Mitsubishi MOTORS Space Runner 1999 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. Use the following manuals

in combination with this manual required.

TECHNICAL INFORMATION MANUAL

WORKSHOP MANUAL

CHASSIS GROUP

ENGINE GROUP

ELECTRICAL WIRING

BODY REPAIR MANUAL

PARTS CATALOGUE

SPACE RUNNER

SPACE WAGON

All

information,

illustrations

descriptions contained in this manual are current

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

the right to make changes at any time without prior

notice or obligation.

"GDI" is the trade mark which Mitsubishi Motors

Corporation holds.

Mitsubishi Motors Corporation

in servicing

PYDE9802

PWDE9803

PWEEjjjj

(Looseleaf edition)

PHDE9802

PHDE9802 - A

PBDE9802

B608V500Aj

B608W500Aj

and

product

May 1999

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

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

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

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

Intake and Exhaust

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

Engine and Emission Control . . . .

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

Automatic Transmission . . . . . . . .

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

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

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

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

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

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

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Mitsubishi MOTORS Space Runner 1999

Page 1: Table Of Contents
We, however, reserve the right to make changes at any time without prior notice or obligation. “GDI” is the trade mark which Mitsubishi Motors Corporation holds. Mitsubishi Motors Corporation May 1999...
Page 2: Workshop Manual
Chassis Electrical ....Heater, Air Conditioner and Ventilation ..... “GDI is the trade mark which Mitsubishi Motors Corporation holds. Mitsubishi Motors Corporation...
Page 3 WARNING! (1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger (from rendering the SRS inoperative).
Page 4 00-1 GENERAL CONTENTS HOW TO USE THIS MANUAL ....Chassis Number ......Engine Model Number .
Page 5: How To Use This Manual
00-2 GENERAL - How to Use This Manual HOW TO USE THIS MANUAL MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. 2000: Indicates models equipped with the 2,000 mL <4G63> petrol engine. 2400: Indicates models equipped with the 2,400 mL <4G64> petrol engine. MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection.
Page 6: Vehicle Identification
00-3 GENERAL - Vehicle Identification VEHICLE IDENTIFICATION MODELS Model code Engine model Transmission model Fuel supply system N63W SNUEL6/R6 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) SNFEL6 SNUJL6 SRUEL6/R6 F4A42 (2WD-4A/T) SRFEL6 SRUJL6 N64W SNHCL6 4G64-DOHC-GDI F5M42 (2WD-5M/T) (2,351 mL) SNGCL6 SNHGL6 SRHCL6 F4A42 (2WD-4A/T) SRGCL6...
Page 7: Chassis Number
00-4 GENERAL - Vehicle Identification CHASSIS NUMBER Items Contents Fixed figure Asia Distribution channel Japan channel Destination For Europe, right hand drive For Europe, left hand drive Body style 3-door station wagon Transmission type 5-speed manual transmission 4-speed automatic transmission Development order SPACE RUNNER (2WD) Engine...
Page 8: Engine Model Number
00-5 GENERAL - Vehicle Identification ENGINE MODEL NUMBER 1. The engine model number is stamped at the cylinder block as shown in the following. Engine model Engine displacement mL 4G63 1,997 4G64 2,351 2. The engine serial number is stamped near the engine model number.
Page 9: Major Specifications
00-6 GENERAL - Major Specifications MAJOR SPECIFICATIONS Items N63W N63W N64W N64W SNUEL6, SRUEL6, SNHCL6, SRHCL6, SNUER6, SRUER6, SNGCL6, SRGCL6, SNFEL6, SRFEL6, SNHGL6 SRHGL6 SNUJL6 SRUJL6 Vehicle Overall length 1 4,290 dimensions Overall width 2 1,695 Overall height 3 1,650 (unladen) 1,680* Wheelbase...
Page 10 11C-1 ENGINE <4G6-MPI> CONTENTS GENERAL ....... . . Manifold Vacuum Check .
Page 11 11C-2 NOTES...
Page 12: General
General/General Information/ 11C-3 ENGINE <4G6-MPI> - Service Specifications GENERAL OUTLINE OF CHANGES The following service procedures have been established in line with the addition of vehicles with 4G63-MPI engine. GENERAL INFORMATION Items 4G63 Total displacement mL 1,997 Bore ´ Stroke mm 85.0 ´...
Page 13: Sealants
11C-4 ENGINE <4G6-MPI> - Service Specifications/Sealants Items Standard value Limit Power steering oil pump and A/C Vibration frequency Hz 114 - 126 compressor drive belt tension Tension N 441 - 539 (When adjusted) Deflection (Reference value) mm 12.5 - 14.3 Power steering oil pump and A/C Vibration frequency Hz 137 - 157...
Page 14: Special Tools
11C-5 ENGINE <4G6-MPI> - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub assem- Checking the ignition timing Checking the idle speed Erasing diagnosis code Measuring the drive belt tension MB991668 Belt tension meter Measuring the drive belt tension (used together with the MUT-II) MD998299 MAS screwdriver...
Page 15: On-Vehicle Service
11C-6 ENGINE <4G6-MPI> - Special Tools/On-vehicle Service Tool Number Name MD998776 Crankshaft rear oil Press-in of the crankshaft rear oil seal seal installer MB990938 Handle Press-in of the crankshaft rear oil seal MD998767 Tension pulley Timing belt tension adjustment socket wrench GENERAL Engine lifter Supporting the engine assembly during...
Page 16: Engine
11C-7 ENGINE <4G6-MPI> - On-vehicle Service <When using the MUT-II> 10 - 20 mm 1. Connect the special tool (belt tension meter set) to the MUT-II. Water pump 2. Connect the MUT-II to the diagnosis connector. pulley 3. Turn the ignition switch to ON and select “Belt Tension MB991668 Crankshaft (Micro-...
Page 17 11C-8 ENGINE <4G6-MPI> - On-vehicle Service ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the alternator pivot bolt. Adjusting bolt 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Standard value: Lock bolt Items...
Page 18: Ignition Timing Check
11C-9 ENGINE <4G6-MPI> - On-vehicle Service <When measuring the deflection> Apply 98 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection. 2. If the tension or deflection is outside the standard value, adjust by the following procedure.
Page 19: Idle Speed Check
11C-10 ENGINE <4G6-MPI> - On-vehicle Service IDLE SPEED CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to “LOCK” (OFF) position and connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. Standard value: 5_ BTDC±3_ 4.
Page 20: Compression Pressure Check
11C-11 ENGINE <4G6-MPI> - On-vehicle Service NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items. COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal.
Page 21: Manifold Vacuum Check
11C-12 ENGINE <4G6-MPI> - On-vehicle Service (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crank angle sensor connector. 11.
Page 22 11C-13 ENGINE <4G6-MPI> - On-vehicle Service 3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N ® D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings.
Page 23 11C-14 ENGINE <4G6-MPI> - On-vehicle Service (4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve High- is open and the lash adjuster will over-compress,...
Page 24: Crankshaft Pulley
11C-15 ENGINE <4G6-MPI> - Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11C-6.) Under Cover Installation 25 Nm Removal steps 1. Drive belt (Power steering and 2. Drive belt (Alternator) A/C) 3.
Page 25: Camshaft And Camshaft Oil Seal
11C-16 ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner Removal and Installation Timing Belt Removal and Installation (Refer to P.11C-27.) 10 Nm (f 3 ± 1 mm) 3.4 Nm 14 Nm Sealant:...
Page 26 11C-17 ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS AA" CAMSHAFT SPROCKET REMOVAL MB990767 MD998719 or MD998754 AB" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL MD998443 Before removing the rocker arm and shaft assembly, install the special tools as shown in the illustration so that the lash adjusters will not fall out.
Page 27 11C-18 ENGINE <4G6-MPI> - Camshaft and Camshaft Oil Seal "BA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the camshaft oil seal lip. 2. Use the special tool to press-fit the camshaft oil seal. MD998713 "CA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal, and then tighten the bolts to the specified torque.
Page 28: Oil Pan
11C-19 ENGINE <4G6-MPI> - Oil Pan OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Oil Level Gauge Removal and Installation Engine Oil Draining and Supplying Front Exhaust Pipe Removal and Installation f 4 ± 1 mm 39 Nm Bolt Groove...
Page 29 11C-20 ENGINE <4G6-MPI> - Oil Pan INSTALLATION SERVICE POINT "AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces Oil pan side as shown in the illustration. Drain plug gasket...
Page 30: Crankshaft Oil Seal
11C-21 ENGINE <4G6-MPI> - Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION <M/T> 127 - 137 Nm 127 - 137 Nm <A/T> <A/T> <M/T> Crankshaft Crankshaft (Engine oil: bolt washer (Engine oil: surface) bolt wash- er surface) Lip section Lip section Sealant: 3M Stud locking 4170 or equivalent Engine oil...
Page 31 11C-22 ENGINE <4G6-MPI> - Crankshaft Oil Seal REMOVAL SERVICE POINTS <M/T> AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to ’99 SPACE RUNNER/SPACE WAGON Workshop Manual (Pub. No. PWDE9803) GROUP 22. Flywheel Caution Do not remove the flywheel mounting bolt shown by the Bolt arrow.
Page 32 11C-23 ENGINE <4G6-MPI> - Crankshaft Oil Seal 2. Apply oil to the bearing surface of the flywheel or drive plate bolts. 3. Apply oil to the crankshaft thread holes. 4. Apply sealant to the threaded mounting holes. Specified sealant: 3M Stud locking 4170 or equivalent 5.
Page 33: Cylinder Head Gasket
11C-24 ENGINE <4G6-MPI> - Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13D Intake Manifold Removal and Installation (Refer to - On-vehicle Service.) <Pre-removal only> GROUP 15.) Engine Coolant Draining and Supplying Thermostat Case Assembly Removal and Installation Engine Oil Draining and Supplying (Refer to GROUP 14 - Water Hose and Pipe.)
Page 34 11C-25 ENGINE <4G6-MPI> - Cylinder Head Gasket REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord.
Page 35 11C-26 ENGINE <4G6-MPI> - Cylinder Head Gasket 4. Tighten the bolts by the following procedure. Intake side Front of engine Step Operation Remarks Tighten to 78 Nm. Carry out in the order shown in the illustration. Fully loosen. Carry out in the reverse order of that shown in the illustration.
Page 36: Timing Belt
11C-27 ENGINE <4G6-MPI> - Timing Belt TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Crankshaft Pulley Removal and Installation (Refer to P.11C-15.) Engine Mount Bracket Removal and Installation 48 Nm 10 - 12 Nm 24 Nm 9 Nm Removal steps 1.
Page 37 11C-28 ENGINE <4G6-MPI> - Timing Belt REMOVAL SERVICE POINT Timing mark (Top Timing mark of cylinder head) Camshaft sprocket AA" TIMING BELT REMOVAL 1. Turn the crankshaft clockwise (right turn) to align each timing mark and to set the No. 1 cylinder at compression top dead centre.
Page 38 11C-29 ENGINE <4G6-MPI> - Timing Belt 4. Once the holes are aligned, insert the set pin. Set pin NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine. "BA TIMING BELT INSTALLATION Timing mark (Top Timing mark...
Page 39 11C-30 ENGINE <4G6-MPI> - Timing Belt "CA TIMING BELT TENSION ADJUSTMENT 50 Nm 1. After turning the crankshaft 1/4 of a revolution in the anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. Tension 2. Loosen the tension pulley fixing bolt, and then use the direction MD998767 special tool and a torque wrench to tighten the fixing...
Page 40: Timing Belt B
11C-31 ENGINE <4G6-MPI> - Timing Belt B TIMING BELT B REMOVAL AND INSTALLATION 19 Nm 108 - 127 Nm Removal steps 1. Timing belt (Refer to P.11C-27.) 4. Timing belt B tensioner AA" "CA 2. Crankshaft sprocket AB" "AA 5. Timing belt B "BA 3.
Page 41 11C-32 ENGINE <4G6-MPI> - Timing Belt B INSTALLATION SERVICE POINTS Counterbalance shaft sprocket Belt tension side "AA TIMING BELT B INSTALLATION, ADJUSTMENT 1. Install timing belt “B” by the following procedure. (1) Ensure that crankshaft sprocket “B” timing mark and Timing marks Timing the counterbalance shaft sprocket timing mark are...
Page 42 11C-33 ENGINE <4G6-MPI> - Timing Belt B "CA CRANKSHAFT SPROCKET INSTALLATION Crankshaft MD998719 or MD998754 sprocket NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt. MB990767...
Page 43: Engine Assembly
11C-34 ENGINE <4G6-MPI> - Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13D Hood Removal and Installation...
Page 44 11C-35 ENGINE <4G6-MPI> - Engine Assembly REMOVAL SERVICE POINTS AA" A/C COMPRESSOR REMOVAL Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached. NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 45 11C-36 ENGINE <4G6-MPI> - Engine Assembly INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped. "BA ENGINE MOUNT STOPPER INSTALLATION Engine side Clamp the engine mount stopper so that the arrow points Arrow in the direction as shown in the diagram.
Page 46 13A-1 FUEL CONTENTS GASOLINE DIRECT INJECTION (GDI) ........MULTIPOINT FUEL INJECTION (MPI) <4G6>...
Page 47 13A-2 GASOLINE DIRECT INJECTION (GDI) CONTENTS GENERAL ....... . . Accelerator Pedal Position Sensor Inspection Accelerator Pedal Position Switch Inspection Outline of Change...
Page 48: General
13A-3 GDI <4G6> - General/Service Specification/Troubleshooting GENERAL OUTLINE OF CHANGES The following service procedures for items which are different from before have been established to correspond to the addition of vehicles with 4G6-GDI engine. Other service procedures are the same as before. An integrated-type accelerator pedal position sensor has been adopted.
Page 49 13A-4 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No.77 Accelerator pedal position sensor (2nd Probable cause channel) system Range of check D Malfunction of the accelerator pedal position sensor D Accelerator pedal position sensor (1st channel) system is normal. (2nd channel) D Communication between the engine-ECU and throttle valve controller is normal.
Page 50 13A-5 GDI <4G6> - Troubleshooting Code No.78 Accelerator pedal position sensor (1st Probable cause channel) system Range of check D Malfunction of the accelerator pedal position sensor D Accelerator pedal position sensor (2nd channel) system is normal. (1st channel) D Communication between the engine-ECU and throttle valve controller is normal. D Open circuit or short-circuited harness wire in the Set conditions accelerator pedal position sensor (1st channel) system,...
Page 51 13A-6 GDI <4G6> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Inspection procedure No. 27 has been changed in line with the adoption of an integrated-type accelerator pedal position sensor. Inspection procedure Nos. 36 and 37 have been added in line with the adoption of a GDI indication lamp.
Page 52 13A-7 GDI <4G6> - GDI <4G6> - Troubleshooting Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 27 Accelerator pedal position switch system Probable cause The accelerator pedal position switch detects that the accelerator pedal is fully closed, D Maladjustment of the accelerator cable and sends a signal to the engine-ECU.
Page 53 13A-8 GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 36 The GDI ECO indication lamp does not illuminate. Probable cause If the GDI ECO indication lamp does not illuminate after turning on the ignition switch, D Burned-out GDI ECO indication lamp bulb the causes listed in the right column are suspected.
Page 54 13A-9 GDI <4G6> - Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that vehicle does not move forward. NOTE 1.*1: When the accelerator pedal position sensor (1st channel) output is 500 - 900 mV, the accelerator pedal position switch should normally change from ON to OFF.
Page 55 13A-10 GDI <4G6> - Troubleshooting Engine-ECU Connector Terminal Arrangement Terminal No. Check items Standard value, Normal condition (Check require- ments) 57- 53 Accelerator pedal position switch Continuity (when the accelerator pedal is released) No continuity (when the accelerator pedal is slightly depressed) CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS TERMINAL VOLTAGE CHECK CHART...
Page 56: On-Vehicle Service
13A-11 GDI <4G6> - On-Vehicle Service ON-VEHICLE SERVICE 1. ACCELERATOR PEDAL POSITION SWITCH AND Accelerator pedal ACCELERATOR PEDAL POSITION SENSOR position sensor ADJUSTMENT Caution (1) The accelerator pedal position sensor is adjusted correctly at the time of shipment from the factory, Power steering and so it should not normally be moved.
Page 57: Accelerator Pedal Position Switch Inspection
13A-12 GDI <4G6> - On-Vehicle Service (2) Measure the resistance between accelerator pedal position sensor connector terminal (1) [accelerator pedal position sensor (1st channel) earth] and terminal (2) [accelerator pedal position sensor (1st channel) power supply], and between terminal (7) [accelerator pedal position sensor (2nd channel) earth] and terminal (8) [accelerator pedal position sensor (2nd channel) power supply].
Page 58 13A-13 GDI <4G6> - On-Vehicle Service (3) If there is a malfunction, replace the accelerator pedal position sensor. Earth NOTE After replacement, adjust the accelerator pedal position sensor. (Refer to P.13A - 11.) Accelerator pedal position switch...
Page 59: Fuel Pump (High Pressure) And Fuel Pressure Regulator (High Pressure)
Fuel Pump (High Pressure) and 13A-14 GDI <4G6> - Fuel Pressure Regulator (High Pressure) FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE REGULATOR (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of fuel discharge <before removal only> Air Cleaner Assembly Removal and Installation Engine Cover Removal and Installation Fuel Leak Check <after installation only>...
Page 60 Fuel Pump (High Pressure) and 13A-15 GDI <4G6> - Fuel Pressure Regulator (High Pressure) Fuel pressure regulator (High 2. Fuel pipe clamp pressure) removal steps "CA 3. Fuel feed pipe "CA 5. Low-pressure fuel pipe 1. Harness connector and clamp 12.
Page 61 Fuel Pump (High Pressure) and Fuel Pump (High Pressure) and 13A-16 GDI <4G6> - GDI <4G6> - Fuel Pressure Regulator (High Pressure) Fuel Pressure Regulator (High Pressure) INSTALLATION SERVICE POINTS "AA PUMP CAMSHAFT CASE ASSEMBLY INSTALLATION 1. Set the No.1 cylinder to the compression top dead centre position.
Page 62 Fuel Pump (High Pressure) and 13A-17 GDI <4G6> - Fuel Pressure Regulator (High Pressure) "EA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure).
Page 63: Injector
13A-18 GDI <4G6> - Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of fuel discharge <before removal only> Intake Manifold Removal and Installation Engine Cover Removal and Installation Fuel Leak Check <after installation only> Air Cleaner Assembly Removal and Installation 10 - 13 Nm 20 - 25 Nm 9 Nm...
Page 64 13A-19 GDI <4G6> - GDI <4G6> - Injector Injector REMOVAL SERVICE POINTS AA" INJECTOR HARNESS CONNECTOR DISCONNECTION Caution Disconnect the battery ( - ) cable from its terminal before carrying out this operation. AB" DELIVERY PIPE ASSEMBLY/FUEL INJECTOR ASSEMBLY REMOVAL Remove the delivery pipe assembly with the fuel injector assembly still attached.
Page 65 13A-20 GDI <4G6> - Injector 4. Align the mating marks on the delivery pipe assembly and the fuel injector, and then install the delivery pipe Fuel injector assembly with the injector assembly still attached. Mating marks Delivery pipe assembly "CA BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION O-ring Install the back-up rings and the O-ring as shown in the...
Page 66 13D-1 MULTIPOINT FUEL INJECTION (4G6-MPI) CONTENTS MULTIPOINT FUEL INJECTION <4G6> Fuel Pump Connector Disconnection (How to Reduce the Fuel Pressure) ....GENERAL ....... Fuel Pump Operation Check .
Page 67: Multipoint Fuel
13D-2 MPI - General/General Information MULTIPOINT FUEL INJECTION (MPI) GENERAL OUTLINE OF CHANGE The following service procedures have been established in line with the addition of SPACE RUNNER vehicles with 4G63-MPI engine. GENERAL INFORMATION The Multipoint Fuel Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control.
Page 68: General Information
13D-3 MPI - General Information SELF-DIAGNOSIS FUNCTION When an abnormality is detected in one code corresponding to the abnormality is of the sensors or actuators related to output. emission control, the engine warning lamp The RAM data inside the engine-ECU that (check engine lamp) illuminates as a is related to the sensors and actuators can warning to the driver.
Page 69 13D-4 MPI - General Information Items Specifications Actuators Control relay type Contact switch type Fuel pump relay type Contact switch type Injector type and number Electromagnetic type, 4 Injector identification mark CDH275 EGR control solenoid valve Duty cycle type solenoid valve Purge control solenoid valve ON/OFF type solenoid valve Fuel pressure...
Page 70 13D-5 MPI - General Information MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM *1 Oxygen sensor (front) z1 Injector Engine-ECU *2 Air flow sensor <M/T> and z2 Purge control solenoid valve Engine-A/T- *3 Intake air temperature sensor z3 Idle speed control servo ECU <A/T> *4 Throttle position sensor z4 EGR control solenoid valve *5 Idle position switch...
Page 71: Service Specifications
13D-6 MPI - Service Specifications/Sealant SERVICE SPECIFICATIONS Items Specifications Basic idle speed r/min 750±50 Throttle position sensor adjusting voltage mV 400 - 1,000 Throttle position sensor resistance kW 3.5 - 6.5 Idle speed control servo coil resistance W 28 - 33 (at 20_C) Intake air temperature sensor 20_C 2.3 - 3.0...
Page 72: Special Tools
13D-7 MPI - Special Tools SPECIAL TOOLS Tool Number Name MB991223 Harness set Fuel gauge simple inspection A: Connector pin contact pressure inspection A: MB991219 A: Test harness B: Power circuit inspection B: MB991220 B: LED harness C: Power circuit inspection C: MB991221 C: LED harness D: Commercial tester connection...
Page 73: Troubleshooting
13D-8 MPI - Special Tools/Troubleshooting Tool Number Name MD998478 Test harness Measurement of voltage during trouble- (3-pin, triangle) shooting Inspection using an analyzer MD998709 Adaptor hose Measurement of fuel pressure MD998742 Hose adaptor MD998706 Injector test set Checking the spray condition of injectors MB991607 Injector test harness...
Page 74 13D-9 MPI - Troubleshooting DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the Multipoint Fuel Injection (MPI) system, the engine warning lamp will illuminate. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.
Page 75 13D-10 MPI - Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item Control contents during malfunction Air flow sensor Uses the throttle position sensor signal and engine speed signal (crank angle sensor signal) to take reading of the basic injector drive time and basic ignition timing from...
Page 76 13D-11 MPI - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor (front) system 13D-12 Air flow sensor system 13D-13 Intake air temperature sensor system 13D-14 Throttle position sensor system 13D-15 Engine coolant temperature sensor system 13D-16 Crank angle sensor system 13D-17...
Page 77 13D-12 MPI - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Oxygen sensor (front) system Probable cause Range of Check D Malfunction of the oxygen sensor (front) D 3 minutes have passed after engine was started. D Improper connector contact, open circuit...
Page 78 13D-13 MPI - Troubleshooting Code No. 12 Air flow sensor system Probable cause Range of Check D Malfunction of the air flow sensor D Engine speed is 500 r/min or more. D Improper connector contact, open circuit Set conditions short-circuited harness wire of the air flow sensor D Sensor output frequency is 3 Hz or less for 4 seconds.
Page 79 13D-14 MPI - Troubleshooting Code No. 13 Intake air temperature sensor system Probable cause Range of Check D Malfunction of the intake air temperature sensor D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the intake air after the engine starts.
Page 80 13D-15 MPI - Troubleshooting Code No. 14 Throttle position sensor system Probable cause Range of Check D Malfunction of the throttle position sensor or D Ignition switch: ON maladjustment D Excluding 60 seconds after the ignition switch is turned to ON or immediately D Improper connector contact,...
Page 81 13D-16 MPI - Troubleshooting Code No. 21 Engine coolant temperature sensor system Probable cause Range of Check D Malfunction of the engine coolant temperature sensor D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the engine coolant after the engine starts.
Page 82 13D-17 MPI - Troubleshooting Code No. 22 Crank angle sensor system Probable cause Range of Check D Malfunction of the crank angle sensor D Engine is cranking. D Improper connector contact, open circuit Set conditions short-circuited harness wire of the crank angle sensor D Sensor output voltage does not change for 4 seconds (no pulse signal input.) D Malfunction engine-ECU...
Page 83 13D-18 MPI - Troubleshooting Code No. 23 Camshaft position sensor system Probable cause Range of Check D Malfunction of the camshaft position sensor D Ignition switch: ON D Improper connector contact, open circuit D Engine speed is approx. 50 r/min or more. short-circuited harness wire of the camshaft position Set conditions sensor circuit...
Page 84 13D-19 MPI - Troubleshooting Code No. 24 Vehicle speed sensor system Probable cause Range of check D Malfunction of the vehicle speed sensor D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed after the engine starts.
Page 85 13D-20 MPI - Troubleshooting Code No. 25 Barometric pressure sensor system Probable cause Range of Check D Malfunction of the barometric pressure sensor D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the barometric pressure after the engine starts.
Page 86 13D-21 MPI - MPI - Troubleshooting Troubleshooting Code No. 31 Detonation sensor system Probable cause Range of Check D Malfunction of the detonation sensor D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the detonation sensor after the engine starts.
Page 87 13D-22 MPI - Troubleshooting Code No. 44 Ignition coil system Probable cause Range of Check D Malfunction of the ignition coil D Engine speed is approx. 50 - 4,000 r/min D Improper connector contact, open circuit D Excluding deceleration driving and sudden acceleration or deceleration driving short-circuited harness wire of the ignition primary Set conditions circuit...
Page 88 13D-23 MPI - Troubleshooting Code No.54 Immobilizer system Probable cause Range of Check D Radio interference of ID codes D Ignition switch: ON D Incorrect ID code Set Conditions D Malfunction of harness or connector D Improper communication between the engine-ECU <M/T> or engine-A/T-ECU <A/T> D Malfunction of immobilizer-ECU and immobilizer-ECU D Malfunction of engine-ECU <M/T>...
Page 89 13D-24 MPI - Troubleshooting Code No. 59 Oxygen sensor (rear) system Probable cause Range of Check D Malfunction of the oxygen sensor (rear) D 3 minutes have passed after engine was started. D Improper connector contact, open circuit D Engine coolant temperature is approx. 80_C or more. short-circuited harness wire D Idle position switch: OFF D Malfunction...
Page 90 13D-25 MPI - Troubleshooting Code No. 61 Communication wire with A/T-ECU system Probable cause <A/T> Range of Check D Malfunction of the harness wire and the connector D 60 seconds or more have passed immediately after engine was started. D Malfunction of the engine-A/T-ECU D Engine speed is approx.
Page 91 13D-26 MPI - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13D-28 with MUT-II is impossible. Communication with engine-ECU <M/T> or engine-A/T-ECU 13D-28 <A/T> only is not possible. Engine warning The engine warning lamp does not illuminate right after the 13D-29...
Page 92 13D-27 MPI - Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Starting Won’t start The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won’t start. Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Page 93 13D-28 MPI - Troubleshooting Items Symptom Stopping Run on The condition in which the engine continues to run after the ignition switch is (“Dieseling”) turned to OFF. Also called “Dieseling”. INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. Probable cause (Communication with all systems is not possible.) The cause is probably a defect in the power supply system (including earth) for the...
Page 94 13D-29 MPI - Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after Probable cause the ignition switch is turned to the ON position. Because there is a burnt-out bulb, the engine-ECU <M/T> or engine-A/T-ECU <A/T> D Burnt-out bulb causes the engine warning lamp to illuminate for five seconds immediately after the D Defective warning lamp circuit ignition switch is turned to ON.
Page 95: Engine
13D-30 MPI - Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (starting impossible) Probable cause In cases such as the above, the cause is probably that a spark plug is defective, D Malfunction of the ignition system or that the supply of fuel to the combustion chamber is defective. D Malfunction of the fuel pump system In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel.
Page 96 13D-31 MPI - Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (starting impossible) In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the ignition system sparks but the sparks are weak, or the initial mixture for starting is not appropriate. D Malfunction of the injector system D Foreign materials in fuel D Poor compression...
Page 97 13D-32 MPI - Troubleshooting INSPECTION PROCEDURE 7 It takes too long time to start. (Incorrect starting) Probable cause In cases such as the above, the cause is probably that the spark is weak and ignition D Malfunction of the ignition system is difficult, the initial mixture for starting is not appropriate, or sufficient compression D Malfunction of the injector system pressure is not being obtained.
Page 98 13D-33 MPI - Troubleshooting INSPECTION PROCEDURE 8 Unstable idling (Rough idling, hunting) Probable cause In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of the ignition system idle speed control (ISC) or compression pressure is defective. D Malfunction of air-fuel ratio control system Because the range of possible causes is broad, inspection is narrowed down to simple D Malfunction of the ISC system...
Page 99 13D-34 MPI - Troubleshooting From the previous page. Check the oxygen sensor (rear) system. (Refer to P.13D-24, IN- MUT-II Data list SPECTION PROCEDURE FOR DIAGNOSIS CODE 59.) 59 Oxygen sensor (rear) (Refer to P.13D-62.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV Check the oxygen sensor (front) system.
Page 100 13D-35 MPI - Troubleshooting INSPECTION PROCEDURE 9 Idling speed is high. (Improper idling speed) Probable cause In such cases as the above, the cause is probably that the intake air volume during D Malfunction of the ISC servo system idling is too great. D Malfunction of the throttle body MUT-II Self-Diag code Refer to P.13D-11, INSPECTION CHART FOR DIAGNOSIS...
Page 101 13D-36 MPI - Troubleshooting INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idling. (Die out) Probable cause In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate D Malfunction of the ISC servo system when the engine is cold, or that the intake air volume is insufficient.
Page 102 13D-37 MPI - Troubleshooting INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idling. (Die out) Probable cause In such cases as the above, the cause is probably that ignition system, air/fuel mixture, D Malfunction of the ignition system idle speed control (ISC) or compression pressure is defective.
Page 103 13D-38 MPI - Troubleshooting From the previous page. Check the oxygen sensor (front) system. (Refer to P.13D-12, IN- MUT-II Data list SPECTION PROCEDURE FOR DIAGNOSIS CODE 11.) 11 Oxygen sensor OK: Changes between 600 - 1,000 mV during sudden racing MUT-II Data list Check the fuel pressure.
Page 104 13D-39 MPI - Troubleshooting INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out) Probable cause In cases such as the above, the cause is probably misfiring due to a weak spark, D Drawing air into intake system or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
Page 105 13D-40 MPI - Troubleshooting INSPECTION PROCEDURE 15 Hesitation, sag or stumble Probable cause In cases such as the above, the cause is probably that ignition system, air/fuel mixture D Malfunction of the ignition system or compression pressure is defective. D Malfunction of air-fuel ratio control system D Malfunction of the fuel supply system D Malfunction of the EGR control solenoid valve system D Poor compression...
Page 106 13D-41 MPI - Troubleshooting From the previous page. MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (Refer to P.13D-82.) air into the air intake OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system idling D Broken intake...
Page 107 13D-42 MPI - Troubleshooting INSPECTION PROCEDURE 18 Poor acceleration Probable cause Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. D Malfunction of the ignition system are suspected. D Malfunction of air-fuel ratio control system D Malfunction of the fuel supply system D Poor compression pressure D Clogged exhaust system MUT-II Self-Diag code...
Page 108 13D-43 MPI - Troubleshooting From the previous page. MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (Refer to P.13D-82.) air into the air intake OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system idling D Broken intake...
Page 109 13D-44 MPI - Troubleshooting INSPECTION PROCEDURE 19 Surge Probable cause Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of the ignition system D Malfunction of air-fuel ratio control system D Malfunction of the EGR control solenoid valve system MUT-II Self-Diag code Refer to P.13D-11, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
Page 110 13D-45 MPI - Troubleshooting INSPECTION PROCEDURE 20 Knocking Probable cause In cases as the above, the cause is probably that the detonation control is defective D Defective detonation sensor or the heat value of the spark plug is inappropriate. D Inappropriate heat value of the spark plug MUT-II Self-Diag code Refer to P.13D-11, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
Page 111 13D-46 MPI - Troubleshooting INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling Probable cause Abnormal air-fuel ratio is suspected. D Malfunction of the air-fuel ratio control system D Deteriorated catalyst MUT-II Self-Diag code Refer to P.13D-11, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.
Page 112 13D-47 MPI - Troubleshooting INSPECTION PROCEDURE 23 Low alternator output voltage (approx. 12.3 V) Probable cause The alternator may be defective, or malfunctions, which are listed in the right column, D Malfunction of charging system may be suspected. D Short circuit in harness between alternator G terminal and engine-ECU <M/T>...
Page 113 13D-48 MPI - Troubleshooting INSPECTION PROCEDURE 25 Fans (radiator fan, A/C condenser fan) are inoperative Probable cause The engine-ECU <M/T> or engine-A/T-ECU <A/T> outputs a duty signal to the D Malfunction of the fan motor relay fan controller depending on the engine coolant temperature, vehicle speed, and D Malfunction of the fan motor air conditioner switch condition.
Page 114 13D-49 MPI - Troubleshooting INSPECTION PROCEDURE 26 Engine-ECU <M/T> or Engine-A/T-ECU <A/T> power Probable cause supply and earth circuit system The engine-ECU <M/T> or engine-A/T-ECU <A/T> may be defective, or that one D Improper connector contact, open circuit of the malfunctions listed at right has occured. short-circuited harness wire in the engine-ECU <M/T>...
Page 115 13D-50 MPI - Troubleshooting INSPECTION PROCEDURE 27 Power supply system and ignition switch-IG system Probable cause When an ignition switch ON signal is input to the engine-ECU <M/T> or engine-A/T-ECU D Malfunction of the ignition switch <A/T>, the engine-ECU <M/T> or engine-A/T-ECU <A/T> turns the control relay ON. D Malfunction of the control relay This causes battery voltage to be supplied to the engine-ECU <M/T>...
Page 116 13D-51 MPI - Troubleshooting INSPECTION PROCEDURE 28 Fuel pump system Probable cause The engine-ECU <M/T> or engine-A/T-ECU <A/T> turns the control relay ON when D Malfunction of the fuel pump relay the engine is cranking or running, and this supplies power to drive the fuel pump. D Malfunction of the fuel pump D Improper connector...
Page 117 13D-52 MPI - Troubleshooting INSPECTION PROCEDURE 29 Idle position switch system Probable cause The idle position switch inputs the condition of the accelerator pedal, i.e. whether D Maladjustment of the accelerator pedal it is depressed or released (HIGH/LOW), to the engine-ECU <M/T> or engine-A/T-ECU D Maladjustment of the fixed SAS <A/T>.
Page 118 13D-53 MPI - Troubleshooting INSPECTION PROCEDURE 31 Ignition switch-ST and inhibitor switch system <A/T> Probable cause D The ignition switch-ST inputs a HIGH signal to the engine-A/T-ECU while the D Malfunction of ignition switch engine is cranking. D Malfunction of inhibitor switch The engine-A/T-ECU controls fuel injection, etc.
Page 119 13D-54 MPI - Troubleshooting INSPECTION PROCEDURE 32 Power steering fluid pressure switch system Probable cause The presence or absence of power steering load is input to the engine-ECU <M/T> D Malfunction of power steering fluid pressure switch or engine-A/T-ECU <A/T>. D Improper connector contact,...
Page 120 13D-55 MPI - Troubleshooting INSPECTION PROCEDURE 34 Ignition circuit system Probable cause The engine-ECU <M/T> or engine-A/T-ECU <A/T> interrupts the ignition coil primary D Malfunction of ignition switch. current by turning the power transistor inside the engine-ECU <M/T> or engine-A/T-ECU D Improper connector contact,...
Page 121 13D-56 MPI - Troubleshooting INSPECTION PROCEDURE 36 Purge control solenoid valve system Probable cause The purge control solenoid valve controls the purging of air from the canister located D Malfunction of solenoid valve inside the intake manifold. D Improper connector contact, open circuit...
Page 122 13D-57 MPI - Troubleshooting INSPECTION PROCEDURE 37 EGR control solenoid valve system Probable cause The EGR control solenoid valve is controlled by the negative pressure resulting from D Malfunction of solenoid valve EGR operation leaking to port “A” of the throttle body. D Improper connector contact,...
Page 123 13D-58 MPI - Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes 10% higher than the standard frequency.
Page 124 13D-59 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Intake air Ignition switch: ON or When intake air - 20_C Code No. 13D-14 temperature with engine running temperature is - 20_C sensor When intake air temperature is 0_C When intake air 20_C...
Page 125 13D-60 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Crank angle Engine: Cranking Compare the engine Accord Code No. 13D-17 sensor Tachometer: speed readings on Connected the tachometer and the MUT-II. Engine: Idling When engine 1,275 - 1,475 rpm Idle position coolant temperature...
Page 126 13D-61 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Engine: Cranking When engine 12 - 19 ms Injectors * coolant temperature is 0_C (injection is carried out for all cylinders simultaneously) When engine 26 - 40 ms coolant temperature is 20_C When engine...
Page 127 13D-62 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Oxygen Transmission: 3,500 r/min 600 - 1,000 mV Code No. 13D-24 sensor 2nd gear <M/T>, (rear) L range <A/T> Drive with throttle widely open ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents...
Page 128 13D-63 MPI - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS Needle-nosed wire probe TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the engine-ECU <M/T>...
Page 129 13D-64 MPI - Troubleshooting Engine-ECU <M/T> Connector Terminal Engine-A/T-ECU <A/T> Connector Terminal Arrangement Arrangement Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> No. 1 injector While engine is idling after having From 11 - 14 V, momentarily warmed up, suddenly depress the drops slightly No.
Page 130 13D-65 MPI - Troubleshooting Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> Air flow sen- Engine: Idle speed 0 - 1V sor reset Engine r/min: 3,000 r/min 6 - 9V signal Fan control- Radiator fan and condenser fan are not 0 - 0.3 V operating Radiator fan and condenser fan are...
Page 131 13D-66 MPI - Troubleshooting Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> Oxygen Engine: Idling after warming up 0 - 3V sensor heat- Engine r/min: 5,000r/min. System voltage Ignition Engine: Cranking 8V or more switch - ST Intake air Ignition switch:...
Page 132 13D-67 MPI - Troubleshooting Terminal Terminal Check item Check condition (Engine condition) Normal condition No. <M/T> No. <A/T> Throttle Ignition switch: Set throttle valve 0.3 - 1.0V position to idle position sensor Fully open throttle 4.5 - 5.5V valve Barometric Ignition switch: When altitude is 3.7 - 4.3V...
Page 133 13D-68 MPI - Troubleshooting Caution If the terminals that should be checked are mistaken, or if connector terminals are not correctly shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU <M/T> or engine-A/T-ECU <A/T> and/or ohmmeter. Be careful to prevent this! 4.
Page 134 13D-69 MPI - Troubleshooting Terminal Terminal Inspection item Normal condition (Check condition) No.<M/T> No. <A/T> 72 - 92 64 - 57 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0_C) 2.3 - 3.0 kW (When intake air temperature is 20_C) 1.0 - 1.5 kW (When intake air temperature is 40_C)
Page 135 13D-70 MPI - Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER Analyzer AIR FLOW SENSOR (AFS) Measurement Method Special 1. Disconnect the air flow sensor connector, and connect patterns pickup the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2.
Page 136 13D-71 MPI - Troubleshooting Examples of Abnormal Wave Patterns Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency.
Page 137 13D-72 MPI - Troubleshooting Standard wave pattern 2 engine revolutions (1 camshaft revolution) The time (cycle time) T is reduced when the engine 75_BTDC speed increases 5_BTDC Crank angle sensor output wave pattern 131° 49° 56° 34° Camshaft posi- tion sensor out- put wave pat- tern Time...
Page 138 13D-73 MPI - Troubleshooting INJECTOR Analyzer Measurement Method 1. Disconnect the injector connector, and then connect the special tool (test harness: MB991348) in between. (Both the power supply side and engine-ECU <M/T> or engine-A/T-ECU <A/T> side should be connected.) Special 2.
Page 139 13D-74 MPI - Troubleshooting Standard Wave Pattern Observation conditions Function Special patterns Pattern height Variable Variable knob Adjust while viewing the wave pattern Pattern selector Display Engine r/min Idle speed Standard wave pattern Point A Solenoid back electromotive force (Approx. 7´10 V) Point B Injector drive time Power voltage...
Page 140 13D-75 MPI - Troubleshooting STEPPER MOTOR Analyzer Measurement Method 1. Disconnect the stepper motor connector, and connect the special tool (test harness: MD998463) in between. Special 2. Connect the analyzer special patterns pickup to the patterns stepper motor-side connector terminal 1 (red clip of special pickup tool), terminal 3 (blue clip), terminal 4 (black clip) and terminal 6 (yellow clip) respectively.
Page 141 13D-76 MPI - Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the stepper motor is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small.
Page 142 13D-77 MPI - Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Power transistor control signal Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991348) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to terminal Special 3 of each ignition coil connector in turn.
Page 143 13D-78 MPI - Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit...
Page 144: Throttle Body (Throttle Valve Area) Cleaning
13D-79 MPI - On-vehicle Service ON-VEHICLE SERVICE THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Start the engine and warm it up until the coolant is heated to 80_C or higher and then stop the engine. 2. Remove the air intake hose from the throttle body. 3.
Page 145: Fixed Sas Adjustment
13D-80 MPI - On-vehicle Service 2. Insert a thickness gauge as follows: <Vehicles without auto-cruise control system> Throttle lever Insert a thickness gauge with a thickness of 0.45 mm between the fixed SAS and the throttle lever. Thick- NOTE ness Fixed Do not insert the thickness gauge 3 mm or more.
Page 146: Basic Idle Speed Adjustment
13D-81 MPI - MPI - On-vehicle Service On-vehicle Service BASIC IDLE SPEED ADJUSTMENT NOTE (1) The standard idling speed has been adjusted by the speed adjusting screw (SAS) by the manufacturer, and there should usually be no need for readjustment. (2) If the adjustment has been changed by mistake, the idle speed may become too high or the idle speed may drop too low when loads from components such...
Page 147: Fuel Pressure Test
13D-82 MPI - On-vehicle Service NOTE Unless the ISC servo is released, the Actuator test mode will continue 27 minutes. 8. Switch OFF the ignition switch. 9. Disconnect the MUT-II. 10. Start the engine again and let it run at idle speed for about 10 minutes;...
Page 148 13D-83 MPI - On-vehicle Service 7. Select “Item No.07” from the MUT-II Actuator test to drive the fuel pump. Check that there are no fuel leaks from any parts. 8. Finish the actuator test or turn the ignition switch to “LOCK” (OFF) position.
Page 149: Fuel Pump Connector Disconnection (How To Reduce The Fuel Pressure)
13D-84 MPI - On-vehicle Service 15. Stop the engine and check change of fuel pressure gauge reading. Normal if the reading does not drop within 2 minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Symptom Probable cause Remedy...
Page 150: Component Location
13D-85 MPI - On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol A/C relay Engine-A/T-ECU <A/T> A/C switch Engine warning lamp (check engine lamp) Air flow sensor (with intake air temperature Idle speed control servo sensor and barometric pressure sensor) Camshaft position sensor Ignition coil Control relay and fuel pump relay Inhibitor switch <A/T>...
Page 151: Control Relay And Fuel Pump Relay Continuity Check
13D-86 MPI - On-vehicle Service CONTROL RELAY AND FUEL PUMP RELAY Fuel pump relay CONTINUITY CHECK Equipment side Battery voltage Terminal No. connector Not supplied Supplied Control relay INTAKE AIR TEMPERATURE SENSOR CHECK Equipment side connector Air flow sensor 1. Disconnect the air flow sensor connector. 2.
Page 152: Throttle Position Sensor Check
13D-87 MPI - On-vehicle Service 4. Apply sealant to threaded portion. Specified sealant: 3M NUT Locking Part No.4171 or equivalent 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 Nm THROTTLE POSITION SENSOR CHECK Equipment side connector 1.
Page 153: Oxygen Sensor Check
13D-88 MPI - On-vehicle Service OXYGEN SENSOR CHECK Equipment side connector <Oxygen sensor (front)> Oxygen sensor 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 2 (red clip of special tool) and terminal 4 (blue clip of special tool) on the oxygen sensor connector.
Page 154: Injector Check
13D-89 MPI - MPI - On-vehicle Service On-vehicle Service <Oxygen sensor (rear)> Equipment side connector 1. Disconnect the oxygen sensor connector and connect the special tool (test harness set) to the connector on Oxygen the oxygen sensor side. sensor 2. Make sure that there is continuity (11 - 18 W at 20_C) (rear) between terminal 3 and terminal 4 on the oxygen sensor connector.
Page 155 13D-90 MPI - On-vehicle Service High-pressure fuel hose MD998741 Return hose MB991607 Pressure regulator (MD116395) Injector MD998706 Clip (MB991608) Battery 4. Connect the MUT-II to the diagnosis connector. 5. Turn the ignition switch to ON. (But do not start the engine.) 6.
Page 156: Idle Speed Control (Isc) Servo (Stepper Motor) Check
13D-91 MPI - On-vehicle Service IDLE SPEED CONTROL (ISC) SERVO Idle speed (STEPPER MOTOR) CHECK control servo Checking the Operation Sound 1. Check that the engine coolant temperature is 20_C or below. NOTE Disconnecting the engine coolant temperature sensor connector and connecting the harness-side of the connector to another engine coolant temperature sensor that is at 20_C or below is also okay.
Page 157: Injector
13D-92 MPI - Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal Operation Fuel Discharge Prevention (Refer to P.13D-84.) 5, 7 O-ring 9 Nm 10 - 13 Nm O-ring Engine oil Removal steps 1. PCV hose connection "AA 7. Fuel pressure regulator AA" 2.
Page 158 13D-93 MPI - Injector REMOVAL SERVICE POINT AA" DELIVERY PIPE/INJECTOR REMOVAL Remove the delivery pipe (with the injectors attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector. INSTALLATION SERVICE POINT "AA INJECTOR/FUEL PRESSURE REGULATOR/ HIGH-PRESSURE FUEL HOSE INSTALLATION 1.
Page 159: Throttle Body
13D-94 MPI - Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Air Cleaner Installation Air Cleaner Removal Engine Coolant Supplying Accelerator Cable Adjustment (GROUP 17 - On-vehicle Service) 19 Nm Removal steps 1. Accelerator cable connection 5.
Page 160 13D-95 MPI - Throttle Body DISASSEMBLY AND REASSEMBLY Disassembly steps "AA 1. Throttle position sensor NOTE 2. Idle speed control body assembly The fixed SAS and the speed adjusting screw are 3. O-ring correctly adjusted at the factory and should not be 4.
Page 161 13D-96 MPI - Throttle Body REASSEMBLY SERVICE POINT "AA THROTTLE POSITION SENSOR (TPS) INSTALLATION 1. Place the throttle position sensor against the throttle body as shown by the dotted line in illustration. 2. Turn the throttle position sensor to the position shown in the illustration, and then tighten the screw.
Page 162 14-1 ENGINE COOLING CONTENTS GENERAL ....... . . SEALANT ........Outline of Changes .
Page 163: General
General/General Information/ 14-2 ENGINE COOLING - Service Specification/Sealant GENERAL OUTLINE OF CHANGES The following service procedures have been established in line with the addition of vehicles with 4G63-MPI engine. Furthermore, other items are the same as for the 4G64-GDI engine. GENERAL INFORMATION Items Specifications...
Page 164: Thermostat <4G6-Mpi
14-3 ENGINE COOLING - Thermostat <4G6-MPI> THERMOSTAT <4G6-MPI> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Air Intake Duct Removal and Installation 13 Nm Removal steps AA" "BA 1. Radiator lower hose connection 3. Water inlet fitting "AA 4.
Page 165 14-4 ENGINE COOLING - Thermostat <4G6-MPI> "BA RADIATOR LOWER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose. INSPECTION THERMOSTAT CHECK 1.
Page 166: Water Hose And Water Pipe
14-5 ENGINE COOLING - Water Hose and Water Pipe WATER HOSE AND WATER PIPE <4G6-MPI> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Suppling Air Cleaner and Air Intake Hose Assembly Removal and Installation 13 Nm f3mm 24 Nm 13 Nm f3mm...
Page 167 14-6 ENGINE COOLING - Water Hose and Water Pipe REMOVAL SERVICE POINT AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. INSTALLATION SERVICE POINTS "AA WATER OUTLET FITTING/THERMOSTAT CASE ASSEMBLY INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without...
Page 168: Intake And Exhaust
15-1 INTAKE AND EXHAUST CONTENTS GENERAL ....... . . INTAKE MANIFOLD <4G6-MPI> .
Page 169 15-2 INTAKE AND EXHAUST - General/Service Specification GENERAL OUTLINE OF CHANGES The following service procedures have been established in line with the addition of vehicles with 4G63-MPI engine. Furthermore, other items are the same as for the 4G64-GDI engine. Service procedures have been established to correspond to changes to the exhaust manifold heat protector in vehicles with 4G64-GDI engine.
Page 170 15-3 INTAKE AND EXHAUST - Intake Manifold <4G6-MPI> INTAKE MANIFOLD <4G6-MPI> REMOVAL AND INSTALLATION <4G6> Pre-removal Operation Post-installation Operation Engine Coolant Draining Throttle Body Installation (Refer to GROUP 13A.) Air Cleaner Removal Air Cleaner Installation Throttle Body Removal (Refer to GROUP 13A.) Engine Coolant Supplying Accelerator Cable Ajdustment (Refer to GROUP 17 - On-vehicle Service.)
Page 171 15-4 INTAKE AND EXHAUST - Intake Manifold <4G6-MPI> 10 - 13 Nm 10 - 12 Nm 9 Nm 20 Nm 20 Nm 20 Nm 31 Nm 6. EGR valve 10. Vacuum pipe assembly 7. PCV hose 11. Solenoid valve assembly 8.
Page 172 15-5 INTAKE AND EXHAUST - Intake Manifold <4G6-MPI> REMOVAL SERVICE POINT AA" DELIVERY PIPE, INJECTOR AND PRESSURE REGULATOR REMOVAL Remove the delivery pipe (with the injectors and pressure regulator attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector.
Page 173: 4G6-Mpi
15-6 INTAKE AND EXHAUST - Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation <4G6-GDI> 49 Nm 12 - 15 Nm 29 Nm 49 Nm 34 Nm 44 Nm <4G6-MPI> 29 Nm 49 Nm 13 Nm 49 Nm 34 Nm...
Page 174 15-7 INTAKE AND EXHAUST - Exhaust Manifold INSPECTION EXHAUST MANIFOLD CHECK 1. Check for damage or cracking of any part. 2. Using a straight edge and thickness gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm...
Page 175 NOTES...
Page 176 16-1 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM GENERAL INFORMATION ....SERVICE SPECIFICATIONS ... . . GENERAL ....... Outline of Change .
Page 177: Charging System
16-2 ENGINE ELECTRICAL - Charging System CHARGING SYSTEM GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G63-MPI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the SPACE WAGON.
Page 178: Starting System
16-3 ENGINE ELECTRICAL - Starting System STARTING SYSTEM GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G63-MPI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the SPACE WAGON.
Page 179: Starter Motor
16-4 ENGINE ELECTRICAL - Starting System STARTER MOTOR The following service procedures have been established to correspond to the addition of a direct drive type starter motor. Items other than those given below are the same as before. INSPECTION FREE RUNNING TEST Current: max.
Page 180 16-5 ENGINE ELECTRICAL - Starting System DISASSEMBLY AND REASSEMBLY <DIRECT DRIVE TYPE> Disassembly steps 1. Screw 9. Brush holder assembly AA" 2. Magnetic switch 10. Yoke assembly 3. Packing 11. Armature 4. Plate 12. Lever 5. Screw 13. Washer 6. Through bolt AB"...
Page 181 16-6 ENGINE ELECTRICAL - Starting System DISASSEMBLY SERVICE POINTS Magnetic switch “S” terminal AA" MAGNETIC SWITCH REMOVAL Disconnect field coil wire from “M” terminal of magnetic switch. “B” terminal “M” terminal Field coil wire AB" SNAP RING/STOP RING REMOVAL Socket 1.
Page 182 16-7 ENGINE ELECTRICAL - Starting System INSPECTION COMMUTATOR CHECK 1. Place the armature in a pair of “V” blocks and check the runout with a dial indicator. Standard value: 0.05 mm Limit: 0.1 mm 2. Measure the commutator outer diameter. Standard value: 32.0 mm Limit: 31.4 mm 3.
Page 183 16-8 ENGINE ELECTRICAL - Starting System BRUSH HOLDER CHECK Check the continuity between brush holder plate and brush Insulated holder. brush holder If there is no continuity, the brush holder is in order. OVERRUNNING CLUTCH CHECK 1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction.
Page 184 16-9 ENGINE ELECTRICAL - Starting System ARMATURE TEST Growler ARMATURE SHORT-CIRCUIT TEST 1. Place armature in a growler. 2. Hold a thin steel blade parallel and just above while rotating armature slowly in growler. A shorted armature will cause blade to vibrate and be attracted to the core. Replace shorted armature.
Page 185: Ignition System
16-10 ENGINE ELECTRICAL - Ignition System IGNITION SYSTEM GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G63-MPI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the SPACE WAGON.
Page 186: Service Specifications
16-11 ENGINE ELECTRICAL - Ignition System IGNITION COIL SPECIFICATIONS Items Specifications Type Molded 2-coil SPARK PLUG SPECIFICATIONS Items Specifications BKR6E-11 DENSO K20PR-U11 SERVICE SPECIFICATIONS IGNITION COIL Items Specifications Secondary coil resistance kW 8.5- 11.5 SPARK PLUG Items Specifications Spark plug gap mm 1.0- 1.1 RESISTIVE CODE Items...
Page 187: On-Vehicle Service
16-12 ENGINE ELECTRICAL - Ignition System ON-VEHICLE SERVICE IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK Check by the following procedure, and replace if there is a malfunction. SECONDARY COIL RESISTANCE CHECK Measure the resistance between the high-voltage terminals of the ignition coil. Standard value: 8.5 - 11.5 kW PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK...
Page 188: Spark Plug Check And Cleaning
16-13 ENGINE ELECTRICAL - Ignition System SPARK PLUG CHECK AND CLEANING 1. Remove the spark plug cables. Caution When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. 2. Remove the spark plugs. 3.
Page 189: Waveform Check Using An Analyzer
16-14 ENGINE ELECTRICAL - Ignition System WAVEFORM CHECK USING AN ANALYZER Ignition Secondary Voltage Check MEASUREMENT METHOD 1. Clamp the SECONDARY PICKUP around the spark plug cable. NOTE 1. The peak ignition voltage will be reversed when the spark cables No. 2 and No. 4, or No. 1 and No. 3 cylinders are clamped.
Page 190 16-15 ENGINE ELECTRICAL - Ignition System STANDARD WAVEFORM Observation Conditions Function Secondary Pattern height High (or Low) Pattern selector Raster Engine revolutions Curb idle speed Spark line (point A) Ignition voltage (point D) Wave damping reduction section (point B) Dwell section Secondary ignition...
Page 191 16-16 ENGINE ELECTRICAL - Ignition System WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal waveform examples, 1, 2, 3 and 4). Spark line Plug gap Condition of Compression Concentration of Ignition timing...
Page 192 16-17 ENGINE ELECTRICAL - Ignition System EXAMPLES OF ABNORMAL WAVEFORMS Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. 01P0215 Example 2 Spark line is low and long, and is Spark plug gap is too small.
Page 193: Ignition Coil
16-18 ENGINE ELECTRICAL - Ignition System IGNITION COIL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation <4G6-MPI> 10 Nm 25 Nm Removal steps 1. Ignition coil connector 3. Ignition coil 2. Spark plug cable 4. Spark plug CAMSHAFT POSITION SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation...
Page 194 17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM <MPI> Vacuum Circuit Diagram ....CRANKCASE EMISSION CONTROL GENERAL ....... SYSTEM .
Page 195: Engine Control System
17-2 ENGINE AND EMISSION CONTROL - Engine Control System <MPI> ENGINE CONTROL SYSTEM <MPI> GENERAL OUTLINE OF CHANGE The following service procedures have been established to correspond to the addition of vehicles with 4G6-MPI engine. SERVICE SPECIFICATION Items Standard value Accelerator cable play mm 1 - 2 ON-VEHICLE SERVICE...

Page 196: Accelerator Cable And Pedal
17-3 ENGINE AND EMISSION CONTROL - Engine Control System <MPI> ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION Post-installation Operation Adjusting the Accelerator Cable (Refer to P.17-2.) <R.H. drive vehicles> <L.H. drive vehicles> 5 Nm 5 Nm 12 Nm 12 Nm Removal steps 1.
Page 197: Emission Control System
17-4 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EMISSION CONTROL SYSTEM <MPI> GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G63-MPI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the SPACE WAGON.

Page 198: Vacuum Hose
17-5 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> VACUUM HOSE VACUUM HOSE PIPING DIAGRAM <4G63-MPI> Air cleaner Fuel pressure regulator PCV valve EGR valve Canister EGR control Purge control solenoid valve solenoid valve Oxygen sensor (front) Oxygen sensor (rear) Three-way catalytic converter VACUUM CIRCUIT DIAGRAM...
Page 199: Crankcase Emission Control System
17-6 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> CRANKCASE EMISSION CONTROL SYSTEM SYSTEM DIAGRAM Ventilation hose Breather hose PCV valve COMPONENT LOCATION PCV valve <4G63-SOHC>...
Page 200: Evaporative Emission Control System
17-7 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EVAPORATIVE EMISSION CONTROL SYSTEM SYSTEM DIAGRAM Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Throttle body From fuel tank Air flow sensor Engine coolant temperature sensor Canister Intake air Purge control temperature sensor solenoid valve Control Barometric pressure...
Page 201: Purge Control System Check
17-8 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> PURGE CONTROL SYSTEM CHECK <4G6> 1. Disconnect the vacuum hose (red stripe) from the throttle Red stripe body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3.
Page 202: System
17-9 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EXHAUST GAS RECIRCULATION (EGR) SYSTEM SYSTEM DIAGRAM <4G63-MPI> control solenoid Air flow sensor valve Engine coolant temperature sensor Crank angle sensor EGR valve Control relay Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Battery COMPONENT LOCATION EGR control solenoid valve...
Page 203: Exaust Gas Recirculation (Egr) Control System Check
17-10 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EXHAUST GAS RECIRCULATION (EGR) <4G63-MPI> CONTROL SYSTEM CHECK Green stripe 1. Disconnect the vacuum hose (green stripe) from the EGR valve, and then connect a hand vacuum pump via the three-way terminal.
Page 204: Egr Port Vacuum Check
17-11 ENGINE AND EMISSION CONTROL - Emission Control System <MPI> EGR PORT VACUUM CHECK 1. Disconnect the vacuum hose (white stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum EGR vacuum nipple pump to the nipple. 2.
Page 205 NOTES...
Page 206 21-1 CLUTCH - General/On-vehicle Service GROUP 21 CLUTCH GENERAL OUTLINE OF CHANGE The following service procedures have been established in line with the addition of a clutch switch. <2400> (1) CLUTCH PEDAL INSPECTION AND ADJUSTMENT (2) CLUTCH PEDAL REMOVAL AND INSTALLATION (3) CLUTCH SWITCH CHECK ON-VEHICLE SERVICE CLUTCH PEDAL INSPECTION AND...
Page 207: Clutch
21-2 CLUTCH - Clutch Pedal CLUTCH PEDAL <2400> REMOVAL AND INSTALLATION Post-installation Operation Clutch Pedal Adjustment (Refer to P.21-1) 12 Nm 12 Nm Removal steps 1. Clutch switch 7. Clutch master cylinder mounting 2. Clip 3. Pedal stopper 8. Master cylinder member mounting 4.
Page 208 23-1 AUTOMATIC TRANSMISSION CONTENTS GENERAL ....... . . ON-VEHICLE SERVICE .
Page 209: General
23-2 AUTOMATIC TRANSMISSION - General/Troubleshooting GENERAL OUTLINE OF CHANGES The following service procedures have been established to correspond to the addition of vehicles with 4G6-MPI and 4G6-GDI engine. Items other than those given below are the same as for the 4G6-GDI engine mounted in the ’99 SPACE WAGON.
Page 210 23-3 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODE Code Diagnosis item Reference page Throttle position sensor system Short circuit 23-4 <4G6-MPI> Open circuit 23-4 Accelerator pedal position sensor system Accelerator pedal position sensor system <4G6-GDI> Sensor maladjustment 23-4 Oil temperature sensor system Open circuit 23-4...
Page 211 23-4 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 11, 12, 14 Throttle position sensor system Probable cause <4G6-MPI>, accelerator pedal position sensor system <4G6-GDI> If the TPS or APS output voltage is 4.8 V or higher when the engine is idling, the D Malfunction of the throttle position sensor <4G6-MPI>...
Page 212 23-5 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 21 Crank angle sensor system Probable cause If no output pulse is detected from the crank angle sensor for 5 seconds or more D Malfunction of the crank angle sensor while driving at 25 km/h or more, it is judged that there is an open circuit in the D Malfunction of connector crank angle sensor and diagnosis code No.
Page 213 23-6 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 23 Output shaft speed sensor system Probable cause If the output from the output shaft speed sensor is continuously 50% lower than the D Malfunction of the output shaft speed sensor vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of D Malfunction of the transfer drive gear or driven gear 30 km/h or more, there is judged to be an open circuit or short-circuit in the output D Malfunction of connector...
Page 214 23-7 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 26 Stop lamp switch system Probable cause If the stop lamp switch is on for 5 minutes or more while driving, it is judged that D Malfunction of the stop lamp switch there is a short circuit in the stop lamp switch and diagnosis code No. 26 is output. D Malfunction of connector D Malfunction of the engine-A/T-ECU <4G6-MPI>...
Page 215 23-8 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 36, 52 Damper clutch control solenoid valve Probable cause system If the resistance value for the damper clutch control solenoid valve is too large or D Malfunction of the damper clutch control solenoid valve too small, it is judged that there is a short-circuit or an open circuit in the damper D Malfunction of connector clutch control solenoid valve and diagnosis code No.
Page 216 23-9 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 41 1st gear ratio does not meet the specification Probable cause Code No. 42 2nd gear ratio does not meet the specification Code No. 43 3rd gear ratio does not meet the specification Code No.
Page 217 23-10 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 51 Abnormal communication with engine-ECU Probable cause If normal communication is not possible for a continuous period of 1 second or more D Malfunction of connector when the ignition switch is at the ON position, the battery voltage is 10 V or more D Malfunction of the engine-ECU and the engine speed is 450 r/min or more, diagnosis code No.
Page 218 23-11 AUTOMATIC TRANSMISSION - Troubleshooting Code No. 56 N range lamp system Probable cause If the N range signal is off after an N range lamp illumination instruction (ON instruction) D Malfunction of the N range lamp bulb has been given, it is judged that there is a short-circuit in the N range lamp earth D Malfunction of connector and diagnosis code No.
Page 219 23-12 AUTOMATIC TRANSMISSION - Troubleshooting Trouble symptom Inspection Reference procedure No. page Displaced shifting points All points 23-32* Some points 23-33* Does not shift No diagnosis codes 23-33* Malfunction while driving Poor acceleration 23-34* Vibration 23-34* Inhibitor switch system 23-14 Dual pressure switch system 23-14 Vehicle speed sensor system...
Page 220 23-13 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 2 MUT-II can not communicate with the engine-A/T-ECU or Probable cause A/T-ECU. It is suspected that this malfunction is caused by an open circuit in engine-A/T-ECU D Malfunction of harness or connector or A/T-ECU power supply circuit or diagnosis output circuit. D Malfunction of the engine-A/T-ECU <4G6-MPI>...
Page 221 23-14 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 17 Inhibitor switch system Probable cause The cause is probably a malfunction of the inhibitor switch circuit, ignition switch D Malfunction of the inhibitor switch circuit or a defective engine-A/T-ECU or A/T-ECU. D Malfunction of the ignition switch D Malfunction of connector D Malfunction of the engine-A/T-ECU <4G6-MPI>...
Page 222 23-15 AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 19 Vehicle speed sensor system Probable cause The cause is probably a defective vehicle speed sensor circuit or a defective D Malfunction of the vehicle speed sensor engine-A/T-ECU or A/T-ECU. D Malfunction of connector D Malfunction of the engine-A/T-ECU <4G6-MPI>...
Page 223 23-16 AUTOMATIC TRANSMISSION - Troubleshooting CHECK AT ENGINE-A/T-ECU TERMINALS <4G6-MPI> Terminal No. Check item Check requirement Standard value A/T control relay Ignition switch: OFF Ignition switch: ON System voltage Sensor earth Always Earth Always Solenoid valve power supply Ignition switch: OFF Ignition switch: ON System voltage Earth...
Page 224 23-17 AUTOMATIC TRANSMISSION - Troubleshooting Terminal No. Check item Check requirement Standard value Inhibitor switch R Selector lever position: R System voltage Selector lever position: Other than above Inhibitor switch 3 Selector lever position: 3 System voltage Selector lever position: Other than above Inhibitor switch L Selector lever position: L System voltage...
Page 225 23-18 AUTOMATIC TRANSMISSION - Troubleshooting CHECK AT A/T-ECU TERMINALS <4G6-GDI> Terminal No. Check item Check requirement Standard value Underdrive solenoid valve Selector lever position: D (1st gear) System voltage Selector lever position: P Approx. 7 - 9 V Solenoid valve power supply Ignition switch: OFF Ignition switch: ON System voltage...
Page 226 23-19 AUTOMATIC TRANSMISSION - Troubleshooting Terminal No. Check item Check requirement Standard value Input shaft speed sensor Measure between terminal No. 31 and No. 43 by Refer to an oscilloscope. P.23-43*, Oscil- Engine: 2,000 r/min loscope inspec- Selector lever position: 3 tion procedure Output shaft speed sensor Measure between terminal No.
Page 227: On-Vehicle Service
23-20 AUTOMATIC TRANSMISSION - Troubleshooting/On-Vehicle Service Terminal No. Check item Check requirement Standard value Inhibitor switch R Selector lever position: R System voltage Selector lever position: Other than above Inhibitor switch D Selector lever position: D System voltage Selector lever position: Other than above Inhibitor switch 2 Selector lever position: 2 System voltage...
Page 228: Front Axle
26-1 FRONT AXLE CONTENTS GENERAL ....... . . DRIVE SHAFT .
Page 229 26-2 FRONT AXLE - General/Drive Shaft GENERAL OUTLINE OF CHANGE The following service procedures have been established in line with the addition of 2000 models and 2400 models. (1) DRIVE SHAFT REMOVAL AND INSTALLATION (2) DRIVE SHAFT DISASSEMBLY AND REASSEMBLY DRIVE SHAFT REMOVAL AND INSTALLATION Caution...
Page 230 26-3 FRONT AXLE - FRONT AXLE - Drive Shaft Drive Shaft REMOVAL SERVICE POINTS Items other than those given below are the same as before. MB990767 AC" DRIVE SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY REMOVAL 1. Use the special tool to push out the drive shafts from the hub.
Page 231 26-4 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY Caution On the vehicles with ABS, when the drive shaft is disassembled or reassembled, be careful not to interfere with the ABS rotor installed to the B.J. outer race to prevent the rotor from damage. <2000-A/T, 2000-M/T (LH), 2400 (LH)>...
Page 232 26-5 FRONT AXLE - Drive Shaft REASSEMBLY SERVICE POINTS The following drive shaft reassembly procedures have been established. Items other than those given below are the same as before. "AA DYNAMIC DAMPER/DAMPER BAND/T.J. BOOT INSTALLATION Install the dynamic damper in the position shown in the illustration.
Page 233 26-6 FRONT AXLE - Drive Shaft B.J. BOOT (RESIN BOOT) REPLACEMENT The following B.J. boot (resin boot) replacement procedures have been established. Items other than those given below are the same as before. Fill the inside of the B.J. boot with the specified amount of the specified grease.
Page 234: Wheel And Tyre
31-1 WHEEL AND TYRE - General GROUP 31 WHEEL AND TYRE GENERAL OUTLINE OF CHANGE Aluminium wheels have been adopted as standard. <2400> Items 2400 N63WSNHGL6 N63WSNHCL6 N63WSRHGL6 N63WSRHCL6 N63WSNGCL6 N63WSRGCL6 Wheel Type Aluminium Size 15 ´ 6JJ Amount of wheel offset mm Pitch circle diame- 114.3...
Page 235: Front Suspension
33A-1 FRONT SUSPENSION - General GROUP 33A FRONT SUSPENSION GENERAL OUTLINE OF CHANGE The coil spring specifications have been changed. <2400> COIL SPRING Item 2400 Wire diameter ´ average diameter ´ free length mm 13 ´ 160 ´ 378...
Page 236: Service Brakes
35A-1 SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM ..........ANTI-SKID BRAKING SYSTEM (ABS) <2WD>...
Page 237 35A-2 BASIC BRAKE SYSTEM - General GROUP 35A BASIC BRAKE SYSTEM GENERAL OUTLINE OF CHANGES The proportioning valve has been abolished and a connector assembly has been added to correspond to the adoption of EBD* (Electronic Brake force Distribution) control carried out by the ABS-ECU. <Vehicles with ABS>...
Page 238 35B-1 ANTI-SKID BRAKING SYSTEM (ABS) <2WD> CONTENTS GENERAL ....... . . ON-VEHICLE SERVICE .
Page 239 35B-2 ABS <2WD> - General GENERAL OUTLINE OF CHANGE The following service procedures have been established to correspond to the addition of an EBD (Electronic Brake force Distribution) function to the ABS-ECU. EBD (Electronic Brake force Distribution) The EBD operates during braking within the range where the slip ratio is relatively low and the ABS does not normally operate.
Page 240 35B-3 ABS <2WD> - General CONSTRUCTION DIAGRAM The following two parts have been added to the ABS component parts to correspond to the addition of an EBD function. Brake warning lamp (used as an EBD warning lamp) Brake warning lamp relay 1.
Page 241 35B-4 ABS <2WD> - General BRAKE WARNING LAMP AND BRAKE WARNING LAMP RELAY The brake warning lamp relay is a normally-closed type of relay which is controlled by the ABS-ECU. When the transistor inside the ABS-ECU turns off, the brake warning lamp relay turns on and causes the brake warning lamp to illuminate.
Page 242 35B-5 ABS <2WD> - General/Troubleshooting ABS-ECU The ABS-ECU has a fail-safe function which controls the EBD in the following way if an abnormality occurs in the ABS system. Fail-Safe Function Problem location Brake warning warning EBD control lamp lamp Front wheel speed sensor 1 ab- Normal control is carried out.
Page 243 35B-6 ABS <2WD> - Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 When the ignition key is turned to “ON” (engine stopped), Probable cause the brake warning lamp does not illuminate. The cause may be an open circuit in the lamp power supply circuit, a blown lamp, D Malfunction of combination meter a malfunction of the brake warning lamp relay or an open circuit between the brake D Malfunction of brake warning lamp relay...
Page 244 35B-7 ABS <2WD> - Troubleshooting Inspection Procedure 2 Even after the engine is started, the brake warning lamp Probable cause does not switch off. (However, the parking brake is released and the brake fluid level, brake fluid sensor and parking brake switch are all normal.) If the ABS warning lamp is also illuminated at the same time, the cause is probably D Malfunction of combination meter...
Page 245 35B-8 ABS <2WD> - On-vehicle Service ON-VEHICLE SERVICE Brake warning lamp relay BRAKE WARNING LAMP RELAY CONTINUITY CHECK Terminal No. Battery voltage Power is not supplied Power is sup- plied...
Page 246 37A-1 STEERING CONTENTS GENERAL ....... . . POWER STEERING OIL PUMP .
Page 247 37A-2 STEERING - General/On-vehicle Service GENERAL OUTLINE OF CHANGES The following procedures have been changed to correspond to the modified oil pump. (1) Oil pump pressure test (2) Power steering oil pressure switch check (3) Power steering oil pump removal and installation (4) Power steering oil pump disassembly and reassembly (5) Power steering hose removal and installation ON-VEHICLE SERVICE...
Page 248 37A-3 STEERING - Power Steering Oil Pump POWER STEERING OIL PUMP REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining Power Steering Fluid Supplying Drive Belt Tension Adjusting Power Steering Fluid Line Bleeding Oil Pump Pressure Check (Refer to P.37A-2.) 57 Nm 28 Nm 32 Nm...
Page 249 37A-4 STEERING - Power Steering Oil Pump DISASSEMBLY AND REASSEMBLY Caution Never disassemble the terminal assembly. 27 Nm 25 - 29 Nm 9.8 Nm 59 Nm NOTE *: Automatic transmission fluid DEXRON or DEXRON II Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit Disassembly steps 1.
Page 250 37A-5 STEERING - Power Steering Oil Pump REASSEMBLY SERVICE POINTS Side plate Plug Items other than those given below are the same as before. "AA O-RINGS INSTALLATION I.D. ´ Width mm 19.8 ´ 2.4 14.8 ´ 1.9 3.8 ´ 1.9 14.8 ´...
Page 251 37A-6 STEERING - Power Steering Hoses POWER STEERING HOSES REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining Under Cover Installation Under Cover Removal Power Steering Fluid Supplying Power Steering Fluid Line Bleeding Flare nut 57 Nm 12 Nm 3, 14, 15 15 Nm 12 Nm...
Page 252 00-1 GENERAL CONTENTS 00109001493 HOW TO USE THIS MANUAL ....Model Code ....... . Chassis Number .
Page 253: How To Use This Manual
00-2 GENERAL – How to Use This Manual HOW TO USE THIS MANUAL 00100010401 SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS AND SERVICING EXPLANATIONS STANDARD VALUE This manual provides explanations, etc. concerning Indicates the value used as the standard for judging procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection or and servicing of the subject model.
Page 254: Model Indications
00-3 GENERAL – How to Use This Manual MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. M/T: Indicates the manual transmission, or models equipped with the manual transmission. SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such an engine.
Page 255: Explanation Of Manual Contents
00-4 GENERAL – How to Use This Manual EXPLANATION OF MANUAL CONTENTS Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Component Diagram A diagram of the component parts is pro- vided near the front of each section in or- der to give a reader a better understand-...
Page 256 00-5 GENERAL – How to Use This Manual Indicates the Indicates the Indicates the Indicates the group title. section title. group num- page number. ber. denotes non-reus- able part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Parts- tightening-torque Table”.
Page 257: How To Use Troubleshooting/Inspection Service Points
00-6 GENERAL – How to Use Troubleshooting/Inspection Service Points HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS 00100020213 Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems still follow this outline.
Page 258: Diagnosis Function
00-7 GENERAL – How to Use Troubleshooting/Inspection Service Points 4. INSPECTION CHART FOR DIAGNOSIS CODES 5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to the next page for how to read the inspection procedures.) 6.
Page 259 00-8 GENERAL – How to Use Troubleshooting/Inspection Service Points 2. METHOD OF ERASING DIAGNOSIS CODES When using the MUT-II Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Connection and disconnection of the MUT-II should always be carried out with the ignition switch in the LOCK (OFF) position.
Page 260: How To Use The Inspection Procedures
00-9 GENERAL – How to Use Troubleshooting/Inspection Service Points HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component.
Page 261: Connector Measurement Service Points
00-10 GENERAL – How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED Harness connector (WITH CIRCUIT IN A CONDITION OF CONTINUITY)
Page 262: Connector Inspection
00-11 GENERAL – How to Use Troubleshooting/Inspection Service Points CONNECTOR INSPECTION Connector disconnected or improperly connected VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out Due to harness tension at terminal section Low contact pressure between male and female terminals Low connection pressure due to rusted terminals or foreign matter lodged in terminals Defective connector contact...
Page 263: Inspection Service Points For A Blown Fuse
00-12 GENERAL – How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all 0 Ω circuits which are connected to this fuse to a condition of continuity.
Page 264: Vehicle Identification
00-13 GENERAL – Vehicle Identification VEHICLE IDENTIFICATION 00100540160 VEHICLE INFORMATION CODE PLATE LOCATION Vehicle information code plate is riveted on the toeboard inside the engine compartment. CODE PLATE DESCRIPTION The plate shows model code, engine model, transmission model, and body colour code. Item Contents MODEL...
Page 265: Models
00-14 GENERAL – Vehicle Identification MODELS 00100030315 Model code Engine model Transmission model Fuel supply system DG1A LNDEL6/R6 4G13–SOHC F5MR1 (2WD–5M/T) (1 299 m ) (1,299 m ) LNDJL6 LNJEL6/R6 LNJJL6 DG5A LNDCL6/R6 4G93–DOHC F5M42 (2WD–5M/T) (1 834 m ) (1,834 m ) LNDGL6 LNJCL6/R6...
Page 266: Chassis Number
00-15 GENERAL – Vehicle Identification CHASSIS NUMBER 00100560135 The chassis number is stamped on the toeboard inside the engine compartment. Items Contents Steering wheel location Left hand drive Right hand drive Body style 5-door hatchback Transmission type 5-speed manual transmission Vehicle line SPACE STAR Development order...
Page 267: Engine Model Number
00-16 GENERAL – Vehicle Identification ENGINE MODEL NUMBER 00100570121 1. The engine model number is stamped at the cylinder block as shown in the following. Engine model Engine displacement 4G13 1,299 4G93 1,834 2. The engine serial number is stamped near the engine model number.
Page 268: Major Specifications
00-17 GENERAL – Major Specifications MAJOR SPECIFICATIONS 00100080204 Items DG1A DG5A LNDEL6/R6, LNJEL6/R6, LNDCL6/R6, LNJCL6/R6, LNDJL6 LNJJL6 LNDGL6 LNJGL6 Vehicle dimen- Overall length 1 4,030 4,030 4,030 4,030 sions mm sions mm Overall width 2 1,695 1,695 1,695 1,695 1,700* 1,700* Overall height 3 1,515,...
Page 269: Precautions Before Service
00-18 GENERAL – Precautions Before Service PRECAUTIONS BEFORE SERVICE 00100050397 SUPPLEMENTAL RESTRAINT SYSTEM (SRS), SEAT BELT WITH PRE-TENSIONER 1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Always use the designated special tools and test equipment.
Page 270 00-19 GENERAL – Precautions Before Service SERVICING THE ELECTRICAL SYSTEM Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (–) cable from the battery in order to avoid damage caused by short-circuiting.
Page 271 00-20 GENERAL – Precautions Before Service MUT-II MUT-II sub-assembly Refer to the MUT-II INSTRUCTION MANUAL for instructions on handling the MUT-II. ROM pack Connect the MUT-II to the diagnosis connector as shown in the illustration. Caution Connection and disconnection of the MUT-II should always be made with the ignition switch in the LOCK (OFF) position.
Page 272 00-21 GENERAL – Precautions Before Service Other precautions: Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Avoid contaminating clothes, particularly underpants, with oil. Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
Page 273: Supplemental Restraint System (Srs)
00-22 GENERAL – Supplemental Restrain System (SRS) and Seat Belt with Pre-tensioner SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER 00100590103 To improve safety, the SRS and seat belt with the front passengers in case of an accident. The pre-tensioner are available as optional parts.
Page 274 00-23 GENERAL – Supplemental Restraint System (SRS) and Seat Belt with Pre-tensioner SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER CONSTRUCTIONS The SRS consists of four air bag modules, SRS at the side of the vehicle is stronger than a certain air bag control unit (SRS-ECU), side impact sensors, set value, in order to protect the upper bodies of SRS warning lamp and clock spring.
Page 275 00-24 GENERAL – Supplemental Restrain System (SRS) and Seat Belt with Pre-tensioner SRS SERVICE PRECAUTIONS 00100600103 1. In order to avoid injury to yourself or others NOTE from accidental deployment of the air bag and If any of these components are diagnosed as faulty, they should only be replaced, in accidental operation of the seat belt with pre-tensioner...
Page 276: Destination
00-25 GENERAL – SRS Service Precautions SRS-ECU Destination of harness Corrective action Terminal No. 1 to 4 – – 5, 14 Body wiring harness Side impact sensor (RH) Correct or replace each wiring harness harness. 6, 34 Body wiring harness Side impact sensor (LH) 7, 8 Body wiring harness...
Page 277 00-26 GENERAL – SRS Service Precautions 6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure. After removing the harness connector cover by sliding it in the direction of the arrow 1 in the illustration, remove the connector housing by sliding it in the direction of arrow 2.
Page 278: Support Locations For Lifting And Jacking
00-27 GENERAL – Support Locations for Lifting and Jacking SUPPORT LOCATIONS FOR LIFTING AND JACKING 00100070089 Caution Do not support the vehicles at locations other than specified supporting points. If do so, this will cause damage, etc. SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS GARAGE JACK AXLE STANDS Notch...
Page 279: Support Positions For A Single-Post Lift Or Double-Post Lift
00-28 GENERAL – Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT Caution When service procedures require removing rear suspension, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.
Page 280: Support Positions And Support Method For An H-Bar Lift
00-29 GENERAL – Support Locations for Lifting and Jacking SUPPORT POSITIONS AND SUPPORT METHOD H-bar lift FOR AN H-BAR LIFT H-bar lift Caution When service procedures require removing rear suspension, fuel tank, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.
Page 281 00-30 GENERAL – Support Locations for Lifting and Jacking PREPARATION OF “ATTACHMENTS” Block (A) 1. Prepare the blocks (wooden) and nails as shown in the figure. 1,800 Item Dimensions mm Quantity Block (A) 1,800 Block (B) Block (C) Nail 70 or more Block (B) Block (C) Caution...
Page 282 00-31 GENERAL – Standard Parts-Tightening-Torque Table STANDARD PARTS-TIGHTENING-TORQUE TABLE 00100110033 Each torque value in the table is a standard value The values in the table are not applicable: for tightening under the following conditions. (1) If toothed washers are inserted. (1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
Page 283 NOTES...
Page 284 11A-1 ENGINE CONTENTS ENGINE <4G9> ..........ENGINE <4G1>...
Page 285 11A-2 ENGINE <4G9> CONTENTS GENERAL INFORMATION ....CRANKSHAFT PULLEY ....SERVICE SPECIFICATIONS .
Page 286: General Information
11A-3 ENGINE <4G9> – General Information/Service Specifications GENERAL INFORMATION Items 4G93 Total displacement m 1,834 Bore Stroke mm 81.0 89.0 Compression ratio 12.0 Combustion chamber Pentroof + ball-in-piston Camshaft arrangement DOHC Number of valve Intake Exhaust Valve timing Intake Opening BTDC 15 Closing ABDC 56...
Page 287 11A-4 ENGINE <4G9> – Service Specifications/Sealants Items Standard value Limit Power steering Vibration When checked 114 – 139 – oil pump and oil pump and frequency Hz frequency Hz When a used belt is installed 121 – 133 – A/C compressor drive belt tension b lt t When a new belt is installed...
Page 288: Special Tools
11A-5 ENGINE <4G9> – Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub Measuring the drive belt tension assembly Checking the ignition timing Checking the idle speed Erasing diagnosis code MB991668 Belt tension meter Measuring the drive belt tension (Used together with the MUT-II) MB990767 End yoke holder...
Page 289 11A-6 ENGINE <4G9> – Special Tools Tool Number Name MB991653 Cylinder head bolt Cylinder head bolt removal and installation wrench MD998767 Tension pulley Timing belt tension adjustment socket wrench GENERAL Engine lifter Supporting the engine assembly during SERVICE removal and installation of the transmission TOOL MZ203827 MB991453...
Page 290: On-Vehicle Service
11A-7 ENGINE <4G9> – On-vehicle Service ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension by the following procedure. Standard value: Vibration frequency Hz 143 – 185 Tension N 294 – 490 Deflection (Reference value) mm 9.7 –...
Page 291 11A-8 ENGINE <4G9> – On-vehicle Service <When using a tension gauge> Use a belt tension gauge to check that the belt tension is within the standard value. Belt tension gauge Crankshaft pulley Alternator pulley <Belt deflection check> Deflection Apply 98 N of force to the middle of the drive belt between 98 N the pulleys (at the place indicated by the arrow) and check Crankshaft...
Page 292 11A-9 ENGINE <4G9> – On-vehicle Service POWER STEERING OIL PUMP AND AIR CONDITIONER <Vehicles with A/C> COMPRESSOR DRIVE BELT TENSION CHECK AND Power steering ADJUSTMENT oil pump pulley 1. Check the drive belt tension by the following procedure. Tension pulley <When using the MUT-II>...
Page 293: Ignition Timing Check
11A-10 ENGINE <4G9> – On-vehicle Service IGNITION TIMING CHECK No.1 ignition coil 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn off the ignition switch and then connect the MUT-II to the diagnosis connector. 3. Set the timing light to the power supply line (terminal No.1) of the ignition coil No.1.
Page 294: Idle Speed Check
11A-11 ENGINE <4G9> – On-vehicle Service IDLE SPEED CHECK Idle speed r/min 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn off the ignition switch and then connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. NOTE Refer to P.11A-10 concerning the check procedure of the –10...
Page 295: Compression Pressure Check
11A-12 ENGINE <4G9> – On-vehicle Service 7. If there is a deviation from the standard value, check the following items: Diagnosis output Fuel pressure Injector Ignition coil, spark plug EGR control system Evaporative emission control system Compression pressure NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.
Page 296: Manifold Vacuum Check
11A-13 ENGINE <4G9> – On-vehicle Service 7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa 8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 and 7.
Page 297: Lash Adjuster Check
11A-14 ENGINE <4G9> – On-vehicle Service LASH ADJUSTER CHECK If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed.
Page 298 11A-15 ENGINE <4G9> – On-vehicle Service NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine.
Page 299 11A-16 ENGINE <4G9> – 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 300: Crankshaft Pulley
11A-17 ENGINE <4G9> – Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Panel RH Removal Drive Belt Tension Adjustment (Refer to P.11A-7.) Under Cover Panel RH Installation 177 – 186 Nm (Engine oil) Removal steps 1.
Page 301: Camshaft And Camshaft Oil Seal
11A-18 ENGINE <4G9> – Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Intake Hose Removal and Installation Pump Camshaft Case Removal and Installation Timing Belt Removal and Installation (Refer to GROUP 13A – High Pressure Fuel Pump.) (Refer to P.11A-29.) Intake Manifold Removal and Installation (Refer to GROUP 15.)
Page 302: Lubrication Points
11A-19 ENGINE <4G9> – Camshaft and Camshaft Oil Seal Lubrication points <Seen from underneath beam camshaft cap> Sealant: 3M ATD Part No.8660 or equivalent Lip section Sealant: Engine oil MITSUBISHI GENUINE PART MD970389 or equivalent <Seen from above cylinder head> Sealant: 3M ATD Part No.8660 or equivalent...
Page 303 11A-20 ENGINE <4G9> – Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINT MB990767 CAMSHAFT SPROCKET REMOVAL MD998719 INSTALLATION SERVICE POINTS Camshaft sprocket side Screw hole AA CAMSHAFT INSTALLATION 1. Apply engine oil to journals and cams of the camshafts. 2. Install the camshafts on the cylinder head. Caution Be careful not to confuse the intake camshaft with the exhaust one.
Page 304 11A-21 ENGINE <4G9> – Camshaft and Camshaft Oil Seal CA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal as shown in the illustration. DA CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque.
Page 305: Oil Pan
11A-22 ENGINE <4G9> – Oil Pan OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Engine Oil Draining and Supplying (Refer to GROUP Front Exhaust Pipe Removal and Installation 12 – On-vehicle Service.) (Refer to GROUP 15.) 7 Nm Groove Bolt hole...
Page 306 11A-23 ENGINE <4G9> – Oil Pan REMOVAL SERVICE POINTS LOWER OIL PAN REMOVAL Place a piece of wood against the lower oil pan, and tap the piece of wood with a hammer to remove the lower oil pan. Caution Because the upper oil pan used is made from aluminium, the oil pan remover (MB998727) should not be used.
Page 307: Crankshaft Oil Seal
11A-24 ENGINE <4G9> – Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION 93 – 103 Nm Crankshaft (Engine oil: bolt seat and threaded hole) (Bolt thread) Sealant: 3M Stud Locking 4170 or equivalent Engine oil Crankshaft front oil seal removal steps Crankshaft rear oil seal removal steps D Timing belt (refer to P.11A-29.) D Transmission assembly (Refer to...
Page 308 11A-25 ENGINE <4G9> – Crankshaft Oil Seal REMOVAL SERVICE POINT PLATE/ADAPTOR PLATE/FLYWHEEL REMOVAL Use the special tool to secure the flywheel, and remove the bolts. MD998781 INSTALLATION SERVICE POINTS Crankshaft AA CRANKSHAFT REAR OIL SEAL INSTALLATION rear oil seal Crankshaft 1.
Page 309: Cylinder Head Gasket
11A-26 ENGINE <4G9> – Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of Fuel Discharge <before removal only> High-pressure Fuel Pump High-pressure (Refer to GROUP 13A – On-vehicle Service.) Pressure Regulator Removal and Installation Engine Coolant Draining and Supplying (Refer to GROUP 13A.) (Refer to GROUP 14 –...
Page 310 11A-27 ENGINE <4G9> – Cylinder Head Gasket Removal steps 1. Injector harness connector 6. Idler pulley 2. Front exhaust pipe connection 7. Timing belt rear cover 3. Exhaust manifold bracket 8. Engine oil level gauge assembly 4. Power steering oil pump bracket 9.
Page 311 11A-28 ENGINE <4G9> – Cylinder Head Gasket BA CYLINDER HEAD BOLT INSTALLATION Head bolt Burred side 1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts. (Engine Head bolt oil)
Page 312: Timing Belt
11A-29 ENGINE <4G9> – Timing Belt TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation Crankshaft Pulley Removal and Installation Under Cover Removal and Installation (Refer to P.11A-17.) 49 Nm 20 – 25 Nm 9 Nm 10 –...
Page 313 11A-30 ENGINE <4G9> – Timing Belt REMOVAL SERVICE POINT Timing mark Timing mark TIMING BELT REMOVAL 1. Turn the crankshaft clockwise to align each timing mark. Caution The crankshaft must always be turned clockwise. 2. Loosen the tensioner pulley center bolt and remove the timing belt.
Page 314 11A-31 ENGINE <4G9> – Timing Belt 4. Once the holes are aligned, insert the set pin. NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine. Set pin BA TIMING BELT INSTALLATION Camshaft sprocket...
Page 315 11A-32 ENGINE <4G9> – Timing Belt 6. Hold the belt in the position shown in the illustration with another double clip. 7. Place the belt onto the idler pulley, water pump sprocket, crankshaft sprocket and tensioner pulley in that order. 8.
Page 316 11A-33 ENGINE <4G9> – Timing Belt CA TIMING BELT TENSION ADJUSTMENT Fixing bolt MD998767 1. After turning the crankshaft a 1/4 turn anti-clockwise, turn it clockwise to the position where the timing marks are aligned. Pin hole 2. Loosen the fixing bolt of the tensioner pulley and using the special tool and a torque wrench, apply tension to the timing belt;...
Page 317: Engine Assembly
11A-34 ENGINE <4G9> – Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. Pre-removal and Post-installation Operation Prevention of Fuel Discharge <before removal only>...
Page 318 11A-35 ENGINE <4G9> – Engine Assembly 12 Nm 22 Nm 44 Nm 49 Nm 67 Nm 57 Nm 98 – 118 Nm* 14. Crank angle sensor connector 22. Power steering oil pump and brack- 15. Injector harness connector et assembly 16.
Page 319 11A-36 ENGINE <4G9> – Engine Assembly REMOVAL SERVICE POINTS POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 320 11A-37 ENGINE <4G9> – Engine Assembly BA ENGINE MOUNT BRACKET INSTALLATION MZ203827 1. Place a garage jack against the engine oil pan with a MB991453 piece of wood in between, and install the engine mount bracket while adjusting the position of the engine. 2.
Page 321 NOTES...
Page 322 11B-1 ENGINE <4G1> CONTENTS 11109000788 GENERAL INFORMATION ....Manifold Vacuum Check ..... Timing Belt Tension Adjustment .
Page 323: General Information
11B-2 ENGINE <4G1> – General Information/Service Specifications GENERAL INFORMATION 11100010582 Items 4G13 Total displacement m 1,299 Bore Stroke mm 71 82 Compression ratio 10.0 Combustion chamber Pentroof type Camshaft arrangement SOHC Number of valve Intake Exhaust Valve timing Intake BTDC 17 Opening Closing ABDC 39...
Page 324: Sealant
11B-3 ENGINE <4G1> – Service Specifications/Sealant Items Standard value Limit Power steering Vibration When checked 137 – 168 – oil pump and oil pump and frequency frequency When a used belt is installed 145 – 160 – A/C compres- sor drive belt sor drive belt When a new belt is installed 174 –...
Page 325: Special Tools
11B-4 ENGINE <4G1> – Special Tools SPECIAL TOOLS 11100060105 Tool Number Name MB991502 MUT–II sub Measuring the drive belt tension Checking the idle speed assembly MB991668 Belt tension meter Measuring the drive belt tension (used together with MUT–II) MD998747 Crankshaft pulley Holding the crankshaft pulley holder MB990767...
Page 326: On-Vehicle Service
11B-5 ENGINE <4G1> – Special Tools/On-vehicle Service Tool Number Name A: MD998304 A: Crankshaft front Press-fitting the crankshaft front oil seal oil seal installer B: MD998305 B: Crankshaft front oil seal guide MB991653 Cylinder head bolt Cylinder head bolt removal and installation wrench GENERAL Engine lifter...
Page 327 11B-6 ENGINE <4G1> – On-vehicle Service 4. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 – 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of 15 ).
Page 328 11B-7 ENGINE <4G1> – On-vehicle Service ALTERNATOR DRIVE BELT TENSION ADJUSTMENT Adjusting 1. Loosen the nut of the alternator pivot bolt. bolt 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Lock bolt Standard value: Items...
Page 329 11B-8 ENGINE <4G1> – On-vehicle Service Standard value: Items When When a When a new checked used belt is belt is installed installed Vibration 137 – 168 145 – 160 174 – 199 frequency Tension N 392 – 588 441 – 539 637 –...
Page 330: Valve Clearance Check And Adjustment
11B-9 ENGINE <4G1> – On-vehicle Service VALVE CLEARANCE CHECK AND ADJUSTMENT 11100150154 1. Start the engine and allow it to warm up until the engine coolant temperature reaches 80 to 95 C. 2. Remove all spark plugs from the cylinder head for easy inspection.
Page 331: Ignition Timing Check And Adjustment
11B-10 ENGINE <4G1> – On-vehicle Service IGNITION TIMING CHECK AND ADJUSTMENT Engine tachometer <LHD> conector 11100160331 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Insert a paper clip from the harness side into the engine tachometer connector (1-pin connector) as shown. 3.
Page 332: Idle Speed Check
11B-11 ENGINE <4G1> – On-vehicle Service 16. Sealing tape is to be attached to the fitting nut only for vehicles for Switzerland. NOTE Sealing tape is attached to all vehicles when new. IDLE SPEED CHECK 11100190521 1. Before inspection, set the vehicle to the pre-inspection condition.
Page 333: Compression Pressure Check
11B-12 ENGINE <4G1> – ENGINE <4G1> – On-vehicle Service On-vehicle Service 7. If there is a deviation from the standard value, check the following items: Diagnosis output Closed-loop control (When the closed-loop control is normal, the output signal of the oxygen sensor changes between 0–400 mV and 600–1,000 mV at idle.) Fuel pressure Injector...
Page 334: Manifold Vacuum Check
11B-13 ENGINE <4G1> – On-vehicle Service 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: max. 100 kPa 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps (7) and (8).
Page 335: Crankshaft Pulley
11B-14 ENGINE <4G1> – Crankshaft Pulley CRANKSHAFT PULLEY 11200160389 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover (R.H.) Removal Drive Belt Tension Adjustment (Refer to P.11B-5.) Under Cover (R.H.) Installation (Engine oil) 118 – 132 Nm Removal steps 1. Drive belt (Power steering and A/C) AA 4.
Page 336: Camshaft And Camshaft Oil Seal
11B-15 ENGINE <4G1> – Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL 11200190524 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner Removal and Installation Distributor Removal and Installation (Refer to GROUP 16.) Timing Belt Removal and Installation (Refer to P.11B-25.) 9.8 Nm 3.5 Nm...
Page 337 11B-16 ENGINE <4G1> – Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINT CAMSHAFT SPROCKET REMOVAL MB990767 MD998719 or MD998754 INSTALLATION SERVICE POINTS AA 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 BA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning...
Page 338: Oil Pan
11B-17 ENGINE <4G1> – Oil Pan OIL PAN 11200280337 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Oil Draining and Supplying Front Exhaust Pipe Removal and Installation (Refer to GROUP 12 – On-vehicle Service.) (Refer to GROUP 15.) 24 Nm 4 1 mm Bolt Groove...
Page 339 11B-18 ENGINE <4G1> – Oil Pan INSTALLATION SERVICE POINT AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces Oil pan side as shown in the illustration. Drain plug gasket...
Page 340: Crankshaft Oil Seals
11B-19 ENGINE <4G1> – Crankshaft Oil Seals CRANKSHAFT OIL SEALS 11200280337 REMOVAL AND INSTALLATION 127 – 137 Nm Lip section Lip section Engine oil Crankshaft front oil seal removal Crankshaft rear oil seal removal steps steps D Timing belt (Refer to P.11B-25.) D Transmission assembly (Refer to 1.
Page 341 11B-20 ENGINE <4G1> – Crankshaft Oil Seals REMOVAL SERVICE POINT ADAPTER PLATE/FLYWHEEL REMOVAL Use the special tool to secure the flywheel, and remove the bolts. MD998781 INSTALLATION SERVICE POINTS AA CRANKSHAFT REAR OIL SEAL INSTALLATION 1. Apply a small mount of engine oil to the entire circumference of the oil seal lip.
Page 342: Cylinder Head Gasket
11B-21 ENGINE <4G1> – Cylinder Head Gasket CYLINDER HEAD GASKET 11200400757 REMOVAL AND INSTALLATION Pre-removal Operation Post-Installation Operation Fuel Line Pressure Releasing Thermostat Case Assembly Installation (Refer to GROUP 13B – On-vehicle Service.) (Refer to GROUP 14 – Water Hose and Water Engine Oil Draining Pipe.) (Refer to GROUP 12 –...
Page 343 11B-22 ENGINE <4G1> – Cylinder Head Gasket 3.4 Nm <Cold engine> 49 Nm 0 Nm 20 Nm +90_ +90_ 24 Nm (Engine oil) 88 Nm 13 Nm 50 Nm 49 Nm 22 Nm 18 Nm 19. Spark plug cables 23. Intake manifold stay 20.
Page 344 11B-23 ENGINE <4G1> – Cylinder Head Gasket REMOVAL SERVICE POINT CYLINDER HEAD BOLT REMOVAL Use the special tool to loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove MB991653 the cylinder head assembly. Caution Because the plug guides cannot be replaced by themselves, be careful not to damage or deform the plug...
Page 345 11B-24 ENGINE <4G1> – Cylinder Head Gasket 4. Use the special tool to tighten the bolts by the following procedure. Step Operation Remarks Tighten to 49 Nm. Carry out in the order shown in the illustration. Fully loosen. Carry out in the reverse order of that shown in the illustration.
Page 346: Timing Belt
11B-25 ENGINE <4G1> – Timing Belt TIMING BELT 11200430619 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Mount Bracket Removal and Installation (Refer to GROUP 32 – Engine Mounting.) Crankshaft Pulley Removal and Installation (Refer to P.11B-14.) 9.8 – 12 Nm 8.9 Nm 22 Nm 22 Nm...
Page 347 11B-26 ENGINE <4G1> – Timing Belt TIMING BELT REMOVAL 1. Turn the crankshaft clockwise (right turn) to align each Timing mark timing mark and to set the No. 1 cylinder at compression Camshaft sprocket top dead centre. Caution The crankshaft should always be turned only clockwise.
Page 348 11B-27 ENGINE <4G1> – Timing Belt 4. Align each of the camshaft sprocket and the crankshaft sprocket timing marks. 5. Install the timing belt in the following order, while making Timing mark Camshaft sure that the tension side of the belt is not slackened. sprcoket (1) Crankshaft sprocket (2) Camshaft sprocket...
Page 349: Engine Assembly
11B-28 ENGINE <4G1> – Engine Assembly ENGINE ASSEMBLY 11200100763 REMOVAL AND INSTALLATION Caution*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal Operations Post-installation Operations Fuel Line Pressure Releasing Front Exhaust Pipe Installation (Refer to GROUP (Refer to GROUP 13B –...
Page 350 11B-29 ENGINE <4G1> – Engine Assembly 22 Nm 12 – 14 Nm 49 Nm 88 Nm 20. Drive belt (power steering, A/C) 23. Battery cable connections 21. Power steering oil pump and brack- 24. Power steering hose mounting bolt et assembly BA 25.
Page 351 11B-30 ENGINE <4G1> – Engine Assembly REMOVAL SERVICE POINTS POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump and bracket with the hose attached from the engine. NOTE Place the removed power steering oil pump where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 352 11B-31 ENGINE <4G1> – Engine Assembly INSTALLATION SERVICE POINTS AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped. BA ENGINE MOUNT BRACKET INSTALLATION MZ203827 1. Place a garage jack against the engine oil pan with a MB991453 piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.
Page 353 NOTES...
Page 354 12-1 ENGINE LUBRICATION CONTENTS 12109000020 Engine Oil Replacement ..... . . GENERAL INFORMATION ....Oil Filter Replacement .
Page 355 12-2 ENGINE LUBRICATION – General Information GENERAL INFORMATION 12100010022 The lubrication method is a fully force-fed, full-flow filtration type. The oil pump is a trochoid type which is directly mounted to the crankshaft. ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil harmful contaminants which may cause skin cancer.
Page 356 12-3 ENGINE LUBRICATION – Lubricants/Special Tools/On-vehicle Service LUBRICANTS 12100040243 Items Engine oil (API classifica- Quantity tion) SG or higher Oil filter Total quantity SPECIAL TOOLS 12100060140 Tool Number Name MB991396 Oil filter wrench Removal and installation of engine oil filter (When using the oil filter of MD135737) MB991610 Oil filter wrench...
Page 357 12-4 ENGINE LUBRICATION – ENGINE LUBRICATION – On-vehicle Service On-vehicle Service ENGINE OIL REPLACEMENT <GDI> 12100100255 Drain plug gasket 1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C. 2.
Page 358 12-5 ENGINE LUBRICATION – On-vehicle Service 6. Apply a small amount of engine oil to the O-ring of a new oil filter. 7. Once the O–ring of the oil filter is touching the flange, use the respective tool in the following table to tighten the oil filter to the specified torque.
Page 359 NOTES...
Page 360 13A-1 FUEL CONTENTS GASOLINE DIRECT INJECTION (GDI) ........MULTIPOINT FUEL INJECTION (MPI) .
Page 361 13A-2 GASOLINE DIRECT INJECTION (GDI) CONTENTS GENERAL INFORMATION ....Injector Driver Control Relay Continuity Check 105 Intake Air Temperature Sensor Check ..SERVICE SPECIFICATIONS .
Page 362 13A-3 GDI – General Information GENERAL INFORMATION The Gasoline Direct Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control. In the engine-ECU which controls the system addition, the engine-ECU is equipped with based on signals from these sensors, and several...
Page 363 13A-4 GDI – General Information SELF-DIAGNOSIS FUNCTION When an abnormality is detected in one code corresponding to the abnormality is of the sensors or actuators related to output. emission control, the engine warning lamp The RAM data inside the engine-ECU that (check engine lamp) illuminates as a is related to the sensors and actuators can warning to the driver.
Page 364 13A-5 GDI – General Information Items Specifications Actuators Engine control relay type Contact switch type Fuel pump relay type Contact switch type Injector driver control relay Contact switch type Injector type and number Electromagnetic type, 4 Injector identification mark DIM 1000G Throttle valve control servo relay Contact switch type Throttle valve control servo...
Page 365 13A-6 GDI – General Information GASOLINE DIRECT INJECTION SYSTEM DIAGRAM Engine- z1 Injector driver (In- *1 Oxygen sensor Power supply Engine control relay *2 Air flow sensor Ignition switch – IG jector) Fuel pump relay z2 EGR valve (Step- Ignition switch – ST Injector driver relay *3 Intake air temper- ature senor...
Page 366 13A-7 GDI – Service Specifications/Sealant SERVICE SPECIFICATIONS Item Standard value Adjustment voltage of throttle position 0.4 – 0.6 sensor (1st channel) V Adjustment voltage of throttle position 4.2 – 4.8 sensor (2nd channel) V Resistance of throttle position sensor kΩ 3.5 –...
Page 367 13A-8 GDI – Special Tools SPECIAL TOOLS Tool Number Name MB991223 Harness set Fuel gauge simple inspection A: Connector pin contact pressure inspection A: MB991219 A: Test harness B: Power circuit inspection B: MB991220 B: LED harness C: Power circuit inspection C: MB991221 C: LED harness D: Commercial tester connection...
Page 368: Troubleshooting
13A-9 GDI – Special Tools/Troubleshooting Tool Number Name MD998709 Adaptor hose Measurement of fuel pressure MD998742 Hose adaptor MB991637 Fuel pressure gauge set TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. NOTE If the engine-ECU is replaced, the immobilizer-ECU and ignition key should be replaced together with it.
Page 369 13A-10 GDI – Troubleshooting Engine warning lamp inspection items Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor (1st channel) Throttle position sensor (2nd channel) Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Injector Abnormal combustion...
Page 370 13A-11 GDI – Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE If the diagnosis system detects any sensor malfunction, the vehicle can be driven safely by using a default control logic instead of the faulty sensors. Defective part or What to do when a sensor is defective function Air flow sensor (1) Disables lean-mixture combustion.
Page 371 13A-12 GDI – Troubleshooting Defective part or What to do when a sensor is defective function Accelerator pedal (1) Disables lean-mixture combustion. position sensor (2nd (2) Controls the throttle valve position by using the accelerator pedal position sensor channel) (1st channel) signal. (3) Disables the electronic-controlled throttle valve system if the accelerator pedal position sensor (1st channel) signal is also defective.
Page 372 13A-13 GDI – Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor system 13A-14 Air flow sensor system 13A-15 Intake air temperature sensor system 13A-16 Throttle position sensor (2nd channel) system 13A-17 Engine coolant temperature sensor system 13A-18 Crank angle sensor system 13A-19...
Page 373 13A-14 GDI – Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Oxygen sensor system Probable cause Range of check Malfunction of the oxygen sensor 3 minutes have passed after engine was started. Improper connector contact, open circuit Engine coolant temperature is approx. 80_C or more. short-circuited harness wire Intake air temperature is 20 –...
Page 374 13A-15 GDI – Troubleshooting Code No.12 Air flow sensor system Probable cause Range of check Malfunction of the air flow sensor Engine speed is 500 r/min or more. Open circuit or short-circuited harness wire of air Set conditions flow sensor circuit Sensor output frequency is 3.3 Hz or less for 4 seconds.
Page 375 13A-16 GDI – Troubleshooting Code No.13 Intake air temperature sensor system Probable cause Range of check Malfunction of the intake air temperature sensor After 60 seconds have passed since the engine have started Open circuit or short-circuited harness wire of the Set conditions intake air temperature sensor circuit Sensor resistance is 0.14 kΩ...
Page 376 13A-17 GDI – Troubleshooting Code No.14 Throttle position sensor system (2nd channel) Probable cause The throttle valve controller determines whether a failure is present or not, and Malfunction of throttle position sensor (2nd channel) sends a signal indicating its result to the engine-ECU. Open circuit or short-circuited harness wire in throttle Range of check position sensor (2nd channel) or poor connector...
Page 377 13A-18 GDI – Troubleshooting Code No.21 Engine coolant temperature sensor system Probable cause Range of check Malfunction of the engine coolant temperature After 60 seconds have passed since the engine have started sensor Set conditions Open circuit or short-circuited harness wire of the Sensor resistance is 50 Ω...
Page 378 13A-19 GDI – Troubleshooting Code No.22 Crank angle sensor system Probable cause Range of check Malfunction of the crank angle sensor Engine: During cranking Open circuit or short-circuited harness wire of the Set conditions crank angle sensor circuit Sensor output voltage does not change for 4 seconds (no pulse signal is Malfunction of the engine-ECU being input).
Page 379 13A-20 GDI – Troubleshooting Code No.23 Camshaft position sensor system Probable cause Range of check Malfunction of the camshaft position sensor While engine is cranking or running Open circuit or short-circuited harness wire of the Set conditions camshaft position sensor Sensor output voltage does not change for 4 seconds (no pulse signal is Malfunction of the engine-ECU being input).
Page 380 13A-21 GDI – Troubleshooting Code No. 24 Vehicles speed sensor system Probable cause Range of check Malfunction of the vehicle speed sensor Ignition switch: ON Improper connector contact, open circuit Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed after the engine starts.
Page 381 13A-22 GDI – Troubleshooting Code No.25 Barometric pressure sensor system Probable cause Range of check Malfunction of the barometric pressure sensor After 60 seconds have passed since the engine have started Open circuit or short-circuited harness wire of the Battery voltage is 8 V or more. barometric pressure sensor Set conditions Malfunction of the engine-ECU...
Page 382 13A-23 GDI – Troubleshooting Code No.31 Detonation sensor system Probable cause Range of check Malfunction of the detonation sensor After 60 seconds have passed since the engine have started Open circuit or short-circuited harness wire of the Set conditions detonation sensor Amount of change in the sensor output voltage (detonation sensor peak Malfunction of the engine-ECU voltage for each half rotation of the crankshaft) is 0.06 V or less for 200...
Page 383 13A-24 GDI – Troubleshooting Code No.41 Injector system Probable cause Range of check Malfunction of the injector Engine: while cranking, or running Faulty injector driver relay Engine speed: 4,000 r/min or less Faulty injector driver System voltage: 10 V or more Open circuit or short-circuited harness wire in the Fuel shut off, or forcible activating of injector (actuator test) is not in operation.
Page 384 13A-25 GDI – Troubleshooting From the previous page Repair Measure at engine-ECU connectors Check the following connectors: B-28, B-30. B-28, B-30 Connect the connector. Voltage between terminal 51 and earth Check trouble symptom. (Ignition switch: ON) OK: 4.0 – 5.2 V Voltage between terminal 1 and Replace the injector driver.
Page 385 13A-26 GDI – Troubleshooting Code No.44 Abnormal combustion Probable cause Range of check Malfunction of the ignition coil While engine is running during lean fuel combustion Malfunction of the spark plug Set conditions Malfunction of the EGR valve Abnormal engine speed due to mis-firing is detected by the crank angle Open circuit or short-circuit in ignition primary sensor circuit...
Page 386 13A-27 GDI – Troubleshooting Code No.54 Immobilizer system Probable cause Range of Check Radio interference of ID codes Ignition switch: ON Incorrect ID code Set Conditions Malfunction of harness or connector Improper communication between the engine-ECU and immobilizer-ECU Malfunction of immobilizer-ECU Malfunction of engine-ECU NOTE (1) If the ignition switches are close each other when starting the engine, radio interference may cause...
Page 387 13A-28 GDI – Troubleshooting Code No.56 Abnormal fuel pressure system Probable cause Range of check Malfunction of the fuel pressure sensor Ignition switch: ON Open circuit or short-circuited harness wire of the Set conditions fuel pressure sensor Sensor output voltage is 4.8 V or more for four seconds. Malfunction of the engine-ECU Malfunction of the fuel pump (high pressure) Sensor output voltage is 0.2 V or less for four seconds.
Page 388 13A-29 GDI – Troubleshooting Replace the high-pressure fuel MUT-II Data list MUT-II Data list regulator (seized regulator). 74 Fuel pressure sensor 74 Fuel pressure sensor Replace the high-pressure return Ignition switch: ON Maintain the engine speed at 2,000 pipe (seized pipe). OK: 0 –...
Page 389 13A-30 GDI – Troubleshooting Code No.64 Alternator FR terminal system Probable cause Range of check Open circuit in alternator FR terminal circuit Engine speed is 50 r/min or more. Malfunction of the engine-ECU Set conditions Input voltage from the alternator FR terminal is system voltage for 20 seconds.
Page 390 13A-31 GDI – Troubleshooting Code No.66 Brake vacuum sensor system Probable cause Range of check Malfunction of the brake vacuum sensor Ignition switch: ON Improper connector contact, open circuit or Set conditions short-circuited harness wire of the brake vacuum Sensor output voltage is 4.8 V or more. sensor Malfunction of the engine-ECU Sensor output voltage is 0.2 V or less.
Page 391 13A-32 GDI – Troubleshooting Code No.77 Accelerator pedal position sensor (2nd Probable cause channel) system Range of check Malfunction of the accelerator pedal position sensor Accelerator pedal position sensor (1st channel) system is normal. (2nd channel) Communication between the engine-ECU and throttle valve controller is normal. Open circuit or short-circuited harness wire in the Set conditions accelerator pedal position sensor (2nd channel)
Page 392 13A-33 GDI – Troubleshooting Code No.78 Accelerator pedal position sensor (1st Probable cause channel) system Range of check Malfunction of the accelerator pedal position sensor Accelerator pedal position sensor (2nd channel) system is normal. (1st channel) Communication between the engine-ECU and throttle valve controller is normal. Open circuit or short-circuited harness wire in the Set conditions accelerator pedal position sensor (1st channel)
Page 393 13A-34 GDI – Troubleshooting Code No.79 Throttle position sensor (1st channel) system Probable cause The throttle valve controller determines a failure, and sends its result to the Malfunction of the throttle position sensor (1st channel) engine-ECU. Open circuit or short-circuited harness wire in the Range of check throttle position sensor (1st channel), or poor Ignition switch: ON...
Page 394 13A-35 GDI – Troubleshooting Code No.89 Abnormal fuel system Probable cause Range of check Malfunction of the fuel pump (high pressure) Engine: Idling (during stoichio-feedback operation) Malfunction of the intake air temperature sensor Set conditions Malfunction of the barometric pressure sensor Fuel injection correction value remains excessively low for ten seconds or more.
Page 395 13A-36 GDI – Troubleshooting Code No.91 Electronic-controlled throttle valve system Probable cause Range of check Short in communication line Ignition switch: ON Malfunction of the engine-ECU Error in communication between the engine-ECU and throttle valve controller Malfunction of the throttle valve controller Set conditions Output voltage of the throttle position sensor (2nd channel) fluctuates significantly (approx.
Page 396 13A-37 GDI – Troubleshooting Code No.94 Communication line system with throttle valve Probable cause controller Range of check Short circuit in communication line Ignition switch: ON Malfunction of the engine-ECU System voltage: 8 V or more Malfunction of the throttle valve controller Engine: not cranking Set condition System detects an error in communication line between the engine-ECU and...
Page 397 13A-38 GDI – Troubleshooting Code No.99 Malfunction in throttle valve control servo Probable cause motor system (2nd phase) Range of check Malfunction of the throttle valve control servo Throttle valve control servo relay: ON Open circuit or short-circuited harness wire in the System voltage: 8V or more throttle valve control servo system, or poor connector Set conditions...
Page 398 13A-39 GDI – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13A-41 with MUT-II is with MUT-II is Communication with engine-ECU only is not possible. 13A-42 impossible. Engine warning The engine warning lamp does not illuminate right after the 13A-43 lamp and...
Page 399 13A-40 GDI – 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 400 13A-41 GDI – Troubleshooting Items Symptom Driving Shock The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated. Surge This is repeated surging ahead during constant speed travel or during variable speed travel. Knocking A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving.
Page 401 13A-42 GDI – Troubleshooting INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU is impossible. Probable cause One of the following causes may be suspected. Malfunction of engine-ECU power supply circuit No power supply to engine-ECU. Malfunction of engine-ECU Defective earth circuit of engine-ECU. Open circuit between the engine-ECU and diagnosis Defective engine-ECU.
Page 402 13A-43 GDI – 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 Burnt-out bulb to illuminate for five seconds immediately after the ignition switch is turned to ON.
Page 403 13A-44 GDI – Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (starting impossible) Probable cause This is caused by incorrect fuel supply into the combustion chamber, and improper Malfunction of the fuel supply system ignition circuit. Besides that, foreign material may be contaminated in fuel. Malfunction of the ignition system Malfunction of the engine-ECU Check system voltage while the engine is cranking.
Page 404 13A-45 GDI – Troubleshooting From the previous page Replace the ignition coil. Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx.
Page 405 13A-46 GDI – Troubleshooting INSPECTION PROCEDURE 6 Initial combustion takes place, but does not complete Probable cause (start impossible), too long time to start (poor start) This may be caused by improper spark plug ignition (poor spark), improper mixture Malfunction of the fuel supply system during engine cranking, improper fuel pressure.
Page 406 13A-47 GDI – Troubleshooting From the previous page Replace the ignition coil. Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx.
Page 407 13A-48 GDI – Troubleshooting INSPECTION PROCEDURE 7 Unstable idling (rough idle, hunting) Probable cause This malfunction is probably caused by a faulty ignition system, improper air/fuel ratio, Malfunction of the ignition system a faulty electronic-controlled throttle valve system, improper compression pressure, Malfunction of the air/fuel ratio control system etc.
Page 408 13A-49 GDI – Troubleshooting From the previous page Check the power steering fluid pressure switch system. (Refer MUT-II Data list to P.13A-71, INSPECTION PROCEDURE 32.) 27 Power steering fluid pressure switch (Refer to P.13A-76.) Check the A/C switch and A/C relay system. (Refer to P.13A-71, MUT-II Data list INSPECTION PROCEDURE 33.) 28 A/C switch (Refer to P.13A-77.)
Page 409 13A-50 GDI – Troubleshooting INSPECTION PROCEDURE 8 Idle speed is high or low (Improper idling) Probable cause The cause is probably that the intake air amount during idling is too great or too Malfunction of the electronic-controlled throttle valve small. system Malfunction of the throttle body MUT-II Self-Diag code...
Page 410 13A-51 GDI – Troubleshooting INSPECTION PROCEDURE 9 When the engine is cold, it stalls at idling. (Die out) Probable cause The cause is probably an incorrect air/fuel ratio or poor intake air amount when the Malfunction of the electronic-control throttle valve engine is cold.
Page 411 13A-52 GDI – Troubleshooting INSPECTION PROCEDURE 10 When the engine is hot, it stalls at idling. (Die out) Probable cause The cause is probably an improper air/fuel ratio, faulty electronic-controlled throttle Malfunction of the ignition system valve system, compression pressure. In addition, if the engine stalls suddenly, another Malfunction of the air/fuel ratio control system possible cause might be a poor connector contact.
Page 412 13A-53 GDI – Troubleshooting From the previous page Check the power steering fluid pressure switch system. (Refer MUT-II Data list to P.13A-71, INSPECTION PROCEDURE 32.) 27 Power steering fluid pressure switch (Refer to P.13A-76.) Check the A/C switch and A/C relay system. (Refer to P.13A-77, MUT-II Data list INSPECTION PROCEDURE 33.) 28 A/C switch (Refer to P.13A-77.)
Page 413 13A-54 GDI – Troubleshooting INSPECTION PROCEDURE 11 The engine stalls when starting the car. (Pass out) Probable cause The cause is probably poor ignition due to a malfunctioning spark plug (weak spark), Malfunction of the ignition system or an incorrect air/fuel ratio when the accelerator is depressed. Malfunction of the EGR valve Air stuck in the air intake system MUT-II Self-Diag code...
Page 414 13A-55 GDI – Troubleshooting INSPECTION PROCEDURE 12 The engine stalls when decelerating. Probable cause The cause is probably an improper air/fuel ratio due to a faulty EGR system, or poor Malfunction of the electronic-controlled throttle valve intake air volume due to a faulty electronic-controlled throttle valve system. system Malfunction of the EGR valve Have the battery terminals been disconnected recently?
Page 415 13A-56 GDI – Troubleshooting INSPECTION PROCEDURE 13 Hesitation, sag, stumble, poor acceleration or surge Probable cause The cause is probably a malfunction of the ignition system, electronic-controlled throttle Malfunction of the ignition system valve system, compression pressure, etc. Malfunction of the air/fuel ratio control system Malfunction of the electronic-controlled throttle valve system Improper compression pressure...
Page 416 13A-57 GDI – Troubleshooting From the previous page Measure high fuel pressure between the fuel pump (high pressure) Repair and injector. (Refer to P.13A-98.) Replace the ignition coil. Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil.
Page 417 13A-58 GDI – Troubleshooting INSPECTION PROCEDURE 15 The feeling of impact when decelerating Probable cause The cause is probably insufficient intake air due to a faulty electronic-controlled throttle Malfunction of the electronic-controlled throttle valve valve system. system MUT-II Self-Diag code (Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS Is a diagnosis code displayed? CODES.)
Page 418 13A-59 GDI – Troubleshooting INSPECTION PROCEDURE 18 To high CO and HC concentration when idling Probable cause The cause is probably an incorrect air/fuel ratio Malfunction of the air/fuel ratio control system Deterioration of the catalyst MUT-II Self-Diag code (Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS Is a diagnosis code displayed? CODES.) Check that the crank angle sensor and timing belt cover are properly...
Page 419 13A-60 GDI – Troubleshooting From the previous page Check the EGR valve system. (Refer to P.13A-68, INSPECTION MUT-II Data list PROCEDURE 29.) 68 EGR valve (Refer to P.13A-78.) Check the purge control solenoid valve system. (Refer to P.13A-70, MUT-II Actuator test INSPECTION PROCEDURE 31.) 08 Purge control solenoid valve (Refer to P.13A-80.) Check trouble symptom.
Page 420 13A-61 GDI – Troubleshooting INSPECTION PROCEDURE 19 Low alternator output voltage (approx. 12.3 V) Probable cause The cause is probably a malfunction of the alternator or one of the problems Malfunction of the charging system listed at right. Open circuit between the alternator G terminal and the engine-ECU Malfunction of the engine-ECU Check the harness wire between...
Page 421 13A-62 GDI – Troubleshooting INSPECTION PROCEDURE 21 Fans (radiator fan, A/C condenser fan) are inoperative. Probable cause The engine-ECU sends a duty signal to the fan controller according to engine coolant Malfunction of the fan motor relay temperature, vehicle speed, or A/C switch load. Malfunction of the fan motor The fan controller controls radiator fan and condenser fan speeds, based on this Malfunction of the fan controller...
Page 422 13A-63 GDI – Troubleshooting INSPECTION PROCEDURE 22 The GDI ECO lamp does not illuminate. Probable cause If the GDI ECO lamp does not illuminate after turning on the ignition switch, the Burned-out GDI ECO lamp bulb causes listed in the right column are suspected. Open circuit or short-circuited harness wire in the GDI ECO lamp circuit Malfunction of the engine-ECU...
Page 423 13A-64 GDI – Troubleshooting INSPECTION PROCEDURE 23 The GDI ECO lamp remains on (does not extinguish). Probable cause If the GDI ECO lamp does not extinguish during high load operation, the causes Short circuit between the GDI ECO lamp and listed in the right column are suspected.
Page 424 13A-65 GDI – Troubleshooting INSPECTION PROCEDURE 25 Engine-ECU power supply and earth circuit system Probable cause The cause is probably a malfunction of the engine-ECU or one of the problems Open circuit or short-circuited harness wire in the listed at right. engine-ECU power supply circuit Open circuit or short-circuited harness wire in the engine-ECU earth circuit...
Page 425 13A-66 GDI – Troubleshooting INSPECTION PROCEDURE 26 Engine control relay and ignition switch-IG system Probable cause When the ignition switch ON signal is input to the engine-ECU, the Malfunction of the ignition switch engine-ECU turns on the engine control relay. Malfunction of the engine control relay This causes system voltage to be supplied to the engine-ECU and to the Open circuit or short-circuited harness wire of the...
Page 426 13A-67 GDI – Troubleshooting INSPECTION PROCEDURE 28 Accelerator pedal position switch system Probable cause The accelerator pedal position switch detects that the accelerator pedal is fully closed, Maladjustment of the accelerator cable and sends a signal to the engine-ECU. The engine-ECU judges if the accelerator Maladjustment of the accelerator pedal position switch pedal position sensor is faulty, based on this signal.
Page 427 13A-68 GDI – Troubleshooting INSPECTION PROCEDURE 29 Fuel pump (low pressure) system Probable cause The engine-ECU turns on the fuel pump relay while the engine is cranking or Malfunction of the fuel pump relay running, and supplies power source to the fuel pump (low pressure). Malfunction of the fuel pump (low pressure) Open circuit or short-circuited harness wire in the fuel pump (low pressure) circuit, or poor connector contact...
Page 428 13A-69 GDI – Troubleshooting INSPECTION PROCEDURE 30 EGR valve (stepper motor) system Probable cause The engine-ECU controls the EGR valve (stepper motor) in order to control the Malfunction of the EGR valve amount of exhaust gas mixed in the intake air. Open circuit or short-circuited harness wire in the EGR valve circuit Malfunction of the engine-ECU...
Page 429 13A-70 GDI – Troubleshooting INSPECTION PROCEDURE 31 Purge control solenoid valve system Probable cause The engine-ECU controls the purge control solenoid valve in order to control Malfunction of the purge control solenoid valve the purge air coming from the canister. Open circuit or short-circuited harness wire in the purge control solenoid valve circuit Malfunction of the engine-ECU...
Page 430 13A-71 GDI – Troubleshooting INSPECTION PROCEDURE 32 Power steering fluid pressure switch system Probable cause The power steering fluid pressure switch sends a signal to the engine-ECU according Malfunction of the power steering fluid pressure switch to power steering load. Open circuit or short-circuited harness wire in the Based on this signal, the engine-ECU controls the throttle control servo so that power steering fluid pressure switch circuit, or poor...
Page 431 13A-72 GDI – Troubleshooting INSPECTION PROCEDURE 34 M/T oil temperature sensor system Probable cause This sensor inputs the manual transmission oil temperature to the engine-ECU. Malfunction of the M/T oil temperature sensor The engine-ECU uses this input to control the idle speed control servo so that Open circuit or short-circuited harness wire in the the idle speed is increased when the manual transmission oil temperature M/T oil temperature sensor circuit...
Page 432 13A-73 GDI – Troubleshooting INSPECTION PROCEDURE 35 Stop lamp switch system Probable cause The engine-ECU determines whether the brake pedal is depressed or not, by means Malfunction of the stop lamp switch of the stop lamp switch input signal. Open circuit or short-circuited harness wire in the stop lamp circuit, or poor connector contact Malfunction of the engine-ECU Check the stop lamp switch.
Page 433 13A-74 GDI – Troubleshooting INSPECTION PROCEDURE 36 Small lamp switch Probable cause The engine-ECU determines whether the small lamp switch is on or off. Improper connector contact, open circuit or According to that information, the engine-ECU controls short-circuited harness wire in the taillamp circuit alternator output current when the vehicle is started.
Page 434 13A-75 GDI – Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE : Within four minutes after starting the engine : In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than the standard time.
Page 435 13A-76 GDI – Troubleshooting Item Check items Requirements Normal condition Inspection Reference procedure page Cranking signal Transmission: Neu- Engine: Stopped Procedure 13A-66 (Ignition switch (Ignition switch tral tral No 27 No.27 Engine: Cranking – ST) Engine coolant Ignition switch: ON Intake air tempera- –20_C Code...
Page 436 13A-77 GDI – Troubleshooting Item Check items Requirements Normal condition Inspection Reference procedure page A/C switch Engine: Idling (The A/C switch: OFF Procedure 13A-71 A/C compressor is A/C com ressor is No.33 No.33 running when the A/C A/C switch: ON switch is on.) Small lamp...
Page 437 13A-78 GDI – Troubleshooting Item Check items Requirements Normal condition Inspection Reference procedure page Brake vacuum Engine coolant Stop the engine from Displayed pressure Code 13A-31 sensor temperature: 80 idling speed, increases. No.66 – 95_C then depress Lamps, electric brake pedal several cooling fan and times with the ignition all accessories:...
Page 438 13A-79 GDI – Troubleshooting Item Check items Requirements Normal condition Inspection Reference procedure page Throttle position Engine coolant Release the acceler- 400 – 600 mV Code 13A-34 sensor (1st temperature: 80 ator pedal. No.79 channel) channel) – 95_C 95_C Depress the acceler- Increases Ignition switch: ator pedal gradually.
Page 439 13A-80 GDI – Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. 1 Engine: Idling condition Code No. 13A-24 injector After having becomes different warmed up/Engine warmed up/Engine (becomes unsta (becomes unsta-...
Page 440 13A-81 GDI – Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement Terminal Check item Check requirements (engine condition) Normal condition Engine: Warm up, and then depress decreases slightly for short No.1 injector the accelerator pedal suddenly from the accelerator pedal suddenly from time from 9 –...
Page 441 13A-82 GDI – Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition Injector driver relay Ignition switch: OFF 0 – 0.1 V Ignition switch: ON 0.5 – 1.0 V Fan controller Radiator and condenser fans are not 0 – 0.3 V operating.
Page 442 13A-83 GDI – Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition A/C switch (1st channel) Engine: idling A/C switch: OFF 0 – 3 V A/C switch: ON System voltage (Compressor is operating) Injector open circuit check Engine: Increase engine speed from Decreases slightly signal idle speed to 4,000 r/min.
Page 443 13A-84 GDI – Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition Engine coolant temperature Ignition switch: Engine coolant 3.2 – 3.8 V sensor temperature: 0_C Engine coolant 2.3 – 2.9 V temperature: 20_C Engine coolant 1.3 – 1.9 V temperature: 40_C Engine coolant 0.3 –...
Page 444 13A-85 GDI – Troubleshooting CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart.
Page 445 13A-86 GDI – Troubleshooting Engine-ECU Harness Side Connector Terminal Arrangement Terminal No. Check item Standard value, normal condition (check require- ments) 36 – 44 Ω (at 20 C) 5 – 12 Purge control solenoid valve 11 – 18 Ω (at 20 C) 6 –...
Page 446 13A-87 GDI – Troubleshooting CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS TERMINAL VOLTAGE CHECK CHART Throttle Valve Controller Terminal Arrangement Terminal Check items Requirements Normal value Throttle valve control servo Ignition switch: ON Decreases slightly from (A+) Accelerator pedal: Fully opened system voltage.
Page 447 13A-88 GDI – Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER Analyzer AIR FLOW SENSOR (AFS) Measurement Method Special 1. Disconnect the air flow sensor connector, and connect patterns pickup the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2.
Page 448 13A-89 GDI – 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 449 13A-90 GDI – 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 Camshaft posi- tion sensor out- put wave pat- tern Time No.
Page 450 13A-91 GDI – Troubleshooting INJECTORS AND INJECTOR OPEN CIRCUIT CHECK SIGNAL Measurement Method 1. Connect the analyzer special patterns pickup to terminal 1 (No.1 injector) of the engine-ECU connector. 2. Connect the analyzer special patterns pickup to terminal 51 (injector open circuit check signal) of the engine-ECU Analyzer connector.
Page 451 13A-92 GDI – Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Power transistor control signal Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991658) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to terminal Special 3 of each ignition coil connector in turn.
Page 452 13A-93 GDI – Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit...
Page 453 13A-94 GDI – Troubleshooting EGR VALVE (STEPPER MOTOR) Analyzer Measurement Method 1. Disconnect the EGR valve connector, and connect the special tool (test harness: MB991658) in between. 2. Connect the analyzer special patterns pickup to the EGR valve-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.
Page 454 13A-95 GDI – Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the EGR control servo is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small.
Page 455 13A-96 GDI – On-vehicle Service ON-VEHICLE SERVICE Fixed SAS Caution 1. Never attempt to tamper the fixed SAS. The fixed SAS is precisely adjusted at factory. 2. Should it be tampered, the full closed position of the throttle valve will be changed. This causes the engine-ECU to learn a wrong position of the throttle valve.
Page 456 13A-97 GDI – On-vehicle Service 6. Check the output voltage of the throttle position sensor (2nd channel) when the throttle valve is fully closed by your finger. Standard value: 4.2 – 4.8 V 7. If not within the standard value, replace the throttle position sensor.
Page 457 13A-98 GDI – On-vehicle Service 4. Loosen the accelerator pedal position sensor mounting bolts, and then rotate it fully anticlockwise. 5. Check that the accelerator pedal position switch is on (there should be continuity between terminals). 6. Slowly rotate the accelerator pedal position sensor clockwise, and find the pint where the accelerator pedal position switch is turned off (there will be no continuity).
Page 458 13A-99 GDI – On-vehicle Service 3. Remove the union joint and bolt from the special tool (adapter hose) and instead attach the special tool (hose MB991637 adapter) to the adapter hose. Gasket 4. Install the special tool (for measuring the fuel pressure) Fuel that was set up in step 3.
Page 459 13A-100 GDI – On-vehicle Service Symptom Probable cause Remedy Fuel pressure too low Clogged fuel filter Replace fuel filter Fuel pressure drops after racing Fuel pressure drops after racing Fuel leaking to return side due to poor Replace fuel pressure regulator fuel pressure regulator (low pressure) (low pressure) valve seating or settled spring...
Page 460 13A-101 GDI – On-vehicle Service MEASUREMENT OF FUEL HIGH PRESSURE BETWEEN FUEL PUMP (HIGH PRESSURE) AND INJECTORS Injector intermediate harness NOTE Measurement of the fuel pressure between the fuel pump (high pressure) and the injectors should be carried out after checking that the fuel pressure between the fuel pump (low pressure) and the fuel pump (high pressure) is normal.
Page 461: Fuel Pump Connector Disconnection (How To Reduce Fuel Pressure)
13A-102 GDI – On-vehicle Service FUEL LEAK CHECK Injector intermediate 1. Connect the MUT-II to the diagnosis connector. harness 2. Disconnect the injector intermediate harness connector. 3. Turn the ignition switch to ON. 4. Select “Item No.74” from the MUT-II Data list. 5.
Page 462: Fuel Pump Operation Check
13A-103 GDI – On-vehicle Service (9) If the engine is started, release fuel pressure by the following procedure: 1) Turn off the ignition switch, and then stop the engine. 2) Disconnect one of the ignition coil connectors. 3) Crank the engine for at least two seconds. 4) If the engine can not be started, use the MUT-II to make sure that the fuel pressure is 0.5 MPa or less.
Page 463: Component Location
13A-104 GDI – On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol A/C relay Fuel pressure sensor A/C switch Fuel pump relay Accelerator pedal position sensors Ignition coil Injectors Air flow sensor (with intake air temperature sensor and barometric pressure sensor) sensor and barometric pressure sensor) Injector driver Camshaft position sensor...
Page 464: Engine Control Relay, Fuel Pump Relay And Throttle Valve Control Servo Relay Continuity Check
13A-105 GDI – On-vehicle Service ENGINE CONTROL RELAY, FUEL PUMP Engine control relay RELAY AND THROTTLE VALVE CONTROL SERVO RELAY CONTINUITY CHECK Battery voltage Terminal No. Not supplied Supplied Fuel pump relay Equipment side connector Throttle valve control servo relay Equipment side connector INJECTOR DRIVER CONTROL RELAY...
Page 465: Engine Coolant Temperature Sensor Check
13A-106 GDI – On-vehicle Service ENGINE COOLANT TEMPERATURE SENSOR CHECK Caution Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Remove the engine coolant temperature sensor. Engine coolant temperature sensor 2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance.
Page 466: Accelerator Pedal Position Sensor Check
13A-107 GDI – On-vehicle Service ACCELERATOR PEDAL POSITION SENSOR Equipment side connector CHECK 1. Disconnect accelerator pedal position sensor connector. 2. Measure resistance between terminal Nos.2 and 1 as well as Nos.8 and 7 of the sensor connector. Standard value: 3.5 – 6.5 kΩ 3.
Page 467: Oxygen Sensor Check
13A-108 GDI – On-vehicle Service OXYGEN SENSOR CHECK 1. Disconnect the oxygen sensor connector and connect the Oxygen sensor special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 – 18 Ω at 20 C) between terminal 1 (red clip of special tool) and terminal 3 (blue clip of special tool) on the oxygen sensor connector.
Page 468: Injector Check
13A-109 GDI – On-vehicle Service INJECTOR CHECK Injector side connec- 1. Disconnect the injector intermediate harness connector. Injector intermediate 2. Measure the resistance between each of the terminals. harness Standard value: 0.9 – 1.1 Ω (at 20 C) Injector Measurement terminal No.1 cylinder 1 –...
Page 469: Fuel Pump (High Pressure)
13A-110 GDI – Fuel Pump (High Pressure) FUEL PUMP (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of Fuel Discharge <before removal only> Air Cleaner Assembly Removal and Installation (Refer to P.13A-102.) Fuel Leak Check <after Installation only.> Engine Cover Removal and Installation (Refer to P.13A-102.) 19 Nm...
Page 470 13A-111 GDI – Fuel Pump (High Pressure) Fuel pressure regulator (high 2. Fuel pipe clamp pressure) removal steps CA 3. Fuel feed pipe CA 5. Fuel low-pressure pipe HA D Air-bleeding of fuel pump (high 12. Fuel return hose connection pressure) EA 13.
Page 471 13A-112 GDI – Fuel Pump (High Pressure) INSTALLATION SERVICE POINTS AA PUMP CAMSHAFT CASE ASSEMBLY INSTALLATION 1. Set the No.1 cylinder to the compression top dead centre O-ring position. 2. Align the mating mark on the housing of the pump camshaft case assembly with the mating mark on the coupling, and then install the pump camshaft case assembly to the Mating marks...
Page 472 13A-113 GDI – Fuel Pump (High Pressure) EA FUEL PRESSURE HOSE INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure). 2.
Page 473 13A-114 GDI – Fuel Pump (High Pressure) HA FUEL PUMP (HIGH PRESSURE) AIR-BLEEDING 1. Drive the engine at 2,000 r/min for at least 15 seconds, and bleed the pump. NOTE Air may enter the fuel pump when it is removed. If air has entered, diagnosis code No.56 is displayed due to an abnormal fuel pressure.
Page 474 13A-115 GDI – Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Prevention of Fuel Discharge <before removal only> Intake Manifold Removal and Installation (Refer to (Refer to P.13A-102.) GROUP 15.) Engine Cover Removal and Installation Fuel Leak Check <after installation only> (Refer to Air Cleaner Assembly Removal and Installation P.13A-102.) 10 –...
Page 475 13A-116 GDI – Injector REMOVAL SERVICE POINTS INJECTOR HARNESS CONNECTOR DISCONNECTION Caution Disconnect the negative battery cable from its terminal before carrying out this operation. DELIVERY PIPE ASSEMBLY/FUEL INJECTOR ASSEMBLY REMOVAL Remove the delivery pipe assembly with the fuel injector assembly still attached.
Page 476 13A-117 GDI – Injector 4. Align the mating marks on the delivery pipe assembly Fuel injector and the fuel injector, and then install the delivery pipe assembly with the injector assembly still attached. Mat- Delivery pipe marks assembly CA BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION O-ring Install the back-up rings and the O-ring as shown in the...
Page 477: Throttle Body
13A-118 GDI – Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 14 – On-vehicle Service.) Engine Cover Removal and Installation Air Intake Hose Removal and Installation 10 – 13 Removal steps 1.
Page 478 13A-119 GDI – Throttle Body DISASSEMBLY AND REASSEMBLY Disassembly steps AA 1. Throttle position sensor 2. Throttle body REASSEMBLY SERVICE POINTS AA THROTTLE POSITION SENSOR (1) Position the throttle position sensor on the throttle body along the dotted line as shown in the illustration. (2) Rotate the throttle position sensor anticlockwise as shown in the illustration, and then tighten the screws.
Page 479: Injector Driver
13A-120 GDI – Injector Driver INJECTOR DRIVER REMOVAL AND INSTALLATION 9 Nm or 5 Nm* 5 Nm 5 Nm Removal steps 1. Injector driver connector NOTE 2. Injector driver Tightening torque marked with * is for earth bolts (head 3. Injector driver control relay marking: E).
Page 480: Throttle Valve Controller
13A-121 GDI – Injector Driver/Throttle Valve Controller INJECTOR DRIVER REMOVAL Caution The injector driver will become hot after the vehicle has been driven, so take care when handling it. THROTTLE VALVE CONTROLLER INSTALLATION SERVICE POINT If the throttle valve controller is replaced, initialize the electronic-controlled throttle valve system.
Page 481 NOTES...
Page 482 13B-1 MULTIPOINT FUEL INJECTION (MPI) CONTENTS 13109000577 GENERAL INFORMATION ....Fuel Pump Operation Check ....Component Location .
Page 483: General Information
13B-2 MPI – General Information GENERAL INFORMATION 13100010647 The Multipoint Fuel Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control. In the engine-ECU which controls the system addition, the engine-ECU is equipped with based on signals from these sensors, and several...
Page 484 13B-3 MPI – General Information OTHER CONTROL FUNCTIONS 1. Fuel Pump Control condenser fan are controlled in response Turns the fuel pump relay ON so that current to the engine coolant temperature and is supplied to the fuel pump while the engine vehicle speed.
Page 485 13B-4 MPI – General Information MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM l1 Injector *1 Oxygen sensor (front) Engine- l2 Purge control solenoid valve *2 Intake air temperature sensor l3 Idle speed control servo *3 Throttle position sensor l4 EGR control solenoid valve *4 Crank angle sensor *5 Engine coolant temperature sensor *6 Vacuum sensor...
Page 486: Service Specifications
13B-5 MPI – Service Specifications/Sealant SERVICE SPECIFICATIONS 13100030469 Items Specifications Basic idle speed r/min 750 50 Idle speed when A/C is ON r/min 850 at neutral position Throttle position sensor adjusting voltage mV 530 – 740 Throttle position sensor resistance kΩ 3.5 –...
Page 487: Special Tools
13B-6 MPI – Special Tools SPECIAL TOOLS 13100060444 Tool Number Name MB991223 Harness set Fuel gauge simple inspection A: Connector pin contact pressure inspection A: MB991219 A: Test harness B: Power circuit inspection B: MB991220 B: LED harness C: Power circuit inspection C: MB991221 C: LED harness D: Commercial tester connection...
Page 488: Troubleshooting
13B-7 MPI – Special Tools/Troubleshooting Tool Number Name MD998709 Adaptor hose Measurement of fuel pressure MD998742 Hose adaptor MB991637 Fuel pressure gauge set Checking the spray condition of injectors MD998706 Injector test set MB991607 Injector test harness MD998741 Injector test adaptor MB991608 Clip...
Page 489 13B-8 MPI – Troubleshooting Engine warning lamp inspection items Engine-ECU Oxygen sensor Vacuum sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Detonation sensor Ignition timing adjustment signal Injector Immobilizer system Caution Engine warning lamp will come on even when terminal for ignition timing adjustment is short-circuited.
Page 490 13B-9 MPI – Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE 13100910398 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 491 13B-10 MPI – Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Oxygen sensor (front) system Probable cause Range of Check Malfunction of the oxygen sensor (front) 3 minutes have passed after engine was started. Improper connector contact, open circuit Engine coolant temperature is approx.
Page 492 13B-11 MPI – Troubleshooting Code No. 13 Intake air temperature sensor system Probable cause Range of Check Malfunction of the intake air temperature sensor Ignition switch: ON Improper connector contact, open circuit Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the intake air after the engine starts.
Page 493 13B-12 MPI – Troubleshooting Code No.14 Throttle position sensor system Probable cause Range of Check Malfunction of the throttle position sensor Ignition switch: ON Improper connector contact, open circuit Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the throttle position after the engine starts.
Page 494 13B-13 MPI – Troubleshooting Code No. 21 Engine coolant temperature sensor system Probable cause Range of Check Malfunction of the engine coolant temperature sensor Ignition switch: ON Improper connector contact, open circuit Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the engine coolant after the engine starts.
Page 495 13B-14 MPI – MPI – Troubleshooting Troubleshooting Code No. 22 Crank angle sensor system Probable cause Range of Check Malfunction of the crank angle sensor Engine is cranking. Improper connector contact, open circuit Set conditions short-circuited harness wire of the crank angle sensor Sensor output voltage does not change for 4 seconds (no pulse signal input.) circuit Malfunction of the engine-ECU...
Page 496 13B-15 MPI – Troubleshooting Code No. 31 Detonation sensor system Probable cause Range of Check Malfunction of the detonation sensor Ignition switch: ON Improper connector contact, open circuit Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the detonation sensor after the engine starts.
Page 497 13B-16 MPI – Troubleshooting Code No.32 Vacuum sensor system Range of Check Range of Check Malfunction of the vacuum sensor Ignition switch: ON Improper connector contact, open circuit Set Conditions short-circuited harness The output voltage of the vacuum sensor is 4.5 V or more for 4 seconds. (This Malfunction of the engine-ECU corresponds to the absolute manifold pressure of 115 kPa or more.) Range of Check...
Page 498 13B-17 MPI – Troubleshooting Code No. 36 Ignition timing adjustment signal system Probable cause Range of Check Short circuit to earth of the ignition timing adjustment Ignition switch: ON signal line Set conditions Malfunction of the engine-ECU The ignition timing adjusting signal wire is shorted to the earth. Repair Measure at the ignition timing adjust- Check the following connector: B-30...
Page 499 13B-18 MPI – Troubleshooting Code No.54 Immobilizer system Probable cause Range of Check Radio interference of ID codes Ignition switch: ON Incorrect ID code Set Conditions Malfunction of harness or connector Improper communication between the engine-ECU and immobilizer-ECU Malfunction of immobilizer-ECU Malfunction of engine-ECU NOTE (1) If the ignition switches are close each other when starting the engine, radio interference may cause...
Page 500 13B-19 MPI – Troubleshooting Code No. 59 Oxygen sensor (rear) system Probable cause Range of Check Malfunction of the oxygen sensor (rear) 3 minutes have passed after engine was started. Improper connector contact, open circuit Engine coolant temperature is approx. 80_C or more. short-circuited harness wire Idle position switch: OFF Malfunction of the engine-ECU...
Page 501 13B-20 MPI – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS 13100880590 Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13B-22 with MUT-II is with MUT-II is Communication with engine-ECU only is not possible. 13B-22 impossible. Engine warning The engine warning lamp does not illuminate right after the 13B-23...
Page 502 13B-21 MPI – Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Starting Won’t start The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won’t start. Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Page 503 13B-22 MPI – 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 Malfunction of the connector the diagnosis line.
Page 504 13B-23 MPI – Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after Probable cause the ignition switch is turned to the ON position. Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp Burnt-out bulb to illuminate for five seconds immediately after the ignition switch is turned to ON.
Page 505 13B-24 MPI – Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (starting impossible) Probable cause In cases such as the above, the cause is probably that a spark plug is defective, Malfunction of the ignition system or that the supply of fuel to the combustion chamber is defective. Malfunction of the fuel pump system In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel.
Page 506 13B-25 MPI – Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (starting impossible) In such cases as the above, the cause is probably that the spark plugs are generating Malfunction of the ignition system sparks but the sparks are weak, or the initial mixture for starting is not appropriate. Malfunction of the injector system Foreign materials in fuel Poor compression...
Page 507 13B-26 MPI – 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 Malfunction of the ignition system ignition is difficult, the initial mixture for starting is not appropriate, or sufficient Malfunction of the injector system compression pressure is not being obtained.
Page 508 13B-27 MPI – Troubleshooting INSPECTION PROCEDURE 8 Unstable idling (Rough idling, hunting) Probable cause In cases as the above, the cause is probably that the ignition system, air/fuel mixture, Malfunction of the ignition system idle speed control (ISC) or compression pressure is defective. Malfunction of air-fuel ratio control system Because the range of possible causes is broad, inspection is narrowed down to Malfunction of the ISC system...
Page 509 13B-28 MPI – Troubleshooting From previous page MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (front) (Refer to P.13B-67.) air into the air intake OK: Changes between 0 – 400 mV and 600 – 1,000 mV system.
Page 510 13B-29 MPI – MPI – 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 Malfunction of the ISC servo system idling is too great.
Page 511 13B-30 MPI – Troubleshooting INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idling. (Die out) Probable cause In such cases as the above, the cause is probably that the air/fuel mixture is Malfunction of the ISC servo system inappropriate when the engine is cold, or that the intake air volume is insufficient.
Page 512 13B-31 MPI – Troubleshooting INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idling. (Die out) Probable cause In such cases as the above, the cause is probably that ignition system, air/fuel Malfunction of the ignition system mixture, idle speed control (ISC) or compression pressure is defective. Malfunction of air-fuel ratio control system In addition, if the engine suddenly stalls, the cause may also be a defective connector Malfunction of the ISC system...
Page 513 13B-32 MPI – Troubleshooting From previous page MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (front) (Refer to P.13B-67.) air into the air intake OK: Changes between 0 – 400 mV and 600 – 1,000 mV system.
Page 514 13B-33 MPI – Troubleshooting INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out) Probable cause In cases such as the above, the cause is probably misfiring due to a weak spark, Drawing air into intake system or an inappropriate air/fuel mixture when the accelerator pedal is depressed. Malfunction of the ignition system MUT-II Self-Diag code Refer to P.13B-9, INSPECTION CHART FOR DIAGNOSIS...
Page 515 13B-34 MPI – Troubleshooting INSPECTION PROCEDURE 15 Hesitation, sag or stumble Probable cause In cases such as the above, the cause is probably that ignition system, air/fuel Malfunction of the ignition system mixture or compression pressure is defective. Malfunction of air-fuel ratio control system Malfunction of the fuel supply system Malfunction of the EGR control solenoid valve system Poor compression...
Page 516 13B-35 MPI – 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 Malfunction of the ignition system accompanying the increase in the spark plug demand voltage during acceleration. MUT-II Self-Diag code Refer to P.13B-9, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
Page 517 13B-36 MPI – Troubleshooting INSPECTION PROCEDURE 18 Poor acceleration Probable cause Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. Malfunction of the ignition system are suspected. Malfunction of air-fuel ratio control system Malfunction of the fuel supply system Poor compression pressure Clogged exhaust system MUT-II Self-Diag code...
Page 518 13B-37 MPI – Troubleshooting INSPECTION PROCEDURE 19 Surge Probable cause Defective ignition system, abnormal air-fuel ratio, etc. are suspected. Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the EGR control solenoid valve system MUT-II Self-Diag code Refer to P.13B-9, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.
Page 519 13B-38 MPI – Troubleshooting INSPECTION PROCEDURE 20 Knocking Probable cause In cases as the above, the cause is probably that the detonation control is defective Defective detonation sensor or the heat value of the spark plug is inappropriate. Inappropriate heat value of the spark plug MUT-II Self-Diag code Refer to P.13B-9, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
Page 520 13B-39 MPI – Troubleshooting INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling Probable cause Abnormal air-fuel ratio is suspected. Malfunction of the air-fuel ratio control system Deteriorated catalyst MUT-II Self-Diag code Refer to P.13B-9, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.
Page 521 13B-40 MPI – 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 Malfundtion of the fan motor relay turning ON and OFF. Malfunction of the fan motor Malfunction of the thermostat Improper...
Page 522 13B-41 MPI – Troubleshooting INSPECTION PROCEDURE 24 Check the engine-ECU power supply and earth circuit. 1. NG Check following Measure the engine-ECU connectors, B-28, B-29, B-31. Repair connector: B-18 Disconnect the connector and measure at the harness side 1. Voltage between 82 and earth (Ignition switch: ON) OK: System voltage 2, 3.
Page 523 13B-42 MPI – 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, Malfunction of the fuel pump relay and this supplies power to drive the fuel pump. Malfunction of the fuel pump Improper connector...
Page 524 13B-43 MPI – 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 Malfunction of ignition switch is cranking. Improper connector contact, open circuit The engine-ECU controls fuel injection, etc. during starting based on this input. short-circuited harness wire Malfunction of the engine-ECU 1.
Page 525 13B-44 MPI – 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 Malfunction of A/C control system control of the idle speed control (ISC) servo, and also operates the A/C compressor Malfunction of A/C switch magnetic clutch.
Page 526 13B-45 MPI – Troubleshooting INSPECTION PROCEDURE 31 Ignition circuit system Probable cause The engine-ECU interrupts the ignition coil primary current by turning the power Malfunction of ignition switch transistor inside the engine-ECU ON and OFF. Improper connector contact, open circuit short-circuited harness wire Malfunction of the engine-ECU 1.
Page 527 13B-46 MPI – Troubleshooting INSPECTION PROCEDURE 32 Idle speed control (ISC) servo (Stepper motor) system Probable cause The engine-ECU controls the intake air volume during idling by opening and closing Malfunction of ISC servo the servo valve located in the bypass air passage. Improper connector contact,...
Page 528 13B-47 MPI – Troubleshooting INSPECTION PROCEDURE 34 EGR control solenoid valve system Probable cause The EGR control solenoid valve is controlled by the negative pressure resulting Malfunction of solenoid valve from EGR operation leaking to port “A” of the throttle body. Improper connector contact,...
Page 529 13B-48 MPI – Troubleshooting DATA LIST REFERENCE TABLE 13100890500 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 intake plenum pressure is sometimes 10% higher than the standard pressure.
Page 530 13B-49 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Power Ignition switch: ON System voltage Procedure 13B-41 supply No. 25 voltage Cranking Ignition switch: ON Engine: Stopped Procedure 13B-43 signal signal No. 27 No. 27 (ignition Engine: Cranking switch-ST)
Page 531 13B-50 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Power Engine: Idling Steering wheel Procedure 13B-43 steering fluid stationary No. 28 pressure pressure switch Steering wheel turning A/C switch Engine: Idling A/C switch: OFF Procedure 13B-44 (when A/C switch is...
Page 532 13B-51 MPI – 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 80 – 95_C 2,500 r/min 1.4 – 2.6 ms Lamps, electric cooling fan and all...
Page 533 13B-52 MPI – Troubleshooting ACTUATOR TEST REFERENCE TABLE 13100900579 Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. 1 Engine: Idling condition Code No. 13B-17 injector After having warmed up/En- becomes different gine is idling gine is idling (becomes...
Page 534 13B-53 MPI – Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS 13100920506 TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement Terminal No. Check item Check condition (Engine condition) Normal condition No. 1 injector While engine is idling after having warmed up, From 11 – 14 V, momentarily suddenly depress the accelerator pedal suddenly depress the accelerator pedal.
Page 535 13B-54 MPI – Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Condenser fan motor Condenser fan is not operating (Engine coolant System voltage relay temperature is 90 C or less) Condenser fan is operating (Engine coolant 0 – 3 V temperature is 105 C or more) Radiator fan motor Radiator fan is not operating (Engine coolant...
Page 536 13B-55 MPI – Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Intake air Ignition switch: ON When intake air 3.2 – 3.8 V temperature sensor temperature is 0_C When intake air 2.3 – 2.9 V temperature is 20_C When intake air 1.5 –...
Page 537 13B-56 MPI – Troubleshooting CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart.
Page 538 13B-57 MPI – Troubleshooting Terminal No. Inspection item Normal condition (Check condition) 28 – 33 Ω (At 20 C) 4 – 12 Stepper motor coil (A1) 17 – 12 Stepper motor coil (A2) 5 – 12 Stepper motor coil (B1) 18 –...
Page 539 13B-58 MPI – Troubleshooting INSPECTION PROCEDURE USING AN Analyzer ANALYZER 13100930363 CRANK ANGLE SENSOR Measurement Method 1. Disconnect the distributor (crank angle sensor) connector and connect the special tool (test harness: MB991348) in between. (All terminals should be connected.) Special 2.
Page 540 13B-59 MPI – Troubleshooting Examples of Abnormal Wave Patterns Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Loose timing belt Abnormality in sensor disk Wave pattern characteristics Wave pattern is displaced to the left or right.
Page 541 13B-60 MPI – Troubleshooting Standard Wave Pattern Observation conditions Function Special patterns Pattern height Variable Variable knob Adjust while viewing the wave pattern Pattern selector Display Engine r/min Idle speed Standard wave pattern Point A Solenoid back electromotive force (Approx. 7 10 V) Point B Injector drive time Power voltage...
Page 542 13B-61 MPI – Troubleshooting IDLE SPEED CONTROL (ISC) SERVO (STEPPER Analyzer MOTOR) Measurement Method 1. Disconnect the ISC servo connector, and connect the Special special tool (test harness: MD998463) in between. patterns 2. Connect the analyzer special patterns pickup to the ISC pickup servo-side connector terminal 1 (red clip of special tool), terminal 3 (blue clip), terminal 4 (black clip) and terminal...
Page 543 13B-62 MPI – 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 544 13B-63 MPI – Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Ignition coil primary signal Refer to GROUP 16 – Ignition System. Power transistor control signal Measurement Method Special 1. Disconnect the distributor connector, and connect the patterns special tool (test harness: MB991348) in between. (All pickup terminals should be connected.) 2.
Page 545 13B-64 MPI – Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit...
Page 546: On-Vehicle Service
13B-65 MPI – On-vehicle Service ON-VEHICLE SERVICE 13100100450 THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Start the engine and warm it up until the coolant is heated to 80 C or higher and then stop the engine. 2. Remove the air intake hose from the throttle body. 3.
Page 547: Basic Idle Speed Adjustment
13B-66 MPI – On-vehicle Service BASIC IDLE SPEED ADJUSTMENT 13100180508 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 548: Fuel Pressure Test
13B-67 MPI – On-vehicle Service FUEL PRESSURE TEST 13100190440 1. Release residual pressure from the fuel pipe line to prevent fuel gush out. (Refer to P.13B-69.) Delivery pipe High-pressure 2. Disconnect the high-pressure fuel hose at the delivery fuel hose pipe side.
Page 549 13B-68 MPI – On-vehicle Service 11. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed by a finger. Standard value: 324–343 kPa at kerb idle 12. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times.
Page 550: Fuel Pump Connector Disconnection (How To Reduce The Fuel Pressure)
13B-69 MPI – MPI – On-vehicle Service On-vehicle Service 18. Replace the O-ring at the end of the fuel high pressure hose with a new one. Furthermore, apply engine oil to the new O-ring before replacement. 19. Fit the fuel high pressure hose over the delivery pipe and tighten the bolt to specified torque.
Page 551: Component Location
13B-70 MPI – On-vehicle Service COMPONENT LOCATION 13100210566 Name Symbol Name Symbol A/C relay Idle speed control servo A/C switch Ignition timing adjustment terminal Control relay and fuel pump relay Injectors Detonation sensor Intake air temperature sensor Diagnosis connector Oxygen sensor (front) Distributor (with ignition coil and crank angle Oxygen sensor (rear) sensor)
Page 552: Control Relay And Fuel Pump Relay Continuity Check
13B-71 MPI – On-vehicle Service CONTROL RELAY AND FUEL PUMP RELAY Control relay CONTINUITY CHECK 13100990248 Battery voltage Terminal No. Equipment Not supplied side connector Supplied Fuel pump relay INTAKE AIR TEMPERATURE SENSOR CHECK Equipment side Intake air connector temperature 13100280314 sensor 1.
Page 553: Throttle Position Sensor Check
13B-72 MPI – On-vehicle Service 2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 2.1 – 2.7 kΩ (at 20 C) 0.26 – 0.36 kΩ (at 80 C) 3. If the resistance deviates from the standard value greatly, replace the sensor.
Page 554: Oxygen Sensor Check
13B-73 MPI – On-vehicle Service OXYGEN SENSOR CHECK Equipment side Oxygen sensor 13100510222 connector (front) <Oxygen sensor (front)> 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (2.5 – 5.0 Ω at 20 C) between terminal 3 and terminal 4 on the oxygen sensor connector.
Page 555: Injector Check
13B-74 MPI – On-vehicle Service <Oxygen sensor (rear)> Oxygen sensor 1. Disconnect the oxygen sensor connector and connect the (rear) special tool (test harness set) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (2.5 – 5.0 Ω at 20 C) between terminal 3 and terminal 4 on the oxygen sensor Equipment side connector.
Page 556: Idle Speed Control (Isc) Servo (Stepper Motor) Check
13B-75 MPI – MPI – On-vehicle Service On-vehicle Service 7. Activate the injector and check the atomized spray Main hose Return hose condition of the fuel. The condition can be considered satisfactory unless it is extremely poor. Injector Battery 8. Stop the actuation of the injector, and check for leakage from the injector’s nozzle.
Page 557: Purge Control Solenoid Valve Check
13B-76 MPI – On-vehicle Service Operation Check 1. Remove the throttle body. 2. Remove the idle speed control servo. 3. Connect the special tool (test harness set: MB991709) to the idle speed control servo connector. 4. Connect the positive (+) terminal of a power supply (approx. 6 V) to the terminals No.2 and No.5.
Page 558 13B-77 MPI – Injector INJECTOR 13100710462 REMOVAL AND INSTALLATION Pre-removal Operation Fuel Discharge Prevention (Refer to P.13B-69.) 8.8 Nm 7, 10 9.8 – 12 Nm O-ring 8.8 Nm O-ring Engine oil Removal steps 1. PCV hose 9. Vacuum hose connection 2.
Page 559 13B-78 MPI – Injector REMOVAL SERVICE POINT DELIVERY PIPE/INJECTOR REMOVAL Remove the delivery pipe (with the injectors attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector. INSTALLATION SERVICE POINT AA INJECTOR/FUEL PRESSURE REGULATOR/HIGH-PRESSURE FUEL HOSE INSTALLATION 1.
Page 560: Throttle Body
13B-79 MPI – Throttle Body THROTTLE BODY 13100770439 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Air Cleaner Installation (Refer to GROUP 14 – On-vehicle Service.) Engine Coolant Supplying Air Cleaner Removal (Refer to GROUP 14 – On-vehicle Service.) Accelerator Cable Adjustment (Refer to GROUP 17 –...
Page 561 13B-80 MPI – Throttle Body DISASSEMBLY AND REASSEMBLY 13100970525 Disassembly steps AA 1. Throttle position sensor (TPS) 4. Throttle body 2. Idle speed control servo 5. Speed adjusting screw 3. O-ring 6. O-ring...
Page 562 13B-81 MPI – Throttle Body CLEANING THROTTLE BODY PARTS 1. Clean all throttle body parts. Do not use solvent to clean the following parts: Throttle position sensor Accelerator pedal position sensor Idle speed control servo assembly If these parts are immersed in solvent, their insulation will deteriorate.
Page 563 NOTES...
Page 564: Fuel Supply
13C-1 FUEL SUPPLY CONTENTS 13509000272 GENERAL INFORMATION ....FUEL TANK ....... Fuel Pump Module .
Page 565 13C-2 FUEL SUPPLY – General Information/Special Tool GENERAL INFORMATION 13500010182 1. The fuel tank is located under the floor of the 3. A plastic fuel tank has been adopted to reduce rear seats to provide increased safety and a weight, and improve anti-corrosion effective- wider luggage space.
Page 566: Fuel Tank
13C-3 FUEL SUPPLY – Fuel Tank FUEL TANK 13500190367 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Draining the Fuel Refilling the Fuel. Reduce the Inner Pressure of Fuel Line and Hose Checking for Fuel Leaks. (Refer to GROUP 13A, B – On-vehicle Service.) 49 Nm 5 Nm 49 Nm...
Page 567 13C-4 FUEL SUPPLY – Fuel Tank INSTALLATION SERVICE POINTS Mating range AA FUEL PUMP MODULE INSTALLATION 1. Check to be sure that the fuel tank packing is not damaged or deformed, and then securely install the packing to the fuel tank. Caution If the packing is installed to the fuel pump module, Mating...
Page 568 13C-5 FUEL SUPPLY – Fuel Tank 4. Check to be sure that the fuel tank packing is not damaged or deformed, and then securely install the packing to the Mating range fuel tank. Caution If the packing is installed to the fuel pump module, packing lip will be damaged when installing the fuel pump module to the fuel tank and the fuel leak will result.
Page 569 13C-6 FUEL SUPPLY – Fuel Tank DISASSEMBLY AND REASSEMBLY 13500460024 FUEL PUMP MODULE Disassembly steps 1. Fuel gauge unit 7. Pump harness 2. Packing 8. Lock bracket 3. Reservoir cup 9. Fuel pump 4. Pump support bracket assembly AA 10. Grommet AA 5.
Page 570 14-1 ENGINE COOLING CONTENTS 14109000277 Engine Coolant Replacement ....GENERAL INFORMATION ....Concentration Measurement .
Page 571: General Information
General Information/ 14-2 ENGINE COOLING – Service Specifications/Lubricant/Sealants GENERAL INFORMATION 14100010279 The cooling system is designed to keep every part The water pump is of the centrifugal type and is of the engine at appropriate temperature in whatever driven by the timing belt <GDI> or drive belt <MPI> condition the engine may be operated.
Page 572: Special Tool
14-3 ENGINE COOLING – Special Tool/Troubleshooting SPECIAL TOOL 14100060038 Tool Number Name MB991223 Harness set Measurement of terminal voltage A: MB991219 A: Test harness A: Connector pin contact pressure inspection B: MB991220 B: LED harness B: Power circuit inspection C: MB991221 C: LED harness C: Power circuit inspection...
Page 573 14-4 ENGINE COOLING – Troubleshooting <Vehicles with A/C> Fusible link (7) check Replace Fan control relay check (Refer to P.14-10.) (1) NG Check the harness wire between fan control relay and fusible Measure at the fan control relay connector A-07X. link (7), and repair if necessary.
Page 574 14-5 ENGINE COOLING – Troubleshooting <Vehicles without A/C> Fusible link (7) check Replace Fan control relay check (Refer to P.14-10.) (1) NG Check the harness wire between fan control relay and fusible Measure at the fan control relay connector A-07X. link (7), and repair if necessary.
Page 575 14-6 ENGINE COOLING – Troubleshooting Inspection Procedure 2 Radiator fan and condenser fan do not change speed or Probable cause stop. <Vehicles with A/C> Radiator fan does not change speed or stop. <Vehicles without A/C> The fan controller carries out step-free control of the radiator fan motor and the Malfunction of fan control relay condenser fan motor speeds using signals transmitted from the engine-ECU.
Page 576 14-7 ENGINE COOLING – Troubleshooting <Vehicles without A/C> Fan control relay check (Refer to P.14-10.) Replace Check the harness wire between fan control relay and engine Repair control relay. Check the harness wire between fan control relay and body earth. Check the harness wire between fan control relay and fan controller.
Page 577: On-Vehicle Service
14-8 ENGINE COOLING – On-vehicle Service ON-VEHICLE SERVICE 14100100150 ENGINE COOLANT LEAK CHECKING Cap adapter 1. Confirm that the coolant level is up to the filler neck. Install a radiator cap tester, adapter and cap adapter to the filler Adapter neck, and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections.
Page 578: Engine Coolant Replacement
14-9 ENGINE COOLING – On-vehicle Service ENGINE COOLANT REPLACEMENT 14100120323 <GDI> 1. Drain the engine coolant by removing the drain plug and then the radiator cap. 2. Remove the drain plug from the cylinder block to drain the engine coolant. 3.
Page 579: Fan Controller Check
14-10 ENGINE COOLING – On-vehicle Service FAN CONTROLLER CHECK <GDI> 14100610011 1. Disconnect the condenser fan motor connector. 2. Start the engine and run it at idle. 3. Turn the A/C switch to ON and maintain the coolant temperature at 80 C or less. 4.

Page 580: Radiator Fan Relay Continuity Check
14-11 ENGINE COOLING – On-vehicle Service RADIATOR FAN RELAY CONTINUITY CHECK Radiator fan relay <MPI> 14100620014 Battery voltage Terminal No. When current is not supplied When current supplied...

Page 581 14-12 ENGINE COOLING – Thermostat THERMOSTAT 14100240357 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-9.) Air Cleaner Removal and Installation <GDI> 17 – 20 Nm <MPI> 22 Nm Removal steps BA 1. Radiator lower hose connection 2.
Page 582 14-13 ENGINE COOLING – Thermostat 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. In addition, be careful not to fold Rubber ring over or scratch the rubber ring when inserting.
Page 583: Water Pump
14-14 ENGINE COOLING – Water Pump WATER PUMP 14100270523 REMOVAL AND INSTALLATION <GDI> Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-9.) Timing Belt Removal and Installation (Refer to GROUP 11A.) Idler Pulley Removal and Installation (Refer to GROUP 11A.) 10 –...
Page 584 14-15 ENGINE COOLING – Water Pump <MPI> Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-9.) Timing Belt Removal and Installation (Refer to GROUP 11B.) Bolt specifications 23 Nm Screw diameter length mm 24 Nm (Bead diameter: 3.0 mm) 12 –...
Page 585: Water Hose And Water Pipe
14-16 ENGINE COOLING – Water Hose and Water Pipe WATER HOSE AND WATER PIPE 14100330412 REMOVAL AND INSTALLATION <GDI> Pre-removal and Post-installation Operation Engine Coolant Draining and Suppling (Refer to P.14-9.) Engine Cover Removal and Installation Air Cleaner Removal and Installation 22 –...
Page 586 14-17 ENGINE COOLING – Water Hose and Water Pipe <MPI> Pre-removal and Post-Installation Operation Engine Coolant Draining and Supplying (Refer to P.14-9.) Air Cleaner Removal and Installation 22 – 25 Nm 12 – 15 Nm 12 – 15 Nm Removal steps CA 1.
Page 587: Sealants
14-18 ENGINE COOLING – Water Hose and Water Pipe 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 588 14-19 ENGINE COOLING – Radiator RADIATOR 14100150391 REMOVAL AND INSTALLATION Pre-removal and Post-Installation Operation Engine Coolant Draining and Supplying (Refer to P.14-9.) Air Cleaner Removal and Installation 12 Nm 12 Nm Radiator removal steps Radiator fan motor and condenser fan motor assembly removal steps 1.
Page 589 14-20 ENGINE COOLING – Radiator REMOVAL SERVICE POINT RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. INSTALLATION SERVICE POINT AA RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION 1.
Page 590 15-1 INTAKE AND EXHAUST CONTENTS 15109000298 GENERAL INFORMATION ....INTAKE MANIFOLD ......SERVICE SPECIFICATIONS .
Page 591: General Information
15-2 INTAKE AND EXHAUST – General Information/Service Specifications/Special Tool/On-vehicle Service GENERAL INFORMATION 15100010160 The intake manifold is made of an aluminium alloy, The exhaust pipe is divided into three parts; the and the shape provides an increased intake inertia front pipe, the center pipe, and the main muffler. effect and has a good volumetric efficiency.
Page 592: Intake Manifold
15-3 INTAKE AND EXHAUST – Intake Manifold INTAKE MANIFOLD 15100300557 REMOVAL AND INSTALLATION <GDI> Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Ignition Coil Removal and Installation (Refer to GROUP 14 – On-vehicle Service.) (Refer to GROUP 16.) Engine Cover Removal and Installation Throttle Body Removal and Installation Air Cleaner Removal and Installation (Refer to GROUP 13A.)
Page 593 15-4 INTAKE AND EXHAUST – Intake Manifold <MPI> Pre-removal Operation Post-installation Operation Fuel Discharge Prevention Throttle Body Installation (Refer to GROUP 13B.) (Refer to GROUP 13B – On-vehicle Service.) Air Cleaner Installation Engine Coolant Draining Engine Coolant Supplying (Refer to GROUP 14 – On-vehicle Service.) (Refer to GROUP 14 –...
Page 594 15-5 INTAKE AND EXHAUST – Intake Manifold 9.8 – 12 Nm 9.8 – 12 Nm 9 Nm 13 Nm 12 – 15 Nm 24 Nm 18 Nm 18 Nm 18 Nm 18 Nm 18 Nm 22 Nm 13. Delivery pipe, fuel return pipe, 19.
Page 595 15-6 INTAKE AND EXHAUST – Intake Manifold REMOVAL SERVICE POINT DELIVERY PIPE, FUEL RETURN PIPE, INJECTOR AND PRESSURE REGULATOR ASSEMBLY REMOVAL Remove the delivery pipe (with the fuel return pipe, injectors and pressure regulator attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector.
Page 596: Exhaust Manifold
15-7 INTAKE AND EXHAUST – Exhaust Manifold EXHAUST MANIFOLD 15100330532 REMOVAL AND INSTALLATION <GDI> Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and installation (Refer to P.15-10.) 29 Nm 13 Nm 12 – 15 Nm 29 Nm 35 Nm 19 Nm Removal steps 1.
Page 597 15-8 INTAKE AND EXHAUST – Exhaust Manifold <MPI> Pre-removal Operation Post-installation Operation Front Exhaust Pipe Removal (Refer to P. 15–10.) Front Exhaust Pipe Installation (Refer to P. 15–10.) Drive Belt Tension Adjustment (Refer to GROUP 11B – On–vehicle Service.) 30 Nm 18 Nm 22 Nm 30 Nm...
Page 598 15-9 INTAKE AND EXHAUST – Exhaust Manifold REMOVAL SERVICE POINT POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the exhaust manifold, and tie it with a cord.
Page 599: Exhaust Pipe And Main Muffler
15-10 INTAKE AND EXHAUST – Exhaust Pipe and Main Muffler EXHAUST PIPE AND MAIN MUFFLER 15100540447 REMOVAL AND INSTALLATION 49 Nm 50 Nm 50 Nm 44 Nm 3, 7, 8, 12 49 Nm 13 Nm 80 Nm Main muffler removal steps 7.
Page 600 16-1 ENGINE ELECTRICAL CONTENTS 16109000233 CHARGING SYSTEM ....IGNITION SYSTEM ....GENERAL INFORMATION .
Page 601 16-2 IGNITION COIL <GDI> ....DISTRIBUTOR <MPI> ....CAMSHAFT POSITION DETONATION SENSOR .
Page 602: Charging System
16-3 ENGINE ELECTRICAL – Charging System CHARGING SYSTEM 16100010341 GENERAL INFORMATION The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads. OPERATION Voltage Rotation of the excited field coil generates AC voltage in the stator.
Page 603 16-4 ENGINE ELECTRICAL – Charging System SYSTEM DIAGRAM <GDI> Stator coil Engine-ECU Field coil Voltage Ignition regulator switch Battery Charging warning lamp – <MPI> Stator coil Charging Ignition warning lamp switch Field coil Voltage Battery regulator –...
Page 604 16-5 ENGINE ELECTRICAL – Charging System ALTERNATOR SPECIFICATIONS Items Type Reduction drive with planetary gear Battery voltage sensing Rated output V/A 12/85, 12/100* 12/90 Voltage regulator Electronic built-in type Electronic built-in type NOTE *: Vehicles for cold climate zone SERVICE SPECIFICATIONS 16100030231 Items Standard value...
Page 605: On-Vehicle Service
16-6 ENGINE ELECTRICAL – Charging System ON-VEHICLE SERVICE 16100090314 ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST – Ammeter Alternator Voltmeter Battery – Terminal B This test determines whether the wiring from the output wire. (Connect the (+) lead of the alternator “B” terminal to the battery (+) terminal ammeter to the “B”...
Page 606 16-7 ENGINE ELECTRICAL – Charging System 6. Reconnect the negative battery cable. 11. If the value displayed on the voltmeter is above the limit value, there is probably a malfunction 7. Connect a tachometer or the MUT-II. 8. Leave the hood open. in the alternator output wire, so check the wiring 9.
Page 607: Output Current Test
16-8 ENGINE ELECTRICAL – Charging System OUTPUT CURRENT TEST 16100100314 <GDI> Load Voltmeter Ammeter Charging warning lamp Ignition switch – – Alternator relay Battery Alternator Engine -ECU <MPI> Load Alternator Charging warning lamp Ignition switch Alternator relay Voltmeter Ammeter Battery –...
Page 608 16-9 ENGINE ELECTRICAL – Charging System This test determines whether the alternator output 10. Turn the light switch on to turn on headlamps and then start the engine. current is normal. 11. Immediately after setting the headlamps to high 1. Before the test, always be sure to check the following.
Page 609: Regulated Voltage Test
16-10 ENGINE ELECTRICAL – Charging System REGULATED VOLTAGE TEST 16100110317 <GDI> Load Ignition Charging warning switch lamp MB991519 Alternator Alternator relay Yellow Voltmeter Engine- Ammeter Battery – – <MPI> Load Ignition Charging warning Alternator switch lamp MB991450 Alternator relay Ammeter Voltmeter –...
Page 610 16-11 ENGINE ELECTRICAL – Charging System This test determines whether the voltage regulator NOTE If the voltage is 0 V, the cause is probably an is correctly controlling the alternator output voltage. 1. Always be sure to check the following before open circuit in the wire or fusible link between the test.
Page 611: Waveform Check Using An Analyzer
16-12 ENGINE ELECTRICAL – Charging System WAVEFORM CHECK USING AN ANALYZER Special Analyzer patterns 16100120211 Alternator pickup MEASUREMENT METHOD Connect the analyzer special patterns pick-up to the alternator B terminal. B terminal STANDARD WAVEFORM Observation Conditions FUNCTION SPECIAL PATTERNS PATTERN HEIGHT VARIABLE VARIABLE knob Adjust while viewing the wave-...
Page 612: Alternator Relay Continuity Check
16-13 ENGINE ELECTRICAL – Charging System EXAMPLES OF ABNORMAL WAVEFORMS NOTE 1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the analyzer. 2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating).
Page 613 16-14 ENGINE ELECTRICAL – Charging System ALTERNATOR 16100140439 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation <GDI> Drive Belt Tension Adjustment <after installation only> Under Cover Removal and Installation (Refer to GROUP 11 – On-vehicle Service.) <GDI>...
Page 614 16-15 ENGINE ELECTRICAL – Charging System DISASSEMBLY AND REASSEMBLY <GDI> 16100160213 Disassembly steps 1. Front bracket assembly 8. Stator 2. Alternator pulley 9. Plate BA 3. Rotor AA 10. Regulator assembly 4. Rear bearing 11. Brush 5. Bearing retainer 12. Slinger 6.
Page 615 16-16 ENGINE ELECTRICAL – Charging System DISASSEMBLY SERVICE POINTS FRONT BRACKET ASSEMBLY REMOVAL Insert a flat tip screwdriver, etc., in the clearance between the front bracket assembly and stator core, to pry open and separate the stator and front bracket. Caution The stator coil could be damaged so do not insert the screwdriver too far.
Page 616 16-17 ENGINE ELECTRICAL – Charging System REASSEMBLY SERVICE POINTS AA REGULATOR ASSEMBLY INSTALLATION Wire After installing the regulator assembly, insert a wire into the hole provided on the rear bracket while pressing in the brush to fix the brush. NOTE The brush is fixed when a wire is inserted, making rotor installation easier.
Page 617 16-18 ENGINE ELECTRICAL – Charging System STATOR CHECK 1. Check the continuity between the coil leads, and if there is continuity, replace the stator. 2. Check the continuity between the coil and core, and if there is continuity, replace the stator. RECTIFIER CHECK 1.
Page 618 16-19 ENGINE ELECTRICAL – Charging System BRUSH CHECK 1. Measure the length of the brush protrusion shown in the illustration, and replace the brush if the measured value is below the limit value. Limit: 2 mm or less Protrusion length 2.
Page 619 16-20 ENGINE ELECTRICAL – Charging System DISASSEMBLY AND REASSEMBLY <MPI> 16100160084 Disassembly steps 1. Rear end cover 7. Rotor assembly 2. Brush holder assembly 8. Rear bearing 3. Stator and rectifier assembly 9. Bearing retainer 4. Bearing cover 10. Front bearing AA 5.
Page 620 16-21 ENGINE ELECTRICAL – Charging System REASSEMBLY SERVICE POINT AA ALTERNATOR PULLEY INSTALLATION 1. Clamp the front bracket in a vise with soft jaws. 2. Use the special tool and a box wrench to hold the nut. MD998703 Then attach a double hexagonal wrench to the rotor shaft and tighten the nut.
Page 621 16-22 ENGINE ELECTRICAL – Charging System RECTIFIERS 1. Check the continuity between terminal (B) and coil leads (A), (C) and (E). If there is continuity in both directions, B terminal there is a short-circuit in the diode, so replace the stator and rectifier assembly.
Page 622: Starting System
16-23 ENGINE ELECTRICAL – Starting System STARTING SYSTEM 16200010290 GENERAL INFORMATION If the ignition switch is turned to the ”START” M terminal to conduct. Thus, current flows to engage position, current flows in the pull-in and holding coils the starter motor. provided inside magnetic switch, attracting the When the ignition switch is returned to the “ON”...
Page 623: Service Specifications
16-24 ENGINE ELECTRICAL – Starting System SERVICE SPECIFICATIONS 16200030173 Items Standard value Limit Pinion gap mm 0.5 – 2.0 – Commutator outer diameter mm 29.4 28.4 Commutator runout mm 0.05 Commutator undercut mm Items Standard value Limit Brush length mm –...
Page 624 16-25 ENGINE ELECTRICAL – Starting System 5. If pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket. MAGNETIC SWITCH PULL-IN TEST <GDI> 1. Disconnect field coil wire from M-terminal of magnetic switch.
Page 625 16-26 ENGINE ELECTRICAL – Starting System FREE RUNNING TEST Carbon-pile rheostat <GDI> 1. Place starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor Ammeter as follows: 2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series with battery positive post and starter Starter motor terminal.
Page 626 16-27 ENGINE ELECTRICAL – Starting System DISASSEMBLY AND REASSEMBLY <GDI> 16200120269 Disassembly steps 1. Screw 12. Packing A 2. Magnetic switch 13. Packing B 3. Screw 14. Plate 4. Through bolt 15. Planetary gear 5. Rear bracket 16. Lever 6. Brush holder AA 17.
Page 627 16-28 ENGINE ELECTRICAL – Starting System DISASSEMBLY SERVICE POINTS S terminal Magnetic MAGNETIC SWITCH REMOVAL switch M terminal Disconnect the field coil wire from terminal M of the magnetic switch. Field coil wire ARMATURE AND BALL REMOVAL When removing the armature, do not lose the ball placed at the end as a bearing.
Page 628 16-29 ENGINE ELECTRICAL – Starting System REASSEMBLY SERVICE POINTS AA STOP RING/SNAP RING INSTALLATION Using an appropriate tool, pull the stop ring over the snap ring. Stop ring Overrunning clutch Stop ring Snap ring INSPECTION 16200130255 COMMUTATOR 1. Place the armature in a pair of “V” blocks and check the runout with a dial indicator.
Page 629 16-30 ENGINE ELECTRICAL – Starting System BRUSH 1. Check the brush for roughness of the surface that contacts the commutator and check the brush length. Limit: Wear limit line 2. In case the contacting surface has been corrected or the brush has been replaced, correct the contacting surface Wear limit line by winding sandpaper around the commutator.
Page 630 16-31 ENGINE ELECTRICAL – Starting System DISASSEMBLY AND REASSEMBLY <MPI> 16200120115 Disassembly steps 1. Rear cover 11. Magnetic switch 2. Rubber 12. Spring 3. Cover 13. Pin 4. Brush spring 14. Plunger 5. Plate 15. Lever 6. Brush AA 16. Snap ring 7.
Page 631 16-32 ENGINE ELECTRICAL – Starting System DISASSEMBLY SERVICE POINTS SNAP RING/STOP RING REMOVAL Socket 1. Press stop ring off snap ring with a suitable socket. Pinion gear Stop ring Overrunning clutch 2. Remove snap ring with snap ring pliers and then remove stop ring and overrunning clutch.
Page 632 16-33 ENGINE ELECTRICAL – Starting System INSPECTION 16200130118 OVERRUNNING CLUTCH 1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If clutch does not function Free properly, replace overrunning clutch assembly. 2.
Page 633: Ignition System
16-34 ENGINE ELECTRICAL – Ignition System IGNITION SYSTEM 16300010118 GENERAL INFORMATION <GDI> This system is equipped with four ignition coils with The engine-ECU determines which ignition coil built-in power transistors for each of the cylinders. should be controlled by means of the signals from Interruption of the primary current flowing in the the camshaft position sensor and the crank angle primary side of an ignition coil generates a high...
Page 634 16-35 ENGINE ELECTRICAL – Ignition System <MPI> Interruption of the primary current flowing in the timing. primary side of the ignition coil generates high The engine-ECU detects the crankshaft position voltage in the secondary side of the ignition coil. by the crank angle sensor incorporated in the The high voltage thus generated is directed by the distributor to provide ignition at the most appropriate distributor to the applicable spark plug.
Page 635: Spark Plug
16-36 ENGINE ELECTRICAL – Ignition System DISTRIBUTOR SPECIFICATIONS <MPI> Items Specifications Type Contact pointless with built-in ignition coil Advance mechanism Electronic Firing order 1 – 3 – 4 – 2 IGNITION COIL SPECIFICATIONS Items Type Molded 4-coil Molded single-coil with a built-in distributor SPARK PLUG SPECIFICATIONS Items...
Page 636: Special Tools
16-37 ENGINE ELECTRICAL – Ignition System SPECIAL TOOLS 16300060070 Tool Number Name MB991348 Test harness set Inspection of ignition primary voltage (power transistor connection) MD998770 Oxygen sensor Detonation sensor removal and installation wrench ON-VEHICLE SERVICE 16300120149 IGNITION COIL CHECK <MPI> 1.
Page 637: Power Transistor Continuity Check
16-38 ENGINE ELECTRICAL – Ignition System POWER TRANSISTOR CONTINUITY CHECK <MPI> 16300130104 – 1. An analogue-type circuit tester should be used. 1.5V 2. Connect the negative (–) prove of the circuit tester to terminal 2. – Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning and power transistor from breakage.

Page 638: Resistive Cord Check
16-39 ENGINE ELECTRICAL – Ignition System 4. Connect the spark plug outer electrode to earth, and then crank the engine. 5. Check if the spark plug sparks. 6. If the spark plug does not spark, replace the ignition coil with a new one and recheck. 7.

Page 639: Crank Angle Sensor Check
16-40 ENGINE ELECTRICAL – Ignition System 4. Measure the spark plug insulation resistance. Replace the spark plug if the measured value is lower than the limit value. Limit: 1 MΩ 5. Clean the spark plug holes. 6. Install the spark plugs. 7.

Page 640: Waveform Check Using An Analyzer
16-41 ENGINE ELECTRICAL – Ignition System WAVEFORM CHECK USING AN ANALYZER <MPI> 16300170199 Ignition Secondary Voltage Check MEASUREMENT METHOD 1. Clamp the spark plug cable of the No. 1 cylinder with the secondary pickup and check the waveform. 2. Connect the secondary pickup to the other cylinders in turn and check the waveforms for each cylinder.

Page 641 16-42 ENGINE ELECTRICAL – Ignition System WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal waveform examples, 1, 2, 3 and 4). Spark line Plug gap Condition of Compression Concentration of Ignition timing...
Page 642 16-43 ENGINE ELECTRICAL – Ignition System EXAMPLES OF ABNORMAL WAVEFORMS Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. 01P0215 Example 2 Spark line is low and long, and is Spark plug gap is too small.
Page 643 16-44 ENGINE ELECTRICAL – Ignition System Ignition Primary Voltage Waveform Check MEASUREMENT METHOD 1. Disconnect the distributor connector and connect the special tool (test harness: MB991348) in between. (All of the terminals should be connected.) 2. Connect the analyzer primary pickup to the distributor Analyzer connector terminal 2.
Page 644 16-45 ENGINE ELECTRICAL – Ignition System STANDARD WAVEFORM Observation conditions FUNCTION SECONDARY PATTERN HEIGHT HIGH (or LOW) PATTERN SELECTOR RASTER Engine Speed Curb idle speed Zener voltage (Point C) Spark line (Approx. 40 10V) (Point A) Vibration damping section (Point B) Dwell section Ignition...
Page 645 16-46 ENGINE ELECTRICAL – Ignition System WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line (refer to abnormal waveform examples 1, 2, 3 and 4) show the following trends. Spark line Plug gap Condition of Compression Concentration of Ignition timing...
Page 646 16-47 ENGINE ELECTRICAL – Ignition System EXAMPLES OF ABNORMAL WAVEFORMS Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. Example 2 Spark line is low and long, and is Spark plug gap is too small.
Page 647 16-48 ENGINE ELECTRICAL – Ignition System IGNITION COIL <GDI> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation 10 Nm 25 Nm Removal steps 1. Ignition coil assembly 2. Spark plug CAMSHAFT POSITION SENSOR <GDI> 9 Nm Camshaft position sensor...
Page 648 16-49 ENGINE ELECTRICAL – Ignition System CRANK ANGLE SENSOR <GDI> 16300250121 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt Front Lower Cover Removal and Installation (Refer to GROUP 11A – Timing Belt.) 10 – 12 Nm Crank angle sensor 9 Nm...
Page 649 16-50 ENGINE ELECTRICAL – Ignition System DISTRIBUTOR <MPI> 16300200256 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Air Cleaner Removal Air Cleaner Installation Ignition Timing Check and Adjustment (Refer to GROUP 11B – On-vehicle Service.) Removal steps 1. Spark plug cable connection 2.
Page 650 16-51 ENGINE ELECTRICAL – Ignition System DISASSEMBLY AND REASSEMBLY 16300220078 1. Distributor cap 2. Rotor 3. Cover 4. O-ring 5. Distributor housing INSPECTION 16300230040 Check the following points; repair or replace if a problem is found. CAP, ROTOR 1. There must be no cracking in the cap. 2.
Page 651 16-52 ENGINE ELECTRICAL – Ignition System DETONATION SENSOR 16300280229 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation <GDI> Air Cleaner Removal and Installation <GDI> <GDI> 9 Nm 26 – 33 Nm 22 Nm <MPI> 26 – 33 Nm 10 –...
Page 652: Continued On Next Page
17-1 ENGINE AND EMISSION CONTROL CONTENTS 17109000063 ENGINE CONTROL SYSTEM ..SPECIAL TOOL ......VACUUM HOSE .
Page 653 17-2 EVAPORATIVE EMISSION CONTROL Component Location ..... SYSTEM ....... Exhaust Gas Recirculation (EGR) Control System Check <GDI>...
Page 654: Engine Control System
17-3 ENGINE AND EMISSION CONTROL – Engine Control System ENGINE CONTROL SYSTEM 17100010027 GENERAL INFORMATION A cable-type accelerator mechanism and a suspended-type pedal have been adopted. SERVICE SPECIFICATIONS 17100030160 Items Standard value Accelerator cable play mm 1 – 2 Engine idle speed r/min 50 –...
Page 655: Accelerator Cable And Pedal
17-4 ENGINE AND EMISSION CONTROL – Engine Control System ACCELERATOR CABLE AND PEDAL 17100120324 REMOVAL AND INSTALLATION Post-installation Operation Accelerator Cable Adjustment (Refer to P.17-3.) 5 Nm <GDI> 5 Nm <MPI> 8 Nm Removal steps 1. Adjusting bolts 5. Split pin 2.
Page 656: Accelerator Pedal Position Sensor
17-5 ENGINE AND EMISSION CONTROL – Engine Control System ACCELERATOR PEDAL POSITION SENSOR <GDI> 17100120324 REMOVAL AND INSTALLATION Post-installation Operation Accelerator Cable Adjustment (Refer to P.17-3.) 5 Nm 24 Nm 5 Nm 5 Nm Removal steps 1. Adjusting bolt 5. Accelerator pedal position sensor 2.
Page 657: Gdi
17-6 ENGINE AND EMISSION CONTROL – Emission Control System EMISSION CONTROL SYSTEM 17300010122 GENERAL INFORMATION The emission control system consists of the following subsystems: Crankcase emission control system Evaporative emission control system Exhaust emission control system <GDI> Items Name Specification Crankcase emission Positive crankcase ventilation (PCV) valve Variable flow type...
Page 658: Emission Control Device Reference Table
17-7 ENGINE AND EMISSION CONTROL – Emission Control System EMISSION CONTROL DEVICE REFERENCE TABLE Related parts Crankcase Evaporative Air/fuel Catalytic Exhaust Reference emission emission ratio converter page control control control recircula- system system system tion system PCV valve 17-12 Purge control solenoid valve 17-17 GDI system GROUP 13A...
Page 659: Vacuum Hose
17-8 ENGINE AND EMISSION CONTROL – Emission Control System VACUUM HOSE 17300090140 VACUUM HOSE PIPING DIAGRAM <GDI> From fuel pump (low pressure) To fuel tank Throttle control servo Air cleaner High pressure fuel regulator assembly EGR valve (Stepper motor) Positive crankcase Canister ventilation...
Page 660: Vacuum Circuit Diagram
17-9 ENGINE AND EMISSION CONTROL – Emission Control System VACUUM CIRCUIT DIAGRAM <GDI> Intake manifold Throttle body combustion From air chamber cleaner Canister Purge control solenoid valve (ON: OPEN) Vacuum hose colour B: Black R: Red <MPI> Intake manifold Throttle body combustion From air chamber...
Page 661: Vacuum Hose Check
17-10 ENGINE AND EMISSION CONTROL – Emission Control System VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected. 2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage.
Page 662: Component Location
17-11 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> Ventilation hose Breather hose PCV valve COMPONENT LOCATION PCV valve <GDI> PCV valve <MPI>...
Page 663: Positive Crankcase Ventilation System
17-12 ENGINE AND EMISSION CONTROL – Emission Control System POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 17300110136 1. Remove the ventilation hose from the PCV valve. 2. Remove the PCV valve from the rocker cover. 3. Reinstall the PCV valve at the ventilation hose. 4.
Page 664: Evaporative Emission Control System
17-13 ENGINE AND EMISSION CONTROL – Emission Control System EVAPORATIVE EMISSION CONTROL SYSTEM 17300510189 GENERAL INFORMATION The evaporative emission control system prevents sent to the combustion chamber. fuel vapours generated in the fuel tank from escaping When the engine coolant temperature is low or when into the atmosphere.
Page 665: Component Location
17-14 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> Engine-ECU Throttle body Vacuum sensor From fuel tank Engine coolant temperature sensor Canister Purge control Intake air solenoid valve temperature sensor (ON: Open) Con- trol relay COMPONENT LOCATION Purge control solenoid valve <GDI> Purge control solenoid valve <MPI>...
Page 666: Purge Control System Check
17-15 ENGINE AND EMISSION CONTROL – Emission Control System PURGE CONTROL SYSTEM CHECK <GDI> 1. Disconnect the vacuum hose (red stripe) from the intake manifold and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3.

Page 667: Purge Control System Check
17-16 ENGINE AND EMISSION CONTROL – Emission Control System PURGE CONTROL SYSTEM CHECK <MPI> Red stripe 17300140166 1. Disconnect the vacuum hose (red stripe) from the throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3.

Page 668: Purge Port Vacuum Check
17-17 ENGINE AND EMISSION CONTROL – Emission Control System PURGE PORT VACUUM CHECK <MPI> 17300150138 Purge port 1. Disconnect the vacuum hose (red stripe) from the throttle vacuum nipple body purge vacuum nipple and connect a hand vacuum pump to the nipple. 2.

Page 669 17-18 ENGINE AND EMISSION CONTROL – Emission Control System EXHAUST GAS RECIRCULATION (EGR) SYSTEM 17300520137 GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers port of the cylinder head to the combustion chamber the nitrogen oxide (NOx) emission level. When the through the intake manifold to decrease the air/fuel air/fuel mixture combustion temperature is high, a mixture combustion temperature, resulting in...
Page 670: Exhaust Gas Recirculation (Egr)
17-19 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> control solenoid valve (ON: Close) Engine-ECU EGR valve Engine coolant temperature sensor Control relay Battery COMPONENT LOCATION EGR control solenoid valve <GDI> EGR valve <MPI> Intake manifold EGR control solenoid valve <MPI> Purge control solenoid valve control...
Page 671: Exhaust Gas Recirculation (Egr) Control System Check
17-20 ENGINE AND EMISSION CONTROL – Emission Control System EXHAUST GAS RECIRCULATION (EGR) Green stripe CONTROL SYSTEM CHECK <MPI> 17300260152 1. Disconnect the vacuum hose (green stripe) from the throttle body, and connect a hand vacuum pump to the vacuum hose.

Page 672: Egr Valve Check
17-21 ENGINE AND EMISSION CONTROL – Emission Control System EGR VALVE CHECK <GDI> Intake Checking the Operation Sound manifold 1. Check that the operation sound of the stepper motor can be heard from the EGR valve when the ignition switch is turned to ON (without starting the engine).

Page 673: Egr Valve Check
17-22 ENGINE AND EMISSION CONTROL – Emission Control System EGR VALVE CHECK <MPI> 17300280110 1. Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly. 2. Connect a hand vacuum pump to the EGR valve. 3.

Page 674: Catalytic Converter
17-23 ENGINE AND EMISSION CONTROL – Emission Control System CATALYTIC CONVERTER 17300530055 GENERAL INFORMATION The three-way catalytic converter, together with the When the mixture is controlled at stoichiometric closed loop air-fuel ratio control based on the oxygen air-fuel ratio, the three-way catalytic converter sensor signal, oxidizes carbon monoxides (CO) and provides the highest purification against the three hydrocarbons (HC) and reduces nitrogen oxides...
Page 675 17-24 ENGINE AND EMISSION CONTROL – Emission Control System CANISTER 17300420024 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner, Air Intake Hose Removal and Installation 25 Nm Removal steps 1. Relay box 3. Purge hose connection 2. Vapour hose connection 4.
Page 676 21-1 CLUTCH CONTENTS 21109000039 GENERAL INFORMATION ....CLUTCH PEDAL ......SERVICE SPECIFICATIONS .
Page 677: General Information
21-2 CLUTCH – General Information/Service Specifications/Lubricants/On-vehicle Service GENERAL INFORMATION 21100010031 The clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control. SERVICE SPECIFICATIONS 21100030198 Items Standard value Clutch pedal height mm 163.5 – 166.5 <L.H. drive vehicles> 162.5 –...
Page 678: Bleeding
21-3 CLUTCH – On-vehicle Service 2. If the height of the clutch pedal is outside the standard Setting nut value, loosen the lock nut and adjust the pedal height Adjusting bolt to the standard value using the adjusting bolt or push rod.
Page 679: Clutch Pedal
21-4 CLUTCH – Clutch Pedal CLUTCH PEDAL 21100160279 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Relay Box Removal and Installation <L.H.Drive Vehicles> Canister Removal and Installation <L.H.Drive Vehicles> Clutch Pedal Adjustment (Refer to P.21-2.) 25 Nm 13 Nm 23 Nm 13 Nm Removal steps 1.
Page 680: Clutch Control
21-5 CLUTCH – Clutch Control CLUTCH CONTROL 21100190254 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Clutch Pedal Adjustment (Refer to P.21-2.) Clutch Fluid Supplying Clutch Line Bleeding (Refer to P.21-3.) Clutch Pedal Adjustment (Refer to P.21-2.) <1300–L.H. drive vehicles> 30 Nm 13 Nm 15 Nm 48 Nm...
Page 681: Clutch Master Cylinder
21-6 CLUTCH – Clutch Control DISASSEMBLY AND REASSEMBLY 21100210219 CLUTCH MASTER CYLINDER Caution Do not disassemble piston assembly. The piston assembly can not be reassembled. 12 Nm Clutch fluid: Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease Disassembly steps 1.
Page 682 22-1 MANUAL TRANSMISSION CONTENTS 22109000371 Reverse Mis-operation Prevention Function GENERAL INFORMATION ....Check ........SERVICE SPECIFICATION .
Page 683: General Information
22-2 MANUAL TRANSMISSION – General Information/Lubricants GENERAL INFORMATION 22100010212 The F5MR1 and F5M42 manual transmissions are designed. Items Specifications Model F5MR1 F5M42 Type Manual, 5-speed, Front wheel drive Gear ratio 3.727 3.583 2.074 1.947 1.321 1.266 0.966 0.970 0.794 0.767 Reverse 3.545 3.363...
Page 684: Special Tools
22-3 MANUAL TRANSMISSION – Sealant/Special Tools SEALANT 22100050016 Item Specified sealant Remark Spring pin MITSUBISHI GENUINE PART Semi-drying sealant MD970389 or equivalent SPECIAL TOOLS 22100060217 Tool Number Name MB990635 or Steering linkage Tie rod end and lower arm disconnection MB991113 puller GENERAL Engine lifter...
Page 685: Transmission Oil Level Check
22-4 MANUAL TRANSMISSION – On-vehicle Service ON-VEHICLE SERVICE 22100090285 TRANSMISSION OIL LEVEL CHECK Filler plug hole Inspect each component for evidence of leakage, and check Transmission oil the oil level by remaining the filler plug. If the oil is contaminated, it is necessary to replace it with new oil.
Page 686: Oil Temperature Sensor Check
22-5 MANUAL TRANSMISSION – On-vehicle Service OIL TEMPERATURE SENSOR CHECK 22100670021 1. Remove the oil drain plug, and then drain the transmission oil. 2. Remove the oil temperature sensor. Oil temperature sensor 3. Measure the resistance between terminals 1 and 2 of the oil temperature sensor connector.
Page 687: Reverse Mis-Operation Prevention Function Check
22-6 MANUAL TRANSMISSION – On-vehicle Service REVERSE MIS-OPERATION PREVENTION FUNCTION CHECK 22100570017 1. Carry out the following checks. Checking procedure Check conditions Check contents (normal condition) Locking knob: Shift lever: Shifts to 1st Cannot be pulled up Move the lever in the select direction (reverse direc direction (reverse direc- Locking knob:...
Page 688: Transmission Control
22-7 MANUAL TRANSMISSION – Transmission Control <F5MR1> TRANSMISSION CONTROL <F5MR1> 22100380283 REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift lever assembly and shift rod assembly. Pre-removal Operation Post-installation Operation Floor Console Box Removal (Refer to GROUP Floor Console Box Installation (Refer to GROUP...

Page 689: Shift Lever Assembly
22-8 MANUAL TRANSMISSION – Transmission Control <F5MR1> SHIFT LEVER ASSEMBLY 22100400125 DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Shift knob 9. Steel rod 2. Spring 10. Shift lever assembly 3. Locking knob 11. Shift bushing 4. Stopper rubber A 12. O-ring 5.
Page 690: Transmission Control
22-9 MANUAL TRANSMISSION – Transmission Control <F5M42> TRANSMISSION CONTROL <F5M42> 22100380290 REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift lever assembly, shift cable and select cable assembly. Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation Floor Console Box Removal and Installation (Refer...

Page 691 22-10 MANUAL TRANSMISSION – Transmission Control <F5M42> INSTALLATION SERVICE POINTS AA SHIFT CABLE AND SELECT CABLE ASSEMBLY/ SHIFT CABLE CONNECTION/SELECT CABLE Shift lever CONNECTION 1. Set the transmission side shift lever and the passenger compartment side shift lever to the neutral position. Neutral position 2.
Page 692: Shift Lever Assembly
22-11 MANUAL TRANSMISSION – Transmission Control <F5M42> SHIFT LEVER ASSEMBLY 22100400132 DISASSEMBLY AND REASSEMBLY 13 Nm 13 Nm Disassembly steps 1. Lever assembly 2. Cable bracket 3. Bracket assembly...
Page 693: Transmission Assembly
22-12 MANUAL TRANSMISSION – Transmission Assembly <F5MR1> TRANSMISSION ASSEMBLY <F5MR1> 22100270450 REMOVAL AND INSTALLATION Caution In order to prevent the insulator from being damaged, mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. Pre-removal Operation Post-installation Operation Transmission Oil Draining (Refer to P.22-4.)

Page 694 22-13 MANUAL TRANSMISSION – Transmission Assembly <F5MR1> 50 Nm 25 Nm 48 Nm 25 Nm 22 – 25 Nm 10 – 12 Nm 88 Nm 59 Nm* 59 Nm* 69 Nm 69 Nm Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent Lifting up of the vehicle 8.
Page 695 22-14 MANUAL TRANSMISSION – Transmission Assembly <F5MR1> CLUTCH RELEASE CYLINDER REMOVAL Remove the clutch release cylinder without disconnecting the oil line connection, and fix it to the vehicle chassis. TRANSMISSION MOUNT BRACKET REMOVAL Jack up the transmission assembly gently with a garage jack, and then remove the transmission mount bracket.
Page 696 22-15 MANUAL TRANSMISSION – Transmission Assembly <F5MR1> NOTE Because there are an odd number of splines on the drive shaft, the pin hole will be off-line by half the width of the hole if the drive shaft is turned 180_. 2.
Page 697: Transmission Assembly
22-16 MANUAL TRANSMISSION – Transmission Assembly <F5M42> TRANSMISSION ASSEMBLY <F5M42> 22100270467 REMOVAL AND INSTALLATION Caution In order to prevent the insulator from being damaged, mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. Pre-removal Operation Post-installation Operation Transmission Oil Draining (Refer to P.22-4.)

Page 698 22-17 48 Nm 48 Nm 52 Nm* 22 – 25 Nm 10 Nm <Flange bolts> 9 Nm <Washer assembled bolts> 25 Nm 88 Nm 52 Nm* 69 Nm 69 Nm Lifting up of the vehicle AA 9. Brake hose clamp 15.
Page 699 22-18 MANUAL TRANSMISSION – Transmission Assembly <F5M42> REMOVAL SERVICE POINTS STARTER MOTOR REMOVAL Remove the starter motor with the starter motor harness still connected and secure it inside the engine compartment. CLUTCH RELEASE CYLINDER REMOVAL Remove the clutch release cylinder without disconnecting the oil line connection, and fix it to the vehicle chassis.
Page 700 22-19 MANUAL TRANSMISSION – Transmission Assembly <F5M42> 2. Suspend the removed drive shaft with a wire so that there are no sharp bends in any of the joints. 3. Use a shop towel to cover the transmission case not to let foreign material get into it.
Page 701 NOTES...
Page 702 26-1 FRONT AXLE CONTENTS 26109000034 GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Hub Axial Play Check .
Page 703: General Information
26-2 FRONT AXLE – General Information/Service Specifications/Sealant GENERAL INFORMATION 26100010203 The wheel bearing and front hub are press-fitted R.J. – T.J.-type constant velocity joints to improve in the axle housing portion of the knuckle to support power transmission efficiency and to reduce the drive shaft.
Page 704: Special Tools
26-3 FRONT AXLE – Special Tools SPECIAL TOOLS 26100060222 Tool Number Name MB990767 End yoke holder Fixing of the hub MB991113 or Steering linkage Removal of the lower arm ball joint and MB990635 puller knuckle Removal of the knuckle and tie rod end ball joint MB990241 Axle shaft puller...
Page 705 26-4 FRONT AXLE – Special Tools Tool Number Name MB991045 Bushing remover Press-fitting of wheel bearing and installer Use together with MB990883 A: MB991050 MB991387 Bushing remover Press-fitting of the outer oil seal and installer MB990685 Torque wrench Measurement of the wheel bearing starting torque MB990326 Preload socket...
Page 706: On-Vehicle Service
26-5 FRONT AXLE – Special Tools/On-vehicle Service MB990925 Tool box Brass bar Bar (snap-in type) Installer adapter Type Tool number O.D. mm Type Tool number O.D. mm MB990926 MB990933 63.5 MB990927 MB990934 67.5 MB990928 49.5 MB990935 71.5 MB990929 MB990936 75.5 MB990930 MB990937 MB990931...
Page 707: Axle Hub
26-6 FRONT AXLE – Axle Hub AXLE HUB 26100170192 REMOVAL AND INSTALLATION Caution For vehicles with ABS, do not strike the speed sensor against other parts when removing or installing it. Otherwise the speed sensor will be damaged. For vehicles with ABS, do not strike the ABS rotors installed to the B.J. outer race of drive shaft against other parts when removing or installing the drive shaft.
Page 708 26-7 FRONT AXLE – Axle Hub DRIVE SHAFT NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut. Otherwise wheel bearing will be damaged. MB990767 LOWER ARM BALL JOINT/TIE ROD END DISCONNECTION MB991113 or MB990635...
Page 709 26-8 FRONT AXLE – Axle Hub DISASSEMBLY AND REASSEMBLY 26100190129 Disassembly steps Reassembly steps 1. Inner oil seal 7. Knuckle 2. Hub AA 5. Wheel bearing 3. Dust cover 4. Snap ring 4. Snap ring BA 6. Outer oil seal 5.
Page 710 26-9 FRONT AXLE – Axle Hub 2. Remove the wheel bearing inner race (outside) from the MB990810 front hub by using the special tool. Caution When removing the inner race (outside) from the hub, be careful not to let the hub drop. Inner race (outside) 3.
Page 711 26-10 FRONT AXLE – Axle Hub CA WHEEL BEARING STARTING TORQUE CHECK 1. Use the special tool to mount the hub onto the knuckle. MB990998 2. Tighten the nut of the special tool to 216–255 Nm. 3. Rotate the hub in order to seat the bearing. MB991017 Tighten the nut with the bolt secured...
Page 712: Drive Shaft
26-11 FRONT AXLE – Drive Shaft DRIVE SHAFT 26100350275 REMOVAL AND INSTALLATION Caution For vehicles with ABS, do not strike the ABS rotors installed to the B.J. outer race of drive shaft against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be damaged. Pre-removal and Post-installation Operation Brake hose Clamp, Speed Sensor Cable Connection <Vehicles with ABS>, Stabilizer Link Connection...
Page 713 26-12 FRONT AXLE – Drive Shaft REMOVAL SERVICE POINTS DRIVE SHAFT NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut. Otherwise wheel bearing will be damaged. MB990767 LOWER ARM BALL JOINT/TIE ROD END DISCONNECTION MB991113 or MB990635...
Page 714 26-13 FRONT AXLE – Drive Shaft Caution Do not apply the vehicle weight to the wheel bearing while MB991000 loosening the drive shaft nut. Otherwise wheel bearing (MB990998) will be damaged. If, however, the vehicle weight must be applied to the bearing (because of moving the vehicle), MB990998 temporarily secure the wheel bearing by using the special tool.
Page 715 NOTES...
Page 716 27-1 REAR AXLE CONTENTS 27109000086 GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Wheel Bearing Axial Play Check .
Page 717: General Information
General Information/Service Specifications/ 27-2 REAR AXLE – Special Tools GENERAL INFORMATION 27100010194 The wheel bearing adopted is a unit ball bearing it is so constructed that appropriate bearing preload (double-row angular contact ball bearing), which is available just by tightening the lock nut to the uses the inside surface of the rear hub as the bearing specified torque.
Page 718: On-Vehicle Service
27-3 REAR AXLE – On-vehicle Service ON-VEHICLE SERVICE 27100090082 WHEEL BEARING AXIAL PLAY CHECK 1. Remove the brake drum. 2. Check the bearing’s axial play. Place a dial gauge against the hub surface; then move the hub in the axial direction and check whether or not there is axial play.
Page 719: Rear Axle Hub
27-4 REAR AXLE – On-vehicle Service/Rear Axle Hub 3. Use the wheel nuts to securely install the new hub bolts, while being careful of the hub bolts and hub. MB990767 REAR AXLE HUB 27100200256 REMOVAL AND INSTALLATION Caution The rear hub unit bearing should not be dismantled. When removing the rear hub assembly, the wheel bearing inner race may be left at the spindle side.
Page 720 27-5 REAR AXLE – Rear Axle Hub INSTALLATION SERVICE POINT Speed sensor AA REAR HUB ASSEMBLY INSTALLATION <VEHICLES WITH ABS> Caution Be careful that the speed sensor and the ABS rotor teeth do not become damaged by striking them against the metal parts.
Page 721 NOTES...
Page 722 31-1 WHEEL AND TYRE CONTENTS 31109000038 GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Tyre Inflation Pressure Check .
Page 723 31-2 WHEEL AND TYRE – General Information/Service Specifications GENERAL INFORMATION 31100010030 Both steel type and aluminium type wheels have A compact spare tyre has been adopted as the been adopted. The type of wheel used depends spare tyre in some models. on the vehicle model.
Page 724: On-Vehicle Service
31-3 WHEEL AND TYRE – Troubleshooting TROUBLESHOOTING 31100070038 Symptom Probable cause Remedy Reference page Rapid wear at Under-inflation Adjust the tyre 31-5. shoulders or lack of rotation pressure. Rapid wear at Over-inflation or centre lack of rotation Cracked treads Under-inflation Adjust the tyre 31-5.
Page 725: Tyre Inflation Pressure Check
31-4 WHEEL AND TYRE – On-vehicle Service/Wheel and Tyre ON-VEHICLE SERVICE 31100090034 TYRE INFLATION PRESSURE CHECK Check the inflation pressure of the tyres. If it is not within the standard value, make the necessary adjustment. TYRE WEAR CHECK 31100100034 Measure the tread depth of tyres. Limit: 1.6 mm If the remaining tread depth is less than the limit, replace the tyre.
Page 726 32-1 POWER PLANT MOUNT CONTENTS 32109000219 GENERAL INFORMATION ....TRANSMISSION MOUNTING ....SERVICE SPECIFICATION .
Page 727: General Information
32-2 POWER PLANT MOUNT – General Information/Service Specification/Special Tools GENERAL INFORMATION[ 32100010198 The engine-transmission mount is of an inertial axis the front upper part of the engine at the front and supporting type whose excellent features have the rear upper part of the transmission at the rear. already been proven in many Mitsubishi vehicles.
Page 728: Engine Mounting
32-3 POWER PLANT MOUNT – Engine Mounting ENGINE MOUNTING 32100010379 REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. Pre-removal Operation Jack Up the Engine and Transmission Assembly Until There is no Weight on the Engine Mount Bracket Insulator.
Page 729: Transmission Mounting
32-4 POWER PLANT MOUNT – Transmission Mounting TRANSMISSION MOUNTING 32100140217 REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation 88 Nm* 49 Nm...
Page 730: Engine Roll Stopper, Centermember
32-5 POWER PLANT MOUNT – Engine Roll Stopper, Centermember ENGINE ROLL STOPPER, CENTERMEMBER 32100200199 REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. 39 Nm 39 Nm 54 Nm*...
Page 731: Crossmember
32-6 POWER PLANT MOUNT – Crossmember CROSSMEMBER 32100320239 REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and Installation Centermember Assembly Removal and Installation (Refer to GROUP 15.)
Page 732 32-7 POWER PLANT MOUNT – Crossmember REMOVAL SERVICE POINT Steering gear and linkage CROSSMEMBER ASSEMBLY REMOVAL 1. Move the crossmember while supporting the steering gear and linkage in the direction shown by the arrow. Crossmember 2. Remove the crossmember while supporting it with a transmission jack.
Page 733 NOTES...
Page 734 33A-1 FRONT SUSPENSION CONTENTS 33109000070 GENERAL INFORMATION ....STRUT ASSEMBLY ......SERVICE SPECIFICATIONS .
Page 735: General Information
33A-2 FRONT SUSPENSION – General Information GENERAL INFORMATION 33100010072 The front suspension is a Mcpherson strut with coil spring. The shock absorber is hydraulic double-acting type. COIL SPRING Items 1300 1800 Wire dia. O.D. free length mm 12 138 354 13 160 383 CONSTRUCTION DIAGRAM Strut insulator...
Page 736: Service Specifications
33A-3 FRONT SUSPENSION – Service Specifications SERVICE SPECIFICATIONS 33100030078 Items Standard value Toe-in At the centre of tyre tread mm Toe-angle (per wheel) 0 00’ 06’ Toe-out angle on turns 21 39’ (inner wheel when outer wheel at 20 ) Steering angle Inner wheel 41 30’...
Page 737: Special Tools
33A-4 FRONT SUSPENSION – Special Tools SPECIAL TOOLS 33100060060 Tools Number Name MB991004 Wheel alignment Measurement of the wheel alignment gauge attachment MB991680 Wrench set Disassembly/assembly of the strut assembly A: MB991681 A: Wrench B: MB991682 B: Socket A: MB991237 A: Spring compres- Compression of the front coil spring sor body...
Page 738: On-Vehicle Service
33A-5 FRONT SUSPENSION – On-vehicle Service ON-VEHICLE SERVICE 33100090212 FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT Measure the wheel alignment with the vehicle parked on a level surface. The front suspension, steering system, and wheels should be serviced to normal condition prior to measurement of wheel alignment.
Page 739: Ball Joint Dust Cover Check
33A-6 FRONT SUSPENSION – On-vehicle Service STEERING ANGLE Standard value: Inner wheel 41 30’ Outer wheel 34 00’ CAMBER, CASTER AND KINGPIN INCLINATION MB991004 Standard value: Camber 0 40’ 30’ Caster 2 54’ Kingpin inclination 13 36’ NOTE 1. Camber and caster are preset at the factory and cannot be adjusted.
Page 740: Strut Assembly
33A-7 FRONT SUSPENSION – Strut Assembly STRUT ASSEMBLY 33200110096 REMOVAL AND INSTALLATION Caution Do not strike the speed sensor against other parts when removing or installing it. Otherwise the speed sensor will be damaged. <Vehicles with SRS> Pre-removal Operation Post-installation Operation Relay Box Removal Relay Box Installation Front Wheel Alignment Adjustment...
Page 741 33A-8 FRONT SUSPENSION – Strut Assembly DISASSEMBLY AND REASSEMBLY 33200130115 59 – 69 Nm Disassembly steps AA 1. Self-locking nut 5. Bump rubber 2. Strut insulator 6. Coil spring 3. Spring seat, upper 7. Spring pad, lower 4. Spring pad, upper 8.
Page 742 33A-9 FRONT SUSPENSION – Strut Assembly BA STRUT ASSEMBLY REMOVAL To discard the strut assembly, place the assembly horizontally with its piston rod extended. Then drill a hole approx. 3 mm in diameter at the location shown in the illustration and discharge the gas.
Page 743: Lower Arm
33A-10 FRONT SUSPENSION – Lower Arm LOWER ARM 33200160091 REMOVAL AND INSTALLATION Caution*: indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition. Otherwise the bush will be damaged. Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger.
Page 744 33A-11 FRONT SUSPENSION – Lower Arm INSPECTION 33200170094 Check the bushing for wear and deterioration. Check the lower arm for bend or breakage. Check the support bracket for deterioration or damage. Check all bolts for condition and straightness. BALL JOINT STARTING TORQUE/TURNING TORQUE CHECK MB991006 1.
Page 745: Stabilizer Bar
33A-12 FRONT SUSPENSION – Lower Arm/Stabilizer Bar 5. Check the dust cover for cracks or damage by pushing it with finger. STABILIZER BAR 33200190106 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Crossmember Removal and Installation (Refer to GROUP 32 – Crossmember.) 27 Nm Removal steps BA 1.
Page 746 33A-13 FRONT SUSPENSION – Stabilizer Bar INSTALLATION SERVICE POINTS Outside of vehicle AA BUSHING/FIXTURE INSTALLATION Place the identification mark of the stabilizer bar to the right, and install the bushing so that the identification mark is at the shown position. Identification mark BA SELF-LOCKING NUT INSTALLATION Tighten the self-locking nut so that the amount of protrusion...
Page 747 NOTES...
Page 748 34-1 REAR SUSPENSION CONTENTS 34109000176 Ball Joint Dust Cover Check ....GENERAL INFORMATION ....CONTROL LINK, UPPER LINK AND LOWER SERVICE SPECIFICATION .
Page 749: General Information
34-2 REAR SUSPENSION – General Information GENERAL INFORMATION 34100010222 The rear suspension is a trailing arm type multi-link assembly is a hydraulic, cylindrical double-acting suspension. The shock absorber used on the strut type. COIL SPRING Items Specifications Wire dia. O.D. free length mm CONSTRUCTION DIAGRAMS...
Page 750: Special Tools
34-3 REAR SUSPENSION – Service Specifications/Special Tools SERVICE SPECIFICATIONS 34100030211 Items Specifications Toe-in At the centre of tyre tread mm Toe-angle (per wheel) 0 09’ 06’ Camber – 0 40’ 30’ Stabilizer link ball joint turning torque Nm 1.7 – 3.1 SPECIAL TOOLS 34100060043 Tool...
Page 751: On-Vehicle Service
34-4 REAR SUSPENSION – Special Tools/On-vehicle Service Tool Number Name MB991237 Spring compressor Compression of the front coil spring body MB991239 Arm set MB990326 Preload socket Checking of stabilizer link ball joint for turning torque MB990685 Torque wrench ON-VEHICLE SERVICE 33100100137 REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT...
Page 752: Ball Joint Dust Cover Check
34-5 REAR SUSPENSION – On-vehicle Service CAMBER MB991004 Standard value: –0 40’ 30’ (The difference between the left and right wheels should be 30’ or less.) NOTE For vehicles equipped with aluminium wheels, measure the camber after tightening the special tool (MB991004) to the specified torque 180 Nm.
Page 753: Control Link, Upper Link And Lower Arm
34-6 REAR SUSPENSION – Control Link, Upper Link and Lower Arm CONTROL LINK, UPPER LINK AND LOWER ARM 34100480054 REMOVAL AND INSTALLATION Caution*: indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition.
Page 754 34-7 REAR SUSPENSION – Control Link, Upper Link and Lower Arm REMOVAL SERVICE POINTS CONTROL LINK/LOWER ARM REMOVAL Mating After making a mating mark on the toe-in or camber marks adjusting bolt, remove the control link and lower arm. UPPER LINK AND TRAILING ARM DISCONNECTION After supporting the lower arm with a jack, separate the connection.
Page 755 34-8 REAR SUSPENSION – Control Link, Upper Link and Lower Arm LOWER ARM BUSHING REPLACEMENT Driving out 34101110044 MB991447 Use the special tools to drive out the press-fit the lower arm bushing. MB991449 MB991449 NOTE MB991448 If the special tool (MB991449) is hard to install, tap it with a plastic hammer.
Page 756: Trailing Arm
34-9 REAR SUSPENSION – Trailing Arm TRAILING ARM 34100420186 REMOVAL AND INSTALLATION Caution*: indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition. Otherwise the bush will be damaged. Pre-removal and Post-installation Operation Rear Brake Removal and Installation (Refer to GROUP 35A –...
Page 757 34-10 REAR SUSPENSION – Trailing Arm REMOVAL SERVICE POINTS LIFTING POINT When removing the trailing arm, move the lifting arm slightly towards the front of the vehicle so that it will not be in the way. REAR SPEED SENSOR REMOVAL Caution Do not strike the speed sensor against other parts when removing it.
Page 758 34-11 REAR SUSPENSION – Trailing Arm INSPECTION 34100430035 Check trailing arm for cracks and deformation. Check bushing for cracks, deterioration and wear. TRAILING ARM BUSHING REPLACEMENT Driving out MB991444 34101130057 Use the special tools to drive out the trailing arm bushing. MB991445...
Page 759: Strut Assembly
34-12 REAR SUSPENSION – Strut Assembly STRUT ASSEMBLY 34100510173 REMOVAL AND INSTALLATION Caution *: indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition. Otherwise the bush will be damaged. Pre-removal and Post-installation Operation Lower arm and trailing arm disconnection (Refer to P.34-9.)
Page 760 34-13 REAR SUSPENSION – Strut Assembly DISASSEMBLY AND REASSEMBLY 34100530131 25 Nm Disassembly steps 1. Cap 7. Upper bushing A DA 2. Self-locking nut 8. Coller 3. Washer 9. Cup 4. Upper bushing B 10. Dust cover CA 5. Bracket 11.
Page 761 34-14 REAR SUSPENSION – Strut Assembly SHOCK ABSORBER REMOVAL To discard the low pressure gas-filled shock absorber, place the assembly horizontally with its piston rod extended. Then drill a hole approx. 3 mm in diameter at the location shown in the illustration and discharge the gas.
Page 762: Stabilizer Bar
34-15 REAR SUSPENSION – Stabilizer Bar STABILIZER BAR 34100560031 REMOVAL AND INSTALLATION Post-installation Operation Wheel Alignment Check (Refer to P.34-4.) 25 Nm 44 Nm 34 Nm 25 Nm 34 Nm 44 Nm Removal steps 1. Stabilizer link BA 4. Stabilizer bar 2.
Page 763 34-16 REAR SUSPENSION – Stabilizer Bar STABILIZER LINK BALL JOINT TURNING TORQUE INSPECTION 34100570140 MB990326 1. Shake the stabilizer link ball joint stud several times before installing the nut to the stud. Then use the special tool to measure the turning torque of the stabilizer link ball joint.
Page 764 35A-1 SERVICE BRAKES CONTENTS 35109000081 BASIC BRAKE SYSTEM ......... ANTI-SKID BRAKING SYSTEM (ABS) .
Page 765 35A-2 BASIC BRAKE SYSTEM CONTENTS 35109000456 Front Disc Brake Rotor Check ....GENERAL INFORMATION ....Brake Disc Thickness Check .
Page 766: General Information
35A-3 BASIC BRAKE SYSTEMS – General Information GENERAL INFORMATION 35100010243 The brake system offers high dependability and durability along with improved braking performance and brake sensitivity. MASTER CYLINDER Type Tandem type I.D. mm 23.81 BRAKE BOOSTER Type Vacuum type, Tandem Effective dia.
Page 767: Service Specifications
35A-4 BASIC BRAKE SYSTEMS – General Information/Service Specifications CONSTRUCTION DIAGRAM Brake booster Master cylinder Rear brake Brake pedal Front brake SERVICE SPECIFICATIONS 35100030287 Items Standard value Limit Brake pedal height mm L.H. drive vehicles 163.5 – 166.5 – R.H. drive vehicles 162.5 –...
Page 768: Special Tools
35A-5 BASIC BRAKE SYSTEMS – Service Specifications/Lubricants/Sealants/Special Tools Items Standard value Limit Rear drum brake Lining thickness mm 4.38 Drum inside diameter mm LUBRICANTS 35100040044 Items Specified Lubricant Brake fluid DOT3 or DOT4 Wheel cylinder body inner surfaces Repair kit grease Rear brake shoe and backing plate contact surfaces Brake grease SAE J310, NLGI No.1 Shoe assembly and auto adjuster assembly contact...
Page 769: On-Vehicle Service
35A-6 BASIC BRAKE SYSTEMS – On-vehicle Service ON-VEHICLE SERVICE 35100090247 BRAKE PEDAL CHECK AND ADJUSTMENT 1. Measure the brake pedal height as illustrated. If the brake Stop lamp Operat- pedal height is not within the standard value, adjust or switch ing rod replace.
Page 770: Stop Lamp Switch Check
35A-7 BASIC BRAKE SYSTEMS – On-vehicle Service 2. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value range.
Page 771: Brake Booster Operating Test
35A-8 BASIC BRAKE SYSTEMS – On-vehicle Service BRAKE BOOSTER OPERATING TEST 35100100155 Good No good For simple checking of the brake booster operation, carry out the following tests: 1. Run the engine for one or two minutes, and then stop If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains...
Page 772: Proportioning Valve Function Test
35A-9 BASIC BRAKE SYSTEMS – On-vehicle Service 2. Check the operation of the check valve by using a vacuum Valve Spring pump. Vacuum pump connection Accept/reject criteria Intake Booster manifold side Connection at the brake A negative pressure (vacu- side booster side (A) um) is created and held.
Page 773: Brake Fluid Level Sensor Check
35A-10 BASIC BRAKE SYSTEMS – On-vehicle Service (3) Output pressure difference between left and right brake lines. Limit: 0.4 MPa 4. If the measured pressures are not within the permissible ranges, replace the proportioning valve. BRAKE FLUID LEVEL SENSOR CHECK 35100910048 The brake fluid level sensor is in good condition if there is no continuity when the float surface is above “MIN”...
Page 774: Front Disc Brake Pad Check And Replacement
35A-11 BASIC BRAKE SYSTEMS – On-vehicle Service FRONT DISC BRAKE PAD CHECK AND When new When worn REPLACEMENT 35100150228 NOTE The brake pads have wear indicators that contact the brake disc when the brake pad thickness becomes 2 mm and emit a squealing sound to warn the driver.
Page 775: Front Disc Brake Rotor Check
35A-12 BASIC BRAKE SYSTEMS – On-vehicle Service FRONT DISC BRAKE ROTOR CHECK 35100270061 CAUTION When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation. Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.
Page 776: Brake Disc Run-Out Check
35A-13 BASIC BRAKE SYSTEMS – On-vehicle Service BRAKE DISC RUN-OUT CHECK 35100170156 1. Remove the caliper support; then raise the caliper assembly upward and secure by using wire. 2. Inspect the disc surface for grooves, cracks and rust. Clean the disc thoroughly and remove all rust. 3.
Page 777: Brake Lining Thickness Check
35A-14 BASIC BRAKE SYSTEMS – On-vehicle Service BRAKE LINING THICKNESS CHECK 35100300241 1. Remove the brake drum. 2. Measure the wear of the brake lining at the place worn the most. Standard value: 4.38 mm Limit: 1.0 mm Replace the shoe and lining assembly if brake lining thickness is less than the limit if it is not worn evenly.
Page 778: Brake Pedal
35A-15 BASIC BRAKE SYSTEMS – Brake Pedal BRAKE PEDAL 35100340328 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Instrument Under Cover Removal Brake booster Installation (Refer to GROUP 52A – Instrument Panel.) (Refer to P.35A-17,18.) Steering Column Assembly Removal Steering Column Assembly Installation (Refer to GROUP 37A –...
Page 779 35A-16 BASIC BRAKE SYSTEMS – Brake Pedal <R.H. drive vehicles> 24 Nm 23 Nm Removal steps 1. Stop lamp switch connector 8. Brake pedal assembly 2. Stop lamp switch 9. Brake pedal shaft bolt 3. Ring 10. Brake pedal 4. Retaining clip 11.
Page 780: Master Cylinder And Brake Booster
35A-17 BASIC BRAKE SYSTEMS – Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER 35100370341 REMOVAL AND INSTALLATION <L.H. drive vehicles> Caution For the reservoir hose marked with * disconnect the reservoir assembly-side connection only and do not lower the disconnected hose below the master cylinder to prevent the air from entering into brake fluid line.
Page 781 35A-18 BASIC BRAKE SYSTEMS – Master Cylinder and Brake Booster <R.H drive vehicles> Caution For the reservoir hose marked with * disconnect the reservoir assembly-side connection only and do not lower the disconnected hose below the master cylinder to prevent the air from entering into brake fluid line.
Page 782 35A-19 BASIC BRAKE SYSTEMS – Master Cylinder and Brake Booster INSTALLATION SERVICE POINTS AA VACUUM HOSE CONNECTION Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure by using the hose clip. BA CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON Calculate clearance A from the B, C and D measurements.
Page 783 35A-20 BASIC BRAKE SYSTEMS – Front Disc Brake FRONT DISC BRAKE 35100600204 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-10.) 80 – 95 Nm 29 Nm Removal steps 1. Brake hose connection 2.
Page 784 35A-21 BASIC BRAKE SYSTEMS – Front Disc Brake 2. After installing the caliper support to the knuckle, install the pad clips and the pads to the caliper support. Caution Do not let any oil, grease or other contamination get onto the friction surfaces of the pads and brake discs. 3.
Page 785 35A-22 BASIC BRAKE SYSTEMS – Rear Drum Brake REAR DRUM BRAKE 35100750183 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Loosening the Parking Brake Cable Adjusting Nut. Brake Line Bleeding (Refer to P.35A-10.) (Refer to GROUP 36 On-vehicle service) Parking Brake Lever Stroke Adjustment Brake Fluid Draining (Refer to GROUP 36 On-vehicle service) 15 Nm...
Page 786 35A-23 BASIC BRAKE SYSTEMS – Rear Drum Brake REMOVAL SERVICE POINT Pin of shoe assembly RETAINER REMOVAL Use a flat-tipped screwdriver or the like to open up the retainer joint, and remove retainer. Retainer INSTALLATION SERVICE POINTS AA WAVE WASHER INSTALLATION Shoe assembly Washer Install the washer in the direction shown in the illustration.
Page 787: Wheel Cylinder
35A-24 BASIC BRAKE SYSTEMS – Rear Drum Brake WHEEL CYLINDER 35100770042 DISASSEMBLY AND REASSEMBLY 7 Nm Grease Grease: Repair kit grease Brake fluid: DOT3 or DOT4 Wheel cylinder repair kit Disassembly steps 1. Boots 5. Spring 2. Piston assembly 6. Bleeder AA 3.
Page 788 35A-25 BASIC BRAKE SYSTEMS – Rear Drum Brake/Proportioning Valve INSPECTION 35100780038 Check the piston and wheel cylinder walls for rust or damage, and if there is any abnormality, replace the entire wheel cylinder assembly. PROPORTIONING VALVE 35100570055 INSTALLATION SERVICE POINT BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit as shown in the illustration.
Page 789 NOTES...
Page 790 35B-1 ANTI-SKID BRAKING SYSTEM (ABS) <2WD> CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ....Brake Pedal Check and Adjustment SERVICE SPECIFICATIONS .
Page 791: Front Disc Brake
35B-2 Proportioning Valve Function Test BRAKE PEDAL ..Refer to GROUP 35A ......Refer to GROUP 35A MASTER CYLINDER AND BRAKE Brake Fluid Level Sensor Check...
Page 792 35B-3 ABS <2WD> – General Information GENERAL INFORMATION The ABS consists of components such as the wheel identified and the trouble symptoms will be speed sensors, stop lamp switch, hydraulic unit memorized by the diagnosis function. assembly (integrated with the ABS-ECU) and the In addition, reading of diagnosis codes and service ABS warning lamp.
Page 793 Service Specifications/Lubricants 35B-4 ABS <2WD> – Sealant/Special Tools SERVICE SPECIFICATIONS Items Standard value Clearance between rear speed sensor pole piece and ABS rotor mm 0.1 – 1.9 Wheel speed sensor’s internal resistance kΩ 1.28 – 1.92 Wheel speed sensor insulation resistance kΩ 100 or more LUBRICANTS Items...
Page 794 35B-5 ABS <2WD> – Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. NOTES WITH REGARD TO DIAGNOSIS The phenomena listed in the following table are not abnormal. Phenomenon Explanation of phenomenon System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment, but this is because the system operation check is being performed,...
Page 795 35B-6 ABS <2WD> – Troubleshooting Without the MUT-II 1. Use the special tool to earth diagnosis connector terminal No. 1. MB991529 2. Turn the ignition switch to ON and then take a reading When diagnosis code No. 23 is output of the diagnosis codes from the flashing of the ABS warning lamp.
Page 796 35B-7 ABS <2WD> – Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Inspect according to the inspection chart that is appropriate for the malfunction code. Diagnosis Inspection item Diagnosis content Reference page code No. Front right wheel speed sensor Open circuit 35B-8 Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor...
Page 797 35B-8 ABS <2WD> – Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Probable cause Code Nos.11, 12, 13 and 14 Wheel speed sensor open circuit Code Nos.21, 22, 23 and 24 Wheel speed sensor short circuit Code Nos.11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit Malfunction of wheel speed sensor in any one of the four wheel speed sensors.
Page 798 35B-9 ABS <2WD> – ABS <2WD> – Troubleshooting Troubleshooting Code No. 16 Power supply system Probable cause The voltage of the ABS-ECU power supply drops lower or rises higher than the Malfunction of wiring harness or connector. specified value. Malfunction of ABS-ECU If the voltage returns to the specified value, this code is no longer output.
Page 799 35B-10 ABS <2WD> – ABS <2WD> – Troubleshooting Troubleshooting Code No. 51 Valve power supply Probable cause This code is output when there is an abnormality in the solenoid valve power supply Malfunction of wiring harness or connector system. Malfunction of ABS-ECU Measure at ABS-ECU connector A-47.
Page 800 35B-11 ABS <2WD> – Troubleshooting ABS WARNING LAMP INSPECTION Check that the ABS warning lamp illuminates as follows. 1. When the ignition switch is turned to “ON”, the ABS warning lamp illuminates for approximately 2 seconds and then switches off. 2.
Page 801 35B-12 ABS <2WD> – 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 reason is probably defect in the power supply system (including earth) for the Malfunction of wiring harness or connector diagnosis line.
Page 802 35B-13 ABS <2WD> – Troubleshooting Inspection Procedure 5 Brake operation is abnormal. Probable cause This varies depending on the driving conditions and the road surface conditions, Improper installation of wheel speed sensor so problem diagnosis is difficult. However, if a normal diagnosis code is displayed, Incorrect sensor harness contact carry out the following inspection.
Page 803 35B-14 ABS <2WD> – Troubleshooting SERVICE DATA REFERENCE TABLE The following items can be read by the MUT-II from the ABS-ECU input data. 1. When the system is normal Item No. Check item Checking requirements Normal value Front-right wheel speed sensor Perform a test run Vehicle speeds displayed on the...
Page 804 35B-15 ABS <2WD> – Troubleshooting CHECK AT ABS-ECU TERMINAL VOLTAGE CHECK CHART 1. Measure the voltages between terminals (16) and (19) (earth terminals) and each respective terminal. 2. The terminal layouts are shown in the illustrations below. Connector Signal Checking requirements Normal condition terminal MUT-II...
Page 805 35B-16 ABS <2WD> – Troubleshooting/On-vehicle Service Connector terminal No. Signal Normal condition 6 – 7 Front-left wheel speed sensor (+ wire) 1.28 – 1.92 kΩ 8 – 9 Rear-left wheel speed sensor (+ wire) 1.28 – 1.92 kΩ 16 – Body earth ABS-ECU earth Continuity 19 –...
Page 806 35B-17 ABS <2WD> – On-vehicle Service Inspecting Waveforms With An Oscilloscope Use the following method to observe the output voltage waveform from each wheel sensor with an oscilloscope. When turning by hand Start the engine, and rotate the front wheels by engaging 1st gear (vehicles with manual transmission) or D range (vehicles with automatic transmission).
Page 807 35B-18 ABS <2WD> – On-vehicle Service HYDRAULIC UNIT CHECK Caution Turn the ignition switch off before connecting or disconnecting the MUT-II. 1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points or place the wheels which are checked on the rollers of the braking force tester. Caution (1) The roller of the braking force tester and the tyre should be dry during testing.
Page 808 35B-19 ABS <2WD> – On-vehicle Service Diagnosis Table Operation Judgement Judgement Probable cause Remedy – Normal – Abnormal (1) Depress brake pedal Brake force re- Wheel does not Clogged brake Check and clean to lock wheel. leased for 1 sec- lock when brake line other than brake line...
Page 809 35B-20 ABS <2WD> – Rear Drum Brake REAR DRUM BRAKE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Loosening the Parking Brake Cable Adjusting Nut. Brake Line Bleeding (Refer to GROUP 35A (Refer to GROUP 36 On-vehicle service) On-vehicle service) Brake Fluid Draining (Refer to GROUP 35A Parking Brake Lever Stroke Adjustment On-vehicle service) (Refer to GROUP 36 On-vehicle service)
Page 810 35B-21 ABS <2WD> – Rear Drum Brake WHEEL CYLINDER ASSEMBLY DISASSEMBLY AND REASSEMBLY 7 Nm Grease Grease: Repair kit grease Brake fluid: DOT3 or DOT4 Wheel cylinder repair kit Disassembly steps 1. Boots 5. Spring 2. Piston assembly 6. Bleeder AA 3.
Page 811 35B-22 ABS <2WD> – Hydraulic Unit HYDRAULIC UNIT REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining A/C Relay Box Installation (Refer to GROUP 35A On-vehicle service) Brake Fluid Supplying A/C Relay Box Removal Brake Line Bleeding (Refer to GROUP 35A On-vehicle service) Brake Pedal Adjustment (Refer to GROUP 36 On-vehicle service) 15 Nm...
Page 812 35B-23 ABS <2WD> – Hydraulic Unit HYDRAULIC UNIT ASSEMBLY REMOVAL Caution 1. The hydraulic unit assembly is heavy, and so care should be taken when removing it. 2. The hydraulic unit assembly is not to be disassembled; its nuts and bolts should absolutely not be loosened. 3.
Page 813 35B-24 ABS <2WD> – Wheel Speed Sensor WHEEL SPEED SENSOR REMOVAL AND INSTALLATION Post-installation Operation Wheel Speed Sensor Output Voltage Check (Refer to P.35B-16.) <Front> <Rear> 14 Nm 25 Nm 65 Nm 25 Nm Front speed sensor removal steps 1. Front speed sensor NOTE 2.
Page 814 35B-25 ABS <2WD> – Wheel Speed Sensor INSTALLATION SERVICE POINT Speed sensor AA REAR SPEED SENSOR INSTALLATION Caution Be careful that the pole piece at the end of the speed sensor and the ABS rotor teeth do not become damaged by striking them against the metal parts.
Page 815 35B-26 ABS <2WD> – Wheel Speed Sensor 3. Check the speed sensor cable for breakage, damage or disconnection; replace with a new one if a problem is found. NOTE When checking for cable damage, remove the cable clamp part from the body and then bend and pull the cable near the clamp to check whether or not temporary disconnection occurs.
Page 816 36-1 PARKING BRAKES CONTENTS 36109000248 GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Parking Brake Lever Stroke Check .
Page 817 36-2 PARKING BRAKES – General Information/Service Specifications/Lubricants/On-vehicle Service GENERAL INFORMATION 36100010219 The parking brake is of a mechanical rear-wheel brake construction in all vehicles. SERVICE SPECIFICATIONS 36100030031 Item Specifications Parking brake lever stroke [Operation force: Approx. 5 – 7 notches 196N] LUBRICANTS 36100040034...
Page 818 36-3 PARKING BRAKES – On-vehicle Service 2. If the parking brake lever stroke is not the standard value, adjust as described below. (1) Loosen the adjusting nut to the end of the cable rod, thus freeing the parking brake cable. (2) With the engine idling, forcefully depress the brake pedal five or six times and confirm that the pedal stroke stops changing.
Page 819: Parking Brake Lever
36-4 PARKING BRAKES – Parking Brake Lever PARKING BRAKE LEVER 36100130243 REMOVAL AND INSTALLATION CAUTION: SRS When removing and installing the floor console, do not let it bump against the SRS-ECU or other components. Before removal of SRS-ECU, refer to GROUP52B – SRS-ECU. Pre-removal Operation Post-installation Operation Floor Console Removal (Refer to GROUP 52A.)
Page 820: Parking Brake Cable
36-5 PARKING BRAKES – Parking Brake Cable PARKING BRAKE CABLE 36100190302 REMOVAL AND INSTALLATION CAUTION: SRS When removing and installing the floor console, do not let it bump against the SRS-ECU or other components. Before removal of SRS-ECU, refer to GROUP52B – SRS-ECU. Pre-removal Operation Post-installation Operation Floor Console Removal (Refer to GROUP 52A.)
Page 821 NOTES...
Page 822 37A-1 STEERING CONTENTS 37209000057 GENERAL INFORMATION ....Drive Belt Tension Check ..... . Fluid Level Check .
Page 823: General Information
37A-2 STEERING – General Information GENERAL INFORMATION 37200010196 The steering wheel is a 3-spoke type for standard type that combines the steering gear and linkage models and a 4-spoke type for vehicles with SRS. into one light-weight and compact assembly. The steering column is equipped with both shock The steering system uses a vane oil pump with absorbing and a tilt steering mechanism.
Page 824: Service Specifications
37A-3 STEERING – Service Specifications/Lubricants/Special Tools SERVICE SPECIFICATIONS 37200030222 Items Standard value Limit Steering wheel free with engine stopped 10 or less – play mm play mm when hydraulic operation – Steering angle Inner wheel 39 00’ 1 30 – Outer wheel (Reference value) 32 00’...
Page 825 37A-4 STEERING – Special Tools Tool Number Name MB990685 Torque wrench Measurement of the ball joint starting torque Measurement of the pinion shaft preload MB990326 Preload socket Measurement of the ball joint starting torque MB990993 or Power steering oil Measurement of oil pressure MB991217 pressure gauge adapter (pump...
Page 826: On-Vehicle Service
37A-5 STEERING – On-Vehicle Service ON-VEHICLE SERVICE 37200100046 STEERING WHEEL FREE PLAY CHECK 1. With engine running (hydraulic operation), set front wheels straight ahead. 2. Measure the play on steering wheel circumference before wheels start to move when slightly moving steering wheel in both directions.
Page 827: Tie Rod End Ball Joint Starting Torque
37A-6 STEERING – On-vehicle Service TIE ROD END BALL JOINT STARTING TORQUE CHECK Cord 37200150171 1. Disconnect tie rod and knuckle with special tool. Ball joint Caution 1. Be sure to use the special tool to loosen the tie MB990635 or rod end mounting nut to prevent the ball joint MB991113 thread from damaging.
Page 828: Checking Steering Wheel Return To Centre
37A-7 STEERING – On-vehicle Service CHECKING STEERING WHEEL RETURN TO CENTRE 37200180057 To make this test, conduct a road test and check as follows. 1. Make both gradual and sudden turns and check the steering “feeling” to be sure that there is not difference in the steering force required and the wheel return between left and right turns.
Page 829: Fluid Replacement
37A-8 STEERING – On-vehicle Service FLUID REPLACEMENT 37200210145 1. Raise the front wheels on a jack, and then support them with rigid racks. 2. Disconnect the return hose connection. 3. Connect a vinyl hose to the return hose, and drain the oil into a container.
Page 830 37A-9 STEERING – On-vehicle Service 3. While operating the starting motor intermittently, turn the steering wheel all the way to the left and right five or six times (for 15 to 20 seconds). Caution (1) The fluid level should be between MIN and MAX of the fluid level gauge during air bleeding.
Page 831: Oil Pump Pressure Test
37A-10 STEERING – On-vehicle Service OIL PUMP PRESSURE TEST 37200230219 Pressure 1. Disconnect the pressure hose from the oil pump, and then gauge (MB990662) Shut-off valve connect the special tools. 2. Bleed the air, and then turn the steering wheel several Temperature Oil pump gauge...
Page 832: Power Steering Oil Pressure Switch Check
37A-11 STEERING – On-vehicle Service POWER STEERING OIL PRESSURE SWITCH CHECK Shut-off valve 37200720198 Adapter (MB990993) Pressure 1. Disconnect the pressure hose from the oil pump, and then gauge connect the special tools. (MB990662) Temperature 2. Bleed the air, and then turn the steering wheel several gauge times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 –...
Page 833: Steering Wheel And Shaft
37A-12 STEERING – Steering Wheel and Shaft STEERING WHEEL AND SHAFT 37200260317 REMOVAL AND INSTALLATION CAUTION: SRS Before removal of air bag module, refer to GROUP 52B – Service Precautions and Air Bag Module and Clock Spring. Pre-removal Operation Post-installation Operation Instrument Under Cover Removal Instrument Under Cover Installation (Refer to GROUP 52A –...
Page 834 37A-13 STEERING – Steering Wheel and Shaft REMOVAL SERVICE POINT MB990803 STEERING WHEEL REMOVAL INSTALLATION SERVICE POINT AA CLOCK SPRING AND COLUMN SWITCH/COLUMN SWITCH INSTALLATION Tighten the screws in an alphabetical order. DISASSEMBLY AND REASSEMBLY 37200280184 Disassembly steps AA 1. Special bolt AA 2.
Page 835 37A-14 STEERING – Steering Wheel and Shaft DISASSEMBLY SERVICE POINT Steering lock bracket STEERING LOCK BRACKET/STEERING LOCK CYLINDER REMOVAL If it is necessary to remove the steering lock cylinder, use a hacksaw to cut the special bolts at the steering lock bracket side.
Page 836: Power Steering Gear Box
37A-15 STEERING – Power Steering Gear Box POWER STEERING GEAR BOX 37200390313 REMOVAL AND INSTALLATION CAUTION: SRS For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative, risking serious driver injury.
Page 837 37A-16 STEERING – Power Steering Gear Box REMOVAL SERVICE POINTS Cord TIE ROD END DISCONNECTION Ball joint Caution 1. Be sure to use the special tool to loosen the tie rod MB990635, end mounting nut to prevent the ball joint thread from MB991113 or MB991406 damaging.
Page 838 37A-17 STEERING – Power Steering Gear Box CHECK THE TIE ROD FOR SWING RESISTANCE 1. Give 10 hard swings to the tie rod. 2. Measure the tie rod swing resistance with a spring balance. Standard value: 6 – 20 N [1.5 – 4.9 Nm] 3.
Page 839 37A-18 STEERING – Power Steering Gear Box REASSEMBLY SERVICE POINTS MB991006 AA TOTAL PINION TORQUE ADJUSTMENT 1. Position rack at its centre. Tighten rack support cover to 15 Nm. 2. In neutral position, rotate pinion shaft clockwise one turn/4 – 6 seconds with special tool. Return rack support cover 30_ –...
Page 840: Power Steering Oil Pump
37A-19 STEERING – Power Steering Oil Pump POWER STEERING OIL PUMP 37200520316 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (Refer to P.37A-8.) Power Steering Fluid Supplying (Refer to P.37A-8.) Drive-belt Tension Adjusting (Refer to GROUP 11 –...
Page 841: Power Steering Hoses
37A-20 STEERING – Power Steering Hoses POWER STEERING HOSES 37200570342 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (Refer to P.37A-8.) Power Steering Fluid Supplying (Refer to P.37A-8.) Power Steering Fluid Line Bleeding (Refer to P.37A-8.) <1300> 8 Nm <R.H.
Page 842 37A-21 STEERING – Power Steering Hoses <1800> 8 Nm <R.H. drive vehicles> 25 Nm 10 Nm 12 – 14 Nm 25 Nm 17 Nm 12 – 14 Nm 11 Nm <L.H. drive vehicles> 25 Nm 12 – 14 Nm 11 Nm 12 –...
Page 843 NOTES...
Page 844: Sealants
42-1 BODY CONTENTS 42109000041 HOOD ......TROUBLESHOOTING ....ON-VEHICLE SERVICE .
Page 845 42-2 Secret Code Registration Method ..TAILGATE ......KEYLESS ENTRY RECEIVER-ECU .
Page 846: Hood
42-3 BODY – Hood HOOD 42100160045 REMOVAL AND INSTALLATION 19 Nm 12 Nm Adjustment of clearance around hood Adjustment of hood step and and height hood striker linkage Front bumper (Refer to GROUP 51.) Hood lock release cable removal 1. Hood latch steps 2.
Page 847: Fender
42-4 BODY – Fender FENDER 42100190204 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Bumper Removal and Installation Delta Garnish Removal and Installation (Refer to (Refer to GROUP 51.) GROUP 51.) Headlamp Removal and Installation (Refer to GROUP 54.) Section A – A Removal steps D Front fender protector moulding (Refer AA 1.
Page 848: Fuel Filler Door
42-5 BODY – Fuel Filler Door FUEL FILLER DOOR 42100250254 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Seat (driver’s side), Rear Seat Removal and Pillar Lower Trim (driver’s side), Quarter Trim (driver’s Installation (Refer to GROUP 52A.) side) Removal and Installation (Refer to GROUP 52A.) Front Scuff Plate (driver’s side), Rear Scuff Plate (driver’s side), Cowl Side Trim (driver’s side) Center <R.H.
Page 849: Window Glass
42-6 BODY – Window Glass WINDOW GLASS 42200050062 ADHESIVES Items Specified adhesives Windshield 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealants or equivalent Sealants or equivalent Quarter window glass Tailgate window glass SPECIAL TOOLS 42200060065 Tool Number Name MB990480 Glass holder...
Page 850 42-7 BODY – Window Glass ITEMS NEEDED Name Remarks Adhesive 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Primer 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent Spacers Available as service part Anti-rust solvent For rust prevention (or Tectyl 506T...Valvoline Oil Company)
Page 851 42-8 BODY – Window Glass WORKING PROCESS Window glass installation procedure Body side Window glass side Reusing the glass Replacing the glass Cleaning of adhesion surface Cleaning of adhesion surface Cleaning of adhesion surface Cut off the residual adhesive until the Competely cut off all of the residual Clean off any dirt adhering to the adhe- thickness is less than 2 mm.
Page 852: Windshield
42-9 BODY – Window Glass WINDSHIELD 42200100255 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Deck Garnish Removal and Installation (Refer to GROUP 51.) Section B – B Section C – C Section A – A Primer Primer Primer Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Removal steps 1.
Page 853 42-10 BODY – Window Glass REMOVAL SERVICE POINTS MB990449 ROOF DRIP MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused. WINDSHIELD REMOVAL 1. In order to protect the body (paint surface), apply cloth tape to all body areas around the installed windshield.
Page 854 42-11 BODY – Window Glass 8. Finish the flange surfaces so that they are smooth. Caution (1) Be careful not to remove more adhesive than is necessary. (2) Be careful also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with repair paint or anti-rust agent.
Page 855 42-12 BODY – Window Glass 5. Fill a sealant gun with adhesive. Then apply the adhesive evenly around the windshield within 30 minutes after applying the primer. NOTE Cut the tip of the sealant gun nozzle into a V shape to simplify adhesive application.
Page 856: Quarter Window Glass
42-13 BODY – Window Glass QUARTER WINDOW GLASS 42200250127 REMOVAL AND INSTALLATION Section B – B Section A – A Unit:mm 14.5 Primer Primer Primer 12.5 Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Removal steps 1.
Page 857 42-14 BODY – Window Glass REMOVAL SERVICE POINT QUARTER WINDOW GLASS REMOVAL Remove the quarter window glass by the same procedure as for the windshield. (Refer to P.42-10.) INSTALLATION SERVICE POINT WINDOW DAM/QUARTER WINDOW GLASS INSTALLATION 1. Use isopropyl alcohol to degrease the window dam and dual lock fastener mounting surfaces on both the glass and the body.
Page 858: Tailgate Window Glass
42-15 BODY – Window Glass TAILGATE WINDOW GLASS 42200370069 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Tailgate Trim Removal and Installation (Refer to Rear Wiper Removal and Installation P.42-49.) (Refer to GROUP 51.) High-mounted Stop Lamp Removal and Installation (Refer to GROUP 54.) Section A –...
Page 859 42-16 BODY – Window Glass REMOVAL SERVICE POINT TAILGATE WINDOW GLASS REMOVAL Remove the tailgate window glass by the same procedure as for the windshield. (Refer to P.42-10.) INSTALLATION SERVICE POINT Centre Clip AA CLIP/DUAL-LOCK FASTENER/TAILGATE GLASS LOWER DAM/TAILGATE GLASS SIDE DAM/TAILGATE GLASS UPPER DAM/TAILGATE WINDOW GLASS INSTALLATION 21 mm...
Page 860: Door
42-17 BODY – Door DOOR 42300030038 SERVICE SPECIFICATIONS Items Standard value FRONT DOOR 3.6 – 5.4 Door outside handle play mm REAR DOOR 2.2 – 5.4 FRONT DOOR 18.4 – 26.8 Door inside handle play mm REAR DOOR 15.3 – 19.5 SEALANT 42300050034 Items...
Page 861: Troubleshooting
42-18 BODY – Door TROUBLESHOOTING 42300070030 INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Power windows Driver’s power window cannot be operated by the power 42-19 window main switch. No power window can be operated by the power window main 42-20 switch (but they can be operated by the sub-switches).
Page 862 42-19 BODY – Door INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Precedure 1 Driver’s power window cannot be operated by the power Probable cause window main switch. The power window main switch or power window regulator assembly may be defective. Malfunction of power window regulator assembly Malfunction of power window main switch Malfunction of wiring harness or connector Power window main switch check...
Page 863 42-20 BODY – Door Inspection Procedure 2 No power window can be operated by the power window Probabble cause main switch (but they can be operated by the sub-switches). The power window main switch or the harness between power window main switch Malfunction of power window main switch and power window sub-switch may be defective.
Page 864 42-21 BODY – Door Inspection Procedure 4 No power window can be operated by the power window Probable cause sub-switches (nor can they be operated by the main switch). The power window main switch, the power window sub-switch or power window Malfunction of power window main switch regulator assembly may be defective.
Page 865 42-22 BODY – Door <Rear> Power window main switch check Replace (Refer to P.42-40.) Power window sub-switch check Replace (Refer to P.42-41.) Measure at the power window sub- Check the following connectors: Repair switch connector(L.H.) E-07 or (R.H.) <L.H.> B-41, E-07, D-17, E-03, B-80, E-17.
Page 866 42-23 BODY – Door Inspection Procedure 5 Automatic operation is not possible. Probable cause Automatic operation is not possible before carrying out the initial setting operation Incorrect initial settings when the battery terminals are disconnected or a fuse or power window regulator Malfunction of power window main switch assembly is replaced.
Page 867 42-24 BODY – Door <Rear> Carry out the initial setting operation. (Refer to P.42-31.) Check trouble symptoms. Power window main switch check Replace (Refer to P.42-40.) Power window sub-switch check Replace (Refer to P.42-41.) Measure at the power window sub- Check the following connectors: Repair switch connector(L.H.) E-07...
Page 868 42-25 BODY – Door Inspection Procedure 7 The window does not lower if it clamps something, or it Probable cause lowers automatically after closing fully. If the window is not lowered when it is obstructed by something while it is more Malfunction of the power window regulator than 15 mm from the fully-closed position, or if it lowers automatically after it is fully closed, the cause is probably a malfunction of the power window regulator...
Page 869 42-26 BODY – Door Inspection Precedure 10 None of the door lock functions operate. Probable cause Power circuit system or earth circuit system of the door lock-ECU or the Malfunction of door lock-ECU keyless entry receiver-ECU may be defective. Malfunction of keyless entry receiver-ECU Malfunction of wiring harness or connector Repair Measure at the door lock-ECU con-...
Page 870 42-27 BODY – Door Inspection Procedure 11 Doors do not lock or unlock when the key cylinder Probable cause (passenger’s side) is operated. The door lock key cylinder switch (passenger’s side) may be defective. Malfunction of the door lock key cylinder switch (passenger’s side) Malfunction of harness or connector Door lock key cylinder switch...
Page 871 42-28 BODY – Door Inspection Procedure 12 Doors do not lock or unlock when the key cylinder (driver’s Probable cause side) is operated. The door lock key cylinder switch (driver’s side) may be defective. Malfunction of the door lock key cylinder switch (driver’s side) Malfunction of harness or connector Door lock key cylinder switch...
Page 872 42-29 BODY – Door Inspection Procedure 13 Doors do not lock or unlock when the tailgate key cylinder Probable cause is operated. The tailgate key cylinder switch may be defective. Malfunction of the tailgate lock key cylinder switch Malfunction of harness or connector Tailgate lock key cylinder switch Replace continuity check (Refer to P.42-44.)
Page 873: On-Vehicle Service
42-30 BODY – Door ON-VEHICLE SERVICE 42300090043 DOOR FIT ADJUSTMENT 1. If the clearance between the door and the vehicle body is uneven, affix protective tape to the fender around the hinge and to the edge of the door. Then use the special MB990900 or tool to loosen the door hinge mounting bolts on the body, MB991164...
Page 874: Power Window Safety Mechanism Check
42-31 BODY – Door POWER WINDOW SAFETY MECHANISM CHECK 42900100065 1. Place a wooden board with a thickness of approximately 10 mm as shown in the illustration and then close the window glass. 2. Check that the window glass lowers by a distance of approximately 150 mm when the window clamps the wooden board.
Page 875: Door Assembly
42-32 BODY – Door DOOR ASSEMBLY 42300220053 REMOVAL AND INSTALLATION Post-installation Operation Door Adjustment (Refer to P.42-30.) Front door 4, 5 11 Nm 21 Nm Rear door 11 Nm 21 Nm Door assembly removal steps Striker removal D Front scuff plate 6.
Page 876 42-33 BODY – Door INSPECTION 42300600031 DOOR SWITCH CONTINUITY CHECK Driver’s door switch Terminal No. Switch position OFF ON Stroke Open (ON) Depressed (OFF) Passenger’s door and rear door switch Switch Terminal No. position Open (ON) Depressed (OFF) Stroke...
Page 877: Door Trim And Waterproof Film
42-34 BODY – Door DOOR TRIM AND WATERPROOF FILM 42300430050 REMOVAL AND INSTALLATION Front door NOTE :Resin clip position Section A – A Clip Sealant: 3M ATD Part. No. 8625 or equivalent Removal steps AA 1. Clip <Vehicles without power win- 5.
Page 878 42-35 BODY – Door Rear door NOTE : Resin clip position Section A – A Clip Sealant: 3M ATD Part. No. 8625 or equivalent Removal steps AA 1. Clip <Vehicles without power win- 5. Cover dows> 6. Power window switch AA 2.
Page 879 42-36 BODY – Door REMOVAL SERVICE POINT CLIP REMOVAL Remove the clip by using a rag, and then remove the regulator handle. INSTALLATION SERVICE POINT AA ESCUTCHEON/REGULATOR HANDLE/CLIP Horizontal line INSTALLATION 1. Install the escutcheon and the clip to the regulator handle. 2.
Page 880: Door Glass And Regulator
42-37 BODY – Door DOOR GLASS AND REGULATOR 42900130040 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Door Trim and Waterproof Film Removal and Installation (Refer to P.42-34,35.) Front door Rear door 10Nm <Vehicles with power window> <Vehicles without power window> <Vehicles with power window>...
Page 881 42-38 BODY – Door REMOVAL SERVICE POINTS POWER WINDOW MOTOR ASSEMBLY Caution Be careful when handling the power window motor assembly, as the force of the spring may cause the wires to pull out of the drum. DOOR DELTA SASH REMOVAL 1.
Page 882 42-39 BODY – Door 2. Pass the springs over the wires, and then install the Lowering lowering wire to the guide first, followed by the lifting wire. wire (The lifting wire should be on top of the lowering wire.) Spring Lifting wire Slit Guide...
Page 883 42-40 BODY – BODY – Door Door (3) Return the drum to its original position while holding the wires to make sure that they do not pull out. 6. After installing the power window motor assembly to the window regulator assembly, cut and remove the wires which are compressing the springs.
Page 884 42-41 BODY – Door 3. Move the window lock switch to the normal position, and then measure the voltage at terminal (14) under the measurement conditions given below. Measurement condition Voltage Apply battery voltage to terminal 9 Battery voltage Remove voltage from terminal (9). Battery voltage (for 30 seconds after voltage is removed)
Page 885: Door Handle And Latch
42-42 BODY – Door DOOR HANDLE AND LATCH 42300460042 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Door Trim Removal (Refer to P.42-34,35.) Door Inside Handle Play Check (Refer to P.42-31.) Door Trim Installation (Refer to P.42-34,35.) Door Fit Adjustment (Refer to P.42-30.) Front door Rear door 6 Nm...
Page 886 42-43 BODY – Door INSTALLAITON SERVICE POINT AA DOOR CHECK INSTALLATION Install the door check so that the identification mark faces Identification mark upwards. Applicable location Identification mark L.H. Front door Rear door R.H. Front door Rear door INSPECTION 42300610034 UNLOCK DOOR LOCK ACTUATOR CHECK LOCK...
Page 887 42-44 BODY – Door DOOR LOOK KEY CYLINDER SWITCH CONTINUITY CHECK 42300630030 <L.H.> Terminal No. Switch position LOCK Neutral (OFF) UNLOCK <R.H.> Switch position Terminal No. LOCK Neutral (OFF) UNLOCK DOOR LOCK ECU CHECK 42300650029 1. Apply battery voltage to terminal 5, and connect terminal 6 to earth.
Page 888: Window Glass Runchannel And Door Opening Weatherstrip
42-45 BODY – Door WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP 42300310040 REMOVAL AND INSTALLATION Front door Rear door Door inner opening weatherstrip Window glass runchannel removal removal steps D Door trim and waterproof film D Centre pillar lower trim (Refer to P.42-34,35.) D Door delta sash (Refer to GROUP 52A.)
Page 889: Tailgate
42-46 BODY – Door/Tailgate INSTALLATION SERVICE POINT AA DOOR OUTER OPENING WEATHERSTRIP INSTALLATION The clip colour identifies the left and right weatherstrips, so be sure to use the colours so as to install correctly. Item Identification colour Front door Left White Right Brown...
Page 890: Troubleshooting
42-47 BODY – Tailgate TROUBLESHOOTING 42400070088 INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Reference page Door lock mechanism does operate. 42-18. ON-VEHICLE SERVICE 42400090039 TAILGATE FIT ADJUSTMENT 1. If the striker and the latch do not mesh properly, move the striker forward or back or to the left or right to adjust. 2.
Page 891: Tailgate Assembly
42-48 BODY – Tailgate TAILGATE ASSEMBLY 42400110124 REMOVAL AND INSTALLATION Post-installation Operation Tailgate fit adjustment (Refer to P.42-47.) 11 Nm 9 Nm 13 Nm Section A – A 9 Nm Adjustment clearance around Adjustment of tailgate step and tailgate tailgate striker linkage Tailgate and tailgate hinge removal 6.
Page 892 42-49 BODY – Tailgate REMOVAL SERVICE POINT TAILGATE GAS SPRING REMOVAL Caution 1. Never try to disassemble the tailgate gas spring or burn it. 2. Always bore a hole in the tailgate gas spring to release the interior gas before the gas spring is discarded. INSTALLATION SERVICE POINT AA TAILGATE OPENING WEATHERSTRIP INSTALLATION...
Page 893: Tailgate Trim
42-50 BODY – Tailgate TAILGATE TRIM REMOVAL AND INSTALLATION Tailgate trim Section A – A Section B – B Tailgate trim Tailgate trim : Resin clip position : Sheet metal clip position...
Page 894: Tailgate Handle And Latch
42-51 BODY – Tailgate TAILGATE HANDLE AND LATCH 42400170054 REMOVAL AND INSTALLATION Post-installation Operation Tailgate Handle Free Play Check (Refer to P.42-47.) 10 Nm 9 Nm Tailgate handle and lock key Tailgate latch removal steps cylinder removal steps Tailgate trim (Refer to P.42-50.) 4.
Page 895: Keyless Entry System
42-52 BODY – Keyless Entry System KEYLESS ENTRY SYSTEM 42800060018 SPECIAL TOOLS Tool Number Name MB991223 Harness set Measurement of terminal voltage A: MB991219 A: Test harness A: Connector pin contact pressure inspection B: MB991220 B: LED harness B: Power circuit inspection C: MB991221 C: LED harness...
Page 896 42-53 BODY – BODY – Keyless Entry System Keyless Entry System INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 None of the doors, including the tailgate, can be locked or Probabble cause unlocked. (However, the central door locking system is functioning normally.) The transmitter battery may be spent, the secret code may not have been registered Malfunction of the battery...
Page 897 42-54 BODY – Keyless Entry System Inspection Procedure 3 Secret codes cannot be registered. Probable cause One of the following items may be defective. Malfunction of the keyless entry receiver-ECU Diagnosis connector Malfunction of the MUT-II Keyless entry receiver-ECU power supply circuit Malfunction of harness or connector Earth circuit Diagnosis output circuit...
Page 898: On-Vehicle Service
42-55 BODY – Keyless Entry System INSPECTION AT KEYLESS ENTRY RECEIVER-ECU TERMINALS 42800220010 TERMINAL VOLTAGE CHART 1. Measure the voltages between terminal (37) (earth terminal) and each respective terminal. 2. The terminal arrangements are shown in the illustrations below. Connector Signal Checking Requirements Normal Condition...
Page 899: Secret Code Registration Method
42-56 BODY – Keyless Entry System SECRET CODE REGISTRATION METHOD 42800100109 Each individual secret code is registered inside the transmitter, and so it is necessary to register these codes with the EEPROM inside the receiver in the following cases. When either the transmitter or receiver is replaced; If a second transmitter is to be used;...
Page 900: Keyless Entry Receiver-Ecu
42-57 BODY – Keyless Entry System When 1 minute has passed after registration mode started; If the MUT-II is disconnected (the earth connection is broken); If the ignition switch is turned to ON; If any of the doors are opened; 8.
Page 901: Sunroof
42-58 BODY – Sunroof SUNROOF 42600060012 SPECIAL TOOLS Tool Number Name MB991223 Harness set Measurement of terminal voltage A: MB991219 A: Test harness A: Connector pin contact pressure inspection B: MB991220 B: LED harness B: Power circuit inspection C: MB991221 C: LED harness C: Power circuit inspection...
Page 902 42-59 BODY – Sunroof INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Sunroof does not operate at all. Probable cause One of the following items may be defective. Malfunction of sunroof switch Sunroof switch Malfunction of front sunroof motor Sunroof motor Malfunction of front sunroof-ECU Sunroof-ECU Malfunction of wiring harness or connector...
Page 903 42-60 BODY – Sunroof Inspection Procedure 2 Sunroof does not operate correctly or it does not re-open Probable cause if it clamps something. The fully-closed position for the sunroof-ECU may have been adjusted incorrectly, Incorrect adjustment of sunroof-ECU fully-closed or there may be a malfunction of the sunroof-ECU. position Malfunction of the sunroof-ECU Malfunction of the harness or connector...
Page 904 42-61 BODY – Sunroof TERMINAL VOLTAGE CHART Terminal No. Check Item Check Condition Normal Condition Sunroof switch (down Sunroof switch (down input) input) position) position) Battery voltage Sunroof switch (up input) Sunroof switch (up position) (up position) Battery voltage Door switch input Driver’s door switch Battery voltage Sunroof switch (open...
Page 905: On-Vehicle Service
42-62 BODY – Sunroof ON-VEHICLE SERVICE 42600090035 Hose WATER TEST Check if there are any leaks in the sunroof by the following Approx. 30cm procedure. 1. Fully close the roof lid glass. 2. Adjust the water pressure so that water comes out of the hose to a height of approximately 50 cm when the hose is held vertically facing upwards.
Page 906 42-63 BODY – Sunroof SUNROOF 42600120031 REMOVAL AND INSTALLATION Post-installation Operation Sunroof Water Test (Refer to P.42-62.) Sunroof Fit Adjustment (Refer to P.42-62.) Sunroof assembly removal steps 2. Headlining BA 3. Sunroof-ECU 1. Sunroof switch and room lamp as- sembly 2.
Page 907 42-64 BODY – Sunroof REMOVAL SERVICE POINTS SUNROOF-ECU REMOVAL 1. Close the roof lid glass fully. 2. Insert a flat-tipped screwdriver, place it on the tab, and then press it to the right. 3. Lower sunroof-ECU and slide to left. Sunroof-ECU DRAIN HOSE REMOVAL Front...
Page 908 42-65 BODY – Sunroof INSPECTION 42600160033 SUNROOF SWITCH CONTINUITY CHECK Switch position Terminal No. Slide OPEN switch it h CLOSE Tilt switch DOWN SUNROOF MOTOR CHECK 42600250013 Check the direction of rotation of the drive gear when the Drive gear Left rotation battery is connected to the connector.
Page 909 42-66 BODY – Sunroof DISASSEMBLY AND REASSEMBLY 42600140037 Disassembly steps 4. Guide assembly 5. Pipe 1. Drain channel assembly 6. Tray seal outer 2. Drive cable 7. Welded tray assembly 3. Strong rear stop...
Page 910 51-1 EXTERIOR CONTENTS 5110900272 SERVICE SPECIFICATIONS ....MOULDING AND GARNISH ....SEALANT AND ADHESIVE .
Page 911: Service Specifications
51-2 EXTERIOR – Service Specifications/Sealant and Adhesive/Special Tools SERVICE SPECIFICATIONS 51100030225 Items Standard value Windshield wiper blade installation position mm Windshield wiper blade installation position mm 30 5 30 5 SEALANT AND ADHESIVE 51100050207 Items Specified sealant and adhesive Side protect moulding to body panel Adhesive tape:3M ATD part No.6382 or equivalent [12 mm wide and 0.8 mm thick] Primer:3M ATD part No.8608 Super Fast Urethane Primer or equivalent and...
Page 912: Front Bumper
51-3 EXTERIOR – Front Bumper FRONT BUMPER 51100140249 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Under Cover Panel Removal and Installation Section A–A Splash shield Clip Section B–B Splash shield Section C–C Clip Clip Removal steps 4. Front fog lamp 1.
Page 913: Rear Bumper
51-4 EXTERIOR – Rear Bumper REAR BUMPER 51100190268 REMOVAL AND INSTALLATION Section A–A Quarter pan- el, inner Clip Removal steps 1. Mud guard 2. Splash shield 3. Bumper assembly DISASSEMBLY AND REASSEMBLY 51100210223 Section B–B Section C–C Clip Disassembly steps 1.
Page 914: Roof Rail
51-5 EXTERIOR – Roof Rail ROOF RAIL 51101660034 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Headlining Removal and Installation Roof rail...
Page 915: Moulding And Garnish
51-6 EXTERIOR – Moulding and Garnish MOULDING AND GARNISH 51100440073 REMOVAL AND INSTALLATION Section B–B Section A–A Section C–C Clip Clip Clip Section F–F Section D–D Section E–E Clip Clip Flange bolt Disassembly steps BA 1. Roof drip moulding AA 3. Side protector moulding 2.
Page 916 51-7 EXTERIOR – Moulding and Garnish Adhesive tape: double-sided tape [12 mm wide and 0.8 mm thick] REMOVAL SERVICE POINT ROOF DRIP MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused.
Page 917 51-8 EXTERIOR – Moulding and Garnish 2. Insert fishing line [Ø0.8 mm] in between the body and the Fishing line moulding, and pull both ends alternately to cut the adhesive section and remove the moulding. Caution (1) If the moulding is to be reused, pull the fishing line along the edge of the body so as not to damage the edge of the moulding.
Page 918 51-9 EXTERIOR – Moulding and Garnish 4. Remove the strip paper from the pressure sensitive double-side tape. NOTE Affix double-sided tape to the end of strip paper for ease of strip paper removal. 5. Remove strip paper from the pressure sensitive Adhesive double-side tape.
Page 919: Windshield Wiper And Washer
51-10 EXTERIOR – Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER 51100760032 REMOVAL AND INSTALLATION CAUTION: SRS Before removal of air bag module and clock spring, refer to GROUP 52B – SRS Service Precautions and Air Bag Module and Clock Spring. Pre-removal and Post-installation Operation Relay Box Removal and Installation <R.H.
Page 920 51-11 EXTERIOR – Windshield Wiper and Washer REMOVAL SERVICE POINT Link assembly WIPER MOTOR REMOVAL Loosen the wiper motor assembly mounting bolts, and then remove the wiper motor assembly. Disconnect the linkage and the motor assembly, and then remove the linkage. Caution Because the installation angle of the crank arm and the motor has been set, do not remove them unless it is...
Page 921 51-12 EXTERIOR – Windshield Wiper and Washer 3. Inspect the intermittent operation time when the wiper switch is turned to INT. Vehicles with variable intermittent control FAST: Approx. 3 seconds SLOW: Approx. 12 seconds WIPER MOTOR CHECK 51101260135 Inspection while Check the wiper motor after disconnecting the wiring harness operating connector, and with the wiper motor remaining installed to...
Page 922 51-13 EXTERIOR – Windshield Wiper and Washer WASHER FLUID EJECTION POINT CHECK R.H. L.H. 51101270138 Adjust the ejection angle by moving a ball in the nozzle. A:270 mm D:50 mm Ceramic end line B:250 mm E:70 mm C:100 mm...
Page 923: Rear Wiper And Washer
51-14 EXTERIOR – Rear Wiper and Washer REAR WIPER AND WASHER 51100880028 REMOVAL AND INSTALLATION CAUTION: SRS Before removal of air bag module and clock spring, refer to GROUP 52B – SRS Service Precautions and Air Bag Module and Clock Spring. 7.4 Nm 9.8 Nm 7.4 Nm...
Page 924 51-15 EXTERIOR – Rear Wiper and Washer REMOVAL SERVICE POINT WIPER ARM AND BLADE REMOVAL Remove the wiper arm from the shaft while the wiper arm is raised. Caution Spring If the wiper arm is forced while it is still lowered, the force tapered section of the wiper arm will be scraped by the shaft serrations and the diameter of the tapered section...
Page 925 51-16 EXTERIOR – Rear Wiper and Washer WIPER MOTOR CHECK 51101290103 Check the wiper motor after first disconnecting the wiring harness connector, and with the wiper motor remaining installed to the body. Wiper Motor Operation Connect a battery to the wiper motor as shown in the illustration and inspect the motor operation.
Page 926: Headlamp Washer
51-17 EXTERIOR – Headlamp Washer HEADLAMP WASHER 51100970121 REMOVAL AND INSTALLATION CAUTION: SRS Before removal of air bag module and clock spring, refer to GROUP 52B – SRS Service Precautions and Air Bag Module and Clock Spring. 1. Column switch assembly Washer tank removal steps (with built-in headlamp washer Draining of washer fluid...
Page 927 51-18 EXTERIOR – Headlamp Washer INSPECTION Connector A 51100980025 HEADLAMP WASHER SWITCH CHECK Switch position Connector A Connector B Terminal No. Terminal No. Connector B Washer switch HEADLAMP WASHER RELAY CHECK 51101320017 1. Connect battery and test lamp to the relay as illustrated. Battery 2.
Page 928: Marks
51-19 EXTERIOR – Marks MARKS 51101180172 REMOVAL AND INSTALLATION "AA 1. GDI mark "AA 4. Three dia. mark "AA 2. GRADE mark "AA 5. SPACE STAR mark "AA 3. GDI mark INSTALLATION SERVICE POINT "AA MARK INSTALLATION Unit: mm GDI MARK GRADE MARK Lamp centre Front turn signal...
Page 929 51-20 EXTERIOR – Marks Three dia. MARK Unit: mm Licence lamp garnish Licence lamp garnish centre Licence lamp garnish end line SPACE STAR MARK Trunk lid end line Trunk lid press line 1. Clean the mark installation surfaces on the body with unleaded petrol.
Page 930: Door Mirror
51-21 EXTERIOR – Door Mirror DOOR MIRROR 51100670038 REMOVAL SERVICE POINT <Manual remote-controlled type> <Electric remote-controlled type> Section A–A Instrument panel NOTE : Clip positions Door mirror removal steps Door mirror control switch removal steps 1. Delta cover, inner 2. Cap 5.
Page 931 51-22 EXTERIOR – Door Mirror INSPECTION 51100650148 REMOTE CONTROL MIRROR ASSEMBLY CHECK 1. Check to be sure that the mirror moves as described in the table when each terminal is connected to the battery. 2. Check if there is continuity between terminals 1 and 2. Battery connection terminal Direction of operation DOWN...
Page 932 52A-1 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS 52109000057 INTERIOR ............SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .
Page 933 52A-2 INTERIOR CONTENTS 52109000460 SERVICE SPECIFICATIONS ....SEAT* ........Front Seat .
Page 934: Special Tool
Service Specifications/Special Tool/ 52A-3 INTERIOR – Instrument Panel SERVICE SPECIFICATIONS 52100030079 Items Standard value Seatback heater resistance (between terminals) Ω (When ambient temperature is 20 C) 6.84–7.92 Seat cushion heater resistance (between terminals) Ω Between terminals 1 and 2 0.38–0.44 (When ambient temperature is 20 C) (When ambient temperature is 20 C) Between terminals 2 and 3...
Page 935: Instrument Panel
52A-4 INTERIOR – Instrument Panel CAUTION: SRS Pre-removal and Post-installation Operation (1) When removing and installing the floor console Floor Console Assembly Removal and Installation (vehicles equipped with SRS), do not let it bump (Refer to P.52A-8.) against the SRS-ECU. (2) For the passenger side air bag module removal/installation, always observe the service procedures of GROUP 52B –...
Page 936 52A-5 INTERIOR – Instrument Panel CLIP AND CLAW POSITIONS View A View B NOTE :Clip position :Claw position Section A – A Section B – Section C – C View A Multi display unit cover Instrument panel switch Side defroster grille assembly Claw Claw...
Page 937 52A-6 INTERIOR – Instrument Panel View D View C NOTE :Clip position :Claw position Section G – G View C Section H – H Instrument panel assembly Instrument panel assembly Clip Claw Passenger’s side lower panel assembly Passenger’s side lower Passenger’s side lower panel assembly panel assembly...
Page 938 52A-7 INTERIOR – Instrument Panel DISASSEMBLY AND REASSEMBLY 5210019 0289 Disassembly steps 1. Defroster nozzle assembly 6. Side air outlet assembly 2. Distribution duct 7. Instrument panel lower bracket 3. Center ventilation duct 8. Instrument panel center 4. Passenger’s air bag module reinforcement assembly 9.
Page 939: Floor Console
52A-8 INTERIOR – Floor Console FLOOR CONSOLE 52100220261 REMOVAL AND INSTALLATION View A View B View C NOTE :Claw position Section A – A Section B – B View A View B Section C – C Claw Claw Section D – D Section F –...
Page 940: Trims
52A-9 INTERIOR – Trims TRIMS 52100110377 REMOVAL AND INSTALLATION View B View A View A Section A – A Section B – B Section C – C Grommet Section D – D Section F – F View B Section E – E Footrest Section G –...
Page 941: Inside Rear View Mirror
52A-10 INTERIOR – Inside Rear View Mirror INSIDE REAR VIEW MIRROR Button 52100270013 REMOVAL SERVICE POINT Remove by pushing in the direction of the arrow in the illustration.
Page 942: Seat
52A-11 INTERIOR – Seat SEAT 52200100025 FRONT SEAT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Floor Console Assembly Removal and Installation (Refer to P.52A-8). CAUTION: SRS When removing and installing the rear floor console (vehicles equipped with SRS), do not let it bump against the SRS-ECU.
Page 943 52A-12 INTERIOR – Seat INSTALLATION SERVICE POINT Inside of vehicle AA FRONT SEAT ASSEMBLY INSTALLATION Tighten the front seat mounting bolts in the order A, B, C, and D. Door side INSPECTION 52200390064 HEATED SEAT SWITCH CONTINUITY CHECK Terminal No. Switch position –...
Page 944 52A-13 INTERIOR – Seat DISASSEMBLY AND REASSEMBLY 52200150372 Seat disassembly steps 1. Reclining knob cap 13. Seatback assembly 2. Reclining knob 14. Headrestraint guide 3. Front seat inner cover 15. Seatback cover 4. Cap 16. Seatback pad and flame assembly 5.
Page 945: Rear Seat
52A-14 INTERIOR – Seat REAR SEAT 52200180319 REMOVAL AND INSTALLATION 49 Nm 49 Nm 49 Nm Removal steps 1. Headrestraint 2. Rear seat assembly...
Page 946 52A-15 INTERIOR – Seat DISASSEMBLY AND REASSEMBLY 52200200138 44 Nm Seat disassembly steps 1. Seat cushion assembly <R.H.> 10. Seat back assembly <L.H.> 2. Seat cushion assembly <L.H.> 11. Inner control cover 3. Seat cushion cover 12. Headrestraint guide 4. Seat cushion pad assembly 13.
Page 947: Seat Belt
52A-16 INTERIOR – Seat Belt SEAT BELT 52300130324 For removal and installation procedures for the seat belt with pre-tensioner, refer to GROUP 52B – Seat Belt with Pre-tensioner. FRONT SEAT BELT REMOVAL AND INSTALLATION 44 Nm 44 Nm 44 Nm 44 Nm AW0230AJ Outer seat belt removal steps...
Page 948: Rear Seat Belt
52A-17 INTERIOR – Seat Belt REAR SEAT BELT 52300160248 REMOVAL AND INSTALLATION 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm Removal steps Rear seat assembly Quarter lower trim (Refer to P.52A-14.) (Refer to P.52A-9.) 1. Rear center seat belt 4.
Page 949 NOTES...
Page 950 52B-1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS 52409000261 GENERAL INFORMATION ....SRS AIR BAG CONTROL UNIT (SRS-ECU) ....... . SRS SERVICE PRECAUTIONS .
Page 951 52B-2 SRS – General Information GENERAL INFORMATION 52400010355 To improve safety, the SRS and seat belts with operational status of the SRS. The clock spring pre-tensioner are available as optional parts. These is installed in the steering column. systems enhance collision safety by restraining the The SRS side air bag deploys if an impact received front passengers in case of an accident.
Page 952 52B-3 SRS – SRS Service Precautions SRS SERVICE PRECAUTIONS 52400030320 1. In order to avoid injury to yourself or others NOTE from accidental deployment of the air bag and If any of these components are diagnosed as accidental operation of the seat belt with faulty, they should only be replaced, in pre-tensioner during...
Page 953 52B-4 SRS – SRS Service Precautions SRS-ECU Destination of harness Corrective action Terminal No. 1 to 4 – – 5, 14 Body wiring harness Side impact sensor (RH) Correct or replace each wiring harness harness. 6, 34 Body wiring harness Side impact sensor (LH) 7, 8 Body wiring harness...
Page 954 52B-5 SRS – SRS Service Precautions 6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure. After removing the harness connector cover by sliding it in the direction of the arrow 1 in the illustration, remove the connector housing by sliding it in the direction of arrow 2.
Page 955 52B-6 SRS – Special Tools SPECIAL TOOLS 52400070247 Tool Number Name MB991502 MUT-II sub Reading diagnosis codes assembly Erasing diagnosis code Reading trouble period Reading erase times MB991613 SRS check Checking the SRS electrical circuitry harness MB991223 H a r n e s s s e t Checking the continuity and measuring the voltage at the SRS-ECU harness connector A: MB991219...
Page 956: Test Equipment
52B-7 SRS – Test Equipment/Troubleshooting TEST EQUIPMENT 52400080134 Tool Name Digital multi-meter Checking the SRS electrical circuitry Use a multi-meter for which the maximum test current is 2 mA or less at the minimum range of resistance measure- ment TROUBLESHOOTING 52400310097 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 –...
Page 957 52B-8 SRS – Troubleshooting Code No. Diagnosis item Reference page 21, 22, 61, 62 Driver’s side air bag module (squib) system 52B-10 24, 25, 64, 65 Front passenger’s side air bag module (squib) system 52B-10 26, 27, 66, 67 Driver’s side pre-tensioner (squib) system 52B-11 28, 29, 68, 69 Front passenger’s side pre-tensioner (squib) system...
Page 958 52B-9 SRS – SRS – Troubleshooting Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No.14, 15, 16, 17, 31, 32, 45, 51, 52, 54, 55, 56, 57, 58, Probable cause 59, 73, 74, 83, 84 System inside SRS-ECU These diagnostic trouble codes are output when a fault is detected in the SRS-ECU. Malfunction of SRS-ECU The defective parts and trouble causes for each diagnosis code No.
Page 959 52B-10 Code No. Trouble causes Short in driver’s side air bag module (squib) or harness short Short in clock spring Open circuit in driver’s side air bag module (squib) or open harness Open circuit in clock spring Disconnected driver’s side air bag module (squib) connector Partial disconnection due to incorrect clock spring neutral position Malfunction of connector contact Short in driver’s side air bag module (squib) harness leading to the power supply...
Page 960 52B-11 SRS – Troubleshooting MUT-II Self-diag code Check the following connectors: B-17, D-25 SRS check har- Disconnect front passen- ness (MB991613) ger’s side air bag module connector B-17, and con- Check trouble symptoms. Repair nect harness side connector to SRS check harness connector 1.
Page 961 52B-12 SRS – Troubleshooting Code No.28, 29, 68 or 69 Front passenger’s side Probable cause pre-tensioner (squib) system These diagnosis codes are output if there is abnormal resistance between the input Malfunction of wiring harnesses or connectors terminals of the front passenger’s side pre-tensioner (squib). Malfunction of front passenger’s side pre-tensioner The trouble causes for each diagnosis code No.
Page 962 52B-13 SRS – Troubleshooting Code No.41 Power circuit system (fuse No.4 circuit) Probable cause Code No.42 Power circuit system (fuse No.11 circuit) Code No.41 is output if the voltage between the IG terminal (SRS–ECU, terminal Malfunction of wiring harnesses or connectors 18) and the earth is lower than the specified value for a continuous period of 5 Malfunction of SRS-ECU seconds or more.
Page 963 52B-14 SRS – Troubleshooting Code No.43 SRS warning lamp drive circuit system Probable cause (Lamp does not switch off.) This diagnosis code is output when a short to earth occurs in the harness between Malfunction of wiring harnesses or connectors the lamp and the SRS-ECU while SRS-ECU is monitoring the SRS warning lamp Malfunction of SRS-ECU and the lamp is ON.
Page 964 52B-15 SRS – Troubleshooting Check the following connectors: D-25, D-21 MUT-II Self-diag code SRS check har- Disconnect side air bag ness (MB991613) module (L.H.) (squib) Check trouble symptoms. Repair connector D-21, connect the harness side connector to SRS check Check the harness wire between the side air bag module (L.H.) harness connector 1.
Page 965 52B-16 SRS – Troubleshooting Code No.91 Side impact sensor (L.H.) power supply circut Probable cause system This diagnosis code is output if the power supply voltage of the side impact sensor Malfunction of wiring harnesses or connectors (L.H.) drops below the rated value for a continuous period of 5 seconds or more. Malfunction of side impact sensor (L.H.) However, code No.91 will be automatically cleared and the SRS warning lamp will Malfunction of SRS-ECU...
Page 966 52B-17 SRS – Troubleshooting Code No.94 Side impact sensor (R.H.) power supply circut Probable cause system This diagnosis code is output if the power supply voltage of the side impact sensor Malfunction of wiring harnesses or connectors (R.H.) drops below the rated value for a continuous period of 5 seconds or more. Malfunction of side impact sensor (R.H.) However, code No.94 will be automatically cleared and the SRS warning lamp will Malfunction of SRS-ECU...
Page 967 52B-18 SRS – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS 52400340294 Get an understanding of the trouble symptoms and check according to the inspection procedure chart. Trouble symptom Inspection procedure No. Reference page Communication with Communication with all systems is not 52B-18 MUT-II is not possible.
Page 968: Srs Maintenance
52B-19 SRS – SRS Maintenance SRS MAINTENANCE 52400390251 The SRS must be inspected by an authorized dealer 10 years after the date of vehicle registration. SRS WARNING LAMP CHECK Turn the ignition key to the “ON” position. Does the SRS warning lamp illuminate for about 7 seconds, turn off and then remain extinguished for at least 5 seconds? If yes, SRS system is functioning properly.
Page 969 52B-20 SRS – SRS Maintenance AIR BAG MODULES, STEERING WHEEL AND CLOCK <Driver’s side> SPRING Connector 1. Remove the air bag modules, steering wheel and clock spring. (Refer to P.52B-30, 31.) Caution The removed air bag modules should be stored in a clean, dry place with the cover face up.
Page 970 52B-21 SRS – SRS Maintenance FRONT SEAT BACK ASSEMBLY (SIDE AIR BAG MODULE) Air bag module 1. Check that there is no abnormality in the seat air bag deployment section module deployment section. 2. Check that there is no connector damage, bent terminals or clamping of the harness.
Page 971 52B-22 SRS – SRS Maintenance BODY WIRING HARNESS Body wiring harness Body wiring harness 1. Check connector for poor connection. 2. Check harnesses for binds, connectors for damage, and terminals for deformation. REPLACE ANY CONNECTORS OR HARNESS THAT FAIL THE VISUAL INSPECTION. (Refer to P.52B-3.) Caution The SRS may not activate if SRS harnesses or connectors are damaged or improperly connected,...
Page 972 52B-23 SRS – Post-collision Diagnosis POST-COLLISION DIAGNOSIS 52400110338 To inspect and service the SRS after a collision (whether or not the air bags have deployed), perform the following steps. SRS-ECU MEMORY CHECK 1. Connect the MUT-II to the diagnosis connector (16-pin). Caution Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected.
Page 973 52B-24 SRS – Post-collision Diagnosis REPAIR PROCEDURE WHEN AIR BAGS (DRIVER’S SIDE AND FRONT PASSENGER’S SIDE) DEPLOY OR SEAT BELT PRE-TENSIONER OPERATES IN A COLLISION. 1. Replace the following parts with new ones. SRS-ECU (Refer to P.52B-28.) Driver’s side air bag module (Refer to P.52B-30.) Front passenger’s side air bag module (Refer to P.52B-30.) Seat belt with pre-tensioner (Refer to P.52B-37.)
Page 974 52B-25 SRS – Post-collision Diagnosis SRS-ECU 1. Check SRS-ECU case and brackets for dents, cracks or SRS-ECU deformation. 2. Check connector damage, terminals deformation. Air bag modules <Driver’s side> Connector 1. Check cover for dents, cracks or deformation. 2. Check connector for damage, terminals deformities, and harness for binds.
Page 975 52B-26 SRS – Post-collision Diagnosis/Individual Component Service Steering wheel, steering column and intermediate joint 1. Check wiring harness (built into steering wheel) and connectors for damage, and terminals for deformation. 2. Install air bag module to check fit or alignment with steering wheel.
Page 976 52B-27 SRS – Warning/Caution Labels WARNING/CAUTION LABELS 52400300100 A number of caution labels relating to the SRS and instructions when servicing SRS and seat belt seat belt with pre-tensioner are found in the vehicle, pre-tensioner. If labels are dirty or damaged, replace as shown in the following illustration.
Page 977 52B-28 SRS – SRS-ECU SRS AIR BAG CONTROL UNIT (SRS-ECU) 52400210236 Caution 1. Disconnect the battery (–) terminal and wait 3. Do not drop or subject the SRS-ECU to for 60 seconds or more before starting work. impact or vibration. Furthermore, disconnected battery...
Page 978 52B-29 SRS – SRS-ECU INSTALLATION SERVICE POINTS AA SRS-ECU INSTALLATION Caution The SRS may not activate if SRS-ECU is not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger. BA HARNESS CONNECTOR CONNECTION Connect the harness-side connector securely to the SRS-ECU connector, and then turn the lock lever in the direction of the arrow to lock the connector.
Page 979 52B-30 SRS – Air Bag Modules and Clock Spring AIR BAG MODULES AND CLOCK SPRING 52400240297 Caution 1. Disconnect the battery (–) terminal and wait 5. Do not expose the air bag modules to for 60 seconds or more before starting work. temperatures over 93_C.
Page 980 52B-31 SRS – Air Bag Modules and Clock Spring <Air bag module (front passenger’s side> Section A-A Instrument panel Claw Air bag module removal steps EA D Post-installation inspection 1. Air bag module D Negative (–) battery cable connection AA D Pre-installation inspection REMOVAL SERVICE POINTS Section A-A AIR BAG MODULE REMOVAL (DRIVER’S SIDE)
Page 981 52B-32 SRS – Air Bag Modules and Clock Spring STEERING WHEEL REMOVAL Caution MB99 8 3 Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism. CLOCK SPRING REMOVAL Caution The removed clock spring should be stored in a clean, dry place.
Page 982 52B-33 SRS – SRS – Air Bag Modules and Clock Spring Air Bag Modules and Clock Spring CA STEERING WHEEL INSTALLATION 1. Before installation of the steering wheel, be sure to first turn the vehicle’s front wheels to the straight-ahead position and align the mating marks of the clock spring.
Page 983 52B-34 SRS – Side Impact Sensor Caution If dents, cracks, deformation, or rust are discovered in the air bag module, replace it with a new one. Dispose of the old one according to the specified procedure. (Refer to P.52B-39.) CLOCK SPRING CHECK Case If, as result of following checks, even one abnormal point Protective tubes...
Page 984 52B-35 Caution 1. Disconnect the battery (–) terminal and wait 3. Do not drop or subject the side impact for 60 seconds or more before starting work. sensor to impact or vibration. Furthermore, disconnected battery If denting, cracking, deformation, or rust are terminal should be covered with tape to discovered in the side impact sensor, insulate it.
Page 985 52B-36 SRS – Side Impact Sensor INSTALLATION SERVICE POINTS AA PRE-INSTALLATION INSPECTION Check the side impact sensor for dents, breakage and measure the resistance between the terminals, even when installing a new side impact sensor. BA SIDE IMPACT SENSOR INSTALLATION Securely connect the connector.
Page 986 52B-37 SRS – Seat Belt with Pre-tensioner SEAT BELT WITH PRE-TENSIONER 52400410063 Caution 1. Never attempt to disassemble or repair the 4. Do expose seat belt with seat belt with pre-tensioner. If faulty, replace pre-tensioner to temperatures over 90_C. 5. After operating the seat belt pre-tensioner, 2.
Page 987 52B-38 SRS – Seat Belt with Pre-tensioner INSTALLATION SERVICE POINTS AA PRE-INSTALLATION INSPECTION When installing a new seat belt with pre-tensioner refer to “INSPECTION”. Caution Disposal of the pre-tensioner must be carried out as stated in the procedure. (Refer to P.52B-39.) BA POST-INSTALLATION INSPECTION 1.
Page 988 52B-39 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES 52400120317 Before disposing of a vehicle which is equipped pre-tensioner themselves, the following procedures with air bags or seat belts with pre-tensioner, or must be used to deploy the air bags or operate when disposing of the air bags or seat belt the seat belt pre-tensioners before disposal.
Page 989 52B-40 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 3. To deploy the air bag module (driver’s side): Body wiring harness (1) Remove the steering column cover lower. connector (2-pin) (2) Remove the connection between the clock spring 2-pin connector (red) and the body wiring harness connector.
Page 990 52B-41 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 7. Connect the clock spring or air bag module (front SRS air bag adapter passenger’s side), side air bag module 2-pin connector harness A (red) to SRS air bag adapter harness A and pass the MB686560 deployment wires out of the vehicle.
Page 991 52B-42 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures Deployment Outside The Vehicle Caution 1. This should be carried out in a wide, flat area at least 6 m away from obstacles and other people. 2. Do not perform deployment outside, if a strong wind is blowing, and if there is even a slight breeze, the air bag module should be placed and deployed downwind from the battery.
Page 992 52B-43 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 4. Set the air bag modules as follows: Air bag module <Air bag module (driver’s side)> (1) Take the SRS air bag adapter harness B that is connected to the wires, pass it beneath the old tyre wheel assembly, and connect it to the air bag module.
Page 993 52B-44 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures (3) Place three old tyres, without wheels, on top of the tyre secured to the air bag module, and secure all tyres with ropes (4 locations). Tyres without wheels Deployment wire <Side air bag module>...
Page 994 52B-45 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures 5. At a location as far away from the air bag module or seat belt pre-tensioner as possible, and from a shielded position, disconnect the two connected wires from each other and connect them to the two terminals of the battery (which has been removed from the vehicle) to deploy the air bag or to operate the seat belt pre-tensioner.
Page 995 52B-46 SRS – Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES After deployment or operation, the air bag module and the seat belt pre-tensioner should be disposed of in the same manner as any other scrap parts, adhering to local laws and/or legislation that may be in force except that the following points should be carefully noted during disposal.
Page 996 54-1 CHASSIS ELECTRICAL CONTENTS 54109000303 BATTERY ......IGNITION SWITCH AND IMMOBILIZER SYSTEM ....... SERVICE SPECIFICATION .
Page 997 54-2 ON-VEHICLE SERVICE ....HAZARD WARNING LAMP SWITCH ......Speedometer Check .
Page 998 54-3 WINDSHIELD WIPER AND WASHER SUPPLEMENTAL RESTRAINT SYSTEM ....Refer to GROUP 51 (SRS) ... Refer to GROUP 52B REAR WIPER AND WASHER HEATER...
Page 999: Battery
54-4 CHASSIS ELECTRICAL – Battery BATTERY 54100030028 SERVICE SPECIFICATION Item Specification Specific gravity of the battery fluid 1.220 – 1.290 [20 C] ON-VEHICLE SERVICE 54100090071 FLUID LEVEL AND SPECIFIC GRAVITY CHECK Good 1. Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks.
Page 1000: Charging
54-5 CHASSIS ELECTRICAL – Battery CHARGING 54100110173 1. When charging a battery while still installed in the vehicle, disconnect the battery cables to prevent damage to electrical parts. 2. The current normally used for charging a battery should be approximately 1/10th of the battery capacity. 3.

Mitsubishi MOTORS Space Runner 1999 Workshop Manual Supplement

Supplement

Engine

Gasoline Direct Injection (Gdi)

Service Specifications

General

Troubleshooting

On-Vehicle Service

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

Injector

Multipoint Fuel Injection (4G6-Mpi)

Engine Cooling

Engine Electrical

Charging System

Starting System

Ignition System

Engine and Emission Control

Automatic Transmission

General

Troubleshooting

On-Vehicle Service

General

How to Use this Manual

How to Use Troubleshooting/Inspection Service Points

Vehicle Identification

Major Specifications

Precautions before Service

Supplemental Restraint System (Srs)

Pre-Tensioner

Support Locations for Lifting and Jacking

Engine

Engine

Gasoline Direct Injection (Gdi)

Troubleshooting

Fuel Pump (High Pressure)

Throttle Body

Injector Driver

Throttle Valve Controller

Multipoint Fuel Injection (Mpi)

General Information

Service Specifications

Special Tools

Troubleshooting

On-Vehicle Service

Throttle Body

Engine Cooling

Intake and Exhaust

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Mitsubishi MOTORS Space Runner 1999