Mitsubishi MOTORS Space Runner 1999 Workshop Manual Supplement

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Page 1: Table Of Contents
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 May 1999...
Page 2 00-1 GENERAL CONTENTS HOW TO USE THIS MANUAL ....Chassis Number ......Engine Model Number .
Page 3: How To Use This Manual
00-2 GENERAL - How to Use This Manual HOW TO USE THIS MANUAL MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. 2000: Indicates models equipped with the 2,000 mL <4G63> petrol engine. 2400: Indicates models equipped with the 2,400 mL <4G64> petrol engine. MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection.
Page 4: Vehicle Identification
00-3 GENERAL - Vehicle Identification VEHICLE IDENTIFICATION MODELS Model code Engine model Transmission model Fuel supply system N63W SNUEL6/R6 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) SNFEL6 SNUJL6 SRUEL6/R6 F4A42 (2WD-4A/T) SRFEL6 SRUJL6 N64W SNHCL6 4G64-DOHC-GDI F5M42 (2WD-5M/T) (2,351 mL) SNGCL6 SNHGL6 SRHCL6 F4A42 (2WD-4A/T) SRGCL6...
Page 5: Chassis Number
00-4 GENERAL - Vehicle Identification CHASSIS NUMBER 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 Transmission type 5-speed manual transmission 4-speed automatic transmission Development order SPACE RUNNER (2WD) Engine...
Page 6: Engine Model Number
00-5 GENERAL - Vehicle Identification ENGINE MODEL NUMBER 1. The engine model number is stamped at the cylinder block as shown in the following. Engine model Engine displacement mL 4G63 1,997 4G64 2,351 2. The engine serial number is stamped near the engine model number.
Page 7: Major Specifications
00-6 GENERAL - Major Specifications MAJOR SPECIFICATIONS Items N63W N63W N64W N64W SNUEL6, SRUEL6, SNHCL6, SRHCL6, SNUER6, SRUER6, SNGCL6, SRGCL6, SNFEL6, SRFEL6, SNHGL6 SRHGL6 SNUJL6 SRUJL6 Vehicle Overall length 1 4,290 dimensions Overall width 2 1,695 Overall height 3 1,650 (unladen) 1,680* Wheelbase...
Page 8 11C-1 ENGINE <4G6-MPI> CONTENTS GENERAL ....... . . Manifold Vacuum Check .
Page 9 11C-2 NOTES...
Page 10: General
General/General Information/ 11C-3 ENGINE <4G6-MPI> - Service Specifications GENERAL OUTLINE OF CHANGES The following service procedures have been established in line with the addition of vehicles with 4G63-MPI engine. GENERAL INFORMATION Items 4G63 Total displacement mL 1,997 Bore ´ Stroke mm 85.0 ´...
Page 11: Sealants
11C-4 ENGINE <4G6-MPI> - Service Specifications/Sealants Items Standard value Limit Power steering oil pump and A/C Vibration frequency Hz 114 - 126 compressor drive belt tension Tension N 441 - 539 (When adjusted) Deflection (Reference value) mm 12.5 - 14.3 Power steering oil pump and A/C Vibration frequency Hz 137 - 157...
Page 12: Special Tools
11C-5 ENGINE <4G6-MPI> - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub assem- Checking the ignition timing Checking the idle speed Erasing diagnosis code Measuring the drive belt tension MB991668 Belt tension meter Measuring the drive belt tension (used together with the MUT-II) MD998299 MAS screwdriver...
Page 13: On-Vehicle Service
11C-6 ENGINE <4G6-MPI> - Special Tools/On-vehicle Service Tool Number Name MD998776 Crankshaft rear oil Press-in of the crankshaft rear oil seal seal installer MB990938 Handle Press-in of the crankshaft rear oil seal MD998767 Tension pulley Timing belt tension adjustment socket wrench GENERAL Engine lifter Supporting the engine assembly during...
Page 14 11C-7 ENGINE <4G6-MPI> - 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 15 11C-8 ENGINE <4G6-MPI> - 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 16: Ignition Timing Check
11C-9 ENGINE <4G6-MPI> - On-vehicle Service <When measuring the deflection> Apply 98 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection. 2. If the tension or deflection is outside the standard value, adjust by the following procedure.
Page 17: Idle Speed Check
11C-10 ENGINE <4G6-MPI> - On-vehicle Service IDLE SPEED CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to “LOCK” (OFF) position and connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. Standard value: 5_ BTDC±3_ 4.
Page 18: Compression Pressure Check
11C-11 ENGINE <4G6-MPI> - On-vehicle Service NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items. COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal.
Page 19: Manifold Vacuum Check
11C-12 ENGINE <4G6-MPI> - On-vehicle Service (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crank angle sensor connector. 11.
Page 20 11C-13 ENGINE <4G6-MPI> - On-vehicle Service 3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N ® D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings.
Page 21 11C-14 ENGINE <4G6-MPI> - 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 High- is open and the lash adjuster will over-compress,...
Page 22: Crankshaft Pulley
11C-15 ENGINE <4G6-MPI> - Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11C-6.) Under Cover Installation 25 Nm Removal steps 1. Drive belt (Power steering and 2. Drive belt (Alternator) A/C) 3.
Page 23: Camshaft And Camshaft Oil Seal
11C-16 ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner Removal and Installation Timing Belt Removal and Installation (Refer to P.11C-27.) 10 Nm (f 3 ± 1 mm) 3.4 Nm 14 Nm Sealant:...
Page 24 11C-17 ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS AA" CAMSHAFT SPROCKET REMOVAL MB990767 MD998719 or MD998754 AB" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL MD998443 Before removing the rocker arm and shaft assembly, install the special tools as shown in the illustration so that the lash adjusters will not fall out.
Page 25 11C-18 ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal "BA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the camshaft oil seal lip. 2. Use the special tool to press-fit the camshaft oil seal. MD998713 "CA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal, and then tighten the bolts to the specified torque.
Page 26: Oil Pan
11C-19 ENGINE <4G6-MPI> - Oil Pan OIL PAN 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 Front Exhaust Pipe Removal and Installation f 4 ± 1 mm 39 Nm Bolt Groove...
Page 27 11C-20 ENGINE <4G6-MPI> - 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 28: Crankshaft Oil Seal
11C-21 ENGINE <4G6-MPI> - Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION <M/T> 127 - 137 Nm 127 - 137 Nm <A/T> <A/T> <M/T> Crankshaft Crankshaft (Engine oil: bolt washer (Engine oil: surface) bolt wash- er surface) Lip section Lip section Sealant: 3M Stud locking 4170 or equivalent Engine oil...
Page 29 11C-22 ENGINE <4G6-MPI> - Crankshaft Oil Seal REMOVAL SERVICE POINTS <M/T> AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to ’99 SPACE RUNNER/SPACE WAGON Workshop Manual (Pub. No. PWDE9803) GROUP 22. Flywheel Caution Do not remove the flywheel mounting bolt shown by the Bolt arrow.
Page 30 11C-23 ENGINE <4G6-MPI> - Crankshaft Oil Seal 2. Apply oil to the bearing surface of the flywheel or drive plate bolts. 3. Apply oil to the crankshaft thread holes. 4. Apply sealant to the threaded mounting holes. Specified sealant: 3M Stud locking 4170 or equivalent 5.
Page 31: Cylinder Head Gasket
11C-24 ENGINE <4G6-MPI> - Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13D Intake Manifold Removal and Installation (Refer to - On-vehicle Service.) <Pre-removal only> GROUP 15.) Engine Coolant Draining and Supplying Thermostat Case Assembly Removal and Installation Engine Oil Draining and Supplying (Refer to GROUP 14 - Water Hose and Pipe.)
Page 32 11C-25 ENGINE <4G6-MPI> - Cylinder Head Gasket REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord.
Page 33 11C-26 ENGINE <4G6-MPI> - Cylinder Head Gasket 4. Tighten the bolts by the following procedure. Intake side Front of engine 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 34: Timing Belt
11C-27 ENGINE <4G6-MPI> - Timing Belt TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Crankshaft Pulley Removal and Installation (Refer to P.11C-15.) Engine Mount Bracket Removal and Installation 48 Nm 10 - 12 Nm 24 Nm 9 Nm Removal steps 1.
Page 35 11C-28 ENGINE <4G6-MPI> - Timing Belt REMOVAL SERVICE POINT Timing mark (Top Timing mark of cylinder head) Camshaft sprocket 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 36 11C-29 ENGINE <4G6-MPI> - Timing Belt 4. Once the holes are aligned, insert the set pin. Set pin NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine. "BA TIMING BELT INSTALLATION Timing mark (Top Timing mark...
Page 37 11C-30 ENGINE <4G6-MPI> - Timing Belt "CA TIMING BELT TENSION ADJUSTMENT 50 Nm 1. After turning the crankshaft 1/4 of a revolution in the anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. Tension 2. Loosen the tension pulley fixing bolt, and then use the direction MD998767 special tool and a torque wrench to tighten the fixing...
Page 38: Timing Belt B
11C-31 ENGINE <4G6-MPI> - Timing Belt B TIMING BELT B REMOVAL AND INSTALLATION 19 Nm 108 - 127 Nm Removal steps 1. Timing belt (Refer to P.11C-27.) 4. Timing belt B tensioner AA" "CA 2. Crankshaft sprocket AB" "AA 5. Timing belt B "BA 3.
Page 39 11C-32 ENGINE <4G6-MPI> - Timing Belt B INSTALLATION SERVICE POINTS Counterbalance shaft sprocket Belt tension side "AA TIMING BELT B INSTALLATION, ADJUSTMENT 1. Install timing belt “B” by the following procedure. (1) Ensure that crankshaft sprocket “B” timing mark and Timing marks Timing the counterbalance shaft sprocket timing mark are...
Page 40 11C-33 ENGINE <4G6-MPI> - Timing Belt B "CA CRANKSHAFT SPROCKET INSTALLATION Crankshaft MD998719 or MD998754 sprocket NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt. MB990767...
Page 41: Engine Assembly
11C-34 ENGINE <4G6-MPI> - Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13D Hood Removal and Installation...
Page 42 11C-35 ENGINE <4G6-MPI> - 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 43 11C-36 ENGINE <4G6-MPI> - 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 44 13A-1 FUEL CONTENTS GASOLINE DIRECT INJECTION (GDI) ........MULTIPOINT FUEL INJECTION (MPI) <4G6>...
Page 45 13A-2 GASOLINE DIRECT INJECTION (GDI) CONTENTS GENERAL ....... . . Accelerator Pedal Position Sensor Inspection Accelerator Pedal Position Switch Inspection Outline of Change...
Page 46: General
13A-3 GDI <4G6> - General/Service Specification/Troubleshooting GENERAL OUTLINE OF CHANGES The following service procedures for items which are different from before have been established to correspond to the addition of vehicles with 4G6-GDI engine. Other service procedures are the same as before. An integrated-type accelerator pedal position sensor has been adopted.
Page 47 13A-4 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES 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.
Page 48 13A-5 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 49 13A-6 GDI <4G6> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Inspection procedure No. 27 has been changed in line with the adoption of an integrated-type accelerator pedal position sensor. Inspection procedure Nos. 36 and 37 have been added in line with the adoption of a GDI indication lamp.
Page 50 13A-7 GDI <4G6> - GDI <4G6> - Troubleshooting Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS 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.
Page 51 13A-8 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 36 The GDI ECO indication lamp does not illuminate. Probable cause If the GDI ECO indication lamp does not illuminate after turning on the ignition switch, D Burned-out GDI ECO indication lamp bulb the causes listed in the right column are suspected.
Page 52 13A-9 GDI <4G6> - Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that vehicle does not move forward. NOTE 1.*1: When the accelerator pedal position sensor (1st channel) output is 500 - 900 mV, the accelerator pedal position switch should normally change from ON to OFF.
Page 53 13A-10 GDI <4G6> - Troubleshooting Engine-ECU Connector Terminal Arrangement Terminal No. Check items Standard value, Normal condition (Check require- ments) 57- 53 Accelerator pedal position switch Continuity (when the accelerator pedal is released) No continuity (when the accelerator pedal is slightly depressed) CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS TERMINAL VOLTAGE CHECK CHART...
Page 54: On-Vehicle Service
13A-11 GDI <4G6> - On-Vehicle Service ON-VEHICLE SERVICE 1. ACCELERATOR PEDAL POSITION SWITCH AND Accelerator pedal ACCELERATOR PEDAL POSITION SENSOR position sensor ADJUSTMENT Caution (1) The accelerator pedal position sensor is adjusted correctly at the time of shipment from the factory, Power steering and so it should not normally be moved.
Page 55: Accelerator Pedal Position Switch Inspection
13A-12 GDI <4G6> - On-Vehicle Service (2) Measure the resistance between accelerator pedal position sensor connector terminal (1) [accelerator pedal position sensor (1st channel) earth] and terminal (2) [accelerator pedal position sensor (1st channel) power supply], and between terminal (7) [accelerator pedal position sensor (2nd channel) earth] and terminal (8) [accelerator pedal position sensor (2nd channel) power supply].
Page 56 13A-13 GDI <4G6> - On-Vehicle Service (3) If there is a malfunction, replace the accelerator pedal position sensor. Earth NOTE After replacement, adjust the accelerator pedal position sensor. (Refer to P.13A - 11.) Accelerator pedal position switch...
Page 57: Fuel Pump (High Pressure) And Fuel Pressure Regulator (High Pressure)
Fuel Pump (High Pressure) and 13A-14 GDI <4G6> - 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 Engine Cover Removal and Installation Fuel Leak Check <after installation only>...
Page 58 Fuel Pump (High Pressure) and 13A-15 GDI <4G6> - Fuel Pressure Regulator (High Pressure) Fuel pressure regulator (High 2. Fuel pipe clamp pressure) removal steps "CA 3. Fuel feed pipe "CA 5. Low-pressure fuel pipe 1. Harness connector and clamp 12.
Page 59: Fuel
Fuel Pump (High Pressure) and Fuel Pump (High Pressure) and 13A-16 GDI <4G6> - GDI <4G6> - Fuel Pressure Regulator (High Pressure) 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.
Page 60 Fuel Pump (High Pressure) and 13A-17 GDI <4G6> - 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 61: Injector
13A-18 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 Engine Cover Removal and Installation Fuel Leak Check <after installation only> Air Cleaner Assembly Removal and Installation 10 - 13 Nm 20 - 25 Nm 9 Nm...
Page 62 13A-19 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 63 13A-20 GDI <4G6> - Injector 4. Align the mating marks on the delivery pipe assembly and the fuel injector, and then install the delivery pipe Fuel injector assembly with the injector assembly still attached. Mating marks Delivery pipe assembly "CA 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...
Page 64 13D-1 MULTIPOINT FUEL INJECTION (4G6-MPI) CONTENTS MULTIPOINT FUEL INJECTION <4G6> Fuel Pump Connector Disconnection (How to Reduce the Fuel Pressure) ....GENERAL ....... Fuel Pump Operation Check .
Page 65: Multipoint Fuel
13D-2 MPI - General/General Information MULTIPOINT FUEL INJECTION (MPI) GENERAL OUTLINE OF CHANGE The following service procedures have been established in line with the addition of SPACE RUNNER vehicles with 4G63-MPI engine. GENERAL INFORMATION The Multipoint Fuel Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control.
Page 66: General Information
13D-3 MPI - 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 67 13D-4 MPI - General Information Items Specifications Actuators Control relay type Contact switch type Fuel pump relay type Contact switch type Injector type and number Electromagnetic type, 4 Injector identification mark CDH275 EGR control solenoid valve Duty cycle type solenoid valve Purge control solenoid valve ON/OFF type solenoid valve Fuel pressure...
Page 68 13D-5 MPI - General Information MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM *1 Oxygen sensor (front) z1 Injector Engine-ECU *2 Air flow sensor <M/T> and z2 Purge control solenoid valve Engine-A/T- *3 Intake air temperature sensor z3 Idle speed control servo ECU <A/T> *4 Throttle position sensor z4 EGR control solenoid valve *5 Idle position switch...
Page 69: Service Specifications
13D-6 MPI - Service Specifications/Sealant SERVICE SPECIFICATIONS Items Specifications Basic idle speed r/min 750±50 Throttle position sensor adjusting voltage mV 400 - 1,000 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 2.3 - 3.0...
Page 70: Special Tools
13D-7 MPI - 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 71: Troubleshooting
13D-8 MPI - 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 MD998706 Injector test set Checking the spray condition of injectors MB991607 Injector test harness...
Page 72 13D-9 MPI - Troubleshooting DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the Multipoint Fuel Injection (MPI) system, the engine warning lamp will illuminate. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.
Page 73 13D-10 MPI - 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 Uses the throttle position sensor signal and engine speed signal (crank angle sensor signal) to take reading of the basic injector drive time and basic ignition timing from...
Page 74 13D-11 MPI - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor (front) system 13D-12 Air flow sensor system 13D-13 Intake air temperature sensor system 13D-14 Throttle position sensor system 13D-15 Engine coolant temperature sensor system 13D-16 Crank angle sensor system 13D-17...
Page 75 13D-12 MPI - 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 circuit...
Page 76 13D-13 MPI - 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 Improper connector contact, open circuit Set conditions short-circuited harness wire of the air flow sensor D Sensor output frequency is 3 Hz or less for 4 seconds.
Page 77 13D-14 MPI - Troubleshooting Code No. 13 Intake air temperature sensor system Probable cause Range of Check D Malfunction of the intake air temperature 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 intake air after the engine starts.
Page 78 13D-15 MPI - Troubleshooting Code No. 14 Throttle position sensor system Probable cause Range of Check D Malfunction of the throttle position sensor or D Ignition switch: ON maladjustment D Excluding 60 seconds after the ignition switch is turned to ON or immediately D Improper connector contact,...
Page 79 13D-16 MPI - Troubleshooting Code No. 21 Engine coolant temperature sensor system Probable cause Range of Check D Malfunction of the engine coolant temperature 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 engine coolant after the engine starts.
Page 80 13D-17 MPI - Troubleshooting Code No. 22 Crank angle sensor system Probable cause Range of Check D Malfunction of the crank angle sensor D Engine is cranking. D Improper connector contact, open circuit Set conditions short-circuited harness wire of the crank angle sensor D Sensor output voltage does not change for 4 seconds (no pulse signal input.) D Malfunction engine-ECU...
Page 81 13D-18 MPI - Troubleshooting Code No. 23 Camshaft position sensor system Probable cause Range of Check D Malfunction of the camshaft position sensor D Ignition switch: ON D Improper connector contact, open circuit D Engine speed is approx. 50 r/min or more. short-circuited harness wire of the camshaft position Set conditions sensor circuit...
Page 82 13D-19 MPI - 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 83 13D-20 MPI - Troubleshooting Code No. 25 Barometric pressure sensor system Probable cause Range of Check D Malfunction of the barometric pressure 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 barometric pressure after the engine starts.
Page 84 13D-21 MPI - MPI - Troubleshooting Troubleshooting Code No. 31 Detonation sensor system Probable cause Range of Check D Malfunction of the detonation 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 detonation sensor after the engine starts.
Page 85 13D-22 MPI - Troubleshooting Code No. 44 Ignition coil system Probable cause Range of Check D Malfunction of the ignition coil D Engine speed is approx. 50 - 4,000 r/min D Improper connector contact, open circuit D Excluding deceleration driving and sudden acceleration or deceleration driving short-circuited harness wire of the ignition primary Set conditions circuit...
Page 86 13D-23 MPI - Troubleshooting Code No.54 Immobilizer system Probable cause Range of Check D Radio interference of ID codes D Ignition switch: ON D Incorrect ID code Set Conditions D Malfunction of harness or connector D Improper communication between the engine-ECU <M/T> or engine-A/T-ECU <A/T> D Malfunction of immobilizer-ECU and immobilizer-ECU D Malfunction of engine-ECU <M/T>...
Page 87 13D-24 MPI - 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...
Page 88 13D-25 MPI - Troubleshooting Code No. 61 Communication wire with A/T-ECU system Probable cause <A/T> Range of Check D Malfunction of the harness wire and the connector D 60 seconds or more have passed immediately after engine was started. D Malfunction of the engine-A/T-ECU D Engine speed is approx.
Page 89 13D-26 MPI - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13D-28 with MUT-II is impossible. Communication with engine-ECU <M/T> or engine-A/T-ECU 13D-28 <A/T> only is not possible. Engine warning The engine warning lamp does not illuminate right after the 13D-29...
Page 90 13D-27 MPI - Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Starting Won’t start The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won’t start. Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Page 91 13D-28 MPI - Troubleshooting Items Symptom Stopping Run on The condition in which the engine continues to run after the ignition switch is (“Dieseling”) turned to OFF. Also called “Dieseling”. INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. Probable cause (Communication with all systems is not possible.) The cause is probably a defect in the power supply system (including earth) for the...
Page 92 13D-29 MPI - 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 <M/T> or engine-A/T-ECU <A/T> D Burnt-out bulb causes the engine warning lamp to illuminate for five seconds immediately after the D Defective warning lamp circuit ignition switch is turned to ON.
Page 93 13D-30 MPI - Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (starting impossible) Probable cause In cases such as the above, the cause is probably that a spark plug is defective, D Malfunction of the ignition system or that the supply of fuel to the combustion chamber is defective. D Malfunction of the fuel pump system In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel.
Page 94 13D-31 MPI - Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (starting impossible) In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the ignition system sparks but the sparks are weak, or the initial mixture for starting is not appropriate. D Malfunction of the injector system D Foreign materials in fuel D Poor compression...
Page 95 13D-32 MPI - Troubleshooting INSPECTION PROCEDURE 7 It takes too long time to start. (Incorrect starting) Probable cause In cases such as the above, the cause is probably that the spark is weak and ignition D Malfunction of the ignition system is difficult, the initial mixture for starting is not appropriate, or sufficient compression D Malfunction of the injector system pressure is not being obtained.
Page 96 13D-33 MPI - Troubleshooting INSPECTION PROCEDURE 8 Unstable idling (Rough idling, hunting) Probable cause In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of the ignition system idle speed control (ISC) or compression pressure is defective. D Malfunction of air-fuel ratio control system Because the range of possible causes is broad, inspection is narrowed down to simple D Malfunction of the ISC system...
Page 97 13D-34 MPI - Troubleshooting From the previous page. Check the oxygen sensor (rear) system. (Refer to P.13D-24, IN- MUT-II Data list SPECTION PROCEDURE FOR DIAGNOSIS CODE 59.) 59 Oxygen sensor (rear) (Refer to P.13D-62.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV Check the oxygen sensor (front) system.
Page 98 13D-35 MPI - Troubleshooting INSPECTION PROCEDURE 9 Idling speed is high. (Improper idling speed) Probable cause In such cases as the above, the cause is probably that the intake air volume during D Malfunction of the ISC servo system idling is too great. D Malfunction of the throttle body MUT-II Self-Diag code Refer to P.13D-11, INSPECTION CHART FOR DIAGNOSIS...
Page 99 13D-36 MPI - Troubleshooting INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idling. (Die out) Probable cause In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate D Malfunction of the ISC servo system when the engine is cold, or that the intake air volume is insufficient.
Page 100 13D-37 MPI - Troubleshooting INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idling. (Die out) Probable cause In such cases as the above, the cause is probably that ignition system, air/fuel mixture, D Malfunction of the ignition system idle speed control (ISC) or compression pressure is defective.
Page 101 13D-38 MPI - Troubleshooting From the previous page. Check the oxygen sensor (front) system. (Refer to P.13D-12, IN- MUT-II Data list SPECTION PROCEDURE FOR DIAGNOSIS CODE 11.) 11 Oxygen sensor OK: Changes between 600 - 1,000 mV during sudden racing MUT-II Data list Check the fuel pressure.
Page 102 13D-39 MPI - Troubleshooting INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out) Probable cause In cases such as the above, the cause is probably misfiring due to a weak spark, D Drawing air into intake system or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
Page 103 13D-40 MPI - Troubleshooting INSPECTION PROCEDURE 15 Hesitation, sag or stumble Probable cause In cases such as the above, the cause is probably that ignition system, air/fuel mixture D Malfunction of the ignition system or compression pressure is defective. D Malfunction of air-fuel ratio control system D Malfunction of the fuel supply system D Malfunction of the EGR control solenoid valve system D Poor compression...
Page 104 13D-41 MPI - Troubleshooting From the previous page. MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (Refer to P.13D-82.) air into the air intake OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system idling D Broken intake...
Page 105 13D-42 MPI - Troubleshooting INSPECTION PROCEDURE 18 Poor acceleration Probable cause Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. D Malfunction of the ignition system are suspected. D Malfunction of air-fuel ratio control system D Malfunction of the fuel supply system D Poor compression pressure D Clogged exhaust system MUT-II Self-Diag code...
Page 106 13D-43 MPI - Troubleshooting From the previous page. MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (Refer to P.13D-82.) air into the air intake OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system idling D Broken intake...
Page 107 13D-44 MPI - Troubleshooting INSPECTION PROCEDURE 19 Surge Probable cause Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of the ignition system D Malfunction of air-fuel ratio control system D Malfunction of the EGR control solenoid valve system MUT-II Self-Diag code Refer to P.13D-11, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
Page 108 13D-45 MPI - Troubleshooting INSPECTION PROCEDURE 20 Knocking Probable cause In cases as the above, the cause is probably that the detonation control is defective D Defective detonation sensor or the heat value of the spark plug is inappropriate. D Inappropriate heat value of the spark plug MUT-II Self-Diag code Refer to P.13D-11, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
Page 109 13D-46 MPI - Troubleshooting INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling Probable cause Abnormal air-fuel ratio is suspected. D Malfunction of the air-fuel ratio control system D Deteriorated catalyst MUT-II Self-Diag code Refer to P.13D-11, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.
Page 110 13D-47 MPI - Troubleshooting INSPECTION PROCEDURE 23 Low alternator output voltage (approx. 12.3 V) Probable cause The alternator may be defective, or malfunctions, which are listed in the right column, D Malfunction of charging system may be suspected. D Short circuit in harness between alternator G terminal and engine-ECU <M/T>...
Page 111 13D-48 MPI - Troubleshooting INSPECTION PROCEDURE 25 Fans (radiator fan, A/C condenser fan) are inoperative Probable cause The engine-ECU <M/T> or engine-A/T-ECU <A/T> outputs a duty signal to the D Malfunction of the fan motor relay fan controller depending on the engine coolant temperature, vehicle speed, and D Malfunction of the fan motor air conditioner switch condition.
Page 112 13D-49 MPI - Troubleshooting INSPECTION PROCEDURE 26 Engine-ECU <M/T> or Engine-A/T-ECU <A/T> power Probable cause supply and earth circuit system The engine-ECU <M/T> or engine-A/T-ECU <A/T> may be defective, or that one D Improper connector contact, open circuit of the malfunctions listed at right has occured. short-circuited harness wire in the engine-ECU <M/T>...
Page 113 13D-50 MPI - Troubleshooting INSPECTION PROCEDURE 27 Power supply system and ignition switch-IG system Probable cause When an ignition switch ON signal is input to the engine-ECU <M/T> or engine-A/T-ECU D Malfunction of the ignition switch <A/T>, the engine-ECU <M/T> or engine-A/T-ECU <A/T> turns the control relay ON. D Malfunction of the control relay This causes battery voltage to be supplied to the engine-ECU <M/T>...
Page 114 13D-51 MPI - Troubleshooting INSPECTION PROCEDURE 28 Fuel pump system Probable cause The engine-ECU <M/T> or engine-A/T-ECU <A/T> turns the control relay ON when D Malfunction of the fuel pump relay the engine is cranking or running, and this supplies power to drive the fuel pump. D Malfunction of the fuel pump D Improper connector...
Page 115 13D-52 MPI - Troubleshooting INSPECTION PROCEDURE 29 Idle position switch system Probable cause The idle position switch inputs the condition of the accelerator pedal, i.e. whether D Maladjustment of the accelerator pedal it is depressed or released (HIGH/LOW), to the engine-ECU <M/T> or engine-A/T-ECU D Maladjustment of the fixed SAS <A/T>.
Page 116 13D-53 MPI - Troubleshooting INSPECTION PROCEDURE 31 Ignition switch-ST and inhibitor switch system <A/T> Probable cause D The ignition switch-ST inputs a HIGH signal to the engine-A/T-ECU while the D Malfunction of ignition switch engine is cranking. D Malfunction of inhibitor switch The engine-A/T-ECU controls fuel injection, etc.
Page 117 13D-54 MPI - Troubleshooting INSPECTION PROCEDURE 32 Power steering fluid pressure switch system Probable cause The presence or absence of power steering load is input to the engine-ECU <M/T> D Malfunction of power steering fluid pressure switch or engine-A/T-ECU <A/T>. D Improper connector contact,...
Page 118 13D-55 MPI - Troubleshooting INSPECTION PROCEDURE 34 Ignition circuit system Probable cause The engine-ECU <M/T> or engine-A/T-ECU <A/T> interrupts the ignition coil primary D Malfunction of ignition switch. current by turning the power transistor inside the engine-ECU <M/T> or engine-A/T-ECU D Improper connector contact,...
Page 119 13D-56 MPI - Troubleshooting INSPECTION PROCEDURE 36 Purge control solenoid valve system Probable cause The purge control solenoid valve controls the purging of air from the canister located D Malfunction of solenoid valve inside the intake manifold. D Improper connector contact, open circuit...
Page 120 13D-57 MPI - Troubleshooting INSPECTION PROCEDURE 37 EGR control solenoid valve system Probable cause The EGR control solenoid valve is controlled by the negative pressure resulting from D Malfunction of solenoid valve EGR operation leaking to port “A” of the throttle body. D Improper connector contact,...
Page 121 13D-58 MPI - 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 122 13D-59 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Intake air Ignition switch: ON or When intake air - 20_C Code No. 13D-14 temperature with engine running temperature is - 20_C sensor When intake air temperature is 0_C When intake air 20_C...
Page 123 13D-60 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Crank angle Engine: Cranking Compare the engine Accord Code No. 13D-17 sensor Tachometer: speed readings on Connected the tachometer and the MUT-II. Engine: Idling When engine 1,275 - 1,475 rpm Idle position coolant temperature...
Page 124 13D-61 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Engine: Cranking When engine 12 - 19 ms Injectors * coolant temperature is 0_C (injection is carried out for all cylinders simultaneously) When engine 26 - 40 ms coolant temperature is 20_C When engine...
Page 125 13D-62 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Oxygen Transmission: 3,500 r/min 600 - 1,000 mV Code No. 13D-24 sensor 2nd gear <M/T>, (rear) L range <A/T> Drive with throttle widely open ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents...
Page 126 13D-63 MPI - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS Needle-nosed wire probe TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the engine-ECU <M/T>...
Page 127 13D-64 MPI - Troubleshooting Engine-ECU <M/T> Connector Terminal Engine-A/T-ECU <A/T> Connector Terminal Arrangement Arrangement Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> No. 1 injector While engine is idling after having From 11 - 14 V, momentarily warmed up, suddenly depress the drops slightly No.
Page 128 13D-65 MPI - Troubleshooting Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> Air flow sen- Engine: Idle speed 0 - 1V sor reset Engine r/min: 3,000 r/min 6 - 9V signal Fan control- Radiator fan and condenser fan are not 0 - 0.3 V operating Radiator fan and condenser fan are...
Page 129 13D-66 MPI - Troubleshooting Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> Oxygen Engine: Idling after warming up 0 - 3V sensor heat- Engine r/min: 5,000r/min. System voltage Ignition Engine: Cranking 8V or more switch - ST Intake air Ignition switch:...
Page 130 13D-67 MPI - Troubleshooting Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> Throttle Ignition switch: Set throttle valve 0.3 - 1.0V position to idle position sensor Fully open throttle 4.5 - 5.5V valve Barometric Ignition switch: When altitude is 3.7 - 4.3V...
Page 131 13D-68 MPI - Troubleshooting Caution If the terminals that should be checked are mistaken, or if connector terminals are not correctly shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU <M/T> or engine-A/T-ECU <A/T> and/or ohmmeter. Be careful to prevent this! 4.
Page 132 13D-69 MPI - Troubleshooting Terminal Terminal Inspection item Normal condition (Check condition) No.<M/T> No. <A/T> 72 - 92 64 - 57 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0_C) 2.3 - 3.0 kW (When intake air temperature is 20_C) 1.0 - 1.5 kW (When intake air temperature is 40_C)
Page 133 13D-70 MPI - 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 134 13D-71 MPI - Troubleshooting Examples of Abnormal Wave Patterns Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency.
Page 135 13D-72 MPI - 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 Time...
Page 136 13D-73 MPI - Troubleshooting INJECTOR Analyzer Measurement Method 1. Disconnect the injector connector, and then connect the special tool (test harness: MB991348) in between. (Both the power supply side and engine-ECU <M/T> or engine-A/T-ECU <A/T> side should be connected.) Special 2.
Page 137 13D-74 MPI - Troubleshooting Standard Wave Pattern Observation conditions Function Special patterns Pattern height Variable Variable knob Adjust while viewing the wave pattern Pattern selector Display Engine r/min Idle speed Standard wave pattern Point A Solenoid back electromotive force (Approx. 7´10 V) Point B Injector drive time Power voltage...
Page 138 13D-75 MPI - Troubleshooting STEPPER MOTOR Analyzer Measurement Method 1. Disconnect the stepper motor connector, and connect the special tool (test harness: MD998463) in between. Special 2. Connect the analyzer special patterns pickup to the patterns stepper motor-side connector terminal 1 (red clip of special pickup tool), terminal 3 (blue clip), terminal 4 (black clip) and terminal 6 (yellow clip) respectively.
Page 139 13D-76 MPI - Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the stepper motor is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small.
Page 140 13D-77 MPI - 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: MB991348) 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 141 13D-78 MPI - Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit...
Page 142: Throttle Body (Throttle Valve Area) Cleaning
13D-79 MPI - 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 143: Fixed Sas Adjustment
13D-80 MPI - On-vehicle Service 2. Insert a thickness gauge as follows: <Vehicles without auto-cruise control system> Throttle lever Insert a thickness gauge with a thickness of 0.45 mm between the fixed SAS and the throttle lever. Thick- NOTE ness Fixed Do not insert the thickness gauge 3 mm or more.
Page 144: Basic Idle Speed Adjustment
13D-81 MPI - MPI - On-vehicle Service On-vehicle Service BASIC IDLE SPEED ADJUSTMENT NOTE (1) The standard idling speed has been adjusted by the speed adjusting screw (SAS) by the manufacturer, and there should usually be no need for readjustment. (2) If the adjustment has been changed by mistake, the idle speed may become too high or the idle speed may drop too low when loads from components such...
Page 145: Fuel Pressure Test
13D-82 MPI - On-vehicle Service NOTE Unless the ISC servo is released, the Actuator test mode will continue 27 minutes. 8. Switch OFF the ignition switch. 9. Disconnect the MUT-II. 10. Start the engine again and let it run at idle speed for about 10 minutes;...
Page 146 13D-83 MPI - On-vehicle Service 7. Select “Item No.07” from the MUT-II Actuator test to drive the fuel pump. Check that there are no fuel leaks from any parts. 8. Finish the actuator test or turn the ignition switch to “LOCK” (OFF) position.
Page 147: Fuel Pump Connector Disconnection (How To Reduce The Fuel Pressure)
13D-84 MPI - On-vehicle Service 15. Stop the engine and check change of fuel pressure gauge reading. Normal if the reading does not drop within 2 minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Symptom Probable cause Remedy...
Page 148: Component Location
13D-85 MPI - On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol A/C relay Engine-A/T-ECU <A/T> A/C switch Engine warning lamp (check engine lamp) Air flow sensor (with intake air temperature Idle speed control servo sensor and barometric pressure sensor) Camshaft position sensor Ignition coil Control relay and fuel pump relay Inhibitor switch <A/T>...
Page 149: Control Relay And Fuel Pump Relay Continuity Check
13D-86 MPI - On-vehicle Service CONTROL RELAY AND FUEL PUMP RELAY Fuel pump relay CONTINUITY CHECK Equipment side Battery voltage Terminal No. connector Not supplied Supplied Control relay INTAKE AIR TEMPERATURE SENSOR CHECK Equipment side connector Air flow sensor 1. Disconnect the air flow sensor connector. 2.
Page 150: Throttle Position Sensor Check
13D-87 MPI - On-vehicle Service 4. Apply sealant to threaded portion. Specified sealant: 3M NUT Locking Part No.4171 or equivalent 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 Nm THROTTLE POSITION SENSOR CHECK Equipment side connector 1.
Page 151: Oxygen Sensor Check
13D-88 MPI - On-vehicle Service OXYGEN SENSOR CHECK Equipment side connector <Oxygen sensor (front)> Oxygen sensor 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 2 (red clip of special tool) and terminal 4 (blue clip of special tool) on the oxygen sensor connector.
Page 152: Injector Check
13D-89 MPI - MPI - On-vehicle Service On-vehicle Service <Oxygen sensor (rear)> Equipment side connector 1. Disconnect the oxygen sensor connector and connect the special tool (test harness set) to the connector on Oxygen the oxygen sensor side. sensor 2. Make sure that there is continuity (11 - 18 W at 20_C) (rear) between terminal 3 and terminal 4 on the oxygen sensor connector.
Page 153 13D-90 MPI - On-vehicle Service High-pressure fuel hose MD998741 Return hose MB991607 Pressure regulator (MD116395) Injector MD998706 Clip (MB991608) Battery 4. Connect the MUT-II to the diagnosis connector. 5. Turn the ignition switch to ON. (But do not start the engine.) 6.
Page 154: Idle Speed Control (Isc) Servo (Stepper Motor) Check
13D-91 MPI - On-vehicle Service IDLE SPEED CONTROL (ISC) SERVO Idle speed (STEPPER MOTOR) CHECK control servo Checking the Operation Sound 1. Check that the engine coolant temperature is 20_C or below. NOTE Disconnecting the engine coolant temperature sensor connector and connecting the harness-side of the connector to another engine coolant temperature sensor that is at 20_C or below is also okay.
Page 155: Injector
13D-92 MPI - Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal Operation Fuel Discharge Prevention (Refer to P.13D-84.) 5, 7 O-ring 9 Nm 10 - 13 Nm O-ring Engine oil Removal steps 1. PCV hose connection "AA 7. Fuel pressure regulator AA" 2.
Page 156 13D-93 MPI - Injector REMOVAL SERVICE POINT AA" DELIVERY PIPE/INJECTOR REMOVAL Remove the delivery pipe (with the injectors attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector. INSTALLATION SERVICE POINT "AA INJECTOR/FUEL PRESSURE REGULATOR/ HIGH-PRESSURE FUEL HOSE INSTALLATION 1.
Page 157: Throttle Body
13D-94 MPI - Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Air Cleaner Installation Air Cleaner Removal Engine Coolant Supplying Accelerator Cable Adjustment (GROUP 17 - On-vehicle Service) 19 Nm Removal steps 1. Accelerator cable connection 5.
Page 158 13D-95 MPI - Throttle Body DISASSEMBLY AND REASSEMBLY Disassembly steps "AA 1. Throttle position sensor NOTE 2. Idle speed control body assembly The fixed SAS and the speed adjusting screw are 3. O-ring correctly adjusted at the factory and should not be 4.
Page 159 13D-96 MPI - Throttle Body REASSEMBLY SERVICE POINT "AA THROTTLE POSITION SENSOR (TPS) INSTALLATION 1. Place the throttle position sensor against the throttle body as shown by the dotted line in illustration. 2. Turn the throttle position sensor to the position shown in the illustration, and then tighten the screw.
Page 160 14-1 ENGINE COOLING CONTENTS GENERAL ....... . . SEALANT ........Outline of Changes .
Page 161: General
General/General Information/ 14-2 ENGINE COOLING - Service Specification/Sealant GENERAL OUTLINE OF CHANGES The following service procedures have been established in line with the addition of vehicles with 4G63-MPI engine. Furthermore, other items are the same as for the 4G64-GDI engine. GENERAL INFORMATION Items Specifications...
Page 162: Thermostat <4G6-Mpi
14-3 ENGINE COOLING - Thermostat <4G6-MPI> THERMOSTAT <4G6-MPI> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Air Intake Duct Removal and Installation 13 Nm Removal steps AA" "BA 1. Radiator lower hose connection 3. Water inlet fitting "AA 4.
Page 163 14-4 ENGINE COOLING - Thermostat <4G6-MPI> "BA RADIATOR LOWER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose. INSPECTION THERMOSTAT CHECK 1.
Page 164: Water Hose And Water Pipe
14-5 ENGINE COOLING - Water Hose and Water Pipe WATER HOSE AND WATER PIPE <4G6-MPI> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Suppling Air Cleaner and Air Intake Hose Assembly Removal and Installation 13 Nm f3mm 24 Nm 13 Nm f3mm...
Page 165 14-6 ENGINE COOLING - Water Hose and Water Pipe REMOVAL SERVICE POINT AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. INSTALLATION SERVICE POINTS "AA WATER OUTLET FITTING/THERMOSTAT CASE ASSEMBLY INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without...
Page 166 15-1 INTAKE AND EXHAUST CONTENTS GENERAL ....... . . INTAKE MANIFOLD <4G6-MPI> .
Page 167: Intake And Exhaust
15-2 INTAKE AND EXHAUST - General/Service Specification GENERAL OUTLINE OF CHANGES The following service procedures have been established in line with the addition of vehicles with 4G63-MPI engine. Furthermore, other items are the same as for the 4G64-GDI engine. Service procedures have been established to correspond to changes to the exhaust manifold heat protector in vehicles with 4G64-GDI engine.
Page 168 15-3 INTAKE AND EXHAUST - Intake Manifold <4G6-MPI> INTAKE MANIFOLD <4G6-MPI> REMOVAL AND INSTALLATION <4G6> Pre-removal Operation Post-installation Operation Engine Coolant Draining Throttle Body Installation (Refer to GROUP 13A.) Air Cleaner Removal Air Cleaner Installation Throttle Body Removal (Refer to GROUP 13A.) Engine Coolant Supplying Accelerator Cable Ajdustment (Refer to GROUP 17 - On-vehicle Service.)
Page 169 15-4 INTAKE AND EXHAUST - Intake Manifold <4G6-MPI> 10 - 13 Nm 10 - 12 Nm 9 Nm 20 Nm 20 Nm 20 Nm 31 Nm 6. EGR valve 10. Vacuum pipe assembly 7. PCV hose 11. Solenoid valve assembly 8.
Page 170 15-5 INTAKE AND EXHAUST - Intake Manifold <4G6-MPI> REMOVAL SERVICE POINT AA" DELIVERY PIPE, INJECTOR AND PRESSURE REGULATOR REMOVAL Remove the delivery pipe (with the injectors and pressure regulator attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector.
Page 171: 4G6-Mpi
15-6 INTAKE AND EXHAUST - Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation <4G6-GDI> 49 Nm 12 - 15 Nm 29 Nm 49 Nm 34 Nm 44 Nm <4G6-MPI> 29 Nm 49 Nm 13 Nm 49 Nm 34 Nm...
Page 172 15-7 INTAKE AND EXHAUST - Exhaust Manifold INSPECTION 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 173 NOTES...
Page 174 16-1 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM GENERAL INFORMATION ....SERVICE SPECIFICATIONS ... . . GENERAL ....... Outline of Change .
Page 175: Charging System
16-2 ENGINE ELECTRICAL - Charging System CHARGING SYSTEM GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G63-MPI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the SPACE WAGON.
Page 176: Starting System
16-3 ENGINE ELECTRICAL - Starting System STARTING SYSTEM GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G63-MPI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the SPACE WAGON.
Page 177: Starter Motor
16-4 ENGINE ELECTRICAL - Starting System STARTER MOTOR The following service procedures have been established to correspond to the addition of a direct drive type starter motor. Items other than those given below are the same as before. INSPECTION FREE RUNNING TEST Current: max.
Page 178 16-5 ENGINE ELECTRICAL - Starting System DISASSEMBLY AND REASSEMBLY <DIRECT DRIVE TYPE> Disassembly steps 1. Screw 9. Brush holder assembly AA" 2. Magnetic switch 10. Yoke assembly 3. Packing 11. Armature 4. Plate 12. Lever 5. Screw 13. Washer 6. Through bolt AB"...
Page 179 16-6 ENGINE ELECTRICAL - Starting System DISASSEMBLY SERVICE POINTS Magnetic switch “S” terminal AA" MAGNETIC SWITCH REMOVAL Disconnect field coil wire from “M” terminal of magnetic switch. “B” terminal “M” terminal Field coil wire AB" SNAP RING/STOP RING REMOVAL Socket 1.
Page 180 16-7 ENGINE ELECTRICAL - Starting System INSPECTION COMMUTATOR CHECK 1. Place the armature in a pair of “V” blocks and check the runout with a dial indicator. Standard value: 0.05 mm Limit: 0.1 mm 2. Measure the commutator outer diameter. Standard value: 32.0 mm Limit: 31.4 mm 3.
Page 181 16-8 ENGINE ELECTRICAL - Starting System BRUSH HOLDER CHECK Check the continuity between brush holder plate and brush Insulated holder. brush holder If there is no continuity, the brush holder is in order. OVERRUNNING CLUTCH CHECK 1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction.
Page 182 16-9 ENGINE ELECTRICAL - Starting System ARMATURE TEST Growler ARMATURE SHORT-CIRCUIT TEST 1. Place armature in a growler. 2. Hold a thin steel blade parallel and just above while rotating armature slowly in growler. A shorted armature will cause blade to vibrate and be attracted to the core. Replace shorted armature.
Page 183: Ignition System
16-10 ENGINE ELECTRICAL - Ignition System IGNITION SYSTEM GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G63-MPI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the SPACE WAGON.
Page 184: Service Specifications
16-11 ENGINE ELECTRICAL - Ignition System IGNITION COIL SPECIFICATIONS Items Specifications Type Molded 2-coil SPARK PLUG SPECIFICATIONS Items Specifications BKR6E-11 DENSO K20PR-U11 SERVICE SPECIFICATIONS IGNITION COIL Items Specifications Secondary coil resistance kW 8.5- 11.5 SPARK PLUG Items Specifications Spark plug gap mm 1.0- 1.1 RESISTIVE CODE Items...
Page 185: Check
16-12 ENGINE ELECTRICAL - Ignition System ON-VEHICLE SERVICE IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK Check by the following procedure, and replace if there is a malfunction. SECONDARY COIL RESISTANCE CHECK Measure the resistance between the high-voltage terminals of the ignition coil. Standard value: 8.5 - 11.5 kW PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK...
Page 186: Spark Plug Check And Cleaning
16-13 ENGINE ELECTRICAL - Ignition System SPARK PLUG CHECK AND CLEANING 1. Remove the spark plug cables. Caution When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. 2. Remove the spark plugs. 3.
Page 187: Waveform Check Using An Analyzer
16-14 ENGINE ELECTRICAL - Ignition System WAVEFORM CHECK USING AN ANALYZER Ignition Secondary Voltage Check MEASUREMENT METHOD 1. Clamp the SECONDARY PICKUP around the spark plug cable. NOTE 1. The peak ignition voltage will be reversed when the spark cables No. 2 and No. 4, or No. 1 and No. 3 cylinders are clamped.
Page 188 16-15 ENGINE ELECTRICAL - Ignition System STANDARD WAVEFORM Observation Conditions Function Secondary Pattern height High (or Low) Pattern selector Raster Engine revolutions Curb idle speed Spark line (point A) Ignition voltage (point D) Wave damping reduction section (point B) Dwell section Secondary ignition...
Page 189 16-16 ENGINE ELECTRICAL - Ignition System WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal waveform examples, 1, 2, 3 and 4). Spark line Plug gap Condition of Compression Concentration of Ignition timing...
Page 190 16-17 ENGINE ELECTRICAL - Ignition System EXAMPLES OF ABNORMAL WAVEFORMS Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. 01P0215 Example 2 Spark line is low and long, and is Spark plug gap is too small.
Page 191: Ignition Coil
16-18 ENGINE ELECTRICAL - Ignition System IGNITION COIL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation <4G6-MPI> 10 Nm 25 Nm Removal steps 1. Ignition coil connector 3. Ignition coil 2. Spark plug cable 4. Spark plug CAMSHAFT POSITION SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation...
Page 192 17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM <MPI> Vacuum Circuit Diagram ....CRANKCASE EMISSION CONTROL GENERAL ....... SYSTEM .
Page 193: Engine Control System
17-2 ENGINE AND EMISSION CONTROL - Engine Control System <MPI> ENGINE CONTROL SYSTEM <MPI> GENERAL OUTLINE OF CHANGE The following service procedures have been established to correspond to the addition of vehicles with 4G6-MPI engine. SERVICE SPECIFICATION Items Standard value Accelerator cable play mm 1 - 2 ON-VEHICLE SERVICE...

Page 194: Accelerator Cable And Pedal
17-3 ENGINE AND EMISSION CONTROL - Engine Control System <MPI> ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION Post-installation Operation Adjusting the Accelerator Cable (Refer to P.17-2.) <R.H. drive vehicles> <L.H. drive vehicles> 5 Nm 5 Nm 12 Nm 12 Nm Removal steps 1.
Page 195: Emission Control System
17-4 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EMISSION CONTROL SYSTEM <MPI> GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G63-MPI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the SPACE WAGON.

Page 196: Vacuum Hose
17-5 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> VACUUM HOSE VACUUM HOSE PIPING DIAGRAM <4G63-MPI> Air cleaner Fuel pressure regulator PCV valve EGR valve Canister EGR control Purge control solenoid valve solenoid valve Oxygen sensor (front) Oxygen sensor (rear) Three-way catalytic converter VACUUM CIRCUIT DIAGRAM...
Page 197: Crankcase Emission Control System
17-6 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> CRANKCASE EMISSION CONTROL SYSTEM SYSTEM DIAGRAM Ventilation hose Breather hose PCV valve COMPONENT LOCATION PCV valve <4G63-SOHC>...
Page 198: Evaporative Emission Control System
17-7 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EVAPORATIVE EMISSION CONTROL SYSTEM SYSTEM DIAGRAM Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Throttle body From fuel tank Air flow sensor Engine coolant temperature sensor Canister Intake air Purge control temperature sensor solenoid valve Control Barometric pressure...
Page 199: Purge Control System Check
17-8 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> PURGE CONTROL SYSTEM CHECK <4G6> 1. Disconnect the vacuum hose (red stripe) from the throttle Red stripe body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3.
Page 200: System
17-9 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EXHAUST GAS RECIRCULATION (EGR) SYSTEM SYSTEM DIAGRAM <4G63-MPI> control solenoid Air flow sensor valve Engine coolant temperature sensor Crank angle sensor EGR valve Control relay Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Battery COMPONENT LOCATION EGR control solenoid valve...
Page 201: Exaust Gas Recirculation (Egr) Control System Check
17-10 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EXHAUST GAS RECIRCULATION (EGR) <4G63-MPI> CONTROL SYSTEM CHECK Green stripe 1. Disconnect the vacuum hose (green stripe) from the EGR valve, and then connect a hand vacuum pump via the three-way terminal.
Page 202: Egr Port Vacuum Check
17-11 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EGR PORT VACUUM CHECK 1. Disconnect the vacuum hose (white stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum EGR vacuum nipple pump to the nipple. 2.
Page 203 NOTES...
Page 204: Clutch
21-1 CLUTCH - General/On-vehicle Service GROUP 21 CLUTCH GENERAL OUTLINE OF CHANGE The following service procedures have been established in line with the addition of a clutch switch. <2400> (1) CLUTCH PEDAL INSPECTION AND ADJUSTMENT (2) CLUTCH PEDAL REMOVAL AND INSTALLATION (3) CLUTCH SWITCH CHECK ON-VEHICLE SERVICE CLUTCH PEDAL INSPECTION AND...
Page 205 21-2 CLUTCH - Clutch Pedal CLUTCH PEDAL <2400> REMOVAL AND INSTALLATION Post-installation Operation Clutch Pedal Adjustment (Refer to P.21-1) 12 Nm 12 Nm Removal steps 1. Clutch switch 7. Clutch master cylinder mounting 2. Clip 3. Pedal stopper 8. Master cylinder member mounting 4.
Page 206 23-1 AUTOMATIC TRANSMISSION CONTENTS GENERAL ....... . . ON-VEHICLE SERVICE .
Page 207: General
23-2 AUTOMATIC TRANSMISSION - General/Troubleshooting GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G6-MPI and 4G6-GDI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the ’99 SPACE WAGON.
Page 208 23-3 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODE Code Diagnosis item Reference page Throttle position sensor system Short circuit 23-4 <4G6-MPI> Open circuit 23-4 Accelerator pedal position sensor system Accelerator pedal position sensor system <4G6-GDI> Sensor maladjustment 23-4 Oil temperature sensor system Open circuit 23-4...
Page 209 23-4 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 11, 12, 14 Throttle position sensor system Probable cause <4G6-MPI>, accelerator pedal position sensor system <4G6-GDI> 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 <4G6-MPI>...
Page 210 23-5 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 211 23-6 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 212 23-7 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 engine-A/T-ECU <4G6-MPI>...
Page 213 23-8 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 214 23-9 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 41 1st gear ratio does not meet the specification Probable cause Code No. 42 2nd gear ratio does not meet the specification Code No. 43 3rd gear ratio does not meet the specification Code No.
Page 215 23-10 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 216 23-11 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 217 23-12 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 23-14 Dual pressure switch system 23-14 Vehicle speed sensor system...
Page 218 23-13 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 2 MUT-II can not communicate with the engine-A/T-ECU or Probable cause A/T-ECU. It is suspected that this malfunction is caused by an open circuit in engine-A/T-ECU D Malfunction of harness or connector or A/T-ECU power supply circuit or diagnosis output circuit. D Malfunction of the engine-A/T-ECU <4G6-MPI>...
Page 219 23-14 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 engine-A/T-ECU or A/T-ECU. D Malfunction of the ignition switch D Malfunction of connector D Malfunction of the engine-A/T-ECU <4G6-MPI>...
Page 220 23-15 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 D Malfunction of the vehicle speed sensor engine-A/T-ECU or A/T-ECU. D Malfunction of connector D Malfunction of the engine-A/T-ECU <4G6-MPI>...
Page 221 23-16 AUTOMATIC TRANSMISSION - Troubleshooting CHECK AT ENGINE-A/T-ECU TERMINALS <4G6-MPI> Terminal No. Check item Check requirement Standard value A/T control relay Ignition switch: OFF Ignition switch: ON System voltage Sensor earth Always Earth Always Solenoid valve power supply Ignition switch: OFF Ignition switch: ON System voltage Earth...
Page 222 23-17 AUTOMATIC TRANSMISSION - Troubleshooting Terminal No. Check item Check requirement Standard value Inhibitor switch R Selector lever position: R System voltage Selector lever position: Other than above Inhibitor switch 3 Selector lever position: 3 System voltage Selector lever position: Other than above Inhibitor switch L Selector lever position: L System voltage...
Page 223 23-18 AUTOMATIC TRANSMISSION - Troubleshooting CHECK AT A/T-ECU TERMINALS <4G6-GDI> Terminal No. Check item Check requirement Standard value Underdrive solenoid valve Selector lever position: D (1st gear) System voltage Selector lever position: P Approx. 7 - 9 V Solenoid valve power supply Ignition switch: OFF Ignition switch: ON System voltage...
Page 224 23-19 AUTOMATIC TRANSMISSION - Troubleshooting Terminal No. Check item Check requirement Standard value Input shaft speed sensor Measure between terminal No. 31 and No. 43 by Refer to an oscilloscope. P.23-43*, Oscil- Engine: 2,000 r/min loscope inspec- Selector lever position: 3 tion procedure Output shaft speed sensor Measure between terminal No.
Page 225: On-Vehicle Service
23-20 AUTOMATIC TRANSMISSION - Troubleshooting/On-Vehicle Service Terminal No. Check item Check requirement Standard value Inhibitor switch R Selector lever position: R System voltage Selector lever position: Other than above Inhibitor switch D Selector lever position: D System voltage Selector lever position: Other than above Inhibitor switch 2 Selector lever position: 2 System voltage...
Page 226 26-1 FRONT AXLE CONTENTS GENERAL ....... . . DRIVE SHAFT .
Page 227 26-2 FRONT AXLE - General/Drive Shaft GENERAL OUTLINE OF CHANGE The following service procedures have been established in line with the addition of 2000 models and 2400 models. (1) DRIVE SHAFT REMOVAL AND INSTALLATION (2) DRIVE SHAFT DISASSEMBLY AND REASSEMBLY DRIVE SHAFT REMOVAL AND INSTALLATION Caution...
Page 228 26-3 FRONT AXLE - FRONT AXLE - Drive Shaft Drive Shaft REMOVAL SERVICE POINTS Items other than those given below are the same as before. MB990767 AC" DRIVE SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY REMOVAL 1. Use the special tool to push out the drive shafts from the hub.
Page 229 26-4 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY 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. <2000-A/T, 2000-M/T (LH), 2400 (LH)>...
Page 230 26-5 FRONT AXLE - Drive Shaft REASSEMBLY SERVICE POINTS The following drive shaft reassembly procedures have been established. Items other than those given below are the same as before. "AA DYNAMIC DAMPER/DAMPER BAND/T.J. BOOT INSTALLATION Install the dynamic damper in the position shown in the illustration.
Page 231 26-6 FRONT AXLE - Drive Shaft B.J. BOOT (RESIN BOOT) REPLACEMENT The following B.J. boot (resin boot) replacement procedures have been established. Items other than those given below are the same as before. Fill the inside of the B.J. boot with the specified amount of the specified grease.
Page 232 31-1 WHEEL AND TYRE - General GROUP 31 WHEEL AND TYRE GENERAL OUTLINE OF CHANGE Aluminium wheels have been adopted as standard. <2400> Items 2400 N63WSNHGL6 N63WSNHCL6 N63WSRHGL6 N63WSRHCL6 N63WSNGCL6 N63WSRGCL6 Wheel Type Aluminium Size 15 ´ 6JJ Amount of wheel offset mm Pitch circle diame- 114.3...
Page 233 33A-1 FRONT SUSPENSION - General GROUP 33A FRONT SUSPENSION GENERAL OUTLINE OF CHANGE The coil spring specifications have been changed. <2400> COIL SPRING Item 2400 Wire diameter ´ average diameter ´ free length mm 13 ´ 160 ´ 378...
Page 234 35A-1 SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM ..........ANTI-SKID BRAKING SYSTEM (ABS) <2WD>...
Page 235 35A-2 BASIC BRAKE SYSTEM - General GROUP 35A BASIC BRAKE SYSTEM GENERAL OUTLINE OF CHANGES The proportioning valve has been abolished and a connector assembly has been added to correspond to the adoption of EBD* (Electronic Brake force Distribution) control carried out by the ABS-ECU. <Vehicles with ABS>...
Page 236 35B-1 ANTI-SKID BRAKING SYSTEM (ABS) <2WD> CONTENTS GENERAL ....... . . ON-VEHICLE SERVICE .
Page 237 35B-2 ABS <2WD> - General GENERAL OUTLINE OF CHANGE The following service procedures have been established to correspond to the addition of an EBD (Electronic Brake force Distribution) function to the ABS-ECU. EBD (Electronic Brake force Distribution) The EBD operates during braking within the range where the slip ratio is relatively low and the ABS does not normally operate.
Page 238 35B-3 ABS <2WD> - General CONSTRUCTION DIAGRAM The following two parts have been added to the ABS component parts to correspond to the addition of an EBD function. Brake warning lamp (used as an EBD warning lamp) Brake warning lamp relay 1.
Page 239 35B-4 ABS <2WD> - General BRAKE WARNING LAMP AND BRAKE WARNING LAMP RELAY The brake warning lamp relay is a normally-closed type of relay which is controlled by the ABS-ECU. When the transistor inside the ABS-ECU turns off, the brake warning lamp relay turns on and causes the brake warning lamp to illuminate.
Page 240 35B-5 ABS <2WD> - General/Troubleshooting ABS-ECU The ABS-ECU has a fail-safe function which controls the EBD in the following way if an abnormality occurs in the ABS system. Fail-Safe Function Problem location Brake warning warning EBD control lamp lamp Front wheel speed sensor 1 ab- Normal control is carried out.
Page 241 35B-6 ABS <2WD> - Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 When the ignition key is turned to “ON” (engine stopped), Probable cause the brake warning lamp does not illuminate. The cause may be an open circuit in the lamp power supply circuit, a blown lamp, D Malfunction of combination meter a malfunction of the brake warning lamp relay or an open circuit between the brake D Malfunction of brake warning lamp relay...
Page 242 35B-7 ABS <2WD> - Troubleshooting Inspection Procedure 2 Even after the engine is started, the brake warning lamp Probable cause does not switch off. (However, the parking brake is released and the brake fluid level, brake fluid sensor and parking brake switch are all normal.) If the ABS warning lamp is also illuminated at the same time, the cause is probably D Malfunction of combination meter...
Page 243 35B-8 ABS <2WD> - On-vehicle Service ON-VEHICLE SERVICE Brake warning lamp relay BRAKE WARNING LAMP RELAY CONTINUITY CHECK Terminal No. Battery voltage Power is not supplied Power is sup- plied...
Page 244 37A-1 STEERING CONTENTS GENERAL ....... . . POWER STEERING OIL PUMP .
Page 245 37A-2 STEERING - General/On-vehicle Service GENERAL OUTLINE OF CHANGES The following procedures have been changed to correspond to the modified oil pump. (1) Oil pump pressure test (2) Power steering oil pressure switch check (3) Power steering oil pump removal and installation (4) Power steering oil pump disassembly and reassembly (5) Power steering hose removal and installation ON-VEHICLE SERVICE...
Page 246 37A-3 STEERING - Power Steering Oil Pump POWER STEERING OIL PUMP REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining Power Steering Fluid Supplying Drive Belt Tension Adjusting Power Steering Fluid Line Bleeding Oil Pump Pressure Check (Refer to P.37A-2.) 57 Nm 28 Nm 32 Nm...
Page 247 37A-4 STEERING - Power Steering Oil Pump DISASSEMBLY AND REASSEMBLY Caution Never disassemble the terminal assembly. 27 Nm 25 - 29 Nm 9.8 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 Disassembly steps 1.
Page 248 37A-5 STEERING - Power Steering Oil Pump REASSEMBLY SERVICE POINTS Side plate Plug Items other than those given below are the same as before. "AA O-RINGS INSTALLATION I.D. ´ Width mm 19.8 ´ 2.4 14.8 ´ 1.9 3.8 ´ 1.9 14.8 ´...
Page 249 37A-6 STEERING - Power Steering Hoses POWER STEERING HOSES REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining Under Cover Installation Under Cover Removal Power Steering Fluid Supplying Power Steering Fluid Line Bleeding Flare nut 57 Nm 12 Nm 3, 14, 15 15 Nm 12 Nm...

Mitsubishi MOTORS Space Runner 1999 Workshop Manual Supplement

Workshop Manual

Engine

Gasoline Direct Injection (Gdi)

General

Troubleshooting

Service Specifications

On-Vehicle Service

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

Injector

Multipoint Fuel Injection (4G6-Mpi)

Engine Cooling

Engine Electrical

Charging System

Starting System

Ignition System

Engine and Emission Control

Automatic Transmission

General

Troubleshooting

On-Vehicle Service

Quick Links

Chapters

Troubleshooting

Related Manuals for Mitsubishi MOTORS Space Runner 1999

Summary of Contents for Mitsubishi MOTORS Space Runner 1999

Table of Contents