassette tape will not be ejected.

The problems covered here are all the result of also possible, and attempting to force the tape out
the use of a bad tape (deformed or not properly of the player can cause damage to the mechanism.
tightened) or of a malfunction of the tape player The player should be taken to a service dealer for
itself. Malfunctions involving the tape becoming repair.
caught in the mechanism and ruining the case are
 CHASSIS ELECTRICAL – Radio and Tape Player 54A-59
C-6 Uneven revolution. Tape speed is fast or slow.

Yes
Does the player play OK if the tape*1 is changed? OK
No
*1
Ensure that the tape label is not loose, that the tape itself
is not deformed and that the tape is tightly wound. Also,
tape of C-120 or greater length often get caught in the
mechanism and should not be used.

Yes
Are there any foreign objects *2 inside the tape player? Remove foreign object(s).
No
*2
Attempting to force a foreign object (e.g., a coin or clip,
etc.) out of the tape player may damage the mechanism.
The player should be taken to a service dealer for repair.

Yes
Is the head or capstan roller dirty? (Refer to the illustration below.) Clean.
No
Repair or replace tape player.

Pinch roller Head Capstan roller

C-7 Faulty auto reverse.

Yes
Does the player play OK if the tape* is changed? OK
No
*:
D Ensure that the tape label is not loose, that the tape
itself is not deformed and that the tape is tightly wound.
D Tapes of C-120 or greater length often get caught
in the mechanism and should not be used.

No
Does the problem only occur while the vehicle is being driven? Repair or replace tape player.
Yes
No
Is the tape player properly installed to the vehicle? Ensure tape player installation.
Yes
Repair or replace tape player.
54A-60 CHASSIS ELECTRICAL – Radio and Tape Player

C-8 Tape gets caught in mechanism*1.

*1
When the tape is caught in the mechanism, the case may
not eject. When this occurs, do not try to force the tape
out as this may damage the tape player mechanism. Take
the cassette to a service dealer for repair.

Yes
Does the player play OK if the tape*2 is changed? Tape used is bad.
No
*2
Ensure that the tape label is not loose, that the tape itself
is not deformed and that the tape is tightly wound. Also,
tapes of C-120 or greater length often get caught in the
mechanism and should not be used.

Repair or replace tape player.

 CHASSIS ELECTRICAL – Radio and Tape Player 54A-61
RADIO AND TAPE PLAYER
REMOVAL AND INSTALLATION
Section A – A
Instrument panel
Clip

2
1

A
1 A

: shows clips.

Removal steps
1. Center panel
2. Radio and tape player
54A-62 CHASSIS ELECTRICAL – CD Autochanger

CD AUTOCHANGER
REMOVAL AND INSTALLATION

3 5

2
1

Removal steps
D Front seat (LH) 3. CD autochanger assembly
1. Lid 4. Bracket
2. Cover 5. CD autochanger
 CHASSIS ELECTRICAL – Speaker 54A-63

SPEAKER
REMOVAL AND INSTALLATION
<Front speaker>

2 1

<Rear speaker>

Front speaker removal steps Rear speaker removal steps

1. Front door trim (Refer to GROUP 3. Quarter trim (Refer to GROUP
42.) 52A.)
2. Speaker 4. Speaker
54A-64 CHASSIS ELECTRICAL – Antenna

ANTENNA
REMOVAL AND INSTALLATION

4
1

Removal steps
1. Radio and tape player (Refer to AA" 3. Antenna assembly
P.54-61.) 4. Antenna base
D Instrument under cover D Instrument panel (Refer to GROUP
(Refer to GROUP 52A.) 52A)
2. Cowl side trim (Refer to GROUP 5. Antenna feeder
52A)

REMOVAL SERVICE POINT

Cord Tape
AA" ANTENNA ASSEMBLY REMOVAL
Observe the following steps to make the feeder cable of
the antenna to be routed easily during reinstallation.
Junction block
Hole 1. Secure a cord to the end of the feeder cable.
Cord
2. Pull out the feeder cable slightly until the tube end of
the antenna can been seen.
3. Insert a cord into the tube end, and secure the cord with
plastic tape as shown.
Caution
         


4. Remove the antenna assembly by pulling it gradually.
 CHASSIS ELECTRICAL – Rear Window Defogger 54A-65

Normal characteristic curve REAR WINDOW DEFOGGER

Voltage
ON-VEHICLE SERVICE
A (Centre point) PRINTED-HEATER LINE CHECK
approx. 6 V
1. Run engine at 2,000 r/min. Check heater element with
battery at full.
2. Turn ON rear window defogger switch. Measure heater
Positive Printed Negative
termi- heater line terminal element voltage with circuit tester at rear window glass
nal centre A.
Abnormal characteristic curve Condition is good if it indicates about 6 V.
3. If 12 V is indicated at A, there is a break in the negative
Voltage terminals from A.
Open-circuit Move test bar slowly to negative terminal to detect where
point voltage changes suddenly (0V).
4. If 0 V is indicated at A, there is a break in the positive
terminals from A. Defect where the voltage changes
suddenly (12 V) in the same method described above.
Positive Printed Negative
termi- heater line terminal
nal

REAR WINDOW DEFOGGER RELAY

CONTINUITY CHECK
Batteryy voltage
g Terminal No.
1 2 3 5
Power is not supplied
Power is supplied
Defogger relay
54A-66 CHASSIS ELECTRICAL – Rear Window Defogger

REAR WINDOW DEFOGGER SWITCH

REMOVAL AND INSTALLATION
Refer to GROUP 55 – Heater Control.

INSPECTION
DEFOGGER SWITCH CONTINUITY CHECK
<Vehicles with heated-mirrors>

Switch position Terminal No.

3 10 – 11 12
OFF IND

<Vehicles with heated-mirrors>

ON IND

NOTE
<Vehicles without heated-mirrors> Turn on the defogger switch, and then check that there is
continuity between the terminals 3 and 12 for 9 to 13 minutes
and after it, the defogger switch is turned off.
<Vehicles without heated-mirrors>

Switch position Terminal No.

10 – 11 12
OFF IND

ON IND
Defogger switch
 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> 54A-67

MULTI-CENTER DISPLAY <MIDDLE GRADE>

SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Removal of center display hood

TROUBLESHOOTING
NOTES WITH REGARD TO SERVICE PROCEDURES
1. Before removing the battery
The audio system has a large amount of data stored in memory which the user enters over time. When
the terminals are disconnected from the battery, the memory which stores this data is affected as shown
in the table below. Accordingly, it is necessary to make sure that you take notes of important information
before disconnecting the battery.

Function Input function/memory When battery is disconnected

Radio Channels which are selected during a search Disappear after a few seconds

Preset channels

Tone/Balance Position set on Bass, Treble, Balance and Fader

Clock set on display Current time Keep a data for approx. one hour

Brightness set for display Position set on display

Unit set for trip computer km or mile, L/100km or mpg or km/L

Average speed on display Average speed after reset

Average fuel consumption Average fuel consumption after reset

on display

Cruising range on display Cruising range, fuel economy

Outside temperature on A temperature after the ignition switch is turned to Keep a data for approx. one hour
display OFF (LOCK). If the engine is hot, the multi center
display might show high tempera-
ture when the display unit is
reconnected after one hour.
54A-68 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade>

2. Diagnosis Function for Audio System

Audio system has the following diagnosis function.
Function Contents

Speaker diagnosis function This function checks if the speakers are all working normally on the audio system or
not.

Service functions There are the following 3 diagnosis modes available.

(1) Check the LCD segments The LCD segments for display available to light on or not.
(2) Check the sensors Outside temperature, voltage of fuel gauge unit and battery, remaining fuel level, fuel
(3) Check units connected economy calculated after refuelling.
into audio system Units connected on display
Voltage on terminal for MUT-II
Engine speed signal, which is sent by ECU
Oscillation of internal clock

3. Speaker Connection Diagnosis

Outline
D This diagnosis function checks whether the more than one wired speakers are normally connected
to the audio unit and the speaker wiring is pinched in the vehicle.
D The test tone sounds from an applicable speaker according to the display (FL, FR, RL, RR).
Function explanation
To diagnose speaker connections, follow the procedure below to enter the test mode.
1. Entry to test mode
(1) Turn the ignition switch to ACC.
(2) Turn off the power supply switch of the audio unit.
(3) Press the “CH1” button.
(4) Press the “Automatic tuning in down button.”
(5) Press the “Automatic tuning in up button.”
(6) Press the “CH6” button. Then the audio unit will enter the test mode.
NOTE
The above operation must be finished within 60 seconds after the power supply switch is turned
off (If 60 seconds have passed, the operation is invalid).
If you fail in the operation, you must push the power supply switch twice to reset the unit. Then
repeat the steps above from step (1).
(7) The test tone will sound at a constant interval. If you want to change an applicable speaker, you
should press the “CH6” button.
2. Cancelling the test mode
The test mode will be canceled by one of the operations below.
D Press any button (except the “CH6” button). In addition, if a mode button (LW/MW/LW, CD, TAPE)
is pressed, the audio unit will enter an applicable function after cancelling the test mode.
D Turn the ignition switch to OFF(LOCK).
 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> 54A-69
4. Service Mode For Multi-center Display
1. Enter and terminate the service mode
(1) To enter the service mode, turn the ignition switch to ACC.
(2) Press the “H” button twice.
(3) Press the “SET” button and (A) button at the same time.
(4) Then the audio unit will enter the service mode.
First of all, the service mode will show model identification for the multi center display and the
vehicle identification. Then the service mode proceeds to three checks; LCD segment check, Sensor
check and Unit check. To switch over these checks, press the “SET” button.
(5) To terminate the service mode, press any button other than the “SET” button.

(A) Button

2. Details of the service mode

The service mode checks the following in that order:
(1) LCD segment check
This screen is divided into four areas. Each area will be active sequentially whenever the “SET”
button is pressed.
When the “SET” button is pressed four times in this screen, the service mode will proceed to
the Sensor check.
(2) Sensor check
This screen shows voltage signals from the outside temperature sensor, the fuel gauge unit, and
the ignition switch as well as fuel economy.
When the “SET” button is pressed once in this screen, the service mode will proceed to the Unit
check.
(3) Unit check connected into audio system
This screen shows an audio equipment, air conditioner or MUT-II connected in the system, percentage
of system voltage, engine speed sent by the engine-ECU, and oscillation of internal clock.
When the “SET” button is pressed once in this screen, the service mode will return to the first
screen (model identification screen).
54A-70 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade>

MAIN UNIT TERMINAL VOLTAGES

1. MULTI-CENTER DISPLAY UNIT

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

1–4 – – – – – –

5 Input ISOK Hi: f f MUT-II cannot be used to check

System engine-ECU.
voltage
Lo: 0 – 1

6 – – – – – –

7 Input/ M–DATA (AUDIO) Hi: 4 – 5 f f Audio display dose not appear. Panel
Output Lo: 0 – 1 switch cannot be operated for audio
unit. Nighttime illumination dose not
appear for audio unit.

8 Input/ M–CLOCK (AUDIO) Hi: 4 – 5 f f Audio display dose not appear. Panel
Output Lo: 0 – 1 switch cannot be operated for audio
unit. Nighttime illumination dose not
appear for audio unit.

9 – 14 – – – – – –

15 Input/ K Hi: f f Values on Trip information screen

Output System (average speed, fuel consumption
voltage and cruising distance) are abnormal.
Lo: 0 – 1 Communication is not possible be-
tween the engine-ECU and the
MUT-II.

16 – – – – – –
 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> 54A-71

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

17 Input/ M–BUSY (AUDIO) Hi: 4 – 5 f f Audio display dose not appear. Panel
Output Lo: 0 – 1 switch cannot be operated for audio
unit. Nighttime illumination dose not
appear for audio unit.

18 – SHIELD–GND – – – –

19 – 22 – – – – – –

23 Input EX–TEMP f f Outside air temperature does not

appear.

24 Input ILL+ Hi: f – Nighttime illumination does not ap-

System pear for any navigation system units.
voltage
Lo: 0 – 1 – f Blown multipurpose fuse.

25 Input ACC (ACC power System f – Screen display does not appear.
supply) voltage
– f Blown multipurpose fuse.

26 Input +B System f – Screen display does not appear.

voltage
– f Blown multipurpose fuse.

27 Input VSS f – No effect.

28 – GND (Ground) – f – Screen display does not appear.

29, 30 – – – – – –

31 – GND–TEMP – f f Outside air temperature does not

appear.

32 – ILL– – – – –

33 Input FUEL GAUGE – f f Abnormal cruising distance display.

34, 35 – – – – – –

36 Input IG1 System f – Communication with engine-ECU is

voltage not possible.
Driving data values displayed are
abnormal.

– f Communication with engine-ECU is

not possible.
Driving data values displayed are
abnormal.
Blown multipurpose fuse.
54A-72 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade>

2. AUDIO UNIT

CD control connector
(DIN cable)
Antenna

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

1 Output SPEAKER 0– f – No sound is output from rear right

RR (+) System speaker.
voltage
(AC) – f No sound is output from rear left and
right speakers.

2 Output SPEAKER 0– f – No sound is output from rear left

RL (+) System speaker.
voltage
(AC) – f No sound is output from rear left and
right speakers.

3 – – – – – –

4 Input ILL (+) Hi: f – Nighttime illumination does not ap-

System pear for audio unit.
voltage
Lo: 0 – 1 – f Blown multipurpose fuse.

5 Output SPEAKER 0– f – No sound is output from front left

FL (+) System speaker.
voltage
(AC) – f No sound is output from front left and
right speakers.

6 Output SPEAKER 0– f – No sound is output from front right

FR (+) System speaker.
voltage
(AC) – f No sound is output from front left and
right speakers.

7 Output SPEAKER 0– f – No sound is output from rear right

RR (–) System speaker.
voltage
(AC) – f No sound is output from rear left and
right speakers.
 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> 54A-73

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

8 Output SPEAKER 0– f – The rear left speaker does not sound.

RL (–) System
voltage – f The rear left and right speakers do
(AC) not sound.

9 – – – – – –

10 Input ACC (ACC power System f – The audio unit power supply does not
supply) voltage turn on.
(System voltage)
– f Blown multipurpose fuse.

11 Input +B System f – Cassette is not ejected when the

(System voltage) voltage ignition switch is at ACC.
The memory are cleared.

– f Blown multipurpose fuse.

12 – ILL (–) – – – –

13 Output SPEAKER 0– f – The front left speaker does not

FL (–) System sound.
voltage
(AC) – f The front left and right speakers do
not sound.

14 Output SPEAKER 0– f – The front right speaker does not

FR (–) System sound.
voltage
(AC) – f The front left and right speakers do
not sound.

21 Input/ M–DATA Hi: f f Panel switches cannot be operated.

Output 4 or more
Lo:
1 or less

22 Input/ M–SCK Hi: f f Panel switches cannot be operated.

Output 4 or more
Lo:
1 or less

23 – 28 – – – – – –

29 Input/ M–BUSY Hi: f f Panel switches cannot be operated.

Output 4 or more
Lo:
1 or less

30 – SHIELD EARTH – – – –
(M–BUS)

31– 36 – – – – – –
54A-74 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade>

INSPECTION CHART CLASSIFIED BY TROUBLE SYMPTOMS

Related Unit Trouble Symptom Inspection Reference
Procedure Page
No.

Malfunction of multi- No display appears after the ignition key is turned to ACC. 1 54A-74
center display
TAPE/CD, UML switches do not work. 2 54A-75

CD switches do not work. 3 54A-76

Outside temperature data is not displayed. /Outside 4 54A-76

temperature data is abnormal.

Abnormal driving data display 5 54A-77

D Abnormal average fuel consumption and average
speed displays.
D Abnormal cruising distance displays

No illumination of audio button 6 54A-78

Dim display 7 54A-78

Clock runs fast or slow 8 54A-78

INSPECTION PROCEDURES FOR EACH TROUBLE SYMPTOM

INSPECTION PROCEDURE 1
No display appears after the ignition key is turned to ACC.

NG
Check the connector: C-52 Repair
OK
YES
Measure at multi-center display connector C-52. Repair the fuse and the harness.
D Ignition switch: ACC
D Voltage between terminal (25), (26) and body earth
OK: System voltage
NO
OK
Measure at multi-center display connector C-52. Repair the harness.
D Check continuity between terminal (28) and body earth.
OK: Continuity exists
NG

Replace the multi-center display unit.

 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> 54A-75
INSPECTION PROCEDURE 2
TAPE/CD, UML switches do not work.

NG Measure at multi center display connec- NG Replace the multi-center display.

Check cassette function with LOAD- tor C-54.
ING/EJECT D Ignition switch: ACC
OK D Voltage between terminal (10), (11)
and body earth
OK: System voltage
OK

Replace the audio unit

OK OK
Check the audio unit connected in sys- Check the detachable key panel. Replace the audio unit.
tem on service mode. (dust or broken button etc.)
Is it available to check?
NG
NG
Replace the key panel and repair
OK
Check the connectors: C-53, C-54 Repair the harness.
OK

NO OK
Are there any audio set as option? Check output signals on the connector Replace the multi-center display unit.
in multi-center display unit side.
YES D Disconnect C-53 connector for
NG M-BUS
Check the reoccurrence of symptom D Monitor output signals on 7, 8, 17
when DIN cable is out. terminal of C-53 connector.
OK NG
OK
Check output signals on the connector Repair the harness.
in audio unit side.
D Disconnect C-54 connector for
M-BUS
D Monitor output signals on 21, 22,
29 terminal of C-54 connector.
NG

Replace the audio unit.

NG
Check the DIN cable. Replace the DIN cable.
OK

Replace the option audio.

54A-76 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade>

INSPECTION PROCEDURE 3
CD switch do not work.

NG
Check the connectors: DIN connector Repair
between audio unit and CD changer.
OK
NG OK
Check the magazine with LOADING/ Check voltage on connector for CD Repair the fuse and the harness.
EJECT function and if lamp light on changer terminal of +B and ACC
the panel. D Ignition switch : ACC
OK: System voltage
OK
NG
OK
Check a signal on connector in CD Replace the CD changer.
changer
D Take out DIN connector from CD
changer.
D Monitor any signals of MBUSY,
MDATA or MSCK terminal for
M-BUS.
NG
OK
Check output signals on connector in Replace the CD changer.
audio unit side.
D Take out DIN connector from audio
unit.
D Monitor any signals of MBUSY,
MDATA or MSCK terminal for
M-BUS.
NG

Replace the audio unit.

INSPECTION PROCEDURE 4
Outside air temperature data is not displayed. /Outside air temperature data is abnormal.

NG
Check the connector: C-52 Repair
OK
NO
Does the multi-center display unit show the vehicle identifications Replace the multi-center display unit.
correctly?
YES
YES
Does the service mode show outside air temperature correctly? End (no abnormality)
NO If the vehicle is driven in places where outside temperature varies
much, an incorrect temperature may be displayed. In that case,
drive the vehicle for a while so that the display shows a correct
temperature.
In addition, if the engine is hot after the battery is replaced or
the multi-center display unit is reinstalled, an incorrect temperature
may be displayed.

Check the harness between the multi-center display and the out- NG Repair
side temperature sensor.
OK
OK
Check the outside thermo sensor. (Refer to P.54A-29.) Replace
OK

Replace the multi-center display unit.

 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> 54A-77
INSPECTION PROCEDURE 5
Abnormal driving data displays.
D Abnormal average fuel consumption and average speed displays.
D Abnormal cruising distance displays.

1. When average fuel consumption and average speed displays are abnormal.
NG
Check the connector: C-52 Repair
OK
YES NG
Check the multi-center display unit con- Check a voltage on (5) terminal of C-53 Check the harness.
nected into system on service mode. connector after C-53 connector shall
Disconnect MUT-II
Does MU light on the display? be out.
D ignition switch : ON
NO OK: Low
OK NG: more than 80% of system
Measure at multi-center display con- voltage
nector C-52.
D Connector disconnected.
NG
D Voltage between terminal (36) and Check the harness between multi-cen-
body earth ter display unit and junction block and
OK: Ignition switch ON: System Replace the if necessary.
voltage
NG: Ignition switch OFF: 0 – 1 V
OK
OK
Check the connections between the Replace the multi-center display unit.
multi-center display unit and the en-
gine-ECU.
NG

Check the harness between the multi-

center display unit and the engine-ECU,
and Replace the if necessary.

2. When cruising distance display is abnormal.

NG
Are the average fuel consumption and average vehicle speed Carry out troubleshooting according to procedure 5.1.
displayed normally?
OK
YES
Does the service mode show fuel amount correctly? End (no abnormality)
NO An inaccurate fuel amount may be displayed for a while after
refuelling.
In addition, it depends on road and driving conditions whether an
accurate fuel amount is displayed.

NG
Measure at multi-center display connector C-52. Check the harness between multi-center display unit and the fuel
D Connector disconnected. gauge unit, and Replace the if necessary.
D Voltage between terminal (33) and body earth
OK: 0.1 – 3.0 V Relative unit : Combination meter, fuel gauge unit
OK

Replace the multi-center display unit.

54A-78 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade>

INSPECTION PROCEDURE 6
No illumination for audio buttons light on.

NO OK
Check if the brightness of display Measure at multi-center display con- Replace the multi-center display.
changes when the lighting switch is on nector C-52.
or off. D Connector disconnected.
YES D Voltage between terminal (24) and
body earth NG
OK: System voltage Repair the fuse and the harness.

NO
Check the function for RADIO/TAPE/CD Carry out troubleshooting according to
YES procedure 2.

OK
Measure at the audio unit connector Replace the audio unit.
B-11.
D Connector disconnected.
D Rheostat : max
D Voltage between terminal (12) and
body earth NG
OK: Low (0 – 3 V) Repair the harness.

INSPECTION PROCEDURE 7
Dim display

NO OK
Check the brightness of display to Measure at multi-center display con- Replace the multi center display.
change, when lighting switch is on or nector C-52.
off. D Connector disconnected.
YES D Voltage between terminal (24) and
body earth NG
OK: System voltage (ILL ON) Repair the fuse and the harness.
0 V (ILL OFF)
NO
Check the setting position for bright- Adjust brightness of display on setting
ness on display, is it correct? mode.
YES

OK
Measure at the multi-center display unit Replace the multi-center display unit.
connector C-52.
D Connector disconnected.
D Rheostat : max
D Voltage between terminal (32) and
body earth NG
OK: Low (0 – 3 V) Repair the harness.

INSPECTION PROCEDURE 8
Clock runs fast or slow/indicate different time

NG
Measure at multi-center display con- Repair the fuse and the harness.
nector C-52.
D Ignition switch : LOCK (OFF)
position
D Voltage between terminal (26) and
body earth
OK: System voltage
YES
YES YES
Does CT segment light on the display? Does it receive a radio station on differ- Turn off the CT function.
NO ent region where has time lag?
NO

Replace the multi-center display.

 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> 54A-79
MULTI-CENTER DISPLAY
REMOVAL AND INSTALLATION
View A

1
3
2

View A Section A – A
1 Section B – B
1
A A Instrument panel

B Clip Instrument panel

B Clip

: shows tabs.
: shows clips.

Removal steps
1. Center display hood 3. Multi-center display
2. Bracket
54A-80 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

MULTI-CENTER DISPLAY <HIGH GRADE>

TROUBLESHOOTING
NOTES WITH REGARD TO SERVICE PROCEDURES
1. Before removing the battery
The multi-center display has a large amount of data stored in memory which the user enters over
time. When the terminals are disconnected from the battery, the memory which stores this data is
affected as shown in the table below. Accordingly, it is necessary to make sure that you take notes
of important information before disconnecting the battery.

Function Input function When battery is disconnected

Radio function Channels which are selected during a search Disappear after a few seconds

Preset channels Do not disappear

Navigation function Current location

Recommended route

Destination

Route search conditions

Sensor initialization data

Language selection setting

Guidance volume setting

Data search function, Registered location names

data display and input
functions Past destinations

Average fuel consumption, average speed, Disappear after a few seconds

cruising range

Clock display function Current time

Vehicle model settings Setting details for vehicle model

for travel data

Monitor backlight Luminance setting value

luminance setting

2. Notes on trouble diagnosis relating to the overall system

(1) If a problem occurs which seems like all of the functions have developed an abnormality simultaneously,
the cause is most likely a communication abnormality between the various systems. Thus you should
use the communication checking service function in the trouble diagnosis service functions in order
to verify the cause.
 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-81
(2) If the above is not the problem, check the connections of the related harness connectors. If a malfunctioning
location is discovered, repair it and then re-check the trouble symptoms.
(3) If there are no abnormalities in the harness connections, check the harnesses themselves. If there
are no abnormalities in the harnesses, replace the relevant unit. Make a note of any error codes
and service function data generated at this time.
NOTE
If the cause of the problem seems to be related to system communication, carry out troubleshooting.
3. Notes on trouble diagnosis when only specific functions are abnormal
(1) If only certain functions are showing an abnormality, use the audio checking function of the service
functions to check the hardware switches.
(2) If the switch functions are normal, check the connections of the related harness connectors. If a
malfunctioning location is discovered, repair it and then re-check the trouble symptoms.
(3) If there are no abnormalities in the harness connections, check the harnesses themselves. If there
are no abnormalities in the harnesses, replace the unit which controls that function.
4. Notes on trouble diagnosis of the navigation function
(1) The vehicle positioning accuracy of the navigation function is limited because of the principle of operation
which it uses. Because of this, the system may be operating normally even though customers might
be reporting a problem.
Before carrying out troubleshooting, get as much information as possible from the customer regarding
things such as usage conditions and driving locations. If it is possible to judge from this that the problem
is not caused by a system abnormality, explain the principle of operation used by the navigation function
and how to utilize it effectively.
(2) If you find that there is a system abnormality, check according to the Inspection Chart Classified by
Trouble Symptoms in the Troubleshooting section.
MITSUBISHI MULTI COMMUNICATION SYSTEM DISPLAY PANEL

F3 switch F4 switch

F2 switch F5 switch

F1 switch F6 switch
54A-82 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

TROUBLE DIAGNOSIS SERVICE FUNCTIONS

The Multi-center Display is equipped with the following trouble diagnosis service functions.
Function Contents

Diagnosis function During normal use, this function constantly monitors the system communication lines,
and displays an error if it finds any abnormalities.

CD-ROM checking function This function displays a message if it cannot read the CD-ROM or if no CD-ROM is
inserted.

Service functions There are five checking modes available: monitor checking, audio checking, automatic
checking by mode, self-diagnosis and diagnosis recording.
1. Monitor checking This mode checks that the image display function is operating normally.
2. Audio checking This mode checks that the speakers and operating switches of the audio system are
all working normally.
3. Automatic diagnosis by In this mode, wiring and communication checking, audio checking, sensor checking
mode and vehicle signal checking are carried out continuously.
4. Self-diagnosis This mode includes functions such as wiring and communication checking, sensor
checking, vehicle signals and version data checking.
D Wiring and commu- This checks system communication between all units.
nication checking
D Sensor checking This checks all of the sensors that are necessary to the navigation system.
D Vehicle signals This displays the current vehicle signal condition.
D Version data This displays the version numbers for each unit in the Multi Center Display.
5. Diagnosis recording This mode displays error codes from communication checking. (Error codes are
erased when the ignition switch is turned to OFF.)

1. ACTIVATING AND ENDING SERVICE MODE

(1) Activating service mode can be carried out by turning
the ignition switch to the ON position while pressing the
DISP switch on the audio unit and the F6 switch. (Continue
pressing each switch for at least 5 seconds after turning
the ignition switch to ON.)
(2) If the special CD-ROM has been inserted into the
navigation unit but the program has not been set up, the
program will then be loaded from the CD-ROM. Service
mode can be used once this process is completed.
NOTE
The special CD-ROM is a map CD-ROM which a distributor
vends.
CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-83
(3) If the F1 switch is pressed at the service mode initial screen,
service mode will be ended and the screen will change to
navigation mode.

2. AUTOMATIC DIAGNOSIS BY MODE

(1) If the F3 switch is pressed at the service mode screen,
automatic diagnosis by mode will start.

(2) A colored bar will appear on the screen of the Multi-center

Display unit, and all units which are connected to the
navigation unit will be checked during this time.

(3) Once the transmission checking is completed, the results

of the wiring and transmission checking will appear on the
screen.
After checking the results, press the F1 switch to proceed
to the next check. The next check will start when the switch
is pressed.
NOTE
1) If the fuel gauge and the engine-ECU are checked
while the ignition switch is at ACC, an error will be
generated, but this is not a sign of an abnormality.
2) If checking is carried out while the fuel tank is full
or the while ignition switch is at ACC, the fuel gauge
may be shown to be not connected, but this is not
a sign of an abnormality.
54A-84 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

(4) The next mode is the sensor checking mode. Press the
F1 switch to start sensor checking.
If you would like to proceed to the next checking operation
without carrying out sensor checking, press the F6 switch.

(5) When sensor checking starts, the gyro output will be

checked first while the vehicle is stopped, so make sure
that the vehicle is stopped for this check.
If the vehicle is moving when the sensor checking starts,
the vehicle speed sensor will be shown as defective.
Follow the guidance message on the multi-center display.

(6) Next, drive the vehicle for approximately 10 meters while

changing the running direction in order to check the vehicle
speed pulse and the gyro sensor output. The sensor
checking will then be completed. If there is an open circuit
in the vehicle speed sensor, sensor checking will not
complete even after the vehicle has travelled more than
10 meters. In this case, press the F5 switch to stop
checking.
If the vehicle does not move or there is an open circuit
in vehicle speed sensor, the vehicle speed sensor will
be shown as defective.

(7) When sensor checking is completed, the check results will

appear on the screen. After checking the results, press the
F1 switch to proceed to the next check.

(8) The next mode is the vehicle signal checking mode. The
lighting switch condition, ignition key position, shift lever
selection (R or a position other than R) and the power
supply voltage drop will be appear on the screen. Check
that the details displayed match the actual vehicle signals,
and then press the F1 switch.
If the vehicles does not move or there is an open circuit
in vehicle speed sensor, the vehicle speed sensor will
be shown as defective.
CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-85
(9) The next mode is speaker checking mode. The test sound
will be output alternately from each speaker each time
the F2 switch is pressed.
At the early mass production, sometimes radio sound will
be output. This is not a sign of abnormality.

(10)Press the F1 switch to end service mode. The screen

will change to navigation mode.

3. MONITOR CHECKING
(1) If the F6 switch is pressed at the service mode initial
screen, monitor checking will start.
54A-86 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

(2) A colored bar will appear on the screen.

Press a function switch to change to another screen. The
screen will return to the service mode initial screen if the F1
switch is pressed.

4. AUDIO CHECKING
(1) If the F5 switch is pressed at the service mode initial
screen, the audio checking menu screen will appear.

(2) Next, press the function switches to carry out audio

checking.
CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-87
(3) Press the F3 switch to display the speaker checking screen.
The test sound will be output alternately from each speaker
each time the F2 switch is pressed.
Press the F1 switch to end speaker checking and return to
the audio checking menu screen.
At the early mass production, sometimes radio sound will
be output. This is not a sign of abnormality.

(4) Press F4 to display the audio key checking screen.

When one of the audio switches is pressed, the screen
display color for that switch should change. This indicates
that this particular switch system is working normally.
Press the F1 switch to check the operation of the F1 switch.
Press the F1 switch once more to return to the audio
checking menu screen.

5. SELF-DIAGNOSIS
(1) If the F5 switch is pressed at the service mode initial
screen, the self-diagnosis menu screen will appear.

(2) Next, use the function switches to carry out self-diagnosis.

(3) When the F5 switch is pressed, self-diagnosis for the wiring

is carried out.
A colored bar will appear on the screen of the Multi-center
Display unit, and all units which are connected to the
navigation unit will be checked during this time.
54A-88 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

(4) Once the transmission checking is completed, the results

of checking will appear on the screen.
After checking the results, press the F1 switch to return to
the self-diagnosis menu screen.

(5) If the F6 switch is pressed at the self-diagnosis menu

screen, sensor checking will start.
Press the F1 switch to start sensor checking.
If you would like to return to the self-diagnosis menu screen
without carrying out sensor checking, press the F5 switch.

(6) When sensor checking starts, the gyro output will be

checked first while the vehicle is stopped, so make sure
that the vehicle is stopped for this check.
If the vehicle is moving when the sensor checking starts,
the vehicle speed sensor will be shown as defective.
Follow the guidance message on the multi-center display.

(7) Next, drive the vehicle for approximately 10 meters while

changing the running direction in order to check the vehicle
speed pulse and the gyro sensor output. The sensor
checking will then be completed. If there is an open circuit
in the vehicle speed sensor, sensor checking will not
complete even after the vehicle has travelled more than
10 meters. In this case, press the F5 switch to stop
checking.
If the vehicle does not move or there is an open circuit
in vehicle speed sensor, the vehicle speed sensor will
be shown as defective.
CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-89
(8) When sensor checking is completed, the check results
will appear on the screen. After checking the results, press
the F1 switch to return to the self-diagnosis menu screen.

(9) If the F6 switch is pressed at the self-diagnosis menu

screen, vehicle signal checking will start.
The lighting switch condition, ignition key position, shift
lever selection (R or a position other than R) and the
power supply voltage drop will be appear on the screen.
Press the F1 switch to return to the self-diagnosis menu
screen.

If the F2 switch is pressed at the self-diagnosis menu

screen, version data self-diagnosis will be carried out,
and the check results will appear on the screen.
Press the F1 switch to return to the self-diagnosis menu
screen.

6. DIAGNOSIS RECORDING
(1) If the F6 switch is pressed at the service mode initial
screen, the diagnosis recording screen will appear.
(2) Press the F1 switch to return to the service mode initial
screen.

(3) Press the F6 switch to clear any error codes which may
still be remaining from diagnosis recording.
When this is done, the clearing confirmation screen will
appear. If it is okay to continue with the clear, press the
F5 switch. To cancel clearing, press the F6 switch.
If the F6 switch is pressed, the screen will return to the
diagnosis recording screen.
54A-90 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

(4) If the F5 switch is pressed, all past error codes will be

cleared, and the screen will return to the diagnosis
recording screen. The Clear button will not be displayed
at this time.

(5) Press the F1 switch to return to the service mode initial

screen.

7. ERROR CODE TABLE

Error Code No. Error Details Detection Method (Reference) Reference

Page
1011 Ambient temperature sensor not connected Connection checking 54A-105
during diagnosis
1021 Fuel gauge not connected during diagnosis Connection checking 54A-106
1031 GPS abnormality during diagnosis Connection checking 54A-106
1041 Engine-ECU not connected during diagnosis Connection checking 54A-106
1051 SWS not connected during diagnosis Connection checking 54A-106
(This error does not occur when correct car
type is set)
1091 CD drive too hot during diagnosis Connection checking 54A-106
1092 – 1096 CD drive abnormality during diagnosis Connection checking 54A-107
10A1, 10B1 Memory of navigation unit abnormality during Connection checking 54A-107
diagnosis
20D1, 30D1 Vehicle speed pulse abnormality during Sensor checking 54A-107
diagnosis
20E1, 20E2, Gyro level abnormality during diagnosis Sensor checking 54A-107
30E1, 30E2
 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-91
MAIN UNIT TERMINAL VOLTAGES
1. MULTI-CENTER DISPLAY UNIT

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

1 Input G+SYTNC (AUDIO) – f f Noise display (random dot pattern)

2 Input B+SYNC (AUDIO) – f f Blue, white, cyan and magenta do not

appear in RGB screen.

3, 4 – – – – – –

5 Input ISOK Hi: f f MUT-II cannot be used to check

System engine-ECU.
voltage
Lo: 0 – 1

6 Input/ DATA Hi: f f Switch operation sound buzzer does

Output System not peep.
voltage
Lo: 0 –1

7 Input/ M–DATA (AUDIO) Hi: 4 – 5 f f Buzzer sounds 30 seconds after the

Output Lo: 0 – 1 power turned to on. Nighttime
illumination does not appear for any
navigation system.

8 Input/ M–CLOCK (AUDIO) Hi: 4 – 5 f f Buzzer sounds 30 seconds after the

Output Lo: 0 – 1 power turned to on. Nighttime
illumination does not appear for any
navigation system.

9, 10 – – – – – –

11 – SHIELD–GND – – – –

12 – – – – – –
54A-92 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

13 Input R+SYNC (AUDIO) – f f Red, white, yellow and magenta do

not appear in RGB screen.

14 – – – – – –

15 Input/ K Hi: f f Values on Trip information screen

Output System (average speed, fuel consumption
voltage and cruising distance) are abnormal.
Lo: 0 – 1 Wiring and communication error.
Communication is not possible be-
tween the engine-ECU and the
MUT-II.

16 – – – – – –

17 Input/ M–BUSY (AUDIO) Hi: 4 – 5 f – Screen display does not appear.

Output Lo: 0 – 1
– f Buzzer sounds 30 seconds after the
power turned to on. Nighttime
illumination does not appear for any
navigation system.

18 – SHIELD–GND – – – –

19 – 21 – – – – – –

22 Input PS–R Hi: f f Current location is not correct when

System reversing.
voltage
Lo: 0 – 1

23 Input EX–TEMP 0–5 f f Outside air temperature does not

appear.

24 Input ILL+ Hi: f – Nighttime illumination does not ap-

System pear for any navigation system units.
voltage
Lo: 0 – 1 – f Blown multipurpose fuse.

25 Input ACC (ACC power System f – Screen display does not appear.
supply) voltage
– f Blown multipurpose fuse.

26 Input +B System f – Screen display does not appear.

voltage
– f Blown multipurpose fuse.

27 Input VSS Hi: 4 – 5 f – No effect.

Lo: 0 – 1

28 – GND (Ground) – f – Screen display does not appear.

29, 30 – – – – – –

31 – GND–TEMP – f f Outside air temperature does not

appear.

32 – ILL – – – – –

33 Input FUEL GAUGE 0–3 f f Abnormal cruising distance display.

 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-93

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

34, 35 – – – – – –

36 Input IG1 System f – Communication with engine-ECU is

voltage not possible.
Driving data values displayed are
abnormal.

– f Communication with engine-ECU is

not possible.
Driving data values displayed are
abnormal.
Blown multipurpose fuse.

2. NAVIGATION UNIT

DIN cable (to audio unit)

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

1–3 – – – – – –

4 Input VEHICLE SPEED Voltage f f Compass display does not change

PULSE should when not following a route.
change Guide does not appear when follow-
when ing a route.
wheels
are
turning.
Hi: 4 – 5
Lo: 0 – 1

5 Input +BATTERY System f – Navigation does not operate.

voltage
– f Blown fuse in +B system.

6 Input ACCESSORY System f – Navigation does not operate.

voltage
– f Blown fuse in ACC system.

7 – 11 – – – – – –

12 – GND – f – Navigation sometimes does not

operate.
54A-94 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

3. AUDIO UNIT
CD control connector
(DIN cable)
Antenna

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

1 Output SPEAKER 0– f – No sound is output from rear right

RR (+) System speaker.
voltage
(AC) – f No sound is output from rear left and
right speakers.

2 Output SPEAKER 0– f – No sound is output from rear left

RL (+) System speaker.
voltage
(AC) – f No sound is output from rear left and
right speakers.

3 – – – – – –

4 Input ILL (+) Hi: f – Nighttime illumination does not ap-

System pear for audio unit.
voltage
Lo: 0 – 1 – f Blown multipurpose fuse.

5 Output SPEAKER 0– f – No sound is output from front left

FL (+) System speaker.
voltage
(AC) – f No sound is output from front left and
right speakers.

6 Output SPEAKER 0– f – No sound is output from front right

FR (+) System speaker.
voltage
(AC) – f No sound is output from front left and
right speakers.

7 Output SPEAKER 0– f – No sound is output from rear right

RR (–) System speaker.
voltage
(AC) – f No sound is output from rear left and
right speakers.
 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-95

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

8 Output SPEAKER 0– f – No sound is output from rear left

RL (–) System speaker.
voltage
(AC) – f No sound is output from rear left and
right speakers.

9 – – – – – –

10 Input ACC (ACC power System f – Audio power supply does not turn on.
supply) voltage
(Battery voltage) – f Blown multipurpose fuse.

11 Input +B System f – Cassette is not ejected when ACC

(Battery voltage) voltage power turned off.
Contents of memory are cleared.

– f Blown multipurpose fuse.

12 Input ILL (–) – – – –

13 Output SPEAKER 0– f – No sound is output from front left

FL (–) System speaker.
voltage
(AC) – f No sound is output from front left and
right speakers.

14 Output SPEAKER 0– f – No sound is output from front right

FR (–) System speaker.
voltage
(AC) – f No sound is output from front left and
right speakers.

21 Input/ M–DATA Hi: f f Panel switches cannot be operated.

Output 4 or more
Lo:
1 or less

22 Input/ M–SCK Hi: f f Panel switches cannot be operated.

Output 4 or more
Lo:
1 or less

23 – – – – – –

24 Output G+SYNC 0–5 f f Abnormal navigation screen color.

25 Output B+SYNC 0–5 f f Abnormal navigation screen color.

26 – 28 – – – – – –

29 Input/ M–BUSY Hi: f f Panel switches cannot be operated.

Output 4 or more
Lo:
1 or less

30 – SHIELD EARTH – – – –
(M–BUS)
54A-96 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from
nal No.
No Output Voltage Harness Problem
(V) Open Short-
Circuit circuit

31 – – – – – –

32 – SHIELD EARTH – – – –

33 – – – – – –

34 Output R+SYNC 0–5 f f Abnormal navigation screen color.

35, 36 – – – – – –

INSPECTION CHART CLASSIFIED BY TROUBLE SYMPTOMS

Related Unit Trouble Symptom Inspection Reference
Procedure Page
No.

Malfunction of navigation TAPE/CD, UML switches do not work. No display appears 1 54A-97
unit, multi-center display, after the ignition key is turned to ACC.
audio unit and related
sensor, harness TAPE/CD, UML switches do not work. (Display appears.) 2 54A-99

No display appears after the ignition key is turned to ACC, 3 54A-100

but TAPE/CD, UML switches can be operative.

CD changer screen display does not appear when 4 54A-101

TAPE/CD switch is operated.

GPS reception is not possible. 5 54A-101

Outside air temperature data is not displayed. 6 54A-101

Abnormal driving data display 7 54A-102

D Abnormal average fuel consumption and average
speed displays.
D Abnormal cruising distance displays

Display moves about. 8 54A-103

Screen colours do not match correctly.

Daytime/nighttime display mode does not change in 9 54A-103

conjunction with lighting switch operations.

Compass display does not rotate , or guidance does not 10 54A-104

appear when following a route.

One of the following messages appears during navigation 11 54A-104

mode.
D The CD drive has failure condition. Check and reload
the disc, please.
D Wrong disc is in the CD drive. Insert a map disc,
please.
D No disc is in the CD drive. Insert a map disc please.
D A music disc is in the CD-drive.
 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-97
INSPECTION PROCEDURES FOR EACH TROUBLE SYMPTOM
INSPECTION PROCEDURE 1
TAPE/CD, UML switches do not work. No display appears after the ignition key is turned to ACC.

NG
Check connectors: C-11, C-53, C-54 Repair
and DIN connectors between audio and
navigation unit
OK
YES OK
Turn off the ignition key and turn to ACC Disconnect multi-center display con- Replace the multi-center display.
position again. Does any screen appear nector C-53.
about 30 seconds after it? D Ignition switch: ACC
D Measure waveform at terminal (7),
NO
(8), (17) of harness connector with
an oscilloscope.
OK: Hi: 4 – 5 V, Lo: 0 – 1 V,
pulse signal
NG
NG
Check the harness between audio C-54 Repair
and multi-center display C-53 connector.
OK
NO
Does the sound turn on/off when the Measure at audio unit connector C-53.
audio VOL/POWER switch operated? D Ignition switch: ACC
YES D Voltage between terminal (10), (11)
NG and body earth
OK: System voltage
OK

Replace the audio unit.

Repair fuse or harness.

NG
Check the DIN cable between audio Replace the DIN cable.
and navigation unit.
OK

Replace the navigation unit.

NG
Measure at the multi-center display Repair fuse or harness.
connector C-52.
D Ignition switch: ACC
D Voltage between terminal (25), (26)
and body earth
OK: System voltage
OK
NG
Check the harness between audio C-54 Repair
and multi-center display C-52 connec-
tor.
OK
NG
Check the DIN cable between audio Replace the DIN cable.
and navigation unit.
OK

To next page
54A-98 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

From previous page

NG NG
Disconnect DIN 20-pin connector from Measure at the navigation unit connec- Repair fuse or harness.
the navigation unit. tor C-50.
D Ignition switch: ACC D Ignition switch: ACC
D Measure waveforms of terminal (8), D Voltage between terminal (5), (6) OK
(15), (17) of navigation unit and body earth Replace the audio unit.
connector with an oscilloscope. OK: System voltage
OK: 2 Vpp (AC) 15.75kHz video
signal
OK
NG
Connect the disconnected connector. Replace the audio unit.
Measure at the multi-center display
connector C-53.
D Ignition switch: ACC
D Measure waveforms of terminal (1),
(2), (13) of navigation unit connector
with an oscilloscope.
OK: 2 Vpp (AC) 15.75kHz video
signal
OK
NO NG
Does the sound turn on/off when the Measure at audio unit connector C-11. Repair fuse or harness.
audio VOL/POWER switch operated? D Ignition switch: ACC
D Voltage between terminal (10), (11)
YES
and body earth
OK: System voltage
OK

Replace the audio unit.

NG
Turn off the ignition key and turn to ACC Replace the multi-center display.
position again.
Does the buzzer sound “PiPi, PiPi, PiPi”
after about 30 seconds?
OK

Replace the navigation unit.

 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-99
INSPECTION PROCEDURE 2
TAPE/CD, UML switches do not work. (Display appears.)

NG
Check connectors: C-11, C-53, C-54 Repair
and DIN connectors between audio and
navigation unit
OK
NO NG
Does the audio sound turn on or off Measure at audio unit connector C-11. Repair fuse or harness.
when operate VOL/POWER switch? D Ignition switch: ACC
D Voltage between terminal (10), (11)
YES
and body earth
OK: System voltage
OK
Replace the audio unit.
NG
Check the harness between audio C-54 Repair
and multi-center display B-09 connector.
OK
NG
Check the DIN cable between audio Replace the DIN cable.
and navigation unit.
OK
NO
Are the result of key checking (audio Malfunction of operation switch.
switch checking in the service function) Replace the audio unit.
normal?
YES
NO YES
Does the navigation screens appear Insert a map CD-ROM. Does the mes- Check again after program-loading is
when NAVI switch is pressed? sage “loading the program” appear? done. If same error happen, replace
navigation unit.
YES NO

Replace the navigation unit.

YES
Is a CD changer connected? Check the connector of CD changer and
NO DIN connector between navigation unit
and CD changer.
YES
Does the sound change in accordance Replace the navigation unit.
with the switch operation?
NO

Replace the audio unit.

54A-100 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

INSPECTION PROCEDURE 3
No display appears after the ignition key is turned to ACC, but TAPE/CD, UML switches can be
operative.

NG
Check connectors: C-11, C-53, C-54 Repair
and DIN connectors between audio and
navigation unit
OK
NO OK
Turn off the ignition key and turn to ACC Measure at the multi-center display Measure at the multi-center display
position again. Does any screen appear connector C-53. connector C-52.
about 30 seconds after it? D Ignition switch: ACC D Ignition switch: ACC
D Measure waveforms of terminal (1), D Voltage between terminal (25), (26)
YES (2), (13) of multi-center display and body earth
connector. OK: Battery voltage
OK: 0 – 2 Vpp 15.75kHz
OK NG
video signal
Repair fuse or harness.
NG

Replace the multi-center display.

NG
Check the harness between audio C-54 Repair
and multi-center display C-53 connector.
OK
NG
Check the DIN cable between audio Replace the DIN cable
and navigation unit.
OK
OK
Disconnect DIN 20-pin connector from Replace the audio unit.
the navigation unit.
D Ignition switch: ACC
D Measure waveforms of terminal (8),
(15), (17) of navigation unit
connector with an oscilloscope.
OK: 2 Vpp (AC) 15.75kHz video
signal
NG

Replace the navigation unit.

OK
Disconnect at the multi-center display Replace the multi-center display.
connector C-53.
D Ignition switch: ACC
D Measure waveforms of terminal (7),
(8), (17) of harness connector with
an oscilloscope.
OK: Hi: 4 – 5 V, Lo: 0 – 1 V
pulse signal
NG
NG
Check the harness between audio C-54 Repair
and multi-center display B-09 connector.
OK
NG
Check the DIN cable between audio Replace the DIN cable
and navigation unit.
OK

Replace the navigation unit.

 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-101
INSPECTION PROCEDURE 4
CD changer screen displays do not appear when TAPE/CD switches are operated.

NG
Check connectors: C-54 and naviga- Repair
tion unit DIN connector
OK
YES NO
Does radio reception occur and does Are the results of the hardware switch Replace the audio unit.
the screen change when the UML checking using the audio switch check-
switch is pressed ing function (service function) normal?
NO YES

Replace the navigation unit. Replace the CD changer.

INSPECTION PROCEDURE 5
GPS reception is not possible.

NO
Is the vehicle in a good reception area? Move the vehicle to a good reception area.
YES
NO
Turn the ignition switch to ACC, and then wait for about 5 minutes. End (no abnormality)
Is GPS reception still not possible?
YES

Replace the multi-center Display unit.

INSPECTION PROCEDURE 6
Outside air temperature data is not displayed.

NG
Check connectors: A-28, C-28, C-52 Repair
OK
NO YES
Carry out a wiring check (service func- Is the selected model is correct? End (no abnormality).
tion). NO
Does the message “Outside air temper-
ature sensor not connected” appear? Select correct model, and repeat wiring
YES check.
OK
Check the connections between the Replace the multi-center display.
multi-center display unit and the outside
air temperature sensor.
NG

Check the harness between the multi-

center display unit and the outside air
temperature sensor, and replace if nec-
essary.
54A-102 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

INSPECTION PROCEDURE 7
Abnormal driving data displays.
D Abnormal average fuel consumption (momentary fuel consumption) and average speed displays.
D Abnormal cruising distance displays.

1. When average fuel consumption (momentary fuel consumption) and average speed displays
are abnormal.
NG
Check connectors: C-02 <L.H. drive Repair
vehicles>, C-52, C-74, C-76
OK
NO
Carry out a wiring and communication End (no abnormality).
check (service function).
Does the message “Engine-ECU not
connected” appear?
YES
NO NG
Carry out a vehicle signals check (ser- Measure at the multi-center display Check the harness between multi-cen-
vice function). connector C-52. ter display and the junction block, and
Does the message “Key position : IG” D Connector disconnected. replace if necessary.
appear? D Voltage between terminal (36) and
body earth
YES OK
OK: Ignition switch ON:
System voltage. Replace the multi-center display.
Ignition switch OFF: 0 – 1 V

OK
Check the connections between the Replace the multi-center display.
multi-center display and the engine-
ECU.
NG

Check the harness between the multi-

center display and the engine-ECU,
and replace if necessary.

2. When cruising distance display is abnormal.

NO
Are the average fuel consumption and Carry out troubleshooting according to
average vehicle speed displayed nor- procedure 1.
mally?
YES
NO
Is the selected model is correct? Select correct model, and repeat wiring
check.
YES
NG OK
Measure at the multi-center display Check the fuel gauge unit. Check the harness between multi-cen-
connector C-52. (Refer to P.54A-25.) ter display and the fuel gauge unit, and
D Connector disconnected. NG replace if necessary.
D Voltage between terminal (33) and
body earth
OK: 0.1 – 3.0 V Replace the fuel gauge unit.
OK

Replace the multi-center display.

 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-103
INSPECTION PROCEDURE 8
Display moves about.
Screen colors do not match correctly.

NG
Check connectors: C-50, C-52, C-53, C-54 and DIN connectors Repair
between navigation unit and audio unit
OK
YES
Do red, blue and green colors appear in the monitor color bar End (no abnormality)
service function?
NO
OK
Check the RGB wave pattern at terminal (1) of the C-53 multi-center Replace the multi-center display unit.
display harness-side connector.
NG
OK
Check the RGB wave pattern at terminal (24) of the C-54 audio Check the harness between B-09 and B-04, and repair if necessary.
unit harness-side connector.
NG
OK
Check the RGB wave pattern at the DIN connector at the audio Replace the audio unit.
unit side of the cable between the audio unit and the navigation
unit.
NG
NG
Check the RGB wave pattern at the DIN connector at the navigation Replace the navigation unit.
unit side of the cable between the audio unit and the navigation
unit. OK
Replace the DIN connector.

INSPECTION PROCEDURE 9
Daytime/nighttime display mode does not change in conjunction with lighting switch operations.

NG
Check connector: C-52 Repair
OK
YES
Carry out a vehicle signal check (service function). End
Does LIGHT SW: ON appear when the lighting switch is ON,
and LIGHT SW: OFF appear when the lighting switch is off?
NO
OK
Measure at the C-52 multi-center display unit connector. Replace the multi-center display unit.
D Connector connected
D Voltage between terminal (24) and body ground
OK:Hi: 10 V or higher, Lo: 0 – 1 V
NG

Check the harnesses between the multi-center display unit and

the ETACS-ECU <vehicles with DRL> or front-ECU (tail lamp
relay) <vehicles without DRL >, and replace if necessary.
54A-104 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

INSPECTION PROCEDURE 10
Compass display does not change when not following a route, or guide does not appear when
searching for and following a route.

NG
Carry out a sensor check (service function). If no vehicle speed is input, the sensor check does not complete.
OK
NO
Carry out a vehicle signal check (service function). End (no abnormality)
D Does “Shift position: R” appear when the shift position is R?
D Does “Shift position: Except R” appear when the shift position
is not R?
YES
NG
Measure at the C-52 multi-center display unit connector. Check the harness between the back-up lamp switch and the
D Connector disconnected multi-center display unit, and repair if necessary.
D Voltage between terminal (22) and body ground
OK: 10 V or higher when shift position is R
OK

Replace the multi-center display unit.

INSPECTION PROCEDURE 11
One of the following messages appears during navigation mode.
D The CD-drive has failure condition. Confirm and reload the disc, please.
D Wrong disc is in the CD-drive. Insert a map disc, please.
D No disc is in the CD-drive. Insert a map disc, please.
D A music disc is in the CD-drive.

1. “The CD-drive has failure condition. Confirm and reload the disc, please.” or “Wrong disc is
in the CD-drive. Insert a map disc, please.” appears.
YES
CD is dirty or damaged. Insert a proper map disc.
NO
YES
Insert the CD once more, and then press the NAVI switch. Does Replace the navigation unit.
the NAVI screen (compass display, outside route, route map) still
not appear?
NO

End

2. “No disc is in the CD-drive. Insert a map disc, please.” or “A music disc is in the CD-drive”
appears.
NO
Press the eject button on the CD-drive. Is the map disc a special Insert a proper map disc.
CD?
YES
NO
Insert the map disc once more, and then press the NAVI switch. Replace the navigation unit.
Does the NAVI screen (compass display, outside route, route
map) still not appear?
YES

End
 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-105
ERROR CODE TABLE <ACCORDING TO SCREEN DISPLAY>
Error Code Error Details Detection Method (Reference) Refer-
No. ence
Page

1011 Ambient temperature sensor not con- Connection checking 54A-105

nected during diagnosis

1021 Fuel gauge not connected during diagnosis Connection checking 54A-106

1031 GPS abnormality during diagnosis Connection checking 54A-106

1041 Engine-ECU not connected during diagno- Connection checking 54A-106

sis

1051 SWS not connected during diagnosis Connection checking 54A-106

1091 CD drive too hot during diagnosis Connection checking 54A-106

1092 – 1096 CD drive abnormality during diagnosis Connection checking 54A-107

10A1, 10B1 Memory of navigation unit abnormality Connection checking 54A-107

during diagnosis

20D1, 30D1 Vehicle speed pulse abnormality during Sensor checking 54A-107
diagnosis

20E1, 20E2, Gyro level abnormality during diagnosis Sensor checking 54A-107
30E1, 30E2

INSPECTION PROCEDURES FOR EACH ERROR CODE <ACCORDING TO

SCREEN DISPLAY>
Error Code No. 1011

NO
Were the wiring check instructions followed? Repeat the wiring check.
YES
NG
Repeat the wiring check. If the same problem occurs, check ambi- Replace the ambient temperature sensor.
ent temperature sensor.
OK
NG
Measure at the multi-center display connector B-08. Check the harness between C-52 and A-89.
D Disconnect connector.
D Resistance between terminal (23) and body eartth.
OK: 500 Ω – 100 kΩ
OK

Replace the multi-center display.

54A-106 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

Error Code No. 1021

NO
Were the wiring check instructions followed? Repeat the wiring check.
YES
NG
Repeat the wiring check. If the same problem occurs, measure Check the harness between C-52 and D-17.
at the multi-center display connector C-52.
D Disconnect connector.
D Ignition switch: ON
D Voltage between terminal (33) and body eartth.
OK: 0.1 V (full tank full) – 3 V (fuel empty)
OK

Replace the multi-center display.

Error Code No. 1031

NO
Were the wiring check instructions followed? Repeat the wiring check.
YES

Repeat the wiring check. If the same problem occurs, there is Replace the multi-center display.
a malfunction of the GPS inside the multi-center display.

Error Code No. 1041

NO
Were the wiring check instructions followed? Repeat the wiring check.
YES
NG
Connect MUT-II and diagnose engine. Check the harness between C-53 and C-19.
OK

Replace the multi-center display.

Error Code No. 1051

NO
Were the wiring check instructions followed? Repeat the wiring check.
YES
NG
Check connector (C-53, C-83) Repair
OK
NG
Check SWS diagnosis trouble code. Refer to GROUP 54B – Troubleshooting.
OK

Replace the multi-center display.

Error Code No. 1091

YES
Is the navigation unit very hot because of direct sunlight, heat Repeat the wiring check after the navigation unit becomes cool.
air, etc.?
NO

Repeat the wiring check. If the same problem occurs, there is Replace the navigation unit.
a malfunction of the CD drive within the navigation unit.
 CHASSIS ELECTRICAL – Multi-Center Display <High Grade> 54A-107
Error Code No. 1092, 1093, 1094, 1095, 1096

NO
Is a CD-ROM for this navigation system inside? Insert the CD-ROM for this navigation system.
YES
YES
Is the CD-ROM inserted upside down? Insert the CD-ROM correctly.
NO
YES
Is the disc dirty, damaged or iced up? Repair or replace the disc.
NO
Repeat the wiring check. If the same problem occurs, there is Replace the navigation unit.
a malfunction of the CD drive within the navigation unit.

Error Code No. 10A1, 10B1

NO
Were the wiring check instructions followed? Repeat the wiring check.
YES

Repeat the wiring check. If the same problem occurs, there is Replace the navigation unit.
a malfunction of the memory within the navigation unit..

Error Code No. 20D1, 30D1

NO
Were the sensor check instructions followed? Repeat the sensor check.
YES
NG
Check connector (B-08, C-50). Repair

OK
NG
Measure at the navigation unit connector B-08. Check the vehicle speed sensor. (Refer to P.54A-27.)
D Disconnect connector.
D Turn on the Ignition switch and then move the vehicle slowly.
D Voltage between terminal (4) and body eartth.
OK: HI: 4 – 5 V, Lo: 0 – 1 V, pulse signal
OK

Replace the navigation unit.

Error Code No. 20E1, 20E2, 30E1, 30E2

NO
Were the sensor check instructions followed? Repeat the sensor check.
YES

Repeat the sensor check. If the same problem occurs, there is Replace the navigation unit.
a malfunction of Gyro sensor within the navigation unit.
54A-108 CHASSIS ELECTRICAL – Multi-Center Display <High Grade>

MULTI-CENTER DISPLAY
REMOVAL AND INSTALLATION
4

2
2

Navigation unit removal steps Multi-center display removal steps

1. Floor console (Refer to GROUP 4. Multi-center display hood
52A – Floor console) (Refer to P.54A-79.)
2. Radio bracket 5. Multi-center display bracket
3. Navigation unit 6. Multi-center display
54-1 CHASSIS ELECTRICAL – General/Speaker

GROUP 54A
CHASSIS ELECTRICAL
GENERAL
OUTLINE OF CHANGE
 Due to the introduction of 5-door models, the rear speaker service procedure has been changed.

SPEAKER
REMOVAL AND INSTALLATION
<Rear speaker>
5-door models

3 2

Rear speaker removal steps

1. Quarter trim, lower (Refer to GROUP 52A.)
2. Rear pillar trim (Refer to GROUP 52A.)
3. Speaker
 SERVICE BULLETIN
PUBLICATION GROUP, AFTER SALES SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV

SERVICE BULLETIN No.: ESB-00E54-502

Date:2000-07-30
<Model> <M/Y>
Subject: CORRECTION TO SERVICE MODE FOR MULTI- (EC)PAJERO 00-10
CENTER DISPLAY PININ/MONTERO io
Group: (H60,H70)
CHASSIS ELECTRICAL Draftno.:99SY111917
INFORMATION/CORRECTION
O. Kai - E.V.P. & G.M.
After Sales Service Dept.

1. Description:
This Service Bulletin ingorms you thet correction has been made to the service mode for the multi-
center display (middle grade)

2. Applicable Manuals:
Manual Pub. No. Language Page(s)
‘00PAJERO PININ CKRE00E1 (English) 54a-69
Workshop Manual chassis CKRF00E1 (French)
CKRG00E1 (German)
CKRD00E1 (Dutch)
CKRI00E1 (Italian)
’00 MONTERO CKRS00E1 (Spanish)
Workshop Manual chassis
3. Details:
CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> (page 2,3 and 4)
 CHASSIS ELECTRICAL – Multi-center Display <Middle Grade> 54A-69
4. Service Mode For Multi-center Display <Correct>
1. Enter and terminate the service mode <Incorrect> LOCK (OFF)
(1) To enter the service mode, turn the ignition switch to ACC
(2) Press the “H” button twice.
(3) Press the “SET” button and (A) button at the same time.
(4) Then the audio unit will enter the service mode.
First of all, the service mode will show model identification for th multi center display and the vehicle
identification. Then the service mode proceeds to three checks. LCD segment check, Sensor check
and Unit check. To switch over these checks, press the “SET” button.
(5) To terminate the service mode, press any button other than the “SET” button.

<Incorrect>

AX0100BN
(A) Button

2. Details of the service mode

The service mode checks the following in that order:
(1) LCD segment check
This screen is divided into four areas. Each area will be active sequentially whenever the “SET”
button is pressed.
When the “SET” button is pressed four times in this screen, the service mode will proceed to the
Sensor check.
(2) Sensor check
This screen shows voltage signals from the outside temperature sensor, the fuel gauge unit, and th
ignition switch as well as fuel economy.
When the “SET” button is pressed once in this screen, the service mode will proceed to the Unit
check.
(3) Unit check connected into audio system
This screen shows an audio equipment, air conditioner or MUT-II connected in the system,
percentage of system voltage engine speed sent by the engine-ECU, and oscillation of internal clock.
When the “SET” button is pressed once in this screen, the service mode will return to the first scree
(model identification screen).

<Correct>
(2) While pressing (A) button, turn the ignition <Incorrect>
switch to ON. With (A) button depressed,
press “H” button twice.
(3) Press “SET” button.
(4) Then th multi-center display will enter th
service mode. Each mode will change eac
time “SET” button is pressed. Add pages 3-4 of
this bulletin here.

2
<Added>
2. Service mode menu and check procedure.
The service mode display changes by pressing “SET” button by following order. (Next to No.9, th
function returns to No.1 and repeats the sequence from No.1.)
No. Mode and display Displayed contents Unit Checking item
1 Model name and vehicle type. A. Display model. Code Confirm the display model
code. (“431” is displayed
for this vehicle
A
B. Vehicle type. Code Confirm the vehicle type.
(“KR” is displayed for this
vehicle.)
AX0345AL
B

2 Segment check.(illuminate) All segment illuminated. _ Check defect segments.

X0346AL

3 Segment check. (only back- Back-lamp only. (all segment _ Check damage, dust etc.
lamp) off)

X0347AL

4-7 ¼ segment check. Each ¼ segment illuminate. _ Check short circuit.

(4 different displays appear.
The left figure shows the first
display.)
X0348AL

8 Temperature sensor and fue A. Calculated outside °C Check the displayed

gauge unit signal check temperate. value.
B. Calculated remaining fuel. ℓ Check the displayed
value.*2
C. Consumed fuel quantity ℓ Check the displayed
since. value.

A B
D. Fuel gauge unit signal V*1 Check th displayed
C
voltage. value. *2
E. IG voltage. V*1 Check the displayed
D E
AY0002AL value. (Battery positive
voltage)
9 Clock and connected A. Voltage of MUT-II % Connect: more than 80,
components check. detection input. Disconnect: less than 50.
B. Calculated vehicle speed. Km/h Check the displayed
A B C value.
C. Clock. Sec Confirm operating.

AX0350AL D. Connecting components. Name Conform connecte

D
components (“MU”: MUT-
II< “AU”: audio)

3
<Added>

NOTE
*1: Display is made in 0.1 volts.
*2: The relationship between the calculated
Calculated
remaining
remaining fuel and the fuel gauge unit signal
fuel ℓ voltage is as sown in the left figure

Fuel gauge unit

signal voltage V
Y0001AL

4
SMART WIRING
SYSTEM (SWS)
Click on the applicable bookmark to selected the required model year
 54B-1

SMART WIRING
SYSTEM (SWS)
CONTENTS

GENERAL INFOMATION . . . . . . . . 54B-2 TROUBLESHOOTING . . . . . . . . . . . 54B-6

SPECIAL TOOLS . . . . . . . . . . . . . . . 54B-5

54B-2 SWS – General Information

GENERAL INFORMATION
COMMUNICATION LINE
Data lines for multiplex communication are connected between the front-ECU, ETACS-ECU, column switch
assembly, multi-center display, power window main switch, and power window motors as illustrated below.

ETACS-ECU MUT-II

Column switch Power window Power window motor-ECU

(column-ECU) main switch (driver’s side)

Front-ECU

Multi-center display Power window motor-ECU

(passenger’s side)

: Uni-directional communication line

: Bi-directional communication line

OPERATION
BUZZER
Light Reminder Warning Function Multi-center Display Buzzer Function
When the driver’s door is opened (driver’s door If there is a request from the multi-center display
switch ON) with light switch in the TAIL or HEAD to make the buzzer sound, the ETACS-ECU causes
position, the buzzer will sound continuously to the buzzer to sound.
remind the driver that the lights (taillights or
headlights) are ON.

CENTRAL DOOR LOCKING SYSTEM

Central Door Locking System Operation Forgotten Key Prevention Function
If a door is locked or unlocked by using any one This function automatically release the door lock
of the key cylinders (driver’s door, passenger’s door if the inside door lock knob is placed in the lock
or back door), all of the doors are locked or unlocked. position with the door opened while the key is still
In addition, all doors can be locked and unlocked in the ignition switch, thereby preventing the key
by using the driver’s door lock knob. from being left behind locked door.
 SWS – General Information 54B-3
POWER WINDOWS
Power Windows Operation Power Window Timer Function
A signal line dedicated for transmission of multiplex With the ignition switch in the ON position, the power
communication data is connected between the window relay and power window switch receipt
power window main switches and the power window permission are turned ON [the power window switch
motor-ECU. receipt permission signal remains ON for 30 seconds
Communication is uni-directional. The power after the ignition switch is turned LOCK (OFF)],
window main switches have a transmitting circuit enabling opening and closing of the windows. The
only, whereas the power window sub switches have power window relay goes ON for additional 30
a receiving circuit only. seconds. If the driver’s door is subsequently closed
during this period, the receipt permission signal goes
OFF. The power window relay goes OFF 10 seconds
after the receipt permission signal goes OFF.
KEYLESS ENTRY SYSTEM
If the transmitter LOCK or UNLOCK switch is flash twice, and the room lamp flashes twice when
pressed while the ignition key is removed and all the doors are locked. Meanwhile, when the doors
of the doors are closed, the doors can be locked are unlocked, the hazard warning lamps flash and
or unlocked. If the doors are closed, the hazard the room lamp illuminate for 15 seconds. The hazard
warning lamps, the room lamp and the horn will answerback functions can be cancelled by using
operate due to answerback function. Because of the MUT-II.
the answerback function, the hazard warning lamps
WINDSHIELD WIPER AND WASHER
Windshield Low-speed (and High-speed) Windshield Mist Wiper Operation
Wiper Operation D If the windshield mist wiper switch of the column
D If the windshield low-speed wiper switch is switch is turned to the ON position with the
turned to the ON position with the ignition switch ignition switch at ACC or ON position, the mist
at the ACC or ON position, the column switch wiper high-speed operation signal is sent to
sends a low-speed wiper ON and high-speed the front-ECU. This signal turns on the wiper
wiper OFF signals to the front-ECU. speed switching relay, causing the wipers to
This turns the wiper signal on and the wiper work at high-speed while the mist switch is on.
speed switching relay off (low-speed), causing D While the windshield mist wiper switch remains
the wipers to operate at low-speed. turned on when the intermittent mode is still
D If the windshield high-speed wiper switch is working, the wipers work as the mist wiper.
turned to the ON position, the column switch However, the wipers return to the intermittent
sends a low-speed wiper OFF and high-speed mode again when the wiper auto stop signal
wiper ON signals to the front-ECU. turns on after the mist wiper switch is turned
This turns both the wiper signal and the wiper off.
speed switching relay on (high-speed), causing Windshield Washer Operation
the wipers to operate at high-speed.
If the windshield washer switch of the column switch
Windshield Intermittent Wiper Operation is turned to the ON position with the ignition switch
The ETACS-ECU calculates the wiper operation at ACC or ON position, the windshield washer ON
interval according to the voltage signal sent from signal is sent to the front-ECU, causing the
the column switch. (For vehicles without variable windshield wiper signal to turn on after 0.3 seconds.
intermittent wiper, the intermittent interval is fixed After the windshield washer switch signal turns off,
at 4 seconds.) Then the ETACS-ECU sends a signal the windshield wiper signal turns off in three
to the front-ECU. The front-ECU determines the seconds.
wiper operation interval and turns on the wiper signal If the windshield wiper switch is turned to the ON
relay. This causes the wiper auto stop relay to turn position while the windshield wiper is at intermittent
on. Then the wiper auto stop relay will turn off after mode, the windshield washer works for that period
the wipers reach the park position. This causes when the windshield washer switch remains on.
the wiper signal relay and then the wipers to turn Then the wipers return to the intermittent mode.
off.
If the wiper signal relay remains off for the wiper
operation interval, the relay turns on again, causing
the wipers to operate in intermittent mode.
54B-4 SWS – General Information

REAR WIPER AND WASHER

Rear Wiper Operation Rear Washer Operation
If the rear wiper switch is turned to the ON position If the rear washer switch is turned to the ON position
with the ignition switch at ACC or ON position, the with the ignition switch at ACC or ON position, the
ETACS-ECU cause the rear wiper to operate rear washer ON signal is sent to the ETACS-ECU,
continuously two times then intermittently at causing the rear wiper signal to turn on after 0.3
eight-second intervals. seconds. After the rear washer switch signal turns
If the shift lever <M/T> selector lever <A/T> is moved off, the rear wiper signal turns off in three seconds.
to the R position when the rear wiper switch is turned If the rear wiper switch is turned to the ON position
to the ON position and the ignition switch at ACC while the rear wiper is at intermittent mode, the
or ON position, back-up lamp switch <M/T> or rear washer works for that period when the washer
inhibitor switch R <A/T> turns ON. One second later, switch remains on. Then the rear wipers return to
the ETACS-ECU causes the rear wiper to operate the intermittent mode.
two times continuously to ensure good rearward
visibility. The ETACS-ECU then causes the rear
wiper to again operate intermittently at eight-second
intervals.
HEADLAMP WASHER
If the headlamp washer switch of the column switch ignition switch in the ACC or ON position, the
assembly is turned to the ON position with the front-ECU turns on the headlamp washer relay.
HEADLAMP
Headlamp Auto-cut Function Headlamp Dimmer Switch Auto-reset
If the ignition switch is turned to LOCK (OFF) or Function
ACC position, when the headlamps are on, the This function allows the dimmer switch to be reset
headlamps will be switched off in three minutes. to the low-beam position whenever the headlamp
If the driver’s door is opened within that three-minute switch is turned ON.
period, the headlamps will be switched off Daytime Running Lamp (DRL) Function
automatically. This prevents the battery from
discharged. If the ignition switch is turned to ON when the
In addition, if the headlamps are turned on when headlamps and tail lamps are off, the headlamps
the ignition switch is at LOCK (OFF) or ACC position, (low-beam) and tail lamps turn on.
the headlamps will not be switched off.
FLASHER TIMER
Turn-signal Lamp Hazard Warning Lamp
When the ignition switch is turned to ON position The system detects a change from ON to OFF of
and turn-signal lamp switch is placed in the ON the hazard lamp input signal and activates the
position for right or left turn signaling, the system hazard lamps if they are not in operation or
generates turn-signal lamp drive signals (flashing deactivates the lamps if they are operating (reversal
signals). of state between activation and deactivation).
The system also notifies of a blown turn-signal lamp
bulb by shortening the flashing intervals of the
corresponding indicator lamp.
FRONT FOG LAMP
The front fog lamp switch becomes active only when off. Whenever the tail lamps are turned on at the
the tail lamps are on. Therefore, if the tail lamps next time, the front fog lamps will always be off
are turned off, the fog lamps will also be switched regardless of the switch positions.
REAR FOG LAMP
The rear fog lamp switch becomes active only when turned on at the next time, the rear fog lamps will
the headlamps or front fog lamps* are on. Therefore, always be off regardless of the switch positions.
if the headlamps and front fog lamps* are turned NOTE
off, the rear fog lamps will also be switched off. *: In vehicles without front fog lamps, these
Whenever the headlamps or front fog lamps* are conditions apply to the headlamps only.
 SWS – General Information/Special Tools 54B-5
ROOM LAMP
With the room lamp switch in the DOOR position, When the ignition key is removed with all the
the ETACS-ECU controls the room lamp operation doors closed, the room lamp is illuminated at
as follows: an intensity of 65% and turned out approx. 30
D When a door is opened from outside or inside seconds later. During that time (timer-controlled
[with the ignition switch turned to LOCK (OFF) period), the room lamp does out if the ignition
position]: key is inserted and turned to ON position or
When a door is opened, the ETACS-ECU the door locking system is activated.
causes the room lamp to be illuminated at the D Room lamp’s answerback operation in response
100% intensity. When the door is closed, it dims to door lock control by keyless entry system:
out the room lamp to 65% intensity and approx.
30 seconds later, turns out the lamp completely. To allow the driver to ascertain the result of
During this period (timer controlled period), the the door locking/unlocking control action by the
room lamp does out if the ignition switch is turned use of the keyless entry system, the
to ON position or the doors are locked. ETACS-ECU causes the room lamp to blink
D When a door is opened or closed with the ignition twice when the doors are locked through the
switch in the ON position: system and to illuminate for approx. 15 seconds
The room lamp illuminates at 100% intensity when the doors are locked.
when a door is opened and turned out when The room lamp’s answerback operation in
it is closed. response to a keyless entry system control
D When no door is opened and the ignition key action is accompanied by operation of the
is removed: hazard warning lamps.

SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub Checking of the SWS
assembly (Diagnosis code display and input check
with the MUT-II)

MB991529 Diagnosis code Simple diagnosis

check harness

A
MB991223 Harness set Measurement of terminal voltage at ECUs
A: MB991219 A: Test harness A: Connector pin contact pressure inspec-
B: MB991220 B: LED harness tion
C: MB991221 C: LED harness B: Power circuit inspection
D: MB991222 adapter C: Power circuit inspection
B D: Probe D: Commercial tester connection

D
54B-6 SWS – Troubleshooting

TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.

DIAGNOSTIC FUNCTION
DIAGNOSIS CODES CHECK
Use the MUT-II to check a diagnosis code.
(Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.)
NOTE
Connect the MUT-II to the 16-pin diagnosis connector (black).

INPUT SIGNAL CHECK

1. Use the MUT-II to check a input signal.
(Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.)
2. In this condition, the following input switches can be checked.
3. If an abnormality is found during the input signal check, carry out troubleshooting while referring to
the Trouble Symptom Check page.
Input Signal Check Function
Input signal Buzzer operation condition

Ignition switch (ACC) Turned from LOCK (OFF) to ACC

Ignition switch (IG1) Turned from ACC to ON

Key reminder switch Ignition key removed from ignition key cylinder
(from inserted position)

Hazard warning lamp switch Turned from OFF to ON

Front fog lamp switch <vehicles with front fog lamp>

Rear fog lamp switch

Back-up lamp switch <M/T> Shift lever moved to R position

Inhibitor switch (reverse) <A/T> Selector lever moved to R position

Rear wiper motor auto-stop signal Rear wiper begins to operate (The input signal
is sent before the rear wiper begins to operate)

Driver’s door switch Driver’s door opened from closed condition

Door switches All doors closed to any door opened

Passenger’s door key cylinder switch <vehicles with central door Passenger’s door locked or unlocked using
locking system> ignition key

Back door key cylinder switch <vehicles with central door locking Back door locked or unlocked using ignition key
system>

Driver’s door lock actuator switch <vehicles with central door locking Driver’s door lock knob moved from lock
system> position to unlock position or vice versa
 SWS – Troubleshooting 54B-7

Input signal Buzzer operation condition

Column switch Tail lamp switch Turned the lighting switch from OFF to tail lamp
position

Headlamp switch Turn the lighting switch from tail lamp position to
headlamp position

Dimmer switch Turned from OFF to ON

Passing switch

Turn-signal lamp switch

Windshield mist wiper switch

Windshield intermittent wiper switch

Windshield low-speed wiper switch

Windshield high-speed wiper switch

Windshield intermittent wiper interval adjusting Rotate the windshield intermittent wiper interval
knob <vehicles with variable windshield inter- adjusting knob from FAST to SLOW when the
mittent wiper> ignition switch is at ON position (The ETACS-
ECU sends a signal around the medium knob
position)

Windshield washer switch Turned from OFF to ON

Rear wiper switch

Rear washer switch

Headlamp washer switch <vehicles with head-

lamp washer>

Power window Any switch <vehicles with power window>

main switch

Transmitter Any switch <vehicles with keyless entry

system>

Multi-center dis- Any switch <vehicles with multi-center display>

play

DIAGNOSIS CODE CHART

Code No. Diagnosis item Reference page

11 Failure concerning the ETACS-ECU 54B-8

12 Failure concerning the column switch or improper connecting with the ETACS-ECU 54B-8

13 Failure concerning the front-ECU 54B-9

21 Short circuit in communication line 54B-10

54B-8 SWS – Troubleshooting

DIAGNOSIS CODE INSPECTION PROCEDURES

Code No.11 Failure concerning the ETACS-ECU Probable cause
The ETACS-ECU monitors its own communication data, and sends a diagnosis D Malfunction of ETACS-ECU
code when an error takes place consecutive fifteen times in 0.6 second.
The diagnosis code will be erased when the ETACS-ECU determines that its
own communication data is sent consecutive 15 times in 0.6 second.

Replace the ETACS-ECU.

Code No.12 Failure concerning the column switch or Probable cause

improper connection with the ETACS-ECU
This diagnosis code is displayed when the column switch sends a signal D Malfunction of column switch
regardless of the transmission request signal from the ETACS-ECU (three times D Malfunction of ETACS-ECU
or more in one second). D Malfunction of wiring harness or connector
The diagnosis code is erased when the column switch continues to send a
signal according to the transmission request signal from the ETACS-ECU for
one second.

No NG
Is diagnosis code No. 12 output Measure at column switch connector Check the following connectors:
when the ignition switch is at the C-63. C-01, C-63, C-72, C-75
ON position? D Disconnect connector and OK NG
measure at harness side.
OK D Voltage between terminal 1 and Repair
body earth.
OK: System voltage
OK Check trouble symptoms
OK NG
Measure at column switch connector Check the following connectors:
C-63. C-02, C-63, C-83 Check the harness wire between col-
D Disconnect connector and NG umn switch and fusible link (3).
OK
measure at harness side.
D Continuity between terminal 4 Repair
and body earth.
OK: Continuity
NG
NG Check trouble symptoms Check the harness wire between col-
umn switch and ETACS-ECU.
NG NG
Check the following connectors: Replace
C-01, C-63 Replace the column switch or ETACS-
OK ECU.
NG
Check trouble symptoms Check the harness wire between col-
umn switch and body earth.
 SWS – Troubleshooting 54B-9
Code No.13 Failure concerning the front-ECU Probable cause
This diagnosis code is displayed when the signals that the front-ECU sends to D Malfunction of front-ECU
the ETACS-ECU are errors consecutive fifteen times in 0.6 second. D Malfunction of ETACS-ECU
The diagnosis code will be erased when the front-ECU sends normal signals to D Malfunction of wiring harness or connector
the ETACS-ECU consecutive 15 times in 0.6 second.

Yes NG
Is diagnosis code No. 12 output Measure at front-ECU connector A-37X. Check the following connector:
when the ignition switch is at the D Disconnect connector and A-37X
ON position? measure at harness side. OK NG
D Voltage between terminal 7 and
No body earth Repair
OK: System voltage
OK
Check trouble symptoms.
Replace the front-ECU.
NG
Check the harness wire between front-
ECU and fusible link (3).

NG NG
Measure at front-ECU connector A-38X. Check the following connector: Repair
D Disconnect connector and A-38X
measure at harness side. OK
D Continuity between terminal 31
and body earth. NG
Check trouble symptoms. Check the harness wire between front-
OK: Continuity ECU and body earth.
OK
NG
Check the following connectors: Repair
A-38X, C-02, C-29, C-83
OK
NG NG
Check the trouble symptoms. Check the harness wire between front- Replace the front-ECU or ETACS-ECU.
ECU and ETACS-ECU.
54B-10 SWS – Troubleshooting

Code No.21 Short circuit in communication lines Probable cause

This diagnosis code is displayed when the SWS communication line voltage D Malfunction of column switch
reaches the LO level for 0.3 second. The diagnosis code is erased when D Malfunction of front-ECU
voltage in the ETACS-ECU data line reaches the HI level for 0.3 second, or D Malfunction of power window main switch
the ETACS-ECU receives a normal signal from other ECUs or switches. While <vehicles with front power window>
this code is displayed, other codes are not displayed. D Malfunction of multi center display <vehicles with
multi center display>
D Malfunction of ETACS-ECU
D Malfunction of wiring harness or connector

NG
Check the following connectors: Repair
A-38X, C-53, C-63, C-83, E-10
OK

Check trouble symptoms.

NG
NG
Check the harness wires between column switch and ETACS-ECU, Repair
front-ECU and ETACS-ECU, power window main switch and
ETACS-ECU, multi-center display and ETACS-ECU.
OK
Yes
Is diagnosis code No. 21 no longer output when column Replace the column switch.
switch connector C-63 is disconnected? (However, code No.
12 is still output.)
No
Yes
Is diagnosis code No. 21 no longer output when front-ECU Replace the front-ECU.
connector A-38X is disconnected? (However, code No. 13 is
still output.)
No
Yes
Is diagnosis code No. 21 no longer output when power Replace the power window main switch.
window main switch connector E-10 is disconnected?
No
Yes
Is diagnosis code No. 21 no longer output when multi-center Replace the multi center display.
display connector C-53 is disconnected?
No

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-11
TROUBLE SYMPTOM CHART
Trouble symptom Inspection Reference
procedure page

Communication with the MUT-II is impossible. A-1 54B-14

Buzzer Light reminder warning function does not work normally. B-1 54B-15

Multi-center display alarm function does not work normally. B-2 54B-15

Central door Central door locking system does not work normally. C-1 54B-16
locking system
Some doors do not lock or unlock. C-2 54B-16

All the doors do not lock or unlock with just the driver’s door lock C-3 54B-17
key cylinder key operation or driver’s inside lock knob operation.

All the doors do not lock or unlock with just the passenger’s or back C-4 54B-17
door lock key cylinder key operation.

Forgotten key prevention function does not work. C-5 54B-17

Power window Power window do not work at all. D-1 54B-18

Power window main switch can not operate driver’s window. D-2 54B-18

Power window sub switch can not operate passenger’s window. D-3 54B-19

Power window main switch can not operate passenger’s window. D-4 54B-20

Power window timer function does not work normally. D-5 54B-20

When the glass is raised, it then lowers automatically. D-6 54B-21

The glass is not lowered when something is jammed in the D-7 54B-21
window.

When the glass is fully raised, it then lowers automatically. D-8 54B-21

Keyless entry Keyless entry system does not operate. E-1 54B-22
system
The room lamp and hazard warning lamps do not operate through E-2 54B-22
the answerback function.

The encrypted code cannot be registered. E-3 54B-22

Windshield wip- Windshield wiper does not operate. F-1 54B-23

er and washer
Any of the windshield wiper switch positions is defective. F-2 54B-24

Windshield wiper does not stop at the predetermined park F-3 54B-24
position.

Windshield intermittent wiper interval cannot be adjusted. F-4 54B-25

Windshield washer does not work. F-5 54B-25

54B-12 SWS – Troubleshooting

Trouble symptom Inspection Reference

procedure page

Rear wiper and Rear wiper does not work at all. G-1 54B-26
washer
Rear wiper does not stop at the predetermined park position. G-2 54B-26

When the shift lever <M/T> or selector lever <A/T> is moved to R G-3 54B-27
position during the rear wiper operation, the rear wiper does not
operate at the continuous mode.

Rear washer does not work. G-4 54B-27

Headlamp Headlamp washer does not work. H-1 54B-28

washer

Headlamp, tail Tail lamp do not illuminate. I-1 54B-29

lamp
Headlamps (low-beam) do no illuminate. I-2 54B-29

Headlamps (high-beam) do no illuminate. I-3 54B-30

Headlamps do not illuminate when the passing switch is operated. I-4 54B-30

The headlamp auto-cut function does not work normally. I-5 54B-31

Headlamp dimmer switch auto-reset function does not work I-6 54B-31
normally.

Daytime running lamp (DRL) function does not work. I-7 54B-31

Flasher timer Turn-signal lamp do not flash when the turn-signal lamp switch is J-1 54B-32
turned on.

Hazard warning lamps do not flash when the hazard warning lamp J-2 54B-33
switch is turned on.

Front fog lamp Front fog lamps do not illuminate when the front fog lamp switch K-1 54B-34
is turned on.

Front fog lamp do not go out when the tail lamps are turned off K-2 54B-34
while the fog lamps are on.

Rear fog lamp Rear fog lamp do not illuminate when the rear fog lamp switch is L-1 54B-35
turned on.

Rear fog lamp do not out when the headlamps and front fog lamps L-2 54B-36
<vehicles with front fog lamp> are turned off while the fog lamp is
on.

Room lamp The room lamp does not illuminate. M-1 54B-36

The doom lamp dimming function does not work normally. M-2 54B-37

Multi-center dis- The multi-center display does not work normally. – GROUP 54A
play – Multi-cen-
ter Display.
 SWS – Troubleshooting 54B-13
DEFECTS FOUND BY INPUT SIGNAL CHECK
If the input signal check finds a defect, follow the table below to check.
Trouble symptom Inspection Reference
procedure page

Ignition switch (ACC) signal is not sent to the ETACS-ECU. N-1 54B-37

Ignition switch (IG1) signal is not sent to the ETACS-ECU. N-2 54B-38

Key reminder switch signal is not sent to the ETACS-ECU. N-3 54B-38

Hazard warning lamp switch signal is not sent to the ETACS-ECU. N-4 54B-39

Front fog lamp switch signal is not sent to the ETACS-ECU. N-5 54B-39

Rear fog lamp switch signal is not sent to the ETACS-ECU. N-6 54B-40

Back-up lamp switch signal is not sent to the ETACS-ECU. <M/T> N-7 54B-40

Inhibitor switch (reverse) signal is not sent to the ETACS-ECU. <A/T> N-8 54B-41

Rear wiper motor auto-stop signal is not sent to the ETACS-ECU. N-9 54B-41

Driver’s door switch signal is not sent to the ETACS-ECU. N-10 54B-42

Door switches signal is not sent to the ETACS-ECU.

Passenger’s door lock key cylinder switch signal is not sent to the ETACS-ECU. N-11 54B-43

Back door lock key cylinder switch signal is not sent to the ETACS-ECU. N-12 54B-43

Driver’s door lock actuator switch signal is not sent to the ETACS-ECU. N-13 54B-44

Column switch Tail lamp switch signal is not sent to the ETACS-ECU. N-14 54B-45

Headlamp switch signal is not sent to the ETACS-ECU.

Dimmer switch signal is not sent to the ETACS-ECU.

Passing switch signal is not sent to the ETACS-ECU.

Turn-signal lamp switch signal is not sent to the ETACS-ECU.

Windshield mist wiper switch signal is not sent to the ETACS-ECU.

Windshield intermittent wiper switch signal is not sent to the

ETACS-ECU.

Windshield low-speed wiper switch signal is not sent to the

ETACS-ECU.

Windshield high-speed wiper switch signal is not sent to the

ETACS-ECU.

Windshield intermittent wiper interval adjusting knob signal is not N-15 54B-45
sent to the ETACS-ECU.

Windshield wiper switch signal is not sent to the ETACS-ECU. N-14 54B-45

Rear wiper switch signal is not sent to the ETACS-ECU.

Rear washer switch signal is not sent to the ETACS-ECU.

Headlamp washer switch signal is not sent to the ETACS-ECU.

54B-14 SWS – Troubleshooting

Trouble symptom Inspection Reference

procedure page

Power window Any switch signal is not sent to the ETACS-ECU. N-16 54B-46
main switch

Transmitter Any switch signal is not sent to the ETACS-ECU. N-17 54B-46

Multi-center dis- Any switch signal is not sent to the ETACS-ECU. N-18 54B-47
play

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure A-1
Communication with the MUT-II is impossible. Probable cause
The harness wires between the ETACS-ECU power supply line or the D Malfunction of ETACS-ECU
ETACS-ECU and the diagnosis connector may be defective. D Malfunction of harness wire or connector

No
Can MUT-II communicate with other system? Check and repair the self-diagnosis system with the MUT-II.
Yes
Yes
Is communication with the MUT-II possible when the ignition Check the ETACS-ECU battery circuit. (Refer to P.54B-47, Inspec-
switch is at the ON position? tion Procedure O-1.)
No
NG
Measure at ETACS-ECU connector C-82. Check following connector:
D Disconnect connector and measure at J/B side. C-01, C-75, C-82
D Continuity between terminal 20 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG

Check the harness wire between ETACS-ECU and body earth.

NG
Check following connector: Repair
C-35, C-83
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between ETACS-ECU and diagnosis con- Repair
nector.
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-15
Inspection Procedure B-1
Buzzer: Light reminder warning function does not work Probable cause
normally.
The ETACS-ECU operates the light reminder warning function, based on input D Malfunction of driver’s door switch
signals from the following switched: D Malfunction of column switch
D Ignition switch (IG1) D Malfunction of ETACS-ECU
D Driver’s door switch D Malfunction of harness wire or connector
D Tail lamp switch
D headlamp switch
If the function does not work normally, a defect on the relevant circuit or the
ETACS-ECU may be suspected.

No
Do all of the following functions operate when the ignition Check the ETACS-ECU battery circuit. (Refer to P.54B-47, Inspec-
key is at the LOCK (OFF) position? tion Procedure O-1.)
D Central door locking system
D Hazard warning lamp
D Room lamp
Yes
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Ignition switch (IG1) by Input Signal Check.)
D Driver’s door switch
D Tail lamp switch
D Headlamp switch
OK

Replace the ETACS-ECU.

Inspection Procedure B-2

Buzzer: Multi-center display buzzer function does not Probable cause
work normally.
If the multi-center display is operating normally, the cause is probably a D Malfunction of multi-center display
malfunction in the harness between the multi-center display and the D Malfunction of ETACS-ECU
ETACS-ECU or in the ETACS-ECU itself. D Malfunction of harness wire or connector

No
Is the multi-center display operating normally? Carry out troubleshooting for the multi-center display. (Refer
Yes to GROUP 54A – Multi-center Display.)

NG
MUT-II input signal check Check the multi-center display input circuit. (Refer to P.54B-47,
D Multi-center display Inspection Procedure N-18.)
OK

Replace the ETACS-ECU.

54B-16 SWS – Troubleshooting

Inspection Procedure C-1

Central door locking system: Central door locking system Probable cause
does not work normally.
The power supply circuit, the circuit shared by door lock actuators, or the D Malfunction of ETACS-ECU
ETACS-ECU may be defective. D Malfunction of harness wire or connector

NG
Measure at ETACS-ECU connector C-82. Check the following connectors:
D Disconnect connector and measure at J/B side. C-77, C-82
D Voltage between terminal 12 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-68, C-75, C-82 Check the harness wire between ETACS-ECU and fusible link(2).
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between ETACS-ECU and door lock actua- Repair
tor.
OK

Replace the ETACS-ECU.

Inspection Procedure C-2

Central door locking system: Some doors do not lock or Probable cause
unlock.
The door lock actuator, or the harness wire between ETACS-ECU and the door D Malfunction of driver’s, passenger’s or back door
lock actuator may be defective. lock actuator
D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
Check the defective door lock actuator. (Refer to GROUP 42 Replace the defective door lock actuator.
– Door.)
OK
NG
Check the following connectors: Repair
<Left door> C-45, C-75, C-82, E-17
<Right door> C-21, C-75, C-82, E-06
<Back door> C-68, C-82, D-15, F-08
OK

Check trouble symptoms.

NG
NG
Check the harness wire between ETACS-ECU and defective door Repair
lock actuator.
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-17
Inspection Procedure C-3
Central door locking system: All the doors do not lock or Probable cause
unlock with just the driver’s door lock key cylinder key
operation or driver’s inside lock knob operation.
The driver’s door lock actuator switch or the ETACS-ECU may be defective. D Malfunction of driver’s door lock actuator
D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
MUT-II input signal check Check the driver’s door lock actuator switch input circuit. (Refer
D Driver’s door lock actuator switch to P.54B-44, Inspection Procedure N-13.)
OK

Replace the ETACS-ECU.

Inspection Procedure C-4

Central door locking system: All the doors do not lock or Probable cause
unlock with just the passenger’s or back door lock key
cylinder key operation.
The passenger’s or back door lock key cylinder or the ETACS-ECU may be D Malfunction of passenger’s or back door lock key
defective. cylinder switch
D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Passenger’s door lock key cylinder switch by Input Signal Check.)
D Back door lock key cylinder switch
OK

Replace the ETACS-ECU.

Inspection Procedure C-5

Central door locking system: Forgotten key prevention Probable cause
function does not work.
The ETACS-ECU operates the forgotten key prevention function, based on the D Malfunction of key reminder switch
input signals from the following switches: D Malfunction of driver’s door switch
D Key reminder switch D Malfunction of driver’s door lock actuator
D Driver’s door switch D Malfunction of ETACS-ECU
D Driver’s door lock actuator switch D Malfunction of harness wire or connector
If the function does not work normally, a defect on the relevant circuit or the
ETACS-ECU may be suspected.

NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Key reminder switch by Input Signal Check.)
D Driver’s door switch
D Driver’s door lock actuator switch
OK

Replace the ETACS-ECU.

54B-18 SWS – Troubleshooting

Inspection Procedure D-1

Power window: Power window do not work at all. Probable cause
The power window relay or the ETACS-ECU may be defective. D Malfunction of power window relay
D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
Check the power window relay. (Refer to GROUP 42 – Door.) Replace
OK
NG
Measure at power window relay connector C-71. Check the following connectors:
D Disconnect connector and measure at J/B side. C-71, C-72
D Voltage between terminal 5 and body earth. OK NG
OK: System voltage
D Voltage between terminal 3 and body earth. Check trouble symptoms. Repair
OK: System voltage
NG
OK
Check the harness wire between power window relay and fusible
Check the following connectors: link (4).
C-21 <R.H. drive vehicles>,
C-45 <L.H. drive vehicles>, C-71, C-74, C-82, E-10
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between power window relay and power Repair
window main switch, power window relay and ETACS-ECU.
OK

Replace the ETACS-ECU.

Inspection Procedure D-2

Power window: Power window main switch can not Probable cause
operate drive’s window.
The cause is probably a malfunction of the power window main switch or D Malfunction of power window main switch
driver’s side power window motor, or an abnormality in the power supply D Malfunction of driver’s power window motor
circuit. D Malfunction of harness wire or connector

NG
MUT-II input signal check Check the power window main switch input circuit. (P.54B-46,
D Power window main switch Inspection Procedure N-16.)
OK
(1) NG
Measure at driver’s power window motor connector E-12 <L.H. Check the following connectors:
drive vehicles> or E-03 <R.H. drive vehicles>. <L.H. drive vehicles> C-45, C-71, E-12
D Disconnect connector and measure at harness side. <R.H. drive vehicles> C-21, C-71, E-03
D Turn the ignition switch to ON position. OK NG
(1) Voltage between terminal 2 and body earth.
OK: System voltage (2) NG
Check trouble symptoms. Repair
(2) Continuity between terminal 1 and body earth.
NG
OK: Continuity
OK Check the harness wire between driver’s power window motor
and power window relay.
Check the following connectors:
<L.H. drive vehicles> E-10, E-12
<R.H. drive vehicles> E-03, E-10 Check the following connectors:
OK NG <L.H. drive vehicles> C-45, E-12
<R.H. drive vehicles> C-21, E-03
Check trouble symptoms. Repair
OK NG
NG
Check trouble symptoms. Repair
Check the harness wire between driver’s power window motor
and power window main switch. NG
OK NG Check the harness wire between driver’s power window motor
and body earth.
Replace the driver’s pow- Repair
er window motor or power
window main switch.
 SWS – Troubleshooting 54B-19
Inspection Procedure D-3
Power window: Power window sub switch can not operate Probable cause
passenger’s window.
The cause is probably a malfunction of the power window main switch or D Malfunction of power window sub switch
driver’s side power window motor, or an abnormality in the power supply D Malfunction of passenger’s power window motor
circuit. D Malfunction of harness wire or connector

NG
Check the power window sub switch. (Refer to GROUP 42 – Door.) Replace the power window sub switch.
OK
NG
Measure at power window sub switch connector E-04 <L.H. drive Check the following connectors:
vehicles> or E-09 <R.H. drive vehicles>. <L.H. drive vehicles> C-21, E-04
D Disconnect connector and measure at harness side. <R.H. drive vehicles> C-45, E-09
D Continuity between terminal 4 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
<L.H. drive vehicles> E-04, E-06 Check the harness wire between power window sub switch and
<R.H. drive vehicles> E-09, E-12 body earth.
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between power window sub switch and Repair
passenger’s power window motor.
NG
(1) NG
Measure at passenger’s power window motor connector E-06 Check the following connectors:
<L.H. drive vehicles> or E-12 <R.H. drive vehicles>. <L.H. drive vehicles> C-21, C-71, E-06
D Disconnect connector and measure at harness side. <R.H. drive vehicles> C-45, C-71, E-12
D Turn the ignition switch to ON position. OK NG
(1) Voltage between terminal 1 and body earth.
OK: System voltage (2) NG
Check trouble symptom Repair
(2) Continuity between terminal 3 and body earth.
OK: Continuity NG

OK Check the harness wire between passenger’s power window motor

and power window relay.
Replace the passenger’s power window motor.

Check the following connectors:

<L.H. drive vehicles> C-21, E-06
<R.H. drive vehicles> C-45, E-12
OK NG

Check trouble symptom Repair

NG

Check the harness wire between passenger’s power window motor

and body earth.
54B-20 SWS – Troubleshooting

Inspection Procedure D-4

Power window: Power window main switch can not Probable cause
operate passenger’s window.
The cause is probably a malfunction of the power window main switch or D Malfunction of power window main switch
driver’s side power window motor, or an abnormality in the power supply D Malfunction of passenger’s power window motor
circuit. D Malfunction of harness wire or connector

No
Can the passenger’s side power window be operated by the Refer to P.54B-19, Inspection Procedure D-3.
power window sub switch?
Yes
NG
MUT-II input signal check Check the power window main switch input circuit. (P.54B-46,
D Power window main switch Inspection Procedure N-16.)
OK
NG
Check the following connectors: Repair
<L.H. drive vehicles> C-21, C-45, E-06, E-10
<R.H. drive vehicles> C-21, C-45, E-10, E-12
OK

Check trouble symptoms.

NG
NG
Check the harness wire between power window main switch and Repair
passenger’s power window motor.
OK

Replace the power window main switch or passenger’s power

window motor.

Inspection Procedure D-5

Power window: Power window timer function does not Probable cause
work normally.
The ETACS-ECU operates the power window timer function, based on the input D Malfunction of driver’s door switch
signals from the following switches: D Malfunction of ETACS-ECU
D Ignition switch (IG1) D Malfunction of harness wire or connector
D Driver’s door switch
If the function does not work normally, a defect on the relevant circuit or the
ETACS-ECU may be suspected.

Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis
OFF (LOCK) position? Code Chart on P.54B-7.
No
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Ignition switch (IG1) by input Signal Check.)
D Driver’s door switch
D Power window main switch
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-21
Inspection Procedure D-6
Power window: When the glass is raised, it then lowers Probable cause
automatically.
If the sliding resistance is too large when the glass is being raised, it is judged D Incorrect window glass adjustment
that something is jammed in the window, and the window is lowered by D Glass slider is incorrectly installed or warped
approximately 150 mm. D Malfunction of power window motor

NG
Check the power window operating currant. (Refer to GROUP Adjust the window glass. (Refer to GROUP 42 – Door.)
42 – Door.)
OK
Check trouble symptoms.
Replace the power window motor. NG

Replace the window regulator assembly.

Inspection Procedure D-7

Power window: The glass is jammed in the window. Probable cause
The cause may be a malfunction of the revolution detection sensor in the D Malfunction of power window motor
power window motor.

Replace the power window motor.

Inspection Procedure D-8

Power window: When the glass is fully raised, it then Probable cause
lowers automatically.
The cause may be a malfunction of the revolution detection sensor in the D Malfunction of power window motor
power window motor.

After disconnecting the battery terminals, set the limit switch.

(Refer to GROUP 42 – DOOR.)

Check trouble symptoms.

NG

Replace the power window motor.

54B-22 SWS – Troubleshooting

Inspection Procedure E-1

Keyless entry system: Keyless entry system does not Probable cause
operate.
The cause may be a malfunction of the receiver and transmitter communication D Malfunction of transmitter
system D Malfunction of ETACS-ECU

No
Is the central door locking system operated normally? Check the central door locking system. (Refer to P54B-11, Trouble
Symptom Chart.)
Yes

NG
MUT-II input signal check Check the transmitter input circuit. (Refer to P.54B-46, Inspection
D Transmitter Procedure N-17.)
OK

Replace the ETACS-ECU.

Inspection Procedure E-2

Keyless entry system: The room lamp and hazard warning Probable cause
lamps do not operate through the answerback function.
The hazard warning lamp answerback function can be selected by the driver’s D Malfunction of turn-signal lamp
desire (can be deactivated). However, the room lamp answerback function can D Malfunction of room lamp
not be deactivated. if all of these device do not operate through the D Malfunction of ETACS-ECU
answerback function, the ETACS-ECU may be defective. D Malfunction of harness wire or connector

Activate the answerback functions. (Refer to GROUP 42 – Keyless

Entry System.)

Check trouble symptoms.

NG
No
Are room lamp and hazard warning lamps operated normally? Check the defective device. (Refer to P.54B-11, Trouble Symptom
Chart.)
Yes

Replace the ETACS-ECU.

Inspection Procedure E-3

Keyless entry system: The encrypted code cannot be Probable cause
registered.
The ETACS-ECU actives the encrypted code register mode according to the D Malfunction of key reminder switch
following switch signals. D Malfunction of hazard warning lamp switch
D Key reminder switch D Malfunction of transmitter
D Hazard warning lamp switch D Malfunction of ETACS-ECU
If the encrypted code register mode is not set, the relevant input signal circuit D Malfunction of harness wire or connector
or the ETACS-ECU may be defective.
If a transmitter can not be registered although the encrypted code register
mode is set, the transmitter or the ETACS-ECU may be defective.

Yes
Is encrypted code register mode set? Check the transmitter battery. (Refer to GROUP 42 – Keyless
entry System.)
No
OK NG

Replace the transmitter. Repair

NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Key reminder switch by input Signal Check.)
D Hazard warning lamp switch
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-23
Inspection Procedure F-1
Windshield wiper and washer: Windshield wiper does not Probable cause
operate.
If the windshield wiper does not work at all, the windshield wiper motor, column D Malfunction of windshield wiper motor
switch or the front-ECU may be defective. D Malfunction of column switch
D Malfunction of front-ECU
D Malfunction of harness wire or connector

NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Windshield mist wiper switch by Input Signal Check.)
D Windshield intermittent wiper switch
D Windshield low-speed wiper switch
D Windshield high-speed wiper switch
OK
NG
Check the windshield wiper motor. (Refer to GROUP 51 – Wind- Replace
shield Wiper and Washer.)
OK
NG
Check the installation of the windshield wiper motor to the vehicle Repair
body.
OK
NG
Measure at front-ECU connector A-38X. Check the following connectors:
D Disconnect connector and measure at relay box side. A-38X, C-72, C-74
D Turn the ignition switch to ACC position. OK NG
D Voltage between terminal 24 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Replace the front-ECU. Check the harness wire between front-ECU and ignition switch
(ACC).
54B-24 SWS – Troubleshooting

Inspection Procedure F-2

Windshield wiper and washer: Any of the windshield wiper Probable cause
switch positions is defective.
The windshield wiper motor, column switch or the front-ECU may be defective. D Malfunction of windshield wiper motor
D Malfunction of column switch
D Malfunction of front-ECU
D Malfunction of harness wire or connector

NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Windshield mist wiper switch by Input Signal Check.)
D Windshield intermittent wiper switch
D Windshield low-speed wiper switch
D Windshield high-speed wiper switch
OK
NG
Check the windshield wiper motor. (Refer to GROUP 51 – Wind- Replace
shield Wiper and Washer.)
OK
NG
Check the following connectors: Repair
A-16, A-38X
OK

Check trouble symptoms.

NG
NG
Check the harness wire between windshield wiper motor and front- Repair
ECU.
OK

Replace the front-ECU.

Inspection Procedure F-3

Windshield wiper and washer: Windshield wiper does not Probable cause
stop at the predetermined park position.
The windshield wiper motor or the front-ECU may be defective. D Malfunction of windshield wiper motor
D Malfunction of front-ECU
D Malfunction of harness wire or connector

NG
Check the windshield wiper motor. (Refer to GROUP 51 – Wind- Replace
shield Wiper and Washer.)
OK
NG
Measure at windshield wiper motor connector A-16. Check the following connectors:
D Disconnect connector and measure at harness side. A-16, C-72, C-74
D Turn the ignition switch to ACC position. OK NG
D Voltage between terminal 3 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between windshield wiper motor and igni-
A-16, A-38X tion switch (ACC).
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between windshield wiper motor and front- Repair
ECU.
OK

Replace the front-ECU.

 SWS – Troubleshooting 54B-25
Inspection Procedure F-4
Windshield wiper and washer: Windshield intermittent Probable cause
wiper interval cannot be adjusted.
The ETACS-ECU calculates the intermittent wiper interval, and sends a signal to D Malfunction of column switch
the front-ECU through the SWS communication line. If the signal is defective, D Malfunction of front-ECU
the front-ECU will ignore the signal and set the intermittent wiper interval to 4 D Malfunction of ETACS-ECU
seconds. D Malfunction of harness wire or connector

NG
MUT-II input signal check Check the windshield wiper interval adjusting knob input circuit.
D Windshield intermittent wiper interval adjusting knob (Refer to P.54B-45, Inspection Procedure N-15.)
OK

Replace the front-ECU or ETACS-ECU.

Inspection Procedure F-5

Windshield wiper and washer: Windshield washer does Probable cause
not work.
The windshield washer motor, the column switch or the front-ECU may be D Malfunction of windshield washer motor
defective. D Malfunction of column switch
D Malfunction of front-ECU
D Malfunction of harness wire or connector

No
Is the windshield wiper operated normally? Check the windshield wiper. (Refer to P.54B-11, Trouble Symptom
Yes Chart.)

NG
MUT-II input signal check Check the windshield washer switch circuit. (Refer to P.54B-45,
D Windshield washer switch Inspection Procedure N-14.)
OK
NG
Check the windshield washier motor. (Refer to GROUP 51 – Wind- Replace
shield Wiper and Washer.)
OK
NG
Measure at windshield washer motor connector A-74. Check the following connector:
D Disconnect connector and measure at harness side. A-74
D Continuity between terminal 1 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
A-38X, A-74 Check the harness wire between windshield washer motor and
OK NG body earth.

Check trouble symptoms. Repair

NG
NG
Check the harness wire between windshield washer motor and Repair
front-ECU.
OK

Replace the front-ECU.

54B-26 SWS – Troubleshooting

Inspection Procedure G-1

Rear wiper and washer: Rear wiper does not work Probable cause
normally.
The ETACS-ECU operates the rear wiper according to the input signals from the D Malfunction of rear wiper motor
following switches: D Malfunction of column switch
D Ignition switch (ACC) D Malfunction of front-ECU
D Rear wiper switch D Malfunction of harness wire or connector
If the rear wiper does not work normally, the relevant input signal circuit, the
rear wiper motor, the column switch or the ETACS-ECU may be defective.

NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Ignition switch (ACC) by Input Signal Check.)
D Rear wiper switch
OK
NG
Check the rear wiper motor. (Refer to GROUP 51 – Rear Wiper Replace
and Washer.)
OK
NG
Measure at rear wiper motor connector F-05. Check the following connector:
D Disconnect connector and measure at harness side. F-05
D Continuity between terminal 1 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-68, C-82, D-15, F-05 Check the harness wire between rear wiper motor and body earth.
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between rear wiper motor and ETACS-ECU. Replace
OK

Replace the front-ECU.

Inspection Procedure G-2

Rear wiper and washer: Rear wiper does not stop at the Probable cause
predetermined park position.
The rear wiper motor or the ETACS-ECU may be defective. D Malfunction of rear wiper motor
D Malfunction of front-ECU
D Malfunction of harness wire or connector

NG
MUT-II input signal check Check the rear wiper auto-stop signal input circuit. (Refer to
D Rear wiper auto-stop signal P.54B-41, Inspection Procedure N-9.)
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-27
Inspection Procedure G-3
Rear wiper and washer: When the shift lever <M/T> or Probable cause
selector lever <A/T> is moved to R position during the rear
wiper operation, the rear wiper does not operate at the
continuous mode.
The ETACS-ECU operates the rear wiper consecutively twice when the shift D Malfunction of back-up lamp switch
lever <M/T> or selector lever <A/T> is moved to R position while the rear wiper D Malfunction of inhibitor switch
is turned on. If the rear wiper does not work consecutively twice, the back-up D Malfunction of ETACS-ECU
lamp switch <M/T> or the inhibitor switch (reverse) <A/T> may be defective. D Malfunction of harness wire or connector

NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Back-up lamp switch <M/T> by Input Signal Check.)
D Inhibitor switch (reverse) <A/T>
OK

Replace the ETACS-ECU.

Inspection Procedure G-4

Rear wiper and washer: Rear washer does not work. Probable cause
The rear washer motor, the column switch or the ETACS-ECU may be defective. D Malfunction of rear washer motor
D Malfunction of column switch
D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

No
Is the rear wiper operated normally? Check the rear wiper. (Refer to P.54B-12, Trouble Symptom Chart.)
Yes

NG
MUT-II input signal check Check the rear washer switch circuit. (Refer to P.54B-45, Inspection
D Rear washer switch Procedure N-14.)
OK
NG
Check the rear washier motor. (Refer to GROUP 51 – Rear Wiper Replace
and Washer.)
OK
NG
Measure at rear washer motor connector A-73. Check the following connector:
D Disconnect connector and measure at harness side. A-73
D Continuity between terminal 1 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
A-73, C-72, C-82 Check the harness wire between windshield washer motor and
OK NG body earth.

Check trouble symptoms. Repair

NG
NG
Check the harness wire between rear washer motor and ETACS- Repair
ECU.
OK

Replace the ETACS-ECU.

54B-28 SWS – Troubleshooting

Inspection Procedure H-1

Headlamp washer: Headlamp washer does not work. Probable cause
The front-ECU operates the headlamp washers if the headlamp washer switch is D Malfunction of headlamp washer motor
turned to ON while the headlamp relays (low and high) are ON and the ignition D Malfunction of column switch
switch is at the ACC or ON position. D Malfunction of front-ECU
If the headlamp washer does not work normally, the headlamp washer motor, D Malfunction of harness wire or connector
the column switch or the front-ECU may be defective.

No
Is the windshield wiper and headlamp operated normally? Check the defective operation. (Refer to P.54B-11, Trouble Symp-
Yes tom Chart.)

NG
MUT-II input signal check Check the headlamp washer switch circuit. (Refer to P.54B-13,
D Headlamp washer switch Inspection Procedure N-13.)
OK
NG
Check the headlamp washier motor. (Refer to GROUP 51 – Head- Replace
lamp Washer.)
OK
NG
Measure at headlamp washer motor connector A-21. Check the following connector:
D Disconnect connector and measure at harness side. A-21
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG

Check the harness wire between headlamp washer motor and

body earth.

NG
Measure at front-ECU connector A-37X. Check the following connector:
D Disconnect connector and measure at relay box side. A-37X
D Voltage between terminal 9 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Check the following connectors:
A-21, A-37X Check the harness wire between front-ECU and fusible link (4).
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between headlamp washer motor and Repair
front-ECU.
OK

Replace the front-ECU.

 SWS – Troubleshooting 54B-29
Inspection Procedure I-1
Headlamp, tail lamp: Tail lamp do not illuminate. Probable cause
The column switch or the front-ECU may be defective. D Malfunction of column switch
D Malfunction of front-ECU
D Malfunction of harness wire or connector

NOTE
If only one lamp does not illuminate, the harness wire between the lamp and front-ECU may be defective
or the light bulb may be burned out. In this case, check the tail lamp circuit.
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis
OFF (LOCK) position? Code Chart on P.54B-7.
No
NG
MUT-II input signal check Check the tail lamp switch input circuit. (Refer to P.54B-45, Inspec-
D Tail lamp switch tion Procedure N-14.)
OK

Replace the Front-ECU.

Inspection Procedure I-2

Headlamp, tail lamp: Headlamps (low-beam) do not Probable cause
illuminate.
The column switch or the front-ECU may be defective. D Malfunction of column switch
D Malfunction of front-ECU
D Malfunction of harness wire or connector

NOTE
If only one of the headlamps (low-beam) does not illuminate, the harness wire between the headlamp
and front-ECU may be defective or the headlamp bulb may be burned out. In this case, check the headlamp
circuit.
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis
OFF (LOCK) position? Code Chart on P.54B-7.
No
NG
MUT-II input signal check Check the headlamp switch input circuit. (Refer to P.54B-45, In-
D Headlamp switch spection Procedure N-14.)
OK

Replace the Front-ECU.

54B-30 SWS – Troubleshooting

Inspection Procedure I-3

Headlamp, tail lamp: Headlamps (high-beam) do not Probable cause
illuminate.
The column switch or the front-ECU is suspected to be defective. D Malfunction of column switch
D Malfunction of front-ECU
D Malfunction of harness wire or connector

NOTE
If only one of the headlamps (high-beam) does not illuminate, the harness wire between the headlamp
and front-ECU may be defective or the headlamp bulb may be burned out. In this case, check the headlamp
circuit.
No
Is the headlamps (low-beam) operated normally? Check the headlamp (low-beam) circuit. (Refer to P.54B-29, In-
Yes spection Procedure I-2.)

NG
MUT-II input signal check Check the dimmer switch input circuit. (Refer to P.54B-45, Inspec-
D Dimmer switch tion Procedure N-14.)
OK

Replace the Front-ECU.

Inspection Procedure I-4

Headlamp, tail lamp: Headlamps do not illuminate when Probable cause
the passing switch is operated.
If the headlamps (low-beam and high-beam) are defective, the column switch or D Malfunction of column switch
the front-ECU is suspected to be defective. D Malfunction of front-ECU
D Malfunction of harness wire or connector

No
Is the headlamps (low-beam and high-beam) operated normally? Check the defective circuit. (Refer to P.54B-12, Trouble Symptom
Yes Chart.)

NG
MUT-II input signal check Check the passing switch input circuit. (Refer to P.54B-45, Inspec-
D Passing switch tion Procedure N-14.)
OK

Replace the Front-ECU.

 SWS – Troubleshooting 54B-31
Inspection Procedure I-5
Headlamp, tail lamp: The headlamp auto-cut function does Probable cause
not work normally.
The ETACS-ECU operates the headlamp auto-cut function, based on the signals D Malfunction of driver’s door switch
from the following switch: D Malfunction of column switch.
D Ignition switch (IG1) D Malfunction of front-ECU
D Driver’s door switch D Malfunction of harness wire or connector
D Tail lamp switch
D Headlamp switch
If the function does work normally, a defect on relevant input circuits, the
ETACS-ECU or the front-ECU is suspected.

Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis
OFF (LOCK) position? Code Chart on P.54B-7.
No
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Ignition switch (IG1) by Input Signal Check.)
D Driver’s door
D Tail lamp switch
D Headlamp switch
OK

Replace the front-ECU.

Inspection Procedure I-6

Headlamp, tail lamp: Headlamps dimmer switch auto-reset Probable cause
function does not work normally.
The headlamp dimmer switch auto-reset function is controlled by the front-ECU. D Malfunction of front-ECU
If a defect appears, the front-ECU may be defective.

Replace the front-ECU.

Inspection Procedure I-7

Headlamp, tail lamp: Daytime running lamp (DRL) function Probable cause
does not work.
The headlamp dimmer switch auto-reset function is controlled by the front-ECU. D Malfunction of ETACS-ECU
If a defect appears, the front-ECU may be defective. D Malfunction of front-ECU
D Malfunction of harness wire or connector.

No
Are the tail lamp and headlamps operated normally? Check the defective device. (Refer to P.54B-12, Trouble Symptom
Yes Chart.)

NG
Measure at ETACS-ECU connector C-83. Check the following connectors:
D Disconnect connector and measure at harness side. C-02, C-83
D Continuity between terminal 29 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Replace the ETACS-ECU or front-ECU.
Check the harness wire between ETACS-ECU and body earth.
54B-32 SWS – Troubleshooting

Inspection Procedure J-1

Flasher timer: Turn-signal lamp do not flash when the Probable cause
turn-signal lamp switch is turned on.
The ETACS-ECU makes the turn-signal lamps flash, based on the input signals D Malfunction of column switch
from the following switched: D Malfunction of ETACS-ECU
D Ignition switch (IG1) D Malfunction of harness wire or connector.
D Turn-signal lamp switch
If the turn-signal lamps do not flash normally, a defect on the relevant circuits or
the ETACS-ECU may be suspected.
If the hazard warning lamps also do not flash, a defect in the ETACS-ECU
power supply line specific to the turn-signal lamps is suspected.

NOTE
If only one of the turn-signal lamp does not flash, the harness wire between the lamp and ETACS-ECU
may be defective or the lamp bulb may be burned out. In this case, check the turn-signal lamp and hazard
warning lamp circuit.
Yes
Is the hazard warning lamp operated normally? MUT-II input signal check
No D Ignition switch (IG1)
D Turn-signal lamp switch
OK NG

Replace the ETACS- Check the defective input

ECU. circuit. (P.54B-13, De-
fects Found by Input Sig-
nal Check.)

NG
Measure at ETACS-ECU connector C-82. Check the following connectors:
D Disconnect connector and measure at J/B side. C-72, C-82
D Voltage between terminal 11 and body earth. OK NG
OK: System voltage.
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-68, C-76, C-78, C-82 Check the harness wire between ETACS-ECU and battery.
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between ETACS-ECU and turn-signal Repair
lamps.
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-33
Inspection Procedure J-2
Flasher timer: Hazard warning lamp do not flash when the Probable cause
hazard warning lamp switch is turned on.
The ETACS-ECU makes the turn-signal lamps flash, base on the input signals D Malfunction of hazard warning lamp switch
from the hazard warning lamp switch. D Malfunction of ETACS-ECU
If the turn-signal lamps do not flash normally, the hazard warning lamp switch D Malfunction of harness wire or connector.
input circuit or the ETACS-ECU may be defective.

NOTE
If only one of the turn-signal lamp does not flash, the harness wire between the lamp and ETACS-ECU
may be defective or the lamp bulb may be burned out. In this case, check the turn-signal lamp and hazard
warning lamp circuit.
No
Is the turn-signal lamp operated normally? Check the turn-signal lamp circuit. (Refer to P.54B-32, Inspection
Yes Procedure J-1.)

NG
Do all of the following functions operate when the ignition key Check the ETACS-ECU battery circuit. (Refer to P.54B-47, Inspec-
is at the LOCK (OFF) position? tion Procedure O-1.)
D Light reminder warning function
D Central door locking system
D Room lamp
OK
NG
MUT-II input signal check Check the hazard warning lamp switch input circuit. (Refer to
D Hazard warning lamp switch P.54B-39, Inspection Procedure N-4.)
OK

Replace the ETACS-ECU.

54B-34 SWS – Troubleshooting

Inspection Procedure K-1

Front fog lamp: Front fog lamps do not illuminate when the Probable cause
front fog lamp switch is turned on.
If the tail lamps illuminate normally, the front fog lamp switch, the front fog lamp D Malfunction of front fog lamp switch
relay, the front-ECU or the ETACS-ECU may be defective. D Malfunction of front fog lamp relay
D Malfunction of front-ECU
D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector.

NOTE
If only one of the front fog lamp or fog lamp indicator lamp does not illuminate, the harness wire between
the lamp and front fog lamp relay may be defective or the lamp bulb may be burned out. In this case,
check the front fog lamp circuit.
NG
Is the tail lamps operated normally? Check the tail lamp circuit. (Refer to P.54B-29, Inspection Proce-
OK dure I-1.)

NG
MUT-II input signal check Check the front fog lamp switch input circuit. (Refer to P.54B-39,
D Front fog lamp switch Inspection Procedure N-5.)
OK
NG
Check the front fog lamp relay. (Refer to GROUP 54A – Headlamp, Replace
Font Turn-signal Lamp and Front Fog Lamp.)
OK
NG
Measure at front fog lamp relay connector A-40X. Check the following connector:
D Disconnect connector and measure at relay box side. A-40X
D Voltage between terminal 3 and body earth. OK NG
OK: System voltage
D Voltage between terminal 4 and body earth. Check trouble symptoms. Repair
OK: System voltage
NG
OK
Check the harness wire between front fog lamp relay and battery.
Check the following connectors:
A-37X, A-40X
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between front fog lamp relay and front-ECU. Repair
OK
NG
Check the following connectors: Repair
A-40X, A-22, A-32, C-06
OK

Check trouble symptoms.

NG
NG
Check the harness wire between front fog lamp relay and front Repair
fog lamps.
OK

Replace the front-ECU.

Inspection Procedure K-2

Front fog lamp: Front fog lamp do not go out when the tail Probable cause
lamps are turned off while the fog lamps are on.
If the malfunction above occurs, the ETACS-ECU may be defective. D Malfunction of ETACS-ECU

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-35
Inspection Procedure L-1
Rear fog lamp: Rear fog lamps do not illuminate when the Probable cause
rear fog lamp switch is turned on.
If the headlamps and front fog lamp <vehicles with front fog lamp> illuminate D Malfunction of rear fog lamp switch
normally, the rear fog lamp switch, the rear fog lamp relay or the ETACS-ECU D Malfunction of rear fog lamp relay
may be defective. D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector.

No
Are the headlamps and front fog lamps <vehicles with front fog Check the defective device. (Refer to P.54B-12, Trouble Symptom
lamp> operated normally? Chart.)
Yes
NG
MUT-II input signal check Check the Rear fog lamp switch input circuit. (Refer to P.54B-40,
D Rear fog lamp switch Inspection Procedure N-6.)
OK
NG
Check the rear fog lamp relay. (Refer to GROUP 54A – Rear Com- Replace
bination Lamp and Rear Fog Lamp.)
OK
NG
Measure at rear fog lamp relay connector C-86. Check the following connectors:
D Disconnect connector and measure at relay box side. C-76, C-77, C-86
D Voltage between terminal 3 and body earth. OK NG
OK: System voltage
D Voltage between terminal 5 and body earth. Check trouble symptoms. Repair
OK: System voltage
NG
OK
Check the harness wire between rear lamp relay and battery.
Check the following connectors:
C-83, C-86
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between rear fog lamp relay and ETACS- Repair
ECU.
OK
NG
Check the rear fog lamp bulb. Replace
OK
NG
Measure at rear fog lamp connector D-40. Check the following connector:
D Disconnect connector and measure at harness side. D-40
D Continuity between terminal 1 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-38 <L.H. drive vehicles> or C-42 <R.H. drive vehicles>, C-86, Check the harness wire between rear fog lamp and body earth.
D-40
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between rear fog lamp relay and rear Repair
fog lamp.
OK

Replace the ETACS-ECU.

54B-36 SWS – Troubleshooting

Inspection Procedure L-2

Rear fog lamp: Rear fog lamp do not go out when the Probable cause
headlamps and front fog lamps <vehicles with front fog
lamp> are turned off while the fog lamps are on.
If the malfunction above occurs, the ETACS-ECU may be defective. D Malfunction of ETACS-ECU

Replace the ETACS-ECU.

Inspection Procedure M-1

Room lamp: The room lamp does not illuminate. Probable cause
If the room lamp does not illuminate at all, the room lamp bulb may be burned D Malfunction of room lamp
out, or the power supply circuit or the ETACS-ECU may be defective. D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

Yes
Does the room lamp turn on when the room lamp switch is Check the following connectors:
set to the ON position? C-73, C-82, D-07
No OK NG

Check trouble symptoms. Repair

NG

Check the harness wire between room lamp and ETACS-ECU.

OK

Replace the ETACS-ECU.

NG
Measure at room lamp connector D-07. Check the following connectors:
D Disconnect connector and measure at harness side. C-72, C-73, D-07
D Voltage between terminal 1 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Replace the room lamp.
Check the harness wire between room lamp and fusible link (3).
 SWS – Troubleshooting 54B-37
Inspection Procedure M-2
Room lamp: The room lamp dimming function does not Probable cause
work normally.
The ETACS-ECU dims the room lamp according to the input signals from the D Malfunction of key reminder switch
following switches: D Malfunction of driver’s door switch
D Ignition switch (IG1) D Malfunction of door switches
D Key reminder switch D Malfunction of driver’s door lock actuator switch
D Driver’s door switch D Malfunction of ETACS-ECU
D Door switches D Malfunction of harness wire or connector
D Driver’s door lock actuator switch <vehicles with keyless entry system>
If the Room lamp does not be dimmed normally, the relevant input signal circuit
or the ETACS-ECU may be defective.

NG
Do all of the following functions operate when the ignition key Check the ETACS-ECU battery circuit. (Refer to P.54B-47, Inspec-
is at the LOCK (OFF) position? tion Procedure O-1.)
D Light reminder warning function
D Central door locking system
D Hazard warning lamp
OK
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-13, Defects Found
D Ignition switch (IG1) by Input Signal Check.)
D Key reminder switch
D Driver’s door switch
D Door switches
D Driver’s door lock actuator switch <vehicles with keyless
entry system>
OK

Replace the ETACS-ECU.

Inspection Procedure N-1

Ignition switch (ACC) signal is not sent to the ETACS-ECU. Probable cause
The ignition switch (ACC) input signal is used to operate the following devices. If D Malfunction of ETACS-ECU
the signal fails, these devices will not work normally. D Malfunction of harness wire or connector
D Windshield wiper and washer
D Rear wiper and washer
D Headlamp washer <vehicles with headlamp washer>

NG
Measure at ETACS-ECU connector A-38X. Check the following connectors:
D Disconnect connector and measure at J/B side. A-38X, C-72, C-74
D Turn the ignition switch to ACC position. OK NG
D Voltage between terminal 24 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Replace the ETACS-ECU. Check the harness wire between ETACS-ECU and ignition switch
(ACC).
54B-38 SWS – Troubleshooting

Inspection Procedure N-2

Ignition switch (IG1) signal is not sent to the ETACS-ECU. Probable cause
The ignition switch (IG1) input signal is used to operate the following devices. If D Malfunction of ETACS-ECU
the signal fails, these devices will not work normally. D Malfunction of harness wire or connector
D Light reminder alarm function
D Power window timer function <vehicles with power window>
D Headlamp auto-cut function
D Turn-signal lamp
D Room lamp dimming function

NG
Measure at ETACS-ECU connector C-82. Check the following connectors:
D Disconnect connector and measure at J/B side. C-72, C-82
D Turn the ignition switch to ON position. OK NG
D Voltage between terminal 16 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Replace the ETACS-ECU. Check the harness wire between ETACS-ECU and ignition switch
(IG1).

Inspection Procedure N-3

Key reminder switch signal is not sent to the ETACS-ECU. Probable cause
The key reminder switch input signal is used to operate the following devices. If D Malfunction of key reminder switch
the signal fails, these devices will not work normally. D Malfunction of ETACS-ECU
D Forgotten key prevention function <Vehicles with keyless entry system> D Malfunction of harness wire or connector
D Keyless entry system <Vehicles with keyless entry system>
D Room lamp dimming function

NG
Check the key reminder switch. (Refer to GROUP 54A – Ignition Replace
Switch and Immobilizer System.)
OK
NG
Measure at key reminder switch connector C-62. Check the following connectors:
D Disconnect connector and measure at harness side. C-01, C-62
D Continuity between terminal 4 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-62, C-83 Check the harness wire between key reminder switch and body
OK NG earth.

Check trouble symptoms. Repair

NG
NG
Check the harness wire between key reminder switch and ETACS- Repair
ECU.
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-39
Inspection Procedure N-4
Hazard warning lamp switch signal is not sent to the Probable cause
ETACS-ECU.
The hazard warning lamp switch input signal is used to operate the following D Malfunction of hazard warning lamp switch
devices. If the signal fails, these devices will not work normally. D Malfunction of ETACS-ECU
D Hazard warning lamp D Malfunction of harness wire or connector
D Keyless entry system (Registering the encrypted code) <vehicles with
keyless entry system>

NG
Check the hazard warning lamp switch. (Refer to GROUP 54A Replace
– Hazard Warning Lamp Switch.)
OK
NG
Measure at hazard warning lamp switch connector C-08. Check the following connectors:
D Disconnect connector and measure at harness side. C-01, C-08
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-08, C–83 Check the harness wire between hazard warning lamp switch and
OK NG body earth.

Check trouble symptoms. Repair

NG
NG
Check the harness wire between hazard warning lamp switch and Repair
ETACS-ECU.
OK

Replace the ETACS-ECU.

Inspection Procedure N-5

Front fog lamp switch signal is not sent to the ETACS-ECU. Probable cause
The front fog lamp switch input signal is used to operate the front fog lamp. If D Malfunction of fog lamp switch
the signal fails, front fog lamp will not work normally. D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
Check the front fog lamp switch. (Refer to GROUP 54A – Head- Replace
lamp, Front Turn-signal Lamp and Front Fog Lamp.)
OK
NG
Measure at fog lamp switch connector C-03. Check the following connectors:
D Disconnect connector and measure at harness side. C-01, C-03
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-03, C-83 Check the harness wire between fog lamp switch and body earth.
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between fog lamp switch and ETACS-ECU. Repair
OK

Replace the ETACS-ECU.

54B-40 SWS – Troubleshooting

Inspection Procedure N-6

Rear fog lamp switch signal is not sent to the ETACS-ECU. Probable cause
The rear fog lamp switch input signal is used to operate the rear fog lamp. If the D Malfunction of fog lamp switch
signal fails, rear fog lamp will not work normally. D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
Check the rear fog lamp switch. (Refer to GROUP 54A – Rear Replace
Combination Lamp and Rear Fog Lamp.)
OK
NG
Measure at fog lamp switch connector C-03. Check the following connectors:
D Disconnect connector and measure at harness side. C-01, C-03
D Continuity between terminal 6 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-03, C-83 Check the harness wire between fog lamp switch and body earth.
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between fog lamp switch and ETACS-ECU. Repair
OK

Replace the ETACS-ECU.

Inspection Procedure N-7

Back-up lamp switch signal is not sent to the ETACS-ECU. Probable cause
<M/T>
The back-up lamp switch input signal is used to operate the rear wiper. If the D Malfunction of back-up lamp switch
signal is an error, the rear wiper will not operate consecutively twice when the D Malfunction of ETACS-ECU
rear wiper is on and the shift lever is moved to R position. D Malfunction of harness wire or connector

NG
Check the back-up lamp switch. Replace
OK
NG
Measure at back-up lamp switch connector B-02. Check the following connectors:
D Disconnect connector and measure at harness side. B-02, C-24, C-74, C-78, D-02
D Turn the ignition switch to ON position. OK NG
D Voltage between terminal 2 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between back-up lamp switch and ignition
B-02, C-02, C-39, C-83, D-02 switch (IG1).
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between back-up lamp switch and ETACS- Repair
ECU.
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-41
Inspection Procedure N-8
Inhibitor switch (reverse) signal is not sent to the Probable cause
ETACS-ECU. <A/T>
The inhibitor switch (reverse) input signal is used to operate the rear wiper. If D Malfunction of inhibitor switch
the signal is an error, the rear wiper will not operate consecutively twice when D Malfunction of ETACS-ECU
the rear wiper is on and the selector lever is moved to R position. D Malfunction of harness wire or connector

NG
Check the inhibitor switch. (Refer to GROUP 23 – On-vehicle Ser- Replace
vice.)
OK
NG
Measure at inhibitor switch connector B-04. Check the following connectors:
D Disconnect connector and measure at harness side. B-04, C-24, C-74, C-78, D-02
D Turn the ignition switch to ON position. OK NG
D Voltage between terminal 8 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between inhibitor switch and ignition switch
B-04, C-02, C-39, C-83, D-02 (IG1).
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between inhibitor switch and ETACS-ECU. Repair
OK

Replace the ETACS-ECU.

Inspection Procedure N-9

Rear wiper motor auto-stop signal is not sent to the Probable cause
ETACS-ECU.
Rear wiper motor auto-stop signal is used to operate the rear wiper. If the signal D Malfunction of rear wiper motor
is an error, the rear wiper will not stop at the predetermined park position. D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
Check the rear wiper motor. (Refer to GROUP 51 – Rear Wiper Replace
and Washer.)
OK
NG
Measure at rear wiper motor connector F-05. Check the following connectors:
D Disconnect connector and measure at harness side. C-68, C-77, D-15, F-05
D Turn the ignition switch to ACC position. OK NG
D Voltage between terminal 4 and ground.
OK: System voltage Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between rear wiper motor and ignition
C-68, C-82, D-15, F-05 switch (ACC).
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between rear wiper motor and ETACS-ECU. Repair
OK

Replace the ETACS-ECU.

54B-42 SWS – Troubleshooting

Inspection Procedure N-10

Driver’s door switch signal is not sent to the ETACS-ECU. Probable cause
Door switches signal is not sent to the ETACS-ECU.
<Driver’s door switch> D Malfunction of driver’s or passenger’s door switch
The driver’s door switch is used to operate the following functions. If the signal D Malfunction of back door latch
fails, these devices will not work normally. D Malfunction of ETACS-ECU
D Light reminder warning function D Malfunction of harness wire or connector
D Forgotten key prevention function <vehicles with keyless entry system>
D Power window timer function <vehicles with power window>
D Headlamp auto-cut function
<Door switches>
The door switches is used to operate the following devices. If the signal fails,
these devices will not work normally.
D Keyless entry system <vehicles keyless entry system>
D Room lamp dimming function

<Driver’s and passenger’s door switch>

NG
Check the driver’s or passenger’s door switch. (Refer to GROUP Replace
42 – Door.)
OK
NG
Check the installation of the driver’s side or passenger’s door Repair
switch to the vehicle body.
OK
NG
Check the following connectors: Repair
<Left door switch> C-68, C-82, D-27
<Right door switch> C-68, C-82, D-05
OK
NG
Check trouble symptoms. Check the harness wire between driver’s or passenger’s door
switch and ETACS-ECU.
OK NG

Replace the ETACS- Repair

ECU.

<Back door switch>

NG
Check the back door latch. (Refer to GROUP 42 – Back Door.) Replace
OK
NG
Measure at back door latch connector F-07. Check the following connector:
D Disconnect connector and measure at harness side F-07
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
C-68, C-82, D-15, F-07 Check the harness wire between back door latch and body earth.
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between back door latch and ETACS-ECU. Repair
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-43
Inspection Procedure N-11
Passenger’s door lock key cylinder switch signal is not Probable cause
sent to the ETACS-ECU.
The passenger’s door lock key cylinder switch is used to operate the central D Malfunction of passenger’s door lock key cylinder
door locking system. If the signal fails, central door locking system will not work switch
normally. D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
Check the passenger’s door lock key cylinder switch. (Refer to Replace
GROUP 42 – Door.)
OK
NG
Measure at passenger’s door lock key cylinder switch connector Check the following connectors:
E-05. <L.H. drive vehicles> C-21, E-05
D Disconnect connector and measure at harness side <R.H. drive vehicles> C-45, E-05
D Continuity between terminal 2 and body earth. NG
OK
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
<L.H. drive vehicles> C-21, C-84, E-05 Check the harness wire between passenger’s door lock key cylin-
<R.H. drive vehicles> C-45, C-84, E-05 der switch and body earth.
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between passenger’s door lock key cylin- Repair
der switch and ETACS-ECU.
OK

Replace the ETACS-ECU.

Inspection Procedure N-12

Back door lock key cylinder switch signal is not sent to the Probable cause
ETACS-ECU.
The back door lock key cylinder switch is used to operate the central door D Malfunction of back door lock key cylinder switch
locking system. If the signal fails, central door locking system will not work D Malfunction of ETACS-ECU
normally. D Malfunction of harness wire or connector

NG
Check the back door lock key cylinder switch. (Refer to GROUP Replace
42 – Back Door.)
OK
NG
Measure at back door lock key cylinder switch connector F-10. Check the following connector:
D Disconnect connector and measure at harness side F-10
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
<L.H. drive vehicles> C-38, C-84, D-39, F-10 Check the harness wire between back door lock key cylinder switch
<R.H. drive vehicles> C-42, C-84, D-39, F-10 and body earth.
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between back door lock key cylinder switch Repair
and ETACS-ECU.
OK

Replace the ETACS-ECU.

54B-44 SWS – Troubleshooting

Inspection Procedure N-13

Driver’s door lock actuator switch signal is not sent to the Probable cause
ETACS-ECU.
The driver’s door lock actuator switch is used to operate the following systems D Malfunction of driver’s door lock actuator
or functions. If the signal fails, these systems or function will not work normally. D Malfunction of ETACS-ECU
D Central door locking system D Malfunction of harness wire or connector
D Forgotten key prevention function <vehicles with keyless entry system>
D Keyless entry system <vehicles with keyless entry system>

NG
Check the driver’s door lock actuator switch. (Refer to GROUP Replace
42 – Door.)
OK
NG
Measure at driver’s door lock actuator connector E-17 <L.H. drive Check the following connectors:
vehicles> or E-06 <R.H. drive vehicles>. <L.H. drive vehicles> C-45, E-17
D Disconnect connector and measure at harness side <R.H. drive vehicles> C-21, E-06
D Continuity between terminal 1 <L.H. drive vehicles> or 3 OK NG
<R.H. drive vehicles> and body earth.
OK: Continuity Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between driver’s door lock actuator and
<L.H. drive vehicles> C-45, C-84, E-17 body earth.
<R.H. drive vehicles> C-21, C-84, E-06
OK NG

Check trouble symptoms. Repair

NG
NG
Check the harness wire between driver’s door lock actuator and Repair
ETACS-ECU.
OK

Replace the ETACS-ECU.

 SWS – Troubleshooting 54B-45
Inspection Procedure N-14
Column switch: Probable cause
D Tail lamp switch signal is not sent to the ETACS-ECU.
D Headlamp switch signal is not sent to the ETACS-ECU.
D Dimmer switch signal is not sent to the ETACS-ECU.
D Passing switch signal is not sent to the ETACS-ECU.
D Turn-signal lamp switch signal is not sent to the
ETACS-ECU.
D Windshield mist wiper switch signal is not sent to the
ETACS-ECU.
D Windshield intermittent wiper switch signal is not sent to
the ETACS-ECU.
D Windshield low-speed wiper switch signal is not sent to the
ETACS-ECU.
D Windshield high-speed wiper switch signal is not sent to
the ETACS-ECU.
D Windshield washer switch is not sent to the ETACS-ECU.
D Rear wiper switch is not sent to the ETACS-ECU.
D Rear washer is not sent to the ETACS-ECU.
D Headlamp washer switch is not sent to the ETACS-ECU.
The column switch is used to operate the following systems or functions. If the D Malfunction of column switch
signal fails, these systems or function will not work normally. D Malfunction of ETACS-ECU
D Light reminder warning function
D Windshield wiper and washer
D Rear wiper and washer
D Headlamp washer <vehicles with headlamp washer>
D Headlamp, tail lamp
D Turn-signal lamp
D Front fog lamp <vehicles with front fog lamp>
D Rear fog lamp

Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis
OFF (LOCK) position? Code Chart on P.54B-7.
No

Replace the column switch or ETACS-ECU.

Inspection Procedure N-15

Column switch: Windshield intermittent wiper interval Probable cause
adjusting knob signal is not sent to the ETACS-ECU.
If the windshield intermittent wiper interval adjusting knob is defective the D Malfunction of column switch
windshield intermittent wiper interval can not be adjusted. D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector

NG
Check the following connectors: Repair
C-63, C-83
OK

Check trouble symptoms.

NG
NG
Check the harness wire between column switch and ETACS-ECU. Repair
OK

Replace the column switch or ETACS-ECU.

54B-46 SWS – Troubleshooting

Inspection Procedure N-16

Power window main switch: Any switch signal is not sent Probable cause
to the ETACS-ECU.
If there is a problem with communication between the power window main D Malfunction of power window main switch
switch and the ETACS-ECU, the input signal check for the power window main D Malfunction of ETACS-ECU
switch can no longer be carried out. In addition, the power window timer function D Malfunction of harness wire or connector
will also stop working.

Yes
Can the driver’s side power window be operated by the power Check the following connectors:
window main switch? <L.H. drive vehicles> C-02, C-45, C-83, E-10
<R.H. drive vehicles> C-02, C-21, C-83, E-10
No
OK NG

Check trouble symptoms. Repair

NG

Check the harness wire between power window main switch and
ETACS-ECU.
OK

Replace the power window main switch or ETACS-ECU.

(1) NG
Measure at power window main switch connector E-10. Check the following connectors:
D Disconnect connector and measure at harness side. <L.H. drive vehicles> C-45, C-71, C-74, E-10
D Turn the ignition switch to ON position. <R.H. drive vehicles> C-21, C-71, C-74, E-10
(1) Voltage between terminal 1 and body earth. OK NG
OK: System voltage
(2) Continuity between terminal 5 and body earth. Check trouble symptoms. Repair
OK: Continuity (2) NG
NG
OK
Check the harness wire between power window main switch and
Replace the power window main switch. power window relay.

Check the following connectors:

<L.H. drive vehicles> C-45, E-10
<R.H. drive vehicles> C-21, E-10
OK NG

Check trouble symptoms. Repair

NG

Check the harness wire between power window main switch and
body earth.

Inspection Procedure N-17

Transmitter: Any switch signal is not sent to the Probable cause
ETACS-ECU.
The transmitter input signal is used to operate the keyless entry system. If the D Malfunction of transmitter
signal fails, keyless entry will not work normally. D Malfunction of ETACS-ECU

No
Has the encrypted code been registered properly? Re-register the encrypted code. (Refer to GROUP 42 – Keyless
Entry System.)
Yes

NG
Check the transmitter battery. (Refer to GROUP 42 – Keyless Entry Replace
System.)
OK
NG
Use an other transmitter to register the secret code. (Refer to Replace the ETACS-ECU.
GROUP 42 – Keyless Entry System.)
OK

Replace the defective transmitter.

 SWS – Troubleshooting 54B-47
Inspection Procedure N-18
Multi-center display: Any switch signal is not sent to the Probable cause
ETACS-ECU.
The cause is probably a malfunction of the multi-center display or the D Malfunction of multi-center display
ETACS-ECU. D Malfunction of ETACS-ECU
D Malfunction of harness wire or connector.

No
Is the multi-center display operated normally? Carry out troubleshooting for the multi-center display. (Refer to
Yes GROUP 54A – Multi-center Display.)

NG
Check the following connectors: Repair
C-02, C-53, C-83
OK

Check trouble symptoms.

NG
NG
Check the harness wire between multi-center display and ETACS- Repair
ECU.
OK

Replace the multi-center display or ETACS-ECU.

Inspection Procedure O-1

Check the circuit (power supply line) from the battery to Probable cause
the ETACS-ECU.
If that power supply circuit is defective, the circuit flowing trough the ignition D Malfunction of ETACS-ECU
switch (IG1) will function as a back-up circuit. In this case, the following D Malfunction of harness wire or connector.
functions will not work when the ignition switch is at LOCK (OFF) position.
D Light reminder alarm function
D Central door lock ing system
D Hazard warning lamp
D Room lamp

NG
Measure at ETACS-ECU connector C-82. Check the following connectors:
D Disconnect connector and measure at J/B side. C-72, C-82
D Voltage between terminal 6 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Replace the ETACS-ECU.
Check the harness wire between ETACS-ECU and fusible link
(3).
NOTES
 SWS – General/Troubleshooting 54B-1

GROUP 54B
SMART WIRING SYSTEM(SWS)
GENERAL
OUTLINE OF CHANGES
 Due to the introduction of 5-door models, the troubleshooting for the rear power windows have been
added.

TROUBLESHOOTING
TROUBLE SYMPTOM CHART
Trouble symptom Inspection Reference
procedure page

Power window Rear power window sub-switches can not operate rear door D-9 54B-2
windows. (However, power window main switch can operate rear
door windows.)
54B-2 SWS – Troubleshooting

Inspection Procedure D-9

Power windows: Rear power window sub-switches can Probable cause
not operate rear door windows. (However, power window
main switch can operate rear door windows.)
Power supply circuit or earth circuit of the rear power window motor, rear power  Malfunction of rear power window sub-switches
window motor or rear power window sub-switches may be defective.  Malfunction of rear power window motors
 Malfunction of wiring harness or connector

NG NG
Measure at rear power window motor Check the following connectors: Repair
connectors E-24 and E-18. C-74, C-39, C-41, D-25, D-09, E-24,
 Disconnect connector and measure E-18
at harness side.
OK
 Ignition switch: ON
NG
 Voltage between terminal 1 and Check trouble symptoms. Check harness wire between junction
body earth block and rear power window motor,
OK: System voltage and repair if necessary.
OK

NG NG
Measure at rear power window motor Check the following connectors: Repair
connectors E-24 and E-18. E-24, E-18, D-25, D-09
 Disconnect connector and measure OK
at harness side.
NG
 Continuity between terminal 3 and
body earth Check trouble symptoms. Check harness wire between rear pow-
OK: Continuity er window motor and earth, and repair
if necessary.
OK

NG
Measure at rear power window sub- Check the following connectors: Repair
switch connectors E-23 and E-19. E-23, E-19, D-25, D-09
 Disconnect connector and measure OK
at harness side.
 Continuity between terminal 4 and Check trouble symptoms. Check harness wire between rear pow-
body earth er window sub-switch and earth, and
OK: Continuity repair if necessary.
OK
NG
Check the following connectors: Repair
E-24, E-18, E-23, E-19
OK
NG NG
Check trouble symptoms. Check the harness wire between rear Repair
power window motor and rear power
window sub-switch.
OK
NG
Check rear power window sub-switch Replace
continuity. (Refer to GROUP 42.)
OK
NG
Check trouble symptoms. Replace the rear power window motor.
 HEATER,
AIR CONDITIONER
AND VENTILATION
Click on the applicable bookmark to selected the required model year
 55-1

HEATER,
AIR CONDITIONER
AND VENTILATION
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 8

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 3 Refrigerant Level Test Through Performance
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 4 Magnetic Clutch Test . . . . . . . . . . . . . . . . . . . . . . . 9
Receiver Drier Test . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor Drive Belt Adjustment . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 4 Dual Pressure Switch Check . . . . . . . . . . . . . . . . 9

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 5 CONTINUED ON NEXT PAGE

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from
rendering the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors 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 (*).
55-2

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BLOWER MOTOR ASSEMBLY AND

Performance Test . . . . . . . . . . . . . . . . . . . . . . . . 14 INSIDE/OUTSIDE AIR CHANGEOVER
DAMPER MOTOR . . . . . . . . . . . . . . . . . . . . . 25
Refrigerant Leak Repair . . . . . . . . . . . . . . . . . . 16
Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . 16 COMPRESSOR AND TENSION
Power Relay Check . . . . . . . . . . . . . . . . . . . . . . 17 PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Idle-up Operation Check . . . . . . . . . . . . . . . . . . 18
CONDENSER AND CONDENSER FAN
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HEATER CONTROL ASSEMBLY AND A/C
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . . 32
HEATER UNIT*, BLOWER UNIT*,
VENTILATORS* . . . . . . . . . . . . . . . . . . . . . . . . . 34
RESISTER* AND EVAPORATOR* . . . . . . . . 22
 HEATER, AIR CONDITIONER AND VENTILATION – General Information 55-3
GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mix refrigerant system has been adopted as a response
system that features high performance and low to restrictions on the use of chlorofluorocarbons.
operating noise, and includes an independent face In addition, an air purifier which carries out fine
air blowing function. The A/C system is basically A/C control has been included.
the same as the conventional system, but a new

Items Specifications

Heater unit Type Two-way-flow full-air-mix system

Heater control assembly Dial type

Compressor Model Scroll type

<KC 50AG or KC 50G>

Dual pressure switch High-pressure switch ON → OFF: 2,650, OFF → ON: 2,050
kPa
Low-pressure switch ON → OFF: 176, OFF → ON: 186

Refrigerant and quantity g R-134a (HFC-134a)

Approx. 550 – 590 (R.H.D.)
Approx. 600 – 640 (L.H.D.)

SAFETY PRECAUTIONS
Because R-134a refrigerant is a hydrofluorocarbon In most instances, moderate heat is required to
(HFC) which contains hydrogen atoms in place of bring the pressure of the refrigerant in its container
chlorine atoms, it will not cause damage to the ozone above the pressure of the system when charging
layer. or adding refrigerant.
Refrigerant R-134a is transparent and colourless A bucket or large pan of hot water not over 40_C
in both the liquid and vapour state. Since it has is all the heat required for this purpose. Do not
a boiling point of –29.8_C, at atmospheric pressure, heat the refrigerant container with a blow torch or
it will be a vapour at all normal temperatures and any other means that would raise temperature and
pressures. The vapour is heavier than air, pressure above this temperature. Do not weld or
non-flammable, and nonexplosive. The following steam clean on or near the system components
precautions must be observed when handling or refrigerant lines.
R-134a. Caution
Caution Keep R-134a containers upright when charging
Wear safety goggles when servicing the the system.
refrigeration system. When metering R-134a into the refrigeration system
R-134a evaporates so rapidly at normal atmospheric keep the supply tank or cans in an upright position.
pressures and temperatures that it tends to freeze If the refrigerant container is on its side or upside
anything it contacts. For this reason, extreme care down, liquid refrigerant will enter the system and
must be taken to prevent any liquid refrigerant from damage the compressor.
contacting the skin and especially the eyes. Always Caution
wear safety goggles when servicing the refrigeration 1. The leak detector for R-134a should be used
part of the A/C system. Keep a bottle of sterile to check for refrigerant gas leaks.
mineral oil handy when working on the refrigeration 2. Do not allow liquid refrigerant to touch bright
system. Should any liquid refrigerant get into the metal.
eyes, use a few drops of mineral oil to wash them
out. R-134a is rapidly absorbed by the oil. Next Refrigerant will tarnish bright metal and chrome
splash the eyes with plenty of cold water. Call your surfaces, and in combination with moisture can
doctor immediately even though irritation has severely corrode all metal surfaces.
ceased after treatment.
Caution
Do not heat R-134a above 40_C
55-4 HEATER, AIR CONDITIONER AND VENTILATION – Service Specifications/Lubricants/Special Tools

SERVICE SPECIFICATIONS
Items Standard value

Idle speed r/min 600 ± 50

Idle up speed r/min A/C at low load 700 ± 50

A/C at high load 800 ± 50

Resistor (for blower motor) Ω LO: 2.3, ML:1.0, MH: 0.3

Air gap (Magnetic clutch) 0.25 – 0.55

LUBRICANTS
Items Specified lubricants Quantity

Each connection of refrigerant line ZXL 200PG As required

Compressor refrigerant unit lubricant mȏ ZXL 200PG 130 – 170 <KC 50AG>
160 – 200 <KC 50G>

SPECIAL TOOLS
Tool Number Name Use
MB991367 Special spanner Removal and installation of armature mounting
nut of compressor

MB991386 Pin
 HEATER, AIR CONDITIONER AND VENTILATION – Troubleshooting 55-5
TROUBLESHOOTING
TROUBLESHOOTING PROCEDURES
Trouble symptom Problem cause Remedy Reference
page

When the ignition Fuse is defective Replace the fuse –

switch is “ON”,
“ON”
the A/C does not Harness or connector is defective Repair the harness or connector –
operate
A/C compressor relay is defective Replace the A/C compressor 55-17
relay

A/C compressor magnetic clutch is defective Replace the armature plate, rotor 55-28
or clutch coil

Refrigerant leak or overfilling of refrigerant Replenish the refrigerant, repair 55-16

the leak or take out some of the
refrigerant

Dual pressure switch is defective Replace the dual pressure switch 55-32

A/C switch is defective Replace the blower switch as- 55-21

sembly

Blower switch is defective Replace the blower switch as- 55-21

sembly

Air thermosensor is defective Replace the air thermosensor 55-22

Engine-ECU is defective Replace the engine-ECU –

When the A/C is Refrigerant leak Replenish the refrigerant and 55-16
operating, tem- repair the leak
perature inside
the passenger Dual pressure switch is defective Replace the dual pressure switch 55-32
compartment
doesn’t decrease Fan controller is defective Replace the fan controller GROUP14
(cool air is not – Radiator
emitted)
Air thermosensor is defective Replace the air thermosensor 55-22

Engine-ECU is defective Replace the engine-ECU –

Blower fan and Fuse is defective Replace the fuse –

motor do not turn
Harness or connector is defective Repair the harness or connector –

Blower relay is defective Replace the blower relay 55-17

Blower fan and motor are defective Replace the blower fan and 55-23
motor

Resistor (for blower motor) is defective Replace the resistor 55-22

Blower switch is defective Replace the blower switch as- 55-26

sembly
55-6 HEATER, AIR CONDITIONER AND VENTILATION – Troubleshooting

Trouble symptom Problem cause Remedy Reference

page

Blower fan and Harness or connector is defective Repair the harness or connector –
motor do not stop
turning Blower switch is defective Replace the blower switch as- 55-21
sembly

Blower relay is defective Replace the blower relay 55-17

When the A/C is Fuse is defective Replace the fuse –

operating con-
denser fan or ra- Harness or connector is defective Repair the harness or connector –
diator fan does
not turn Condenser fan motor is defective Replace the condenser fan motor 55-30

Radiator fan motor is defective Replace the radiator fan motor GROUP14
– Radiator

Engine-ECU is defective Replace the engine-ECU –

Inside and out- Harness or connector is defective Repair the harness or connector –
side changeover
does not operate Inside and outside changeover switch is Replace the blower switch as- 55-21
defective sembly

Inside and outside changeover damper motor Replace the inside and outside 55-25
is defective changeover damper motor
 HEATER, AIR CONDITIONER AND VENTILATION – Troubleshooting 55-7
INSPECTION AT THE ENGINE-ECU TERMINAL

Terminal Check item Checking requirements Normal condition

No.

21 Fan controller output A/C switch: OFF 5V

A/C switch: ON 0V

8*1 A/C compressor output A/C compressor relay: OFF 0V

22*2
A/C compressor relay: ON System voltage

45 A/C switch input A/C switch: OFF 0V

A/C switch: ON System voltage

73 1
73* Air thermosensor earth Air thermosensor detection tem
temperature:
erature: 25
25_C
C 2.0 – 2.9 V
77*2

92 Air thermosensor input Always 0V

NOTE
*1: Vehicles with immobilizer
*2: Vehicles without immobilizer
*3: Vehicles for Hong Kong
*4: Except vehicles for Hong Kong
55-8 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service

Low-pressure
ON-VEHICLE SERVICE
valve High-pressure valve
REFRIGERANT LEVEL TEST THROUGH
PERFORMANCE TEST
1. Park the vehicle to be tested in a place that is not in
direct sunlight.
2. Set conditions for outside air temperature as follows:
Charging Dry-bulb temperature: 22_C or more
Gauge manifold
hose (red) Relative humidity: 60 to 100%
3. Close all of the doors with the windows fully closed.
4. Close the valves of the gauge manifold.
5. Connect the charging hose (red) to the gauge manifold
Charging- Quick joint
(high-pressure side) and the quick joint (for high-pressure)
hose (blue) (for high-pressure) to the end of the hose.
6. Connect the charging hose (blue) to the gauge manifold
(low-pressure side) and the quick joint (for low-pressure)
Quick joint (for to the end of the hose.
low-pressure) Low- High- 7. Connect the quick joints to the appropriate service valves
pressure pressure
service service of the vehicle.
valve valve
A/C system Caution
To connect the quick joint, press section “A” firmly
against the service valve until a click is heard.
When connecting, run your hand along the hose while
pressing the section “A” to ensure that there are no
bends in the hose.
Sleeve
8. Start the engine.
9. Turn the blower switch to HI position.
A 10. Turn on the A/C switch, and set the A/C control to MAX.
COOL.
11. Set the air outlet changeover to FACE mode and the inside
High-pressure or-
low-pressure ser- air/outside air changeover to the inside air recirculation
vice valve mode.
12. Adjust the engine speed to 1,500 r/min.

Air temperature out of FACE duct (_C)

13. Check if the outside air temperature and air temperature
blown out of FACE duct, and the outside air temperature
16 and refrigerant pressure (high-pressure and low-pressure
sides) are within the normal value range shown in the
12
graphs.
8 14. If the temperature and pressure are below the given range,
Normal replenish the refrigerant. If above, drain the refrigerant.
4 (For charging, refer to P.55-10.)
0 NOTE
15 20 25 30 35 40 (_C)
In the graph below, see the following:
Outside air temperature
kPa kPa [A]: Refrigerant pressure (high-pressure side)
2942 686 [B]: Refrigerant pressure (low-pressure side)
2452 High-pressure side 588
490
1961 [B]
[A] 392
1471
294
981
196
490 Low-pressure side
98
0 0
15 20 25 30 35 40 (_C)
Outside air temperature
 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service 55-9
MAGNETIC CLUTCH TEST
1. Disconnect the connector (1-pin) to the magnetic clutch.
2. Connect battery (+) voltage directly to the connector for
the magnetic clutch.
3. If the magnetic clutch is normal, there will be “click”. If
the pulley and armature do not make contact (‘click’), there
is a malfunction.

RECEIVER DRIER TEST

Operate the unit and check the piping temperature by touching
the receiver drier outlet and inlet.
If there is a difference in the temperatures, the receiver drier
is restricted.
Replace the receiver drier.

COMPRESSOR DRIVE BELT ADJUSTMENT

Refer to GROUP 11 – On-vehicle Service.

DUAL PRESSURE SWITCH CHECK

1. Remove the dual pressure switch connector and connect
the high/low pressure side terminals located on the harness
side as shown in the illustration.
2. Install a gauge manifold to the high-pressure side service
valve of the refrigerant line. (Refer to Performance Test.)
3. When the high/low pressure sides of the dual pressure
Dual pressure switch are at operation pressure (ON) and there is
switch
continuity between the respective terminals, then the
condition is normal. If there is no continuity, replace the
switch.
LOW-PRESSURE HIGH-PRESSURE
SIDE SIDE

ON

OFF
177 " 20 186 " 20
2,050 2,650
" 200 " 200
kPa
55-10 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service

CHARGING
1. With the handles turned back all the way (valve closed),
Low-pressure High-pressure install the adaptor valve to the low-pressure side of the
valve valve gauge manifold.
2. Connect the charging hose (blue) to the adaptor valve.
3. Connect the quick joint (for low-pressure) to the charging
hose (blue).
4. Connect the quick joint (for low-pressure) to the low-
pressure service valve.
Gauge manifold
NOTE
Charging hose The low-pressure service valve should be connected to
Adapter (yellow)
valve the suction hose.
Charging hose Caution
(blue)
Switch (1) Use tools that are suited to R-134a.
R-12 con- R-134a
connection (2) To install the quick joint, press section “A” firmly
nection
port port against the service valve until a click is heard.
When connecting, run your hand along the hose
Vacuum
Quick pump while pressing to ensure that there are no bends
joint (for adaptor in the hose.
low pres- Vacuum
sure) pump 5. Close the high and low-pressure valves of the gauge
Power supply manifold.
plug
6. Install the vacuum pump adaptor to the vacuum pump.
Switch 7. Connect the vacuum pump plug to the vacuum pump
Low-pressure adaptor.
service valve 8. Connect the charging hose (yellow) to the R-134a
A connection port of the vacuum pump adaptor.
9. Tighten the adaptor valve handle (valve open).
Sleeve
10. Open the low-pressure valve of the gauge manifold.
11. Turn the power switch of the vacuum pump to the ON
position.
NOTE
Even if the vacuum pump power switch is turned ON,
the vacuum pump will not operate because of the power
supply connection in step (7).
 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service 55-11
12. Turn the vacuum pump adaptor switch to the R-134a side
to start the vacuum pump.
Caution
Do not operate the compressor for evacuation.
13. Evacuate to a vacuum reading of 100 kPa or higher (takes
approx. 10 minutes).
14. Turn the vacuum pump adaptor switch OFF and allow
to stand it for 5 minutes.
Caution
Do not operate the compressor in the vacuum
condition; damage may occur.
15. Carry out a leak test. (Good if the negative pressure does
not drop.)
Caution
If the negative pressure drops, increase the tightness
of the connections, and then repeat the evacuation
procedure from step (12).
Low-pressure
service valve Vacuum pump

16. With the handle turned back all the way (valve open),
Valve open
install the charging valve to the service can.
17. Turn the handle of the adaptor valve back all the way
Valve close (valve closed), remove it from the gauge manifold and
install the service can.
Charging 18. Tighten the handle of the charging valve (valve closed)
valve to puncture the service can.
Adaptor valve
Service can

19. Turn the handle of the charging valve back (valve open) and
Charging valve
tighten the handle of the adaptor valve (valve open) to
charge the system with refrigerant.
Caution
If the service can is inverted, liquid refrigerant may
be drawn into the compressor damaging it by liquid
compression. Keep the service can upright to ensure
that refrigerant is charged in gas state.
20. If the refrigerant is not drawn in, turn the handle of the
adaptor valve back all the way (valve closed).
Service can
(Refrigerant 21. Check for gas leaks using a leak detector.
container) If a gas leak is detected, re-tighten the connections, and
then repeat the charging procedure from evacuation in
step (12).
Caution
Low-pressure The leak detector for R-134a should be used.
service valve
22. Start the engine.
23. Operate the A/C and set to the lowest temperature (MAX.
COOL).
55-12 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service

24. Fix the engine speed at 1,500 r/min.

25. Tighten the handle of the adaptor valve (valve open) to
charge the required volume of refrigerant.
Caution
If the service can is inverted, liquid refrigerant may
be drawn into the compressor damaging it by liquid
compression. Keep the service can upright to ensure
that refrigerant is charged in gas state.
26. After charging with refrigerant, turn the handle of the
adaptor valve back all the way (valve closed).
27. Tighten the charging valve handle (valve closed).
Remove the quick joint (for low-pressure) from the
low-pressure service valve.
NOTE
If the service can is not emptied completely, keep the
handles of the charging valve and adaptor valve closed
for the next charging.

Valve open CORRECTING LOW REFRIGERANT LEVEL IN CASE THE

Charge valve SERVICE CAN IS USED.
Valve close
1. Install the charge valve with the handle turned all the
Adaptor valve way back (valve open) to the service can.
2. Install the adaptor valve with the handle turned all the
way back (valve close) to the charging valve.
Charging hose (blue)
Service can 3. Connect the charging hose (blue) to the adaptor valve.
(Refrigerant 4. Connect the charging hose (blue) to the quick joint (for
container)
low-pressure).
5. Tighten the handle of the charge valve (valve close), and
Quick joint (for low-pressure)
pierce the service can.
6. Turn the handle of the adaptor valve to bleed the air.
7. Install the quick joint (for low-pressure) to the low-pressure
service valve.
Quick joint NOTE
(for low-pressure) The low-pressure service valve should be connected to
the suction hose.

Low-pressure
service valve
 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service 55-13
8. Start the engine.
Charging valve 9. Operate the air conditioner and set at the lowest
temperature (MAX. COOL).
10. Fix the engine speed at 1,500 r/min.
11. Tighten the handle of the adaptor valve (valve open), and
replenish refrigerant while checking the quantity through
the sight glass.
Caution
If the service can is inverted, liquid refrigerant may
be draw into the compressor damaging it by liquid
Service can (Refriger- compression. Keep the service can upright to ensure
ant container) that refrigerant is changed in gas state.
12. After replenishing is completed, turn the handle of the
adaptor valve all the way back (valve close), and remove
the quick joint.
Low-pressure NOTE
service valve When there is remainder of refrigerant in the service can,
keep it for next use with the charge value and the valve
of the adaptor valve being closed.

DISCHARGING SYSTEM
1. Run the engine at an engine speed of 1,200–1,500 r/min
for approximately 5 minutes with the A/C operating to
return to the oil.
A NOTE
Returning the oil will be more effective if it is done while
driving.
Sleeve 2. Stop the engine.
3. Connect the charging hose (blue) to the adaptor valve
with its handle turned back all the way (valve closed).
4. Connect the quick joint to the charging hose (blue).
5. Install the quick joint to the low-pressure service valve.
Charging hose (blue)
NOTE
The low-pressure service valve should be connected to
Quick joint the suction hose.
Caution
To connect the quick joint, press section “A” firmly
against the service valve until a click is heard.
When connecting, run your hand along the hose while
Low-pressure pressing to ensure that there are no bends in the hose.
service valve
6. Place the adaptor valve inside the container and discharge
the refrigerant by opening the handle gradually so that
oil does not gush out.
NOTE
Any oil remaining in the container should be returned to
the A/C system.
Adaptor valve
Oil
55-14 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service

REFILLING OF OIL IN THE A/C SYSTEM

Too little oil will provide inadequate compressor lubrication
and cause a compressor failure. Too much oil will increase
discharge air temperature.
When a compressor is installed at the factory, it contains 120
mȏ of refrigerant oil. While the A/C system is in operation,
the oil is carried through the entire system by the refrigerant.
Some of this oil will be trapped and retained in various parts
of the system.
When the following system components are changed, it is
necessary to add oil to the system to replace the oil being
removed with the component.
Compressor oil: ZXL 200PG
Quantity
Condenser: 10 mȏ
Evaporator: 40 mȏ
Suction hose: 6.5 mȏ

PERFORMANCE TEST
Low-pressure valve High-pressure valve 1. The vehicles to be tested should be in a place that is
not in direct sunlight.
2. Close the high and low-pressure valve of the gauge
manifold.
3. Connect the charging hose (blue) to the low-pressure valve
and connect the charging hose (red) to the high-pressure
Gauge manifold valve of the gauge manifold.
Charging 4. Install the quick joint (for low-pressure) to the charging
hose (red) hose (blue), and connect the quick joint (for high-pressure)
Charging to the charging hose (red).
hose (blue) 5. Connect the quick joint (for low-pressure) to the
A low-pressure service valve and connect the quick joint
Adaptor
valve (for low (for high-pressure) to the high-pressure service valve.
pressure) Sleeve
NOTE
Adaptor valve The high-pressure service valve is on liquid pipe A and
(for high pressure)
the low-pressure service valve is on the suction hose.
Low- High-
pressure pressure Caution
service service
valve valve To connect the quick joint, press section “A” firmly
against the service valve until a click is heard.
When connecting, run your hand along the hose while
pressing to ensure that there are no bends in the hose.
6. Start the engine.
 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service 55-15
7. Set the controls to the A/C as follows:
A/C switch: A/C – ON position
Mode selection: Face position
Temperature control: Max. cooling position
Air selection: Recirculation position
Blower switch: HI (Fast) position
8. Adjust engine speed to 1,000 r/min with A/C clutch
engaged.
9. Engine should be warmed up with doors and windows
closed.

10. Insert a thermometer in the center A/C outlet and operate

Thermometer
the engine for 20 minutes.
11. Note the discharge air temperature.
NOTE
If the clutch cycles, take the reading before the clutch
disengages.

Performance Temperature Chart

Garage ambient temperature _C 20 25 35 40

Discharge air temperature _C 2.5 – 4.5 2.5 – 4.5 4.0 – 6.5 6.5 – 9.0

Compressor high-pressure kPa 765 – 960 765 – 960 1,325 – 1,420 1,570 – 1,765

Compressor low-pressure kPa 40 – 135 40 – 135 80 – 175 155 – 255

55-16 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service

REFRIGERANT LEAK REPAIR HANDLING TUBING AND FITTINGS

LOST CHARGE Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
If the system has lost all charge due to a leak:
capacity of the entire system. High pressures are
1. Evacuate the system. (See procedure.)
produced in the system when it is operating. Extreme
2. Charge the system with approximately one
care must be exercised to make sure that all
pound of refrigerant.
connections are pressure tight. Dirt and moisture
3. Check for leaks.
can enter the system when it is opened for repair
4. Discharge the system.
or replacement of lines or components. The following
5. Repair leaks.
precautions must be observed. The system must
6. Replace receiver drier.
be completely discharged before opening any fitting
Caution of connection in the refrigeration system. Open
Replacement filter-drier units must be sealed fittings with caution even after the system has been
while in storage. The drier used in these discharged. If any pressure is noticed as a fitting
units will saturate water quickly upon is loosened, allow trapped pressure to bleed off
exposure to the atmosphere. When installing very slowly.
a drier, have all tools and supplies ready Never attempt to rebend formed lines to fit. Use
for quick reassembly to avoid keeping the the correct line for the installation you are servicing.
system open any longer than necessary. A good rule for the flexible hose lines is keep the
7. Evacuate and charge system. radius of all bends at least 10 times the diameter
of the hose.
LOW CHARGE Sharper bends will reduce the flow of refrigerant.
The flexible hose lines should be routed so that
If the system has not lost all of its refrigerant charge; they are at least 80 mm from the exhaust manifold.
locate and repair all leaks. If it is necessary to It is good practice to inspect all flexible hose lines
increase the system pressure to find the leak at least once a year to make sure they are in good
(because of an especially low charge) add condition and properly routed.
refrigerant. If it is possible to repair the leak without Unified plumbing connections with O-rings, these
discharging the refrigerant system, use the O-rings are not reusable.
procedure for correcting low refrigerant level.

COMPRESSOR NOISE ADJUSTMENT

You must first know the conditions when the noise 1. Select a quiet area for testing. Duplicate
occurs. These conditions are: weather, vehicle conditions as much as possible. Switch
speed, in gear or neutral, engine temperature or compressor on and off several times to clearly
any other special conditions. identify compressor noise. To duplicate high
Noises that develop during A/C operation can often ambient conditions (high head pressure), restrict
be misleading. For example: what sounds like a air flow through condenser. Install manifold
failed front bearing or connecting rod, may be gauge set to make sure discharge pressure
caused by loose bolts, nuts, mounting brackets, doesn’t exceed 2,070 kPa.
or a loose clutch assembly. Verify accessory drive 2. Tighten all compressor mounting bolts, clutch
belt tension (power steering or alternator). mounting bolt, and compressor drive belt. Check
Improper accessory drive belt tension can cause to assure clutch coil is tight (no rotation or
a misleading noise when the compressor is engaged wobble).
and little or no noise when the compressor is 3. Check refrigerant hoses for rubbing or
disengaged. interference that can cause unusual noises.
Drive belts are speed-sensitive. That is, at different 4. Check refrigerant charge. (See “Charging
engine speeds, and depending upon belt tension, System”.)
belts can develop unusual noises that are often 5. Recheck compressor noise as in Step 1.
mistaken for mechanical problems within the 6. If noise still exists, loosen compressor mounting
compressor. bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and
repeat Step 1.
 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service 55-17
POWER RELAY CHECK
BLOWER RELAY
Batteryy voltage
g Terminal No.
1 3 2 5
Power is not supplied
Power is supplied
Blower relay

A/C COMPRESSOR RELAY

A/C compressor relay
Batteryy voltage
g Terminal No.
1 3 4 5
Power is not supplied
Power is supplied

FAN CONTROL RELAY

Refer to GROUP 14 – Radiator.
55-18 HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service

IDLE-UP OPERATION CHECK

1. Before inspection and adjustment, set vehicle in the
following condition:
D Engine coolant temperature: 80 – 90_C
D Lights, electric cooling fan and accessories: Set to
OFF
D Transmission: Neutral (N or P for vehicles with A/T)
D Steering wheel: Straightforward
2. Check whether or not the idling speed is the standard
value.
Standard value: 600 ± 50 r/min
3. When the A/C is running after turning the A/C switch to
ON, and the blower switch to the MH or HI position, check
to be sure that the idle speed is at the standard value.
Standard value: A/C at low load 700 ± 50 r/min
A/C at high load 800 ± 50 r/min
NOTE
There is no necessity to make an adjustment, because
the idling speed is automatically adjusted by the ISC
system. If, however, there occurs a deviation from the
standard value for some reason, check the ISC system.
(Refer to GROUP 13A – On-vehicle Service.)
 Heater Control Assembly and
HEATER, AIR CONDITIONER AND VENTILATION – A/C switch 55-19
HEATER CONTROL ASSEMBLY AND A/C SWITCH
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Center Air Outlet Assembly, Instrument Under Cover D Radio, Tape Player Removal and Installation (Refer
Removal and Installation (Refer to GROUP 52A – to GROUP 54.)
Instrument Panel.)

Removal steps
"BA 1. Air mix damper cable connection
"AA 2. Air outlet changeover damper cable
connection
3. Heater control assembly

Air outlet changeover INSTALLATION SERVICE POINTS

damper lever
"AA AIR OUTLET CHANGEOVER DAMPER CABLE
CONNECTION
DEF position
1. Set the air outlet changeover control knob on the heater
control assembly to the DEF position.
2. Set the air outlet changeover damper lever of the heater
unit to the DEF position (turn clockwise the damper lever
unit it stops), and then connect the cable to the lever.

"BA AIR MIX DAMPER CABLE CONNECTION

MAX HOT 1. Set the temperature control knob on the heater control
position assembly to the MAX HOT position.
2. Set the air mix damper lever of the heater unit to the
MAX HOT position (turn clockwise the damper lever until
it stops), and then connect the cable to the lever.

Air mix damper

lever
 Heater Control Assembly and
55-20 HEATER, AIR CONDITIONER AND VENTILATION – A/C switch

INSPECTION
BLOWER SWITCH CONTINUITY CHECK
Switch position Terminal No.
1 2 3 4 5 6
OFF
D (LO)

D (ML)

D (MH)

D (HI)

INSIDE/OUTSIDE AIR CHANGEOVER SWITCH

CONTINUITY CHECK
Inside/outside air-
changeover switch
Switch Terminal No.
position
iti
1 2 3 IND 4 8 9
RECIRC

FRESH ILL

A/C SWITCH CONTINUITY CHECK

A/C switch Switch position Terminal No.
5 IND 6 7 8 9
OFF
ON

ILL
 Heater Control Assembly and
HEATER, AIR CONDITIONER AND VENTILATION – A/C switch 55-21
DISASSEMBLY AND REASSEMBLY

6 2
5
1

4
3

Disassembly steps
1. Knob assembly AA" 4. Air mix damper cable
2. Bulb harness 5. Heater control panel
AA" 3. Air outlet changeover damper cable 6. Blower switch assembly

DISASSEMBLY SERVICE POINT

AA" AIR OUTLET CHANGEOVER DAMPER
Flat-tipped CABLE/AIR MIX DAMPER CABLE REMOVAL
screwdriver
Insert a flat-tipped screwdriver into the control base clip from
inner side, and then remove the cable by lifting the claw part
Claw of the clip.
part
 Heater Unit, Blower Unit,
55-22 HEATER, AIR CONDITIONER AND VENTILATION – Resister and Evaporator

HEATER UNIT, BLOWER UNIT, RESISTER AND EVAPORATOR

REMOVAL AND INSTALLATION
Caution: SRS
When removing and installing the floor console assembly from vehicles equipped with SRS, do
not let it bump against the SRS-ECU or the components.

Piping connection

8 OĆring

9 Compressor oil:
ZXL 200PG

7 8

4 6 2

Heater unit and blower unit removal steps

D Discharging and Charging of D Selector Lever Assembly Removal
Refrigerant (Refer to P.55-10.) and Installation (Refer to GROUP 23
D Discharging and Charging of Engine – Transmission Control.) <A/T>
Coolant (Refer to GROUP 14 – D SRS–ECU (Refer to GROUP 52B.)
On-vehicle Service.) D Floor Carpet Removal and Installation.
D Engine Cover Removal and Installa- 1. Instrument panel assembly
tion (Refer to GROUP 11 – Engine (Refer to GROUP 52A.)
Assembly.) 2. Intermediate connector
D Air Cleaner Assembly Removal and connections
Installation. 3. Antenna feeder cable connection
D Front Scuff Plate, Rear Scuff Plate, 4. DIN cable
Cowl Side Trim and Glove Box 5. Rear heater duct B
Removal and Installation (Refer to 6. Rear heater duct A
GROUP 52A – Trims.) 7. Heater hoses connection
D Front Seat Assembly (Driver’s side) 8. Refrigerant line connection
Removal and Installation (Refer to 9. Blower unit, heater unit and deck
GROUP 52A – Seat.) crossmember assembly
D Shift Lever Assembly Removal and
Installation (Refer to GROUP 22 –
Transmission Control.) <M/T>
 Heater Unit, Blower Unit,
HEATER, AIR CONDITIONER AND VENTILATION – Resister and Evaporator 55-23

10

14 19

15
16
21

13

14

18
12
17

11

10. Blower unit D Glove Box (Refer to GROUP 52A

14. Foot duct – Instrument Panel.)
19. Heater unit assembly 11. Joint duct
Evaporator and Resister removal 12. Resistor
steps 13. Cover
14. Foot duct
D Discharging and Charging of Re- 8. Refrigerant line connection
frigerant (Refer to P.55-10.) 15. Expansion valve
D Engine Cover (Refer to GROUP 11 16. Joint
– Engine Assembly.) 17. Evaporator
D Air Cleaner 18. Air thermosensor
 Heater Unit, Blower Unit,
55-24 HEATER, AIR CONDITIONER AND VENTILATION – Resister and Evaporator

INSPECTION
RESISTOR CHECK
Use a circuit tester to measure the resistance between the
terminals as indicated below. Check that the measured value
is at the standard value.
Standard value:
Measurement terminal Standard value Ω

Between terminals 1 and 3 (LO) 2.3

Between terminals 1 and 6 (ML) 1.0

Between terminals 1 and 4 (MH) 0.3

DISASSEMBLY AND REASSEMBLY

2

7
5

Disassembly steps 4. Joint

1. Cover 5. Cover
2. Heater core 6. Evaporator
3. Expansion valve 7. Air thermosensor

Resis- INSPECTION
tance kΩ
25 AIR THERMOSENSOR CHECK
15 Measure the resistance between terminals under two or more
temperature conditions. The resistance should be close to
10 the values shown in the graph.
5

0
–10 0 10 20 30 40_C
Temperature
 HEATER, AIR CONDITIONER Blower Motor Assembly and Inside/Outside
AND VENTILATION – Air Changeover Damper Motor 55-25
BLOWER MOTOR ASSEMBLY AND INSIDE/OUTSIDE AIR
CHANGEOVER DAMPER MOTOR
REMOVAL AND INSTALLATION
4

Blower motor assembly removal Inside/outside air changeover

steps damper motor removal steps
1. Under cover 3. Instrument panel
2. Blower motor assembly (Refer to GROUP 52A)
4. Inside/outside air changeover
damper motor

INSPECTION
BLOWER MOTOR CHECK
When battery voltage is applied between the terminals, check
that the motor operates. Also, check that there is no abnormal
noise.
 HEATER, AIR CONDITIONER Heater Unit, Blower Unit, Resister and
55-26 AND VENTILATION – Evaporator/Compressor and Tension Pulley

INSIDE/OUTSIDE CHANGEOVER DAMPER MOTOR

CHECK
Battery connection terminal Lever operation
4 6 7
Moves to the inside air
position
Moves to the outside air
Inside/outside air change- position
over damper motor
Caution
Cut off the battery voltage when the damper is in the
inside air position or outside air position.

COMPRESSOR AND TENSION PULLEY

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Discharging of Refrigerant (Refer to P.55-13.) D Charging of Refrigerant (Refer to P.55-10.)
D Drive Belt Tension Adjustment
(Refer to GROUP 11 – On-vehicle Service.)

25 Nm
Piping connection
4
2

5
3 3

OĆring

Compressor oil:
ZXL 200PG

Removal steps
D Washer tank D Under cover
(Refer to GROUP 51.) AB" "AA 4. Compressor
1. Drive belt (Refer to GROUP 11.) 5. Compressor bracket
2. Tension pulley
AA" 3. Suction hose and discharge hose
connection
HEATER, AIR CONDITIONER AND VENTILATION – Compressor and Tension Pulley 55-27

REMOVAL SERVICE POINTS

AA" SUCTION HOSE, DISCHARGE HOSE
DISCONNECTION
Plug the nipples of the disconnected hose and compressor
to prevent from foreign materials from entering.
Caution
Plug the nipples with material that is not permeable to
air as compressor oil and receiver absorb water vapour
easily.

AB" COMPRESSOR REMOVAL

When doing this work, be careful not to spill the compressor
oil.

INSTALLATION SERVICE POINT

"AA COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of
oil according to the procedures described below, and then
install the compressor.
1. Measure the amount (X mȏ) of oil within the removed
compressor.
2. Drain (from the new compressor) the amount of oil
calculated according to the following formula, and then
install the new compressor.
New compressor oil amount
<KC 50AG>
150 mȏ – X mȏ = Y mȏ
<KC 50G>
180 mȏ – X mȏ = Y mȏ
NOTE
(1) Y mȏ indicates the amount of oil in the refrigerant
line, the condenser, the evaporator etc.
(2) When replacing the following parts at the same time
as the compressor, subtract the rated oil amount of
the each part from Y mȏ and discharge from the new
compressor.
Quantity
Evaporator: 40 mȏ
Condenser: 10 mȏ
Suction hose: 6.5 mȏ
55-28 HEATER, AIR CONDITIONER AND VENTILATION – Compressor and Tension Pulley

INSPECTION
COMPRESSOR MAGNETIC CLUTCH OPERATION
INSPECTION
Connect the battery (+) terminal to the compressor side
terminal, and earth the battery (–) terminal to the body of
the compressor. The condition is normal if the sound of the
magnetic clutch (click) can be heard.

MAGNETIC CLUTCH
DISASSEMBLY AND REASSEMBLY

6
4

5
3
2

Magnetic clutch disassembly steps "AA 3. Snap ring

"BA D Air gap adjustment 4. Rotor
AA" 1. Armature plate 5. Snap ring
2. Shims 6. Clutch coil

DISASSEMBLY SERVICE POINT

AA" ARMATURE PLATE REMOVAL
MB991386

MB991367
 HEATER, AIR CONDITIONER AND VENTILATION – Compressor and Tension Pulley 55-29

REASSEMBLY SERVICE POINTS

Rotor Field core
"AA SNAP RING INSTALLATION
Snap ring Install the snap ring so that the tapered surface is at the outer
side.

Tapered part

AV1079AE

"BA AIR GAP ADJUSTMENT

Check whether or not the air gap of the clutch is within the
standard value.
Standard value: 0.25 – 0.55 mm
NOTE
If there is a deviation of the air gap from the standard value,
make the necessary adjustment by adjusting the number of
shims.
 Condenser and Condenser
55-30 HEATER, AIR CONDITIONER AND VENTILATION – Fan Motor

CONDENSER AND CONDENSER FAN MOTOR

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation

Piping connection 8
3

12 Nm

10 OĆring
11
Compressor oil:
ZXL 200PG

12 Nm
9

12 Nm

12

7
10
5
6
4
1

Condenser assembly removal steps 11. Radiator mounting bolt

D Discharging and charging of D Engine cover
refrigerant (Refer to P.55-10.) (Refer to GROUP 11A.)
D Radiator grille (Refer to GROUP 51.) AB" 12. Condenser assembly
"AA 1. Receiver Condenser fan and motor assembly
2. Receiver bracket removal steps
3. Air intake duct 4. Condenser fan motor and shroud
4. Fan motor and shroud assembly assembly
8. Radiator fan motor and shroud as- 5. Condenser motor and fan controller
sembly (Refer to GROUP 14) assembly
9. Condense tank 6. Condenser fan
AA" 10. Discharge hose connection 7. Condenser fan shroud
 Condenser and Condenser
HEATER, AIR CONDITIONER AND VENTILATION – Fan Motor 55-31
REMOVAL SERVICE POINTS
AA" DISCHARGE HOSE DISCONNECTION
Plug the nipples of the disconnected pipe, hose and condenser
assembly to prevent foreign materials from entering.
Caution
Plug the nipples with material that is not permeable to
air as compressor oil and the receiver absorb water vapour
easily.

AB" CONDENSER ASSEMBLY REMOVAL

1. Remove the mounting bolts from the front side of the
headlamp support member.
2. Disengage the lower part of the radiator, and then move
the radiator slightly toward the engine.
3. Raise the condenser assembly to remove from the engine
compartment.

INSTALLATION SERVICE POINT

"AA RECEIVER INSTALLATION
Install the pipe coming from the condenser to the side stamped
“IN”.

INSPECTION
CONDENSER FAN CHECK
Terminals connected to battery Condenser fan condition
1 2
Operates
55-32 HEATER, AIR CONDITIONER AND VENTILATION – Refrigerant Line

REFRIGERANT LINE
REMOVAL AND INSTALLATION
<L.H. DRIVE VEHICLES>
Pre-removal and Post-installation Operation
D Discharging and Charging of Refrigerant
(Refer to P.55-10.)
D Engine Cover Removal and Installation
(Refer to GROUP 11 – Engine Assembly.)
D Air Cleaner Assembly Removal and Installation.

Piping connection

OĆring

Compressor oil:
ZXL 200PG

3
 HEATER, AIR CONDITIONER AND VENTILATION – Refrigerant Line 55-33
<R.H. DRIVE VEHICLES>

Piping connection

OĆring

Compressor oil:
ZXL 200PG

Removal steps
AA" 1. Pipe assembly 4. Liquid pipe
AA" 2. Suction hose AA" 5. Dual pressure switch
AA" 3. Discharge hose

REMOVAL SERVICE POINT

AA" HOSE/PIPE DISCONNECTION
Plug the nipples of the disconnected hose, receiver, evaporator
and compressor to prevent foreign materials from entering.
Caution
Plug the nipples with material that is not permeable to
air as compressor oil and the receiver absorb water vapour
easily.
55-34 HEATER, AIR CONDITIONER AND VENTILATION – Ventilators

VENTILATORS
Caution: SRS
When removing and installing the floor console assembly from vehicles equipped with SRS, do
not let it bump against the SRS-ECU or the components.
3

Rear heater duct B removal steps Foot distribution duct and rear heater
D Front scuff plate, cowl side trim and duct A removal steps
center console assembly (Refer to D Floor console assembly
GROUP 52A – Instrument Panel.) (Refer to GROUP 52A.)
D Floor console assembly D Instrument panel assembly
(Refer to GROUP 52A.) (Refer to GROUP 52A.)
D Front seat D Blower motor
(Refer to GROUP 52A.) (Refer to P.55-25.)
D Floor carpet 5. Rear heater duct A
1. Under cover 6. Foot distribution duct
2. Rear heater duct B
NOTE
Defroster nozzle and distribution For the center air outlet assembly and the side air outlet
duct removal steps assembly, refer to GROUP 52A – Instrument panel.
D Instrument panel
(Refer to GROUP 52A.)
3. Defroster nozzle assembly
4. Distribution duct assembly
 HEATER, AIR CONDITIONER AND VENTILATION – Ventilators 55-35

7 8

7. Rear ventilation garnish NOTE

8. Rear ventilation duct A For the front deck garnish, refer to GROUP 51 –
Rear vent duct removal steps Windshield Wiper and Washer.
D Rear bumper (Refer to GROUP 51.)
9. Rear ventilation duct
NOTES
 HEATER, AIR CONDITIONER AND VENTILATION – General/On-vehicle Service/Resister 55-1
GROUP 55
HEATER, AIR CONDITIONER AND VENTILATION
GENERAL
OUTLINE OF CHANGES
The following service procedure has been established due to the addition of condenser fan relay and
the changes on the resister. The other service procedures are the same as before.

Condenser fan relay ON-VEHICLE SERVICE

CONDENSER FAN RELAY CONTINUITY CHECK
System
y voltage
g Terminal No.
1 3 4 5
When current is
not supplied
When current is
supplied

RESISTER
INSPECTION
Resister Check
Standard values:
Test terminals Standard value (Ω)
HI – LO (between terminals 2 and 4) 2.3
HI – ML (between terminals 2 and 1) 1.0
HI – MH (between terminals 2 and 3) 0.3
NOTES
 SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN No.: MSB-01E55-502

Date: 2001-09-20 <Model> <M/Y>
Subject: AIR CONDITIONING REFRIGERANT (EC)PAJERO PININ 00-10
PROCEDURE (H60,H70)
(EC)PAJERO (V60,70) 01-10
(EC)SPACE 99-10
RUNNER/SPACE
WAGON(N60,80,90)
(EC)COLT/LANCER 93-10
(CK01,CJ0A)
(EC)L200(K00T,K30T) 97-10
(EC)L300(P00) 95-10
Group: HEATER, A/C & Draft No.: 00AL112911 (EC)L400(PA0-PD0) 95-10
VENTILATION (EC)PAJERO SPORT 99-10
(K80W,K90W)
CORRECTION INTERNATIONAL (EC)SPACE STAR 97-10
CAR
ADMINISTRATION
(EC)CARISMA
T.MASAKI-MANAGER
OFFICE TECHNICAL SERVICE PLANNING (EC)GALANT(EA0A)
1. Description:
The air conditioning refrigerant discharging procedure has been changed as described below.

2. Applicable Manuals:
Manual Pub. No. Language Page(s)
’00 PAJERO PININ/MONTERO iO CKRE00E1 (English) 55-13
Workshop Manual CKRS00E1 (Spanish)
CKRF00E1 (French)
CKRG00E1 (German)
CKRD00E1 (Dutch)
’99 SPACE RUNNER/SPACE WAGON PWDE9803 (English) 55-13
Workshop Manual PWDS9804 (Spanish)
PWDF9805 (French)
PWDG9806 (German)
PWDD9807 (Dutch)
PWDW9808 (Swedish)
’96 COLT/LANCER PWME9511 (English) 55-13
Workshop Manual PWMS9512 (Spanish)
PWMF9513 (French)
PWMG9514 (German)
PWMD9515 (Dutch)
PWMW9516 (Swedish)
 Manual Pub. No. Language Page(s)
’99 SPACE STAR CMXE99E1 (English) 55-13
Workshop Manual CMXS99E1 (Spanish)
CMXF99E1 (French)
CMXG99E1 (German)
CMXD99E1 (Dutch)
CMXW99E1 (Swedish)
CMXI99E1 (Italian)
’97 L200 PWTE96E1 (English) 55-12
Workshop Manual PWTS96E1 (Spanish)
PWTF96E1 (French)
PWTG96E1 (German)
’99 PAJERO SPORT/MONTERO SPORT PWJE9812 (English) 55-14
Workshop Manual PWJS9813 (Spanish)
PWJF9814 (French)
PWJG9815 (German)
’96 CARISMA PWDE9502 (English) 55-12
Workshop Manual PWDS9503 (Spanish)
PWDF9504 (French)
PWDG9505 (German)
PWDD9506 (Dutch)
PWDW9507 (Swedish)
’95 L400 PWWE9410 (English) 55-20
Workshop Manual PWWS9411 (Spanish)
PWWF9412 (French)
PWWG9413 (German)
PWWD9414 (Dutch)
PWWW9415 (Swedish)
’97 GALANT PWDE9611 (English) 55-13
Workshop Manual PWDS9612 (Spanish)
PWDF9613 (French)
PWDG9614 (German)
PWDD9615 (Dutch)
PWDW9616 (Swedish)
’93 COLT/LANCER PWME9117-D (English) 55-18-4
PWMS9118-D (Spanish)
PWMF9119-D (French)
PWMG9120-D (German)
PWMD9121-D (Dutch)
PWMW9122-D (Swedish)

2
 Manual Pub. No. Language Page(s)
’01 PAJERO/MONTERO PWJE00001 (English) 55A-14
Workshop Manual VOL.2 PWJS00002 (Spanish)
’95 L300 PWWE9409 (English) 55-67-4
Workshop Manual

CD-ROM
Manual Pub. No. Language Page(s)
1992-1995 COLT/LANCER PWMM0009R (English) 55-18-4
Workshop Manual PWMM0009R (French)
PWMM0009R (German)
PWMM0009R (Dutch)
1996-2001 COLT/LANCER PWMH0018R (English) 55-13
Workshop Manual PWMH0018R (Spanish)
PWMH0018R (Swedish)
PWMK0019R (French)
PWMK0019R (German)
PWMK0019R (Dutch)
2001 PAJERO/MONTERO PWJT0008R (English) 55A-14
Workshop Manual PWJT0008R (Spanish)
PWJT0008R (French)
PWJT0008R (German)
1999 SPACE RUNNER/SPACE WAGON PWDH1816R (English) 55-13
Workshop Manual PWDH1816R (Spanish)
PWDH1816R (Swedish)
PWDK9817R (French)
PWDK9817R (German)
PWDK9817R (Dutch)
2000 PAJERO PININ/MONTERO iO CKRX00E1CD (English) 55-13
Workshop Manual CKRX00E1CD (Spanish)
CKRZ00E1CD (French)
CKRZ00E1CD (German)
CKRZ00E1CD (Dutch)
CKRZ00E1CD (Italian)
1999 PAJERO SPORT/MONTERO SPORT PWJT9818R (English) 55-14
Workshop Manual PWJT9818R (Spanish)
PWJT9818R (French)
PWJT9818R (German)
1999 SPACE STAR CMXX99E1CD (English) 55-13
Workshop Manual CMXX99E1CD (Spanish)
CMXX99E1CD (Swedish)
CMXZ99E1CD (French)
CMXZ99E1CD (German)
CMXZ99E1CD (Dutch)
CMXZ99E1CD (Italian)

3
3. Details: DISCHARGING SYSTEM
Use the refrigerant recovery unit to discharge refrigerant gas from the system.
<Correct> NOTE
Refer to the Refrigerant Recovery and Recycling Unit Instruction Manual for
operation of the unit.

HEATER, AIR CONDITIONER AND VENTILATION – On-vehicle Service

8. Start the engine.

Charging valve 9. Operate the air conditioner and set at the lowest temperature
(MAX. COOL).
10. Fix the engine speed at 1,500 r/min.
11. Tighten the handle of the adaptor valve (valve open), and
replenish refrigerant while checking the quantity through the
sight glass.
Caution
Service can If the service can is inverted, liquid refrigerant may be
(Refrigerant draw into the compressor damaging it by liquid
container)
compression. Keep the service can upright to ensure the
refrigerant is changed in gas state.
12. After replenishing is completed, turn the handle of the adaptor
Low-pressure
service valve valve all the way back (valve close), and remove the quick joint.
NOTE
When there is remainder of refrigerant in the service can,
A20X0108
keep it for next use with the charge value and the valve of the
adaptor valve being closed. <Incorrect>
DISCHARGING SYSTEM
1. Run the engine at an engine speed of 1,200-1,500 r/min for
approximately 5 minutes with the A/C operating to return to the
A oil.
NOTE
Sleeve
Returning the oil will be more effective if it is done while
driving.
2. Stop the engine
Charging hose (blue)
3. Connect the charging hose (blue) to the adaptor valve with its
handle turned back all the way (valve closed).
Quick joint 4. Connect the quick joint to the charging hose (blue).
5. Install the quick joint to the low-pressure service valve.
NOTE
The low-pressure service valve should be connected to the
Low-pressure suction hose.
service valve
Caution
To connect the quick joint, press section “A” firmly against
the service valve until a click is heard. When connecting,
run your hand along the horse while pressing to ensure
Adaptor valve that there are no bends in the hose.
Oil
6. Place the adaptor valve inside the container and discharge the
refrigerant by opening the handle gradually so that oil does not
A20X0106 gush out.
NOTE
Any oil remaining in the container should be returned to the
A/C system.
4