Mitsubishi MOTORS Colt 2000 Workshop Manual Supplement

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WORKSHOP MANUAL

SUPPLEMENT

FOREWORD

This

manual

outlines changes

procedures related to the chassis including vehicle

inspections, adjustments and improvements in the

newly equipped models.

Please read this manual carefully so that it will be of

assistance for your service activities.

Please note that the following service manuals are

also available and should be used in conjunction

with this manual.

TECHNICAL INFORMATION MANUAL

WORKSHOP MANUAL

CHASSIS GROUP

PWME9511-A (Supplement)

PWME9511-B (Supplement)

ENGINE GROUP

ELECTRICAL WIRING

BODY REPAIR MANUAL PBME9501 (Basic)

PARTS CATALOGUE

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.

Mitsubishi Motors Corporation

in servicing

PYME9501

PYME9501-1

PWME9511 (Basic)

PWEE____

(Looseleaf edition)

PHME9511 (Basic)

PHME9511-A (Supplement)

PHME9511-B (Supplement)

PHME9511-C (Supplement)

PBME9501-1 (Supplement)

PBME9501-2 (Supplement)

B806F006A_

and

product

Jun. 2000

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

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

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

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

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

Intake and Exhaust . . . . . . . . . . . . .

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

Engine and Emission Control . . . .

Automatic Transmission . . . . . . . .

Table of Contents

Chapters

Table of Contents

Troubleshooting

Need help?

Do you have a question about the Colt 2000 and is the answer not in the manual?

Questions and answers

Jonathan

May 7, 2025

Battery sigh and yellow light on dashboard

1 comments:

Mr. Anderson

May 18, 2025

The battery sign and yellow light (engine warning lamp) on the dashboard of a Mitsubishi Colt 2000 indicate possible issues with the ignition system, fuel system, battery voltage, engine ECU, or other engine-related components. The engine warning lamp lights up when the ECU detects a problem with the MPI system or related sensors/actuators. The battery should be checked to ensure cranking voltage is 8V or higher. Diagnostic trouble codes can help identify the specific issue.

This answer is automatically generated

Summary of Contents for Mitsubishi MOTORS Colt 2000

Page 1 PARTS CATALOGUE B806F006A_ information, illustrations product 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. Mitsubishi Motors Corporation Jun. 2000...
Page 2 WARNING! (1) Improper service or maintenance of any component of the SRS and any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag or to the driver and passenger (from rendering the SRS inoperative). (2) SRS components 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 sensor and front seat assembly (side air bag module) before drying or baking the vehicle after painting.
Page 3 00-1 GENERAL CONTENTS VEHICLE IDENTIFICATION ....MAJOR SPECIFICATIONS ....Models .
Page 4 00-2 GENERAL - Vehicle Identification VEHICLE IDENTIFICATION MODELS Model code Engine model Transmission model Fuel supply system CJ1A MNDEL6/R6 4G13 (1,298 mL) F5M41 <5M/T> (Electronically Controlled MNJEL6/R6 Multi Point Fuel Injection) CJ4A MNJEL6/R6 4G92 MPI (1,597 mL) MRJEL6/R6 F4A41 <INVECS-II 4A/T> MODEL CODE M N J E L 6 Items...
Page 5 00-3 GENERAL - Vehicle Identification CHASSIS NUMBER The chassis number is stamped on the toeboard inside the engine compartment. Items Contents Fixed figure Asia Distribution channel Japan channel Destination For Europe, right hand drive For Europe, left hand drive Body style 2-door hatchback Transmission type 5-speed manual transmission...
Page 6 00-4 GENERAL - Major Specifications MAJOR SPECIFICATIONS HATCHBACK Items CJ1A CJ1A CJ4A CJ4A MNDEL6, MNJEL6, MNJEL6, MNJEL6, MNDER6 MNJER6 MNJER6 MNJER6 Vehicle Overall length 3,900 3,900 3,900 3,900 dimensions Overall width 1,680 1,680 1,680 1,680 Overall height (unladen) 1,365, 1,365, 1,365, 1,365, 1,380*...
Page 7 11A-1 ENGINE CONTENTS ENGINE <4G1> ............ENGINE <4G9>...
Page 8: Table Of Contents
11A-2 ENGINE <4G1> CONTENTS GENERAL ....... . . ON-VEHICLE SERVICE .
Page 9: General
General/General Information/ 11A-3 ENGINE <4G1> - Service Specifications/Sealant GENERAL OUTLINE OF CHANGES The following service procedures have been The compression pressure has been changed. established due to the addition of the 4G13-SOHC An auto-lash adjuster has been adopted. 16 valve MPI engine. Furthermore, other items are Camshaft and camshaft oil seal removal and the same as for the 4G13-SOHC 12 valve MPI installation...
Page 10: Special Tools
11A-4 ENGINE <4G1> - Special Tools SPECIAL TOOLS Tool Number Name MB990767 Front hub and Holding the camshaft sprocket flange yoke holder MD998719 Crankshaft pulley holder pin MD998443 Auto-lash adjuster Supporting of lash adjuster holder MD998713 Camshaft oil seal Press-in of the camshaft oil seal installer MD998304 Crankshaft front oil...
Page 11: On-Vehicle Service
11A-5 ENGINE <4G1> - On-vehicle Service ON-VEHICLE SERVICE COMPRESSION PRESSURE CHECK The disconnection of the distributor connector has been changed to the disconnection of the crank angle sensor connector due to the change of the crank angle sensor. Other service procedures are the same as before. Standard value (at engine speed of 250 - 400 r/min): 1,598 kPa Limit (at engine speed of 250 - 400 r/min):...
Page 12 11A-6 ENGINE <4G1> - 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 13 11A-7 ENGINE <4G1> - On-vehicle Service 2. Run the engine at idle for 1 - 3 minutes to let it warm Drive pattern for air bleeding Gradually open the Close the throttle 3. With no load on the engine, repeat the drive pattern shown throttle valve.
Page 14: Camshaft And Camshaft Oil Seal
11A-8 ENGINE <4G1> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner Removal and Installation Ignition Coil Removal and Installation (Refer to GROUP16.) Apply engine oil to all 3.5 Nm moving parts during 5.0 Nm installation.
Page 15 11A-9 ENGINE <4G1> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS AA" CAMSHAFT SPROCKET REMOVAL Timing mark 1. Turn the crankshaft in the forward direction (clockwise) to align the timing mark so that No.1 cylinder is at the compression TDC. Caution Always turn the crankshaft in the forward direction (clockwise).
Page 16 11A-10 ENGINE <4G1> - 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 17: Crankshaft Front Oil Seal
11A-11 ENGINE <4G1> - Crankshaft Front Oil Seal CRANKSHAFT FRONT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt Removal and Installation Crank angle sensor Removal and Installation (Refer to GROUP16.) (Lip) Engine oil Removal steps "BA 1. Crankshaft sprocket "BA 4.
Page 18: Cylinder Head Gasket
11A-12 ENGINE <4G1> - Crankshaft Front Oil Seal/Cylinder Head Gasket "BA CRANKSHAFT SPACER/CRANKSHAFT SENSING Crankshaft BLADE/SPRING PIN/CRANKSHAFT SPROCKET sensing blade INSTALLATION Crankshaft Install the crankshaft sprocket assembled with the spring pin, sprocket the crankshaft sensing blade, and the crankshaft spacer to Crankshaft the crankshaft.
Page 19 11A-13 ENGINE <4G1> - Cylinder Head Gasket 49 Nm ® 0 Nm ® 20 Nm ® +90° ® +90° (Cold engine) (Engine oil) 5.0 Nm 10 - 12 Nm 10 - 12 Nm 24 Nm (Engine oil) 35 Nm 88 Nm 50 Nm Removal steps 1.
Page 20 11A-14 ENGINE <4G1> - Cylinder Head Gasket REMOVAL SERVICE POINTS AA" CAMSHAFT SPROCKET REMOVAL Timing mark 1. Turn the crankshaft in the forward direction (clockwise) to align the timing mark so that No.1 cylinder is at the compression TDC. Caution Always turn the crankshaft in the forward direction (clockwise).
Page 21 11A-15 ENGINE <4G1> - Cylinder Head Gasket INSTALLATION SERVICE POINTS "AA CYLINDER HEAD GASKET INSTALLATION 1. Wipe off all oil and grease from the gasket mounting surface. Caution Do not allow foreign material to enter the engine coolant or oil passages and the cylinder. 2.
Page 22 11A-16 ENGINE <4G1> - Cylinder Head Gasket (4) Mark the cylinder head bolts and the cylinder head with Step (4) Step (5) paint, and then tighten the bolts in the shown sequence to 90°. (5) Tighten the bolts in the shown sequence to additional 90°, and check that the paint marks on the cylinder head bolts are flush with the paint marks on the cylinder head.
Page 23 11B-1 ENGINE <4G9> CONTENTS GENERAL ....... . . Ignition Timing Check .
Page 24: General
General/General Information/ 11B-2 ENGINE <4G9> - Special Tool/On-vehicle Service GENERAL OUTLINE OF CHANGES The following service procedures have been The ignition timing has been changed. changed. Furthermore, other items are the same An auto-lash adjuster has been added. as before. The timing belt lower cover has been changed.
Page 25 11B-3 ENGINE <4G9> - On-vehicle Service Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters.
Page 26 11B-4 ENGINE <4G9> - On-vehicle Service 1. Check the engine oil and replenish or replace the oil if necessary. NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage.
Page 27: Camshaft And Camshaft Oil Seal
11B-5 ENGINE <4G9> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION 28 - 34 Nm Apply engine oil to all sliding parts during installation. Removal steps AA" "AA 1. Lash adjuster, intake rocker arm and shaft assembly AA"...
Page 28: Timing Belt
11B-6 ENGINE <4G9> - Timing Belt TIMING BELT REMOVAL AND INSTALLATION 10 Nm 10 Nm Removal steps 1. Crank angle sensor connector "AA 2. Timing belt lower cover INSTALLATION SERVICE POINT "AA TIMING BELT LOWER COVER INSTALLATION 1. Mount the bolt shown in the illustration (M6 ´ 20 mm) first.
Page 29 12-1 ENGINE LUBRICATION - General/On-vehicle Service GROUP 12 ENGINE LUBRICATION GENERAL OUTLINE OF CHANGE A quality of the engine oil has been changed. ON-VEHICLE SERVICE Specified Engine Oil (ACEA and API classification): ACEA A1, A2, A3/API SG or higher...
Page 30 NOTES...
Page 31 13A-1 MULTIPOINT FUEL INJECTION (MPI) CONTENTS MULTIPOINT FUEL INJECTION (MPI) Basic Idle Speed Adjustment ....<4G1> ......Component Location .
Page 32: Multipoint Fuel Injection (Mpi) <4G1
13A-2 MPI <4G1> - General/General Information MULTIPOINT FUEL INJECTION (MPI) <4G1> GENERAL OUTLINE OF CHANGES The service procedures have been established to describe revised sections due to the changed items shown below. On-board Diagnostics System has been adopted, diagnostic items have been expanded, and diagnostic code numbering system has been changed.
Page 33: Multi-Point Fuel Injection System
13A-3 MPI <4G1> - General Information MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM L1 Oxygen sensor (front) l1 Injector Engine- L2 Vacuum sensor l2 Purge control solenoid valve L3 Intake air temperature sensor l3 Idle speed control valve L4 Throttle position sensor l4 EGR control servo valve L5 Camshaft position sensor L6 Crank angle sensor...
Page 34: Service Specifications
13A-4 MPI <4G1> - Service Specifications/Special Tools SERVICE SPECIFICATIONS Items Standard value Intake air temperature sensor resistance kW 20_C 2.3 - 3.0 80_C 0.30 - 0.42 Oxygen sensor output voltage (during revving) V 0.6 - 1.0 Oxygen sensor heater resistance (at 20_C) W Front 4.5 - 8.0 Rear...
Page 35: Troubleshooting
13A-5 MPI <4G1> - Troubleshooting 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 Engine warning lamp the diagnosis code output.
Page 36 13A-6 MPI <4G1> - Troubleshooting NOTE 1. If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read. 2. After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is next turned on and the same malfunction is re-detected.
Page 37 13A-7 MPI <4G1> - Troubleshooting FREEZE FRAME DATA When the engine-ECU detects a malfunction and stores a diagnosis code, it also stores a current status of the engine. This function is called “freeze frame data.” By analyzing this “freeze frame” data with the MUT-II, an effective troubleshooting can be performed.
Page 38: Fail-Safe Function Reference Table
13A-8 MPI <4G1> - 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 Vacuum 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 39: Inspection Chart For Diagnosis Codes
13A-9 MPI <4G1> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page P0105 Vacuum sensor system 13A-10 P0110 Intake air temperature sensor system 13A-12 P0115 Engine coolant temperature sensor system 13A-13 P0120 Throttle position sensor system 13A-16 P0125 Feedback system...
Page 40 13A-10 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No. P0105 Vacuum sensor system Range of Check Range of Check D Malfunction of the vacuum sensor D Ignition switch: ON D Improper connector contact, open circuit Set Conditions short-circuited harness D The output voltage of the vacuum sensor is 4.5 V or more for 2 seconds.
Page 41 13A-11 MPI <4G1> - Troubleshooting From the previous page Measure at engine-ECU connector Check the following connector: Repair B-34. B-34 D Measure the voltage at the engine-ECU terminal. D Ignition switch: ON Check the harness between the D Voltage between terminal 85 and vacuum sensor and the engine-ECU, earth and repair if necessary.
Page 42 13A-12 MPI <4G1> - Troubleshooting Code No. P0110 Intake air temperature sensor system Probable cause Range of Check D Malfunction of intake air temperature sensor D Two seconds have passed since the ignition switch is turned ON or the D Open or short circuit in intake air temperature engine starting process is completed.
Page 43 13A-13 MPI <4G1> - Troubleshooting From the previous page Measure at intake air temperature Check the following connector: Repair sensor connector A-54. B-34 D Use the test harness (MB991348) to connect only terminals 1 and 3, and then measure at the Check the harness between the pick-up harness.
Page 44 13A-14 MPI <4G1> - Troubleshooting MUT-II Data list Transient malfunction 21 Engine coolant temperature (Refer to GROUP 00 - Points to sensor Note for Intermittent Malfunctions.) OK: When the engine is cold, the temperature is roughly the same as ambient tem- perature.
Page 45 13A-15 MPI <4G1> - Troubleshooting From the previous page Repair Measure at engine coolant Check the engine coolant temperature sensor connector A-72. temperature sensor. D Use test harness (MB991658) to (Refer to P.13A-83*.) connect the connector, and measure at the pick-up harness. Repair D Ignition switch: ON Check the following connector:...
Page 46 13A-16 MPI <4G1> - Troubleshooting Code No. 0120 Throttle position sensor system Probable cause Range of Check D Malfunction of throttle position sensor D Ignition switch: ON D Open or short circuit in the throttle position sensor D Excluding 2 seconds after the ignition switch is turned to ON or immediately circuit or loose connector contact after the engine starts.
Page 47 13A-17 MPI <4G1> - Troubleshooting From the previous page (1), (2) NG Check the following connector: Measure at throttle position sensor Repair B-34 connector A-05. D Use test harness (MB991536) to connect the connector, and measure at the pick-up harness. Check the harness wire between D Ignition switch: ON throttle position sensor and the...
Page 48 13A-18 MPI <4G1> - Troubleshooting Code No. P0125 Feedback system Probable cause Range of Check D Malfunction of oxygen sensor (front) D The engine coolant temperature is approx. 80_C or more. D Open or short circuit in the oxygen sensor (front) D During stoichiometric feedback control circuit or loose connector contact D The vehicle is not being decelerated.
Page 49: Code
13A-19 MPI <4G1> - Troubleshooting Code No. P0130 Oxygen sensor (front) system Probable cause <sensor 1> Range of Check D Malfunction of oxygen sensor (front) D Three minutes have been passed since the engine has been started. D Open or short circuit in the oxygen sensor (front) D The engine coolant temperature is approx.
Page 50 13A-20 MPI <4G1> - Troubleshooting Repair Check the following connector: A-106 Measure at oxygen sensor (front) Check the following connector: Repair connector A-106. B-34 D Disconnect the connector and measure at the harness side. D Resistance between terminal 2 Check the harness wire between the Repair and earth oxygen sensor (front) and the...
Page 51 13A-21 MPI <4G1> - Troubleshooting Code No. P0135 Oxygen sensor heater (front) system Probable cause <sensor 1> Range of Check D Malfunction of oxygen sensor heater (front) D The engine coolant temperature is approx. 20_C or more. D Open or short circuit in the oxygen sensor heater D The oxygen sensor heater (front) remains on.
Page 52 13A-22 MPI <4G1> - Troubleshooting Code No. P0136 Oxygen sensor (rear) system Probable cause <sensor 2> Range of Check D Malfunction of oxygen sensor (rear) D Three minutes have been passed since the engine has been started. D Open or short circuit in the oxygen sensor (rear) D The engine coolant temperature is approx.
Page 53 13A-23 MPI <4G1> - Troubleshooting Repair Check the following connector: A-108 Measure at oxygen sensor (rear) Check the following connector: Repair connector A-108. B-34 D Disconnect the connector and measure at the harness side. D Resistance between terminal 2 Check the harness wire between the Repair and earth oxygen sensor (rear) and the...
Page 54 13A-24 MPI <4G1> - Troubleshooting Code No. P0141 Oxygen sensor heater (rear) system Probable cause <sensor 2> Range of Check D Malfunction of oxygen sensor heater (rear) D The engine coolant temperature is approx. 20_C or more. D Open or short circuit in the oxygen sensor heater D The oxygen sensor heater (rear) remains on.
Page 55 13A-25 MPI <4G1> - Troubleshooting Code No. P0170 Abnormal fuel system Probable cause Range of Check D Incorrect fuel pressure D Engine: Being learning the air-fuel ratio D Malfunction of injector Set Conditions D Malfunction of oxygen sensor (front) D Two seconds or more have been passed while the fuel injection amount D Malfunction of intake air temperature sensor compensation value is too low.
Page 56 13A-26 MPI <4G1> - Troubleshooting Code No. P0201 No. 1 injector system Probable cause Code No. P0202 No. 2 injector system Code No. P0203 No. 3 injector system Code No. P0204 No. 4 injector system Range of Check D Malfunction of the injector D Engine speed is approx.
Page 57 13A-27 MPI <4G1> - Troubleshooting Code No. P0300 Random cylinder misfire detected Probable cause Range of Check D Malfunction of the ignition system D Engine speed is approx. 50 - 4,500 r/min. D Abnormal compression D When the engine is running except deceleration and sudden acceleration. D Malfunction of injector Set Conditions D Abnormal signal from the crank angle sensor...
Page 58 13A-28 MPI <4G1> - Troubleshooting Code No. P0301 No. 1 cylinder misfire detected Probable cause Code No. P0302 No. 2 cylinder misfire detected Code No. P0303 No. 3 cylinder misfire detected Code No. P0304 No. 4 cylinder misfire detected Range of Check D Malfunction of the ignition system D The engine speed is 500 - 4,500 r/min.
Page 59 13A-29 MPI <4G1> - Troubleshooting Code No. P0325 Detonation sensor system Probable cause Range of Check D Malfunction of the detonation sensor D Engine: Two seconds after the engine has been started D Open or short circuit in the detonation sensor Set Conditions circuit or loose connector contact D Changes in sensor output voltage (detonation sensor peak voltage per 1/2...
Page 60 13A-30 MPI <4G1> - Troubleshooting Intermittent malfunction MUT-II Data list (Refer to GROUP 00 - Points to 22 Crank angle sensor Note for Intermittent Malfunctions.) OK: Refer to P.13A-65, DATA LIST REFERENCE TABLE. Repair Check the following connector: A-84 (1) NG Check the harness between the Measure at the crank angle sensor connector A-84.
Page 61 13A-31 MPI <4G1> - Troubleshooting Code No. P0340 Camshaft position sensor system Probable cause Range of Check D Malfunction of the camshaft position sensor D After the engine was started D Open or short circuit in the camshaft position Set Conditions sensor circuit or loose connector contact.
Page 62 13A-32 MPI <4G1> - Troubleshooting Code No. P0403 EGR control solenoid valve system Probable cause Range of Check D Malfunction of the EGR control solenoid valve D Ignition switch: ON D Open or short circuit in the EGR control solenoid D Battery voltage is 10 V or more.
Page 63 13A-33 MPI <4G1> - Troubleshooting Code No. P0421 Catalyst malfunction Probable cause Range of Check D Malfunction of catalyst D The engine speed is 4,000 r/min or less. D Malfunction of the oxygen sensor (front) D During driving D Malfunction of the oxygen sensor (rear) D During air/fuel ratio feedback control D Malfunction of engine-ECU Set Conditions...
Page 64 13A-34 MPI <4G1> - Troubleshooting Code No. P0443 Purge control solenoid valve system Probable cause Range of Check D Malfunction of the purge control solenoid valve D Ignition switch: ON D Open or short circuit in the purge control solenoid D Battery voltage is 10 V or more.
Page 65 13A-35 MPI <4G1> - Troubleshooting Code No. P0500 Vehicle speed sensor system Probable cause Range of Check D Malfunction of the vehicle speed sensor D Engine: Two seconds after the engine was started D Open or short circuit in the vehicle speed sensor D Idle switch: OFF circuit or loose connector contact D Engine speed: 2,500 r/min or more...
Page 66 13A-36 MPI <4G1> - Troubleshooting Code No. P0505 Idle speed control (ISC) system Probable cause Check Area D Malfunction of idle speed control (ISC) servo D Vehicle speed has reached 1.5 km/h at least once. D Improper connector contact, open circuit or D Under the closed loop idle speed control.
Page 67 13A-37 MPI <4G1> - Troubleshooting MUT-II Self-Diag Code Refer to P.13A-9, INSPECTION CHART FOR DIAGNOSIS Is any diagnosis code other than No. P0505 output? CODES. Repair Check intake air hose and intake manifold for air intake. Check the throttle body (around the throttle valve) for Clean around the throttle valve.
Page 68 13A-38 MPI <4G1> - Troubleshooting Code No. P1610 Immobilizer system Probable cause Range of Check D Open or short circuit, or loose connector contact D Ignition switch: ON D Malfunction of the immobilizer-ECU Set Conditions D Malfunction of the engine-ECU D Improper communication between the engine-ECU and the immobilizer-ECU NOTE (1) If the registered ignition keys are close each other when starting the engine, radio interference may...
Page 69: Inspection Chart For Trouble Symptoms
13A-39 MPI <4G1> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13A-40 with MUT-II is Communication with engine-ECU only is not possible. 13A-40 impossible. Engine warning The engine warning lamp does not illuminate right after the 13A-41 lamp and ignition switch is turned to the ON position.
Page 70: Inspection Procedure For Trouble Symptoms
13A-40 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. Probable cause (Communication with all systems is not possible.) The cause is probably a defect in the power supply system (including earth) for the D Malfunction of the connector diagnosis line.
Page 71 13A-41 MPI <4G1> - 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 72 13A-42 MPI <4G1> - 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 73 13A-43 MPI <4G1> - 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.
Page 74 13A-44 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE 7 In 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 75 13A-45 MPI <4G1> - 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 76 13A-46 MPI <4G1> - Troubleshooting From previous page MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (front) (Refer to P.13A-78*.) air into the air intake OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system.
Page 77 13A-47 MPI <4G1> - 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 system idling is too great. D Malfunction of the throttle body MUT-II Self-Diag code Refer to P.13A-9, INSPECTION CHART FOR DIAGNOSIS...
Page 78 13A-48 MPI <4G1> - 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 system when the engine is cold, or that the intake air volume is insufficient.
Page 79 13A-49 MPI <4G1> - 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 80 13A-50 MPI <4G1> - Troubleshooting From previous page MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (front) (Refer to P.13A-78*.) air into the air intake OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system.
Page 81 13A-51 MPI <4G1> - 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 82 13A-52 MPI <4G1> - 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...
Page 83 13A-53 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE 16 The feeling of impact or vibration when accelerating Probable cause In cases such as the above, the cause is probably that there is an ignition leak D Malfunction of the ignition system accompanying the increase in the spark plug demand voltage during acceleration.
Page 84 13A-54 MPI <4G1> - 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 85 13A-55 MPI <4G1> - 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.13A-9, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
Page 86 13A-56 MPI <4G1> - 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.13A-9, INSPECTION CHART FOR DIAGNOSIS...
Page 87 13A-57 MPI <4G1> - 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.13A-9, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.
Page 88 13A-58 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE 23 Fans (radiator fan, A/C condenser fan) are inoperative. Probable cause The fan motor relay is controlled by the power transistor inside the engine-ECU turning D Malfunction of the fan motor relay ON and OFF. D Malfunction of the fan motor D Malfunction of the thermostat D Improper...
Page 89 13A-59 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE 24 Check the engine-ECU power supply and earth circuit. 1. NG Check following Measure the engine-ECU connectors, B-34, B-36, B-37. Repair connectors: B-32, B-70 D Disconnect the connector and measure at the harness side 1.
Page 90 13A-60 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE 26 Fuel pump system Probable cause The engine-ECU turns the fuel pump relay ON when the engine is cranking or running, D Malfunction of the fuel pump relay and this supplies power to drive the fuel pump. D Malfunction of the fuel pump D Improper connector...
Page 91 13A-61 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE 27 Ignition switch-ST system Probable cause The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is D Malfunction of ignition switch cranking. D Improper connector contact, open circuit The engine-ECU controls fuel injection, etc. during starting based on this input. short-circuited harness wire D Malfunction of the engine-ECU Check the following con-...
Page 92 13A-62 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE 29 A/C switch and A/C relay system Probable cause When an A/C ON signal is input to the engine-ECU, the engine-ECU carries out D Malfunction of A/C control system control of the idle speed control (ISC) servo, and also operates the A/C compressor D Malfunction of A/C switch magnetic clutch.
Page 93 13A-63 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE 30 Ignition circuit system Probable cause The engine-ECU interrupts the ignition coil primary current by turning the power transistor D Malfunction of ignition coil inside the engine-ECU ON and OFF. D Malfunction of ignition failure sensor D Improper connector contact,...
Page 94 13A-64 MPI <4G1> - Troubleshooting From the previous page Check following 1. NG Measure at the ignition failure sensor connector A-107. Repair connector: B-35 D Disconnect the connector and measure at the harness side. 1. Voltage between 2 and earth (Ignition switch: ON) OK: 4 V or more 2.
Page 95: Data List Reference Table
13A-65 MPI <4G1> - Troubleshooting DATA LIST REFERENCE TABLE NOTE *1: In a new vehicle [driven approximately 500 km or less], the air intake plenum pressure is sometimes 10 % higher than the standard pressure. *2: The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power supply voltage is 11 V.
Page 96 13A-66 MPI <4G1> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Power Ignition switch: ON System voltage Procedure 13A-59 supply No. 25 voltage Cranking Ignition switch: ON Engine: Stopped Procedure 13A-61 signal signal No. 27 No.
Page 97 13A-67 MPI <4G1> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Power Engine: Idling Steering wheel Procedure 13A-61 steering fluid stationary No. 28 pressure Steering wheel switch turning A/C switch Engine: Idling A/C switch: OFF Procedure 13A-62 (when A/C switch is...
Page 98 13A-68 MPI <4G1> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Injectors* Engine coolant Engine is idling 1.7 - 2.9 ms temperature: 80 – 95_C 2,500 r/min 1.4 - 2.6 ms Lamps, electric cooling fan and all cooling fan and all accessories: OFF When engine is...
Page 99 13A-69 MPI <4G1> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Long-term Engine: Warm, 2,500 r/min without any load - 12.5 - 12.5 % Code No. 13A-25 fuel com- (during closed loop) P0170 pensation Short-term Engine: Warm, 2,500 r/min without any load - 17 - 17 % Code No.
Page 100: Actuator Test Reference Table
13A-70 MPI <4G1> - 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-26 injector After having warmed up/En- becomes different P0201 gine is idling (becomes...
Page 101: Check At The Engine-Ecu Terminals
13A-71 MPI <4G1> - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART The following items have been added. The ignition timing adjustment terminal (terminal No. 52) and inhibitor switch-A/T (terminal No. 91) has been discontinued. Terminal No. Check item Check condition Normal condition Ignition coil - No.
Page 102: Inspection Procedure Using An Analyzer
13A-72 MPI <4G1> - Troubleshooting INSPECTION PROCEDURE USING AN Camshaft position Analyzer sensor connector ANALYZER Special patterns CAMSHAFT POSITION SENSOR AND CRANK ANGLE pick-up SENSOR Measurement Method 1. Disconnect the camshaft position sensor connector and connect the special tool (test harness: MB991709) in between.
Page 103 13A-73 MPI <4G1> - Troubleshooting Standard wave pattern 2 engine revolutions (1 camshaft revolution) The time (cycle time) T is reduced when the engine 75_BTDC 5_BTDC speed increases Crank angle sensor output wave pattern 145° 130° 35° 50° Camshaft posi- tion sensor out- put wave pat- tern...
Page 104 13A-74 MPI <4G1> - Troubleshooting IDLE SPEED CONTROL (ISC) SERVO (STEPPER Special patterns pickup MOTOR) Analyzer Measurement Method 1. Disconnect the ISC servo connector, and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to the ISC servo-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.
Page 105 13A-75 MPI <4G1> - 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 106 13A-76 MPI <4G1> - 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 107 13A-77 MPI <4G1> - 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 wave pattern build-up section and maximum Probable cause voltage Rises from approx. 2 V to approx. 4.5 V at the top-right Normal 2 V rectangular wave Open-circuit in ignition primary circuit...
Page 108: On-Vehicle Service
13A-78 MPI <4G1> - 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 as the A/C are placed on the engine.
Page 109: Component Location
13A-79 MPI <4G1> - 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 110: Intake Air Temperature Sensor Check
13A-80 MPI <4G1> - On-vehicle Service INTAKE AIR TEMPERATURE SENSOR CHECK Vacuum Equipment side connector sensor 1. Disconnect the vacuum sensor connector. 2. Measure resistance between terminals 1 and 3. Standard value: 2.3 - 3.0 kW (at 20_C) 0.30 - 0.42 kW (at 80_C) 3.
Page 111 13A-81 MPI <4G1> - On-vehicle Service 5. Use a jumper wire to connect terminal 1 (red clip) of Jumper the oxygen sensor connector to the battery (+) terminal wire and terminal 3 (blue clip) to the battery ( - ) terminal. Caution White Be very careful when connecting the jumper wire;...
Page 112: Injector
13A-82 MPI <4G1> - Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of Fuel Discharge <before removal only> Accelerator Cable Adjustment Fuel Leak Check <after installation only> 5.0 Nm Apply engine oil to all O-rings during installation. 10 - 12 Nm 9.0 Nm 10 - 13 Nm Removal steps...
Page 113 13A-83 MPI <4G1> - Injector REMOVAL SERVICE POINT AA" DELIVERY PIPE AND INJECTOR ASSEMBLY 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 O-RING/INJECTOR ASSEMBLY/HIGH-PRESSURE FUEL HOSE/FUEL PRESSURE REGULATOR...
Page 114: Multipoint Fuel Injection (Mpi) <4G9
13A-84 MPI <4G9> - General/General Information MULTIPOINT FUEL INJECTION (MPI) <4G9> GENERAL OUTLINE OF CHANGES Due to the changes shown below, the service procedures regarding the different description from the previous version have been established. On-board Diagnostics System has been adopted to expand the diagnostic items and to change diagnosis code numbering system.
Page 115: Troubleshooting
13A-85 MPI <4G9> - Troubleshooting TROUBLESHOOTING DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the MPI system, the engine warning lamp will illuminate or flash. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.
Page 116 13A-86 MPI <4G9> - Troubleshooting Code No. Diagnosis item P0403 EGR valve system P0420 Catalyst malfunction P0443 Purge control solenoid valve system P0505 Idle speed control system P0551 Power steering fluid pressure switch system NOTE 1. If the engine warning lamp illuminates because of a malfunction of the engine-ECU <M/T> or engine-A/T-ECU <A/T>, communication between MUT-II and the engine-ECU <M/T>...
Page 117 13A-87 MPI <4G9> - Troubleshooting METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS USING DIAGNOSIS 2 MODE 1. Switch the diagnosis mode of the engine control unit to DIAGNOSIS 2 mode using the MUT-II. 2.
Page 118 13A-88 MPI <4G9> - Troubleshooting FREEZE FRAME DATA When the engine-ECU <M/T> or engine-A/T-ECU <A/T> detects a malfunction and stores a diagnosis code, it also stores a current status of the engine. This function is called “Freeze frame data.” By analyzing this “freeze frame” data with the MUT-II, an effective troubleshooting can be performed.
Page 119: Fail-Safe Function Reference Table
13A-89 MPI <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 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 120: Inspection Chart For Diagnosis Codes
13A-90 MPI <4G9> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page P0100 Air flow sensor system 13A-92 P0105 Barometric pressure sensor system 13A-94 P0110 Intake air temperature sensor system 13A-96 P0115 Engine coolant temperature sensor system 13A-98 P0120 Throttle position sensor 1 system...
Page 121 13A-91 MPI <4G9> - Troubleshooting NOTE 1. Do not replace the engine-ECU <M/T> or engine-A/T-ECU <A/T> until a through terminal check reveals there are no short/open circuit. 2. Check that the engine-ECU <M/T> or engine-A/T-ECU <A/T> earth circuit is normal before checking for the cause of the problem.
Page 122: Inspection Procedure Classified By Diagnosis Code
13A-92 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No. P0100 Air flow sensor system Probable cause Range of Check D Malfunction of air flow sensor D Engine speed: 500 r/min or more D Open or short circuit in air flow sensor circuit or Set Conditions loose connector contact D The sensor output frequency is 3.3 Hz or less for four seconds.
Page 123 13A-93 MPI <4G9> - Troubleshooting From the previous page Repair Measure at air flow sensor connector Check the following connector: A-99 A-99. D Use test harness (MB991709) to connect the connector, and measure at the pick-up harness. Check the harness between the air Repair D Ignition switch: ON flow sensor and the engine-ECU...
Page 124 13A-94 MPI <4G9> - Troubleshooting Code No. P0105 Barometric pressure sensor system Probable cause Range of Check D Malfunction of barometric pressure sensor D Two seconds have passed since the ignition switch is turned ON or the D Open or short circuit in barometric pressure engine starting process is completed.
Page 125 13A-95 MPI <4G9> - Troubleshooting From the previous page (1) NG Measure at air flow sensor connector Check the following connector: Repair (3) NG A-99. B-34 <M/T>, B-94 <A/T> D Connect connector terminals No. 1, No. 2 and No. 5 only by using test harness (MB991709), and Check the harness between the air measure at the pick-up harness.
Page 126 13A-96 MPI <4G9> - Troubleshooting Code No. P0110 Intake air temperature sensor system Probable cause Range of Check D Malfunction of intake air temperature sensor D Two seconds have passed since the ignition switch is turned ON or the D Open or short circuit in intake air temperature engine starting process is completed.
Page 127 13A-97 MPI <4G9> - Troubleshooting From the previous page Repair Measure at air flow sensor connector Check the following connectors: A-99. A-99, B-34 <M/T>, B-94 <A/T> D Use the test harness (MB991709) to connect only terminals 5 and 6, and then measure at the Check the harness between the air pick-up harness.
Page 128 13A-98 MPI <4G9> - MPI <4G9> - Troubleshooting Troubleshooting Code No. P0115 Engine coolant temperature sensor Probable cause system Range of Check D Malfunction of engine coolant temperature sensor D Engine: Two seconds after the engine has been started D Open or short circuit in the engine coolant Set Conditions temperature sensor circuit or loose connector D The sensor output voltage is 4.6 V or more for four seconds (equivalent to...
Page 129 13A-99 MPI <4G9> - Troubleshooting From the previous page (1) NG Measure at engine-ECU <M/T> or Measure at engine coolant Check the following connector: temperature sensor connector A-72. engine-A/T-ECU <A/T> connector B-34 <M/T>, B-94 <A/T> B-34 <M/T>, B-94 <A/T>. D Disconnect the connector and measure at the harness side.
Page 130 13A-100 MPI <4G9> - Troubleshooting Code No. 0120 Throttle position sensor system Probable cause Range of Check D Malfunction of throttle position sensor D Ignition switch: ON D Open or short circuit in the throttle position sensor D The throttle position sensor is normal. circuit or loose connector contact Set Conditions D Malfunction of the engine-ECU <M/T>...
Page 131 13A-101 MPI <4G9> - MPI <4G9> - Troubleshooting Troubleshooting From the previous page (1), (2) NG Measure at throttle position sensor Check the following connector: Repair connector A-05. B-34 <M/T>, B-94 <A/T> D Use test harness (MB991536) to connect the connector, and measure at the pick-up harness.
Page 132 13A-102 MPI <4G9> - Troubleshooting Repair Check the following connector: A-106 Measure at oxygen sensor (front) Repair Check the following connectors: connector A-106. A-106, B-34 <M/T>, B-94 <A/T> D Disconnect the connector and measure at the harness side. D Resistance between terminal 2 Check the harness wire between the Repair and earth...
Page 133 13A-103 MPI <4G9> - Troubleshooting Code No. P0130 Oxygen sensor (front) system Probable cause <sensor 1> Range of Check D Malfunction of oxygen sensor (front) D Three minutes have been passed since the engine has been started. D Open or short circuit in the oxygen sensor (front) D The engine coolant temperature is approx.
Page 134 13A-104 MPI <4G9> - Troubleshooting Repair Check the following connector: A-106 Check the following connectors: Repair Measure at oxygen sensor (front) A-106, B-34 <M/T>, B-94 <A/T> connector A-106. D Disconnect the connector and measure at the harness side. Check the harness wire between the Repair D Resistance between terminal 2 oxygen sensor (front) and the...
Page 135 13A-105 MPI <4G9> - Troubleshooting Code No. P0135 Oxygen sensor heater (front) system Probable cause <sensor 1> Range of Check D Malfunction of oxygen sensor heater (front) D The engine coolant temperature is approx. 20_C or more. D Open or short circuit in the oxygen sensor heater D The oxygen sensor heater (front) remains on.
Page 136 13A-106 MPI <4G9> - Troubleshooting Code No. P0136 Oxygen sensor (rear) system <sensor Probable cause 2> Range of Check D Malfunction of oxygen sensor (rear) D Three minutes have been passed since the engine has been started. D Open or short circuit in the oxygen sensor (rear) D The engine coolant temperature is approx.
Page 137 13A-107 MPI <4G9> - Troubleshooting Repair Check the following connector: B-108 Measure at oxygen sensor (rear) Check the following connectors: Repair connector B-108. B-34 <M/T>, B-94 <A/T>, B-108 D Disconnect the connector and measure at the harness side. D Resistance between terminal 2 Check the harness wire between the Repair and earth...
Page 138 13A-108 MPI <4G9> - Troubleshooting Code No. P0141 Oxygen sensor heater (rear) system Probable cause <sensor 2> Range of Check D Malfunction of oxygen sensor heater (rear) D The engine coolant temperature is approx. 20_C or more. D Open or short circuit in the oxygen sensor heater D The oxygen sensor heater (rear) remains on.
Page 139 13A-109 MPI <4G9> - Troubleshooting Code No. P0170 Abnormal fuel system Probable cause Range of Check D Incorrect fuel pressure D Engine: Being learning the air-fuel ratio D Malfunction of fuel supply system Set Conditions D Malfunction of oxygen sensor (front) D Ten seconds or more have been passed while the fuel injection amount D Malfunction of intake air temperature sensor compensation value is too low.
Page 140 13A-110 MPI <4G9> - Troubleshooting Code No. P0201 No. 1 injector system Probable cause Code No. P0202 No. 2 injector system Code No. P0203 No. 3 injector system Code No. P0204 No. 4 injector system Range of Check D Malfunction of the injector D Engine speed is approx.
Page 141 13A-111 MPI <4G9> - MPI <4G9> - Troubleshooting Troubleshooting Code No. P0300 Ignition coil (power transistor) system Probable cause Range of Check D Malfunction of the ignition coil D Engine speed is approx. 50 - 4,000 r/min. D Malfunction of the ignition failure sensor D Engine is not cranking.
Page 142 13A-112 MPI <4G9> - Troubleshooting Code No. P0301 No. 1 cylinder misfire detected Probable cause Code No. P0302 No. 2 cylinder misfire detected Code No. P0303 No. 3 cylinder misfire detected Code No. P0304 No. 4 cylinder misfire detected Range of Check D Malfunction of the ignition system D The engine speed is 500 - 4,500 r/min.
Page 143 13A-113 MPI <4G9> - MPI <4G9> - Troubleshooting Troubleshooting Code No. P0325 Detonation sensor system Probable cause Range of Check D Malfunction of the detonation sensor D Engine: Two seconds after the engine has been started D Open or short circuit in the detonation sensor Set Conditions circuit or loose connector contact D Changes in sensor output voltage (detonation sensor peak voltage per 1/2...
Page 144 13A-114 MPI <4G9> - Troubleshooting From the previous page (1) NG Measure at the crank angle sensor Check the harness between the connector A-84. crank angle sensor and earth, and D Disconnect the connector and repair if necessary. measure at the harness side. (2) NG (1) The resistance between terminal Measure at engine-ECU <M/T>...
Page 145 13A-115 MPI <4G9> - Troubleshooting Code No. P0340 Camshaft position sensor system Probable cause Range of Check D Malfunction of the camshaft position sensor D After the engine was started D Open or short circuit in the camshaft position Set Conditions sensor circuit or loose connector contact.
Page 146 13A-116 MPI <4G9> - Troubleshooting Repair Check the following connector: A-70 (1) NG Repair Check the following connectors: Measure at camshaft position sensor connector A-70. A-10, B-13 D Disconnect the connector and measure at the harness side. (1) The voltage between terminal 3 Check the harness wire between the and earth camshaft position sensor connector...
Page 147 13A-117 MPI <4G9> - Troubleshooting Code No. P0403 EGR control solenoid valve system Probable cause Range of Check D Malfunction of the EGR control solenoid valve D Ignition switch: ON D Open or short circuit in the EGR control solenoid D Battery voltage is 10 V or more.
Page 148 13A-118 MPI <4G9> - Troubleshooting Code No. P0420 Catalyst malfunction Probable cause Range of Check D Malfunction of catalyst D The engine speed is 3,000 r/min or less. D Malfunction of the oxygen sensor (front) D During driving D Malfunction of the oxygen sensor (rear) D During air/fuel ratio feedback control D Malfunction of engine-ECU <M/T>...
Page 149 13A-119 MPI <4G9> - Troubleshooting Code No. P0443 Purge control solenoid valve system Probable cause Range of Check D Malfunction of the purge control solenoid valve D Ignition switch: ON D Open or short circuit in the purge control solenoid D Battery voltage is 10 V or more.
Page 150 13A-120 MPI <4G9> - Troubleshooting Code No. P0500 Vehicle speed sensor system Probable cause Range of Check D Malfunction of the vehicle speed sensor D Engine: Two seconds after the engine was started D Open or short circuit in the vehicle speed sensor D Idle switch: OFF circuit or loose connector contact D Engine speed: 2,500 r/min or more...
Page 151 13A-121 MPI <4G9> - Troubleshooting MUT-II Self-Diag code Refer P.13A-90, INSPECTION Is any diagnosis code other than No. CHART FOR DIAGNOSIS CODES. P0505 output? Check intake air hose and intake Repair manifold for air intake. Check the throttle body (around the Clean around the throttle valve.
Page 152 13A-122 MPI <4G9> - Troubleshooting From the previous page Check the following connector: Repair A-56 Check the harness wire between the Repair engine control relay and the idle speed control servo, and between the idle speed control servo and the engine-ECU <M/T>...
Page 153 13A-123 MPI <4G9> - Troubleshooting Code No. P0551 Power Steering fluid Pressure Switch Probable cause System Check Area D Power steering fluid pressure switch failed. D Intake air temperature is - 10_C or higher. D Open or shorted power steering fluid pressure D Barometric pressure is 76 kPa or higher.
Page 154 13A-124 MPI <4G9> - Troubleshooting Code No. P1610 Immobilizer system Probable cause Range of Check D Open or short circuit, or loose connector contact D Ignition switch: ON D Malfunction of the immobilizer-ECU Set Conditions D Malfunction of the engine-ECU <M/T> D Improper communication between the engine-ECU <M/T>...
Page 155: Inspection Chart For Trouble Symptoms
13A-125 MPI <4G9> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13A-126 with MUT-II is Communication with engine-ECU <M/T> or engine-A/T-ECU 13A-126 impossible. <A/T> only is not possible. Engine warning The engine warning lamp does not illuminate right after the 13A-127...
Page 156: Inspection Procedure For Trouble Symptoms
13A-126 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. Probable cause (Communication with all systems is not possible.) The cause is probably a defect in the power supply system (including earth) for the D Malfunction of the connector diagnosis line.
Page 157 13A-127 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after Probable cause the ignition switch is turned to the ON position. Because there is a burnt-out bulb, the engine-ECU <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...
Page 158 13A-128 MPI <4G9> - 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 159 13A-129 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (starting impossible) In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the ignition system sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
Page 160 13A-130 MPI <4G9> - 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 161 13A-131 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 8 Unstable idling (Rough idling, hunting) Probable cause In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of the ignition system idle speed control (ISC) or compression pressure is defective. D Malfunction of air-fuel ratio control system Because the range of possible causes is broad, inspection is narrowed down to simple D Malfunction of the ISC system...
Page 162 13A-132 MPI <4G9> - Troubleshooting From the previous page Check the oxygen sensor (rear) system. (Refer to P.13A-106, IN- MUT-II Data list SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.) 59 Oxygen sensor (rear) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV MUT-II Data list...
Page 163 13A-133 MPI <4G9> - MPI <4G9> - Troubleshooting 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.
Page 164 13A-134 MPI <4G9> - 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 165 13A-135 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idling. (Die out) Probable cause In such cases as the above, the cause is probably that ignition system, air/fuel mixture, D Malfunction of the ignition system idle speed control (ISC) or compression pressure is defective.
Page 166 13A-136 MPI <4G9> - Troubleshooting From the previous page MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-103, IN- 11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.) OK: Changes between 600 - 1,000 mV during sudden racing MUT-II Data list Check the fuel pressure.
Page 167 13A-137 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out) Probable cause In cases such as the above, the cause is probably misfiring due to a weak spark, D Drawing air into intake system or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
Page 168 13A-138 MPI <4G9> - 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...
Page 169 13A-139 MPI <4G9> - Troubleshooting From the previous page MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (Refer to P.13A-78*.) air into the air intake OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system idling D Broken intake...
Page 170 13A-140 MPI <4G9> - 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 171 13A-141 MPI <4G9> - Troubleshooting From the previous page 1. Inspect the intake of MUT-II Data list Check the fuel pressure. 11 Oxygen sensor (Refer to P.13A-78*.) air into the air intake system OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling D Broken intake manifold gasket...
Page 172 13A-142 MPI <4G9> - 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.13A-90, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
Page 173 13A-143 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 20 Knocking Probable cause In cases as the above, the cause is probably that the detonation control is defective D Defective detonation sensor or the heat value of the spark plug is inappropriate. D Inappropriate heat value of the spark plug MUT-II Self-Diag code Refer to P.13A-90, INSPECTION CHART FOR DIAGNOSIS...
Page 174 13A-144 MPI <4G9> - 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.13A-90, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.
Page 175 13A-145 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 23 Idling speed is improper when A/C is operating Probable cause If the engine-ECU <M/T> or engine-A/T-ECU <A/T> detects that the air D Malfunction of the A/C control system conditioner is on, it activates the idle speed control (ISC) servo to control idle-up D Improper connector contact, open circuit or operation.
Page 176 13A-146 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 24 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 177 13A-147 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 25 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 occurred. short-circuited harness wire in the engine-ECU <M/T>...
Page 178 13A-148 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 26 Power supply system and ignition switch-IG system Probable cause When an ignition switch ON signal is input to the engine-ECU <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 179 13A-149 MPI <4G9> - Troubleshooting From the previous page Check the following connectors: Measure at fuel pump relay connector Repair B-32, B-70 B-12. D Disconnect the connector, and measure at the harness side. D Voltage between terminals 3, 4 and Check the trouble symptom.
Page 180 13A-150 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 28 Ignition switch-ST system Probable cause The ignition switch-ST outputs a HIGH signal to the engine-ECU <M/T> or D Malfunction of the ignition switch engine-A/T-ECU <A/T> while the engine is cranking. D Malfunction of the inhibitor switch <A/T> The engine-ECU <M/T>...
Page 181 13A-151 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE 29 A/C switch and A/C relay system Probable cause When an A/C ON signal is input to the engine-ECU <M/T> or engine-A/T-ECU <A/T>, D Malfunction of A/C control system the engine-ECU <M/T> or engine-A/T-ECU <A/T> carries out control of the idle speed D Malfunction of A/C switch control (ISC) servo, and also operates the A/C compressor magnetic clutch.
Page 182 13A-152 MPI <4G9> - Troubleshooting From the previous page (1) NG Repair Check the following connector: Measure at the ignition coil connectors A-107 A-73, A-79. D Disconnect the connector, and measure at the harness side. (1) Voltage between 1 and earth Check the harness wire between the Check the trouble symptom.
Page 183: Data List Reference Table
13A-153 MPI <4G9> - Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes 10 % higher than the standard frequency.
Page 184 13A-154 MPI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Throttle Ignition switch: ON Set to idle position 300 - 1,000 mV Code No. 13A-100 position P0120 Gradually open Increases in pro- sensor portion to throttle opening angle Open fully 4,500 - 5,500 mV...
Page 185 13A-155 MPI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Vehicle Drive at 40 km/h Approximately 40 Code No. 13A-120 speed sen- km/h P0500 Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code No.
Page 186 13A-156 MPI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page (step- Engine coolant A/C switch: OFF 2 - 25 STEP per) motor temperature: position* 80 - 95_C Lamps, Lamps, electric electric cooling fan and all A/C switch: Increases by 10 - accessories: OFF...
Page 187 13A-157 MPI <4G9> - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Throttle Engine coolant Release the acceler- 6 - 20 % Code No. 13A-100 position temperature: ator pedal. P0120 sensor 80 - 95_C Depress the acceler- Increase in re- (Throttle...
Page 188: Actuator Test Reference Table
13A-158 MPI <4G9> - Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. Engine: After having warmed Idling condition Code No. 13A-110 1 injector up/Engine is idling becomes different P0201 (becomes unsta-...
Page 189: Check At The Engine-Ecu Terminals
13A-159 MPI <4G9> - 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 190 13A-160 MPI <4G9> - Troubleshooting Engine-ECU <M/T> Connector Terminal Engine-A/T-ECU <A/T> Connector Terminal Arrangement Arrangement NOTE: Vehicles with immobilizer system. 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...
Page 191 13A-161 MPI <4G9> - Troubleshooting Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> Power supply Ignition switch: ON System voltage Air flow sen- Engine: Idle speed 0 - 1 V sor reset Engine r/min: 3,000 r/min 6 - 9 V signal Fan motor...
Page 192 13A-162 MPI <4G9> - Troubleshooting Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> Oxygen Engine: Idling after warming up 0 - 3 V sensor (front) Engine r/min: 5,000 r/min System voltage heater Oxygen Engine: Idling after warming-up 0 - 3 V sensor (rear) Engine r/min: 5,000 r/min...
Page 193 13A-163 MPI <4G9> - 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 - 1.0 V position to idle position sensor Fully open throttle 4.5 - 5.5 V valve Barometric Ignition switch:...
Page 194 13A-164 MPI <4G9> - 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 195 13A-165 MPI <4G9> - 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 196: Inspection Procedure Using An Analyzer
13A-166 MPI <4G9> - Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER On A/T models, the engine-A/T-ECU (combination ECU) has been introduced. Due to this, only the inspection procedures at the engine-A/T-ECU terminals are described below (On M/T models, the inspection procedures at the engine-ECU terminals are not changed).
Page 197 14-1 ENGINE COOLING - General/Service Specifications/Thermostat GROUP 14 ENGINE COOLING GENERAL OUTLINE OF CHANGE The service procedures have been established due to the change of the thermostat, the thermostat case assembly and the water inlet pipe assembly in vehicles with 4G1 engine. Other service procedures are the same as before.
Page 198 14-2 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 199 14-3 ENGINE COOLING - Water Hose and Water Pipe <4G1> WATER HOSE AND WATER PIPE <4G1> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Battery and Battery Tray Removal and Installation Air Cleaner Removal and Installation 24 Nm 13 Nm 13 Nm...
Page 200 14-4 ENGINE COOLING - Water Hose and Water Pipe <4G1> INSTALLATION SERVICE POINTS Thermostat case assembly or cylinder block "AA O-RING INSTALLATION Insert the O-ring to the water inlet pipe assembly, and coat the outer circumference of the O-ring with water or engine coolant.
Page 201 15-1 INTAKE AND EXHAUST - General/Special Tool/Intake Manifold GROUP 15 INTAKE AND EXHAUST GENERAL OUTLINE OF CHANGE The service procedures have been established due to the adoption of the intake manifold made of steel pipe for the 4G1 engine and the exhaust manifold incorporated with the catalytic converter. Other service procedures are the same as before.
Page 202 15-2 INTAKE AND EXHAUST - Intake Manifold 21 Nm 9.0 Nm 9.0 Nm 5.0 Nm 9.0 Nm 18 Nm 9.0 Nm 18 Nm 18 Nm 27 - 34 Nm Removal steps 1. Vacuum sensor 9. EGR valve gasket 2. O-ring 10.
Page 203 15-3 INTAKE AND EXHAUST - Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Drive Belt Tension Adjustment <4G1> <after installation only> <4G1> 27 - 32 Nm 44 Nm 27 - 32 Nm 27 - 32 Nm 17 Nm 40 Nm...
Page 204 15-4 INTAKE AND EXHAUST - Exhaust Manifold <4G9> 12 - 14 Nm 44 Nm 12 - 14 Nm 17 Nm 27 - 32 Nm 27 - 32 Nm 12 - 15 Nm 19 Nm 35 Nm (Engine oil) 35 Nm 50 Nm Removal steps 1.
Page 205 16-1 ENGINE ELECTRICAL CONTENTS IGNITION SYSTEM ....Ignition Coil (with Built-in Power Transistor) Check ........GENERAL .
Page 206: Ignition System
16-2 ENGINE ELECTRICAL - ENGINE ELECTRICAL - Ignition System Ignition System IGNITION SYSTEM GENERAL OUTLINE OF CHANGES <4G1> <4G9> The following service procedures have been An ignition failure sensor has been added. The established to correspond to the addition of vehicles crank angle sensor has been changed.
Page 207: Special Tool
16-3 ENGINE ELECTRICAL - Ignition System SPECIAL TOOL Tool Number Name MD998773 Detonation sensor Detonation sensor removal and installation wrench ON-VEHICLE SERVICE IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK <4G1> Check by the following procedure, and replace if there is a malfunction.
Page 208: Ignition Failure Sensor Check
16-4 ENGINE ELECTRICAL - Ignition System IGNITION FAILURE SENSOR CHECK NOTE An analog-type circuit tester should be used. Check that the resistance between terminals 3 and 4 is at the standard value. Standard value: 0.1 W or less...
Page 209: Ignition Coil
16-5 ENGINE ELECTRICAL - Ignition System IGNITION COIL REMOVAL AND INSTALLATION <4G1> 10 Nm 10 Nm 25 Nm 5.0 Nm 25 Nm Ignition coil removal steps Ignition failure sensor removal steps 1. Ignition coil connector 2. Spark plug cable assembly 5.
Page 210: Camshaft Position Sensor
16-6 ENGINE ELECTRICAL - Ignition System <4G9> 5.0 Nm Removal steps 1. Ignition failure sensor connector 2. Ignition failure sensor CAMSHAFT POSITION SENSOR <4G1> Camshaft position sensor 8.8 Nm...
Page 211: Crank Angle Sensor
16-7 ENGINE ELECTRICAL - Ignition System CRANK ANGLE SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt Cover Removal and Installation <4G1> 10 - 12 Nm 8.8 Nm <4G9> 9.8 Nm Removal steps 1. Crank angle sensor bracket 2. Crank angle sensor...
Page 212: Detonation Sensor
16-8 ENGINE ELECTRICAL - Ignition System DETONATION SENSOR Caution Do not subject the detonation sensor to any shocks. REMOVAL AND INSTALLATION <4G1> Pre-removal and Post-installation Operation Intake Manifold Stay Removal and Installation (Refer to GROUP 15.) 20 - 25 Nm AA"...
Page 213 17-1 ENGINE AND EMISSION CONTROL CONTENTS EMISSION CONTROL SYSTEM ..EVAPORATIVE EMISSION CONTROL SYSTEM ....... . GENERAL .
Page 214: Emission Control System
17-2 ENGINE AND EMISSION CONTROL - Emission Control System EMISSION CONTROL SYSTEM GENERAL OUTLINE OF CHANGES Service adjustment procedures have been established for items which are different from before in order to correspond to the following changes. <4G1> The purge control solenoid valve control has been changed from ON/OFF control to duty control, and the purge inlet port in the throttle body has been changed from the upstream side of the throttle valve to the downstream side.
Page 215: Vacuum Hose
17-3 ENGINE AND EMISSION CONTROL - Emission Control System VACUUM HOSE VACUUM HOSE PIPING DIAGRAM <4G1> Air cleaner PCV valve EGR valve Canister Oxygen sensor (front) EGR control Purge control solenoid valve solenoid valve Oxygen sensor (ON: Close) (ON: Open) (rear) <4G9>...
Page 216: Vacuum Circuit Diagram
17-4 ENGINE AND EMISSION CONTROL - Emission Control System VACUUM CIRCUIT DIAGRAM <4G1> Intake manifold Throttle body From combustion chamber cleaner Fuel pressure regulator Red paint EGR control mark solenoid valve (ON: Close) Vacuum hose colour Canister Purge control EGR valve B: Black solenoid valve G: Green...
Page 217: Evaporative Emission Control System
17-5 ENGINE AND EMISSION CONTROL - Emission Control System EVAPORATIVE EMISSION CONTROL SYSTEM SYSTEM DIAGRAM <4G1> Engine-ECU Throttle body From Vacuum sensor fuel tank Engine coolant Canister temperature Purge control sensor solenoid valve (ON: Open) Control relay Intake air temperature sensor Battery <4G9>...
Page 218: Component Location
17-6 ENGINE AND EMISSION CONTROL - ENGINE AND EMISSION CONTROL - Emission Control System Emission Control System COMPONENT LOCATION Purge control solenoid valve <4G1> Purge control solenoid valve <4G9> PURGE CONTROL SYSTEM CHECK <4G1> 1. Disconnect the vacuum hose (red stripe <4G1>, black stripe <4G9>) from the throttle body and connect it to a hand vacuum pump.
Page 219: Purge Port Vacuum Check
17-7 ENGINE AND EMISSION CONTROL - Emission Control System PURGE PORT VACUUM CHECK <4G1> 1. Disconnect the vacuum hose (red stripe <4G1>, black stripe <4G9>) from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple. Purge port vacuum nipple Plug...
Page 220: Exhaust Gas Recirculation (Egr)
17-8 ENGINE AND EMISSION CONTROL - Emission Control System EXHAUST GAS RECIRCULATION (EGR) SYSTEM <4G1> COMPONENT LOCATION EGR valve EGR control solenoid valve EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK Inspection procedures have not changed. Plug Green stripe EGR PORT VACUUM CHECK Inspection procedures have not changed.
Page 221 23-1 AUTOMATIC TRANSMISSION CONTENTS GENERAL ....... . . TROUBLESHOOTING ..... . . Outline of Changes .
Page 222 23-2 AUTOMATIC TRANSMISSION - General/Troubleshooting GENERAL OUTLINE OF CHANGES The following service procedures for items which are different from before have been established to correspond to the following changes: The ECU has been changed from the A/T-ECU to the engine-A/T-ECU. TROUBLESHOOTING INSPECTION CHART FOR DIAGNOSIS CODE Code...
Page 223 23-3 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 11, 12, 14 Throttle position sensor system (TPS) Probable cause If the TPS output voltage is 4.8 V or higher when the engine is idling, the output D Malfunction of the throttle position sensor is judged to be too high and diagnosis code No.
Page 224 23-4 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 22 Input shaft speed sensor system Probable cause If no output pulse is detected from the input shaft speed sensor for 1 second or D Malfunction of the input shaft speed sensor more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged D Malfunction of the underdrive clutch retainer to be an open circuit or short-circuit in the input shaft speed sensor and diagnosis D Malfunction of connector...
Page 225 23-5 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 226 23-6 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 *: Refer to ’96 COLT/LANCER Workshop Manual (Pub.
Page 227 23-7 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 228 23-8 AUTOMATIC TRANSMISSION - Troubleshooting Probable cause Code No. 41 1st gear ratio does not meet the specification 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 229 23-9 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 54 A/T control relay system Probable cause If the A/T control relay voltage is less than 7 V after the ignition switch has been D Malfunction of the A/T control relay turned ON, it is judged that there is an open circuit or a short-circuit in the A/T control D Malfunction of connector relay earth and diagnosis code No.
Page 230 23-10 AUTOMATIC TRANSMISSION – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS *: Refer to ’96 COLT/LANCER Workshop Manual (Pub. No. PWME9511). Trouble symptom Inspection Reference procedure No. page Communication with MUT-II is not possible 23-11 Driving impossible Starting impossible 23-26* Does not move forward 23-26* Does not reverse 23-27*...
Page 231 23-11 AUTOMATIC TRANSMISSION – Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible Probable cause If communication with the MUT-II is not possible, the cause is probably a defective D Malfunction of diagnosis line diagnosis line or the engine-A/T-ECU is not functioning.
Page 232 23-12 AUTOMATIC TRANSMISSION – Troubleshooting INSPECTION PROCEDURE 17 Dual pressure switch system Probable cause The cause is probably a defective dual pressure switch circuit or a defective D Malfunction of the dual pressure switch engine-A/T-ECU. D Malfunction of connector D Malfunction of A/C system D Malfunction of the engine-A/T-ECU *: Refer to ’96 COLT/LANCER Workshop Manual (Pub.
Page 233 23-13 AUTOMATIC TRANSMISSION – Troubleshooting CHECK AT ENGINE-A/T-ECU TERMINALS *: Refer to ’96 COLT/LANCER Workshop Manual (Pub. No. PWME9511). Terminal No. Check item Check requirement Standard value Crank angle sensor Engine: Idling 2.0 – 2.4 V A/T control relay Ignition switch: OFF Ignition switch: ON System voltage Earth...
Page 234 23-14 AUTOMATIC TRANSMISSION – Troubleshooting Terminal No. Check item Check requirement Standard value Damper clutch control sole- Selector lever position: L (1st gear) System voltage noid valve Selector lever position: 3 (50 km/h in 3rd gear) Other than system voltage Inhibitor switch R Selector lever position: R System voltage...

Mitsubishi MOTORS Colt 2000 Workshop Manual Supplement

Section 1

Section 2

Multipoint Fuel Injection (Mpi)

Engine Electrical

Engine and Emission Control

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Troubleshooting

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