Mitsubishi MOTORS Lancer Evolution-VII 2001 Workshop Manual

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WORKSHOP MANUAL

EVOLUTION-VII

Pub. No. S0105CT9A

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Troubleshooting

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Page 1 www.TuningEvo.Club WORKSHOP MANUAL EVOLUTION-VII Pub. No. S0105CT9A...
Page 2: Table Of Contents
Electrical Wiring ....Body Repair ....Mitsubishi Motors Corporation May 2001...
Page 3 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).
Page 4 00-1 GENERAL CONTENTS HOW TO USE THIS MANUAL ....Models ........Model Code .
Page 5: How To Use This Manual
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 and servicing of the subject model.
Page 6: Model Indications
00-3 GENERAL - How to Use This Manual MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection. DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an engine.
Page 7: Explanation Of Manual Contents
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 provided near the front of each section in order to give a reader a better under-...
Page 8 00-5 GENERAL - How to Use This Manual Indicates the Indicates the Indicates the Indicates the page number. group title. section title. group num- ber. denotes non-re- usable part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Parts- tightening-torque Table”.
Page 9: How To Use
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.
Page 10 00-7 GENERAL - How to Use Troubleshooting/Inspection Service Points 4. INSPECTION CHART FOR DIAGNOSIS CODES 5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-10 for how to use the inspection procedures.) 6.
Page 11 00-8 GENERAL - How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP MB991529 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. 2. Turn the ignition switch to “ON” position. 3. Read out a diagnosis code by observing how the warning lamp flashes.
Page 12 00-9 GENERAL - How to Use Troubleshooting/Inspection Service Points INPUT SIGNAL CHECK <SWS> MUT- Ⅱ WHEN USING THE MUT-II 1. Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Turn the ignition switch to “LOCK”(OFF) position before connecting or disconnecting the MUT-II.
Page 13: How To Use The Inspection Procedures
00-10 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.
Page 14: Connector Measurement Service Points
00-11 GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED Harness connector (WITH CIRCUIT IN A CONDITION OF CONTINUITY)
Page 15: Connector Inspection
00-12 GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR INSPECTION Connector disconnected or improperly 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...
Page 16: Inspection Service Points For A Blown Fuse
00-13 GENERAL - How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition Battery of continuity.
Page 17: Vehicle Identification
00-14 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. Item Contents Contents...
Page 18: Model Code
00-15 GENERAL - Vehicle Identification MODEL CODE Items Contents CT 9 A S N D F Development MITSUBISHI LANCER EVOLUTION-VII Engine type 1,997 mL petrol engine 2 3 4 5 6 7 8 9 Sort Passenger car Body style 4-door sedan Transmission type 5-speed manual transmission...
Page 19: Chassis Number
00-16 GENERAL - GENERAL - Vehicle Identification Vehicle Identification CHASSIS NUMBER The chassis number is stamped on the toeboard inside the engine compartment. Items Contents Fixed figure Asia Distribution channel Japan channel Destination For Europe and General Export Body style 4-door sedan Transmission type 5-speed manual transmission...
Page 20: Major Specifications
00-17 GENERAL - Major Specifications MAJOR SPECIFICATIONS Items CT9A SNDFZL/R SNGFZL/R Vehicle Front track 1 1,500, 1,515 dimensions Overall width 2 1,770 Front overhang 3 895 Wheel base 4 2,625 Rear overhang 5 935 Overall length 6 4,455 Ground clearance 7 140 (unladen) Overall height (unladen)
Page 21: Precautions Before Service
00-18 GENERAL - Precautions Before Service 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.
Page 22 00-19 GENERAL - GENERAL - Precautions Before Service 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.
Page 23 00-20 GENERAL - GENERAL - Precautions Before Service Precautions Before Service 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 MUT- Ⅱ...
Page 24: Supplemental Restraint System
00-21 GENERAL - Supplemental Restraint System (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) To improve safety, the SRS and seat belts with instrument panel indicates the operational status pre-tensioner. These systems enhance collision of the SRS. The clock spring is installed in the safety by restraining the front passengers in case steering column.
Page 25: Srs Service Precautions
00-22 GENERAL - Supplemental Restraint System (SRS) SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others NOTE from accidental deployment of the air bag and If any of these components are diagnosed as accidental operation of the seat belt with faulty, they should only be replaced, in pre-tensioner during servicing,...
Page 26 00-23 GENERAL - Supplemental Restraint System (SRS) SRS-ECU Destination of harness Corrective action Terminal No. Instrument panel wiring harness → Earth Repair or replace each wiring harness harness Instrument panel wiring harness → Combination meter (SRS warning lamp) 9, 10 Instrument panel wiring harness →...
Page 27: Support Locations For Lifting And Jacking
00-24 GENERAL - Support Locations for Lifting and Jacking 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.
Page 28: Double-Post Lift
00-25 GENERAL - Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT Caution 1. If rubber attachments with grooves that are too thick are used at the front support positions, the front fender may become bent, so be sure to use rubber attachments with groove thicknesses of 18 mm or less.
Page 29: Support Positions And Support Method For An H-Bar Lift
00-26 GENERAL - Support Locations for Lifting and Jacking PLATE TYPE LIFT To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift. NOTE The wooden block should be 100 mm wide and 50 mm high. SUPPORT POSITIONS AND SUPPORT METHOD H-bar lift FOR AN H-BAR LIFT...
Page 30 00-27 GENERAL - Support Locations for Lifting and Jacking PREPARATION OF “ATTACHMENTS” Block (A) 1. Prepare the blocks (wooden) and nails as shown in the figure. 1,800 Item Dimensions mm Quantity Block (A) 90 × 95 × 1,800 Block (B) 60 ×...
Page 31: Standard Part/Tightening-Torque Table
00-28 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.
Page 32 11A-1 ENGINE CONTENTS ENGINE ............ENGINE OVERHAUL .
Page 33 11A-2 ENGINE CONTENTS GENERAL INFORMATION ....Manifold Vacuum Check ..... Lash Adjuster Check .
Page 34: General Information
11A-3 ENGINE <4G6> - General Information GENERAL INFORMATION Items 4G63 Total displacement mL 1,997 Bore × Stroke mm 85.0 × 88.0 Compression ratio Combustion chamber Pentroof type Camshaft arrangement DOHC Number of valve Intake Exhaust Valve timing Intake Opening BTDC 21_ Closing ABDC 59_ Exhaust...
Page 35: Service Specifications
11A-4 ENGINE - Service Specifications/Sealants SERVICE SPECIFICATIONS Items Standard value Limit Drive belt tension Vibration frequency Hz (Reference) 110 - 144 Tension N (Reference) 245 - 412 Basic ignition timing 5_BTDC ± 3_ Ignition timing Approximetely 5_BTDC Idle speed r/min 850 ±...
Page 36: Special Tools
11A-5 ENGINE - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub Measuring the drive belt tension assembly Checking the ignition timing Checking the idle speed Erasing diagnosis code Measuring the timing belt B tension MB991668 Belt tension meter Measuring the drive belt tension (used together with MUT-II) Measuring the timing belt B tension...
Page 37 11A-6 ENGINE - Special Tools Tool Number Name MB991367 Special spanner For retaining the crankshaft sprocket MB991385 MB991704 Battery harness Measuring the timing belt B tension (used together with MUT-II) MD998767 Tensioner pulley For adjusting timing belt tension socket wrench MD998738 Adjusting bolt For retaining the tensioner arm and the...
Page 38: On-Vehicle Service
11A-7 ENGINE - On-vehicle Service ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK 1. Check that the indicator marking of the auto-tensioner is within the range as shown in the illustration A of the tensioner bracket. Caution Inspection must be carried out after turning the Indicator crankshaft clockwise for more than once.
Page 39 11A-8 ENGINE - On-vehicle Service (4) Hold the special tool (MB991668) to the middle of Power steering 10 - 20 mm the belt between the pulleys (at the place indicated oil pump pulley by the arrow) about 10 - 20 mm away from the rear MB991668 15°...
Page 40: Ignition Timing Check
11A-9 ENGINE - ENGINE - On-vehicle Service On-vehicle Service IGNITION TIMING CHECK MUT-II 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.
Page 41: Idle Mixture Check
11A-10 ENGINE - ENGINE - On-vehicle Service On-vehicle Service Standard value: 5_ BTDC ± 3_ 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: 850 ±...
Page 42: Compression Pressure Check
11A-11 ENGINE - ENGINE - ENGINE - On-vehicle Service On-vehicle Service On-vehicle Service 10. Turn the ignition switch to the “LOCK” (OFF) position and then remove the MUT-II. COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal.
Page 43: Manifold Vacuum Check
11A-12 ENGINE - On-vehicle Service 12. Install the ignition coils and spark plugs. 13. Use the MUT-II to erase the self-diagnosis codes or disconnect the battery cable from the battery ( - ) terminal for 10 seconds or more and then reconnect the cable. NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.
Page 44 11A-13 ENGINE - On-vehicle Service (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.
Page 45 11A-14 ENGINE - On-vehicle Service 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.
Page 46: Crankshaft Pulley
11A-15 ENGINE - Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) Side Cover Removal and Installation...
Page 47: Camshaft And Camshaft Oil Seal
11A-16 ENGINE - Crankshaft Pulley/Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINT AA" DRIVE BELT REMOVAL Due to the adoption of the Serpentine drive system with the auto-tensioner, the following operation is required: 1. Insert the 12.7sq. spinner handle and etc. into the tool hole of the auto-tensioner and rotate it counterclockwise until the auto-tensioner gets to the stopper.
Page 48 11A-17 ENGINE - Camshaft and Camshaft Oil Seal 3.0 ± 0.5 N·m 3.5 ± 0.5 N·m 11 ± 1 N·m 11 ± 1 N·m 8.8 ± 1.0 N·m 5.0 ± 1.0 N·m Removal steps 1. Accelerator cable connection 6. Camshaft position sensor connector <L.H.
Page 49 11A-18 ENGINE - Camshaft and Camshaft Oil Seal 20 ± 1 N·m 10 ± 2 N·m 89 ± 9 N·m 11 ± 1 N·m 22 ± 4 N·m 14 ± 1 N·m Apply engine oil to all sliding parts at the time of installation.
Page 50 11A-19 ENGINE - Camshaft and Camshaft Oil Seal LUBRICATION AND SEALING POINTS <The bottom view of the rocker cover> 10 mm 10 mm Rocker Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent cover Cylinder <View A> head 10 mm Sealant: 3M ATD Part No.8660 10 mm 10 mm or equivalent...
Page 51 11A-20 ENGINE - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS AA" RADIATOR UPPER HOSE DISCONNECTION Indicate the mating marks on the radiator upper hose and the hose clamp for release. AB" CAMSHAFT SPROCKET REMOVAL Hold the hexagon part of the camshaft with a wrench and loosen the mounting bolt, then remove the camshaft sprocket.
Page 52 11A-21 ENGINE - Camshaft and Camshaft Oil Seal 2. Since the shape of camshaft bearing caps No.2 - 5 is identical, check the identification marks so that the bearing cap No., intake side, or exhaust side cannot be mistaken to install to the direction as shown in the illustration. Bearing cap No.
Page 53 11A-22 ENGINE - Camshaft and Camshaft Oil Seal "FA 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. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent...
Page 54: Oil Pan
11A-23 ENGINE - Camshaft and Camshaft Oil Seal/Oil Pan "JA CAMSHAFT END SEAL INSTALLATION Apply sealant to the positions of the camshaft end seal as shown in the illustration and install to the cylinder head. Specified sealant: 3M ATD Part No.8660 or equivalent 10 mm 10 mm Cylinder Head...
Page 55 11A-24 ENGINE - Oil Pan 9.0 ± 1.0 N·m 22 ± 4 N·m 14 ± 1 N·m 42 ± 2 N·m 9.0 ± 3.0 N·m 26 ± 5 N·m <Bolt with washer> 39 ± 5 N·m 9.0 ± 1.0 N·m <Flange bolt>...
Page 56 11A-25 ENGINE - Oil Pan INSTALLATION SERVICE POINTS "AA OIL PAN INSTALLATION 1. Remove sealant remained on the oil pan and the cylinder block. 2. Apply sealant on the mounting surface of oil pan without any gap as indicated in the figure, and install oil pan on cylinder block.
Page 57: Crankshaft Oil Seal
11A-26 ENGINE - Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. (at the lip) (at the lip) Engine oil...
Page 58 11A-27 ENGINE - Crankshaft Oil Seal REMOVAL SERVICE POINT AA" FLYWHEEL BOLT REMOVAL MD998781 INSTALLATION SERVICE POINTS Oil Seal "AA CRANKSHAFT REAR OIL SEAL INSTALLATION Crankshaft 1. Apply small quantity of engine oil on the circumference MB990938 of oil seal lip. 2.
Page 59: Cylinder Head Gasket
11A-28 ENGINE - Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Pre-removal and Post-installation Operation Fuel Outflow Preventive Operation (Refer to GROUP 13A - On-vehicle Service.) <Before removal only>...
Page 60 11A-29 ENGINE - Cylinder Head Gasket 5.0 ± 1.0 N·m 5.0 ± 1.0 N·m 9.0 ± 1.0 N·m 9.0 ± 1.0 N·m 13 ± 1 N·m (Engine oil) Removal steps 1. Ignition coil connector 12. Engine coolant temperature sensor 2. Crank angle sensor connector connector 3.
Page 61 11A-30 ENGINE - Cylinder Head Gasket 78 ± 2 N·m to 0 N·m to 20 ± 2 N·m 5.0 ± 1.0 N·m to +90_ to +90_ (cold start) (Engine oil) (Engine oil) 44 ± 5 N·m 31 ± 3 N·m 35 ±...
Page 62 11A-31 ENGINE - Cylinder Head Gasket REMOVAL SERVICE POINT AA" CYLINDER HEAD BOLTS REMOVAL Use the special tool to loosen the bolt in 2 to 3 times in the order of the numbers shown in the illustration for removal. MB991654 Engine Front INSTALLATION SERVICE POINTS "AA CYLINDER HEAD GASKET INSTALLATION...
Page 63 11A-32 ENGINE - Cylinder Head Gasket 3. Use special tool to tighten bolts according to the following procedure (tightening for plastic zone) (1) According to the sequence specified in the figure, tighten the bolt to the specified torque 78 ± 2 N·m. (2) In the reverse sequence of the figure, fully loosen MB991654 bolts.
Page 64 11A-33 ENGINE - Cylinder Head Gasket 3. In case of not rotating smoothly, remove the fuel high pressure hose and insert it to the delivery pipe again after checking damage of the O-ring since there is a possibility of O-ring engagement. 4.
Page 65: Timing Belt And Timing Belt B
11A-34 ENGINE - Timing Belt and Timing Belt B TIMING BELT AND TIMING BELT B REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) Side Cover Removal and Installation...
Page 66 11A-35 ENGINE - Timing Belt and Timing Belt B 19 ± 3 N·m (Engine oil) 8.8 ± 1.0 N·m 162 ± 5 N·m 12. Crank angle sensor "BA D Timing belt B tension adjustment AB" "CA 13. Crankshaft sprocket "AA 15. Timing belt B tensioner "CA 14.
Page 67 11A-36 ENGINE - Timing Belt and Timing Belt B AC" TIMING BELT B REMOVAL Caution When the timing belt B is reused, use a chalk to indicate an arrow of rotation direction on the back of the belt so that it can be re-assembled in the same direction as before.
Page 68 11A-37 ENGINE - Timing Belt and Timing Belt B <When using MUT-II> (1) Connect the special tool (MB991668) to the MUT-II. (2) Connect the special tool (MB991704) to the MUT-II and the battery. (3) Rotate the crankshaft clockwise for two rounds to position No.1 cylinder at compression TDC and check that timing marks of each sprocket are aligned with each other.
Page 69 11A-38 ENGINE - Timing Belt and Timing Belt B "CA CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION Engine Front 1. Clean and degrease the crankshaft sensing blade and the crankshaft sprocket mounting surfaces of the Crankshaft crankshaft sprocket and the crankshaft. 2. Install the crankshaft sensing blade and crankshaft Crankshaft sprocket sprocket to the direction as shown in the illustration.
Page 70 11A-39 ENGINE - Timing Belt and Timing Belt B "FA TIMING BELT INSTALLATION 1. Check that timing marks of camshaft sprocket, crankshaft Timing Mark sprocket, and oil pump sprocket are aligned with each other. Camshaft sprocket Crankshaft sprocket Timing Mark Timing Mark Oil pump...
Page 71 11A-40 ENGINE - Timing Belt and Timing Belt B (2) Hook the timing belt with exhaust side of the camshaft sprocket and retain the specified position indicated in the figure with paper clips. Paper clip (3) Use two wrenches to hook the timing belt to the intake Timing Mark side of the camshaft sprocket while aligning the timing marks on the rocker cover and camshaft sprocket.
Page 72 11A-41 ENGINE - Timing Belt and Timing Belt B 2. Rotate the crankshaft counterclockwise for 1/4 round. 3. Rotate the crankshaft clockwise and mate timing marks with each other to position No.1 cylinder at compression TDC. 4. Loosen the temporarily tightened tensioner pulley mounting bolt.
Page 73 11A-42 ENGINE - Timing belt and timing belt B INSPECTION AUTO-TENSIONER CHECK 1. Check the sealant for oil leakage and replace if necessary. 2. Check the rod end for wear or damage and replace if necessary. 3. Measure the deflection of the rod end pressed against the metal (cylinder block, etc) with the force of 98 - 196 98 - 196 N N while holding the auto-tensioner with a hand.
Page 74: Engine Assembly
11A-43 ENGINE - Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. 2.
Page 75 11A-44 ENGINE - Engine Assembly 5.0 ± 1.0 N·m 5.0 ± 1.0 N·m 26 ± 5 N·m 14 ± 3 N·m 11 ± 1 N·m Removal steps 1. Ignition coil connector 11. Engine coolant temperature gauge 2. Crank angle sensor connector unit connector 3.
Page 76 11A-45 ENGINE - Engine Assembly 5.0 ± 1.0 N·m (Engine oil) 67 ± 7 N·m* 12 ± 2 N·m 22 ± 4 N·m 22 ± 4 N·m 98 ± 10 N·m* 40 ± 5 N·m 42 ± 2 N·m 42 ± 2 N·m 19.
Page 77 11A-46 ENGINE - Engine Assembly REMOVAL SERVICE POINTS AA" DRIVE BELT REMOVAL Due to the adoption of the Serpentine drive system with the auto-tensioner, the following operation is required: 1. Insert the 12.7sq. spinner handle into the tool hole of the auto-tensioner and rotate it counterclockwise until the auto-tensioner reaches to the stopper.
Page 78 11A-47 ENGINE - Engine Assembly AD" ENGINE ASSEMBLY REMOVAL After checking that all the cables, hoses, and harness connectors have been disconnected, lift the engine with a chain block slowly and remove the engine assembly located at the upper engine room. INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly while checking that none of cables,...
Page 79 NOTES...
Page 80 11B-1 ENGINE OVERHAUL CONTENTS GENERAL DESCRIPTION ....SECONDARY AIR SYSTEM AND INTAKE MANIFOLD ....... SPECIFICATIONS .
Page 81: General Description
11B-2 ENGINE OVERHAUL - General Description GENERAL DESCRIPTION LIST OF MODELS Vehicle name Vehicle model Engine model Displacement mL Specifications LANCER Evolution VII CT9A 4G63 - 7 2000 DOHC 16 valve T/C SPECIFICATIONS Items Specifications Bore × stroke mm 85 × 88 Total displacement mL 1,997 Combustion chamber shape...
Page 82: Service Specifications
11B-3 ENGINE OVERHAUL - Specifications SPECIFICATIONS SERVICE SPECIFICATIONS Unit: mm Items Standard value Limited value Timing belt Timing belt B Vibration frequency Hz (during inspection) 56 - 92 Vibration frequency Hz (when re-tensing working belt) 76 - 92 Vibration frequency Hz (when mounting new belt) 76 - 92 Deflection amount <reference value>...
Page 83 11B-4 ENGINE OVERHAUL - Specifications Unit: mm Items Standard value Limited value Oil pump, oil pan Oil pump Side clearance Drive gear 0.08 - 0.14 Driven gear 0.06 - 0.12 Piston, connecting rod Piston Press-in load N 7,355 - 17,162 Piston ring Clearance between ring and ring groove No.
Page 84: Machining Standards
11B-5 ENGINE OVERHAUL - Specifications MACHINING STANDARDS Unit: mm Items Standard value Limited value Cylinder head, valve Cylinder head Oversize valve guide hole diameter 0.05 O.S. 12.05 - 12.07 0.25 O.S. 12.25 - 12.27 0.50 O.S. 12.50 - 12.52 Oversize valve seat hole diameter Intake 0.3 O.S.
Page 85 11B-6 ENGINE OVERHAUL - Specifications Items Tightening torque N·m Camshaft sprocket bolt 88 ± 10 Fuel system Throttle body bolt 19 ± 3 EGR valve bolt 20 ± 2 Fuel pressure regulator bolt 8.8 ± 2.0 Delivery pipe and injector bolt 11 ±...
Page 86 11B-7 ENGINE OVERHAUL - Specifications Items Tightening torque N·m Water outlet fitting bolt 10 ± 1 Thermostat housing bolt 23 ± 4 Water inlet pipe bolt (M6) 10 ± 1 Water inlet pipe bolt (M8) 13 ± 2 Water pump bolt 14 ±...
Page 87: Sealants
11B-8 ENGINE OVERHAUL - Specifications SEALANTS Item Specified sealant Quantity Engine support bracket bolt AAD Part No. 8672 or equivalent As required Semi-circular packing AAD Part No. 8672 or equivalent As required Rocker cover AAD Part No. 8672 or equivalent As required Water outlet fitting Mitsubishi Genuine Part No.
Page 88: Special Tools
11B-9 ENGINE OVERHAUL - Special Tools SPECIAL TOOLS Tool Number Name MD998781 Flywheel stopper Fixing of flywheel MD998778 Crankshaft Removal of crankshaft sprocket and sprocket crankshaft sprocket B MB998785 Sprocket stopper Holding of counter balance shaft sprocket MB991704 Battery harness Measurement of timing belt B tension (Use together with MUT-II.) MB991502...
Page 89 11B-10 ENGINE OVERHAUL - Special Tools Tool Number Name MD998442 Air bleed wire Bleeding of lash adjuster MB991654 Cylinder head bolt Loosening/tightening of cylinder head bolt wrench MD998772 Valve spring Compression of valve spring compressor MD998735 Valve spring Compression of valve spring compressor MD998737 Valve stem seal...
Page 90 11B-11 ENGINE OVERHAUL - Special Tools Tool Number Name MD998372 Silent shaft bearing Removal of counter balance shaft rear bearing puller MB991603 Silent shaft Guide stopper when removing/pressing in bearing installer counter balance shaft rear bearing stopper MD998705 Silent shaft bearing Press in of counter balance shaft front and rear installer bearings...
Page 91: Alternator And Ignition System
11B-12 ENGINE OVERHAUL - Alternator and Ignition System ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 3 ± 0.5 N•m 10 ± 2 N•m 8.8 ± 1.0 N•m 25 ± 5 N•m 13 ± 1 N•m 22 ± 4 N•m 44 ± 10 N•m 8.8 ±...
Page 92: Timing Belt
11B-13 ENGINE OVERHAUL - Timing Belt TIMING BELT REMOVAL AND INSTALLATION 3.5 ± 0.5 N•m 11 ± 1 N•m 49 ± 6 N•m 21 ± 4 N•m 23 ± 3 N•m 11 ± 1 N•m 11 ± 1 N•m 162 ± 5 N•m 49 ±...
Page 93 11B-14 ENGINE OVERHAUL - Timing Belt REMOVAL SERVICE POINTS AA" TIMING BELT REMOVAL 1. To ensure that the timing belt is assembled in the same direction when reused, using chalk, etc., make an arrow showing the rotation direction on the back surface of the timing belt.
Page 94 11B-15 ENGINE OVERHAUL - Timing Belt AE" TIMING BELT B REMOVAL To ensure that the timing belt is assembled in the same direction when reused, using chalk, etc., make an arrow showing the rotation direction on the back surface of the timing belt.
Page 95 11B-16 ENGINE OVERHAUL - Timing Belt "BA ENGINE SUPPORT BRACKET INSTALLATION Before tightening, apply sealant on the bolt at the position shown in the illustration. Sealant Specified sealant: AAD Part No. 8672 or equivalent "CA SEMI-CIRCULAR PACKING INSTALLATION Apply sealant at the position shown in the illustration. Sealant Specified sealant: AAD Part No.
Page 96 11B-17 ENGINE OVERHAUL - Timing Belt 3. Apply form-in-place gasket on the rocker cover at the Timing belt side position shown in the illustration. Sealant Specified sealant: AAD Part No. 8672 or equivalent 4. Install the rocker cover onto the cylinder head before the form-in-place gasket hardens.
Page 97 11B-18 ENGINE OVERHAUL - Timing Belt 3. Confirm that the tensioner B centre and bolt centre are Belt tension side positioned as shown in the illustration. Tensioner Timing belt B Tensioner B centre Installation bolt centre 4. Apply tension on the timing belt by lifting tensioner B in the direction of the arrow with a finger, and tension the tension side until it is “tight”.
Page 98 11B-19 ENGINE OVERHAUL - Timing Belt Caution (1) Measure when the belt’s surface temperature is close to room temperature. (2) Make sure that water or oil, etc., do not get on the mike. (3) If strong winds contact the mike or if noise is generated in the area while measuring, a value that differs from the actual value may be indicated.
Page 99 11B-20 ENGINE OVERHAUL - Timing Belt "JA OIL PUMP SPROCKET INSTALLATION 1. Stop the rotation of the counter balance shaft in the same manner as for removal. 2. Install the oil pump sprocket. 3. Apply the minimum required amount of engine oil on the flange nut seat surface.
Page 100 11B-21 ENGINE OVERHAUL - Timing Belt 2. Align the timing mark of the intake side camshaft sprocket to the timing mark on the rocker cover. Timing marks NOTE Even when the sprocket and rocker cover timing marks are aligned, the intake camshaft will rotate slightly in the clockwise direction by the force of the valve spring and will stabilize.
Page 101 11B-22 ENGINE OVERHAUL - Timing Belt 8. Rotate the intake side camshaft sprocket in the counterclockwise direction. Attach the belt at a position where the timing mark is deviated by one tooth in the counterclockwise direction, and then fix with a paper clip. NOTE Even if the belt is attached at a position deviated by one tooth, the intake camshaft will rotate slightly in the...
Page 102 11B-23 ENGINE OVERHAUL - Timing Belt 14. Using the special tool, rotate the tensioner pulley in the counterclockwise direction to tense the timing belt, and then fix by temporarily tightening the tensioner fixing bolt. MD998767 NOTE Remove the deflection of the timing belt between the intake side and exhaust side camshafts.
Page 103 11B-24 ENGINE OVERHAUL - Timing Belt INSPECTION 1. TIMING BELT Inspect each section of the belt in detail, and if any of the following type of damage is found, replace the belt with a new part. (1) Hardening of backface rubber. The backface is glossy, marks are not made even when a fingernail is run cross it, and there is no elasticity.
Page 104 11B-25 ENGINE OVERHAUL - Timing Belt (4) Measure the depression amount when the rod is pressed with a force of 98 to 196 N. If not at the 98 - 196 N standard value, replace the auto tensioner. Standard value: 1 mm or less Depression amount...
Page 105: Fuel System
11B-26 ENGINE OVERHAUL - Fuel System FUEL SYSTEM REMOVAL AND INSTALLATION 11 ± 1 N•m 19 ± 3 N•m 9 ± 1 N•m 11 ± 1 N•m 20 ± 2 N•m 8.8 ± 2.0 N•m 9 ± 1 N•m 9 ± 1 N•m 9 ±...
Page 106 11B-27 ENGINE OVERHAUL - Fuel System INSTALLATION SERVICE POINTS "AA INJECTOR INSTALLATION 1. Apply a small amount of new engine oil on the O-ring. 2. While rotating the injector to the left and right, insert the O-ring into the delivery pipe while taking care not to damage it.
Page 107: Secondary Air System And Intake Manifold
11B-28 ENGINE OVERHAUL - Secondary Air System and Intake Manifold SECONDARY AIR SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION 22 ± 4 N•m 24 ± 3 N•m 22 ± 4 N•m 11 ± 1 N•m 23 ± 4 N•m 36 ± 6 N•m 5 ±...
Page 108 11B-29 ENGINE OVERHAUL - Secondary Air System and Intake Manifold INSTALLATION SERVICE POINTS "AA INTAKE MANIFOLD STAY INSTALLATION Check that the intake manifold stay is seated against the intake manifold and cylinder block boss, and then tighten at the specified torque 31 ± 3 N•m. Intake manifold stay "BA MANIFOLD DIFFERENTIAL PRESSURE (MDP) SENSOR INSTALLATION...
Page 109: Exhaust Manifold
11B-30 ENGINE OVERHAUL - Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION 17 ± 2 N•m 59 ± 5 N•m 19 ± 3 N•m 11 ± 1 N•m 33 ± 6 N•m 31 ± 2 N•m 10 ± 1 N•m 55 ± 10 N•m 42 ±...
Page 110 11B-31 ENGINE OVERHAUL - Exhaust Manifold INSTALLATION SERVICE POINTS "AA EXHAUST MANIFOLD INSTALLATION 1. Lightly tighten the installation nut for the exhaust manifold. 2. Following the tightening order shown in the illustration, tighten the M8 nuts at the tightening torque 29 N•m. 3.
Page 111: Water Pump And Water Hose
11B-32 ENGINE OVERHAUL - Water Pump and Water Hose WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION 10 ± 1 N•m 23 ± 4 N•m 13 ± 2 N•m 29 ± 10 N•m 23 ± 4 N•m 10 ± 1 N•m 10.8 ±...
Page 112 11B-33 ENGINE OVERHAUL - Water Pump and Water Hose INSTALLATION SERVICE POINTS "AA O-RING/WATER INLET PIPE INSTALLATION Replace the O-ring for the water inlet pipe with a new part, and apply water on the periphery of the O-ring so that it can be inserted easily into the water pump and thermostat housing.
Page 113: Rocker Arms And Camshaft
11B-34 ENGINE OVERHAUL - Rocker Arm and Camshaft ROCKER ARM AND CAMSHAFT REMOVAL AND INSTALLATION 10 ± 2 N•m 14 ± 1 N•m 20 ± 1 N•m 22 ± 4 N•m 8.8 ± 1.0 N•m 11 ± 1 N•m Apply engine oil on all sliding sections before installing.
Page 114 11B-35 ENGINE OVERHAUL - Rocker Arm and Camshaft REMOVAL SERVICE POINT AA" LASH ADJUSTER REMOVAL Caution When reusing the lash adjuster, always clean and inspect it before installing. (Refer to the section on checking the lash adjuster.) INSTALLATION SERVICE POINTS "AA LASH ADJUSTER INSTALLATION Caution When reusing the lash adjuster, always clean and inspect...
Page 115 11B-36 ENGINE OVERHAUL - Rocker Arm and Camshaft 3. Apply sealant on the contact surfaces with the head shown in the illustration. Sealant Specified sealant: AAD Part No. 8672 or equivalent 4. Install the bearing caps onto the cylinder head, and in two to three steps tighten strongly.
Page 116 11B-37 ENGINE OVERHAUL - Rocker Arm and Camshaft INSPECTION 1. CAMSHAFT Measure the cam height (length). Replace if it exceeds the limit value. Standard value: Intake 35.79 mm Exhaust 35.49 mm Limit value: Intake 35.29 mm Exhaust 34.99 mm 2. LASH ADJUSTER Caution (1) The lash adjuster is a sophisticated part, so make sure that foreign matter, such as dirt, does not...
Page 117 11B-38 ENGINE OVERHAUL - Rocker Arm and Camshaft (3) Lightly press down on the steel ball inside using the special tool MD998442. Remove all matter and deteriorated oil adhered on the plunger by pressing the tool back and forth five to ten times until the plunger moves smoothly.
Page 118 11B-39 ENGINE OVERHAUL - Rocker Arm and Camshaft (7) Submerge the lash adjuster in vat C, and lightly press down on the steel ball inside using the special tool MD998442. Caution Do not use vat C for cleaning. If vat C is used for cleaning, foreign matter, etc., could enter the pressure chamber when filling it with diesel oil.
Page 119: Cylinder Head And Valve
11B-40 ENGINE OVERHAUL - Cylinder Head and Valve CYLINDER HEAD AND VALVE REMOVAL AND INSTALLATION 78 ± 2 N•m → Completely loosen 20 ± 2 N•m → 90_ + 90_ Apply engine oil on all sliding sections before installing. Removal steps 11.
Page 120 11B-41 ENGINE OVERHAUL - Cylinder Head and Valve REMOVAL SERVICE POINTS AA" CYLINDER HEAD BOLT REMOVAL Remove the cylinder head bolt using the special tool. MB991654 AB" RETAINER LOCK REMOVAL Compress the valve spring using the special tool, and remove the retainer lock.
Page 121 11B-42 ENGINE OVERHAUL - Cylinder Head and Valve "BA VALVE SPRING INSTALLATION Spring Install the valve spring so that the painted surface faces the retainer Painted rocker arm. surface Stem seal Spring seat "CA RETAINER LOCK INSTALLATION Compress the valve spring using the special tool, and install the retainer lock.
Page 122 11B-43 ENGINE OVERHAUL - Cylinder Head and Valve 3. Following the tightening order, tighten at 78 ± 2 N•m. Timing belt side 4. Completely loosen the bolts. 5. Next, following the tightening order, tighten the loosened bolts at the torque 20 ± 2 N•m again. 6.
Page 123 11B-44 ENGINE OVERHAUL - Cylinder Head and Valve 2. VALVE (1) If there is a faulty contact, one - sided contact or improper seating with the valve seat, correct the valve seat. Contact (2) Replace the valve if the margin exceeds the limit (Must be at centre of face) value.
Page 124 11B-45 ENGINE OVERHAUL - Cylinder Head and Valve 5. VALVE SEAT Valve shaft end Assemble the valve, and measure the amount that the valve protrudes from the valve shaft end between the Valve protrusion spring seat surfaces when the valve is pressed against amount the valve seat.
Page 125 11B-46 ENGINE OVERHAUL - Cylinder Head and Valve Valve Guide Replacement 1. Using a press, push the valve guide to the cylinder block side. 2. Machine the valve guide hole on the cylinder head to match the oversized valve guide into which it is to be pressed in.
Page 126: Oil Pump And Oil Pan
11B-47 ENGINE OVERHAUL - Oil Pump and Oil Pan OIL PUMP AND OIL PAN REMOVAL AND INSTALLATION 19 ± 3 N•m Apply engine oil on all sliding sections before installing. 23 ± 3 N•m 54 ± 5 N•m 10 ± 2 N•m 17 ±...
Page 127 11B-48 ENGINE OVERHAUL - Oil Pump and Oil Pan REMOVAL SERVICE POINTS MD998727 AA" OIL PAN REMOVAL 1. Remove the oil pan tightening bolts. 2. Tap the special tool between the oil pan and cylinder block. 3. Tap on the edge of the special tool, slide the tool and remove the oil pan.
Page 128 11B-49 ENGINE OVERHAUL - Oil Pump and Oil Pan AE" COUNTER BALANCE SHAFT REAR BEARING REMOVAL MB991603 1. Pull out the counter balance shaft rear bearing right from the cylinder block using the special tool (MD998372). 2. When removing the counter balance shaft rear bearing MD998372 left, install the special tool (MB991603) onto the front of the cylinder block, and then remove the bearing using...
Page 129 11B-50 ENGINE OVERHAUL - Oil Pump and Oil Pan 3. Align and insert the special tool into the guide pin, and tap in the counter balance shaft rear bearing right. MD998705 Guide pin MD998705 "CA COUNTER BALANCE SHAFT FRONT BEARING INSTALLATION 1.
Page 130 11B-51 ENGINE OVERHAUL - Oil Pump and Oil Pan 4. Align and insert the special tool into the guide pin, and tap in the counter balance shaft front bearing. MD998705 Guide pin "DA OIL PUMP OIL SEAL INSTALLATION Install the oil pump oil seal using an appropriate socket wrench. Socket wrench Oil seal Oil pump case...
Page 131 11B-52 ENGINE OVERHAUL - Oil Pump and Oil Pan "GA OIL PUMP DRIVE GEAR/OIL PUMP DRIVEN GEAR INSTALLATION Apply sufficient engine oil onto the gears, align the match Match marks marks, and assemble. "HA OIL PUMP CASE INSTALLATION Counter balance 1.
Page 132 11B-53 ENGINE OVERHAUL - Oil Pump and Oil Pan "JA PLUG CAP INSTALLATION MD998162 1. Install a new O-ring onto the oil pump case. 2. Lightly tighten the plug cap by hand. 3. As shown in the illustration, fit the special tool (MD998162) into the notch on the plug cap, and while supporting with the special tool (MD998783), tighten the plug cap at the specified torque 23 ±...
Page 133 11B-54 ENGINE OVERHAUL - Oil Pump and Oil Pan "MADRAIN PLUG GASKET INSTALLATION Drain plug Replace the gasket with a new part, and install at the direction shown in the illustration. Caution Incorrect installation direction will lead to oil leaks. Oil pan Gasket Oil pan side...
Page 134 11B-55 ENGINE OVERHAUL - Oil Pump and Oil Pan 3. OIL PUMP (1) Assemble the drive gear and driven gear into the oil pump case. (2) Inspect the side clearance with a thickness gauge. Standard value: Drive gear 0.08 - 0.14 mm Driven gear 0.06 - 0.12 mm...
Page 135: Piston And Connecting Rod
11B-56 ENGINE OVERHAUL - Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Apply engine oil on all sliding sections before installing. 20 ± 2 N•m + 90_ - 94_ Removal steps "GA 1. Connecting rod cap nut "CA 7.
Page 136 11B-57 ENGINE OVERHAUL - Piston and Connecting Rod REMOVAL SERVICE POINTS AA" CONNECTING ROD CAP REMOVAL Note the cylinder No. on the side of the connecting rod’s Cylinder No. large end for identification during reassembly. AB" PISTON PIN REMOVAL Guide A: 17.9 mm The special tool’s piston pin setting tool (MD998780) is Push rod Guide B...
Page 137 11B-58 ENGINE OVERHAUL - Piston and Connecting Rod INSTALLATION SERVICE POINTS "AA PISTON PIN INSTALLATION 1. Measure the length of the following parts. A : Piston pin installation section B : Between piston boss C : Piston pin D : Connecting rod 2.
Page 138 11B-59 ENGINE OVERHAUL - Piston and Connecting Rod "BA OIL RING INSTALLATION 1. Assemble the oil ring’s spacer into the piston ring groove. Next, assemble the upper side rail, and then assemble the lower side rail. Upper Lower side side NOTE rail rail...
Page 139 11B-60 ENGINE OVERHAUL - Piston and Connecting Rod "DA PISTON AND CONNECTING ROD ASSEMBLY Side rail No. 1 ring INSTALLATION 1. Apply sufficient engine oil on the piston ring’s periphery, piston ring and oil ring. 2. Align the piston ring and oil ring (side rail, spacer) closed Piston pin gap positions as shown in the illustration.
Page 140 11B-61 ENGINE OVERHAUL - Piston and Connecting Rod 4. If there is no identification, measure the oil clearance and select. "FA CONNECTING ROD CAP INSTALLATION 1. Align the marks made during disassembly, and install the bearing cap onto the connecting rod. When using a new connecting rod that has no match marks, assemble Cylinder No.
Page 141 11B-62 ENGINE OVERHAUL - Piston and Connecting Rod 9. Check that the thrust clearance at the large end of the connecting rod is correct. Standard value: 0.10 - 0.25 mm Limit value: 0.4 mm INSPECTION 1. PISTON RING (1) Inspect the clearance between the piston ring and ring groove.
Page 142 11B-63 ENGINE OVERHAUL - Piston and Connecting Rod 2. CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Wipe off the oil from the crankshaft pin and connecting rod bearing. (2) Set a plastic gauge as long as the bearing width on the pin shaft so that straightly aligned with the shaft centre.
Page 143: Crankshaft And Cylinder Block
11B-64 ENGINE OVERHAUL - Crankshaft and Cylinder Block CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION 11 ± 1 N•m 132 ± 5 N•m 9 ± 1 N•m 11 ± 1 N•m 32 ± 2 N•m Apply engine oil on all sliding sections before installing.
Page 144 11B-65 ENGINE OVERHAUL - Crankshaft and Cylinder Block INSTALLATION SERVICE POINTS "AA THRUST BEARING INSTALLATION 1. Install the thrust bearing onto the cylinder block side of the No. 3 bearing section. The bearing can be installed easily by applying engine oil. 2.
Page 145 11B-66 ENGINE OVERHAUL - Crankshaft and Cylinder Block 3. Select the bearing from the above table according to Crankshaft bearing side the identification confirmed in steps 1 and 2. identification mark position [Example of selecting bearing] (1) If the measured outer diameter of the crankshaft journal is 57.000 mm, Class 1 applies, and the identification colour is yellow.
Page 146 11B-67 ENGINE OVERHAUL - Crankshaft and Cylinder Block 8. After installing the beam bearing cap, inspect the end play of the crankshaft. If the end play exceeds the limit value, replace the crankshaft bearing. Standard value: 0.05 - 0.25 mm Limit value: 0.4 mm "DA REAR OIL SEAL INSTALLATION Press in the rear oil seal using the special tool.
Page 147 11B-68 ENGINE OVERHAUL - Crankshaft and Cylinder Block INSPECTION Plastic gauge 1. CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) The oil clearance can be measured easily by using the “plastic gauge”. Use the following steps to use the “plastic gauge”. (1) Wipe off all oil from the crankshaft’s outer diameter and bearing’s inner diameter.
Page 148 11B-69 ENGINE OVERHAUL - Crankshaft and Cylinder Block 3. CYLINDER BORING (1) Select the oversized piston to be used using the maximum inner diameter cylinder as a reference. (2) There are two types of oversized pistons (0.50 mm, 1.00 mm), so bore so that the clearance is at the specified value that matches the piston’s outer diameter.
Page 149 NOTES...
Page 150 12-1 ENGINE LUBRICATION CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Engine Oil Check .
Page 151: General Information
12-2 ENGINE LUBRICATION - General Information GENERAL INFORMATION The lubrication method is a fully force-fed, full-flow filtration type. The oil pump is a gear type which 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.
Page 152: Service Specifications
12-3 ENGINE LUBRICATION - Service Specifications/Sealant/Lubricants/Special Tool SERVICE SPECIFICATIONS Items Standard value Oil pressure kPa at idle 29 or more at 3,500 r/min 294 - 686 SEALANT Items Specified sealant Remark Oil pressure switch 3M ATD Part No. 8660 or equivalent Semi-drying sealant LUBRICANTS Items...
Page 153: On-Vehicle Service
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 petrol mixed in, and that it has sufficient viscosity.
Page 154: Oil Filter Replacement
12-5 ENGINE LUBRICATION - On-vehicle Service OIL FILTER 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. Commercially- available tool 3. Remove the drain plug to drain oil. Caution Use care as oil could be hot.
Page 155 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...
Page 156: Engine Oil Cooler
12-7 ENGINE LUBLICATION - Engine Oli Cooler ENGINE OIL COOLER REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Pre-removal and Post-installation Operation Engine Oil Draining and Supplying (Refer to P.12-4.) Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
Page 157 NOTES...
Page 158: Fuel
13A-1 FUEL CONTENTS MULTIPOINT FUEL INJECTION (MPI) ........FUEL SUPPLY .
Page 159 13A-2 MULTIPOINT FUEL INJECTION (MPI) CONTENTS GENERAL INFORMATION ....Fuel Pump Relay 3 Continuity Check ..Fuel Pump Resistor Check .
Page 160 13A-3 MPI - General Information 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...
Page 161: General Specifications
13A-4 MPI - General Information OTHER CONTROL FUNCTIONS 1. Fuel Pump Control 3. Fan Motor Control Turns the fuel pump relay ON so that current The revolutions of the radiator fan and is supplied to the fuel pump while the engine condenser fan are controlled in response to is cranking or running.
Page 162 13A-5 MPI - General Information MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM L1 Oxygen sensor (front) l1 Injector L2 Oxygen sensor (rear) l2 Idle speed control servo L3 Air flow sensor l3 Fuel pressure control solenoid valve Engine-ECU L4 Intake air temperature sensor l4 Waste gate solenoid valve L5 Throttle position sensor l5 EGR control solenoid valve...
Page 163 13A-6 MPI - Service Specifications/Sealant SERVICE SPECIFICATIONS Items Specifications Basic idle speed r/min 850 ± 100 Throttle position sensor adjusting voltage mV 535 - 735 Throttle position sensor resistance kΩ 3.5 - 6.5 Idle speed control servo coil resistance (at 20_C) Ω 28 - 33 Intake air temperature sensor - 20_C...
Page 164 13A-7 MPI - Special Tools SPECIAL TOOLS Tool Number Name MB991223 Harness set Check at the ECU terminals A: Connector pin contact pressure inspection A: MB991219 A: Test harness B: Power circuit inspection B: MB991220 B: LED harness C: Power circuit inspection C: MB991221 C: LED harness D: Commercial tester connection...
Page 165 13A-8 MPI - Special Tools Tool Number Name MD998478 Test harness Measurement of voltage during trouble- (3-pin, triangle) shooting Inspection using an analyzer 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...
Page 166 13A-9 MPI - Troubleshooting TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Point. NOTE If the engine-ECU 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.
Page 167 13A-10 MPI - MPI - Troubleshooting Troubleshooting Code No. Diagnosis item P0443 Purge control solenoid valve system P0500 Vehicle speed sensor system P0505 Idle speed control system P0551 Power steering fluid pressure switch P1104 Waste gate solenoid valve system P1105 Fuel pressure control solenoid valve system NOTE If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication between...
Page 168 13A-11 MPI - MPI - Troubleshooting Troubleshooting CONFIRMING 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 MUT-II, an effective troubleshooting can be performed.
Page 169 13A-12 MPI - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page P0100 Air flow sensor system 13A-13 P0105 Barometric pressure sensor system 13A-15 P0110 Intake air temprature sensor system 13A-16 P0115 Engine coolant temperature sensor system 13A-19 P0120 Throttle position sensor system...
Page 170 13A-13 MPI - Troubleshooting DIAGNOSTIC TROUBLE CODE INSPECTION PROCEDURE Code No. P0100 Air flow sensor system Probable cause Inspection Range D Air flow sensor malfunction D Engine speed: More than 500 r/min D Air flow sensor circuit disconnection, short-circuit, Evaluation Conditions or connector contact defect D The sensor output frequency is less than 3 Hz for 4 seconds.
Page 171 13A-14 MPI - Troubleshooting From the previous page Repair Check the following connector: Measure at the B-31 air flow sensor C-126 connector. D Using the test harness (MB991709), connect the connector, and measure at the Repair Check the harness between the air pickup.
Page 172 13A-15 MPI - Troubleshooting Code No. P0105 Barometric pressure sensor system Probable cause Inspection Range D Barometric pressure sensor malfunction D 2 seconds after the ignition switch is set to the “ON” position, or after the D Barometric pressure sensor circuit disconnection, completion of start of engine.
Page 173 13A-16 MPI - Troubleshooting From the previous page (1), (2) NG Measure at the B-31 air flow sensor Check the following connectors: Repair connector. C-115 D Using the test harness (MB991709), connect only connector terminals No. 1, No. 2, Check and repair the harness between and No.
Page 174 13A-17 MPI - Troubleshooting MUT-II Data list Intermittent malfunction D No. 13 Intake air temperature (Refer to GROUP 00 - Points to Note sensor for Intermittent Malfunctions.) OK: Ambient temperature (More or less the same as the air temperature) Repair Check the following connector: B-31 Check the intake air temperature...
Page 175 13A-18 MPI - Troubleshooting From the previous page Measure at the B-31 air flow sensor Check the following connectors: Repair connector. C-115 D Using the test harness (MB991709), connecting only connector terminals No. 5 and Check and repair the harness between No.
Page 176 13A-19 MPI - Troubleshooting Code No. P0115 Engine coolant temperature sensor Probable cause system Inspection Range D Engine coolant temperature sensor malfunction D After setting the ignition switch to the “ON” position, or 2 seconds after D Engine coolant temperature sensor circuit completion of engine start.
Page 177 13A-20 MPI - Troubleshooting From the previous page (1) NG Measure at the B-118 engine coolant Measure at the C-115 engine-ECU Check the following connector: temperature sensor connector. connector. C-115 D Disconnect the connector to D Measure the engine-ECU terminal measure at the harness side voltage.
Page 178 13A-21 MPI - Troubleshooting From the previous page Measure at the B-118 engine coolant Check the following connector: Repair temperature sensor connector. C-115 D Using the test harness (MB991658), connect the connector, and measure at the Check and repair the harness between pickup harness.
Page 179 13A-22 MPI - Troubleshooting From the previous page (1) NG Measure at the B-02 throttle position Measure at the C-115 engine-ECU Check the following connector: sensor connector. connector. C-115 D Disconnect the connector to D Measure engine-ECU terminal measure at the harness side voltage.
Page 180 13A-23 MPI - Troubleshooting From the previous page (1), (2) NG Measure at the B-02 throttle position Check the following connector: Repair sensor connector. C-115 D Using the test harness (MB991536), connect the connector, and measure at the Check and repair the harness between pickup harness.
Page 181 13A-24 MPI - Troubleshooting Code No. P0130 Oxygen sensor (front) system Probable cause Inspection Range D Oxygen sensor (front) malfunction D More than 3 minutes passed after completion of start of engine D Oxygen sensor (front) circuit disconnection, D The engine coolant temperature is approximately more than 80_C. short-circuit, or connector contact defect.
Page 182 13A-25 MPI - Troubleshooting From the previous page Repair Test at the C-115 engine-ECU Check the following connector: connector. C-115 D Measure the engine-ECU terminal voltage. D Engine: After warm-up Check and repair the harness between D Voltage between terminal No. 76 the oxygen sensor (front) and and earth.
Page 183 13A-26 MPI - Troubleshooting Code No. P0135 Oxygen sensor heater (front) system Probable cause Inspection Range D Oxygen sensor heater (front) malfunction D The engine coolant temperature is approximately more than 20_C. D Oxygen sensor heater (front) circuit disconnection, D The oxygen sensor heater (front) is ON. short-circuit, or connector contact defect D The engine speed is more than 50 r/min.
Page 184 13A-27 MPI - Troubleshooting Code No. P0136 Oxygen sensor (rear) system Probable cause Inspection Range D Oxygen sensor (rear) malfunction D More than 3 minutes passed after completion of start of engine D Oxygen sensor (rear) circuit disconnection, D The engine coolant temperature is approximately more than 80_C. short-circuit, or connector contact defect.
Page 185 13A-28 MPI - Troubleshooting From the previous page Repair Test at the C-115 engine-ECU Check the following connector: connector. C-115 D Measure the engine-ECU terminal voltage. D Engine: After warm-up Check and repair the harness between D Voltage between terminal No. 75 the oxygen sensor (rear) and and earth.
Page 186 13A-29 MPI - Troubleshooting Code No. P0141 Oxygen sensor heater (rear) system Probable cause Inspection Range D Oxygen sensor heater (rear) malfunction D The engine coolant water temperature is approximately more than 20_C. D Oxygen sensor heater (rear) circuit disconnection, D The oxygen sensor heater (rear) is ON.
Page 187 13A-30 MPI - Troubleshooting Code No. P0201 No. 1 injector system Probable cause Inspection Range D No. 1 injector malfunction D The engine speed is 50 - 1,000 r/min. D No. 1 injector circuit disconnection, short-circuit, or D The throttle position sensor output voltage is 1.15 V or less. connector contact defect D MUT-II forced drive (actuator test) is not being carried out.
Page 188 13A-31 MPI - Troubleshooting Code No. P0202 No. 2 injector system Probable cause Inspection Range D No. 2 injector malfunction D The engine speed is 50 - 1,000 r/min. D No. 2 injector circuit disconnection, short-circuit, or D The throttle position sensor output voltage is 1.15 V or less. connector contact defect D MUT-II forced drive (actuator test) is not being carried out.
Page 189 13A-32 MPI - Troubleshooting Code No. P0203 No. 3 injector system Probable cause Inspection Range D No. 3 injector malfunction D The engine speed is 50 - 1,000 r/min. D No. 3 injector circuit disconnection, short-circuit, or D The throttle position sensor output voltage is 1.15 V or less. connector contact defect D MUT-II forced drive (actuator test) is not being carried out.
Page 190 13A-33 MPI - Troubleshooting Code No. P0204 No. 4 injector system Probable cause Inspection Range D No. 4 injector malfunction D The engine speed is 50 - 1,000 r/min. D No. 4 injector circuit disconnection, short-circuit, or D The throttle position sensor output voltage is 1.15 V or less. connector contact defect D MUT-II forced drive (actuator test) is not being carried out.
Page 191 13A-34 MPI - Troubleshooting Code No. P0325 Detonation sensor system Probable cause Inspection Range D Malfunction of the detonation sensor D Ignition switch: ON D Detonation sensor circuit disconnection, short-circuit, D Excluding for 2 seconds after ignition switch is set to “ON” position or 2 seconds or connector contact defect after engine start is completed.
Page 192 13A-35 MPI - Troubleshooting Code No. P0335 Crank angle sensor system Probable cause Inspection Range D Malfunction of crank angle sensor D Engine: During cranking D Open or short circuit in the crank angle sensor circuit Evaluation Conditions or loose connector contact D The sensor output voltage does not change for 2 seconds (no pulse signal output) D Malfunction of engine-ECU MUT-II Data list...
Page 193 13A-36 MPI - Troubleshooting From the previous page Measure the output waveform at the Check the following connector: Repair B-121 crank angle sensor connector B-11X (using an analyzer). D Using the test harness (MD998478), connect the Repair Check the harness between the crank connector, and measure at the angle sensor and engine control relay.
Page 194 13A-37 MPI - Troubleshooting Code No. P0340 Camshaft position sensor system Probable cause Inspection Range D Malfunction of camshaft position sensor D Ignition switch: ON D Open or short circuit in the camshaft position sensor D The engine speed is approximately 50 r/min or more. or loose connector contact Evaluation Conditions D Malfunction of engine-ECU...
Page 195 13A-38 MPI - Troubleshooting From the previous page Measure the output waveform at the Check the following connector: Repair B-116 camshaft position sensor B-11X connector (using an analyzer). D Using the test harness (MB991709), connect the Repair Check the harness between the connector, and measure at the camshaft position sensor connector pickup harness.
Page 196 13A-39 MPI - Troubleshooting Code No. P0403 EGR control solenoid valve system Probable cause Inspection Range D EGR control solenoid valve malfunction D The battery voltage is 10 V or more. D EGR control solenoid valve circuit disconnection, Evaluation Conditions short-circuit, or connector contact defect D Solenoid coil’s surge voltage (battery voltage +2 V) is not detected when EGR D Engine-ECU malfunction...
Page 197 13A-40 MPI - Troubleshooting From the previous page Check the harness between the EGR Repair control solenoid valve and engine control relay. D Check for damage of the power cable. MUT-II Actuator test Intermittent malfunction D No. 10: EGR control solenoid valve (Refer to GROUP 00 - Points to Note OK: Operation sound is heard, for Intermittent Malfunctions.)
Page 198 13A-41 MPI - 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.
Page 199 13A-42 MPI - Troubleshooting From the previous page Check the harness between the purge Repair control solenoid valve and engine control relay. D Check for damage of the power cable. MUT-II Actuator test Intermittent malfunction D No. 08: Purge control solenoid (Refer to GROUP 00 - Points to Note valve for Intermittent Malfunctions.)
Page 200 13A-43 MPI - Troubleshooting Code No. P0500 Vehicle speed sensor system Probable cause Inspection Range D Vehicle speed sensor malfunction D Ignition switch: ON D Vehicle speed sensor circuit disconnection, D After 2 seconds from setting ignition switch to ON position or completion of engine short-circuit, or connector contact defect starting D Engine-ECU malfunction...
Page 201 13A-44 MPI - Troubleshooting Code No. P0505 Idle speed control system Probable cause Range of Check D Malfunction of idle speed control servo D Vehicle speed has reached 1.5 Km/h at least once. D Open or short circuit in the idle speed control servo D Under the closed loop idle speed control.
Page 202 13A-45 MPI - Troubleshooting Check the following connector: Repair B-115 Measure at the B-115 idle speed Replace the idle speed control servo. control servo connector. D Disconnect the connector to measure at the idle speed control servo side. D Resistance between terminal No. 1 and terminal No.
Page 203 13A-46 MPI - Troubleshooting Code No. P0551 Power steering fluid pressure switch Probable cause system Range of Check D Power steering fliud pressure switch failed D Intake air temperature is - 10_C or higher. D Open or short circuit in the power steering fluid D Barometric pressure is 76 kPa or more.
Page 204 13A-47 MPI - Troubleshooting Code No. P1104 Waste gate solenoid valve system Probable cause Inspection Range D Waste gate solenoid valve malfunction D Battery voltage is more than 10 V. D Engine-ECU malfunction Evaluation Conditions D Solenoid coil’s surge voltage (battery voltage +2 V) is not detected when the waste gate solenoid valve turned from ON to OFF.
Page 205 13A-48 MPI - Troubleshooting Code No. P1105 Fuel pressure control solenoid valve Probable cause system Inspection Range D Fuel pressure control solenoid valve malfunction D Battery voltage is more than 10 V. D Engine-ECU malfunction Evaluation Conditions D Solenoid coil’s surge voltage (battery voltage +2 V) is not detected when the fuel pressure control solenoid valve turned from ON to OFF.
Page 206 13A-49 MPI - Troubleshooting Code No. P1500 Alternator FR terminal system Probable cause Inspection Range D Open circuit in the alternator FR terminal circuit D Engine speed: More than 50 r/min D Malfunction of engine-ECU Evaluation Conditions D The input voltage from the alternator FR terminal is between 4.8 V and 5.2 V or is the battery voltage for 20 seconds.
Page 207 13A-50 MPI - Troubleshooting Code No. P1603 Battery backup line malfunction Probable cause Inspection Range D Battery backup line disconnection, short circuit or D Ignition switch: ON connector contact defect Evaluation Conditions D Engine-ECU malfunction D The backup RAM information set at the last time when the ignition switch was turned to the OFF position is not memorized.
Page 208 13A-51 MPI - Troubleshooting Code No.P1610 Immobilizer system <Europe and Probable cause General Export-spec. models> Inspection Range 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...
Page 209 13A-52 MPI - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Inspection Check items Reference page procedure Communication between MUT-II and entire system is not possible. 13A-54 Only communication between MUT-II and engine-ECU is not possible. 13A-55 Engine warning lamp does not illuminate immediately after ignition switch is set to ON position. 13A-56 Engine warning lamp stays illuminated and does not turn OFF.
Page 210 13A-53 MPI - 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.
Page 211 13A-54 MPI - Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Communication between MUT-II and entire system is not Probable cause possible. Causes shown on right are suspected. D Diagnosis connector malfunction D MUT-II malfunction Check the following connector: Repair C-22 (1) NG...
Page 212 13A-55 MPI - Troubleshooting Inspection Procedure 2 Only communication between MUT-II and engine-ECU is Probable cause not possible. Causes shown on right are suspected. D Ignition switch malfunction D Engine control relay malfunction D Engine-ECU malfunction Check the engine warning lamp. Check the Inspection Procedure 22: D Ignition switch: ON Engine-ECU power supply, engine...
Page 213 13A-56 MPI - Troubleshooting Inspection Procedure 3 Engine warning lamp does not illuminate immediately Probable cause after ignition switch is set to ON position. The engine-ECU illuminates the engine warning lamp for 5 seconds immediately after D Engine warning lamp bulb dead ignition switch is set to “ON”...
Page 214 13A-57 MPI - Troubleshooting Inspection Procedure 4 Engine warning lamp stays illuminated and does not turn Probable cause OFF. The engine-ECU illuminates the engine warning lamp when the occurrence of a D Engine-ECU malfunction diagnosis code is recorded. MUT-II Self-Diag code INSPECTION CHART FOR DIAGNO- D Is a diagnosis code output? SIS CODE...
Page 215 13A-58 MPI - Troubleshooting Inspection Procedure 5 Starting disabled (Starter does not rotate.) Probable cause Causes shown on right are suspected. D Battery malfunction D Ignition switch malfunction D Starter malfunction Check the battery. Replace the battery. (Refer to GROUP 54 - Battery.) MUT-II Data list Check the following connector: Repair...
Page 216 13A-59 MPI - Troubleshooting Inspection Procedure 6 Starting disabled (Starter rotates but initial combustion Probable cause does not occur.) Causes shown on right are suspected. D Battery malfunction D Ignition switch malfunction D Ignition system malfunction D Fuel system malfunction D Throttle valve malfunction D Timing belt malfunction D Engine-ECU malfunction-...
Page 217 13A-60 MPI - Troubleshooting From the previous page Replace the spark plug cable. Check the spark plug cable. (Refer to GROUP 16 - Ignition Device.) Replace the spark plug. Check the spark plug. (Refer to GROUP 16 - Ignition Device.) Replace the ignition coil.
Page 218 13A-61 MPI - Troubleshooting Inspection Procedure 7 Starting disabled (Initial combustion occurs but is Probable cause incomplete.), improper starting (Starting time is long.) Causes shown on right are suspected. D Battery malfunction D Ignition system malfunction D Fuel system malfunction D Intake system malfunction D EGR valve malfunction D Timing belt malfunction...
Page 219 13A-62 MPI - Troubleshooting From the previous page Replace the spark plug cable. Check the spark plug cable. (Refer to GROUP 16 - Ignition Device.) Replace the spark plug. Check the spark plug. (Refer to GROUP 16 - Ignition Device.) Check the following connectors: B-103, B-119 Repair Replace the ignition coil.
Page 220 13A-63 MPI - Troubleshooting Inspection Procedure 8 Unstable idling (Rough idling, hunting), inappropriate Probable cause idling speed (High or low idling speed), engine stalls (Die out) during idling Causes shown on right are suspected. D Idle speed control system malfunction D Air/fuel ratio control system malfunction D Ignition system malfunction D Fuel system malfunction...
Page 221 13A-64 MPI - Troubleshooting From the previous page Check the Code No. P0136: Oxygen sensor (rear) system. MUT-II Data list (Refer to P.13A-27.) D No. 59: Oxygen sensor (rear) (Refer to P.13A-105.) (1) NG Measure at the C-115 and C-126 Check the following connectors: Repair engine-ECU connectors.
Page 222 13A-65 MPI - Troubleshooting From the previous page Replace the spark plug cable. Check the spark plug cable. (Refer to GROUP 16 - Ignition Device.) Replace the spark plug. Check the spark plug. (Refer to GROUP 16 - Ignition Device.) Check the following connectors: B-114, B-119 Repair Replace the ignition coil.
Page 223 13A-66 MPI - Troubleshooting Inspection Procedure 9 Engine stalls when starting travel. (Pass out) Probable cause Causes shown on right are suspected. D Ignition system malfunction D Intake system malfunction D Exhaust gas purifier system malfunction D Throttle body malfunction D Engine-ECU malfunction Has the battery terminal been disconnected recently? After warming up the engine, idle for approximately 10 minutes.
Page 224: Engine Stalls During Deceleration
13A-67 MPI - Troubleshooting Inspection Procedure 10 Engine stalls during deceleration Probable cause Causes shown on right are suspected. D Idle speed control system malfunction D Exhaust gas purifier system malfunction D Throttle valve malfunction D Engine-ECU malfunction Has the battery terminal been disconnected recently? After warming up the engine, idle for approximately 10 minutes.
Page 225 13A-68 MPI - Troubleshooting Inspection Procedure 11 Pulsation (Hesitation, sag), poor acceleration, stumbling, Probable cause surging Causes shown on right are suspected. D Air/fuel ratio control system malfunction D Ignition system malfunction D Fuel system malfunction D Intake and exhaust system malfunction D Exhaust gas purifier system malfunction D Improper compression pressure D Turbocharger system malfunction...
Page 226 13A-69 MPI - Troubleshooting From the previous page Replace the spark plug cable. Check the spark plug cable. (Refer to GROUP 16 - Ignition Device.) Replace the spark plug. Check the spark plug. (Refer to GROUP 16 - Ignition Device.) Check the following connectors: B-123, B-119 Repair Replace the ignition coil.
Page 227: Shock During Acceleration
13A-70 MPI - Troubleshooting Inspection Procedure 12 Shock during acceleration Probable cause The occurrence of ignition leaks, etc., due to the rise in voltage required for the spark D Ignition system malfunction plugs during acceleration is a probable cause. MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODE D Is a diagnosis code output? (Refer to P.13A-12.)
Page 228: Shock During Deceleration
13A-71 MPI - Troubleshooting Inspection Procedure 13 Shock during deceleration Probable cause The idle speed control may be incorrect. D Idle speed control system malfunction MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODE D Is a diagnosis code output? (Refer to P.13A-12.) Check the Code No.P0120: Throttle position sensor system.
Page 229 13A-72 MPI - Troubleshooting Inspection Procedure 14 Knocking Probable cause Causes shown on right are suspected. D Detonation sensor malfunction D Knocking control system malfunction D Spark plug malfunction D Ignition system malfunction D Engine-ECU malfunction MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODE D Is a diagnosis code output? (Refer to P.13A-12.) Replace the spark plug cable.
Page 230: Deviation Of Ignition Interval
13A-73 MPI - Troubleshooting Inspection Procedure 15 Deviation of ignition interval Probable cause Causes shown on right are suspected. D Crank angle sensor malfunction D Camshaft position sensor malfunction D Timing belt malfunction D Engine-ECU malfunction MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODE D Is a diagnosis code output? (Refer to P.13A-12.) Check the trouble symptoms.
Page 231 13A-74 MPI - Troubleshooting Inspection Procedure 16 Run on (Dieseling) Probable cause Causes shown on right are suspected. D Injector malfunction D Engine-ECU malfunction Replace the injectors for all cylinders. Check the trouble symptoms. Replace the engine-ECU.
Page 232 13A-75 MPI - Troubleshooting Inspection Procedure 17 Abnormal odor, white smoke, black smoke, high CO or HC Probable cause concentration when idling Causes shown on right are suspected. D Air/fuel ratio control system malfunction D Ignition system malfunction D Fuel system malfunction D Intake and exhaust system malfunction D Exhaust gas purifier system malfunction D Improper compression pressure...
Page 233 13A-76 MPI - Troubleshooting From the previous page Replace the purge control solenoid valve. Check the purge control solenoid valve. (Refer to GROUP 17 - Exhaust Gas Purifier Check.) Replace the EGR control solenoid valve. Check the EGR control solenoid valve. (Refer to GROUP 17 - Exhaust Gas Purifier Check.) Replace the EGR valve.
Page 234: Battery Dies
13A-77 MPI - Troubleshooting Inspection Procedure 18 Battery dies Probable cause Causes shown on right are suspected. D Battery malfunction D G terminal short - circuit D Alternator malfunction D Engine-ECU malfunction Check the battery. Replace the battery. (Refer to GROUP 54 - Battery.) Check the following connector: Repair B-14...
Page 235 13A-78 MPI - Troubleshooting From the previous page Measure at the C-122 engine-ECU Check and repair the harness between connector. the alternator intermediate connector D Disconnect the connector to and engine-ECU. measure at the harness side. D Check for short-circuit of output D Ignition switch: ON cable.
Page 236 13A-79 MPI - Troubleshooting Inspection Procedure 19 Overheating Probable cause Causes shown on right are suspected. D Engine coolant insufficient or deteriorated D Fan controller malfunction D Engine coolant temperature sensor malfunction D Thermostat malfunction D Water pump malfunction D Condenser fan relay malfunction D Radiator core malfunction D Engine-ECU malfunction MUT-II Self-Diag Code...
Page 237: Abnormal Radiator Fan Motor Rotation
13A-80 MPI - Troubleshooting Inspection Procedure 20 Abnormal radiator fan motor rotation Probable cause Causes shown on right are suspected. D Fan controller malfunction D Engine-ECU malfunction Check the following connector: Repair C-126 Check the radiator fan motor drive. Check the trouble symptoms. Intermittent malfunction (Refer to D Disconnect the C-126 GROUP 00 - Points to Note for...
Page 238 13A-81 MPI - Troubleshooting Inspection Procedure 21 A/C ineffective Probable cause Causes shown on right are suspected. D A/C refrigerant insufficient or over- charged D A/C compressor relay malfunction D Condenser fan system malfunction D A/C-ECU malfunction D Engine-ECU malfunction MUT-II Self-Diag cord INSPECTION CHART FOR DIAGNOSIS CODE (Refer to Is a diagnosis code output?
Page 239 13A-82 MPI - Troubleshooting Inspection Procedure 22 Engine-ECU power supply, engine control relay, ignition Probable cause switch-IG1 system When the ignition switch ON signal is input to the engine-ECU, the engine-ECU D Ignition switch malfunction turns the engine control relay ON. D Engine control relay malfunction This starts the supply of the battery voltage to the engine-ECU, sensor and D Engine-ECU malfunction...
Page 240 13A-83 MPI - Troubleshooting From the previous page Repair Check the following connector: C-126 Measure at the C-115 engine-ECU Check the following connector: Repair connector. C-115 D Measure the engine-ECU terminal voltage. D Ignition switch: ON Check the ignition switch. (Refer to Replace the ignition switch.
Page 241 13A-84 MPI - Troubleshooting From the previous page Check the following connector: C-126 Repair Check the harness between the engine control relay and Repair engine-ECU. D Check for disconnection, short-circuit and damage of the output cable. Check the harness and connector of the engine control relay Repair output power for short-circuit.
Page 242: Fuel Pump System
13A-85 MPI - Troubleshooting Inspection Procedure 23 Fuel pump system Probable cause D The engine-ECU turns the fuel pump relay ON during cranking and engine D Fuel pump relay 1 malfunction operation, and supplies the drive power to the fuel pump. D Fuel pump relay 2 malfunction D When operating with a low load, the engine-ECU supplies power to the fuel D Fuel pump relay 3 malfunction...
Page 243 13A-86 MPI - Troubleshooting From the previous page Measure at the C-221 fuel pump Check and repair the harness relay 2 connector. between the fuel pump relay 1 and D Disconnect the connector to fuel pump relay 2. measure at the harness side. (1) Voltage between terminal No.
Page 244: Radiator Fan Control Relay System
13A-87 MPI - Troubleshooting Inspection Procedure 24 Radiator fan control relay system Probable cause When the engine control relay turns ON, the radiator fan control relay turns ON D Radiator fan control relay malfunction simultaneously, and power is supplied to the fan controller. D Fan controller malfunction The radiator fan motor is driven when the fan motor drive signal is input to the D Radiator fan motor malfunction...
Page 245 13A-88 MPI - Troubleshooting From the previous page Check the following connector: C-126 Repair Check the radiator fan motor drive. MUT-II Actuator Test Intermittent malfunction (Refer to D Disconnect the C-126 D No. 21: Fan controller GROUP 00 - Points to Note for engine-ECU connector.
Page 246: Engine Cooling
13A-89 MPI - Troubleshooting Inspection Procedure 25 Condenser fan relay system Probable cause The condenser fan relay turns ON with the signal from the engine-ECU, and D Condenser fan relay (HI) malfunction power is supplied to the condenser fan motor. D Condenser fan relay (LOW) malfunction D Condenser fan motor malfunction D Condenser fan circuit disconnection, short-circuit,...
Page 247 13A-90 MPI - Troubleshooting From the previous page Measure at the A-45 condenser fan Check and repair the harness motor connector. between the condenser fan relay D Disconnect the connector to (LOW) and engine-ECU. measure at the harness side. D Check for disconnection of the D Disconnect the C-122 power cable.
Page 248 13A-91 MPI - Troubleshooting From the previous page Check the following connectors: Measure at the C-122 engine-ECU C-122, C-136 <R.H. drive vehicles>, connector. A-43 <L.H. drive vehicles> D Measure the engine-ECU terminal voltage. D Ignition switch: ON D Voltage between terminal No. 32 Check and repair the harness and earth between the condenser fan relay...
Page 249 13A-92 MPI - Troubleshooting Inspection Procedure 26 A/C switch system Probable cause When the A/C switch on the control panel is turned ON, the A/C switch ON D Control panel A/C switch malfunction signal is input to the engine-ECU. After receiving this signal, the engine-ECU D A/C system malfunction turns the A/C compressor ON.
Page 250: Clutch
13A-93 MPI - Troubleshooting Inspection Procedure 27 A/C compressor relay system Probable cause When the A/C switch ON signal is input to the engine-ECU, the engine-ECU D A/C compressor relay malfunction turns the A/C compressor relay ON. D A/C compressor magnetic clutch malfunction The A/C compressor magnetic clutch starts with this.
Page 251 13A-94 MPI - Troubleshooting From the previous page Measure at the C-126 engine-ECU Check the following connector: C-126 Repair connector. D Measure the engine-ECU terminal voltage. Repair Check the harness between the A/C D Ignition switch: ON compressor relay and engine-ECU. D Voltage between terminal No.
Page 252 13A-95 MPI - Troubleshooting Inspection Procedure 28 A/C load signal system Probable cause The size of the A/C compressor load is detected according to the difference in D A/C-ECU malfunction set temperature. When the A/C large load signal is input to the engine-ECU, the D Engine-ECU malfunction engine-ECU judges that the A/C compressor load is large, and controls the throttle valve control servo so that the idling speed increases.
Page 253: Secondary Air Control Solenoid Valve System
13A-96 MPI - Troubleshooting Inspection Procedure 29 Secondary air control solenoid valve system Probable cause The secondary air control solenoid valve switches the pressure led into the D Secondary air control solenoid valve malfunction secondary air valve between the intake manifold and the atmospheric pressure. D Engine-ECU malfunction MUT-II Actuator Test Intermittent malfunction (Refer to...
Page 254: Intercooler Water Spray Circuit System
13A-97 MPI - Troubleshooting Inspection Procedure 30 Intercooler water spray circuit system Probable cause D When the intercooler water spray switch (manual) turns ON, the intercooler D Intercooler water spray switch malfunction water spray manual ON signal is input to the engine-ECU. After receiving D Intercooler water spray relay malfunction this signal, the engine-ECU turns the intercooler water spray relay ON.
Page 255 13A-98 MPI - Troubleshooting Form the previous page Measure at the C-222 intercooler water Check the following connectors: Repair spray relay connector. C-209, C-210, C-201, C-208, C-102 <L.H. drive vehicles> D Disconnect the connector to measure at the harness side. D Voltage between terminal No.
Page 256: Intercooler Water Spray Lamp System
13A-99 MPI - Troubleshooting Inspection Procedure 31 Intercooler water spray lamp system Probable cause The engine-ECU illuminates the intercooler water spray lamp when the D Intercooler water spray lamp bulb dead intercooler water spray switch (automatic) is ON. D Ignition switch malfunction D Intercooler water spray lamp circuit disconnection, short-circuit, or connector contact defect D Intercooler water spray switch circuit disconnection,...
Page 257 13A-100 MPI - Troubleshooting Inspection Procedure 32 Ignition coil (integrated power transistor) system Probable cause The engine-ECU allows the ignition coil primary current to flow intermittently by D Ignition coil malfunction turning the power transistor in the unit OFF and ON. D Spark plug malfunction D Spark plug cable malfunction D Ignition primary circuit disconnection, short-circuit, or...
Page 258 13A-101 MPI - Troubleshooting From the previous page Check the harness between the Repair ignition coil and ignition coil relay. D Check for damage of the power cable. Check the harness between the Repair ignition coil and engine-ECU. D Check for damage of the output cable.
Page 259 13A-102 MPI - Troubleshooting DATA LIST REFERENCE TABLE NOTE *1. In a new Vehicle [driven approximately 500 km or less], the air flow sensor output frequency time is sometimes 10% longer than the standard time. *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.
Page 260 13A-103 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Throttle Ignition switch: “ON” Set to idle position 535 - 735 mV Code No. 13A-21 position position P0120 P0120 Gradually open Increases in pro- sensor portion to throttle opening angle Open fully...
Page 261 13A-104 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Barometric Ignition switch: ON Altitude: 0 m 101 kPa Code No. 13A-15 pressure pressure P0105 P0105 Altitude: 0 m 95 kPa sensor Altitude: 0 m 88 kPa Altitude: 0 m 81 kPa...
Page 262 13A-105 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Ignition ad- Engine: After Engine: Idle operation 0 - 13_BTDC vance having warmed Timing lamp is set (The timing set. (The timing 2,500 r/min 20 - 40_BTDC lamp is set in order to check actual ignition...
Page 263 13A-106 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Oxygen Engine: After having When at 4,000 r/min, 200 mV or less Code No. 13A-24 sensor warmed up engine is suddenly de- P0130 (front) (Air/fuel mixture is celerated made leaner when made leaner when...
Page 264 13A-107 MPI - Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. Engine: After having warmed Idling condition Code No. 13A-30 1 injector up/Engine is idling becomes different P0201 (becomes unsta...
Page 265 13A-108 MPI - Troubleshooting Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Radiator fan Ignition switch: “ON” Fan motor rotates Procedure 13A-87 controller motor is at high speed. No. 24 driven. Secondary Solenoid valve Ignition switch: “ON” Sound of opera- Procedure 13A-96...
Page 266 13A-109 MPI - MPI - Troubleshooting Troubleshooting Engine-ECU Connector Terminal Arrangement Terminal No. Check item Check condition (Engine condition) Normal condition No. 1 injector While engine is idling after having warmed up, From 11 - 14 V, momentarily suddenly depress the accelerator pedal suddenly depress the accelerator pedal.
Page 267 13A-110 MPI - Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Power supply Ignition switch: “ON” System voltage Air flow sensor reset Engine: Idle operation 0 - 1 V signal signal Engine speed: 3,000 r/min 6 - 9 V Fan controller Radiator fan is not operating 0 - 0.3 V...
Page 268 13A-111 MPI - Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Power steering fluid Engine: Idling after When steering wheel System voltage pressure switch warming up is stationary When steering wheel 1 V or less is turned Engine control relay Ignition switch: “LOCK”...
Page 269 13A-112 MPI - Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Intake air Ignition switch: “ON” Intake air 3.8 - 4.4 V temperature sensor temperature: - 20_C Intake air 3.2 - 3.8 V temperature: 0_C Intake air 2.3 - 2.9 V temperature: 20_C Intake air...
Page 270 13A-113 MPI - Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Vehicle speed sensor Ignition switch: “ON” 0 ↔ 5 V Move the vehicle slowly forward (Changes repeatedly) Camshaft position Engine: Cranking 0.4 - 3.0 V sensor sensor Engine: Idle operation 0.5 - 2.0 V...
Page 271 13A-114 MPI - Troubleshooting 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.
Page 272 13A-115 MPI - Troubleshooting Terminal No. Inspection item Normal condition (Check condition) 3 - 12 Fuel pressure control solenoid valve 28 - 36 Ω (at 20_C) 4 - 12 Stepper motor coil (A1) 28 - 33 Ω (at 20_C) 17 - 12 Stepper motor coil (A2) 5 - 12 Stepper motor coil (B1)
Page 273 13A-116 MPI - Troubleshooting INSPECTION PROCEDURE USING AN Analyzer ANALYZER AIR FLOW SENSOR Special Measurement Method patterns pickup 1. Disconnect the air flow sensor connector, and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2.
Page 274 13A-117 MPI - Troubleshooting Examples of Abnormal Wave Patterns Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency.
Page 275 13A-118 MPI - Troubleshooting Standard Wave Pattern Observation condition Function Special patterns Pattern height Pattern selector Display Engine r/min Idle speed Standard Wave Pattern 2 engine revolutions (1 camshaft revolution) The time (cycle time) T is reduced when the engine 75_BTDC speed increases 5_BTDC...
Page 276 13A-119 MPI - Troubleshooting 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.
Page 277 13A-120 MPI - Troubleshooting Standard wave pattern Point A Solenoid back electromotive force (Approx. 7×10 V) Point B Injector drive time Power voltage 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...
Page 278 13A-121 MPI - Troubleshooting IDLE SPEED CONTROL SERVO (STEPPER MOTOR) Analyzer Measurement Method 1. Disconnect the idle speed control servo connector, and connect the special tool (test harness: MB991709) in Special between. patterns 2. Connect the analyzer special patterns pickup to the idle pickup speed control servo-side connector terminal No.
Page 279 13A-122 MPI - Troubleshooting 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.
Page 280 13A-123 MPI - Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Ignition coil primary signal Refer to GROUP 16 - Ignition system. Power transistor control signal Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991658) in between. (All Special terminals should be connected.) patterns...
Page 281 13A-124 MPI - Troubleshooting 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 approximately 2 V to approximately 4.5 V at the Normal top-right 2 V rectangular wave...
Page 282 13A-125 MPI - On-vehicle Service ON-VEHICLE SERVICE 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.
Page 283 13A-126 MPI - On-vehicle Service THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Remove the air intake hose from the throttle body. 2. Spray cleaning fluid on a clean cloth. 15 mm 3. Wipe off the dirt around the throttle valve with the cloth sprayed with cleaning fluid.
Page 284 13A-127 MPI - On-vehicle Service 4. If not within the standard value, loosen the throttle position sensor mounting bolts. Then rotate the sensor body to adjust. 5. Turn the ignition switch to “LOCK” (OFF) position. 6. Remove the MUT-II. If the MUT-II is not used, remove the special tool, and then connect the throttle position sensor connector.
Page 285: Fuel Pressure Test
13A-128 MPI - On-vehicle Service 6. If not within the standard value range, turn the speed adjusting screw to make the necessary adjustment. 7. Press the MUT-II clear key, and release the idle speed control servo from the Actuator test mode. NOTE Unless the idle speed control servo is released, the Actuator test mode will continue 27 minutes.
Page 286 13A-129 MPI - On-vehicle Service <When using the fuel pressure gauge> Fuel pressure gauge set (1) Install the fuel pressure gauge on the special tool (for measuring the fuel pressure) putting a suitable O-ring or gasket O-ring or gasket between them. MD998709 (2) Install the special tool which was set up in step (1) between the high-pressure fuel hose and the delivery...
Page 287 13A-130 MPI - On-vehicle Service 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 Fuel pressure too low Clogged fuel filter Replace fuel filter Fuel pressure drops after racing Fuel pressure drops after racing...
Page 288 13A-131 MPI - On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol A/C relay Fuel pump relay 1, 2 A/C switch Fuel pump relay 3 Air flow sensor (integrated intake air tempera- Fuel pump resistor ture sensor and barometric pressure sensor) Camshaft position sensor Idle speed control servo (stepper motor) Crank angle sensor...
Page 289: Engine Control Relay Continuity Check
13A-132 MPI - On-vehicle Service ENGINE CONTROL RELAY CONTINUITY CHECK Engine control Equipment Tester Battery voltage Normal state relay side connector connection terminal 2 - 3 Not energized Continuity 1 - 4 Not energized No continuity Energized [Connect terminal No. 2 Continuity to battery (+) terminal, and connect terminal No.
Page 290 13A-133 MPI - On-vehicle Service 3. Measure resistance while heating the sensor using a hair drier. Intake air Normal condition: temperature sensor 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.
Page 291: Oxygen Sensor Check
13A-134 MPI - On-vehicle Service THROTTLE POSITION SENSOR CHECK Throttle position 1. Disconnect the throttle position sensor connector. sensor 2. Measure the resistance between the throttle position sensor side connector terminal No. 1 and terminal No. Throttle Standard value: 3.5 - 6.5 kΩ body 3.
Page 292 13A-135 MPI - On-vehicle Service 5. Use the jumper wire to connect terminal No. 1 of the Jumper oxygen sensor connector to the battery (+) terminal and wire terminal No. 3 to the battery ( - ) terminal. Caution Black Be very careful when connecting the jumper wire;...
Page 293 13A-136 MPI - On-vehicle Service INJECTOR CHECK OPERATION SOUND CHECK Using a sound scope, check the operation sound of the injector (“chh” sound) during idling and cranking. Check that the operation sound increases when the speed increases. Caution The sound of other injectors operating may be heard even when the injector being checked is not operated.
Page 294 13A-137 MPI - On-vehicle Service High-pressure fuel hose MD998741 Return hose MB991607 Fuel pressure regulator Clip (MB991608) MD998706 Injector Battery 4. Connect the MUT-II to the diagnosis connector. 5. Turn the ignition switch to “ON” position. (But do not start the engine.) 6.
Page 295 13A-138 MPI - On-vehicle Service RESISTOR (FOR INJECTOR) CHECK Resistor 1. Disconnect the resistor connector. (for injector) 2. Measure the resistance between each terminal. Standard value: Measurement terminal Resistance Ω 1 - 3 5.8 - 6.2 (at 20_C) 4 - 3 Fuel pump relay 3 5 - 3 6 - 3...
Page 296 13A-139 MPI - On-vehicle Service Checking the Coil Resistance 1. Disconnect the idle speed control servo connector. 2. Measure the resistance between terminal No. 2 and either terminal No. 1 or terminal No. 3 of the connector at the idle speed control servo side. Standard value: 28 - 33 Ω...
Page 297 13A-140 MPI - On-vehicle Service FUEL PRESSURE CONTROL SOLENOID Fuel pres- VALVE CHECK sure control solenoid OPERATION CHECK valve 1. Disconnect the vacuum hose from the solenoid valve. 2. Separate the harness connector. 3. Connect the hand vacuum pump to the solenoid valve’s A nipple.
Page 298 13A-141 MPI - Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to P.13A-125.) Air Hose E, Air By-pass Hose, Air Pipe C Removal Strut Tower Bar Removal and Installation and Installation (Refer to GROUP 15 - Intercooler.) (Refer to GROUP 42.) Fuel Leakage Check 5.0 ±...
Page 299 13A-142 MPI - 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.
Page 300: Throttle Body
13A-143 MPI - Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Air Hose E, Air By-pass Hose, Air Pipe C Removal (Refer to GROUP 51 - Front Bumper.) and Installation (Refer to GROUP 15 - Intercooler.) Engine Coolant Draining and Supplying Accelerator Cable Adjustment (Refer to GROUP 17 (Refer to GROUP 14 - On-vehicle Service.)
Page 301 13A-144 MPI - Throttle Body DISASSEMBLY AND REASSEMBLY 2.0 ± 0.5 N•m Removal steps "AA 1. Throttle position sensor 4. Fixed SAS 2. Idle speed control servo 5. O-ring 3. O-ring 6. Throttle body INSTALLATION SERVICE POINT "AA THROTTLE POSITION SENSOR INSTALLATION 1.
Page 302 13A-145 MPI - Throttle Body 3. After installing the Throttle position sensor, check that Throttle position the output voltage is at the standard value. If deviated sensor output from the standard value, loosen the screw, readjust to Throttle position the standard position, and then fix. Repeat this step until Earth sensor power the output voltage is at the standard value.
Page 303 13A-146 MPI - Engine Control Resistor, Relay ENGINE CONTROL RESISTOR, RELAY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Strut Tower Bar Removal and Installation (Refer to GROUP 42.) Harness Connector Connection 5.0 ± 1.0 N·m AYC relay 5.0 ± 1.0 N·m <L.H.
Page 304 13A-147 MPI - Engine ENGINE-ECU REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Glove Box Assembly Removal and Installation (Refer to GROUP 52A - Instrument Panel.) 5.0 ± 1.0 N·m Removal steps 1. Engine-ECU connector 2. Engine-ECU...
Page 305 NOTES...
Page 306: Fuel Supply
13B-1 FUEL SUPPLY CONTENTS GENERAL INFORMATION ....FUEL TANK ....... ON-VEHICLE SERVICE .
Page 307 13B-2 FUEL SUPPLY - General Information/On-vehicle Service GENERAL INFORMATION The steel fuel tank is located under the floor of the rear seats to provide increased safety and increase the amount of luggage compartment space. The fuel tank has been equipped with a valve assembly which incorporates a fuel cut-off valve to prevent fuel from leaking out in the event of a collision for adjusting the pressure inside the fuel tank.
Page 308: Fuel Tank
13B-3 FUEL SUPPLY - On-vehicle Service/Fuel tank FUEL PUMP AND GAUGE ASSEMBLY, PIPE <Fuel pump and gauge assembly> AND GAUGE ASSEMBLY (FUEL GAUGE UNIT) High-pressurefuel tube Harness 1. Remove the rear seat cushion assembly. connector (Refer to GROUP 52A.) 2. Remove the service hole cover. 3.
Page 309 13B-4 FUEL SUPPLY - Fuel Tank <Fuel tank assembly> 2.5 ± 0.5 N·m 2.5 ± 0.5 N·m 26 ± 4 N·m 22 ± 4 N·m Removal steps <Fuel tank assembly> 1. Filler neck pipe, Filler neck vapour "AA 8. Suction hose pipe connection "AA 9.
Page 310 13B-5 FUEL SUPPLY - Fuel Tank <Fuel filler neck assembly> 24 ± 4 N·m Removal steps <Filler neck assembly> 25. Filler neck protector 29. Fuel filler neck assembly 26. Filler neck hose connection 30. Fuel shut-off valve 27. Filler neck vapour hose connection 31.
Page 311 13B-6 FUEL SUPPLY - Fuel Tank INSTALLATION SERVICE POINT Corresponding side High-pressure fuel tube "AA HIGH-PRESSURE FUEL HOSE/SUCTION HOSE INSTALLATION Caution Snap the high-pressure fuel hose or suction hose one-touch joint into place, then pull back slightly on the 3 mm hose to assure it is securely fitted.
Page 312 13B-7 FUEL SUPPLY - Fuel Tank DISASSEMBLY AND REASSEMBLY <FUEL PUMP AND GAUGE ASSEMBLY> Removal steps 1. Fuel gauge unit 8. Assist pump 2. Gauge harness 9. Fuel suction hose 3. Bracket 10. Fuel return hose 4. Fuel pump cushion 11.
Page 313 13B-8 FUEL SUPPLY - Fuel Tank <PIPE AND GAUGE ASSEMBLY> 1.2 ± 0.2 N·m Removal steps 1. Packing 4. Connector 2. Filter "AA 5. O-ring 3. Gauge unit 6. Pipe assembly INSTALLATION SERVICE POINT "AA O-RING/GROMMET INSTALLATION Apply a fuel to O-ring and grommet before installing them, to prevent them from being damaged or twisted.
Page 314 14-1 ENGINE COOLING CONTENTS GENERAL INFORMATION ....Engine Coolant Replacement ....Concentration Measurement .
Page 315: General Information
General Information/ 14-2 ENGINE COOLING - Service Specifications/Lubricant/Sealant 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 driven by the drive belt from the crankshaft. whatever condition the engine may be operated.
Page 316: Special Tools
14-3 ENGINE COOLING - Special Tools/Troubleshooting SPECIAL TOOLS Tool Number Name MB991223 Harness set Measurement of terminal voltage Inspection of radiator fan controller A: MB991219 A: Test harness A: Connector pin contact pressure B: MB991220 B: LED harness inspection C: MB991221 C: LED harness B: Power circuit inspection D: MB991222...
Page 317 14-4 ENGINE COOLING - Troubleshooting D Fusible link (2) check Replace D Radiator fan relay continuity check (Refer to P.14-8.) D Radiator fan motor check (Refer to P.14-10.) (1) NG Measure at the radiator fan control relay connector A-09X. Check the harness wire between radiator fan relay and fusible link (2), and repair if necessary.
Page 318 14-5 ENGINE COOLING - Troubleshooting Inspection Procedure 2 Radiator fan does not change speed or stop. Probable cause Radiator fan controller uses the signal from engine-ECU to control radiator fan D Malfunction of radiator fan relay motor in a continously variable mode. D Malfunction of radiator fan controller D Malfunction of engine-ECU D Malfunction of harness, connector...
Page 319: On-Vehicle Service
14-6 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. Adapter Install a radiator cap tester and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections.
Page 320: Concentration Measurement
14-7 ENGINE COOLING - ENGINE COOLING - On-vehicle Service On-vehicle Service 3. Remove the cylinder block drain plug from the cylinder block to drain the engine coolant. 4. Remove the reserve tank to drain the engine coolant. 5. When the engine coolant has drained, pour in water from the radiator cap to clean the engine coolant line.
Page 321: Radiator Fan Relay Continuity Check
14-8 ENGINE COOLING - On-vehicle Service RADIATOR FAN RELAY CONTINUITY CHECK Air cleaner Battery voltage Terminal No. When current is not supplied When current supplied RADIATOR FAN CONTROLLER CHECK Radiator fan controller <Vehicles without A/C> 1. Remove the center under cover. (Refer to GROUP 51 - Front Bumper.) 2.
Page 322 14-9 ENGINE COOLING - On-vehicle Service 5. Connect the special tool (MB991658) to the harness side of the engine coolant temperature sensor connector. 6. Connect the special tool [MB991791(APS)] to the special MB991791(APS) tool (MB991658). 7. Start the engine and let it run at idle. NOTE Since the resistance value of the special tool (APS) indicates a low engine coolant temperature, engine speed...
Page 323: Radiator Fan Motor Check
14-10 ENGINE COOLING - On - vehicle Service RADIATOR FAN MOTOR CHECK Radiator fan motor 1. Remove the center under cover. (Refer to GROUP 51 - Front Bumper.) 2. Disconnect the radiator fan motor connector. 3. Check that the motor rotates when energizing battery voltage between the terminals of connectors of the radiator fan motor side.Check that there is abonormal noise from the radiator fan motor then.
Page 324: Thermostat
14-11 ENGINE COOLING - ENGINE COOLING - Thermostat Thermostat THERMOSTAT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-6.) Air Duct Assembly Removal and Installation (Refer to GROUP 15 - Air Cleaner.) Vacuum Pipe, Secondary Air Pipe Assembly Removal and Installation (Refer to GROUP 15 - Secondary Air Supply System.) 10 ±...
Page 325 14-12 ENGINE COOLING - Thermostat INSTALLATION SERVICE POINTS "AA THERMOSTAT INSTALLATION Install the thermostat being careful not to fold over or scratch the rubber ring. Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat. In addition, be careful not to fold over or scratch the rubber ring when inserting.
Page 326: Water Pump
14-13 ENGINE COOLING - Water Pump WATER PUMP Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. REMOVAL AND INSTALLATION Pre-remobal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-6.)
Page 327: Water Hose And Water Pipe
14-14 ENGINE COOLING - Water Hose and Water Pipe WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION Pre-remobal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-6.) Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 - Air Cleaner.) Air Bypass Valve Assembly, Air Bypass Hose, Air Hose E and Air Pipe C, Air Hose D Removal and Installation (Refer to GROUP 15 - Intercooler.) Secondary Air Control Valve Bracket Removal and Installation...
Page 328: Radiator
14-15 ENGINE COOLING - Water Hose and Water Pipe/Radiator REMOVAL SERVICE POINT AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the hose and the hose clamp, disconnect the hose. INSTALLATION SERVICE POINTS Water pump or thermostat case "AA O-RING INSTALLATION Fit an O-ring into the groove of the water inlet pipe and apply water to the circumference of the O-ring or the...
Page 329 14-16 ENGINE COOLING - Radiator 5.0 ± 1.0 N·m 12 ± 2 N·m 12 ± 2 N·m 3.5 ± 0.4 N·m 4.0 ± 0.4 N·m 4.5 ± 0.4 N·m 12 ± 1 N·m Radiator removal steps Radiator fun controller and radiator fun motor removal steps 1.
Page 330 14-17 ENGINE COOLING - ENGINE COOLING - Radiator Radiator REMOVAL SERVICE POINTS AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE REMOVAL After making mating marks on the radiator hose and the hose clamp,disconnect the radiator hose. AB" AIR PIPE B MOUNTING BOLT REMOVAL After removing the bolt, position air pipe B out of the way so that the pipe does not interfere with the radiator assembly or the radiator fan motor, the fan and shroud assembly.
Page 331 NOTES...
Page 332 15-1 INTAKE AND EXHAUST CONTENTS GENERAL INFORMATION ....Vacuum Tank Check ......AIR CLEANER .
Page 333: General Information
15-2 INTAKE AND EXHAUST - General Information GENERAL INFORMATION SUPERCHARGING PRESSURE CONTROL By controlling the duty of the waste gate solenoid valve, the waste gate actuator functions to control the supercharging pressure. This allows a supercharged pressure matching the engine operation state to be attained. Control is carried out to prevent excessive supercharging and thereby prevent engine damage.
Page 334: Special Tool
15-3 INTAKE AND EXHAUST - Service Specifications/Special Tool/On-vehicle Service SERVICE SPECIFICATIONS Item Standard value Limit Turbocharger supercharging pressure (waste gate solenoid 59 - 84 valve not operating) kPa Initial activation pressure of waste gate actuator (at the stroke Approximately 100 of approximately 1 mm) kPa Waste gate solenoid valve coil resistance (at 20_C) Ω...
Page 335: Supercharging Pressure Control System Check
15-4 INTAKE AND EXHAUST - On-vehicle Service 4. When the indicated supercharging is more than standard value, supercharging control may be faulty, therefore check the followings. Malfunction of the waste gate actuator Malfunction of waste gate valve Disconnection or cracks of the waste gate actuator rubber hose SUPERCHARGING PRESSURE CONTROL Throttle body...
Page 336: Waste Gate Solenoid Valve Check
15-5 INTAKE AND EXHAUST - On-vehicle Service 3. If there is a significant deviation from the standard value, check the actuator or the waste gate valve: replace actuator or turbocharger assembly if necessary. WASTE GATE SOLENOID VALVE CHECK OPERATION CHECK 1.
Page 337: Intake Manifold Pressure Check
15-6 INTAKE AND EXHAUST - On-vehicle Service INTAKE MANIFOLD PRESSURE CHECK Refer to GROUP 11A – On-vehicle Service. SECONDARY AIR CONTROL SYSTEM CHECK 1. Start the engine and carry out idling. 2. Confirm that the secondary air valve lifts up when the engine-ECU connector No.
Page 338: Secondary Air Valve Check
15-7 INTAKE AND EXHAUST - On-vehicle Service COIL RESISTANCE CHECK Measure the resistance between the solenoid valve terminals. Standard value: 29 – 35 Ω (at 20_C) SECONDARY AIR VALVE CHECK 1. Disconnect the secondary air valve. 2. Connect the hand vacuum pump to the secondary air valve’s nipple.
Page 339: Air Cleaner
15-8 INTAKE AND EXHAUST - Air Cleaner AIR CLEANER REMOVAL AND INSTALLATION Caution Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions. 1. Avoid any shock or load to these parts when removing and installing them. 2.
Page 340: Intercooler
15-9 INTAKE AND EXHAUST - Intercooler INTERCOOLER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner Removal and Installation (Refer to P.15-8.) Front Bumper Removal and Installation (Refer to Water Spray Hose Connection removal GROUP 51.) Installation (Refer to P.15-10.) 12 ±...
Page 341 15-10 INTAKE AND EXHAUST - Intercooler Water Spray INTERCOOLER WATER SPRAY Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to Front Bumper Removal and Installation (Refer to GROUP 51 - Front Bumper.) GROUP 51.) REMOVAL AND INSTALLATION <WATER SPRAY SWITCH> Water spray switch removal steps 1.
Page 342: Intercooler Water Spray
15-11 INTAKE AND EXHAUST - Intercooler Water Spray <WATER SPRAY NOZZLE/WATER SPRAY HOSE/WASHER TANK> 11 ± 2 N·m 11 ± 2 N·m Water spray nozzle/Water spray Washer tank removal steps hose removal steps 2. Water spray hose connection 2. Water spray hose connection 8.
Page 343 15-12 INTAKE AND EXHAUST - Intercooler Water Spray INSTALLATION SERVICE POINTS WATER SPRAY HOSE/TAPE INSTALLATION "AA Attach the water spray hose to the front bumper with a tape as shown in the illustration. <Tape attachment position> Tape Tape Tape Tape 65 mm 30 mm 0 mm...
Page 344 15-13 INTAKE AND EXHAUST - Intercooler Water Spray INSPECTION <Water spray switch> 1. WATER SPRAY SWITCH CONTINUITY CHECK Switch position Switch position Terminal No Terminal No. AUTO MANUAL EARTH ILL (+) ILL ( - ) AUTO NEUTRAL 2. WATER SPRAY MOTOR CHECK <Water spray motor>...
Page 345: Secondary Air Supply System
15-14 INTAKE AND EXHAUST - Secondary Air Supply System SECONDARY AIR SUPPLY SYSTEM REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Duct Removal and Installation (Refer to P.15-8.) Strut Tower Bar Removal and Installation (Refer to GROUP 42.) 5.9 ± 1.0 N·m Air pipe C 23 ±...
Page 346 15-15 INTAKE AND EXHAUST - Secondary Air Supply System INSTALLATION SERVICE POINTS "AA GASKET INSTALLATION Install the gasket so that its salient can face towards the direction as shown in the illustration. Salient Secondary air pipe assembly "BA GASKET INSTALLATION Install the gasket so that its protrusion can face towards the Protrusion direction as shown in the illustration.
Page 347: Intake Manifold
15-16 INTAKE AND EXHAUST - Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Duct Removal and Installation (Refer to P.15-8.) Crossmember Bar Removal and Installation (Refer Strut Tower Bar Removal and Installation to GROUP 32 - Engine Roll Stopper, Centermember.) (Refer to GROUP 42.) Front Exhaust Pipe Removal and Installation (Refer Under Cover Removal and Installation...
Page 348 15-17 INTAKE AND EXHAUST - INTAKE AND EXHAUST - Intake Manifold Intake Manifold 5.0 ± 1.0 N·m 20 ± 2 N·m 20 ± 2 N·m 20 ± 2 N·m 11 ± 1 N·m 9.0 ± 1.0 N·m 36 ± 6 N·m 20 ±...
Page 349 15-18 INTAKE AND EXHAUST - Intake Manifold INSTALLATION SERVICE POINTS "AA FUEL HIGH-PRESSURE HOSE CONNECTION 1. Apply a drop of new engine oil to the O-ring. Caution Be sure not to let engine oil enter 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.
Page 350: Exhaust Manifold
15-19 INTAKE AND EXHAUST - Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Air Pipe A, Air Pipe C, Air Hose D, Air Pipe B Removal (Refer to GROUP 51 - Front bumper.) and Installation (Refer to P.15-9.) Radiator Removal and Installation Crossmember Bar Removal and Installation (Refer...
Page 351 15-20 INTAKE AND EXHAUST - INTAKE AND EXHAUST - Exhaust Manifold Exhaust Manifold REMOVAL SERVICE POINT AA" OXYGEN SENSOR REMOVAL Use special tool to remove the oxygen sensor. MD998770 Oxygen sensor AB" OIL FEED PIPE REMOVAL Take care not to let foreign objects get into the oil passage hole of the turbocharger after the oil feed pipe is removed.
Page 352 15-21 INTAKE AND EXHAUST - Exhaust Manifold "CA OIL RETURN PIPE GASKET INSTALLATION Print Install the gasket so that its print part can face towards the oil pan side. Gasket INSPECTION Check the following points; replace the part if a problem is found.
Page 353: Turbocharger
15-22 INTAKE AND EXHAUST - Turbocharger TURBOCHARGER DISASSEMBLY AND REASSEMBLY 11.3 ± 1.5 Nm Disassembly steps D Inspection of turbocharger waste gate "DA 4. Turbine housing "FA actuator operation AA" "CA 5. Snap ring 1. E-ring AB" "BA 6. Turbine wheel assembly 2.
Page 354 15-23 INTAKE AND EXHAUST - Turbocharger DISASSEMBLY SERVICE POINTS AA" SNAP RING REMOVAL Lay the unit with the compressor cover side facing down and using snap ring pliers, remove the compressor cover attaching snap ring. Caution When removing the snap ring, hold it with fingers to prevent it from springing away.
Page 355 15-24 INTAKE AND EXHAUST - Turbocharger "CA SNAP RING INSTALLATION Chamfered edge Lay the assembly with the compressor cover facing down Snap ring and fit the snap ring. Caution Fit the snap ring with its chamfered side facing up. Turbine wheel assembly Compressor cover...
Page 356 15-25 INTAKE AND EXHAUST - Turbocharger COMPRESSOR COVER Oil passage Check the compressor cover for traces of contact with the Turbine wheel compressor wheel and other damage. TURBINE WHEEL ASSEMBLY 1. Check the turbine and compressor wheel blades for bend, burr, damage, corrosion and traces of contact on the back side and replace if defective.
Page 357: Exhaust Pipe And Main Muffler
15-26 INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) Crossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.) 13 ±...
Page 358 16-1 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM ....IGNITION SYSTEM ....GENERAL INFORMATION .
Page 359: Charging System
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. OPERATION Voltage Rotation of the excited field coil generates AC voltage in the stator.
Page 360: Service Specifications
16-3 ENGINE ELECTRICAL - Charging System ALTERNATOR SPECIFICATIONS Items Specifications Type Battery voltage sensing Rated output V/A 12/90 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...
Page 361: On-Vehicle Service
16-4 ENGINE ELECTRICAL - Charging System ON-VEHICLE SERVICE ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST Ammeter Alternator Voltmeter Battery Terminal B This test determines whether the wiring from the between the “B” terminal and the disconnected alternator “B” terminal to the battery (+) terminal output wire.
Page 362: Output Current Test
16-5 ENGINE ELECTRICAL - Charging System (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 (Refer to GROUP 11 - On-vehicle Service.) in the alternator output wire, so check the wiring (8) Leave the hood open.
Page 363 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.
Page 364: Regulated Voltage Test
16-7 ENGINE ELECTRICAL - Charging System REGULATED VOLTAGE TEST Load Ammeter Ignition MB991519 switch Black Alternator Voltmeter Blue Yellow Battery Engine-ECU This test determines whether the voltage regulator (6) Connect a DC test ammeter with a range of is correctly controlling the alternator output voltage. 0 - 100 A in series between the “B”...
Page 365: Waveform Check Using An Analyzer
16-8 ENGINE ELECTRICAL - Charging System (14)If the voltage reading conforms to the value (17)Remove the tachometer or the MUT-II. in the voltage regulation, then the voltage (18)Disconnect the negative battery cable. regulator is operating normally. (19)Disconnect the ammeter and voltmeter. If the voltage is not within the standard value, (20)Connect the alternator output wire to the there is a malfunction of the voltage regulator...
Page 366 16-9 ENGINE ELECTRICAL - Charging System Voltage at alternator 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.
Page 367: 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).
Page 368 16-11 ENGINE ELECTRICAL - Charging System 5.0 ± 1.0 N·m 11 ± 1 N·m 9.0 ± 1.0 N·m 13 ± 1 N·m 36 ± 6 N·m 9.0 ± 1.0 N·m 14 ± 3 N·m 20 ± 2 N·m (Engine oil) 22 ±...
Page 369 16-12 ENGINE ELECTRICAL - Charging System REMOVAL SERVICE POINTS AA" DELIVERY PIPE, INJECTOR, AND FUEL PRESSURE REGULATOR ASSEMBLY REMOVAL After loosening the installed parts, set the related parts aside to make some space for removing the alternator. AB" DRIVE BELT REMOVAL Due to the adoption of the Serpentine drive system with the auto-tensioner, the following operation is required: 1.
Page 370 16-13 ENGINE ELECTRICAL - Charging System DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Front bracket assembly 8. Stator AA" AC" 2. Alternator pulley 9. Plate AB" "BA 3. Rotor AC" "AA 10. Regulator assembly 4. Rear bearing 11. Brush 5. Bearing retainer 12.
Page 371 16-14 ENGINE ELECTRICAL - Charging System DISASSEMBLY SERVICE POINTS AA" FRONT BRACKET ASSEMBLY REMOVAL Insert a flat tip screwdrivers or the like in the clearance between the front bracket assembly and stator core, to pry open and separate the stator and front bracket. Caution Do not insert a screwdriver too far, or the stator coil gets damaged.
Page 372 16-15 ENGINE ELECTRICAL - Charging System "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.
Page 373 16-16 ENGINE ELECTRICAL - Charging System RECTIFIERS 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.
Page 374: Starting System
16-17 ENGINE ELECTRICAL - Starting System STARTING SYSTEM GENERAL INFORMATION If the ignition switch is turned to the “START” and M terminal to conduct. Thus, current flows to position, current flows in the pull-in and holding engage the starter motor. coils provided inside magnetic switch, attracting When the ignition switch is returned to the “ON”...
Page 375: Starter
16-18 ENGINE ELECTRICAL - Starting System STARTER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP51 - Front Bumper.) Crossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.) Front Exhaust Pipe Assembly Removal and Installation (Refer to GROUP 15.) 13 ±...
Page 376 16-19 ENGINE ELECTRICAL - Starting System 5. If pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket. MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2.
Page 377 16-20 ENGINE ELECTRICAL - Starting System MAGNETIC SWITCH RETURN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12 V battery between M-terminal and body. Battery Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.
Page 378 16-21 ENGINE ELECTRICAL - Starting System DISASSEMBLY AND REASSEMBLY 16 14 Disassembly steps 12. Packing A 13. Packing B 1. Cover 14. Plate 2. Screw 15. Planetary gear 3. Magnetic switch AA" 16. Lever 4. Screw AC" "AA 17. Snap ring 5.
Page 379 16-22 ENGINE ELECTRICAL - Starting System DISASSEMBLY SERVICE POINTS “S” terminal “B” terminal AA" MAGNETIC SWITCH REMOVAL Disconnect field coil wire from “M” terminal of magnetic switch. Field coil “M” terminal wire AB" ARMATURE/BALL REMOVAL Caution When removing the armature, take care not to lose the ball (which is used as a bearing) in the armature end.
Page 380 16-23 ENGINE ELECTRICAL - Starting System REASSEMBLY SERVICE POINT "AA STOP RING/SNAP RING INSTALLATION Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring. Stop ring Overrunning Stop ring clutch Snap ring INSPECTION COMMUTATOR CHECK 1. Place the armature in a pair of “V” blocks and check the runout with a dial indicator.
Page 381 16-24 ENGINE ELECTRICAL - Starting System OVERRUNNING CLUTCH CHECK 1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch assembly. Free 2.
Page 382 16-25 ENGINE ELECTRICAL - Starting System ARMATURE COIL OPEN-CIRCUIT INSPECTION Check the continuity between segments. If there is continuity, the coil is in order. MAGNETIC SWITCH COIL DISCONNECTION TEST Confirm that there is continuity between the “M” terminal and body A. If there is no continuity, replace the magnetic switch.
Page 383: Ignition System
16-26 ENGINE ELECTRICAL - Ignition System IGNITION SYSTEM GENERAL INFORMATION This system is equipped with two ignition coils (A causes the primary currents in the ignition coils and B) with built-in power transistors for the No. to be alternately interrupted and allowed to flow 1 and No.
Page 384: Service Specifications
16-27 ENGINE ELECTRICAL - Ignition System IGNITION COIL SPECIFICATIONS Items Specifications Type Molded 2-coil SPARK PLUG SPECIFICATIONS Items Specifications IGR7A-G DENSO VW22PR-DA7 SERVICE SPECIFICATIONS IGNITION COIL Items Standard value Secondary coil resistance kΩ 8.5 - 11.5 SPARK PLUG Items Standard value Limit Spark plug gap mm 0.6 - 0.7...
Page 385: On-Vehicle Service
16-28 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...
Page 386: Spark Plug Check, Cleaning And Replacement
16-29 ENGINE ELECTRICAL - Ignition System SPARK PLUG CHECK, CLEANING AND REPLACEMENT SPARK PLUG GAP CHECK Caution 1. Do not adjust the gap of the iridium plug. 2. Cleaning of the iridium plug could damage the tip of the electrode. Thus, if the plug must be cleaned because of soot, etc., use a plug cleaner and clean within a short time of 20 seconds or less to protect the electrode.
Page 387: Waveform Check Using An Analyzer
16-30 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.
Page 388 16-31 ENGINE ELECTRICAL - Ignition System STANDARD WAVEFORM Observation Conditions Function Secondary Pattern height High (or Low) Pattern selector Raster Engine revolutions Curb idle speed Spark line (point A) Ignition voltage (point D) Wave damping reduction section (point B) Dwell section Secondary ignition...
Page 389 16-32 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...
Page 390 16-33 ENGINE ELECTRICAL - Ignition System 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.
Page 391: Ignition Coil
16-34 ENGINE ELECTRICAL - Ignition System IGNITION COIL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Center Cover Removal and Installation (Refer to GROUP 11A - Camshaft and Camshaft Oil Seal.) 10 ± 2 N·m 10 ± 2 N·m 25 ± 4 N·m Removal steps 1.
Page 392: Camshaft Position Sensor
16-35 ENGINE ELECTRICAL - Ignition System CAMSHAFT POSITION SENSOR REMOVAL AND INSTALLATION 8.8 ± 1.0 N·m Removal steps 1. Camshaft position sensor connector 2. Camshaft position sensor 3. O-ring CRANK ANGLE SENSOR REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
Page 393 16-36 ENGINE ELECTRICAL - Ignition System 8.8 ± 1.0 N·m 12 ± 2 N·m 22 ± 4 N·m 22 ± 4 N·m 12 ± 2 N·m 22 ± 4 N·m 40 ± 5 N·m 49 ± 9 N·m 49 ± 9 N·m 8.8 ±...
Page 394: Detonation Sensor
16-37 ENGINE ELECTRICAL - Ignition System DETONATION SENSOR REMOVAL AND INSTALLATION Caution Do not give any impact during removal and installation of detonation sensor. Pre-removal and Post-installation Operation Intake Manifold Stay Removal and Installation (Refer to GROUP 15 - Intake Manifold.) 23 ±...
Page 395 NOTES...
Page 396 17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM ..EVAPORATIVE EMISSION CONTROL SYSTEM ....... GENERAL INFORMATION .
Page 397: Engine Control System
17-2 ENGINE AND EMISSION CONTROL - Engine Control System ENGINE CONTROL SYSTEM GENERAL INFORMATION A cable-type accelerator mechanism and a suspended-type pedal have been adopted. SERVICE SPECIFICATIONS Items Standard value Accelerator cable play mm 1 - 2 Engine idle speed r/min Engine idle speed r/min 850 ±...
Page 398: Accelerator Cable And Pedal
17-3 ENGINE AND EMISSION CONTROL - Engine Control System ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION Post-installation Operation Accelerator Cable Adjustment (Refer to P.17-2.) <L.H. drive vehicles> 5.0 ± 1.0 N·m 10 ± 2 N·m 12 ± 2 N·m <R.H. drive vehicles> 5.0 ±...
Page 399: Emission Control System
17-4 ENGINE AND EMISSION CONTROL - Emission Control System EMISSION CONTROL SYSTEM GENERAL INFORMATION The emission control system consists of the following subsystems: Crankcase emission control system Evaporative emission control system Exhaust emission control system Items Name Specification Crankcase emission Positive crankcase ventilation (PCV) valve Variable flow type control system...
Page 400: Service Specifications
17-5 ENGINE AND EMISSION CONTROL - Emission Control System SERVICE SPECIFICATIONS Items Standard value Purge control solenoid valve coil resistance (at 20_C) Ω 30 - 34 EGR control solenoid valve coil resistance (at 20_C) Ω 29 - 35 VACUUM HOSE VACUUM HOSE PIPING DIAGRAM From fuel tank...
Page 401: Vacuum Circuit Diagram
17-6 ENGINE AND EMISSION CONTROL - Emission Control System VACUUM CIRCUIT DIAGRAM Intake manifold Throttle body combustion From air chamber cleaner Vacuum Purge control tank solenoid valve Fuel pressure solenoid valve Air by-pass valve Fuel pressure EGR control regulator solenoid valve Secondary air control solenoid valve Check valve...
Page 402: Vacuum Hose Check
17-7 ENGINE AND EMISSION CONTROL - Emission Control System 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.
Page 403: Crankcase Emission Control System
17-8 ENGINE AND EMISSION CONTROL - Emission Control System CRANKCASE EMISSION CONTROL SYSTEM GENERAL INFORMATION The crankcase emission control system prevents crankcase ventilation (PCV) valve. blow-by gases from escaping inside the crankcase The PCV valve lifts the plunger according to the into the atmosphere.
Page 404: Component Location
17-9 ENGINE AND EMISSION CONTROL - Emission Control System COMPONENT LOCATION PCV valve 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.
Page 405: Evaporative Emission Control System
17-10 ENGINE AND EMISSION CONTROL - Emission Control System EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents When the engine coolant temperature is low or fuel vapours generated in the fuel tank from when the intake air quantity is small (when the escaping into the atmosphere.
Page 406: Purge Control System Check
17-11 ENGINE AND EMISSION CONTROL - Emission Control System PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (red stripe) from throttle Throttle body body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3.
Page 407: Purge Control Solenoid Valve Check
17-12 ENGINE AND EMISSION CONTROL - Emission Control System PURGE 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 from the solenoid valve. 2.
Page 408: Exhaust Gas Recirculation (Egr) System
17-13 ENGINE AND EMISSION CONTROL - Emission Control System EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers the exhaust port of the cylinder head to the the nitrogen oxide (NOx) emission level. When the combustion chamber through the intake manifold air/fuel mixture combustion temperature is high, to decrease the air/fuel mixture combustion...
Page 409: Component Location
17-14 ENGINE AND EMISSION CONTROL - Emission Control System COMPONENT LOCATION EGR valve EGR control solenoid valve Throttle body Vacuum tank Alternator EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (green stripe) from the EGR control solenoid valve, and then connect a hand vacuum pump via the three-way terminal.
Page 410: Egr Valve Check
17-15 ENGINE AND EMISSION CONTROL - Emission Control System 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.
Page 411: Egr Control Solenoid Valve Check
17-16 ENGINE AND EMISSION CONTROL - Emission Control System 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, white stripe) from the solenoid valve.
Page 412: Egr Valve
17-17 ENGINE AND EMISSION CONTROL - Emission Control System EGR VALVE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Hose E Removal and Installation (Refer to GROUP 15 - Inter Cooler.) 21 ± 4 N·m Removal steps 1. Vacuum hose connection 2.
Page 413: Canister
17-18 ENGINE AND EMISSION CONTROL - Emission Control System CANISTER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Pipe C, Air Hose D Removal and Installation (Refer to GROUP 15 - Inter Cooler.) Battery and Battery Tray Removal and Installation Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 - Air Cleaner.) Canister removal steps 1.
Page 414: Catalytic Converter
17-19 ENGINE AND EMISSION CONTROL - Emission Control System CATALYTIC CONVERTER GENERAL INFORMATION The three-way catalytic converter, together with When the mixture is controlled at stoichiometric the closed loop air-fuel ratio control based on the air-fuel ratio, the three-way catalytic converter oxygen sensor signal, oxidizes carbon monoxides provides the highest purification against the three (CO) and hydrocarbons (HC) and reduces nitrogen...
Page 415 NOTES...
Page 416 21A-1 CLUTCH CONTENTS CLUTCH ............CLUTCH OVERHAUL .
Page 417 21A-2 CLUTCH CONTENTS GENERAL INFORMATION ....Bleeding ........Clutch Pedal Position Switch Adjustment .
Page 418: General Information
21A-3 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 202.1 - 206.1 <L.H. drive vehicles> 173.5 - 177.5 <R.H.
Page 419: Bleeding
21A-4 CLUTCH - On-Vehicle Service 3. If the height of the clutch pedal is outside the standard value, loosen the setting nut to adjust the pedal height Setting nut to the standard value. Caution Do not push in the master cylinder push rod at this time, otherwise the clutch will not operate properly.
Page 420: Clutch Pedal
21A-5 CLUTCH - On-Vehicle Service/Clutch Pedal 5. Fix the clutch pedal position switch by rotating approx. quarter turn to clockwise in the position as shown in the illustration. 6. Connect the connector to the clutch pedal position switch. Full stroke 7.
Page 421 21A-6 CLUTCH - Clutch Pedal Removal steps D Column cover, under cover, lower 7. Clevis pin frame (Refer to GROUP 52A.) 8. Clutch master cylinder mounting nut 1. Connector connection 9. Master cylinder member mounting bolt 2. Clutch pedal position switch 10.
Page 422: Clutch Control
21A-7 CLUTCH - Clutch Control CLUTCH CONTROL REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Clutch Fluid Draining Clutch Fluid Supplying Clutch Pedal Adjustment (Refer to P.21A-3.) Clutch Pedal Position Switch Adjustment (Refer to P.21A-4.) Clutch Line Bleeding (Refer to P.21A-4.) <L.H.
Page 423 21A-8 CLUTCH - Clutch Control <R.H. drive vehicles> Release fork Release cylinder push rod 13 ± 2 N·m Specified grease: MITSUBISHI genuine grease Part No. 0101011 15 ± 1 N·m 18 ± 3 N·m 6, 8 Clutch master cylinder removal Clutch release cylinder removal steps steps...
Page 424: Clutch Master Cylinder
21A-9 CLUTCH - Clutch Control DISASSEMBLY AND REASSEMBLY CLUTCH MASTER CYLINDER Caution Do not disassemble piston assembly. 13 ± 2 N·m <L.H. drive vehicles> <R.H. drive vehicles> Clutch fluid: Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease Disassembly steps 1.
Page 425 NOTES...
Page 426 21B-1 CLUTCH OVERHAUL CONTENTS GENERAL DESCRIPTION ....LUBRICANTS ......SPECIFICATIONS .
Page 427 21B-2 General Description/Specifications/Service Specifications/ CLUTCH OVERHAUL - Tightening Torque/Lubricants GENERAL DESCRIPTION The pull-type clutch has been adopted to improve the cut-off at high rotations and reduce the clutch pedal pressing force. SPECIFICATIONS Clutch disc Type Dry single-disc type Facing dimension mm 240 ×...
Page 428 21B-3 CLUTCH OVERHAUL - Clutch CLUTCH REMOVAL AND INSTALLATION 18 ± 3 N•m 9.8 ± 2 N•m 18 ± 3 N•m 15 ± 2 N•m 18 ± 3 N•m 22 ± 2 N•m Removal steps 1. Clutch fluid line bracket "CA 11.
Page 429 21B-4 CLUTCH OVERHAUL - Clutch REASSEMBLY SERVICE POINTS "AA BUSH INSTALLATION Press the bush into the position of the release valve shown in the illustration. Bush "BA RELEASE FORK INSTALLATION Apply grease on the release fork at the position shown in the illustration.
Page 430 21B-5 CLUTCH OVERHAUL - Clutch INSPECTION CLUTCH COVER (1) Check the pressure plate surface for wear, cracks or discoloration. (2) Check the strap plate rivet for looseness. If loose, replace the clutch cover. CLUTCH DISC Caution Do not wash the clutch disc with cleaning oil. (1) Check the facing for decomposition caused by rivet looseness, single-side contact or seizure, and check for the presence of grease.
Page 431 21B-6 CLUTCH OVERHAUL - Clutch Release Cylinder CLUTCH RELEASE CYLINDER DISASSEMBLY AND REASSEMBLY 11 ± 1 N•m Disassembly step 1. Cap "AA 5. Piston cup 2. Air breather "AA 6. Piston 3. Push rod 7. Conical spring 4. Boot 8. Release cylinder...
Page 432 21B-7 CLUTCH OVERHAUL - Clutch Release Cylinder REASSEMBLY SERVICE POINT "AA PISTON/PISTON CUP INSTALLATION After applying brake fluid on the inner surface of the release cylinder and circumference of the piston and piston cup, insert the piston and piston cup into the release cylinder. Brake fluid Specified fluid: MITSUBISHI genuine brake fluid “DIA-QUEEN...
Page 433 NOTES...
Page 434: Manual Transmission
22A-1 MANUAL TRANSMISSION CONTENTS MANUAL TRANSMISSION ........MANUAL TRANSMISSION OVERHAUL .
Page 435 22A-2 MANUAL TRANSMISSION CONTENTS GENERAL ....... . . ACD Operation Check <Vehicles with ACD or vehicles with ACD and AYC>...
Page 436: General
General/General Information/ 22A-3 MANUAL TRANSMISSION - Service Specification/Lubricants GENERAL OUTLINE OF CHANGE With the addition of the EVOLUTION-VII, the W5M51 transmission service adjustment procedure has been set as follows. GENERAL INFORMATION Items Specifications Grade RS, RS II RS, RS II (With super cross gear) Transmission model W5M51 Engine model...
Page 437: Special Tools
22A-4 MANUAL TRANSMISSION - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II Sub as- Diagnosis code checking sembly MB991529 Diagnosis code checking harness G sensor check MB991348 Test harness set MD998330 Oil pressure gauge Hydraulic pressure measurement <ACD> (including (3.0 MPa) MD998331) MB991705...
Page 438: Troubleshooting
22A-5 MANUAL TRANSMISSION - Troubleshooting <ACD> TROUBLESHOOTING <ACD> BASIC TROUBLESHOOTING CONDITIONS Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. NOTE Before starting the troubleshooting procedure, make sure that the following items have been checked okay. Is the appropriate steering wheel installed at the center of the steering column shaft correctly? Are the tire, wheel size, specifications, air pressure, balance, and wear state normal? Is the wheel alignment normal? Has the engine, suspension, etc.

Page 439 22A-6 MANUAL TRANSMISSION - Troubleshooting <ACD> INSPECTION CHART FOR DIAGNOSIS CODES Diagnosis Diagnosis items Reference page code No. Power supply voltage (valve power supply) system open circuit or short-circuit 22A-8 Fail-safe relay system <inside 4WD-ECU> open circuit or short-circuit 22A-8 Wheel speed sensor <FR>...
Page 440 22A-7 MANUAL TRANSMISSION - Troubleshooting <ACD> Diagnosis Diagnosis items Reference page code No. Electric pump relay system open circuit or short-circuit 22A-29 electric pump malfunction 22A-30 or pressure sensor defect AYC control error Refer to GROUP 27B. ACD control error NOTE Code No.85 is not a code number output due to malfunction, but a code number output when control for the 4WD-ECU to protect the ACD is stopped in excessive driving.
Page 441 22A-8 MANUAL TRANSMISSION - Troubleshooting <ACD> INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No.12 Power supply voltage (valve power supply) Probable cause system The power supply circuit opens or short-circuits if the power supply voltage of the D Defective harness or connector 4WD-ECU is below 9 V or above 18 V.
Page 442 22A-9 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.21 Wheel speed sensor <FR> system Probable cause Code No.22 Wheel speed sensor <FL> system Code No.23 Wheel speed sensor <RR> system Code No.24 Wheel speed sensor <RL> system A diagnosis code corresponding to the open circuit or short circuit of the wheel D Wheel speed sensor fault speed sensor is output when one wheel speed sensor has detected a vehicle D Rotor fault...
Page 443 22A-10 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
Page 444 22A-11 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.25 Wrong-diameter tire Probable cause Code No.25 is output as wrong-diameter tire when one of the four vehicle D Tire fault speeds is outside the range of specified values in respect to the average of the D Wheel speed sensor fault four vehicle speed sensors, when the vehicle speed is above 20 km/h with the D Rotor fault...
Page 445 22A-12 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
Page 446 22A-13 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.26 Wheel speed sensor system (faulty output Probable cause signal) Code No.26 is output as output signal error of the wheel speed sensor when D Tire fault one wheel speed is outside the specified range at the vehicle speed of above D Wheel speed sensor fault 20 km/h.
Page 447 22A-14 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
Page 448 22A-15 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.31 Steering wheel sensor <ST-1, ST-2, ST-N> Probable cause system Code No.31 is output when open circuit or short circuit of the steering wheel D Steering wheel sensor fault sensor output line (ST-1, ST-2, or ST-N) occurs. D Harness or connector fault D 4WD-ECU fault MUT-II Diagnosis Code...
Page 449 22A-16 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.32, 33 Steering wheel sensor <ST-N> system Probable cause Code No.32 is output when the steering wheel sensor ST-N has been detected D Harness or connector fault at the neutral position in a state where the steering wheel has been determined D Steering wheel sensor fault to have changed above 40_C from steering wheel sensor ST-1 and ST-2.
Page 450 22A-17 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.34 Steering wheel sensor <ST-1, ST-2> system Probable cause Code No.34 is output when no change in the steering wheel sensor signal at a D Harness or connector fault vehicle speed of above 15 km/h is detected for a total of more than 15 minutes D Steering wheel sensor fault <ST-1, ST-2>, and turning is detected during this time.
Page 451 22A-18 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.41, 42 TPS system Probable cause Code No.41 is output as excessively small output when the TPS output is below D TPS fault 0.2 V In the idling state. D Harness or connector fault Code No.42 is output as excessively large output when the TPS output is more D 4WD-ECU fault than 4.8 V for more than 2 minutes continuously below a vehicle speed of 10...
Page 452 22A-19 MANUAL TRANSMISSION - Troubleshooting <ACD> MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.45 Pressure sensor system (Open circuit or Probable cause ground) Code No.45 is output when the output signal from the pressure sensor is below D Harness or connector fault 0.2 V.
Page 453 22A-20 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.47 Pressure sensor system (Abnormal power Probable cause supply) Code No.47 is output when the pressure sensor power supply voltage is above D Harness or connector fault 4.0V during pressure sensor power OFF or less than 4.0V during pressure D Pressure sensor fault sensor power ON.
Page 454 22A-21 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.51 Longitudinal G sensor system Probable cause Code No.51 is output when the output signal of the longitudinal G sensor is less D Harness or connector fault than 0.5 V or above 4.5 V. D Longitudinal G sensor fault D ABS-ECU fault <Vehicles with ACD and AYC>...
Page 455 22A-22 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.52 Longitudinal G sensor system Probable cause Code No.52 is output when the G sensor has exceeded the specified value in a D Harness or connector fault state where the ABS and brake are not operating above the vehicle speed of 10 D Longitudinal G sensor fault km/h.
Page 456 22A-23 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.56 Lateral G sensor system Probable cause Code No.56 is output when the output signal of the lateral G sensor is below D Harness or connector fault 0.5 V or above 4.5 V. D Lateral G sensor fault D ABS-ECU fault <Vehicles with ACD and AYC>...
Page 457 22A-24 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.57 Lateral G sensor system Probable cause Code No.57 is output when the G sensor has exceeded the specified value in a D Harness or connector fault state where the ABS and brake are not operating above the vehicle speed of 10 D Lateral G sensor fault km/h.
Page 458 22A-25 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.61 Stop lamp switch system Probable cause Code No.61 is output when the stop lamp switch is ON for more than 15 D Brake pedal fault minutes when the vehicle speed is above 15 km/h. D Stop lamp switch fault D Harness or connector fault D 4WD-ECU fault...
Page 459 22A-26 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.62 ACD mode switch system Probable cause Code No.62 is output when the ACD mode switch is ON for more than 60 D ACD mode switch fault seconds. D Harness or connector fault D 4WD-ECU fault MUT-II Data List D No.63 ACD mode switch...
Page 460 22A-27 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.63 Parking brake switch system Probable cause Code No.63 is output when the parking brake switch is ON for more than 15 D Parking brake switch fault minutes with the vehicle speed above 15 km/h. D Harness or connector fault D ABS-ECU fault <Vehicles with ACD and AYC>...
Page 461 22A-28 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.65 ABS monitor system Probable cause Code No.65 is output when ABS is detected to be operating for more than 1 D Harness or connector fault minute continuously. D ABS-ECU fault <Vehicles with ACD and AYC> D 4WD-ECU fault <Vehicles with ACD and AYC>...
Page 462 22A-29 MANUAL TRANSMISSION - Troubleshooting <ACD> MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.74 Proportional valve <ACD> system Probable cause Code No.74 is output when open circuit or short circuit of the control circuit of D Proportional valve <ACD> fault the proportional valve <ACD> has occurred. D Harness or connector fault D 4WD-ECU fault MUT-II Data List...
Page 463 22A-30 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.82 Electric pump relay system Probable cause Code No.82 is output when the pressure sensor does not reach the specified D Insufficient fluid value even if the 4WD-ECU has output the electric pump motor drive command. D Pressure sensor fault D Electric pump relay fault D Hydraulic unit fault...
Page 464 22A-31 MANUAL TRANSMISSION - Troubleshooting <ACD> INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference procedure No. page No communication possible between MUT-II and all systems. 22A-31 No communication possible between MUT-II and 4WD-ECU. 22A-32 ACD mode indicator lamp does not light up when the ignition switch is set to ”ON“ 22A-33 (engine is stopped).
Page 465 22A-32 MANUAL TRANSMISSION - Troubleshooting <ACD> Inspection procedure 2 No communication is possible between the MUT-II and Probable cause 4WD-ECU. The diagnostic output circuit, 4WD-ECU power supply circuit, earth circuit, or D Harness or connector fault 4WD-ECU may be faulty. D 4WD-ECU fault Measure at diagnosis connector C-22 and 4WD-ECU Check the following connectors:...
Page 466 22A-33 MANUAL TRANSMISSION - Troubleshooting <ACD> Inspection procedure 3 The ACD mode indicator lamp does not light up when the Probable cause ignition switch is turned “ON” (engine stop). The ACD mode indicator lamp circuit or 4WD-ECU may be faulty. D Harness or connector fault D ACD mode indicator lamp assembly fault D 4WD-ECU fault...
Page 467 22A-34 MANUAL TRANSMISSION - Troubleshooting <ACD> Inspection procedure 4 More than two ACD mode indicator lamps remain lit even Probable cause after the engine starts The output circuit of the ACD mode indicator lamp may be faulty. D Harness or connector fault D 4WD-ECU fault D ACD mode indicator lamp assembly fault NOTE...
Page 468 22A-35 MANUAL TRANSMISSION - Troubleshooting <ACD> DATA LIST REFERENCE TABLE Item Check item Check condition Normal conditions Wheel speed sensor Execute actual driving. The speed meter dis- <FR> play and MUT-II dis- play match. Wheel speed sensor <FL> Wheel speed sensor <RR>...
Page 469 22A-36 MANUAL TRANSMISSION - Troubleshooting <ACD> Item Check item Check condition Normal conditions Pressure sensor power Ignition switch: ON Approx.5 V supply Valve power supply Ignition switch: ON System voltage Steering wheel sensor Ignition switch: ON Steering wheel: Turn 1 - 2 V and 2.5 - 4.5 V voltage <ST-1>...
Page 470 22A-37 MANUAL TRANSMISSION - Troubleshooting <ACD> ACTUATOR TEST JUDGEMENT VALUE Item Check item Test description Normal state Bleeding <ACD> Input current to the Proportional valve Make sure no air leaks from the bleeder according to the steering angle, and operate screw on the transfer.
Page 471 22A-38 MANUAL TRANSMISSION - Troubleshooting <ACD> CHECK AT 4WD-ECU TERMINALS NOTE: 1. * indicates the eliminated terminal when only ACD is installed. 2. * indicates the terminal added when only ACD is installed. Termi- Check item Check condition Normal state nal no.
Page 472 22A-39 MANUAL TRANSMISSION - Troubleshooting <ACD> Termi- Check item Check condition Normal state nal no. Longitudinal G sensor Any time 1 V or less earth, lateral G sensor earth ECU earth Any time 1 V or less ECU backup power Any time System voltage supply...
Page 473: Transmission Oil Replacement
22A-40 MANUAL TRANSMISSION - On-vehicle Service MANUAL TRANSMISSION - On-vehicle Service ON-VEHICLE SERVICE TRANSMISSION OIL CHECK Filler plug hole 1. Remove the oil filler plug. Transmission oil 2. Oil level should be at the lower portion of the filler plug hole.
Page 474: Fluid Check
22A-41 MANUAL TRANSMISSION - On-vehicle Service 4. Fill with specified oil till the level comes to the lower portion of oil filler plug hole. Specified transfer oil: MITSUBISHI Genuine Gear Oil Part No.8149630 EX, CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD (GL-5, SAE 80W - 90) or equivalent Quantity: 0.55 L <Vehicles without ACD or vehicles without...

Page 475: Bleeding
22A-42 MANUAL TRANSMISSION - On-vehicle Service BLEEDING <VEHICLES WITH ACD OR VEHICLES WITH ACD AND AYC> 1. Lift up the vehicle. 2. Set the MUT-II to the 16-pin diagnosis connector. Caution Turn the ignition switch to the “LOCK”(OFF) position before connecting or disconnecting the MUT-II. 3.

Page 476: Hydraulic Pressure Check
22A-43 MANUAL TRANSMISSION - On-vehicle Service 4. Set the gear to the 2nd gear or above, operate the MUT-II, and check from the service data (Item No.09) that the wheel speed is within 10 km/h to 20 km/h. NOTE (1) Set the steering wheel to the neutral position (2) The ACD may continue operating (operation sounds can be heard) when the steering wheel is steered, this is not a system fault.

Page 477: Wheel Speed Sensor Output Voltage
22A-44 MANUAL TRANSMISSION - On-vehicle Service (2) If the hydraulic unit function has been stopped by fail-safe, the hydraulic unit cannot be forcibly driven. 6. Check that the generated oil pressure of the hydraulic unit satisfies the standard value. Standard value: 1.0 – 1.6 MPa Caution While the oil pressure is checked, add fluid as necessary to ensure that it is left in the oil reservoir...
Page 478 22A-45 MANUAL TRANSMISSION - On-vehicle Service Output voltage: Above 70 mV when measured with the circuit tester Above 200 mVP-P when measured with the oscilloscope 4. If the output voltage is lower than the above values, the following reasons may be suspected. Check or replace the wheel speed sensor.
Page 479: Transmission Control
22A-46 MANUAL TRANSMISSION - Transmission Control TRANSMISSION CONTROL REMOVAL AND INSTALLATION Pre-removal Operation Caution: SRS Strut Tower Bar Removal and Installation (Refer Be careful not to subject the SRS-ECU to any to GROUP 42.) shocks during removal and installation of the Air Cleaner Removal (Refer to GROUP 15.) shift cable and select cable assembly.
Page 480 22A-47 MANUAL TRANSMISSION - Transmission Control REMOVAL SERVICE POINT Shift cable, AA" CLIP/SELECT CABLE CONNECTION Clip select cable Claws (TRANSMISSION)/SHIFT CABLE (TRANSMISSION) INSTALLATION Push up the claws of the clip using a screwdriver, etc., and then remove the clip from the bracket together with the cables. INSTALLATION SERVICE POINT "AA CLIP/SELECT CABLE AND SHIFT CABLE ASSEMBLY/SHIFT CABLE CONNECTION/SELECT...
Page 481 22A-48 MANUAL TRANSMISSION - Transmission Control SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 2 N·m ± 1 N·m ± Disassembly steps 7. Cap 8. Shift lever 1. Bolt 9. Shift lever bushing 2. Select lever 10. Distance piece 3. Bushing 11. Bushing 4.
Page 482: Transfer Assembly
22A-49 MANUAL TRANSMISSION - Transfer Assembly TRANSFER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) Side Under Cover Removal and Installation Transmission Oil Draining and Supplying (Refer to P.22A-40.) Transfer Oil Draining and Supplying (Refer to P.22A-40.) Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) Crossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
Page 483 22A-50 MANUAL TRANSMISSION - Transfer Assembly 5 N·m ± 9 N·m ± ± 9 N·m 7 N·m* ± 7 N·m* ± 10 N·m ± 10 N·m ± 9. Rear roll stopper connection bolt 14. Dust seal guard 10. Centermember assembly 15.
Page 484 22A-51 MANUAL TRANSMISSION - Transfer Assembly AB" DRIVE SHAFT <L.H.>/DRIVE SHAFT <R.H.> <L.H.> DISCONNECTION 1. As shown in the figure, pull out the transfer shaft <L.H.> Transmission side from the transmission using the pry bar. As shown in the illustration, press a hammer, etc. against the driveshaft <R.H.>, and pull out the driveshaft from the transfer assembly using the pry shaft.
Page 485: Transmission Assembly
22A-52 MANUAL TRANSMISSION - Transmission Assembly TRANSMISSION ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Transfer Assembly Removal and Installation (Refer to P.22A-49.) Starter Motor Removal and Installation (Refer to GROUP 16.) Air Cleaner Bracket Removal and Installation (Refer to GROUP 15 - Air Cleaner.) Rear Roll Rod Assembly and Rear Roll Rod Bracket <L.H.
Page 486 22A-53 MANUAL TRANSMISSION - Transmission Assembly 7 N·m* ± ± 7 N·m* ± 5 N·m 5 N·m ± 5 N·m ± ± 5 N·m 1.0 N·m ± 5 N·m ± 8. Transmission assembly upper part 13. Transmission assembly lower part coupling bolts coupling bolts 9.
Page 487 22A-54 MANUAL TRANSMISSION - Transmission Assembly AB" ENGINE ASSEMBLY SUPPORTING MZ203827 Set the special tool to the vehicle to support the engine assembly. MB991453 AC" CLUTCH RELEASE BEARING SEPARATION 1. Remove the cover from the service hole in the clutch housing.
Page 488: 4Wd-Ecu
22A-55 4WD-ECU <Vehicles with ACD or vehicles MANUAL TRANSMISSION - with ACD and AYC> 4WD-ECU <VEHICLES WITH ACD OR VEHICLES WITH ACD AND AYC> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Cowl Side Trim <R.H.> Removal and Installation. (Refer to GROUP 52A - Trims.) <L.H. drive vehicles> Front floor Console Removal and Installation.

Page 489 Sensor, Switch and Relay <Vehicles with ACD 22A-56 MANUAL TRANSMISSION - or vehicles with ACD and AYC> SENSOR, SWITCH AND RELAY <VEHICLES WITH ACD OR VEHICLES WITH ACD AND AYC> REMOVAL AND INSTALLATION Caution Before removing the steering wheel and air bag module assembly, be sure to refer to GROUP 52B Precautions in Servicing and Airbag Module Clock Spring.
Page 490 Sensor, Switch and Relay <Vehicles with ACD or 22A-57 MANUAL TRANSMISSION - vehicles with ACD and AYC> INSPECTION ELECTRIC PUMP RELAY CONTINUITY CHECK 1. Using a jumper wire, connect a battery (+) to terminal 13 of the electric pump relay and battery ( - ) to terminal 2.
Page 491 NOTES...
Page 492 22B-1 MANUAL TRANSMISSION OVERHAUL CONTENTS GENERAL DESCRIPTION ....OUTPUT SHAFT ......SPECIFICATIONS .
Page 493: General Description
22B-2 MANUAL TRANSMISSION OVERHAUL - General Description GENERAL DESCRIPTION SECTIONAL VIEW <W5M51 - 2 - X5B3>...
Page 494 22B-3 MANUAL TRANSMISSION OVERHAUL - General Description SECTIONAL VIEW <W5M51 - 2 - X5B1>...
Page 495 22B-4 MANUAL TRANSMISSION OVERHAUL - General Description SECTIONAL VIEW <W5M51 - 2 - X5B2>...
Page 496 22B-5 MANUAL TRANSMISSION OVERHAUL - General Description SECTIONAL VIEW <W5M51 - 2 - X5B, X5B 4>...
Page 497: Specifications
22B-6 MANUAL TRANSMISSION OVERHAUL - Specifications/Service Specifications SPECIFICATIONS TRANSMISSION MODEL TABLE Transmission Gear ratio Speedometer Final Front LSD Vehicle model Engine model model gear ratio reduction ratio W5M51- 2 - X5B 28/36 4.529 CT9A 4G63 - I/C•T/C Provided W5M51- 2 - X5B1 28/36 4.529 Not provided...
Page 498: Sealants
22B-7 MANUAL TRANSMISSION OVERHAUL - Sealants SEALANTS TRANSMISSION Items Specified sealants Clutch housing and transmission case contact surface MITSUBISHI genuine sealant Part No MD997740 or equivalent No.MD997740 or equivalent Control housing and transmission case contact surface Under cover and transmission case contact surface Air breather 3M SUPER WEATHERSTRIP No.8001 or equivalent...
Page 499: Lubricants
22B-8 MANUAL TRANSMISSION OVERHAUL - Lubricants LUBRICANTS TRANSMISSION Items Specified lubricants Drive shaft oil seal lip section MITSUBISHI genuine “DIA-QUEEN” multi gear oil <75W/85W> or equivalent gear oil <75W/85W> or equivalent Input shaft oil seal lip section Control shaft oil seal lip section Select lever shoe MITSUBISHI genuine grease Part No.0101011 or equivalent...
Page 500: Snap Rings, Spacers And Thrust
Snap Rings, Spacers and Thrust 22B-9 MANUAL TRANSMISSION OVERHAUL - Plates for Adjustment SNAP RINGS, SPACERS AND THRUST PLATES FOR ADJUSTMENT SPACERS (FOR ADJUSTMENT OF INPUT SHAFT END PLAY) Thickness mm Identification Part No. Thickness mm Identification Part No. 1.34 MD723600 1.61 MD723609...
Page 501 22B-10 Snap Rings, Spacers and Thrust MANUAL TRANSMISSION OVERHAUL - Plates for Adjustment SNAP RINGS (FOR ADJUSTMENT OF OUTPUT SHAFT BEARING CLEARANCE) Thickness mm Identification Part No. Thickness mm Identification Part No. 1.36 Yellow MD748449 1.55 White MD748452 1.40 Green MD748450 1.58 Brown...
Page 502: Tightening Torque
22B-11 MANUAL TRANSMISSION OVERHAUL - Tightening Torque TIGHTENING TORQUE TRANSMISSION Items Tightening torque N•m Under cover mounting bolt 6.9 ± 1 Interlock plate bolt 30 ± 3 Clutch housing and transmission case tightening bolt 44 ± 5 Clutch release bearing retainer mounting bolt 9.8 ±...
Page 503: Special Tools
22B-12 MANUAL TRANSMISSION OVERHAUL - Special Tools SPECIAL TOOLS Tool Number Name MB990887 Arm bush remover Installation of transfer oil seal and installer ring MB990891 Bush remover and Installation of transfer oil seal installer base MB990928 Installer adapter Installation of input shaft oil seal MB990932 Installer adapter Removal of differential case taper roller...
Page 504 22B-13 MANUAL TRANSMISSION OVERHAUL - Special Tools Tool Number Name MD998364 Camshaft oil seal Installation of each gear, bearing and sleeve installer MD998800 Oil seal installer Installation of differential oil seal and transfer cover oil seal MD998801 Bearing remover Installation and removal of each gear, bearing and sleeve MD998812 Installer cap...
Page 505 22B-14 MANUAL TRANSMISSION OVERHAUL - Special Tools Tool Number Name MD998821 Installer adapter Installation of 4th speed gear, 5th speed gear (44) sleeve and 5th-reverse speed synchronizer MD998824 Installer adapter Installation of 1st-2nd speed synchronizer (50) hub, 2nd speed gear sleeve and 3rd speed gear MD998825 Installer adapter...
Page 506: Transmission
22B-15 MANUAL TRANSMISSION OVERHAUL - Transmission TRANSMISSION DISASSEMBLY AND REASSEMBLY 18 ± 3 N•m 18 ± 3 N•m 32 ± 2 N•m 69 ± 9 N•m 32 ± 2 N•m 3.9 ± 1 N•m 69 ± 9 N•m 69 ± 9 N•m Disassembly steps 1.
Page 507 22B-16 MANUAL TRANSMISSION OVERHAUL - Transmission Apply gear oil on all sliding sections before installing. 18 ± 3 N•m 30 ± 3 N•m 44 ± 5 N•m 48 ± 5 N•m 6.9 ± 1 N•m Disassembly steps 11. Interlock plate bolt "EA 19.
Page 508 22B-17 MANUAL TRANSMISSION OVERHAUL - Transmission Apply gear oil on all sliding sections before installing. Disassembly steps "CA 27. Spring pin AB" "BA 34. 5th-reverse speed shift rail 28. 1st-2nd speed shift rail AB" "BA 35. 5th-reverse speed shift fork 29.
Page 509 22B-18 MANUAL TRANSMISSION OVERHAUL - Transmission DISASSEMBLY SERVICE POINTS 5th-reverse speed shift AA" SPRING PIN REMOVAL fork Shift the 5th-reverse speed shift fork in the direction shown in the illustration, and remove the spring pin. AB" 3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED 3rd-4th speed SHIFT FORK/5TH-REVERSE SPEED SHIFT shift rail...
Page 510 22B-19 MANUAL TRANSMISSION OVERHAUL - Transmission (3) Set solder (10 mm long, 1.6 mm diameter) on the Solder transmission case at the position shown in the illustration. (4) Install the outer race onto the transmission case. (5) Install the transmission case, and tighten the bolt with the specified torque.
Page 511 22B-20 MANUAL TRANSMISSION OVERHAUL - Transmission (2) Slide each shift rail in the direction shown in the illustration, 3rd-4th speed and then install onto the shift rail hole on the clutch shift rail housing. 5th-reverse speed shift rail "CA SPRING PIN INSTALLATION Install the spring pin onto the shift rail so that the slit faces the direction shown in the illustration.
Page 512 22B-21 MANUAL TRANSMISSION OVERHAUL - Transmission "GA CONTROL HOUSING INSTALLATION Apply sealant at the positions of the transmission case shown in the illustration. Sealant Specified sealant: MITSUBISHI genuine sealant Part No.MD997740 or equivalent Caution Evenly squeeze out the agent so that it is not insufficient or excessive.
Page 513: Input Shaft
22B-22 MANUAL TRANSMISSION OVERHAUL - Input Shaft INPUT SHAFT DISASSEMBLY AND REASSEMBLY Apply gear oil on all sliding sections before installing. Disassembly steps "MA 1. Snap ring "EA 12. 3rd-4th speed synchronizer hub 2. Ball bearing 13. Outer synchronizer ring AA"...
Page 514 22B-23 MANUAL TRANSMISSION OVERHAUL - Input Shaft DISASSEMBLY SERVICE POINTS MD998801 AA" BALL BEARING REMOVAL Using the special tool, remove the ball bearing from the input shaft. AB" THRUST PLATE STOPPER REMOVAL Using a screwdriver, lift the stopper at the position shown in the illustration, and remove the thrust plate stopper.
Page 515 22B-24 MANUAL TRANSMISSION OVERHAUL - Input Shaft REASSEMBLY SERVICE POINTS "AA OIL SEAL INSTALLATION 3.5 mm Oil seal Accurately tap in the oil seal to the dimensions shown in the illustration. "BA BALL BEARING INSTALLATION MD998812 Using the special tool, install the ball bearing onto the input shaft.
Page 516 22B-25 MANUAL TRANSMISSION OVERHAUL - Input Shaft Caution (1) Press in so that the synchronizer ring does not bite MD998812 MD998813 MD998801 (2) After assembling, confirm that the 3rd speed gear rotates smoothly. MD998825 "FA SYNCHRONIZER SLEEVE INSTALLATION speed speed (1) Install the synchronizer sleeve onto the input shaft at Identification side...
Page 517 22B-26 MANUAL TRANSMISSION OVERHAUL - Input Shaft "IA 5TH SPEED GEAR INSTALLATION MD998812 Using the special tool, install the 5th speed gear onto the MD998813 input shaft. MD998801 Caution MD998825 (1) Press in so that the synchronizer ring does not bite (2) After assembling, confirm that the 4th speed gear rotates smoothly.
Page 518 22B-27 MANUAL TRANSMISSION OVERHAUL - Input Shaft INSPECTION INPUT SHAFT (1) There must be no damage, abnormal wear or seizure on the outer diameter of the needle bearing installation section. (2) Check the spline for damage and wear. NEEDLE BEARING (1) When the needle bearing is assembled with the input shaft and gears and rotated, the needle bearing must rotate smoothly without play or abnormal noise.
Page 519 22B-28 MANUAL TRANSMISSION OVERHAUL - Input Shaft (2) Assemble the outer ring, inner ring and cone. Press “A” against the gears and check the clearance “A”. Replace Outer ring if “A” is less than the limit value. Cone Limit value: 0.5 mm Caution When replacing, replace the outer ring, inner ring and cone as a set.
Page 520: Output Shaft
22B-29 MANUAL TRANSMISSION OVERHAUL - Output Shaft OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY Apply gear oil on all sliding sections before installing. 19 18 Disassembly steps "PA 1. Snap ring 19. Needle roller bearing AA" "OA 2. Taper roller bearing AE" "GA 20. 2nd speed gear sleeve AB"...
Page 521 22B-30 MANUAL TRANSMISSION OVERHAUL - Output Shaft DISASSEMBLY SERVICE POINTS Taper roller MD998801 bearing AA" TAPER ROLLER BEARING REMOVAL Using the special tool, remove the taper roller bearing from the output shaft. AB" REVERSE GEAR BEARING SLEEVE REMOVAL MD998801 Sleeve Install the special tool on the reverse gear, and remove the reverse gear bearing sleeve from the output shaft.
Page 522 22B-31 MANUAL TRANSMISSION OVERHAUL - Output Shaft AF" 1ST SPEED GEAR SLEEVE REMOVAL Using the special tool, remove the 1st speed gear sleeve from the output shaft. MD998801 Sleeve AG" TAPER ROLLER BEARING REMOVAL Taper roller MD998801 Using the special tool, remove the taper roller bearing from bearing the output shaft.
Page 523 22B-32 MANUAL TRANSMISSION OVERHAUL - Output Shaft "DA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring at the position shown in the illustration. Synchronizer spring "EA 1ST-2ND SPEED SYNCHRONIZER HUB Using the special tool, install the 1st-2nd speed synchronizer speed speed side side hub onto the output shaft in the direction shown in the...
Page 524 22B-33 MANUAL TRANSMISSION OVERHAUL - Output Shaft "GA 2ND SPEED GEAR SLEEVE INSTALLATION MD998812 Using the special tool, install the 2nd speed gear sleeve onto the output shaft. MD998814 Sleeve MD998824 MD998364 "HA 3RD SPEED GEAR INSTALALTION MD998812 Using the special tool, install the 3rd speed gear onto the output shaft.
Page 525 22B-34 MANUAL TRANSMISSION OVERHAUL - Output Shaft "LA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring at the position shown in the illustration. Synchronizer spring "MA5TH-REVERSE SPEED SYNCHRONIZER HUB Reverse INSTALLATION side speed side Using the special tool, install the 5th-reverse synchronizer hub onto the output shaft in the direction shown in the illustration.
Page 526 22B-35 MANUAL TRANSMISSION OVERHAUL - Output Shaft "PA SNAP RING INSTALLATION Snap ring Select and install the snap ring onto the output shaft so that the output shaft rear bearing clearance is at the standard value. Standard value: 0.01 mm tight to 0.09 mm loose INSPECTION OUTPUT SHAFT Check the spline for damage and wear.
Page 527 22B-36 MANUAL TRANSMISSION OVERHAUL - Output Shaft OUTER SYNCHRONIZER RING, INNER SYNCHRONIZER RING AND SYNCHRONIZER CONE (1) The gear teeth and cone surface must not be damaged or broken. (2) Assemble the outer ring, inner ring and cone. Press Gear against the gears and check the clearance “A”.
Page 528: Reverse Idler Gear
22B-37 MANUAL TRANSMISSION OVERHAUL - Reverse Idler Gear REVERSE IDLER GEAR DISASSEMBLY AND REASSEMBLY Apply gear oil on all sliding sections before installing. Disassembly steps 1. Snap ring 5. Reverse idler gear 2. Cone spring 6. Needle roller bearing 3. Thrust washer 7.
Page 529: Speedometer Gear
22B-38 MANUAL TRANSMISSION OVERHAUL - Speedometer Gear SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Apply gear oil on all sliding sections before installing. Disassembly steps 1. e-clip 2. Speedometer driven gear 3. O-ring 4. Sleeve...
Page 530: Select Lever
22B-39 MANUAL TRANSMISSION OVERHAUL - Select Lever SELECT LEVER DISASSEMBLY AND REASSEMBLY 11 ± 1 N•m Disassembly steps "AA 1. Dust cover 6. Select lever shoe 2. Nut 7. Select lever 3. Spring washer 8. Select lever bush 4. Plane washer "AA 9.
Page 531: Control Housing
22B-40 MANUAL TRANSMISSION OVERHAUL - Control Housing CONTROL HOUSING DISASSEMBLY AND REASSEMBLY 18 ± 3 N•m Disassembly steps 1. Lock pin 10. Neutral return spring AA" "FA 2. Interlock plate 11. Control shaft 3. Control finger "CA 12. Air breather 4.
Page 532 22B-41 MANUAL TRANSMISSION OVERHAUL - Control Housing DISASSEMBLY SERVICE POINT AA" LOCK PIN REMOVAL Lock pin Tap out the lock pin from the direction shown in the illustration. Control finger REASSEMBLY SERVICE POINTS Control housing "AA NEEDLE BEARING INSTALLATION Press the needle bearing into the dimensions shown in the Needle illustration so that the type stamp side faces the indicated bearing...
Page 533 22B-42 MANUAL TRANSMISSION OVERHAUL - Control Housing "DA SPRING PIN INSTALLATION Stopper body Control shaft Install the spring pin onto the stopper body from the direction shown in the illustration. Installation direction Slit Spring "EA SPRING PIN INSTALLATION Install the spring pin onto the stopper body. Spring pin "FA LOCK PIN INSTALLATION Tap the lock pin into the control finger from the direction...
Page 534: Clutch Housing
22B-43 MANUAL TRANSMISSION OVERHAUL - Clutch Housing CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY 9.8 ± 2 N•m Disassembly steps 1. Clutch release bearing retainer "BA 5. Bush* "EA 2. Oil seal "AA 6. Cover A AA" "DA 3. Outer race "AA 7. Cover B AB"...
Page 535 22B-44 MANUAL TRANSMISSION OVERHAUL - Clutch Housing AB" OUTER RACE REMOVAL Using the special tool, remove the outer race from the clutch MD999566 housing. REASSEMBLY SERVICE POINTS Cover A "AA COVER A/COVER B INSTALLATION Cover B Install each cover onto the clutch housing in the direction shown in the illustration.
Page 536 22B-45 MANUAL TRANSMISSION OVERHAUL - Clutch Housing "DA OUTER RACE INSTALLATION MB990938 Using the special tool, install the outer race onto the clutch MB991445 housing. "EA OIL SEAL INSTALLATION (1) Apply transmission oil on the oil seal lip section. Transmission oil Specified oil: MITSUBISHI genuine “DIA-QUEEN”...
Page 537: Transmission Case
22B-46 MANUAL TRANSMISSION OVERHAUL - Transmission Case TRANSMISSION CASE DISASSEMBLY AND REASSEMBLY Disassembly steps "CA 1. Oil seal "AA 3. Bush* "BA 2. Needle bearing* 4. Transmission case NOTE *: Refer to the installation procedures only when replacing the transmission case. REASSEMBLY SERVICE POINTS "AA BUSH INSTALLATION Press in the bush to the position shown in the illustration...
Page 538 22B-47 MANUAL TRANSMISSION OVERHAUL - Transmission Case Bush 3 mm "BA NEEDLE BEARING INSTALLATION Press in to the flush with the type stamp side facing the Needle bearing Type stamp side direction shown in the illustration. "CA OIL SEAL INSTALLATION (1) Apply transmission oil on the oil seal lip section.
Page 539: Center Differential
22B-48 MANUAL TRANSMISSION OVERHAUL - Center Differential CENTER DIFFERENTIAL DISASSEMBLY AND REASSEMBLY Apply gear oil on all sliding sections before installing. 132 ± 5 N•m Disassembly steps "DA 1. Center differential drive gear "CA 10. Pinion shaft holder "CA 2. Center differential flange "CA 11.
Page 540 22B-49 MANUAL TRANSMISSION OVERHAUL - Center Differential AB" TAPER ROLLER BEARING REMOVAL Using the special tool, remove the taper roller bearing from the center differential case. MD998917 MB990932 REASSEMBLY SERVICE POINTS "AA TAPER ROLLER BEARING INSTALLATION MB990937 Using the special tool, install the taper roller bearing onto the center differential case.
Page 541 22B-50 MANUAL TRANSMISSION OVERHAUL - Center Differential (5) Install the front output shaft onto the side gear, and install the snap ring. (6) After assembling the side gear into the center differential case, install the spacer onto the side gear. (7) Match the alignment marks, install the center differential flange, and temporarily fix the machine screw.
Page 542: Transfer
22B-51 MANUAL TRANSMISSION OVERHAUL - Transfer TRANSFER DISASSEMBLY AND REASSEMBLY Apply gear oil on all sliding sections before installing. 23 ± 3 N•m Disassembly steps 1. Dust seal guard "CA 6. Oil seal "EA 2. Oil seal "BA 7. Oil seal "DA 3.
Page 543 22B-52 MANUAL TRANSMISSION OVERHAUL - Transfer REASSEMBLY SERVICE POINTS "AA O-RING INSTALLATION Apply hypoid gear oil on the O-ring. Hypoid gear oil Specified oil: MITSUBISHI genuine “DIA-QUEEN SUPER” hypo- id gear oil (GL-5) or equivalent "BA OIL SEAL INSTALLATION Apply hypoid gear oil on the lip section of the oil seal, and MD998800 install using the special tool.
Page 544 25-1 PROPELLER SHAFT CONTENTS GENERAL INFORMATION ....SEALANT ........SERVICE SPECIFICATIONS .
Page 545: Propeller Shaft
General Information/Service Specification/ 25-2 PROPELLER SHAFT - Lubricant/Sealant/Special Tool GENERAL INFORMATION 3 way split 4-joint type propeller shaft with center bearing is adopted. SERVICE SPECIFICATION Items Standard value Limit Propeller shaft runout mm LUBRICANT Items Specified lubricant Quantity Front propeller shaft sleeve Hypoid gear oil SAE 75W-90 or 75W-85W or 80W As required yoke...
Page 546 25-3 PROPELLER SHAFT - Propeller Shaft PROPELLER SHAFT REMOVAL AND INSTALLATION Gear Oil: Hypoid gear oil SAE 75W-90 or 75W-85W or 80W conforming to API GL-4 30 ± 4 N·m 30 ± 4 N·m 32 ± 2 N·m Removal steps 1.
Page 547 25-4 PROPELLER SHAFT - Propeller Shaft INSTALLATION SERVICE POINT "AA 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 Oil seal 1.
Page 548 25-5 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY AND REASSEMBLY 187 ± 29 N·m 34 ± 5 N·m 187 ± 29 N·m 34 ± 5 N·m LJ kit LJ boot kit Disassembly steps 1. Bolt 10. Center propeller shaft 2. Front propeller shaft assembly 11.
Page 549 25-6 PROPELLER SHAFT - Propeller Shaft Lubrication and Adhesive Points Rubber mount Repair kit grease: Adhesive: 3M Stud Locking 4170 Quantity: 75 ± 5 g or equivalent...
Page 550 25-7 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY SERVICE POINTS AA" COMPANION FLANGE REMOVAL Mating marks Make mating marks on the companion flange and center propeller shaft. Then, remove the companion flange. AB" CENTER BEARING ASSEMBLY REMOVAL Center bearing assembly MD998801 AC"...
Page 551 25-8 PROPELLER SHAFT - Propeller Shaft 3. Using puller (general service tool), remove the inner race Cage Inner race and cage from the center propeller shaft assembly. 4. Wipe out grease on the outer race, inner race, cage and ball then clean. Puller (General service tool) AE"...
Page 552 25-9 PROPELLER SHAFT - Propeller Shaft 4. Apply a little specific sealant to the surface which has groove (for packing) of LJ assembly (allow as shown Rubber packing in the illustration), fix the rubber packing. Specified sealant: 3M Stud Locking 4170 or equivalent 5.
Page 553 25-10 PROPELLER SHAFT - Propeller Shaft "DA CENTER BEARING ASSEMBLY/COMPANION Center propeller shaft rear side Companion FLANGE/SELF LOCKING NUT INSTALLATION Center bearing flange assembly 1. Install the center bearing assembly to the rear propeller shaft in the direction shown as the illustration. Self 2.
Page 554 26-1 FRONT AXLE CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Wheel Bearing Axial Play Check .
Page 555: General Information
26-2 FRONT AXLE - General Information GENERAL INFORMATION The front axle consists of front hubs, knuckles, ABS rotors for detecting the wheel speeds are wheel bearings and drive shafts, and it has the press-fitted to the B.J. outer wheels in vehicles following features.
Page 556: Service Specifications
26-3 FRONT AXLE - Service Specifications/Lubricants/Special Tools SERVICE SPECIFICATIONS Item Standard value Limit Wheel bearing axial play mm 0.06 Wheel bearing rotation starting torque N·m Wheel bearing rotation starting torque N·m 1 03 or less 1.03 or less Setting of T.J. boot length mm 85 ±...
Page 557 26-4 FRONT AXLE - Special Tools Tool Number Name MB990685 Torque wrench Measurement of wheel bearing rotation starting torque MB990326 Preload socket Measurement of wheel bearing rotation starting torque A: MB991017 A,B:Front hub Provisional holding of the wheel bearing Measurement of wheel bearing rotation B: MB990998 remover and starting torque...
Page 558: On-Vehicle Service
26-5 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.
Page 559 26-6 FRONT AXLE - Hub and Knuckle Assembly HUB AND KNUCKLE ASSEMBLY REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 560: Hub And Knuckle Assembly
26-7 FRONT AXLE - Hub and Knuckle Assembly REMOVAL SERVICE POINTS AA" CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, etc. Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
Page 561 26-8 FRONT AXLE - Hub and Knuckle Assembly INSTALLATION SERVICE POINT Washer "AACASTLE NUT INSTALLATION 1. Be sure to install the castle nut washer in the specified direction. 2. Using the special tool, tighten the castle nut. Caution Before securely tightening the castle nuts, make sure 245±29 N·m there is no load on the wheel bearings.
Page 562 26-9 FRONT AXLE - Hub and Knuckle Assembly DISASSEMBLY AND REASSEMBLY 88 ± 10 N·m Disassembly steps 1. Knuckle 2. Front hub assembly...
Page 563: Drive Shaft
26-10 FRONT AXLE - Drive Shaft DRIVE SHAFT REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 564 26-11 FRONT AXLE - Drive Shaft REMOVAL SERVICE POINTS MB991113 MB990635 AA" TIE ROD END DISCONNECTION Caution 1. Loosen the nut only; do not remove it from the ball Cord joint. Otherwise ball joint thread will be damaged. 2. The special tool should be suspended by a cord to prevent it from coming off.
Page 565 26-12 FRONT AXLE - Drive Shaft AC"OUTPUT SHAFT REMOVAL MB991721 Use the special tool to pull out the output shaft. Caution Do not damage the oil seal of the transmission by the output shaft splines. Output shaft INSTALLATION SERVICE POINTS "AA OUTPUT SHAFT/DRIVE SHAFT INSTALLATION Caution Do not damage the oil seal of the transmission by the...
Page 566 26-13 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY Caution (1) On the vehicles with ABS or ACD, when the drive shaft is disassembled or reassembled, be careful not to interfere with the rotor for wheel speed sensor installed to the B.J. outer race to prevent the rotor from damage.
Page 567 26-14 FRONT AXLE - Drive Shaft DISASSEMBLY SERVICE POINTS AA" T.J. CASE/SPIDER ASSEMBLY REMOVAL 1. Wipe off grease from the spider assembly and the inside of the T.J. case. 2. Always clean the spider assembly when the grease contains water or foreign material. Caution Do not disassemble the spider assembly.
Page 568 26-15 FRONT AXLE - Drive Shaft "BA T.J. BOOT BAND (SMALL)/T.J. BOOT BAND (LARGE) INSTALLATION Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot bands securely. Standard value (A): 85±3 mm INSPECTION Check the drive shaft for damage, bending or corrosion.
Page 569 26-16 FRONT AXLE - Drive Shaft (2) The adjusting bolt should not be turned more than once. 6. Install the boot band (small) in order to create clearance as B.J. boot A and B in the illustration. B.J. boot band (small) Projection 7.
Page 570 26-17 FRONT AXLE - Drive Shaft 10. Fill the inside of the B.J. boot with the specified amount of the specified grease. Specified grease: Repair kit grease Amount to use: 110±10 g Caution The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
Page 571 NOTES...
Page 572 27B-1 REAR AXLE CONTENTS GENERAL INFORMATION ....Wheel Bearing Axial Play Check ....Wheel Bearing Rotary-sliding Resistance Check SERVICE SPECIFICATIONS .
Page 573: General Information
27B-2 REAR AXLE - General Information GENERAL INFORMATION The rear axle consists of rear hubs, wheel bearings, ABS rotors for detecting the wheel speeds are drive shafts, and rear differential and, it has the press-fitted to the B.J. outer wheels in vehicles following features.
Page 574: Service Specifications
27B-3 REAR AXLE - Service Specifications/Lubricants SERVICE SPECIFICATIONS Item Standard value Limit Rear axle total backlash mm Wheel bearing rotation starting torque N·m Wheel bearing axial play mm 0.05 or less Wheel bearing rotary-sliding resistance N 22 or less TJ boot assembly dimension mm 90 ±...
Page 575: Sealants
27B-4 REAR AXLE - Lubricants/Sealants/Special tools Item Specified lubricants Quantity Vehicles with Hydraulic piping fluid ATF-SPⅢ ACD and ACD and Torque transfer mechanism oil Vaseline As required seal lips B.J. joint Repair kit grease 85 ± 10 g T.J. joint Repair kit grease 105 ±...
Page 576 27B-5 REAR AXLE - Special Tools Tool Number Name MB991115 Oil seal installer Press-fitting of oil seal (AYC differential: used in combination with MB990938) MD998812 Installer cap Press-fitting of oil seal (torque transfer mechanism of vehicles with AYC) MD998813 Installer100 MD998829 Installer adapter...
Page 577 27B-6 REAR AXLE - Special Tools Tool Number Name MB990685 Torque wrench Measurement of the starting torque of wheel bearing MB990326 Preload socket MB991113 or Steering linkage Disconnection of ball joint MB990635 puller MB990641 Lower arm bush Removal and press-fitting of differential (A) remover &...
Page 578 27B-7 REAR AXLE - Special Tools Tool Number Name MB990850 End yoke holder Removal of the self-locking nut Adjustment of the drive pinion turning torque MB990339 Bearing puller Drive pinion rear bearing inner race removal MB990648 Bearing remover MB990835 Drive pinion setting Adjustment of drive pinion height gauge set A: MB990836...
Page 579 27B-8 REAR AXLE - Special Tools/Troubleshooting <AYC> Number Name O.D. MB990551 – MB990989 Base – Base Base MB990990 Tool A MB990991 Tool B Tool Tool MB990992 Tool C Toolbox Brass bar Installer adapter Bar (one-touch type) O.D. mm O.D. mm Tool number Tool number MB990926...
Page 580 27B-9 REAR AXLE - Troubleshooting <AYC> ERASING THE DIAGNOSIS CODES Connect the MUT-II to the 16-pin diagnosis connector and erase the diagnosis code. (Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.) Caution Turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting the MUT-II.
Page 581 27B-10 REAR AXLE - Troubleshooting <AYC> Diagnosis Diagnosis items Reference page code No. Stop lamp switch system open-circuit Refer to GROUP 22 GROUP 22. ACD mode changeover switch stuck Parking brake switch system short-circuit or not re- turned ABS monitor system open-circuit or defective Proportioning valve <AYC>...
Page 582 27B-11 REAR AXLE - Troubleshooting <AYC> INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 71 Proportioning valve system Probable cause Thiscodeisoutputwhenthe proportioningvalve controlcircuit isopen- orshort-circuited. D Defective proportioning valve D Defective harness or connector D Defective 4WD-ECU <Vehicles with ACD + AYC> Measure at proportioning valve con- Replace the hydraulic unit.
Page 583 27B-12 REAR AXLE - Troubleshooting <AYC> Code No. 72 Directional control valve (right) system Probable cause This code is output when the directional control valve (right) control circuit is open- D Defective directional control valve (right) or short-circuited. D Defective harness or connector D Defective 4WD-ECU <Vehicles with ACD + AYC>...
Page 584 27B-13 REAR AXLE - Troubleshooting <AYC> Code No. 73 Directional control valve (left) system Probable cause This code is output when the directional control valve (left) control circuit is open- D Defective directional control valve (left) or short-circuited. D Defective harness or connector D Defective 4WD-ECU <Vehicles with ACD + AYC>...
Page 585 27B-14 REAR AXLE - REAR AXLE - Troubleshooting <AYC> Troubleshooting <AYC> INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference procedure No. page Communication between MUT-II and the whole system is not possible. Refer to GROUP 22 GROUP 22. Communication between MUT-II and 4WD-ECU is not possible. 3 ACD mode indicator lamps do not light up when the ignition key is turned to “ON”...
Page 586 27B-15 REAR AXLE - Troubleshooting <AYC> INSPECTION PROCEDURE 6 Rear tires are noisy during low-speed cornering. Probable cause Vehicle skews. The hydraulic unit or torque transfer differential is probably defective. D Defective hydraulic unit D Defective torque transfer differential NOTE This symptom is limited only when the diagnosis code is correct.
Page 587: On-Vehicle Service
27B-16 REAR AXLE - On-vehicle Service DATA LIST REFERENCE TABLE For check, refer to GROUP 22. ACTUATOR TEST REFERENCE TABLE For check, refer to GROUP 22. CHECK AT 4WD-ECU TERMINALS For check, refer to GROUP 22. ON-VEHICLE SERVICE Mating marks REAR AXLE TOTAL BACKLASH CHECK 1.
Page 588: Gear Oil Change
27B-17 REAR AXLE - On-vehicle Service <Vehicles with AYC> Filler plug Differential part 1. Remove the filler plug. 2. Check that the gear oil level is within the specified range from the bottom end of the filler plug hole. 3. If the gear oil level exceeds the standard value, add the specified gear oil up to the bottom end of the filler plug hole.
Page 589 27B-18 REAR AXLE - REAR AXLE - On-vehicle Service On-vehicle Service Specified gear oil: Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No. 8149630 EX, CASTROL HYPOY LS (GL-5, SAE 90), Gear oil SHELL-LSD (GL-5, SAE 80W - 90) or equivalent Quantity: 0.55 L 4.
Page 590: Fluid Level Check
27B-19 REAR AXLE - On-vehicle Service FLUID LEVEL CHECK 1. Remove the maintenance lid located in the luggage compartment. 2. <Not using MUT-II> If the vehicle has been run, leave it for 90 min. or more in an ordinary temperature (10_C – 30_C) to allow the accumulator internal pressure to drop.
Page 591: Ayc Operation Check
27B-20 REAR AXLE - On-vehicle Service 6. Remove the cap of the left bleeder screw on the torque transfer differential and connect a vinyl hose. 7. Gradually turn the steering wheel clockwise from the straight-ahead position. At this time, loosen the left bleeder Bleeder screw and check that fluid is discharged with air.
Page 592: Oil Pressure Check
27B-21 REAR AXLE - On-vehicle Service 5. Operate the MUT-II, drive the torque transfer differential (item No.06 and 07) forcibly. NOTE (1) Drive the clutch operating mode forcibly for 1 minutes, release the operation automatically. Drive can also be cleared forcibly using the Clear key of MUT-II. (2) If the hydraulic unit function has been stopped by fail-safe, the torque transfer differential cannot be forcibly driven.
Page 593: Wheel Bearing Axial Play Check
27B-22 REAR AXLE - On-vehicle Service 8. If the measured value exceeds the standard value, replace the hydraulic unit. 9. Connect the hydraulic unit and the hydraulic unit hose assembly, and connect the torque transfer differential and hydraulic unit hose assembly, tighten the flare nut in specified torque.
Page 594: Hub Bolt Replacement
27B-23 REAR AXLE - On-vehicle Service 3. If the limit value is exceeded, loosen the flange nut and then tighten it to the specified torque 225 ± 25 N·m and check the rear hub rotary sliding resistance again. 4. Replace the rear hub assembly if an adjustment cannot be made to within the limit.
Page 595: Action When Battery Runs Out
27B-24 REAR AXLE - On-vehicle Service Torque transfer mechanism part MD998829 1. Remove the drive shaft. (Refer to P. 27B-29.) 2. Remove the oil seal from the differential carrier. 3. Using the special tool, drive a new oil seal all the way into position.
Page 596: Rear Hub Assembly
27B-25 REAR AXLE - Rear Hub Assembly REAR HUB ASSEMBLY REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 597 27B-26 REAR AXLE - Rear Hub Assembly REMOVAL SERVICE POINTS AA" REAR BRAKE CALIPER REMOVAL Suspend the rear brake caliper from the body with wire, etc. to prevent it from falling. Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
Page 598 27B-27 REAR AXLE - Rear Hub Assembly INSPECTION MB991000 (MB990998) MB991017 MB990326 WHEEL BEARING ROTATION STARTING TORQUE CHECK 1. Tighten special tools in rear hub assembly to the specified torque. 2. Hold rear hub assembly in a vice by way of wooden block.
Page 599: Knuckle
27B-28 REAR AXLE - Knuckle KNUCKLE REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 600: Drive Shaft
27B-29 REAR AXLE - Drive Shaft DRIVE SHAFT REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 601 27B-30 REAR AXLE - Drive Shaft REMOVAL SERVICE POINTS AA" REAR BRAKE CALIPER REMOVAL Suspend the rear brake caliper from the body with wire, etc. to prevent it from falling. Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
Page 602 27B-31 REAR AXLE - Drive Shaft (4) To prevent entry of foreign matter into the differential carrier, use the special tool as a cover. <Vehicles with mechanical LSD (RH)> MB991460 INSTALLATION SERVICE POINTS "AA DRIVE SHAFT INSTALLATION Caution When installing the drive shaft to the differential carrier, be careful that the spline part of the drive shaft does not damage the oil seal.
Page 603 27B-32 REAR AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY Caution (1) On the vehicles with ABS or ACD, when the drive shaft is disassembled or reassembled, be careful not to interfere with the rotor for wheel speed sensor installed to the B.J. outer race to prevent the rotor from damage.
Page 604 27B-33 REAR AXLE - Drive Shaft DISASSEMBLY SERVICE POINTS AA" T.J. CASE/SPIDER ASSEMBLY REMOVAL 1. Wipe off grease from the spider assembly and the inside of the T.J. case. 2. Always clean the spider assembly when the grease contains water or foreign material. Caution Do not disassemble the spider assembly.
Page 605 27B-34 REAR AXLE - Drive Shaft "BA T.J. BOOT BAND (SMALL)/T.J. BOOT BAND (LARGE) INSTALLATION Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot bands securely. Standard value (A): 90±3 mm INSPECTION Check the drive shaft for damage, bending or corrosion.
Page 606: Differential Carrier
27B-35 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> DIFFERENTIAL CARRIER <VEHICLES WITH MECHANICAL LSD> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Differential Gear Oil Draining (Refer to P.27B-17.) Drive Shaft Installation (Refer to P. 27B-29.) Lower Arm Assembly Removal (Refer to GROUP Rear Stabilizer Installation (Refer to GROUP 34.) 34.) Lower Arm Assembly Installation (Refer to GROUP...

Page 607 27B-36 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> REMOVAL SERVICE POINTS AA" PROPELLER SHAFT DISCONNECTION Suspend the removed propeller shaft from the body with a wire to prevent bending. AB"REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY REMOVAL 1. Using a jack, support the differential carrier from its underside.
Page 608 27B-37 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> BUSHING REPLACEMENT <Differential mount bracket> 1. Remove and press fit the bush with special tool. (About removal and press fitting the bush of the differential support arm, refer to P. 27B-57.) 2.
Page 609 27B-38 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> DISASSEMBLY Disassembly steps D Inspection before disassembly 15. Companion flange AA" AF" 1. Filler plug 16. Drive pinion front shim (For adjusting 2. Drain plug preload of drive pinion) 3. Differential cover assembly 17.
Page 610 27B-39 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> DISASSEMBLY SERVICE POINTS AA" INSPECTION BEFORE DISASSEMBLY MB990909 and 1. Remove the cover. MB991116 2. Hold the special tool in a vise, and install the differential carrier assembly to the special tool. DRIVE GEAR BACKLASH 1.
Page 611 27B-40 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 2. Insert the brass between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive MB990939 gear so that the revolution torque (approximate 2.5 - 3.0 N·m) is applied to the drive pinion.
Page 612 27B-41 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> AB" DIFFERENTIAL CASE ASSEMBLY/ SIDE BEARING SPACER/SIDE BEARING OUTER RACE REMOVAL Use the handle of a hammer to remove the differential case assembly, side bearing spacers and side bearings. Caution When taking out the differential case assembly, be careful not to drop and damage the side bearing spacers or the side bearing outer races.
Page 613 27B-42 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> AF" DRIVE PINION ASSEMBLY/COMPANION FLANGE MB990810 REMOVAL 1. Make the mating marks to the drive pinion and companion flange. Caution Do not make mating marks on the contact surfaces Companion of the companion flange and propeller shaft.
Page 614 27B-43 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> REASSEMBLY 36 ± 5 N·m 49 ± 9 N·m Final drive gear set 37 ± 2 N·m 84 ± 4 N·m 186 ± 29 N·m 64 ± 4 N·m Reassembly steps 1.
Page 615 27B-44 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> Lubrication and Adhesive Points 2 - 3mm (bead diameter) Vent plug Adhesive: 3M Stud Locking Sealant: 3M ATD Part No.8661, 8663 4170 or equivalent or equivalent REASSEMBLY SERVICE POINTS "AA OIL SEAL PRESS-FITTING MB990938 MB991115...
Page 616 27B-45 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> "BA DRIVE PINION REAR BEARING OUTER RACE PRESS-FITTING MB990938 MB990935 "CA DRIVE PINION FRONT BEARING OUTER RACE PRESS-FITTING MB990938 MB990932 "DA DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures: 1.
Page 617 27B-46 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 4. Clean the side bearing hub. Notch MB990392 5. Place special tool between the side bearing hub of the (MB990835) gear carrier, and position the notch as shown in the illustration.
Page 618 27B-47 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 3. Measure the drive pinion turning torque (without the oil MB990326 MB990685 seal). Standard value: Bearing division Turning torque 0.88 - 1.17 N · Caution Take care not to fit gear oil on the bearing. 4.
Page 619 27B-48 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 7. Measure the drive pinion turning torque (with oil seal) MB990326 MB990685 to verify that the drive pinion turning torque complies with the standard value. Standard value: Bearing Companion flange lubrication Turning torque division None (With anti-rust agent)
Page 620 27B-49 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> "HA BEARING CAP INSTALLATION/FINAL DRIVE GEAR BACKLASH ADJUSTMENT Adjust drive gear backlash as follows: 1. Assemble the differential case with the side bearing outer race to the gear carrier. 2. Press the differential case to one side to measure the clearance of the side bearing outer race and the gear carrier.
Page 621 27B-50 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 11. Measure the drive gear runout. Limit: 0.05 mm 12. When drive gear runout exceeds the limit, remove the differential case and then the drive gears, moving them to different positions and reinstall them. 13.
Page 622 27B-51 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> REMOVAL SERVICE POINT AA" SCREWS REMOVAL 1. Check out the alignment marks. 2. Loosen a uniform amount little by little the screws securing differential case A to B. 3. Separate differential case B from differential case A and remove their components.
Page 623 27B-52 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 5. Find dimension (B) between the spring plate faying Differential Differential surfaces when differential case A and B are assembled case B case A together. B = C + D - E 6.
Page 624 27B-53 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> INSPECTION Friction disc DIFFERENTIAL CASE INTERNAL PARTS CONTACT/ SLIDING SURFACE CHECK 1. Clean the disassembled parts with cleaning oil and dry them with compressed air. 2. Check each plate, disc, and pressure ring for the following: A.
Page 625 27B-54 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> FRICTION PLATE AND FRICTION DISC DISTORTION CHECK Apply a dial indicator to the friction plate or disc on a surface plate and, turning the friction plate or disc, measure the distortion (flatness).
Page 626: Differential Carrier
27B-55 REAR AXLE - Differential Carrier <Vehicles with AYC> DIFFERENTIAL CARRIER <VEHICLES WITH AYC> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Hydraulic Piping Fluid Draining Drive Shaft Installation (Refer to P. 27B-29.) Differential Gear Oil Draining (Refer to P. 27B-17.) Rear Stabilizer Installation (Refer to GROUP 34.) Lower Arm Assembly Removal (Refer to GROUP Lower Arm Assembly Installation (Refer to GROUP...

Page 627 27B-56 REAR AXLE - Differential Carrier <Vehicles with AYC> REMOVAL SERVICE POINT AA" PROPELLER SHAFT DISCONNECTION Suspend the removed propeller shaft from the body with a wire to prevent bending. INSTALLATION SERVICE POINTS Upper stopper "AA LOWER STOPPER/UPPER STOPPER INSTALLATION Install the lower and upper stopper as shown in the illustration.
Page 628 27B-57 REAR AXLE - Differential Carrier <Vehicles with AYC> BUSHING REPLACEMENT <Differential support member> 1. Remove and press fit the bush with special tool. 2. Press fit th bush so that the hollow of the bush is on the position shown as the illustration. 3.
Page 629 27B-58 REAR AXLE - Differential Carrier <Vehicles with AYC> TORQUE TRANSFER DIFFERENTIAL <VEHICLES WITH AYC> DISASSEMBLY AND REASSEMBLY Caution 1. The differential carrier assembly is non-maintainable. 2. No foreign matter should be allowed inside and at the joints of the differential carrier assembly. 49 ±...
Page 630 27B-59 REAR AXLE - Differential Carrier <Vehicles with AYC> Lubrication and Adhesive Points Sealant: 3M ATD Part Grease: Vaseline No.8661, 8663 or equivalent Sealant: 3M ATD Part No.8661, 8663 or equivalent DISASSEMBLY SERVICE POINT AA" SELF-LOCKING NUT REMOVAL MB990850...
Page 631 27B-60 REAR AXLE - Differential Carrier <Vehicles with AYC> ASSEMBLY SERVICE POINTS MD998829 "AA OIL SEAL PRESS-FITTING 1. Using the special tool, pressfit the oil seal as far as it will go. 2. Apply the specified grease to the oil seal lip. Specified grease: Vaseline MD998812 MD998813...
Page 632 27B-61 REAR AXLE - Hydraulic Unit <Vehicles with ACD+AYC> HYDRAULIC UNIT <VEHICLES WITH ACD+AYC> REMOVAL AND INSTALLATION Caution (1) When connecting the return hose and suction hose, do not apply lubricant. (2) No foreign matter should be allowed in the hydraulic piping and joints. Pre-removal Operation Post-installation Operation Trunk Side Trim Removal (Refer to GROUP 52A.)
Page 633: Hydraulic Unit
27B-62 REAR AXLE REAR AXLE - Hydraulic Unit <Vehicles with ACD+AYC> - Hydraulic Unit <Vehicles with ACD+AYC> REMOVAL SERVICE POINTS Hose AA" HYDRAULIC UNIT HOSE ASSEMBLY REMOVAL 1. Disconnect the hydraulic unit side pipe and hose. Pipe 2. Put down the differential support arm, remove the Hydraulic unit hydraulic unit hose assembly.
Page 634 31-1 WHEEL AND TYRE CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Tyre Inflation Pressure Check .
Page 635: General Information
31-2 WHEEL AND TYRE - General Information/Service Specifications GENERAL INFORMATION The wheels and tyres of the following specifications have been established. SPECIFICATIONS Items RS (standard) RS (option), RS-II Wheel Type Steel type Aluminium type Size 15 × 6JJ 17 × 8JJ Amount of wheel offset mm Pitch circle...
Page 636: Front Suspension
31-3 WHEEL AND TYRE - Troubleshooting TROUBLESHOOTING Symptom Probable cause Remedy Reference page Rapid wear at Under-inflation Adjust the tyre 31-6 shoulders or lack of rotation pressure. Rapid wear at Over-inflation or centre lack of rotation Cracked treads Under-inflation Adjust the tyre 31-6 pressure.
Page 637 31-4 WHEEL AND TYRE - Troubleshooting WHEEL BALANCE ACCURACY PURPOSE This section contains tips and procedures for Check your balancer’s calibration approximately achieving accurate wheel balance. Steering wheel every 100 balances. Your wheel balancer’s vibration and /or body shake can result if any of instruction manual should include calibration these procedures are not carefully observed.
Page 638 31-5 WHEEL AND TYRE - Troubleshooting If the imbalance is 5 g or less, the zero If the imbalance is within specification, the static calibration is OK. Rebalance the wheel, then balance calibration is correct. Go to Step 5 go to Step 4 to check static balance. to check the dynamic balance.
Page 639: Tyre Inflation Pressure Check
31-6 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.
Page 640 32-1 POWER PLANT MOUNT CONTENTS GENERAL INFORMATION ....TRANSMISSION MOUNTING ....SPECIAL TOOL .
Page 641: General Information
32-2 POWER PLANT MOUNT - General Information GENERAL INFORMATION Inertia principal axes system is incorporated into Upper installation of roll mount reduces engine the engine mount system. rolling, and increase of insulator bore also reduces idle vibration. CONSTRUCTION DIAGRAM <Engine mount, Transmission mount> Engine mount Transmission mount <Engine roll stopper, Centermember, Crossmember: L.H.
Page 642: Special Tool
32-3 POWER PLANT MOUNT - General Information/Special Tool <Engine roll stopper, Centermember, Crossmember: R.H. drive vehicles> Rear roll mount bracket Rear roll stopper Crossmember Front roll mount bracket Front roll stopper Crossmember bar Centermember SPECIAL TOOL Tool Number Name MB990635 Steering linkage Tie rod end disconnection MB991113 or...
Page 643: Engine Mounting
32-4 POWER PLANT MOUNT - Engine Mounting ENGINE MOUNTING REMOVAL AND INSTALLATION Caution *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to Raise the engine and transmission assembly until...
Page 644: Transmission Mounting
32-5 POWER PLANT MOUNT - Transmission Mounting TRANSMISSION MOUNTING REMOVAL AND INSTALLATION Caution *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal Operation Post-installation Operation Under Cover Removal (Refer to GROUP 51 - Front...
Page 645: Engine Roll Stopper, Centermember
32-6 POWER PLANT MOUNT - Engine Roll Stopper, Centermember ENGINE ROLL STOPPER, CENTERMEMBER REMOVAL AND INSTALLATION Caution *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) <L.H.
Page 646 32-7 POWER PLANT MOUNT - Engine Roll Stopper, Centermember <R.H. drive vehicles> ± 10 N·m 5 N·m * ± ± 10 N·m 7 N·m * ± 7 N·m * ± 5 N·m * ± 10 N·m ± 10 N·m ± ±...
Page 647: Crossmember
32-8 POWER PLANT MOUNT - Crossmember CROSSMEMBER REMOVAL AND INSTALLATION Caution 1. Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B - Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so that they are facing straight forward, and remove the ignition key.
Page 648 32-9 POWER PLANT MOUNT - Crossmember <L.H. drive vehicles> ± 10 N·m 2 N·m ± ± 7 N·m ± 3 N·m 5 N·m* ± 4 N·m ± ± 4 N·m 7 N·m* ± ± 4 N·m ± 10 N·m 5 N·m ±...
Page 649 32-10 POWER PLANT MOUNT - Crossmember <R.H. drive vehicles> 2 N·m ± ± 3 N·m 9 N·m ± ± 7 N·m ± 5 N·m* ± 4 N·m 11 12 4 N·m ± ± 4 N·m ± 7 N·m* 10 N·m ±...
Page 650 32-11 POWER PLANT MOUNT - Crossmember REMOVAL SERVICE POINTS Wooden block AA" LOWER ARM ASSEMBLY REMOVAL Lift the transmission with a transmission jack, and then withdraw the front mounting bolt on the left lower arm assembly. Mounting bolt Transmission jack AB"TIE ROD END AND KNUCKLE DISCONNECTION Cord Caution...
Page 651 NOTES...
Page 652 33A-1 FRONT SUSPENSION CONTENTS GENERAL INFORMATION ....Ball Joint Dust Cover Check ....STRUT ASSEMBLY .
Page 653: General Information
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 Item RS <Vehicles with steel wheels>, RS <Vehicles with aluminium wheels> RS-II Wire diameter ×...
Page 654: Service Specifications
33A-3 FRONT SUSPENSION - Service Specifications/Special Tools SERVICE SPECIFICATIONS Items Standard value Toe-in At the centre of tyre tread mm 0 ± 2 Toe-angle (per wheel) 0_00’ ± 05’ Toe-out angle on turns (inner wheel when outer wheel at 20_) 22_00’...
Page 655: On-Vehicle Service
33A-4 FRONT SUSPENSION - Special Tools/On-vehicle Service Tools Number Name MB990800 Ball joint remover & Lower arm ball joint dust cover press-in installer MB990651 Lower arm pillow ball bushing removal and press-fitting MB990816 Bushing remover & installer base MB991576 Base MB990635, Steering linkage...
Page 656: Ball Joint Dust Cover Check
33A-5 FRONT SUSPENSION - On-vehicle Service Tightening torque: 52 ± 2 N·m 3. Confirm that the toe-in is at the standard value. 4. Use a turning radius gauge to check that the steering angle is at the standard value. Standard value: Inner wheels 31_45’...
Page 657: Strut Assembly
33A-6 FRONT SUSPENSION - Strut Assembly STRUT ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Wheel alignment check and adjustment (Refer to P.33A-4.) 44 ± 5 N·m 167 ± 9 N·m Removal steps 1. Front wheel speed sensor harness 3. Knuckle connection bracket <Vehicles with ABS or ACD>...
Page 658 33A-7 FRONT SUSPENSION - Strut Assembly DISASSEMBLY AND REASSEMBLY 60 ± 10 N·m Disassembly steps 1. Dust cover 6. Dust cover AA" "AA 2. Self-locking nut 7. Coil spring 3. Strut insulator assembly 8. Lower spring pad 4. Upper spring seat assembly 9.
Page 659 33A-8 FRONT SUSPENSION - Strut Assembly 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.
Page 660: Lower Arm Assembly
33A-9 FRONT SUSPENSION - Lower Arm Assembly LOWER ARM ASSEMBLY REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 661 33A-10 FRONT SUSPENSION - Lower Arm Assembly REMOVAL SERVICE POINT Wooden block AA" LOWER ARM AND CROSSMEMBER DISCONNECTION Lift the transmission with a transmission jack, and then withdraw the front mounting bolt on the left lower arm assembly. Mounting Bolt Transmission jack INSPECTION Pillow ball bushing...
Page 662 33A-11 FRONT SUSPENSION - Lower Arm Assembly LOWER ARM BALL JOINT DUST COVER REPLACEMENT MB990800 Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: Dust cover 1. Remove the dust cover. 2. Apply multipurpose grease to the lip and inside of the dust cover.
Page 663: Stabilizer Bar
33A-12 FRONT SUSPENSION - Lower Arm Assembly/Stabilizer Bar 3. Use the special tools to press in the bushing until its outer tube is flush with the lower arm assembly surface. MB990651 MB991576 Outer tube Lower arm assembly MB991816 STABILIZER BAR REMOVAL AND INSTALLATION Caution 1.
Page 664 33A-13 FRONT SUSPENSION - Stabilizer Bar Pre-removal Operation Post-installation Operation Steering Wheel and Air Bag Module Assembly Front Exhaust Pipe Installation (Refer to GROUP Removal (Refer to GROUP 37A.) 15.) Clock Spring Removal (Refer to GROUP 52B.) Centermember Installation (Refer to GROUP 32.) Crossmember Bar Removal (Refer to P.33A-15.) Crossmember Bar Installation (Refer to P.33A-15.) Centermember Removal (Refer to GROUP 32.)
Page 665 33A-14 FRONT SUSPENSION - Stabilizer Bar REMOVAL SERVICE POINTS MB991406, MB990635 or AA" TIE ROD END AND KNUCKLE DISCONNECTION MB991113 Caution 1. To prevent the ball joint thread from damage, the tie rod end mounting nut must be only loosened but not Cord removed from the ball joint.
Page 666: Crossmember Bar
33A-15 FRONT SUSPENSION - Crossmember Bar CROSSMEMBER BAR <RS (Vehicles with aluminium wheels), RS-II> REMOVAL AND INSTALLATION 49 ± 10 N·m Crossmember bar...
Page 667 NOTES...
Page 668 34-1 REAR SUSPENSION CONTENTS GENERAL INFORMATION ....UPPER ARM ASSEMBLY ....SERVICE SPECIFICATIONS .
Page 669: General Information
34-2 REAR SUSPENSION - General Information GENERAL INFORMATION A trailing arm type multi-link suspension has been adopted as the rear suspension. The shock absorber is a hydraulic, cylindrical double-acting type. COIL SPRING Item Specification Wire diameter mm 9 - 12 <RS > 12 <RS-II>...
Page 670: Service Specifications
34-3 REAR SUSPENSION - Service Specifications/Special Tools SERVICE SPECIFICATIONS Items Standard value TOE-IN At the centre of tyre tread 3 ±2 Toe-angle (per wheel) 0_09’ ± 06’ Camber - 1_00’ ± 30’* Thrust angle 0_00’ ± 0_09’ Upper arm ball joint rotation torque N·m 0.5 - 2.5 Trailing arm ball joint rotation torque N·m 0.5 - 2.5...
Page 671: On-Vehicle Service
34-4 REAR SUSPENSION - REAR SUSPENSION - On-vehicle Service On-vehicle Service ON-VEHICLE SERVICE WHEEL ALIGNMENT CHECK AND ADJUSTMENT 1. The rear suspension, wheels and tyres should be serviced to normal condition prior to measurement of wheel alignment. 2. Measure the wheel alignment with the vehicle parked on a level surface.
Page 672: Ball Joint Dust Cover Check
34-5 REAR SUSPENSION - On-vehicle Service 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 or suspension arms. NOTE Cracks or damage of the dust cover may cause damage of the ball joint.
Page 673: Rear Suspension Assembly
34-6 REAR SUSPENSION - Rear Suspension Assembly REAR SUSPENSION ASSEMBLY REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper, because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 674 34-7 REAR SUSPENSION - Rear Suspension Assembly Removal steps 1. Fuel filler cap AB" "BA 10. Propeller shaft connection 2. Protector 11. Upper arm mounting bolt 3. Bolt 12. Trailing arm mounting bolt 4. Shockabsorber mounting nut 13. Toe control arm mounting bolt 5.
Page 675: Upper Arm Assembly
34-8 REAR SUSPENSION - Rear Suspension Assembly/Upper Arm Assembly "BA PROPELLER SHAFT CONNECTION Install the difference career and propeller shaft by alining the mating mark. Caution If there is oil or grease on the thread of the mounting bolt or nut, they will loosen. So after wiping out oil or grease of the thread,tighten the mounting bolt.
Page 676 34-9 REAR SUSPENSION - Upper Arm Assembly REMOVAL SERVICE POINTS AA" UPPER ARM BALL JOINT AND KNUCKLE MB991406, MB990635 or DISCONNECTION MB991113 Caution Ball joint 1. To prevent the ball joint thread from damage, only Cord loosen but do not remove the nut securing the upper arm to the knuckle from the ball joint and use the special tool.
Page 677: Trailing Arm Assembly
34-10 REAR SUSPENSION - Trailing Arm Assembly TRAILING ARM ASSEMBLY REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper, because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 678 34-11 REAR SUSPENSION - Trailing Arm Assembly INSPECTION TRAILING ARM BALL JOINT ROTATION TORQUE MB990326 CHECK 1. After shaking the trailing arm ball joint stud several times, use the special tool to measure the rotation torque of the trailing arm ball joint. MB990968 Standard value: 0.5 - 2.5 N·m 2.
Page 679: Lower Control Arm Assembly/Toe Control Arm Assembly
34-12 REAR SUSPENSION - Lower Arm Assembly/Toe Control Arm Assembly LOWER CONTROL ARM ASSEMBLY/TOE CONTROL ARM ASSEMBLY REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper, because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 680 34-13 REAR SUSPENSION - Lower Arm Assembly/Toe Control Arm Assembly REMOVAL SERVICE POINTS AA" LOWER ARM ASSEMBLY MOUNTING BOLT REMOVAL Mating marks Mark the mating marks on the lower arm and the decentering cam bolt,then remove the lower arm and the decentering cam bolt.
Page 681 34-14 REAR SUSPENSION - Lower Arm Assembly/Toe Control Arm Assembly 3. When the measured value is lower than the standard value, check that the toe control arm ball joint turns smoothly without excessive play. If there is no excessive play, the ball joint can be reused. TOE CONTROL ARM SLIDE BUSHING ROTATION MB990968 TORQUE CHECK...
Page 682 34-15 REAR SUSPENSION - Lower Arm Assembly/Toe Control Arm Assembly LOWER ARM PILLOW BALL ROTATION TORQUE CHECK 1. Insert the bolt to the lower arm pillow ball bush,in the opposite direction,insert the washer then install the nut.After rotating the inner sleeve (contained washer) several times, measure the rotation torque of the lower arm below ball bush using the special tool.
Page 683: Shock Absorber Assembly
34-16 REAR SUSPENSION - Shock Absorber Assembly SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper, because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 684 34-17 REAR SUSPENSION - REAR SUSPENSION - Shock Absorber Assembly Shock Absorber Assembly DISASSEMBLY AND REASSEMBLY 25 ± 5 N·m Disassembly steps AA" "DA 1. Self-locking nut 7. Collar 2. Washer 8. Cup assembly 3. Upper bushing B 9. Dust cover "CA 4.
Page 685 34-18 REAR SUSPENSION - Shock Absorber Assembly REASSEMBLY SERVICE POINTS Lower bushing "AA COIL SPRING INSTALLATION inner pipe 1. Use the special tools (MB991237, MB991239) to compress the coil spring, and install it to the spring seat of the shock absorber. Caution Bracket Do not use an impact wrench as it will cause the...
Page 686: Stabilizer Bar
34-19 REAR SUSPENSION - Stabilizer Bar STABILIZER BAR REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper, because the paint of caliper will be scratched. And if there is brake fluid on the caliper,wipe out quickly.
Page 687 34-20 REAR SUSPENSION - Stabilizer Bar INSTALLATION SERVICE POINTS "AA STABILIZER BAR/BUSHING/STABILIZER BAR BRACKET INSTALLATION Aline the stabilizer bar until the identification color of the stabilizer bar is out of the dimension shown as the illustration from the bush to the vehicle center,after tightening the stabilizer bracket mounting bolt A, tighten the mounting bolt B.
Page 688 34-21 REAR SUSPENSION - Stabilizer Bar 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. Then install the clip ring end in order to position on 90 degrees toward the axis of the link.
Page 689 NOTES...
Page 690: Service Brakes
35A-1 SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM ......... ANTI-SKID BRAKING SYSTEM (ABS) <4WD>...
Page 691 35A-2 BASIC BRAKE SYSTEM CONTENTS GENERAL INFORMATION ....Bleeding ........Brake Fluid Level Sensor Check .
Page 692: General Information
35A-3 BASIC BRAKE SYSTEM - General Information GENERAL INFORMATION The brake system offers high dependability and durability along with improved braking performance and brake sensitivity. SERVICE PRECAUTION <VEHICLES WITH BREMBO BRAKING SYSTEM> Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. SPECIFICATIONS Items Specifications...
Page 693 35A-4 BASIC BRAKE SYSTEM - General Information CONSTRUCTION DIAGRAM <Vehicles with ABS> Brake booster* Hydraulic unit* Rear disc brake Parking brake Master cylinder* Front disc brake <Vehicles without ABS> Brake booster* Master cylinder and proportioning valves* Rear disc brake Parking brake Front disc brake NOTE For R.H.
Page 694: Service Specifications
35A-5 BASIC BRAKE SYSTEM - Service Specifications SERVICE SPECIFICATIONS Items Standard value Limit Brake pedal height mm 169.1 - 172.1 Brake pedal play mm 3 - 8 Brake pedal to floorboard clearance when the brake pedal is depressed mm 90 or more Brake booster push rod protrusion amount mm 8.98 - 9.23 Proportioning valve...
Page 695: Lubricants
35A-6 BASIC BRAKE SYSTEM - Lubricants/Sealant/Special Tools LUBRICANTS Items Specified Lubricant Quantity Brake fluid DOT3 or DOT4 As required Piston, wheel cylinder body Piston boot, piston seal, shim Repair kit grease Guide pin, lock pin, pin boot <Except for Brembo disc brake> Pad assembly <Brembo disc brake>...
Page 696: On-Vehicle Service
35A-7 BASIC BRAKE SYSTEM - On-vehicle Service ON-VEHICLE SERVICE BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT 1. Turn up the carpet, etc. under the brake pedal. 2. Measure the brake pedal height as illustrated. Standard value (A): 169.1 - 172.1 mm 3.
Page 697: Brake Booster Operating Test
35A-8 BASIC BRAKE SYSTEM - On-vehicle Service 2. If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary: Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod Brake pedal height Installation position of the stop lamp switch, etc.
Page 698: Check Valve Operation Check
35A-9 BASIC BRAKE SYSTEM - On-vehicle Service CHECK VALVE OPERATION CHECK 1. Remove the vacuum hose. (Refer to P.35A-17.) 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.
Page 699: Vehicles Without Abs
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.
Page 700: Brake Fluid Level Sensor Check
35A-11 BASIC BRAKE SYSTEM - On-vehicle Service 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 there is continuity when the float surface is below “MIN”. DISC BRAKE PAD CHECK AND REPLACEMENT <Except for Brembo disc brake>...
Page 701 35A-12 BASIC BRAKE SYSTEM - On-vehicle Service <Brembo disc brake> Caution Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. NOTE The wear indicator contacts the brake disc when the brake pad thickness reaches approximately 2 mm and emit a...
Page 702: Disc Brake Rotor Check
35A-13 BASIC BRAKE SYSTEM - On-vehicle Service (5) Apply repair kit grease to the portions of the pads Front Rear indicated on the left. At this time, make sure that the grease will not be applied to any other surfaces. (6) Mount the pads to the caliper so that its side with the wear indicator is on the outside of the vehicle.
Page 703: Brake Disc Thickness Check
35A-14 BASIC BRAKE SYSTEM - On-vehicle Service BRAKE DISC THICKNESS CHECK Caution: Brembo disc brake Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. 1.
Page 704 35A-15 BASIC BRAKE SYSTEM - On-vehicle Service 3. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc. Limit: 0.03 mm or less 4. If the brake disc run-out exceeds the limit, correct it as follows: (1) Chalk phase marks on the wheel stud and the brake disc, which run-out is excessive.
Page 705: Brake Pedal
35A-16 BASIC BRAKE SYSTEM - Brake Pedal BRAKE PEDAL REMOVAL AND INSTALLATION Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-7.) 12 ± 2 N·m 14 ± 3 N·m Removal steps 1. Harness connector 6. Pin assembly 2. Stop lamp switch 7.
Page 706: Proportioning Valve, Master Cylinder And Brake Booster
Brake Pedal/Proportioning Valve, 35A-17 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster INSPECTION STOP LAMP SWITCH CHECK 1. Connect an ohmmeter between the stop lamp switch connector terminals. 2. There should be no continuity between the terminals when Continuity No continuity the plunger is pushed in as shown.
Page 707: Master Cylinder
Proportioning Valve, Master Cylinder 35A-18 BASIC BRAKE SYSTEM - and Brake Booster Master cylinder removal steps 5. Brake pipe connection 8. Master cylinder 1. Clutch hose connection "BA D Push rod protrusion amount check and 2. Brake fluid level sensor connector adjustment 3.
Page 708 Proportioning Valve, Master Cylinder Proportioning Valve, Master Cylinder 35A-19 BASIC BRAKE SYSTEM - BASIC BRAKE SYSTEM - and Brake Booster 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.
Page 709: Disc Brake
35A-20 BASIC BRAKE SYSTEM - Disc Brake DISC BRAKE REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 710 35A-21 BASIC BRAKE SYSTEM - Disc Brake INSTALLATION SERVICE POINT <Front> "AA DISC BRAKE ASSEMBLY INSTALLATION MB990998 <Except for Brembo disc brake> 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.
Page 711 35A-22 BASIC BRAKE SYSTEM - Disc Brake DISASSEMBLY AND REASSEMBLY Front <Except for Brembo disc brake> Clip set 74 ± 10 N·m 7.9 ± 0.9 N·m 74 ± 10 N·m Grease Brake caliper kit Pad set Shim set Seal and boot kit Disassembly steps "AA 1.
Page 712 35A-23 BASIC BRAKE SYSTEM - Disc Brake Front <Brembo disc brake> Caution Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. 14 ±...
Page 713 35A-24 BASIC BRAKE SYSTEM - Disc Brake Rear <Except for Brembo disc brake> 44 ± 5 N·m 7.9 ± 0.9 N·m Clip set Grease Brake caliper kit Pad set Shim set Seal and boot kit Disassembly steps "AA 1. Guide pin 8.
Page 714 35A-25 BASIC BRAKE SYSTEM - Disc Brake Rear <Brembo disc brake> Caution Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. 14 ±...
Page 715 35A-26 BASIC BRAKE SYSTEM - Disc Brake LUBRICATION POINTS <Except for Brembo disc brake> 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...
Page 716 35A-27 BASIC BRAKE SYSTEM - Disc Brake DISASSEMBLY SERVICE POINTS Caution: Brembo disc brake Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. AA"...
Page 717 35A-28 BASIC BRAKE SYSTEM - Disc Brake "AA LOCK PIN/GUIDE PIN INSTALLATION Lock pin <Front> <Except for Brembo disc brake> Identification mark ”L” As shown in the illustration, align the identification mark on the caliper body and the head mark of the guide pin/lock pin, then install the guide pin/lock pin.
Page 718: Braking System
35B-1 ANTI-SKID BRAKING SYSTEM (ABS) <4WD> CONTENTS GENERAL INFORMATION ....Disc Brake Rotor Check . . . Refer to GROUP 35A Brake Disc Thickness Check SERVICE SPECIFICATIONS .
Page 719 35B-2 ABS <4WD> - General Information GENERAL INFORMATION ABS has been adopted as optional equipment in By adding lateral G sensor, longitudinal G RS-II to maintain directional stability and steering sensor and steering wheel sensor, optimized performance during sudden braking or braking on ABS control at the time of cornering.
Page 720 35B-3 ABS <4WD> - General Information/Service Specifications CONSTRUCTION DIAGRAM Parking brake switch Steering ABS warning lamp wheel sensor* Hydraulic unit assembly* (integrated with the ABS-ECU) Wheel speed sensor Lateral G sensor Longitudinal G sensor Diagnosis connector* Stop lamp Wheel speed sensor switch* NOTE For R.H.
Page 721 35B-4 ABS <4WD> - Special Tools/Troubleshooting SPECIAL TOOLS Tool Number Name 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) MB991348 Test harness set...
Page 722 35B-5 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.
Page 723 35B-6 ABS <4WD> - Troubleshooting When not using the MUT-II NOTE If the ABS-ECU function has been stopped because of fail-safe operation, it will not be possible to erase the diagnosis codes. 1. Stop the engine. MB991529 2. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector.
Page 724 35B-7 ABS <4WD> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Diagnosis code No. Inspection item Reference page Front right wheel speed sensor (Open circuit or short circuit) 35B-9 Front left wheel speed sensor (Open circuit or short circuit) Rear right wheel speed sensor (Open circuit or short circuit) Rear left wheel speed sensor (Open circuit or short circuit) ABS-ECU power supply system (Abnormal voltage drop or rise) 35B-10...
Page 725 35B-8 ABS <4WD> - Troubleshooting Diagnosis code No. Inspection item Reference page Steering wheel sensor (ST-1) system (Open circuit or short circuit) 35B-14 Steering wheel sensor (ST-2) system (Open circuit or short circuit) Steering wheel sensor (ST-N) system (Open circuit or short circuit) NOTE: diagnosis code No.16, 52, 63 1.
Page 726 35B-9 ABS <4WD> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Probable cause Code Nos.11, 12, 13 and 14 Wheel speed sensor (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.
Page 727 35B-10 ABS <4WD> - Troubleshooting 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 above D Malfunction of battery the rated values. D Malfunction of wiring harness or connector Furthermore, turning the ignition switch to ACC will erase this code.
Page 728 35B-11 ABS <4WD> - Troubleshooting Code No.32 Longitudinal G sensor system Probable cause This code is output in the following cases. D Malfunction of longitudinal G sensor D If the longitudinal G sensor output voltage is less than 0.5 V or more than 4.5 V D Malfunction of wiring harness or connector <open circuit or short circuit of longitudinal G sensor circuit>...
Page 729 35B-12 ABS <4WD> - Troubleshooting 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...
Page 730 35B-13 ABS <4WD> - Troubleshooting Code No.71 Lateral G sensor system Probable cause This code is output in the following cases. D Malfunction of lateral G sensor D If lateral G sensor output voltage is less than 0.5 V or more than 4.5 V D Malfunction of wiring harness or connector <open circuit or short circuit in the lateral G sensor circuit>...
Page 731 35B-14 ABS <4WD> - Troubleshooting Code No.81 Steering wheel sensor (ST-1) system (open Probable cause circuit or short circuit) Code No.82 Steering wheel sensor (ST-2) system (open circuit or short circuit) Code No.83 Steering wheel sensor (ST-N) system (open circuit or short circuit) These codes are output if there is a fault in the steering wheel sensor, an open circuit D Malfunction of steering wheel sensor or short circuit in the steering signal line, or the internal circuit in the hydraulic unit...
Page 732 35B-15 ABS <4WD> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptoms Inspection procedure Reference page Communication between the MUT-II and the whole system is not 35B-16 possible. Communication between the MUT-II and the ABS-ECU is not possible. 35B-17 When the ignition key is turned to “ON” (engine stopped), the ABS 35B-18 warning lamp does not illuminate.
Page 733 35B-16 ABS <4WD> - Troubleshooting 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 of D Malfunction of diagnosis connector the diagnosis connector.
Page 734 35B-17 ABS <4WD> - Troubleshooting 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 Measure at the diagnosis connector C-22 and the ABS-ECU...
Page 735 35B-18 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 or an open circuit between the ABS warning lamp and the earth.
Page 736 35B-19 ABS <4WD> - Troubleshooting Inspection Procedure 5 In the inspection by MUT-II service data, the parking brake Probable cause switch is not turned ON or turn OFF. ABS-ECU optimizes the ABS control when pulling the parking brake lever, parking D Malfunction of parking brake switch brake switch signal is used as support.
Page 737 35B-20 ABS <4WD> - Troubleshooting Inspection Procedure 6 The neutral position learning of the steering wheel sensor Probable cause is not finished. The diagnosis is difficult because it depends on driving condition and road surface, D Equipment the odd diameter tyre if the diagnosis code displays the normal code, carry out the following check.
Page 738 35B-21 ABS <4WD> - Troubleshooting Inspection Procedure 7 Faulty ABS operation Probable cause This varies depending on the driving conditions and the road surface conditions, so D Improper installation of wheel speed sensor problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry D Malfunction of wiring harness or connector out the following inspection.
Page 739 35B-22 ABS <4WD> - Troubleshooting 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 Front-right wheel speed sensor Perform a test run Vehicle speeds displayed on the...
Page 740 35B-23 ABS <4WD> - Troubleshooting 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 of Items No.
Page 741 35B-24 ABS <4WD> - Troubleshooting CHECK AT ABS-ECU Lock lever Use the following steps to remove the connector cover and measure the terminal voltage. 1. Move the lock lever of the ABS-ECU connector as shown in the illustration, and then disconnect the ABS-ECU connector.
Page 742 35B-25 ABS <4WD> - Troubleshooting Terminal No. Check item Checking requirements Normal condition ABS-ECU power Ignition switch: ON System voltage supply supply Ignition switch: START or ACC Solenoid valve power Always System voltage supply Lateral G sensor input Ignition switch: ON 2.4 - 2.6 V (horizontal position) Longitudinal G sensor Always...
Page 743 35B-26 ABS <4WD> - Troubleshooting/On-vehicle Service 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.
Page 744 35B-27 ABS <4WD> - On-vehicle Service 4. 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 Rear sensor left right left...
Page 745 35B-28 ABS <4WD> - On-vehicle Service Symptom Probable causes Remedy 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...
Page 746 35B-29 ABS <4WD> - On-vehicle Service 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 Steady pressure position 2 seconds Reduction in pressure 1 seconds Lock...
Page 747 35B-30 ABS <4WD> - Hydraulic Unit and ABS-ECU HYDRAULIC UNIT AND ABS-ECU REMOVAL AND INSTALLATION <L.H. drive vehicles> Pre-removal Operation Post-installation Operation Strut Tower Bar Removal (Refer to GROUP 42.) Brake Fluid Supplying and Brake Line Bleeding Brake Fluid Draining (Refer to GROUP 35A - On-vehicle Service.) Hydraulic Unit Check (Refer to P.35B-28.) Strut Tower Bar Installation (Refer to GROUP 42.)
Page 748 35B-31 ABS <4WD> - Hydraulic Unit and ABS-ECU <R.H. drive vehicles> Pre-removal Operation Post-installation Operation Strut Tower Bar Removal (Refer to GROUP 42.) Brake Fluid Supplying and Brake Line Bleeding Brake Fluid Draining (Refer to GROUP 35A - On-vehicle Service.) Air Intake Hose and Air Cleaner Removal Hydraulic Unit Check (Refer to P.35B-28.) Air Intake Hose and Air Cleaner Installation...
Page 749 35B-32 ABS <4WD> - Hydraulic Unit and ABS-ECU 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. AB" HYDRAULIC UNIT AND ABS-ECU REMOVAL Caution 1.
Page 750 35B-33 ABS <4WD> - Wheel Speed Sensor WHEEL SPEED SENSOR REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 751 35B-34 ABS <4WD> - Wheel Speed Sensor INSTALLATION SERVICE POINT "AA WHEEL SPEED SENSOR <REAR> Wheeel speed sensor <rear> INSTALLATION Install the wheel speed sensor crossing with the parking brake cable. Parking brake cable INSPECTION CHECK OF RESISTANCE BETWEEN WHEEL SPEED SENSOR TERMINALS Caution The pole piece can become magnetized because of the...
Page 752 35B-35 ABS <4WD> - G Sensors and Steering Wheel Sensor G SENSORS AND STEERING WHEEL Parking brake lever SENSOR REMOVAL AND INSTALLATION Refer to GROUP 22 - Sensor, Switch and Relay. Longitudinal G sensor Lateral G sensor Steering wheel sensor...
Page 753 NOTES...
Page 754 36-1 PARKING BRAKES CONTENTS GENERAL INFORMATION ....Parking Brake Switch Check ....Lining Running-In .
Page 755: General Information
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 lever SERVICE SPECIFICATIONS Items Standard value...
Page 756: On-Vehicle Service
36-3 PARKING BRAKES - On-Vehicle Service ON-VEHICLE SERVICE PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 1. Pull the parking brake lever with a force of approx. 200 N and count the number of notches. Standard value: 5 - 7 notches 2.
Page 757: Lining Running-In
36-4 PARKING BRAKES - On-Vehicle Service LINING RUNNING-IN Pull Carry out running-in by the following procedure when replacing the parking brake linings or the rear brake disc rotors, or when brake performance is insufficient. Spring balance Caution Carry out running-in in a place with good visibility, and pay careful attention to safety.
Page 758: Parking Brake Lever
36-5 PARKING BRAKES - Parking Brake Lever PARKING BRAKE LEVER REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Rear Floor Console Assembly and Rear Console Parking Brake Lever Stroke Adjustment Bracket Removal (Refer to GROUP 52A-Floor Console.) (Refer to P.36-3.) Rear Floor Console Assembly and Rear Console Bracket Installation (Refer to GROUP 52A-Floor Console.) Section B - B...
Page 759 36-6 PARKING BRAKES - Parking Brake Cable PARKING BRAKE CABLE REMOVAL AND INSTALLATION CAUTION If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 760: Parking Brake Drum
36-7 PARKING BRAKES - Parking Brake Drum PARKING BRAKE DRUM REMOVAL AND INSTALLATION CAUTION If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Page 761 36-8 PARKING BRAKES - Parking Brake Drum REMOVAL SERVICE POINT AA" REAR BRAKE CALIPER ASSEMBLY REMOVAL Remove the rear brake caliper assembly and support it with wire or similar. CAUTION: Brembo disc brake Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
Page 762 37A-1 STEERING CONTENTS GENERAL INFORMATION ....Power Steering Fluid Level Check ... . . Power Steering Fluid Replacement .
Page 763 37A-2 STEERING - General Information GENERAL INFORMATION The system has been equipped with the MOMO type that combines the steering gear and linkage leather 3-spoke-type steering wheel with built-in into one light-weight and compact assembly. SRS airbag. The steering system uses a vane oil pump with The steering column is equipped with tilt steering a fluid flow control system, so that steering effort mechanism.
Page 764 37A-3 STEERING - General Information CONSTRUCTION DIAGRAM <L.H. drive vehicles> Steering wheel Steering column and shaft Reservoir tank Return hose Suction hose Pressure hose Oil pump assembly Steering gear Cooler tube and linkage <R.H. drive vehicles> Steering wheel Steering column and shaft Reservoir tank Return hose Suction hose...
Page 765: Service Specifications
37A-4 STEERING - Service Specifications/Lubricants/Sealant/Special Tools SERVICE SPECIFICATIONS Items Standard value Limit Steering wheel free play mm when engine running 30 or less with engine stopped 0 - 10 Steering angle Inner wheel 31_45’ ± 1_30’ Outer wheel <for reference> 27_15’...
Page 766 37A-5 STEERING - Special Tools Tool Number Name MB991006 Preload socket Measurement of the total pinion torque MB990326 Preload socket Measurement of the ball joint turning torque MB990993 Power steering oil Measurement of oil pressure pressure gauge adapter (pump side) MB990994 Power steering oil pressure gauge...
Page 767 37A-6 STEERING - Special Tools Tool Number Name MB991197 Bar (long type) Press fitting of rack housing bearing To press in the oil seal for the rack MB991214 Rack installer Rack installation MB990925 Bearing and oil Installation of the oil seal and bearing seal installer set (Refer to GROUP 26 - Special Tools.) MB991120...
Page 768: On-Vehicle Service
37A-7 STEERING - On-vehicle Service ON-VEHICLE SERVICE STEERING WHEEL FREE PLAY CHECK 1. With engine running (hydraulic operation), set front wheels straight ahead. 2. Measure the play on steering wheel circumference before wheels start to move when slightly moving steering wheel in both directions.
Page 769: Stationary Steering Effort Check
37A-8 STEERING - On-vehicle Service 2. Move ball joint stud several times and install nut on stud. MB990326 Measure ball joint turning torque with special tool. Standard value: 1.0 - 3.0 N·m 3. When the turning torque exceeds the standard value, replace tie rod end.
Page 770: Power Steering Fluid Level Check
37A-9 STEERING - On-vehicle Service POWER STEERING FLUID LEVEL CHECK Fluid level change: Within 5 mm 1. Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60_C. 2.
Page 771: Oil Pump Pressure Test
37A-10 STEERING - On-vehicle Service 9. If the level changes more than 5 mm, the air is badly Fluid level change: Within 5 mm bled. So, bleed air again. Caution (1) If the fluid level rises suddenly after the engine is stopped, the bleeding is incomplete.
Page 772: Power Steering Oil Pressure Switch Check
37A-11 STEERING - On-vehicle Service POWER STEERING OIL PRESSURE SWITCH Adapter CHECK Shut-off valve (MB990993) Pressure gauge 1. Disconnect the pressure hose from the oil pump, and (MB990662) then connect the special tools. Temperature 2. Bleed the air, and then turn the steering wheel several gauge times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60_C.
Page 773: Steering Wheel
37A-12 STEERING - Steering Wheel STEERING WHEEL REMOVAL AND INSTALLATION Caution: Before removing the steering wheel and air bag module assembly, refer to GROUP 52B – Service Precautions and Air Bag Module and Clock Spring. Post-installation Operation Checking Steering Wheel Position with Wheels Straight Ahead <RS (standard)>...
Page 774 37A-13 STEERING - Steering Wheel REMOVAL SERVICE POINTS AA" STEERING WHEEL REMOVAL <RS (standard)> MB990784 AB" COVER REMOVAL <RS (option), RS-II> Insert the special tool from the indicated position to remove the cover. NOTE MB990784 The special tool can be inserted through the notch behind the position shown.
Page 775: Steering Shaft
37A-14 STEERING - Steering Shaft STEERING SHAFT REMOVAL AND INSTALLATION Caution: Before removing clock spring, refer to GROUP 52B – Service Precautions and Air Bag Module and Clock Spring. Pre-removal Operation Post-installation Operation Steering Wheel Removal (Refer to P.37A-12.) Instrument Under Cover Installation Instrument Under Cover Removal (Refer to GROUP 52A.) (Refer to GROUP 52A.)
Page 776 37A-15 STEERING - Steering Shaft DISASSEMBLY AND REASSEMBLY Disassembly steps AA" "AA 1. Special bolt 5. Steering shaft assembly "AA 2. Steering lock bracket 6. Tilt spring "AA 3. Steering lock cylinder assembly 7. Steering column assembly 4. Snap ring DISASSEMBLY SERVICE POINT Left-hand tap Special bolt...
Page 777: Power Steering Gear Box And Linkage
37A-16 STEERING - Power Steering Gear Box and Linkage POWER STEERING GEAR BOX AND LINKAGE REMOVAL AND INSTALLATION Caution: SRS Before removing steering gear box, refer to GROUP 52B. Also, put the front wheels in straight-ahead position. Failure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which results serious driver injury.
Page 778 37A-17 STEERING - Power Steering Gear Box and Linkage <R.H. drive vehicles> 15 ± 3 N·m 70 ± 10 N·m 57 ± 7 N·m Removal steps 1. Crossmember 4. Return tube (Refer to GROUP 32.) 5. Pressure hose connection 2. Joint cover grommet 6.
Page 779 37A-18 STEERING - Power Steering Gear Box and Linkage 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: 8 - 27 N (1.5 - 4.9 N·m) 3.
Page 780 37A-19 STEERING - Power Steering Gear Box and Linkage DISASSEMBLY AND REASSEMBLY <L.H. drive vehicles> Flare nut 22 ± 4 N·m 13 ± 3 N·m Repair kit grease 59 ± 10 N·m 52 ± 2 N·m 15 14 23 ± 2 N·m → - 30_ 11 35 25 ±...
Page 781 37A-20 STEERING - Power Steering Gear Box and Linkage <R.H. drive vehicles> Flare nut 13 ± 3 N·m 22 ± 4 N·m Re p ai r k i t g re ase 11 35 17 31 59 ± 10 N·m 29 28 25 ±...
Page 782 37A-21 STEERING - Power Steering Gear Box and Linkage Lubrication and Sealing Points Fluid: Automatic transmission fluid DEXRON II Fluid: Automatic transmission fluid DEXRON II Fluid: Automatic transmission fluid DEXRON II Grease: Repair kit grease Sealant: 3M ATD part No. 8661, 8663 or equivalent Fluid: Automatic transmission...
Page 783 37A-22 STEERING - Power Steering Gear Box and Linkage DISASSEMBLY SERVICE POINTS AA" RACK SUPPORT COVER REMOVAL MB991204 AB" LOWER 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.
Page 784 37A-23 STEERING - Power Steering Gear Box and Linkage AF" RACK STOPPER/RACK BUSHING/OIL SEAL/ O-RING/RACK ASSEMBLY 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 surface of the rack bushing.
Page 785 37A-24 STEERING - Power Steering Gear Box and Linkage REASSEMBLY SERVICE POINTS MB991199 "AA OIL SEAL INSTALLATION MB991197 Gear housing Oil seal "BA NEEDLE BEARING/LOWER BEARING MB990925 Needle MB990925 (MB990938) bearing INSTALLATION (MB990938) MB991202 MB991202 Lower bearing "CA RACK ASSEMBLY INSTALLATION Vent hole 1.
Page 786 37A-25 STEERING - Power Steering Gear Box and Linkage "DA OIL SEAL/RACK BUSHING INSTALLATION 1. Apply specified fluid to the outer surface of the oil seal. MB990925 Using the special tool, press in the oil seal until it is flush (MB990927) with the bushing end face.
Page 787 37A-26 STEERING - Power Steering Gear Box and Linkage "HA LOWER OIL SEAL INSTALLATION Approx. 1 mm MB990941 Using the special tool, press the oil seal into the valve housing. The upper surface of the oil seal must project outwards about seal 1 mm from the housing end surface.
Page 788 37A-27 STEERING - Power Steering Gear Box and Linkage 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.
Page 789 37A-28 STEERING - Power Steering Gear Box and Linkage 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> Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2).
Page 790: Power Steering Oil Pump
37A-29 STEERING - Power Steering Oil Pump POWER STEERING OIL PUMP REMOVAL AND INSTALLATION Caution After temporary tightening all bolts in * part, tighten in specific torque. Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (Refer to P.37A-9.) Power Steering Fluid Supplying and Bleeding (Refer to P.37A-9.) Drive Belt Tension Adjusting (Refer to GROUP 11A –...
Page 791: Power Steering Oil Hoses
37A-30 STEERING - Power Steering Oil Pump/Power Steering Oil Hoses "BA PRESSURE HOSE ASSEMBLY/SUCTION HOSE Suction hose REMOVAL Install the pressure hose assembly and suction hose as illustrated. Pressure hose Marking assembly Notch DISASSEMBLY AND REASSEMBLY 21 ± 3 N·m 39 ±...
Page 792 37A-31 STEERING - Power Steering Oil Hoses <L.H. drive vehicles> Pre-removal and Post-installation Operation Power Steering Fluid Draining and Refilling (Refer to P.37A-9.) 18 ± 3 N·m 12 ± 2 N·m 12 ± 2 N·m 12 ± 2 N·m 15 ± 3 N·m 57 ±...
Page 793 37A-32 STEERING - Power Steering Oil Hoses <R.H. drive vehicles> Pre-removal and Post-installation Operation Power Steering Fluid Draining and Refilling (Refer to P.37A-9.) 12 ± 2 N·m 18 ± 3 N·m 12 ± 2 N·m 12 ± 2 N·m 12 ± 2 N·m 15 ±...
Page 794 37A-33 STEERING - Power Steering Oil Hoses REMOVAL SERVICE POINT AA" EYE BOLT/RETURN TUBE REMOVAL 1. Loosen the crossmember mounting bolts and nuts, and lower the crossmember to a position so that the eye bolts or return tube at the steering gear side can be removed. NOTE In this case, do not remove the crossmember mounting bolts and nuts.
Page 795 NOTES...
Page 796 42-1 BODY CONTENTS HOOD ADHESIVES ............. SPECIAL TOOLS .
Page 797: Hood
42-2 BODY - Hood HOOD ON - VEHICLE SERVICE ADJUSTMENT OF CLEARANCE AROUND HOOD ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER ADJUSTMENT OF HOOD HEIGHT With the marker as guide, turn the hood bumper to adjust the hood height. The hood bumper height changes approx. 3mm (new hood bumper with one complete turn).
Page 798: Hood
42-3 BODY - Hood HOOD REMOVAL AND INSTALLATION 9.0 ± 2.0 N·m Section B - B Section A - A Clip Clip Remarks indicate the clip position. 7. Head lamp weather strip 1. Hood bumper 8. Hood support rod Hood lock release cable removal 9.
Page 799: Fender
42-4 BODY - Hood/Fender REMOVAL SERVICE POINTS "AA HOOD HINGE BOLT INSTALLATION Caution Use the special parts as the aluminum hood uses special coatings on the <hood side> of the hood hinge bolt. FENDER SPECIAL TOOLS Tool Number Name MB990784 Ornament remover Side turn signal lamp removal...
Page 800: Fender
42-5 BODY - Fender FENDER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Front Bumper Removal and Installation (Refer to Front Deck Garnish Removal and Installation (Refer GROUP 51.) to GROUP 51.) Removal steps D Side air dam (Refer to GROUP 3.
Page 801 42-6 BODY - Fender REMOVAL SERVICE POINTS Front of vehicle AA" SIDE TURN SIGNAL LAMP REMOVAL Side turn signal lamp Use the special tool to release the claw part of the fender panel and remove the side turn signal lamp. MB990784 Section A - A MB990784...
Page 802: Fuel Filler Door
42-7 BODY - Fuel Filler Door FUEL FILLER DOOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Rear Seat Removal and Installation. (Refer to GROUP (Driver’s Side), Center Pillar Lower Trim (Driver’s 52A.) Side), Quarter Trim (Driver’s Side) Removal and Front Scuff Plate (Driver’s Side), Rear Scuff Plate Installation (Refer to GROUP 52A –...
Page 803: Strut Tower Bar And Rear End Cross Bar
42-8 BODY - Strut Tower Bar and Rear End Cross Bar STRUT TOWER BAR AND REAR END CROSS BAR REMOVAL AND INSTALLATION 44 ± 5 N·m Strut tower bar Rear end cross bar...
Page 804: Window Glass
42-9 BODY - Window Glass WINDOW GLASS ADHESIVE Items Specified adhesive Windshield 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Rear window glass SPECIAL TOOLS Tool Number Name MB990480 Window glass Removal and Installation of Window Glass holder MB990784 Ornament remover...
Page 805 42-10 BODY - Window Glass 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.
Page 806 42-11 BODY - Window Glass WINDSHIELD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Deck Garnish Removal and Installation Front Pillar Trim Removal and Installation (Refer to GROUP 51-Windshield Wiper and Washer.) (Refer to GROUP 52A.) Headlining Removal and Installation Section A - A Section B - B Seal line center Seal line center...
Page 807 42-12 BODY - Window Glass REMOVAL SERVICE POINTS AA" WINDSHIELD AND WINDSHEILD MOLDING REMOVAL 1. In order to protect the body (paint surface), apply cloth tape to all body areas around the installed windshield. 2. Use any of the following methods to cut off adhesive. <Using the piano wire>...
Page 808 42-13 BODY - Window Glass 3. Make alignment marks on the windshield and body. MB990480 4. Use the special tool to remove the windshield. 5. Use a knife to cut away remaining adhesive to 2 mm thick or less around the entire circumference of the body flange.
Page 809: Windshield
42-14 BODY - Window Glass INSTALLATION SERVICE POINTS "AAWINDSHIELD SPACER/SPACER/GLASS STOPPER/WINDOW DAM/WINDSHIELD MOLDING/WINDSHIELD INSTALLATION 1. When replacing the windshield, first align it with the body, and then matchmark them. 2. Use isopropyl alcohol to clean the inside edge of the windshield and the body flange.
Page 810 42-15 BODY - Window Glass 6. Install the windshield molding. 7. Within thirty minutes after the primer application, fill a sealant gun with the adhesive, and then apply the adhesive evenly around the windshield. NOTE Cut the tip of the sealant gun nozzle into a V shape to simplify adhesive application.
Page 811: Rear Window Glass
42-16 BODY - Window Glass REAR WINDOW GLASS REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Rear Pillar Trim Removal and Installation High Mount Stop Lamp Assembly Removal and (Refer to GROUP 52A.) Installation (Refer to GROUP 54A) Headlining Removal and Installation Rear Shelf Trim Removal and Installation (Refer to GROUP 52A.) Section A - A...
Page 812 42-17 BODY - Window Glass REMOVAL SERVICE POINTS AA" REAR WINDOW LOWER MOLDING REMOVAL Pry the rear window lower molding off with the special tool. MB990784 Caution Do not use a deformed molding. AB" REAR WINDOW GLASS REMOVAL Remove the rear window glass in the same manner as for the windshield.
Page 813 42-18 BODY - Window Glass Glass stopper and window dam installation position Glass end line Align the window Glass stopper dam end with the seal line mark. 18 mm Align the glass Mark stopper end with the ceramic notch. Seal line 19 mm Ceramic line Ceramic line...
Page 814: Doors
42-19 BODY - BODY - Doors Doors DOORS SERVICE SPECIFICATIONS Items Standard value Door outside handle play mm Front 2.3 ± 2.1 Rear 1.3 ± 1.7 Power window operating current (power supply 14.5 ± 0.5 V, 25_C) A 5 ± 1 Front 9.6 ±...
Page 815: Troubleshooting
42-20 BODY - BODY - Doors Doors Tool Number Name MB991223 Harness set Terminal voltage measurement 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 adapter D: MB991222...
Page 816: Door Window Glass Adjustment
42-21 BODY - Doors 3. If the door does not open and close smoothly (1) Adjustment with the striker (inside the vehicle and up and down directions) Change the striker fixing bolt to a temporary bolt, and using the special tool (MB990939) and hammer, gently hit the top of the temporary bolt in the direction to be adjusted.
Page 817: Window Malfunction
42-22 BODY - Doors ADJUSTMENTS AND REPLACEMENT DURING Runchannel POWER WINDOW MALFUNCTION Door sash If the window glass does not rise but automatically descends, adjust and replace the window glass as follows: 1. Remove the door trim and waterproof film. (P.42-27) 2.
Page 818: Door Outside Handle Looseness Check
42-23 BODY - Doors DOOR OUTSIDE HANDLE LOOSENESS CHECK 1. Check that the looseness of the door outside handle satisfies the standard value. Standard value (A): Front 2.3 ± 2.1 mm Rear 1.3 ± 1.7 mm 2. Check the door outside handle and door latch assembly. If faulty, replace.
Page 819: Door Inside Handle Looseness Check And Adjustment
42-24 BODY - Doors DOOR INSIDE HANDLE LOOSENESS CHECK Section B - B AND ADJUSTMENT 1. Check that the door inside handle looseness satisfies the standard value. Standard value (A): Front 9.6 ± 9.2 mm Rear 9.0 ± 9.2 mm 2.
Page 820: Door Assembly
42-25 BODY - Doors DOOR ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Door Adjustment (Refer to P.42-20.) <FRONT DOOR> 27 ± 5 N·m 11 ± 2 N·m 1.5 ± 0.5 N·m 21 ± 4 N·m 11 ± 2 N·m 27 ± 5 N·m 21 ±...
Page 821 42-26 BODY - Doors INSTALLATION SERVICE POINTS Striker center Latch center "AA STRIKER INSTALLATION Align the center of the striker and latch within 1.5 mm, and ± +1.5 mm install. - 1.5 mm Striker Latch INSPECTION DOOR SWITCH CONTINUITY CHECK Switch position Terminal No.
Page 822 42-27 BODY - Doors DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION <FRONT DOOR> <REAR DOOR> Sealant: 3M ATD Part No. 8625 or equivalent <FRONT DOOR> <REAR DOOR> Removal steps "BA 6. Escutcheon <Vehicles without power windows> 1. Cap "BA 7. Regulator handle <Vehicles without 2.
Page 823 42-28 BODY - Doors CLIP AND CLAW POSITIONS <FRONT DOOR> View C View B View A Note Clips positions Claws positions View A View B View C Power window Front door trim switch panel assembly AW0461AU Section B - B Section A - A Power window switch panel assembly...
Page 824 42-29 BODY - Doors <REAR DOOR> View C View B View A Note Clips positions Claws positions View B View C View A Rear door trim Power window switch panel assembly AW0461AU Section B - B Section A - A Power window switch panel assembly Clip...
Page 825 42-30 BODY - Doors REMOVAL SERVICE POINTS Tapping screw cap AA" DOOR INSIDE HANDLE COVER REMOVAL 1. Insert the driver into the tapping screw cap end of the door inside handle cover and pry the cap the way shown in the illustration to remove the cap, and then unscrew the tapping screw.
Page 826: Waterproof Film
42-31 BODY - Doors INSTALLATION SERVICE POINTS <FRONT DOOR> "AA WATERPROOF FILM INSTALLATION Apply the specified adhesive on the waterproof film as shown in the illustration, and then glue it on the door window glass. Specified sealant: 3M ATD Part No. 8625 or equivalent Waterproof film <REAR DOOR>...
Page 827: Door Glass And Regulator
42-32 BODY - Doors DOOR GLASS AND REGULATOR REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Door Trim and Waterproof Film Removal (Refer to Door Window Glass Adjustment (Refer to P.42-21.) P.42-27.) Door Trim and Waterproof Film Installation (Refer to P.42-27) <REAR DOOR>...
Page 828 42-33 BODY - Doors REMOVAL SERVICE POINTS AA" WINDOW REGULATOR ASSEMBLY/POWER MB990480 WINDOW MOTOR ASSEMBLY REMOVAL 1. Loosen the door window glass assembly mounting bolts. 2. Raise the door window glass assembly, and then adhere the special tool on the glass as shown in the illustration to prevent from falling.
Page 829 42-34 BODY - BODY - Doors Doors "BA OPERATION CHECK <Vehicles with power window> 1. Install the glass to the window regulator assembly. Caution (1) As fully open position which is programed in the power window-ECU is released (initialized), the window regulator assembly should not be operated until it is installed to the glass.
Page 830: Door Handle And Latch
42-35 BODY - Doors DOOR HANDLE AND LATCH REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Door Trim Removal (Refer to P.42-27.) Door Inside Handle Looseness Check (Refer to P.42-24.) Door Outside Handle Looseness Check (Refer to P.42-23.) Door Trim Installation (Refer to P.42-27.) <REAR DOOR>...
Page 831 42-36 BODY - BODY - Doors Doors "BA LOWER SASH INSTALLATION Be sure to install the lower sash to the window rear sash (at door) securely. "CA DOOR INSIDE HANDLE INSTALLATION Clip 1. Install the inside lock cable to the door inside handle Inner cable as follows: Outer cable...
Page 832 42-37 BODY - Doors Rear door <Rear door> <Left side> <Left side> Lock Rod position Rod operation Terminal No. View A LOCK LOCK to UNLOCK UNLOCK UNLOCK to LOCK <Right side> Unlock Rod position Rod operation Terminal No. <Right side> LOCK LOCK to UNLOCK Lock...
Page 833: Window Glass Runchannel And Door Opening Weatherstrip
42-38 BODY - Doors WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP REMOVAL AND INSTALLATION <FRONT DOOR> Sectional view of clip position Sectional view of clip position Section A - A Door Door inner opening weatherstrip Door beltline inner weatherstrip removal steps removal steps D Scuff plate (Refer to GROUP 52A.) D Door trim (Refer to P.42-27.)
Page 834 42-39 BODY - Doors Sectional view of <REAR DOOR> clip position Sectional view of clip position Section A - A Door Section B - B Door Door inner opening weatherstrip Door beltline inner weatherstrip removal steps removal steps D Scuff plate (Refer to GROUP 52A.) D Door trim (Refer to P.42-27.) D Center pillar lower trim (Refer to 5.
Page 835 42-40 BODY - Doors INSTALLATION SERVICE POINTS "AA DOOR OUTER OPENING WATHERSTRIP INSTALLATION The clip colour identifies the left and right weatherstrips so be sure to use the colours as install correctly. Applicable side Identification colour Right door Pink Left door Natural (White)
Page 836: Trunk Lid
42-41 BODY - Trunk lid TRUNK LID REMOVAL AND INSTALLATION Measure of Section A - A length mm Section B - B 8.9 ± 1.9 N·m Trunk lid weatherstrip removal 4. Trunk lid striker steps Trunk lid panel removal steps D Rear end trim <RS- Ⅱ>...
Page 837 42-42 BODY - Trunk lid Grease application area REMOVAL SERVICE POINT Trunk lid torsion bar AA" TRUNK LID TORSION BAR REMOVAL Insert the tire lever into the torsion bar, and then pull upward the tire lever to remove the torsion bar as shown in the illustration.
Page 838 42-43 BODY - Trunk Lid "BA TRUNK LID WEATHERSTRIP INSTALLATION aligning the trunk lid weatherstrip marking section at the body center to install. Marking section Joint section INSPECTION TRUNK LID LATCH SWITCH CONTINUITY CHECK Switch position Terminal No. Earth Latch open Latch closed Trunk lid latch assembly...
Page 839 NOTES...
Page 840 51-1 EXTERIOR CONTENTS FRONT BUMPER ....REAR SPOILER ......WINDSHIELD WIPER AND WASHER ADHESIVE .
Page 841: Front Bumper
51-2 EXTERIOR - Front Bumper FRONT BUMPER ADHESIVE Application Brand Front air dam Double-sided tape [10 mm width 1.2 mm thickness] FRONT BUMPER REMOVAL AND INSTALLATION Section A – A Clip Section B – B Clip Fender Section C – C 1,2,3 Clip Removal steps...
Page 842: Front Bumper
51-3 EXTERIOR - Front Bumper DISASSEMBLY AND REASSEMBLY Section A – A Clip Section B – B Clip Section C – C Clip Disassembly steps 1. Front bumper plate 10. Front bumper side blade "CA 2. Front bumper center net 11.
Page 843 51-4 EXTERIOR - Front Bumper Section A – A Front bumper face Front bumper lower plate Front air dam Front air dam Double-sided tape: Generic products: 10mm width, 1.2mm thickness DISASSEMBLY SERVICE POINTS AA" RIVET REMOVAL Use the drill (ø4.0 mm) to make a hole in the rivet for removal. Rivet Front bumper...
Page 844 51-5 EXTERIOR - Front Bumper "BA RIVET INSTALLATION Riveter Use the recommended tool shown in the illustration to secure the rivet in the following procedure. Bumper face 1. Insert the rivet into the main materials (front bumper face and front bumper side plate.) 2.
Page 845: Rear Bumper
51-6 EXTERIOR - Rear Bumper REAR BUMPER REMOVAL AND INSTALLATION Pre-removal and post-installation operations Removal and installation of rear combination lamp (Refer to GROUP 54A.) Removal and installation of rear end trim, washer tank lid and AYC reservoir tank lid (Refer to GROUP 52A – Trim.) Removal and installation of rear splash shield Section A –...
Page 846 51-7 EXTERIOR - Rear Bumper DISASSEMBLY AND REASSEMBLY Disassembly steps 1. License plate bracket 4. Rear bumper side plate 2. Rear bumper center reinforcement 5. Rear bumper face AA" "AA 3. Rivet DISASSEMBLY SERVICE POINTS AA" RIVET REMOVAL Use the drill (ø 4.0 mm) to make a hole in the rivet for removal. Rivet Front bumper...
Page 847: Side Air Dam, Molding And Garnish
51-8 EXTERIOR - Rear Bumper / Side Air Dam, Molding and Garnish REASSEMBLY SERVICE POINTS Riveter "AA RIVET INSTALLATION Bumper face Use the recommended tool shown in the illustration to secure the rivet in the following procedure. 1. Insert the rivet into the main materials (rear bumper face and rear bumper side plate.) 2.
Page 848: Side Air Dam Molding Garnish
51-9 EXTERIOR - Side Air Dam, Molding and Garnish SIDE AIR DAM, MOLDING AND GARNISH REMOVAL AND INSTALLATION Section A – A Section B – B Section D – D Section C – C Clip Clip Clip Clip Section F – F Section E –...
Page 849 51-10 EXTERIOR - Side Air Dam, Molding and Garnish REMOVAL SERVICE POINTS AA" ROOF DRIP MOLDING REMOVAL Use the special tool to pry the molding from the rear of the body for removal. Caution Do not use the deformed mold again. MB990449 AB"...
Page 850 51-11 EXTERIOR - Side Air Dam, Molding and Garnish 4. Remove strip paper from the pressure sensitive Backing paper double-sided tape. NOTE Affix double-sided tape to the end of strip paper for ease of strip paper removal. (Refer to P.51-9.) 5.
Page 851: Rear Spoiler
51-12 EXTERIOR - Rear Spoiler REAR SPOILER ADHESIVE Application Brand Rear spoiler Double-sided tape [15 mm width 1.2 mm thickness, 30 mm width 1.2 mm thickness] REAR SPOILER REMOVAL AND INSTALLATION 5.2 ± 0.2 N·m 5.2 ± 0.2 N·m 5.2 ± 0.2 N·m 5.2 ±...
Page 852: Windshield Wiper And Washer
51-13 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER SERVICE SPECIFICATIONS Item Standard value Stop position of the windshield wiper arm/blade assembly (distance between the edge of Stop position of the windshield wiper arm/blade assembly (distance between the edge of ±...
Page 853 51-14 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER REMOVAL AND INSTALLATION View A Section A - A 3, 4 Clip A NOTE Section B - B indicates the clip A location. indicates the clip B location. 3 ,4 Clip B 13 ±...
Page 854 51-15 EXTERIOR - Windshield Wiper and Washer 5.0 ± 1.0 NSm NOTE: Refer to P.51-19 for more information regarding removal and installation of rear washer nozzle. Washer hose removal steps Washer tank and windshield washer motor assembly removal steps D Splash shild <Right side> (Refer to GROUP 42 –...
Page 855 51-16 EXTERIOR - Windshield Wiper and Washer REMOVAL SERVICE POINT Windshield wiper motor assembly AA" WINDSHIELD WIPER MOTOR ASSEMBLY REMOVAL 1. Remove the windshield wiper motor assembly mounting bolt. 2. Use the flat-tipped screw driver to disengage the link between the windshield wiper motor assembly and the Link assembly link assembly to remove the windshield wiper motor connection...
Page 856 51-17 EXTERIOR - Windshield Wiper and Washer INSPECTIONS WINDSHIELD WIPER MOTOR CHECK Inspection of windshield wiper motor is conducted by removing the harness connector with the motor attached to the vehicle. Operation inspection of windshield wiper motor rotation in a low or high speed Connect the battery to the windshield wiper motor to inspect the operation of motor rotation in a low or high speed.
Page 857 51-18 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WASHER NOZZLE INJECTION POSITION CHECK Move the nozzle to adjust the position so that the injection can be done in an area shown in the illustration. Caution On R.H. drive vehicles, the illustration is symmetrical. Unit:mm Windshield washer nozzle perpendicular...
Page 858 51-19 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH AND WINDSHIELD INTERMITTENT WIPER INTERVAL ADJUSTING KNOB CHECK <L.H.drive vehicles> (1) Windshield wiper and washer switch, rear wiper and washer switch. Switch position Terminal No. Windshield wiper mist switch ON Windshield intermittent wiper switch ON Windshield low-speed wiper switch ON Windshield high-speed wiper switch ON...
Page 859: Marks
51-20 EXTERIOR - Marks MARKS REMOVAL AND INSTALLATION 1. Three-diamond mark "AA 4. LANCER mark "AA 2. Three-diamond mark "AA 5. RECARO decal <RS- II> "AA 3. Evolution - VII mark INSTALLATION SERVICE POINT "AA ATTACHMENT OF EACH MARK 1. ATTACHED POSITION...
Page 860 51-21 EXTERIOR - Marks (2) Three - diamond mark, (3) Evolution - VII mark Section C - C Press line 73 mm 73 mm Press line Vehicle centerline Three - diamond mark Press line Press line View A Vehicle centerline 8.5 mm 23 mm 73 mm...
Page 861 51-22 EXTERIOR - Marks (5) RECARO decal <RS - II> <Right> Stationary Application tape terminal RECARO decal terminal window glass 31 mm 15 mm 52 mm 16 mm Stationary window weather strip terminal Stationary <Left> window glass Application tape terminal RECARO decal terminal 28 mm 19 mm...
Page 862: Outside Mirror
51-23 EXTERIOR - Outside Mirror OUTSIDE MIRROR SPECIAL TOOL Tool Number Name Application MB990784 Ornament remover Removal of power remote control outside mirror switch OUTSIDE MIRROR REMOVAL AND INSTALLATION Section A - A Claw 7.4 ± 1.4 N·m Outside mirror removal steps Remote control outside mirror switch removal steps 1.
Page 863 51-24 EXTERIOR - EXTERIOR - Outside Mirror Outside Mirror REMOVAL SERVICE POINT Section A – A Mirror AA" MIRROR REMOVAL Tilt the mirror upward, insert the flat-tipped screw driver wrapped around with the protection tape between the notch Flat-tipped screw driver located behind the mirror and pivot plate, and pry off the mirror.
Page 864 51-25 EXTERIOR - Outside Mirror CONTINUITY INSPECTION OF POWER REMOTE CONTROL MIRROR SWITCH<RS - II> Switch Switch position Terminal number Left Right Mirror adjustment switch Down Left Right...
Page 865 NOTES...
Page 866 52A-1 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS INTERIOR ............SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .
Page 867 52A-2 INTERIOR CONTENTS SPECIAL TOOL ......SEAT ........Front Seat .
Page 868: Special Tool
52A-3 INTERIOR - Special Tool/Instrument Panel SPECIAL TOOL Tool Number Name Application MB990784 Ornament remover Removal of switches and trims INSTRUMENT PANEL REMOVAL AND INSTALLATION The following bolts and screws are used for installing the instrument panel. Bolts and screws are indicated as marks shown in the illustration in the sections of “Removal and Installation” and “Disassembly and Reassembly.”...
Page 869 52A-4 INTERIOR - Instrument Panel <L.H. DRIVE VEHICLE> Caution: SRS 1. Refer to GROUP 52B-SRS Service Precautions and Air bag Module and Clock Spring before removing the passenger side 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 Removal and Installation of Front Pillar Trim (Refer to P.52A-15.)
Page 870 52A-5 INTERIOR - Instrument Panel CLIP AND CLAW POSITIONS NOTE : Clip positions : Claw positions Section A - A Section B - B Section C - C Clip Column cover Claw Instrument panel Claw Instrument panel Section D - D Section E - E Section F - F Clip...
Page 871 52A-6 INTERIOR - Instrument Panel REMOVAL SERVICE POINT AA" SRS FRONT PASSENGER’S AIR BAG MODULE REMOVAL Insert the flat tipped screw driver into the position shown in the illustration and pull up the screw driver to disengage the claws for removal of the front passenger’s air bag module. Caution 1.
Page 872 52A-7 INTERIOR - INTERIOR - Instrument Panel Instrument Panel <R.H. DRIVE VEHICLE> Caution: SRS 1. Refer to GROUP 52B-SRS Service Precautions and Air bag Module and Clock Spring before removing the passenger side 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 Removal and Installation of Front Pillar Trim (Refer to P.52A-15.)
Page 873 52A-8 INTERIOR - Instrument Panel CLIP AND CLAW POSITIONS NOTE : Clip location : Claw location Section A - A Section B - B Section C - C Clip Column cover Claw Claw Instrument panel Instrument panel Section D - D Section E - E Section F - F Clip...
Page 874 52A-9 INTERIOR - Instrument Panel REMOVAL SERVICE POINT AA" SRS FRONT PASSENGER’S AIR BAG MODULE REMOVAL Insert the flat tipped screw driver into the position shown in the illustration and pull up the screw driver to disengage the claws for removal of the front passenger’s air bag module. Caution 1.
Page 875: Front Floor Console
52A-10 INTERIOR - Front Floor Console FRONT FLOOR CONSOLE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Rear Foor Console (Refer to P.52A - 12.) < L.H. DRIVE VEHICLE> Removal steps 1. Console side cover 7. Shift lever cover 2.
Page 876 52A-11 INTERIOR - Front Floor Console REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Rear Floor Console (Refer to P.52A-12.) <R.H. DRIVE VEHICLE> Removal steps 1. Console side cover 7. Shift lever cover 2. Shift lever knob 8.
Page 877: Rear Floor Console
52A-12 INTERIOR - Rear Floor Console REAR FLOOR CONSOLE REMOVAL AND INSTALLATION <Type A> <Type B> Removal steps 1. Console box mat D Rear scuff plate (Refer to P.52A-15.) D Center pillar trim, lower 2. Rear console assembly (Refer to P.52A-15.) D Rear seat cushion assembly D Floor carpet (Refer to P.52A-22.)
Page 878 52A-13 INTERIOR - Rear Floor Console DISASSEMBLY AND REASSEMBLY <Type A> <Type B> Disassembly steps 1. Ashtray 6. Console lid 2. Cup holder 7. Lower lid striker 3. Hole lock 8. Hinge bracket 4. Rear floor console 9. Box 5. Console lid assembly 10.
Page 879 52A-14 INTERIOR - Rear Floor Console DISASSEMBLY SERVICE POINT Console lid assembly AA" REMOVAL OF CONSOLE LID ASSEMBLY Insert the special tool into the hinges of the console lid assembly and the rear floor console through the ashtray mounting hole to pry for removal. Rear floor console Ashtray...
Page 880: Trims
52A-15 INTERIOR - Trims TRIMS REMOVAL AND INSTALLATION 44 ± 10 N•m NOTE Refer to GROUP42 for more information regarding door trim. Removal steps 1. Front scuff plate 9. Center pillar trim, upper 2. Cowl side trim 10. Rear pillar trim 3.
Page 881 52A-16 INTERIOR - Trims CLIP POSITION NOTE : Clip position : Claw position Section A - A Section B - B Section C - C Front scuff plate, Front pillar trim Clip Rear scuff plate Headlining Clip Front pillar trim, Clip Center pillar trim, upper,...
Page 882: Headlining
52A-17 INTERIOR - Trims/Headlining REMOVAL SERVICE POINT Section A – A AA" FRONT PILLAR TRIM REMOVAL Release the clip to pull towards the direction shown in the Front pillar trim Front pillar trim illustration and remove the front pillar trim. Instrument panel HEADLINING...
Page 883 52A-18 INTERIOR - Headlining REMOVAL SERVICE POINTS AA" SUNVISOR HOLDER REMOVAL Insert the special tool into sides claws of the sunvisor holder through the both sides of the sunvisor holder to remove the MB990784 hinges. Sunvisor holder MB990784 AB" HEADLINING REMOVAL Bend the headlining to remove from the front passenger’s door.
Page 884: Seat
52A-19 INTERIOR - Seat SEAT FRONT SEAT REMOVAL AND INSTALLATION 44 ± 10 NSm 44 ± 10 NSm 30 ± 5 NSm 30 ± 5 NSm 1. Headrest Front seat assembly removal steps 2. Front seat anchor cover 3. Front seat assembly "AA INSTALLATION SERVICE POINT "AA INSTALLATION OF FRONT SEAT ASSEMBLY...
Page 885 52A-20 INTERIOR - Seat DISASSEMBLY AND REASSEMBLY HIGHT ADJUSTER SEAT 12 13 44 ± 10 NSm 12 ± 2 NSm Section A - A Claw 8, 9 9 ± 2 NSm 44 ± 10 NSm Disassembly steps 1. Reclining knob 11.
Page 886 52A-21 INTERIOR - Seat RECARO SEAT 22 ± 3 NSm 22 ± 3 NSm Disassembly steps 1. Reclining knob 5. Front seat back assembly 2. Reclining cover 6. Seat rail R.H. 3. Cap 7. Seat rail L.H. 4. Front seat cushion assembly 8.
Page 887: Rear Seat
52A-22 INTERIOR - Seat REMOVAL SERVICE POINT AA" REMOVAL OF HEADREST GUIDE REAR SEAT REMOVAL AND INSTALLATION 22 ± 4 NSm Disassembly steps 1. Rear seat cushion assembly 3. Rear seat hook "BA 2. Rear seatback assembly "AA...
Page 888 52A-23 INTERIOR - Seat INSTALLATION SERVICE POINTS "AA INSTALLATION OF REAR SEATBACK Rear seat back ASSEMBLY/REAR SEATBACK SIDE ASSEMBLY assembly L.H., R.H. Press the rear seatback assembly in the direction shown in the illustration and fit the attachment wire into the hook securely to install the rear seatback assembly.
Page 889 52A-24 INTERIOR - Seat DISASSEMBLY AND REASSEMBLY Removal steps 1. Rear seat cushion cover 3. Rear seatback cover 2. Rear seat cushion pad 4. Rear seatback pad...
Page 890: Seat Belt
52A-25 INTERIOR - Seat Belt SEAT BELT FRONT SEAT BELT REMOVAL AND INSTALLATION 44 ± 10 NSm 44 ± 10 NSm 44 ± 10 NSm 44 ± 10 NSm Outer seat belt removal steps Inner seat belt removal steps 1. Sash guide cover D Shield cover (Refer to P.52A-20.) 2.
Page 891: Rear Seat Belt
52A-26 INTERIOR - Seat belt REAR SEAT BELT REMOVAL AND INSTALLATION 44 ± 10 NSm 44 ± 10 NSm 44 ± 10 NSm 44 ± 10 NSm Removal steps D Rear seat cushion assembly 1. Inner seat belt (Refer to P.52A-22.) 2.
Page 892 52B-1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS GENERAL INFORMATION ....SRS AIR BAG CONTROL UNIT (SRS-ECU) ....... . SRS SERVICE PRECAUTIONS .
Page 893: General Information
52B-2 SRS - SRS - General Information General Information GENERAL INFORMATION To improve safety, the SRS and seat belts with instrument panel indicates the operational status pre-tensioner. These systems enhance collision of the SRS. The clock spring is installed in the safety by restraining the front passengers in case steering column.
Page 894: Srs Service Precautions
52B-3 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 and If any of these components are diagnosed as accidental operation of the seat belt with faulty, they should only be replaced, in pre-tensioner during servicing,...
Page 895 52B-4 SRS - SRS Service Precautions SRS-ECU Destination of harness Corrective action Terminal No. Instrument panel wiring harness → Earth Repair or replace each wiring harness harness 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 →...
Page 896: Special Tools
52B-5 SRS - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub Reading and erasing diagnosis codes assembly Reading trouble period Reading erase times MB991865 Dummy resistor Checking SRS air bag circuit MB991866 Resistor harness MB991613 SRS check Checking SRS electrical circuitry harness MB991223 Harness set...
Page 897: Test Equipment
52B-6 SRS - Special Tools/Test Equipment/Troubleshooting Tool Number Name MB686560 SRS air bag Deploying front passenger’s air bag module adapter harness inside or outside vehicle MR203491or SRS air bag Deploying driver’s air bag module inside MB628919 adapter harness vehicle <RS> TEST EQUIPMENT Tool Name...
Page 898 52B-7 SRS - Troubleshooting SRS SYSTEM CIRCUIT DIAGRAM Ignition switch (IG SRS-ECU No.2 No.3 (common fuse) 7.5A 7.5A Combination Meter Connector lock switch* Connector lock switch* Connector lock switch* Driver’s air bag module (squib) C-207 C-22 Clock spring C-204 Diagnosis connector Front pas- senger’s seat Connector lock switch*...
Page 899 52B-8 SRS - Troubleshooting CONNECTOR FOR SRS AIR BAG The SRS air bag system connector is yellow or red. To enhance system reliability, a connector lock switch is adopted for the SRS-ECU connector, and each air bag module and clock spring connector, each seat belt with pre-tensioner <the connector A in the following illustration (black)>).
Page 900 52B-9 SRS - Troubleshooting WARNING LAMP CIRCUIT CONNECTOR LOCK SWITCH Ignition switch (IG Mechanism to automatically short-circuit the power supply terminal and the earth terminal of the warning lamp circuit when the SRS-ECU connector is disconnected. The structure is the same as that of squib circuit connector lock switch. SRS warning lamp SRS-ECU harness side connector...
Page 901 52B-10 SRS - Troubleshooting Code no. Diagnostic item Page Connector lock system 52B-29 SRS-ECU (deployed air bag) system 52B-29 Power supply circuit system (fuse No.2 circuit) 52B-30 Power supply circuit system (fuse No.3 circuit) 52B-32 SRS warning lamp drive circuit system Lamp does not illumi- 52B-33 nate.
Page 902 52B-11 SRS - Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No.14, 15, 16, 31, 32, 45, 51, 52, 54, 55, 56, 57, 58, 59 Probable cause System inside SRS-ECU Malfunction is present inside SRS-ECU. See table below for what each code D Malfunction of SRS-ECU tells.
Page 903 52B-12 SRS - Troubleshooting Code No.21 Driver’s air bag module (squib) system Possible Cause This code is output when short circuit occurs between terminals of the D Connector engagement faulty or short bar faulty* SRS-ECU driver’s air bag module (squib) circuit. D Short circuit in the clock spring However, SRS warning lamp goes out when a normal operation is resumed D Short circuit between terminals of the driver’s air...
Page 904 52B-13 SRS - Troubleshooting <RS> <Clock spring check> Dummy resistor MUT-II self-diag code (MB991865) Resistor harness D Release the clock spring connector (2- pin) C-204. resistance (3Ω) (MB991866) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866). D Insert the resistor harness (MB991866) behind the harness side connector C-204.
Page 905 52B-14 SRS - Troubleshooting <RS-II> <Driver’s seat air bag module (squib) check> MUT-II self-diag code Resistor harness D Disconnect the clock spring connector No.1 (connector connected with Dummy resistor (MB991866) the air bag module). (MB991865) D Connect the dummy resistor (MB991865) to the resistor harness resistance (3Ω) (MB991866).
Page 906 52B-15 SRS - Troubleshooting From Previous Page Check connector: C- 21, C-204 <Check the circuit between the SRS-ECU and clock spring> Measure at the SRS-ECU connector C- 21 . D Disconnect the SRS-ECU connector C-21. Correct Check the trouble D Release the the clock spring connector C-204. symptoms.
Page 907 52B-16 SRS - Troubleshooting Code No.22 Driver’s air bag module (squib) system Possible Cause This code is output when open circuit occurs in the SRS-ECU driver’s air bag D Open in the clock spring module (squib) circuit. D Half open in the circuit due to improper neutral However, SRS warning lamp goes out when a normal operation is resumed positioning of the clock spring (diagnosis code is not cleared.)
Page 908 52B-17 SRS - Troubleshooting <RS> <Clock spring check> Dummy resistor MUT-II self-diag code (MB991865) Resistor harness D Release the clock spring connector (2- pin) C-204. resistance (3Ω) (MB991866) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866). D Insert the resistor harness (MB991866) behind the harness side connector C-204.
Page 909 52B-18 SRS - Troubleshooting <RS-II> <Driver’s seat air bag module (squib) check> Dummy resistor MUT-II self-diag code Resistor harness D Disconnect the clock spring connector No.1 (connector connected with (MB991865) (MB991866) the air bag module). resistance (3Ω) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866).
Page 910 52B-19 SRS - Troubleshooting From Previous Page <Check the circuit between the SRS-ECU and clock Check connector: C-21, C-204 spring> Measure at the C-21 SRS-ECU connector and C-204 clock spring connector. Correct Check the trouble D Disconnect the SRS-ECU connector C-21 and the clock symptoms.
Page 911 52B-20 SRS - Troubleshooting Code No.24 Front passenger’s air bag module (squib) Possible Cause system This code is output when short circuit occurs between terminals of the D Connector engagement faulty or short bar faulty* SRS-ECU front passenger’s air bag (squib) circuit. D Short circuit between terminals of the front However, SRS warning lamp goes out when a normal operation is resumed passenger’s air bag (squib) circuit...
Page 912 52B-21 SRS - Troubleshooting <Check the front passenger’s air bag module (squib)> Dummy resistor MUT-II self-diag code Resistor harness (MB991865) (MB991866) D Connect the dummy resistor (MB991865) to the resistor harness resistance (3Ω) (MB991866). D Disconnect the front passenger’s air bag module connector C-109 Instrumental panel and insert the resistor harness (MB991866) behind the harness side wiring harness...
Page 913 52B-22 SRS - Troubleshooting Code No.25 Front passenger’s air bag module (squib) Possible Cause system This code is output when open circuit occurs in the SRS-ECU front passenger’s D Open in the front passenger’s air bag module air bag (squib) circuit. (squib) circuit However, SRS warning lamp goes out when a normal operation is resumed D Connector improper contact...
Page 914 52B-23 SRS - Troubleshooting Code No.26 Driver’s seat belt pre-tensioner (squib) Possible Cause system This code is output when short circuit occurs between terminals of the D Connector engagement faulty or short bar faulty* SRS-ECU driver’s seat belt pre-tensioner (squib) circuit. D Short circuit between terminals of the driver’s seat However, SRS warning lamp goes out when a normal operation is resumed belt pre-tensioner (squib) circuit...
Page 915 52B-24 SRS - Troubleshooting <Check the driver’s seat belt pre-tensioner (squib)> MUT-II self-diag code Resistor harness D Connect the dummy resistor (MB991865) to the resistor harness Dummy resistor (MB991865) (MB991866) (MB991866). resistance (3Ω) D Disconnect the driver’s seat belt pre-tensioner connector D-28* D-26 and connect to the resistor harness (MB991866) behind the harness side connector.
Page 916 52B-25 SRS - Troubleshooting Code No.27 Driver’s seat belt pre-tensioner (squib) Possible Cause system This code is output when open circuit occurs in the SRS-ECU driver’s seat belt D Connector improper contact pre-tensioner (squib) circuit. D Open in the driver’s seat pre-tensioner (squib) However, SRS warning lamp goes out when a normal operation is resumed circuit (diagnosis code is not cleared.)
Page 917 52B-26 SRS - Troubleshooting Code No.28 Front passenger’s seat belt pre-tensioner Possible Cause (squib) system This code is output when short circuit occurs between terminals of the D Connector engagement faulty or short bar faulty* SRS-ECU front passenger’s seat belt pre-tensioner (squib) circuit. D Short circuit between terminals of the front However, SRS warning lamp goes out when a normal operation is resumed passenger’s seat belt pre-tensioner (squib) circuit...
Page 918 52B-27 SRS - Troubleshooting <Check the front passenger’s seat belt pre-tensioner (squib)> MUT-II self-diag code Resistor harness Dummy resistor D Connect the dummy harness (MB991865) to the resistor harness (MB991866) (MB991865) (MB991866). resistance (3Ω) D Disconnect the front passenger’s seat belt pre-tensioner connector D-28* and D-26* and insert the resistor harness (MB991866) behind...
Page 919 52B-28 SRS - Troubleshooting Code No.29 Front passenger’s seat belt pre-tensioner Possible Cause (squib) system This code is output when open circuit occurs in the SRS-ECU front passenger’s D Open in the front passenger’s seat pre-tensioner seat belt pre-tensioner (squib) circuit. (squib) circuit However, SRS warning lamp goes out when a normal operation is resumed D Connector improper contact...
Page 920 52B-29 SRS - Troubleshooting Code No.34 Connector Lock System Probable Cause The SRS-ECU connector is mounted with a connector lock switch terminal for D Faulby connector detecting the connected state of the connector. D SRS-ECU inperable SRS-ECU connector is poorly connected. However, when the vehicle condition returns to normal, this code will be automatically erased, and the SRS warning lamp will go out.
Page 921: Electrical Wiring
52B-30 SRS - Troubleshooting Code No.41 Power supply circuit system (fuse No.2 Possible Cause circuit) This codes output when the voltage between terminal IG (SRS-ECU, terminal D Harness or connector fault No.16) and earth has been below the standard value for 5 seconds. D SRS-ECU inoperable However, code No.41 is automatically erased and SRS warning lamp goes out when a normal operation is resumed.
Page 922 52B-31 SRS - Troubleshooting From Previous Page <Check the circuit between the SRS-ECU and the junction block> Check the harness between the SRS-ECU and junction block, Measure at the SRS - ECU connector C-21. and repair if necessary. D Disconnect the SRS-ECU connector C-21 and measure at the harness side.
Page 923: Electrical Wiring
52B-32 SRS - Troubleshooting Code No.42 Power supply circuit system (fuse No.3 Possible Cause circuit) This code is output when the voltage between terminal IG (SRS-ECU, terminal D Harness or connector fault No.13) and earth has been below the standard value for 5 seconds. D SRS-ECU inoperable However, code No.42 is automatically erased and SRS warning lamp goes out when a normal operation is resumed.If code No.41 and 42 are output at the...
Page 924 52B-33 SRS - Troubleshooting Code No.43 SRS warning lamp drive circuit system (lamp Possible Cause does not illuminate) This code is output when open circuit has occurred in the SRS warning lamp D Harness or connector fault drive circuit for 5 seconds or more. However, if the code is output due to open D Bulb fault circuit faulty, code No.43 is automatically erased and the SRS warning lamp D SRS-ECU inoperable...
Page 925 52B-34 SRS - Troubleshooting Code No.61 Driver’s air bag module (squib) system Possible Cause (short-circuited to power supply) Code No.62 Driver’s air bag module (squib) system (short-circuited to earth) This code is output when the input terminal of the SRS-ECU driver’s air bag D Clock spring fault module (squib) is short-circuited to power supply (code No.61) or short-circuited D Harness or connector fault...
Page 926 52B-35 SRS - Troubleshooting <RS> <Check the clock spring and the driver’s air bag module (squib)> Dummy resistor (MB991865) MUT-II self-diag code Resistor harness resistance (3Ω) D Release the clock spring connector (2- pin) C-204. (MB991866) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866).
Page 927 52B-36 SRS - Troubleshooting <RS-II> <Driver’s air bag module (squib) check> MUT-II self-diag code Resistor harness Dummy resistor D Disconnect the clock spring connector No.1 (connector connected with (MB991865) (MB991866) the air bag module). resistance (3Ω) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866).
Page 928 52B-37 SRS - Troubleshooting From Previous Page YES (when No.61 is output) YES (when No.62 is output) <Check the circuit between the SRS-ECU and <Check the circuit between the SRS-ECU and clock spring> clock spring> Measure at the SRS-ECU connector C-21. Measure at the SRS-ECU connector C-21.
Page 929 52B-38 SRS - Troubleshooting Code No.64 Front passenger’s air bag module (squib) Possible Cause system (short-circuited to power supply) Code No.65 Front passenger’s air bag module (squib) system (short-circuited to earth) This code is output when the input terminal of the SRS-ECU front passenger’s D Harness or connector fault air bag module (squib) is short-circuited to power supply (code No.64) or D The harness of the front passenger’s air bag...
Page 930 52B-39 S R S - Tr o u b l e s h o o t i n g Code No.66 Driver’s seat belt pre-tensioner (squib) Possible Cause system (short-circuited to power supply) Code No.67 Driver’s seat belt pre-tensioner (squib) system (short-circuited to earth) This code is output when the input terminal of the SRS-ECU driver’s seat belt D Harness or connector fault...
Page 931 52B-40 S R S - Tr o u b l e s h o o t i n g Code No.68 Front passenger’s seat belt pre-tensioner Possible Cause (squib) system (short-circuited to power supply) Code No.69 Front passenger’s seat belt pre-tensioner (squib) system (short-circuited to earth) This code is output when the input terminal of the SRS-ECU front passenger’s D Harness or connector fault...
Page 932 52B-41 SRS - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Study the trouble symptoms and check according to the inspection procedure chart. Trouble Inspection procedure No(s). Reference page Communication with MUT-II is impossible. 52B-41 SRS warning lamp does not illuminate. See diagnosis code No.43. 52B-33 SRS warning lamp does not go out.
Page 933: Srs Maintenance
52B-42 SRS - SRS Maintenance 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, and then go out? If yes, SRS system is functioning properly.
Page 934 52B-43 SRS - SRS Maintenance AIR BAG MODULES, STEERING WHEEL AND CLOCK <Driver’s side> Inflator SPRING AND SEAT BELT WITH PRE-TENSIONER <RS> 1. Remove the air bag modules, steering wheel and clock spring. (Refer to P.52B-52.) Caution The removed air bag modules should be stored in a clean, dry place with the cover face up.
Page 935 52B-44 SRS - SRS Maintenance REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION. (Refer to P.52B-52.) 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.
Page 936: Post-Collision Diagnosis
52B-45 SRS - Post-collision Diagnosis 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...
Page 937 52B-46 SRS - Post-collision Diagnosis REPAIR PROCEDURE DEPLOYED DRIVER’S AND FRONT PASSENGER’S AIR BAGS OR OPERATED SEAT BELT PRE-TENSIONER. 1. Replace the following parts with new ones. SRS-ECU (Refer to P.52B-50.) Driver’s air bag module (Refer to P.52B-52.) Front passenger’s air bag module (Refer to P.52B-52.) Seat belt with pre-tensioner (Refer to P.52B-61.) 2.
Page 938 52B-47 SRS - Post-collision Diagnosis 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. Driver’s and passenger’s air bag modules <Driver’s side>...
Page 939 52B-48 SRS - Post-collision Diagnosis Steering wheel, steering column and intermediate joint 1. Check the driver’s air bag module for proper installation to the steering wheel. 2. Check the steering wheel for noise, binds or difficult operation and excessive free play. Harness connector (Instrument panel wiring harness, Floor wiring harness) Check the harness for binds, the connector for damage and...
Page 940: Individual Component Service
52B-49 SRS - Individual Component Service/Warning/Caution Labels 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 the service procedures that follow. Caution 1. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, driver’s air bag module<RS>, steering wheel - air bag module<RS-Ⅱ>, front passenger’s air bag module, clock spring, and seat belt with pre-tensioner before drying or baking the vehicle after painting.
Page 941: Srs Air Bag Control Unit (Srs-Ecu)
52B-50 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.
Page 942 52B-51 SRS - SRS-ECU 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 POST-INSTALLATION CHECK 1. Turn the ignition switch to ON. 2.
Page 943: Air Bag Modules And Clock Spring
52B-52 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.
Page 944 52B-53 SRS - Air Bag Modules and Clock Spring REMOVAL AND INSTALLATION <Driver’s air bag module, clock spring> Pre-removal Operation Disconnect the Negative ( - ) Battery Terminal. <RS: Steering wheel and air bag module separate type> 41 ± 8 N·m 0.9 ±...
Page 945 52B-54 S RS - Air Bag Modules and Clock Spring <RS-II: Steering wheel and air bag module incorporate type> 50 ± 5 N·m Steering wheel - driver’s air bag Steering wheel - driver’s air bag module assembly removal steps module assembly installation steps 1.
Page 946 52B-55 SRS - Air Bag Modules and Clock Spring <Front passenger’s air bag module> Removal steps Installation steps D Instrument panel assembly "AA D Pre-installation inspection (Refer to GROUP 52A - Instrument 1. Passenger’s air bag module panel.) D Instrument panel assembly 1.
Page 947 52B-56 SRS - Air Bag Modules and Clock Spring STEERING WHEEL REMOVAL " MB990803 AC" CLOCK SPRING REMOVAL Caution Keep the removed clock spring in a clean and dry place. AD" COVER REMOVAL Use the special tool to insert into the notch as shown in the illustration and remove the cover.
Page 948 52B-57 SRS - Air Bag Modules and Clock Spring AF" PASSENGER’S AIR BAG MODULE REMOVAL Insert the screwdriver ( - ) into the position specified in the figure and lift the screwdriver upward to release the pawls engaged, and then remove the passenger’s air bag module. Caution 1.
Page 949 52B-58 SRS - Air Bag Modules and Clock Spring "CA STEERING WHEEL/STEERING WHEEL - AIR BAG MODULE ASSEMBLY INSTALLATION 1. After checking that centering of the clock spring has been done, install the steering wheel or the steering wheel - air bag module assembly.
Page 950 52B-59 SRS - Air Bag Modules and Clock Spring INSPECTION <Driver’s side> Inflator <RS> DRIVER’S AND PASSENGER’S AIR BAG MODULE 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.
Page 951 52B-60 SRS - Air Bag Modules and Clock Spring 4. Align the paint mark on the connector No.1 of the SRS check harness (MB991606 or MB991613) with the mark Paint Marking indicated by an arrow on the connector No.3 of the clock spring for connector connection.
Page 952 52B-61 S RS - Seat Belt with Pre-tensioner SEAT BELT WITH PRE-TENSIONER Caution: 1. Wait least seconds after 4. Do not place a heavy object on top of the disconnecting the negative ( - ) terminal of seat belt pre-tensioner. the battery before starting any operation.The 5.
Page 953 52B-62 S RS - Seat Belt with Pre-tensioner INSTALLATION SERVICE POINTS "AA PRE-INSTALLATION INSPECTION 1. Pre-installation inspection must be carried out even when installing a new seat belt with pre-tensioner. (Refer to Inspections.) Caution If the seat belt with pre-tensioner is discarded, discard it after operating the seat belt pre-tensioner according to the specified procedure.
Page 954: Seat Belt Pre-Tensioner
52B-63 S RS - Seat belt with Pre-tensioner INSPECTION SEAT BELT PRE-TENSIONER If any faulty is discovered by the following inspections, replace the seat belt with pre-tensioner with a new one. Discard the old parts according to the specified procedure after operating the seat belt pre-tensioner.(Refer to P.52B-64.) Caution Do not measure the circuit resistance of the seat belt...
Page 955: Air Bag Module And Seat Belt Pre-Tensioner Disposal Procedures
Air Bag Module and Seat Belt Pre-tensioner 52B-64 SRS - Disposal Procedures AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES Carry out the following procedure of air bag with pre-tensioner or the vehicle with SRS air bag deployment and seat belt pre-tensioner operation and seat belt with pre-tensioner.
Page 956 Air Bag Module and Seat Belt Pre-tensioner 52B-65 SRS - Disposal Procedures 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).
Page 957 Air Bag Module and Seat Belt Pre-tensioner 52B-66 SRS - Disposal Procedures Front passenger’s air bag module (1) Remove the glove box. (Refer to GROUP 52A – Instrument Panel.) (2) Disconnect the front passenger’s air bag module 2-pin Instrument panel wiring connector (red) and instrument panel wiring harness harness connector...
Page 958 Air Bag Module and Seat Belt Pre-tensioner 52B-67 SRS - Disposal Procedures (6) Separate the deployment harnesses as far from the vehicle as possible and connect to the terminals of 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.
Page 959 Air Bag Module and Seat Belt Pre-tensioner 52B-68 SRS - Disposal Procedures (5) Close all the doors with the windows fully closed and put a cover over the vehicle to minimize report. Cover Caution The cover is required as the glass, if already damaged, may break.
Page 960 Air Bag Module and Seat Belt Pre-tensioner 52B-69 SRS - Disposal Procedures (2) Connect deployment harnesses longer than 6 m to Short-circuited each SRS air bag adapter harness and insulate the Deployment harness connections with plastic tape. Also, connect the deployment harness in the other SRS air bag ends to connect (short-circuit).
Page 961 Air Bag Module and Seat Belt Pre-tensioner 52B-70 SRS - Disposal Procedures (7) Separate the deployment harnesses as far from the driver’s side air bag module as possible and connect to the terminals of the battery removed from the vehicle. Then deploy. Caution 1) Before the deployment, see that no one is near around the driver’s air bag module.
Page 962 Air Bag Module and Seat Belt Pre-tensioner 52B-71 SRS - Disposal Procedures (4) Release the secured connector of the steering Steering wheel - driver’s air bag Deployment module assembly harness wheel - driver’s air bag module assembly to cut off the connector from the harness with a nipper and etc.
Page 963 Air Bag Module and Seat Belt Pre-tensioner 52B-72 SRS - Disposal Procedures Front passenger’s air bag module (1) Remove the front passenger’s air bag module from the vehicle. (Refer to P.52B-52.) Caution Once disconnected, both electrodes of the front passenger’s air bag module connector short automatically to prevent accidental deployment caused by static etc.
Page 964 Air Bag Module and Seat Belt Pre-tensioner 52B-73 SRS - Disposal Procedures (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.
Page 965 Air Bag Module and Seat Belt Pre-tensioner 52B-74 SRS - Disposal Procedures (3) Route a thick wire through the holes in the seat belt Seat belt pre-tensioner retractor bracket to secure at the top of the wheel (convex part). (two locations) (4) Connect the seat belt pre-tensioner connector to the the SRS air bag adapter harness with the operation harness attached.
Page 966 Air Bag Module and Seat Belt Pre-tensioner 52B-75 SRS - Disposal Procedures DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES Discard the deployed air bag module or the operated seat belt with pre-tensioner paying attention to the following items. 1.
Page 967 NOTES...
Page 968 54A-1 CHASSIS ELECTRICAL CONTENTS CHASSIS ELECTRICAL ........SMART WIRING SYSTEM (SWS) .
Page 969 54A-2 CHASSIS ELECTRICAL CONTENTS ......Speedometer Check ..... . BATTERY Tachometer Check .
Page 970 54A-3 SIDE TURN-SIGNAL LAMP ... . SPECIAL TOOL ......HAZARD WARNING LAMP SWITCH .
Page 971: Battery
54A-4 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Battery Battery 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.
Page 972: Battery Testing Procedure
54A-5 CHASSIS ELECTRICAL - Battery Caution 1. The battery plugs should be removed during charging. 2. The battery electrolyte level may rise and overflow from the battery during charging. 3. Explosions may occur if the battery is brought close to naked flames during charging. 4.
Page 973: Ignition Switch And Immobilizer System
54A-6 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System IGNITION SWITCH AND IMMOBILIZER SYSTEM SPECIAL TOOLS Tool Number Name MB991502 MUT-II Sub as- Checking the immobilizer system sembly MB990784 Ornament remover Instrument panel under cover and column cover removal TROUBLESHOOTING IGNITION SWITCH The ignition switch is controlled by the Smart Wiring System (SWS).
Page 974 54A-7 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE Code No. 11 Problem related to communication with the Probable cause ignition key When the ignition switch is at the ON position, the encrypted codes are not D Malfunction of ignition key transmitted from the ignition key to the immobilizer-ECU.
Page 975 54A-8 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS Inspection procedure 1 Diagnosis code No.1610 is generated by the Probable cause engine-ECU. The cause is probably a problem with communication between the engine-ECU D Malfunction of harness or connector and the immobilizer-ECU.
Page 976 54A-9 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System Inspection procedure 2 The ignition keys cannot be registered using the MUT-II. Probable cause The ignition key has not been registered with the immobilizer-ECU. Or that there D Malfunction of ignition key is a problem with the immobilizer-ECU.
Page 977: Immobilizer-Ecu Check
54A-10 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System Inspection procedure 4 Immobilizer-ECU power supply and earth circuit system check (1) NG Check the following connectors: Measure at immobilizer-ECU connector C-202-1. <L.H. drive vehicles> C-202 - 1, C-202, C-129, D-108 D Ignition switch: ON <R.H.
Page 978: Ignition Switch
54A-11 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System IGNITION SWITCH REMOVAL AND INSTALLATION Removal steps 1. Lower column cover (Refer to GROUP 5. Steering lock cylinder AA" 52A - Instrument Panel.) 6. Ignition switch 2. Upper column cover (Refer to GROUP 7.
Page 979 54A-12 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System INSPECTION IGNITION SWITCH CONTINUITY CHECK With ignition switch installed on the vehicle, disconnect ignition switch connector for inspection. Ignition key Terminal No. position LOCK START KEY REMINDER SWITCH CONTINUITY CHECK With key reminder switch installed on the vehicle, disconnect key reminder switch connector for inspection.
Page 980 54A-13 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System 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.
Page 981: Combination Meter
54A-14 CHASSIS ELECTRICAL - Combination Meter COMBINATION METER Caution Never remove pointer of combination meter. This may cause damage of combination meter. SERVICE SPECIFICATIONS Item Standard value Limit value At 40 km/h 37 - 45 – Indication range of speedometer km/h At 80 km/h 75 - 88 –...
Page 982: Troubleshooting
54A-15 CHASSIS ELECTRICAL - Combination Meter SPECIAL TOOLS Tools Number Name MB991223 Harness set Brief test for fuel gauge and water temperature gauge A: MB991219 A: Inspection har- B: MB991220 ness A: For inspection of connector pin contact C: MB991221 B: LED Harness pressure D: MB991222...
Page 983 54A-16 CHASSIS ELECTRICAL - Combination Meter INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection procedure 1 Speedometer inoperative (other meters are operated) Probable cause Failure may occur on engine-ECU system, harnesses, connectors, meter D Engine-ECU fault assembly. D Harness or connector fault D Meter assembly fault MUT-II Self-Diag.
Page 984 54A-17 CHASSIS ELECTRICAL - Combination Meter Inspection procedure 3 Fuel gauge inoperative (other meters are operated) Probable cause When speedometer and tachometer are properly operated, harness from power D Fuel gauge unit fault source to combination meter is normal. D Harness or connector fault D Meter assembly fault Replace main fuel gauge unit.
Page 985 54A-18 CHASSIS ELECTRICAL - Combination Meter Inspection procedure 4 Water temperature gauge inoperative (other meters are Probable cause operated) When speedometer and tachometer are properly operated, harness from power D Water temperature gauge unit fault source to combination meter is normal. D Harness or connector fault D Meter assembly fault Check water temperature gauge circuit.
Page 986: On-Vehicle Service
54A-19 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Combination Meter Combination Meter Inspection procedure 5 All meters inoperative Probable cause When individual indicators and warning lamps are properly operated, harness D Meter assembly fault from power source (IG1) to combination meter is normal. D Harness or connector fault Check the following connectors: Repair...
Page 987: Tachometer Check
54A-20 CHASSIS ELECTRICAL - Combination Meter TACHOMETER CHECK Engine speed indicator Paper clip 1. Insert paper clip (Zem clip) from harness side of the probe for detection of engine speed to connect engine speed indicator. 2. Compare measured values of individual engine speed Probe for detection of engine speed with tachometer values, and ensure that indication...
Page 988: Engine Coolant Temperature Gauge
54A-21 CHASSIS ELECTRICAL - Combination Meter FLOAT HEIGHT OF FUEL GAUGE UNIT Main fuel gauge unit When float is moved to contact float arm on stopper, ensure that Position F (A) and E (B) are within standard value. Standard Value: Float Position Float Position Main fuel gauge unit...
Page 989: Combination Meter
54A-22 CHASSIS ELECTRICAL - Combination Meter COMBINATION METER REMOVAL AND INSTALLATION Removal steps 1. Meter bezel 2. Instrument panel ornament 3. Combination meter INSPECTION COMBINATION METER INTERNAL RESISTANCE CHECK Use circuit tester to measure combination meter internal resistance. Standard Value: Measuring Terminal name Standard...
Page 990 54A-23 CHASSIS ELECTRICAL - Combination Meter DISASSEMBLY AND REASSEMBLY Disassembly step 1. Glass 4. Bulb 2. Window plate 5. Meter assembly 3. Circuit board cover...
Page 991: Headlamp Assembly
54A-24 CHASSIS ELECTRICAL - Headlamp Assembly HEADLAMP ASSEMBLY SERVICE SPECIFICATIONS Item Standard value Limit Headlamp aiming Low beam Vertical 120mm (0.69_) below hor- ± 0.29_ direction izontal line (H) Horizontal Position at which the ± 0.5_ direction startup point of 15_ is crossed with vertical line Vertical The center of high intensi-...
Page 992 54A-25 CHASSIS ELECTRICAL - Headlamp Assembly 4. If the fuel tank is not full, place a weight in luggage room of vehicle to simulate weight of a full tank 0.8 kg per litre. 5. There should be no other load in the vehicle other than driver or substituted weight of approximately 75 kg placed in driver’s position.
Page 993 54A-26 CHASSIS ELECTRICAL - Headlamp Assembly Limit: (Vertical direction) ± 0.29_ (Horizontal direction) ± 0.5_ NOTE The illustration shows L.H. drive vehicles. For R.H. drive vehicles, it is symmetrical. 3. Alternately turn the adjusting screw to adjust the headlamp Horizontal low beam aiming.
Page 994 54A-27 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Headlamp Assembly Headlamp Assembly 2. Check if the high beam shining onto the screen is at the standard value. Lamp centre Standard value: (Vertical and horizontal direction) The center of high intensity zone is on the point of intersection of line (H) and line (V).
Page 995: Headlamp Intensity Measurement
54A-28 CHASSIS ELECTRICAL - Headlamp Assembly HEADLAMP INTENSITY MEASUREMENT 1. Using a photometer, and following its manufacture’s instruction manual. 2. Maintain an engine speed of 2,000 r/min., with the battery in the charging condition 3. Set the headlamps to high beam 4.
Page 996: Headlamp Bulb (High Beam)Replacement
54A-29 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Headlamp Assembly Headlamp Assembly Headlamp Assembly HEADLAMP BULB (HIGH BEAM)REPLACEMENT (1) Disconnect battery. (2) Disconnect connector. (3) Screw out socket to pull out bulb. (4) After bulb is replaced, properly reconnect connector. Caution Do not touch bulb surface bare-handed or with dirty Headlamp bulb...
Page 997: Headlamp Assembly
54A-30 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Headlamp Assembly Headlamp Assembly HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION AY2103AU 1. Headlamp leveling switch 2. Air guide panel 3. Headlamp assembly Headlamp removal steps D Front bumper (Refer to GROUP 51) INSPECTION HEADLAMP LEVELING SWITCH CONTINUITY CHECK Switch Position Resistance between the termi- nal 4 and 5 (Ω)
Page 998: Side Turn-Signal Lamp
54A-31 CHASSIS ELECTRICAL - Side Turn-signal Lamp/Room Lamp SIDE TURN-SIGNAL LAMP SPECIAL TOOL Tools Number Name MB990784 Ornament remover Side turn-signal lamp removal SIDE TURN-SIGNAL LAMP REMOVAL SERVICE POINT MB990784 Use special tool, etc. to press and deflect hook to vehicle Side turn-signal lamp front from fender, and unhook the pawls to remove side turn-signal lamp.
Page 999: Rear Combination Lamp
54A-32 CHASSIS ELECTRICAL Rear Combination Lamp REAR COMBINATION LAMP SPECIAL TOOL Tool Number Name MB990784 Ornament remover Rear combination lamp removal TROUBLESHOOTING For troubleshooting on rear combination lamps, refer to GROUP 54B. REAR COMBINATION LAMP REMOVAL AND INSTALLATION 1. Rear fog lamp switch Removal steps 2.
Page 1000 54A-33 CHASSIS ELECTRICAL Rear Combination Lamp INSPECTION REAR FOG LAMP SWITCH CONTINUITY CHECK Switch position Terminal No. REAR FOG LAMP RELAY CONTINUITY CHECK Battery Voltage Terminal No. De-energized Energized Rear fog lamp relay...

Mitsubishi MOTORS Lancer Evolution-VII 2001 Workshop Manual

16 Manual

Engine

Seal

Timing Belt and Timing Belt B 34

Engine Overhaul

Manifold

Piston and Connecting Rod 56

Engine Lubrication

Engine

Engine and Emission Control

Engine Cooling

Intake and Exhaust

Engine Electrical

Charging System

Starting System

Ignition System

Engine and Emission Control

Clutch

Service Specifications

Lubricants

On-Vehicle Service

Clutch Pedal

Clutch Control

Manual Transmission

On-Vehicle Service

Sensor, Switch and Relay

With Acd or Vehicles with Acd and

Manual Transmission Overhaul

Front Axle

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Mitsubishi MOTORS Lancer Evolution-VII 2001