Mitsubishi MOTORS Space Runner 1998 Workshop Manual

Table of Contents

Quick Links

Download this manual

WORKSHOP MANUAL

FOREWORD

This Workshop Manual contains procedures for

service mechanics, including removal, disassembly,

inspection,

adjustment,

installation.

Use

the

combination with this manual as required.

TECHNICAL INFORMATION MANUAL

WORKSHOP MANUAL

ENGINE GROUP

ELECTRICAL WIRING

BODY REPAIR MANUAL

PARTS CATALOGUE

SPACE RUNNER

SPACE WAGON

All

information,

illustrations

descriptions contained in this manual are current

as at the time of publication. We, however, reserve

the right to make changes at any time without prior

notice or obligation.

"GDI" is the trade mark which Mitsubishi Motors

Corporation holds.

Mitsubishi Motors Corporation

reassembly

and

following

manuals

PYDE9802

PWEEjjjj

(Looseleaf edition)

PHDE9802

PBDE9802

B608V509Aj

B608W509Aj

and

product

Aug. 1998

General . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust

Engine Electrical . . . . . . . . . . . . . . .

Engine and Emission Control . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission . . . . . . . . . . .

Automatic Transmission . . . . . . . .

Propeller Shaft . . . . . . . . . . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . . .

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tyre . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . .

Service Brakes . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . . .

Body . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

Interior and Supplemental

Restraint System (SRS) . . . . . . . . .

Chassis Electrical . . . . . . . . . . . . . .

Heater, Air Conditioner and

Ventilation . . . . . . . . . . . . . . . . . . . . . .

00109000812

. . . . . . . . . . . .

Chapters

Table of Contents

Troubleshooting

Need help?

Do you have a question about the Space Runner 1998 and is the answer not in the manual?

Questions and answers

Joy

March 2, 2025

Can the drivers seat be lifted also petrol gadge not working

1 comments:

Mr. Anderson

May 14, 2025

The context does not provide information about adjusting the driver's seat in a 1998 Mitsubishi Space Runner.

To fix a non-working petrol gauge, follow these steps based on the context:

1. Remove the rear seat, rear seat rail cover, rear scuff plate, center pillar lower trim, and turn over the carpet.
2. Remove the service hole cover.
3. Disconnect the harness connector, fuel hose, and fuel tube.
4. Unscrew the mounting nuts to remove the pipe and gauge assembly and fuel pump module.
5. Install the new pipe and gauge assembly and fuel pump module. Tighten the mounting nuts to the specified torque: 2–3 Nm.
6. Reconnect the fuel hose, fuel tube, and harness connector. Gently pull the tubes to ensure they are firmly connected.
7. Reinstall the service hole cover, turn back the carpet, and reinstall the removed parts.

This process replaces the fuel gauge unit, which may fix the petrol gauge issue.

This answer is automatically generated

Summary of Contents for Mitsubishi MOTORS Space Runner 1998

Page 1: Table Of Contents
Chassis Electrical ....Heater, Air Conditioner and “GDI” is the trade mark which Mitsubishi Motors Ventilation ..... .
Page 2 WARNING! (1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger (from rendering the SRS inoperative).
Page 3: General
00-1 GENERAL CONTENTS 00109000829 Models ........HOW TO USE THIS MANUAL .
Page 4: How To Use This Manual
00-2 GENERAL - How to Use This Manual HOW TO USE THIS MANUAL 00100010302 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 5: 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. 1800: Indicates models equipped with the 1,800 mL <4G93> petrol engine. 2400: Indicates models equipped with the 2,400 mL <6G64> petrol engine. GDI: Indicates the gasoline direct injection.
Page 6: 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 7 00-5 GENERAL - How to Use This Manual Indicates the Indicates the Indicates the Indicates the group title. section title. group num- page number. ber. Denotes non-reus- able part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Parts- tightening-torque Table”.
Page 8: Troubleshooting/Inspection Service Points
00-6 GENERAL - How to Use Troubleshooting/Inspection Service Points HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS 00100020152 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 9: Diagnosis Function
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.00-9 for how to use the inspection procedures.) 6.
Page 10 00-8 GENERAL - How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. 2. To check ABS system, remove the valve relay. NOTE That is because the valve relay is off and the warning MB991529 lamp remains illuminated if there is a fault in the ABS...
Page 11: How To Use The Inspection Procedures
00-9 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 12: Connector Measurement Service Points
00-10 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 13: Connector Inspection
00-11 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 14: Inspection Service Points For A Blown Fuse
00-12 GENERAL - How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition of continuity.
Page 15: Vehicle Identification
00-13 GENERAL - Vehicle Identification VEHICLE IDENTIFICATION 00100540085 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 MODEL...
Page 16 00-14 GENERAL - Vehicle Identification <SPACE WAGON> Model code Engine model Transmission model Fuel supply system N84W LNUCL6/R6 4G64-DOHC-GDI F5M42 (2,351 mL) (2WD-5M/T) LNFCL6 LNUGL6 LNHCL6/R6 LNGCL6 LNHGL6 LRUCL6/R6 F4A42 (2WD-4A/T) LRFCL6 LRUGL6 LRHCL6/R6 LRGCL6 LRHGL6 N94W LNUCL6/R6 W5M42 (4WD-5M/T) LNFCL6 LNHCL6/R6 LNGCL6...
Page 17: Model Code
00-15 GENERAL - Vehicle Identification MODEL CODE 00100040257 Items Contents Development N6: SPACE RUNNER (2WD) N8: SPACE WAGON (2WD) 1 2 3 4 5 6 7 8 9 N9: SPACE WAGON (Full time 4WD) Engine type 1: 1,800 mL petrol engine 4: 2,400 mL petrol engine Body type W: Wagon...
Page 18: Chassis Number
00-16 GENERAL - Vehicle Identification CHASSIS NUMBER 00100560104 The chassis number is stamped on the toeboard inside the engine compartment. Items Contents Fixed figure Asia Distribution channel Japan channel Destination For Europe, right hand drive For Europe, left hand drive Body style 3-door station wagon 4-door station wagon...
Page 19: Engine Model Number
00-17 GENERAL - Vehicle Identification ENGINE MODEL NUMBER 00100570107 <4G93> 1. The engine model number is stamped at the cylinder block as shown in the following. Engine model Engine displacement 4G93 1,834 4G64 2,351 2. The engine serial number is stamped near the engine model number.
Page 20: Major Specifications
00-18 GENERAL - Major Specifications MAJOR SPECIFICATIONS 00100080143 <SPACE RUNNER> Items N61W N61W SNUCL6, SRUCL6, SNUCR6, SRUCR6, SNFCL6, SRFCL6, SNUGL6 SRUGL6 Vehicle Overall length 1 4,290 4,290 dimensions Overall width 2 1,695 1,695 Overall height 3 1,650 1,650 (unladen) 1,680* 1,680* Wheelbase 4 2,550...
Page 21 00-19 GENERAL - Major Specifications <SPACE WAGON> Items N84W N84W N84W N84W N94W N94W LNUCL6, LNHCL6, LRUCL6, LRHCL6, LNUCL6, LNHCL6, LNUCR6, LNHCR6, LRUCR6, LRHCR6, LNUCR6, LNHCR6, LNFCL6, LNGCL6, LRFCL6, LRGCL6, LNFCL6 LNGCL6 LNUGL6 LNHGL6 LRUGL6 LRGHL6 Vehicle Overall length 1 4,600 4,600 4,600 4,600...
Page 22: Precautions Before Service
00-20 GENERAL - Precautions Before Service PRECAUTIONS BEFORE SERVICE 00100050229 SUPPLEMENTAL RESTRAINT SYSTEM (SRS), SEAT BELT WITH PRE-TENSIONER 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 23 00-21 GENERAL - Precautions Before Service SERVICING THE ELECTRICAL SYSTEM Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative ( - ) cable from the battery in order to avoid damage caused by short-circuiting.
Page 24 00-22 GENERAL - Precautions Before Service MUT-II MUT-II Refer to the “MUT-II REFERENCE MANUAL” or “MUT-II sub-assembly OPERATING INSTRUCTIONS” for instructions on handling the MUT-II. ROM pack Connect the MUT-II to the diagnosis connector as shown in the illustration. Caution Connection and disconnection of the MUT-II should always be made with the ignition switch in the OFF position.
Page 25 00-23 GENERAL - Precautions Before Service Other precautions: Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Avoid contaminating clothes, particularly underpants, with oil. Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
Page 26: And Seat Belt With Pre-Tensioner
Supplemental Restraint System (SRS) 00-24 GENERAL - and Seat Belt with Pre-tensioner SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER 00100590073 To improve safety, the SRS and seat belts with operational status of the SRS. The clock spring pre-tensioner are available as optional parts. These is installed in the steering column.
Page 27 Supplemental Restraint System (SRS) 00-25 GENERAL - and Seat Belt with Pre-tensioner SEAT BELT WITH PRE-TENSIONER The seat belts with pre-tensioners are installed on belt slack. This prevents a passenger from moving both center pillars. forwards excessively. After this, the ELR works to The pre-tensioner, which is controlled by the SRS- inhibit the seat belt.
Page 28 Supplemental Restraint System (SRS) 00-26 GENERAL - and Seat Belt with Pre-tensioner 4. After disconnecting the battery cable, wait 60 seconds Insulating tape Battery or more before proceeding with the following work. The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is...
Page 29 Supplemental Restraint System (SRS) 00-27 GENERAL - and Seat Belt with Pre-tensioner 6. Inspection of the SRS-ECU harness connector <vehicles with SRS side air bag> should be carried out by the following procedure. Insert the special tool (narrow probe in the harness set) into connector from harness side (rear side), and connect the tester to this probe.
Page 30: Support Locations For Lifting And Jacking
00-28 GENERAL - Support Locations for Lifting and Jacking SUPPORT LOCATIONS FOR LIFTING AND JACKING 00100070065 Caution Do not support the vehicles at locations other than specified supporting points. If do so, this will cause damage, etc. SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS GARAGE JACK Caution Never support any point other than the specified one, or it will be deformed.
Page 31: Support Positions For A Single-Post Lift Or Double-Post Lift
00-29 GENERAL - Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR A Caution When service procedures require removing rear SINGLE-POST LIFT OR DOUBLE-POST suspension, spare tyre and rear bumper, place LIFT additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.
Page 32: Support Positions And Support Method For An H-Bar Lift
00-30 GENERAL - Support Locations for Lifting and Jacking SUPPORT POSITIONS AND SUPPORT METHOD H-bar lift FOR AN H-BAR LIFT H-bar lift Caution When service procedures require removing rear suspension, fuel tank, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.
Page 33 00-31 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 34: Standard Part/Tightening-Torque Table
00-32 GENERAL - Standard Part/Tightening-Torque Table STANDARD PART/TIGHTENING-TORQUE TABLE 00100110033 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 35: Engine
11A-1 ENGINE CONTENTS 11109000276 ENGINE <4G6> ..........ENGINE <4G9>...
Page 36 11A-2 ENGINE <4G6> CONTENTS Lash Adjuster Check ......GENERAL INFORMATION ....CRANKSHAFT PULLEY .
Page 37 11A-3 ENGINE <4G6> - General Information/Service Specifications GENERAL INFORMATION Items 4G64-GDI Total displacement mL 2,350 Bore ´ Stroke mm 86.5 ´ 100.0 Compression ratio 11.5 Combustion chamber Pentroof + ball-in-piston Camshaft arrangement DOHC Number of valve Intake Exhaust Valve timing Intake Opening BTDC 16_...
Page 38 11A-4 ENGINE <4G6> - Service Specifications/Sealants Items Standard value Limit Power steering Vibration When checked 108 - 132 oil pump and frequency Hz When a used belt is installed 114 - 126 A/C compressor drive belt tension When a new belt is installed 137 - 157 Tension N When checked...
Page 39 11A-5 ENGINE <4G6> - 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 MB991668 Belt tension meter Measuring the drive belt tension (used together with the MUT-II) MB990767 End yoke holder...
Page 40 11A-6 ENGINE <4G6> - Special Tools/On-vehicle Service Tool Number Name MD998382 Crankshaft front oil Installation of crankshaft front oil seal seal installer MD998285 Crankshaft front oil seal guide MD998767 Tension pulley Timing belt tension adjustment socket wrench GENERAL Engine lifter Supporting the engine assembly during SERVICE removal and installation of the transmission...
Page 41 11A-7 ENGINE <4G6> - On-vehicle Service <When using the MUT-II> 10 - 20 mm 1. Connect the special tool (belt tension meter set) to the MUT-II. Water pump 2. Connect the MUT-II to the diagnosis connector. pulley 3. Turn the ignition switch to ON and select “Belt Tension MB991668 Crankshaft (Micro-...
Page 42 11A-8 ENGINE <4G6> - On-vehicle Service ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the alternator pivot bolt. Adjusting bolt 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Standard value: Lock bolt Items...
Page 43 11A-9 ENGINE <4G6> - On-vehicle Service POWER STEERING OIL PUMP AND AIR CONDITIONER <Vehicles without A/C> Oil pump pulley COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100130127 98 N 1. Check if the belt tension is within the standard value using one of the methods below.
Page 44 11A-10 ENGINE <4G6> - On-vehicle Service IGNITION TIMING CHECK Idle speed r/min 1. Before inspection, set the vehicle to the pre-inspection condition. For vehicles with manual transmission, drive the vehicle for 15 minutes or more to warm the engine, and then carry out the checking while the transmission oil temperature is more than 50°C.
Page 45 11A-11 ENGINE <4G6> - On-vehicle Service 9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine.
Page 46 11A-12 ENGINE <4G6> - On-vehicle Service 5. Check the idle speed. Select item No. 22 and take a reading of the idle speed. Standard value: Items Idle speed r/min 600 ± 100 (700 ± 100)* 650 ± 100 (700 ± 100)* NOTE (1) *: Indicates the values when more than 4 minutes have passed since the idling condition was started.
Page 47 11A-13 ENGINE <4G6> - ENGINE <4G6> - On-vehicle Service On-vehicle Service COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition. 2. Remove all of the ignition coils and spark plugs. 3.
Page 48 11A-14 ENGINE <4G6> - On-vehicle Service MANIFOLD VACUUM CHECK 1. Before inspection, set the vehicle to the pre-inspection Vacuum gauge condition. 2. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose. 3.
Page 49 11A-15 ENGINE <4G6> - On-vehicle Service 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters.
Page 50 11A-16 ENGINE <4G6> - On-vehicle Service (4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes.
Page 51 11A-17 ENGINE <4G6> - Crankshaft Pulley CRANKSHAFT PULLEY 11200160303 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11A-6.) Under Cover Installation 25 Nm Removal steps 1. Drive belt (Power steering and 2. Drive belt (Alternator) A/C) 3.
Page 52 11A-18 ENGINE <4G6> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL 11200190418 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Air Intake Hose Assembly Removal Fuel Pump (High Pressure) Installation (Refer to Timing Belt Removal (Refer to P.11A-30.) GROUP 13A.) Engine Coolant Draining Intake Manifold Installation (Refer to GROUP 15.)
Page 53 11A-19 ENGINE <4G6> - Camshaft and Camshaft Oil Seal Lubrication points <Seen from underneath beam camshaft cap> f3mm Sealant: 3M ATD Part No.8660 or equivalent Lip section Sealant: Engine oil MITSUBISHI GENUINE PART MD970389 or equivalent <Seen from above cylinder head> Sealant: 3M ATD Part No.8660 or equivalent...
Page 54 11A-20 ENGINE <4G6> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS AA" CAMSHAFT SPROCKET REMOVAL MB990767 MD998715 or MD998719 INSTALLATION SERVICE POINTS Camshaft sprocket side Screw hole "AA CAMSHAFT INSTALLATION 1. Apply engine oil to journals and cams of the camshafts. 2.
Page 55 11A-21 ENGINE <4G6> - Camshaft and Camshaft Oil Seal "CA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal as shown in the illustration. MD998713 "DA CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque.
Page 56: Oil Pan
11A-22 ENGINE <4G6> - Oil Pan OIL PAN 11200280207 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Oil Level Gauge Removal and Installation Engine Oil Draining and Supplying (Refer to GROUP Front Exhaust Pipe Removal and Installation (Refer 12 - On-vehicle Service.) to GROUP 15.) f 4 ±...
Page 57 11A-23 ENGINE <4G6> - Oil Pan INSTALLATION SERVICE POINT "AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces Oil pan side as shown in the illustration. Drain plug gasket...
Page 58 11A-24 ENGINE <4G6> - Crankshaft Oil Seal CRANKSHAFT OIL SEAL 11200310135 REMOVAL AND INSTALLATION 127 - 137 Nm <M/T> 127 - 137 Nm <A/T> <M/T> <A/T> Crankshaft Crankshaft (Engine oil: (Engine oil: bolt wash- bolt washer er surface) surface) Lip section Lip section Engine oil Sealant: 3M Stud locking 4170 or equivalent...
Page 59 11A-25 ENGINE <4G6> - Crankshaft Oil Seal REMOVAL SERVICE POINTS <M/T> AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Flywheel Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become Bolt out of balance and damaged.
Page 60 11A-26 ENGINE <4G6> - Crankshaft Oil Seal "BA DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER PLATE INSTALLATION 1. Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate. 2. Apply oil to the bearing surface of the flywheel or drive plate bolts.
Page 61: Cylinder Head Gasket
11A-27 ENGINE <4G6> - Cylinder Head Gasket CYLINDER HEAD GASKET 11200400542 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13A Fuel Pressure Regulator (High Pressure) and Fuel - On-vehicle Service.) <Pre-removal only> Pump (High Pressure) Removal and Installation (Refer Engine Coolant Draining and Supplying (Refer to to GROUP 13A.) GROUP 14 - On-vehicle Service.)
Page 62 11A-28 ENGINE <4G6> - Cylinder Head Gasket REMOVAL SERVICE POINT AA" CYLINDER HEAD BOLT REMOVAL Use the special tool to loosen the bolts in two or three steps in the order of the numbers shown in the illustration, and then remove the bolts. If the washer is caught on valve spring and the bolt is not removed, pull up the bolt slightly and remove the bolt while tilting the washer by using a magnet, etc.
Page 63 11A-29 ENGINE <4G6> - Cylinder Head Gasket 4. Tighten the bolts by the following procedure. Step Operation Remarks Tighten to 78 Nm. Carry out in the order shown in the illustration. Fully loosen. Carry out in the reverse order of that shown in the illustration.
Page 64 11A-30 ENGINE <4G6> - Timing Belt and Timing Belt B TIMING BELT AND TIMING BELT B 11200430473 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation Engine Mount Bracket Removal and Installation (Refer Under Cover Removal and Installation to GROUP 32 - Engine Mounting.) Crankshaft Pulley Removal and Installation (Refer to P.11A-17.)
Page 65 11A-31 ENGINE <4G6> - Timing Belt and Timing Belt B REMOVAL SERVICE POINT Timing marks AA" TIMING BELT REMOVAL 1. Turn the crankshaft clockwise (right turn) to align each timing mark and to set the No. 1 cylinder at compression top dead centre.
Page 66 11A-32 ENGINE <4G6> - Timing Belt B and Timing Belt B INSTALLATION SERVICE POINTS Counterbalance shaft sprocket Belt tension side "AA TIMING BELT B/TIMING BELT B TENSIONER INSTALLATION 1. Install timing belt B by the following procedure. Timing marks Timing (1) Ensure that crankshaft sprocket B timing mark and marks the counterbalance shaft sprocket timing mark are...
Page 67 11A-33 ENGINE <4G6> - Timing Belt and Timing Belt B "CA CRANKSHAFT SPROCKET INSTALLATION 1. Apply the minimum amount of engine oil to the seat surface and thread of the crankshaft bolt. 2. Hold the crankshaft sprocket as same as for removal, and then tighten the bolt to the specified torque.
Page 68 11A-34 ENGINE <4G6> - Timing Belt and Timing Belt B "EA TIMING BELT INSTALLATION Timing marks 1. Align the timing marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket. Camshaft sprocket Timing marks Timing Oil pump marks sprocket Crankshaft sprocket 2.
Page 69 11A-35 ENGINE <4G6> - Timing Belt and Timing Belt B (3) Place the timing belt on the intake-side sprocket while Timing marks using two wrenches to align the timing marks. (4) Hold the belt in the position shown in the illustration with another paper clip.
Page 70 11A-36 ENGINE <4G6> - Timing Belt and Timing Belt B 3. Turn the crankshaft two revolutions in the clockwise direction so that the timing marks are aligned. After leaving it for 15 minutes, measure the amount of protrusion of the auto tensioner. Standard value (A): 3.8 - 4.5 mm 4.
Page 71 11A-37 ENGINE <4G6> - Engine Assembly ENGINE ASSEMBLY 11200090015 REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13A Hood Removal and Installation (Refer to GROUP 42.)
Page 72 11A-38 ENGINE <4G6> - Engine Assembly REMOVAL SERVICE POINTS AA" A/C COMPRESSOR REMOVAL Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached. NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 73 11A-39 ENGINE <4G6> - Engine Assembly INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped. "BA ENGINE MOUNT STOPPER INSTALLATION Engine side Clamp the engine mount stopper so that the arrow points Arrow in the direction as shown in the diagram.
Page 74 NOTES...
Page 75 11B-1 ENGINE <4G9> CONTENTS Lash Adjuster Check ......GENERAL INFORMATION ....CRANKSHAFT PULLEY .
Page 76 11B-2 ENGINE <4G9> - General Information/Service Specifications GENERAL INFORMATION Items 4G93 Total displacement mL 1,834 Bore ´ Stroke mm 81.0 ´ 89.0 Compression ratio 12.5 Combustion chamber Pentroof + ball-in-piston Camshaft arrangement DOHC Number of valve Intake Exhaust Valve timing Intake Opening BTDC 15_...
Page 77 11B-3 ENGINE <4G9> - Service Specifications Items Standard value Limit Power steering Vibration When checked 114 - 139 oil pump and frequency Hz When a used belt is installed 121 - 133 A/C compressor drive belt tension When a new belt is installed 145 - 166 Tension N When checked...
Page 78 11B-4 ENGINE <4G9> - Sealants/Special Tools SEALANTS Items Specified sealants Remarks Beam camshaft cap 3M ATD Part No.8660 or equivalent Cylinder head Cam position sensor support MITSUBISHI GENUINE PART Semi-drying sealant MD970389 or equivalent Oil pan Flywheel or drive plate bolt 3M Stud Locking 4170 or equivalent SPECIAL TOOLS Tool...
Page 79 11B-5 ENGINE <4G9> - Special Tools Tool Number Name MD998776 Crankshaft rear oil Press-in of the crankshaft rear oil seal seal installer MB990938 Handle MD998717 Crankshaft front oil Press-in of the crankshaft front oil seal seal installer MD998767 Tension pulley Timing belt tension adjustment socket wrench GENERAL...
Page 80 11B-6 ENGINE <4G9> - On-vehicle Service ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension by the following procedure. <When using the MUT-II> 1. Connect the special tool (belt tension meter kit) to the MB991668 MUT-II.
Page 81 11B-7 ENGINE <4G9> - On-vehicle Service <Belt deflection check> Deflection Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check 98 N Crankshaft that the amount of deflection is within the standard value. pulley Standard value: Vibration frequency Hz...
Page 82 11B-8 ENGINE <4G9> - On-vehicle Service POWER STEERING OIL PUMP AND AIR CONDITIONER <Vehicles without A/C> Oil pump pulley COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100130127 98 N 1. Check if the belt tension is within the standard value using one of the methods below.
Page 83 11B-9 ENGINE <4G9> - On-vehicle Service IGNITION TIMING CHECK Idle speed r/min 1. Before inspection, set the vehicle to the pre-inspection condition. For vehicles with manual transmission, drive the vehicle for 15 minutes or more to warm the engine, and then carry out the checking while the transmission oil temperature is more than 50°C.
Page 84 11B-10 ENGINE <4G9> - On-vehicle Service 10. Check that ignition timing is at the standard value. Standard value: approx. 16_BTDC NOTE (1) The ignition timing will become approximately 6_BTDC after more than 4 minutes have passed since the basic ignition timing set mode was released. (2) The ignition timing may fluctuate within ±7_BTDC.
Page 85 11B-11 ENGINE <4G9> - On-vehicle Service 6. If the idle speed is outside the standard value, inspect the GDI components by referring to GROUP 13B - Troubleshooting. IDLE MIXTURE CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2.
Page 86 11B-12 ENGINE <4G9> - ENGINE <4G9> - On-vehicle Service On-vehicle Service COMPRESSION PRESSURE CHECK Crank angle 1. Before inspection, check that the engine oil, starter and sensor battery are normal. In addition, set the vehicle to the connector pre-inspection condition. 2.
Page 87 11B-13 ENGINE <4G9> - On-vehicle Service MANIFOLD VACUUM CHECK 1. Before inspection, set the vehicle to the pre-inspection Ventilation hose condition. 2. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose. 3.
Page 88 11B-14 ENGINE <4G9> - On-vehicle Service 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters.
Page 89 11B-15 ENGINE <4G9> - On-vehicle Service (4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes.
Page 90 11B-16 ENGINE <4G9> - Crankshaft Pulley CRANKSHAFT PULLEY 11200160303 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11B-6.) Under Cover Installation 177 - 186 Nm (Engine oil) Removal steps 1. Drive belt (Power steering and AA"...
Page 91 11B-17 ENGINE <4G9> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Intake Hose Removal and Installation Pump Camshaft Case Removal and Installation Timing Belt Removal and Installation (Refer to GROUP 13B - Fuel Pump (High Pressure).) (Refer to P.11B-28.) Intake Manifold Removal and Installation (Refer to GROUP 15.)
Page 92 11B-18 ENGINE <4G9> - Camshaft and Camshaft Oil Seal Lubrication points f3mm <Seen from underneath beam camshaft cap> Sealant: 3M ATD Part No.8660 or equivalent Lip section Sealant: Engine oil MITSUBISHI GENUINE PART MD970389 or equivalent <Seen from above cylinder head> Sealant: 3M ATD Part No.8660 or equivalent...
Page 93 11B-19 ENGINE <4G9> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINT MB990767 AA" CAMSHAFT SPROCKET REMOVAL MD998719 INSTALLATION SERVICE POINTS Camshaft sprocket side Screw hole "AA CAMSHAFT INSTALLATION 1. Apply engine oil to journals and cams of the camshafts. 2.
Page 94 11B-20 ENGINE <4G9> - Camshaft and Camshaft Oil Seal "CA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal as shown in the illustration. MD998713 "DA CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque.
Page 95 11B-21 ENGINE <4G9> - Oil Pan OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Engine Oil Draining and Supplying (Refer to GROUP Front Exhaust Pipe Removal and Installation 12 - On-vehicle Service.) (Refer to GROUP 15.) 7 Nm Groove Bolt hole...
Page 96 11B-22 ENGINE <4G9> - Oil Pan REMOVAL SERVICE POINTS AA" LOWER OIL PAN REMOVAL Place a piece of wood against the lower oil pan, and tap the piece of wood with a hammer to remove the lower oil pan. Caution Because the upper oil pan used is made from aluminium, the oil pan remover (MB998727) should not be used.
Page 97 11B-23 ENGINE <4G9> - Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION 93 - 103 Nm <M/T> 93 - 103 Nm <A/T> <A/T> <M/T> Crankshaft Crankshaft (Engine oil: (Engine oil: bolt seat and bolt seat threaded hole) threaded hole) (Bolt thread) (Bolt thread) Sealant: 3M Stud Locking 4170 or equivalent...
Page 98 11B-24 ENGINE <4G9> - Crankshaft Oil Seal REMOVAL SERVICE POINT AA" PLATE <M/T>/ADAPTOR PLATE/FLYWHEEL <M/T>/DRIVE PLATE <A/T> REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts. MD998781 INSTALLATION SERVICE POINTS Crankshaft "AA CRANKSHAFT REAR OIL SEAL INSTALLATION rear oil seal Crankshaft 1.
Page 99 11B-25 ENGINE <4G9> - Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of Fuel Discharge <before removal only> Fuel Pump (High pressure) and Fuel Pressure (Refer to GROUP 13B - On-vehicle Service.) Regulator (High pressure) Removal and Installation Engine Coolant Draining and Supplying (Refer to GROUP 13B.) (Refer to GROUP 14 - On-vehicle Service.)
Page 100 11B-26 ENGINE <4G9> - Cylinder Head Gasket Removal steps 1. Injector harness connector 6. Idler pulley 2. Front exhaust pipe connection 7. Timing belt rear cover 3. Exhaust manifold bracket 8. Engine oil level gauge assembly 4. Power steering oil pump bracket 9.
Page 101 11B-27 ENGINE <4G9> - Cylinder Head Gasket "BA CYLINDER HEAD BOLT INSTALLATION Head bolt Burred side 1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts. (Engine Head bolt oil)
Page 102: Timing Belt
11B-28 ENGINE <4G9> - Timing Belt TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation Crankshaft Pulley Removal and Installation Under Cover Removal and Installation (Refer to P.11B-16.) 49 Nm 20 - 25 Nm 9 Nm 10 - 12 Nm 49 Nm 12 - 15 Nm...
Page 103 11B-29 ENGINE <4G9> - Timing Belt Timing marks REMOVAL SERVICE POINT Timing marks AA" TIMING BELT REMOVAL 1. Turn the crankshaft clockwise to align each timing mark. Caution The crankshaft must always be turned clockwise. 2. Loosen the tensioner pulley center bolt and remove the timing belt.
Page 104 11B-30 ENGINE <4G9> - Timing Belt "BA TIMING BELT INSTALLATION Camshaft sprocket Timing marks Timing marks 1. Align the timing marks of each camshaft sprocket and the crankshaft sprocket. 2. Loosen the tensioner pulley center bolt. 3. Move the crankshaft sprocket half a tooth width in the anti-clockwise direction.
Page 105 11B-31 ENGINE <4G9> - Timing Belt 7. Place the belt onto the idler pulley, water pump sprocket, crankshaft sprocket and tensioner pulley in that order. 8. Remove the two paper clips. Idler pulley Tensioner pulley Water pump sprocket Crankshaft sprocket 9.
Page 106 11B-32 ENGINE <4G9> - Timing Belt NOTE Even if the 2 mm Allen wrench cannot be easily inserted, then it is satisfactory if the amount of protrusion of the auto tensioner rod is within the standard value. Standard value (A): 3.8 - 4.5 mm If it is outside the standard value, repeat the operations in steps 1 to 4.
Page 107 11B-33 ENGINE <4G9> - Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. Pre-removal and Post-installation Operation Prevention of Fuel Discharge <before removal only>...
Page 108 11B-34 ENGINE <4G9> - Engine Assembly 12 Nm 22 Nm 44 Nm 49 Nm 67 Nm 57 Nm 98 - 118 Nm* 14. Crank angle sensor connector 21. Power steering oil pump bracket 15. Injector harness connector stay 16. Heater hose connection AA"...
Page 109 11B-35 ENGINE <4G9> - Engine Assembly REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 110 11B-36 ENGINE <4G9> - Engine Assembly INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped. "BA ENGINE MOUNT BRACKET INSTALLATION MZ203827 1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.
Page 111: Engine Lubrication
12-1 ENGINE LUBRICATION CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Engine Oil Check .
Page 112 12-2 ENGINE LUBRICATION - General Information GENERAL INFORMATION The lubrication method is a fully force-fed, full-flow belt. filtration type. The oil pump for 4G9 engines is Furthermore, the oil level sensor is located in the a trochoid type which is directly mounted to the oil pan, and a system is equipped whereby an crankshaft, and the one for 4G6 engines is a gear indicator gives a warning when the oil level drops.
Page 113 12-3 ENGINE LUBRICATION - Service Specifications/Sealant/Lubricants/Special Tools SERVICE SPECIFICATIONS Item Standard value Limit Oil pressure kPa at idle 29 or more at 3,500 r/min 294 - 686 SEALANT Item Specified sealant Remark Oil pressure switch 3M ATD Part No. 8660 or equivalent LUBRICANTS Items Specifications...
Page 114 12-4 ENGINE LUBRICATION - On-vehicle Service ON-VEHICLE SERVICE ENGINE OIL CHECK 1. Pull out the level gauge slowly and check that the oil level is in the illustrated range. 2. Check that the oil is not excessively dirty, that there is no coolant or gasoline mixed in, and that it has sufficient viscosity.
Page 115 12-5 ENGINE LUBRICATION - On-vehicle Service OIL FILTER REPLACEMENT 1. Start the engine and allow it to warm up until the MB991610 or temperature of the coolant reaches 80_C to 90_C. commercially- 2. Remove the engine oil filler cap. available tool 3.
Page 116 12-6 ENGINE LUBRICATION - On-vehicle Service OIL LEVEL WARNING SYSTEM CHECK <4G6> 1. Check that the proper amount of oil has been filled. 2. When the ignition switch is turned to ON (do not start the engine), check that the oil level warning lamp illuminates.
Page 117 12-7 ENGINE LUBRICATION - On-vehicle Service OIL PRESSURE CHECK <4G6> 1. Check engine oil quantity. 2. Remove the oil pressure switch terminal. Oil pressure switch <4G9> Oil pressure switch 3. Use the special tool (oil pressure switch wrench) to remove MD998054 the oil pressure switch.
Page 118 12-8 ENGINE LUBRICATION - On-vehicle Service 9. Use the special tool to tighten the oil pressure switch MD998054 to the specified torque. Tightening torque: 19 Nm Caution Do not start the engine within one hour after the oil pressure switch has been installed. 10.
Page 119: Fuel
13A-1 FUEL CONTENTS GASOLINE DIRECT INJECTION (GDI) <4G6> ......GASOLINE DIRECT INJECTION (GDI) <4G9> .
Page 120 13A-2 GASOLINE DIRECT INJECTION (GDI) <4G6> CONTENTS Engine Coolant Temperature Sensor Check GENERAL INFORMATION ....Throttle Position Sensor Check ....SERVICE SPECIFICATIONS .
Page 121 13A-3 GDI <4G6> - General Information GENERAL INFORMATION The Gasoline Direct Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control. In the engine-ECU which controls the system addition, the engine-ECU is equipped with based on signals from these sensors, and several...
Page 122 13A-4 GDI <4G6> - General Information SELF-DIAGNOSIS FUNCTION When an abnormality is detected in one code corresponding to the abnormality is of the sensors or actuators related to output. emission control, the engine warning lamp The RAM data inside the engine-ECU that (check engine lamp) illuminates as a is related to the sensors and actuators can warning to the driver.
Page 123 13A-5 GDI <4G6> - General Information Items Specifications Sensors Air flow sensor Karman vortex type Barometric pressure sensor Semiconductor type Intake air temperature sensor Thermistor type Engine coolant temperature sensor Thermistor type Oxygen sensor Zirconia type Accelerator pedal position sensor (1st Variable resistor type and 2nd channels) Accelerator pedal position switch...
Page 124 13A-6 GDI <4G6> - General Information GASOLINE DIRECT INJECTION SYSTEM DIAGRAM Engine- Engine control relay *1 Oxygen sensor Power supply z1 Injector driver (In- Fuel pump relay (front) Ignition switch - IG jector) Injector driver relay *2 Air flow sensor Ignition switch - ST z2 EGR valve (Step- Throttle...
Page 125 13A-7 GDI <4G6> - Service Specifications/Sealant SERVICE SPECIFICATIONS Item Standard value Adjustment voltage of throttle position sensor 0.4 - 0.6 (1st channel) V Adjustment voltage of throttle position sensor 4.2 - 4.8 (2nd channel) V Resistance of throttle position sensor kW 1.7 - 3.8 Adjustment voltages (1) and (2) of accelerator pedal position 0.4 - 1.0...
Page 126 13A-8 GDI <4G6> - Special Tools SPECIAL TOOLS Tool Number Name MB991223 Harness set Fuel gauge simple inspection 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 127 13A-9 GDI <4G6> - Special Tools/Troubleshooting Tool Number Name MB991529 Diagnosis code Reading diagnosis code check harness MD998709 Adaptor hose Measurement of fuel pressure MD998742 Hose adaptor MB991637 Fuel pressure gauge set TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
Page 128 13A-10 GDI <4G6> - Troubleshooting Engine warning lamp inspection items Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor (1st channel) Throttle position sensor (2nd channel) Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Injector...
Page 129 13A-11 GDI <4G6> - Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE If the diagnosis system detects any sensor malfunction, the vehicle can be driven safely by using a default control logic instead of the faulty sensors. Defective part or What to do when a sensor is defective function Air flow sensor (1) Disables lean-mixture combustion.
Page 130 13A-12 GDI <4G6> - Troubleshooting Defective part or What to do when a sensor is defective function Accelerator pedal (1) Disables lean-mixture combustion. position sensor (1st (2) Controls the throttle valve position by using the accelerator pedal position sensor channel) (2nd channel) signal.
Page 131 13A-13 GDI <4G6> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor (front) system 13A-14 Air flow sensor system 13A-15 Intake air temperature sensor system 13A-16 Throttle position sensor (2nd channel) system 13A-17 Engine coolant temperature sensor system 13A-18 Crank angle sensor system 13A-19...
Page 132 13A-14 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Oxygen sensor (front) system Probable cause Range of check D Malfunction of the oxygen sensor (front) D 3 minutes have passed after engine was started. D Improper connector contact, open...
Page 133 13A-15 GDI <4G6> - Troubleshooting Code No.12 Air flow sensor system Probable cause Range of check D Malfunction of the air flow sensor D Engine speed is 500 r/min or more. D Open circuit or short-circuited harness wire of air Set conditions flow sensor circuit D Sensor output frequency is 3.3 Hz or less for 4 seconds.
Page 134 13A-16 GDI <4G6> - Troubleshooting Code No.13 Intake air temperature sensor system Probable cause Range of check D Malfunction of the intake air temperature sensor D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the Set conditions intake air temperature sensor circuit D Sensor resistance is 0.14 kW or less for 4 seconds.
Page 135 13A-17 GDI <4G6> - Troubleshooting Code No.14 Throttle position sensor system (2nd Probable cause channel) The throttle valve controller determines whether a failure is present or not, and sends D Malfunction of throttle position sensor (2nd channel) a signal indicating its result to the engine-ECU. D Open circuit or short-circuited harness wire in throttle Range of check position sensor (2nd channel) or poor connector...
Page 136 13A-18 GDI <4G6> - Troubleshooting Code No.21 Engine coolant temperature sensor system Probable cause Range of check D Malfunction of the engine coolant temperature D After 60 seconds have passed since the engine have started sensor Set conditions D Open circuit or short-circuited harness wire of the D Sensor resistance is 50 W or less for 4 seconds.
Page 137 13A-19 GDI <4G6> - Troubleshooting Code No.22 Crank angle sensor system Probable cause Range of check D Malfunction of the crank angle sensor D Engine: During cranking D Open circuit or short-circuited harness wire of the Set conditions crank angle sensor circuit D Sensor output voltage does not change for 4 seconds (no pulse signal is D Malfunction of the engine-ECU being input).
Page 138 13A-20 GDI <4G6> - Troubleshooting Code No.23 Camshaft position sensor system Probable cause Range of check D Malfunction of the camshaft position sensor D While engine is cranking or running D Open circuit or short-circuited harness wire of the Set conditions camshaft position sensor D Sensor output voltage does not change for 4 seconds (no pulse signal is D Malfunction of the engine-ECU...
Page 139 13A-21 GDI <4G6> - Troubleshooting Code No. 24 Vehicles speed sensor system Probable cause Range of check D Malfunction of the vehicle speed sensor D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed after the engine starts.
Page 140 13A-22 GDI <4G6> - Troubleshooting Code No.25 Barometric pressure sensor system Probable cause Range of check D Malfunction of the barometric pressure sensor D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the D Battery voltage is 8 V or more.
Page 141 13A-23 GDI <4G6> - Troubleshooting Code No.31 Detonation sensor system Probable cause Range of check D Malfunction of the detonation sensor D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the Set conditions detonation sensor D Amount of change in the sensor output voltage (detonation sensor peak...
Page 142 13A-24 GDI <4G6> - Troubleshooting Code No.41 Injector system Probable cause Range of check D Malfunction of the injector D Engine: while cranking, or running D Faulty injector driver relay D Engine speed: 4,000 r/min or less D Faulty injector driver D System voltage: 10 V or more D Open circuit or short-circuited harness wire in the D Fuel shut off, or while forcible activating of injector (actuator test) is in operation.
Page 143 13A-25 GDI <4G6> - Troubleshooting From the previous page Measure at engine-ECU connector Repair Check the following connectors: B-52. B-52, B-54 D Connect the connector. D Voltage between terminal 51 and earth (Ignition switch: ON) Check trouble symptom. OK: 4.0 - 5.2 V D Voltage between terminal 1 and earth Replace the injector driver.
Page 144 13A-26 GDI <4G6> - Troubleshooting Code No.44 Abnormal combustion Probable cause Range of check D Malfunction of the ignition coil D While engine is running during lean fuel combustion D Malfunction of the spark plug Set conditions D Malfunction of the EGR valve D Abnormal engine speed due to mis-firing is detected by the crank angle D Open circuit or short-circuit in ignition primary sensor...
Page 145 13A-27 GDI <4G6> - Troubleshooting Code No.54 Immobilizer system Probable cause Range of Check D Radio interference of encrypted codes D Ignition switch: ON D Incorrect encrypted code Set Conditions D Malfunction of harness or connector D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-ECU D Malfunction of engine-ECU NOTE...
Page 146 13A-28 GDI <4G6> - Troubleshooting Code No.56 Abnormal fuel pressure Probable cause Range of check D Malfunction of the fuel pressure sensor D Ignition switch: ON D Open circuit or short-circuited harness wire of the Set conditions fuel pressure sensor D Sensor output voltage is 4.8 V or more for four seconds.
Page 147 13A-29 GDI <4G6> - Troubleshooting From the previos page Measure at the fuel pressure sensor Measure at the fuel pressure sensor Check the following connector: connector A-77. connector A-77. B-51 D Connect the connector. (Use test D Disconnect the connector, and harness MB991348) measure at the harness side.
Page 148 13A-30 GDI <4G6> - Troubleshooting Code No. 59 Oxygen sensor (rear) system Probable cause Range of Check D Malfunction of the oxygen sensor (rear) D 3 minutes have passed after engine was started. D Improper connector contact, open circuit D Engine coolant temperature is approx. 80_C or more. short-circuited harness wire D Idle position switch: OFF D Malfunction of the engine-ECU...
Page 149 13A-31 GDI <4G6> - GDI <4G6> - Troubleshooting Troubleshooting Code No.61 Communication wire with A/T-ECU system Probable cause Range of check D Short circuit in ECU communication circuit D After 60 seconds have passed since the engine have started D Malfunction of the engine-ECU Set conditions D Malfunction of the A/T-ECU D Torque reduction request signal from A/T-ECU is input continuously for 1.5...
Page 150 13A-32 GDI <4G6> - Troubleshooting Code No.66 Brake vacuum sensor system Probable cause Range of check D Malfunction of the brake vacuum sensor D Ignition switch: ON D Improper connector contact, open circuit or Set conditions short-circuited harness wire of the brake vacuum D Sensor output voltage is 4.8 V or more.
Page 151 13A-33 GDI <4G6> - Troubleshooting Code No.77 Accelerator pedal position sensor (2nd Probable cause channel) system Range of check D Malfunction of the accelerator pedal position sensor D Accelerator pedal position sensor (1st channel) system is normal. (2nd channel) D Communication between the engine-ECU and throttle valve controller is normal. D Open circuit or short-circuited harness wire in the Set conditions accelerator pedal position sensor (2nd channel)
Page 152 13A-34 GDI <4G6> - Troubleshooting Code No.78 Accelerator pedal position sensor (1st Probable cause channel) system Range of check D Malfunction of the accelerator pedal position sensor D Accelerator pedal position sensor (2nd channel) system is normal. (1st channel) D Communication between the engine-ECU and throttle valve controller is normal. D Open circuit or short-circuited harness wire in the Set conditions accelerator pedal position sensor (1st channel) system,...
Page 153 13A-35 GDI <4G6> - Troubleshooting Code No.79 Throttle position sensor (1st channel) system Probable cause The throttle valve controller determines a failure, and sends it result to the engine-ECU. D Malfunction of the throttle position sensor (1st channel) Range of check D Open circuit or short-circuited harness wire in the D Ignition switch: ON throttle position sensor (1st channel), or poor connector...
Page 154 13A-36 GDI <4G6> - Troubleshooting Code No.89 Abnormal fuel pressure system Probable cause Range of check D Malfunction of the fuel pump (high pressure) D Engine: Idling (during stoichio-feedback operation) D Malfunction of the intake air temperature sensor Set conditions D Malfunction of the barometric pressure sensor D Fuel injection correction value remains excessively low for ten seconds or more.
Page 155 13A-37 GDI <4G6> - Troubleshooting Code No.92 Throttle valve position feedback system Probable cause The throttle valve controller determines if a failure is present, and sends its result D Malfunction of the throttle position sensor (1st channel) to the engine-ECU. D Open circuit or short-circuited harness wire in the Range of check throttle position sensor system (1st channel), or poor...
Page 156 13A-38 GDI <4G6> - Troubleshooting Code No.95 Malfunction in throttle valve control servo Probable cause motor system (1st phase) Range of check D Malfunction of the throttle valve control servo D Throttle valve control servo relay: ON D Open circuit or short-circuited harness wire in throttle D System voltage: 8 V or more valve control servo system, or poor connector contact Set conditions...
Page 157 13A-39 GDI <4G6> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13A-41 with MUT-II is impossible. Communication with engine-ECU only is not possible. 13A-42 Engine warning The engine warning lamp does not illuminate right after the 13A-43 lamp and ignition switch is turned to the ON position.
Page 158 13A-40 GDI <4G6> - 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 159 13A-41 GDI <4G6> - Troubleshooting Items Symptom Driving Shock The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated. Surge This is repeated surging ahead during constant speed travel or during variable speed travel. Knocking A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving.
Page 160 13A-42 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU is impossible. Probable cause One of the following causes may be suspected. D Malfunction of engine-ECU power supply circuit D No power supply to engine-ECU. D Malfunction of engine-ECU D Defective earth circuit of engine-ECU.
Page 161 13A-43 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after Probable cause the ignition switch is turned to the ON position. Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Burnt-out bulb to illuminate for five seconds immediately after the ignition switch is turned to ON.
Page 162 13A-44 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (starting impossible) Probable cause This is caused by incorrect fuel supply into the combustion chamber, and improper D Malfunction of the fuel supply system ignition circuit. Besides that, foreign material may be contaminated in fuel. D Malfunction of the ignition system D Malfunction of the engine-ECU Check system voltage while the engine is cranking.
Page 163 13A-45 GDI <4G6> - Troubleshooting From the previous page Check ignition coil spark for each cylinder. Replace the ignition coil. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx.
Page 164 13A-46 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 6 Initial combustion takes place, but does not complete Probable cause (start impossible), too long time to start (poor start) This may be caused by improper spark plug ignition (poor spark), improper mixture D Malfunction of the fuel supply system during engine cranking, improper fuel pressure.
Page 165 13A-47 GDI <4G6> - Troubleshooting From the previous page Replace the ignition coil. Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx.
Page 166 13A-48 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 7 Unstable idling (rough idle, hunting) Probable cause This malfunction is probably caused by a faulty ignition system, improper air/fuel ratio, D Malfunction of the ignition system a faulty electronic-controlled throttle valve system, improper compression pressure, D Malfunction of the air/fuel ratio control system etc.
Page 167 13A-49 GDI <4G6> - Troubleshooting From the previous page Measure fuel high-pressure between the fuel pump (high pressure) MUT-II Data list 11 Oxygen sensor (front) and injector. (Refer to P.13A-99.) OK: 0 - 400 mV and 600 - 1,000 mV alternates when the engine is idling (wait for four minutes after the engine started).
Page 168 13A-50 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 8 Idle speed is high or low (Improper idling) Probable cause The cause is probably that the intake air amount during idling is too great or too D Malfunction of the electronic-controlled throttle valve small.
Page 169 13A-51 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 9 When the engine is cold, it stalls at idling. (Die out) Probable cause The cause is probably an incorrect air/fuel ratio or poor intake air amount when the D Malfunction of the electronic-control throttle valve engine is cold.
Page 170 13A-52 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 10 When the engine is hot, it stalls at idling. (Die out) Probable cause The cause is probably an improper air/fuel ratio, faulty electronic-controlled throttle D Malfunction of the ignition system valve system, compression pressure. In addition, if the engine stalls suddenly, another D Malfunction of air/fuel ratio control system possible cause might be a poor connector contact.
Page 171 13A-53 GDI <4G6> - Troubleshooting From the previous page Check the power steering fluid pressure switch system. (Refer MUT-II Data list to P.13A-71, INSPECTION PROCEDURE 31.) 27 Power steering fluid pressure switch (Refer to P.13A-77.) Check the A/C switch and A/C relay system. (Refer to P.13A-71, MUT-II Data list 28 A/C switch (Refer to P.13A-77.) INSPECTION PROCEDURE 32.)
Page 172 13A-54 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 11 The engine stalls when starting the car. (Pass out) Probable cause The cause is probably poor ignition due to a malfunctioning spark plug (weak spark), D Malfunction of the ignition system or an incorrect air/fuel ratio when the accelerator is depressed. D Malfunction of the EGR valve D Air stuck in the air intake system (Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS...
Page 173 13A-55 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 12 The engine stalls when decelerating. Probable cause The cause is probably an improper air/fuel ratio due to a faulty EGR system, or poor D Malfunction of the electronic-controlled throttle valve intake air volume due to a faulty electronic-controlled throttle valve system. system D Malfunction of the EGR valve Have the battery terminals been disconnected recently?
Page 174 13A-56 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 13 Hesitation, sag, stumble, poor acceleration or surge Probable cause The cause is probably a malfunction of the ignition system, electronic-controlled throttle D Malfunction of the ignition system valve system, compression pressure, etc. D Malfunction of the air/fuel ratio control system D Malfunction of the electronic-controlled throttle valve system...
Page 175 13A-57 GDI <4G6> - Troubleshooting From the previous page Measure high fuel pressure between the fuel pump (high pressure) Repair and injector. (Refer to P.13A-99.) Check ignition coil spark for each cylinder. Replace the ignition coil. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil.
Page 176 13A-58 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 15 The feeling of impact when decelerating Probable cause The cause is probably insufficient intake air due to a faulty electronic-controlled throttle D Malfunction of the electronic-controlled throttle valve valve system. system (Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS MUT-II Self-Diag code Is a diagnosis code displayed? CODES.)
Page 177 13A-59 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 18 Too high CO and HC concentration when idling Probable cause The cause is probably an incorrect air/fuel ratio D Malfunction of air/fuel ratio control system D Deterioration of the catalyst (Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS MUT-II Self-Diag code Is a diagnosis code displayed? CODES.)
Page 178 13A-60 GDI <4G6> - Troubleshooting From the previous page Check the EGR valve system. (Refer to P.13A-69, INSPECTION MUT-II Data list PROCEDURE 29.) 68 EGR valve (Refer to P.13A-79.) Check purge control solenoid valve system. (Refer to P.13A-70, MUT-II Actuator test INSPECTION PROCEDURE 30.) 08 Purge control solenoid valve (Refer to P.13A-81.) Replace the injector.
Page 179 13A-61 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 19 Low alternator output voltage (approx. 12.3 V) Probable cause The cause is probably a malfunction of the alternator or one of the problems D Malfunction of the charging system listed at right. D Open circuit between the alternator G terminal and the engine-ECU D Malfunction of the engine-ECU...
Page 180 13A-62 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 21 Fans (radiator fan, A/C condenser fan) are inoperative. Probable cause The engine-ECU sends a duty signal to the fan controller according to engine coolant D Malfunction of the fan motor relay temperature, vehicle speed, or A/C switch. D Malfunction of the fan motor The fan controller controls radiator fan and condenser fan speeds, based on this D Malfunction of the fan controller...
Page 181 13A-63 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 22 Clutch switch system malfunction Probable cause The clutch pedal switch sends a signal indicating clutch pedal depression to the D Malfunction of the clutch switch engine-ECU. The engine-ECU controls the fuel injection properly according to this D Open circuit or short-circuited harness wire in the clutch signal, thus prevents the fluctuation of the engine speed during shift change.
Page 182 13A-64 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 23 Engine-ECU power supply and earth circuit system Probable cause The cause is probably a malfunction of the engine-ECU or one of the problems D Open circuit or short-circuited harness wire in the listed at right.
Page 183 13A-65 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 24 Engine control relay and ignition switch-IG system Probable cause When the ignition switch ON signal is input to the engine-ECU, the engine-ECU D Malfunction of the ignition switch turns on the engine control relay. D Malfunction of the engine control relay This causes system voltage to be supplied to the engine-ECU and to the D Open circuit or short-circuited harness wire of the...
Page 184 13A-66 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 26 Ignition switch-ST and inhibitor switch system <A/T> Probable cause The ignition switch-ST outputs a HIGH signal to the engine-ECU while the D Malfunction of the ignition switch engine is cranking, and the engine-ECU uses this signal to carry out functions D Malfunction of the inhibitor switch such as fuel injection control during starting.
Page 185 13A-67 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 27 Accelerator pedal position switch system Probable cause The accelerator pedal position switch detects that the accelerator pedal is fully closed, D Maladjustment of the accelerator cable and sends a signal to the engine-ECU. The engine-ECU controls idle speed, based D Maladjustment of the accelerator pedal position switch on this signal.
Page 186 13A-68 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 28 Fuel pump (low pressure) system Probable cause The engine-ECU turns on the fuel pump relay while the engine is cranking or running, D Malfunction of the fuel pump relay and supplies power source to the fuel pump (low pressure). D Malfunction of the fuel pump (low pressure) D Open circuit or short-circuited harness wire in the fuel pump (low pressure) circuit, or poor connector contact...
Page 187 13A-69 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 29 EGR valve (stepper motor) system Probable cause The engine-ECU controls the EGR valve (stepper motor) in order to control the D Malfunction of the EGR valve amount of exhaust gas mixed in the intake air. D Open circuit or short-circuited harness wire in the EGR valve circuit D Malfunction of the engine-ECU...
Page 188 13A-70 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 30 Purge control solenoid valve system Probable cause The engine-ECU controls the purge control solenoid valve in order to control the D Malfunction of the purge control solenoid valve purge air coming from the canister. D Open circuit or short-circuited harness wire in the purge control solenoid valve circuit D Malfunction of the engine-ECU...
Page 189 13A-71 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 31 Power steering fluid pressure switch system Probable cause The power steering fluid pressure switch sends a signal to the engine-ECU according D Malfunction of the power steering fluid pressure switch to power steering load. D Open circuit or short-circuited harness wire in the power Based on this signal, the engine-ECU controls the throttle control servo so that idle steering fluid pressure switch circuit, or poor connector...
Page 190 13A-72 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 33 M/T oil temperature sensor system Probable cause This sensor inputs the manual transmission oil temperature to the engine-ECU. D Malfunction of the M/T oil temperature sensor The engine-ECU uses this input to control the idle speed control servo so that D Open circuit or short-circuited harness wire in the the idle speed is increased when the manual transmission oil temperature M/T oil temperature sensor circuit...
Page 191 13A-73 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 34 Stop lamp switch system Probable cause The engine-ECU determines whether the brake pedal is depressed or not, by means D Malfunction of the stop lamp switch of the stop lamp switch input signal. D Open circuit or short-circuited harness wire in the stop lamp circuit, or poor connector contact D Malfunction of the engine-ECU...
Page 192 13A-74 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 35 Small lamp switch Probable cause The engine-ECU determines whether the small lamp switch is on or off. D Improper connector contact, open circuit or According to that information, the engine-ECU controls short-circuited harness wire in the taillamp circuit alternator output current when the vehicle is started.
Page 193 13A-75 GDI <4G6> - Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE : Within four minutes after starting the engine : In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than the standard time.
Page 194 13A-76 GDI <4G6> - Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page Throttle posi- Engine coolant Release the accel- 4,000 - 4,900 mV Code 13A-17 tion sensor temperature: erator pedal. No.14 (2nd channel) 80 - 95_C Depress the accel- Voltage decreases Ignition switch:...
Page 195 13A-77 GDI <4G6> - Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page Barometric Ignition switch: ON Altitude: 0 m 101 kPa Code 13A-22 pressure sen- No.25 Altitude: 600 m 95 kPa Altitude: 1,200 m 88 kPa Altitude: 1,800 m 81 kPa Accelerator...
Page 196 13A-78 GDI <4G6> - Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page Injector drive Engine coolant Idling 0.4 - 0.6 ms* time * temperature: 80 - 95_C Lamps, electric 2,500 r/min 0.4 - 0.8 ms cooling fan and all accessories: Transmission: Sudden racing...
Page 197 13A-79 GDI <4G6> - Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page EGR valve Engine coolant Idling 0 - 15 STEP Procedure 13A-69 temperature: No.29 80 - 95_C Lamps, electric cooling fan and all accessories: 2,500 r/min 0 - 10 STEP Transmission: Neutral...
Page 198 13A-80 GDI <4G6> - Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page Throttle posi- Engine coolant Release the accel- 450 - 800 mV Code 13A-35 tion sensor (1st temperature: erator pedal. No.79 channel) 80 - 95_C Depress the accel- Increases in re- Ignition switch:...
Page 199 13A-81 GDI <4G6> - Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. 1 Engine: Idling condition Code No. 13A-24 injector After having becomes different warmed up/Engine (becomes unsta- Cut fuel to No.
Page 200 13A-82 GDI <4G6> - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement Terminal Check item Check requirements (engine condition) Normal condition No.1 injector Engine: Warm up, and then depress Decreases slightly for short the accelerator pedal suddenly from time from 9 - 13 V.
Page 201 13A-83 GDI <4G6> - Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition Injector driver relay Ignition switch: OFF 0 - 0.1 V Ignition switch: ON 0.5 - 1.0 V Fan controller Radiator and condenser fans are not 0 - 0.3 V operating.
Page 202 13A-84 GDI <4G6> - Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition Brake vacuum sensor Engine: Stop the engine from idle Voltage increases speed, turn the ignition switch ON, and then depress the brake pedal several times. Clutch switch <M/T> Depress the clutch pedal 0 - 3 V Release the clutch pedal...
Page 203 13A-85 GDI <4G6> - Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition Oxygen sensor (front) Engine: Warm up, and then hold the 0 « 0.8 V alternates. engine speed at 2,500 r/min (Use a digital voltmeter). Sensor power supply Ignition switch: ON 4.5 - 5.5 V Power supply to accelerator...
Page 204 13A-86 GDI <4G6> - Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition Air flow sensor Engine: Idling 2.2 - 3.2 V Engine: 2,500 r/min Inhibitor switch <A/T> Ignition switch: Selector lever: P 0 - 3 V or N range Selector lever: 8 - 14 V Other than P or N...
Page 205 13A-87 GDI <4G6> - Troubleshooting Engine-ECU Harness Side Connector Terminal Arrangement Terminal No. Check item Standard value, normal condition (check require- ments) 5 - 12 Purge control solenoid valve 36 - 44 W (at 20_C) 6 - 12 Oxygen sensor heater control 11 - 18 W (at 20_C) 13 - Body earth Earth...
Page 206 13A-88 GDI <4G6> - Troubleshooting CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS TERMINAL VOLTAGE CHECK CHART Throttle Valve Controller Terminal Arrangement Terminal Check items Requirements Normal value Throttle valve control servo Ignition switch: ON Decreases slightly from (A+) Accelerator pedal: Fully opened ® system voltage.
Page 207 13A-89 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER Analyzer AIR FLOW SENSOR (AFS) Measurement Method Special 1. Disconnect the air flow sensor connector, and connect patterns pickup the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2.
Page 208 13A-90 GDI <4G6> - 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 209 13A-91 GDI <4G6> - Troubleshooting 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 Crank angle sensor output wave pattern 159° 144° 44° 59° Camshaft posi- tion sensor out- put wave pat- tern...
Page 210 13A-92 GDI <4G6> - Troubleshooting INJECTORS AND INJECTOR OPEN CIRCUIT CHECK SIGNAL Measurement Method 1. Connect the analyzer special patterns pickup to terminal 1 (No.1 injector) of the engine-ECU connector. 2. Connect the analyzer special patterns pickup to terminal 51 (injector open circuit check signal) of the engine-ECU Analyzer connector.
Page 211 13A-93 GDI <4G6> - Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Power transistor control signal Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991658) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to terminal Special 3 of each ignition coil connector in turn.
Page 212 13A-94 GDI <4G6> - 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 approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit...
Page 213 13A-95 GDI <4G6> - Troubleshooting EGR VALVE (STEPPER MOTOR) Analyzer Measurement Method 1. Disconnect the EGR valve connector, and connect the special tool (test harness: MB991658) in between. 2. Connect the analyzer special patterns pickup to the EGR valve-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.
Page 214 13A-96 GDI <4G6> - Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the EGR control servo is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern Probable cause...
Page 215 13A-97 GDI <4G6> - On-vehicle Service ON-VEHICLE SERVICE Fixed SAS Caution (1) Never attempt to tamper the fixed SAS. The fixed SAS is precisely adjusted at factory. (2) Should it be tampered, the full closed position of the throttle valve will be changed. This causes the engine-ECU to learn a wrong position of the throttle valve.
Page 216 13A-98 GDI <4G6> - On-vehicle Service 6. Check the output voltage of the throttle position sensor (2nd channel) when the throttle valve is fully closed by your finger. Standard value: 4.2 - 4.8 V 7. If not within the standard value, replace the throttle position sensor.
Page 217 13A-99 GDI <4G6> - On-vehicle Service 4. Loosen the accelerator pedal position sensor (1st channel) mounting bolts, and then rotate it fully anticlockwise. 5. Check that the accelerator pedal position switch is on (there is continuity between terminals). 6. Slowly rotate the accelerator pedal position sensor (1st channel) clockwise, and find the pint where the accelerator pedal position switch is turned off (there will be no continuity).
Page 218 13A-100 GDI <4G6> - On-vehicle Service 3. Remove the union joint and bolt from the special tool (adapter hose) and instead attach the special tool (hose MB991637 adapter) to the adapter hose. Gasket 4. Install the special tool (for measuring the fuel pressure) Fuel that was set up in step 3.
Page 219 13A-101 GDI <4G6> - On-vehicle Service Symptom Probable cause Remedy Fuel pressure too low Clogged fuel filter Replace fuel filter Fuel pressure drops after racing Fuel leaking to return side due to poor Replace fuel pressure regulator fuel pressure regulator (low pressure) (low pressure) valve seating or settled spring Low fuel pump (low pressure)
Page 220 13A-102 GDI <4G6> - On-vehicle Service MEASUREMENT OF FUEL HIGH PRESSURE BETWEEN FUEL PUMP (HIGH PRESSURE) AND INJECTORS Injector intermediate harness NOTE Measurement of the fuel pressure between the fuel pump (high pressure) and the injectors should be carried out after checking that the fuel pressure between the fuel pump (low pressure) and the fuel pump (high pressure) is normal.
Page 221 13A-103 GDI <4G6> - On-vehicle Service FUEL LEAK CHECK 1. Connect the MUT-II to the diagnosis connector. Injector intermediate harness 2. Disconnect the injector intermediate harness connector. 3. Turn the ignition switch to ON. 4. Select “Item No.74” from the MUT-II Data list. 5.
Page 222 13A-104 GDI <4G6> - On-vehicle Service 8. If the engine is started, release fuel pressure by the following procedure: (1) Turn off the ignition switch, and then stop the engine. (2) Disconnect one of the ignition coil connectors. (3) Crank the engine for at least two seconds. (4) If the engine is not be started, use the MUT-II to make sure that the fuel pressure is 0.5 MPa or less.
Page 223 13A-105 GDI <4G6> - On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol A/C relay Fuel pressure sensor A/C switch Fuel pump relay Accelerator pedal position sensor (1st and Ignition coil 2nd channels) Inhibitor switch <A/T> Air flow sensor (with intake air temperature Injectors sensor and barometric pressure sensor) Injector driver...
Page 224 13A-106 GDI <4G6> - On-vehicle Service ENGINE CONTROL RELAY, FUEL PUMP RELAY, INJECTOR DRIVER CONTROL RELAY Equipment side connector AND THROTTLE VALVE CONTROL SERVO RELAY CONTINUITY CHECK Fuel pump relay Battery voltage Terminal No. Engine control relay Injector driver relay Not supplied Supplied Equipment side connector...
Page 225 13A-107 GDI <4G6> - On-vehicle Service 2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 2.1 - 2.7 kW (at 20_C) 0.26 - 0.36 kW (at 80_C) 3. If the resistance deviates from the standard value greatly, replace the sensor.
Page 226 13A-108 GDI <4G6> - On-vehicle Service ACCELERATOR PEDAL POSITION SENSOR Equipment side connector (1ST CHANNEL) CHECK 1. Disconnect the accelerator pedal position sensor (1st channel) connector. 2. Measure resistance between terminal Nos.1 and 4 of the sensor connector. Accelerator pedal position sensor Standard value: 3.5 - 6.5 kW 3.
Page 227 13A-109 GDI <4G6> - On-vehicle Service ACCELERATOR PEDAL POSITION SWITCH Equipment side connector CHECK 1. Disconnect the accelerator pedal position sensor (1st channel) connector. 2. Check continuity between terminal Nos. 3 (accelerator pedal position switch) and 4 (sensor earth) of the Accelerator pedal connector.
Page 228 13A-110 GDI <4G6> - On-vehicle Service 7. While repeatedly racing the engine, measure the oxygen sensor output voltage. Standard value: Engine Oxygen sensor Remarks output voltage When 0.6 - 1.0 V If you make the air/fuel ratio racing the rich by racing the engine engine repeatedly, a normal oxy- gen sensor will output a...
Page 229 13A-111 GDI <4G6> - On-vehicle Service INJECTOR CHECK Injector side connector 1. Disconnect the injector intermediate harness connector. Injector intermediate 2. Measure the resistance between each of the terminals. harness Standard value: 0.9 - 1.1 W (at 20_C) Injector Measurement terminal No.1 cylinder 1 - 2 No.2 cylinder...
Page 230 13A-112 GDI <4G6> - On-vehicle Service PURGE CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 - Emission Control System. EGR VALVE CHECK Refer to GROUP 17 - Emission Control System.
Page 231 13A-113 GDI <4G6> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE REGULATOR (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of fuel discharge <before removal only> Air Cleaner Assembly Removal and Installation (Refer to P.13A-103.) Fuel Leak Check <after installation only>...
Page 232 13A-114 GDI <4G6> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) "CA 3. Fuel feed pipe Fuel pressure regulator (High "CA 5. Low-pressure fuel pipe pressure) removal steps 11. Fuel return hose connection 1. Harness connector and clamp "EA 12.
Page 233 13A-115 GDI <4G6> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) "BA BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION O-ring Install the back-up rings and the O-ring as shown in the Back-up ring A illustration. Caution 1. Install the back-up ring B facing its cutaway surface toward the opposite side of the O-ring as shown in Cutaway the illustration.
Page 234 13A-116 GDI <4G6> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) "EA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure).
Page 235 13A-117 GDI <4G6> - Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of fuel discharge <before removal only> Intake Manifold Removal and Installation (Refer to (Refer to P.13A-103.) GROUP 15.) Engine Cover Removal and Installation Fuel Leak Check <after installation only> (Refer to Air Cleaner Assembly Removal and Installation P.13A-103.) 10 - 13 Nm...
Page 236 13A-118 GDI <4G6> - GDI <4G6> - Injector Injector REMOVAL SERVICE POINTS AA" INJECTOR HARNESS CONNECTOR DISCONNECTION Caution Disconnect the battery ( - ) cable from its terminal before carrying out this operation. AB" DELIVERY PIPE ASSEMBLY/FUEL INJECTOR ASSEMBLY REMOVAL Remove the delivery pipe assembly with the fuel injector assembly still attached.
Page 237 13A-119 GDI <4G6> - GDI <4G6> - Injector Injector 3. If the fuel injector does not turn smoothly, the cause may be that the O-ring is getting caught. Remove the fuel injector, check the O-ring for damage and re-connect the fuel injector to the delivery pipe assembly and then re-check.
Page 238 13A-120 GDI <4G6> - Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) Engine Cover Removal and Installation Air Cleaner Assembly Removal and Installation 10 - 13 Nm Removal steps 1.
Page 239 13A-121 GDI <4G6> - Throttle Body "BA THROTTLE BODY INSTALLATION throttle body replaced, initialize electronic-controlled throttle valve system. Initialization Turn on the ignition switch, and turn off it within one second. Then leave it for at least ten seconds with the ignition switch off.
Page 240 13A-122 GDI <4G6> - Throttle Body DISASSEMBLY AND REASSEMBLY Disassembly steps "AA 1. Throttle position sensor 2. Throttle body REASSEMBLY SERVICE POINTS "AA THROTTLE POSITION SENSOR (1) Position the throttle position sensor on the throttle body along the dotted line as shown in the illustration. (2) Rotate the throttle position sensor anticlockwise as shown in the illustration, and then tighten the screws.
Page 241 13A-123 GDI <4G6> - Injector Driver INJECTOR DRIVER REMOVAL AND INSTALLATION 5 Nm 5 Nm 44 Nm Removal steps AA" 1. Injector driver 2. Bracket...
Page 242 13A-124 GDI <4G6> - Injector Driver/Throttle Valve Controller REMOVAL SERVICE POINT Lock AA" INJECTOR DRIVER REMOVAL Press the injector driver connector in the place shown in the illustration to disconnect the injector driver connector. Caution 1. Disconnect the battery ( - ) cable from its terminal before carrying out this operation.
Page 243 13B-1 GASOLINE DIRECT INJECTION (GDI) <4G9> CONTENTS Intake Air Temperature Sensor Check ..GENERAL INFORMATION ....Engine Coolant Temperature Sensor SERVICE SPECIFICATIONS .
Page 244 13B-2 GDI <4G9> - General Information GENERAL INFORMATION The Gasoline Direct Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control. In the engine-ECU which controls the system addition, the engine-ECU is equipped with based on signals from these sensors, and several...
Page 245 13B-3 GDI <4G9> - General Information OTHER CONTROL FUNCTIONS 1. Fuel Pump Control condenser fan are controlled in response Turns the fuel pump relay ON so that current to the engine coolant temperature and is supplied to the fuel pump while the engine vehicle speed.
Page 246 13B-4 GDI <4G9> - General Information Items Specifications Actuators Engine control relay type Contact switch type Fuel pump relay type Contact switch type Injector driver control relay Contact switch type Injector type and number Electromagnetic type, 4 Injector identification mark DIM 1000G Air by-pass control solenoid valve (ON/OFF) ON/OFF type solenoid valve...
Page 247 13B-5 GDI <4G9> - General Information GASOLINE DIRECT INJECTION SYSTEM DIAGRAM *1 Oxygen sensor Engine-ECU z1 Injector driver (injector) *2 Air flow sensor z2 Idle speed control servo *3 Intake air temperature sensor z3 EGR valve (stepper motor) *4 Throttle position sensor z4 Purge control solenoid valve *5 Camshaft position sensor z5 Air...
Page 248 13B-6 GDI <4G9> - Service Specifications/Sealant SERVICE SPECIFICATIONS Items Specifications Basic idle speed r/min 750 ± 50 Throttle position sensor adjusting voltage mV 535 - 735 Throttle position sensor resistance kW 3.5 - 6.5 Idle speed control servo coil resistance W 28 - 33 (at 20_C) Intake air temperature sensor 20_C...
Page 249 13B-7 GDI <4G9> - Special Tools SPECIAL TOOLS Tool Number Name MB991223 Harness set Fuel gauge simple inspection 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 250 13B-8 GDI <4G9> - Special Tools/Troubleshooting 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 TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
Page 251 13B-9 GDI <4G9> - Troubleshooting Engine warning lamp inspection items Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Injector Abnormal combustion Immobilizer system Abnormal fuel pressure Excessive intake air amount...
Page 252 13B-10 GDI <4G9> - Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item Control contents during malfunction Air flow sensor (1) Lean fuel combustion driving and feedback control driving are prevented.
Page 253 13B-11 GDI <4G9> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor system 13B-12 Air flow sensor system 13B-13 Intake air temperature sensor system 13B-14 Throttle position sensor system 13B-15 Engine coolant temperature sensor system 13B-16 Crank angle sensor system 13B-17...
Page 254 13B-12 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Oxygen sensor system Probable cause Range of check D Malfunction of the oxygen sensor D 3 minutes have passed after engine was started. D Improper connector contact, open circuit D Engine coolant temperature is approx.
Page 255 13B-13 GDI <4G9> - Troubleshooting Code No.12 Air flow sensor system Probable cause Range of check D Malfunction of the air flow sensor D Engine speed is 500 r/min or more. D Open circuit or short-circuited harness wire of air Set conditions flow sensor circuit D Sensor output frequency is 3.3 Hz or less for 4 seconds.
Page 256 13B-14 GDI <4G9> - Troubleshooting Code No.13 Intake air temperature sensor system Probable cause Range of check D Malfunction of the intake air temperature sensor D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the Set conditions intake air temperature sensor circuit D Sensor resistance is 0.14 kW or less for 4 seconds.
Page 257 13B-15 GDI <4G9> - Troubleshooting Code No.14 Throttle position sensor system Probable cause Range of check D Malfunction of the throttle position sensor D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the Set conditions throttle position sensor circuit D Sensor output voltage is 0.2 V or less for 4 seconds.
Page 258 13B-16 GDI <4G9> - Troubleshooting Code No.21 Engine coolant temperature sensor system Probable cause Range of check D Malfunction of the engine coolant temperature D After 60 seconds have passed since the engine have started sensor Set conditions D Open circuit or short-circuited harness wire of the D Sensor resistance is 50 W or less for 4 seconds.
Page 259 13B-17 GDI <4G9> - Troubleshooting Code No.22 Crank angle sensor system Probable cause Range of check D Malfunction of the crank angle sensor D Engine: During cranking D Open circuit or short-circuited harness wire of the Set conditions crank angle sensor circuit D Sensor output voltage does not change for 4 seconds (no pulse signal is D Malfunction of the engine-ECU being input).
Page 260 13B-18 GDI <4G9> - Troubleshooting Code No.23 Camshaft position sensor system Probable cause Range of check D Malfunction of the camshaft position sensor D While engine is cranking or running D Open circuit or short-circuited harness wire of the Set conditions camshaft position sensor D Sensor output voltage does not change for 4 seconds (no pulse signal is D Malfunction of the engine-ECU...
Page 261 13B-19 GDI <4G9> - Troubleshooting Code No. 24 Vehicle speed sensor system Probable cause Range of check D Malfunction of the vehicle speed sensor D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed after the engine starts.
Page 262 13B-20 GDI <4G9> - Troubleshooting Code No.25 Barometric pressure sensor system Probable cause Range of check D Malfunction of the barometric pressure sensor D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the D Battery voltage is 8 V or more.
Page 263 13B-21 GDI <4G9> - Troubleshooting Code No.31 Detonation sensor system Probable cause Range of check D Malfunction of the detonation sensor D After 60 seconds have passed since the engine have started D Open circuit or short-circuited harness wire of the Set conditions detonation sensor D Amount of change in the sensor output voltage (detonation sensor peak...
Page 264 13B-22 GDI <4G9> - Troubleshooting Code No.41 Injector system Probable cause Range of check D Malfunction of the injector D While engine is cranking or running D Malfunction of the injector driver control relay D Engine speed is 4,000 r/min or less. D Malfunction of the injector driver D System voltage is 10 V or more.
Page 265 13B-23 GDI <4G9> - Troubleshooting Code No.44 Abnormal combustion Probable cause Range of check D Malfunction of the ignition coil D While engine is running during lean fuel combustion D Malfunction of the spark plug Set conditions D Open circuit or short-circuit in ignition primary D Abnormal engine speed due to mis-firing is detected by the crank angle circuit sensor...
Page 266 13B-24 GDI <4G9> - Troubleshooting Code No.54 Immobilizer system Probable cause Range of Check D Radio interference of encrypted codes D Ignition switch: ON D Incorrect encrypted code Set Conditions D Malfunction of harness or connector D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-ECU D Malfunction of engine-ECU NOTE...
Page 267 13B-25 GDI <4G9> - Troubleshooting D Replace the high-pressure fuel MUT-II Data list MUT-II Data list regulator (seized regulator). 74 Fuel pressure sensor 74 Fuel pressure sensor D Replace the high-pressure return D Ignition switch: ON D Maintain the engine speed at 2,000 OK: 0 - 8 MPa r/min for at least fifteen seconds.
Page 268 13B-26 GDI <4G9> - GDI <4G9> - Troubleshooting Troubleshooting Code No.58 Excessive intake air amount Probable cause Range of check D Malfunction of the idle speed control servo D While engine is running in lean compression mode D Open circuit or short-circuited harness wire of the D Engine speed is 3,000 r/min or less.
Page 269 13B-27 GDI <4G9> - Troubleshooting Code No.64 Alternator FR terminal system Probable cause Range of check D Open circuit in alternator FR terminal circuit D Engine speed is 50 r/min or more. D Malfunction of the engine-ECU Set conditions D Input voltage from alternator FR terminal is system voltage for 20 seconds. Measure at the alternator connector Measure at the alternator connector Check the following connectors:...
Page 270 13B-28 GDI <4G9> - Troubleshooting Code No.66 Brake vacuum sensor system Probable cause Range of check D Malfunction of the brake vacuum sensor D Ignition switch: ON D Improper connector contact, open circuit or Set conditions short-circuited harness wire of the brake vacuum D Sensor output voltage is 4.8 V or more.
Page 271 13B-29 GDI <4G9> - Troubleshooting Code No.89 Abnormal fuel pressure Probable cause Range of check D Malfunction of the fuel pump (high pressure) D Engine: Idling (during stoichio-feedback operation) D Malfunction of the intake air temperature sensor Set conditions D Malfunction of the barometric pressure sensor D Fuel injection correction value remains excessively low for ten seconds or more.
Page 272 13B-30 GDI <4G9> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13B-32 with MUT-II is impossible. Communication with engine-ECU only is not possible. 13B-33 Engine warning The engine warning lamp does not illuminate right after the 13B-34 lamp and ignition switch is turned to the ON position.
Page 273 13B-31 GDI <4G9> - 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 274 13B-32 GDI <4G9> - Troubleshooting Items Symptom Driving Shock The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated. Surge This is repeated surging ahead during constant speed travel or during variable speed travel. Knocking A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving.
Page 275 13B-33 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU is impossible. Probable cause One of the following causes may be suspected. D Malfunction of engine-ECU power supply circuit D No power supply to engine-ECU. D Malfunction of engine-ECU D Defective earth circuit of engine-ECU.
Page 276 13B-34 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after Probable cause the ignition switch is turned to the ON position. Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Burnt-out bulb to illuminate for five seconds immediately after the ignition switch is turned to ON.
Page 277 13B-35 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (starting impossible) Probable cause The cause is probably a problem with the supply of fuel to the combustion D Malfunction of the fuel supply system chambers or a malfunction of the ignition circuit. Furthermore, there is a slight D Malfunction of the ignition system possibility that the fuel is contaminated.
Page 278: Initial Combustion But No Complete Combustion
13B-36 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (starting impossible) Long time to start (improper starting) The cause is probably poor ignition due to a malfunctioning spark plug (weak D Malfunction of the fuel supply system spark), an incorrect air/fuel ratio when starting or incorrect fuel pressure D Malfunction of the fuel pressure sensor switching.
Page 279 13B-37 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 7 Unstable idling (Rough idling, hunting) Probable cause The cause is probably a malfunction of the ignition system, or incorrect air/fuel D Malfunction of the ignition system ratio, idle speed control, air by-pass control or compression pressure. Because D Malfunction of air/fuel ratio control system the probable range of causes is so wide, checking starts from those items which D Malfunction of the idle speed control system...
Page 280 13B-38 GDI <4G9> - Troubleshooting From previous page Check the ignition switch-ST and inhibitor switch system. <A/T> MUT-II Data list (Refer to P.13B-52, INSPECTION PROCEDURE 25.) 29 Inhibitor switch (Refer to P.13B-64.) Check the M/T oil temperature sensor system. (Refer to P.13B-59, MUT-II Data list INSPECTION PROCEDURE 33.) 48 M/T oil temperature sensor (Refer to P.13B-66.)
Page 281 13B-39 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 8 Idling speed is high, Idling speed is low (Improper idling Probable cause speed) The cause is probably that the intake air amount during idling is too great or too D Malfunction of the idle speed control system small.
Page 282 13B-40 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 9 When the engine is cold, it stalls at idling. (Die out) Probable cause The cause is probably an incorrect air/fuel ratio when the engine is cold, or D Malfunction of the idle speed control system insufficient intake air.
Page 283 13B-41 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 10 When the engine is hot, it stalls at idling. (Die out) Probable cause The cause is probably a malfunction of the ignition system, or incorrect air/fuel D Malfunction of the ignition system ratio, idle speed control, air by-pass control or compression pressure.
Page 284 13B-42 GDI <4G9> - Troubleshooting From previous page Check the power steering fluid pressure switch. (Refer to P.13B-58, MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13B-64.) INSPECTION PROCEDURE 31.) Check the A/C switch. (Refer to P.13B-58, INSPECTION PROCE- MUT-II Data list DURE 32.) 28 A/C switch (Refer to P.13B-64.)
Page 285 13B-43 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 11 The engine stalls when starting the car. (Pass out) Probable cause The cause is probably poor ignition due to a malfunctioning spark plug (weak D Malfunction of the ignition system spark), or an incorrect air/fuel ratio when the accelerator is depressed. D Malfunction of the air by-pass control system D Malfunction of the EGR valve D Air leaking into air intake system...
Page 286 13B-44 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 12 The engine stalls when decelerating Probable cause The cause is probably insufficient intake air due to an idle speed control D Malfunction of the idle speed control system malfunction, or incorrect air/fuel ratio due to an air by-pass control or EGR D Malfunction of the air by-pass control system malfunction.
Page 287 13B-45 GDI <4G9> - Troubleshooting From previous page Check the ignition timing. (Refer to GROUP 11B - On-vehicle Ser- Check that the crank angle sensor and timing belt cover are installed vice) properly. Check the intake air temperature sensor system. (Refer to P.13B-14, MUT-II Data list Code No.13.) 13 Intake air temperature sensor (Refer to P.13B-62.)
Page 288 13B-46 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 14 The feeling of impact when accelerating Probable cause The cause is probably an ignition leak being generated in line with an increase D Malfunction of the ignition system in the spark plug demand voltage during acceleration. Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS MUT-II Self-Diag code Is a diagnosis code displayed?
Page 289 13B-47 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 17 Run-on (Dieseling) Probable cause The cause is probably a leaking injector. D Malfunction of the injector Replace the injector. INSPECTION PROCEDURE 18 Too high CO and HC concentration when idling Probable cause The cause is probably an incorrect air/fuel ratio.
Page 290 13B-48 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 19 Low alternator output voltage (approx. 12.3 V) Probable cause The cause is probably a malfunction of the alternator or one of the problems D Malfunction of the charging system listed at right. D Open circuit between the alternator G terminal and the engine-ECU D Malfunction of the engine-ECU...
Page 291 13B-49 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 21 Fans (radiator fan, A/C condenser fan) are inoperative. Probable cause The engine-ECU sends a duty signal to the fan controller according to engine coolant D Malfunction of the fan motor relay temperature, vehicle speed, or A/C switch. D Malfunction of the fan motor The fan controller controls radiator fan and condenser fan speeds, based on this D Malfunction of the fan controller...
Page 292 13B-50 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 22 Engine-ECU power supply and earth circuit system Probable cause The cause is probably a malfunction of the engine-ECU or one of the problems D Open circuit or short-circuited harness wire in the listed at right.
Page 293 13B-51 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 23 Engine control relay and ignition switch-IG system Probable cause When the ignition switch ON signal is input to the engine-ECU, the engine-ECU D Malfunction of the ignition switch turns on the engine control relay. D Malfunction of the engine control relay This causes system voltage to be supplied to the engine-ECU and to the D Open circuit or short-circuited harness wire of the...
Page 294 13B-52 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 25 Ignition switch-ST and inhibitor switch system <A/T> Probable cause The ignition switch-ST outputs a HIGH signal to the engine-ECU while the D Malfunction of the ignition switch engine is cranking, and the engine-ECU uses this signal to carry out functions D Malfunction of the inhibitor switch such as fuel injection control during starting.
Page 295 13B-53 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 26 Idle speed control servo (ISC) system Probable cause The engine-ECU controls the amount of intake air during idling by opening and D Malfunction of the idle speed control servo closing the servo valve which is located in the air by-pass passage. D Open circuit or short-circuited harness wire in the idle speed control servo circuit D Malfunction of the engine-ECU...
Page 296 13B-54 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 27 Air by-pass control solenoid valve system Probable cause The engine-ECU controls the two ON/OFF and DUTY solenoid valves in order to D Malfunction of the air by-pass control solenoid adjust the by-pass air amount. valves (ON/OFF, DUTY) D Open circuit or short-circuited harness wire in the air by-pass control solenoid valves (ON/OFF,...
Page 297 13B-55 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 28 Fuel pump (low pressure) system Probable cause The engine-ECU turns on the fuel pump relay while the engine is cranking or running, D Malfunction of the fuel pump relay and supplies power source to the fuel pump (low pressure). D Malfunction of the fuel pump (low pressure) D Open circuit or short-circuited harness wire in the fuel pump (low pressure) circuit, or poor connector contact...
Page 298 13B-56 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 29 EGR valve (stepper motor) system Probable cause The engine-ECU controls the EGR valve (stepper motor) in order to control the D Malfunction of the EGR valve amount of exhaust gas mixed in the intake air. D Open circuit or short-circuited harness wire in the EGR valve circuit D Malfunction of the engine-ECU...
Page 299 13B-57 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 30 Purge control solenoid valve system Probable cause The engine-ECU controls the purge control solenoid valve in order to control the D Malfunction of the purge control solenoid valve purge air coming from the canister. D Open circuit or short-circuited harness wire in the purge control solenoid valve circuit D Malfunction of the engine-ECU...
Page 300 13B-58 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 31 Power steering fluid pressure switch system Probable cause This switch inputs the amount of power steering load to the engine-ECU. D Malfunction of the power steering fluid pressure The engine-ECU uses this input to control the idle speed control servo so that switch the idle speed is increased when the power steering is operating.
Page 301 13B-59 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 33 M/T oil temperature sensor system Probable cause This sensor inputs the manual transmission oil temperature to the engine-ECU. D Malfunction of the M/T oil temperature sensor The engine-ECU uses this input to control the idle speed control servo so that D Open circuit or short-circuited harness wire in the the idle speed is increased when the manual transmission oil temperature M/T oil temperature sensor circuit...
Page 302 13B-60 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 34 Stop lamp switch system Probable cause This switch inputs the brake pedal depression amount to the engine-ECU. D Malfunction of the stop lamp switch The engine-ECU uses this input to detect brake operation in order to switch the D Open circuit or short-circuited harness wire in the fuel injection mode.
Page 303 13B-61 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 35 Small lamp switch Probable cause The engine-ECU determines whether the small lamp switch is ON or OFF. D Improper connector contact, open circuit or According to that information, the engine-ECU controls short-circuited harness wire in the taillamp circuit alternator output current when the vehicle is started.
Page 304 13B-62 GDI <4G9> - Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes 10% higher than the standard frequency.
Page 305 13B-63 GDI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Throttle Ignition switch: ON Release the acceler- 535 - 735 mV Code No. 13B-15 position ator pedal. sensor Depress the acceler- Increases in ator pedal gradually. proportion to throttle opening angle...
Page 306 13B-64 GDI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Crank angle Engine: Cranking Compare the engine Accord Code No. 13B-17 sensor Tachometer: speed readings on Connected the tachometer and the MUT-II. Engine: Idling When engine 1,200 - 1,400 Idle position...
Page 307 13B-65 GDI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Air flow sen- Engine: After having Engine is idling Code 13B-13 reset warmed up No.12 3,000 r/min signal Volumetric Engine coolant Engine is idling 15 - 35% efficiency efficiency...
Page 308 13B-66 GDI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Engine coolant A/C switch: OFF 10 - 55 STEP (stepper) temperature: motor 80 - 95_C position * Lamps, electric A/C switch: Increases by cooling fan and all OFF ®...
Page 309 13B-67 GDI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Fuel Engine coolant Engine; Idling 4 - 7 MPa Code No. 13B-24 pressure temperature: sensor 80 - 95_C Lamps, electric cooling fan and all accessories: Transmission: Neutral (A/T: P range)
Page 310 13B-68 GDI <4G9> - Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. 1 Engine: Idling condition Code No. 13B-22 injector After having becomes different warmed up/Engine (becomes unsta- Cut fuel to No.
Page 311 13B-69 GDI <4G9> - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement Terminal Check item Check condition (Engine condition) Normal condition No.1 injector Engine: Warm up the engine, and Decreases slightly for short then depress the accelerator pedal time from 9 - 13 V.
Page 312 13B-70 GDI <4G9> - Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Air flow sensor reset signal Engine: Idling 0 - 0.1 V Engine: 3,000 r/min 6 - 9 V Air flow sensor Engine: Idling 2.2 - 3.2 V Engine: 2,500 r/min Injector driver control relay Ignition switch: OFF...
Page 313 13B-71 GDI <4G9> - Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Engine control relay Ignition switch: OFF 0 - 3 V Ignition switch: ON System voltage Brake vacuum sensor When the engine is running at idle, Voltage increases stop the engine, and then turn the ignition switch to ON and depress the brake pedal several times.
Page 314 13B-72 GDI <4G9> - Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Intake air temperature Ignition switch: Intake air temper- 3.2 - 3.8 V sensor ature: 0_C Intake air temper- 2.3 - 2.9 V ature: 20_C Intake air temper- 1.5 - 2.0 V ature: 40_C Intake air temper-...
Page 315 13B-73 GDI <4G9> - Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Camshaft position sensor Engine: Cranking 0.4 - 3.0 V Engine: Idling 0.5 - 2.0 V Crank angle sensor Engine: Cranking 0.4 - 4.0 V Engine: Idling 1.5 - 2.5 V Inhibitor switch Ignition switch:...
Page 316 13B-74 GDI <4G9> - Troubleshooting Engine-ECU Harness Side Connector Terminal Arrangement Terminal No. Check item Standard value, normal value (Check condition) 3 - 12 Air by-pass control solenoid valve 8 - 11 W (At 20_C) (ON/OFF) 16 - 12 Air by-pass control solenoid valve (DUTY) 8 - 11 W (At 20_C) 4 - 12 Idle speed control servo (A)
Page 317 13B-75 GDI <4G9> - Troubleshooting Terminal No. Check item Standard value, normal value (Check condition) 83 - 92 Engine coolant temperature sensor 5.1 - 6.5 kW (When coolant temperature is 0_C) 2.1 - 2.7 kW (When coolant temperature is 20_C) 0.9 - 1.3 kW (When coolant temperature is 40_C) 0.26 - 0.36 kW...
Page 318 13B-76 GDI <4G9> - Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER Analyzer AIR FLOW SENSOR (AFS) Measurement Method Special 1. Disconnect the air flow sensor connector, and connect patterns pickup the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2.
Page 319 13B-77 GDI <4G9> - 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 320 13B-78 GDI <4G9> - Troubleshooting 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 Crank angle sensor output wave pattern 131° 49° 56° 34° Camshaft posi- tion sensor out- put wave pat- tern...
Page 321 13B-79 GDI <4G9> - Troubleshooting INJECTORS AND INJECTOR OPEN CIRCUIT CHECK SIGNAL Measurement Method 1. Connect the analyzer special patterns pickup to terminal 1 (No.1 injector) of the engine-ECU connector. 2. Connect the analyzer special patterns pickup to terminal 51 (injector open circuit check signal) of the engine-ECU Analyzer connector.
Page 322 13B-80 GDI <4G9> - Troubleshooting IDLE SPEED CONTROL (ISC) SERVO Analyzer (STEPPER MOTOR) Measurement Method 1. Disconnect the ISC servo connector and connect the Special special tool (test harness: MB991709) in between. patterns 2. Connect the analyzer special patterns pickup to the ISC pickup servo-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.
Page 323 13B-81 GDI <4G9> - Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the ISC servo is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small.
Page 324 13B-82 GDI <4G9> - Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Power transistor control signal Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991658) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to terminal Special 3 of each ignition coil connector in turn.
Page 325 13B-83 GDI <4G9> - 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 approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit...
Page 326 13B-84 GDI <4G9> - Troubleshooting EGR VALVE (STEPPER MOTOR) Analyzer Measurement Method 1. Disconnect the EGR valve connector, and connect the special tool (test harness: MB991658) in between. 2. Connect the analyzer special patterns pickup to the EGR valve-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.
Page 327 13B-85 GDI <4G9> - Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the EGR valve 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 328 13B-86 GDI <4G9> - On-vehicle Service ON-VEHICLE SERVICE THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Start the engine and warm it up until the coolant is heated to 80_C or higher and then stop the engine. 2. Remove the air intake hose from the throttle body. 3.
Page 329 13B-87 GDI <4G9> - On-vehicle Service 2. Turn the ignition switch to ON (but do not start the engine). 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value, loosen the throttle position sensor mounting bolts, and then rotate the sensor body to adjust the output voltage.
Page 330 13B-88 GDI <4G9> - On-vehicle Service 4. Select the item No.30 of the MUT-II Actuator test. NOTE This holds the idle speed control servo at the basic step to adjust the basic idle speed. 5. Check the basic idle speed. Standard value: 750 ±...
Page 331 13B-89 GDI <4G9> - On-vehicle Service FUEL PRESSURE TEST Fuel pump (high pressure) MEASUREMENT OF FUEL LOW PRESSURE BETWEEN FUEL PUMP (LOW PRESSURE) AND FUEL PUMP (HIGH PRESSURE) High-pressure 1. Release residual pressure from the fuel pipe line to prevent fuel hose fuel gush out.
Page 332 13B-90 GDI <4G9> - On-vehicle Service 5. Connect the MUT-II to the diagnosis connector. 6. Turn the ignition switch to ON. (But do not start the engine.) 7. Select “Item No.07” from the MUT-II Actuator test to drive the fuel pump (low pressure) at the fuel tank side. Check that there are no fuel leaks from any parts.
Page 333 13B-91 GDI <4G9> - On-vehicle Service 16. Replace the O-ring at the end of the high-pressure fuel hose with a new one. Furthermore, apply engine oil to the new O-ring before replacement. 17. Fit the high-pressure fuel hose to the fuel pump (high pressure) and tighten the mounting bolt to specified torque.
Page 334 13B-92 GDI <4G9> - On-vehicle Service 11. Measure fuel pressure while the engine is running at idle. Standard value: 4 - 7 MPa 12. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times. 13.
Page 335 13B-93 GDI <4G9> - On-vehicle Service Caution If the fuel pressure is less than 1 MPa, there may be a partial fuel leak in the high-pressure fuel system. Check this system. 7. Turn the ignition switch to OFF. 8. Reconnect the injector intermediate connector. 9.
Page 336 13B-94 GDI <4G9> - On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol A/C relay Engine warning lamp (check engine lamp) A/C switch Fuel pressure sensor Air by-pass control solenoid valve (DUTY) Idle speed control (ISC) servo Air by-pass control solenoid valve (ON/OFF) Ignition coil Air flow sensor (with intake air temperature Inhibitor switch <A/T>...
Page 337 13B-95 GDI <4G9> - On-vehicle Service ENGINE CONTROL RELAY, FUEL PUMP Fuel pump relay RELAY AND INJECTOR DRIVER CONTROL RELAY CONTINUITY CHECK Equipment side connector Battery voltage Terminal No. Not supplied Supplied Engine control relay Injector driver control relay Equipment side connector Equipment side connector INTAKE AIR TEMPERATURE SENSOR CHECK...
Page 338 13B-96 GDI <4G9> - On-vehicle Service 2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 2.1 - 2.7 kW (at 20_C) 0.26 - 0.36 kW (at 80_C) 3. If the resistance deviates from the standard value greatly, replace the sensor.
Page 339 13B-97 GDI <4G9> - On-vehicle Service OXYGEN SENSOR CHECK Oxygen sensor 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. Equipment side 2. Make sure that there is continuity (11 - 18 W at 20_C) connector between terminal 2 (red clip) and terminal 4 (blue clip) on the oxygen sensor connector.
Page 340 13B-98 GDI <4G9> - On-vehicle Service INJECTOR CHECK 1. Disconnect the injector intermediate harness connector. Injector intermediate harness 2. Measure the resistance between each of the terminals. Standard value: 0.9 - 1.1 W (at 20_C) Injector side Injector Measurement terminal connector No.1 cylinder 1 - 2...
Page 341 13B-99 GDI <4G9> - On-vehicle Service IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) CHECK Checking the Operation Sound 1. Check that the engine coolant temperature is 20_C or below. Idle speed NOTE control Disconnecting the engine coolant temperature sensor Throttle servo connector and connecting the harness-side of the body...
Page 342 13B-100 GDI <4G9> - On-vehicle Service Operation Check 1. Remove the throttle body. 2. Remove the stepper motor. 3. Connect the special tool (test harness: MB991709) to the idle speed control servo connector. 4. Connect the positive (+) terminal of a power supply (approx.
Page 343 13B-101 GDI <4G9> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE REGULATOR (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of fuel discharge <before removal only> Air Cleaner Assembly Removal and Installation (Refer to P.13B-93.) Fuel Leak Check <after installation only>...
Page 344 13B-102 GDI <4G9> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) 2. Fuel pipe clamp Fuel pressure regulator (High "CA 3. Fuel feed pipe pressure) removal steps "CA 5. Low-pressure fuel pipe 1. Harness connector and clamp 12.
Page 345 13B-103 GDI <4G9> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) INSTALLATION SERVICE POINTS "AA PUMP CAMSHAFT CASE ASSEMBLY INSTALLATION 1. Set the No.1 cylinder to the compression top dead centre position. O-ring 2. Align the mating mark on the housing of the pump camshaft case assembly with the mating mark on the coupling, and then install the pump camshaft case Mating marks...
Page 346 13B-104 GDI <4G9> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) "DA FUEL PUMP (HIGH PRESSURE) INSTALLATION Use a torque wrench with a precision of 0.5 Nm to tighten the fuel pump mounting bolts according to the following procedure.
Page 347 13B-105 GDI <4G9> - Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) "GA FUEL PRESSURE SENSOR/FLANGE INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pressure regulator (high pressure) assembly.
Page 348 13B-106 GDI <4G9> - Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of fuel discharge <before removal only> Intake Manifold Removal and Installation (Refer to (Refer to P.13B-93.) GROUP 15.) Engine Cover Removal and Installation Fuel Leak Check <after installation only> (Refer to Air Cleaner Assembly Removal and Installation P.13B-92.) 10 - 13 Nm...
Page 349 13B-107 GDI <4G9> - GDI <4G9> - Injector Injector REMOVAL SERVICE POINTS AA" INJECTOR HARNESS CONNECTOR DISCONNECTION Caution Disconnect the battery ( - ) cable from its terminal before carrying out this operation. AB" DELIVERY PIPE ASSEMBLY/FUEL INJECTOR ASSEMBLY REMOVAL Remove the delivery pipe assembly with the fuel injector assembly still attached.
Page 350 13B-108 GDI <4G9> - GDI <4G9> - Injector Injector 3. If the fuel injector does not turn smoothly, the cause may be that the O-ring is getting caught. Remove the fuel injector, check the O-ring for damage and re-connect the fuel injector to the delivery pipe assembly and then re-check.
Page 351 13B-109 GDI <4G9> - Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to Engine Cover Removal and Installation GROUP 14 - On-vehicle Service.) Air Cleaner Assembly Removal and Installation Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.) 19 Nm Removal steps...
Page 352 13B-110 GDI <4G9> - Throttle Body DISASSEMBLY AND REASSEMBLY Disassembly steps "AA 1. Throttle position sensor NOTE 2. Idle speed control servo The speed adjusting screw is correctly adjusted at the 3. O-ring factory and should not be removed. 4. Throttle body If the speed adjusting screw has been removed, carry 5.
Page 353 13B-111 GDI <4G9> - Throttle Body/Injector Driver CLEANING THROTTLE BODY PARTS 1. Clean all throttle body parts. Do not use solvent to clean the following parts: Throttle position sensor Accelerator pedal position sensor Idle speed control body assembly If these parts are immersed in solvent, their insulation will deteriorate.
Page 354 NOTES...
Page 355: Fuel Supply
13C-1 FUEL SUPPLY CONTENTS 13509000197 GENERAL INFORMATION ....FUEL TANK .......
Page 356 13C-2 FUEL SUPPLY - General Information GENERAL INFORMATION 13500010120 The steel fuel tank is located under the floor A plastic snap-fitting hose (high-pressure fuel of the rear seats to provide increased safety hose) has been adopted between the fuel pump increase amount luggage...
Page 357 13C-3 FUEL SUPPLY - Fuel Tank FUEL TANK 13500190244 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Fuel Draining Fuel Supplying. Reduce the Inner Pressure of Fuel Line and Hose Checking for Fuel Leaks (Refer to GROUP 13A - On-vehicle Service.) Propeller Shaft Installation <4WD>...
Page 358 13C-4 FUEL SUPPLY - Fuel tank INSTALLATION SERVICE POINT "AA PRESSURE TUBE/SUCTION TUBE spot=IA CONNECTION Caution After the connection, pull the pressure tube and suction tube gently in the direction of removal to check that they are firmly connected. INSPECTION 13500300104 VALVE CHECK If the sound of the float valve moving (knocking sound) can...
Page 359: Engine Cooling
14-1 ENGINE COOLING CONTENTS 14109000208 Engine Coolant Replacement ....GENERAL INFORMATION ....Concentration Measurement .
Page 360 14-2 ENGINE COOLING - General Information/Service Specifications/Lubricant/Sealants GENERAL INFORMATION 14100010217 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 timing belt or drive belt from the whatever condition the engine may be operated.
Page 361 14-3 ENGINE COOLING - Special Tool/Troubleshooting SPECIAL TOOL 14100060038 Tool Number Name MB991223 Harness set Measurement of terminal voltage A: MB991219 A: Test harness A: Connector pin contact pressure inspection B: MB991220 B: LED harness B: Power circuit inspection C: MB991221 C: LED harness C: Power circuit inspection...
Page 362 14-4 ENGINE COOLING - Troubleshooting <Vehicles with A/C> D Fusible link (7) check Replace D Fan control relay check (Refer to P.14-11.) (1) NG Check the harness wire between fan control relay and fusible link Measure at the fan control relay connector A-20X. (7), and repair if necessary.
Page 363 14-5 ENGINE COOLING - Troubleshooting <Vehicles without A/C> D Fusible link (7) check Replace D Fan control relay check (Refer to P.14-11.) (1) NG Check the harness wire between fan control relay and fusible link Measure at the fan control relay connector A-20X. (7), and repair if necessary.
Page 364 14-6 ENGINE COOLING - Troubleshooting Inspection Procedure 2 Radiator fan and condenser fan do not change speed or Probable cause stop. <Vehicles with A/C> Radiator fan does not change speed or stop. <Vehicles without A/C> The fan controller carries out step-free control of the radiator fan motor and the condenser D Malfunction of fan control relay fan motor speeds using signals transmitted from the engine-ECU.
Page 365 14-7 ENGINE COOLING - Troubleshooting <Vehicles without A/C> Fan control relay check (Refer to P.14-11.) Replace D Check the harness wire between fan control relay and engine Repair control relay. D Check the harness wire between fan control relay and body earth.
Page 366 14-8 ENGINE COOLING - On-vehicle Service ON-VEHICLE SERVICE 14100100136 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 367 14-9 ENGINE COOLING - ENGINE COOLING - On-vehicle Service On-vehicle Service ENGINE COOLANT REPLACEMENT <4G6> 14100120231 1. Drain the engine coolant by removing the drain plug and then the radiator cap. 2. Remove the drain plug from the cylinder block to drain the engine coolant.
Page 368 14-10 ENGINE COOLING - On-vehicle Service 10. Start the engine and warm the engine until the thermostat opens. (Touch the radiator hose with your hand to check that warm water is flowing.) 11. After the thermostat opens, race the engine several times, and then stop the engine.
Page 369 14-11 ENGINE COOLING - On-vehicle Service FAN CONTROL RELAY CONTINUITY CHECK 14100620014 Battery voltage Terminal No. When current is not supplied Fan control relay When current is supplied...
Page 370 14-12 ENGINE COOLING - Thermostat THERMOSTAT 14100240265 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-9.) Air Intake Duct Removal and Installation <4G6> 13 Nm <4G9> 13 Nm Removal steps AA" "BA 1. Radiator lower hose connection "AA 3.
Page 371 14-13 ENGINE COOLING - Thermostat REMOVAL SERVICE POINT AA" RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. INSTALLATION SERVICE POINTS Jiggle valve "AA THERMOSTAT INSTALLATION Install the thermostat so that the jiggle valve is facing straight Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat.
Page 372 14-14 ENGINE COOLING - Water Pump <4G6> WATER PUMP <4G6> 14100270363 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-9.) Engine Cover Removal Timing Belt Removal and Installation (Refer to GROUP 11A.) Bolt specifications 8 ´...
Page 373 14-15 ENGINE COOLING - Water Pump <4G9> WATER PUMP <4G9> 14100270370 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Idler Pulley Removal and Installation (Refer to P.14-9.) (Refer to GROUP 11B - Timing Belt.) Timing Belt Removal and Installation (Refer to GROUP 11B.) 10 - 12 Nm Sealant:...
Page 374 14-16 ENGINE COOLING - Water Hose and Water Pipe WATER HOSE AND WATER PIPE 14100330306 REMOVAL AND INSTALLATION <4G6> Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Engine Cover Removal and Installation (Refer to P.14-9.) Air Cleaner Assembly Removal and Installation 13 Nm 24 Nm 13 Nm...
Page 375 14-17 ENGINE COOLING - Water Hose and Water Pipe <4G9> Pre-removal and Post-installation Operation Engine Coolant Draining and Suppling (Refer to P.14-9.) Engine Cover Removal and Installation Air Cleaner Assembly and Air Intake Hose Removal and Installation 22 - 25 Nm 14 Nm 14 Nm Sealant:...
Page 376 14-18 ENGINE COOLING - Water Hose and Water Pipe REMOVAL SERVICE POINT AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. INSTALLATION SERVICE POINTS Thermostat case assembly, water pump or cylinder block "AA O-RING INSTALLATION Insert the O-ring to the water inlet pipe assembly or the heater...
Page 377 14-19 ENGINE COOLING - Radiator RADIATOR 14100150285 REMOVAL AND INSTALLATION Pre-removal operation Post-installation Operation Engine Coolant Draining (Refer to P.14-9.) Air Intake Duct Assembly Installation Air Intake Duct Assembly Removal Engine Coolant Supplying (Refer to P.14-9.) Battery and Battery Cover Removal A/T Fluid Supplying and Checking (Refer to GROUP 23 - On-vehicle Service.) Battery and Battery Cover Installation...
Page 378 14-20 ENGINE COOLING - Radiator REMOVAL SERVICE POINTS AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. AB" TRANSMISSION FLUID COOLER HOSE AND PIPE ASSEMBLY REMOVAL After disconnecting the hoses from the radiator and the transmission, plug all of the pipes and hoses to prevent dirt and other foreign objects from getting inside.
Page 379: Intake And Exhaust
15-1 INTAKE AND EXHAUST CONTENTS 15109000250 GENERAL INFORMATION ....INTAKE MANIFOLD ......SERVICE SPECIFICATION .
Page 380 15-2 INTAKE AND EXHAUST - General Information/Service Specification/Special Tool GENERAL INFORMATION 15100010061 The intake manifold is made of an aluminium alloy, The exhaust manifold is made of stainless steel. and the shape provides an increased intake inertia The exhaust pipe is divided into three parts; the effect and has a good volumetric efficiency.
Page 381: Intake Manifold
15-3 INTAKE AND EXHAUST - Intake Manifold INTAKE MANIFOLD 15100300441 REMOVAL AND INSTALLATION <4G6> Pre-removal and Post - installation Operation Engine Coolant Draining and Supplying Ignition Coil Removal and Installation (Refer to GROUP 14 - On-vehicle Service.) (Refer to GROUP 16.) Engine Cover Removal and Installation Throttle Body Removal and Installation Air Cleaner Assembly Removal and Installation...
Page 382 15-4 INTAKE AND EXHAUST - Intake Manifold <4G9> Pre-removal and Post - installation Operation Engine Coolant Draining and Supplying Air Cleaner Assembly Removal and Installation (Refer to GROUP 14 - On-vehicle Service.) Throttle Body Removal and Installation Engine Cover Removal and Installation (Refer to GROUP 13B.) Ignition Coil Removal and Installation (Refer to GROUP 16.)
Page 383 15-5 INTAKE AND EXHAUST - Intake Manifold Intake manifold removal steps 1. Brake booster vacuum pipe 16. Air intake plenum resonator assembly 2. Brake booster vacuum hose 17. Harness connector clamp 3. Harness connector 18. Intake manifold stay 4. Vacuum hose EGR valve removal steps 5.
Page 384 15-6 INTAKE AND EXHAUST - Exhaust Manifold EXHAUST MANIFOLD 15100330440 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation <4G6> 49 Nm 12 - 15 Nm 29 Nm 49 Nm 34 Nm 44 Nm 18 Nm <4G9> 29 Nm 13 Nm 29 Nm...
Page 385 15-7 INTAKE AND EXHAUST - Exhaust Manifold INSPECTION 15100340061 EXHAUST MANIFOLD CHECK 1. Check for damage or cracking of any part. 2. Using a straight edge and thickness gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm...
Page 386: Exhaust Pipe And Main Muffler
15-8 INTAKE AND EXHAUST - INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler Exhaust Pipe and Main Muffler EXHAUST PIPE AND MAIN MUFFLER 15100540355 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Hanger installation bolt tightening torque 5, 8, 13 13 Nm 13 Nm...
Page 387: Engine Electrical
16-1 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM ....IGNITION SYSTEM ....GENERAL INFORMATION .
Page 388: 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. Voltage OPERATION Rotation of the excited field coil generates AC voltage in the stator.
Page 389 16-3 ENGINE ELECTRICAL - Charging System <4G6> Stator coil Engine-ECU Field coil Voltage Ignition regulator switch Battery Charging warning lamp ALTERNATOR SPECIFICATIONS Items Type Battery voltage sensing Battery voltage sensing Rated output V/A 12/85 <Except cold climate zone> 12/100 12/100 <Cold climate zone> Voltage regulator Electronic built-in type Electronic built-in type...
Page 390 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 output wire. (Connect the (+) lead of the alternator “B” terminal to the battery (+) terminal ammeter to the “B”...
Page 391 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 8. Leave the hood open. in the alternator output wire, so check the wiring 9.
Page 392 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.
Page 393 16-7 ENGINE ELECTRICAL - ENGINE ELECTRICAL - Charging System Charging System REGULATED VOLTAGE TEST Load Charging warning Ignition lamp switch MB991519 Alternator Alternator relay Yellow Engine- Ammeter Voltmeter Battery This test determines whether the voltage regulator 6. Connect a DC test ammeter with a range of is correctly controlling the alternator output voltage.
Page 394 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.
Page 395 16-9 ENGINE ELECTRICAL - Charging System WAVEFORM CHECK USING AN ANALYZER Special Analyzer patterns Alternator MEASUREMENT METHOD pickup Connect the analyzer special patterns pick-up to the alternator B terminal. B terminal STANDARD WAVEFORM Observation Conditions FUNCTION SPECIAL PATTERNS PATTERN HEIGHT VARIABLE VARIABLE knob Adjust while viewing the waveform.
Page 396 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 397 16-11 ENGINE ELECTRICAL - Charging System ALTERNATOR 16100140286 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover and Side Cover (R.H. side) Removal Drive Belt Tension Adjustment (Refer to GROUP 11 - On-vehicle Service.) Under Cover and Side Cover (R.H. side) Installation <4G6>...
Page 398 16-12 ENGINE ELECTRICAL - Charging System DISASSEMBLY AND REASSEMBLY Disassembly steps AA" 1. Front bracket assembly AC" 8. Startor AB" 2. Alternator pulley 9. Plate AB" 3. Rotor AC" "AA 10. Regulator assembly 4. Rear bearing 11. Brush 5. Bearing retainer 12.
Page 399 16-13 ENGINE ELECTRICAL - Charging System DISASSEMBLY SERVICE POINTS AA" FRONT BRACKET ASSEMBLY REMOVAL Insert 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 the screwdriver too far, or the stator coil gets damaged.
Page 400 16-14 ENGINE ELECTRICAL - Charging System REASSEMBLY SERVICE POINTS "AA REGULATOR ASSEMBLY INSTALLATION Wire After installing the regulator assembly, insert a wire into the hole provided on the rear bracket while pressing in the brush to fix the brush. NOTE The brush is fixed when a wire is inserted, making rotor installation easier.
Page 401 16-15 ENGINE ELECTRICAL - Charging System STATOR CHECK 1. Check the continuity between the coil leads, and if there is continuity, replace the stator. 2. Check the continuity between the coil and core, and if there is continuity, replace the stator. RECTIFIER CHECK 1.
Page 402 16-16 ENGINE ELECTRICAL - Charging System BRUSH CHECK 1. Measure the length of the brush protrusion shown in the illustration, and replace the brush if the measured value is below the limit value. Limit: 2 mm or less Protrusion length 2.
Page 403: 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 404 16-18 ENGINE ELECTRICAL - Starting System STARTER MOTOR Switch <4G9> INSPECTION PINION GAP ADJUSTMENT Battery 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and M-terminal. Wire 3. Set switch to “ON”, and pinion will move out. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.
Page 405 16-19 ENGINE ELECTRICAL - Starting System MAGNETIC SWITCH PULL-IN TEST <4G9> 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and Battery M-terminal. Caution This test must be performed quickly (in less than Wire 10 seconds) to prevent coil from burning.
Page 406 16-20 ENGINE ELECTRICAL - Starting System FREE RUNNING TEST <4G9> Carbon-pile rheostat 1. Place starter motor in a vise equipped with soft jaws Ammeter and connect a fully-charged 12-volt battery to starter motor as follows: 2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series with battery positive post and starter Starter Battery...
Page 407 16-21 ENGINE ELECTRICAL - Starting System DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Screw 12. Packing A AA" 2. Magnetic switch 13. Packing B 3. Screw 14. Plate 4. Through bolt 15. Planetary gear 5. Rear bracket 16. Lever 6. Brush holder AC"...
Page 408 16-22 ENGINE ELECTRICAL - Starting System DISASSEMBLY SERVICE POINTS S terminal Magnetic AA" MAGNETIC SWITCH REMOVAL switch M terminal Disconnect the field coil wire from terminal M of the magnetic switch. Field coil wire AB" ARMATURE AND BALL REMOVAL When removing the armature, do not lose the ball placed at the end as a bearing.
Page 409 16-23 ENGINE ELECTRICAL - Starting System REASSEMBLY SERVICE POINTS "AA STOP RING/SNAP RING INSTALLATION Using an appropriate tool, pull the stop ring over the snap ring. Stop ring Overrunning clutch Stop ring Snap ring INSPECTION COMMUTATOR 1. Place the armature in a pair of “V” blocks and check the runout with a dial indicator.
Page 410 16-24 ENGINE ELECTRICAL - Starting System BRUSH 1. Check the brush for roughness of the surface that contacts the commutator and check the brush length. Limit: Wear limit line 2. In case the contacting surface has been corrected or the brush has been replaced, correct the contacting Wear limit line surface by winding sandpaper around the commutator.
Page 411: Ignition System
16-25 ENGINE ELECTRICAL - Ignition System IGNITION SYSTEM GENERAL INFORMATION This system is equipped with four ignition coils with The engine-ECU determines which ignition coil built-in power transistors for each of the cylinders. should be controlled by means of the signals from Interruption of the primary current flowing in the the camshaft position sensor and the crank angle primary side of an ignition coil generates a high...
Page 412 16-26 ENGINE ELECTRICAL - Ignition System SERVICE SPECIFICATIONS SPARK PLUG Items Standard value Limit Spark plug gap mm 0.5 - 0.6 0.75 Spark plug insulation resistance MW ON-VEHICLE SERVICE 1.5 V IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK NOTE 1.
Page 413 16-27 ENGINE ELECTRICAL - Ignition System 5. Check that spark is produced between the electrodes of the spark plug. 6. If no spark is produced, replace the ignition coil with a new one and recheck. 7. If spark is produced with the new ignition coil, replace the old one as it is faulty.
Page 414 16-28 ENGINE ELECTRICAL - Ignition System CAMSHAFT POSITION SENSOR CHECK Refer to GROUP 13A - Troubleshooting <4G6> or GROUP 13B - Troubleshooting <4G9>. CRANK ANGLE SENSOR CHECK Refer to GROUP 13A - Troubleshooting <4G6> or GROUP 13B - Troubleshooting <4G9>. DETONATION SENSOR CHECK Check the detonation sensor circuit if self-diagnosis code, No.
Page 415 16-29 ENGINE ELECTRICAL - Ignition System IGNITION COIL 16300320174 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation 10 Nm 25 Nm Removal steps 1. Ignition coil connector 2. Ignition coil 3. Spark plug CRANK ANGLE SENSOR 16300350036 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation...
Page 416: Camshaft Position Sensor
16-30 ENGINE ELECTRICAL - Ignition System CAMSHAFT POSITION SENSOR 16300340026 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation <4G6> 9 Nm Camshaft position sensor <4G9> 9 Nm Camshaft position sensor...
Page 417 16-31 ENGINE ELECTRICAL - Ignition System DETONATION SENSOR 16300280144 REMOVAL AND INSTALLATION Caution Do not subject the detonation sensor to any shocks. Pre-removal and Post-installation Operation Engine Cover Removal and Installation Intake Manifold Stay Removal and Installation Air Cleaner Assembly Removal and Installation (Refer to GROUP 15.) <4G6>...
Page 418 NOTES...
Page 419 17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM ..CRANKCASE EMISSION CONTROL SYSTEM ......GENERAL INFORMATION .
Page 420: Engine And Emission Control
17-2 ENGINE AND EMISSION CONTROL - Engine Control System ENGINE CONTROL SYSTEM 17100010102 GENERAL INFORMATION A cable-type accelerator mechanism and a Accelerator pedal position sensor is used for suspended-type pedal have been adopted. vehicles with 4G6 engine which is equipped with the electronically-controlled fuel injection system.
Page 421 17-3 ENGINE AND EMISSION CONTROL - Engine Control System ACCELERATOR PEDAL POSITION SENSOR CHECK 17100190011 Refer to GROUP 13A - On-vehicle Service.
Page 422 17-4 ENGINE AND EMISSION CONTROL - Engine Control System ACCELERATOR CABLE AND PEDAL 17100120256 REMOVAL AND INSTALLATION Post-installation Operation Adjusting Accelerator Cable (Refer P.17-2 plink=17100090052 <4G6> <4G9 - R.H. drive vehicles> <4G9 - L.H. drive vehicles> 10 Nm 5 Nm 5 Nm 12 Nm <4G6>...
Page 423 17-5 ENGINE AND EMISSION CONTROL - Engine Control System ACCELERATOR PEDAL POSITION SENSOR <4G6> 17100180018 REMOVAL AND INSTALLATION Post-installation Operation Adjusting the Accelerator Cable (Refer to P.17-2.) 10 - 13 Nm 10 Nm 10 - 13 Nm 10 - 13 Nm Removal steps 1.
Page 424: Emission Control System
17-6 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 425: Vacuum Hose
17-7 ENGINE AND EMISSION CONTROL - Emission Control System SERVICE SPECIFICATIONS Items Standard value Purge control solenoid valve coil resistance (at 20_C) W 36 - 44 EGR valve coil resistance (at 20_C) W 10 - 20 SPECIAL TOOL Tool Number Name MB991658 Test harness set...
Page 426 17-8 ENGINE AND EMISSION CONTROL - Emission Control System <4G6> From fuel pump (low-pressure) To fuel tank Fuel pressure regulator (high-pressure) EGR valve (stepper motor) Canister PCV valve Injector Purge control Fuel pump (high-pressure) solenoid valve Oxygen sensor Catalytic converter...
Page 427 17-9 ENGINE AND EMISSION CONTROL - Emission Control System VACUUM CIRCUIT DIAGRAM Intake manifold Throttle body combustion From air chamber cleaner Canister Purge control solenoid valve (ON: OPEN) Vacuum hose colour B: Black R: Red VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected.
Page 428: Crankcase Emission Control System
17-10 ENGINE AND EMISSION CONTROL - Emission Control System CRANKCASE EMISSION CONTROL SYSTEM GENERAL INFORMATION The crankcase emission control system prevents The PCV valve lifts the plunger according to the blow-by gases from escaping inside the crankcase intake manifold vacuum so as to regulate the flow into the atmosphere.
Page 429 17-11 ENGINE AND EMISSION CONTROL - Emission Control System 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 430: Evaporative Emission Control System
17-12 ENGINE AND EMISSION CONTROL - Emission Control System EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents sent to the combustion chamber. fuel vapours generated in the fuel tank from When the engine coolant temperature is low or escaping into the atmosphere.
Page 431 17-13 ENGINE AND EMISSION CONTROL - Emission Control System PURGE CONTROL SYSTEM CHECK <4G9> 1. Disconnect the vacuum hose (red stripe) from the throttle Vacuum hose (red stripe) body <4G9>, intake manifold <4G6>, and connect it to a hand vacuum pump. 2.
Page 432 17-14 ENGINE AND EMISSION CONTROL - Emission Control System 2. Start the engine and check that the vacuum remains fairly Vacuum constant after racing the engine. NOTE If vacuum changes, it is possible that the throttle body purge port may be clogged and require cleaning. Engine speed (r/min) PURGE CONTROL SOLENOID VALVE CHECK NOTE...
Page 433 17-15 ENGINE AND EMISSION CONTROL - ENGINE AND EMISSION CONTROL - Emission Control System 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.
Page 434 17-16 ENGINE AND EMISSION CONTROL - Emission Control System EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK Refer to GROUP 13 - Troubleshooting. EGR VALVE (STEPPER MOTOR) CHECK <4G9> Checking the Operation Sound 1. Check that the operation sound of the stepper motor can be heard from the EGR valve when the ignition switch is turned to ON (without starting the engine).
Page 435: Catalytic Converter
17-17 ENGINE AND EMISSION CONTROL - Emission Control System Operation Check 1. Remove the EGR valve. 2. Connect the special tool (test harness set) to the EGR valve-side connector. 3. Connect terminal No.2 and terminal No.5 to the positive (+) terminal of power supply of approximately 6 V. 4.
Page 436 NOTES...
Page 437: Clutch
21-1 CLUTCH CONTENTS 21109000190 GENERAL INFORMATION ....CLUTCH PEDAL ......SERVICE SPECIFICATIONS .
Page 438 21-2 CLUTCH - General Information/Service Specifications/Lubricants/On-vehicle Service GENERAL INFORMATION 21100010093 The clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control. SERVICE SPECIFICATIONS 21100030150 Items Standard value Clutch pedal height mm 224 - 227 <L.H. drive vehicles> 211 - 214 <R.H.
Page 439 21-3 CLUTCH - On-vehicle Service 3. If the clutch pedal height and the clutch pedal clevis pin play are outside the standard value, turn the setting nut Setting nut to adjust them to the standard value. Caution Do not push in the master cylinder push rod at this time, otherwise the clutch will not operate properly.
Page 440: Clutch Pedal
21-4 CLUTCH - Clutch Pedal CLUTCH PEDAL 21100160224 REMOVAL AND INSTALLATION Post-installation Operation Clutch Pedal Adjustment (Refer to P.21-2) 12 Nm 12 Nm Removal steps 1. Clutch switch 6. Clutch master cylinder mounting nut 2. Clip 7. Master cylinder member mounting bolt 3.
Page 441: Clutch Control
21-5 CLUTCH - Clutch Control CLUTCH CONTROL 21100190216 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Clutch Fluid Draining Clutch Fluid Supplying Clutch Line Bleeding (Refer to P.21-3) Clutch Pedal Adjustment (Refer to P.21-2) <L.H. drive vehicles> 12 Nm 29 Nm 12 Nm 19 Nm Release...
Page 442 21-6 CLUTCH - Clutch Control <R.H. drive vehicles> 12 Nm 12 Nm 19 Nm Release Release fork cylinder push rod 15 Nm Specified grease: MITSUBISHI genuine grease Part No. 0101011 Clutch master cylinder removal Clutch release cylinder removal steps steps 1.
Page 443 21-7 CLUTCH - Clutch Control DISASSEMBLY AND REASSEMBLY 21100210172 CLUTCH MASTER CYLINDER Caution Do not disassemble piston assembly. <L.H. drive vehicles> 12 Nm <R.H. drive vehicles> 12 Nm 44 Nm Clutch fluid: Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease Disassembly steps 1.
Page 444 21-8 CLUTCH - Clutch Control INSTALLATION SERVICE POINT "AA PUSH ROD ASSEMBLY INSTALLATION Set the length of the push rod assembly to the shown dimension to make the adjustment of clutch pedal easier. <L.H. drive vehicles> 103 mm <R.H. drive vehicles> 121 mm...
Page 445: Manual Transmission
22-1 MANUAL TRANSMISSION CONTENTS 22109000395 Transfer Oil Change ......LUBRICANT ....... Oil Temperature Sensor Check .
Page 446 22-2 MANUAL TRANSMISSION - Lubricant/Special Tools LUBRICANT 22100040310 Item Specified lubricant Quantity L Transmission oil Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4 Transfer oil Hypoid gear oil SAE 75W - 90 or 75W - 85W 0.53 conforming to API GL-4 SPECIAL TOOLS...
Page 447 22-3 MANUAL TRANSMISSION - On-vehicle Service ON-VEHICLE SERVICE 22100090308 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. 3. Check that the transmission oil is not noticeably dirty, and that it has a suitable viscosity.
Page 448 22-4 MANUAL TRANSMISSION - On-vehicle Service TRANSFER OIL CHANGE 22100120137 1. Remove the oil drain plug to drain oil. 2. Install the oil drain plug, and then tighten it to the specified Transfer oil torque. Tightening torque: 32 Nm 3. Remove the oil filler plug, and then fill with specified oil till the level comes to the lower portion of filler plug hole.
Page 449 22-5 MANUAL TRANSMISSION - Transmission Control TRANSMISSION CONTROL 22100380238 REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift cable and select cable assembly. Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation Battery and Battery Tray Removal and Installation 12 Nm...
Page 450 22-6 MANUAL TRANSMISSION - Transmission Control REMOVAL SERVICE POINTS Tabs AA" CLIP REMOVAL Pry the tabs of the clip with a screwdriver or similar, and then remove the clip. INSTALLATION SERVICE POINTS "AA SHIFT CABLE AND SELECT CABLE ASSEMBLY/ Shift lever SHIFT CABLE CONNECTION/SELECT CABLE CONNECTION 1.
Page 451 22-7 MANUAL TRANSMISSION - Transmission Control SHIFT LEVER ASSEMBLY 22100400101 DISASSEMBLY AND REASSEMBLY 14 Nm 9 Nm 12 Nm 10 Nm 9 Nm Disassembly steps 1. Lever assembly 9. Shift lever 2. Bolt 10. Shift lever bushing 3. Select lever 11.
Page 452 22-8 MANUAL TRANSMISSION - Transmission Assembly TRANSMISSION ASSEMBLY 22100270290 <2WD> REMOVAL AND INSTALLATION Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body. Pre-removal and Post-installation Operation Transmission Oil Draining and Refilling (Refer to Front Exhaust Pipe Removal and Installation (Refer P.22-3.)
Page 453 22-9 MANUAL TRANSMISSION - Transmission Assembly 57 Nm* 81 Nm* 48 Nm 39 Nm 40 Nm 9 Nm 98 - 118 Nm 49 - 64 Nm* 44 Nm 49 - 64 Nm* 196 - 255 Nm 22 Nm 78 Nm 177 Nm 177 Nm 78 Nm...
Page 454 22-10 MANUAL TRANSMISSION - Transmission Assembly <4WD> REMOVAL AND INSTALLATION Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body. Pre-removal and Post-installation Operation Transmission Oil Draining and Refilling (Refer to Under Cover Removal and Installation P.22-3.) Front Exhaust Pipe Removal and Installation (Refer...
Page 455 22-11 MANUAL TRANSMISSION - Transmission Assembly 57 Nm* 81 Nm* 48 Nm 39 Nm 44 Nm 9 Nm 98 - 118 Nm 49 - 64 Nm* 22 Nm 49 - 64 Nm* 196 - 255 Nm 78 Nm 177 Nm 177 Nm 78 Nm 11.
Page 456 22-12 MANUAL TRANSMISSION - Transmission Assembly REMOVAL SERVICE POINTS Cord AA" TIE ROD END DISCONNECTION Ball joint Caution 1. Use the special tool to loosen the tie rod end mounting MB990635 or nut. Only loosen the nut; do not remove it from the MB991113 ball joint.
Page 457 22-13 MANUAL TRANSMISSION - Transmission Assembly AD" OUTPUT SHAFT REMOVAL MB991721 1. Use the special tool to withdraw the output shaft. Caution Be careful not to damage the oil seal of the transmission by the spline of the output shaft. 2.
Page 458 22-14 MANUAL TRANSMISSION - Transmission Assembly "BA OUTPUT SHAFT/DRIVE SHAFT INSTALLATION Caution Be careful not to damage the oil seal of the transmission or transfer by the spline of the drive shaft or the output shaft. "CA LOWER ARM INSTALLATION Knuckle 1.
Page 459: Transfer Assembly
22-15 MANUAL TRANSMISSION - Transfer Assembly TRANSFER ASSEMBLY REMOVAL AND INSTALLATION Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body. Pre-removal and Post-installation Operation Transmission Oil Draining and Refilling (Refer to Front Exhaust Pipe Removal and Installation (Refer P.22-3.) to GROUP 15.)
Page 460 NOTES...
Page 461: Automatic Transmission
23-1 AUTOMATIC TRANSMISSION CONTENTS 23109000576 Torque Converter Stall Test ....SERVICE SPECIFICATIONS ....Hydraulic Pressure Test .
Page 462 23-2 AUTOMATIC TRANSMISSION - Service Specifications/Lubricant/Special Tools SERVICE SPECIFICATIONS 23100030284 Items Standard value Oil temperature sensor kW at 0_C 16.5 - 20.5 at 100_C 0.57 - 0.69 Resistance of damper clutch control solenoid valve coil (at 20_C) W 2.7 - 3.4 Resistance of Low-Reverse solenoid valve coil (at 20_C) W 2.7 - 3.4 Resistance of second solenoid valve coil (at 20_C) W...
Page 463 23-3 AUTOMATIC TRANSMISSION - Special Tools Tool Number Name MB990635 or Steering linkage Ball joint disconnection MB991113 puller MB991610 Oil filter wrench Removal and installation of automatic trans- mission oil filter GENERAL Engine lifter Supporting the engine assembly during SERVICE removal and installation of the transmission TOOL MZ203827...
Page 464 23-4 AUTOMATIC TRANSMISSION - Troubleshooting TROUBLESHOOTING 23100760657 STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING Gathering information from custom- Check ATF. Replace ATF. Check trouble symptoms. Communication with MUT-II not possible Read the diagnosis code (GROUP 00 Inspection Chart Trouble - How to Use Troubleshooting/In- Symptoms (Refer to P.23-24.) spection Service Points.) Diagnosis code...
Page 465 23-5 AUTOMATIC TRANSMISSION - Troubleshooting DIAGNOSIS FUNCTION 23100770292 1. N range lamp The N range lamp flashes at a frequency of approximately 1 Hz if there is an abnormality in any of the items in the table below which are related to the A/T system. Check the diagnosis code output if the N range lamp is flashing at a frequency of approximately 1 Hz.
Page 466: Road Test
23-6 AUTOMATIC TRANSMISSION - Troubleshooting ROAD TEST 23100780622 Check by the following procedure. State prior to test Test and operation Judgement value Check item Diag- Inspection and operation nosis procedure page code if there is an abnormality Ignition switch: Ignition switch Data list No.
Page 467 23-7 AUTOMATIC TRANSMISSION - Troubleshooting State prior to test Test and operation Judgement value Check item Diag- Inspection and operation nosis procedure page code if there is an abnormality Engine: Idling Brake pedal Data list No. 26 Stop lamp Stop lamp switch (Retest) switch system (23-16)
Page 468 23-8 AUTOMATIC TRANSMISSION - Troubleshooting State prior to test Test and operation Judgement value Check item Diag- Inspection and operation nosis procedure page code if there is an abnormality Selector lever Selector lever Data list No. 63 Shift condition position: N position and (2) 1st, (4) 3rd, (3) (Carry out on a...
Page 469 23-9 AUTOMATIC TRANSMISSION - Troubleshooting State prior to test Test and operation Judgement value Check item Diag- Inspection and operation nosis procedure page code if there is an abnormality Use the MUT-II to Monitor data list For (1), (2) and (3), Malfunction Shocks and when shifting...
Page 470 23-10 AUTOMATIC TRANSMISSION - Troubleshooting State prior to test Test and operation Judgement value Check item Diag- Inspection and operation nosis procedure page code if there is an abnormality Selector lever Monitor data list The ratio between Does not shift Input shaft speed sensor position: N...
Page 471 23-11 AUTOMATIC TRANSMISSION - Troubleshooting <4G64> UPSHIFT PATTERN Thick line: Standard shift pattern Throttle opening % 2 ® 3 movement range 3 ® 4 movement range 3,000 4,000 7,000 1,000 2,000 5,000 6,000 Output shaft speed r/min DOWNSHIFT PATTERN Throttle opening % Thick line: Standard shift pattern 2 (L) 4 (L,2,3)
Page 472 23-12 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODE 23100790588 Code Diagnosis item Reference page Throttle position sensor system Short circuit 23-13 <4G93> Open circuit 23-13 Accelerator pedal position sensor system Accelerator pedal position sensor system <4G64> Sensor maladjustment 23-13 Oil temperature sensor system Open circuit...
Page 473 23-13 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 11, 12, 14 Throttle position sensor system Probable cause <4G93>, accelerator pedal position sensor system <4G64> If the TPS or APS output voltage is 4.8 V or higher when the engine is idling, the D Malfunction of the throttle position sensor <4G93>...
Page 474 23-14 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 21 Crank angle sensor system Probable cause If no output pulse is detected from the crank angle sensor for 5 seconds or more D Malfunction of the crank angle sensor while driving at 25 km/h or more, it is judged that there is an open circuit in the D Malfunction of connector crank angle sensor and diagnosis code No.
Page 475 23-15 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 23 Output shaft speed sensor system Probable cause If the output from the output shaft speed sensor is continuously 50% lower than the D Malfunction of the output shaft speed sensor vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of D Malfunction of the transfer drive gear or driven gear 30 km/h or more, there is judged to be an open circuit or short-circuit in the output D Malfunction of connector...
Page 476 23-16 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 26 Stop lamp switch system Probable cause If the stop lamp switch is on for 5 minutes or more while driving, it is judged that D Malfunction of the stop lamp switch there is a short circuit in the stop lamp switch and diagnosis code No. 26 is output. D Malfunction of connector D Malfunction of the A/T-ECU Stop lamp switch check (Refer to GROUP 35 - Brake Pedal.)
Page 477 23-17 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 36, 52 Damper clutch control solenoid valve Probable cause system If the resistance value for the damper clutch control solenoid valve is too large or D Malfunction of the damper clutch control solenoid valve too small, it is judged that there is a short-circuit or an open circuit in the damper D Malfunction of connector clutch control solenoid valve and diagnosis code No.
Page 478 23-18 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 41 1st gear ratio does not meet the specification Probable cause If the output from the output shaft speed sensor multiplied by the 1st gear ratio is D Malfunction of the input shaft speed sensor not the same as the output from the input shaft speed sensor after shifting to 1st D Malfunction of the output shaft speed sensor gear has been completed, diagnosis code No.
Page 479 23-19 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 42 2nd gear ratio does not meet the specification Probable cause If the output from the output shaft speed sensor multiplied by the 2nd gear ratio D Malfunction of the input shaft speed sensor is not the same as the output from the input shaft speed sensor after shifting to D Malfunction of the output shaft speed sensor 2nd gear has been completed, diagnosis code No.
Page 480 23-20 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 43 3rd gear ratio does not meet the specification Probable cause If the output from the output shaft speed sensor multiplied by the 3rd gear ratio is D Malfunction of the input shaft speed sensor not the same as the output from the input shaft speed sensor after shifting to 3rd D Malfunction of the output shaft speed sensor gear has been completed, diagnosis code No.
Page 481 23-21 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 44 4th gear ratio does not meet the specification Probable cause If the output from the output shaft speed sensor multiplied by the 4th gear ratio is D Malfunction of the input shaft speed sensor not the same as the output from the input shaft speed sensor after shifting to 4th D Malfunction of the output shaft speed sensor gear has been completed, diagnosis code No.
Page 482 23-22 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 46 Reverse gear ratio does not meet the Probable cause specification If the output from the output shaft speed sensor multiplied by the reverse gear ratio D Malfunction of the input shaft speed sensor is not the same as the output from the input shaft speed sensor after shifting to D Malfunction of the output shaft speed sensor reverse gear has been completed, diagnosis code No.
Page 483 23-23 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 51 Abnormal communication with engine-ECU Probable cause If normal communication is not possible for a continuous period of 1 second or more D Malfunction of connector when the ignition switch is at the ON position, the battery voltage is 10 V or more D Malfunction of the engine-ECU and the engine speed is 450 r/min or more, diagnosis code No.
Page 484 23-24 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 56 N range lamp system Probable cause If the N range signal is off after an N range lamp illumination instruction (ON instruction) D Malfunction of the N range lamp bulb has been given, it is judged that there is a short-circuit in the N range lamp earth D Malfunction of connector and diagnosis code No.
Page 485 23-25 AUTOMATIC TRANSMISSION - Troubleshooting Trouble symptom Inspection Reference procedure No. page Displaced shifting points All points 23-32 Some points 23-33 Does not shift No diagnosis codes 23-33 Malfunction while driving Poor acceleration 23-34 Vibration 23-34 Inhibitor switch system 23-35 Dual pressure switch system 23-35 Vehicle speed sensor system...
Page 486 23-26 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 2 MUT-II can not communicate with the A/T-ECU. Probable cause It is suspected that this malfunction is caused by an open circuit in A/T-ECU power D Malfunction of harness or connector supply circuit or diagnosis output circuit. D Malfunction of A/T-ECU Measure at diagnosis connector B-25 Repair...
Page 487 23-27 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 3 Starting impossible Probable cause Starting is not possible when the selector lever is in P or N range. In such cases, D Malfunction of the inhibitor switch system the cause is probably a defective inhibitor switch system, transmission control cable D Malfunction of the transmission control cable assembly assembly, engine system, torque converter or oil pump.
Page 488 23-28 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 5 Does not reverse Probable cause If the vehicle does not reverse when the selector lever is shifted from N to R range D Abnormal reverse clutch pressure while the engine is idling, the cause is probably abnormal pressure in the reverse D Abnormal low and reverse brake pressure clutch or low and reverse brake or a malfunction of the reverse clutch, low and reverse D Malfunction of the low and reverse solenoid valve...
Page 489 23-29 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 7 Engine stalling when shifting Probable cause If the engine stalls when the selector lever is shifted from N to D or R range while D Malfunction of the engine system the engine is idling, the cause is probably a malfunction of the engine system, damper D Malfunction of the damper clutch control solenoid valve clutch solenoid valve, valve body or torque converter (damper clutch malfunction).
Page 490 23-30 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 9 Shocks when changing from N to R and large time lag Probable cause If abnormal shocks or a time lag of 2 seconds or more occurs when the selector D Abnormal reverse clutch pressure lever is shifted from N to R range while the engine is idling, the cause is probably D Abnormal low and reverse brake pressure abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction...
Page 491 23-31 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 10 Shocks when changing from N to D, N to R and large time Probable cause If abnormal shocks or a time lag of 2 seconds or more occur when the selector D Abnormal line pressure lever is shifted from N to D range and from N to R range while the engine is idling, D Malfunction of the oil pump the cause is probably abnormal line pressure or a malfunction of the oil pump or...
Page 492 23-32 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 12 All points (Displaced shifting points) Probable cause If all shift points are displaced while driving, the cause is probably a malfunction of D Malfunction of the output shaft speed sensor the output shaft speed sensor, TPS or of a solenoid valve. D Malfunction of the throttle position sensor D Malfunction of each solenoid valve D Abnormal line pressure...
Page 493 23-33 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 13 Some points (Displaced shifting points) Probable cause If some of the shift points are displaced while driving, the cause is probably a malfunction D Malfunction of the valve body of the valve body, or it is related to control and is not an abnormality. L: Refer to the Transmission Workshop Manual.
Page 494: Poor Acceleration
23-34 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 15 Poor acceleration Probable cause If acceleration is poor even if downshifting occurs while driving, the cause is probably D Malfunction of the engine system a malfunction of the engine system or of a brake or clutch. D Malfunction of the brake or clutch L: Refer to the Transmission Workshop Manual.
Page 495 23-35 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 17 Inhibitor switch system Probable cause The cause is probably a malfunction of the inhibitor switch circuit, ignition switch D Malfunction of the inhibitor switch circuit or a defective A/T-ECU. D Malfunction of the ignition switch D Malfunction of connector D Malfunction of the A/T-ECU Inhibitor switch check (Refer to P.23-48.)
Page 496 23-36 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 19 Vehicle speed sensor system Probable cause The cause is probably a defective vehicle speed sensor circuit or a defective A/T-ECU. D Malfunction of the vehicle speed sensor D Malfunction of connector D Malfunction of the A/T-ECU Check the vehicle speed sensor.
Page 497 23-37 AUTOMATIC TRANSMISSION - Troubleshooting DATA LIST REFERENCE TABLE 23100810284 Item No. Check item Check requirement Normal value Throttle position sensor Engine: Stopped Accelerator pedal: 300 - 1,000 mV <4G93> Released Selector lever Accelerator pedal position: P Accelerator pedal: Gradually rises from the position sensor Half depressed above value...
Page 498 23-38 AUTOMATIC TRANSMISSION - Troubleshooting Item No. Check item Check requirement Normal value Damper clutch control Selector lever Driving at 50 km/h in solenoid valve duty % position: 3 3rd gear with accelerator released Driving at constant speed Approx. 70 - 90 % of 70 km/h in 3rd gear Amount of damper Selector lever...
Page 499 23-39 AUTOMATIC TRANSMISSION - Troubleshooting ACTUATOR TEST JUDGEMENT VALUE 23100820157 Item No. Check item Test content Check requirement Normal value Low reverse solenoid valve Drive the solenoid Ignition switch: ON The operation sound should valve specified by be audible when the solenoid Selector lever Underdrive solenoid valve the MUT-II at 50 %...
Page 500 23-40 AUTOMATIC TRANSMISSION - AUTOMATIC TRANSMISSION - Troubleshooting Troubleshooting CHECK AT A/T-ECU TERMINALS 23100840252 Terminal Check item Check requirement Standard value Underdrive solenoid valve Selector lever position: D (1st gear) Battery voltage Selector lever position: P Approx.7 - 9 V Solenoid valve power supply Ignition switch: OFF Ignition switch: ON...
Page 501 23-41 AUTOMATIC TRANSMISSION - Troubleshooting Terminal Check item Check requirement Standard value Earth Always Input shaft speed sensor Measure between terminal No. 31 and No. 43 by Refer to P.23-43, an oscilloscope. Oscilloscope inspection Engine: 2,000 r/min procedure. Selector lever position: 3 Output shaft speed sensor Measure between terminal No.
Page 502 23-42 AUTOMATIC TRANSMISSION - Troubleshooting Terminal Check item Check requirement Standard value Wide open throttle switch Accelerator pedal: Released 4.5 - 5.5 V Accelerator pedal: Depressed Less than 0.4 V Inhibitor switch R Selector lever position: R Battery voltage Selector lever position: Other than above Inhibitor switch D Selector lever position: D Battery voltage...
Page 503 23-43 AUTOMATIC TRANSMISSION - Troubleshooting OSCILLOSCOPE INSPECTION PROCEDURE 23100850132 Check item Check requirement Normal condition (Waveform sample) Crank angle sensor Selector lever position: N Idling (Vehicle stopped) Waveform A Input shaft speed Selector lever position: 3 Driving at constant speed of 50 Waveform B sensor km/h in 3rd gear...
Page 504 23-44 AUTOMATIC TRANSMISSION - On-vehicle Service ON-VEHICLE SERVICE 23100090374 ESSENTIAL SERVICE AUTOMATIC TRANSMISSION FLUID CHECK Caution When the transmission has been replaced or overhauled, or driving has been carried out under the severe condition, the transmission fluid cooler line flushing should always be carried out and also, the transmission fluid and oil filters (special filters for transmission only) should always be replaced.
Page 505 23-45 AUTOMATIC TRANSMISSION - On-vehicle Service AUTOMATIC TRANSMISSION FLUID REPLACEMENT 23100100411 Caution When the transmission has been replaced or overhauled, the transmission fluid cooler line flushing should always be carried out before installing the transmission fluid cooler hose. If you have a fluid changer, use this changer to replace the fluid.
Page 506 23-46 AUTOMATIC TRANSMISSION - On-vehicle Service 9. Reconnect the hose which was disconnected in step 1 above, and firmly replace the oil level gauge. 10. Start the engine and run it at idle for 1 - 2 minutes. 11. Move the selector lever through all positions, and then move it to the N position.
Page 507 23-47 AUTOMATIC TRANSMISSION - On-vehicle Service 3. Pour the new fluid in through the oil filler tube. Adding volume: Approx. 3.5 L Caution Stop pouring if the 3.5 lit. of fluid cannot be poured 4. Repeat the procedure in step 2. NOTE Drain the fluid from the cooler hose 7.0 lit.
Page 508 23-48 AUTOMATIC TRANSMISSION - On-vehicle Service INHIBITOR SWITCH CONTINUITY CHECK 23100140475 Inhibitor switch Terminal No. Items INHIBITOR SWITCH AND CONTROL CABLE Transmission Adjusting nut control cable ADJUSTMENT 23100150201 1. Set the selector lever to the “N” position. 2. Loosen the control cable to manual control lever coupling nut to free the cable and lever.
Page 509 23-49 AUTOMATIC TRANSMISSION - On-vehicle Service 4. Loosen the inhibitor switch body mounting bolts and the 10 - 12 Nm turn the inhibitor switch body so the hole in the end of the manual control lever and the hole (cross section A - A Mounting bolts in the figure on the left) in the flange of the inhibitor switch body flange are aligned.
Page 510 23-50 AUTOMATIC TRANSMISSION - On-vehicle Service A/T CONTROL COMPONENT LOCATION 23100860319 Name Symbol Name Symbol Accelerator position sensor <4G64> Oil temperature sensor A/T control relay Output shaft speed sensor A/T-ECU Shift indicator lamp Crank angle sensor Solenoid valve Diagnosis connector Stop lamp switch Dual pressure switch Throttle position sensor <4G93>...
Page 511 23-51 AUTOMATIC TRANSMISSION - On-vehicle Service A/T CONTROL COMPONENT CHECK 23100900134 CRANK ANGLE SENSOR CHECK Refer to GROUP 13 - Troubleshooting link=13100850034 THROTTLE POSITION SENSOR CHECK <4G93> 23100390337 Refer to GROUP 13B - On-vehicle Service link=13100320030 ACCELERATOR PEDAL POSITION SENSOR CHECK <4G64>...
Page 512 23-52 AUTOMATIC TRANSMISSION - AUTOMATIC TRANSMISSION - On-vehicle Service On-vehicle Service DUAL PRESSURE SWITCH CHECK 23100470185 Refer to GROUP 55 - On-vehicle Service link=55201040068 WIDE OPEN THROTTLE SWITCH CHECK 23100890080 Refer to P.23-64. A/T CONTROL RELAY CHECK 23100930119 1. Remove the A/T control relay. A/T control relay 2.
Page 513 23-53 AUTOMATIC TRANSMISSION - On-vehicle Service 3. Measure the resistance between terminals 1 and 2 of each solenoid valve. Standard value: Name Resistance Damper clutch solenoid valve 2.7 - 3.4 W (at 20_C) Low and reverse solenoid valve Second solenoid valve Underdrive solenoid valve Overdrive solenoid valve 4.
Page 514 23-54 AUTOMATIC TRANSMISSION - On-vehicle Service 2. Check both rear wheels (left and right). 3. Pull the parking brake lever on, with the brake pedal fully depressed. 4. Start the engine. 5. Move the selector lever to the D position, fully depress the accelerator pedal and take a reading of the maximum engine speed at this time.
Page 515 23-55 AUTOMATIC TRANSMISSION - On-vehicle Service HYDRAULIC PRESSURE TEST 23100550285 sub=01 1. Warm up the engine until the automatic transmission fluid temperature is 80 - 100_C. 2. Jack up the vehicle so that the wheels are free to turn. 3. Connect the special tools (2,942 kPa oil pressure gauge [MD998330] and joints [MD998332, MD998900]) to each pressure discharge port.
Page 516 23-56 AUTOMATIC TRANSMISSION - On-vehicle Service STANDARD HYDRAULIC PRESSURE TEST sub=02 <4G93> Measurement condition Standard hydraulic pressure kPa Selector Shift posi- Engine Under- Reverse Overdrive Low and Second Torque lever tion speed drive clutch clutch reverse brake converter position (r/min) clutch pressure pressure...
Page 517 23-57 AUTOMATIC TRANSMISSION - On-vehicle Service HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE sub=03 Trouble symptom Probable cause All hydraulic pressures are high. Incorrect transmission control cable adjustment Malfunction of the regulator valve All hydraulic pressures are low. Incorrect transmission control cable adjustment Malfunction of the oil pump Clogged internal oil filter Clogged external oil filter...
Page 518 23-58 AUTOMATIC TRANSMISSION - On-vehicle Service Trouble symptom Probable cause Malfunction of the oil seal D Only overdrive hydraulic pressure is abnormal. Malfunction of the oil seal E Malfunction of the oil seal F Malfunction of the overdrive solenoid valve Malfunction of the overdrive pressure control valve Malfunction check ball Clogged orifice...
Page 519 23-59 AUTOMATIC TRANSMISSION - On-vehicle Service OIL SEAL LAYOUT sub=04...
Page 520 23-60 AUTOMATIC TRANSMISSION - On-vehicle Service HYDRAULIC CIRCUIT 23100880193 PARKING AND NEUTRAL R ND 1. Reverse clutch 18. Overdrive pressure control valve 2. Low-reverse brake 19. Damper clutch control solenoid 3. Second brake valve 4. Underdrive clutch 20. Low-reverse solenoid valve 5.
Page 521 23-61 AUTOMATIC TRANSMISSION - On-vehicle Service LINE PRESSURE ADJUSTMENT 23100170177 1. Discharge the automatic transmission fluid, and then remove the valve body cover. 2. Turn the adjusting screw shown in the illustration at left to adjust the underdrive pressure to the standard value. The pressure increases when the screw is turned to the left.
Page 522 23-62 AUTOMATIC TRANSMISSION - On-vehicle Service KEY INTERLOCK AND SHIFT LOCK SYSTEM CHECK 1. Carry out the following inspection: <Key interlock> Inspection Requirements Normal condition procedure Brake pedal: Turn the ignition key to The selector lever push button can not be pushed, Depressed “LOCK”, or remove it.
Page 523 23-63 AUTOMATIC TRANSMISSION - Transmission Control TRANSMISSION CONTROL 23100660247 REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the transmission control cable, the key interlock cable, the selector lever assembly or the A/T-ECU. Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation (Refer Operation Check of Instruments <after installation...
Page 524 23-64 AUTOMATIC TRANSMISSION - Transmission Control INSTALLATION SERVICE POINT Manual transmis- Adjusting nut sion control cable "AA NUT INSTALLATION 1. Put the selector lever in the “N” position and the manual control lever in neutral position. 2. Install the transmission control cable, and tighten the adjusting nut.
Page 525 23-65 AUTOMATIC TRANSMISSION - Transmission Control SELECTOR LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 2.5 Nm 12 Nm 9 Nm 9 Nm Disassembly steps 1. Lever assembly 8. Lock cam 2. Bracket 9. Stopper 3. Snap ring 10. Base bracket 4. Sleeve 11.
Page 526 23-66 AUTOMATIC TRANSMISSION - Shift Lock and Key Interlock Mechanisms SHIFT LOCK AND KEY INTERLOCK MECHANISMS 23100660247 REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the key interlock cable or shift lock cable. Pre-removal and Post-installation Operation Shift Knob, Indicator Panel Removal and Installation (Refer to P.23-63.)
Page 527 23-67 AUTOMATIC TRANSMISSION - Shift Lock and Key Interlock Mechanisms INSTALLATION SERVICE POINTS Key interlock cable "AA KEY INTERLOCK CABLE INSTALLATION Lock piece 1. After assembling the shift lock cable to the lever, pull up the key interlock cable lock piece to unlock. Then install the interlock cable end to the cam, and then install the outer cap to the lower case.
Page 528 23-68 AUTOMATIC TRANSMISSION - Transmission Assembly TRANSMISSION ASSEMBLY 23100570274 REMOVAL AND INSTALLATION Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body. Pre-removal Operation Carry out the essential service for the troubleshooting Under Cover Removal and Installation <before removal only>...
Page 529 23-69 AUTOMATIC TRANSMISSION - Transmission Assembly 57 Nm* 81 Nm* 48 Nm 45 - 52 Nm 39 Nm 44 Nm 9 Nm 98 - 118 Nm 49 - 64 Nm* 49 - 64 Nm* 22 Nm 196 - 225 Nm 177 Nm 177 Nm 78 Nm...
Page 530 23-70 AUTOMATIC TRANSMISSION - AUTOMATIC TRANSMISSION - Transmission Assembly Transmission Assembly REMOVAL SERVICE POINTS AA" TIE ROD END DISCONNECTION MB990635 or MB991113 Caution Ball joint 1. Use the special tool to loosen the tie rod end mounting Cord nut. Only loosen the nut; do not remove it from the ball joint.
Page 531 23-71 AUTOMATIC TRANSMISSION - Transmission Assembly AF" TRANSMISSION ASSEMBLY LOWER PART COUPLING BOLTS/TRANSMISSION ASSEMBLY REMOVAL 1. Support the transmission assembly with a transmission jack. 2. Push the torque converter into the transmission case until the torque converter does not remain at the engine side.
Page 532 NOTES...
Page 533: Propeller Shaft
25-1 PROPELLER SHAFT CONTENTS GENERAL INFORMATION ....ADHESIVE ....... . . SERVICE SPECIFICATIONS .
Page 534 25-2 PROPELLER SHAFT - General Information/Service Specifications/Lubricant/Adhesive GENERAL INFORMATION The propeller shaft is a 3-shaft and 4-joint type with center bearing. Furthermore, a L.J. is used for the No.3 joint. Center bearing Center bearing Rear propeller shaft Center propeller shaft No.2 joint Front propeller shaft Sleeve yoke...
Page 535 25-3 PROPELLER SHAFT - Special Tools SPECIAL TOOLS Tool Number Name MB990840 Universal joint Disassembly and reassembly of the universal remover and joint installer MB991193 Plug Preventing of entry of foreign objects into the transmission and transfer MD998801 Bearing remover Removal of the center bearing assembly...
Page 536 25-4 PROPELLER SHAFT - Propeller Shaft PROPELLER SHAFT REMOVAL AND INSTALLATION Gear Oil: Hypoid gear oil 29 - 34 Nm 29 Nm 40 Nm Removal steps 1. Insulator AA" "AA 3. Propeller shaft assembly 2. Spacer...
Page 537 25-5 PROPELLER SHAFT - Propeller Shaft REMOVAL SERVICE POINT Joint boot Cloth AA" PROPELLER SHAFT ASSEMBLY REMOVAL 1. Make mating marks on the differential companion flange and on the flange yoke, and then remove the propeller shaft assembly. Caution Straighten front, center and rear shafts when removing Center propeller the propeller shaft.
Page 538 25-6 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY AND REASSEMBLY 186 Nm 186 Nm 34 Nm 12 11 12 14 10 13 Grease Grease L.J. repair kit L.J. boot repair kit Universal joint repair kit Disassembly steps AA" "GA 1. Snap ring AF"...
Page 539 25-7 PROPELLER SHAFT - Propeller Shaft LUBRICATION POINTS Rubber mount Repair kit grease 3M ATD Part No.8155 or equivalent Quantity: 45 - 55 g...
Page 540 25-8 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY SERVICE POINTS AA" SNAP RING REMOVAL Make mating marks on the yoke and on the propeller shaft, and then remove the snap ring. Mating marks AB" JOURNAL BEARING REMOVAL Journal bearing Use the special tool to press-out the journal bearing from the yoke and propeller shaft.
Page 541 25-9 PROPELLER SHAFT - Propeller Shaft 2. Make mating marks on the outer race, cage and on the inner race, and then remove the outer race and balls. NOTE Outer race Note the positions of balls so that they can be reinstalled in their original positions.
Page 542 25-10 PROPELLER SHAFT - Propeller Shaft "CA L.J. ASSEMBLY INSTALLATION 1. Apply a thin coat of the specified grease to the ball grooves of the inner and outer races. Specified grease: Repair kit grease 2. Assemble the L.J. assembly as follows: (1) Put the cage on the inner race with the mating marks Ball Recessed...
Page 543 25-11 PROPELLER SHAFT - Propeller Shaft 7. Align the bolt holes in the L.J. boot and the L.J. assembly using a mounting bolts, and then tighten the mounting Bolt bolts to fix the L.J. boot on the L.J. assembly. 8. Fit the rubber packing for the companion flange to the companion flange using the same procedure as in step L.J.
Page 544 25-12 PROPELLER SHAFT - Propeller Shaft 2. Press-in the journal bearing by the following procedure: (1) Align the mating marks on the yoke and propeller shaft. (2) Set the base on the special tool. (3) Use the special tool to press-in the yoke and bearing. MB990840 NOTE Base...
Page 545: Front Axle
26-1 FRONT AXLE CONTENTS 26109000201 GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Wheel Bearing Axial Play Check .
Page 546 26-2 FRONT AXLE - General Information/Service Specifications GENERAL INFORMATION 26100010234 The front axle consists of a knuckle, front hub, row angular contact ball bearing. The drive shaft unit bearing and drive shaft. The unit bearing is has a Tripod joint (T.J.) on the transmission side press-fitted to the front hub and bolted to the and a Birfield joint (B.J.) on the wheel side.
Page 547 26-3 FRONT AXLE - Lubricants/ Special Tools LUBRICANTS 26100040271 Items Specified lubricant Quantity g T.J. SPACE RUNNER Repair kit grease SPACE WAGON - 2WD Repair kit grease SPACE WAGON - 4WD Repair kit grease Dust seal inner Multipurpose grease 14 - 20 Dust seal outer Multipurpose grease 8 - 12...
Page 548 26-4 FRONT AXLE - Special Tools Tool Number Name MB990326 Preload socket Wheel bearing rotation starting torque mea- surement MB990925 Bearing and oil Center bearing press-out seal installer set Center bearing press-fitting Dust seal press-fitting MB990197 Puller body Inner shaft press-out MB990302 Hook MB991172...
Page 549 26-5 FRONT AXLE - Special Tools MB990925 Tool box Brass bar Bar (snap-in type) Installer adapter Type Tool number O.D. mm Type Tool number O.D. mm MB990926 MB990933 63.5 MB990927 MB990934 67.5 MB990928 49.5 MB990935 71.5 MB990929 MB990936 75.5 MB990930 MB990937 MB990931 MB990938...
Page 550 26-6 FRONT AXLE - On-vehicle Service ON-VEHICLE SERVICE 26100090115 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 551 26-7 FRONT AXLE - Front Hub Assembly FRONT HUB ASSEMBLY 26100170222 REMOVAL AND INSTALLATION Caution The front hub assembly should not be dissembled. When removing the front hub assembly, the wheel bearing inner race may be left at the spindle side.
Page 552 26-8 FRONT AXLE - Front Hub Assembly REMOVAL SERVICE POINTS AA" CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, so that it does not fall. AB" DRIVE SHAFT NUT REMOVAL Caution MB990767 Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut, or the ball bearing will be damaged.
Page 553 26-9 FRONT AXLE - Front Hub Assembly INSTALLATION SERVICE POINT 196 - 255 Nm "AA DRIVE SHAFT NUT INSTALLATION 1. Install the drive shaft washer in the specified direction. 2. Using the special tool, tighten the drive shaft nut. MB990767 Caution Before securely tightening the drive shaft nuts, make Washer...
Page 554 26-10 FRONT AXLE - Knuckle KNUCKLE 26100240183 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Hub Assembly Removal and Installation (Refer to P.26-7.) 106 Nm 9 Nm Removal steps 1. Dust shield 2. Knuckle...
Page 555 26-11 FRONT AXLE - Drive Shaft DRIVE SHAFT 26100350305 REMOVAL AND INSTALLATION Caution On the vehicles with ABS, when the drive shaft is removed or installed, be careful not to interfere with the ABS rotor installed to the B.J. outer race to prevent the rotor from damage. Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger.
Page 556 26-12 FRONT AXLE - Drive Shaft REMOVAL SERVICE POINTS AA" DRIVE SHAFT NUT REMOVAL MB990767 Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut, or the ball bearing will be damaged. AB" TIE ROD END DISCONNECTION MB991406, Caution MB990635 or...
Page 557 26-13 FRONT AXLE - Drive Shaft 3. Remove the drive shaft or the drive shaft and inner shaft Fig. 1 assembly from the transmission by the following Transmission procedure: 2WD (except SPACE WAGON - M/T - R.H.), Fig. 1 4WD (L.H.) 2WD (SPACE WAGON - M/T - R.H.) Fig.
Page 558 26-14 FRONT AXLE - Drive Shaft INSTALLATION SERVICE POINTS "AA OUTPUT SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY/DRIVE SHAFT INSTALLATION Caution Be careful not to damage the oil seal of the transmission or transfer by the spline of the shaft. "BA DRIVE SHAFT NUT INSTALLATION 196 - 255 Nm 1.
Page 559 26-15 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY 26100370325 Caution On the vehicles with ABS, when the drive shaft is disassembled or reassembled, be careful not to interfere with the ABS rotor installed to the B.J. outer race to prevent the rotor from damage. <2WD (except SPACE WAGON - M/T - R.H.)>...
Page 560 26-16 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 561 26-17 FRONT AXLE - Drive Shaft REASSEMBLY SERVICE POINTS "AA DYNAMIC DAMPER/DAMPER BAND/T.J. BOOT INSTALLATION 1. Install the dynamic damper in the position shown in the illustration. Items A (large) B (small) SPACE RUNNER L.H. 215 mm R.H. 395 mm SPACE WAGON L.H.
Page 562 26-18 FRONT AXLE - Drive Shaft "CA CENTER BEARING INSTALLATION MB990938 MB990933 Bearing "DA DUST SEAL INNER/DUST SEAL OUTER INNER DUST SEAL INSTALLATION 1. Apply multi-purpose grease to the rear surfaces of all MB990938 dust seals. MB990933 Amount to use: Dust seal inner 14 - 20 g Dust seal outer 8 - 12 g 2.
Page 563 26-19 FRONT AXLE - Drive Shaft 2. Use the special tools to support the T.J. case. Pipe 3. Use a pipe [Ø 30 mm] to press the seal plate into the T.J. case T.J. case. Seal plate MB991248 "CA T.J. BOOT BAND (SMALL)/T.J. BOOT BAND (LARGE) INSTALLATION Set the T.J.
Page 564 26-20 FRONT AXLE - Drive Shaft B.J. BOOT (RESIN BOOT) REPLACEMENT 26100520157 1. Remove the B.J. boot bands (large and small). NOTE The B.J. boot bands cannot be re-used. 2. Remove the B.J. boot. 3. Wrap a plastic tape around the shaft spline, and assemble the B.J.
Page 565 26-21 FRONT AXLE - Drive Shaft 7. Place the B.J. boot band (small) against the projection at B.J. boot the edge of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration. B.J.
Page 566 26-22 FRONT AXLE - Drive Shaft 12. Engage the large diameter side of the B.J. boot into the Groove B.J. housing groove. <2WD> 13. Install the B.J. boot band (large) so that there is the clearance (C) between it and the B.J. housing is at the standard value.
Page 567: Rear Axle
27A-1 REAR AXLE CONTENTS 27109000246 REAR AXLE <2WD> ........REAR AXLE <4WD>...
Page 568 27A-2 REAR AXLE <2WD> CONTENTS 27109000253 GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Wheel Bearing Axial Play Check .
Page 569: General Information
27A-3 REAR AXLE <2WD> - General Information/Service Specifications/Special Tools GENERAL INFORMATION 27100010224 A unit bearing (double-row angular contact ball For the vehicles with ABS, the hub has a ABS bearing) is used as the wheel bearing. rotor for detecting the wheel rotation speed. Rear hub assembly Lower arm assembly Unit bearing...
Page 570: On-Vehicle Service
27A-4 REAR AXLE <2WD> - On-vehicle Service ON-VEHICLE SERVICE 27100090174 WHEEL BEARING AXIAL PLAY CHECK 1. Remove the caliper assembly and secure it with wire so that it does not fall, and then remove the brake disc. 2. Remove the hub cap. 3.
Page 571: Rear Hub Assembly
27A-5 REAR AXLE <2WD> - Rear Hub Assembly REAR HUB ASSEMBLY 27100200294 REMOVAL AND INSTALLATION Caution 1. For the vehicles with ABS, care must be taken not to scratch or damage the teeth of the ABS rotor. The ABS rotor must never be dropped. If the teeth of the ABS rotor are chipped, resulting in a deformation of the ABS rotor, it will not be able to accurately detect the wheel rotation speed, and the system will not function normally.
Page 572 27A-6 REAR AXLE <2WD> - Rear Hub Assembly REMOVAL SERVICE POINTS AA" CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, so that it does not fall. AB" FLANGE NUT REMOVAL Caution MB990767 Do not apply the vehicle weight to the wheel bearing while loosening the flange nut, or the wheel bearing will be damaged.
Page 573 27B-1 REAR AXLE <4WD> CONTENTS 27109000260 Limited Slip Differential Condition Check GENERAL INFORMATION ....(VCU Type) ....... . . SERVICE SPECIFICATIONS .
Page 574: General Information
27B-2 REAR AXLE <4WD> - General Information/Service Specifications GENERAL INFORMATION 27100010231 The drive shaft has two joints (D.O.J. and B.J.) In addition, for vehicles with ABS, an ABS rotor at each side. The D.O.J. joint at the differential for detecting vehicle wheel speed is mounted in side can slide smoothly in the axial direction.
Page 575: Lubricants
27B-3 REAR AXLE <4WD> - Lubricants/Sealants and Adhesives/Special Tools LUBRICANTS 27100040131 Items Specified lubricant Quantity Gear oil Hypoid gear oil API classification GL-5 or higher 0.55 L SAE viscosity No. 90, 80W B.J. Vehicles without ABS Repair kit grease 75 g Vehicles with ABS Repair kit grease 145 g...
Page 576 27B-4 REAR AXLE <4WD> - Special Tools Tool Number Name MB990241 Axle shaft puller Drive shaft removal Rear hub assembly removal A: MB990242 A: Puller shaft B: MB990244 B: Puller bar A: MB991017 A, B: Front hub Wheel bearing provisional holding remover and MB991000, which belongs to MB990998, B: MB990998...
Page 577 27B-5 REAR AXLE <4WD> - Special Tools Tool Number Name MB990810 Bearing puller Side bearing inner race removal Companion flange removal MB990850 End yoke holder Companion flange removal and installation MB990339 Bearing puller Drive pinion rear bearing inner race removal MB990374 Pinion bearing remover...
Page 578: On-Vehicle Service
27B-6 REAR AXLE <4WD> - Special Tools/On-vehicle Service Tool Number Name MB991357 Side gear holding Limited slip differential gear backlash tool inspection ON-VEHICLE SERVICE 27100120156 REAR AXLE TOTAL BACKLASH CHECK If the vehicle vibrates and produces a booming sound due to an imbalance of the driving system, measure the rear axle total backlash by the following procedures to see if the differential carrier assembly requires removal.
Page 579: Gear Oil Level Check
27B-7 REAR AXLE <4WD> - On-vehicle Service GEAR OIL LEVEL CHECK 27200120135 1. Remove the filler plug. Gear oil 2. Check that the gear oil level is between the upper limit (the bottom of a filler plug) and the lower limit. 3.
Page 580: Limited Slip Differential Condition Check (Vcu Type)
27B-8 REAR AXLE <4WD> - On-vehicle Service LIMITED SLIP DIFFERENTIAL CONDITION CHECK (VCU TYPE) 27300100033 1. Place the shift lever in the neutral position and block the front wheels with chocks. 2. Release the parking brake lever fully. 3. Jack up the rear wheels and apply rigid racks to the specified positions of the side sills.
Page 581: Rear Hub Assembly
27B-9 REAR AXLE <4WD> - Rear Hub Assembly REAR HUB ASSEMBLY 27100200300 REMOVAL AND INSTALLATION Removal steps 1. Rear hub assembly (Refer to GROUP 34 - Lower Arm Assembly.) 2. Hub bolt...
Page 582: Drive Shaft
27B-10 REAR AXLE <4WD> - Drive Shaft DRIVE SHAFT 27100330085 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Main Muffler Assembly Removal and Installation <Right drive shaft only> (Refer to GROUP 15.) 54 - 64 Nm 196 - 255 Nm Removal steps 1.
Page 583 27B-11 REAR AXLE <4WD> - Drive Shaft Caution Do not apply the vehicle weight to the wheel bearing as 196 - 255 Nm possible while loosening the drive shaft nut. Otherwise the wheel bearing may be damaged. If, however, the vehicle weight must be applied to the bearing (because of moving the vehicle), temporarily secure the wheel bearing by using the special tool.
Page 584 27B-12 REAR AXLE <4WD> - Drive Shaft DISASSEMBLY AND REASSEMBLY 27100350067 B.J. repair kit D.O.J. repair kit B.J. boot repair kit D.O.J. boot repair kit Disassembly steps "DA 1. D.O.J. boot band (large) AB" "BA 8. D.O.J. cage "DA 2. D.O.J. boot band (small) AC"...
Page 585 27B-13 REAR AXLE <4WD> - Drive Shaft DISASSEMBLY SERVICE POINTS AA" D.O.J. OUTER RACE REMOVAL Withdraw the D.O.J. outer race from the B.J. assembly, and then clean wipe grease from the D.O.J. outer race. AB" BALL/SNAP RING/D.O.J. INNER RACE/D.O.J. Mating marks CAGE REMOVAL 1.
Page 586 27B-14 REAR AXLE <4WD> - Drive Shaft REASSEMBLY SERVICE POINTS "AA B.J. BOOT/D.O.J. BOOT INSTALLATION 1. Wrap a plastic tape around the spline of the drive shaft, and then remove the B.J. boot and D.O.J. boot in that order. 2. Fill the specified grease inside the B.J. and B.J. boot. Specified grease: Repair kit grease Amount to use: <Vehicles without ABS>...
Page 587 27B-15 REAR AXLE <4WD> - Drive Shaft "CA BALL/D.O.J. OUTER RACE INSTALLATION 1. Apply the specified grease to the balls, D.O.J cage and D.O.J. inner race, and then align the mating marks on the D.O.J. cage and D.O.J. inner race to assemble the balls.
Page 588: Differential Mount
27B-16 REAR AXLE <4WD> - Differential Mount DIFFERENTIAL MOUNT 27200650016 REMOVAL AND INSTALLATION 98 - 118 Nm 103 Nm 54 - 64 Nm 108 - 127 Nm 29 - 34 Nm Bracket assembly removal steps Differential support member removal steps AA"...
Page 589 27B-17 REAR AXLE <4WD> - Differential Mount AC" BRACKET ASSEMBLY REMOVAL 1. Support the bottom of the differential carrier with a transmission jack, and then remove the bracket assembly retaining bolts. 2. Lower the front of the differential carrier, and then remove the bracket assembly.
Page 590 27B-18 REAR AXLE <4WD> - Differential Mount INSPECTION 2720660019 Check the bracket assembly for cracks or deformation. Check the differential support member for cracks or deformation. Check the bushings for cracks or deterioration. BUSHING REPLACEMENT 27200670012 Bushing A Bushing B BUSHING A MB991318 1.
Page 591 27B-19 REAR AXLE <4WD> - Differential Mount BUSHING B MB990651 1. Position special tool MB991407 on the shorter projection Differential support member of the bushing inner pipe, and then press out the bushing. MB991407 MB990884 MB990890 Inner pipe 2. Press in the bushing so that the longer projection of the Differential carrier side bushing inner pipe is at the differential carrier side.
Page 592: Differential Carrier
27B-20 REAR AXLE <4WD> - Differential Carrier DIFFERENTIAL CARRIER 27200200174 REMOVAL AND INSTALLATION 98 - 118 Nm 103 Nm 29 - 34 Nm 49 Nm 59 - 69 Nm 54 - 64 Nm Removal steps "CA 1. Filler plug AC" 5.
Page 593 27B-21 REAR AXLE <4WD> - Differential Carrier AC" DIFFERENTIAL CARRIER ASSEMBLY REMOVAL Support the bottom of the differential carrier with a transmission jack, and then remove the differential support member bolts and the bracket assembly retaining bolts. Transmission jack AD" COMPANION SHAFT REMOVAL Secure the differential carrier in a vise, and then use the MB991354 special tool to withdraw the companion shaft.
Page 594 27B-22 REAR AXLE <4WD> - Differential Carrier DISASSEMBLY 27200220170 <Conventional differential> 11 12 23 24 25 21 22 17 18 <Limited slip differential> Disassembly steps AA" D Inspection before disassembly 16. Limited slip differential case assem- 1. Differential cover assembly bly (Refer to P.27-37.) 2.
Page 595 27B-23 REAR AXLE <4WD> - Differential Carrier DISASSEMBLY SERVICE POINTS MB991116 AA" INSPECTION BEFORE DISASSEMBLY MB990909 Hold the special tool in a vice, and attach the differential carrier to the special tool. DRIVE GEAR BACKLASH CHECK Check the drive gear backlash by the following procedure: 1.
Page 596 27B-24 REAR AXLE <4WD> - Differential Carrier Attachment DIFFERENTIAL GEAR BACKLASH CHECK Wedge Check the differential gear backlash by the following procedure: 1. Lock a piece of wood between the side gear and the pinion shaft to hold one of the side gears in place. Then place a dial gauge (through a suitable extension) on one Pinion shaft of the pinion gears, and check if the backlash is within...
Page 597 27B-25 REAR AXLE <4WD> - Differential Carrier Standard tooth contact pattern Problem Solution Narrow tooth side Tooth contact pattern resulting from Drive-side tooth surface excessive pinion height (the side applying power during forward movement) Wide tooth side Coast-side tooth surface (the side applying power during reverse movement) The drive pinion is positioned too far...
Page 598 27B-26 REAR AXLE <4WD> - Differential Carrier AB" DIFFERENTIAL CASE ASSEMBLY REMOVAL Caution Remove the differential case assembly, slowly and carefully so that the side bearing outer race is not dropped. NOTE Be sure to keep the side bearing spacers and outer races in order so that they may be reinstalled in their original positions.
Page 599 27B-27 REAR AXLE <4WD> - Differential Carrier AG" DRIVE PINION ASSEMBLY REMOVAL MB990810 1. Make mating marks on the drive pinion and the companion flange for reassembly purpose. Caution Mating marks should not be made to the contact surfaces of companion flange and propeller shaft. Companion 2.
Page 600 27B-28 REAR AXLE <4WD> - Differential Carrier REASSEMBLY 27200230159 <Conventional differential> 34 - 39 Nm* 35 Nm 186 Nm 78 - 88 Nm* 26 27 13 12 <Limited slip differential> 27 26 Differential gear set Final drive gear set 78 - 88 Nm* 26 27 Reassembly steps 1.
Page 601 27B-29 REAR AXLE <4WD> - Differential Carrier LUBRICATION, SEALING AND ADHESIVE POINTS 3.0 mm Sealant: 3M ATD Part No. 8663 or equivalent <Conventional differential> <Limited slip differential> Adhesive: 3M Stud Locking Part No. 4170 or equivalent...
Page 602 27B-30 REAR AXLE <4WD> - Differential Carrier REASSEMBLY SERVICE POINTS "AA OIL SEAL INSTALLATION 1. Use the special tool to press in the new oil seal fully. MB990938 2. Lightly apply multipurpose grease to the oil seal lip. MB991115 "BA DRIVE PINION REAR BEARING OUTER FRONT BEARING REAR BEARING RACE/DRIVE PINION FRONT BEARING OUTER...
Page 603 27B-31 REAR AXLE <4WD> - Differential Carrier 4. Clean the side bearing seat thoroughly. MB990392 Cutout section 5. Set the special tools in place of the side bearings, and (MB990835) align the cutout section as shown. Then make sure that the special tools are secured.
Page 604 27B-32 REAR AXLE <4WD> - Differential Carrier 2. Tighten the companion flange to the specified torque by using special tools. 186 Nm MB990850 3. Measure the drive pinion turning torque (without the oil seal) by using the special tools. MB990326 Standard value: Bearing Bearing lubrication...
Page 605 27B-33 REAR AXLE <4WD> - Differential Carrier 8. Measure the drive pinion turning torque (with the oil seal) MB990326 by using the special tools to verify that the drive pinion turning torque complies with the standard value. Standard value: Bearing Bearing lubrication Turning division...
Page 606 27B-34 REAR AXLE <4WD> - Differential Carrier "FA LOCK PIN INSTALLATION 1. Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin. 2. Stake the lock pin with a punch at two points. "GA DRIVE GEAR INSTALLATION 1.
Page 607 27B-35 REAR AXLE <4WD> - Differential Carrier 2. Push the differential case to one side, and measure the clearance between the gear carrier and the side bearing adjusting spacer with a thickness gauge. 3. Measure the thickness of the side bearing spacers on one side, select two pairs of spacers which correspond to that thickness plus one half of the clearance plus 0.05 mm, and then install one pair each to the drive pinion...
Page 608 27B-36 REAR AXLE <4WD> - Differential Carrier 7. With the drive pinion locked in place, measure the drive gear backlash with a dial indicator on the drive gear. NOTE Measure at four points or more on the circumference of the drive gear. Standard value: 0.11 - 0.16 mm 8.
Page 609: Lsd Case Assembly
27B-37 REAR AXLE <4WD> - LSD Case Assembly LSD CASE ASSEMBLY 27300140066 DISASSEMBLY AND REASSEMBLY Disassembly steps AA" D Inspection before disassembly "BA 5. Pinion mate washer 1. Screw "BA 6. Differential pinion mate "AA 2. Differential case (A) 7. Differential pinion shaft AB"...
Page 610 27B-38 REAR AXLE <4WD> - LSD Case Assembly 3. Insert the special tool in the splined portion of the differential side gear (R.H.) and make sure that the side gear (R.H.) turns. 4. Replace the thickness gauges with 0.09 mm thickness Thickness gauges gauges.
Page 611 27B-39 REAR AXLE <4WD> - LSD Case Assembly REASSEMBLY SERVICE POINTS Differential "AA DIFFERENTIAL CASE (B)/DIFFERENTIAL CASE case (B) (A) INSTALLATION Install the differential cases (A) and (B) with their mating Differential Mating marks case (A) marks in alignment. MB990989 "BA DIFFERENTIAL PINION MATE/PINION MATE Pinion mate WASHER INSTALLATION...
Page 612 27B-40 REAR AXLE <4WD> - LSD Case Assembly INSPECTION 27300150038 Differential side gear (R.H.) 1. Check each gear and the differential pinion shaft for wear Differential pinion mate and damage. 2. Check the splined portion of the differential side gear (R.H.) for damage and shoulder.
Page 613 31-1 WHEEL AND TYRE CONTENTS 31109000182 GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Tyre Inflation Pressure Check .
Page 614 31-2 WHEEL AND TYRE - General Information/Service Specifications GENERAL INFORMATION 31100010276 The wheels and tyres of the following specifications have been established. SPECIFICATIONS 31100030135 Items Specification Wheel Type Steel Aluminium* 15 ¢ 6JJ Size Amount of wheel offset mm Pitch circle diameter (P.C.D.) mm 114.3 Tyre Size...
Page 615 31-3 WHEEL AND TYRE - Troubleshooting TROUBLESHOOTING 31100070205 Symptom Probable cause Remedy Reference page Rapid wear at Under-inflation Adjust the tyre 31-4. shoulders or lack of rotation pressure. Rapid wear at Over-inflation or centre lack of rotation Cracked treads Under-inflation Adjust the tyre 31-4.
Page 616 31-4 WHEEL AND TYRE - On-vehicle Service/Wheel and Tyre ON-VEHICLE SERVICE 31100090164 TYRE INFLATION PRESSURE CHECK NOTE For information on tyre inflation pressure, refer to the label attached to the driver’s side front door. TYRE WEAR CHECK 31100100034 Measure the tread depth of tyres. Limit: 1.6 mm If the remaining tread depth is less than the limit, replace the tyre.
Page 617 32-1 POWER PLANT MOUNT CONTENTS 32109000165 GENERAL INFORMATION ....FRONTMEMBER ......ENGINE MOUNTING .
Page 618 32-2 POWER PLANT MOUNT - General Information GENERAL INFORMATION 32100010150 The engine-transmission mount is of an inertial axis the front upper part of the engine at the front and supporting type whose excellent features have the rear upper part of the transmission at the rear. already been proven in many Mitsubishi vehicles.
Page 619: Engine Mounting
32-3 POWER PLANT MOUNT - Engine Mounting ENGINE MOUNTING 32100110263 REMOVAL AND INSTALLATION Caution Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Engine Cover Removal and Installation Jack Up the Engine and Transmission Assembly until Weight is off the Insulator.
Page 620 32-4 POWER PLANT MOUNT - Transmission Mounting TRANSMISSION MOUNTING 32100140170 REMOVAL AND INSTALLATION Caution Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation (Refer to GROUP 15) Frontmember Removal and Installation...
Page 621: Power Plant Mount
32-5 POWER PLANT MOUNT - Transmission Mounting/Frontmember INSTALLATION SERVICE POINT Engine side "AA TRANSMISSION MOUNT STOPPER INSTALLATION Install the transmission mount stopper so that the arrow faces the direction shown. Transmission NOTE mount Transmission Disregard F and R stamped as a shared part. bracket mount stopper FRONTMEMBER...
Page 622 32-6 POWER PLANT MOUNT - Frontmember 39 Nm 12 Nm 39 Nm 69 Nm 44 Nm* 98 - 118 Nm 13 Nm 57 Nm* 98 - 118 Nm* 88 - 108 Nm 177 Nm 78 Nm 88 - 108 Nm* 177 Nm 57 Nm* Frontmember removal steps...
Page 623 32-7 POWER PLANT MOUNT - Frontmember REMOVAL SERVICE POINT AA" STEERING GEAR AND LINKAGE MOUNTING BOLT REMOVAL Use a wire to fix the steering gear box on the vehicle before removing the steering gear and linkage mounting bolts. AB" FRONTMEMBER MOUNTING BOLT REMOVAL Wooden 1.
Page 624 32-8 POWER PLANT MOUNT - Roll Stopper ROLL STOPPER 32100140170 Caution Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the engine on the vehicle body. 44 Nm* 57 Nm* 57 Nm* 98 - 118 Front roll stopper removal steps...
Page 625 33A-1 FRONT SUSPENSION CONTENTS 33109000094 GENERAL INFORMATION ....STRUT ASSEMBLY ......SERVICE SPECIFICATIONS .
Page 626: General Information
33A-2 FRONT SUSPENSION - General Information/Service Specifications GENERAL INFORMATION 33100010089 The front suspension is a McPherson strut with coil spring. The shock absorber is hydraulic double-acting type. COIL SPRING Items SPACE RUNNER SPACE WAGON - 2WD SPACE WAGON - 4WD Wire diameter ´...
Page 627: Special Tools
33A-3 FRONT SUSPENSION - Special Tools SPECIAL TOOLS 33100060077 Tools Number Name MB991004 Wheel alignment Wheel alignment measurement gauge attachment <Vehicles with aluminium type wheelsd A: MB991237 A: Spring compres- Coil spring compression sor body B: MB991238 B: Arm set A: MB991619 A: Wrench Strut assembly disassembly and reassembly...
Page 628: On-Vehicle Service
33A-4 FRONT SUSPENSION - Special Tools/On-vehicle Service Tools Number Name MB991164 Door adjusting Stabilizer bar bracket mounting bolt removal wrench and installation ON-VEHICLE SERVICE 33100090267 WHEEL ALIGNMENT CHECK AND ADJUSTMENT Measure the wheel alignment with the vehicle parked on a level surface.
Page 629: Ball Joint Dust Cover Check
33A-5 FRONT SUSPENSION - On-vehicle Service CAMBER, CASTER AND KINGPIN INCLINATION MB991004 Standard value: Item SPACE SPACE RUNNER WAGON Camber (difference between right 0_00’ ± 30’ - 0_10’ ± 30’ and left wheel: less than 30’) Caster (difference between right 2_45’...
Page 630: Strut Assembly
33A-6 FRONT SUSPENSION - Strut Assembly STRUT ASSEMBLY 33200110126 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Injector Driver Removal (Refer to GROUP 13.) Injector Driver Installation (Refer to GROUP 13.) Check the Dust Cover for Cracks or Damage by Pushing it with Finger. Wheel Alignment Check and Adjustment (Refer to P.33A-4.) 44 Nm...
Page 631 33A-7 FRONT SUSPENSION - Strut Assembly DISASSEMBLY AND REASSEMBLY 33200130139 69 - 78 Nm Disassembly steps AA" "AA 1. Self-locking nut 6. Upper spring pad 2. Washer 7. Bump rubber 3. Strut insulator assembly 8. Coil spring 4. Bearing 9. Spring tube 5.
Page 632 33A-8 FRONT SUSPENSION - Strut Assembly DISASSEMBLY SERVICE POINT MB991238 AA" SELF-LOCKING NUT REMOVAL 1. Use the special tools to compress the coil spring. Caution (1) To compress the coil spring sufficiently, install the special tools evenly, and so that the maximum length will be attained within the installation range.
Page 633 33A-9 FRONT SUSPENSION - Strut Assembly 5. Using the special tool, tighten the self-locking nut to the specified torque. MB991682 Specified torque: 69 - 78 Nm Caution MB991619 Do not use an impact wrench as internal parts of the strut assembly will be loosened. INSPECTION 33200140064 Check the bearing for wear or rust.
Page 634: Lower Arm Assembly
33A-10 FRONT SUSPENSION - Lower Arm Assembly LOWER ARM ASSEMBLY 33200160121 REMOVAL AND INSTALLATION Caution To prevent bushings from breakage”the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger.
Page 635 33A-11 FRONT SUSPENSION - Lower Arm Assembly REMOVAL SERVICE POINTS AA" TIE ROD END DISCONNECTION MB991406, MB990635 or Caution MB991113 1. Loosen the nut of the special tool, but do not remove Ball joint it. If it is removed, the ball joint thread will be damaged. Cord 2.
Page 636 33A-12 FRONT SUSPENSION - Lower Arm Assembly INSPECTION 33200170117 Check the bushing for wear and deterioration. Check the lower arm for bend or breakage. Check the stay for deterioration or damage. Check all bolts for condition and straightness. LOWER ARM BALL JOINT ROTATION STARTING TORQUE CHECK MB991006 1.
Page 637 33A-13 FRONT SUSPENSION - Lower Arm Assembly BUSHING REPLACEMENT Bushing 33200810118 Replace the rear bushing by the following procedure. 1. Use the special tools to drive out the bushing. MB990651 Lower arm MD998716 assembly Piece metal 2. Use the special tools to presss in the bushing. 3.
Page 638: Stabilizer Bar
33A-14 FRONT SUSPENSION - Stabilizer Bar STABILIZER BAR 33200190137 REMOVAL AND INSTALLATION Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger. 39 Nm 39 Nm 39 Nm Removal steps 1. Stabilizer link NOTE D Front member (Refer to GROUP 32.) If only the bushing is removed and installed, refer to "AA 2.
Page 639 33A-15 FRONT SUSPENSION - Stabilizer Bar INSPECTION 332000200076 Check the bushing for wear and deterioration. Check the stabilizer bar for deterioration or damage. Check all bolts for condition and straightness. STABILIZER LINK BALL JOINT TURNING TORQUE MB990326 CHECK 1. After shaking the ball joint stud several times, install the nut to the stud and use the special tool to measure the turning torque of the ball joint.
Page 640 33A-16 FRONT SUSPENSION - Stabilizer Bar 3.Use the special tool to remove the stabilizer bar bracket mounting bolt. Stabilizer bar bracket 4. Remove the stabilizer bar bracket. MB991164 Bushing 5. Position a new bushing so that its cut is as shown. Front side of 6.
Page 641 34-1 REAR SUSPENSION CONTENTS 34109000206 GENERAL INFORMATION ....SHOCK ABSORBER ASSEMBLY ... SERVICE SPECIFICATIONS .
Page 642: General Information
34-2 REAR SUSPENSION - General Information/Service Specifications GENERAL INFORMATION 34100010277 The rear suspension is a semi-trailing arm type suspension. COIL SPRING Items SPACE RUNNER SPACE WAGON Wire diameter ´ average diameter ´ free length mm 13 ´ 113 ´ 278 14 - 15 ´...
Page 643: Special Tools
34-3 REAR SUSPENSION - Special Tools SPECIAL TOOLS 34100060180 Tool Number Name MB991004 Wheel alignment Wheel alignment measurement gauge attachment cVehicles with aluminium type wheelsd Rear hub assembly removal <4WD> MB990241 Axle shaft puller A: MB990242 A: Puller shaft B: MB990244 B: Puller bar MB991354 Puller body...
Page 644: On-Vehicle Service
34-4 REAR SUSPENSION - Special Tools/On-vehicle Service Tool Number Name A: MB991017 A, B: Front hub Wheel bearing provisional holding remover and MB991000, which belongs to MB990998, B: MB990998 installer should be used as a spacer. C: MB991000 C: Spacer MB990326 Preload socket Wheel bearing rotation starting torque...
Page 645: Wheel Bearing Axial Play Check <4Wd
34-5 REAR SUSPENSION - On - vehicle Service CAMBER MB991004 Standard value: - 0_45’ ± 30’ (difference between right and left wheels: less than 30’ ) NOTE 1. Camber is preset at the factory and can not be adjusted. 2. For vehicles equipped with aluminium wheels, measure the camber after tightening the special tool (MB991004) to the specified torque 226 Nm.
Page 646: Shock Absorber Assembly
34-6 REAR SUSPENSION - Shock Absorber Assembly SHOCK ABSORBER ASSEMBLY 34100510197 REMOVAL AND INSTALLATION Caution To prevent a bushing from breakage, the part indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. 44 Nm 103 Nm* Removal steps...
Page 647 34-7 REAR SUSPENSION - Shock Absorber Assembly DISASSEMBLY AND REASSEMBLY 34100530155 25 Nm Disassembly steps AA" "AA 1. Self-locking nut 7. Upper bushing 2. Washer 8. Cup assembly 3. Collar 9. Bump rubber 4. Upper bushing 10. Dust cover 5. Gasket 11.
Page 648: Rear Spring
34-8 REAR SUSPENSION - Rear spring REAR SPRING 34100610019 REMOVAL AND INSTALLATION Caution To prevent bushings from breakage”the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal Operation Post-installation Operation Main Muffler assembly Removal <4WD>...
Page 649 34-9 REAR SUSPENSION - Rear spring REMOVAL SERVICE POINTS AA" BOLT REMOVAL <4WD> Remove the bolt, and then hold the drive shaft to the vehicle body with a wire. AB" SHOCK ABSORBER MOUNTING BOLT REMOVAL Support the lower arm assembly with a transmission jack, and after compressing the coil spring, remove the shock absorber mounting bolt.
Page 650: Lower Arm Assembly
34-10 REAR SUSPENSION - Lower Arm Assembly LOWER ARM ASSEMBLY 34100650011 REMOVAL AND INSTALLATION <2WD> Caution To prevent bushings from breakage”the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal Operation Post-installation Operation Brake Fluid Draining...
Page 651 34-11 REAR SUSPENSION - Lower Arm Assembly <4WD> Caution To prevent bushings from breakage”the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal Operation Post-installation Operation Brake Fluid Draining Coil Spring Installation (Refer to P.34-8.) Drive Shaft Removal...
Page 652 34-12 REAR SUSPENSION - Lower Arm Assembly REMOVAL SERVICE POINTS Mating marks AA" BOLT ASSEMBLY REMOVAL Matchmark the lower arm bolt assembly and the crossmember, and remove the bolt assembly. Crossmember Bolt assembly AB" REAR HUB ASSEMBLY REMOVAL <4WD> Caution MB991354 The ball bearing will be damaged when the rear hub is removed.
Page 653 34-13 REAR SUSPENSION - Lower Arm Assembly INSTALLATION SERVICE POINTS MB991400 "AA WHEEL BEARING INSTALLATION <4WD> Wheel bearing Lower arm assembly MB991401 "BA REAR HUB ASSEMBLY INSTALLATION <4WD> MB991400 Rear hub assembly Lower arm assembly MB991411 "CABOLT ASSEMBLY INSTALLATION Align the marks on the lower arm bolt assembly and the crossmember, and tighten the nut.
Page 654 34-14 REAR SUSPENSION - Lower Arm Assembly INSPECTION 34100660014 Check the lower arm for deformation and deterioration. Check all bolts for condition and straightness. Check the spring seats for cracks and wear. WHEEL BEARING ROTATION STARTING TORQUE CHECK <4WD> 1. Install the special tool to the rear hub assembly and tighten the nut to the specified torque 196 - 255 Nm.
Page 655: Suspension Crossmember
34-15 REAR SUSPENSION - Suspension Crossmember SUSPENSION CROSSMEMBER 34100680010 REMOVAL AND INSTALLATION Caution To prevent bushings from breakage”the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal Operation Post-installation Operation Brake Fluid Draining...
Page 656 34-16 REAR SUSPENSION - Suspension Crossmember REMOVAL SERVICE POINTS AA" LIFT SUPPORTING POINT When the suspension crossmember is lowered from the vehicle, slide a lift arm to the front side of the vehicle slightly to make sure that the crossmember does not interfere with nearby parts.
Page 657 34-17 REAR SUSPENSION - Suspension Crossmember SUSPENSION CROSSMEMBER BUSHING REAR FRONT REPLACEMENT MB991318 34101420017 MB991318 1. Make a mark on the crossmember bracket to match the slits on the old bushing, and use these marks to position the new bushing. 2.
Page 658: Stabilizer Bar
34-18 REAR SUSPENSION - Stabilizer Bar STABILIZER BAR 34100710016 REMOVAL AND INSTALLATION 29 - 34 Nm 23 Nm Removal steps "CA 1. Self-locking nut 6. Collar 2. Bolt "AA 7. Fixture 3. Joint cap A "AA 8. Bushing 4. Stabilizer rubber AA"...
Page 659 34-19 REAR SUSPENSION - Stabilizer Bar INSTALLATION SERVICE POINTS Inside of the Approx. 10 mm vehicle "AA STABILIZER BAR/BUSHING/FIXTURE INSTALLATION Position the stabilizer bar at the left side of the vehicle so that its identification mark is as shown, and then tighten the fixture mounting nut assembly.
Page 660 NOTES...
Page 661: Service Brakes
35A-1 SERVICE BRAKES CONTENTS 35109000463 BASIC BRAKE SYSTEM ......... ANTI-SKID BRAKING SYSTEM (ABS) <2WD>...
Page 662 35A-2 BASIC BRAKE SYSTEM CONTENTS 35109000470 Disc Brake Pad Check and Replacement ..GENERAL INFORMATION ....Disc Brake Rotor Check .
Page 663: General Information
35A-3 BASIC BRAKE SYSTEM - General Information GENERAL INFORMATION 35100010298 The brake system offers high dependability and durability along with improved braking performance and brake sensitivity. Items Specifications Master cylinder Type Tandem type I.D. mm 25.4 Brake booster Type Vacuum type, single Effective dia.
Page 664 35A-4 BASIC BRAKE SYSTEM - General Information CONSTRUCTION DIAGRAM SPACE RUNNER Brake booster Hydraulic unit Rear brake Proportioning valve <Vehicles without ABS> Master cylinder Proportioning valve <Vehicles with ABS> Front brake SPACE WAGON Brake booster Hydraulic unit Rear brake Load sensing proportioning valve Master cylinder Front brake...
Page 665: Service Specifications
35A-5 BASIC BRAKE SYSTEM - Service Specifications SERVICE SPECIFICATIONS 35100030379 Items Standard value Limit Brake pedal height mm L.H. drive vehicles 219 - 222 R.H. drive vehicles 206 - 209 Brake pedal free play mm 3 - 8 Brake pedal to floor board clearance mm 90 or more Proportioning valve Split point MPa...
Page 666: Lubricants
35A-6 BASIC BRAKE SYSTEM - Lubricants/Special Tools LUBRICANTS 35100040167 Items Specified Lubricant Brake fluid DOT3 or DOT4 Brake piston seal Repair kit grease Slide pin boot and slide pin bush inner surfaces Brake piston boot inner surfaces Piston boot mounting grooves SPECIAL TOOLS 35100060187 Tool...
Page 667: On-Vehicle Service
35A-7 BASIC BRAKE SYSTEM - On-vehicle Service ON-VEHICLE SERVICE 35100090285 BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT Stop lamp Operating switch 1. Turn up the carpet, etc. under the brake pedal. 2. Measure the brake pedal height as illustrated. Operating rod lock nut Standard value (A):...
Page 668: Brake Booster Operating Test
35A-8 BASIC BRAKE SYSTEM - On-vehicle Service BRAKE PEDAL FREE PLAY 1. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value range.
Page 669: Check Valve Operation Check
35A-9 BASIC BRAKE SYSTEM - On-vehicle Service 2. With the engine stopped, step on the brake pedal several When engine is When engine is times. stopped started Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition.
Page 670: Proportioning Valve Function Test
35A-10 BASIC BRAKE SYSTEM - On-vehicle Service PROPORTIONING VALVE FUNCTION TEST Pressure gauge <SPACE RUNNER> 35100110257 1. Connect two pressure gauges at the input and output side of the proportioning valve as shown. Caution The proportioning valves are installed independently Proportioning for the right and left brake lines.

Page 671: Load Sensing Proportioning Valve Function Test
35A-11 BASIC BRAKE SYSTEM - On-vehicle Service LOAD SENSING PROPORTIONING VALVE Pressure gauge FUNCTION TEST <SPACE WAGON> 35100130048 1. Connect pressure gauges to the input and output ports of the load sensing proportioning valve. 2. Bleed the system. (Refer to P.35A-12.) 3.

Page 672: Brake Fluid Level Sensor Check
35A-12 BASIC BRAKE SYSTEM - On-vehicle Service BRAKE FLUID LEVEL SENSOR CHECK 35100910147 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”. BLEEDING 35100140089 Caution...
Page 673: Disc Brake Pad Check And Replacement
35A-13 BASIC BRAKE SYSTEM - On-vehicle Service DISC BRAKE PAD CHECK AND REPLACEMENT When new When worn 35100230045 NOTE The left side outer brake pad has a wear indicator. The wear indicator contacts the brake disc when the brake pad thickness becomes 2 mm and emit a squealing sound to warn the driver.
Page 674: Disc Brake Rotor Check
35A-14 BASIC BRAKE SYSTEM - On-vehicle Service DISC BRAKE ROTOR CHECK 35100290012 Caution When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation. Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.
Page 675: Brake Disc Run-Out Check
35A-15 BASIC BRAKE SYSTEM - On-vehicle Service BRAKE DISC RUN-OUT CHECK 35100250027 1. Remove the caliper support; then raise the caliper assembly upward and secure by using wire. 2. Inspect the disc surface for grooves, cracks and rust. Clean the disc thoroughly and remove all rust. 3.
Page 676: Brake Pedal
35A-16 BASIC BRAKE SYSTEM - Brake Pedal BRAKE PEDAL 35100340359 REMOVAL AND INSTALLATION Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-7.) 14 Nm 12 Nm Removal steps 1. Harness connector 6. Pin assembly 2. Stop lamp switch 7. Split pin <A/T> 3.
Page 677: Master Cylinder And Brake Booster
35A-17 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER 35100370389 REMOVAL AND INSTALLATION Caution For the reservoir hose marked with *, disconnect the reservoir assembly-side connection only and do not lower the disconnected hose below the master cylinder to prevent the air from entering into brake fluid line.
Page 678 35A-18 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster INSTALLATION SERVICE POINT "AA PUSH ROD PROTRUDING LENGTH CHECK AND ADJUSTMENT 1. Measure dimension A. Standard value: 9.98 - 10.23 mm Measuring dimension A Block gauge 2. If the protruding length is not within the standard value range, adjust by changing the push rod length by turning the end of the push rod.
Page 679: Master Cylinder
35A-19 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster MASTER CYLINDER 35100420190 DISASSEMBLY AND REASSEMBLY Master cylinder kit Brake fluid: DOT3 or DOT4 Disassembly steps 1. Spring pin 5. Primary piston assembly 2. Nipple 6. Secondary piston assembly 3. Reservoir seal 7.
Page 680: Disc Brake
35A-20 BASIC BRAKE SYSTEM - Disc Brake DISC BRAKE 35100800048 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-12.) <FRONT> <REAR> 90 - 110 Nm 55 - 65 Nm 29 Nm Removal steps 1.
Page 681 35A-21 BASIC BRAKE SYSTEM - Disc Brake (3) Use a spring balance to measure the rotary-sliding resistance of the hub in the forward direction. 2. After installing the caliper support to the knuckle, install the pad clips and the pads to the caliper support. Caution Do not let any oil, grease or other contamination get onto the friction surfaces of the pads and brake discs.
Page 682 35A-22 BASIC BRAKE SYSTEM - Disc Brake DISASSEMBLY AND REASSEMBLY 35100820044 <FRONT> Clip set 74 Nm 8 Nm 74 Nm Grease Grease 8 7 6 Brake caliper kit Pad set Seal and boots kit Shim set Disassembly steps "AA 1. Guide pin AA"...
Page 683 35A-23 BASIC BRAKE SYSTEM - Disc Brake <REAR> 43 Nm 8 Nm Clip set Grease Brake caliper kit Pad set Shim set Seal and boots kit Disassembly steps "AA 1. Guide pin AA" 8. Piston "AA 2. Lock pin AB" 9.
Page 684 35A-24 BASIC BRAKE SYSTEM - Disc Brake LUBRICATION POINTS Piston seal Grease: Repair kit grease Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off. Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Grease: Repair kit grease...
Page 685 35A-25 BASIC BRAKE SYSTEM - Disc Brake DISASSEMBLY SERVICE POINTS AA" PISTON BOOT/PISTON REMOVAL <FRONT> Withdraw the piston and piston boot while applying compressed air through the brake hose connection hole. At this time, use a plastic hammer as shown to adjust so that the two pistons will protrude evenly.
Page 686 35A-26 BASIC BRAKE SYSTEM - Disc Brake INSPECTION 35100630173 Check cylinder for wear, damage or rust. Check piston surface for wear, damage or rust. Check caliper body or sleeve for wear. Check pad for damage or adhesion of grease, check backing metal for damage.
Page 687 35A-27 BASIC BRAKE SYSTEM - Proportioning Valve <SPACE RUNNER> PROPORTIONING VALVE <SPACE RUNNER> 35100570260 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-12.) <Vehicles without ABS> 15 Nm <Vehicles with ABS> 30 Nm Removal steps 1.
Page 688 35A-28 BASIC BRAKE SYSTEM - Load Sensing Proportioning Valve <SPACE WAGON> LOAD SENSING PROPORTIONING VALVE <SPACE WAGON> 35100540025 REMOVAL AND INSTALLATION Caution Do not disassemble the load sensing proportioning valve. Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-12.) 15 Nm Removal steps...
Page 689 35B-1 ANTI-SKID BRAKING SYSTEM (ABS) <2WD> CONTENTS 35209000299 GENERAL INFORMATION ....Brake Fluid Level Sensor Check ......Refer to GROUP 35A SERVICE SPECIFICATIONS .
Page 690: Proportioning Valve
35B-2 BRAKE PEDAL ..Refer to GROUP 35A LOAD SENSING PROPORTIONING VALVE <SPACE WAGON> ..Refer to GROUP 35A MASTER CYLINDER AND BRAKE BOOSTER ... . Refer to GROUP 35A HYDRAULIC UNIT AND ABS-ECU .
Page 691 35B-3 ABS <2WD> - General Information/Service Specifications GENERAL INFORMATION 35200010314 The ABS consists of components such as the wheel identified and the trouble symptoms will be speed sensors, stop lamp switch, hydraulic unit memorized by the diagnosis function. assembly (integrated with the ABS-ECU) and the In addition, reading of diagnosis codes and service ABS warning lamp.
Page 692 35B-4 ABS <2WD> - Special Tools/Troubleshooting SPECIAL TOOLS 35200060210 Tool Number Name MB991502 MUT-II sub For checking of ABS (Diagnosis code display assembly when using the MUT-II) MB991529 Diagnosis code For checking of ABS (Diagnosis code display check harness when using the ABS warning lamp) TROUBLESHOOTING 35201110129 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING...
Page 693 35B-5 ABS <2WD> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES 35201130583 Inspect according to the inspection chart that is appropriate for the malfunction code. Diagnosis code No. Inspection item Reference page Front right wheel speed sensor (Open circuit or short circuit) 35B-6 Front left wheel speed sensor (Open circuit or short circuit) 35B-6...
Page 694 35B-6 ABS <2WD> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code Nos.11, 12, 13 and 14 Wheel speed sensor Probable cause (open circuit or short circuit) Code Nos.21, 22, 23 and 24 Wheel speed sensor Code Nos 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit or D Malfunction of wheel speed sensor short-circuit in the (+) wire or (- ) wire in any one of the four wheel speed sensors.
Page 695 35B-7 ABS <2WD> - 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, if the voltage returns to normal, this code is no longer output.
Page 696 35B-8 ABS <2WD> - Troubleshooting ABS WARNING LAMP INSPECTION 35201200178 ABS warning lamp 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.
Page 697 35B-9 ABS <2WD> - 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 698 35B-10 ABS <2WD> - 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 Measure at the diagnosis connector B-25 and the ABS-ECU connec-...
Page 699 35B-11 ABS <2WD> - Troubleshooting Inspection Procedure 3 When the ignition key is turned to “ON” (engine stopped), Probable cause the ABS warning lamp does not illuminate. The cause may be an open circuit in the lamp power supply circuit, a blown lamp, D Blown fuse a malfunction of the ABS warning lamp relay or an open circuit between the ABS D Burn out ABS warning lamp bulb...
Page 700 35B-12 ABS <2WD> - Troubleshooting Inspection Procedure 4 Even after the engine is started, the ABS warning lamp Probable cause remains illuminated. The cause is probably a short-circuit in the ABS warning lamp illumination circuit. D Malfunction of combination meter D Malfunction of ABS warning lamp relay D Malfunction of wiring harness (short circuit) D Malfunction of hydraulic unit...
Page 701 35B-13 ABS <2WD> - Troubleshooting Inspection Procedure 5 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 702 35B-14 ABS <2WD> - Troubleshooting DATA LIST REFERENCE TABLE 35201150206 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 703 35B-15 ABS <2WD> - Troubleshooting CHECK AT ABS-ECU 35201180366 Remove the harness connector cover and measure the terminal voltage of the ABS - ECU. Harness connector TERMINAL VOLTAGE CHECK CHART cover Locks 1. Measure the voltage between each terminal and earth. 2.
Page 704 35B-16 ABS <2WD> - Troubleshooting RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS 1. Turn the ignition switch off and disconnect the ABS-ECU connectors before checking resistance and continuity. 2. Check them between the terminals indicated in the table below. 3. The terminal layouts are shown in the illustrations below. Terminal No.
Page 705 35B-17 ABS <2WD> - On-vehicle Service ON-VEHICLE SERVICE 35200160323 WHEEL SPEED SENSOR OUTPUT VOLTAGE Harness CHECK connector cover 1. Lift up the vehicle and release the parking brake. 2. Remove the harness connector cover of the ABS-ECU Locks and measure. 3.
Page 706 35B-18 ABS <2WD> - On-vehicle Service Points In Waveform Measurement Symptom Probable causes Remedy Too small or zero waveform Faulty wheel speed sensor Replace sensor amplitude Waveform amplitude fluctuates Axle hub eccentric or with large runout Replace hub excessively (this is no problem if the minimum amplitude is 100 mV or more) Noisy or disturbed waveform...
Page 707 35B-19 ABS <2WD> - On-vehicle Service HYDRAULIC UNIT CHECK 35200170227 Caution Turn the ignition switch off before connecting or disconnecting the MUT-II. 1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points or place the wheels which are checked on the rollers of the braking force tester.
Page 708 35B-20 ABS <2WD> - On-vehicle Service 7. If the result of inspection is abnormal, correct according to the “Diagnosis Table”. Diagnosis Table Operation Judgement Judgement Probable cause Remedy - Normal - Abnormal (1) Depress brake pedal Brake force Wheel does not Clogged brake Check and clean to lock wheel.
Page 709 35B-21 ABS <2WD> - Hydraulic Unit and ABS-ECU HYDRAULIC UNIT AND ABS-ECU 35200860407 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Air Cleaner Removal <R.H. drive vehicles> Brake Line Bleeding Wiper Motor Removal <L.H. drive vehicles> (Refer to GROUP 35A - On-vehicle Service.) Hydraulic Unit Inspection (Refer to P.35B-19.)
Page 710 35B-22 ABS <2WD> - Hydraulic Unit and ABS-ECU REMOVAL SERVICE POINTS AA" HARNESS CONNECTOR REMOVAL Locking lever Raise the locking lever as shown in the illustration, and then disconnect the harness connector. AB" HYDRAULIC UNIT AND ABS-ECU REMOVAL Caution 1. The hydraulic unit assembly is heavy, and so care should be taken when removing it.
Page 711 35B-23 ABS <2WD> - Wheel Speed Sensor WHEEL SPEED SENSOR 35200830569 REMOVAL AND INSTALLATION Post-installation Operation Wheel Speed Sensor Output Voltage Check (Refer to P.35B-17.) <FRONT> <REAR> Front wheel speed sensor removal steps NOTE D Splash Shield Removal The front ABS rotor is integrated with the drive shaft, and (Refer to GROUP 42 - Fender.) the rear ABS rotor with the hub assembly.
Page 712 35B-24 ABS <2WD> - Wheel Speed Sensor INSTALLATION SERVICE POINT "AA FRONT WHEEL SPEED SENSOR/REAR WHEEL SPEED SENSOR INSTALLATION Caution Be sure not to damage the pole piece at the tip of the wheel speed sensor and the ABS rotor tooth surface by striking them against other parts.
Page 713 35B-25 ABS <2WD> - Wheel Speed Sensor INSPECTION 35200840296 CHECK OF RESISTANCE BETWEEN WHEEL SPEED SENSOR TERMINALS Caution The pole piece can become magnetized because of the magnet but into the wheel speed sensor, with the result that metallic foreign material easily adheres to it. Moreover, the pole piece may not be able to function to correctly sense the wheel rotation speed if it is damaged.
Page 714 NOTES...
Page 715 35C-1 ANTI-SKID BRAKING SYSTEM (ABS) <4WD> CONTENTS 35209000305 GENERAL INFORMATION ....Bleeding ....Refer to GROUP 35A Disc Brake Pad Check and Replacement SERVICE SPECIFICATIONS...
Page 716 35C-2 BRAKE PEDAL ..Refer to GROUP 35A HYDRAULIC UNIT AND ABS-ECU ......Refer to GROUP 35B MASTER CYLINDER AND BRAKE BOOSTER...
Page 717 35C-3 ABS <4WD> - General Information/Service Specifications/Special Tool GENERAL INFORMATION 35200010321 The ABS consists of components such as the wheel symptoms will be memorized by the diagnosis speed sensors, G sensor, stop lamp switch, function. hydraulic unit assembly (integrated with the In addition, reading of diagnosis codes and service ABS-ECU) and the ABS warning lamp.
Page 718 35C-4 ABS <4WD> - Troubleshooting TROUBLESHOOTING 35201130590 For troubleshooting other than those listed below, refer to GROUP 35B - Troubleshooting. INSPECTION CHART FOR DIAGNOSIS CODE Diagnosis code No. Inspection item Reference page G sensor system 35C-4 INSPECTION PROCEDURE FOR DIAGNOSIS CODE Code No.32 G sensor system Probable cause This code is output in the following cases.
Page 719 35C-5 ABS <4WD> - Wheel Speed Sensor WHEEL SPEED SENSOR 35200830576 REMOVAL AND INSTALLATION Post-installation Operation Wheel Speed Sensor Output Voltage Check (Refer to GROUP 35B - On-vehicle Service.) <REAR> <FRONT> Front wheel speed sensor removal steps NOTE D Splash Shield Removal The front ABS rotor is integrated with the front drive shaft, (Refer to GROUP 42 - Fender.) and the rear ABS rotor with the rear drive shaft.
Page 720 35C-6 ABS <4WD> - Wheel Speed Sensor REMOVAL SERVICE POINT AA" FRONT WHEEL SPEED SENSOR/REAR WHEEL SPEED SENSOR REMOVAL Caution Be careful when handling the pole piece at the tip of the wheel speed sensor and the toothed edge of the rotor so as not to damage them by striking against other parts.
Page 721 35C-7 ABS <4WD> - G Sensor G SENSOR 35201010177 REMOVAL AND INSTALLATION Caution Do not drop the G sensor or subject it to any shocks. Removal steps 1. Parking cover 2. G sensor INSPECTION 35201020156 Label 1. Remove the G sensor. 2.
Page 722 NOTES...
Page 723 36-1 PARKING BRAKES CONTENTS 36109000255 GENERAL INFORMATION ....Parking Brake Switch Check ....Lining Running-In .
Page 724: General Information
General Information/Service Specifications 36-2 PARKING BRAKES - /Lubricants/Special Tool GENERAL INFORMATION 36100010226 The parking brake is of a mechanical control type a parking brake lever which is in an offset position acting on the rear wheels. A lever is used to apply at the passenger’s side.
Page 725: On-Vehicle Service
36-3 PARKING BRAKES - On-Vehicle Service ON-VEHICLE SERVICE 36100090213 Adjusting nut PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 1. Pull the parking brake lever with a force of approx. 196 N and count the number of notches. Standard value: 3 - 5 notches Cable rod 2.
Page 726: Parking Brake Switch Check
36-4 PARKING BRAKES - On-Vehicle Service (5) Turn the adjusting nut to adjust the parking brake lever Adjusting nut stroke to the standard value. After adjusting, check that there is no space between the adjusting nut and the parking brake lever. Caution If the parking brake lever stroke is below the standard value and the braking is too firm, the...
Page 727: Parking Brake Lever
36-5 PARKING BRAKES - Parking Brake Lever PARKING BRAKE LEVER 36100130267 REMOVAL AND INSTALLATION Post-installation Operation Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3.) Ratchet plate Section B - B Section A - A Ratchet pawl Removal steps 1.
Page 728: Parking Brake Cable
36-6 PARKING BRAKES - Parking Brake Cable PARKING BRAKE CABLE 36100190333 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Parking Cover and Rear Seat Removal Parking Brake Lever Stroke Check and Adjustment (Refer to GROUP 52A.) (Refer to P.36-3.) Parking Cover and Rear Seat Installation (Refer to GROUP 52A.) 55 - 65 Nm Removal steps...
Page 729 36-7 PARKING BRAKES - Parking Brake Cable REMOVAL SERVICE POINTS AA" REAR BRAKE CALIPER ASSEMBLY REMOVAL Remove the rear brake caliper assembly and support it with wire or similar. AB" SHOE HOLD-DOWN CUP REMOVAL Shoe hold-down cup Extend the shoe and lining assembly, and remove the shoe hold-down cup.
Page 730: Parking Brake Drum
36-8 PARKING BRAKES - Parking Brake Drum PARKING BRAKE DRUM 36100250161 REMOVAL AND INSTALLATION Caution For 2WD-vehicles with ABS, care must be taken not to scratch or damage the teeth of the ABS rotor. The ABS rotor must never be dropped. If the teeth of the ABS rotor are chipped, resulting in a deformation of the ABS rotor, it will not be able to accurately detect the wheel rotation speed, and the system will not function normally.
Page 731 36-9 PARKING BRAKES - Parking Brake Drum INSPECTION 36100260096 BRAKE LINING AND BRAKE DRUM CHECK 1. Measure the thickness of the brake lining at several places. Standard value: 2.8 mm Limit: 1.0 mm 2. If the thickness of the brake lining has worn down to the limit value or more, replace the shoe and lining assemblies on both sides of the vehicle.
Page 732 NOTES...
Page 733 37A-1 STEERING CONTENTS 37209000286 GENERAL INFORMATION ....Drive Belt Tension Check ..... Fluid Level Check .
Page 734: General Information
37A-2 STEERING - General Information GENERAL INFORMATION 37200010202 Three-spoke and four-spoke steering wheels are The power steering is an integral rack and pinion used, and a supplemental restraint system (SRS) type that combines the steering gear and linkage air bag can be fitted in all models. (An air bag into one light-weight and compact assembly.
Page 735: Service Specifications
37A-3 STEERING - Service Specifications/Lubricants SERVICE SPECIFICATIONS 37200030277 Items Standard value Limit Steering wheel free play when hydraulic operation 30 or less with engine stopped 0 - 10 Steering angle Inner wheel SPACE RUNNER 38_00’ ± 2_ SPACE WAGON 39_00’ ± 2_ Outer wheel SPACE RUNNER 31_00’...
Page 736: Sealant
37A-4 STEERING - Sealant/Special Tools SEALANT 37200050136 Items Specified sealant Remarks End plug screw 3M ATD Part No. 8661 or equivalent Semi-drying sealant Power steering rack support cover screw Dust cover lip for tie rod end ball joint SPECIAL TOOLS 37200060177 Tool Number...
Page 737 37A-5 STEERING - Special Tools Tool Number Name MB990803 Steering wheel Disconnection of the steering wheel puller MB991202 Oil seal and Press fitting of rack housing bearing bearing installer MB991197 Bar (long type) To press in the oil seal for the rack MB991199 Oil seal installer MB991213...
Page 738: On-Vehicle Service
37A-6 STEERING - Special Tools/On-vehicle Service Tool Number Name MB990941 Torque tube Installation of valve housing oil seal bearing installer MB991614 Angle gauge Installation of rack support cover MB991561 Boot band crimp- Installation of bellows band ing tool MB990776 Front axle base Installation of dust cover for tie rod end ball joint ON-VEHICLE SERVICE 37200100138...
Page 739: Steering Angle Check
37A-7 STEERING - On-vehicle Service STEERING ANGLE CHECK 37200110261 1. Locate front wheels on turning radius gauge and measure steering angle. Standard value: Item SPACE RUNNER SPACE WAGON Inner wheel 38_00’ ± 2_ 39_00’ ± 2_ Outer wheel 31_00’ 32_00’ 2.
Page 740: Stationary Steering Effort Check
37A-8 STEERING - On-vehicle Service STATIONARY STEERING EFFORT CHECK 37200170238 1. With the vehicle stopped on a flat, paved surface, turn the steering wheel to the straight ahead position. 2. Start the engine and set it to 1,000±100 r/min. Caution After checking the engine r/min must return to the standard idling r/min.
Page 741: Fluid Level Check
37A-9 STEERING - On-vehicle Service FLUID LEVEL CHECK 37200200043 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 742: Bleeding
37A-10 STEERING - On-vehicle Service BLEEDING 37200220155 1. Jack up the front wheels and support them by using a rigid rack. 2. Manually turn the oil pump pulley a few times. 3. Turn the steering wheel all the way to the left and to the right five or six times.
Page 743: Oil Pump Pressure Test
37A-11 STEERING - On-vehicle Service OIL PUMP PRESSURE TEST Pressure 37200230240 gauge Temperature 1. Disconnect the pressure hose from the oil pump, and Shut-off valve (MB990662) gauge then connect the special tools. 2. Bleed the air, and then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60_C.
Page 744: Power Steering Oil Pressure Switch Check
37A-12 STEERING - On-vehicle Service POWER STEERING OIL PRESSURE SWITCH Shut-off valve CHECK Adapter 37200720228 (MB990993) Pressure 1. Disconnect the pressure hose from the oil pump, and gauge then connect the special tools. (MB990662) 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 745: Steering Wheel And Shaft
37A-13 STEERING - Steering Wheel and Shaft STEERING WHEEL AND SHAFT 37200260454 REMOVAL AND INSTALLATION Caution: 1. Before removal of air bag module, refer to GROUP 52B - Service Precautions and Air Bag Module and Clock Spring. 2. One of the steering shaft assembly mounting bolts must be the earth bolt. The earth bolt has a “E”...
Page 746 37A-14 STEERING - Steering Wheel and Shaft REMOVAL SERVICE POINT MB990803 AA" STEERING WHEEL REMOVAL DISASSEMBLY AND REASSEMBLY 37200280191 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.
Page 747 37A-15 STEERING - Steering Wheel and Shaft DISASSEMBLY SERVICE POINT Left-hand tap Special bolt AA" SPECIAL BOLT REMOVAL Steering lock 1. Drill in the special bolt a hole deep enough for the tap bracket to stand. 2. Remove the special bolt with a left-hand tap. Steering lock body REASSEMBLY SERVICE POINT "AA STEERING LOCK CYLINDER...
Page 748: Power Steering Gear Box
37A-16 STEERING - Power Steering Gear Box POWER STEERING GEAR BOX 37200390405 REMOVAL AND INSTALLATION Caution: SRS For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative, risking serious driver injury.
Page 749 37A-17 STEERING - Power Steering Gear Box REMOVAL SERVICE POINTS Cord AA" TIE ROD END AND KNUCKLE DISCONNECTION Ball joint Caution 1. Loosen the nut of the special tool, but do not remove it. If it is removed, the ball joint thread may be MB990635, damaged.
Page 750 37A-18 STEERING - Power Steering Gear Box 3. If the total pinion turning torque cannot be adjusted to within the standard range by adjusting the rack support cover, check the rack support cover, rack support spring, rack support and replace any parts if necessary. TIE ROD SWING RESISTANCE CHECK 1.
Page 751 37A-19 STEERING - Power Steering Gear Box DISASSEMBLY AND REASSEMBLY 37200410170 <L.H. drive vehicles> 18 Nm Steering gear seal kit 31 33 44 Nm Flare nut 20 Nm® - 45° 49 - 54 Nm 25 Nm 88 Nm 27 25 69 - 78 Nm Disassembly steps 1.
Page 752 37A-20 STEERING - Power Steering Gear Box <R.H. drive vehicles> Flare nut 22 Nm 13 Nm Steering gear seal kit 25 Nm 59 Nm 59 Nm 15 Nm® - 30° 88 Nm 49 - 54 Nm Disassembly steps 1. Feed pipe AB"...
Page 753 37A-21 STEERING - Power Steering Gear Box Lubrication and Sealing Points Fluid: Fluid: Automatic transmission fluid Automatic transmission DEXRON or DEXRON II fluid DEXRON or DEXRON II Fluid: Automatic transmission fluid DEXRON or DEXRON II <R.H. drive vehicles> Sealant: 3M ATD Part No. 8661 or equivalent Grease: Repair kit grease <L.H.
Page 754 37A-22 STEERING - Power Steering Gear Box DISASSEMBLY SERVICE POINTS AA" RACK SUPPORT COVER REMOVAL MB991204 Use the special tool to remove the rack support cover from the gear box. AB" OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL Using a plastic hammer, gently tap the pinion to remove it. AC"...
Page 755 37A-23 STEERING - Power Steering Gear Box AF" RACK STOPPER/RACK BUSHING/OIL SEAL/O RING/RACK REMOVAL 1. Gently pull out the rack assembly to remove the rack stopper, rack bushing, oil seals and O-rings. 2. Partially bend the oil seals to remove from the rack bushing.
Page 756 37A-24 STEERING - Power Steering Gear Box REASSEMBLY SERVICE POINTS MB991199 "AA OIL SEAL INSTALLATION MB991197 Gear housing Oil seal "BA NEEDLE ROLLER BEARING/BALL BEARING Needle MB990925 MB990925 roller INSTALLATION (MB990938) (MB990938) bearing MB991202 MB991202 Ball bearing "CA RACK INSTALLATION Vent hole 1.
Page 757 37A-25 STEERING - Power Steering Gear Box 2. Apply the specified fluid to the oil seal inner surface and the O-ring. Rack Specified fluid: Automatic transmission fluid DEXRON or DEXRON II 3. Wrap the rack end with plastic tape, and push the rack bushing onto the rack.
Page 758 37A-26 STEERING - Power Steering Gear Box 3. Insert the tapered side of the special tool from the pinion gear side, and compress the seal ring. "HA OIL SEAL INSTALLATION Use the special tool to press the oil seal into the valve housing. The upper surface of the oil seal should project outwards MB990941 approx.
Page 759 37A-27 STEERING - Power Steering Gear Box "KA TOTAL PINION TORQUE ADJUSTMENT MB991006 1. Using the special tool, rotate the pinion shaft at the rate of one rotation in 4 to 6 seconds to check the total pinion torque and the change in torque. Standard value: Total pinion torque: 0.7 - 1.4 Nm Change in torque: 0.4 Nm or less...
Page 760 37A-28 STEERING - Power Steering Gear Box "MABELLOWS BAND INSTALLATION MB991561 1. Turn the adjusting bolt of the special tool to adjust the Stopper opening dimension (W) to the standard value. Standard value (W): 2.9 mm <When more than 2.9 mm> Screw in the adjusting bolt.
Page 761 37A-29 STEERING - STEERING - Power Steering Gear Box Power Steering Gear Box INSPECTION 37200440131 RACK CHECK Check the rack tooth surfaces for damage or wear. Check the oil seal contact surfaces for uneven wear. Check the rack for bends. PINION AND VALVE ASSEMBLY CHECK Check the pinion gear tooth surfaces for damage or wear.
Page 762: Power Steering Oil Pump
37A-30 STEERING - Power Steering Oil Pump POWER STEERING OIL PUMP 37200520446 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (Refer to P.37A-9.) Power Steering Fluid Supplying (Refer to P.37A-9.) Drive Belt Tension Adjusting (Refer to GROUP 11 - On-vehicle Service.) Power Steering Fluid Line Bleeding (Refer to P.37A-10.) Oil Pump Pressure Check (Refer to P.37A-11.)
Page 763 37A-31 STEERING - Power Steering Oil Pump REMOVAL SERVICE POINT AA" ACCUMULATOR REMOVAL Be sure to drill a hole in the position shown to discharge the packed gas when the accumulator is discarded. Caution 1. Never handle the accumulator in such ways as putting into fire, disassembling, pressing or welding as high-pressure gas is packed inside.
Page 764 37A-32 STEERING - Power Steering Oil Pump DISASSEMBLY AND REASSEMBLY <SPACE RUNNER> 37200540312 Caution Never disassemble the pressure switch assembly and valve sub assembly. 20 Nm Oil pump seal kit 25 - 29 Nm 3.4 - 4.0 Nm NOTE *: Automatic transmission fluid DEXRON or DEXRON II Disassembly steps 1.
Page 765 37A-33 STEERING - STEERING - Power Steering Oil Pump Power Steering Oil Pump "BA OIL SEAL INSTALLATION MB990938 Install the oil seal to the oil pump body with the special tools. MB991203 "CA ROTOR INSTALLATION Punch mark Install the rotor with its punch mark towards the side plate (F).
Page 766 37A-34 STEERING - Power Steering Oil Pump DISASSEMBLY AND REASSEMBLY <SPACE WAGON> 37200540410 Caution Never disassemble the terminal assembly and valve assembly. 27 Nm 25 - 29 Nm 12 Nm 59 Nm NOTE *: Automatic transmission fluid DEXRON or DEXRON II Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit...
Page 767 37A-35 STEERING - STEERING - Power Steering Oil Pump Power Steering Oil Pump REASSEMBLY SERVICE POINTS Valve assembly Side plate "AA O-RINGS INSTALLATION Apply the specified fluid on O-rings to install. I.D. ´ Width mm 15.8 ´ 1.9 21.0 ´ 1.9 14.8 ´...
Page 768 37A-36 STEERING - Power Steering Oil Pump "EA VANE INSTALLATION Round Install the vane to the rotor with its round edge outwards edge (towards cam ring). Vane INSPECTION 37200550148 Check the valve assembly for clogging. Check the oil pump pulley and shaft for wear or damage. Check the groove of rotor and vanes for “stepped”...
Page 769: Power Steering Hoses
37A-37 STEERING - Power Steering Hoses POWER STEERING HOSES 37200570410 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (Refer to P.37A-9.) Under Cover Installation Under Cover Removal Power Steering Fluid Supplying (Refer to P.37A-9.) Power Steering Fluid Line Bleeding (Refer to P.37A-10.) >...
Page 770 37A-38 STEERING - Power Steering Hoses > <SPACE WAGON Flare nut 12 Nm 12 Nm 14, 15 15 Nm 57 Nm <R.H. drive vehicles> 12 Nm 12 Nm 12 Nm <L.H. drive vehicles> 12 Nm 12 Nm Removal steps 1. Eye bolt 9.
Page 771 37A-39 STEERING - Power Steering Hoses REMOVAL SERVICE POINT AA" ACCUMULATOR REMOVAL <SPACE WAGON> Be sure to drill a hole in the position shown to discharge the packed gas when the accumulator is discarded. Caution 1. Never handle the accumulator in such ways as putting into fire, disassembling, pressing or welding as high-pressure gas is packed inside.
Page 772 NOTES...
Page 773 42-1 BODY CONTENTS 42109000324 HOOD ......TROUBLESHOOTING ....ON-VEHICLE SERVICE .
Page 774 42-2 SLIDE DOOR ..... . . TAILGATE ASSEMBLY ....TAILGATE TRIM AND WATERPROOF SERVICE SPECIFICATIONS .
Page 775: Hood
42-3 BODY - Hood HOOD 42100160045 REMOVAL AND INSTALLATION 22 Nm 22 Nm 9 Nm Adjustment of hood step and Adjustment of clearance around hood striker linkage hood and height 1. Hood lock release handle Hood latch removal steps 2. Hood weatherstrip D Radiator grille (Refer to GROUP 51.) 3.
Page 776: Fender
42-4 BODY - Hood/Fender Clip positions Section A - A Hood inner panel FENDER 42100050137 SEALANT Item Specified sealant Remark Splash shield 3M ATD Part No. 8625 or equivalent Ribbon sealer Fender...
Page 777: Fender
42-5 BODY - Fender FENDER 42100190204 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Bumper Removal and Installation Side Sill Cover Removal and Installation (Refer to (Refer to GROUP 51.) GROUP 51 - Aero Parts.) Headlamp Removal and Installation Hood Removal and Installation (Refer to P.42-3.) (Refer to GROUP 54.) <SPACE WAGON>...
Page 778 42-6 BODY - Fender REMOVAL SERVICE POINT Fender Fender AA" SIDE TURN SIGNAL LAMP REMOVAL <SPACE RUNNER> Use a flat-tipped screwdriver to disengage the hook from the fender, and then remove the side turn signal lamp. Hook <SPACE WAGON> Use a flat-tipped screwdriver to disengage the lock from the Fender fender, and then remove the side turn signal lamp.
Page 779: Fuel Filler Door
42-7 BODY - Fuel Filler Door FUEL FILLER DOOR 42100250346 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Seat (driver’s side), Rear Seat Removal and Quarter Lower Trim (driver’s side) Removal and Installation (Refer to GROUP 52A.) Installation (Refer to GROUP 52A.) Front Scuff Plate (driver’s side), Rear Scuff Plate (driver’s side), Center Pillar Lower Trim (driver’s side), <SPACE RUNNER>...
Page 780 42-8 BODY - Fuel Filler Door <SPACE WAGON> <R.H. drive vehicles> <L.H. drive vehicles> Removal steps AA" "AA 1. Rivet 4. Fuel filler door hook assembly 2. Fuel filler door panel assembly 5. Lid lock release handle 3. Clip 6. Fuel filler door lock release cable...
Page 781 42-9 BODY - Fuel Filler Door REMOVAL SERVICE POINT AA" RIVET REMOVAL Use a drill (Ø4.0 - 5.5 mm) to break the rivet by drilling a hole, and then remove the rivet. Rivet Fuel filler door panel assembly Drill INSTALLATION SERVICE POINT Riveter "AA RIVET INSTALLATION Use a riveter shown to install the rivet by the following...
Page 782: Window Glass
42-10 BODY - Window Glass WINDOW GLASS 42200050161 ADHESIVE Items Specified adhesive Windshield 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Quarter window glass Slide door window glass Tailgate window glass SPECIAL TOOLS 42200060164 Tool Number Name MB990480...
Page 783 42-11 BODY - Window Glass ITEMS NEEDED Name Remarks Adhesive 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Primer 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent Spacers Available as service part Anti-rust solvent For rust prevention (or Tectyl 506T...Valvoline Oil Company)
Page 784 42-12 BODY - Window Glass WORKING PROCESS Window glass installation procedure Body side Window glass side Reusing the glass Replacing the glass Cleaning of adhesion surface Cleaning of adhesion surface Cleaning of adhesion surface Cut off the residual adhesive until the Completely cut off all of the residual Clean off any dirt adhering to the adhe- thickness is less than 2 mm.
Page 785: Windshield
42-13 BODY - Window Glass WINDSHIELD 42200100378 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Pillar Trim Removal and Installation Headlining Removal and Installation (Refer to GROUP 52A.) Section A - A Section B - B Primer Primer Primer Section C - C Adhesive: 3M ATD Part No.
Page 786 42-14 BODY - Window Glass REMOVAL SERVICE POINTS MB990449 AA" ROOF DRIP MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused. AB" WINDSHIELD REMOVAL 1. In order to protect the body (paint surface), apply cloth tape to all body areas around the installed windshield.
Page 787 42-15 BODY - Window Glass INSTALLATION SERVICE POINTS Centre "AA WINDSHIELD UPPER MOULDING/WINDOW 300 mm 300 mm SPACER/GLASS STOPPER/WINDSHIELD INSTALLATION 1. When replacing the windshield, temporarily set the windshield against the body, and place a mating mark on the windshield and body. 2.
Page 788: Quarter Window Glass
42-16 BODY - Window Glass QUARTER WINDOW GLASS 42200250196 REMOVAL AND INSTALLATION <SPACE RUNNER> Pre-removal and Post-installation Operation Quarter Upper Trim Removal and Installation Headlining Removal and Installation (Refer to GROUP 52A.) Section A - A Section B - B Primer 14.5 Primer...
Page 789 42-17 BODY - Window Glass <SPACE WAGON> Pre-removal and Post-installation Operation Quarter Upper Trim, Retractor Trim and Belt Line Trim Headlining Removal and Installation Removal and Installation (Refer to GROUP 52A.) Section A - A Section B - B 14.5 Primer Primer Section C - C...
Page 790 42-18 BODY - Window Glass REMOVAL SERVICE POINT AA" QUARTER WINDOW DAM/QUARTER WINDOW GLASS/QUARTER WINDOW GARNISH REMOVAL <SPACE RUNNER> Removal procedure is same as for the windshield except for the service points mentioned below. (Refer to P.42-14.) (1) Break a clip A to remove it. (2) If the quarter window glass or quarter window garnish is re-used, make the positioning mark on it before removing in order to re-install it correctly.
Page 791: Side Window Glass
42-19 BODY - Window Glass 5. Disassemble the quarter window glass and quarter window garnish, and degrease that contact surfaces in the same manner as for the windshield. Apply primer and adhesive to the contact surfaces, and then assemble them. 6.
Page 792: Slide Door Window Glass
42-20 BODY - Window Glass SLIDE DOOR WINDOW GLASS <SPACE RUNNER> 42200250196 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Slide Door Sash Trim Removal and Installation Slide Door Upper Trim Removal and Installation (Refer to P.42-59.) (Refer to P.42-59.) Section B - B Section A - A 15.5 Primer...
Page 793 42-21 BODY - Window Glass REMOVAL SERVICE POINT AA" SLIDE DOOR WINDOW GLASS ASSEMBLY REMOVAL Remove the slide door window glass assembly in the same manner as for the windshield, except the glass stopper. (Refer to P.42-14.) INSTALLATION SERVICE POINT "AA SLIDE DOOR WINDOW GLASS ASSEMBLY INSTALLATION...
Page 794: Tailgate Window Glass
42-22 BODY - Window Glass TAILGATE WINDOW GLASS 42200370243 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Side Tailgate Trim, Lower Tailgate Trim Removal and Rear Wiper Removal and Installation Installation (Refer to P.42-67.) (Refer to GROUP 51.) <SPACE RUNNER> Section B - B Section A - A 18.5 28.5...
Page 795 42-23 BODY - Window Glass <SPACE WAGON> Section A - A Section B - B 18.5 Primer 18.5 Primer Section C - C Section D - D Primer Primer 18.5 18.5 Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Section E - E Removal steps 1.
Page 796: Door
42-24 BODY - Door DOOR 42300030168 SERVICE SPECIFICATIONS Items Standard value Door outside handle play mm Front <SPACE RUNNER> 2.1 or more <SPACE WAGON> 1.9 or more Rear 2.4 or more Power window operating current A 5 ± 1 (for 14 - 15 V power supply at 25_C) Door inside handle play mm 5.3 or more SEALANT...
Page 797: Troubleshooting
42-25 BODY - Door TROUBLESHOOTING 42300070238 DIAGNOSIS FUNCTION INPUT SIGNAL INSPECTION POINTS <VEHICLES WITH ETACS-ECU> 1. Connect the MUT-II to the diagnosis connector. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) 2. If buzzer of the MUT-II sounds once when door lock actuator switch is operated (LOCK/UNLOCK), the ETACS-ECU input signal for that switch circuit system is normal.
Page 798 42-26 BODY - Door INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 The power windows cannot be operated by any of the Probable cause power window switches. The cause may be a malfunction of the power window relay, power window relay D Malfunction of power window relay drive circuit and of the ETACS-ECU.
Page 799 42-27 BODY - Door Inspection Procedure 2 Driver’s side power window cannot be operated by the Probable cause power window main switch. The cause may be a malfunction of power window main switch, power window D Malfunction of power window main switch motor-ECU, or open circuit or short circuit in the communication line between power D Malfunction of power window motor-ECU window main switch and power window motor-ECU.
Page 800 42-28 BODY - Door Inspection Procedure 3 Passenger’s side power window cannot be operated by Probable cause the power window main switch. (However, it can be operated by the power window sub-switch.) The cause may be open circuit or short circuit in the communication line between D Malfunction of wiring harness or connector power window main switch and passenger’s side power window motor-ECU, or a D Malfunction of power window main switch...
Page 801 42-29 BODY - Door Inspection Procedure 6 When the glass is fully raised, it then lowers Probable cause automatically. When the window is within 15 mm of being fully closed, the limit switch turns off D Malfunction of the power window motor-ECU to prevent the window from being lowered.
Page 802 42-30 BODY - Door Inspection Procedure 8 None of the doors lock or unlock when the driver’s-side Probable cause inside door locking knob is operated (including by means of the door key). (However, keyless entry system operates.) The cause may be a malfunction of the door lock actuator switch, the ETACS-ECU D Malfunction of front door lock actuator or of a wiring harness or connector.
Page 803: On-Vehicle Service
42-31 BODY - Door ON-VEHICLE SERVICE 42300090166 DOOR FIT ADJUSTMENT MB990900 or 1. If the clearance between the door and the vehicle body MB991164 is uneven, affix protective tape to the fender around the hinge and to the edge of the door. Then use the special tool to loosen the door hinge mounting bolts on the body, and adjust the clearance around the door so that it becomes even.
Page 804: Adjustment And Replacement When There Is A Malfunction Of The Power Windows
42-32 BODY - Door ADJUSTMENT AND REPLACEMENT WHEN Runchannel THERE IS A MALFUNCTION OF THE POWER Door WINDOWS sash 42900190109 If the window glass automatically starts moving downwards at the wrong time while it is being raised, carry out the following adjustment or replacement procedures.
Page 805: Door Outside Handle Play Check
42-33 BODY - Door DOOR OUTSIDE HANDLE PLAY CHECK 42300160164 Section A - A 1. Check that the door outside handle play is within the standard value range. Standard value (B): Front door: <SPACE RUNNER> 2.1 mm or more <SPACE WAGON> 1.9 mm or more Rear door: 2.4 mm or more 2.
Page 806: Door Inside Handle Play Check And Adjustment
42-34 BODY - Door DOOR INSIDE HANDLE PLAY CHECK AND Section B - B ADJUSTMENT 42300150260 1. Check that the door inside handle play is within the standard value range. Standard value (A): 5.3 mm or more 2. If the door inside handle play is outside the standard value range, remove the door trim.
Page 807: Door Assembly
42-35 BODY - Door DOOR ASSEMBLY 42300220299 REMOVAL AND INSTALLATION Post-installation Operation Door Adjustment (Refer to P.42-31.) Front door 4, 5 12 Nm 22 Nm 26 Nm Rear door <SPACE WAGON> 12 Nm 26 Nm 22 Nm Door assembly removal steps Striker removal steps 1.
Page 808 42-36 BODY - Door INSPECTION 42300600093 DOOR SWITCH CONTINUITY CHECK Terminal No. Switch position Open (ON) Depressed Stroke (OFF)
Page 809: Door Trim And Waterproof Film
42-37 BODY - Door DOOR TRIM AND WATERPROOF FILM 42300430272 REMOVAL AND INSTALLATION Front door <SPACE RUNNER> Sealant: 3M ATD Part No. 8625 or equivalent Section B - B Section A - A Section C - C Clip and tab positions Door beltline Clip inner weatherstrip...
Page 810 42-38 BODY - Door Front door <SPACE WAGON> Sealant: 3M ATD Part No. 8625 or equivalent Section C - C Section B - B Section A - A Clip and tab positions Clip Door inner panel Door inner panel Door beltline inner weatherstrip Section D - D Section E - E...
Page 811 42-39 BODY - Door Rear door <SPACE WAGON> Sealant: 3M ATD Part No. 8625 or equivalent Section B - B Section A - A Clip and tab positions Door beltline inner weatherstrip Door inner panel Door inner panel Section C - C Section D - D Clip Door inner panel...
Page 812 42-40 BODY - Door REMOVAL SERVICE POINT AA" POWER WINDOW SWITCH PANEL REMOVAL Power window switch panel <SPACE RUNNER> Use the special tool to pry up the rear end of the power window switch panel to remove it. Section A - A Power window switch panel Door trim Section B - B...
Page 813 42-41 BODY - Door <SPACE WAGON> Front Use the special tool to pry up the rear end of the power window switch panel to remove it. Power window switch panel Rear Section A - A Power window switch panel Door trim Section B - B Door trim Power window switch panel...
Page 814 42-42 BODY - Door AC" DOOR TRIM/INSIDE HANDLE COVER REMOVAL Inside handle <SPACE WAGON> 1. Insert the special tool between the inside handle upper end and the inside handle cover, and pry off the inside handle cover from the upper tabs of the inside handle. 2.
Page 815: Door Glass And Regulator
42-43 BODY - Door DOOR GLASS AND REGULATOR 42900130378 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Door Trim and Waterproof Film Removal (Refer to Door Window Glass Adjustment (Refer to P.42-31.) P.42-37, 38, 39.) Door Trim and Waterproof Film Installation (Refer to P.42-37, 38, 39.) Front door Rear door <SPACE WAGON>...
Page 816 42-44 BODY - Door REMOVAL SERVICE POINTS AA" DOOR CENTER SASH REMOVAL 1. Remove the door outer opening weatherstrip from the door center sash only. 2. Remove the door center sash mounting screws, and then remove the door center sash from the door panel. Door outer opening weatherstrip...
Page 817 42-45 BODY - Door (2) Turn the drum to position the glass bracket as shown in the illustration. Support the drum and the guide with Glass your hand while turning the drum, otherwise the wires bracket may pull out of the drum. (3) If the wires pull out of the drum, re-insert them by following the drum and regulator wire installation procedure.
Page 818 42-46 BODY - Door 3. Use some narrow-gauge wire (approx. 0.5 mm diameter) to compress the springs, and then tie the narrow-gauge wires to the slits in the guide. Narrow- gauge wire Slit 4. Insert the end of the lowering wire into the wire hole at the bottom of the drum, and then wrap the wire securely around the groove of the drum from the bottom so that Lowering wire...
Page 819 42-47 BODY - Door (3) Return the drum to its original position while holding the wires to make sure that they do not pull out. 6. After installing the power window motor assembly to the window regulator assembly, cut and remove the wires which are compressing the springs.
Page 820 42-48 BODY - Door INSPECTION 42900180168 Power window relay POWER WINDOW RELAY CONTINUITY CHECK Terminal No. Battery voltage Not applied Applied...
Page 821: Door Handle And Latch
42-49 BODY - Door DOOR HANDLE AND LATCH 42300460318 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Door Trim Removal (Refer to P.42-37, 38, 39.) Door Inside Handle Play Check (Refer to P.42-34.) Door Outside Handle Play Check (Refer to P.42-33.) Door Trim Installation (Refer to P.42-37, 38, 39.) Front door Rear door <SPACE WAGON>...
Page 822 42-50 BODY - BODY - Door Door INSPECTION <Passenger’s side> FRONT DOOR LOCK ACTUATOR CHECK 42300610140 Lock <Passenger’s side> View A Unlock Rod position Terminal No. Rod operation LOCK LOCK position ® UNLOCK position UNLOCK UNLOCK position ® LOCK position <Driver’s side>...
Page 823: Window Glass Runchannel And Door Opening Weatherstrip
42-51 BODY - Door WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP 42300310248 REMOVAL AND INSTALLATION Front door Rear door <SPACE WAGON> : Section of clip : Section of clip Door inner opening weatherstrip Door window glass runchannel removal steps removal steps D Scuff plate (Refer to GROUP 52A.) 3.
Page 824: Slide Door
42-52 BODY - Slide Door SLIDE DOOR <SPACE RUNNER> SERVICE SPECIFICATIONS Item Standard value ± Door outside handle play mm 10.5 ± Door inside handle play mm 14.2 SEALANT Item Specified sealant Remark Waterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer SPECIAL TOOLS 42400060030...
Page 825: On-Vehicle Service
42-53 BODY - Slide Door ON-VEHICLE SERVICE Striker DOOR FIT ADJUSTMENT 1. If the striker is not properly engaged with the latch, adjust the door fit by moving the striker horizontally and vertically. 2. Check if the stopper touches the vehicle body properly when the door is closed.
Page 826: Door Outside Handle Play Check And Adjustment
42-54 BODY - Slide Door DOOR OUTSIDE HANDLE PLAY CHECK AND ADJUSTMENT ± Standard value (A): 10.5 1.5 mm If the shown distance is outside the standard value, adjust the door outside handle play according to the following steps: 1. Remove the slide door trim and waterproof film (Refer to P.42-59.) 2.
Page 827: Slide Door Assembly
42-55 BODY - Slide Door SLIDE DOOR ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Slide door fit adjustment (Refer to P.42-53.) Slide door removal steps Lower rail removal steps D Sash trim, front (Refer to P.42-59.) D Slide door rail cover (Refer to GROUP D Sash trim, rear (Refer to P.42-59.) 52A.) D Trim, upper (Refer to P.42-59.)
Page 828 42-56 BODY - Slide Door REMOVAL SERVICE POINT AA" LOWER ROLLER ARM COVER/LOWER ROLLER ARM GUIDE REMOVAL Open the slide door, and then hold the door by operating the fully closed locking mechanism. Then remove the lower roller arm cover and the lower roller arm guide. AB"...
Page 829 42-57 BODY - Slide Door DISASSEMBLY AND REASSEMBLY "AA 1. Stopper (A) Upper rail disassembly steps 2. Shim 10. Upper rail "AA 3. Stopper (B) 11. Upper stopper 4. Door switch cap 5. Door switch Upper roller arm disassembly steps 6.
Page 830 42-58 BODY - Slide Door INSTALLATION SERVICE POINT Stopper (B) Stopper (A) "AA STOPPER (B), (A) INSTALLATION The notch on stopper (A) and the arrow mark on stopper Inside (B) should face the inside of the vehicle. of vehicle Inside of vehicle Notch INSPECTION...
Page 831: Slide Door Trim And Waterproof Film
42-59 BODY - Slide Door SLIDE DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION Section B - B Section A - A Clip Clip 1, 2 Section C - C Sealant: 3M ATD Part No. 8625 or equivalent Clip Section D - D Clip 3, 4 Section E - E...
Page 832: Slide Door Handle And Latch
42-60 BODY - Slide Door SLIDE DOOR HANDLE AND LATCH REMOVAL AND INSTALLATION Post-installation operation Door outside handle play check and adjustment (Refer Door inside handle play check and adjustment (Refer to P.42-54.) to P.42-54.) D Waterproof film, upper (Refer to Slide door inside handle removal P.42-59.) steps...
Page 833: Slide Door Weatherstrip
42-61 BODY - Slide Door INSTALLATION SERVICE POINTS "AA SLIDE DOOR CHILD PROTECTION INSTALLATION 1. Move the child protection lever to “LOCK” position. 2. Hook the rod to the lever securely, and then install the child protection to the door. INSPECTION Lock Rod position...
Page 834: Tailgate
42-62 BODY - Tailgate TAILGATE 42400030031 SERVICE SPECIFICATION Item Standard value Tailgate handle free play mm 1.5 - 5.5 SEALANT 42400050044 Item Specified sealant Remark Waterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer SPECIAL TOOLS 42400060030 Tool Number Name MB990784...
Page 835: Troubleshooting
42-63 BODY - Tailgate TROUBLESHOOTING 42400070118 INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Reference page Door lock mechanism does operate. 42-50 ON-VEHICLE SERVICE 42400090060 TAILGATE FIT ADJUSTMENT 1. If the striker and the latch do not mesh properly, move the striker forward or back or to the left or right to adjust. 2.
Page 836: Tailgate Assembly
42-64 BODY - Tailgate TAILGATE ASSEMBLY 42400110209 REMOVAL AND INSTALLATION Post-installation Operation Tailgate fit adjustment (Refer to P.42-63.) <SPACE RUNNER> Adjustment of clearance around tailgate 12 Nm 5 Nm 22 Nm 15 Nm Adjustment of tailgate step and 5 Nm tailgate striker linkage Tailgate assembly removal steps Tailgate opening weatherstrip...
Page 837 42-65 BODY - Tailgate <SPACE WAGON> Clearance around the tailgate 12 Nm 5 Nm 22 Nm 13 Nm Adjustment of tailgate step and 14 Nm tailgate striker linkage Tailgate assembly removal steps Tailgate opening weatherstrip removal D High-mounted stop lamp (Refer to GROUP 54.) 8.
Page 838 42-66 BODY - Tailgate REMOVAL SERVICE POINT AA" TAILGATE GAS SPRING REMOVAL Caution 1. Never try to disassemble the tailgate gas spring or burn it. 2. Always bore a hole in the tailgate gas spring to release the interior gas before the gas spring is discarded. INSTALLATION SERVICE POINT "AA TAILGATE OPENING WEATHERSTRIP INSTALLATION...
Page 839: Tailgate Trim And Waterproof Film
42-67 BODY - Tailgate TAILGATE TRIM AND WATERPROOF FILM 42400110079 REMOVAL AND INSTALLATION <SPACE RUNNER> Section C - C Section A - A Section B - B Clip Clip Clip Section E - E Section D - D Clip Clip Sealant: 3M ATD Part No.8625 or equivalent Removal steps 1.
Page 840 42-68 BODY - Tailgate <SPACE WAGON> Section A - A Section B - B Section C - C Section D - D Clip Clip Clip Clip Section F - F Section E - E Clip Sealant: 3M ATD Part No. 8625 or equivalent Removal steps 1.
Page 841: Tailgate Handle And Latch
42-69 BODY - Tailgate TAILGATE HANDLE AND LATCH 42400170054 REMOVAL AND INSTALLATION Post-installation Operation Tailgate Handle Free Play Check (Refer to P.42-63.) 9 Nm Tailgate handle and lock key Tailgate latch removal steps cylinder removal steps D Tailgate trim and waterproof film (Refer D Tailgate trim and waterproof film (Refer to P.42-67, 68.) D Tailgate garnish...
Page 842: Keyless Entry System
42-70 BODY - Keyless Entry System KEYLESS ENTRY SYSTEM 42800060032 SPECIAL TOOL Tool Number Name MB991502 MUT-II sub assembly Recording secret codes TROUBLESHOOTING 42800180073 INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection procedure No. Reference page None of the doors can be locked or unlocked using the transmitter. 42-70 All of the doors can be locked and unlocked using the transmitter, 42-72...
Page 843 42-71 BODY - Keyless Entry System From previous page Measure at the ETACS-ECU connectors B-104, B-106. Check the following connectors: B-104, B-106, B-90 D Disconnect the connector, and measure at the harness side. D Continuity between 20 and body earth D Continuity between 23 and body earth OK: Continuity exists.
Page 844 42-72 BODY - Keyless Entry System INSPECTION PROCEDURE 2 All of the doors can be locked and unlocked using the Probable cause transmitter, but the room lamp or turn-signal lamp does not flash or illuminate. (However, the room lamp operates normally when the doors are opened and closed.) If the room lamp operates normally when the doors are opened and closed, the cause D Malfunction of ETACS-ECU...
Page 845 42-73 BODY - Keyless Entry System INSPECTION PROCEDURE 3 Secret codes cannot be registered. Probable cause The cause may be a malfunction of the diagnosis connector,a malfunction of the D Malfunction of MUT-II ETACS-ECU or a malfunction of the diagnosis output circuit. D Malfunction of connector or wiring harness D Malfunction of ETACS-ECU Measure at diagnosis connector B-25 and ETACS-ECU connector...
Page 846: On-Vehicle Service
42-74 BODY - Keyless Entry System Battery ON-VEHICLE SERVICE 42800090079 Open HOW TO REPLACE A BATTERY OF THE Claw TRANSMITTER 1. Remove the set screw to remove the battery from the transmitter. 2. Install a battery with its (+) side face-down. Battery required for replacement: Screw Coin type battery CR2032...
Page 847 42-75 BODY - Keyless Entry System 3. Within 10 seconds after connecting the MUT-II, press the hazard switch six times. MUT-II connected NOTE The doors will lock and unlock once at this time and Within 10 seconds the system will switch to registration mode. 4.
Page 848: Keyless Entry System
42-76 BODY - Keyless Entry System KEYLESS ENTRY SYSTEM 42800130221 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Side Cover Removal and Installation (Refer to GROUP 52A - Instrument Panel.) ETACS-ECU...
Page 849: Sunroof
42-77 BODY - BODY - Sunroof Sunroof SUNROOF 42600060082 SERVICE SPECIFICATION Items Standard value Roof lid glass operating current A (at 20_C) 7 or less TROUBLESHOOTING 42600200131 INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection procedure Reference page The sunroof does not operate when the ignition switch is turned 42-78 to ON.
Page 850 42-78 BODY - Sunroof INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 The sunroof does not operate when the ignition switch is Probable cause turned to ON. One of the following items may be defective. D Malfunction of sunroof switch D Sunroof switch D Malfunction of sunroof motor D Sunroof motor...
Page 851 42-79 BODY - Sunroof Inspection Procedure 2 The motor does not reverse its direction when a load of Probable cause 140 N or more is applied while the sunroof is closing. The sunroof-ECU monitors the load conditions from the amount of current flowing D Malfunction of sunroof-ECU to the motor.
Page 852 42-80 BODY - BODY - Sunroof Sunroof Inspection Procedure 4 Opening or closing of the sunroof is possible immediately Probable cause after turning the ignition switch to OFF, but the timer function does not operate continuously for another 30 seconds if the driver’s side door is opened within 30 seconds.
Page 853: On-Vehicle Service
42-81 BODY - Sunroof ON-VEHICLE SERVICE 42600090127 Hose WATER TEST Check if there are any leaks in the sunroof by the following Approx. 30cm procedure. 1. Fully close the roof lid glass. 2. Adjust the water pressure so that water comes out of the hose to a height of approximately 50 cm when the hose is held vertically facing upwards.
Page 854: Sunroof
42-82 BODY - Sunroof SUNROOF 42600120321 REMOVAL AND INSTALLATION Post-installation Operation Sunroof Water Test (Refer to P.42-81.) Sunroof Fit Adjustment (Refer to P.42-81.) 1. Roof lid glass assembly Sunroof motor removal steps D Headlining Sunroof switch removal steps AB" "AA 5. Sunroof motor 2.
Page 855 42-83 BODY - Sunroof REMOVAL SERVICE POINTS AA" DRAIN HOSE REMOVAL Tie a cord to the end of the drain hose, and wind tape around the tie until it is smooth. Then pull the drain hose out from the passenger compartment. Drain hose Cord AB"...
Page 856 42-84 BODY - Sunroof INSPECTION 42600130140 ROOF LID GLASS OPERATION CURRENT CHECK 1. Remove the sunroof fuse and connect a circuit analyser as shown in the illustration. 2. Press the sunroof switch to the ON position, and then measure the operation current in the intervals between the points when the sunroof starts to operate, when it is fully open, when it is fully closed and when it is fully tilted up.
Page 857 42-85 BODY - Sunroof SUNROOF SWITCH CONTINUITY CHECK Terminal No. Switch position Slide open Tilt up Slide close, Tilt down...
Page 858 42-86 BODY - Sunroof DISASSEMBLY AND REASSEMBLY 42600140105 Disassembly steps 1. Roof lid glass assembly 9. Cable guide casing 2. Weatherstrip 10. Side deflector 3. Sunroof motor 11. Drive cable assembly 4. Roof wind deflector panel 12. Seal 5. Roof drip channel 13.
Page 859 51-1 EXTERIOR CONTENTS 51109000210 FRONT BUMPER ....WINDSHIELD WIPER AND WASHER ......SPECIAL TOOL .
Page 860: Front Bumper
51-2 EXTERIOR - Front Bumper FRONT BUMPER SPECIAL TOOL 51100060071 Tool Number Name MB990784 Ornament remover Removal of front bumper assembly...
Page 861: Front Bumper
51-3 EXTERIOR - Front Bumper FRONT BUMPER 51100140201 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Splash Shield Removal and Installation (Refer to GROUP 42 - Fender.) Radiator Grille Removal and Installation (Refer to P.51-12.) <SPACE RUNNER> Section A - A Clip Removal steps 1.
Page 862 51-4 EXTERIOR - Front Bumper <SPACE WAGON> Section A - A Clip Removal steps 1. License plate bracket assembly 4. Front turn signal lamp assembly 2. Fog lamp AA" 5. Front bumper assembly 3. Fog lamp bezel <Vehicles without 6. License plate bracket fog lamp>...
Page 863 51-5 EXTERIOR - Front Bumper DISASSEMBLY AND REASSEMBLY 51100160238 <SPACE RUNNER> Section C - C Section A - A Section B - B Clip Clip Clip Disassembly steps 1. Front bumper side plate 4. Front air dam 2. Front bumper upper reinforcement 5.
Page 864 51-6 EXTERIOR - Front Bumper <SPACE WAGON> Section A - A Clip Section C - C Section D - D Section E - E Section B - B Clip Splash shield Clip Clip Clip Disassembly steps 1. Front bumper side plate 5.
Page 865: Rear Bumper
51-7 EXTERIOR - Front Bumper/Rear Bumper DISASSEMBLY SERVICE POINT MB990784 AA" FRONT BUMPER FACE REMOVAL MB990784 1. Use the special tool to pull up the centre pin in the clip. 2. Remove the clip. Clip REAR BUMPER SPECIAL TOOL 51100060071 Tool Number Name...
Page 866: Rear Bumper
51-8 EXTERIOR - Rear Bumper REAR BUMPER 51100140201 REMOVAL AND INSTALLATION <SPACE RUNNER> Section C - C Section D - D Section B - B Section A - A Quarter Clip inner panel Clip Clip Clip Removal steps 1. Rear mud guard 4.
Page 867 51-9 EXTERIOR - Rear Bumper <SPACE WAGON> Section A - A Section B - B Quarter Clip inner panel Clip Removal steps 1. Rear mud guard AA" 3. Rear bumper assembly 2. Rear splash shield 4. Rear bumper reinforcement REMOVAL SERVICE POINT AA"...
Page 868 51-10 EXTERIOR - Rear Bumper DISASSEMBLY AND REASSEMBLY 51100160238 <SPACE RUNNER> Section A - A Section B - B Clip Clip Disassembly steps 1. Rear bumper side plate AA" 3. Rear bumper face 2. Rear air dam 4. Rear bumper garnish...
Page 869 51-11 EXTERIOR - EXTERIOR - Rear Bumper Rear Bumper <SPACE WAGON> Section B - B Section A - A Clip Clip Disassembly steps 1. Rear bumper side plate 3. Rear air dam 2. Corner protector AA" 4. Rear bumper face DISASSEMBLY SERVICE POINT MB990784 AA"...
Page 870: Radiator Grille
51-12 EXTERIOR - Radiator Grille RADIATOR GRILLE 51100280026 REMOVAL AND INSTALLATION <SPACE RUNNER> <SPACE WAGON> Removal steps AA" 1. Radiator grille 2. Trim clip 3. Radiator grille clip REMOVAL SERVICE POINT Flat-tipped screwdriver AA" RADIATOR GRILLE REMOVAL Remove the radiator grille by pushing the tab of the radiator grille clips in the direction of the arrows with a flat-tipped screwdriver, while lightly pulling the radiator grille towards you.
Page 871: Roof Rail
51-13 EXTERIOR - Roof Rail ROOF RAIL 51101660010 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Headlining Removal and Installation Roof rail...
Page 872: Moulding And Garnish
51-14 EXTERIOR - Moulding and Garnish MOULDING AND GARNISH 51100470157 SEALANT AND ADHESIVE 51100050207 Items Specified sealant and adhesive Side protect moulding to body panel Adhesive tape: 3M ATD part No.6382 or equivalent [7 mm width and 1.2 mm thickness] Primer: 3M ATD part No.8608 Super Fast Urethane Primer or equivalent and 3M ATD part No.8609 Super Fast Urethane Primer or equivalent...
Page 873: Moulding And Garnish
51-15 EXTERIOR - Moulding and Garnish MOULDING AND GARNISH 51100060033 REMOVAL AND INSTALLATION <SPACE RUNNER> Section A - A Section C - C Section B - B Clip Windshield Clip Clip 4, 5 AA" "BA 1. Roof drip moulding AB" "AA 3. Side protect moulding 2.
Page 874 51-16 EXTERIOR - Moulding and Garnish <SPACE WAGON> Section A - A Section B - B Section C - C Section D - D Slide bolt Clip Windshield Clip Clip 4, 5 Packing AA" "BA 1. Roof drip moulding AB" "AA 3. Side protect moulding 2.
Page 875 51-17 EXTERIOR - Moulding and Garnish <SPACE RUNNER> Adhesive tape: double-sided tape [7 mm width and 1.2 mm thickness] <SPACE WAGON> Adhesive tape: double-sided tape [7 mm width and 1.2 mm thickness]...
Page 876 51-18 EXTERIOR - Moulding and Garnish REMOVAL SERVICE POINT AA" ROOF DRIP MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused. MB990449 AB" SIDE PROTECT MOULDING REMOVAL 1.
Page 877 51-19 EXTERIOR - Moulding and Garnish 4. Remove strip paper from the pressure sensitive double-sided tape. NOTE Affix double-sided tape to the end of strip paper for ease of strip paper removal. (Refer to P.51-17.) 5. Install the side protect moulding. Adhesive tape NOTE Backing paper...
Page 878: Aero Parts
51-20 EXTERIOR - Aero Parts AERO PARTS 51100500184 SEALANT AND ADHESIVE 51100050207 Items Specified sealant and adhesive Side air dam Adhesive tape: 3M ATD part No.6382 or equivalent [5 mm width and 1.5 mm thickness] Primer: 3M ATD part No.8608 Super Fast Urethane Primer or equivalent and 3M ATD part No.8609 Super Fast Urethane Primer or equivalent SPECIAL TOOL 51100060033...
Page 879: Aero Parts
51-21 EXTERIOR - Aero Parts <SPACE WAGON> Section A - A Section B - B Section C - C Clip Clip Clip Grommet Adhesive tape: double-sided tape [5 mm width and 1.5 mm thickness] Side air dam removal steps Tailgate spoiler removal steps AA"...
Page 880 51-22 EXTERIOR - Aero Parts REMOVAL SERVICE POINT AA" SIDE AIR DAM REMOVAL Remove the side air dam in the same manner as for the side protect moulding (Refer to P.51-18). INSTALLATION SERVICE POINT "AA SIDE AIR DAM INSTALLATION Install the side air dam in the same manner as for the side protect moulding (Refer to P.51-18).
Page 881: Windshield Wiper And Washer
51-23 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER SERVICE SPECIFICATIONS Items Standard value Park position of windshield wiper arm and Driver’s side 45 ± 5 blade assembly (Distance between wiper Passenger’s side 52 ± 5 blade and front deck garnish end) SPECIAL TOOLS Tool Number...
Page 882: Troubleshooting
51-24 EXTERIOR - Windshield Wiper and Washer TROUBLESHOOTING DIAGNOSIS FUNCTION INPUT SIGNAL INSPECTION PROCEDURE 1. Connect the MUT-II or a voltmeter to the diagnosis connector to check input signal. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) 2.
Page 883 51-25 EXTERIOR - Windshield Wiper and Washer INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 When the wiper switch is set to “LO” position, the wipers Probable cause do not operates at “LO” mode. The cause may be a malfunction of the wiper switch input circuit, harness or connector, D Malfunction of column switch windshield wiper motor, back-up circuit or front-ECU.
Page 884 51-26 EXTERIOR - Windshield Wiper and Washer Inspection Procedure 2 When the wiper switch is set to “HI” position, the wipers Probable cause do not operates at “LO” mode instead of “HI” mode. The cause may be a malfunction of the wiper switch input circuit, harness or connector, D Malfunction of column switch windshield wiper motor, back-up circuit or front-ECU.
Page 885 51-27 EXTERIOR - Windshield Wiper and Washer Inspection Procedure 4 The wipers do not stop when the wiper switch is turned off Probable cause during the low wiper speed. Probably the front-ECU has stored the conditions before defects take place by a D Malfunction of column switch fail-safe function as the windshield wiper motor was shorted or a malfunction occurred D Malfunction of windshield wiper motor...
Page 886 51-28 EXTERIOR - Windshield Wiper and Washer Inspection Procedure 6 The washers do not operate when the washer switch is Probable cause operated. The cause may be a malfunction of the vehicle speed sensor input circuit, harness D Malfunction of column switch or connector, windshield washer motor or front-ECU.
Page 887 51-29 EXTERIOR - Windshield Wiper and Washer Inspection Procedure 7 The wipers do not operate when the washer switch is Probable cause operated (However, the washer operates normally.) The cause may be a malfunction of harness or connector, windshield wiper motor D Malfunction of windshield wiper motor or front-ECU.
Page 888: Windshield Wiper And Washer
51-30 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER 51100760032 REMOVAL AND INSTALLATION 13 Nm 13 Nm 9 Nm 5 Nm 12 Nm 5 Nm 9 Nm Section A - A Section C - C Section B - B Clip Clip Clip...
Page 889 51-31 EXTERIOR - Windshield Wiper and Washer REMOVAL SERVICE POINT Linkage assembly AA" WIPER MOTOR REMOVAL 1. Remove the wiper motor mounting bolts. 2. Use a flat-tipped screwdriver to separate the wiper motor crank arm from the linkage assembly, and then remove the wiper motor.
Page 890 51-32 EXTERIOR - Windshield Wiper and Washer INSPECTION 51100770035 WIPER MOTOR CHECK 51101260135 Disconnect the wiring harness connector, and then check the wiper motor operation with the wiper motor remaining installed to the body. Wiper Motor Operation Speed Connect a battery to the wiper motor as shown in the illustration and check the operation speed.
Page 891 51-33 EXTERIOR - Windshield Wiper and Washer WASHER FLUID EJECTION POINT CHECK 51101270138 L.H. drive vehicles Adjust the ejection angle by moving the nozzle. <Passen- <Driver’s side> ger’s side> Item Distance mm Item Distance mm Ceramic end line 70 mm 50 mm Area to be ejected R.H.
Page 892: Rear Wiper And Washer
51-34 EXTERIOR - Rear Wiper and Washer REAR WIPER AND WASHER 51100880028 SPECIAL TOOLS 42300060143 Tool Number Name MB991502 MUT-II sub Diagnosis code check assembly ETACS-ECU input signal check MB991529 Diagnosis code Diagnosis code check check harness ETACS-ECU input signal check by using a voltmeter TROUBLESHOOTING 42300070238...
Page 893 51-35 EXTERIOR - Rear Wiper and Washer INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 When the wiper switch is turned on, the wiper does not Probable cause operates. The cause may be a malfunction of the wiper switch input circuit, harness or connector, D Malfunction of column switch rear wiper motor, or ETACS-ECU.
Page 894 51-36 EXTERIOR - Rear Wiper and Washer Inspection Procedure 2 When the selector lever is moved to “R” position during Probable cause the intermittent wiper operation, the wiper does not operate at the continuous mode. The cause may be a malfunction of the “R” position input circuit system or ETACS-ECU. D Malfunction of back-up lamp switch <M/T>...
Page 895 51-37 EXTERIOR - Rear Wiper and Washer Inspection Procedure 3 When the wiper switch is turned off, the wiper does not Probable cause stop. There can be a short circuit in harness or the rear wiper motor, a malfunction of D Malfunction of rear wiper motor the column switch or the ETACS-ECU.
Page 896 51-38 EXTERIOR - Rear Wiper and Washer Inspection Procedure 5 When the washer switch is turned on for 0.3 seconds or Probable cause more, the wiper does not operate. The cause may be a malfunction of the rear wiper motor, harness or connector, or D Malfunction of rear wiper motor ETACS-ECU.
Page 897: Rear Wiper And Washer
51-39 EXTERIOR - Rear Wiper and Washer REAR WIPER AND WASHER 51100880028 REMOVAL AND INSTALLATION <SPACE RUNNER> 8 Nm Wiper motor assembly removal Rear washer hose removal steps steps D Scuff plate, quarter trim (Refer to GROUP 52A.) 1. Cover D Front seat and rear seat (Refer to AA"...
Page 898 51-40 EXTERIOR - Rear Wiper and Washer <SPACE WAGON> 8 Nm 10 Nm Wiper motor assembly removal Rear washer hose removal steps steps D Scuff plate and quarter trim (Refer to 1. Cover GROUP 52A.) D Front seat and rear seat (Refer to AA"...
Page 899 51-41 EXTERIOR - EXTERIOR - Rear Wiper and Washer Rear Wiper and Washer INSTALLATION SERVICE POINT <SPACE RUNNER> "AA WIPER ARM AND BLADE ASSEMBLY INSTALLATION <SPACE RUNNER> Install so that the wiper blade is positioned at the tailgate window glass ceramic end line when the wiper arm stops. <SPACE WAGON>...
Page 900: Headlamp Washer
51-42 EXTERIOR - Headlamp Washer HEADLAMP WASHER SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub Diagnosis code check assembly ETACS-ECU input signal check MB991529 Diagnosis code Diagnosis code check check harness ETACS-ECU input signal check by using a voltmeter TROUBLESHOOTING DIAGNOSIS FUNCTION INPUT SIGNAL INSPECTION PROCEDURE <VEHICLES WITH ETACS-ECU>...
Page 901 51-43 EXTERIOR - Headlamp Washer INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Headlamp washer does not operate when the headlamp Probable cause washer switch is turned on (when headlamp is illuminated). The cause may be a malfunction of the headlamp washer switch input circuit, wiring D Malfunction of column switch harness or connector, headlamp washer motor and of the front-ECU.
Page 902 51-44 EXTERIOR - Headlamp Washer Inspection Procedure 2 Headlamp washer switch input circuit system check Measure at the column switch connector B-87. Check the fusible link No.5 and the special fuse No.6. D Disconnect the connector, and measure at the harness side. D Voltage between terminal No.1 and earth OK: System voltage Replace...
Page 903: Headlamp Washer
51-45 EXTERIOR - Headlamp Washer HEADLAMP WASHER 51100970107 REMOVAL AND INSTALLATION Caution: SRS Before removal of air bag module and clock spring, refer to GROUP 52B - SRS Service Precautions and Air Bag Module and Clock Spring. Nozzle and check valve removal Washer tank removal steps steps D Draining of washer fluid...
Page 904 51-46 EXTERIOR - Headlamp Washer INSPECTION 51101320055 CHECK VALVE CHECK 51101330058 Apply pressure to the inlet of the check valve to check its opening pressure. Opening pressure: 78 kPa HEADLAMP WASHER MOTOR CHECK 51101340051 1. With the washer motor installed to the washer tank, fill the washer tank with water.
Page 905: Marks
51-47 EXTERIOR - Marks MARKS 51101180110 <SPACE RUNNER> REMOVAL AND INSTALLATION "AA 1. “GDI” mark "AA 2. THREE DIAMOND and “SPACE RUNNER” mark INSTALLATION SERVICE POINT "AA INSTALLATION OF MARKS APPLICATION POSITION Dimensions A, B, C and D (dimension from corner of mark to notch on mark) are equal to dimensions A’, B’, C’...
Page 906 51-48 EXTERIOR - Marks (2) THREE DIAMOND and “SPACE RUNNER” mark (1) “GDI” mark Press line Tailgate end line 37 mm Center line 12 mm Tailgate garnish 12 mm 33 mm Press line Tailgate garnish line <SPACE WAGON> REMOVAL AND INSTALLATION "AA 1.
Page 907 51-49 EXTERIOR - Marks INSTALLATION SERVICE POINT "AA INSTALLATION OF MARKS APPLICATION POSITION (1) “GDI” mark Press line Side turn signal lamp 16 mm 5 mm Tailgate end line 39 mm 12 mm (2) “MITSUBISHI” and “4 X 4” mark Tailgate end line Press line 25 mm...
Page 908: Door Mirror
51-50 EXTERIOR - Door Mirror DOOR MIRROR 51100640121 REMOVAL AND INSTALLATION Section A - A Instru- ment panel View A View A Section B - B Mirror Tabs NOTE : tab positions Door mirror removal steps Electronically remote-controlled mirror switch removal steps 1.
Page 909 51-51 EXTERIOR - Door Mirror REMOVAL SERVICE POINT Section A - A Flat-tipped AA" MIRROR REMOVAL spot=RA screwdriver Mirror 1. Using a hand, push the upper part of mirror to tilt it. Apply a protection tape as shown in the illustration. Insert a flat-tipped screwdriver between a notch behind the mirror and the pivot plate, and then pry off the lower part of mirror from the pivot plate.
Page 910 51-52 EXTERIOR - Door Mirror 2. While holding the pivot plate with a flat-tipped screwdriver, Section A - A push the mirror to engage the clips at its lower part with the pivot plate. Mirror Pivot plate Flat-tipped screwdriver INSPECTION 51100650100 <Vehicles with door mirror heater>...
Page 911 51-53 EXTERIOR - Door Mirror ELECTRONICALLY REMOTE-CONTROLLED MIRROR SWITCH CONTINUITY CHECK Switch Switch Terminal No. position Left mirror Right mirror Adjustment switch DOWN LEFT RIGHT Illumination DOOR MIRROR PRINTED HEATING WIRE CHECK Check that there is continuity between the terminal No.1 and the terminal No.2.
Page 912 NOTES...
Page 913 52A-1 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS INTERIOR ............SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .
Page 914 52A-2 INTERIOR CONTENTS SERVICE SPECIFICATIONS ....FRONT SEAT* ......SPECIAL TOOL .
Page 915: Service Specifications
52A-3 INTERIOR - Service Specifications/Special Tool/Instrument Panel SERVICE SPECIFICATIONS Items Standard value Seat back heater resistance (between terminals) W (When ambient temperature is 20_C) 6.84 - 7.92 Seat cushion heater resistance (between terminals) W Between terminals 1 and 2 0.38 - 0.44 (When ambient temperature is 20_C) Between terminals 2 and 3 6.84 - 7.92...
Page 916 52A-4 INTERIOR - Instrument Panel Caution: SRS 1. For the passenger side air bag module removal/installation, always observe the service procedures of GROUP 52B - Air Bag Module and Clock Spring. 2. Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel. Removal steps 1.
Page 917 52A-5 INTERIOR - Instrument Panel CLIP AND CLAW POSITIONS View A NOTE View B : Clip position View C : Claw position View A Section A - A Section C - C Section B - B Instrument Clip Clip panel Claw Claw assembly...
Page 918 52A-6 INTERIOR - Instrument Panel NOTE :Claw position Section I - I Section J - J Section K - K Section A - A Instrument panel assembly Clip Claw Center Clip console Center Instrument console panel Clip assembly Section M - M Section L - L Claw Claw (Column...
Page 919 52A-7 INTERIOR - Instrument Panel DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Defroster duct 8. Side defroster grille 2. Center ventilation duct 9. Side air outlet assembly 3. Glove box striker 10. Front passenger’s side upper cover 4. Air bag module 11.
Page 920: Trims
52A-8 INTERIOR - Trims TRIMS <SPACE RUNNER - L.H. drive vehicles> REMOVAL AND INSTALLATION <L.H.> 44 Nm 44 Nm 44 Nm D Rear seat 5. Luggage tray lid (Refer to GROUP 52A-24.) 6. Rear end Trim 1. Cowl side trim 7.

Page 921 52A-9 INTERIOR - Trims <R.H.> 44 Nm 44 Nm 44 Nm D Rear seat 6. Center pillar upper trim (Refer to GROUP P.52A-24.) 7. Slide door rail cover 1. Cowl side trim 8. Tonneau cover 2. Front scuff plate 9. Luggage tray lid 3.
Page 922 52A-10 INTERIOR - Trims CLIP POSITIONS <L.H.> View A View A Section A – A Section B – B Clip Trim Trim Clip Section D – D Section F – F Section G – G Section C – C Section E – E Clip Trim Trim...
Page 923 52A-11 INTERIOR - Trims <R.H.> View A View A Section A – A Section B – B Clip Trim Trim Clip Section D – D Section E – E Section F – F Section C – C Trim Clip Trim Clip Trim Clip...
Page 924: Trims
52A-12 INTERIOR - Trims TRIMS <SPACE RUNNER - R.H. drive vehicles> REMOVAL AND INSTALLATION <R.H.> 44 Nm 44 Nm 44 Nm D Rear seat 5. Luggage tray lid (Refer to GROUP 52A-24.) 6. Rear end trim 1. Cowl side trim 7.

Page 925 52A-13 INTERIOR - Trims <L.H.> 44 Nm 44 Nm 44 Nm D Rear seat 7. Slide door rail cover (Refer to GROUP 52A-24.) 8. Tonneau cover 1. Cowl side trim 9. Luggage tray lid 2. Front scuff plate 10. Rear end Trim 3.
Page 926 52A-14 INTERIOR - Trims CLIP POSITIONS <R.H.> View A View A Section B – B Section A – A Clip Trim Trim Clip Section F – F Section G – G Section E – E Section C – C Section D – D Clip Trim Trim...
Page 927 52A-15 INTERIOR - Trims <L.H.> View A View A Section A – A Section B – B Clip Trim Trim Clip Section C – C Section D – D Section E – E Section F – F Trim Clip Trim Clip Trim Clip...
Page 928: Trims
52A-16 INTERIOR - Trims TRIMS <SPACE WAGON> REMOVAL AND INSTALLATION 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm D Third seat 8. Quarter upper trim (Refer to GROUP 52A-34.) 9. Quarter armrest assembly 1. Front scuff plate 10. Tonneau cover 2.

Page 929 52A-17 INTERIOR - Trims CLIP POSITIONS Section B – B Section D – D Section C – C Section A – A Clip Clip Clip Trim Trim Trim Trim Clip Section E – E Section F – F Section G – G Section H –...
Page 930: Inside Rear View Mirror
52A-18 INTERIOR - Inside Rear View Mirror/Front Seat INSIDE REAR VIEW MIRROR Button REMOVAL SERVICE POINT Remove by pushing in the direction of the arrow in the illustration. NOTE 1. The mirror spring fits firmly in the groove of the button Spring that is attached to the glass.
Page 931 52A-19 INTERIOR - Front Seat REMOVAL SERVICE POINT AA" SEAT ANCHOR COVER REMOVAL NOTE Remove the seat anchor covers A and B with a bar supplied with the vehicle. Seat anchor cover A Section A – A Section C – C Seat anchor Seat anchor cover B cover A...
Page 932 52A-20 INTERIOR - Front Seat INSTALLATION SERVICE POINT "AA FRONT SEAT ASSEMBLY INSTALLATION Tighten the nut and bolt shown in the illustration with no load on the seat cushion. INSPECTION HEATED SEAT SWITCH CONTINUITY CHECK Switch position Terminal No. Driver’s seat switch Passen-...
Page 933 52A-21 INTERIOR - Front Seat SEAT CUSHION HEATER CHECK Measure the resistance between terminals. Standard value (When ambient temperature is 20°C): Between terminals 1 and 2: 0.38 - 0.44 W Between terminals 2 and 3: 6.84 - 7.92 W Between terminals 1 and 3: 6.46 - 7.48 W...
Page 934 52A-22 INTERIOR - Front Seat DISASSEMBLY AND REASSEMBLY Caution: Do not disassemble the front seat back assembly with built-in side air bag module. Disassembly steps 1. Reclining adjuster knob 15. Front seat back assembly AA" 2. Reclining cover AB" 16. Headrestraint guide AA"...
Page 935 52A-23 INTERIOR - Front Seat DISASSEMBLY SERVICE POINTS AA" RECLINING COVER/SHIELD COVER REMOVAL For the reclining cover, disengage the claws at section A - A, and then disengage the claw at section B - B. For the shield cover, disengage the claws at section C - C, and then disengage the claw at section D - D.
Page 936: Rear Seat
52A-24 INTERIOR - Rear Seat <SPACE RUNNER> REAR SEAT <SPACE RUNNER> REMOVAL AND INSTALLATION Removal steps 1. Headrestraint 2. Rear seat assembly...

Page 937 52A-25 INTERIOR - Rear Seat <SPACE RUNNER> DISASSEMBLY AND REASSEMBLY <Rear seat cushion Section A – A rear view> : Hog ring position Section B – B 25 22 Disassembly steps 1. Striker cover 16. Rear seat back cover and pad 2.
Page 938 52A-26 INTERIOR - Rear Seat <SPACE RUNNER> DISASSEMBLY SERVICE POINTS AA" RECLINING COVER A REMOVAL 1. Disengage the claws at section A - A. 2. Disengage the clip at section B - B. 3. Disengage the claw at section C - C. Section A –...
Page 939: Second Seat
52A-27 INTERIOR - Second Seat <SPACE WAGON> SECOND SEAT <SPACE WAGON> REMOVAL AND INSTALLATION <Personal seat> 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm <Bench seat> 44 Nm 44 Nm 44 Nm 1. Headrestraint Second seat removal steps AA"...

Page 940 52A-28 INTERIOR - Second Seat <SPACE WAGON> DISASSEMBLY AND REASSEMBLY <Personal seat> Section A – A Section B – B 18 19 Clip 4, 5, 21, 25 Disassembly steps 1. Inner cover A 14. Bush 2. Reclining adjuster knob 15. Armrest bracket 3.
Page 941 52A-29 INTERIOR - Second Seat <SPACE WAGON> <Second seat cushion rear view> : Hog ring position "BA 26. Slide cable A connection 35. Second seat cushion bottom cover "BA 27. Tip up cable connection 36. Second seat cushion frame 28. Link 37.
Page 942 52A-30 INTERIOR - Second Seat <SPACE WAGON> <Bench seat> Section A – A Section B – B Clip 1, 4, 16, 21 Disassembly steps AC" 1. Inner cover A 12. Headrestraint guide 2. Reclining adjuster knob 13. Fall down knob 3.
Page 943 52A-31 INTERIOR - Second Seat <SPACE WAGON> <Second seat cushion rear view> : Hog ring position 22. Hinge cover 33. Second seat cushion frame "BA 23. Slide cable A connection 34. Slide cable "BA 24. Tip up cable connection 35. Tip up cable 25.
Page 944 52A-32 INTERIOR - Second Seat <SPACE WAGON> DISASSEMBLY SERVICE POINTS AA" RECLINING COVER A <PERSONAL SEAT> REMOVAL 1. Disengage the claws at section A - A. 2. Disengage the clip at section B - B. 3. Disengage the claw at section C - C. <Personal seat>...
Page 945 52A-33 INTERIOR - Second Seat <SPACE WAGON> AC" HEADRESTRAINT GUIDE REMOVAL REASSEMBLY SERVICE POINTS "AA SLIDE CABLE B <BENCH SEAT> INSTALLATION Cable Turn the nuts to adjust the cable as shown in the illustration. 2 mm "BA TIP UP CABLE/SLIDE CABLE A INSTALLATION Turn the nuts to adjust the cable as shown in the illustration.
Page 946: Third Seat
52A-34 INTERIOR - Third Seat <SPACE WAGON> THIRD SEAT <SPACE WAGON> REMOVAL AND INSTALLATION Removal steps 1. Headrestraint 2. Third seat assembly...

Page 947 52A-35 INTERIOR - Third Seat <SPACE WAGON> DISASSEMBLY AND REASSEMBLY <Third seat cushion rear view> 11 10 : Hog ring position Disassembly steps 1. Striker cover 14. Third seat back cover and pad 2. Third seat unit cover A assembly 3.
Page 948 52A-36 INTERIOR - Third Seat <SPACE WAGON> DISASSEMBLY SERVICE POINTS AA" RECLINING COVER REMOVAL 1. Disengage the claws at section A - A. 2. Disengage the clip at section B - B. 3. Disengage the claw at section C - C. Section B –...
Page 949: Seat Adjuster And Striker
52A-37 INTERIOR - Seat Adjuster and Striker SEAT ADJUSTER AND STRIKER REMOVAL AND INSTALLATION Pre - removal and Post - Installation Operation Rear Seat Assembly Removal and Installation Third Seat Assembly Removal and Installation <SPACE RUNNER> (Refer to P.52A-24) <SPACE WAGON >(Refer to P.52A-34) Second Seat Assembly Removal and Installation <SPACE WAGON >(Refer to P.52A-27) <SPACE RUNNER>...
Page 950 52A-38 INTERIOR - Seat Adjuster and Striker REMOVAL SERVICE POINTS AA" SEAT ADJUSTER END COVER REMOVAL > <SPACE WAGON Section A – A Section B – B : Seat adjuster end cover AB" STRIKER COVER REMOVAL Section A – A...
Page 951: Seat Belt
52A-39 INTERIOR - Seat Belt SEAT BELT For removal and installation procedures for the seat belt with pre-tensioner, refer to GROUP 52B – Seat Belt with Pre-tensioner FRONT SEAT BELT REMOVAL AND INSTALLATION 44 Nm 44 Nm 44 Nm 44 Nm Outer seat belt removal steps Inner seat belt removal steps D Quarter lower trim assembly and...
Page 952: Rear Seat Belt
52A-40 INTERIOR - Seat Belt REAR SEAT BELT<SPACE RUNNER> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Quarter Lower Trim Removal and Installation (Refer to P.52A-8, 9, 12, 13.) 44 Nm 44 Nm 44 Nm Removal steps 1. Sash guide cover 2.

Page 953: Second Seat Belt And Third Seat Belt
52A-41 INTERIOR - Seat Belt SECOND SEAT BELT AND THIRD SEAT BELT <SPACE WAGON> REMOVAL AND INSTALLATION 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm D Shield cover <personal seat> Second seat belt removal steps (Refer to P.52A-28.) D Quarter lower trim assembly 7.

Page 954 NOTES...
Page 955 52B-1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS 52409000292 GENERAL INFORMATION ....SRS AIR BAG CONTROL UNIT (SRS-ECU) ....... SRS SERVICE PRECAUTIONS .
Page 956: General Information
52B-2 SRS - General Information GENERAL INFORMATION 52400010461 To improve safety, the SRS and seat belts with the operational status of the SRS. The clock spring pre-tensioner are available as optional parts. These is installed in the steering column. systems enhance collision safety by restraining the The SRS side air bag deploys if an impact received front passengers in case of an accident.
Page 957 52B-3 SRS - General Information SRS warning lamp Front passenger’s side air bag module Clock spring Driver’s side air bag module Diagnosis Driver’s side air bag connector Seat belt with Front passenger’s pre-tensioner side air bag SRS-ECU Seat belt with pre-tensioner Side air bag module Side impact sensor...
Page 958: Srs Service Precautions
52B-4 SRS - SRS Service Precautions SRS SERVICE PRECAUTIONS 52400030443 1. In order to avoid injury to yourself or others Front air bag module (Driver‘s side or front from accidental deployment of the air bag and passenger’s side) accidental operation of the seat belt with Side air bag module pre-tensioner during servicing, read and Side impact sensor...
Page 959 52B-5 SRS - SRS Service Precautions SRS-ECU Destination of harness Corrective action Terminal No. Instrument panel wiring harness ® Earth Correct or replace each wiring harness. Instrument panel wiring harness ® Combination meter (SRS warning lamp) 5, 6 Instrument panel wiring harness ® Air bag module (Front passenger’s side) 7, 8 Instrument panel wiring harness ®...
Page 960: Special Tools
52B-6 SRS - SRS Service Precautions/Special Tools 7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (driver’s side and front passenger’s side), clock spring, side impact sensors, front seat assemblies (side air bag module), and seat belts with pre-tensioner before drying or baking the vehicle after painting.
Page 961: Test Equipment
52B-7 SRS - Special Tools/Test Equipment Tool Number Name MR372530 SRS air bag Deployment of driver’s side air bag module adapter harness inside the vehicle MB686560 SRS air bag Deployment of front passenger’s side air bag adapter harness module, side air bag module and seat belt pre-tensioner inside or outside the vehicle MR203491 SRS air bag...
Page 962: Troubleshooting
52B-8 SRS - Troubleshooting TROUBLESHOOTING 52400310097 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION 52400320083 DIAGNOSIS CODES CHECK Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check diagnosis codes.
Page 963 52B-9 SRS - Troubleshooting Code No. Diagnosis item Reference page SRS warning lamp drive circuit Lamp does not illuminate.* 52B-14 system Lamp does not switch off. 52B-14 SRS warning lamp drive circuit system 52B-14 Internal circuit system of non-volatile memory (EEPROM) inside SRS-ECU 52B-10 Driver’s side air bag module (squib ignition drive circuit) system 52B-10...
Page 964 52B-10 SRS - Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No.14, 15, 16, 17, 31, 32, 45, 52, 55, 57, 59, 74, 84 Probable cause system inside SRS-ECU These diagnostic trouble codes are output when a fault is detected in the SRS-ECU. D Malfunction of SRS-ECU The defective parts and trouble causes for each diagnosis code No.
Page 965 52B-11 SRS - Troubleshooting Code No.21, 22, 61 or 62 Driver’s side air bag module Probable cause (squib) system These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of clock spring terminals of the driver’s side air bag module (squib). D Partial disconnection due to incorrect clock spring The trouble causes for each diagnosis code No.
Page 966 52B-12 SRS - Troubleshooting Code No.24, 25, 64 or 65 Front passenger’s side air bag Probable cause module (squib) system These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of wiring harnesses or connectors terminals of the front passengers side air bag module (squib).
Page 967 52B-13 SRS - Troubleshooting Code No.35 SRS-ECU (deployed air bag) system Probable cause This diagnosis code is output after the air bag deploys. If this code is output before D Malfunction of SRS-ECU the air bag has deployed, the cause is probably a malfunction inside the SRS-ECU. Replace the SRS-ECU.
Page 968 52B-14 SRS - Troubleshooting Code No.43 SRS warning lamp drive circuit system Probable cause (Lamp does not illuminate.) This diagnosis code is output when an open circuit occurs for a continuous period D Malfunction of wiring harnesses or connectors of 5 seconds while the SRS-ECU in monitoring the SRS warning lamp and the lamp D Blown bulb is OFF (transistor OFF).
Page 969 52B-15 SRS - Troubleshooting Code No.66 or 67 Driver’s side pre-tensioner (squib) Probable cause system These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of wiring harnesses or connectors terminals of the driver’s side pre-tensioner (squib). D Malfunction of driver’s side pre-tensioner (squib) The trouble causes for each diagnosis code No.
Page 970 52B-16 SRS - Troubleshooting Code No.68 or 69 Front passenger’s side pre-tensioner Probable cause (squib) system These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of wiring harnesses or connectors terminals of the front passenger’s side pre-tensioner (squib). D Malfunction of front passenger’s side pre-tensioner The trouble causes for each diagnosis code No.
Page 971 52B-17 SRS - Troubleshooting Code No.71, 72, 75 or 76 Side air bag module (L.H.) (squib) Probable cause system These diagnosis codes are output if the resistance value between the side air bag D Malfunction of wiring harnesses or connectors module (L.H.) (squib) input terminals of the SRS-ECU is abnormal.
Page 972 52B-18 SRS - Troubleshooting Code No.81, 82, 85 or 86 Side air bag module (R.H.) (squib) Probable cause system These diagnosis codes are output if the resistance value between the side air bag D Malfunction of wiring harnesses or connectors module (R.H.) (squib) input terminals of the SRS-ECU is abnormal.
Page 973 52B-19 SRS - Troubleshooting Code No.91 Side impact sensor (L.H.) power supply circut Probable cause system This diagnosis code is output if the power supply voltage of the side impact sensor D Malfunction of wiring harnesses or connectors (L.H.) drops below the rated value for a continuous period of 5 seconds or more. D Malfunction of side impact sensor (L.H.) However, code No.91 will be automatically cleared and the SRS warning lamp will D Malfunction of SRS-ECU...
Page 974 52B-20 SRS - Troubleshooting Code No.94 Side impact sensor (R.H.) power supply circut Probable cause system This diagnosis code is output if the power supply voltage of the side impact sensor D Malfunction of wiring harnesses or connectors (R.H.) drops below the rated value for a continuous period of 5 seconds or more. D Malfunction of side impact sensor (R.H.) However, code No.94 will be automatically cleared and the SRS warning lamp will D Malfunction of SRS-ECU...
Page 975 52B-21 SRS - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS 52400340447 Get an understanding of the trouble symptoms and check according to the inspection procedure chart. Trouble symptom Inspection procedure No. Reference page Communication with Communication with all systems is not 52B-21 MUT-II is not possible.
Page 976: Srs Maintenance
52B-22 SRS - SRS Maintenance SRS MAINTENANCE 52400390350 The SRS must be inspected by an authorized dealer 10 years after the date of vehicle registration. SRS WARNING LAMP CHECK SRS warning lamp Turn the ignition switch to the “ON” position. Does the SRS warning lamp illuminate for about 7 seconds, turn off and then remain extinguished for at least 5 seconds? If yes, SRS system is functioning properly.
Page 977 52B-23 SRS - SRS Maintenance AIR BAG MODULES, STEERING WHEEL AND CLOCK <Driver’s side> SPRING Connector 1. Remove the air bag modules, steering wheel and clock Inflator case spring. (Refer to P.52B-33.) Caution The removed air bag modules should be stored in a clean, dry place with the cover face up.
Page 978 52B-24 SRS - SRS Maintenance 11. Check steering wheel for excessive free play. REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION. (Refer to P.52B-33.) 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 979 52B-25 SRS - SRS Maintenance INSTRUMENT PANEL WIRING HARNESS/FLOOR WIRING HARNESS/ASSIST WIRING HARNESS/SIDE AIR BAG WIRING HARNESS Instrument panel wiring harness Assist wiring harness Floor wiring harness Side air bag wiring harness 1. Check connector for poor connection. 2. Check harnesses for binds, connectors for damage, and terminals for deformation.
Page 980: Post-Collision Diagnosis
52B-26 SRS - Post-collision Diagnosis POST-COLLISION DIAGNOSIS 52400110505 To inspect and service the SRS after a collision (whether or not the air bags have deployed), perform the following steps. SRS-ECU MEMORY CHECK 1. Connect the MUT-II to the diagnosis connector (16-pin). Caution Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected.
Page 981 52B-27 SRS - Post-collision Diagnosis REPAIR PROCEDURE WHEN AIR BAGS (DRIVER’S SIDE AND FRONT PASSENGER’S SIDE) DEPLOY OR SEAT BELT PRE-TENSIONER OPERATES IN A COLLISION. 1. Replace the following parts with new ones. SRS-ECU (Refer to P.52B-31.) Driver’s side air bag module (Refer to P.52B-33.) Front passenger’s side air bag module (Refer to P.52B-33.) Seat belt with pre-tensioner (Refer to P.52B-43.)
Page 982 52B-28 SRS - Post-collision Diagnosis SRS-ECU SRS-ECU 1. Check SRS-ECU case and brackets for dents, cracks or deformation. 2. Check connector for damage, and terminals for deformation. Air bag modules <Driver’s side> 1. Check cover for dents, cracks or deformation. Connector 2.
Page 983: Individual Component Service
52B-29 SRS - Post-collision Diagnosis/Individual Component Service Steering wheel, steering column and intermediate joint 1. Check wiring harness (built into steering wheel) and connectors for damage, and terminals for deformation. 2. Install air bag module to check fit or alignment with steering wheel.
Page 984: Warning/Caution Labels
52B-30 SRS - Warning/Caution Labels WARNING/CAUTION LABELS 52400300124 A number of caution labels relating to the SRS label instructions when servicing SRS and seat and seat belt with pre-tensioner are found in the belt pre-tensioner. If labels are dirty or damaged, vehicle, as shown in the following illustration.
Page 985: Srs Air Bag Control Unit
52B-31 SRS - SRS-ECU SRS AIR BAG CONTROL UNIT (SRS-ECU) 52400210359 Caution 1. Disconnect the battery ( - ) terminal and wait 3. Do not drop or subject the SRS-ECU to for 60 seconds or more before starting work. impact or vibration. Furthermore, disconnected battery...
Page 986 52B-32 SRS - SRS-ECU INSTALLATION SERVICE POINTS "AA SRS-ECU INSTALLATION Caution The SRS may not activate if SRS-ECU is not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger. "BA POST-INSTALLATION INSPECTION SRS warning lamp 1.
Page 987: Air Bag Modules And Clock Spring
52B-33 SRS - Air Bag Modules and Clock Spring AIR BAG MODULES AND CLOCK SPRING 52400240457 Caution 1. Disconnect the battery ( - ) terminal and wait 5. Do not expose the air bag modules to for 60 seconds or more before starting work. temperatures over 93_C.
Page 988 52B-34 SRS - Air Bag Modules and Clock Spring REMOVAL AND INSTALLATION <Driver’s side Air bag module, clock spring> Pre-removal Operation After setting the steering wheel and the front wheels to the straight ahead position, remove the ignition key. <SPACE RUNNER> 0.69 Nm 41 Nm 9 Nm...
Page 989 52B-35 SRS - Air Bag Modules and Clock Spring <Front passenger’s side air bag module, front seat back assembly with side air bag module> Side air bag module Front passenger’s side air bag Front seat back assembly with side module removal steps air bag module removal steps "EA D Post-installation inspection D Negative (- ) battery cable connection...
Page 990 52B-36 SRS - Air Bag Modules and Clock Spring REMOVAL SERVICE POINTS Section A - A AA" DRIVER’S SIDE AIR BAG MODULE REMOVAL 1. Remove the air bag module mounting screws (torx screws) at the sides of the steering wheel. <SPACE WAGON> NOTE Do not remove the screws from the holders.
Page 991 52B-37 SRS - Air Bag Modules and Clock Spring AD" FRONT PASSENGER’S SIDE AIR BAG MODULE Section A - A REMOVAL Pry out B shown with a flat-tipped screwdriver to disengage Claw the 12 claws. Caution The removed air bag module should be stored in a clean, Front passenger’s side air bag module dry place with the pad cover face up.
Page 992 52B-38 SRS - Air Bag Modules and Clock Spring "BA CLOCK SPRING INSTALLATION Align the mating marks of the clock spring and, after turning the front wheels to the straight-ahead position, install the clock spring to the column switch. Mating Mark Alignment Turn the clock spring clockwise fully, and then turn back it approx.
Page 993 52B-39 SRS - Air Bag Modules and Clock Spring "EA POST-INSTALLATION INSPECTION SRS warning lamp 1. Turn the steering wheel right and left lightly to see its smooth operation, being free from abnormal noise. (Driver’s side air bag module, clock spring) 2.
Page 994 52B-40 SRS - Air Bag Modules and Clock Spring CLOCK SPRING CHECK Case If, as result of following checks, even one abnormal point is discovered, replace the clock spring with a new one. 1. Check connectors and protective tubes for damage, and terminals for deformation.
Page 995: Side Impact Sensor
52B-41 SRS - Side Impact Sensor SIDE IMPACT SENSOR 52400460068 Caution 1. Disconnect the battery ( - ) terminal and wait 3. Do not drop or subject the side impact for 60 seconds or more before starting work. sensor to impact or vibration. Furthermore, disconnected battery...
Page 996 52B-42 SRS - Side Impact Sensor INSTALLATION SERVICE POINTS "AA PRE-INSTALLATION INSPECTION Even if new side impact sensors are installed, it is necessary to check before installation. (Refer to INSPECTION.K "BA SIDE IMPACT SENSOR INSTALLATION Securely connect the connector. Center pillar Caution If the side impact sensor is not installed securely and correctly, the side air bag may not operate normally.
Page 997: Seat Belt With Pre-Tensioner
52B-43 SRS - Seat Belt with Pre-tensioner SEAT BELT WITH PRE-TENSIONER 52400410070 Caution 1. Never attempt to disassemble or repair the 4. Do expose seat belt with seat belt with pre-tensioner. If faulty, replace pre-tensioner to temperatures over 90_C. 5. After operating the seat belt pre-tensioner, 2.
Page 998 52B-44 SRS - Seat Belt with Pre-tensioner INSTALLATION SERVICE POINTS "AA PRE-INSTALLATION INSPECTION 1. When installing a new seat belt with pre-tensioner refer to “INSPECTION”. Caution Disposal of the pre-tensioner must be carried out as stated in the procedure. (Refer to P.52B-42.) 2.
Page 999: Air Bag Module And Seat Belt Pre-Tensioner Disposal Procedures
52B-45 SRS - Seat Belt with Pre-tensioner/Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures INSPECTION 52400420073 SEAT BELT WITH PRE-TENSIONER CHECK If any part is found to be faulty during the inspection, it must be replaced with a new one. Dispose of the old one according to the specified procedure.
Page 1000 52B-46 SRS - Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 4. Suitable ear protection should be worn by personnel performing these procedures or by people in the immediate area. DEPLOYMENT INSIDE THE VEHICLE 1. Move the vehicle to an isolated spot. 2.

This manual is also suitable for:

Space wagon 1998

Mitsubishi MOTORS Space Runner 1998 Workshop Manual

Workshop Manual

Section 2

Section 3

Front Suspension

Rear Suspension

Basic Brake System

General Information

Service Specifications

Lubricants

Special Tools

On-Vehicle Service

Brake Pedal

Master Cylinder and Brake Booster

Disc Brake

Proportioning Valve

Load Sensing Proportioning Valve

Space Runner

Space Wagon

Parking Brakes

Steering

Table of Contents

Hood

Fender

Fuel Filler Door

Window Glass

Door

Slide Door

Tailgate

Keyless Entry System

Sunroof

Exterior

Front Bumper

Rear Bumper

Radiator Grille

Roof Rail

Moulding and Garnish

Aero Parts

Windshield Wiper and Washer

Rear Wiper and Washer

Headlamp Washer

Marks

Door Mirror

Interior

Vehicles>

Vehicles>

Supplemental Restraint System (Srs)

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Mitsubishi MOTORS Space Runner 1998

Summary of Contents for Mitsubishi MOTORS Space Runner 1998