Mitsubishi MOTORS Lancer 2005 Workshop Manual Supplement
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Mitsubishi MOTORS Lancer 2005 Workshop Manual Supplement

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LANCER
WORKSHOP MANUAL
SUPPLEMENT
FOREWORD
This Workshop manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
manual as required.
TECHNICAL INFORMATION MANUAL
WORKSHOP MANUAL
CHASSIS GROUP
BODY REPAIR MANUAL
PARTS CATALOGUE
All information, illustrations and 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

GROUP INDEX

General . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
PYME0302
PYME0302-A
PYME0302-B
PWME0302
PWME0302-A
PWME0302-B
PBME0302
PBME0302-A
PBME0302-B
B606K006A_
Oct. 2005
00
13

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  • Page 1 B606K006A_ All information, illustrations and 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 Oct. 2005...
  • Page 2 00-1 GROUP 00 GENERAL CONTENTS VEHICLE IDENTIFICATION ..00-2 GENERAL DATA AND SPECIFICATIONS ....00-3...

  • Page 3: Vehicle Identification

    00-2 GENERAL VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION M1001000401448 MODELS Model code Engine model Price class Transmission model Fuel supply system CS9A SRHML6 4G63-DOHC (1,997 mL) Intense F4A4B <2WD, 4A/T> No. Item Content MODEL CODE Development CS: MITSUBISHI LANCER Engine type 9: 1,997mL Sort A: Passenger car CS 9 W...

  • Page 4: General Data And Specifications

    00-3 GENERAL GENERAL DATA AND SPECIFICATIONS GENERAL DATA AND SPECIFICATIONS M1001000901197 AC303990AB Items CS9A SRHML6 Vehicle dimensions mm Front track 1,470 Overall width 1,715 Front overhang Wheel base 2,600 Rear overhang Overall length 4,535 Ground clearance (unladen) Overall height (unladen) 1,415 Rear track 1,470...
  • Page 5 NOTES...

  • Page 6: Table Of Contents

    13D-1 MULTIPOINT FUEL INJECTION (MPI) <4G63> CONTENTS GENERAL ....... . . Basic Idle Speed Adjustment .

  • Page 7: General

    13D-2 MPI <4G63> General GENERAL OUTLINE OF CHANGE Following service procedures have been established due to the addition of vehicles with 4G63-MPI engine for Russia.

  • Page 8: General Information

    13D-3 MPI <4G63> General Information GENERAL INFORMATION The Multipoint Fuel Injection System consists carries out activities such as fuel injection of sensors which detect the engine conditions, control, idle speed control and ignition timing the engine-A/T-ECU which controls the system control.

  • Page 9: General Specifications

    13D-4 MPI <4G63> MPI <4G63> General Information General Information OTHER CONTROL FUNCTIONS 1. Fuel Pump Control 3. Fan Motor Control Turns the fuel pump relay ON so that current The revolutions of the radiator fan and is supplied to the fuel pump while the engine condenser fan are controlled in response to is cranking or running.
  • Page 10 13D-5 MPI <4G63> General Information MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM L1 Oxygen sensor (front) l1 Injector L2 Oxygen sensor (rear) l2 Idle speed control servo L3 Air flow sensor Engine-A/T-ECU (Stepper motor) L4 Intake air temperature sensor l3 EGR control solenoid valve L5 Throttle position sensor l4 Purge control solenoid valve L6 Camshaft position sensor...

  • Page 11: Service Specifications

    13D-6 MPI <4G63> Service Specifications/Sealant SERVICE SPECIFICATIONS Items Specifications Basic idle speed r/min Throttle position sensor adjusting voltage mV Throttle position sensor resistance k Idle speed control servo coil resistance (at 20_C) Intake air temperature sensor 20_C resistance k resistance k 20_C 40_C 60_C...

  • Page 12: Special Tools

    13D-7 MPI <4G63> Special Tools SPECIAL TOOLS Tool Number Name MB991502 M.U.T.-II sub Reading diagnosis code assembly MPI system inspection Measurement of fuel pressure MB991955 M.U.T.-III sub Reading diagnosis code assembly MPI system inspection A: MB991824 Measurement of fuel pressure B: MB991827 C: MB991910 D: MB991911...
  • Page 13 13D-8 MPI <4G63> Special Tools Tool Number Name MB991709 Test harness Measurement of voltage during troubleshooting Inspection using an oscilloscope Check of idle speed control servo MD998478 Test harness Measurement of voltage during (3-pin, triangle) Troubleshooting Inspection using an oscilloscope MB991536 Check harness for Measurement of voltage during...
  • Page 14 13D-9 MPI <4G63> Special Tools Tool Number Name MD998709 Adaptor hose Measurement of fuel pressure MD998742 Hose adaptor MB991637 Fuel pressure gauge set MB991981 Fuel pressure gauge set MB992076 Injector test set Checking the spray condition of injectors MB991607 Injector test harness MD998741 Injector test...

  • Page 15: Group

    13D-10 MPI <4G63> Troubleshooting TROUBLESHOOTING Engine warning lamp (check engine lamp) DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Point. NOTE If the engine-A/T-ECU is replaced, ring antenna with built in immobilizer-ECU should be replaced, ignition key can be kept, but must be registered.
  • Page 16 13D-11 MPI <4G63> Troubleshooting METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points. INSPECTION USING M.U.T.-II/III DATA LIST AND ACTUATOR TESTING 1. Carry out inspection by means of the data list and the actuator test function.
  • Page 17 13D-12 MPI <4G63> Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor (front) system 13D-13 Air flow sensor system 13D-15 Intake air temperature sensor system 13D-16 Throttle position sensor system 13D-18 Engine coolant temperature sensor system 13D-20 Crank angle sensor system 13D-22...
  • Page 18 13D-13 MPI <4G63> Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODE Code No. 11 Oxygen sensor (front) system Probable cause Range of Check D Malfunction of the oxygen sensor (front) D More than 3 minutes passed after completion of start of engine D Oxygen sensor (front) circuit disconnection, D The engine coolant temperature is approximately more than 80_C.
  • Page 19 13D-14 MPI <4G63> Troubleshooting From the previous page Measure at the C-126 engine-A/T-ECU Check the following connector: Repair connector. C-126 D Measure the engine-A/T-ECU terminal voltage. D Engine: After warm-up Check and repair the harness between D Voltage between terminal No. 71 the oxygen sensor (front) and and earth.
  • Page 20 13D-15 MPI <4G63> Troubleshooting Code No. 12 Air flow sensor system Probable cause Range of Check D Malfunction of the air flow sensor D The engine speed is more than 500 r/min D Air flow sensor circuit disconnection, short-circuit, Set Condition or connector contact defect D The sensor output frequency is less than 3.3 Hz for 4 seconds.
  • Page 21 13D-16 MPI <4G63> Troubleshooting From the previous page Repair Check the following connector: Measure at the B-08 air flow sensor C-122 connector. D Using the test harness (MB991709), connect the connector, and measure at the Repair Check the harness between the air pickup.
  • Page 22 13D-17 MPI <4G63> Troubleshooting M.U.T.-II/III Data list Intermittent malfunction D No. 13 Intake air temperature (Refer to GROUP 00 Points to Note sensor for Intermittent Malfunctions.) OK: Ambient temperature (More or less the same as the air temperature) Repair Check the following connector: B-08 Check the intake air temperature Replace the intake air temperature...
  • Page 23 13D-18 MPI <4G63> Troubleshooting From the previous page Measure at the B-08 air flow sensor Check the following connectors: Repair connector. C-122, C-124 D Using the test harness (MB991709), connecting only connector terminals No. 5 and Check and repair the harness between No.
  • Page 24 13D-19 MPI <4G63> Troubleshooting From the previous page (1) NG Measure at throttle position sensor Measure at engine-A/T-ECU Check the following connector: connector B-06. connector C-124. C-124 D Disconnect the connector and D Measure the voltage at the measure at the harness side. engine-A/T-ECU terminals.
  • Page 25 13D-20 MPI <4G63> Troubleshooting From the previous page Check the following connector: Measure at the engine-A/T-ECU Repair C-126 connector C-126 D Measure voltage at the engine-A/T-ECU terminal. Check the harness wire between the D Ignition switch: ON throttle position sensor and the D Voltage between terminal 78 and engine-A/T-ECU, and repair if earth...
  • Page 26 13D-21 MPI <4G63> Troubleshooting From the previous page (1) NG Check the following connector: Measure at engine-A/T-ECU Measure at engine coolant C-124 connector C-124. temperature sensor connector B-111. D Disconnect the connector and D Measure the voltage at the engine-A/T-ECU terminal. measure at the harness side.
  • Page 27 13D-22 MPI <4G63> 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 Open or short circuit in the crank angle sensor Set Condition circuit or loose connector contact. D Sensor output voltage does not change for 4 seconds (no pulse signal input).
  • Page 28 13D-23 MPI <4G63> Troubleshooting From the previous page Use an analyzer to measure the Check the crank angle sensor vane. Replace output waveform at the crank angle sensor connector B-116. D Use the test harness Replace the crank angle sensor. (MD998478) to connect the connector, and measure at the pick-up harness side.
  • Page 29 13D-24 MPI <4G63> Troubleshooting Code No. 23 Camshaft position sensor system Probable cause Range of Check D Malfunction of the camshaft position sensor D During engine cranking and driving D Open or short circuit in the camshaft position Set Condition sensor circuit or loose connector contact.
  • Page 30 13D-25 MPI <4G63> Troubleshooting Code No. 24 Vehicle speed signal system Probable cause Range of Check D Malfunction of the output shaft speed sensor D 60 seconds after the ignition switch is set to the “ON” position, or after the D Open or short circuit in the output shaft speed completion of start of engine.
  • Page 31 13D-26 MPI <4G63> Troubleshooting Code No. 25 Barometric pressure sensor system Probable cause Range of Check D Malfunction of the barometric pressure sensor D 60 seconds after the ignition switch is set to the “ON” position, or after the D Barometric pressure sensor circuit disconnection, completion of start of engine.
  • Page 32 13D-27 MPI <4G63> Troubleshooting From the previous page (1) NG Measure at the B-08 air flow sensor Check the following connector: Repair connector. C-124 D Using the test harness (MB991709), connect only connector terminals No. 1, No. 2, Check and repair the harness between and No.
  • Page 33 13D-28 MPI <4G63> Troubleshooting Code No. 31 Detonation sensor system Probable cause Range of Check D Malfunction of the detonation sensor D 60 seconds after the ignition switch is set to the “ON” position, or after the D Open or short circuit in the detonation sensor completion of start of engine.
  • Page 34 13D-29 MPI <4G63> Troubleshooting Code No. 41 Injector system Probable cause Range of Check D Malfunction of the injector D Fuel cut and injector not in forced drive (actuator test) mode. D Improper connector contact, open circuit or short-cir- D The engine speed is 50 1,000 r/min cuited harness wire of the injector circuit D The throttle position sensor output voltage is 1.15 V or less.
  • Page 35 13D-30 MPI <4G63> Troubleshooting Code No. 44 Ignition coil system Probable cause Range of Check D Malfunction of the ignition coil D The engine speed is 1,500 D Improper 4,500 r/min connector contact, open circuit D Volumetric efficiency 30 55 % short-circuited harness wire of the ignition primary D Fuel cut and injector not in forced drive (actuator test) mode.
  • Page 36 13D-31 MPI <4G63> Troubleshooting Cord No. 54 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 Condition D Malfunction of the engine-A/T-ECU D Improper communication between the engine-A/T-ECU and the immobilizer-ECU NOTE (1) If the registered ignition keys are close each other when starting the engine, radio interference may...
  • Page 37 13D-32 MPI <4G63> Troubleshooting Code No. 59 Oxygen sensor (rear) system Probable cause Range of Check D Malfunction of the oxygen sensor (rear) D More than 3 minutes passed after completion of start of engine D Oxygen sensor (rear) circuit disconnection, D The engine coolant temperature is approximately more than 80_C.
  • Page 38 13D-33 MPI <4G63> Troubleshooting From the previous page Measure at the C-126 engine-A/T-ECU Check the following connector: Repair connector. C-126 D Measure the engine-A/T-ECU terminal voltage. D Engine: After warm-up Check and repair the harness between D Voltage between terminal No. 73 the oxygen sensor (rear) and and earth.
  • Page 39 13D-34 MPI <4G63> Troubleshooting Code No. 64 Alternator FR terminal system Probable cause Range of Check D Open circuit in alternator FR terminal circuit D During the engine running. D Malfunction of the engine-A/T-ECU Set Condition D Input voltage from the alternator FR terminal is system voltage for 20 seconds.
  • Page 40 13D-35 MPI <4G63> Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13D-39 with M.U.T.-II/ with M.U.T. II/ III is impossi- Communication with engine-A/T-ECU only is not possible. 13D-39 ble.
  • Page 41 13D-36 MPI <4G63> 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 42 13D-37 MPI <4G63> Troubleshooting PROBLEM SYMPTOMS TABLE Inspection Trouble symptom Reference procedure page Communication with all system is not possible 13D-39 Communication with engine-A/T-ECU only is not possible 13D-39 The engine warning lamp does not illuminate right after the ignition switch is turned 13D-40 to the “ON”...
  • Page 43 13D-38 MPI <4G63> Troubleshooting Inspection Trouble symptom Reference procedure page A/C switch and A/C relay system 13D-63 Idle speed control (ISC) servo (Stepper motor) system 13D-64 Purge control solenoid valve system 13D-65 EGR control solenoid valve system 13D-65...
  • Page 44 13D-39 MPI <4G63> Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with M.U.T.-II/III 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 D Malfunction of the harness wire diagnosis line.
  • Page 45 13D-40 MPI <4G63> 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-A/T-ECU causes the engine warning D Burnt-out bulb lamp to illuminate for five seconds immediately after the ignition switch is turned to D Defective warning lamp circuit ON.
  • Page 46 13D-41 MPI <4G63> 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 47: Initial Combustion But No Complete Combustion

    13D-42 MPI <4G63> 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 48 13D-43 MPI <4G63> 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 49 13D-44 MPI <4G63> 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 the 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 50 13D-45 MPI <4G63> Troubleshooting From the previous page Check the oxygen sensor (rear) system. M.U.T.-II/III Data list (RefertoP.13D-32,INSPECTIONPROCEDUREFORDIAGNOSIS 59 Oxygen sensor (rear) CODE 59.) D Transmission: D range D Driving with throttle widely open OK: 600 1,000 mV Check the oxygen sensor (front) system. M.U.T.-II/III Data list (RefertoP.13D-13,INSPECTIONPROCEDUREFORDIAGNOSIS 11 Oxygen sensor (front)
  • Page 51 13D-46 MPI <4G63> MPI <4G63> 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 52 13D-47 MPI <4G63> 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 probablythatthe air/fuelmixture isinappropriate D Malfunction of the ISC servo system when the engine is cold, or that the intake air volume is insufficient. D Malfunction of the throttle body D Malfunction of the injector system D Malfunction of the ignition system...
  • Page 53 13D-48 MPI <4G63> 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 54 13D-49 MPI <4G63> Troubleshooting From the previous page M.U.T.-II/III Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (front) (Refer to P.13D-92.) air into the air intake OK: Changes between 0 400 mV and 600 1,000 mV during system.

  • Page 55: The Engine Stalls When Decelerating

    13D-50 MPI <4G63> 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 56 13D-51 MPI <4G63> 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 the 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 57: The Feeling Of Impact Or Vibration When Accelerating

    13D-52 MPI <4G63> MPI <4G63> Troubleshooting Troubleshooting From the previous page M.U.T.-II/III Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (front) (Refer to P.13D-92.) air into the air intake OK: Changes between 0 400 mV and 600 1,000 mV during system.

  • Page 58: Poor Acceleration

    13D-53 MPI <4G63> 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 the air-fuel ratio control system D Malfunction of the fuel supply system D Poor compression pressure D Clogged exhaust system M.U.T.-II/III Self-Diag code...
  • Page 59 13D-54 MPI <4G63> Troubleshooting From the previous page Check the oxygen sensor (front) system. M.U.T.-II/III Data list (RefertoP.13D-13,INSPECTIONPROCEDUREFORDIAGNOSIS 11 Oxygen sensor (front) CODE 11.) OK: 600 1,000 mV during sudden racing M.U.T.-II/III Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (front) (Refer to P.13D-92.) air into the air intake...
  • Page 60 13D-55 MPI <4G63> MPI <4G63> Troubleshooting Troubleshooting From the previous page Check the oxygen sensor (rear) system. M.U.T.-II/III Data list (RefertoP.13D-32,INSPECTIONPROCEDUREFORDIAGNOSIS 59 Oxygen sensor (rear) D Transmission: D range CODE 59.) D Driving with throttle widely open OK: 600 1,000 mV Check the oxygen sensor (front) system.

  • Page 61: Too High Co And Hc Concentration When Idling

    13D-56 MPI <4G63> 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 Refer to P.13D-12, INSPECTION CHART FOR DIAGNOSIS M.U.T.-II/III Self-Diag code CODES.
  • Page 62 13D-57 MPI <4G63> 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 the charging system may be suspected. (Refer to GROUP 16 Charging System.) D Short circuit in harness between alternator G terminal and engine-A/T-ECU...
  • Page 63 13D-58 MPI <4G63> Troubleshooting INSPECTION PROCEDURE 25 Fans (radiator fan, A/C condenser fan) are inoperative. Probable cause The engine-A/T-ECU sends a duty signal to the fan controller according to engine D Malfunction of the fan motor relay coolant temperature, vehicle speed, or A/C switch. D Malfunction of the fan motor The fan controller controls radiator fan and condenser fan speeds, based on this D Malfunction of the fan controller...
  • Page 64 13D-59 MPI <4G63> Troubleshooting INSPECTION PROCEDURE 26 Check the engine-A/T-ECU power supply and earth circuit. (1) NG Check the following Measure the engine-A/T-ECU connectors, C-124, C-126. Repair connectors: C-14, D Disconnect the connector and measure at the harness side C-209, C 210 (1) Voltage between 98 and earth (Ignition switch: ON) OK: System voltage (2), (3) NG...

  • Page 65: Fuel Pump System

    13D-60 MPI <4G63> Troubleshooting INSPECTION PROCEDURE 28 Fuel pump system Probable cause Engine-A/T-ECU turns fuel pump relay ON to supply drive voltage to fuel pump while D Malfunction of the fuel pump relay (1) engine is cranked and rotated. D Malfunction of the fuel pump relay (2) D Malfunction of the fuel pump D Improper connector...
  • Page 66 13D-61 MPI <4G63> Troubleshooting From the previous page. Measure at the C-122 engine-A/T-ECU Repair Check the following connectors: connector. C-14, C-212, C 220 D Disconnect connector measure at the harness side D Voltage of terminal No. 21 earth Check the trouble symptom. Check and repair harness from fuel D Ignition switch: ON pump relay (2) to engine-A/T-ECU...
  • Page 67 13D-62 MPI <4G63> Troubleshooting INSPECTION PROCEDURE 29 Ignition switch-ST and inhibitor switch system Probable cause D The ignition switch-ST inputs a HIGH signal to the engine-A/T-ECU while the D Malfunction of the ignition switch engine is cranking. D Malfunction of the inhibitor switch The engine-A/T-ECU controls fuel injection, etc.
  • Page 68 13D-63 MPI <4G63> Troubleshooting INSPECTION PROCEDURE 30 Power steering fluid pressure switch system Probable cause The presence or absence of power steering load is input to the engine-A/T-ECU. D Malfunction of the power steering fluid pressure switch The engine-A/T-ECU controls the idle speed control (ISC) servo based on this input. D Improper connector contact,...
  • Page 69 13D-64 MPI <4G63> Troubleshooting INSPECTION PROCEDURE 32 Idle speed control (ISC) servo (Stepper motor) system Probable cause The engine-A/T-ECU controls the intake air volume during idling by opening and closing D Malfunction of the ISC servo the servo valve located in the bypass air passage. D Improper connector contact,...
  • Page 70 13D-65 MPI <4G63> MPI <4G63> Troubleshooting Troubleshooting INSPECTION PROCEDURE 33 Purge control solenoid valve system Probable cause The purge control solenoid valve controls the purging of air from the canister located D Malfunction of the solenoid valve inside the intake manifold. D Improper connector contact,...
  • Page 71 13D-66 MPI <4G63> 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 : In a new vehicle [driven approximately 500 km or less], the air intake plenum pressure is sometimes 10% higher than the standard pressure.
  • Page 72 13D-67 MPI <4G63> Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Throttle Ignition switch: ON Set to idle position 535 735 mV Code No. 13D-18 position position Gradually open Increases in sensor proportion to throttle opening angle Open fully 4,500 5,000 mV...
  • Page 73 13D-68 MPI <4G63> Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code No. 13D-58 pressure pressure At altitude of 600 m 95 kPa sensor At altitude of 1,200 m 88 kPa At altitude of 1,800 m 81 kPa...
  • Page 74 13D-69 MPI <4G63> Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Engine coolant A/C switch: OFF 2 25 STEP (stepper) temperature: motor motor 85 95_C 85 95 C position *4 Lamps, electric A/C switch: Increases by cooling fan and all 10 70 steps accessories: OFF...
  • Page 75 13D-70 MPI <4G63> Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal Inspection Reference item condition procedure page Injectors Cut fuel to No. 1 Engine: Idling condi- Code No. 13D-29 injector After having warmed up/En- tion becomes gine is idling gine is idling different (be-...
  • Page 76 13D-71 MPI <4G63> Troubleshooting CHECK AT THE ENGINE-A/T-ECU TERMINALS Needle-nosed wire probe TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (test harness: MB991223) to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the engine-A/T-ECU connector terminals from the wire side, and measure the voltage while referring to the check chart.
  • Page 77 13D-72 MPI <4G63> MPI <4G63> Troubleshooting Troubleshooting Engine-A/T-ECU Connector Terminal Arrangement Terminal Check item Check condition (Engine condition) Normal condition No. 1 injector While engine is idling after having warmed From 11 14 V, up suddenly depress the accelerator pedal up, suddenly depress the accelerator pedal.
  • Page 78 13D-73 MPI <4G63> Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition A/C relay Engine: Idle speed System voltage or momentarily 6 V A/C switch: OFF ON (A/C compressor or more 1 V or less is operating) Fuel pump relay Ignition switch: “ON”...
  • Page 79 13D-74 MPI <4G63> Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Alternator FR Engine: Warm, idle (radiator fan: OFF) Voltage decreases terminal terminal Headlamp: OFF Headlamp: OFF Stop lamp: OFF Rear defogger switch: OFF Barometric pres- Ignition switch: When altitude is 0 m 4.2 V sure sensor...
  • Page 80 13D-75 MPI <4G63> Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition A/C switch Engine: Idle speed Turn the A/C switch 0.5 V or less Turn the A/C switch System voltage ON (A/C compressor is operating) Ignition switch Ignition switch: “ON” System voltage...
  • Page 81 13D-76 MPI <4G63> Troubleshooting CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to “LOCK” (OFF) position. 2. Disconnect the engine-A/T-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-A/T-ECU harness-side connector while referring to the check chart.
  • Page 82 13D-77 MPI <4G63> Troubleshooting Engine-A/T-ECU Harness Side Connector Terminal Arrangement Terminal Inspection item Normal condition (Check condition) No. 1 injector 10.5 13.5 (At 20_C) No. 2 injector No. 3 injector No. 4 injector Oxygen sensor (front) heater (At 20_C) EGR control solenoid valve (At 20_C) Stepper motor coil (A) (At 20_C)
  • Page 83 13D-78 MPI <4G63> Troubleshooting Terminal Inspection item Normal condition (Check condition) Intake air temperature sensor 17 k (When intake air temperature is 20_C) 6.7 k (When intake air temperature is 0_C) 3.0 k (When intake air temperature is 20_C) 1.5 k (When intake air temperature is 40_C) 0.56 0.76 k...
  • Page 84 13D-79 MPI <4G63> Troubleshooting INSPECTION PROCEDURE USING Oscilloscope OSCILLOSCOPE The output signals of the sensors and the conditions of the actuation signals of the actuators can be inspected visually Special by observing the waveforms on the oscilloscope. patterns pickup AIR FLOW SENSOR Measurement Method 1.
  • Page 85 13D-80 MPI <4G63> Troubleshooting Standard wave pattern The time (cycle time) T is reduced when the amount of intake air increases. Times T1 and T2 are equal. Time Observation conditions (from conditions above engine speed is increased by racing.) Time Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
  • Page 86 13D-81 MPI <4G63> 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 87 13D-82 MPI <4G63> Troubleshooting Standard Wave Pattern Observation condition Function Special patterns Pattern height Pattern selector Display Engine r/min Idle 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...
  • Page 88 13D-83 MPI <4G63> 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 Loose timing belt Abnormality in sensor disk Wave pattern characteristics Wave pattern is displaced to the left or right.
  • Page 89 13D-84 MPI <4G63> Troubleshooting Standard Wave Pattern Observation conditions Function Special patterns Pattern height Variable Variable knob Adjust while viewing the wave pattern Pattern selector Display Engine speed Idle Standard wave pattern Point A Solenoid back electromotive force (Approx. 7 10 V) Point B Injector drive time Time...
  • Page 90 13D-85 MPI <4G63> Troubleshooting IDLE SPEED CONTROL (ISC) SERVO (STEPPER Oscilloscope MOTOR) Measurement Method 1. Disconnect the ISC servo connector, and connect the Special special tool test harness (MB991709) in between. patterns 2. Connect the oscilloscope special patterns pickup to the pickup ISC servo side connector terminal No.
  • Page 91 13D-86 MPI <4G63> Troubleshooting Standard wave pattern The wave pattern Point A appears for an Point B Induced electromotive force instant, but soon Coilreverse electromotive from the motor turning disappears. force (Approx. 3 10 V) Stepper motor control signal wave pattern Time Wave pattern Observation Points...
  • Page 92 13D-87 MPI <4G63> Troubleshooting Examples of Abnormal Wave Pattern Example 1 Cause of problem Motor is malfunctioning. (Motor is not operating.) Wave pattern characteristics Induced electromotive force from the motor turning does not appear. Example 2 Cause of problem Open circuit Open circuit in the line between the stepper motor and side...
  • Page 93 13D-88 MPI <4G63> Troubleshooting IGNITION COIL AND POWER TRANSISTOR Oscilliscope Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool test harness set (MB991348) in between (All Special terminals should be connected). patterns pickup 2. Connect the oscilloscope special patterns pickup to terminal No.
  • Page 94 13D-89 MPI <4G63> Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2). Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approximately 2 V to approximately 4.5 V at the Normal top-right 2 V rectangular wave...

  • Page 95: On-Vehicle Service

    13D-90 MPI <4G63> On-vehicle Service ON-VEHICLE SERVICE THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Remove the air intake hose from the throttle body. 2. Spray cleaning fluid on a clean cloth. Caution Do not spray the cleaning fluid directly to the throttle valve.

  • Page 96: Basic Idle Speed Adjustment

    13D-91 MPI <4G63> On-vehicle Service 4. If not within the standard value, loosen the throttle position sensor mounting bolts. Then rotate the sensor body to adjust. 5. Turn the ignition switch to ”LOCK” (OFF) position. 6. Remove the M.U.T.-II/III. If the M.U.T.-II/III is not used, remove the special tool, and then connect the throttle position sensor connector.

  • Page 97: Fuel Pressure Test

    13D-92 MPI <4G63> On-vehicle Service NOTE (1) The engine speed may be 20 to 100 r/min lower than indicated above for a new vehicle [driven approximately 500 km or less], but no adjustment is necessary. (2) If the engine stalls or the engine speed is low even though the vehicle has been driven approximately 500 km or more, it is probable that deposits are adhered to the throttle valve, so clean it (Refer to...
  • Page 98 13D-93 MPI <4G63> On-vehicle Service <When using the fuel pressure gauge> (1) Remove the union joint and bolt from special tool adaptor hose (MD998709) and attach the special tool hose adaptor (MD998742) to the adaptor hose. (2) Via a suitable O-ring or gasket, install the fuel pressure gauge to the special tool that has already assembled MB991981 as described in (a) above.
  • Page 99 13D-94 MPI <4G63> On-vehicle Service NOTE If the fuel flow rate is low, there will be no fuel pressure in the return hose. 14. If any of fuel pressure measured in steps 10 to 13 is out of specification, troubleshoot and repair according to the table below.

  • Page 100: Component Location

    13D-95 MPI <4G63> On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol Air flow sensor Engine warming lamp (with intake air temperature sensor and (check engine lamp) barometric pressure sensor) barometric pressure sensor) Fan controller A/C compressor relay Fuel pump relay (1) and (2) A/C switch Idle speed control servo Camshaft position sensor...

  • Page 101: Engine Control Relay Continuity Check

    13D-96 MPI <4G63> On-vehicle Service ENGINE CONTROL RELAY CONTINUITY CHECK Engine control relay Tester Connection Battery Voltage Normal State Relay box’s Terminal triangle marks No Voltage Continuity No Voltage No continuity Voltage (Connect Continuity positive (+) terminal of battery to termi- Equipment nal No.

  • Page 102: Intake Air Temperature Sensor Check

    13D-97 MPI <4G63> On-vehicle Service INTAKE AIR TEMPERATURE SENSOR CHECK 1. Disconnect the air flow sensor connector. Air flow sensor 2. Measure resistance between terminals No. 5 and No. Standard value: 17 k 20_C) 6.7 k (at 0_C) 3.0 k (at 20_C) 1.5 k (at 40_C)

  • Page 103: Engine Coolant Temperature Sensor Check

    13D-98 MPI <4G63> On-vehicle Service ENGINE COOLANT TEMPERATURE SENSOR CHECK Engine coolant Caution temperature sensor Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Remove the engine coolant temperature sensor. Equipment side connector 2.

  • Page 104: Oxygen Sensor Check

    13D-99 MPI <4G63> On-vehicle Service OXYGEN SENSOR CHECK Oxygen sensor (front) Oxygen sensor (front) connector 1. Disconnect the oxygen sensor connector and connect the special tool test harness (MD998464) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (4.5 at 20˚C) between terminal No.
  • Page 105 13D-100 MPI <4G63> On-vehicle Service Oxygen sensor (rear) 1. Disconnect the oxygen sensor connector and connect Oxygen sensor the special tool test harness (MB991658) to the connector (rear) on the oxygen sensor side. 2. Make sure that there is continuity (11 at 20˚C) between terminal No.

  • Page 106: Injector Check

    13D-101 MPI <4G63> On-vehicle Service INJECTOR CHECK Check the Operation Sound Injector 1. Use a stethoscope to listen to the operation sound Equipment (clicking) of the injectors while the engine is idling or side connector cranking. Caution Beware that the operation sounds of other injectors can be heard even if the injector that is being inspected might not be operating.

  • Page 107: Idle Speed Control (Isc) Servo (Stepper Motor Check

    13D-102 MPI <4G63> On-vehicle Service 7. Activate the injector and check the atomized spray condition of the fuel. The condition can be considered satisfactory unless it is extremely poor. 8. Stop the actuation of the injector, and check for leakage from the injector’s nozzle.
  • Page 108 13D-103 MPI <4G63> On-vehicle Service Check the Coil Resistance 1. Disconnect the idle speed control servo connector. 2. Measure the resistance between terminal No. 2 and either terminal No. 1 or terminal No. 3 of the connector at the idle speed control servo side. Standard value: 28 (at 20_C) 3.

  • Page 109: Purge Control Solenoid Valve Check

    13D-104 MPI <4G63> On-vehicle Service PURGE CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 Emission Control System. EGR CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 Emission Control System.

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